BMW Series 6 E63 E64 Service Repair Workshop Manual Cu Diagrame

2004-2010 BMW 645Ci BMW 650i
GENERAL INFORMATION
Commonly Used Abbreviations
* PLEASE READ THIS FIRST *
NOTE: This article is intended for general information purposes only. This information
may not apply to all makes and models. Not all abbreviations are covered as
manufacturers add new ones every day.
"A"
A
Amperes
ABS
Anti-Lock Brakes
ABRS
Air Bag Restraint System
AC
Alternating Current
A/C
Air Conditioning
ACCS
A/C Cycling Switch
ACCUM
Accumulator
ACCY
Accessory
ACT
2005 BMW 645Ci
GENERAL INFORMATION Commonly Used Abbreviations
Air Charge Temperature Sensor
ADJ
Adjust or Adjustable
ADV
Advance
AFS
Airflow Sensor
AI
Air Injection
AIR or A.I.R.
Air Injection Reactor
AIS
Air Injection System
Alt.
Alternator or Altitude
Amp./amp/amps
Ampere
ASCS
Air Suction Control Solenoid
ASD
Auto Shutdown
ASDM
Air Bag System Diagnostic Module

2005 BMW 645Ci
ASV
Air Suction Valve
A/T
Automatic Transmission/Transaxle
ATC
Automatic Temperature Control
ATDC
After Top Dead Center
ATF
Automatic Transmission Fluid
ATS
Air Temperature Sensor
Aux.
Auxiliary
Avg.
Average
AXOD
Automatic Transaxle Overdrive (Ford Models Only)
"B"
BAC
By-Pass Air Control
BAP
Barometric Absolute Pressure Sensor

2005 BMW 645Ci
BARO
Barometric
Batt.
Battery
Bbl.
Barrel (Example: 4-Bbl.)
BCM
Body Control Module
BHP
Brake Horsepower
BMAP
Barometric and Manifold Absolute Pressure Sensor
BOO
Brake On-Off Switch
B/P
Backpressure
BPS
Barometric Pressure Sensor
BPT
Backpressure Transducer
BTDC
Before Top Dead Center
BTU
2005 BMW 645Ci
British Thermal Unit
BVSV
Bimetallic Vacuum Switching Valve
"C"
°C
Celsius (Degrees)
Calif.
California
CANP
Canister Purge
CARB
California Air Resources Board
CAT
Catalytic Converter
CB
Circuit Breaker
CBD
Closed Bowl Distributor
cc
cubic centimeter
CCC
Computer Command Control
CCD
2005 BMW 645Ci
Computer Controlled Dwell
CCOT
Cycling Clutch Orifice Tube
CCW
Counterclockwise
CDI
Capacitor Discharge Ignition
CEC
Computerized Engine Control
CID
Cubic Inch Displacement
cm
Centimeter
CMP
Camshaft Position Sensor
CO
Carbon Monoxide
CO2
Carbon Dioxide
Cont.
Continued
CONV
Convertible
2005 BMW 645Ci
CP
Canister Purge
CKP
Crankshaft Position Sensor
CTS
Coolant Temperature Sensor
Cu. In.
Cubic Inch
CVC
Constant Vacuum Control
CV
Check Valve or Constant Velocity
CW
Clockwise
CYL or Cyl.
Cylinder
C3 I
Computer Controlled Coil Ignition
C4
Computer Controlled Catalytic Converter
"D"
"D"
Drive
2005 BMW 645Ci
DC
Direct Current Or Discharge
DDD
Dual Diaphragm Distributor
Def.
Defrost
Defog.
Defogger
DERM
Diagnostic Energy Reserve Module
DFI
Digital Fuel Injection
Diag.
Diagnostic
DTC
Diagnostic Trouble Code
DIC
Driver Information Center
DIS
Distributorless Ignition System
DIST
Distribution
DLC
2005 BMW 645Ci
Data Link Connector
DOHC
Double Overhead Cam
DOT
Department of Transportation
DRB-II
Diagnostic Readout Box
DVOM
Digital Volt-Ohmmeter
"E"
EACV
Electric Air Control Valve
EATX
Electronic Automatic Transaxle
EBCM
Electronic Brake Control Module
EBL
Electronic Back Light
ECM
Engine Control Module
ECT
Engine Coolant Temperature Sensor
EDIS
2005 BMW 645Ci
Electronic Distributorless Ignition System
EEC
Electronic Engine Control
EECS
Evaporative Emission Control System
EEPROM
Electronically Erasable PROM
EFE
Early Fuel Evaporation
EGO
Exhaust Gas Oxygen Sensor
EGR
Exhaust Gas Recirculation
ESA
Electronic Spark Advance
ESC
Electronic Spark Control
EST
Electronic Spark Timing
EVAP
Fuel Evaporative System
EVIC
Electronic Vehicle Information Center

2005 BMW 645Ci
EVP
EGR Valve Position Sensor
Exc.
Except
"F"
°F
Fahrenheit (Degrees)
F/B
Fuse Block
Fed.
Federal
FI
Fuel Injection
FICU
Fuel Injection Control Unit
FIPL
Fuel Injector Pump Lever
FPR-VSV
Fuel Pressure Regulator Vacuum Switching Valve
Ft. Lbs.
Foot Pounds
FWD
Front Wheel Drive

2005 BMW 645Ci
"G"
g
grams
Gals.
gallons
GND or GRND
Ground
"H"
HAC
High Altitude Compensation
HC
Hydrocarbons
H/D
Heavy Duty
HO2S
Heated Exhaust Gas Oxygen Sensor
Hg
Mercury
Hgt.
Height
HLDT
Headlight
HO
2005 BMW 645Ci
High Output
HO2S
Heated Oxygen Sensor
HP
High Performance
HSC
High Swirl Combustion
HSO
High Specific Output
HTR
Heater
Hz
Hertz (Cycles Per Second)
"I"
IAC
Idle Air Control
IACV
Idle Air Control Valve
IAT
Intake Air Temperature
IC
Integrated Circuit
ID
2005 BMW 645Ci
Identification
I.D.
Inside Diameter
Ign.
Ignition
IMRC
Intake Manifold Runner Control
In.
Inches
INCH Lbs.
Inch Pounds
in. Hg
Inches of Mercury
Inj.
Injector
IP
Instrument Panel
ISC
Idle Speed Control
IVSV
Idle Vacuum Switching Valve
"J"
J/B
2005 BMW 645Ci
Junction Block
"K"
KAPWR
Keep Alive Power
k/ohms
kilo-ohms (1000 ohms)
kg
Kilograms (weight)
kg/cm2
Kilograms Per Square Centimeter
KM/H
Kilometers Per Hour
KOEO
Key On, Engine Off
KOER
Key On, Engine Running
KS
Knock Sensor
kW
Kilowatt
kV
Kilovolt
"L"
2005 BMW 645Ci
Liter
lbs. (Lbs. when used in table)
Pounds
LCD
Liquid Crystal Display
L/D
Light Duty
LDP
Leak Detection Pump (Part of EVAP system.)
LED
Light Emitting Diode
LH
Left Hand
"M"
mA
Milliamps
MA or MAF
Mass Airflow
MAFS
Mass Airflow Sensor
MAP
Manifold Absolute Pressure

2005 BMW 645Ci
MAT
Manifold Air Temperature
Mem.
Memory
MEM-CAL
Memory Calibration Chip
mfd.
Microfarads
MFI
Multiport Fuel Injection
MIL
Malfunction Indicator Light
MPI
Multi-Point (Fuel) Injection
mm
Millimeters
MPH
Miles Per Hour
mV
Millivolts
"N"
NA
Not Available
2005 BMW 645Ci
NCA
No Color Available
NGS
New Generation Star
N.m
Newton Meter
No.
Number
Nos.
Numbers
NOx
Oxides of Nitrogen
"O"
O2
Oxygen
OBD
On-Board Diagnostics
OC
Oxidation Catalyst
OD
Overdrive
O.D.
Outside Diameter
2005 BMW 645Ci
OHC
Overhead Camshaft
OSS
Output Speed Sensor
O/S
Oversize
oz.
Ounce
ozs.
Ounces
"P"
"P"
Park
P/C
Printed Circuit
PCM
Powertrain Control Module
PCS
Purge Control Solenoid
PC-SOL
Purge Control Solenoid
PCV
Positive Crankcase Ventilation

2005 BMW 645Ci
PFI
Port Fuel Injection
PGM-FI
Programmed Fuel Injection
PID
Parameter Identification
PIP
Profile Ignition Pick-up
PNP
Park Neutral Position Switch
P/N
Park/Neutral
PRNDL
Park Reverse Neutral Drive Low
PROM
Programmable Read-Only Memory
psi
Pounds Per Square Inch
P/S
Power Steering
PSPS
Power Steering Pressure Switch
PTC
2005 BMW 645Ci
Positive Temperature Coefficient
PTO
Power Take-Off
Pts.
Pints
Pwr.
Power
"Q"
Qts.
Quarts
"R"
RABS
Rear Anti-Lock Brake System
RECIRC
Recirculation
RH
Right Hand
RPM
Revolutions Per Minute
RWAL
Rear Wheel Anti-Lock Brake
RWD
Rear Wheel Drive

2005 BMW 645Ci
"S"
SBC
Single Bed Converter
SBEC
Single Board Engine Controller
SES
Service Engine Soon
SFI
Sequential (Port) Fuel Injection
SIL
Shift Indicator Light
SIR
Supplemental Inflatable Restraint
SOHC
Single Overhead Cam
SOL or Sol.
Solenoid
SPFI
Sequential Port Fuel Injection
SPK
Spark Control
SPOUT
Spark Output
2005 BMW 645Ci
SRI
Service Reminder Indicator
SRS
Supplemental Restraint System (Air Bag)
STAR
Self-Test Automatic Readout
STO
Self-Test Output
SUB-O2
Sub Oxygen Sensor
Sw.
Switch
Sys.
System
"T"
TAB
Thermactor Air By-Pass
TAC
Throttle Actuator Module
TAD
Thermactor Air Diverter
TBC
Body Control Module

2005 BMW 645Ci
TBI
Throttle Body Injection
TCC
Torque Converter Clutch
TDC
Top Dead Center
Temp.
Temperature
TFI
Thick Film Ignition
THERMAC
Thermostatic Air Cleaner
TPM
Tire Pressure Monitor
TPMS
Tire Pressure Monitor System
TPS
Throttle Position Sensor/Switch
TS
Temperature Sensor
TV
Thermovalve
TWC
2005 BMW 645Ci
Three-Way Catalyst
"V"
V
Valve
Vac.
Vacuum
VAF
Vane Airflow
VAPS
Variable Assist Power Steering
VCC
Viscous Converter Clutch
VCRM
Variable Control Relay Module
VIN
Vehicle Identification Number
VM
Vacuum Modulator
Volt.
Voltage
VOM
Volt-Ohmmeter (Analog)
VRV
2005 BMW 645Ci
Vacuum Regulator Valve
VSS
Vehicle Speed Sensor
VSV
Vacuum Switching Valve
"W"
W/
With
W/O
Without
WAC
Wide Open Throttle A/C Switch
WOT
Wide Open Throttle

2005 BMW 645Ci
2004-05 ACCESSORIES & BODY, CAB Audio, Navigation & Anti-Theft Systems - Repair Instructions - E63
2004-05 ACCESSORIES & BODY, CAB
Audio, Navigation & Anti-Theft Systems - Repair Instructions - E63
MONO RADIO
65 11 ... INSTRUCTIONS ON SETTING THE INSTALLATION LOCATION ON THE CD CHANGER
NOTE: To ensure trouble-free CD changer operation, ensure both suspension springs

are correctly positioned (horizontal/vertical). If necessary, correct adjustment.
To avoid premature contamination of the CD changer, make sure the magazine
compartment flap is permanently closed.
NOTE: For purposes of clarity, the following graphics show the CD changer removed.
NOTE:  Observe the following repair instructions if the magazine cannot be

removed from the CD changer.
 E60, E61, E63, E64: Remove CD changer magazine, refer to 65 11 ...
REMOVING AND INSTALLING/REPLACING CD CHANGER
MAGAZINE .
Remove cover cap (1) from CD changer (2).

2005 BMW 645Ci
Fig. 1: Removing Cover Cap From CD Changer

Courtesy of BMW OF NORTH AMERICA, INC.
Move installation location of CD changer (1) using a suitable tool.

2005 BMW 645Ci
Fig. 2: Moving Installation Location Of CD Changer

65 11 ... REMOVING AND INSTALLING/REPLACING CD CHANGER MAGAZINE
Special tools required:
NOTE: For special tools, refer to AUDIO, NAVIGATION & ANTI-THEFT - SPECIAL
TOOLS - 645CI (E63) .
 65 1 170
NOTE: Carry out the following work steps if the CD changer magazine is not
automatically ejected.
Insert special tool 65 1 170 on left under CD changer magazine (1) and carefully remove special tool with CD
changer magazine (1) from CD changer (2).
2005 BMW 645Ci
Installation:
Check position of CDs in CD changer magazine.
Fig. 3: Checking Position Of CDs In CD Changer Magazine

NOTE: A modified CD changer magazine is available from 10/2004 which eliminates

incorrect loading.
Checking CD changer magazine:
Pull CD slot (1) out of CD changer (2) and check top side at retaining lugs (3) on right/left.
(A): CD changer magazine before 10/04:
No retaining lugs on right/left.

2005 BMW 645Ci
Replace CD changer magazine.
(B): CD changer magazine from 10/04:
Retaining lugs (3) present on right/left.
Fig. 4: Identifying Modified CD Changer Magazine

65 11 072 REMOVING AND INSTALLING/REPLACING CD CHANGER
IMPORTANT: Read and comply with notes on protection against electrostatic damage (ESD
protection), refer to 61 35 ... NOTES ON ESD PROTECTION (ELECTRO STATIC
DISCHARGE) .
Necessary preliminary tasks:

2005 BMW 645Ci
INSTALLING/REPLACING LUGGAGE COMPARTMENT FLOOR TRIM PANEL .

 Disconnect battery negative lead, refer to 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND
CONNECTING BATTERY .
NOTE: Comply with notes and instructions on handling optical waveguides, refer to 61
00 ... NOTES ON HANDLING OPTICAL FIBERS .
Fold back covers (1) on CD changer (3).
Release screws (2).
Pull back CD changer (3) slightly.
Unlock and disconnect associated plug connection, remove CD changer (3).
Installation:
Tightening torque, refer to 65 11 1AZ in AUDIO, NAVIGATION AND ANTI-THEFT - TIGHTENING .
Observe tightening torque (risk of damage).

2005 BMW 645Ci
Fig. 5: Removing Luggage Compartment Floor Trim

Installation:
When pushing CD changer in, lay associated wire harness carefully by hand. For this purpose, in advance:
Remove bottom right trim panel from instrument panel, refer to 51 45 181 REMOVING AND
INSTALLING/REPLACING BOTTOM RIGHT TRIM FOR INSTRUMENT PANEL .
Replacement:
Carry out programming/coding, refer to DIAGNOSIS PROGRAMMING/CODING .
Diagnosis Programming/Coding
Using the current TIS CD:

2005 BMW 645Ci
 Document type: Select SI Diagnosis Coding.

 Index number 11: Select Programming Information to display the table of contents.
 Select the current IDC for the appropriate vehicle.
65 12 220 REMOVING AND INSTALLING/REPLACING SATELLITE RADIO (US VERSION ONLY)
DISCHARGE) .
NOTE: Follow instructions for handling optical fibres, refer to 61 00 ... NOTES ON
HANDLING OPTICAL FIBERS .
 Disconnect negative battery cable, refer to 61 20 900 DISCONNECTING AND CONNECTING

BATTERY NEGATIVE LEAD .
 Remove luggage compartment wheel arch trim on left, refer to 51 47 151 REMOVING AND
INSTALLING/REPLACING LEFT LUGGAGE COMPARTMENT WHEEL ARCH TRIM .
 If necessary, remove satellite radio, refer to 65 12 240 REMOVING AND INSTALLING DIGITAL
RADIO (IBOS) .
Release screws (1) and remove bracket (2) with satellite radio.
2005 BMW 645Ci
Fig. 6: Releasing Screws (1) And Removing Bracket (2) With Satellite Radio
Disconnect plug connections (1) and remove complete bracket with satellite radio.
2005 BMW 645Ci
Fig. 7: Disconnecting Plug Connections (1) And Removing Complete Bracket With Satellite Radio
Replacement:
Release screws (1) on both sides and remove satellite radio (2) from bracket (3).
2005 BMW 645Ci
Fig. 8: Releasing Screws (1) On Both Sides And Removing Satellite Radio (2) From Bracket (3)
Release screws (1) and remove satellite radio (2) from bracket (3).
2005 BMW 645Ci
Fig. 9: Releasing Screws (1) And Removing Satellite Radio (2) From Bracket (3)
65 12 240 REMOVING AND INSTALLING DIGITAL RADIO (IBOS)
DISCHARGE) .
2005 BMW 645Ci
Release nuts (1) and remove bracket with digital radio (2).
Fig. 10: Releasing Nuts (1) And Removing Bracket With Digital Radio (2)
Release screws (1) and disconnect plug connections (2).

2005 BMW 645Ci
Fig. 11: Releasing Screws (1) And Disconnecting Plug Connections (2)
STEREO RADIO, AMPLIFIER

65 00 ... OVERVIEW OF AUDIO COMPONENTS
2005 BMW 645Ci
Fig. 12: Identifying Audio Components

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

SPEAKER
 Remove front seat, refer to 52 16 000 REMOVING AND INSTALLING FRONT SEAT
(SPORTS/ELECTRIC), LEFT OR RIGHT .
 Remove front entrance cover strip, refer to 51 47 000 REMOVING AND
INSTALLING/REPLACING FRONT (INSIDE) LEFT OR RIGHT ENTRANCE COVER STRIP .
Release screws (1).
Remove bass speaker trim (2).
Fold back floor trims (3) in direction of arrow.

2005 BMW 645Ci
Fig. 13: Removing Bass Speaker Trim

Unscrew nut (1).
Raise front entrance cable cover (2) in direction of arrow and lay to one side slightly.
2005 BMW 645Ci
Fig. 14: Raising Front Entrance Cable Cover

Unscrew nut (1).
Detach front heating duct for rear compartment (2) in direction of arrow from rear heating duct for rear
compartment (3).
2005 BMW 645Ci
Fig. 15: Detaching Front Heating Duct For Rear Compartment

Unfasten plug connection (1) and disconnect.
Unfasten screws (2) and nuts (3).
Feed out central bass speaker (4) in direction of arrow and remove.
2005 BMW 645Ci
Fig. 16: Feeding Out Central Bass Speaker

Installation:
Make sure seal (1) and rubber damper (2) are correctly seated on central bass speaker (3).
2005 BMW 645Ci
Fig. 17: Installing Seal And Rubber Damper

65 12 070 REMOVING AND INSTALLING/REPLACING AMPLIFIER
Pull out retaining plate (2) in direction of arrow.
Installation:
Make retaining plate (2) is correctly seated.

2005 BMW 645Ci
Remove amplifier (3) from holder (4).
Fig. 18: Removing Amplifier From Holder

65 12 072 REMOVING AND INSTALLING (REPLACING) AMPLIFIER (TOP HI-FI SYSTEM)
DISCHARGE) .
NOTE: Follow instructions for handling optical fibers, refer to 61 00 ... NOTES ON
2005 BMW 645Ci
Release screws (1) and remove holder (2).
Fig. 19: Releasing Screws (1) And Removing Holder (2)

Unlock plug connections (1) and disconnect.
Pull out retaining plates (2) in direction of arrow.
Installation:
Make retaining plates (2) are correctly seated.
Remove amplifier (3) from holder (4).

2005 BMW 645Ci
Fig. 20: Removing Amplifier From Holder

Replacement:
65 12 200 REMOVING AND INSTALLING (REPLACING) AUDIO SYSTEM CONTROLLER
DISCHARGE) .
 Remove luggage compartment floor trim, refer to 51 47 101 REMOVING AND

2005 BMW 645Ci
 Remove middle trim for instrument panel, refer to 51 45 310 REMOVING AND INSTALLING
(REPLACING) CENTER TRIM FOR INSTRUMENT PANEL .
IMPORTANT: Do not scratch decorative trims (1), cover if necessary.
Release screws (2).
Pull back audio system controller (3) slightly.
Unlock associated plug connections and disconnect.
Remove audio system controller (3).

2005 BMW 645Ci
Fig. 21: Pulling Back Audio System Controller

Replacement:
65 12 220 REMOVING AND INSTALLING/REPLACING SATELLITE RADIO (US VERSION ONLY)
DISCHARGE) .

2005 BMW 645Ci
 Disconnect negative battery cable, refer to 61 20 900 DISCONNECTING AND CONNECTING

 If necessary, remove satellite radio, refer to 65 12 240 REMOVING AND INSTALLING DIGITAL
RADIO (IBOS) .
Release screws (1) and remove bracket (2) with satellite radio.
Fig. 22: Releasing Screws (1) And Removing Bracket (2) With Satellite Radio
Disconnect plug connections (1) and remove complete bracket with satellite radio.
2005 BMW 645Ci
Fig. 23: Disconnecting Plug Connections (1) And Removing Complete Bracket With Satellite Radio
Replacement:
Release screws (1) on both sides and remove satellite radio (2) from bracket (3).
2005 BMW 645Ci
Fig. 24: Releasing Screws (1) On Both Sides And Removing Satellite Radio (2) From Bracket (3)
Release screws (1) and remove satellite radio (2) from bracket (3).
2005 BMW 645Ci
Fig. 25: Releasing Screws (1) And Removing Satellite Radio (2) From Bracket (3)
65 12 240 REMOVING AND INSTALLING DIGITAL RADIO (IBOS)
DISCHARGE) .
2005 BMW 645Ci
Release nuts (1) and remove bracket with digital radio (2).
Fig. 26: Releasing Nuts (1) And Removing Bracket With Digital Radio (2)
Release screws (1) and disconnect plug connections (2).

2005 BMW 645Ci
Fig. 27: Releasing Screws (1) And Disconnecting Plug Connections (2)
SPEAKER AND COVER

65 13 050 REMOVING AND INSTALLING/REPLACING SPEAKER (TREBLE SPEAKER IN
QUARTERLIGHT MIRROR TRIM)
 Remove front door trim panel, refer to 51 41 000 REMOVING AND INSTALLING LEFT OR
RIGHT FRONT DOOR TRIM PANEL .
NOTE: Quarterlight mirror trim is clipped into place at bottom (1) and secured at top via
a vertical guide (2).
2005 BMW 645Ci
Fig. 28: Removing Front Door Trim Panel

Expose speaker cable (1) and unlock and disconnect associated plug connection.
Unclip quarterlight mirror trim (2) at bottom out of catch (3) and feed out at top in direction of arrow from
mounting (4).
Remove mirror triangle trim (2).

2005 BMW 645Ci
Fig. 29: Removing Mirror Triangle Trim

Remove foam wedge (1) in direction of arrow from quarterlight mirror trim (2).
2005 BMW 645Ci
Fig. 30: Removing Foam Wedge In Direction Of Arrow From Quarterlight Mirror Trim
Installation:
Guides (3) on quarterlight mirror trim (2) must not be damaged.
Unlock catches (1) in direction of arrow and remove speaker (2) upwards out of quarterlight mirror trim (3).
2005 BMW 645Ci
Fig. 31: Removing Speaker Upwards Out Of Quarterlight Mirror Trim

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

INSTRUMENT PANEL)
 Remove speaker frame, refer to 51 45 115 REMOVING AND INSTALLING SPEAKER FRAME ON
PANEL FOR INSTRUMENT PANEL AT TOP .
Release screws (1).
Lever speaker (2) slightly out of instrument panel (3) and disconnect associated plug connection.
Remove speaker (2).

2005 BMW 645Ci
Fig. 32: Removing Screw From Speaker Frame

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

DOOR AT FRONT)
Release screws (1).
Remove speaker (2) in direction of arrow from front door trim panel (3).
2005 BMW 645Ci
Fig. 33: Removing Speaker In Direction Of Arrow From Front Door Trim Panel
65 13 080 REMOVING AND INSTALLING/REPLACING SPEAKER (TWEETER IN REAR SIDE

TRIM PANEL)
 Remove rear side trim panel, refer to 51 43 002 REMOVING AND INSTALLING REAR LEFT OR
RIGHT SIDE TRIM PANEL .
Screw off threaded ring (1) in counterclockwise direction.
Remove speaker (2) in direction of arrow from rear side trim panel (3).
2005 BMW 645Ci
Fig. 34: Removing Speaker In Direction Of Arrow From Rear Side Trim Panel
Installation:
Make sure speaker (1) is correctly installed with locking device (2).
2005 BMW 645Ci
Fig. 35: Installing Locking Device

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

REAR SIDE TRIM PANEL)
Release screws (1).
Remove speaker (2) in direction of arrow from rear side trim panel (3).
2005 BMW 645Ci
Fig. 36: Removing Speaker In Direction Of Arrow From Rear Side Trim Panel
65 13 188 REMOVING AND INSTALLING/REPLACING REAR MID-RANGE SPEAKER (IN REAR

SHELF)
TOOLS - 645CI (E63) .
 00 9 341
Lever speaker cover (1) with special tool 00 9 341 out of rear shelf (2).
2005 BMW 645Ci
Fig. 37: Identifying Lever Speaker Cover With Special Tool 00 9 341
Installation:
Locks (1) of speaker cover (2) must not be damaged.
Make sure speaker cover (2) is fully engaged.

2005 BMW 645Ci
Fig. 38: Identifying Speaker Cover

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

2005 BMW 645Ci
Fig. 39: Removing Mid-Range Speaker (2) Upwards From Rear Shelf
AERIAL/ANTENNA
65 20 090 REMOVING AND INSTALLING/REPLACING ANTENNA AMPLIFIER (DIVERSITY)
 Remove head restraint at rear left, refer to 52 24 390 REMOVING AND INSTALLING /
REPLACING REAR HEAD RESTRAINTS .
 Remove panel for roof pillar on rear left, refer to 51 43 251 REMOVING AND
INSTALLING/REPLACING TRIM PANEL FOR LEFT OR RIGHT REAR ROOF PILLAR
(CPILLAR) .

2005 BMW 645Ci
Release screws (2).
Remove antenna amplifier (3) in direction of arrow.
Fig. 40: Removing Antenna Amplifier

65 20 150 REMOVING AND INSTALLING/REPLACING BACK-UP ANTENNA
 Remove panel for parcel shelf, refer to 51 46 006 REMOVING AND INSTALLING/REPLACING
TRIM FOR REAR PARCEL SHELF .
Release screws (2).

2005 BMW 645Ci
Remove back-up antenna (3) towards top from parcel shelf (4).
Fig. 41: Removing Back-Up Antenna Towards Top From Parcel Shelf
65 20 320 REMOVING AND INSTALLING/REPLACING MULTIPLE-BAND ANTENNA
 Remove panel for rear lid, refer to 51 49 000 REMOVING AND INSTALLING OR REPLACING
TRIM FOR REAR LID .
Release screws (2).
Remove multiple-band antenna (3) in direction of arrow from rear lid (4).
2005 BMW 645Ci
Fig. 42: Removing Multiple-Band Antenna In Direction Of Arrow From Rear Lid
REAR WINDOW AERIAL/ANTENNA

65 24 020 REMOVING AND INSTALLING OR REPLACING BLOCKING CIRCUIT
 Remove rear right head restraint, refer to 52 24 390 REMOVING AND INSTALLING / REPLACING
REAR HEAD RESTRAINTS .
 Remove panel for roof pillar at rear left, refer to 51 43 251 REMOVING AND
(CPILLAR) .
Release screw (2).

2005 BMW 645Ci
Remove blocking circuit (3) in direction of arrow.
Fig. 43: Removing Blocking Circuit

Installation:
Fit blocking circuit (1) so that screw (2) engages thread (3) and locating pin (4) engages bore (5).
2005 BMW 645Ci
Fig. 44: Installing Blocking Circuit So Screw Engages Thread

65 24 030 REMOVING AND INSTALLING/REPLACING A TV AMPLIFIER
 Remove rear right head restraint, refer to 52 24 390 REMOVING AND INSTALLING / REPLACING
REAR HEAD RESTRAINTS .
 Remove panel for roof pillar at rear left, refer to 51 43 251 REMOVING AND
(CPILLAR) .
Release screw (2).

2005 BMW 645Ci
NOTE: The second TV amplifier (4) is removed in the same way.
Fig. 45: Removing TV Amplifier

Installation:
Fit TV amplifier (1) so that screw (2) engages thread (3) and locating pin (4) engages bore (5).
2005 BMW 645Ci
Fig. 46: Installing TV Amplifier So That Screw Engages Thread And Locating Pin Engages Bore
AERIAL/ANTENNA DIVERSITY
65 20 090 REMOVING AND INSTALLING/REPLACING ANTENNA AMPLIFIER (DIVERSITY)
(CPILLAR) .
Release screws (2).

2005 BMW 645Ci
Fig. 47: Removing Antenna Amplifier

INTERFERENCE SUPPRESSION
65 31 005 REMOVING AND INSTALLING/REPLACING SUPPRESSION FILTER
(CPILLAR) .

2005 BMW 645Ci
Remove suppression filter (3) in direction of arrow.
Fig. 48: Removing Suppression Filter

VIDEOS AND TV SETS

65 50 011 REMOVING AND INSTALLING (REPLACING) VIDEO MODULE FOR ON-BOARD
MONITOR
DISCHARGE) .
2005 BMW 645Ci
Release screws (1).
Pull holder (2) with devices forwards slightly in direction of arrow.
Fig. 49: Pulling Holder With Devices

Installation:
Do not mix up antenna connectors (2).
Mark antenna plugs (2) and disconnect.

2005 BMW 645Ci
Release screws (3).
Feed video module for on-board monitor (4) out of holder (5) and remove.
Fig. 50: Releasing Screw Video Module For On-Board Monitor Out Of Holder
Replacement:
ANTI-THEFT ALARM SYSTEM

65 75 080 REMOVING AND INSTALLING/REPLACING INTERIOR MOVEMENT DETECTION
MODULE IN LEFT OR RIGHT FRONT DOOR
DISCHARGE) .

2005 BMW 645Ci
 Remove front door trim, refer to 51 41 000 REMOVING AND INSTALLING LEFT OR RIGHT
FRONT DOOR TRIM PANEL .
Release screws (1).
Remove interior movement detection module (2) in direction of arrow from front door trim panel (3).
Fig. 51: Removing Front Door Trim

Replacement:
65 75 090 REMOVING AND INSTALLING/REPLACING INTERIOR MOVEMENT DETECTION

MODULE IN LEFT OR RIGHT B-PILLAR
DISCHARGE) .
2005 BMW 645Ci
Release screws (1).
Remove interior movement detection module (2) in direction of arrow from rear side panel (3).
Fig. 52: Removing Rear Side Trim Panel

Replacement:
65 75 557 REMOVING AND INSTALLING/REPLACING EMERGENCY POWER SIREN WITH

TILT SENSOR
2005 BMW 645Ci
DISCHARGE) .
 Remove rear right bumper bracket, refer to 51 12 801 REPLACING BRACKET FOR REAR
BUMPER AT LEFT OR RIGHT .
Unscrew nut (1).
Remove emergency power siren cover (2) from bumper bracket (3).
Fig. 53: Removing Emergency Power Siren Cover From Bumper Bracket
Remove emergency power siren (2) in direction of arrow from rear right bumper bracket (2).
2005 BMW 645Ci
Fig. 54: Removing Emergency Power Siren

Replacement:
AIRBAG TRIGGERING UNIT, DIAGNOSTICS

65 77 ... NOTES ON SCRAPPING BMW VEHICLES WITH GAS GENERATORS (CENTRAL
AIRBAG CONTROL UNIT, AIRBAG SYSTEM)
The gas generator is a pyrotechnic component of:
 Airbag module
 Driver's/passenger airbag
 Side airbags
 Head airbag
 Knee airbag
 Belt tensioner
 Belt buckle tensioner
2005 BMW 645Ci
 Safety battery terminal
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
airbag unit - danger of burning hands! Wash skin with water after contact
with fired gas generators!
1. Vehicles with central airbag control unit (all airbags, seat belt tensioners, safety battery
terminal)
1.1 Expose airbag control, refer to 65 77 016 REMOVING AND INSTALLING/REPLACING
AIRBAG CONTROL UNIT (BUILD DATE FROM 09/2005) .
2005 BMW 645Ci
65 77 ... NOTES ON SCRAPPING BMW VEHICLES WITH GAS GENERATORS (VEHICLES WITH
GATEWAY MODULE, AIRBAG SYSTEM, UP TO BUILD DATE 09/2005)
 Airbag module
 Side airbags
 Head airbag
 Knee airbag
 Belt tensioner
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
handling airbag system components) be removed and disposed of by special disposal companies!
If a firing operation has failed:

used parts.
Firing
be observed.
2005 BMW 645Ci
handling a fired gas generator! The burning of solid fuel will heat up
1. Vehicles with gateway module (all airbags, seat belt tensioners, safety battery terminal)
1.1 Expose airbag plug connections.
1.2 Connect "Airbagmaster". For subsequent procedure, refer to SEDA operating instructions.
65 77 016 REMOVING AND INSTALLING/REPLACING AIRBAG CONTROL UNIT (BUILD DATE

FROM 09/2005)
WARNING: Note airbag safety instructions! Refer to 61 35 ... NOTES ON ESD

PROTECTION (ELECTRO STATIC DISCHARGE) . Incorrect handling can
activate airbag and cause injury.
DISCHARGE) .
 Remove center console, refer to 51 16 200 REMOVING AND INSTALLING STORAGE
COMPARTMENT .
If necessary, remove rear compartment air duct and disconnect associated plug connections.
Disconnect plug connection (1).
Release screws (2) and remove airbag control unit (3).

2005 BMW 645Ci
Fig. 55: Disconnecting Plug Connection (1), Releasing Screws (2) And Removing Airbag Control Unit (3)
65 77 541 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT

ACCELERATION SENSOR
NOTE: Acceleration sensor only fitted in US version!
Remove front bumper trim, refer to 51 11 156 REMOVING AND INSTALLING FRONT BUMPER
TRIM .

2005 BMW 645Ci
Release screws (2) and remove acceleration sensor (3).
Fig. 56: Disconnecting Plug Connection (1), Releasing Screws (2) And Removing Acceleration Sensor (3)
Installation:
Replace screws (2).
65 77 600 REPLACING SENSOR MAT FOR PASSENGER SEAT OCCUPANCY DETECTOR
WARNING: US/CND front passenger seat (with OC3 mat) only: Seat cover must not be
separated from padding. All parts must be replaced completely and
released with the diagnosis system in event of defective fan, seat cover,
seat heating, OC3 mat or padding.
This operation is described in:

2005 BMW 645Ci
"Replacing seat cover for left or right front seat", refer to 52 13 400 REPLACING SEAT COVER ON LEFT
OR RIGHT FRONT SEAT (NORMAL/MANUAL) or 52 16 400 REPLACING SEAT COVER FOR
LEFT OR RIGHT FRONT SEAT (SPORTS/ELECTRIC) .
65 77 680 REMOVING AND INSTALLING (REPLACING) AIRBAG CONTROL UNIT WITH

GATEWAY MODULE
DISCHARGE) .
WARNING: Note airbag safety instructions! Incorrect handling can activate airbag
and cause injury.
 Disconnect battery negative lead and cover, refer to 12 00 ... INSTRUCTIONS FOR
DISCONNECTING AND CONNECTING BATTERY .
 Remove trim for instrument panel at bottom right, refer to 51 45 181 REMOVING AND
Unlock catches (1) in direction of arrow.
Pull airbag control unit with gateway module (2) out of equipment carrier (3) slightly.
Remove airbag control unit with gateway module (2).

2005 BMW 645Ci
Fig. 57: Removing Trim For Instrument Panel At Bottom

Replacement:
65 77 720 REMOVING AND INSTALLING (REPLACING) LEFT B-PILLAR SENSOR
DISCHARGE) .
WARNING: Note airbag safety instructions! Incorrect handling can activate airbag
and cause injury.
2005 BMW 645Ci

 Disconnect battery negative lead and cover, refer to 12 00 ... INSTRUCTIONS FOR
 Remove rear left side trim panel, refer to 51 43 002 REMOVING AND INSTALLING REAR LEFT
OR RIGHT SIDE TRIM PANEL .
Fig. 58: Removing Rear Left Side Trim Panel

Release screw (1).
Slacken screws (2)
Installation:
Raise B-pillar sensor (3) slightly through opening in B-pillar and feed out towards rear.
2005 BMW 645Ci
If necessary, unclip cable duct (4).
Remove B-pillar sensor (2).
Fig. 59: Removing B-Pillar Sensor

Installation:
Clips (3) of cable duct (4) must not be damaged.
Installation:
Make sure metal nut (1) is correctly positioned on B-pillar sensor (2).
2005 BMW 645Ci
Fig. 60: Ensure Metal Nut (1) Is Correctly Positioned On B-Pillar Sensor (2)
Replacement:
65 77 730 REMOVING AND INSTALLING (REPLACING) VEHICLE CENTER SENSOR
DISCHARGE) .

2005 BMW 645Ci

CONNECTING BATTERY
COMPARTMENT .
Release screws (2), tightening torque, refer to 65 77 6AZ in AUDIO, NAVIGATION AND ANTI-THEFT -
TIGHTENING .
Remove vehicle center sensor (3).

2005 BMW 645Ci
65 77 740 REMOVING AND INSTALLING (REPLACING) LEFT FRONT DOOR SENSOR
DISCHARGE) .

FRONT DOOR TRIM PANEL .
 Detach sound insulation in work area, refer to 51 48 060 REMOVING AND
INSTALLING/REPLACING SOUND INSULATION IN FRONT DOOR, LEFT OR RIGHT .
Release screw (1) and remove front door sensor (2) from door.

2005 BMW 645Ci
Fig. 62: Releasing Screw (1), Removing Front Door Sensor (2) From Door And Disconnecting Plug
Connection (3)
Installation:
Make sure rubber ring and sensor are securely seated.
72 12 ... OVERVIEW OF AIRBAG MODULES, SEAT BELTS AND AIRBAG CONTROL UNITS
2005 BMW 645Ci
Fig. 63: Identifying Airbag Modules, Seat Belts And Airbag Control Components
ON-BOARD COMPUTER
65 81 060 REMOVING AND INSTALLING/REPLACING OUTSIDE TEMPERATURE SENSOR
 Remove front underbody protection, refer to 51 47 490 REMOVING AND INSTALLING /

REPLACING FRONT UNDERBODY PROTECTION .
Unclip outside temperature sensor (2) in direction of arrow from panel (3) and remove.
2005 BMW 645Ci
Fig. 64: Uncliping Outside Temperature Sensor (2) In Direction Of Arrow From Panel (3) And Removing
Installation:
Make sure outside temperature sensor (2) is correctly engaged.
CENTRAL DISPLAY AND ON-BOARD MONITOR

65 82 050 REMOVING AND INSTALLING (REPLACING) ONBOARD MONITOR
DISCHARGE) .
IMPORTANT: Proceed with care so as to avoid damaging the on-board monitor and adjoining
trims.
2005 BMW 645Ci
Fold out on-board monitor (2) in direction of arrow.
Fig. 65: Identifying Out On-Board Monitor In Direction Of Arrow

Installation:
Ensure correct cable routing.
Remove on-board monitor (2).

2005 BMW 645Ci
Fig. 66: Removing On-Board Monitor

Replacement:
CAR COMMUNICATION COMPUTER

65 83 010 REMOVING AND INSTALLING/REPLACING CAR COMMUNICATION COMPUTER
DISCHARGE) .

CONNECTING BATTERY
IMPORTANT: Do not scratch decorative trims (1), cover if necessary.
Release screws (2).

2005 BMW 645Ci
Pull back Car Communication Computer (3) slightly.
Remove Car Communication Computer (3).
Fig. 67: Removing Car Communication Computer

Replacement:
65 83 550 REMOVING AND INSTALLING/REPLACING FAN FOR CAR COMMUNICATION

COMPUTER
DISCHARGE) .
 Remove Car Communication Computer, refer to 65 83 010 REMOVING AND

INSTALLING/REPLACING CAR COMMUNICATION COMPUTER .
Raise retaining hook (1) and turn fan for Car Communication Computer (2) in direction of arrow.
Remove fan for Car Communication Computer (2) from Car Communication Computer (3).
2005 BMW 645Ci
Fig. 68: Removing Fan For Car Communication Computer From Car Communication Computer
65 83 560 REMOVING AND INSTALLING/REPLACING FRONT TRIM FOR CAR

COMMUNICATION COMPUTER
DISCHARGE) .

Release screws (1).
Fold down front panel for Car Communication Computer (2) and set down.
2005 BMW 645Ci
Fig. 69: Removing Car Communication Computer

NOTE: "LIF" stands for Low Insert Force.
Open catch of LIF plug (2) in direction of arrow and feed out LIF cable (1).
Remove front trim for Car Communication Computer (4) from Car Communication Computer (3).
Fig. 70: Removing Front Trim For Car Communication Computer From Car
65 83 570 REMOVING AND INSTALLING/REPLACING CD DRIVE FOR CAR COMMUNICATION

COMPUTER
TOOLS - 645CI (E63) .
 64 1 020
DISCHARGE) .
 Remove front trim for Car Communication Computer, refer to 65 83 560 REMOVING AND
INSTALLING/REPLACING FRONT TRIM FOR CAR COMMUNICATION COMPUTER .
2005 BMW 645Ci
Fig. 71: Raising Cover (1) With Special Tool 64 1 020 All Round And Removing From Car
Communication Computer (2)
Release screws (1).
Feed CD drive for Car Communication Computer (2) in direction of arrow out of Car Communication
Computer (3) and set down.
Fig. 72: Feeding CD Drive For Car Communication Computer

Installation:
Ensure correct routing of cables.
Release screws (1).
Remove CD drive trim (2) in direction of arrow from CD drive for Car Communication Computer (3).
2005 BMW 645Ci
Fig. 73: Removing CD Drive Trim In Direction Of Arrow From CD Drive For Car Communication
Computer
Installation:
Disconnect plug connections (1) and (2) in direction of arrow and remove CD drive for Car Communication
Computer (3).
Fig. 74: Disconnecting Plug Connections

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


2005 BMW 645Ci
TOOLS - 645CI (E63) .
 64 1 020
DISCHARGE) .
 Remove front trim for Car Communication Computer, refer to 65 83 560 REMOVING AND
INSTALLING/REPLACING FRONT TRIM FOR CAR COMMUNICATION COMPUTER .
Raise cover (1) with special tool 64 1 020 all round and remove from Car Communication Computer (2).
Fig. 75: Raising Cover (1) With Special Tool 64 1 020 All Round And Removing From Car
Release screws (1).

2005 BMW 645Ci
Fig. 76: Releasing Screws

Release screws (1).
Feed DVD drive for Car Communication Computer (2) in direction of arrow out of Car Communication
Computer (3) and set down.
Fig. 77: Feeding DVD Drive For Car Communication Computer (2) In Direction Of Arrow Out Of Car
Disconnect plug connection (1) in direction of arrow.

2005 BMW 645Ci
Fig. 78: Disconnecting Plug Connection

NOTE: "LIF" stands for Low Insert Force.
Open catch of LIF plug (2) in direction of arrow and feed out LIF cable (3).
Remove DVD drive for Car Communication Computer (5) from Car Communication Computer (4).
65 83 590 REMOVING AND INSTALLING/REPLACING GYRO SENSOR DRIVE FOR CAR

DISCHARGE) .

Release screws (1).
Remove floor pan (2) towards bottom and set down.
IMPORTANT: Contact spring strip (3) on floor pan (2) must not be bent: otherwise risk of
short-circuiting! When reinstalling floor pan (2), make sure individual springs
of contact spring strip (3) are correctly seated.
2005 BMW 645Ci
Fig. 79: Removing Floor Pan Towards Bottom And Set Down
Release screw (1).
Detach gyro sensor for Car Communication Computer (2) in direction of arrow from plug-in contact (3).
Fig. 80: Detaching Gyro Sensor For Car Communication Computer

65 83 600 REPLACING HIP MODULE FOR CAR COMMUNICATION COMPUTER
DISCHARGE) .

2005 BMW 645Ci
Release screws (1).
Remove floor pan (2) towards bottom and set down.
IMPORTANT: Contact spring strip (3) on floor pan (2) must not be bent: otherwise risk of
short-circuiting! When reinstalling floor pan (2), make sure individual springs
of contact spring strip (3) are correctly seated.
Fig. 81: Remove Floor Pan (2) Towards Bottom And Set Down
Press catches (1) and feed out HIP module for Car Communication Computer (2) in direction of arrow.
Fig. 82: Pressing Catches And Feed Out HIP Module For Car Communication Computer
Installation:
2005 BMW 645Ci
Make sure guides (3) of HIP module for Car Communication Computer (2) are correctly seated.
Disconnect plug connection (1) in direction of arrow and remove HIP module for Car Communication
Computer (2).
Fig. 83: Removing HIP Module For Car Communication Computer

Installation:
Carry out initialization with DIS.
NAVIGATION SYSTEMS
65 90 ... NOTES ON HANDLING NAVIGATION COMPUTERS
CAUTION: Risk Of Damage! The navigation computer must not be disconnected from
the power supply while the LED on the computer remains lit (the LED goes
out after approx. 1 minute).
NOTE: To ensure full operation of all the communications components, it is necessary

in new cars to insert a Road Map CD in the navigation computer. This is
absolutely essential as certain functions are disabled for distribution channels.
These functions will only be available again after a Road Map CD has been
inserted. The mode preset at the factory is automatically reset when this CD is
inserted.
Software installation:
The navigation software must be loaded with terminal 15 activated and the navigation system ready for
operation.
2005 BMW 645Ci
Make sure there is a stable power supply. If necessary, connect a battery charger to the vehicle.
The charging operation must not be interrupted (terminal 15 remains activated).
When replacing navigation computer:
From E65/66:
 Carry out coding of navigation computer with aid of Diagnosis and Information System via "CIP".
To E65/66:
 Carry out coding of navigation computer with aid of Diagnosis and Information System in path "1
Recoding".
E46 (with radio navigation) only:
When replacing navigation computer:
 Connect Diagnosis and Information System to vehicle.

 Switch on ignition.
 Select Coding/Programming.
 Select path "3 Coding ZCS".
 Select vehicle.
 Select path "4 Retrofitting".
 Select menu item "3 Instrument cluster".
 Select menu item "2 Language".
 Select the desired languages following the user prompting.
 Start coding of the instrument cluster.
 After the prompt from the Diagnosis and Information System "Now follow the instructions on the on-
board monitor", insert the operating software CD.
 The following note appears from DIS CD 25 software (and higher):
"With radio navigation insert the operating software CD in the computer and wait until it is ejected. Then
follow the instructions on the display. This procedure takes several minutes".
NOTE: The ignition must not be turned off and then on again during this procedure.
The software is loaded when the operating software CD is ejected.
 Carry out coding of navigation computer with aid of Diagnosis and Information System in path "1
Recoding".
2005 BMW 645Ci
configured for a navigation system (radio navigation or navigation system).

2006 BMW 650i
2003-06 ACCESSORIES & BODY, CAB Audio - SI Techniques - E60, E61, E63, E64, E65, E66
Audio - SI Techniques - E60, E61, E63, E64, E65, E66
FUNCTIONS CHANGED AFTER VEHICLE PROGRAMMING E60, E61, E63,

E64, E65, E66, E87, E90, E91
NOTE: Refer to FUNCTIONS CHANGED AFTER VEHICLE PROGRAMMING E60, E61,

E63, E64, E65, E66, E87, E90, E91 .

E64

E63, E64 .
SATELLITE DIGITAL AUDIO RADIO SERVICE E60, E61, E63, E64, E90, E91
Fig. 1: Identifying Satellite Digital Audio Radio Service

2006 BMW 650i
In the USA, BMW supports the digital radio reception system SDARS (Satellite Digital Audio Radio Service).
The following providers offer SDARS:
 "Sirius Satellite Radio Inc."

 "XM Satellite Radio Inc."
BMW uses the SDARS system of "Sirius Satellite Radio Inc.". For system overview, refer to SDARS
SYSTEM OVERVIEW: E60, E61, E63, E64, E90, E91 .
The installation of special equipment creates the prerequisites in the car for using SDARS. These items of
special equipment include the hardware and software for digital radio reception.
 Option 655 "BMW satellite tuner" together with

 Option 645 "Radio Control US"
SDARS System Overview: E60, E61, E63, E64, E90, E91
This system overview contains the following overviews:
 Input/output
 System circuit diagram
 Overview of control units and busses
> E60, E61, E63, E64 up to 09/2005
> E60, E61, E63, E64 from 09/2005
> E90, E91
Inputs/Outputs
2006 BMW 650i
Fig. 2: SDARS Inputs/Outputs Component Block Diagram

System Circuit Diagram

2006 BMW 650i
Fig. 3: SDARS System Circuit Diagram

2006 BMW 650i
Fig. 4: Legend For SDARS System circuit diagram

Overview Of Control Units And Buses Involved In SDARS (E60, E61, E63, E64 up to 09/2005)
2006 BMW 650i
Fig. 5: Overview Of Control Units And Buses Involved In SDARS (E60, E61, E63, E64 up to 09/2005)
2006 BMW 650i
Fig. 6: Legend For Overview Of Control Units And Buses Involved In SDARS (E60, E61, E63, E64 up to
09/2005)
Overview Of Control Units And Buses Involved In SDARS (E60, E61, E63, E64 from 09/2005)
2006 BMW 650i
Fig. 7: Overview Of Control Units And Buses Involved In SDARS (E60, E61, E63, E64 from 09/2005)
2006 BMW 650i
Fig. 8: Legend For Overview Of Control Units And Buses Involved In SDARS (E60, E61, E63, E64 from
09/2005)
Overview Of Control Units And Buses Involved In SDARS (E90, E91)

2006 BMW 650i
Fig. 9: Overview Of Control Units And Buses Involved In SDARS (E90, E91)
2006 BMW 650i
Fig. 10: Legend For Overview Of Control Units And Buses Involved In SDARS (E90, E91)
NEW FEATURES:
 Digital radio reception from satellites and stationary antennae for terrestrial reception. For more
information, refer to SDARS TECHNOLOGY: E60, E61, E63, E64, E90, E91 .
 Radio text: Information concerning radio programs are displayed.
SDARS Technology: E60, E61, E63, E64, E90, E91
Satellite Technology
The following firms in the USA supply the Satellite Digital Audio Radio Service (SDARS):
 "Sirius Satellite Radio Inc."

 "XM Satellite Radio Inc."
2006 BMW 650i
BMW uses "Sirius Satellite Radio Inc.". With "Sirius Satellite Radio Inc." 3 Sirius satellites circle the earth on
an elliptical orbit. The orbit around the earth and the positions of the Sirius satellites were deliberately selected
so that 2 Sirius satellites always transmit to the reception area. The illustration below shows the orbit and
satellites.
Fig. 11: Identifying Satellite Orbit Of SDARS System

The advantages of "Sirius Satellite Radio Inc." (as compared to "XM Satellite Radio Inc.") are:
 Higher orbit, eliminating screening from mountains and buildings.

 Fewer stationary antennae for terrestrial reception are required.
Sirius needs approx. 105 stationary antennae for terrestrial reception. "XM Satellite Radio Inc." requires 1500
stationary antennae for terrestrial reception.
2006 BMW 650i
Generates and distributes the radio program through:
 National "Sirius Satellite Radio Inc." station

 Transmitting antennae (parabolic antennae)
 Satellites
 Satellite control centre
 Stationary antennae for terrestrial reception
The vehicle needs:
 SDARS antenna for satellite reception

 SDARS antenna for terrestrial reception
 Satellite tuner (SDARS)
 Audio system (HiFi system or TOP-HIFI system)
2006 BMW 650i
Fig. 12: SDARS Signal Diagram

2006 BMW 650i
Fig. 13: Legend For SDARS Signal Diagram

National Radio Station "Sirius Satellite Radio Inc." is located in the Rockefeller Center, New York City. The
radio programs are transmitted by cable from the studios to the transmitting antennae.
Transmitting Antennae The transmitting antennae are parabolic antennae to focus the antenna beam onto the
satellites. The transmitting antennae are connected by cable to the national radio station in New York. Digital
signals are transmitted to the 3 Sirius satellites from the transmitting antennae.
2006 BMW 650i
Fig. 14: Identifying SDARS Ground Transmitting Antenna

The digital signals are transmitted to the 3 Sirius satellites from the transmitting antennae as follows:
 2 antennae in New Jersey transmit to 2 satellites.

 1 antenna at the radio station in New York transmits to 1 satellite.
Satellite Control Station The satellite control station continually monitors the 3 Sirius satellites of the "Sirius
Satellite Radio Inc.".
Stationary Antennae For Terrestrial Reception The stationary antennae disperse the signals from the
satellites into reception areas where there is no satellite reception.
2006 BMW 650i
Fig. 15: Identifying SDARS System Stationary Antenna Signal

Frequency Range The SDARS systems work in the frequency range 2320 MHz to 2345 MHz. The SDARS
system used by BMW uses the frequency range 2320 MHz to 2332.5 MHz.
NOTE: SDARS can only be received by digital tuners. Radios for AM (Amplitude
Modulation: medium waves, long waves, short waves) or FM (Frequency
Modulation: VHF) are not able to pick up digital signals.
BENEFITS:
 Low degree of interference from outside sources (no noise) because signals are transmitted digitally.
 Reception of the national radio station is possible over the whole of mainland USA.
 Sound quality is nearly as good as from Compact Disk or MiniDisk.
 Radio program not interrupted for commercials.
 At present, some 100 radio programs can be received digitally.
 Approximately 20 current affairs and "talk" radio programs can be received digitally.
 Dividing the stations into groups allows a particular musical style or information station to be found
quickly.
2006 BMW 650i
 Additional information is available with radio text: Station name, artist, song title.
BRIEF DESCRIPTION OF COMPONENTS
The components involved can be split into the following functional areas:
 Master control unit and aerials

 Central display and control
 Audio
Master Control Unit And Aerials
Satellite Tuner: Tuner For Satellite Digital Audio Radio Service
The satellite tuner converts the digital signals from the SDARS aerials into optical signals (light signals). The
satellite tuner transmits these optical signals onto the MOST bus (Media-Oriented System Transport).
Installation Location
On E60, E61, E63, E64 the satellite tuner is located on the side panel on the left-hand side of the luggage
compartment.
2006 BMW 650i
Fig. 16: Locating Satellite Tuner (E60, E61, E63, E64)

On E90, E91 the satellite tuner is located on the base plate in the luggage compartment.
2006 BMW 650i
Fig. 17: Locating Satellite Tuner (E90, E91)

Design
The satellite tuner has connections for 2 SDARS antennas:
 1 antenna connector for SDARS antenna for satellite reception

 1 antenna connector for SDARS antenna for terrestrial reception
The satellite tuner is connected to the MOST bus via an internal interface. The same plug is also used for the
power supply.
2006 BMW 650i
Fig. 18: Rear View Of Satellite Tuner & Connections

Pin Assignment
PIN ASSIGNMENTS FOR SATELLITE TUNER CONNECTOR X14062, 4-PIN

Pin Type Description
1 V Terminal 30g (= terminal 30 active), activation of the Car Access System (CAS)
2 - -
3 M Terminal 31, earth
2006 BMW 650i
4 - -
M = Ground
V = Supply
For current specifications regarding pin assignments, please refer to BMW diagnosis system.
How It Works
The digital signals (high-frequency signals) are fed to the satellite tuner from the following 2 SDARS antennas:

 SDARS antenna for satellite reception The digital signals have a varying modulation (frequency or time
modulation) but carry the same information. They are first processed separately and then evaluated to
ensure the best possible quality of data transmission.
After they have been amplified, the digital signals are routed to an intermediate-frequency amplifier and
converted into intermediate-frequency signals (ZF signals).
The ZF signals are then sent separately to two analogue/digital converters and converted into digital signals.
The separate processing and evaluation of the signals ensures that the best possible combination of signals from
the 3 separate sources (Sirius satellite 1, Sirius satellite 2 and stationary antennae for terrestrial reception) is
always used.
The processed signals are converted into optical signals (light signals) in an integrated MOST
transmitter/receiver. The optical signal generated in the MOST transmitter/receiver is emitted on the MOST
bus.
SDARS Antennas
High-frequency signals (digital signals) from satellites and stationary aerials for terrestrial reception are picked
up by 2 SDARS aerials on the vehicle. Separate aerial cables route the signals to the satellite tuner.
SDARS aerials:
 1 SDARS aerial for terrestrial reception from stationary aerials

 1 SDARS aerial for satellite reception
On E60, E61, E90, E91, the antennas are located in the fin on the rear edge of the roof.
2006 BMW 650i
Fig. 19: Locating SDARS Antennas (E60, E61, E90, E90)

On E63, E64, the antennas are located under the interior trim of the tailgate. As the tailgate is made of plastic,
there is no interference with reception.
2006 BMW 650i
Fig. 20: Locating SDARS antennas (E63, E64)

Design
The fin can house the following antennas:
 Telephone antenna 1
 Telephone antenna 2
 SDARS antenna for satellite reception
 GPS antenna for navigation systems (GPS: Global Positioning System).
The individual antennas are combined as a single casing as follows.

2006 BMW 650i
Fig. 21: Sectional View Of "Fin" Type Antenna

The antenna connectors for the individual antennas are shown in the following illustration.
2006 BMW 650i
Fig. 22: Identifying Connectors For "Fin" Type Antenna

How It Works
The SDARS antennas are receiving antennas.
 SDARS Antenna For Terrestrial Reception The SDARS antenna for terrestrial reception picks up the
signals from the terrestrial antennae. Terrestrial antennae are stationary antennae located, for example on
masts or in tunnels. The stationary antennae for terrestrial reception are needed as satellite signals cannot
be received everywhere.
 SDARS Antenna For Satellite Reception The SDARS antenna for the satellite reception picks up the
signals direct from the 3 Sirius satellites.
Central Display And Operation
RAD2: BMW "Professional" Radio

2006 BMW 650i
> E90, E91
The BMW "Professional" radio is an item of special equipment.
The radio serves as the gateway (data interface) between the MOST bus and the K-CAN.
SDARS is controlled on the radio.
SDARS is only available in conjunction with the following equipment:
 BMW "Professional" radio (RAD2)

 Car Communication Computer (CCC)
M-ASK: Multi-audio system controller
> E60, E61, E64, E65
M-ASK is an item of special equipment.
M-ASK is the interface for operating the satellite tuner. The radio stations and other SDARS information are
displayed on the Central Information Display (CID).
CCC: Car Communication Computer
The CCC is installed in connection with one of the following options:
 Navigation system "Professional"

 "Voice recognition system"
 "TV function" (not US version)
On the CCC, several control units and the CD-ROM/MD/DVD drives are integrated into a single housing. The
CCC is used to control all information and communication systems, including SDARS.
CID: Central Information Display
The menus for the M-ASK and CCC are displayed on the CID.
CON: Controller
The menus on the CID are selected with the controller.
Audio
AMP: TOP-HiFi Amplifier (Optional)
Option 677 "HiFi system Professional LOGIC7" guarantees the best possible interior sound. The TOP-HiFi
2006 BMW 650i
Loudspeaker
Tweeters, mid-range loudspeakers and woofers are arranged to give the best possible interior sound.
SYSTEM FUNCTIONS
The following SDARS system functions are described:
 Digital radio reception

 Optimised radio reception
 Wide selection of radio programs, grouped according to musical style
Digital Radio Reception
The "Sirius Satellite Radio Inc." radio station records the radio programs in digital form. Parabolic antennae
transmit the signals to the 3 Sirius satellites.
The digital signals are transmitted back to Earth as follows:
 2 satellites transmit to all parts of the Earth. The signals are received by the car's SDARS aerial for
satellite reception.
 1 satellite transmits the digital signals to stationary antennae for terrestrial reception. The aerials transmit
digital signals in all directions. The vehicle's SDARS aerial for terrestrial reception receives these digital
signals.
Different reception paths for digital signals ensure that reception is good even if there is no direct visual contact
between the vehicle and the Sirius satellites.
If there is not direct visual contact, the signal will be received via the stationary antennae for terrestrial
reception.
Satellite reception can be prevented by topographical and constructional features (e.g. valleys, skyscrapers,
tunnels).
Very good reception across the entire region covered is achieved through the following measures:
 Satellites positioned in a high elliptical orbit

 Use of additional stationary antennae for terrestrial reception
Optimised Radio Reception
The quality of the signal is further improved by a special process for evaluating the signal.
Wide Selection Of Radio Programs, Grouped According To Musical Style
 A wide selection of musical styles can be grouped together in the following categories:
2006 BMW 650i
 "Rock"
 "Hip-Hop"
 "Country"
 "Dance"
 "Jazz/Standards"
 "Popular"
 "Rhythm and Blues"
 "Variety"
 "Classical"
 "News"
 "Sports"
 "Entertainment"
OPERATION
NOTE: "Sirius Satellite Radio Inc." may only be used with a valid contractual
agreement.
 A contract must be signed with the company before the "Sirius Satellite
Radio Inc." service can be used.
 "Sirius Satellite Radio Inc." may block the service through the satellite
contact: e.g. if payment obligations are not met.
NOTE: SDARS must be enabled.

After enablement, perform initial operation of SDARS as described in the
operating instructions. How to use the satellite tuner is described in detail in the
operating instructions.
Depending on the vehicle's equipment, the SDARS will be operated as follows:
 On the BMW "Professional" radio (RAD2)

 On the M-ASK or CCC: with the Central Information Display (CID) and Controller (CON)
 With the multi-function steering wheel (buttons for station-search: upwards/downwards)
 With voice input (only if Car Communication Computer (CCC) is fitted)
 With buttons in the centre console (selection of radio station: upwards/downwards)
NOTES FOR SERVICE STAFF
Service staff should note the following points:
 General information: refer to SDARS, GENERAL INFORMATION FOR SERVICE STAFF (E60,
2006 BMW 650i
 Diagnosis: refer to SDARS DIAGNOSIS (E60, E61, E63, E64, E90, E91) .
 Encoding/programming: refer to ENCODING/PROGRAMMING SDARS (E60, E61, E63, E64, E90,
E91) .
 Car and Key Memory: refer to CAR & KEY MEMORY FOR SDARS (E60, E61, E63, E64, E90,
E91) .
E90, E91: Almost all Car & Key Memory functions are programmed inside the vehicle itself. (See
"Personal Profile" in the Owner's Handbook: Individual settings for a maximum of 3 remote control units
via the display in the instrument cluster or via the Central Information Display)
Subject to change.
SDARS, General Information For Service Staff (E60, E61, E63, E64, E90, E91)
IMPORTANT: Do not subject fibre-optic cables to mechanical loads during assembly work.
When performing assembly work on the satellite tuner and on the M-ASK or
CCC, make sure the fibre-optic cables (for the MOST bus) are handled
correctly:
 Do not pull on the fibre-optic cable.

 Do not crush the fibre-optic cable.
 Do not kink the fibre-optic cable.
Incorrect handling could affect the function of the fibre-optic cables. A total
failure of the SDARS system is the result of a broken fibre-optic cable.
Using A Satellite Tuner For The First Time
The first time a satellite tuner decodes a signal from a satellite, the so-called "Preview Channel" can be heard
for a period of 6 months without a contract. ("Preview Channel: selected station for trials purposes) Once this
period has been exceeded, the radio station will block sound output. (The list of stations will still be displayed.)
Continued use of the radio station requires enablement. To this end, a contract must be concluded with "Sirius
Satellite Radio Inc.".
For reasons of quality assurance, some satellite tuners are tested by the manufacturer. These satellite tuners are
marked with a blue label. The date of manufacture is shown on the white label. That means: The trials period
with the "Preview Channel" has been running since the date of manufacture. For this reason, it may occasionally
happen that the trials period has expired before the satellite tuner is first used in the vehicle.
2006 BMW 650i
Fig. 23: Identifying Satellite Tuner & Label

SDARS Diagnosis (E60, E61, E63, E64, E90, E91)
Option 645 "Radio Control US" together with option 655 "BMW satellite tuner" can be diagnosed with the
BMW diagnosis system over the vehicle's diagnosis interface. The BMW diagnosis system displays the
necessary operations as it guides the user through the menus.
Software update, maintenance and troubleshooting: Like all other subscribing control units the satellite tuner
2006 BMW 650i
changed via the diagnosis log.
Encoding/Programming SDARS (E60, E61, E63, E64, E90, E91)
Programming/Replacing Control Unit
Most of the selected settings for SDARS are retained even if the relevant control units are reprogrammed. The
following procedure is executed:
 Before programming or encoding starts, the data is automatically read off by CIP (Encoding,
Individualisation, Programming) into the intermediate memory.
 After programming, the data is stored again in the respective control units.
Car & Key Memory For SDARS (E60, E61, E63, E64, E90, E91)
With the Car & Key Memory, 12 channels can be stored as individual default settings ("Presets"). The presets
are stored in the satellite tuner (SDARS). The presets are specified for a specific ignition key by means of a
code. When the car is started the satellite tuner finds the last radio station that was being listened to prior to
switching off.
NOTE: Personal Profile on the E90, E91. Please refer to the Personal Profile section in
the Owner's Handbook: Individual default settings are stored for p to 3 remote
controls.
DIGITAL AND ANALOGUE TELEVISION E60, E61, E63, E64, E65, E66
NOTE: Television in front is inactive while the vehicle is being driven.

For safety reasons television is forbidden in the front when the vehicle is in
motion. For this reason the television is switched off in the front when the
vehicle is in motion. The sound is not switched off.
2006 BMW 650i
Fig. 24: Identifying Digital And Analogue Television System

INTRODUCTION
The television can be ordered as special equipment (option 601). The Control Display or Central Information
Display in the instrument panel act as a monitor for the television (control display in the E65, E66; Central
Information Display in the E60, E61, E63, E64).
With option 603, "Rear monitor", it is possible to use the television in the rear seat area too. Option 603 is not
available for the E65 or E66.
New feature: The newly developed video modules receive both analogue and digital television in accordance
with the international standard DVB-T. The abbreviation "DVB-T" stands for "Digital Video Broadcasting -
Terrestrial".
Depending on the series there are the following equipment versions for analogue and digital television:
1. Front television:
Viewing television in the front is only possible when the vehicle is stationary.
 E60, E61, E63, E64 - Television in front without amplifier (AMP)
For System Overview, refer to E60, E61, E63, E64 - SYSTEM OVERVIEW OF TV IN FRONT
2006 BMW 650i
 E60, E61, E63, E64 - Television in front with amplifier (AMP)
For System Overview, refer to E60, E61, E63, E64 - SYSTEM OVERVIEW OF TV IN FRONT
WITH AMPLIFIER .
 E65, E66: Television in front without navigation system
For System Overview, refer to E65, E66: SYSTEM OVERVIEW OF TV IN FRONT

WITHOUT NAVIGATION SYSTEM .
 E65, E66: Television in front with navigation system
For System Overview, refer to E65, E66 - SYSTEM OVERVIEW OF TV IN FRONT WITH
NAVIGATION SYSTEM .
2. Television in front and rear is only available with E65, E66.
When the vehicle is in motion it is only possible to watch television in the rear seat area. It is only
possible to watch television in the front when the vehicle is stationary.
 E65, E66: television in front and rear, with or without navigation system
For System Overview, refer to E65, E66: SYSTEM OVERVIEW OF TELEVISION IN

FRONT AND REAR .
NOTE: The Japan national version has its own system overview.
There is a separate television system overview for the Japan national version.
Please refer to the NATIONAL VERSION section.
E60, E61, E63, E64 - System Overview Of TV In Front Without Amplifier
NOTE: The overviews also include the Japan version of the television with navigation
system. On the Japan version, the navigation system has its own control unit:
JNAV (Japan navigation system) The RGB wire for this navigation system
(JNAV) is controlled by the video module.
2006 BMW 650i
Fig. 25: Inputs/Outputs Block Diagram - E60, E61, E63, E64 (Television In Front Without Amplifier)
2006 BMW 650i
Fig. 26: Legend For Inputs/Outputs Block Diagram - E60, E61, E63, E64 (Television In Front Without
Amplifier)
2006 BMW 650i
Fig. 27: System Circuit Diagram - E60, E61, E63, E64 (Television In Front Without Amplifier)
2006 BMW 650i
Fig. 28: Legend For System Circuit Diagram - E60, E61, E63, E64 (Television In Front Without
Amplifier)
E60, E61, E63, E64 - System Overview Of TV In Front With Amplifier

2006 BMW 650i
Fig. 29: Inputs/Outputs Block Diagram - E60, E61, E63, E64 (Television In Front With Amplifier)
2006 BMW 650i
Fig. 30: Legend For Block Diagram - E60, E61, E63, E64 (Television In Front With Amplifier)
NOTE: The overviews also include the Japan version of the television with navigation
system. On the Japan version, the navigation system has its own control unit:
JNAV: Japan navigation system. The RGB wire for the navigation system is
controlled by the video module.
The illustration shows the television in the front with HiFi amplifier. On the television with HiFi amplifier, the
amplifier (AMP) only actuates the woofer. The mid-range loudspeakers and tweeters are actuated by the Car
Communication Computer (CCC). On vehicles with TOP-HiFi amplifier ("LOGIC 7"), the TOP-HiFi amplifier
actuates all loudspeakers.
2006 BMW 650i
Fig. 31: System Circuit Diagram - E60, E61, E63, E64 (Television In Front With Amplifier)
2006 BMW 650i
Fig. 32: Legend For System Circuit Diagram - E60, E61, E63, E64 (Television In Front With Amplifier)
E65, E66: System Overview Of TV In Front Without Navigation System

2006 BMW 650i
Fig. 33: Inputs/Outputs Block Diagram - E65, E66 (Television In Front Without Navigation System)
2006 BMW 650i
Fig. 34: Legend For Inputs/Outputs Block Diagram - E65, E66 (Television In Front Without Navigation
System)
2006 BMW 650i
Fig. 35: System Circuit Diagram - E65, E66 (Television In Front Without Navigation System)
2006 BMW 650i
Fig. 36: Legend For System Circuit Diagram - E65, E66 (Television In Front Without Navigation System)
E65, E66 - System Overview Of TV In Front With Navigation System

2006 BMW 650i
Fig. 37: Inputs/Outputs Block Diagram - E65, E66 (Television In Front With Navigation System)
2006 BMW 650i
Fig. 38: Legend For Inputs/Outputs - E65, E66 (Television In Front With Navigation System)
2006 BMW 650i
Fig. 39: System Circuit Diagram - E65, E66 (Television In Front With Navigation System)
2006 BMW 650i
Fig. 40: Legend For System Circuit Diagram - E65, E66 (Television In Front With Navigation System)
E65, E66: System Overview Of Television In Front And Rear

2006 BMW 650i
Fig. 41: Inputs/Outputs Block Diagram - E65, E66 (Television In Front And Rear)
2006 BMW 650i
Fig. 42: Legend For Inputs/outputs - E65, E66 (Television In Front And Rear)
2006 BMW 650i
Fig. 43: System Circuit Diagram - E65, E66 (Television In Front And Rear)
2006 BMW 650i
Fig. 44: Legend For System Circuit Diagram - E65, E66 (Television In Front And Rear)
The following components supply signals or data for the television:
TV Aerial
The TV aerial receive the signals for the television.

2006 BMW 650i
2 or 3 TV aerials are used as follows for the best possible TV reception under varying reception conditions:
 E60, E61, E63, E64 - Television in front, digital and analogue 2 TV aerials
 E65, E66 without navigation system: Television in front, digital and analogue 3 TV antennae
 E65, E66: Television in front and rear, analogue: 2 TV aerials
 E65, E66: Television in front and rear, analogue and digital: 3 TV aerials
2 TV aerials are used at all times to guarantee optimum reception.
The TV aerials are in the rear window. The heating areas for the rear-window heater are also used as TV aerials.
MOST port
Control units for the television are programmed and encoded via the MOST port.
Aerial Amplifier
There are always 2 aerial amplifiers (TV tuners) installed.
On equipment versions with 3 TV aerials, 2 TV aerials are amplified by one aerial amplifier. One more TV
aerial is amplified by the 2nd aerial amplifier.
The aerial amplifiers are to the right and left of the rear window.
The aerial signals are transmitted to the video module via coaxial cables.
Diagnosis Lead
Control units for the television are diagnosed via the diagnosis lead.
AMP: Amplifier
NOTE: The following control units are involved in the television system (in alphabetical
order):
The amplifier issues the audio signals to the loudspeakers.
The following amplifier is fitted, depending on equipment variant:
 HiFi amplifier without AMP control unit

 TOP-HiFi amplifier with AMP control unit:
This amplifier belongs to the "TOP-HiFi amplifier" option (Logic 7).
The TOP-HiFi amplifier is a control unit in the MOST network.

2006 BMW 650i
The audio signals are transmitted to the TOP-HiFi amplifier via the MOST bus.
ASK: Audio System Controller
> E65, E66
The audio system controller controls the sound.
The audio system controller is a control unit in the MOST network.
BZMF: Control centre, rear compartment centre armrest
> E65, E66
The rear compartment centre armrest control centre controls the headphones.
The BZMF is a control unit in the K-CAN system.
CCC: Car Communication Computer
> E60, E61, E63, E64
The Car Communication Computer controls the information and communication systems.
Depending on the equipment and national version, the CCC processes RGB signals or FBAS signals (RGB: red-
green-blue; FBAS: Composite Video Burst Synchronisation).
The CCC converts the analogue picture signals into digital LVDS signals (LVDS: Low Voltage Differential
Signalling). The LVDS signals are transmitted to the screen via a special LVDS data wire (monitor is the CD or
the CID).
The CCC is a control unit in the MOST network.
For more information, please refer to SI Technology bulletin (SBT) 84 06 03 053. Refer to CAR
COMMUNICATION COMPUTER (CCC) E60, E61, E64, E65 .
CD: Control Display
> E65, E66
The Control Display is the screen for the television and other information and communication systems (e.g.
navigation system).
The CD is a control unit in the MOST network.
CID: Central Information Display

2006 BMW 650i
> E60, E61, E63, E64
The Central Information Display is the screen for the television and other information and communication
systems (e.g. for the navigation system).
The CID is a control unit on the K-CAN.
For more information, please refer to SI Technology bulletin (SBT) 62 01 03 027. Refer to iDRIVE,
CENTRAL INFORMATION DISPLAY AND CONTROLLER E60, E61, E63, E64, E87, E90, E91 .
CON: Controller
The controller is integrated in the centre console switch centre (BZM). The CON is the operating unit and the
control unit for operating the screen (Control Display or Central Information Display, see below).
The controller is a control unit on the K-CAN system or K-CAN
(K-CAN-S for E65, E66; K-CAN for E60, E61, E63, E64).
For more information, please refer to SI Technology bulletin (SBT) 62 01 03 027. Refer to IDRIVE,
CENTRAL INFORMATION DISPLAY AND CONTROLLER E60, E61, E63, E64, E87, E90, E91 .
DVD Changer
> E65, E66
The E65 and E66 also have a DVD changer (DVDC). The films on DVD use the components and software of
the television.
FCON: Rear Compartment Controller
> E65, E66
The rear compartment controller is part of the "Rear seat area entertainment" option.
The rear compartment controller is integrated into the rear compartment centre armrest control centre (BZMF).
The rear compartment controller is the operating unit and control unit for operating the rear display.
The rear compartment controller is a control unit on the K-CAN system
Signal path when operating the FCON:
FCON -> K-CAN SYSTEM -> BZMF -> K-CAN SYSTEM -> SG-FD -> VM.
KHI: Headphone Interface

2006 BMW 650i
> E65, E66
The headphones interface is part of the "Rear seat area entertainment" option.
The headphones interface transmits audio data to the headphones connection module.
The headphones interface is a control unit in the MOST network.
NAV: Navigation System
The navigation system is important for the equipment variant "Television in front" (E60, E61, E63, E64, E65,
E66).
With the equipment variant "Television in front", the NAV control unit works as an RGB decoder:
The navigation system converts FBAS signals into RGB signals.
The navigation system is a control unit in the MOST network.
SG-FD: Rear Display Control Unit
> E65, E66
The rear compartment controller control unit is only provided with the option "Rear seat area entertainment".
The SG-FD is installed beneath the rear display.
The SG-FD is a control unit on the K-CAN system
The SG-FD converts the image signal into the screen display on the rear display: e.g. RGB signals into LVDS
signals.
The SG-FD is actuated by the video module.
Signal path: VM -> RGB wire -> SG-FD -> LVDS data wire -> FD
SGM: Safety And Gateway Module
The safety and gateway module is the data interface between the K-CAN or K-CAN system and the diagnosis
cable.
The control units are diagnosed via the SGM.
VM: Video module
The video module is the central receiver unit for the picture signals from the TV aerials. In addition, the video
2006 BMW 650i
 The video module is the master control unit for the television.
 The video module edits the picture signals from the TV aerials and from the DVD drive or DVD changer.
The video module is a control unit in the MOST network.
The video module (VM) is the master control unit for the television.
Video module is fitted at the rear left in the luggage compartment.
Construction
The video module comprises the following components:
 2 Or 3 Aerial Connectors
 TV Tuner
 2 Large Connectors
 Electronic Circuitry For Signal Processing
2006 BMW 650i
Fig. 45: Identifying Video Monitor

The illustration shows the video module on the E65, E66 for digital and analogue television in the front and
rear. The video module with Japan navigation system has a different housing and different aerial inputs (VM5
RGB). For details of the classification of the equipment variants for video modules, see below.
Aerial Connector
Depending on the equipment variant, the following aerial connectors may be fitted:
On vehicles with television in the front and rear, the video module has 2 aerial inputs.
2006 BMW 650i
The video module has 3 aerial input with the following equipment variants:
 E65, E66: with analogue and digital television in the front and rear
 E65, E66: Television in front without navigation system
These 3 aerial inputs use the following aerial connectors:
 Aerial connector FAKRA E, green: TV 1 with signal and screening (item "3" in illustration)
 Aerial connector FAKRA F, brown: TV 2 with signal and screening (item "4" in illustration)
 Aerial connector FAKRA F, pink: TV 3 with signal and screening (equipment variant television in front
and rear; this connector is shown as item "5" in the illustration)
FAKRA is the name of a standard. FAKRA stands for "Fachausschuss Kraftfahrzeuge" (technical committee for
motor vehicles).
The video module also receives TV signals if only one aerial is working. However, signal processing will then
be restricted.
Aerial Amplifier
Each aerial amplifier (TV tuner) is connected to its own aerial input.
 Vehicles with television in the front: The video module has 2 aerial amplifiers.
 Vehicles with television in the front and rear: The video module has 3 aerial amplifiers in 2 housings.
The aerial amplifiers work as follows:
Each aerial amplifier is independent of the other aerial amplifiers.
The aerial amplifiers are flexibly used as follows:
 Flexible reception: Depending on reception conditions, each aerial amplifier is able to receive a TV
program in the foreground. The best reception quality is then used.
 Flexible background search: An aerial amplifier conducts a background search to find a new frequency
for the current TV station. The other aerial amplifier receives the current TV program.
Each aerial amplifier is able to search for new frequencies. This means that the frequency range is scanned as
quickly as possible. The list of stations is thus kept as current as possible. Alternative frequencies for the TV
program selected are kept on standby.
2 Large Connectors
Depending on equipment variant, the two large connectors have different pin assignments:
 Pin assignment of video module for television in front: X18803 and X18804
2006 BMW 650i
 Pin assignment of video module for television in front and rear: X18803 and X18804
Television In Front:
PIN ASSIGNMENT X18803, 18+2-PIN WITH MOST, ENCODING C (BLUE)

1 M Terminal 31
2 - -
3 - -
4 A Composite Video Burst Synchronisation (FBAS), output
5 - -
6 - -
7 - -
8 - -
9 - -
10 - -
11 V Terminal 30
12 A Screening 1: The wire for the image signal to the Car Communication Computer
(CCC) has additional screening (for improved electromagnetic compatibility).
13 A Composite Video Burst Synchronisation (FBAS), terminal 31, earth
14 - -
15 - -
16 - -
18 - -
19 - -
20 - -
MOST E/A 2 pins
A = Output
E/A = Input/output
M = Earth
V = Supply voltage
For current specifications regarding pin assignment, please refer to BMW diagnosis system.
PIN ASSIGNMENT X18804, 18-PIN, ENCODING B (NATURAL, I.E. COLOURLESS)

1 - -
2 - -
3 E DVD changer (DVDC), Composite Video Burst Synchronisation (FBAS)
4 - -
5 - -
2006 BMW 650i
6 - -
7 - -
8 - -
9 - -
10 - -
11 M DVD changer (DVDC), Composite Video Burst Synchronisation (FBAS), terminal
31, earth
12 - -
13 - -
14 - -
15 - -
16 - -
17 - -
18 - -
E = Input
M = Earth
Television In Front And Rear:
PIN ASSIGNMENT X18803, 18-PIN WITH MOST, ENCODING C (BLUE)

1 M Terminal 31
2 - -
3 A Red 1, 75 ohm
4 A Green 1, 75 ohm
5 A Blue 1, 75 ohm
6 M Red-green-blue 2
7 - -
8 - -
9 - -
10 - -
11 V Terminal 30
13 M Composite Video Burst Synchronisation (FBAS), terminal 31, earth
14 A Red 2, 75 ohm
15 A Green 2, 75 ohm
16 A Blue 2, 75 ohm
2006 BMW 650i
19 - -
20 - -
MOST E/A 2 pins
A = Output
E/A = Input/output
M = Earth
V = Supply voltage
PIN ASSIGNMENT X18804, 18-PIN, ENCODING B (NATURAL, I.E. COLOURLESS)

1 - -
2 - -
3 E DVD changer (DVDC), Composite Video Burst Synchronisation (FBAS)
4 - -
5 E Red-green-blue, terminal 31
6 - -
7 - -
8 E AUX-In connection (if fitted)
9 - -
10 - -
11 M DVD changer (DVDC), Composite Video Burst Synchronisation (FBAS), terminal
31, earth
12 E Red, 75 ohm
13 E Green, 75 ohm
14 E Blue, 75 ohm
15 - -
16 - -
17 E AUX-In connection, Composite Video Burst Synchronisation (FBAS), terminal 31,
earth (if fitted)
18 E Synchronisation pulse from Japan navigation system (if fitted):
The JNAV has an external synchronisation pulse. This synchronisation pulse is
transmitted by the JNAV to the video module.
The current video modules (VM hybrid) no longer need this synchronisation pulse.
E = Input
M = Earth
How It Works
The following functions are described:
 Power Supply
2006 BMW 650i
 Various Equipment Variants (List)

 Video Modules And Aerial Inputs
Power Supply A cycled current supply (switching power unit) provides power. The power unit creates very
little power loss. Voltage peaks are avoided by switching on and off (hence the name "switching power unit").
In addition, a power supply is also created in standby mode.
Various Equipment Specifications Depending on the model series and equipment variant, the video module
can work in different ways. In general, the following as described:
 "Analogue": The video module is only suitable for analogue television.

 "Hybrid": The video module is suitable for analogue and digital television.
 "Drive": The video module is suitable for watching television while the vehicle is moving. It is only
possible to watch television in the rear while the vehicle is moving.
 "FBAS": The video module is connected to an FBAS wire. Inputs and outputs have FBAS wires. This
video module is always hybrid, i.e. suitable for analogue and digital television.
 "RGB": The video module is connected to RGB wires. This video module supports analogue television.
To date, only analogue video modules have been fitted. The analogue video modules work either on the basis of
FBAS or on the basis of RGB (FBAS: Composite Video Burst Synchronisation; RGB: red-green-blue).
ANALOGUE VIDEO MODULES: HOW IT WORKS AND MODEL SERIES

How it works E name E60, E61, E63, E65, E66 Japan E60, Japan E65, E66
E64 E61, E63, E64
RGB VM5 RGB 0 0 1 with JNAV 1
FBAS VM5 ECE 1 1 0 0
DRIVE (with VM5 DRIVE 0 1 0 1
RGB outputs) With TV in rear
and as video
switch with rear
seat area
entertainment
with external
navigation
1: fitted
0: not fitted
E name: development code
Since 09/2004, hybrid video modules have been fitted in countries with DVB-T (in model series E60, E61, E63,
E64, E65, E66). Hybrid video modules process analogue and digital television. The hybrid video modules also
work on the basis of either FBAS or RGB.
HYBRID VIDEO MODULES: HOW IT WORKS AND MODEL SERIES

2006 BMW 650i
How it works E name E60, E61, E63, E65, E66 Japan E60, Japan E65, E66
E64 E61, E63, E64
FBAS VM hybrid 1 1 0 0
FBAS Without TV in
rear
DRIVE (RGB) VM hybrid 0 1 0 0
DRIVE with TV in rear
or
with TV in front
without NAV
1: fitted
0: not fitted
E name: development code
NOTE: In Japan there is only analogue television. Japan does not have DVB-T. For this
reason, an analogue video module is fitted for television in the front in Japan
(on RGB basis). With equipment variant television in front and rear, the video
module VM5 DRIVE is fitted in Japan (analogue video module on RGB basis).
Video Modules And Aerial Inputs All video module have 2 aerial inputs, except: video module 5 hybrid
DRIVE.
Monitors: Control Display or Central Information Display
NOTE: The following components are controlled:
> E65, E66: Control Display
> E60, E61, E63, E64: Central Information Display
FD: Rear Display
> E65, E66
The rear display is part of the "Rear seat area entertainment" option.
The rear display is the monitor for the television in the rear.
The rear display is mounted on the centre console between the driver's and front passenger's seats.
The rear display is actuated by the SG-FD (rear display control unit, via the LVDS data wire).
The rear display is a control unit on the K-CAN system
Loudspeakers
2006 BMW 650i
The following loudspeakers are actuated for television sound output:
 Tweeters and medium-range loudspeakers: The loudspeakers are actuated by the CCC or ASK.
(CCC: Car Communication Computer: E60, E61, E63, E64)
(ASK: audio system controller: E65, E66)
 Woofers: If an amplifier (AMP) is fitted (HiFi amplifier or TOP-HiFi amplifier), the woofers are actuated
by the amplifier.
KHA: Headphones Connector Module
> E65, E66:
The headphones connector module is integrated into the rear compartment centre armrest control centre.
The headphones are connected to the KHA.
FBAS Wire
NOTE: The following wires are important:
FBAS: Farbbild-Austast-Synchronsignal,
English CVBS: Composite Video Burst Synchronisation
> E60, E61, E63, E64:
The FBAS wire connects the video module to the Car Communication Computer.
The FBAS wire consists of 2 wires:
 One wire is used to transmit all three 3 RGB signals (red-green-blue) together.
The synchronisation pulse (for a sharp TV picture) are also transmitted on the wire for RGB signals.
 The other wire is used for screening and earthing.
Coaxial cable
The coaxial cables transmit high-frequency signals, e.g. between the aerial amplifier and the video module
(VM):
 E60, E61, E63, E64, E65, E66: between the video module and the aerial amplifier
 E65, E66: between the DVD changer and video module
2006 BMW 650i
Construction of coaxial cable:
 Inner conductor ("core"), insulated

 The outer conductor forms a mantle around the inner conductor
LVDS Data Wire
LVDS stands for "Low Voltage Differential Signalling".
There is always a LVDS data wire between the display control unit and the monitor:
 E60, E61, E63, E64:
Between the Car Communication Computer and Central Information Display
 E65, E66:
Between the rear display control unit and the rear display
LVDS is a special technology for fast and secure data transmission:
There are 2 wires for each signal. The signal is transmitted positively on one wire, negatively on the other
(inverted). This means that each pair of wires is electrically neutral.
Interference from outside has no effect on the signal transmission: such interference affects both wires equally.
The signal information is thus unaffected. This is because:
The control unit processes the difference between the positive and negative signals. This difference remains
unchanged even in the event of interference from outside.
The LVDS data wire for the television consists of the following wires:
 2 wires for red

 2 wires for green
 2 wires for blue
 2 earth wires
 Screening
The synchronised pulses are transmitted on the wire for image signals.
RGB Wire
> E60, E61, E63, E64: between the video module and the CCC
> E60, E61, E63, E64: between the NAV and CD

2006 BMW 650i
> E65, E66: between the video module and the CD
> E65, E66: between the video module and SG-FD
The RGB wire has 3 wires for image signals: red-green-blue. The synchronised pulse is transmitted on the wire
for the green signal.
The RGB wire is screened. The screening carries no current.
In addition, the RGB wire has its own earth wire for improved electromagnetic compatibility. The earth wire
conducts current.
MOST Bus
The MOST bus connects the control units for the vehicle's information and communication systems. These
control units are programmed via the MOST port.
K-CAN or K-CAN SYSTEM: Body CAN or Body CAN SYSTEM:
> E60, E61, E63, E64: K-CAN
> E65, E66: K-CAN SYSTEM
For more information, please refer to SI Technology bulletin (SBT) 61 02 03 015]BUS DIAGNOSIS ALL
MODELS FROM E60 .
SYSTEM FUNCTIONS
The video module comprises the following functions:
 Digital and analogue television

 Television when the vehicle is stationary (front)
 Television when the vehicle is in motion (rear compartment only)
 Television reception
 Image buildup
 Sound reception
 Transmission of image signals in the vehicle
 Sound output
 Mute
 Station selection
 Aerial diversity for TV aerials TV 1, TV 2 and TV 3 (only E65, E66 with television in front and rear):
Aerial diversity for TV aerials is not a separate component, but rather a software component within the
video module.
2006 BMW 650i
 Video switch
NOTE: Digital television: Basic principles and introduction in various countries

This SI Technology bulletin (SBT) describes digital television as used by BMW.
The enclosures also include the following information:
 Fundamental information about digital television

 An overview of the conversion from analogue to digital television in
various countries
Overview Of E60, E61, E63, E64, E65, E66: Digital Television
This SI Technology bulletin (SBT) principally describes digital television as used by BMW. In addition, the
following information is provided:
 Fundamental information: Advantages of and standards for digital television

 An overview of the conversion from analogue to digital television in various countries
Basic Principles Of Digital Television
Advantages of digital television:
 Number of TV Programs
Digital television makes better use of the band-width when broadcasting TV programs than analogue
television:
The digital signals can be transmitted and compressed without loss. Example: A TV picture with 625
lines (PAL) has an uncompressed data transmission rate of 216 Mbit/s.
With MPEG-2, this TV picture is compressed at least to 8 MBit/s.
Data compression is variable and dynamic, depending on the content of the TV picture.
This provides the following possibilities:

 Multiplex: Several TV stations on one channel:
Because of the data compression, up to 5 TV stations can be digitally broadcast on a single

conventional UHF or VHF channel.
This transmission is known as "Bouquet".
 Specification of UHF and VHF channels:

 VHF channel for television: 48-67 MHz
2006 BMW 650i
VHF: Very High Frequency, frequency range: 30-300 MHz
 UHF channel for television: 471-860 MHz
UHF: Ultra High Frequency, frequency range: 300 MHz to 3 GHz
 Higher transmission quality due to data compression:
The band-width is used for TV stations with higher resolution (HDTV: High Definition Television,
previously only used in Australia).
 Improved Transmission Performance
DVB-T has a better transmission performance than analogue television:
Digital television is some 10 dB "better" than analogue television. This means that a lower transmission
output is needed for the same range.
 Interference-Free Data Transmission Due To Multipath Reception
Analogue television produces "shadows" when a TV program is received more than once (caused by the
reflection of the signal): A TV picture appears superimposed on top of the same TV picture, shifted
slightly to one side and significantly weaker.
Multipath reception is useful for digital reception: Even reflected signals are used for building up the
picture.
 Mobility
Because digital television is resistant to interference, is also supports mobile reception: Stable reception is
possible at speeds of up to 200 km/h under favourable conditions.
 Universal Coverage Of Large Areas With Single-Frequency Network
Several geographically separate TV stations are linked in a single-frequency network (SFN). The single-
frequency network functions as follows:
All TV stations work on the same transmission frequency. The TV stations are synchronised by GPS so
that exactly the same information is transmitted to within 100 nanoseconds. Because the information is
precisely synchronised, only one frequency is needed for a TV program, even in a large reception area.
 Loss-Free Recording
TV Programs can be stored without loss on CD, PC and laptop.
Digital television (DVB: Digital Video Broadcasting) has the following standards:
2006 BMW 650i
 DVB-S: Digital television for data transmission via satellite

 DVB-C: Digital television for data transmission via cable networks
 DVB-T: Digital television for data transmission via stationary antennae for terrestrial reception
(frequency ranges: VHF or UHF).
 Terrestrial, digital television in USA: Standard for digital television in USA: ATSC
(Advanced Television Systems Committee).
 Terrestrial, digital television in Japan: Standard for digital television in Japan: ISDB
(Integrated Services Digital Broadcasting).
 DVB-H: Digital television for asynchronised transmission onto mobile final devices (handheld
units), also terrestrial.
Digital And Analogue Television
Depending on the equipment variant, analogue and/or digital television can be received.
For digital television the DVB-T standard is supported. Only terrestrial reception is possible.
The abbreviation "DVB-T" stands for "Digital Video Broadcasting" - Terrestrial. In other words "DVB-T"
means: digital television transmitted via antenna ("terrestrial").
There are two equipment specifications for analogue and digital television:
1. Television when the vehicle is stationary

2. Television when the vehicle is in motion
Television When The Vehicle Is Stationary (Front)
Viewing television in the front is only possible when the vehicle is stationary.
The television is deactivated when the vehicle reaches walking pace. The sound remains unaffected.
Television in the front is available for the following model series:
> E60, E61, E63, E64, E65 and E66
Television When The Vehicle Is In Motion (Rear Compartment Only)
Television in the rear is only available with the model series E65 and E66.
It is also possible to watch television in the rear when the vehicle is in motion.
Television Reception
The analogue television supports the following television standards:

2006 BMW 650i
 NTSC: NTSC is most common in North and South America and in Japan. NTSC is an analogue television
standard for colour transmission.
NTSC stands for "National Television Standards Committee".
 PAL: PAL is most common in Europe.
PAL is also used in Australia and in most African and Asian countries (except for Japan). PAL is
common in all countries that do not have NTSC and SECAM.
PAL is an analogue television standard for colour transmission.
PAL is a further development of NTSC. As with NTSC, the TV pictures are transmitted in lines. PAL,
however, evens out colour faults.
PAL stands for "Phase Alternating Line".
 SECAM: SECAM is most common in France and Eastern Europe.
SECAM stands for "Sequentielle Couleur a Memoire", i.e. "sequential colour memory".
Digital television supports data transmission via MPEG.
MPEG stands for "Motion Picture Experts Group". MPEG is the designation of a data compression standard for
image signals.
Transmission Of Image Signals In Vehicle
Image signals are transmitted as follows, depending on equipment fitted:
 E65, E66: Television in front:
Depending on the vehicle's equipment, the video module or the navigation system will transmit the RGB
signals to the control unit for the monitor (CD or SG-FD:
Control Display or rear display control unit):
If a navigation system is fitted, the navigation system will transmit the RGB signals to the monitor
(exception: Japan navigation system)
The red-green-blue image signals are transmitted via the RGB wire.
Signal path: Aerial -> Aerial cable -> Aerial amplifier -> Video module (VM) -> FBAS wire ->
Navigation system (NAV) -> RGB wire -> CD (Control Display).
If there is no navigation system fitted, the video module will transmit the image signal to the monitor as
2006 BMW 650i
 E60, E61, E63, E64: from the video module through the FBAS wire to the Car Communication
Computer (CCC).
A LVDS data wire transmits the image signal between the CCC and the CID (Central Information
Display).
 E65, E66: From the video module through the RGB wire to the Control Display
 Television in front and rear (E65, E66 only)
The navigation system transmits its image data to the video module.
The image signals are transmitted between the SG-FD and rear display through a LVDS data wire.
Image Buildup
E60, E61, E63, E64, E65, E66:
The TV picture is built up as follows:
 Colours are made up of individual red, green and blue pixels.

 The TV picture is built up line by line.
 Synchronisation of image signals: For a sharp TV picture, the pixels must be precisely synchronised. The
synchronisation works as follows:
 Horizontal synchronisation defines when a line ends and a new line starts.
 Vertical synchronisation defines when a new image buildup is to start (in the top left corner.
A separate electrical pulse is provided for synchronisation: The synchronisation pulse. The
synchronisation pulse is transmitted with the green signal (all model series).
Sound Reception
The sound signal is received together with the image signal in the TV signal.
Signal path for sound: Aerial -> Aerial cable -> Aerial amplifier -> Coaxial cable -> Video module -> MOST
bus -> Radio or amplifier (AMP) -> Loudspeakers.
The video module processes the sound for the television.
Sound Output
Sound is output in mono or stereo as follows:
 Analogue TV sound in mono:
The video module receives the analogue TV sound in mono.

2006 BMW 650i
The analogue TV sound is digitalised.
The video module lays the digitalised signal on both the left and right synchronous channel of the MOST
bus.
The ASK or CCC emit the audio signals to the loudspeakers (via the amplifier, depending on equipment
variant).
 Digital TV sound in stereo:
The digital TV sound is received and emitted in stereo.
Precondition: The TV program is transmitted in stereo.
 2-channel sound:
2-channel sound is only available with digital television reception.
2-channel sound allows, for example, a foreign-language broadcast to be overdubbed in English. With 2-
channel sound, the language of the country concerned will be output through the loudspeakers. The other
language will be muted.
Depending on the equipment variant, the loudspeakers are actuated by amplifiers are follows:
 HiFi amplifier
> E60, E61, E63, E64, E65, E66
The HiFi amplifier actuates the woofers. CCC or ASK actuate the mid-range loudspeakers and the
tweeters.
 TOP-HiFi amplifier "Logic 7"
> E60, E61, E63, E64, E65, E66
The TOP-HiFi amplifier actuates all loudspeakers.
Mute
If necessary, sound output can be switched between navigation system and television.
The sound signals from the radio and television are muted under the following conditions:
 Telephone call
 Navigation system announcements
 Traffic reports
2006 BMW 650i
The CCC or the ASK controls the muting.
Station Selection
The video module manages a list of all the television stations that can currently be received.
This list of stations is shown on the Control Display (CD) or Central Information Display (CID) as follows:
 Where station names for individual TV programmes can be determined, the list starts with the station
names arranged in alphanumeric order (e.g. ARD, BR3, SAT1 ...).
 After this, a list will appear showing the reception channels with unknown station names. This list is also
alphanumerically ordered: e.g. CH3, CH7, CH12, ... for Channel 3, Channel 7, Channel 12.
> E65, E66: Front and rear seat television: The list of stations is updated automatically.
> E60, E61, E63, E64 and E65, E66 with television in front: The list of stations is updated manually by
selecting "Autostore".
The list of stations is also updated if another entertainment module is selected (e.g. if you change to the radio or
CD changer). When the television is called up again the current list of stations is offered automatically.
Aerial Diversity
> E65, E66 Only: television in front and rear, analogue and digital
The "aerial diversity" function is only available with 3 TV aerials.
To ensure optimum reception, these 3 TV antennae work as follows:
 2 TV aerials receive the required television station.

 1 TV aerial searches in the background for other transmission frequencies for this television station.
The required television station is received on the transmission frequencies with the highest signal strength.
Aerial diversity works as follows:
If more than one station have the same name when analogue TV is in use, then there are alternative frequencies.
e.g. "Television station 1" is being received on 3 different analogue frequencies. In this case the television
station is displayed just once.
Aerial diversity automatically selects the best frequency. "Television station 1" is shown in the display.
If, however, a television station is transmitting "Television station 1" analogue on several frequencies and "1st
digital" digitally on another frequency, then the display shows the following:
 Aerial diversity combines all frequencies for analogue television.

2006 BMW 650i
The best frequency is selected and displayed. e.g.: "Television station 1".
 However, aerial diversity is not able to combine the following TV stations: Analogue reception for
"Television station 1" and digital reception for the "1st digital".
This is because: The video module cannot assign the two different notations and meanings to one another.
This means "Television station 1" appears twice in the list of stations: Once analogue as "Television station 1"
and once digitally as the "1st digital".
Video Switch
The video module switchers between the various video sources, e.g. between television and video.
This function is called "video switch".
OPERATION
The following operations are described:
 Adjusting screen settings

 Selecting television stations
 Updating list of stations
NOTE: Please comply with instructions in Owner's Handbook.

Detailed instructions for the television can be found in the vehicle's Owner's
Handbook.
Adjusting Screen Settings
Users can adjust the screen settings for colour, contrast and brightness: Call up the corresponding menu (using
the CD and controller on the E65, E66; using the CID and controller on the E60, E61, E63, E64).
The controller controls the monitor settings.
Depending on the equipment specification, the screen setting is processed in the following control units:
 Vehicles with television in the front:
> E60, E61, E63, E64: Car Communication Computer (CCC)
> E65, E66:
For vehicles with a navigation system the screen setting is processed in the control unit for the navigation
system (NAV).
2006 BMW 650i
On vehicles without navigation system, the video module processes the monitor settings.
 Vehicles with rear display (E65, E66 only): The video module processes the monitor settings.
Selecting Television Stations
 Select country
(On the Control Display or Central Information Display; CD on E65, E66; CID on E60, E61, E63, E64):
When a country is selected, the video module will set the correct television standard.
 Select the required television station from the list of stations.
The video module administers a list of stations with all receivable television stations. This list is
displayed on the CD or CID.
Updating List Of Stations
On vehicles with television in the front, the list of stations is manually updated as follows: Call up "Autostore".
SWITCH-ON CONDITIONS
The television is available from terminal R ON.
The following information is available for service staff:
 General information: N/A

 Diagnosis: refer to E60, E61, E63, E64, E65, E66: TELEVISION DIAGNOSIS .
 Encoding/programming: N/A
 Car & Key Memory: The last settings made remain stored when the vehicle is shut down. The video
module remembers the last TV station selected. The colour settings are also stored (in either the video
module or navigation system, depending on equipment variant).
E60, E61, E63, E64, E65, E66: Television Diagnosis
The following information is available for diagnosis on the television:
 Measuring With And Without Adapter

 Check Signal Paths Of FBAS Signal And RGB Signal
 Self-Diagnosis For Aerials And Aerial Amplifiers
Measuring With And Without Adapter

2006 BMW 650i
IMPORTANT: Only connect control units to oscilloscope using adapter. If measurements are
made without an adapter, the voltage values will be twice as high as they would
be with an adapter. The adapter works as a power diplexer.
Measuring Without Adapter
When measuring without an adapter, the second control unit (SG2, e.g. NAV) is disconnected. The signal is
only measured using the resistance R. This means that the signal a voltage that is twice as high as it would be if
measured with an adapter.
The illustration shows a measurement without adapter.

2006 BMW 650i
Fig. 46: Measuring Signal Without Adapter

2006 BMW 650i
2006 BMW 650i
Measuring With Adapter
When measuring with an adapter, the second control unit (SG2, e.g. NAV) remains connected. The signal is
only measured across the parallel circuit of the two resistances R1 and R2. This means that the signal a voltage
that is half that it would be if measured without an adapter.
2006 BMW 650i
Fig. 48: Measuring Signal With Adapter

2006 BMW 650i
Fig. 49: Signal Path Of An FBAS Signal On The Oscilloscope (Measured With An Adapter)
Check Signal Paths of FBAS Signal and RGB Signal

2006 BMW 650i
The following signal paths may differ from the voltage values. However, the path must agree at the points
marked.
Checking FBAS Signal
FBAS signal path:

2006 BMW 650i
Fig. 50: Checking FBAS Signal Path

Composite Video Burst Synchronisation With FBAS, the image signals (red-green-blue) are transmitted via a
2006 BMW 650i
These points are meaningful for the measurement.
Checking RGB Signal
RGB signal path: red-green-blue

2006 BMW 650i
2006 BMW 650i
Fig. 51: Checking RGB Signal Path

With the RGB signal, the image signals are separated according to colour and transmitted through 3 wires:
green, yellow and blue.
The synchronisation pulse for the RGB signals is carried on the green signal. The signal path has 2 important
points. These points are independent of the oscillograph displayed. These points are meaningful for the
measurement.
Self-Diagnosis For Aerials And Aerial Amplifiers
The video module recognises how many aerial amplifiers are fitted in the vehicle.
The video module diagnoses the aerial inputs by measuring the supply voltage and supply current.
With hybrid video modules (VM5 hybrid), each aerial input is diagnosed individually. The range 20 mA to 100
mA is recognised as valid. This means that diagnosis is independent of the different aerial amplifiers and their
supply currents.
The video module recognises the following states:
 Short circuit: In the event of a short circuit, the power supply from the video module to the aerial
amplifier remains switched off until the video module is restarted.
 1 aerial amplifier connected (all other aerial amplifiers failed or electrically disconnected)
 2 aerial amplifiers connected (depending on equipment variant, 3rd aerial amplifier failed or electrically
disconnected)
 3 aerial amplifiers connected (only with analogue and digital television in rear)
The video module recognises the following states as faults:
 The aerial amplifiers draw too little current (less than 20 mA).
 The aerial amplifiers draw too much current (more than 100 mA).
Self-diagnosis cannot be deactivated.
NATIONAL VERSIONS
Digital television is already available in many countries.
There are numerous analogue television standards worldwide. The video module supports these television
standards and frequencies.
NOTE: Subscription TV is not supported.

Because special cards and decoders are needed for subscription TV (pay TV),
2006 BMW 650i
Pay TV is available, for example in the Netherlands and in the UK.

Free TV stations in the UK are supported.
The following details are available with regard to national versions:
 US national version
 Japan national version
 Different switch-off conditions when driving in different national versions
NOTE: The Japan national version is also valid for China and Korea.
The equipment specifications for the Japanese national version also support
television reception in China and Korea.
US National Version
In the US version, the television is deactivated by encoding.
Reason: watching television in cars is forbidden in the USA.
However, a video module is fitted, depending on the equipment. This video module serves as a video switch
between the different entertainment sources (e.g. radio, CD changer).
ANTI-THEFT ALARM SYSTEM E63/E64
NOTE: Refer to AUDIO, NAVIGATION & ANTI-THEFT - SI TECHNIQUES .

2005 BMW 645Ci
2002-05 AUTOMATIC TRANSMISSIONS Servicing - GA6HP26Z
2002-05 AUTOMATIC TRANSMISSIONS
Servicing - GA6HP26Z
APPLICATION
For transmission application, see AUTOMATIC TRANSMISSION APPLICATION table. For transmission
application and oil recommendation, see Fig. 1 -Fig. 3 . Also see LUBRICATION .
AUTOMATIC TRANSMISSION APPLICATION

Application Transmission Model
5-Series (E63)
545Ci (2004-05) GA 6HP26Z
6-Series (E63)
645Ci (2004-05) GA 6HP26Z
7-Series (E65)
745i (11/01 To 2005) GA 6HP26Z
7-Series (E66)
745Li (3/02 To 2005) & 760Li (9/02 To 2005) GA 6HP26Z
X5 (N62)
4.4 L (2004-05) GA 6HP26Z
2005 BMW 645Ci
Fig. 1: BMW Transmission Identification Code (1 Of 2)

2005 BMW 645Ci
Fig. 2: BMW Transmission Identification Code (2 Of 2)

2005 BMW 645Ci
LUBRICATION
NOTE: Transmission is sealed at factory for life of transmission. If any leaks are found,
factory recommends replacing transmission assembly.
SERVICE INTERVALS
Transmission fluid replacement is not necessary, except for some newer model vehicles with Condition Based
Service.
CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION (GA6HP26Z/6HP32Z)
Installation: tighten down filler plug using:
 Hexagon Wrench 8 A/F

 Torque Wrench
 Socket 8 A/F
See Fig. 4 .
Fig. 4: Tightening Filler Plug

2005 BMW 645Ci
Topping Up Transmission Fluid After A Repair
Stand vehicle on a level surface and secure against rolling off. Undo filler plug (1). See Fig. 5 . Upon
installation: replace sealing ring. Top up transmission fluid until it emerges from filling orifice. Start engine.
Replenish transmission fluid until it emerges from filling orifice. Screw in filler plug (1). Tighten to
specification. See TORQUE SPECIFICATIONS . Press brake pedal to floor and shift through gears 1 to 6
several times at idle speed. Then shift to "P" position (Park). Then check fluid level.
Fig. 5: Locating Filler Plug

Checking Fluid Level
Connect BMW Diagnosis and Information System (DIS) or BMW MoDiC to vehicle. Call up Service functions
(drive). Carry out fluid level check in accordance with instructions.
RECOMMENDED FLUID
Transmission fluid has a condition based service interval of approximately 100,000 miles. Never mix any other
oil with this transmission fluid when doing repairs or topping off. Use Shell (M-1375.4), BMW part No. (83 22
0 142 516).
ADJUSTMENTS
ADJUSTING SELECTOR LEVER
2005 BMW 645Ci
NOTE: Numbers in text refer to numbers in figures.
Check cable for ease of movement. More selector lever to "P" setting. Grip clamping sleeve (1). See Fig. 6 .
Slacken nut (2). Press selector lever (3) forwards into park position. Press cable (4) in direction of arrow and
release again. Grip clamping sleeve (1). Tighten nut (2) to 88 INCH lbs. (10 N.m). Move selector lever to "P"
position. Check whether parking lock is engaged by turning propeller shaft.
Fig. 6: Adjusting Selector Lever

REMOVAL & INSTALLATION

REMOVING AND INSTALLING/SEALING OR REPLACING TRANSMISSION SUMP
(GA6HP26Z/6HP32Z)
CAUTION: Remove transmission sump only after it has cooled down. After
completion of work, check transmission fluid level. See
CHECKING/TOPPING UP FLUID LEVEL IN AUTOMATIC TRANSMISSION
(GA6HP26Z/6HP32Z) . Use only the approved transmission fluid. See
RECOMMENDED FLUID . Failure to comply with this requirement will
result in serious damage to the automatic transmission.
2005 BMW 645Ci
1. E65 only: Unfasten screws. Remove transmission underguard (1). See Fig. 7 .
Fig. 7: Removing Transmission Underguard

2. E60/ E63/ E64 only: Remove rear underbody protection.

3. Remove cross-member from exhaust system on transmission (N62 only).
Remove oil drain plug (1). See Fig. 8 . Drain automatic transmission fluid. Catch and dispose of escaping
transmission fluid. Observe country-specific waste-disposal regulations. Upon installation: replace oil drain
plug. Tighten to specification. See TORQUE SPECIFICATIONS .
2005 BMW 645Ci
Fig. 8: Locating Oil Drain Plug

NOTE: GA6HP26Z plastic oil sump version only. From 10/04 new bolt with M6x28.5 T40
Torx head can be retrospectively replaced.
Unscrew all bolts. Remove transmission sump (1). See Fig. 9 . Upon installation: insert screws (2) until screw
heads make contact. Insert all further screws in diagonal sequence from inside to outside until screw heads
make contact. Tighten to specification. See TORQUE SPECIFICATIONS .
2005 BMW 645Ci
Fig. 9: Locating Transmission Sump Bolts

Remove gasket (1) from transmission sump. See Fig. 10 . Clean sealing faces and groove with a cloth. Insert
new gasket in transmission sump groove. DO NOT degrease transmission sump with cleaning agent.
2005 BMW 645Ci
Fig. 10: Removing Gasket From Transmission Sump

Replace sealing ring (1) on oil filter tube. See Fig. 11 .
Fig. 11: Locating Sealing Ring On Oil Filter Tube

Installation: the gasket is correctly installed when it is engaged in the locating opening of the transmission
sump. See Fig. 12 .
2005 BMW 645Ci
Fig. 12: Installing Gasket

REPLACING OUTPUT FLANGE SHAFT SEAL (GA6HP26Z/6HP32Z)
CAUTION: After completion of work, check transmission fluid level. See

Remove complete exhaust system. See REMOVING AND INSTALLING COMPLETE EXHAUST SYSTEM
(N62).
Remove transmission underbody protection (E65 only).
Remove heat shields (1) and (2). See Fig. 13 .

2005 BMW 645Ci
Fig. 13: Removing Heat Shields

Support transmission from underneath: support with Special Tools (24 5 306, 24 5 301) and (00 2 030). See Fig.
14 . Set up Special Tool (24 5 30):
 All supports to "B".

 Supports 3 and 4 are at rear of transmission.
 Support lettering points forwards.
2005 BMW 645Ci
Fig. 14: Supporting Transmission

Release screws (1) and nuts (2) and remove transmission cross-member. See Fig. 15 .
2005 BMW 645Ci
Fig. 15: Removing Transmission Cross-Member

Release screws and remove transmission supporting block from transmission. Illustration shows E65. See Fig.
16 . Upon installation, tighten screws to specification. See TORQUE SPECIFICATIONS .
2005 BMW 645Ci
Fig. 16: Removing Transmission Supporting Block

NOTE: To rotate propeller shaft, unlock parking gear.
Unflange propeller shaft from transmission and tie up to one side. See Fig. 17 .
2005 BMW 645Ci
Fig. 17: Disconnecting/Connecting Joint Disc From Transmission

Grip output flange (1) with Special Tool (23 0 020). See Fig. 18 . Release nut with Special Tool (24 2 380).
Upon installation: replace nut and tighten to specification. See TORQUE SPECIFICATIONS . Secure with a
mandrel (8 mm) by caulking.
2005 BMW 645Ci
Fig. 18: Gripping Output Flange With Special Tool

Detach output flange from output shaft. Remove spacer.
Attach Special Tool (24 2 353) to output shaft (1). See Fig. 19 .
2005 BMW 645Ci
Fig. 19: Attaching Special Tool To Output Shaft

Screw in Special Tool (24 2 351) until it is firmly connected with shaft seal. See Fig. 20 . Pull out radial shaft
seal by screwing in Special Tool (24 2 352).
2005 BMW 645Ci
Fig. 20: Pulling Out Radial Shaft Seal

Oil sealing lip of radial seal (1). See Fig. 21 . Drive in radial seal (1) with Special Tool (24 2 370) as far as it
will go.
Fig. 21: Driving In Radial Seal

REPLACING SELECTOR SHAFT SEAL (GA6HP26Z/6HP32Z)

E65/N62 only: unfasten screws. Remove transmission underguard (1). See Fig. 7 . Remove left oxygen sensor.
See REPLACING LEFT OXYGEN MONITOR SENSOR (N62).
E60/ E63/ E64, N62 only: remove rear underbody protection. Remove left oxygen sensor (N62 only). See
REPLACING LEFT OXYGEN MONITOR SENSOR (N62).
2005 BMW 645Ci
E65 only: Unfasten nut. Remove cable (1). See Fig. 22 . Upon installation: adjusting cable:
 Release nut
 Adjust cable by means of holder (2) Distance A 3 1 mm.
Fig. 22: Removing Cable

E60/ E63/ E64, E53 only: grip clamping sleeve (1) and slacken nut (2). See Fig. 23 . Detach retainer (3) towards
bottom using a screwdriver. Pull cable (4) out of holder. Upon installation, Tighten nut to specification. See
TORQUE SPECIFICATIONS . Adjust selector lever. See ADJUSTING SELECTOR LEVER .
2005 BMW 645Ci
Fig. 23: Detaching Selector Lever Cable

Unscrew screw. Take off holder (1). See Fig. 24 . Illustration shows E65. Upon installation, tighten screw to
specification. See TORQUE SPECIFICATIONS .
2005 BMW 645Ci
Fig. 24: Taking Off Holder

Screw in Special Tool (24 5 361) until it is firmly connected with shaft seal. See Fig. 25 .
2005 BMW 645Ci
Fig. 25: Screwing In Special Tool

Screw Special Tool (24 5 362) onto Special Tool (24 5 361) and tighten down. See Fig. 26 . This pulls the shaft
seal out of the transmission housing.
2005 BMW 645Ci
Fig. 26: Pulling Shaft Seal Out Of Transmission Housing

Oil sealing lip on shaft seal (1). Screw in shaft seal (1) with Special Tools (24 5 366) and (24 5 364) as far as it
will go. See Fig. 27 .
2005 BMW 645Ci
Fig. 27: Screwing In Shaft Seal

REPLACING SEALING SLEEVE FOR TRANSMISSION HOUSING (GA6HP26Z)

Remove exhaust system at manifold and lower. See REMOVING AND INSTALLING COMPLETE
EXHAUST SYSTEM (N62).
Support transmission with hydraulic jack.
Release screws (1) and nuts (2) and remove transmission cross-member. See Fig. 15 .
CAUTION: DO NOT support transmission on transmission fluid sump. Risk of

damage.
Remove transmission sump. See REMOVING AND INSTALLING/SEALING OR REPLACING

2005 BMW 645Ci
TRANSMISSION SUMP (GA6HP26Z/6HP32Z) .
Unlock and disconnect plug (1) by turning. See Fig. 28 .
Fig. 28: Unlocking Plug

Insert Special Tool (24 2 390) in sealing sleeve (1). See Fig. 29 .
2005 BMW 645Ci
Fig. 29: Inserting Special Tool In Seating Sleeve

Unlock sealing sleeve with slide (1). See Fig. 30 .

2005 BMW 645Ci
Fig. 30: Unlocking Sealing Sleeve

Note position of sealing sleeve. Pull out sealing sleeve (1). See Fig. 31 . Upon installation: screw in sealing
sleeve partially (lug in upper area). Turn until lug engages in groove of transmission. Slide in sealing sleeve.
Lug on sealing sleeve must not be damaged.
2005 BMW 645Ci
Fig. 31: Pulling Out Sealing Sleeve

REPLACING A PRESSURE CONTROL VALVE (ELECTRONIC PRESSURE ACTUATOR)

GA6HP26Z
CAUTION: After completion of work, perform "Mechatronic adjustment" service

function using DIS Tester. Check transmission fluid level. See
CAUTION: Risk of damage: Electronics module can be destroyed by electrostatic

charge. Lay mechatronics on Special Tool (12 7 192) (antistatic mat) and
ground. Failure to comply with this instruction will result in serious
damage to electronic components.
Remove mechatronics. See REPLACING MECHATRONICS (GA6HP26Z/6HP32Z) .
NOTE: Tasks are identical for electronic pressure control valves. See Fig. 32 .
2005 BMW 645Ci
Fig. 32: Locating Pressure Actuators

Unlock plug (1) and remove. See Fig. 33 .

2005 BMW 645Ci
Fig. 33: Removing Plug

Release screws (1). See Fig. 34 . Upon installation, tighten screws to specification. See TORQUE
SPECIFICATIONS .
2005 BMW 645Ci
Fig. 34: Locating Screws

Carefully lift electronics module (1) with a suitable tool and remove in direction of arrow. See Fig. 35 .
2005 BMW 645Ci
Fig. 35: Removing Electronics Module

Installation: piston (1) of parking lock cylinder must be attached in slide (2) of selector lever position switch.
See Fig. 36 .
2005 BMW 645Ci
Fig. 36: Locating Piston Of Parking Lock Cylinder

Release screws (1). See Fig. 37 . Remove retaining plate (2) for electronic pressure control valves. Upon
installation, tighten screws to specification. See TORQUE SPECIFICATIONS .
2005 BMW 645Ci
Fig. 37: Removing Retaining Plate For Electronic Pressure Control Valves
Remove electronic pressure control valve (1) in direction of arrow. See Fig. 38 . Note installation position.
Fig. 38: Removing Electronic Pressure Control Valve

REPLACING SOLENOID VALVE SV 1 GA6HP26Z
Tasks are identical for electronic pressure control valves. See REPLACING A PRESSURE CONTROL
VALVE (ELECTRONIC PRESSURE ACTUATOR) GA6HP26Z .
REPLACING MECHATRONICS (GA6HP26Z/6HP32Z)
CAUTION: After completion of work, load specific data version with DIS. Check
transmission fluid level. See CHECKING/TOPPING UP FLUID LEVEL IN
AUTOMATIC TRANSMISSION (GA6HP26Z/6HP32Z) . Use only the approved
transmission fluid. See RECOMMENDED FLUID . Failure to comply with
this requirement will result in serious damage to the automatic
transmission.
E65 only: unfasten nut. See Fig. 22 . Remove cable (1). Upon installation, adjusting cable:
2005 BMW 645Ci
 Release nut
 Adjust cable by means of holder (2) until spacing A = 1 mm is obtained
 Tighten down nut
E60/ E53 only: grip clamping sleeve (1) and slacken nut (2). See Fig. 23 . Detach retainer (3) towards bottom
using a screwdriver. Pull cable (4) out of holder. Upon installation, adjust selector lever. See ADJUSTING
SELECTOR LEVER .
Secure lever (1) with a cable tie (2) or wire in vertical position. See Fig. 39 . Illustration shows E65.
Fig. 39: Securing Lever

CAUTION: Mechatronics can be destroyed by static discharges. Therefore the

contacts inside the plug must not be touched. Insert special tool
immediately after work step.
Unscrew plug (1) and disconnect. See Fig. 28 .
Insert Special Tool (24 2 390) in sealing sleeve (1). See Fig. 29 .
REMOVING AND INSTALLING/SEALING OR REPLACING

2005 BMW 645Ci
TRANSMISSION SUMP (GA6HP26Z/6HP32Z) .
Unlock sealing sleeve with slide (1). See Fig. 30 .
Note position of sealing sleeve. Pull out sealing sleeve (1). See Fig. 31 . Upon installation, screw in sealing
sleeve partially (lug in upper area). Turn until lug engages in groove of transmission. Slide in sealing sleeve.
Lug on sealing sleeve must not be damaged.
Release all screws (1 and 2). See Fig. 40 . 1 = M6 x 58 mm. 2 = M6 x 20 mm. Remove mechatronics.
Fig. 40: Removing Mechatronics

NOTE: Mechatronics without protective bar for solenoid valve must not be reused after
removal. See Fig. 41 .
2005 BMW 645Ci
Fig. 41: Identifying Mechatronics Without Protective Bar

NOTE: Fit/reuse only mechatronics with protective bar (1) for solenoid valve. See Fig.
42 .
2005 BMW 645Ci
Fig. 42: Identifying Mechatronics With Protective Bar

Installation: check gaskets (1 and 2) for damage, replace gaskets if necessary. See Fig. 43 . Coat new seals with
automatic transmission fluid and install.
2005 BMW 645Ci
Fig. 43: Locating Gaskets

CAUTION: Tighten down screws in order. Failure to comply with this requirement will
Installation: insert screws (3) alternately until contact is made with each screw head. See Fig. 44 . Insert all
further screws contact is made with each screw head. Tighten down screws in order 1-10. See Fig. 45 . Tighten
to specification. See TORQUE SPECIFICATIONS .
2005 BMW 645Ci
Fig. 44: Installing Mechatronics

2005 BMW 645Ci
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Double Hexagon Nut/Output Flange 59 (80)
Flexible Disk-To-Propeller Shaft & Transmission Output Flange
M10 8.8 Thread 35 (48)
M10 10.9 Thread 47 (64)
M12 8.8 Thread 66 (90)
Oil Drain Plug 18 (25)
Oil Filler Plug
GA6HP26Z/GA6HP19Z 26 (35)
GA6HP26Z M30x1.5 Thread 59 (80)
Transmission Cross-Member-To-Body 15 (21)
Transmission Mount-To-Transmission/Transmission Cross-Member 14 (19)
Transmission Support Block-To-Transmission 28 (38)
INCH Lbs. (N.m)
Clamping Screw On Shift Lever 89 (10)
Selector Lever On Transmission 89 (10)
Transmission Oil Sump 89 (10)
Valve Body-To-Transmission 71 (8)
2005 BMW 645Ci
AUTOMATIC TRANSMISSION Overview - All Models
AUTOMATIC TRANSMISSION
Overview - All Models
STANDARD/AUTOMATIC TRANSMISSION
In today's modern vehicles, the automatic transmission has become a vital part of the powertrain. Automatic
transmissions provide overall better fuel economy and efficiency while adapting to changing road conditions
and driving habits. Standard transmissions offer more driver interaction with the vehicle, however automatic
transmissions reduce driver fatigue and increase safety by shifting automatically. Automatic transmissions also
offer improved driveability in stop and go traffic. If there is a disadvantage to an automatic transmission, it
would be complexity and cost of manufacturing. See Fig. 1.
2005 BMW 645Ci
Fig. 1: Standard & Automatic Transmission Comparison

HYDRAULIC TRANSMISSION VS. ELECTRO-HYDRAULIC TRANSMISSION

Since the introduction of the automatic transmission there have been numerous refinements to improve shift
comfort as well as fuel economy. Early automatic transmissions used only hydraulic control, there was no
electronic intervention. In 1986 BMW introduced their first EH (Electro-Hydraulic) transmission into
production vehicles. The acronym EGS is used by BMW for its electronic transmission control system. EGS
stands for "Electronic Transmission Control" which comes from the German words "Elektronisch Getriebe
Steurung". In order to comply with SAE terminology we will refer to the EGS control module as the TCM
2005 BMW 645Ci
"Transmission Control Module". EH controlled transmissions allow for optimized shift points by closely
monitoring changing conditions. Engine speed, road speed and throttle angle are some of the inputs that are
monitored by the TCM to determine optimal shift points. The TCM will then process this information and
control shift point via electronic solenoids mounted on the valve body. With the introduction of Adaptive
Transmission Control, shift comfort and fuel economy was further improved. The TCM now monitors throttle
angle deviations, wheel speeds and CAN Bus information to fine tune shift points. See Fig. 2.
Fig. 2: Electronic Transmission Control System

TRANSMISSION IDENTIFICATION
BMW automatic transmissions are manufactured by two suppliers for the US market:
 Zahnradfabrik Friedrichshafen: Commonly referred to as ZF. ZF manufactures both manual and

automatic transmissions.
 GM Powertrain - Hydramatic: Hydramatic is a manufacturing division of General Motors located in
Strasbourg France. Hydramatic supplies automatic transmissions to BMW for four and six-cylinder
vehicles.
BMW has developed an internal numbering system for their transmissions for parts ordering, information
research and identification. Also, each manufacturer uses their own internal identification system. Here is a
2005 BMW 645Ci
Fig. 3: Transmission Code Breakdown

TRANSMISSION HYDRAULICS
TRANSMISSION FLUID (OIL)
The automatic transmission provides pressure regulated hydraulic fluid which is filtered for all of the
transmissions functional requirements. See Fig. 4. All BMW automatic transmissions are designed to operate
with specific fluids. Use of non-approved oil will cause malfunctions and irreparable transmission damage
which is not covered by BMW warranty. The transmission fluid provides the following functions:
 Lubricates mechanical components (planetary gears, bearings etc.).

 Removes heat and transfers heat to transmission cooling system. (heat exchanger).
 Removes debris and contaminants to sump and filter when circulated.
 Provides a transfer of kinetic energy in the torque converter.
 Allows hydraulic operation of mechanical components (clutches, brakes) via control of the valve body.
2005 BMW 645Ci
Also, transmission fluid has various properties to prevent oxidation and breakdown from heat and friction. Each
type of transmission fluid has properties specific for each transmission application. Fluid level is crucial in the
proper operation of an automatic transmission. Improper fluid levels will cause improper operation and
eventually irreparable transmission damage. Improper fluid level can cause:
 A low fluid level can cause an interruption in oil flow during fast acceleration or hard braking which can
cause gear shift malfunctions.
 An excessively high fluid level can cause the rotating mechanical components to paddle in the oil. This
produces foam which introduces air into the hydraulic system.
 A low fluid level can also cause transmission overheating causing premature transmission failure.
Fig. 4: Identifying Transmission Hydraulics

TRANSMISSION FLUID APPLICATION
There are numerous types of transmission fluid used in BMW transmissions. With the exception of the early
transmissions (4HP22/24, A4S310/270R and the A5S310Z) all current BMW transmissions use "Lifetime Fill"
transmission fluid. There is no maintenance required for these transmissions. It is important to use the correct
fluid. Incorrect use of the transmission fluid can cause non-warrantable transmission damage.
When performing repairs on transmissions with lifetime fluid, it is important to drain the transmission fluid in to
a clean container for re-use. New fluid should only be used for transmission replacement and for topping off
after repairs.
Also, transmission fluid level is vital to the proper operation of the transmission. See Fig. 5.
2005 BMW 645Ci
Fig. 5: Transmission Fluid Application

TORQUE CONVERTER
In standard transmissions the crankshaft is linked to the transmission input shaft via the clutch assembly. Power
flows from the crankshaft through the flywheel. The pressure plate transfers power to the clutch disc which is
splined to the transmission input shaft. The pressure plate is used to disconnect (or interrupt) power flow to the
transmission input shaft. Because the engine is mechanically connected to the driveline, power flow must be
interrupted when the vehicle is stationary. Otherwise the engine would stall. In automatic transmissions, there is
a fluid coupling between the engine and transmission. This fluid coupling is more commonly referred to as the
torque converter. In the torque converter there is no rigid connection between the engine and transmission
(except for lock up clutch). In order to understand the operation of the torque converter, we must first start with
the components. The breakdown of the components are as follows:
 The Impeller, which is rigidly connected to the torque converter housing.

 The Turbine, which is splined to the input shaft (turbine shaft) of the transmission.
2005 BMW 645Ci
 The Stator, which has a one-way clutch. The inner race of the one-way clutch is splined to a stationary
shaft attached to the transmission. See Fig. 6.
The addition of the stator allows the fluid coupling to be referred to as a torque converter. The stator provides
for a multiplication of torque at low speeds. Without the stator there would be no multiplication of torque.
2005 BMW 645Ci
Fig. 6: Identifying Impeller, Turbine & Stator

When the engine is running, the impeller which is directly connected to the converter housing, rotates at engine
2005 BMW 645Ci
speed. Fluid is directed from the impeller blades to the turbine blades. The fluid drives the turbine which is
splined to the input (turbine) shaft of the transmission. This functions the same way as a waterfall acting on a
paddle wheel. The ratio of the impeller speed to turbine speed is approximately 1.1 to 1. This ratio is improved
to 1:1 with the addition of the torque converter clutch which is discussed later.
Torque Converter Operation At Low Speeds
1. At low engine speeds there is a large difference in rotational speed between the impeller and the turbine
2. Fluid flow is directed from the impeller to the turbine. Fluid strikes the vanes of the turbine. The turbine
is driven forward in the direction of engine rotation.
3. Fluid flow is then directed back towards the impeller.
4. Before the fluid reaches the impeller, the fluid strikes the vanes of the stator.
5. When the fluid strikes the stator, the one way clutch prevents the stator from rotating.
6. The fluid is then re-directed by the curved vanes of the stator. The fluid is now flowing in the same
direction as the impeller.
7. The fluid that is acting on the impeller increases the force on the impeller which multiplies torque. See
Fig. 7.
2005 BMW 645Ci
Fig. 7: Torque Converter Operation At Low Speed

Torque Converter Operation at High Speed

2005 BMW 645Ci
1. As engine speed increases, the turbine speed approaches the speed of the impeller.
2. The fluid flow is directed from the turbine to the back side of the impeller blades.
3. The one-way clutch in the stator unlocks and the stator blades turn in the direction of engine rotation.
4. Fluid is no longer re-directed and torque multiplication no longer takes place.
5. This is referred to as "Coupling Speed". The turbine never reaches the same speed as the impeller as fluid
flow would come to a halt. Ratio is approximately 1.1 to 1. See Fig. 8.
2005 BMW 645Ci
Fig. 8: Torque Converter Operation At High Speed

Torque Converter Clutch

2005 BMW 645Ci
Since the efficiency of the torque converter at coupling speed is approximately 1.1 to 1, fuel economy is
compromised. To offset this a torque converter clutch was added on EH controlled transmissions. The torque
converter clutch locks the turbine to the converter housing. This creates a mechanical coupling with a ratio of
1:1. This can only be achieved at higher engine speeds. The torque converter clutch must be disengaged at low
engine speeds to prevent stalling. There are two methods for controlling the torque converter clutch on BMW
transmissions:
 A4S310/270R, 4HP22/24 EH, A5S310Z - These transmission use an on/off control method to lock and
unlock the torque converter. The TCC is either completely engaged or completely disengaged. This
method of engagement provides an abrupt sensation when the TCC is locking and unlocking. This abrupt
sensation can be unpleasant and undesirable to some drivers.
 A5S560Z, A5S440Z, A5S325Z, GA6HP26Z,A5S360/390R - These transmissions use a gradual approach
to TCC control. The TCC is gradually applied and released, this method reduces the abrupt feel of the
on/off type TCC. The TCC solenoid is controlled by pulse width modulation. This allows fluid to be
gradually introduced and released to the TCC.
The TCC is spring loaded to the engaged position. Pressurized fluid releases the TCC, when the pressurized
fluid is released, the TCC is engaged. Depending on transmission application, the TCC can be engaged in 3rd,
4th or 5th gear. The TCC must be disengaged at low speeds to prevent stalling. See Fig. 9 and Fig. 10 .
Fig. 9: Identifying TCC Operation

2005 BMW 645Ci
Fig. 10: TCC Oil Control Circuit

2005 BMW 645Ci
OIL PUMP
The transmission oil pump is used to circulate oil and provide pressure for hydraulic operation. The pump is
driven by the torque converter shell and rotates with engine. Fluid is drawn from the sump through the filter and
distributed to the various transmission hydraulic systems. The output pressure is regulated to an operating
pressure of approximately 25 bar. Currently there are two types of oil pumps used in BMW transmissions:
Crescent type and Vane type. See Fig. 11.
Fig. 11: Locating Oil Pump

Crescent Type Oil Pump (All except A5S360/390R)
The crescent type is an internal gear pump containing a drive gear and a driven gear. The inner gear is driven by
2005 BMW 645Ci
teeth varies from the input, through the crescent and to the output of the pump. A low pressure area is created
on the input side of the pump by the widening gap between the gear teeth. The oil is drawn to the crescent and
transferred to the output side of the pump, where the pressure is increased by the narrowing gap between the
gear teeth. The output pressure of the pump is controlled by spring loaded pressure regulator. See Fig. 12.
Fig. 12: Identifying Crescent Type Oil Pump

Oil Volume Control
On the A5S440Z transmission, oil pump output volume is controlled based on engine RPM. High oil volume is
initially required at start up to quickly fill the transmission requirements. As engine RPM increases, the volume
is greater than is required. The Oil Volume Control Damper regulates the pump output volume based on engine
RPM. This helps improve fuel economy by reducing the load on the engine at high RPM.
Vane Type Pump (A5S360/390R)
The new A5S360/390R (GM5) transmission uses a vane type pump. See Fig. 13. The torque converter drives
2005 BMW 645Ci
the pump rotor and 13 vanes. The rotor and vanes are placed inside a slide mechanism. As the rotor spins, the
vanes sweep oil from the pump intake to the output along the mating surface on the vane ends and the interior
surface of the slide. The slide is mounted on a pivot pin. As it pivots, it changes the eccentricity of the rotor to
slide mating surface. This in turn will alter the output oil volume. This provides the same function as the Oil
Control Volume Damper on the A5S440Z. The slide's position is influenced by a calibrated spring and
hydraulic control pressure from the main pressure regulator solenoid on the valve body. See Fig. 14. The benefit
of changing the slide position is to optimize pump output volume to meet the following operating conditions:
 Provide maximum volume during engine start-up. This condition provides a fast priming action of the
pump for immediate lubrication and for hydraulic pressure operation.
 Regulated output volume at higher engine speeds. Maximum pump volume is not required at all times.
Fig. 13: Identifying Vane-Type Pump

2005 BMW 645Ci
Fig. 14: Rotary Vane Pump Slide Adjustment

HYDRAULIC CONTROL COMPONENTS
Electro/Hydraulic Valve Body
The valve body assembly is the main shift control element in the transmission. In non-EH transmissions the
valve body was only hydraulically controlled. In the current EH (electrohydraulic) transmissions the valve body
is similar in design, but now also housing a number of shift solenoids which are controlled by the TCM. The
valve body consists of a number of sub-assemblies. Each sub-assembly contains a number of spool valves
which are hydraulically controlled. Most spool valves are opposed by spring pressure. The spool valves are used
to direct hydraulic fluid flow to the various shift elements in the transmission. There is also a manual valve
which is connected to the shift assembly by a cable. The manual valve allows the drivers to select the basic
operating mode (or ratio). See Fig. 15. The valve body is responsible for the following:
2005 BMW 645Ci
 Controlling fluid flow to shift elements for Upshifts and Downshifts.

 Providing for manual operation by driver via manual valve.
 Reverse Lockout.
 Failsafe Operation.
 Shift Comfort through: Overlap Shift Control (ZF) Pressure Accumulators (GM).
 Torque Converter Control.
 Distribution of lubrication.
Fig. 15: Identifying Electro/Hydraulic Valve Body Components

Shift Valves
Shift valves are used to direct application pressure to the various shift elements. Shift valves are regulated by
spring pressure and control pressure for the shift solenoids. Shift valves come in various configurations
depending upon application and transmission type. The most basic is the 3/2 shift valve. The 3/2 shift valve has
2 positions which are switched through one or two control pressures.
2005 BMW 645Ci
With no control pressure from shift solenoid present, the shift valve is moved to its end travel (left) by spring
pressure. Operating pressure is blocked to the shift component. Also in this position any application pressure is
drained from the shift component. See Fig. 16.
Once the control pressure is applied to the 3/2 shift valve, the shift valve moves to the right. This allows
operating pressure to reach the shift component. When the control pressure is again reduced, spring pressure
returns the 3/2 shift valve to the rest position. This drains and operating pressure from the shift component. See
Fig. 17.
Operating Pressure to Shift Component. The example shown is a 4/2 shift valve. The operation is similar to the
3/2 valve. The primary difference is that the 4/2 shift valve affects 2 shift components. See Fig. 18.
Fig. 16: Shift Valve Operation (1 Of 3)

2005 BMW 645Ci

2005 BMW 645Ci

Pressure Regulation
Pressurized oil from the pump must be regulated for use within the transmission. Otherwise, the high pressure
directly from the pump would influence shift quality. The shifts would be more abrupt and harsh. In order to
"fine tune" the pressures within the transmission, there is a pressure regulating valve and a pressure regulating
solenoid. The pressure regulating valve is located in the oil pump housing or the valve body dependent upon
transmission type. The pressure regulating solenoid is a pulse width modulated (PWM) solenoid. Current is
controlled by the TCM. The pressure regulating solenoid is normally closed, there is maximum line pressure
available when minimum (or no) current is applied to the pressure regulating solenoid. Depending upon
application, pressure regulating solenoid can be PWM with B- or B+ control. GM transmissions use B+ control
with a constant ground supply. ZF transmissions uses B- control with a constant B+ supply.
There are also pressure regulators used in ZF transmissions that are used to control shift pressures. The
A5S440Z and A5S560Z both use EDS solenoids for "Overlap Shift Control" this will be explained later in this
text. There are a few different names for pressure regulating solenoids depending upon the transmission type
and manufacturer:
 ZF transmissions use the following terms - EDS solenoid (valve), or MV (magnetic valve).
 Hydramatic (GM) transmissions use the following terms: DR solenoid, Force Motor Solenoid or Variable
Bleed Solenoid.
Transmission operating pressures are regulated based on engine speed, throttle angle and engine load. The
regulated pressure from the pressure regulating solenoid is referred to as throttle pressure. This pressure is fed to
the main pressure regulating valve. See Fig. 19.
2005 BMW 645Ci
Fig. 19: Identifying Transmission Operating Pressure

Pressure Regulation
As the diagram shows, regulating valve pressure is fed to the pressure regulating solenoid. See Fig. 20. This
pressure is then regulated to create throttle pressure. Throttle pressure is modified based on throttle angle,
engine speed and engine load. Throttle pressure is then fed to the pressure regulating valve. As throttle pressure
increases, the regulating valve piston is moved to the left (with respect to the diagram). As the regulating valve
piston is moved to the left , operating pressure is increased to the 4/2 shift valve. The operating pressure to the
4/2 shift valve will be fed to Shift Component A or Shift Component B depending the position on the 4/2 shift
valve. The operating pressure to the shift components will be increased or decreased depending upon the
throttle valve pressure. As engine speed and load are increased, the operating pressure will be increased to
provide higher clamping forces on the shift components. When there is no electrical power present to the
pressure regulator solenoid, throttle pressure will be a maximum. Therefore maximum operating pressure will
be available at the 4/2 shift valve. This condition would exist if the transmission was operating in failsafe mode.
2005 BMW 645Ci
Fig. 20: Identifying Transmission Regulation Pressure

APPLY COMPONENTS
Multi - Plate Clutches and Brakes
Multi Plate Clutches and Brakes are used to drive or hold members of the planetary gear set. See Fig. 21. As a
general rule, Multi Plate Clutches connect one planetary member to another. Multi Plate Brakes connect a
planetary member to the case to hold it stationary. The clutches and brakes consist of a number of friction discs
and steel discs. The friction discs are coated with a friction material and have engaging lugs (splines) on the
inner perimeter. The steel discs are steel on both sides and have engaging lugs located on the outer perimeter.
The engaging lugs on the friction discs are usually engaged with a planetary member. The engaging lugs on the
steel discs are usually engaged with the clutch piston housing. In addition to the friction and steel discs, there is
also an apply piston, housing and return spring. Once hydraulic fluid is applied to the clutch assembly, the
friction discs and steel discs will be locked together. Once hydraulic pressure is released, the return spring will
cause the clutch piston to return to its rest position which will unlock the clutch assembly. See Fig. 22.
2005 BMW 645Ci
Fig. 21: Identifying Multi-Plate Clutches & Brakes

Fig. 22: Multi-Plate Clutch Identification

2005 BMW 645Ci
In order to carry out a shift in ratio, fluid needs to be applied or released from the Multi - Plate Clutch (or
Brake). As shown in the example at the right, the following sequence occurs:
1. Fluid from a shift valve in the valve body is applied to the clutch assembly.
2. Fluid pressure builds behind the apply piston and overcomes the resistance from the diaphragm spring.
3. The friction and steel discs are compressed together and become locked, preventing any slippage between
them.
4. Two planetary members are now locked together.
5. When fluid pressure is released, the steel and friction discs are allowed to unlock.
6. The diaphragm spring pushes against the apply piston and returns the piston back to the rest position.
7. The check ball in the apply piston is unseated by centrifugal force which allows the clutch to drain
completely. See Fig. 23.
Fig. 23: Multi-Plate Clutch Operation

BAND BRAKES
On some BMW transmissions there is a band type brake used for some applications. The A4S270/310R and the
A5S310Z use a band type brake. The brake band is a circular band with friction material bonded to the inner
surface. The band wraps around a particular planetary component (clutch drum) and locks that component to the
2005 BMW 645Ci
transmission case. The brake band is applied and released by the clutch apply piston. The brake band is not
adjustable on the A5S310Z, however there is some adjustment allowed when needed on the A4S270/310R. The
brake band functions in the following manner on BMW transmissions:
 A4S270/310R - The brake band is active (applied) in first and second gear. The brake band holds the
reaction sun drum stationary. The reaction sun drum is splined to the reaction sun gear.
 A5S310Z - The brake band is active (applied) in second, third and fifth gear. The brake band holds the
forward sun gear to the case. See Fig. 24.
Fig. 24: Identifying Band Brake Operation

ONE-WAY CLUTCHES (FREEWHEEL)
The one way clutch consists of an inner and outer ring with a locking device between the two. The one way
clutch is designed to lock in one direction and to allow free rotation in the other direction. See Fig. 25.
Currently there are two types of one way clutches used in BMW transmissions:
 Roller type which consists of spring loaded rollers between the inner and outer race of the one way
clutch. (Roller type is also used without springs on some applications).
 Sprag type which consists of asymmetrical shaped wedges located between the inner and outer race of the
one way clutch.
2005 BMW 645Ci
In both versions of the one way clutch (freewheel), rotation is only allowed in one direction. Using the diagrams
above, imagine that the inner races were locked stationary. The outer race would only be allowed to turn
counter clock wise. In the clock wise direction, the outer race of both versions would be locked. In the roller
type, the helper springs would push the rollers up the ramp on the outer race. This would force the rollers in to
the smaller area which would cause the outer race to lock, In the sprag type, the asymmetrical wedges would
lock between the inner and outer race. The one way clutches are used in the transmission to prevent an
interruption of drive torque during certain gear shifts and to allow engine braking during coasting. Also there is
a one way clutch in the stator of the torque converter.
Fig. 25: Identifying One-Way Clutches

PLANETARY GEAR SET
Planetary gear seats are compact gear units that receive input drive torque and provide the required output ratios
for all forward gears and reverse gear. The planetary gear set consists of four main components:
1. Internal ring gear.

2. Planetary gears (pinions).
3. Sun gear.
4. Planetary gear carrier.
Various ratios are obtained by driving or holding different components in the planetary gear set. The example
shown is a simple planetary gear set. See Fig. 26. Today's modern transmissions use a combination of multiple
planetary gear sets referred to as a compound planetary gear set.
2005 BMW 645Ci
Fig. 26: Identifying Planetary Gear Set

Advantages of Planetary Design
There are distinct advantages to the planetary gear set in comparison with a standard transmission gear set.
Primarily, drive torque does not need to be interrupted to change gears. The planetary members are in constant
mesh and there are more teeth engaged in any given ratio. This allows more torque to be transferred through the
transmission.
Basic Power Flow Example
As an example of power flow in reverse gear, planetary gear carrier (4) is held stationary. The sun gear (3) is
driven in a clockwise direction. The planetary pinions (2) are driven counterclockwise, which in turn drives the
2005 BMW 645Ci
internal ring gear (1) counter clockwise as well. See Fig. 27.
Fig. 27: Identifying Basic Power Flow

Compound Planetary Gear Sets
Compound planetary gear sets use multiple planetary components which are a variation on the simple planetary
gear set. Since the inception of the simple planetary gear set, there have been numerous compound gear sets
introduced. BMW transmissions use the following gear sets:
 Simpson Gear Set - used on 4HP22 and 4HP24.

 Ravigneax Gear Set - used on A4S270R, A4S310R, A5S310Z, A5S325Z, A5S360R and A5S390R.
 Wilson Gear Set - used on A5S440Z and A5S560Z.
 Lepelletier Gear Set - used on the GA6HP26Z.
2005 BMW 645Ci
Simpson Gear Set
The Simpson Gear Set is one of the early variations on the simple set. It is capable of 3 forward gears and one
reverse. On BMW transmissions, the Simpson Gear set is used in the 4HP transmission which is a four speed
automatic. See Fig. 28. Fourth gear (overdrive) is obtained by the addition of an auxiliary gear set (simple).
Characteristics of the Simpson Gear set are as follows:
 Two Internal Ring Gears, one rear input ring and one attached to the rear planetary carrier.
 Two Planetary carriers, each containing three planetary pinions.
 One common Sun gear, which meshes with both sets of planetary pinions.
Fig. 28: Identifying Simpson Gear Set

Ravigneaux Gear Set
A new version on the planetary design is the Ravigneaux gear set. See Fig. 29. This gear set is capable of 4
forward gears and one reverse. However, depending upon application it may be used with an auxiliary gear set.
Here are some examples:
 The A4S310/270R uses the Ravigneax set for 3 forward gears and one reverse. Overdrive is obtained by
2005 BMW 645Ci
the auxiliary gear set.

 The A5S310Z uses a combination of the Ravigneaux gear set and the auxiliary gear set to obtain 5
forward gear and one reverse. First, second and reverse gears are achieved by using a combination of both
gear sets.
 The A5S360/390R uses a modified version of the Ravigneaux set that provides five forward gears and
one reverse. There is no auxiliary gear set used.
Fig. 29: Identifying Ravigneaux Gear Set

Characteristics of the Ravigneaux Gear Set are:
 One planetary carrier which is common to both sets of planetary pinions.

 Two sets of planetary pinions, one long set with small diameter and one short set with large diameter.
 Two sun gears, one input sun gear and one reaction sun gear.
 One common ring gear.
NOTE: The Ravigneaux Gear Set shown in the figure is a typical representation.
There are a few variations of this arrangement used on BMW
transmissions.
2005 BMW 645Ci
On BMW transmissions, the Wilson gear set is only used on the A5S440Z and A5S560Z. See Fig. 30. The
Wilson Gear Set consists of three planetary gear sets. The ring gear of the first gear set, the planetary carrier of
the second gear set and the ring gear of the third planetary gear set and directly connected to the "Pot". The
"Pot" is a cylindrical device that slides over all of the components to unitize the individual gear sets into an
assembly. The characteristics of the Wilson Gear Set are:
 Three planetary carriers.

 Three ring gears, with ring gear 1 and 3 meshed to "Pot" assembly.
 Three sun gears, sun gear 2 and 3 are common (attached). Sun gears 2 and 3 are also referred to as the
"Double Sun Gear".
Fig. 30: Identifying Wilson Gear Set

Lepelletier Gear Set
The Lepelletier Gear Set was introduced to BMW on the ZF GA6HP26Z. See Fig. 31. This gear set allows for 6
forward speeds and one reverse gear using a light weight design. The planetary gear train consists of a single
carrier planetary gear train and a downstream double planetary gear train.
2005 BMW 645Ci
Fig. 31: Identifying Lepelletier Gear Set

Planetary Gear Set Operation
In order to understand planetary gear set operation, it is important to understand some basic rules of operation:
 It is assumed that engine rotation is clockwise when referring to power flow charts and diagrams.
 Planetary pinions will always rotate in the same direction as the internal ring gear.
2005 BMW 645Ci
will rotate counter clockwise (reverse gear).

 When two or more planetary members are locked together, the assembly will rotate together. The ratio
from input to output is 1:1.
 When the sun gear is held stationary and the planetary carrier is driven clockwise, the ring gear will be
driven clockwise in an overdrive ratio (.75:1)
When trying to understand power flow schematics, it is important to be able to draw a comparison between the
actual planetary components and the schematic symbols. The diagram below outlines the relationship between
these components and the power flow schematic. The schematic is a representation of a cross section of the
transmission, but you only see the top half of the cross section. The transmission is shown as though it has been
quartered lengthwise. See Fig. 32.
Fig. 32: Identifying Gear Set Operation

POWER FLOW SCHEMATIC
In order to understand power flow schematics, a relationship must be drawn between the actual components and
the schematic representation. This example uses the 4HP22/24 power flow schematic. The 4HP22/24
transmission uses a Simpson Planetary Gearset and an auxiliary gearset. The auxiliary gear set is a simple
planetary gearset. See Fig. 33.
2005 BMW 645Ci
Fig. 33: Identifying Power Flow Schematic

Power Flow In First Gear
Drive torque is applied to the torque converter impeller and transferred to the turbine. The turbine shaft rotates
clockwise (CW). The "A" clutch locks the turbine shaft to the rear input ring gear. The rear input ring gear
rotates CW driving the rear planet pinions CW. The planetary pinions drive the common sun gear CCW, which
in turn drive the front planet pinions CW. The front planetary carrier is held from rotating CCW by one way
2005 BMW 645Ci
planetary carrier is rotating CW and is driving the planetary carrier from the auxiliary gear set. The "E" clutch
in the auxiliary gear set is holding the Sun gear and the ring gear together. Therefore the auxiliary gear set is
locked in a 1:1 ratio. See Fig. 34.
One Way Clutch "J" is locked to prevent the front planetary carrier from rotating CCW. One Way Clutch "H" is
not used and One Way Clutch "K" is locked. One way clutch "K" is used to prevent an interruption in power
flow before the "E" clutch is locked during the 4-3 shift. See Fig. 35.
Fig. 34: Power Flow Schematic In First Gear

2005 BMW 645Ci
Fig. 35: Power Flow In First Gear

Second Gear
Drive torque is applied to the torque converter impeller and transferred to the turbine. See Fig. 36. The turbine
shaft rotates clockwise (CW). The "A" clutch locks the turbine shaft to the rear input ring gear. The rear input
ring gear rotates CW driving the rear planet pinions CW. The sun gear is held stationary by the C' clutch. The
rear planet pinions rotate around the fixed sun gear CW. The rear planetary carrier will rotate CW. The rear
planetary carrier will drive the auxiliary gear set and will rotate as a complete unit. The auxiliary gear set is
locked in a 1:1 ratio due to the "E" clutch locking the sun and ring gear together. The "C" clutch is locking the
outer race of the "H" freewheel to the case. This is used for the 3/2 downshift. Freewheel "J" is not active and
Freewheel "K" is locked.
2005 BMW 645Ci
Fig. 36: Power Flow Schematic In Second Gear

Third Gear
shaft rotates clockwise (CW). The "A" clutch and the "B" clutch are locked, this causes the rear input ring gear
to be locked to the sun gear in the Simpson Gear set. The Simpson gear set is locked in a 1:1 ratio. The "E"
clutch is locked which locks the ring gear to the sun gear in the Simpson gear set. The entire transmission
planetary system is now locked in a 1:1 ratio. Freewheel "H" is overrun and freewheel "J" is not used.
Freewheel "K" continues to be locked.
Fig. 37: Power Flow Schematic In Third Gear

Fourth Gear
shaft rotates clockwise (CW). (The turbine shaft can also be driven by the lock up clutch when engaged). The
"A" clutch and the "B" clutch are locked, this causes the rear input ring gear to be locked to the sun gear in the
2005 BMW 645Ci
gear in the auxiliary gear set to the case. The Simpson gear set drives the planetary carrier CW. The planet
pinions walk around the fixed sun gear in a CW direction. This causes the ring gear to rotate CW as well. The
ring gear, which is the output of the transmission is driven in an overdrive ratio. Freewheel "H" and "K" are
overrun. Freewheel "J" is not used.
Fig. 38: Power Flow Schematic In Fourth Gear

Reverse Gear
shaft rotates clockwise (CW). The "B" clutch is locked which drives the sun gear in the Simpson gear set CW.
The sun gear drives the planet pinions CCW. The planetary carrier is held stationary by the "D" clutch. The
planet pinions cause the front ring gear to rotate CCW. The front ring gear (and rear carrier) drive the auxiliary
gear set CCW which rotates at a ratio of 1:1 due to the "E" clutch locking the sun and ring gear of the auxiliary
gear set. Freewheel "H" and "J" are not used. Freewheel "K" is locked.
Fig. 39: Power Flow Schematic In Reverse Gear

SHIFT CONTROL
2005 BMW 645Ci
Freewheel Shifting
In order to prevent an interruption in power flow, freewheel (One Way Clutches) are used to lock members of
the planetary gear set. Certain transmissions such as the 4HP22/24, A4S270/310R and the A5S360R use
freewheel shifting on all gear shifts. Transmissions such as A5S310Z, A5S440Z, A5S560Z and GA6HP26Z use
freewheel shifting for only specific shifts. Other shifts in these transmissions use overlap shifting technology.
To demonstrate how the freewheel is used, the freewheel "H" in the 4HP22/24 transmission will be examined.
In third gear, the sun gear is rotating clockwise. Freewheel "H" is overrun (unlocked) allowing the sun gear to
rotate. Clutch "C" is active which locks the outer race of freewheel "H" to the case. During a 3/2 downshift,
clutch "B" is released. The sun gear is held from rotating counter clockwise by freewheel "H" and the "C"
clutch. Freewheel "H" is used to stop the counter clockwise rotation of the sun gear before the "C" clutch can
engage. This prevents an interruption of power flow during the 3/2 downshift. If freewheel "H" fails to operate,
there would be an increase in engine RPM from 3rd to 2nd gear. See Fig. 40 and Fig. 41 .
Fig. 40: Freewheel Shifting (Second Gear)

Fig. 41: Freewheel Shifting (Third Gear)

Overlap Shift Control

2005 BMW 645Ci
GA6HP26Z use overlap shift technology on most gear changes. The advantages of this design allows for the
reduction of the use of One Way Clutches (freewheel) and a significant improvement in shift quality. During an
overlap shift, the releasing clutch pressure is reduced at the same rate that the engaging clutch pressure is
increased. The result is a smooth transfer or torque between gear ratios.
As shown in the diagram, clutch 1 is fully engaged with maximum pressure. Clutch 2 is fully released. During
overlap shifting, the TCM closely monitors the rotational speeds of the turbine (input) shaft and output shaft.
The TCM then uses the EDS solenoids to control pressures during shifting to provide the optimum shift timing
and overlap control. See Fig. 42.
Fig. 42: Identifying Overlap Shift Control

Overlap Shifting
During the transition of overlap, the clutches run through a slip zone. The torque is gradually transferred from
the clutch that is releasing to the clutch that is engaging. The new gear engages the moment the torque level
exceeds that of the first clutch. This is described as overlap. If the overlap is correct, (zero overlap) the engaging
clutch takes over as much torque as the disengaging clutch releases. The result is a seemingly unnoticed shift of
the best quality. See Fig. 43 and Fig. 44 .
2005 BMW 645Ci
Fig. 43: Identifying Overlap Shifting (Clutch 1 Engaged)

2005 BMW 645Ci
Fig. 44: Identifying Overlap Shifting (Clutch 1 Disengaged)

Negative Overlap
Negative overlap occurs when the engaging clutch takes over too late or the releasing clutch drops pressure too
early. The result is that the drive torque is briefly interrupted. When the engine is operating under load, the
engine speed increases due to the interruption. When coasting the engine speed drops. See Fig. 45.
Fig. 45: Identifying Negative Overlap

Positive Overlap
If positive overlap occurs, the engaging clutch takes over too early or the releasing clutch pressure drops too
late. The gear set would become momentarily blocked if this condition occurs during an upshift. When this
occurs the ratio of the gear set becomes 1:1 momentarily. The result is a loss in drive torque during a gear shift.
See Fig. 46.
2005 BMW 645Ci
Fig. 46: Identifying Positive Overlap

TRANSMISSION CONTROL MODULE

The TCM receives inputs, processes information and actuates the output elements to provide optimal shift
points. The TCM is programmed for maximum shift comfort and fuel economy. The TCM on most BMW
vehicles is located in the E-Box next to the ECM (DME). There are several types of TCM housings:
 35 Pin TCM (TCU) - used on the 4HP transmissions.

 55 Pin TCM used on the A4S310R (THM-R1).
 88 Pin TCM used on all others up to 98.
 134 Pin TCM used on all BMW transmission from the 99 model year. (Note- the 134 pin TCM was
introduced on the 98 Models equipped with the A5S440Z).
The 134 Pin TCM is also referred to as SKE (Standard Shell Construction). The SKE housing uses 5 separate
connectors. On transmission applications only three connectors (1, 3 and 4) are used. Connectors 2 and 5 are
blank and are NOT used. The connectors are Blue in color to avoid confusion with the ECM (DME) connectors
which are Black. See Fig. 47.
2005 BMW 645Ci
Fig. 47: Identifying Transmission Control Modules & Connectors

2005 BMW 645Ci
2004-05 AUTOMATIC TRANSMISSION Removal & Installation - 545i & 645Ci (6HP26Z/N62)
2004-05 AUTOMATIC TRANSMISSION
Removal & Installation - 545i & 645Ci (6HP26Z/N62)
IDENTIFICATION
NOTE: For further information, see AUTOMATIC TRANSMISSION article.
VEHICLE IDENTIFICATION
Model (Chassis Code) Engine Size (Code)
2004-05
545i (E60) 4.4 L (N62)
645Ci (E63) 4.4 L (N62)
CAUTION: Disconnecting vehicle battery will cancel fault codes of control units. On
vehicles with radio codes, after disconnecting battery, radio codes must
be re-entered. Obtain radio code card from customer. Note stored stations
and restore then after connecting battery. Also, where applicable, initialize
sunroof and set steering angle.
CAUTION: 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. Catch and dispose properly escaping
transmission fluid.
NOTE: For filling and servicing, see SERVICING - A/T .
Removal
1. Disconnect battery. See INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY.

2. Remove underbody protection at front and rear.
3. Remove reinforcement plate.
4. Remove exhaust system after catalytic converter. See REMOVING AND INSTALLING COMPLETE
5. Remove heat shields (1) and (2). See Fig. 1 .
6. Detach plug (1) from speed sensor. See Fig. 2 . Release screw (2) and remove speed sensor.
2005 BMW 645Ci
7. Detach plug (1) from oil level sensor and unclip cable from fixtures. See Fig. 3 .
8. Detach plug (1) and unclip cable duct (3) from transmission housing. See Fig. 4 . Tie wiring harness to
one side.
9. Grip clamping sleeve (1). See Fig. 5 . Slacken selector lever nut (2). Detach retainer (3) towards bottom
using a screwdriver. Pull cable (4) out of holder.
10. Support transmission. Support with Special Tools (24 5 306, 24 5 301) and (00 2 030). See Fig. 6 . Set up
Special Tool (24 5 306):
 All supports to "B".
 Supports 3 and 4 are at rear of transmission.
 Support lettering points forwards.
11. Release screws (1) and nuts (2) and remove transmission cross-member. See Fig. 7 .
12. Remove propeller shaft and tie to one side. See REMOVING AND INSTALLING COMPLETE
PROPELLER SHAFT.
13. Unlock and disconnect mechatronics control module plug (1) by turning. See Fig. 8 . Release cable from
retainers. Insert Special Tool (24 2 390) in sealing sleeve. Mechatronics can be destroyed by static
discharges. Contacts inside plug must not be touched. Insert Special Tool (24 2 390) immediately in
sealing sleeve (1). See Fig. 9 .
14. Unscrew bolt (1). See Fig. 10 . Disconnect hydraulic lines (2) to transmission fluid cooler.
15. Crank engine at vibration damper in direction of rotation until screw is visible in opening. See Fig. 11 .
Release all screws of torque converter with Special Tool (24 1 110). Crank engine further and release
remaining 3 screws.
16. Prepare Special Tool (24 4 161) (1) with shaped piece (24 4 164) (2). See Fig. 12 . Shaped piece (24 4
163) (3) is not required.
17. Insert Special Tool (24 4 1601) into opening of transmission housing and clamp gently with screw (1).
See Fig. 13 . Twist in screw (2) and clamp down. Then tighten down screw (1).
18. Unfasten screws of transmission-to-engine. See Fig. 14 .
2005 BMW 645Ci

2005 BMW 645Ci
Fig. 2: Detaching Speed Sensor Plug

2005 BMW 645Ci
Fig. 3: Detaching Oil Level Sensor Plug

2005 BMW 645Ci
Fig. 4: Detaching Transmission Housing Plug

2005 BMW 645Ci
Fig. 5: Detaching Selector Lever Cable

2005 BMW 645Ci

2005 BMW 645Ci

2005 BMW 645Ci

2005 BMW 645Ci
Fig. 9: Inserting Special Tool In Seating Sleeve

2005 BMW 645Ci
Fig. 10: Disconnecting Transmission Fluid Cooler Lines

2005 BMW 645Ci
Fig. 11: Releasing Torque Converter Screws

2005 BMW 645Ci
Fig. 12: Preparing Special Tool (24 4 161)

2005 BMW 645Ci
Fig. 13: Inserting Special Tool (24 4 160)

2005 BMW 645Ci
Fig. 14: Locating Transmission-To-Engine Screws

Installation
CAUTION: Oil cooler and lines must always be flushed before a replacement
transmission is installed.
CAUTION: When joining up engine and transmission, ensure ease of movement of

torque converter.
2005 BMW 645Ci
1. To install, reverse removal procedure. If replacing transmission, fit shift lever, bracket for cable and
retainers for oxygen sensor cable from old transmission to new transmission.
2. Bore (1) in driving disk must be accessible from opening on engine oil pan. See Fig. 15 .
3. Check that dowel sleeves are correctly seated. See Fig. 16 . Replace damaged dowel sleeves.
4. Rotate torque converter until bore in torque converter is flush with bore in driving disk. Flange automatic
transmission to engine. See Fig. 14 . Tighten transmission-to-engine screws to specification. See
TORQUE SPECIFICATIONS .
5. Tighten torque converter-to-flywheel screws to specification. See Fig. 11 . See TORQUE
SPECIFICATIONS .
6. Replace sealing rings on hydraulic lines. See Fig. 10 .
7. Install propeller shaft. See REMOVING AND INSTALLING COMPLETE PROPELLER SHAFT.
8. Install transmission cross-member. See . Tighten fasteners to specification. See TORQUE
SPECIFICATIONS .
9. Grip clamping sleeve (1). See Fig. 17 . Slacken nut (2). Press selector lever (3) forwards into park
position. Press cable (4) in direction of arrow and release again. Grip clamping sleeve (1) and tighten nut
(2) to specification. See TORQUE SPECIFICATIONS .
10. To install reinforcement plate, torque screws to specification. See TORQUE SPECIFICATIONS .
11. After completion of work, check transmission fluid level. Top up if necessary.
2005 BMW 645Ci
Fig. 15: Locating Bore In Drive Plate

2005 BMW 645Ci
Fig. 16: Checking Dowel Sleeves

2005 BMW 645Ci

Center Mount-To-Body 15 (21)
Driveshaft-To-Drive Flange (Rear Axle)
Version, Universal Joint: Compression Nut 47 (64)
Version, Universal Joint: Torx Bolt 63 (85)
Version, Constant-Velocity Joint: Torx Bolt E60 52 (70)
Version, Constant-Velocity Joint: Compression Nut M8 Thread 24 (32)
Compression Nut M10 Thread 47 (64)
Finned Nut M8 Thread 32 (43)
Finned Nut M10 Thread 52 (70)
Flexible Disk-To-Front Axle Differential 44 (60)
Flexible Disk-To-Propeller Shaft & Transmission Output Flange (Aluminum)
Flexible Disk-To-Transmission Output Flange (100)
2005 BMW 645Ci
M12 10.9 Thread 66 (90)

M10 10.9 Thread 47 (64)
Flexible Disk-To-Propeller Shaft & Transmission Output Flange (Steel)
M10 8.8 Thread 35 (48)
M10 10.9 Thread 47 (64)
M12 8.8 Thread 66 (90)
Reinforcement Plate-To-Front Axle Support/Engine Carrier
Step 1 41 (56)
Step 2 Additional 90°
Step 3 Additional 15°
Torque Converter-To-Flywheel 33 (45)
Transmission Cross-Member-To-Body 15 (21)
Transmission Mount-To-Transmission/Transmission Cross-Member 15 (21)
Transmission-To-Engine
Hex Screws
M8 Thread 18 (24)
M10 Thread 33 (45)
M12 Thread 60 (82)
Torx Bolts
M8 Thread 15 (21)
M10 Thread 31 (42)
M12 Thread 53 (72)
INCH Lbs. (N.m)
2006 BMW 650i
SUSPENSION Rear - 650i, M6
SUSPENSION
Rear - 650i, M6
00 GENERAL
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.
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!

2006 BMW 650i
 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 ... ... RAISING VEHICLE WITH TROLLEY JACK

2006 BMW 650i
IMPORTANT: Observe the following trolley-jack-related instructions:
1. Use only BMW-distributed/approved trolley jacks which have rubber plate

contact points.
2. Trolley jacks must be regularly serviced and always checked for
functional reliability before they are used!
3. Check the rubber plate on the trolley jack prior to each use, replacing if
necessary.
Fig. 1: Identifying Trolley Jack

WARNING: The vehicle may be raised with a trolley jack only at the following jacking
points!
1. Car jacking point

2. Side car jacking points
3. Rear differential
Risk of damage: It is not permitted to raise the vehicle at the rear

differential cover!
2006 BMW 650i
Fig. 2: Identifying Side Car Jacking Points

33 ... . REAR AXLE LAYOUT

2006 BMW 650i
Fig. 3: Identifying Rear Axle Components

33 00 ... INFORMATION ON REPLACING SHOCK ABSORBERS
Facts:
When a shock absorber is faulty on one side (leaking, noises, limit values exceeded on the shock tester), often
both shock absorbers on the axle in question are replaced.
E32, E34, E38, E39 : In the case of rear spring struts with ride-height control, there is always a slight oil
spillage on the piston rod. These spring struts are permitted to be wet with oil over a maximum of half the shock
absorber length on the outer tube, i.e. they are permitted to "sweat".
Consequence:
2006 BMW 650i
This is not necessary for technical reasons and causes the manufacturer not to recognize the unnecessarily
removed shock absorbers as damaged parts. Unnecessarily high costs for the customer can be avoided by
replacing the shock absorber on one side only.
Procedure:
Shock absorbers may be replaced on one side only until they have completed 50 000 km service.
Exception : On all M-models, when a limit value is exceeded on one side, it is still necessary always to replace
both shock absorbers on the relevant axle.
33 00 ... INSTRUCTIONS (CHASSIS COMPONENTS MADE OF ALUMINUM)
Due to the chemical and corrosion characteristics of aluminum, always comply with the following points when
handling aluminum components:
 Do not bring into contact with battery acid!

 Do not clean with wire brushes made of brass or iron! Always use wire brushes with stainless steel
bristles!
 Do not expose to flying sparks when grinding/separating! Cover components!
 Do not strike with steel welding splashes! Cover components!
 Do not expose to temperatures > 80 °C, even for brief periods! Temperatures in paint facilities do not
have the same impact
33 00 ... NOTES ON REPAIRING THREADS
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.
2006 BMW 650i
Fig. 4: Helicoil Thread Insert

33 00 ... REAR AXLE: 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:

 Swinging arm, front/rear, to rear axle carrier
 Swinging arm to integral link / wheel carrier
 Integral link to wheel carrier
 Guide arm to rear axle carrier
 Control arm to rear axle carrier
 Replacement of following parts:

1. Rear axle carrier
2. Swinging arm
2006 BMW 650i
3. Integral link
4. Wheel carrier / ball joint
5. Control arm
6. Guide arm
33 10 ... OVERVIEW OF REAR DIFFERENTIAL/OUTPUT SHAFTS
Fig. 6: Rear Differential/Output Shafts

33 31 ... OVERVIEW OF REAR AXLE CARRIER WITH RUBBER MOUNTS

2006 BMW 650i
Fig. 7: Rear Axle Carrier With Rubber Mounts

33 32 ... OVERVIEW OF STEERING LINKS

2006 BMW 650i
Fig. 8: Steering Links

10 FINAL DRIVE
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.
Undo oil filler plug (1).
Check oil level.
If necessary, pour in rear differential oil up to lower edge of opening for oil filler plug (1). See OPERATING
FLUIDS - REAR AXLE .
2006 BMW 650i
Fig. 9: Identifying Oil Filler Plug

Installation:
A. Oil filler plug with sealing ring:
Replace sealing ring (1).
Tightening torque: 33 11 3AZ . See 11-REAR DIFFERENTIAL CASE WITH COVER .
B. Oil filler plug with O-ring:
Replace oil filler plug (2).
Fig. 10: Identifying Oil Filler Plug And Sealing Ring

2006 BMW 650i

approved transmission oils in the 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. See
OPERATING FLUIDS - REAR AXLE .
Recycling:
Catch and dispose of emerging differential oil.
Observe country-specific waste-disposal regulations
Oil drain plug present:
Place oil collecting apparatus underneath.
Remove oil drain plug (1).
Drain and dispose of differential oil.
Add differential oil up to lower edge of opening for oil filler plug (2). Refer to REAR AXLE - TECHNICAL
DATA .
Fig. 11: Identifying Oil Drain Plug And Oil Filler Plug
Installation:
2006 BMW 650i
A. Oil drain or oil filler plug with sealing ring:
Tightening torque 33 11 3AZ . See 11-REAR DIFFERENTIAL CASE WITH COVER .
B. Oil drain or oil filler plug with O-ring:
Replace oil drain or oil filler plug (2).
Fig. 12: Identifying Sealing Ring And Oil Filler Plug

No oil drain plug:
Add differential oil up to lower edge of opening for oil filler plug (1).
2006 BMW 650i

Installation:

2006 BMW 650i
REAR DIFFERENTIAL MODEL SERIES REFERENCE

Model series Engine Rear differential Remark
E63 N52 188L / 188LW
N62, N62TU 215K
S85 215 with lock
E64 N52 188L / 188LW
N62, N62TU 215K
K Compact
L Light-running
LW Light-running, efficiency-optimized
33 10 010 REMOVING AND INSTALLING/REPLACING REAR DIFFERENTIAL
 33 4 420 See REAR AXLE - SPECIAL TOOLS .
IMPORTANT: Use only approved rear differential oils !

M5, M6: After the running-in phase of 2000 km, it is essential to carry out a rear
differential oil change . See REAR AXLE - OPERATING FLUIDS .
 Remove propeller shaft from rear differential . See 11 PROPELLER SHAFT ASSEMBLY .
 Remove output shaft from rear differential at both ends and tie back.
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.
To avoid grinding noises, make sure the dust plates are not damaged (e.g.
bent).
2006 BMW 650i
Fig. 15: Identifying Special Tool 33 4 420

Unfasten screws.

If necessary, unclip scavenging air line and screw off bracket.
Release nut and pull out screw towards rear.
Slowly lower workshop jack and remove rear differential towards rear.
2006 BMW 650i
Fig. 17: Locating Nut

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.
Installation sequence:
1. Install rear differential with workshop jack and special tool 33 4 420 . See BRAKES - SPECIAL
TOOLS .
2. Insert bolts (1) (do not tighten down)
3. Insert bolt (2), replace and screw on nut (do not tighten down).
4. Lower workshop jack and place to one side
5. Tighten down screws (1)
Tightening torque 33 17 1AZ . See 17-FINAL DRIVE MOUNTING .
6. Tighten down screw (2)

2006 BMW 650i
Fig. 18: Identifying Bolts

After installation:
 Check rear differential oil level , correct if necessary
11 FINAL DRIVE WITH COVER

33 11 ... REPLACING REAR COVER GASKET ON REAR DIFFERENTIAL (188L / 188LW)
IMPORTANT: To avoid leaks from the rear differential cover, do not use a paper gasket in
cars with liquid gaskets!
To prevent the differential oil from foaming over, make sure that no remnants
of the liquid gasket are pressed into the rear differential housing.
Release screws (1).
Tightening torque (M10x60) 33 11 1AZ . See 11-REAR DIFFERENTIAL CASE WITH COVER .
Unscrew screws (2).
Remove cover.
If necessary, remove remnants of liquid gasket with scraper.
Clean sealing face on cover and rear differential.
Installation:
2006 BMW 650i
Fig. 19: Identifying Screws

33 11 ... REPLACING REAR COVER GASKET ON REAR DIFFERENTIAL (215K)
Release screw (1).
Unscrew screws (2).
Remove cover.
Installation:
If a paper gasket was fitted, a paper or liquid gasket can be used.

2006 BMW 650i

33 11 ... REPLACING REAR COVER GASKET ON REAR DIFFERENTIAL (215 WITH LOCK)
Release screws (1). Tightening torque, see (M10x82) 33 11 1AZ in 33 11 REAR DIFFERENTIAL CASE
WITH COVER . Remove cover (2). 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.
Fig. 21: Identifying Rear Cover Gasket Differential Screws


2006 BMW 650i
Unscrew screws (1) and (2). Tightening torque, see (M10x75) 33 11 1AZ in 11-FINED DRIVE WITH
COVER . Tightening torque (M10x25), see 33 11 1AZ in 11-FINED DRIVE WITH COVER .
Remove cover. If necessary, remove remnants of liquid gasket with scraper. Clean sealing face on cover and
rear differential.
Installation: If a paper gasket was fitted, a paper or liquid gasket can be used.
Fig. 22: Unscrew Screws (1) And (2)

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
2006 BMW 650i
TOOLS .
 33 1 150
 33 1 341
 33 3 440
 33 3 470
 33 3 480
IMPORTANT: Use only approved gear oils .

Failure to comply with this instruction will result in serious damage to the rear
differential!
See OPERATING FLUIDS - REAR AXLE .
 Remove propeller shaft from rear differential drive flange , remove complete propeller shaft if necessary.
See 11 PROPELLER SHAFT ASSEMBLY .
Removing drive flange:
Lift out retaining plate.
Mark position of collar nut (1) on drive shaft with peening tool.
Fig. 23: Identifying Collar Nut On Drive Shaft

Brace drive flange with special tool 23 0 020 and release collar nut.
2006 BMW 650i

NOTE: Read and comply with document Rear differential: Assignment to model series .
215K / with lock:
Remove drive flange with special tools 31 2 101 , 31 2 102 , 31 2 103 / 31 2 104 .
Fig. 25: Identifying Special Tools

188K/L:
Remove drive flange with special tool 33 1 150 .

2006 BMW 650i

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.
 188K/L: Use special tools 00 5 500 and 33 3 470

 215K / with lock: Use special tools 00 5 500 and 33 3 440
2006 BMW 650i

Installing drive flange:
Coat sealing lips of shaft seal and sealing surface of drive flange with differential oil. See OPERATING
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.
2006 BMW 650i
Fig. 30: Identifying Collar Nut

Drive in new retaining plate with following special tools (depending on rear differential ) as far as it will go.

Fig. 31: Identifying Special Tool 00 5 500, 33 3 480 And 33 3 490

After installation:
 Only for rear differentials 188K to 215K / with lock: Change rear differential oil . See OPERATING
 Only for rear differential 188L: Correct rear differential fluid level
33 11 091 REPLACING DRIVE FLANGE ON LEFT OR RIGHT OF REAR DIFFERENTIAL
WARNING: Risk of burning on the exhaust system!

2006 BMW 650i
IMPORTANT: When replacing the drive flange, you must also replace the shaft seal!
 Remove output shaft from rear differential and tie back. See 33 21 000 Removing and
installing/replacing left or right output shaft.
Drive out drive flange.
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.
IMPORTANT: High installation forces indicate that the spline teeth on the drive
flange/differential bevel gear are damaged/deformed!
Check spline teeth, replaced damaged parts.
Fig. 32: Driving Out Drive Flange

Install retaining ring (1).
Installation:
Clean shaft seal race on drive flange thoroughly.
Coat drive flange at contact face of shaft seal with approved rear differential oil . See OPERATING FLUIDS -
REAR AXLE .
2006 BMW 650i
Fig. 33: Identifying Retaining Ring

Replacement:
Replace shaft seal .
After installation:
 Correct gearbox oil level/change differential oil . See OPERATING FLUIDS - REAR AXLE .
33 11 151 REPLACING SHAFT SEAL FOR DRIVE FLANGE LEFT OR RIGHT
 00 5 010
 00 5 500
 32 1 060
 33 1 308
 33 3 400
 33 4 240
 33 4 250
 33 5 030 . Many special tools are identified in illustrations. Also see REAR AXLE - SPECIAL
TOOLS .
 Remove drive flange from rear differential

 If necessary, press off dust cover
Withdraw shaft seal with special tools 00 5 010 and 32 1 060 / 33 1 308 .
2006 BMW 650i

Coat housing plate flange and sealing lips of new shaft seal with approved rear differential oil . See
Drive in new shaft seal as far as it will go with following special tool(s) (depending on rear differential /outside
diameter).
00 5 500 + 33 3 400 : 168K/L - 78x44x10
00 5 500 + 33 4 240 : 188K/L/LW - 90x44x10
00 5 500 + 33 4 250 : 215K/L/LW, 220K to 230K - 100x50x10
33 5 030 : 210, 215 with lock - 76x50x10

2006 BMW 650i
After installation:
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 or draw off rear differential oil

 Remove Rear Differential
NOTE: Read and comply with document Rear differential: Assignment To Model
Series .
Select rear differential:
 188L / 188LW
 215K
 215 with lock
After installation:
 Add rear differential oil . See OPERATING FLUIDS - REAR AXLE .
17 FINAL DRIVE MOUNTING

33 17 004 REPLACING ALL FRONT RUBBER MOUNTS FOR REAR DIFFERENTIAL MOUNTING
 33 3 312
 33 4 161
 33 4 162
 33 4 166
 33 4 311
 33 4 312
 33 4 465
2006 BMW 650i
Withdraw front rubber mount with special tools 33 3 312 , 33 4 161 , 33 4 162 , 33 4 466 and 33 4 465 .
NOTE: Milled recess of special tool 33 4 161 must point upwards to rear axle carrier.

IMPORTANT: Coat bearing bushing in rear axle carrier and new rubber mount with Circolight.
Align rubber mount by way of slots (1) to vehicle transversal direction.
Fig. 37: Identifying Slots

Insert rubber mount in special tool 33 4 311 .
NOTE: Align rubber mount so that side slots (1) line up with marking (M) on special
2006 BMW 650i

Draw in rubber mount with special tools 33 4 465 , 33 4 466 , 33 4 166 , 33 4 311 and 33 4 312 as far as it will
go.

33 17 004 REPLACING ALL RUBBER MOUNTS FOR REAR DIFFERENTIAL MOUNTINGS AT

FRONT (M6)
 33 3 312
 33 4 161
 33 4 162
 33 4 466
2006 BMW 650i
Withdraw rubber mount with special tools 33 3 312, 33 4 161, 33 4 162, 33 4 466 and 33 4 465.
Fig. 40: Withdraw Rubber Mount With Special Tools

IMPORTANT: Coat bearing bushing in rear axle carrier and rubber mount with Circolight
Fig. 41: Align Rubber Mount By Way Of Slots (1) To Vehicle Transversal Direction
Draw in rubber mount with special tools 33 4 465, 33 4 466, 33 4 166 and 33 4 461 as far as it will go.
2006 BMW 650i
Fig. 42: Draw In Rubber Mount With Special Tools

33 17 005 REPLACING RUBBER MOUNT FOR REAR DIFFERENTIAL MOUNTING AT REAR
 33 4 281
 33 4 282
 33 4 283
 33 4 284
 33 4 465
Withdraw rubber mount with special tools 33 4 282 , 33 4 281 , 33 4 466 , 33 4 465 and nut (1).
2006 BMW 650i
Fig. 43: Identifying Special Tool 33 4 281, 33 4 282, 33 4 466 And 33 4 465
Align rubber mount by way of elongated hole (1) to vehicle transversal direction.
Fig. 44: Identifying Elongated Hole

Push new rubber mount (1) into special tool 33 4 283 .
Align rubber mount (1) by way of elongated hole to vehicle transversal direction.
Draw in rubber mount with special tools 33 4 282 , 33 4 283 , 33 4 284 , 33 4 466 , 33 4 465 and nut (2) as far
as it will go.
2006 BMW 650i
Fig. 45: Installing Rubber Mount With Special Tools


(M6)
 33 4 281
 33 4 282
 33 4 283
 33 4 284
 33 4 465
IMPORTANT: Do not draw rear PUR mount as far as it will go into special tool 33 4 281.
Withdraw rear PUR mount with special tools 33 4 282 , 33 4 281 , 33 4 466 , 33 4 465 and nut (1).
2006 BMW 650i
Fig. 46: Withdraw Rear PUR Mount With Special Tools

Disassemble special tools. Withdraw rear PUR mount with the aid of a vice from special tool 33 4 281.
IMPORTANT: Coat bearing bushing in rear axle carrier and new rear PUR mount (1) with
Circolight
Install rear PUR mount (1) in special tool 33 2 182.
Fig. 47: Install Rear PUR Mount (1) In Special Tool

Draw in rear PUR mount (1) with special tools 33 4 181, 33 2 182, 33 4 284, 33 4 466 and 33 4 465 as far as it
will go.
2006 BMW 650i
Fig. 48: Draw In Rear PUR Mount (1) With Special Tools
21 OUTPUT SHAFTS
33 21 ... PRESSING OUTPUT SHAFT OUT OF DRIVE FLANGE AND DRAWING IN (OUTPUT
SHAFT REMOVED FROM REAR DIFFERENTIAL)
 33 2 111
 33 2 115
 33 2 116
 33 2 117
 33 2 118
 33 2 119
 33 2 160
 33 2 201
 33 2 202
 33 2 203
 33 2 205
 33 2 206
 33 2 207
WARNING: Risk of injury!

It is not permitted to use the impact screwdriver to press out and draw in
the output shaft.
2006 BMW 650i

To avoid damaging the output shaft and adjoining parts, it is essential during
the pressing-out process to repeatedly check and if necessary correct the
position of the output shaft.
IMPORTANT: To avoid damaging the dust sleeve, use special tool 33 2 160 to press out and
draw in the output shaft after removing the brake disk.
NOTE: Rounded inside edge of special tool 33 2 160 must point to drive flange.

Special tool 33 2 200:
Secure output shaft against falling out.
Screw on special tool 33 2 203 , 33 2 207 and 33 2 201 with all wheel studs to drive flange.
Press output shaft out of drive flange; in so doing, grip basic body 33 2 201 with special tools 33 2 202 and 33 5
070 .
2006 BMW 650i

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.
Fig. 51: Identifying Special Tool 33 2 205 And 33 2 206

Mount special tool 33 2 201 with three wheel studs to drive flange.
Draw in output shaft with special tool 33 2 205 up to stop; in so doing, grip basic body 33 2 201 with special
tools 33 2 202 and 33 5 070 .
2006 BMW 650i

070 .


2006 BMW 650i

tools 33 2 202 and 33 5 070 .

33 21 ... RIBBED TEETH
IMPORTANT: Bolts with ribbed teeth must be replaced after they have been released!
2006 BMW 650i
Fig. 56: Identifying Ribbed Teeth Of Bolt

33 21 000 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT OUTPUT SHAFT
WARNING: Scalding hazard!

Only perform the following tasks after the vehicle has cooled down.
Apply handbrake.
Remove rear wheel .
Unscrew collar nut.
Installation:
Replace collar nut, apply a light coating of oil to contact surface and tighten down.
Tightening torque 33 41 3AZ , see 41 WHEEL BEARING .
Secure collar nut by peening on flat areas of output shaft.

2006 BMW 650i
Fig. 57: Locating Collar Nut

Remove exhaust system . See EXHAUST SYSTEM - REPAIR INSTRUCTIONS
Release bolts and remove with washers (1).
Force output shaft off drive flange with a suitable tool.
Installation:
Before installing output shaft, make sure that drive flange is fully engaged in rear differential.
Replace bolts and washers (1).
Tightening torque 33 21 1AZ . See 21-OUTPUT SHAFTS .
Fig. 58: Locating Bolts And Washers

2006 BMW 650i
Press output shaft (1) out of drive flange and remove towards centre of car.
Fig. 59: Identifying Output Shaft

After installation:
 Check that output shaft is correctly seated in rear differential.
33 21 000 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT OUTPUT SHAFT (M6)
Remove rear wheel.
Release collar nut, activate handbrake for this purpose.
Fig. 60: Release Collar Nut

Installation: Replace collar nut, oil collar nut/wheel bearing contact surface lightly and tighten down.
2006 BMW 650i
No oil permitted on thread of shaft journal or collar nut. Tightening torque 33 41 3AZ, see 41 WHEEL
BEARING . Secure collar nut by positive peening on flat areas of output shaft.
Remove exhaust system. E64: Remove rear left or right tension strut.
Release bolts and remove with washers (1). Force output shaft off drive flange with a suitable tool.
Installation: Before installing output shaft, make sure that drive flange is fully engaged in rear differential.
Replace bolts and washers (1). Tightening torque, see 33 21 1AZ in 21-OUTPUT SHAFTS .
Fig. 61: Release Bolts And Remove With Washers

Remove stabilizer link from swinging arm. Remove spring strut shock absorber from wheel carrier.
Raise wheel carrier for feeding output shaft out and in with workshop jack approx. 20 mm.
Fig. 62: Raise Wheel Carrier For Feeding Output Shaft Out And In With Workshop Jack
2006 BMW 650i
Do not drive output shaft out of drive flange with an impact tool.
Press output shaft out of drive flange and remove towards centre of vehicle.
After installation: Check that output shaft is correctly seated in rear differential.
33 21 071 REPLACING BOTH GAITERS ON LEFT AND RIGHT OF OUTPUT SHAFT
 21 2 120
 26 1 110
 33 2 100 . See REAR AXLE - SPECIAL TOOLS .
 Remove output shaft from rear differential at both ends.
Clean output shaft.
Press off sealing cap (1).
Installation:
Press on sealing cap with a thrust ring
Coat sealing faces of sealing cap with sealing compound.
Fig. 63: Removing Sealing Cap

2006 BMW 650i
Press cap (3) off together with gaiter.
Remove circlip (4).
Installation:
Turn new gaiter with cap (3) so that fastener of large hose clamp is between two bores of constant-velocity
joint.
Fig. 64: Identifying Hose Clip, Cap And Circlip

Special tool 26 1 110 must be used in accordance with diameter of output shaft. Bearing inner race must rest on
rib of special tool.
Hollow shaft only: Also use special tool 21 2 120 .
Press splined shaft out of constant-velocity joint.
Clean constant-velocity joint carefully and remove all traces of old grease.
Check constant-velocity joint for damage, replace if necessary.
Detach gaiter from splined shaft.

2006 BMW 650i

Installation:
Pull gaiter onto cap (3).
Coat sealing surface of cap (3) with sealing compound and press with a thrust ring onto constant-velocity joint.
Fill constant-velocity joint with high-temperature grease.
Install new circlip.
Press constant-velocity joint and cap (3) over inner bearing race on splined shaft.
Mount special tool 33 2 100 with corresponding insert. See REAR AXLE - SPECIAL TOOLS .
Push new gaiter onto splined shaft.
Fig. 66: Identifying Cap And Special Tool 33 2 100

2006 BMW 650i
Release hose clamps (5, 6).
Clean joint carefully and remove all traces of old grease.
Installation:
Pull new gaiter on.
Thoroughly clean joint while assembled and remove old grease completely.
Fig. 67: Detaching Gaiter From Splined Shaft

Disassembling/assembling constant-velocity joint:
NOTE: Mark positions of ball hub, ball cage and joint with respect to each other with
electric inscriber.
Ensure all parts are clean prior to assembly.
2006 BMW 650i
31 REAR SUB-FRAME
33 31 000 REMOVING AND INSTALLING COMPLETE REAR AXLE CARRIER
 00 2 030
 00 2 040
 33 4 232
 33 4 233 . Special tools are identified in illustrations. Also see REAR AXLE - SPECIAL TOOLS .
IMPORTANT: Adhere to the utmost cleanliness. Do not allow any dirt to enter the hydraulic
system.
Seal off pipe connections with plugs.
 Remove brake disc on both sides . See BRAKES - REPAIR INSTRUCTIONS .

 Disconnect handbrake cable on both sides of wheel brake and remove from hanging hook. See BRAKES
- REPAIR INSTRUCTIONS .
 Remove propeller shaft from rear differential and tie back or remove completely if necessary. See 11
PROPELLER SHAFT ASSEMBLY .
 E64 M6: Remove rear left and right tension struts.
 E64 except M6: Remove cross strut.
 Detach plug connection for pulse generator on both sides and expose line up to control arm
 Detach plug connection for brake pad wear sensor on right and expose line up to control arm
 If necessary, disconnect plug connection from ride-height sensor
 Remove Spring Strut Shock Absorber On Both Sides From Wheel Carrier .


Insert special tools 33 4 233 and 33 4 232 into corresponding mountings of special tool 00 2 040 .
2006 BMW 650i
Support rear axle carrier by raising special tool 00 2 030 .
Version with Dynamic Drive:
Disconnect pressure lines at point of separation II and seal with plugs. See 37 13 100 REMOVING AND
INSTALLING/REPLACING PRESSURE LINES FOR OSCILLATING MOTOR/FRONT AXLE .
Remove tension struts.
Release screws (1) and remove stop plate (2).
Lower rear axle carrier (3).
Installation:
Check threads for damage; if necessary, repair with Helicoil thread inserts .
First install tension struts and then tighten down bolts (1).
Tightening torque 33 33 3AZ , see 33-AXLE MOUNTING .

2006 BMW 650i
Fig. 70: Identifying Stop Plate And Rear Axle Carrier

After installation:
 Version with Dynamic Drive:

 Fill and bleed hydraulic system . See 32 13 006 BLEEDING POWER STEERING (VERSION
WITH DYNAMIC DRIVE) .
 Check pipe connections for leaks
 If necessary, carry out initial Dynamic Drive operation . See 37 10 001 INITIAL OPERATION
WITH TEST RUN OF DYNAMIC DRIVE .
 Adjust handbrake . See 34 10 014 ADJUSTING HANDBRAKE .
33 31 011 REPLACING REAR AXLE CARRIER
system.
Close off pipe connections with plugs.

 Remove complete rear axle carrier and if necessary with other workers assisting set down on a suitable
surface. See 33 31 503 Lowering/raising rear axle carrier.
 Version with Dynamic Drive: Disconnect pressure lines for oscillating motor of rear axle from rear axle
carrier. See 13 CONNECTING LINES .
 Remove both stabilizer links from stabilizer . See 33 55 040 Replacing stabilizer links for stabilizer.
 Remove stabilizer from rear axle carrier.
 Remove ride-height sensor with holder from rear axle carrier . See 37 14 512 REPLACING REAR
RIDE-HEIGHT SENSOR .
2006 BMW 650i
Remove swinging arm on both sides from rear axle carrier . See 33 32 064 Removing And
Installing/Replacing Left Or Right Swinging Arm.
Remove control arm on both sides from rear axle carrier . See 33 32 071 Replacing one upper control arm.
Remove guide arm on both sides from rear axle carrier . See 33 32 091 Replacing a guide arm.
Remove wheel carrier on both sides with output shaft, swinging arm and suspension arms.
Fig. 71: Identifying Rear Axle Carrier

After installation:


 Perform chassis alignment check . See 00 ELECTRONIC CHASSIS ALIGNMENT .
 If necessary, carry out initial Dynamic Drive operation . See 37 10 001 INITIAL OPERATION WITH
TEST RUN OF DYNAMIC DRIVE .
33 31 503 LOWERING/RAISING REAR AXLE CARRIER
 00 2 030
 00 2 040
 33 3 274
 33 4 232
2006 BMW 650i
 Remove rear wheels

 Remove exhaust system. See EXHAUST SYSTEM - REPAIR INSTRUCTIONS
 M6: Remove tension strut.
 Partially detach heat insulation at rear
 E64: Remove cross strut
 Remove handbrake Bowden cable on both sides from hanging hook
 Disconnect plug connection from ride-height sensor
 Remove spring strut shock absorber on both sides from wheel carrier . See 33 52 100 Removing and
installing rear left or right spring strut shock absorber.


Align special tool 00 2 040 to rear axle carrier.
If necessary, lower special tool 33 3 274 .

2006 BMW 650i
Partially detach pressure lines for rear axle oscillating motor on floorpan and remove right bracket from rear
axle carrier. See 37 13 100 REMOVING AND INSTALLING/REPLACING PRESSURE LINES FOR
OSCILLATING MOTOR/FRONT AXLE .
Remove tension struts .
Installation:

2006 BMW 650i

32 CONTROL ARMS AND STRUT

33 32 051 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT PUSH ROD/INTEGRAL
LINK
NOTE: If the integral link is detached from the wheel carrier or swinging arm, it is
necessary after reinstallation to carry out a wheel/chassis alignment check.
 Remove rear wheel .

 E61: Deactivate and empty air spring system
 Remove output shaft from rear differential
Support wheel carrier with workshop jack.
Release nut (1) and remove screw.
Release screw (2), press swinging arm downward and remove integral link (3).
Installation:
Replace self-locking nut.
First install swinging arm hand-tight, then tighten down screw (2).
Tighten screw/bolt connections in normal position .
Tightening torque (nut), see 33 32 22AZ in 32-CONTROL ARMS AND STRUTS .

2006 BMW 650i
Tightening torque (bolt), see 33 32 21AZ in 32-CONTROL ARMS AND STRUTS .
Fig. 74: Identifying Integral Link

After installation:

 E61: Activate and fill air suspension system
 Perform chassis alignment check
33 32 064 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT SWINGING ARM
NOTE: If the swinging arm is detached from the integral link/wheel carrier or rear axle
carrier, it is necessary after reinstallation to carry out a wheel/chassis alignment
check.

 Remove jointed rod of ride-height sensor from swinging arm
 Remove stabilizer link from swinging arm
Mark position of eccentric screw to rear axle carrier.

2006 BMW 650i
Fig. 75: Locating Eccentric Screw Position

Release nut (1) and remove eccentric washer (2).
Remove eccentric screw towards front.
Installation:
Note insertion direction of eccentric screw.
Align eccentric screw by means of marking to rear axle carrier.
Refit eccentric washer.
Tighten bolt connection in normal position .

2006 BMW 650i
Fig. 76: Identifying Nut And Eccentric Washer

Tightening torque 33 32 20AZ , see 32-CONTROL ARMS AND STRUTS .
Release nut and pull out bolt towards rear.
Installation:
Fig. 77: Pulling Out Bolt

Unfasten nut.
Remove screw towards rear and remove swinging arm.
Installation:

2006 BMW 650i
Fig. 78: Locating Self-Locking Nut

After installation:

33 32 071 REPLACING ONE UPPER CONTROL ARM
NOTE: If the control arm is detached from the rear axle carrier, it is necessary after
reinstallation to carry out a wheel/chassis alignment check.
Shown on vehicle at rear right:
Unclip line for pulse generator (1) from holder (2).
Only on right side: Unclip line for brake pad wear sensor (3) from holder (2).
2006 BMW 650i
Fig. 79: Identifying Pulse Generator, Holder And Brake Pad Wear Sensor
Release nut (1); if necessary, grip at external hexagon/Torx socket.
Remove control arm at top from wheel carrier.
Installation:
Keep control arm to wheel carrier connection clean and free from oil and grease.
Fig. 80: Identifying Nut

Unscrew nut (1).

2006 BMW 650i
Remove upper control arm.
Installation:
Note insertion direction of bolt.
Fig. 81: Removing Upper Control Arm

Replacement:
Unclip holder on control arm.
After installation:
33 32 091 REPLACING A GUIDE ARM
IMPORTANT: The guide arm to wheel carrier connection has been changed from a conical
seat to a ball seat! Spare parts are offered for both variants.
To ensure a correct bolt connection, check before installing the guide arm
whether the seat for the guide arm matches the seat for the wheel carrier.
For reasons of driving dynamics, the guide arms may only be replaced in pairs!
Variants:
2006 BMW 650i
A. M10 journal: Conical seat

B. M12 journal: Ball seat
Fig. 82: Identifying Conical Seat And Ball Seat Of Guide Arm
NOTE: If the guide arm is detached from the rear axle carrier, it is necessary after
Unscrew nut (1).
Remove guide arm from wheel carrier.
Installation:
Keep guide arm to wheel carrier connection clean and free from oil and grease.

2006 BMW 650i

Mark position of eccentric screw (3) to rear axle carrier.
Pull out eccentric screw (3) and remove guide arm.
Installation:

2006 BMW 650i
Fig. 84: Pulling Out Eccentric Screw

After installation:
33 32 125 REPLACING A BALL JOINT IN LOWER STEERING KNUCKLE / WHEEL CARRIER
 33 3 333
 33 4 191
 33 4 192
 33 4 193
 Remove push rod/integral link

 Remove spring strut shock absorber/shock absorber from wheel carrier/swinging arm
Reconditioning special tool:
Cut highlighted area out of special tool 33 4 191 and then deburr.
2006 BMW 650i

Remove circlip (1).
Pull out ball joint with special tools 33 4 193 , 33 4 191 , 33 4 192 and 33 3 333 . Slotted side of special tool 33
4 191 must point to wheel carrier.
Installation:
Install new circlip (1).
Fig. 86: Identifying Circlip And Special Tools

Draw in new ball joint (1) with special tools 33 3 333 , 33 4 19 2, 33 4 191 and 33 4 194 as far as it will go.
2006 BMW 650i
Fig. 87: Identifying Ball Joint And Special Tools

After installation:
33 32 131 REMOVING AND INSTALLING / REPLACING A STEERING KNUCKLE / WHEEL

CARRIER
Remove rear wheel .
IMPORTANT: Expand turning lock sufficiently to avoid damaging thread when releasing
collar nut.
Unscrew collar nut.
Release handbrake.
Installation:

2006 BMW 650i

Remove rear brake disk . See 34 21 320 REMOVING AND INSTALLING OR REPLACING BOTH
REAR BRAKE DISCS .
Disconnect handbrake Bowden cable from expander lock . See 34 41 120 REMOVING AND
INSTALLING/REPLACING BOTH HANDBRAKE BOWDEN CABLES .
Replacement only: drive out drive flange for rear axle shaft .
Remove pulse generator . See 34 52 535 REPLACING A REAR PULSE GENERATOR .
Remove stabilizer link from stabilizer .
Remove spring strut shock absorber from wheel carrier .
Remove integral link .
Press output shaft out of drive flange .
Remove guide arm from wheel carrier .
Remove upper control arm from wheel carrier and remove wheel carrier.
Replacement:
 Modify rear wheel brake . See 34 21 171 REMOVING AND INSTALLING/REPLACING A BRAKE
CARRIER/BRAKE GUARD AT REAR
 Install new wheel bearing.
 Modify or replace drive flange.
2006 BMW 650i
 Adjust handbrake . See BRAKES - REPAIR .

33 AXLE MOUNTING
33 33 001 REPLACING LEFT OR RIGHT REAR AXLE CARRIER COMPRESSION STRUT
IMPORTANT: Observe safety instructions for raising the vehicle

Driving without tension and compression struts is not permitted!
Risk of damage!
The rear axle carrier must be supported at the front if both compression struts
have to be replaced!
 If necessary, remove rear tension strut

 Remove tank cover
 Version with Dynamic Drive: Disconnect pressure lines for oscillating motor of rear axle from tension
strut. See 37 13 100 REMOVING AND INSTALLING/REPLACING PRESSURE LINES FOR
Release screws (2).
Release bolt (1) and remove compression strut.
Secure rear axle carrier by inserting bolt (1).
Installation:

2006 BMW 650i
Fig. 89: Identifying Bolt And Screws

33 33 111 REPLACING ALL RUBBER MOUNTS FOR REAR AXLE CARRIER
 33 4 153
 33 4 154
 33 4 155
 33 4 271
 33 4 272
 33 4 274
WARNING: Danger of explosion!

Do not point air jet from hot air blower at fuel tank!
 Lower rear axle carrier
Withdrawing rubber mount:
Assemble special tools 33 4 154 , 33 4 155 , 33 4 272 , 33 4 274 and 33 4 275 as illustrated.
Check installation position of special tool 33 4 274 to rubber mount and 33 4 272 to bearing bushing, correct if
necessary.
Using a hot air blower, heat bearing bushing at max. 600 °C outlet temperature for approx. 2 minutes.
2006 BMW 650i
Pull out rubber mount by turning special tool 33 4 155 .

Drawing in rubber mount (view from below):
If necessary, apply a marking to special tool 33 4 272 .
Coat rubber mount with Circolight anti-friction agent and insert in special tool 33 4 272 .
IMPORTANT: Arrows or stops (2) of inner sleeve must point in vehicle longitudinal direction
(F) when rubber mount is installed. A maximum deviation (A) of ± 7° must be
observed.
Align rubber mount using arrows or stops (2) to marking on special tool 33 4 272 .
Fig. 91: Identifying Rubber Mount Deviation And Inner Sleeve Stops
2006 BMW 650i
Assemble special tools 33 4 154 , 33 4 155 , 33 4 271 , 33 4 272 as illustrated.
Check installation position of rubber mount to marking on special tool 33 4 272 , correct if necessary.
Align special tool 33 4 272 using marking to vehicle longitudinal direction, fit on rear axle carrier and screw on
special tool 33 4 153 .
Check installation position of special tools 33 4 272 and 33 4 153 , correct if necessary.
Draw in rubber mount by turning special tool 33 4 155 .

41 WHEEL BEARINGS
33 41 000 REPLACING DRIVE FLANGE ON LEFT/RIGHT REAR AXLE SHAFT
 33 2 116
 33 2 160
 33 2 201
Apply handbrake.
Remove rear wheel .
Unscrew collar nut.
Remove brake disc . See DISC - 650I .

2006 BMW 650i
Installation:

Force drive flange with special tools 33 2 116 / 33 2 201 , 33 2 160 , 33 4 200 and 5 wheel bolts out of wheel
bearing.
Fig. 94: Identifying Special Tool 33 2 116/33 2 201, 33 2 160 And 33 4 200
2006 BMW 650i
IMPORTANT: The wheel bearing is destroyed when the drive flange is removed and cannot
be reused!
Replace wheel bearing .
Installation:
Oil drive flange lightly and attach to splines of output shaft.
Draw drive flange into wheel bearing .
After installation:
33 41 ... DETACHING WHEEL BEARING INNER RACE FROM DRIVE FLANGE (DRIVE FLANGE
REMOVED)
Special Tool Required
 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
Position special tool 33 1 307 on drive flange. Select one of the following special tools using the wheel bearing
inner race 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 in special tool 33 4 402 until tapered attachment of spindle comes into contact
with special tool 33 4 401. Position special tool 33 4 401 with corresponding insert on groove of wheel bearing
inner race.
2006 BMW 650i
Fig. 95: Positioning Special Tool 33 4 401 With Corresponding Insert On Groove Of Wheel Bearing
Inner Race
Compress special tool 33 4 401 with wrenches 33 4 403 and 33 4 404 until special tool can still just be turned in
groove. Detach wheel bearing inner race by turning special tool 33 4 402.
Fig. 96: Compressing Special Tool 33 4 401 With Wrenches 33 4 403 And 33 4 404 Until Special Tool Can
Still Just Be Turned In Groove
33 41 151 REPLACING LEFT OR RIGHT WHEEL BEARING ON REAR AXLE SHAFT
 Remove Drive Flange For Rear Axle Shaft

 Detach Wheel Bearing Inner Race From Drive Flange
If necessary, raise wheel carrier slightly with workshop jack.

2006 BMW 650i
Release screws with 3/8 Torx socket.
Remove wheel bearing.

Installation:
Keep contact surface (2) of wheel bearing/wheel carrier clean and free from oil and grease.
Except when replacing: Recondition tapped holes (1).
Install new wheel bearing.
Fig. 98: Identifying Contact Surface Of Wheel Bearing/Wheel Carrier

2006 BMW 650i
52 SHOCK ABSORBER
Facts:
Consequence:
Procedure:
33 52 100 REMOVING AND INSTALLING REAR LEFT OR RIGHT SPRING STRUT SHOCK
ABSORBER
 Remove rear wheel.

 Remove Stabilizer Link From Swinging Arm
IMPORTANT: Before tightening screw connection, check that spring strut shock absorber pin
is correctly positioned in wheel carrier.
Screw must not be used as an aid to installing the spring strut shock absorber!
Release screw.
IMPORTANT: Secure spring strut shock absorber against falling out.
Remove spring strut shock absorber from wheel carrier and tie up.
2006 BMW 650i
Installation:
Replace screw.
Tightening torque 33 52 1AZ , see 52 SHOCK ABSORBER .
Fig. 99: Locating Screw

Remove luggage compartment wheel arch trim . See 51 47 151 REMOVING AND
INSTALLING/REPLACING LUGGAGE COMPARTMENT WHEEL ARCH TRIM .
If necessary, remove sound insulation.
M6: Disconnect plug connection for Electronic Damper Control (EDC).
Unscrew nuts (1).
Installation:
Replace self-locking nuts.

2006 BMW 650i
Fig. 100: Identifying Nuts

Press wheel carrier downwards, guide spring strut shock absorber downwards between guide arm and control
arm and then remove in upwards direction.
Fig. 101: Removing Spring Strut Shock Absorber

33 52 131 REPLACING REAR LEFT OR RIGHT SPRING STRUT SHOCK ABSORBER
 31 3 341
 31 3 357 See FRONT AXLE - SPECIAL TOOLS .
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
2006 BMW 650i
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.
NOTE: Read and comply with Information on replacing shock absorbers .
Version with EDC:
In a warranty case you must always provide a fault memory printout, even where there is no fault memory
entry, with the defective part.
 Remove rear spring strut shock absorber
Removing:
Clamp special tool 31 3 341 in vice.
Fit special tools 31 3 357 from above on special tool 31 3 341 until locking pins (1) can be felt and heard to
snap into place.
Check seating of special tools 31 3 357 , correct if necessary.
Fig. 102: Identifying Locking Pins And Special Tools

2006 BMW 650i
WARNING: Coils of coil spring must be located completely in recesses of special

tools 31 3 357 when tensioned!
Compress coil spring until stress on piston rod is relieved.
Clean coil spring to remove all coarse dirt and mount on special tools 31 3 357 .
Fig. 103: Identifying Special Tools 31 3 357

Mark installation position of support bearing to spring strut shock absorber using a stud (arrow).
Fig. 104: Locating Stud

Release nut (gripping piston rod in the process).
Remove plate and support bearing with upper spring pad.

2006 BMW 650i
pad sideways from tensioned coil spring.
Fig. 105: Releasing Nut

Remove support pot, rear auxiliary damper (1) with protective tube and lower spring pad (2).
Assembly:
Check lower spring pad (2), if necessary replace and position on spring plate.
Check rear auxiliary damper (1) with protective tube for damage, replace if necessary and attach to piston rod.
Attach support pot to piston rod.
Fig. 106: Identifying Rear Auxiliary Damper And Lower Spring Pad
Replacement only: Carry over marking from old part to new part.
Insert spring strut shock absorber in tensioned coil spring and align to end of coil spring using lower spring pad.
2006 BMW 650i
Fig. 107: Identifying Spring Strut Shock Absorber In Tensioned Coil Spring
NOTE: Make sure end of coil spring is correctly seated in lower spring pad.
Fig. 108: Identifying Coil Spring Installing Position In Lower Spring Pad
Check support bearing for damage, replace if necessary.
Attach support bearing to piston rod. Use lower spring pad to align support bearing to end of coil spring.
2006 BMW 650i
Fig. 109: Identifying Support Bearing Alignment With End Of Coil Spring
Attach plate to piston rod.
Replace self-locking nut and screw on as far as possible to avoid damaging the piston rod when relieving
tension on the coil spring.
Align support bearing by way of a stud (arrow) to marking on spring strut shock absorber.
Fig. 110: Align Support Bearing By Way Of A Stud (Arrow)

Relieve tension on coil spring slightly.
NOTE: Make sure that lower and upper coils of coil spring rest completely in recess of
spring plate or support bearing.
Tighten down nut (gripping piston rod in the process).

2006 BMW 650i
Fully relieve tension on coil spring.

After installation:
 Carry out coding (dependent on type code number)
NOTE: Coding is only required on listed vehicles from 03/2005 with Electronic Damper
Control (EDC).
 31 3 341
springs.
and operational reliability.
2006 BMW 650i
Version with EDC:
Removing:
snap into place.


2006 BMW 650i

Fig. 114: Mark Installation Position Of Support Bearing To Spring Strut Shock Absorber Using A Stud
(Arrow)
Remove spring strut shock absorber with support pot, rear auxiliary damper, protective tube and lower spring
2006 BMW 650i

Assembly:
2006 BMW 650i
2006 BMW 650i


2006 BMW 650i

33 52 161 REPLACING REAR LEFT OR RIGHT THRUST BEARING FOR SPRING STRUT /
SHOCK ABSORBER
NOTE: See rear spring strut shock absorber.
53 SPRINGS WITH SUSPENSION

33 53 ... 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).
2006 BMW 650i
Fig. 122: Identifying Ride-Level Height Of Vehicle

33 53 000 REMOVING AND INSTALLING / REPLACING REAR LEFT OR RIGHT COIL SPRING
 31 3 341
springs.
IMPORTANT: Except M5, M6 and E67: Both coil springs on the relevant axle must be
replaced only in the event of corrosion breakage!
M5, M6 and E67: For safety reasons, both coil springs on the relevant axle must
always be replaced on motorsport and safety vehicles!

2006 BMW 650i
Removing:
Fit special tool 31 3 357 from above on special tool 31 3 341 until locking pins (1) can be felt and heard to snap
into place.


2006 BMW 650i

(Arrow)

2006 BMW 650i
Relieve tension on coil spring.
Remove coil spring from special tools 31 3 357 .

Assembly:

Do not compress coil spring to full extent.
Accommodate coil spring with special tools 31 3 357 .
NOTE: M5: Make sure when tensioning that the upper section of the coil spring is
covered by a protective tube.
Position the coil spring so that both ends of the spring lie outside special tools
31 3 357 by approx. one turn (W).
Tension coil spring.

2006 BMW 650i

Check rear auxiliary damper (1), protective tube and lower spring pad (2) for damage, replace if necessary.
2006 BMW 650i
2006 BMW 650i
Fig. 133: Align Support Bearing By Way Of A Stud (Arrow) To Marking On Spring Strut Shock
Absorber

2006 BMW 650i
 Check headlight adjustment, correct if necessary
33 53 000 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT COIL SPRING (M

MODEL)
IMPORTANT: 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: Procedure is described in Replacing rear left or right spring strut shock
absorber.
55 STABILIZER BAR
33 55 000 REMOVING AND INSTALLING / REPLACING REAR STABILIZER
 Remove Stabilizer Link On Both Sides From Stabilizer.
If necessary, remove vibration damper from right retaining bracket of stabilizer.
Tightening torque 33 55 6AZ , see 55 STABILIZER BAR .
Release nuts at both ends.
Remove stabilizer sideways.
Installation:
Check rubber mount on both sides, replace if necessary.

2006 BMW 650i

Replacement:
Remove rubber mount on both sides from stabilizer .
33 55 021 REPLACING BOTH RUBBER MOUNTS FOR STABILIZER MOUNTING
E61: If necessary, remove vibration damper from right retaining bracket of stabilizer.
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.
2006 BMW 650i
Fig. 136: Identifying Retaining Bracket And Rubber Mount

33 55 040 REPLACING STABILIZER LINKS FOR STABILIZER
Release nut (1); if necessary, grip at Torx socket.
Installation:
Remove stabilizer link.
Installation:

2006 BMW 650i

33 55 041 REPLACING ANTI-ROLL BAR LINK FOR ANTI-ROLL BAR ON LEFT OR RIGHT
Release nut (1); if necessary, grip at Torx socket. Installation note: Replace self-locking nut. Tightening torque,
see 33 55 2AZ in 55 STABILIZER BAR .
Fig. 138: Identifying Nuts (1) And (2)
Release nut (2); if necessary, grip at Torx socket. Remove anti-roll bar link. Installation note: Replace self-
locking nut. Tightening torque, see 33 55 2AZ in 55 STABILIZER BAR .
90 TROUBLESHOOTING
33 90 ... REAR AXLE TROUBLESHOOTING
Observe troubleshooting for shock absorbers .

2006 BMW 650i
Fault Cause Remedy

Grinding noise (only when Refer to Brake article
cornering) Wheel bearings faulty Replace wheel bearings
Vibration (90 - 160 km/h) Wheel imbalance Balance wheels
Radial/lateral rim runout Check rims , replace if necessary
Radial tyre runout Match or replace tyres
Imbalance in output shaft Replace output shaft
Drumming Rubber mount of final drive Replace rubber mount
suspension faulty
Rubber mount of rear axle carrier Replace rubber mount
faulty
Rattling noise Refer to shock absorbers
Stabilizer link loose or defective Check screw connection, replace
stabilizer link if necessary
Rubber mount of rear axle carrier Check seat, replace rubber mount
loose or faulty if necessary
Poor straight-running stability Rubber mount of rear axle carrier Replace rubber mount
(steering wheel inclination) faulty
Rubber mount/ball joint of control Replace control or guide arm
or guide arm faulty
Ball joint in wheel carrier faulty Replace ball joint
Rubber mount of swinging arm Replace swinging arm
faulty
Rear axle alignment incorrectly Carry out chassis/wheel alignment
adjusted check , align rear axle if necessary
Unsteady taking of curves due to Rubber mount of rear axle carrier Replace rubber mount
self-steering or poor rear end track faulty
stability Rubber mount of final drive Replace rubber mount
suspension faulty
Refer to shock absorbers
Excessive tyre wear Front or rear axle alignment Carry out chassis/wheel alignment
incorrectly adjusted check , align rear axle if necessary
33 90 ... TROUBLESHOOTING SHOCK ABSORBER
Read and comply with Information on replacing shock absorbers .
SHOCK ABSORBER TROUBLESHOOTING CHART

Fault Cause Remedy
Wheel knocking (bottoming) Auxiliary spring faulty Visually inspect auxiliary spring
for cracking, replace auxiliary
spring
Shock absorber leaking (oil/gas) Replace shock absorber
2006 BMW 650i
Rattling noise Shock absorber mounting loose Tighten shock absorber

Support bearing loose Secure support bearing
Support bearing defective Visually inspect for cracking,
(cracked) replace support bearing
Protective tube defective/failed Visually inspect protective tube
for cracking, replace protective
tube
Rubber mount/joint eye for lower Replace rubber mount/joint eye
shock absorber mounting
defective
Worn down areas (flattened areas) Shock absorber leaking (gas/oil) Replace shock absorber
on tyre profile
Long after-swinging of body after Shock absorber leaking Replace shock absorber
driving over rough road (insufficient shock absorber
effect)
Building-up of body in case of Shock absorber leaking Replace shock absorber
successive uneven surfaces (insufficient shock absorber
effect)
Wheels jumping even on normal Shock absorber leaking Replace shock absorber
road surfaces (insufficient shock absorber
effect)
2005 BMW 645Ci
2004-05 DRIVE AXLES Axle Shafts - 645Ci
2004-05 DRIVE AXLES
Axle Shafts - 645Ci
MODEL IDENTIFICATION
2004 MODEL & ENGINE IDENTIFICATION
2004
645Ci (E63) 4.4L (N62)
REMOVAL, DISASSEMBLY, REASSEMBLY & INSTALLATION

AXLE SHAFTS
Removal
Apply parking brake. Unclip hub cover. Unscrew collar nut. See Fig. 1. Remove rear wheel. Remove exhaust
system up to catalytic converter. Remove bolts. See Fig. 2. Cover swinging arm with a cloth. Press axle shaft
off drive flange with a small screw driver and place it on the cloth. See Fig. 3. Press axle shaft out of drive
flange and remove toward center of vehicle.
Installation
To install, reverse removal procedure. Replace collar nut and lock in place by peening at flat areas of axle shaft.
Replace bolts and shims. See TORQUE SPECIFICATIONS.
2005 BMW 645Ci

2005 BMW 645Ci
Fig. 2: Identifying Bolts & Shims At Axle Shaft

2005 BMW 645Ci
Fig. 3: Pressing Axle Shaft Off Drive Flange

AXLE SHAFT DRIVE FLANGE
NOTE: Wheel bearing is destroyed when drive flange is removed and cannot be
reused.
Removal & Installation
1. Apply parking brake. Unclip hub cover. Unscrew collar nut. See Fig. 1. Remove rear wheel. Remove rear
brake disc. Remove rear speed sensor. Assemble Special Tools (332116, 332160, 334201, 334202,
334203 and 334204) and attach to drive flange. Drive out drive flange with Special Tool (334203). See
Fig. 4. Remove wheel bolts and remove drive flange from special tools. Detach wheel bearing inner race
from drive flange.
2. To install, reverse removal procedure. Oil drive flange lightly and attach to splines of axle shaft. Draw in
drive flange with Special Tools (332115, 332116, 332118 and 332160) and wheel nuts. See Fig. 5.
2005 BMW 645Ci

2005 BMW 645Ci
Fig. 5: Installing Drive Flange

AXLE SHAFT WHEEL BEARING
Remove rear axle shaft drive flange. See AXLE SHAFT DRIVE FLANGE. Remove 4 bolts. See Fig. 6.
Remove wheel bearing. To install, reverse removal procedure. Use a new wheel bearing. Keep tapped holes and
mating surfaces of wheel bearing and wheel carrier clean and free from grease. See Fig. 7.
2005 BMW 645Ci
Fig. 6: Removing 4 Bolts

2005 BMW 645Ci
Fig. 7: Installing Wheel Bearing

CV JOINT BOOTS
Removal
Remove axle shaft. See AXLE SHAFTS. Clean axle shaft. Press off sealing cap. See Fig. 8. Unfasten hose
clip. Press cap off together with boot. Remove circlip. See Fig. 9. Press splined shaft out of CV joint. Use
Special Tool (261110) in accordance with diameter of axle shaft. See Fig. 10. Bearing inner race must rest on
rib of special tool. Clean CV joint carefully and remove all traces of old grease. Check CV joint for damage and
replace if necessary. Remove hose clamps. See Fig. 11. Detach boot from splined shaft.
2005 BMW 645Ci
Fig. 8: Pressing Off Sealing Cap

2005 BMW 645Ci
Fig. 9: Removing Circlip

2005 BMW 645Ci
Fig. 10: Pressing Axle From CV Joint

2005 BMW 645Ci
Fig. 11: Locating Hose Clamps

Installation
Press on sealing cap with a thrust ring Coat sealing faces of sealing cap with sealing compound. Turn new boot
with cap so that fastener of large hose clamp is between 2 bores of CV joint. Pull boot onto cap. Coat sealing
surface of cap with sealing compound and press with a thrust ring onto CV joint. Fill CV joint with high
temperature grease. Install new circlip. Press CV joint and cap over inner bearing race on splined shaft. Mount
Special Tool (332130). See Fig. 12. Push new gaiter onto splined shaft. Fill CV joint with high temperature
grease. Pull on new boot.
2005 BMW 645Ci
Fig. 12: Using Special Tool 33 2 130

DIFFERENTIAL DRIVE FLANGE (LEFT OR RIGHT)
Removal
Remove axle shaft from rear differential. Place shaft aside and tie up out of the way. Place a plastic mallet in
position and knock out drive flange with another hammer. See Fig. 13.
2005 BMW 645Ci
Fig. 13: Removing Drive Flange

Installation
Install retaining ring. See Fig. 14. Press in drive flange further until retaining ring snaps in place audibly. Insert
drive flange and rotate until spline on flange meshes with teeth on differential bevel gear. Coat drive flange at
contact face of shaft seal with rear differential oil. Clean shaft seal race on drive flange thoroughly. If the
retaining ring was installed in rear differential, twist retaining ring until both ends settle into the groove.
2005 BMW 645Ci
Fig. 14: Installing Retaining Ring

DIFFERENTIAL DRIVE FLANGE SHAFT SEAL (LEFT OR RIGHT)
Removal
Remove drive flange from rear differential. See DIFFERENTIAL DRIVE FLANGE (LEFT OR RIGHT).
Remove shaft seal with Special Tools (005010) and (321060/331308). See Fig. 15.
2005 BMW 645Ci
Fig. 15: Removing Shaft Seal

Installation
Coat housing plate flange and sealing lips of new shaft seal with differential oil. See Fig. 16. Drive shaft seal
firmly in place with Special Tool (005500) and an additional tool depending on rear differential model and
outside diameter:
 Model 168K uses 78x44x10 mm tool (333400).

 Model 188K uses 90x44x10 mm tool (334240).
 Model 210K to 230K uses 100x50x10 mm tool (334250).
2005 BMW 645Ci
Fig. 16: Installing Drive Shaft Seal

Drive Flange-To-Axle Shaft Collar Nut
27 mm Thread 310 (420)
Output Shaft-To-Final Drive Unit & Drive Flange
Fillister Head Bolt 61 (83)
With Locking Teeth
10 mm Thread 71 (96)
12 mm Thread 81 (110)
Torx Bolt 61 (83)
With Ribbed Teeth
Black
8 mm Thread 47 (64)
2005 BMW 645Ci
Silver
8 mm Thread 38 (52)
10 mm Thread 59 (80)
12 mm Thread 100 (135)
2005 BMW 645Ci
2004-2005 BODY & ACCESSORIES Body Equipment - Tightening Torques - 645Ci
2004-2005 BODY & ACCESSORIES
Body Equipment - Tightening Torques - 645Ci
FRONT BUMPER
51 11FRONT BUMPER
FRONT BUMPER TIGHTENING SPECIFICATION

Application Type Thread Tightening Specification Measure
1AZ Bumper to bracket E32 M6 9 Nm
E36 M8 22 Nm
E34 M10 43 Nm
2AZ Bumper and bracket E31 M10 Install bolts with bolt 22 Nm
to impact absorber cement.
E38 / E39 / M10 41 Nm
E46
E36 M10 Install bolts with bolt 55 Nm
cement.
E32 / E34 / M12 48 Nm
E30 / Mod. 88
3AZ Impact E30 / E24 23 Nm
absorber/bracket to body
E31 / E32 / M6 9 Nm
E34 / E36 /
E38 / E39
E32 / E34 M10 48 Nm
E46 M8 20 Nm
4AZ Carrier to body E46 / E65 / M8 18 Nm
E66 / E67
E87 / E90 / M8 20 Nm
E91
E60 / E61 / M8 21.4 Nm
E63 / E64
5AZ Carrier to E85 M10 38 Nm
deformation element
E83 M8 28 Nm
6AZ Deformation E85 M8 19 Nm
element to body
E83 M8 21.4 Nm
7AZ License plate to E60 / E63 / 1 Nm
bumper E64
8AZ License plate to E60 / E63 / M5 4.5 Nm
2005 BMW 645Ci
REAR BUMPER
51 12 REAR BUMPER
REAR BUMPER TIGHTENING SPECIFICATION

Tightening
Application Type Thread Specification Measure
1AZ Bumper E31 M10 40 Nm
to carrier
E32 / M8 22 Nm
E34 / E36
E34 M10 42 Nm
2AZ E36 M10 Install bolts 42 Nm
Bumper / with bolt
carrier to cement.
impact
absorber
E38 M12 45 Nm
E39 M10 45 Nm
E46 M10 41 Nm
E31 / M12 48 Nm
E32 /
E34 /
E30 /
Mod. 88
E53 M12 55 Nm
E85 US 19 Nm
E60 / M10 36 Nm
E61 /
E63 / E64
3AZ Impact E30 / E24 23 Nm
absorber /
carrier to
body
E31 / M6 9 Nm
E32 / E34
E36 / E46 M8 22 Nm
E39 M8 20 Nm
E53 M8 24 Nm
E65 / 38 Nm
E66 / E67
E85 19 Nm
E60 / M10 36 Nm
2005 BMW 645Ci
E63 / E64
E83 M12 71 Nm
E87 / M12 66 Nm
E90 / E91
4AZ Bumper E30 7 Nm
to side panel
5AZ Bracket E36 / E46 3 Nm
to side panel
E39 6 Nm
6AZ Holder, E36 8.5 Nm
bottom, to
body
7AZ Screw E36 2.5 Nm
for lower
panel
8AZ Bumper E60 M6 Replace screw 2.5 Nm
on rear apron with sealing
washer
9AZ Guide to E83 2 Nm
side panel
E61 / E87 3 Nm
10AZ Guide E83 / E87 2.8 Nm
to rear trim
panel
E61 4.5 Nm
TRIM PARTS, COVERS, HANDLE

51 13 TRIM PARTS, COVERS, HANDLE TRIM
TRIM PARTS, COVERS, HANDLE TRIM TIGHTENING SPECIFICATION

Tightening
Application Type Thread specification Measure
1AZ Bracket, roof Z3 and M Coupe / M10 20 Nm
luggage rack on E39 / E46
body
2AZ Water drain to E46 1 Nm
body (plastic nut)
Water drain to body E46 1.8 Nm
(metal nut or rivet
nut)
3AZ Roof railing to E39 Center, front, rear 24 Nm
body
2005 BMW 645Ci
settling time 15 min

Check 16 Nm
E83 M8 Front
Jointing torque 20.5Nm
Release nut after 15 min
settling time
Jointing torque 20.5 Nm
Torque angle 120+/-10°
E83 M8 Centre, rear 20.5 N
settling time 15 min
Check 20.5 Nm
4AZ Handle strip to E39 / Touring 3 Nm
rear lid
E46 / E53 2.5 Nm
E83 1.8 Nm
5AZ Cowl panel E60 / E61 / E63 / 2.5 Nm
cover to body E64
6AZ Centre trim to E65 / E66 / E67 M8 2.5 Nm
rear lid
7AZ Trim to E90 / E91 2 +/-0.4 Nm
hood/bonnet
MIRRORS, COVERS, ASHTRAY

51 16 MIRRORS, FINISHERS, ASHTRAYS, CONSOLES
MIRRORS, FINISHERS, ASHTRAYS, CONSOLES TIGHTENING SPECIFICATION

Application Type Measure
1AZ Mirror to front door E31 / E36 / Z3 / E38 / E39 / E46 / 6 Nm
E52 / E53 / E60 / E61 / E63 / E64 /
E65 / E66 / E67 / E83 / E85 / E87 /
E90 / E91
Only for new rearview mirror E46 / E53 / E60 / E61 / E63 / E64 / 8 Nm
(replacement) for initial screw E65 / E66 / E67 / E83 / E85 / E87 /
connection (shaping of thread cutting E90 / E91
screws)
2AZ Center console (plastic nut) E30 5 Nm
3AZ Wooden finisher on carrier E38 0.6 Nm
6AZ Cup holder, front, on function E38 1.3 Nm
carrier
2005 BMW 645Ci
front
8AZ Screw-in pin to wooden finisher of E46 0.3 Nm
instrument panel and door panel
9AZ Housing for rearview mirror to E46 M3 Coupe 1.3 Nm
carrier
E60 M5 / E63 M6 0.7 Nm
E85 1.1Nm
10AZ Brush cable unit to function carrier E65 / E66 / E67 0.5+/-0.1 Nm
11AZ Roller sun blind to function carrier E65 / E66 / E67 0.5+/-0.1 Nm
12AZ Roller sun blind to brush cable E65 / E66 / E67 1.2+/-0.2 Nm
unit
13AZ Flap to storage box E85 0.5 Nm
14AZ Rearview mirror retaining ring on E60 M5 / E63 M6 1.1 Nm
reinforcement plate
15AZ Notch adapter to mirror base E60 M5 / E63 M6 3.0 Nm
FRONT DOOR LOCKS HANDLE

51 21 FRONT DOOR LOCKS
FRONT DOOR LOCKS TIGHTENING SPECIFICATION

Application Type Tightening specification Measure
1AZ Door lock to front E31 / E36 Install bolt with bolt 9 Nm
door cement.
E46 / E53 / E87 / E90 / 9 Nm
E91
E60 / E61 / E63 / E64 / 8 Nm
E65 / E66 / E67 / E85
E83 10 Nm
2AZ Outside handle to E31 / E36 10 Nm
front door
3AZ Door striker to body E24 / E30 24 Nm
E31 / E32 / E34 28 Nm
E60 / E61 / E63 / E64 / 19 Nm
E65 / E66 / E67 / E83 /
E85 / E87 / E90 / E91
4AZ Adjustment screw to E46 3 +2 Nm
door lock
5AZ Outside handle to lock E53 3.2 Nm
actuator
E46 / E60 / E61 / E63 / 2 Nm
E64 / E83
2005 BMW 645Ci
front door
E46 / Compact 2.7 Nm
E65 / E66 / E85 3 Nm
E67 4 Nm
7AZ Lock actuator/front E60 / E61 / E63 / E64 2.5 Nm
cover to front door
8AZ Lock actuator/rear E60 / E61 / E63 / E64 3.3 Nm
cover to front door
9AZ Door retainer to A- E87 / E90 / E91 22 Nm
pillar
10AZ Door retainer to door E87 / E90 / E91 11.6 Nm
REAR DOOR LOCKS HANDLE

51 22 REAR DOOR LOCKS
REAR DOOR LOCKS TIGHTENING SPECIFICATION

Application Type Tightening Specification Measure
1AZ Door lock to rear door E36 Install bolt with bolt cement. 9 Nm
E46 / E53 / E87 / 9 Nm
E90 / E91
E60 / E61 / E63 / 10 Nm
E64 / E65 / E66 /
E67 / E85
2AZ Outside handle to rear E36 10 Nm
door
3AZ Door striker to body E32 / E34 24 Nm
E60 / E61 / E63 / 19 Nm
E64 / E65 / E66 /
E67 / E85 / E87 /
E90 / E91
4AZ Adjustment screw to E46 3 +2 Nm
door lock
5AZ Outside handle to E53 3.2 Nm
lock actuator
E46 / E60 / E61 / 2 Nm
E63 / E64 / E83
6AZ Inside door opener to E46 / E67 4 Nm
rear door
E65 / E66 3 Nm
E87 7.5 Nm
7AZ Lock actuator/front E60 / E61 / E63 / 2.5 Nm
cover to rear door E64
2005 BMW 645Ci
8AZ Lock actuator/rear E60 / E61 / E63 / 3.3 Nm

cover to rear door E64
9AZ Side impact E61 18.5 Nm
protection to rear door, top
10AZ Door retainer to B- E87 / E90 / E91 22 Nm
pillar
11AZ Door retainer to door E87 / E90 / E91 11.6 Nm
HOOD LATCH LOCKS

51 23 HOOD/BONNET LOCKS
HOOD/BONNET LOCKS TIGHTENING SPECIFICATION

1AZ Retaining hook to hood/bonnet E60 / E61 / E63 / E64 / E65 / 10 Nm
E66 / E83 / E85 / E87 / E90 / E91
2AZ Lock to body E60 / E61 / E63 / E64 / E65 / 10 Nm
E66 / E83 / E87 / E90 / E91
E85 8+/-1.2 Nm
FRONT MANUALLY OPERATE

51 32 FRONT DOOR WINDOWS
FRONT DOOR WINDOWS TIGHTENING SPECIFICATION

1AZ Door window glass holder to roller guide E31 / E36 / Coupe/Convertible 9 Nm
2AZ Door window glass to holder E31 / E36 / Coupe/Convertible 6 Nm
E38 / E39 / E46 / E60 / E61 8 Nm
E85 9 Nm
E63 / E64 / E65 / E66 10 Nm
3AZ Main stop to window regulator E31 / E36 9 Nm
4AZ Window guide to body E36 10 Nm
5AZ Window winder E36 6 Nm
FRONT ELECTRICALLY OPERATE

51 33 POWER WINDOWS, FRONT
POWER WINDOWS, FRONT TIGHTENING SPECIFICATION

1AZ Motor to window regulator E31 / E36 / E65 / E66 5 Nm
2005 BMW 645Ci
E46 / E85 4.5+/-0.5 Nm

E83 3 Nm
E60 / E61 / E87 / E90 6 Nm
E63 / E64 6 +/- 0.6 Nm
2AZ Window regulator to door E38 / E39 / E60 / E61 / E65 / 8 Nm
E66 / E83 / E85 / E87 / E90
E46 Replace nut (selflocking) 9.5 Nm
E63 / E64 9.5 Nm
3AZ Window regulator to door E36 9 Nm
FRONT DOOR TRIM PANEL

51 41 FRONT DOOR TRIM PANEL WITH ARMRESTS
FRONT DOOR TRIM PANEL WITH ARMRESTS TIGHTENING SPECIFICATION

1AZ Door trim panel to front door (screw under E46 / Convertible / Coupe 2.7+/-0.5 Nm
airbag sticker)
E85 / E46 / Compact 4.2+/-0.8 Nm
E60 / E61 / E65 / E66 / E67 8.0 Nm
E83 8.2 Nm
2AZ Door trim panel to front door (screw to E46 / Saloon / Touring 2.7+/-0.5 Nm
armrest or door handle)
E46 / Convertible / Coupe 3.0+/-0.5 Nm
E87 / E46 / Compact 4.2+/-0.8 Nm
E63 / E64 / E90 / E91 3.5+/-0.5 Nm
E65 / E66 / E67 8.0 Nm
E83 8.2 Nm
E85 7.0+/-0.4 Nm
3AZ Armrest to door trim panel E46 / Convertible / Coupe 2.5+/-0.5 Nm
E87 2.0+/-0.4 Nm
4AZ Door trim panel to front door E46 / Compact 1.1+/-0.2 Nm
E60 / E61 0.8 Nm
E65 / E66 / E67 1.5+/-0.2 Nm
E63 / E64 3.0 Nm
5AZ Wood/decorative strip to door trim E65 / E66 / E67 1.2+/-0.2 Nm
E60 / E61 0.4 Nm
6AZ Speaker frame to door trim E65 / E66 / E67 0.5+/-0.2 Nm
7AZ Sheet metal nut E65 / E66 / E67 1.0+/-0.2 Nm
8AZ Door handle to door trim panel E85 0.5+/-0.1 Nm
E87 2.0+/-0.4 Nm
2005 BMW 645Ci
9AZ Carrier to door trim panel E60 / E61 7.0 Nm
SIDE COVERING WITH ARM

51 43 SIDE TRIM PANEL WITH ARMRESTS
SIDE TRIM PANEL WITH ARMRESTS TIGHTENING SPECIFICATION

Application Type Thread Measure
1AZ Trim, rear roof pillar (C-pillar) on E38 / E60 3.0 Nm
body
E61 / E65 / E66 / 4.0 Nm
E67
E83 2.0 Nm
E87 / E90 / E91 2.5 Nm
2AZ Trim, front E46 1.8 +0.4 Nm
roof pillar (A-
pillar) on body
E60 / E61 / E63 / 2.5 Nm
E64 / E87 / E90 /
E91
E83 2.0 Nm
E65 / E66 / E67 4.5 Nm
3AZ Side trim panel to body E46 / Coupe 3+/-0.5 Nm
E46 / Compact 4.2+/-0.8 Nm
4AZ Armrest to side trim panel E46 / Coupe 2.5+/-0.5 Nm
LOOSE BODY PARTS

51 71 SEALS AND LOOSE BODY PARTS
SEALS AND LOOSE BODY PARTS TIGHTENING SPECIFICATION

Tightening
Application Type Thread Specification Measure
1AZ Front spoiler to E36 / M3 - - 3 Nm
bumper
2AZ Rear spoiler E34 / Touring M6 - 5 Nm
- E36 / M3 M6 - 7 Nm
- E36 / Z3 M6 - 6 Nm
Coupe, M
Coupe
- E53 / E91 - - 3 Nm
- E83 M6 - 10 Nm
2005 BMW 645Ci
3AZ Reinforcement E46 without - Replace screws -

plate to front axle AWD / E85
support/engine
carrier
- - - Jointing torque 59 Nm
- - - Torque angle 90°
4AZ Tension strut in E85 - Jointing torque 30 Nm
engine compartment
- E60 / E61 / M8 Screw connection again 20 Nm
E63 / E64
- - - New component / initial 25.5 Nm
screw connection
- E83 M8 - 19 Nm
- E90 / E91 M10 Jointing torque 56 Nm
- E90 / E91 M12 x 1.5 Jointing torque 100 Nm
5AZ Reinforcing E85 / E46 / M10 Replace screws -
plate/ tension strut to Convertible
rear axle
6AZ Reinforcing E85 M8 - 21 Nm
plate to rear axle
7AZ Tension strut to E46 / M8 - 24 Nm
rear axle Convertible
- E60 M5 / E63 M8 - 21.4+/-3 Nm
M6
- E61 / E64 / M12 Replace screws -
E91
- E61 / E64 M8 Nut 19 Nm
- E91 M10 - 50 Nm
- E85 Replace nut 24
Nm
8AZ Cross-member, E52 M8 - 18.5 Nm
A-pillar, to mounting
9AZ Cross-member, E52 M8 - 10 Nm
A-pillar, middle
10AZ Strut to cardan E52 M8 - 18.5 Nm
2005 BMW 645Ci
11AZ Cross- E52 M6 - 11.2 Nm

member, A-pillar,
bottom, to mounting
12AZ Support tube E65 / E66 / M8 - 21 Nm
to support, steering E67
column upper section
- E87 / E90 / M8 - 19 Nm
E91
13AZ Support tube E85 M8 - 19.5 Nm
to body
14AZ Heater to E85 / E87 / - - 4 Nm
support tube E90 / E91
15AZ Support tube E60 / E61 / M8 - 21 Nm
to body E63 / E64 /
E87 / E90 /
E91
16AZ Take-up, E83 M8 - 5 Nm
cover, sill to body
17AZ Structural E61 / E64 M12 Replace screws -
tension strut, front
- E61 / E64 M6 Replace screws -
- Jointing torque 8 Nm
18AZ Cross E61 / E64 M10 Nuts 41 Nm
strut/rear
- - - Screws 59 Nm
19AZ Bracket, E87 / E90 / - - 3.5 Nm
handle, to body E91
20AZ Multifunction E87 / E90 / M6 - 8 Nm
pan to body E91
- E60 M5 - - 3 Nm
21AZ Bracket, E91 - - 11 Nm
suspension, dividing
net to body
2005 BMW 645Ci
2004-05 ACCESSORIES & BODY, CAB Exterior/Interior Trim - Repair Instructions - E63
Exterior/Interior Trim - Repair Instructions - E63
GENERAL
51 00 ... OVERVIEW OF FRONT DOOR
Fig. 1: Identifying Front Door Components

51 00 ... INSTRUCTIONS ON STICKING FILM
1. General notes
 Bonding at room and object temperature of 18 to 25 °C.
 Newly painted parts may only be bonded after a drying time of at least 24 hours.
 Optimal attachment of the film to the background surface is achieved after approx. 48 hours. Film
must not be exposed to mechanical strain beforehand (car wash, strength test, etc.).
2005 BMW 645Ci
2. Auxiliary materials and tools

 Spirit, plastic squeegee, needle, cleaning cloth
 Low-surface-tension water
NOTE: Mixture ratio: 3 drops low-surface-tension detergent to 1 litre tap water.
3. Preparations
 If necessary, heat defective/old film with hot air blower and detach
 Remove all remnants of adhesive or clean new part thoroughly
 Clean the areas to be bonded with spirit immediately before bonding to remove silicone and grease
residues.
NOTE: Observe ventilation time greater than or equal to 1 minute.
4. Bonding
4.1 Moist bonding
 Thoroughly moisten the background surface to be bonded with low-surface-tension water.
 Pull off the backing film, position the film on the background surface and slide into position.
NOTE: In the case of small-size film, the backing film can be pulled off
completely and the adhesive side of the film can be moistened
with low-surface-tension water.
 Press film down with plastic squeegee in overlapping strokes from inside outwards.
 Remove remaining water with a clean cloth.
 If necessary, carefully and slowly pull off protective film flat.
 Check film for bubbles and folds. If necessary, remove bubbles or folds with plastic squeegee
or pierce with a needle and force out air or water.
4.2 Dry bonding
 Pull off backing film on adhesive side.
 Align film in correct position on car.
 Press film down with plastic squeegee in overlapping strokes (watch out for formation of
bubbles and folds).
 If necessary, carefully and slowly pull off protective film flat.
 If necessary, pierce bubbles with a needle and force out air with plastic squeegee.
51 00 ... SAFETY INSTRUCTIONS FOR WORKING ON CARS WITH AIRBAG SYSTEMS
WARNING: If work is carried out in area of airbag systems, e.g. on:

2005 BMW 645Ci
 Interior trims
 Instrument panel etc.
the ignition must be turned off in each case.
 The ignition must always be off.

 The ignition key must be removed from the ignition lock.
This eliminates the risk of injury.
51 00 ... SERVICE POSITION OF ENGINE HOOD
NOTE: For special tools, refer to BODY EQUIPMENT - SPECIAL TOOLS - 645CI (E63) .
Special tool setup:
SPECIAL TOOL
Model series Special tool
E46, E90, R50, R52, R53 51 2 160
E53, E85, E60, E61, E63, E64, E87 51 2 170
E65, E66: 51 2 180
E83 51 0 040
WARNING: A second person must hold the engine hood (risk of injury and damage).
NOTE: The illustrations below serve as examples for all corresponding vehicles.
The operation is described on the left side; proceed in the same way for the
right side.
Special tool can only be used on housing (1) of gas spring strut (thick part).
NOTE: Gas spring strut can also be installed the other way round (housing on hood).
Special tool can be used in both directions.

2005 BMW 645Ci
Fig. 2: Identifying Gas Spring Strut Housing

Release gas spring strut on left/right housing side, refer to 51 23 265 REMOVING AND
INSTALLING/REPLACING LEFT OR RIGHT GAS STRUT FOR ENGINE BONNET/HOOD.
Slide special tool (1) over housing (2) of gas spring strut.
2005 BMW 645Ci
Fig. 3: Sliding Special Tool Over Housing Of Gas Spring Strut

Clip ball socket of special tool on ball stud.
Proceed in same way on other side.
51 11 ... OVERVIEW OF FRONT BUMPER
Fig. 4: Identifying Front Bumper Components

51 12 ... SURVEY OF REAR BUMPER
Fig. 5: Identifying Rear Bumper Components

51 16 ... OVERVIEW OF STORAGE COMPARTMENT (CENTRE CONSOLE)

2005 BMW 645Ci
Fig. 6: Identifying Center Console Components

51 21 ... OVERVIEW OF FRONT DOOR LOCKS
Fig. 7: Identifying Front Door Lock Components

51 45 ... OVERVIEW OF INSTRUMENT PANEL

2005 BMW 645Ci
Fig. 8: Identifying Instrument Panel Components

51 23 131 ADJUSTING LEFT OR RIGHT STRIKER ON ENGINE HOOD
NOTE: Operation is described in:
 Adjusting hood/bonnet, refer to 51 23 131 ADJUSTING LEFT OR RIGHT STRIKER ON ENGINE

HOOD.
51 23 265 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT GAS STRUT FOR

ENGINE BONNET/HOOD
Operation is described in removing and installing/replacing left or right gas strut for engine bonnet/hood, refer
to 51 23 265 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT GAS STRUT FOR
ENGINE BONNET/HOOD.
FRONT BUMPER
51 11 ... INSTALLING/REPLACING LICENSE PLATE (WITHOUT BASE)
Initial fitting:
Place drilling hole template (1) on bumper (2).

2005 BMW 645Ci
Fig. 9: Placing Drilling Hole Template On Bumper

NOTE: Hole diameter = 2.5 mm (see template).
Drill holes according to license plate.
Remove template (1).
Secure license plate with screws provided.
Installation:
Tightening torque, refer to 51 11 7AZ in BODY EQUIPMENT - TIGHTENING TORQUES - 645CI .
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 (M5 x 20).
Installation:

2005 BMW 645Ci
Fig. 10: Securing License Plate With License Plate Screw

51 11 ... OVERVIEW OF FRONT BUMPER
Fig. 11: Overview Of Front Bumper

51 11 050 REMOVING AND INSTALLING / REPLACING CARRIER FOR FRONT BUMPER TRIM
 Remove front bumper trim, refer to 51 11 156 REMOVING AND INSTALLING FRONT BUMPER
TRIM.
Detach wiring harness (1) from impact absorber (2).
Version with ACC:

2005 BMW 645Ci
Fig. 12: Removing Wiring Harness From Impact Absorber

Version with headlight washer system:
If necessary, disconnect line (2) on right from washer fluid reservoir coming from T-distributor (1).
Fig. 13: Disconnecting Line On Right From Washer Fluid Reservoir

IMPORTANT: Carrier must not be separated from deformation elements.
NOTE: The operation is described on the left side; proceed in the same way for the
right side.
Release screw (1).
If necessary, drill out rivets (3).

2005 BMW 645Ci
Release screws (2).
Remove carrier (4) with deformation element towards front.
Fig. 14: Removing Carrier With Deformation Element

Installation:
If necessary, use screws and locking pins (instead of rivets) to secure deformation element.
Replacement:
 Remove impact absorber

 If necessary, replace high-pressure nozzle of headlight washer system.
51 11 156 REMOVING AND INSTALLING FRONT BUMPER TRIM
right side.
Raise hood lid.
Release screws (1) on bumper trim (2).

2005 BMW 645Ci
Fig. 15: Removing Screws On Bumper Trim

Lever out trim (1 and 2) in direction of arrow.
Fig. 16: Identifying Direction For Removing Bumper Trim

Installation:
Make sure trims (2) are in correct installation position.
Installation:
Catches (1) on trim (2) must not be damaged.

2005 BMW 645Ci
Fig. 17: Identifying Catches On Trim

Installation:
Catches (1) and guide (2) on trim (3) must not be damaged.
Fig. 18: Identifying Catches And Guide On Trim

Release screws (1) on bumper trim (2).

2005 BMW 645Ci
Fig. 19: Releasing Screws On Bumper Trim

Release screws (1) on wheel arch trim (2).
Fig. 20: Releasing Screws On Wheel Arch Trim

IMPORTANT: Do not damage bumper trim when pulling off.
Pull bumper trim (1) in direction of arrow off side guide.

2005 BMW 645Ci
Fig. 21: Identifying Direction For Removing Bumper Trim

Pull off bumper trim (1) towards front.
Version without headlight cleaning system:
If necessary, disconnect plug connections on fog lamps (2) 2nd/or Park Distance Control (3).
Fig. 22: Identifying Plug Connections On Fog Lamps 2Nd/Or Park Distance Control
Remove bumper trim (1) towards front (with aid of a 2nd person).
Version with headlight cleaning system:
NOTE: Have a rubber plug on hand. Unlock hose (1), detach and seal pump outlet (2).
Remove bumper trim towards front (with aid of 2nd person).
2005 BMW 645Ci
Fig. 23: Unlocking Hose And Detaching And Seal Pump Outlet
Installation:
Tabs (1) on bumper trim (2) must not be damaged.
Fig. 24: Identifying Tabs On Bumper Trim

51 11 157 REPLACING FRONT BUMPER TRIM
TRIM.
2005 BMW 645Ci
Fig. 25: Removing Front Bumper Trim

 Remove cover cap (1) for tow lug.

 Remove spray nozzles of headlight washer system (2), refer to 61 67 045 REMOVING AND
INSTALLING/REPLACING SPRAY NOZZLES FOR LEFT OR RIGHT HEADLIGHT
CLEANING SYSTEM .
 Remove front fog lamp (3) (not for M6), refer to 63 17 060 REMOVING AND INSTALLING
(REPLACING) LEFT OR RIGHT FRONT FOG LAMP .
 Remove damping lip/spoiler (4) (not for M6)
 If necessary, remove trim for ACC (5) (not for M6)
 Remove trim grille in bumper trim (6), refer to 51 11 180 REMOVING AND
INSTALLING/REPLACING TRIM GRILL IN BUMPER TRIM.
 If necessary, remove license plate (7), refer to 51 11 ... INSTALLING/REPLACING LICENSE
PLATE (WITHOUT BASE).
 If necessary, remove baseplate for license plate, refer to 51 11 158 REPLACING BASEPLATE FOR
LICENCE PLATE.
 If necessary, remove wiring harness and PDC ultrasonic sensor (8).
 Remove middle front radiator grille (9), refer to 51 13 001 REMOVING AND
INSTALLING/REPLACING FRONT RADIATOR GRILL, MIDDLE LEFT OR RIGHT.
51 11 158 REPLACING BASEPLATE FOR LICENCE PLATE
Release screws (1).
Remove license plate holder (2).

2005 BMW 645Ci
Fig. 26: Removing License Plate Holder

51 11 180 REMOVING AND INSTALLING/REPLACING TRIM GRILL IN BUMPER TRIM
TRIM.
Version with headlight cleaning system:
If necessary, feed out hose (1) of headlight cleaning system.
Unhook catches (2) from trim grill (3).
Remove trim grill (3).
Installation:
Catches (2) on bumper trim (4) must not be damaged.

2005 BMW 645Ci
Fig. 27: Removing And Installing Grill

Installation:
Ribs (1) and line arrangements (2) on trim grill must not be damaged.
Fig. 28: Identifying Ribs And Line Arrangements On Trim Grill

51 11 701 REPLACING LEFT OR RIGHT BRACKET FOR FRONT BUMPER
TRIM.
Release screws (1).

2005 BMW 645Ci
Fig. 29: Removing Bracket

Installation:
Catches (1) on holder (2) must not be damaged.
Fig. 30: Identifying Catches On Holder

REAR BUMPER
51 12 ... SURVEY OF REAR BUMPER
For survey of rear bumper, refer to 51 12 ... SURVEY OF REAR BUMPER
51 12 050 REMOVING AND INSTALLING/REPLACING CARRIER FOR REAR BUMPER TRIM

2005 BMW 645Ci
 Remove rear bumper trim, refer to 51 12 156 REMOVING AND INSTALLING REAR BUMPER
TRIM.
Unscrew nuts (1).
Remove carrier (2) straight towards rear.
Fig. 31: Removing Rear Bumper Trim Carrier

Installation:
51 12 156 REMOVING AND INSTALLING REAR BUMPER TRIM
Special tools required
 00 9 317
 Partially remove luggage compartment wheel arch trim on left, refer to 51 47 151 REMOVING AND
INSTALLING/REPLACING LEFT LUGGAGE COMPARTMENT WHEEL ARCH TRIM.
 Remove license plate, refer to 51 11 ... INSTALLING/REPLACING LICENSE PLATE (WITHOUT
BASE).
right side.
2005 BMW 645Ci
Release screws (1) on wheel arch trim (2).
Fig. 32: Releasing Screws On Wheel Arch Trim

Release expander rivet (1) on bumper trim (2).
Fig. 33: Releasing Expander Rivet On Bumper Trim

Release expander rivet (1) on guide (2).
Unclip guide (2) with special tool 00 9 317 from bumper trim (3).
2005 BMW 645Ci
Fig. 34: Releasing Expander Rivet On Guide

Disconnect plug connection (1) and feed out wiring harness with cable grommet (2) in direction of arrow.
Fig. 35: Disconnecting Plug Connection And Removing Wiring Harness With Cable Grommet
Release expander rivets (1) on bumper trim (2).
Unclip bumper trim (2) to side panel outwards.
Remove bumper trim (2) towards rear (with aid of a 2nd person).
2005 BMW 645Ci
Fig. 36: Removing Bumper Trim Towards Rear

51 12 157 REPLACING REAR BUMPER TRIM
TRIM.
Remove rear light in bumper (1).
Remove cover cap (2) for tow lug.
Remove license plate light (3).
With optional PDC:
Remove all ultrasonic transducers (4).

2005 BMW 645Ci
Fig. 37: Removing Rear Bumper Trim

51 12 158 REMOVING AND INSTALLING/REPLACING BASEPLATE FOR NUMBER/LICENSE

PLATE (US)
 Remove rear bumper trim, refer to 51 12 157 REPLACING REAR BUMPER TRIM.
Release screws (1) and remove number/license plate baseplate.
Fig. 38: Releasing Screws (1) And Removing Number/License Plate Baseplate
Replacement:
Remove impact absorber (1).
If necessary, replace faulty metal nuts (2).

2005 BMW 645Ci
Fig. 39: Identifying Impact Absorber And Metal Nuts

51 12 801 REPLACING BRACKET FOR REAR BUMPER AT LEFT OR RIGHT
 Remove rear bumper trim, refer to 51 12 157 REPLACING REAR BUMPER TRIM.
Release expander rivet (1) on wheel cover (2).

2005 BMW 645Ci
Fig. 40: Releasing Expander Rivet On Wheel Cover

Release screw (1) and nut (2) and remove holder (3) in direction of arrow.
Fig. 41: Removing Holder

2005 BMW 645Ci
Installation:
If necessary, replace faulty metal nut (2).

51 12 810 REMOVING AND INSTALLING / REPLACING DEFORMATION ELEMENT ON

BUMPER CARRIER ON LEFT OR RIGHT
 Remove carrier for rear bumper trim, refer to 51 12 050 REMOVING AND
INSTALLING/REPLACING CARRIER FOR REAR BUMPER TRIM.
Release screws (1).
Remove locator (2) straight towards rear.

2005 BMW 645Ci
Fig. 43: Removing Locator

Installation:
Installation:
Foam seal (1) on locator (2) must not be damaged.
Fig. 44: Identifying Foam Seal On Locator

51 12 826 REMOVING AND INSTALLING/REPLACING GUIDE FOR REAR BUMPER
 Remove rear bumper trim, refer to 51 12 050 REMOVING AND INSTALLING/REPLACING

2005 BMW 645Ci
Unscrew nuts (1).
IMPORTANT: Carefully feed guide (2) out of rear lights (3) in direction of arrow (risk of
damage).
Fig. 45: Removing Guide Out Of Rear Lights

Installation:
Rests (1) on guide (2) must not be damaged.
Fig. 46: Identifying Rests On Guide

51 12 827 REMOVING AND INSTALLING / REPLACING GUIDE FOR BOTTOM REAR BUMPER

2005 BMW 645Ci
 Remove rear bumper trim, refer to 51 12 050 REMOVING AND INSTALLING/REPLACING

CARRIER FOR REAR BUMPER TRIM.
All models except M6:
Release nuts (1) on guide (2).
Remove guide (2).
Fig. 47: Removing Nuts And Guide (All Models Except M6)
Installation:
If necessary, replace faulty nuts (1).
M6 only:
Bend guide (1) downwards slightly and release nuts (2) behind.
Remove guide (1).
Installation:
If necessary, replace faulty nuts (2).

2005 BMW 645Ci
Fig. 48: Removing Guide (M6 Only)

TRIM, COVERS, HANDLE TRIM

51 13 ... REPLACING FRONT RADIATOR GRILL, MIDDLE LEFT OR RIGHT
NOTE: Representation created using the E85 as an example. There may be differences
in detail in the case of other vehicle models.
Lever out upper catches (3) and separate inner section (2) from chrome ring (1).
Fig. 49: Levering Out Upper Catches And Separating Inner Section From Chrome Ring
Installation:
Check inner section (1) for damage.

2005 BMW 645Ci
Retaining lugs (3) and (4) along line (2) must not be damaged.
Fig. 50: Checking Inner Section

Installation:
Check chrome ring (1) for damage.
Catches (4) and guides (3) along line (2) must not be damaged.
Fig. 51: Checking Chrome Ring For Damage

Installation:
Assemble chrome ring (1) and inner section (2).
Make sure catch (3) is correctly assembled.

2005 BMW 645Ci
Fig. 52: Assembling Chrome Ring And Inner Section

51 13 001 REMOVING AND INSTALLING/REPLACING FRONT RADIATOR GRILL, MIDDLE

LEFT OR RIGHT
 Remove bumper trim
Lever out catches (1) and (2) and remove middle front grill (3) towards front.
Fig. 53: Removing Middle Front Grill

Installation:
All catches and guides on middle front grill must not be damaged.
2005 BMW 645Ci
Fixtures (1) must engage correctly.
Fig. 54: Installing Front Radiator Grill Into Bumper Trim

NOTE: The following work step ends here: "Removing and installing middle left or right
front radiator grill." Replacement:
 Replace front radiator grill, middle left or right.
51 13 045 REMOVING AND INSTALLING/REPLACING TRIM ON FRONT LEFT OR RIGHT SIDE

PANEL
Operation is identical to:
Removing and installing/replacing front left or right auxiliary turn signal lamp, refer to 63 13 200
REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT AUXILIARY TURN
SIGNAL LAMP .
51 13 115 REMOVING AND INSTALLING/REPLACING COWL PANEL COVER
 Remove both windshield wiper arms

 Remove lower microfilter housing section on left and right
Release clip on left/right.
Turn quick-release fasteners (2) approx. 90° counterclockwise.
NOTE: The fastener is closed if the arrow tips point to each other.
2005 BMW 645Ci
Unscrew bolt (1).
Remove cowl panel cover towards top.
Installation:
Tighten down screw (1) to tightening torque, refer to 51 13 5AZ in BODY EQUIPMENT - TIGHTENING
TORQUES - 645CI .
Check cover (3) for correct seating.
Tighten quick-release fasteners (2) from the middle.
Fig. 55: Removing Cowl Panel Cover

51 13 280 REMOVING AND INSTALLING TRIM STRIP ON ROOF FRAME AT LEFT OR RIGHT
 00 9 321
Lever out trim strip (1) with special tool 00 9 321 first at rear, unclip remainder up to front and pull out of seal
(2) towards rear.
2005 BMW 645Ci
Fig. 56: Levering Out Trim Strip With Special Tool 00 9 321
If necessary, replace defective clips (1) on roof outer skin.
Fig. 57: Removing Defective Clips On Roof Outer Skin

Installation:
Following parts of trim strip (6) must not be damaged or missing:

2005 BMW 645Ci
Fig. 58: Identifying Seals And Foam

Installation:
First push trim strip (2) at front into seal (1), clip in at rear flush with edge (3) and then clip in remainder.
Fig. 59: Installing Trim Strip

51 13 316 REMOVING AND INSTALLING/REPLACING TRIM STRIP ON ROOF GUTTER AT

LEFT OR RIGHT
Detach mucket (1) in area of trim strip (2).

2005 BMW 645Ci
Fig. 60: Detaching Mucket In Area Of Trim Strip

IMPORTANT: Make sure that body is not damaged.
Start at front, pull off trim strip (1) in direction of arrow from clips (2).
Fig. 61: Identifying Clips And Trim Strip

Installation:
To avoid leaks and noises, check all clips (2) for visible damage.
If necessary, replace faulty clips (2).
Installation:
Make sure sealing strip (2) is correctly seated on trim strip (1).
2005 BMW 645Ci
Sealing strip (2) must not be damaged.
Fig. 62: Identifying Correct Seating Of Sealing Strip On Trim Strip

IMPORTANT:  Carry trim strip by its middle section only (risk of damage)
 Perform installation work with a second person helping
 Prepositioning of trim strip
 Ensure drip moulding runs parallel to side frame (risk of breakage)
BMW EMBLEMS, MODEL EMBLEMS

51 14 ... INSTRUCTIONS FOR ATTACHING NUMBER/LETTER DESIGNATION COMBINATION
NOTE: The model designation is attached with adhesive and cannot be re-used. The
model designation must be attached at room temperature. The model
designation must be removed at stove enameling temperatures exceeding 80°C.
NOTE: The following work steps are described using the "316 i" as the example.
Removing:
Coat nylon string or strong yarn with tensides (e.g. washing-up liquid).
Cut through adhesive layer and remove model designation (1) from rear lid (2).
2005 BMW 645Ci
Fig. 63: Removing Number/Letter Designation Combination

Remove remainder of adhesive layer with adhesive remover.
Assembly:
Number and letter combinations (1) of the model designation are not connected to each other and are supplied
on a carrier film (2).
IMPORTANT: Adhesive areas must be dry and free of dust and grease. Once it has been
cleaned, do not touch the adhesive area with bare hands.
Remove liner (3) (protective strip for adhesive surface).
Press on model designation firmly.
Remove carrier film (2).

2005 BMW 645Ci
Fig. 64: Assembling Number/Letter Designation Combination

51 14 000 REMOVING AND INSTALLING/REPLACING FRONT BMW BADGE
 00 9 318
Lever out badge with special tool 00 9 318 and remove towards top.
Fig. 65: Removing Badge With Special Tool 00 9 318

Installation:
Following parts of badge (1) must not be damaged or missing:
(2) Guide pins
(3) Grommets
2005 BMW 645Ci
Fig. 66: Identifying Guide Pins And Grommet

51 14 010 REMOVING AND INSTALLING/REPLACING REAR BMW BADGE
 00 9 322
NOTE: The rear BMW badge is secured with adhesive tape. The position of the badge
is determined by two guide pins on the back. The BMW badge must be fitted at
room temperature.
Carefully heat BMW badge with a hot air blower.
Use special tool 00 9 322 to remove.

2005 BMW 645Ci
Fig. 67: Removing BMW Badge With Special Tool 00 9 322

Installation:
Adhesive tape and residue must be removed prior to fitting.
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 (E63, E64):
Fig. 68: Identifying Fitting Dimensions Of Rear Model Designations

Stick on adhesive tape (1) up to top edge "A". Mark measurement "B" from edge of rear lid (2) on adhesive tape
(1).
Dimensions:
NOTE: E63, E64 (without M6) A = 50 mm B = 36 mm
M6 A = 45 mm B = 54 mm
NOTE: Measurements C, D, E and F are for information purposes only, as determined

by carrier film. 630 i: C = 6 mm, D = 7.0 mm, E = 22 mm, 645 Ci: C = 7.5 mm, D =
11 mm, E = 20 mm, F = 7.5 mm, M6: C = 7.5 mm
MIRRORS/COVERS/ASHTRAYS/SHELVES/TRAYS
2005 BMW 645Ci
51 16 ... CEMENTING OF MIRROR BASE
Material Requirements:
Repair set for cementing of mirror base.
Primer XW 775.
1. Preparations
1.1 Cement at room temperature and make sure that, in cold weather, the window glass and base
are brought to room temperature in the workshop long enough to prevent moisture forming on the
surface.
1.2 Mark location of the mirror mount on the outside of the windshield. Scratch off cement residue
on glass and base with a sharp tool.
1.3 Clean cement 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 colorless, diluted primer to surface of windshield intended for cementing with help of cotton buds
(Q-Tips or similar).
Specified ventilation time at least 10 minutes, maximum 1 hour
3. Cement Coat
3.1 Mixing Cement
Trim off sealing tips on containers of cement and hardener using a knife.
Make sure that both openings are equal in size, as otherwise there would be mistakes in mixing.
The sealing cap for subsequent plugging of the double injector is located between both pistons of
the injector. Break off sealing cap.
The required amount of cement and hardener is removed by applying light pressure on the pistons.
The mixing ratio for cement and hardener is 1 : 1 (weight and volume). It is important that the same
volumes of cement and hardener are removed (increase size of openings if necessary).
Both components react chemically with each other. Thorough, intensive and homogenous mixing is
a requirement for this reaction and for the quality of cementing.
Consequently both components must be mixed in such a way that there is a uniform, ream-free
color mixture.
3.2 Application
2005 BMW 645Ci
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 cement on base with spatula and press base onto
glass in such a way that cement obtains good contact with windshield across the entire surface area.
NOTE: The temperature for the hardening process should not be lower than
+18 °C.
3.3 Fixing Bonded Parts
Epoxide resin cement does not have an initial strength property. It is therefore necessary to fix all
bonded parts (cement 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 cement
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
CAUTION: Cement is dangerous for health when vapours are inhaled or through
contact with the skin.
As is the case for all epoxide resins, sensitive persons might be
confronted with an alergy through contact with the skin.
If the product gets on the skin, wash off with soap and water
immediately.
If it gets in an eye, rinse the eye thoroughly in water and consult
doctor.
Make sure that the room is well ventilated and gloves are worn for the
application of cement.
51 16 ... REMOVING AND INSTALLING/REPLACING CENTRE ARMREST CARRIER
 Remove storage compartment

2005 BMW 645Ci
Fig. 69: Detaching Hinge Cover

Disconnect connector (1).
Disconnect Bowden cable (2).
Release screws (3) and remove lock mechanism (4).
Fig. 70: Removing Lock Mechanism

Release screws (1).

2005 BMW 645Ci
Fig. 71: Releasing Screws (1)

Depress actuator (1) for centre armrest and remove centre armrest carrier in upwards direction.
Fig. 72: Depressing Actuator

Replacement:
 Remove cover for centre armrest

 Remove lock cylinder for storage box
 If necessary, remove eject box.
51 16 ... REMOVING AND INSTALLING/REPLACING MOUNTING FOR CUP HOLDER AT

FRONT

2005 BMW 645Ci
Release screws (1).
Release holder (2) from trim (3).
Fig. 73: Releasing Holder From Trim

Installation:
Following parts must not be damaged or missing:
Fig. 74: Identifying Catches, Spring And Plates

51 16 000 REMOVING AND INSTALLING/REPLACING MIRROR ON LEFT OR RIGHT FRONT

DOOR
2005 BMW 645Ci
 Remove front door trim panel

 Remove speaker (tweeter)
 Partially remove sound insulation in front door
Release cable ties (1).
Lever out clip (2) and disconnect plug connection (3).
Feed wiring harness (4) out of cable duct (5).

Installation:
If necessary, replace faulty clip (2).
Fold rubber guide (1) to one side.
Release screws (2) and feed out mirror (3) with wiring harness.
2005 BMW 645Ci
Fig. 76: Removing Screws And Mirror

Installation:
Replacement:
Due to the self-tapping screws, the tightening torque of the new mirror is increased by 2 Nm.
Installation:
Sound insulation (1) on mirror (2) must not be damaged.
Fig. 77: Identifying Sound Insulation On Mirror

2005 BMW 645Ci
Check function.
51 16 026 REPLACING MIRROR GLASS
 00 9 317
WARNING: Move mirror glass with hand carefully and slowly. If mirror glass is
damaged: Wear protective goggles and cut-proof gloves.
IMPORTANT: Bring door mirror to room temperature to prevent catches from breaking off.
Press mirror glass (1) on side vehicle by hand to full extent.
NOTE: Secure mirror glass (1) against falling out. Unclip mirror glass (1) from outer
side with special tool 00 9 317 all round. Unlock and disconnect associated plug
connections, remove mirror glass (1).
Fig. 78: Unclipping Mirror Glass From Outer Side With Special Tool 00 9 317
Installation:
Retaining lugs (1) must not be damaged.
Fit mirror glass (2) with retaining lugs (1) flush on mirror adjusting drive and clip into place.
2005 BMW 645Ci
Fig. 79: Fitting Mirror Glass With Retaining Lugs Flush On Mirror Adjusting Drive
Ensure correct locking.
Make sure mirror adjusting drive functions correctly.
51 16 040 REMOVING AND INSTALLING/REPLACING HOUSING ON LEFT OR RIGHT DOOR

MIRROR
 Remove mirror glass
NOTE: Housing on door mirror (2) is secured without play by four multitooth catches
(1) on retaining ring (3). Secure housing on door mirror (2) against falling out.
Unlock multitooth catches (1) with a screwdriver.
Unclip housing on door mirror (2) forwards from retaining ring (3) and remove.
2005 BMW 645Ci
Fig. 80: Installing Housing On Door Mirror

Installation:
Multitooth catches (1) and guide (2) on housing on door mirror (3) must not be damaged.
Fig. 81: Identifying Multitooth Catches And Guide

Installation:
Fixtures (1) on retaining plate (2) must not be damaged.

2005 BMW 645Ci
Fig. 82: Identifying Fixtures On Retaining Plate

51 16 045 REMOVING AND INSTALLING/REPLACING RETAINING RING ON LEFT OR RIGHT

DOOR MIRROR
 64 1 020
 Remove housing on door mirror

 Remove drive for electrically adjustable door mirror
NOTE: Version with door mirror light: Disconnect plug connection (1).
Release screws (2) and remove complete retaining ring on door mirror (3) from carrier (4).
2005 BMW 645Ci
Fig. 83: Removing Complete Retaining Ring On Door Mirror From Carrier
Installation:
Version with door mirror light:
Unclip retaining ring on door mirror (1) with special tool 64 1 020 all round and remove from retaining plate
(2).
Fig. 84: Unclipping Retaining Ring On Door Mirror With Special Tool 64 1 020
51 16 060 REMOVING AND INSTALLING OR REPLACING INTERIOR REARVIEW MIRROR
NOTE: On version with remote control for central locking: If necessary, disconnect
negative lead from battery. On version with compass: Check compass function
2005 BMW 645Ci
after disconnecting mirror plug connection or battery or after replacement. If

necessary, calibrate compass in interior rearview mirror.
NOTE: There are five different versions of the interior rearview mirror:
A. Version without cable (X) with full foot

B. Version with cable (X) and with plug cover
C. Version without cable (X) and with mirror arm end caps
D. Version with cable (X) and with mirror arm end caps
E. Version with rain sensor and with mirror arm end caps
Version with cable (X) for:
 Automatic dim action (electro-chrome technology) for interior rearview mirror

 Fogging sensor
 Remote control (infrared or radio)
 Garage door opener
 Compass
 Rain sensor
IMPORTANT: Do not snap out the interior rearview mirror (1) towards the rear (windscreen
breakage). Do not under any circumstances twist the interior rearview mirror
when removing. Twisting the mirror off the mirror mount will damage the rear
catch. If the rear catch is damaged, the mirror will be loose when installed and
must be replaced.
Removal of version (B):
Version with automatic dim action (electro-chrome technology) for interior mirror and/or remote control:
Lever out plug cover and disconnect plug connection.

2005 BMW 645Ci

IMPORTANT: Do not remove interior mirror (1) towards rear or by twisting (risk of damage).
Snap out interior mirror (1) from mirror mount towards front by striking with ball of thumb and remove.
Fig. 86: Removing Interior Mirror From Mirror Mount

Installation:
1. Twist mirror foot by approx. 45° and fit to mirror mount.

2. Turn mirror foot until it engages on mirror base.
2005 BMW 645Ci
Fig. 87: Identifying Angle For Twisting Mirror

Only replace with version with remote control for central locking:
Installation:
Initialize all transmitters (ignition keys), refer to Owner's Handbook.
Removal of versions (C) and (D):
Press end caps (1) towards mirror housing (2); this releases clip connection of both caps (1).
Fig. 88: Disconnecting Clip Connection Of Both Caps

Twist mirror (1) at an angle towards front and right/top.
Swivel left end cap (2) off ball neck in direction of arrow; this detaches the engagement clip (3) from the metal
2005 BMW 645Ci
Fig. 89: Identifying Swivel Left End Cap

Twist 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.
Fig. 90: Identifying Swivel Right End Cap


2005 BMW 645Ci

Snap out interior mirror (1) from mirror mount (2) towards front by striking with ball of thumb and remove.

Installation:
Clips (1) and retaining hooks (2) of end caps (3) must not be damaged, replace if necessary.
2005 BMW 645Ci
Fig. 93: Identifying Clips And Retaining Hooks

Installation:


Removal of version (E) with rain sensor:
Press on end caps (1) and at same time press them apart; this releases clip connection of both caps (1).
2005 BMW 645Ci
Fig. 95: Disconnecting Clip Connection Of Both Caps

Twist mirror (1) at an angle towards front and right/top.
Swivel left end cap (2) off ball neck in direction of arrow; this detaches the engagement clip (3) from the metal
foot.
Fig. 96: Identifying Swivel Left End Cap

Twist 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.
2005 BMW 645Ci
Fig. 97: Identifying Swivel Right End Cap

Pay attention to cable guide (2) for rain sensor.

2005 BMW 645Ci

When snapping out, do not damage control unit (3) for rain sensor.
Snap out interior mirror (1) from mirror mount (2) towards front by striking with ball of thumb and remove.

Installation:
Clips (1) and retaining hooks (2) of end caps (3) must not be damaged, replace if necessary.
2005 BMW 645Ci
Fig. 100: Identifying Clips And Retaining Hooks

Installation:


Only replace with version with remote control for central locking:
Installation:
Initialize all transmitters (ignition keys), refer to Owner's Handbook.
51 16 080 REMOVING AND INSTALLING OR REPLACING SUN VISOR AND LEFT OR RIGHT
COUNTER SUPPORT
2005 BMW 645Ci
Lever sun visor (1) out of counter support.
Release screws (2) and remove sun visor towards bottom.
Version with interior light package:
If necessary, release screws (2).
Detach sun visor (1) towards bottom slightly, disconnect plug connection and remove sun visor (1).
Fig. 102: Removing Sun Visor

Installation:
Perform function check on lighting.
Lever out trims (1).
Release screws (2) and remove counter-support (3).

2005 BMW 645Ci
Fig. 103: Removing Counter-Support

51 16 196 REMOVING AND INSTALLING/REPLACING (BOTH) COVERS FOR CENTRE

ARMREST
Open cover.
Release screws (1).
Remove cover (2).
NOTE: Illustration shows the front cover, remove the rear cover in the same way.
Fig. 104: Removing And Installing/Replacing Covers For Centre Armrest

51 16 200 REMOVING AND INSTALLING STORAGE COMPARTMENT

2005 BMW 645Ci
 00 9 317
 Remove trim for preselector lever (gear lever)

 Remove trim for storage compartment
 Remove central trim for instrument panel
 Remove rear seat
 Remove rear cup holder
Specification with telephone:
 Disconnect plug for eject box
Fold rear centre armrest back.
Unclip covers (1) on openings (2) in direction of arrows and release screws underneath.
Fig. 105: Unclipping Covers On Openings

Installation:
Catches (1) on cover (2) must not be damaged.

2005 BMW 645Ci
Fig. 106: Identifying Catches On Cover

Release screws (1) on storage compartment (2).
Fig. 107: Removing Screws On Storage Compartment

Release screws (1) on instrument panel (2).

2005 BMW 645Ci
Fig. 108: Releasing Screws On Instrument Panel

Release screw (1) on transmission tunnel (2).
Fig. 109: Releasing Screw On Transmission Tunnel

Unclip gaiter (1) upwards with special tool 00 9 317.
Raise storage compartment (2) and if necessary disconnect plug connections from below.
Feed out storage compartment (2) past gaiter (1) and remove towards top rear.
2005 BMW 645Ci
Fig. 110: Unclipping Gaiter Upwards With Special Tool 00 9 317

51 16 201 REPLACING STORAGE COMPARTMENT

 Remove centre armrest carrier
 Remove cup holder mounting
 Remove controller
 Remove servodrive for storage compartment
 Remove button unit
Pull off trim (1) on left/right in direction of arrow.
Fig. 111: Removing Trim On Left/Right

Release retainers (1) and remove trim (2).

2005 BMW 645Ci
Feed cable (3) out of storage compartment.
Fig. 112: Removing Storage Compartment

51 16 204 REMOVING AND INSTALLING/REPLACING REAR CUP HOLDER
Fold rear center armrest back.
Lift out cup holder (1).

2005 BMW 645Ci
Fig. 113: Removing Cup Holder

Unclip holder (1) towards top.
Fig. 114: Unclipping Holder Towards Top

Installation:

2005 BMW 645Ci

51 16 210 REMOVING AND INSTALLING/REPLACING TRIM FOR PRESELECTOR LEVER

(GEARSHIFT LEVER)
 00 9 341
 Apply parking brake

 Version with automatic transmission: Move selector lever into N position
 Version with manual transmission: Engage neutral
NOTE: Removing the trim for the preselector lever or gearshift lever is virtually
identical. The illustrations show the removal of the trim for the preselector lever
in versions with automatic transmissions.
IMPORTANT: Do not shear off turning lock of selector lever knob (1).
Therefore do not twist selector lever knob (1) when removing.
Pull off selector lever knob (1) with a forceful jerk.
Press sides of selector lever cover (2) together and feed out towards top.
Unclip trim for preselector lever (4) with special tool 00 9 341 from mounting points (3).
2005 BMW 645Ci
Fig. 116: Identifying Preselector Lever Knob

Disconnect associated plug connections and remove trim for preselector lever (4) towards top.
Installation:
Make sure retainers (1) are correctly seated in appropriate mounts of trim for preselector lever (2).
2005 BMW 645Ci
Fig. 117: Identifying Correct Seating Of Retainers

Replacement:
If necessary, remove driving dynamics switch.
51 16 212 REMOVING AND INSTALLING TRIM FOR CENTER CONSOLE
 Remove middle trim for instrument panel

 Remove finisher for preselector lever
Release screws (1).
Feed out trim for storage tray (2) with center console switch cluster (3) in direction of arrow.
2005 BMW 645Ci
Unlock and disconnect associated plug connections, remove trim for storage tray (2) with center console switch
cluster (3).
Fig. 118: Removing Center Console Trim

51 16 245 REMOVING AND INSTALLING/REPLACING LOCK CYLINDER FOR STORAGE BOX
Release screws (3) and remove lock mechanism (4).

2005 BMW 645Ci
Fig. 119: Removing Lock Mechanism

IMPORTANT: Ignition key must be inserted in lock cylinder otherwise coding of lock cylinder
may fall out. Proceed with extreme care when releasing catches (2). Catches (2)
must not break off.
Carefully release catches (2) and pull out lock (1) with ignition key.
2005 BMW 645Ci
Fig. 120: Identifying Catches And Lock

51 16 345 REMOVING AND INSTALLING/REPLACING BUTTON AND BOWDEN CABLE FOR

GLOVEBOX
Removing and installing/replacing right decorative strip on instrument panel
51 16 342 REMOVING AND INSTALLING/REPLACING LOCK CYLINDER FOR PASSENGER

AIRBAG DEACTIVATION
2005 BMW 645Ci
Fig. 121: Identifying Individual Parts/Switch For Passenger Airbag Deactivation

(1) Ignition key (2) Lock cylinder (3) Switch housing (4) Sealing ring (5) Guide (6) Switch unit (7) PCB (8)
Housing Cover (9) Screws
Remove switch for passenger airbag deactivation.
Release screws (1). Remove housing cover (2) and PCB (3) underneath.
2005 BMW 645Ci
Fig. 122: Releasing Screws (1), Removing Housing Cover (2) And PCB (3)
Remove switch unit (1) in upward direction. Installation: Switch unit (1) can only be installed in one position.
PCB (4) can be inserted turned through 180°. Position of magnet sensor (3) of PCB (4) must match up with
permanent magnet (2) of switch unit (1).
Fig. 123: Removing Switch Unit (1) In Upward Direction

Remove guide (1) in upward direction. Installation: Guide (1) can only be installed in one position. Fit seal (2)
on guide (1) and insert in switch housing
Fig. 124: Removing Guide (1) In Upward Direction

IMPORTANT: Ignition key must be inserted in lock cylinder, otherwise this will be destroyed
when removed.
2005 BMW 645Ci
Important! Ignition key must be inserted in lock cylinder, otherwise this will be destroyed when removed. Insert
ignition key in lock cylinder (2). Carefully release catches (1) in outward direction and press out lock cylinder
(2) with ignition key.
Fig. 125: Carefully Release Catches (1) In Outward Direction And Press Out Lock Cylinder (2) With
Ignition Key
Installation: Lock cylinder (2) can only be inserted in "ON" or "OFF" switch position. Lock cylinder.
51 16 366 REMOVING AND INSTALLING RIGHT GLOVEBOX WITH HOUSING (WITHOUT

ACTIVE KNEE PROTECTION)
 Remove trim for instrument panel, bottom right
Release screws (1).
Release screws (2) and pull back right glovebox with housing (4).
2005 BMW 645Ci
Fig. 126: Removing And Installing Right Glovebox With Housing (Without Active Knee Protection)
Installation:
Make sure right glovebox with housing (4) is correctly seated in associated mountings.
Disconnect associated Bowden cable (3).
Unlock associated plug connections, disconnect and remove right glovebox with housing (4).
51 16 367 REMOVING AND INSTALLING RIGHT GLOVEBOX WITH HOUSING (WITH ACTIVE
KNEE PROTECTION)
WARNING: Read and comply with safety regulations for handling airbag modules and
pyrotechnical belt tensioners. Incorrect handling can activate airbag and
cause injury.
2005 BMW 645Ci
 Remove luggage compartment floor trim

 Disconnect battery negative lead
Subsequent work is described in:
"Removing right glovebox with housing (without active knee protection)".
LIDS
51 23 004 ADJUSTING HOOD/BONNET LOCK
NOTE: Operation is identical to:
 Adjusting hood/bonnet, refer to 51 23 131 ADJUSTING LEFT OR RIGHT

STRIKER ON ENGINE HOOD.
51 23 100 REMOVING AND INSTALLING/REPLACING RIGHT ENGINE HOOD LOCK
Removing and installing/replacing left engine hood lock, refer to 51 23 110 REMOVING AND
INSTALLING/REPLACING LEFT HOOD/BONNET LOCK.
51 23 110 REMOVING AND INSTALLING/REPLACING LEFT HOOD/BONNET LOCK
Unclip coupling (1) from side panel.
Open cover (2).
Lever cable (3) out of coupling (1).
NOTE: The operation "Disconnect cable for hood/bonnet locks" ends here.
2005 BMW 645Ci
Fig. 127: Removing Cable Out Of Coupling

Unscrew screws (1).
Feed out hood/bonnet lock (2) with cable (3) in direction of arrow.
2005 BMW 645Ci
Fig. 128: Removing Hood/Bonnet Lock With Cable

Disengage cable (1) from hood/bonnet lock (2).

2005 BMW 645Ci
Fig. 129: Disengaging Cable From Hood/Bonnet Lock


51 23 160 REMOVING AND INSTALLING/REPLACING ARRESTER HOOK ON ENGINE HOOD
Raise bonnet/hood lid.
Release screws (1) and remove arrester hook (2).

2005 BMW 645Ci
Fig. 130: Removing Arrester Hook

51 23 211 REMOVING AND INSTALLING/REPLACING CABLE FOR FRONT ENGINE HOOD

LOCKS (TO PASSENGER COMPARTMENT)
 Disconnect cable for hood/bonnet locks

 Remove lower section of microfilter housing
 Remove trim panel for pedal assembly
 Remove footwell side trim panel on A-pillar
Release screws (1).
Remove fixture (2) and feed out Bowden cable (3).

2005 BMW 645Ci
Fig. 131: Removing Fixture And Bowden Cable

Feed Bowden cable (1) out of grommet (2).
Carefully feed Bowden cable (1) with grommet (3) out of vehicle interior.
2005 BMW 645Ci
Fig. 132: Identifying Bowden Cable With Grommets

IMPORTANT: Make sure grommets (2 and 3) are correctly seated (water ingress).
Installation:
Lay Bowden cable (1) without kinks.
51 23 212 REMOVING AND INSTALLING/REPLACING CABLE FOR HOOD/BONNET LOCKS (TO

LOCKS)
 Remove left/right hood/bonnet locks
Release cable (1) from cable holders (2).

2005 BMW 645Ci
Feed cable (1) out of carrier (3).
Fig. 133: Removing And Installing/Replacing Cable For Hood/Bonnet Locks (To Locks)
Installation:
If necessary, replace cable holders (2).

ENGINE BONNET/HOOD
WARNING: Risk of injury and damage! For the following tasks, you must take the
appropriate measures to support the engine bonnet/hood. As an
alternative, you can enlist the help of a second person to hold the
bonnet/hood.

2005 BMW 645Ci
1. Push retainer spring to end of gas spring strut.

2. Remove gas spring strut from ball head.
Fig. 134: Removing Gas Spring Strut

FRONT DOOR LOCKS, HANDLES, FITTINGS

51 21 003 REPLACING DOOR DETENT (LOCK STRIKER), FRONT LEFT OR RIGHT
Release screws (1) and remove door detent (3).
Installation:
Basic adjustment via crosswire on B-pillar (4) and notches (2) on door detent (3).
2005 BMW 645Ci
Adjust door detent.
Fig. 135: Removing And Installing Door Detent (Lock Striker)

51 21 004 ADJUSTING FRONT LEFT OR RIGHT DOOR DETENT (LOCK WEDGE)
Adjusting left or right front door detent as necessary.
51 21 090 REMOVING AND INSTALLING/REPLACING DOOR LOCK IN LEFT OR RIGHT FRONT

DOOR
 51 2 190
2005 BMW 645Ci
 Remove door window glass

 Release power window unit in rear area only
 Remove Bowden cable for inside door opener.
Disconnect Bowden cable at bottom (1) and top (3) from door lock (2).
IMPORTANT: Bowden cable must be correctly located in mounts on door lock (2). Seal (4)
must be correctly positioned on Bowden cable.
NOTE: The operations for "Removing Bowden cable from door lock" ends here.
Fig. 136: Disconnecting Bowden Cable At Bottom

Unlock plug connection (1) at lugs (2) and detach from door lock (3).
Unclip locking rod (4) from door lock (3).

2005 BMW 645Ci
IMPORTANT: Do not damage door lock seal during removal.
Release screws (1).
Remove door lock (2) from inside.
IMPORTANT: To avoid leakage and electrical malfunction: Pull door lock (2) with special tool
into corner (3), see Fig. 141 and Fig. 142.
Fig. 138: Removing Door Lock

Driver's door only:
Installation:
Insert inside door lock (1) correctly into paddle (2) of lock cylinder (3).
2005 BMW 645Ci
Installation:
Seal (1) on door lock (2) must not be damaged.
Fig. 140: Installing Seal On Door Lock

Installation:
 Install door lock and insert screws (1), do not tighten down.
 Slide special tool 51 2 190 into opened rotary latch until latch engages in first stage.
Fig. 141: Installing Door Lock

Installation:
 Pretension door lock (1) with knurled screw (2) until special tool 51 2 190 just contacts corner points (3).
2005 BMW 645Ci
Fig. 142: Pretensioning Door Lock With Knurled Screw

IMPORTANT: To tension door lock (1), it is only permitted to turn knurled screw (2) by a
further 1 to 1.5 turns (max.) (risk of damage). Door lock seal must rest
uniformly on inner door plate (water ingress).
 Tighten down door lock screws, tightening torque, refer to 51 21 1AZ in BODY EQUIPMENT -
TIGHTENING TORQUES - 645CI .
51 21 125 REMOVING AND INSTALLING/REPLACING CARRIER FOR LEFT OR RIGHT

OUTSIDE DOOR HANDLE WITH LOCK CYLINDER
 Remove cover on outside handle

 Disconnect Bowden cable from door lock
Driver's side only:
 Remove door lock on front door
Unlock catches (2) on carrier (1).
Press lock cylinder (4) behind door outer skin (3).

2005 BMW 645Ci
Fig. 143: Identifying Lock Cylinder

Pull carrier (3) towards rear/top until screw (1) of sheet metal slot (2) is free.
Remove carrier (3) for outside door handle.
Fig. 144: Removing Carrier For Outside Door Handle

Installation:
Seals (1) on carrier (3) must not be damaged.
IMPORTANT: Water drainage channel (2) must not be fouled/clogged.

2005 BMW 645Ci
Fig. 145: Identifying Water Drainage Channel

NOTE: The following work step ends here: Removing and installing carrier for left or
right outside door handle with lock cylinder.
Replacement only:
 Remove lock cylinder completely from front door

 Remove Bowden cable for outside door handle on front door
51 21 126 REMOVING AND INSTALLING/REPLACING CARRIER FOR LEFT OR RIGHT

OUTSIDE DOOR HANDLE WITHOUT LOCK CYLINDER
NOTE: Operation is (except for tasks relating to removing door lock) identical to:
 Removing and installing/replacing carrier for outside door handle with

lock cylinder, refer to 51 21 125 REMOVING AND INSTALLING/REPLACING
CARRIER FOR LEFT OR RIGHT OUTSIDE DOOR HANDLE WITH LOCK
CYLINDER.
51 21 140 REMOVING AND INSTALLING/REPLACING COMPLETE LOCK CYLINDER IN LEFT

OR RIGHT FRONT DOOR
 Remove carrier for outside door handle with lock cylinder
Lever retainer (1) out of lock (2).
Pull retainer (1) out of guide (3).
Connection between carrier (5) and lock cylinder (4) is released.

2005 BMW 645Ci
Fig. 146: Removing Retainer Out Of Lock

Installation:
Catches (1) of retainer (2) must not be damaged.
Fig. 147: Identifying Catches Of Retainer

Pull lock cylinder (1) out of carrier (2).

2005 BMW 645Ci
Fig. 148: Removing Lock Cylinder Out Of Carrier

Installation:
Following parts on lock cylinder (3) must not be damaged or missing:
1. Paddle
2. Guides
Fig. 149: Identifying Lock Cylinder Parts

51 21 170 REMOVING AND INSTALLING OR REPLACING OUTSIDE HANDLE FROM LEFT OR

RIGHT FRONT DOOR
 51 2 220
2005 BMW 645Ci
2-door Models:
Remove trim (1).
Fig. 150: Removing Trim (2-Door Models)

4-door Models:
Remove trim (1).
Fig. 151: Removing Trim (4-Door Models)

NOTE: Protect bore (1) against scratching (risk of corrosion).
IMPORTANT: If the screw is not correctly secured, the lock mechanism can jump back and
the sound insulation must be removed.
Pull outside handle (2) outwards/upwards until screw (3) is accessible and hold.
2005 BMW 645Ci
Using special tool 51 2 220, turn screw (3) counterclockwise and screw down.
Fig. 152: Pulling Outside Handle Outwards/Upward

A. Pull off outside handle (1) from rear lock actuator (2).
B. Pull off outside handle (1) downwards (as shown in illustration) from front lock actuator (3).
Fig. 153: Removing Outside Handle

Installation:
Following parts on outside handle (4) must not be damaged or missing:
1. Rear mounting
2. Front mounting
3. Felt strip (if available for refitting/replacement no longer required)
2005 BMW 645Ci
Fig. 154: Identifying Outside Handle Parts

Installation:
Stop pad (1) must be fitted.
Insert outside handle (4) with bore (3) correctly in mounting (2).
Engage mounting (5) of outside handle (4) correctly in lock actuator (6).
Fig. 155: Engaging Mounting Of Outside Handle Correctly In Lock Actuator

NOTE: Protect bore (1) against scratching/damaged paintwork (risk of corrosion).
IMPORTANT: If the screw is not correctly secured, the lock mechanism can jump back and
the sound insulation must be removed.
Using special tool 51 2 220, turn screw (3) counterclockwise and screw down.
2005 BMW 645Ci
Fig. 156: Turning Screw Using Special Tool 51 2 220

Installation:
Carry out function check only with door open.
51 21 180 REMOVING AND INSTALLING/REPLACING COVER ON OUTSIDE HANDLE
 Remove outside handle
2-door Models:
Remove plate (2).
Fig. 157: Removing Plate (2-Door Models)

2005 BMW 645Ci
4-door Models:
Remove plate (2).
Fig. 158: Removing Plate (4-Door Models)

NOTE: Protect bore (1) against scratching (risk of corrosion). Unscrew bolt (2).
Installation:
Press cover (3) slightly towards rear when screwing down (gap).
Fig. 159: Identifying Bore

Remove stop pad (1).

2005 BMW 645Ci
Fig. 160: Removing Stop Pad

Loosen screw (1).
Fig. 161: Loosening Screw

Press mounting (2) back, lever out cover (3) at rear and remove in direction of arrow.
Installation:
Following parts of cover on outside handle (5) must not be damaged or missing:
2005 BMW 645Ci
Fig. 162: Identifying Parts Of Cover On Outside Handle

51 21 225 REMOVING AND INSTALLING OR REPLACING INSIDE DOOR OPENER IN LEFT OR

RIGHT FRONT DOOR
Lever door opener (1) in direction of arrow out of door trim panel (2).
Fig. 163: Removing Door Opener From Door Trim Panel

Replacement:
Unclip handle light (2) from catches (1).

2005 BMW 645Ci
Fig. 164: Unclipping Handle Light From Catches

Installation:
Catches (1) must not be damaged
Installation:
Fixtures (1) on door opener (2) must not be damaged.
Fig. 165: Identifying Fixtures On Door Opener

51 21 233 REMOVING AND INSTALLING/REPLACING BOWDEN CABLE FOR OUTSIDE DOOR

HANDLE ON LEFT OR RIGHT FRONT DOOR
 Remove carrier for outside door handle

2005 BMW 645Ci
Disconnect Bowden cable (1) from fixtures (4 and 5) and detach from carrier (6).
Fig. 166: Removing And Installing/Replacing Bowden Cable For Outside Door Handle On Left Or Right
Front Door
51 21 235 REMOVING AND INSTALLING/REPLACING BOWDEN CABLE FOR INSIDE DOOR

OPENER ON LEFT OR RIGHT FRONT DOOR
 Remove front door trim
A. Lever out Bowden cable sleeve (1) in direction of arrow

B. Disconnect Bowden cable (2) towards top
Fig. 167: Removing And Installing/Replacing Bowden Cable For Inside Door Opener On Left Or
Right Front Door
51 21 280 REMOVING AND INSTALLING OR REPLACING DOOR RETAINER ON LEFT OR

2005 BMW 645Ci
 Close door windows

 Remove sound insulation in front area only
Unclip clips (1) on cable duct (2).
Remove cable duct (2) from inner door panel (3).
Release screw (4) on window guide (5).
Fig. 168: Removing Cable Duct From Inner Door Panel

Installation:
Clips (1) on cable duct (2) must not be damaged.
NOTE: Secure front door against falling closed.
Lever out seal (1).
Unfasten screws (2 and 3).

2005 BMW 645Ci
Fig. 169: Removing Seal

Remove door retainer (1) via cutout (2).
Fig. 170: Removing Door Retainer Via Cutout

Installation:
Following parts of door retainer (3) must not be damaged:
1. Hinge
2. Thread
2005 BMW 645Ci
Fig. 171: Identifying Door Retainer Parts

Installation:
Seal (1) must not be damaged.
Fig. 172: Identifying Seal

51 21 300 REMOVING AND INSTALLING OR REPLACING WINDOW RECESS COVER STRIP ON

OUTSIDE OF LEFT OR RIGHT FRONT DOOR
 00 9 311
Attach adhesive tape (1) below window cavity cover strip (2) (risk of damage).
2005 BMW 645Ci
Using special tool 00 9 311 (beginning at front proceeding to rear), lever out window cavity cover strip (1).
Fig. 173: Removing Window Cavity Cover Strip Using Special Tool 00 9 311
Pull window cavity cover strip (1) out of 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.
Fig. 174: Removing Window Cavity Cover Strip Out Of Mirror

Installation:
Seal (1) must be correctly fitted in chrome strip (2).

2005 BMW 645Ci
Fig. 175: Fitting Seal In Chrome Strip

51 21 330 REMOVING AND INSTALLING/REPLACING WINDOW CAVITY COVER STRIP ON

INNER FRONT DOOR
IMPORTANT: Cover strip comes in one part and runs up to bottom edge of door.
Unclip clips (1 and 2).
Detach cover strip (3) in direction of arrow from front door.
Installation:
If necessary, replace faulty clips (1 and 2).
Fig. 176: Identifying Clips

2005 BMW 645Ci
Detach cover strip (1) towards top.
Installation:
Fig. 177: Detaching Cover Strip Towards Top

Installation:
Make sure inner cover strip (1) is in correct installation position in relation to outer cover strip (2) and door
window glass (3).
Fig. 178: Installing Window Cavity Cover Strip

Installation:
2005 BMW 645Ci
Fig. 179: Installing Catches On Cover Strip

Installation:
Coat cover strip (1) with water before fitting.

Start with installation at front.
Fig. 180: Identifying Cover Strip

51 21 370 REMOVING AND INSTALLING/REPLACING COVER (SEAL) ON FRONT DOOR AT

BOTTOM LEFT OR RIGHT
Detach cover (1) in direction of arrow from front door (2).
Installation:
Start clipping in cover (1) at rear (B-pillar) (risk of damage).
Clip clips of cover (1) correctly into bores (3).

2005 BMW 645Ci
Fig. 181: Removing Cover (Seal) On Front Door At Bottom Left Or Right
Installation:
Clips (1) of cover (2) must not be damaged.
Cover (2) has an aluminium insert (3).
Fig. 182: Installing Clips Of Cover

Only press on clips (1) when installing otherwise cover (2) will become uneven.
HOOD LATCH LOCKS

51 23 ... ADJUSTING/REPLACING ENGINE HOOD BUMP STOP
Following parts must not be damaged:
 (1) Bump stop

2005 BMW 645Ci
Fig. 183: Identifying Bump Stop

Adjust bump stop (1) to correct height by turning left or right.
Fig. 184: Adjusting Bump Stop

51 23 004 ADJUSTING HOOD/BONNET LOCK
NOTE: Operation is identical to:

51 23 100 REMOVING AND INSTALLING/REPLACING RIGHT ENGINE HOOD LOCK
Removing and installing/replacing left engine hood lock, refer to 51 23 110 REMOVING AND
INSTALLING/REPLACING LEFT HOOD/BONNET LOCK.
2005 BMW 645Ci
51 23 110 REMOVING AND INSTALLING/REPLACING LEFT HOOD/BONNET LOCK
Unclip coupling (1) from side panel.
Open cover (2).
Lever cable (3) out of coupling (1).
NOTE: The operation "Disconnect cable for hood/bonnet locks" ends here.
Fig. 185: Removing Cable Out Of Coupling

Unscrew screws (1).
Feed out hood/bonnet lock (2) with cable (3) in direction of arrow.
Fig. 186: Removing Hood/Bonnet Lock With Cable

Disengage cable (1) from hood/bonnet lock (2).

2005 BMW 645Ci
Fig. 187: Disengaging Cable From Hood/Bonnet Lock


51 23 160 REMOVING AND INSTALLING/REPLACING ARRESTER HOOK ON ENGINE HOOD
Release screws (1) and remove arrester hook (2).
Fig. 188: Removing And Installing/Replacing Arrester Hook On Engine Hood

2005 BMW 645Ci
51 23 211 REMOVING AND INSTALLING/REPLACING CABLE FOR FRONT ENGINE HOOD

LOCKS (TO PASSENGER COMPARTMENT)
 Disconnect cable for hood/bonnet locks

 Remove lower section of microfilter housing
 Remove footwell side trim panel on A-pillar
Release screws (1).
Remove fixture (2) and feed out Bowden cable (3).
Fig. 189: Removing Fixture

Feed Bowden cable (1) out of grommet (2).
Carefully feed Bowden cable (1) with grommet (3) out of vehicle interior.
IMPORTANT: Make sure grommets (2 and 3) are correctly seated (water ingress).
2005 BMW 645Ci
Fig. 190: Removing Bowden Cable Out Of Grommet

Installation:
Lay Bowden cable (1) without kinks.
51 23 212 REMOVING AND INSTALLING/REPLACING CABLE FOR HOOD/BONNET LOCKS (TO

LOCKS)
 Remove left/right hood/bonnet locks
Release cable (1) from cable holders (2).
Feed cable (1) out of carrier (3).
Fig. 191: Removing And Installing/Replacing Cable For Hood/Bonnet Locks (To Locks)
2005 BMW 645Ci
If necessary, replace cable holders (2).

ENGINE BONNET/HOOD
WARNING: Risk of injury and damage! For the following tasks, you must take the
appropriate measures to support the engine bonnet/hood. As an
alternative, you can enlist the help of a second person to hold the
bonnet/hood.
Removing gas spring strut at top and bottom:
1. Push retainer spring to end of gas spring strut.

2. Remove gas spring strut from ball head.
Fig. 192: Removing And Installing/Replacing Left Or Right Gas Strut For Engine Bonnet/Hood
TRUNK LATCH, LOCKS

51 24 004 ADJUSTING REAR LID LOCK (LOWER SECTION OF REAR LID LOCK)
NOTE: Rear lid must be correctly adjusted to fit before adjustment of rear lid lock.
If necessary
Adjust rear lid.
Screw in detent buffers for rear lid on left/right completely.

2005 BMW 645Ci
Fig. 193: Screwing Detent Buffers For Rear Lid On Left/Right Completely
Check fulcrum pads on lower section of rear lid lock for damage and replace if necessary.
Fig. 194: Checking Fulcrum Pads On Lower Section Of Rear Lid Lock
Version with cover caps on rear apron trim:
If necessary, remove cover caps.
Slacken screws in lower section of rear lid lock until it is just able to move and centers itself.
The lower section of the rear lid lock must not scrape against the rear lid lock.
2005 BMW 645Ci
Fig. 195: Removing Rear Lid Lock (Version With Cover Caps On Rear Apron Trim)
NOTE: Adjusting lower section of rear lid lock: Close trunk lid. This enables the lower
section of the rear lid lock to adjust itself correctly.
Fig. 196: Checking Rear Lid And Rear Lid Lock

Open rear lid.
Tighten down screws on lower section of rear lid lock.
Check adjustment of rear lid and rear lid lock, repeating adjustment if necessary.
Unscrew detent buffer until closed rear lid abuts against left/right detent buffers.
IMPORTANT: The rear lid must not be higher than the side panels, otherwise there is preload
on height adjustment!
2005 BMW 645Ci

51 24 100 REMOVING AND INSTALLING/REPLACING REAR LID LOCK (UPPER SECTION)
 Remove panel for rear lid.
Release screws (2) and feed out upper section of rear lid lock (3).

Installation:
Use self-tapping screws.
Remove lock (1).

2005 BMW 645Ci
Lever out actuating rod (2) and remove upper section of rear lid lock (3).
Fig. 199: Levering Out Actuating Rod And Removing Upper Section Of Rear Lid Lock
Installation:
Engage lock (1) correctly.
Installation:
Perform function check with trunk lid open.
51 24 130 REMOVING AND INSTALLING/REPLACING STRIKER FOR REAR LID LOCK
 Remove trim on rear apron.
Release screws (1).
Remove striker for rear lid lock (2) (lower section of rear lid lock).
2005 BMW 645Ci
Fig. 200: Removing Striker For Rear Lid Lock

Installation:
Adjust rear lid lock.
IMPORTANT: Striker and rear lid lock must not be greased.
51 24 146 REMOVING AND INSTALLING BUTTON FOR ACTUATING REAR LID
 Remove panel for rear lid.
Unclip Bowden cable (1) and feed in direction of arrow out of mounting.
Version with manual rear lid unlocking:
Detach Bowden cable (2) in direction of arrow from button (3).

2005 BMW 645Ci
Disconnect plug connection (1) at microswitch.
Release screws (2).
Turn retaining ring (3) in direction of arrow and remove towards bottom.
Fig. 202: Disconnecting Plug Connection At Microswitch

Remove button (1) in direction of arrow from rear lid (2).

2005 BMW 645Ci
Fig. 203: Removing Button From Rear Lid

Installation:
Seal (1) must not be damaged.
Perform function check with rear lid open.

51 24 147 REPLACING BUTTON FOR ACTUATING REAR LID
 Remove button for actuating rear lid

 Remove BMW badge
51 24 165 REMOVING AND INSTALLING/REPLACING SIDE LEFT OR RIGHT BUFFER STOPS

ON REAR LID
2005 BMW 645Ci
right side. Press plug (1) on buffer stop (2) in direction of arrow.
IMPORTANT: Plugs must not drop into rear lid.
Installation:
Adjust both buffer stops (2) (work is described in Adjusting rear lid lock).
Fig. 205: Removing And Installing/Replacing Side Left Or Right Buffer Stops On Rear Lid
51 24 300 REMOVING AND INSTALLING OR REPLACING LEFT OR RIGHT GAS STRUT FOR
TRUNK LID
Remove luggage compartment wheel arch trim
IMPORTANT: When working on the rear gas struts, there is a risk of paintwork damage in
areas (A and B) of rear lid (1) and side panels (2). Open and close carefully. If
necessary, remove rear lid.
2005 BMW 645Ci
Fig. 206: Identifying Paintwork Area Of Rear Lid And Side Panels
Lever out both retaining springs (1).
Lever out gas strut (2) from ball pins of side panel and rear lid hinge (3) and remove.
Fig. 207: Removing And Installing Or Replacing Left Or Right Gas Strut For Trunk Lid
FRONT AND REAR WINDOWS

51 31 ... INSTRUCTIONS ON GLUING WINDSCREEN
IMPORTANT: The following topics were included or amended in March 2005: Storage
temperature of all adhesive products of 5°C to 25°C must be observed. Special
instructions for hot processing must be observed:
 Temperature of cartridge oven must be checked every morning with DIS

or GT1
2005 BMW 645Ci
bubbles/blisters (gluing/cementing not permitted)

 Insufficient heating (< 1 hour) results in the formation of bubbles/blisters
(gluing/cementing not permitted)
 Heating time or a cartridge max. 8 hours
 Mistake in mixing in event of an interruption in application >1 minute
(gluing/cementing not permitted)
 A test bead of 50...70 mm must be rejected after an interruption in
application
 Cartridge may only be heated up once; if the lower label is black, this
adhesive may only still be used cold without accelerator while adhering to
the Best before date.
These instructions are not applicable to door window cementing (door "centre") on the E38/L7:
Work steps for removing and installing windscreens:
 is displayed at the end of this document by clicking on the "framed cross-reference"
General:
The windscreen and rear window (also the rear side windows if necessary) are bonded to the body. This
gluing will increase the torsional strength of the vehicle. To obtain perfect bonding, comply with the
installation procedure described in the following.
It is possible to tow or drive without windscreen or rear window.
The windscreen must be secured with yellow plastic adhesive tape after being installed. The paint must be
completely hardened after painting work.
 Set down window glass and process on BMW-approved X-universal stand.

 In winter, the vehicles must stand in a room with a temperature of at least 15 °C.
On-the-job safety:
When working with adhesive products (adhesive, cleaning agent, bonding agent etc.):
 Wear protective goggles, protective gloves and if necessary an apron.

 Ensure rooms are 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
2005 BMW 645Ci
 Comply with the relevant safety regulations

 Do not eat, drink or smoke in areas of PUR processing.
Replacement of windscreens:
Version with head-up display (HUD):
 Marking for HUD must be present on the windscreen
Version with front passenger airbag:
 Stick on reminder label
Tools for cutting through adhesive bead:
ADHESIVE BEAD CUTTING TOOL

Type Model Order/part number
Special cutter Pneumatically operated 81 43 9 429 183
(manufacturer: Fein) with Electrically operated 81 43 9 427 786
oscillating blade
BMW blade set All required blades 81 43 9 428 596
Blade (U-shape) 19.5 mm (1) 6 39 03 118 01 3
24 mm 6 39 03 076 01 6
36 mm 6 39 03 079 01 2
45 mm 6 39 03 154 01 0
Blade (straight with stop roller) 16 to 35 mm (adjustable) 6 39 03 143 01 3
10 mm (fixed) (1) 6 39 03 189 01 0
14 mmxed) 6 39 03 082 01 6
"Roll Out 2000" Wire cutting system (1) 81 62 0 301 76 8
Scalpel for heavy-duty applications (1)
Handles for cutting wire Self-locking (1) special tool 51 3 270
(1) Not included in BMW blade set
Storage temperature:
Storage temperature of all adhesive products of 5°C to 25°C must be observed.
Adhesive:
The BMW-approved 1-component polyurethane adhesive must be used for bonding.
 Adhesive cartridge (part number BMW 83 19 0 152 031, MINI 83 19 0 152 032)
2005 BMW 645Ci
Adhesive is applied to window glass with cartridge gun (pneumatically or electrically operated.
When using accelerator (hot processing):
 Temperature (min. 80 +/- 5 °C) of cartridge oven must be checked every morning. Connect temperature
sensor to DIS or GT1 (in conjunction with MIB (Measurement Interface Box))
 Heat adhesive for at least 1 hour in cartridge oven to 80 +/- 5 °C
 Write date and time on adhesive when inserting into cartridge oven
 Insufficient heating (< 1 hour) results in the formation of bubbles/blisters (gluing/cementing not
permitted)
 Temperature < 80 +/- 5 °C results in the formation of bubbles/blisters (gluing/cementing not
permitted)
 Remove cured adhesive prior to further processing.
 Mistake in mixing in event of an interruption in application >1 minute (gluing/cementing not permitted)
 A test bead of 50...70 mm must be rejected after an interruption in application
 Best before dates of accelerator and adhesive must not be more than 3 months apart
 Best before date >3 months results in the formation of bubbles/blisters (gluing/cementing not
permitted)
Sealed adhesive:
 May only be stored for a maximum of 8 hours once it has been heated up to 80 +/- 5 °C.
 The adhesive will be damaged if this time is exceeded (gluing/cementing not permitted)
 Damaged adhesive must not be used and must be disposed of in compliance with national regulations
 Cartridge may only be heated up once
 If the lower label is black, this adhesive may only still be used cold without accelerator while
adhering to the Best before date.
IMPORTANT: Not all window glass may be bonded with accelerator (hot processing).
If hot processing is not permitted, this is described in the relevant document.
Adhesive Best before date:
Repair kit and adhesive cartridges are marked with a date (Best before).
The adhesive cannot be used after this date.
Adhesive disposal:
Pure hardened adhesive is handled as normal waste.
The adhesive is disposed of in paper bags so that it can react with moisture.
2005 BMW 645Ci
Non-hardened adhesive, cartridges and mixtures of adhesive and solvents and the like must be disposed of as
special waste.
Accelerator:
Accelerator is screwed onto the adhesive cartridge and contains a reactio paste which is mixed with the heated
adhesive.
IMPORTANT: The accelerator may only be paired with the adhesive cartridge of an unopened
package (bubbling). Adhesive and accelerator must be paired while taking into
account the Best before dates. The accelerator may no longer be used if the
Best before dates are more than 3 months apart.
Bonding agent (activator):
The BMW-approved bonding agents must be used to treat bonding areas:
 "Glass Activator 1" (on glass ceramic material)

 "Paint Activator A" (on sheet metal flange or residual adhesive bead)
Bonding agent Best before date:
Repair kit and bonding agent are marked with a date (Best before).
 The bonding agent may only be used up to this date (if not already opened previously).
 Once it has been opened (locking ring broken), use for 1 week only even if the "Best before" date has not
been reached.
NOTE: Write the date on the bottle when opening the bonding agent for the first
time.
Close the bottle immediately after extracting the bonding agent (reaction
with air).
Removal of window glass:
IMPORTANT: As of E63 and E87 it will only be possible to remove the rear window with the
"Roll Out 2000".
Cover side panels, roof antenna and if necessary interior trim with protective covers.
Tape off body with fabric adhesive tape (e.g. Tesa) in areas where the oscillating blade could damage the
window glass or the paint.
When using cutting wire, pull cutting wire ends through special tool 51 3 270, bend and tape off with fabric
adhesive tape (e.g. Tesa) (risk of injury and damage).
2005 BMW 645Ci
When removing the windscreen:
 Wear protective goggles and gloves.
Cut through adhesive bead of window glass:
 with "Roll Out 2000" (wire cutting system); no paint is damaged here in the case of narrow gaps
 with special cutter and oscillating blade
Prior to each use, regrind the blade with a grinding stone while the machine is running (new blades also).
Avoid damage to paintwork on body cutout.
Guide blade carefully between body and window glass.
Run blade of knife parallel to glass.
Cut through adhesive bead as closely as possible to window glass.
To remove adhesive bead in body cutout (and on window glass if reusing):
 Use a scalpel for heavy-duty applications

 Cut off residual adhesive to a thickness of approx. 0.5 mm
 Remove residual bead only briefly before bonding
Damage to paintwork in body aperture:
To ensure long-term corrosion protection, it is absolutely essential to touch up damage to paintwork!
The "BMW Color System" painting handbook forms the basis of these repair instructions and must be observed
without fail.
Touch up damage to paintwork on body cutout with BMW multibase filler.
Grind out scratches in non-visible areas and touch up with BMW multibase filler.
Grind extensive areas of damage down to the bare metal and coat with BMW multibase filler (coating thickness
30 ... 40 ace;mum).
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
2005 BMW 645Ci
If a complete build-up of paint is required in the visible area:
 Tape off primed bonding flange before applying top coat
IMPORTANT: Observe hardening time of BMW multibase filler otherwise a perfect bond
cannot be guaranteed!
Treatment of glued area in body:
GLUE TREATMENT
Glue Treatment
a. Clean with spirit (available in pharmacies).
b. Observe an air drying time of at least 1 minute (at least 15
Bonding and sealing compound for minutes when applied to residual bead)
car window glass c. Apply "Paint Activator A" to paint and residual bead
d. Observe an air drying time of at least 1 minute (at least 10
minutes when applied to residual bead)
IMPORTANT: Do not use Sika remover 208 for cleaning in the bonding area.
Preparation for assembly:
Prepare plastic nozzle(s) for shaping adhesive bead (when not using the standard nozzle), can be cut to size
during the air drying time.
Lay a test bead of approx. 50 mm - watch out for formation of bubbles/blisters when hot cementing; if OK,
apply immediately to window glass.
 Interruption must be < 5 second (incorrect mixture ratio).
Cartridge must be vertical to window glass.
Black ceramic material impermeable to UV light is located on the peripheral zone of the inside edge of the
window to protect the adhesive bead.
Glass ceramic material must not be damaged and must be treated as follows.
Treatment of glass ceramic surface (inside of window):
GLASS CERAMIC SURFACE TREATMENT (INSIDE OF WINDOW)

Adhesive (with part numbers) Treatment
Hot cementing:
2005 BMW 645Ci
372
Cold cementing:
a. Clean with spirit (available in pharmacies).
 BMW 83 19 0 147 369, MINI 83 19 0 147 b. Observe an air drying time of at least 1 minute
371 c. Apply a thin coating of "Glass Activator 1"
d. Observe an air drying time of at least 10
Adhesive cartridge:
minutes
 BMW 83 19 0 152 031, MINI 83 19 0 152
032
Version with inspection window for vehicle identification number in windscreen only (all except US/GB):
 Seal inspection window (bottom left) with Sika primer 206 G+P
Adhesive quantities:
Approx. 1 1/4 adhesive cartridges are needed to cement 7 Series windscreens.
In the case of hot cementing (with accelerator), the missing residual bead is applied from a second adhesive
cartridge (not contained in the repair kit) but while cold and without accelerator (bubbling).
Minimum hardening period is thus not increased.
IMPORTANT: If a second cartridge is required for cementing:
 First apply cold adhesive to cowl panel at bottom (skin formation time)
 Accelerator from repair kit must not be used with the second cartridge
(bubbling)
Bubbling results in leakage and insufficient bonding strength (torsional

rigidity, passenger airbag).
Effect of differing adhesive quantities:
DIFFERING ADHESIVE QUANTITIES EFFECT

Too little adhesive: Too much adhesive:
 Windscreen rests too high in body cutout

 Windscreen rests too low in body
 Wind noise may occur
cutout
 Strains/tensions may occur  Strains/tensions may occur (windscreen breakage)
(windscreen breakage)  Fouling of add-on parts by emerging adhesive
2005 BMW 645Ci
bead (leaking) antenna(s) (interference of reception)
Spacer buffers:
Before sticking on new spacer buffers, remove all remaining traces of old spacer buffers completely.
Position of spacer buffers must be observed exactly.
Incorrectly fitted spacer buffers will result in:
 Windscreen glass breakage

 Leakage (if the spacer buffer is in the adhesive area)
 Wind noises
Assembly:
To prevent a pressure increase in the vehicle interior when the doors are closed:
 Open a window
IMPORTANT: After the adhesive bead has been applied, the window glass must be fitted
within 5 to 10 minutes (depending on air humidity, temperature and use of
accelerator). After 5 to 10 minutes the adhesive bead forms a skin which can no
longer guarantee a perfect bond. To secure the windscreen, use only the yellow
plastic adhesive tape (sourcing reference: BMW Parts Service, part number 83
19 9 410 979). The glass will slip down if other adhesive tapes are used.
Windscreen slippage will result in leaks and wind noises.
Remove adhesive residue immediately with adhesive remover (Sika remover 208). Do not press out the window
glass again.
Hardened adhesive can only be removed by machine.
Check height of windscreen/rear window with special tool 51 0 010 or 51 3 210.
Assemble car.
Hardening:
The adhesive hardens as it reacts with air humidity (with accelerator also due to mixed-in reaction paste) at
room temperature.
Minimum hardening time (table) is obtained from 22 °C and 38 % relative air humidity.
At ambient temperatures above 23 °C and 50 % relative air humidity (hot countries), the adhesive open time is
2005 BMW 645Ci
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 adhesive bond.
Do not subject the vehicle to load on one side during the minimum hardening time (see table, without passenger
airbag), such as e.g.:
 one wheel on curb

 lifting platform
 etc.
Maneuvering inside garage/workshop:
 only permitted on level ground

 do not under any circumstance driver over access ramps, e.g. into multi-store car parks
Remove adhesive tapes after hardening time.
If you fail to adhere to the minimum hardening times (see table, without passenger airbag):
 leaks and wind noises will occur when the windscreen is moved
Glues and their minimum hardening times:
MINIMUM HARDENING TIME OF GLUES

Minimum hardening time Minimum hardening time "with
"without passenger passenger airbag" (countries
airbag" (after which vehicle can where seatbelt use is not
Glue be moved) required by law)
Hot processing with accelerator 2 hours 3 hours (1)
Cold processing 9 hours 20 hours (1)
(1) Vehicles with passenger airbag.
The vehicle can be handed over to the customer after the hardening period (vehicle can be moved,
adhesive-dependent) with the following warning:
Once the windscreen glass has been bonded, all occupants must travel with their seatbelts attached for "...
hours"!
The time is taken from the "Minimum hardening period" table for countries where seatbelt use is not required
by law.
IMPORTANT: If the minimum hardening time is not adhered to:

2005 BMW 645Ci
vehicle in the event of an accident after the front passenger airbag has
been triggered
Locate leaks:
 by spraying water underneath sealing lips

 with ultrasonic leak detector
If necessary, seal leakage with appropriate nozzle.
Version with GPS navigation system 1 (up to 9/97):
After installation of rear window:
 Recalibrate magnetic field sensor
Version with rain sensor or rain/light sensor:
Removing rain sensor or rain/light sensor.
After replacing windscreen:
 Initialize rain sensor or rain/light sensor
Version with fogging sensor:
After replacing windscreen:
Replace fogging sensor.
Version with head-up display (HUD):
Before bonding, install windscreen with seal(s) and check HUD; if necessary, press expanding foam tape down
with hand roller.
After bonding windscreen, check and if necessary adjust HUD.
Work steps for removing and installing windscreens:
NOTE: If no document is displayed after you have clicked on a "framed cross-

reference":
It is not necessary or permitted for the model selected in the TIS.
51 31 ... REMOVING WINDSCREEN WITH "ROLL OUT 2000"

2005 BMW 645Ci
 51 3 270
Windscreen removal system "Roll Out 2000"
Fig. 208: Identifying Windscreen Removal System "Roll Out 2000"

NOTE: Using the "Roll Out 2000" system: Workshop Equipment and Planning
Documentation) minimizes paintwork and ergonomic damage as well as
damage that is hazardous to health.
WARNING: Follow safety instructions for working on cars with airbag systems (risk
of injury).
IMPORTANT: Take care when handling sharp-edged tools and cutting wire (risk of damage to
head airbag).
IMPORTANT: Always keep both suckers dry and clean to ensure their optimum adhesion on
the windscreen. Lubricate coil if interlock rattling becomes too loud. Always
wear protective goggles and gloves for your own safety.
Preparatory work:
 To avoid paintwork damage, tape off working area over large area at outlet of wire starter (2) with fabric
adhesive tape (1)
 Cut off required length (A) from cutting wire
(A) = Window diagonal x 4

2005 BMW 645Ci
joint and guide cutting wire past
Fig. 209: Protecting Working Area With Tape

Pulling cutting wire into car:
 Push wire starter (2) from inside at a suitable point through adhesive bead
 Feed wire end (1) into hole of wire starter (2) and bend back
Fig. 210: Feeding Wire End (1) Into Hole Of Wire Starter (2) And Bending Back
 Pull in both wires in succession crossways
NOTE: Crossing the wires cuts through the adhesive bead completely.
Laying cutting wire around windscreen:

2005 BMW 645Ci
windscreen
 Pull excess wire into car interior
IMPORTANT: Make sure the cutting wire is located at all four corner points below the
windscreen.
Check that the cutting wire is not caught on retainers or body.
Secure window on outside with adhesive tape against slipping
Fig. 211: Laying Cutting Wire Around Windscreen

NOTE: Windows (1) with fitted seals (3) or sprayed-on surrounds:
 Moisten cutting wire (4) and seals (3) on window (1) with water
 Insert cutting wire (4) in bend (without kinking) between window (1) and
body cutout (2)
Fig. 212: Moistening Cutting Wire And Seals On Window With Water
2005 BMW 645Ci
 To avoid damage and if necessary dirt, protect A-pillars, roof and instrument panel by means of parabolic
tool (1) or plastic washer (2)
 Move parabolic tool (1) during removal so that wire cannot get caught
 Always guide plastic washer (2) between wire and panel
Fig. 213: Identifying Parabolic Tool (1) And Plastic Washer (2)
Starting removal:
 Place windlass (1) on windscreen

 Feed wire end into coil of windlass (1)
NOTE: Coil can only be turned in one direction.
 Make sure the wire is always situated in the guide channel of the windlass (1)
 Fit reversible ratchet (2) on coil and tension wire
 Start by cutting lower adhesive bead
 Grip second wire end in special tool 51 3 270
2005 BMW 645Ci
Fig. 214: Identifying Windlass (1) And Reversible Ratchet (2)

Moving windlass:
 Before moving windlass, remove reversible ratchet, extension and parabolic tool
 Release sucker on windlass
 Pull and hold black locking button (1)
 Turn windlass and move with sucker
 Refit reversible ratchet, parabolic tool and if necessary extension
 When cutting the corner points, make sure the wire is situated in the guide channel of the windlass; this
makes the cutting job easier
Fig. 215: Identifying Windlass Locking Button

Installing second windlass:
 Secure second windlass by suction on windscreen

 Feed second wire end into coil
2005 BMW 645Ci
 Cut left side and top left corner point, as described above
 Finish removal
 Remove "Roll Out 2000"
Fig. 216: Installing Second Windlass

Windlass with double coil:
For use with small windows.
 Attach windlass firmly to window so that both coils are turned away from application point of wire
 Feed either the upper wire end into the lower coil or the lower wire end into the upper coil
 Fit reversible ratchet on coil and tension wire
 Cut through approx. 10 cm of bonding joint
Fig. 217: Identifying Windlass With Double Coil

 Feed other wire end into free coil so that the wires cross
2005 BMW 645Ci
 Continue cutting bonding joint by alternately using the coils

 Both wires meet ahead of both coils when removal is completed
 Remove "Roll Out 2000"
Fig. 218: Identifying Wires Meeting Point

51 31 000 REMOVING AND INSTALLING/REPLACING WINDSCREEN
IMPORTANT: The "Instructions for window cementing", refer to 51 31 ... REMOVING

WINDSCREEN WITH "ROLL OUT 2000", serve as the basis for these repair
instructions and must be followed without fail.
51 31 015 REPAIRING DAMAGE TO WINDSCREENS CAUSED BY PITTING (STONE CHIPS)

(CLEAR AND TINTED LAMINATED SAFETY GLASS)
Field of vision (no repairs acceptable):
Fig. 219: Identifying Dimensions Of Damage To Windscreens Caused By Pitting (Stone Chips) (Clear
2005 BMW 645Ci
IMPORTANT: Repairs must only be carried out outside of the field of vision.
51 31 021 REMOVING AND INSTALLING/REPLACING RUBBER FRAME FOR WINDSCREEN
IMPORTANT: Rubber frame (1) features an aluminium section inlay (2). If necessary, remove
fitted spacer buffers (8). Carefully unwind rubber frame (1) (windscreen
breakage).
NOTE: Tear-off lip (5) may be stuck to adhesive (4). When rubber frame (1) is removed,
tear-off lip (5) can tear off and remain in vehicle.
(3) windscreen
(6) Bridge
(7) Pinched butyl
Fig. 220: Removing And Installing/Replacing Rubber Frame For Windscreen (1 Of 2)

Installation:
Clean cutout.
There is no tear-off lip (3) in area (A) but there is acoustic foam fitted in the top area.
Pay attention to center marking on rubber frame (1) and windscreen.
Replacement of rubber frame without windscreen removal:
Detach tear-off lip (4) from rubber frame (1).

2005 BMW 645Ci
If adhesive leaks over tear-off lip (4) at bridge (5), this area must be cut out partially.
To facilitate installation, coat rubber frame (1) and body cutout with water.
Replacement of rubber frame with removed or new windscreen:
Fit rubber frame (1) with tear-off lip (4).
(2) Aluminum strip
(3) Butyl
Fig. 221: Removing And Installing/Replacing Rubber Frame For Windscreen (2 Of 2)

51 31 200 REMOVING AND INSTALLING/REPLACING REAR WINDOW
IMPORTANT: The "Instructions for window cementing", refer to 51 31 ... INSTRUCTIONS ON

GLUING WINDSCREEN, serve as the basis for these repair instructions and
must be followed without fail.
51 31 231 REPLACING REAR WINDOW (COMPLETE REAR WINDOW)
Operation is described in:
Remove and install rear window,
refer to 51 31 200 REMOVING AND INSTALLING/REPLACING REAR WINDOW .
FRONT MANUALLY OPERATED WINDOWS

51 32 154 ADJUSTING LEFT OR RIGHT FRONT DOOR WINDOW GLASS
2005 BMW 645Ci
 51 3 080
NOTE: Basic settings apply to Coupe and Convertible. It is possible to adjust the door
window glass without having to remove the door trim panel.
IMPORTANT: The vehicle must be standing on its wheels during this adjustment procedure
(not on the lifting platform or jacked up).
NOTE: Check/adjust presettings after removing or replacing power window unit or

door window glass. Prerequisite: Front door must be correctly adjusted to fit.
Convertible top correctly adjusted.
Ideal adjustment:
Door window glass (1) must rest in seal (2) over entire width.
Areas (A) must rest on seal (3) (wind noises, water ingress).
Fig. 222: Adjusting Door Window Glass

Vertical adjustment (retraction depth):
 Close convertible top if necessary

 Open front door
 Attach special tool 51 3 080 to door window glass
 Close front door and door window
 Measure retraction depth
2005 BMW 645Ci
NOTE: 3 items of special tool 51 3 080 are required for rapid adjustment of retraction
depths.
Fig. 223: Attaching Special Tool 51 3 080 To Door Window Glass

Ideal adjustment:
Measure retraction depth in areas (A and B).
Measurement (C)
4 +/- 0.5 mm
IMPORTANT: Front door must open and close without the door window glass touching the
roof trim strip.
Fig. 224: Identifying Retraction Depth In Areas (A And B) And Measurement C

2005 BMW 645Ci
Top edge of door window (1) must be adjusted parallel to contour (2) of water drain.
Fig. 225: Adjusting Top Edge Of Door Window To Contour Of Water Drain
Open door window.
Lever out covers (1 and 2) from bottom of door.
Height of door window is adjusted by turning screw (3). Check adjustment.
Fig. 226: Removing Covers From Bottom Of Door

Longitudinal Adjustment Without Dismantling Door Trim Panel:
 Remove cover from outside door handle
Ideal adjustment:
2005 BMW 645Ci
Distance (A) of trim (2) to door window glass (1):
Measurement (A)
10 +/- 0.5 mm
NOTE: If necessary, check that trim (2) is correctly seated on door window (3).
Fig. 227: Identifying Distance Of Trim To Door Window Glass

When door window glass (1) is closed, rear edge of glass must rest against moulded corner (2) of cavity seal
(3).
Fig. 228: Identifying Seating Of Rear Edge Of Glass On Moulded Corner Of Cavity Seal
Lever out cover (1) in direction of arrow.

2005 BMW 645Ci
NOTE: Close door window glass completely so that screw (2) can be reached.
Fig. 229: Removing Cover

Slacken screw (2) in clockwise direction and carry out longitudinal adjustment by moving door window glass
(3).
Installation:
Checking emergency function (pretension):
Ideal adjustment:
Close door window glass (1).
Close rotary latch while front door is open.
Door window glass (1) now moves into end position.
Press front door against lock striker.
NOTE: In this door position, top edge of door window glass (1) must rest on door seal
(2).
It must be possible to pull out the paper strip with moderate friction resistance.
Measurement (D)
= 9 mm
2005 BMW 645Ci
Fig. 230: Checking Emergency Function (Pretension)

Adjusting pretension:
Lever out cover (1).
Slacken nuts (2).
Adjust pretension by moving screws (2) in elongated holes (3).
NOTE: Repeat procedure until ideal adjustment is reached.

Tighten down nuts (2).
Tightening torque, refer to 51 33 4AZ in BODY EQUIPMENT - TIGHTENING
TORQUES - 645CI .
Fig. 231: Adjusting Pretension

Longitudinal adjustment with door trim panel removed:

2005 BMW 645Ci
 If necessary, remove sound insulation
Door window glass (1) must be opened to dimension (A).
Measurement (A)
approx. 350 mm
Fig. 232: Identifying Dimension Of Opening Door Window Glass

Slacken screw (1) through bore (2) on inner door panel.
Move door window glass (3) in longitudinal direction.
NOTE: Ideal adjustments, refer to: "LONGITUDINAL ADJUSTMENT WITHOUT

DISMANTLING DOOR TRIM PANEL".
2005 BMW 645Ci
Fig. 233: Moving Door Window Glass In Longitudinal Direction

51 32 170 REMOVING AND INSTALLING/REPLACING DOOR WINDOW GLASS, FRONT LEFT

OR RIGHT
 Remove inner window cavity cover strip

 Remove outer window cavity cover strip
 Remove sound insulation
Door window glass (1) must be opened to dimension (A).
A= approx. 350 mm
Fig. 234: Identifying Door Window Glass Dimension

IMPORTANT: Disconnect plug connection (1) from power window motor (2) (risk of trapping).
2005 BMW 645Ci
Fig. 235: Disconnecting Plug Connection From Power Window Motor

Release screw (1) through bore on inner door panel (2).
Installation:
Insert door window glass (3) with clamping plate (4) in mounting (5).
Fig. 236: Releasing Screw Through Bore On Inner Door Panel

Slide locking clip (1) in direction of arrow.
Turn door window glass (3) and feed towards top rear out of guide rail (2).
2005 BMW 645Ci
Fig. 237: Sliding Locking Clip

Installation:
Adjust door window glass.
Installation:
Sliding block (1) must be correctly positioned in guide (2).
Clamping plate (4) must be correctly engaged with shim (3) on door window glass (5).
Fig. 238: Identifying Correct Positioning Of Sliding Box In Guide

Replacement:
Lever out catch (2) from shim (4) and remove with clamping plate (3) from door window glass (1).
2005 BMW 645Ci
Fig. 239: Removing Clamping Plate From Shim

Installation:
Catches (2 and 5) must not be damaged.
51 32 211 REPLACING FRONT LEFT OR RIGHT RUBBER GUIDE FOR LEFT OR RIGHT DOOR
WINDOW
 Remove rear-view mirror on front door

Release clip (1).
Pull rubber guide (2) out of window guide rail.
Fig. 240: Pulling Rubber Guide Out Of Window Guide Rail

2005 BMW 645Ci
Installation:
Moisten rubber guide (2) with water before fitting.
Insert rubber guide (2) at front/bottom into window guide rail.
Remove rubber guide (1) in direction of arrow from front door.
Fig. 241: Removing Rubber Guide From Front Door

Installation:
Rubber guide (1) must not be damaged in corners (2).
Fig. 242: Checking Rubber Guide

FRONT ELECTRICALLY OPERATED WINDOWS

2005 BMW 645Ci
51 33 000 REMOVING AND INSTALLING / REPLACING POWER WINDOW UNIT IN LEFT OR

RIGHT FRONT DOOR
IMPORTANT: Disconnect plug connection (1) from power window motor (2) (risk of trapping).
Fig. 243: Disconnecting Plug Connection From Power Window Motor

Lever out cover (1) and release nuts (2) underneath. Unscrew nuts (3).
Installation:
Fig. 244: Levering Out Cover And Release Nuts

2005 BMW 645Ci
Unclip power window unit (3) at clip (1 and 2).
Installation:
Clips (1 and 2) must not be damaged.
Make sure clips (1 and 2) are in correct position.
Fig. 245: Identifying Correct Positioning Of Clips

Removal of power window unit
Fig. 246: Removing Front And Rear Window Lift Rail

Installation:
Insert adjusting plate (1) on rear window lift rail (3) correctly into guide on window lift support (2).
2005 BMW 645Ci
Fig. 247: Inserting Adjusting Plate On Rear Window Lift Rail Correctly Into Guide On Window Lift
Support
Replacement:
Release screws (1) and detach flat motor (2).
Installation:
Carry out normalization of power window unit.
Fig. 248: Detaching Flat Motor

Basic settings of power window unit:
Height adjustment via wedge (1).

2005 BMW 645Ci
3 ... 4 mm
Fig. 249: Adjusting Height Via Wedge

Longitudinal adjustment via elongated hole (1) of wedge (2) on power window unit (3).
Fig. 250: Identifying Longitudinal Adjustment Via Elongated Hole Of Wedge On Power Window Unit
HINGED WINDOW
51 36 070 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT REAR SIDE WINDOW
IMPORTANT: The "Window cementing instructions", refer to 51 31 ... INSTRUCTIONS ON

GLUING WINDSCREEN, serve as the basis for this repair instruction and must
be observed without fail.
2005 BMW 645Ci
51 37 240 REMOVING AND INSTALLING/REPLACING OUTER WINDOW CAVITY COVER

STRIP FOR DOOR WINDOW, REAR LEFT OR RIGHT
 00 9 317
Release window cavity cover strip (1) with special tool 00 9 317 in direction of arrow from clips (2).
Fig. 251: Removing Window Cavity Cover Strip

Installation:
Check clips (1) for damage and correct seating.
Fig. 252: Identifying Correct Seating Of Clips

2005 BMW 645Ci
51 37 261 REMOVING AND INSTALLING/REPLACING WINDOW CAVITY COVER STRIP FOR

DOOR WINDOW, REAR LEFT OR RIGHT
NOTE: For special tools, refer to BODY EQUIPMENT - SPECIAL TOOLS - 645CI (E63)
 00 9 317
Lever out window cavity cover strip (1) upwards with special tool 00 9 317.
Fig. 253: Removing Window Cavity Cover Strip Upwards With Special Tool 00 9 317
Installation:
Clips (1) must not be damaged.

2005 BMW 645Ci

FRONT DOOR TRIM PANEL WITH ARM REST

51 41 000 REMOVING AND INSTALLING LEFT OR RIGHT FRONT DOOR TRIM PANEL
 00 9 317
WARNING: Model with side airbag: Follow safety instructions for working on cars
with airbag systems. Side airbag is mounted on door trim panel:
Disconnect battery.
IMPORTANT: Do not use any sharp-edged tools to remove the panel - risk of damage to
airbag.
 Remove rocker switch for side window operation

 Remove footwell light
 Remove trim on armrest
Press on point (A) and tilt out cover.
Release screw underneath.
Installation:
IMPORTANT: Replace damaged screws and nuts.

2005 BMW 645Ci
Fig. 255: Removing Screws And Nuts

Press on point (A) and tilt out cover (1).
IMPORTANT: Cover (1) must not drop into side air duct of door trim panel.
Release screw (2) underneath.
Fig. 256: Pressing On Point (A) And Tilting Out Cover (1)
Installation:
Release screws (1) on door trim panel (3).
Unclip LED for inner door compartment (2).

2005 BMW 645Ci
Fig. 257: Unclipping LED For Inner Door Compartment

NOTE: Start unclipping at bottom. Unclip clips (1) for door trim panel (2) with special
tool 00 9 317.
Fig. 258: Unclipping Clips For Door Trim Panel

Carefully unclip door trim panel (1) at top from retainers (2).
2005 BMW 645Ci
Fig. 259: Unclipping Door Trim Panel At Top From Retainers

Version with LED for door handle/door compartment light:
If necessary, detach plug connections (1).
Version with loudspeaker:
If necessary, detach plug connections (2).
Release cable holder (3) on door trim panel (4).
Fig. 260: Detaching Plug Connections

WARNING: Disconnect plug connection on side airbag.

2005 BMW 645Ci
 Tighten release lever (1).

 Lever out lock (2).
 Remove Bowden cable (3) towards rear/top.
Fig. 261: Removing Bowden Cable For Release Lever

Installation:
For fitting, press release lever (1) fully against door trim.
Feed Bowden cable (1) out of door trim panel (2).
Fig. 262: Removing Bowden Cable Out Of Door Trim Panel

Installation:
Make sure Bowden cable (1) is in correct position.

2005 BMW 645Ci
Installation:
All clips (1) are white.
Fit all clips with sealing ring.

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 41 001 REPLACING FRONT LEFT OR RIGHT DOOR TRIM PANEL
 Remove airbag module in front door.

 Remove inside door opener.
 Remove speaker.
Unlock catches (1) and remove trim (2) in direction of arrow from door trim (3).
Replace all clips (4).

2005 BMW 645Ci
Fig. 264: Replacing Front Left Or Right Door Trim Panel

51 41 070 REMOVING AND INSTALLING/REPLACING UPPER SECTION ON FRONT ARMREST
 00 9 317
Lever upper section (1) out of door trim panel (2) with special tool 00 9 317 in direction of arrow.
Fig. 265: Levering Upper Section (1) Out Of Door Trim Panel (2) With Special Tool 00 9 317
Installation:
Guides (1) on upper section (2) must not be damaged.

2005 BMW 645Ci
Fig. 266: Identifying Guides On Upper Section

51 41 075 REMOVING AND INSTALLING/REPLACING TRIM ON ARMREST ON LEFT OR

RIGHT REAR DOOR
 00 9 317
Lever out trim (1) on door trim panel (2) with special tool 00 9 317 in direction of arrow and remove.
IMPORTANT: Do not damage door trim panel (1) when removing.
Fig. 267: Removing Trim On Door Trim Panel With Special Tool 00 9 317
Installation:
2005 BMW 645Ci
Catch (1) and guides (2) must not be damaged.
Fig. 268: Identifying Catch And Guides

51 48 060 REMOVING AND INSTALLING/REPLACING SOUND INSULATION IN FRONT DOOR,

LEFT OR RIGHT
 00 9 317
Partial removal:
Complete removal:
 Remove control unit in front door
Using special tool 00 9 317, lever out sealing bead (1) of sound insulation (2) completely or if necessary
partially.
Feed wires (3) out of sound insulation (2).

2005 BMW 645Ci
Fig. 269: Removing Sealing Bead Of Sound Insulation

Installation:
In case of replacement or partial detachments, lay butylene tape depending on the conditions on inner door
panel or acoustic insulation.
Seal cable penetrations with butylene tape.
NOTE: Position of butylene tape (1) on inner door panel is identified by center punch
marks.
IMPORTANT: Do not damage Bowden cable (2) and lock knob control rod (3).
Fig. 270: Identifying Position Of Butylene Tape On Inner Door Panel

NOTE: Position of butylene tape (1) on acoustic insulation (2).

2005 BMW 645Ci
Fig. 271: Identifying Position Of Butylene Tape On Acoustic Insulation

NOTE: A marking (2) is provided all round on the acoustic insulation (1). Butylene tape
(3) rests on or inside the marking (2).
Fig. 272: Identifying Marking Round Acoustic Insulation

Clean bonding area with adhesive remover.
Air drying time: 1 minute
IMPORTANT: Adhesive area must be dry and free from dust and grease. Once it has been
Lay single row of 6 mm dia. butylene tape or double row of 3 mm dia. tape in specified adhesive area.
Heat butylene tape (hot air blower) and press down firmly on sound insulation all round.
2
2005 BMW 645Ci
Manual contact pressure: approx. 10 N/cm2
NOTE: Firm thumb pressure has approx. 50 N/cm2
SIDE COVERING WITH ARMRESTS

51 43 ... REMOVING AND INSTALLING/REPLACING TRIM ON ARMREST OF LEFT OR RIGHT
SIDE TRIM PANEL
 00 9 317
Lever out trim (1) on side trim panel (2) with special tool 00 9 317 in direction of arrow and remove.
IMPORTANT: Do not damage side trim panel (1) when removing.
Fig. 273: Removing Trim On Side Trim Panel With Special Tool 00 9 317
Installation:
Guides (1) must not be damaged.

2005 BMW 645Ci
Fig. 274: Identifying Guides

51 43 002 REMOVING AND INSTALLING REAR LEFT OR RIGHT SIDE TRIM PANEL
 00 9 317
 Remove entrance cover strip

 Partially detach backrest for rear seat
 Remove panel for door pillar
 Remove trim on armrest of side trim panel
Release screws (1).
Detach mucket (2) on side trim panel (3).

2005 BMW 645Ci
Fig. 275: Detaching Mucket On Side Trim Panel

Unclip clips (1) with special tool 00 9 317.
Carefully unclip side trim panel (3) at top from retainers (2).
Remove side trim panel (3) towards inside.
Fig. 276: Removing Side Trim Panel

Installation:
If necessary, replace faulty nuts (1) and/or retainers (2).

2005 BMW 645Ci
Fig. 277: Identifying Faulty Nuts And/Or Retainers

Installation:
Fit all clips (1) with sealing ring.
Fig. 278: Identifying Clips With Sealing Ring

51 43 005 REPLACING REAR LEFT OR RIGHT SIDE TRIM PANEL
 Remove rear side trim panel

 Remove speaker
51 43 070 REMOVING AND INSTALLING/REPLACING SIDE TRIM PANEL, FOOTWELL, ON A-

PILLAR, LEFT
2005 BMW 645Ci
 Remove front entrance cover strip (inside)
Release door mucket (1) in area of footwell side trim panel on A-pillar on left (2).
Unscrew bolt (3).
Remove engine hood actuator lever (4) from footwell side trim panel on A-pillar on left (2).
Fig. 279: Removing Engine Hood Actuator Lever From Footwell Side Trim Panel
Unscrew bolt (1).
Unclip footwell side trim panel on A-pillar on left (3) in direction of arrow from retaining points (2) and
remove.
Fig. 280: Removing Footwell Side Trim Panel

2005 BMW 645Ci
If necessary, lever out clips (1) remaining in bore.
Place footwell side trim panel on A-pillar on left (2) preinstalled with clips (1) on associated bores and clip into
place.
Fig. 281: Placing Footwell Side Trim Panel On A-Pillar On Left

Replacement:
Press catches and remove switch for unlocking rear lid (3).
51 43 075 REMOVING AND INSTALLING/REPLACING SIDE TRIM PANEL, FOOTWELL, ON A-

PILLAR, RIGHT
 Remove front entrance cover strip (inside)
Release door mucket (1) in area of footwell side trim panel on A-pillar on right (2).
Unclip footwell side trim panel on A-pillar on right (2) in direction of arrow from retaining points (3).
Remove footwell side trim panel on A-pillar on right (2).

2005 BMW 645Ci
Fig. 282: Removing Footwell Side Trim Panel On A-Pillar On Right

Installation:
If necessary, lever out clips (1) remaining in bores.
Place footwell side trim panel on A-pillar on right (2) preinstalled with clips (1) on associated bores and clip
into place.
Fig. 283: Placing Footwell Side Trim Panel On A-Pillar On Right

51 43 148 REMOVING AND INSTALLING OR REPLACING TRIM ON LEFT OR RIGHT DOOR

PILLAR (TOP)
2005 BMW 645Ci
 00 9 317
Lever out cap (1).
Release screw (2) and detach seatbelt strap (5).
Fig. 284: Releasing Screw And Detaching Seatbelt Strap

Installation:
Tightening torque, 44 N.m.
Partially loosen edge protection (1).
Unclip clips (2) of panel (3) with special tool 00 9 317 in direction of arrow.
Feed out seatbelt strap (4) and remove panel (3).
Fig. 285: Removing Seat Belt Strap And Panel

2005 BMW 645Ci
Installation:
Clips (1) of panel (2) must not be damaged.

51 43 201 REMOVING AND INSTALLING OR REPLACING TRIM FOR FRONT LEFT OR RIGHT
ROOF PILLAR
WARNING: Follow safety instructions for working on cars with airbag systems.
IMPORTANT: Do not use any sharp-edged tools to remove trim (risk of damage to head
airbag).
2005 BMW 645Ci
Unclip protective cap (3) and remove.
Fig. 287: Removing Mucket

Release screw (1), tightening torque, refer to 51 43 2AZ in BODY EQUIPMENT - TIGHTENING
TORQUES - 645CI .
Unclip trim for front roof pillar (2) from mounting point (3).
Feed trim for front roof pillar (2) out of instrument panel trim (4) and remove.
Fig. 288: Removing Trim For Front Roof Pillar

Installation:
If necessary, lever out clip (1) remaining in bore.

2005 BMW 645Ci
If necessary, replace faulty clip (1).
Make sure guide (3) of trim for front roof pillar (2) are correctly seated in associated mounting.
Position trim for front roof pillar (2) preassembled with clip (1) on associated bore and clip into place.
Fig. 289: Positioning Trim For Front Roof Pillar

51 43 251 REMOVING AND INSTALLING/REPLACING TRIM PANEL FOR LEFT OR RIGHT

REAR ROOF PILLAR (CPILLAR)
Unclip clips (1) of trim panel (2) at top in direction of arrow.
Feed out trim panel (2) at bottom in direction of arrow.
Fig. 290: Removing Trim Panel For Left Or Right Rear Roof Pillar (Cpillar)
Installation:
2005 BMW 645Ci
Guide (2) of trim panel (3) must not be damaged.
Fig. 291: Identifying Clips And Guides Of Trim Panel

ROOF TRIM PANEL

51 44 ... REMOVING AND INSTALLING FRONT ROOFLINER TRIM
 00 9 341
 Remove complete ceiling light.
Unclip front roofliner trim (1) with special tool 00 9 341 in area (2).
Feed front roofliner trim (1) in direction of arrow out of moulded roofliner (3).
Remove front roofliner trim (1).

2005 BMW 645Ci
Fig. 292: Removing Front Roofliner Trim

Installation:
Guides (1) and catches in area (2) must not be damaged.
Make sure front roofliner trim (3) is correctly seated.
Fig. 293: Installing Front Roofliner Trim

51 44 005 REMOVING AND INSTALLING/REPLACING ROOFLINER (VERSION WITHOUT

GLASS TILT SUNROOF)
Preliminary work for removing roofliner is identical to:
Removing and installing/replacing roofliner (with tilt sunroof).
Unclip split trim (1) towards bottom and detach towards front.
2005 BMW 645Ci
Fig. 294: Removing Split Trim

Installation:
Catches (2) on trim (3) must not be damaged.

2005 BMW 645Ci
Fig. 295: Identifying Clips And Catches On Trim

Release expander rivet (1) at rear of headliner (2).

2005 BMW 645Ci
Fig. 296: Releasing Expander Rivet At Rear Of Headliner

 Move both front seat backrests as far back as possible.

 Pull off mucket on front doors and side windows at rear.
IMPORTANT: The following tasks must be carried out with a second person assisting:
Support headliner at front.
Release screws (1) under bracket on headliner (2).
Fig. 297: Releasing Screws Under Bracket On Headliner

Press roofliner (1) towards rear out of metal lugs (2).
Fig. 298: Pressing Roofliner (1) Towards Rear Out Of Metal Lugs (2)
Move roofliner (1) downwards, turn carefully and remove through door opening.
2005 BMW 645Ci
51 44 007 REMOVING AND INSTALLING/REPLACING ROOFLINER (VERSION WITH GLASS

TILT SUNROOF)
 Remove both trim panels for front roof pillar

 Remove both sun visors and counter supports
 Remove front roofliner trim
 Remove mirror light
 Remove both trim panels for door pillar (top)
 Remove both trim panels for rear roof pillar (C-pillar trim panel)
 Remove additional stop light trim
right side.
Unclip cover (1) on roofliner from bottom upwards.
Release screw (2) underneath and remove roofliner mounting carrier (3).
Installation:
Catches on cover (1) must not be damaged.
Fig. 299: Unclipping Roofliner Cover

Press on clothes hook (1).
Release screw (2) and remove clothes hook (3).

2005 BMW 645Ci
Fig. 300: Removing Clothes Hook

Release expander rivet (1) at rear of roofliner (2).
Fig. 301: Releasing Expander Rivet At Rear Of Roofliner

Installation:
If necessary, replace faulty expander rivet (1).
Release screw (1) on front roofliner support (2).

2005 BMW 645Ci
Fig. 302: Releasing Screw On Front Roofliner Support

 Move both front seat backrests as far back as possible.

 Pull off mucket on front doors and side windows at rear.
IMPORTANT: The following tasks must be carried out with a second person assisting:
Support headliner at front.
Release catches (1) on roofliner (2).
Fig. 303: Releasing Catches On Roofliner

Press roofliner (1) towards rear out of metal lugs (2).
Move roofliner (1) downwards, turn carefully and remove through door opening.
2005 BMW 645Ci
Fig. 304: Removing Roofliner

Installation:
Guides (1) on roofliner (2) must not be damaged.
Fig. 305: Identifying Guides On Roofliner

Installation:
Retainers (1) on sunroof frame (2) must not be damaged.

2005 BMW 645Ci
Fig. 306: Identifying Retainers On Sunroof Frame

INSTRUMENT CLUSTER TRIM PANEL

51 45 030 REMOVING AND INSTALLING INSTRUMENT PANEL TRIM
NOTE: Observe the following instructions to facilitate removal of the instrument panel
trim:
 Move front seats back completely and lower

 Move steering column into "lower" and "extended" position
 Remove both trims for front roof pillar

 Remove fixture for steering column stalks
 Remove Instrument cluster
 Remove light operator unit
 Remove decorative strip on instrument panel on left
 Remove on-board monitor
 Remove footwell side trim panel on A-pillar, left
 Remove center console
 Remove speaker
 Remove trim for instrument panel, bottom left
 Remove right glovebox with housing
 Remove decorative strip on instrument panel on right
 Remove airbag module on front passenger side
2005 BMW 645Ci
 Remove panel for active knee protection, left

 Remove trim for head-up display
 Remove audio system controller
 Remove Car Communication Computer
Fig. 307: Removing And Installing Instrument Panel Trim

Release mucket (1) in area of instrument panel trim (5).
Remove screws (2) and (3).
Unscrew nuts (4).
Pull back trim for instrument panel (5) and remove.
Installation:
Make sure guides (1) of instrument panel trim (2) are correctly seated in mountings.
Make sure seals are correctly seated on air ducts.
If necessary, detach right fresh-air grill to facilitate fitting of associated air duct.
2005 BMW 645Ci
Fig. 308: Identifying Guides On Instrument Panel Trim

51 45 031 REPLACING INSTRUMENT PANEL TRIM
 Remove instrument panel trim

 Remove right fresh-air grill
Unclip both heated-air duct trims (1) in direction of arrow and remove from instrument panel trim (3).
Unclip passenger-side vent (2) in direction of arrow and remove from instrument panel trim (3).
Fig. 309: Removing Passenger Side Vent From Instrument Panel Trim
Release clips (2).
Remove top steering column cover (1) in direction of arrow from instrument panel trim (3).
2005 BMW 645Ci
Remove driver's-side air duct (5) from instrument panel trim (3).
Fig. 310: Removing Top Steering Column Cover

Release screws (1).
Remove passenger-side air duct (2) from instrument panel trim (3).
2005 BMW 645Ci
Fig. 311: Removing Passenger-Side Air Duct From Instrument Panel Trim
Remove clips (1).
NOTE: Replace damaged clips (1):
A. Turn clip (1) with screwdriver to left by approx. 60°.

B. Lever out clip (1) from below.
Fig. 312: Turning And Removing Clips

Release screws (1).
Remove instrument panel function carrier (2) from instrument panel trim (3).
Removal all metal nuts (4) from instrument panel trim (3).
2005 BMW 645Ci
Fig. 313: Removing Instrument Panel Function Carrier From Instrument Panel Trim
Version with head-up display:
Release screws (1).
Remove head-up display frame (2) in direction of arrow from instrument panel trim (3).
Fig. 314: Removing Head-Up Display Frame From Instrument Panel Trim
51 45 115 REMOVING AND INSTALLING SPEAKER FRAME ON PANEL FOR INSTRUMENT

PANEL AT TOP
 00 9 341
2005 BMW 645Ci
Unclip speaker frame (1) with special tool 00 9 341 at points (2).
Fig. 315: Uncliping Speaker Frame (1) With Special Tool 00 9 341 At Points (2)
Raise speaker frame (1) slightly from instrument panel (3) and disconnect plug connection at solar sensor.
Remove speaker frame (1).
Installation:
Retainers (1) on speaker frame (2) must not be damaged.
Replacement:
Remove solar sensor (3).
Fig. 316: Removing Solar Sensor

51 45 177 REMOVING AND INSTALLING/REPLACING PANEL FOR ACTIVE KNEE PROTECTOR

2005 BMW 645Ci
pyrotechnical belt tensioners. Incorrect handling can activate airbag and
cause injury.
 Remove luggage compartment floor trim

Release screws (1) and lower panel for left active knee protection (2).
Installation:
Replace screws.
Unlock plug connection (3) of panel for left active knee protection (2), disconnect and remove panel for left
active knee protection (2).
Fig. 317: Removing And Installing/Replacing Panel For Active Knee Protector On Left
IMPORTANT: Always replace panel for active knee protector on left complete. Do not carry
out any repairs on the panel for the left active knee protection.
51 45 181 REMOVING AND INSTALLING/REPLACING BOTTOM RIGHT TRIM FOR

INSTRUMENT PANEL
Release screws (1).

2005 BMW 645Ci
Disconnect plug connection of footwell light (3).
Remove bottom right instrument panel trim (2).
Fig. 318: Removing Bottom Right Trim For Instrument Panel

Installation:
Mounts (1) and guide (2) of bottom right instrument panel trim (3) must not be damaged.
Replacement:
 Remove footwell light (4).
Fig. 319: Identifying Mounts And Guide Of Bottom Right Instrument Panel Trim
51 45 185 REMOVING AND INSTALLING/REPLACING TRIM FOR PEDAL ASSEMBLY
Release screws (1).

2005 BMW 645Ci
Unclip trim for pedal assembly (3) at retaining points (2).
Pull back panel for pedals (3) in direction of arrow.
Disconnect associated plug connections and remove trim for pedal assembly (3).
Fig. 320: Removing Pedal Assembly Trim

Installation:
Guides (1) and clips (2) of trim for pedal assembly (3) must not be damaged.
Replacement:
 Remove speaker of hands-free system (4).

 Remove footwell light (5).
Fig. 321: Identifying Guides And Trims Of Pedal Assembly

2005 BMW 645Ci
PANEL
 00 9 341
 Remove center fresh air grill
Release screws (1).
Partially fit special tool 00 9 341 as illustrated, refer to Fig. 322.
Unclip center trim for instrument panel (3) at retaining points (2) all round and pull back.
Unlock and disconnect associated plug connections, remove center trim for instrument panel (3).
Fig. 322: Removing Center Trim For Instrument Panel

Replacement:
Remove control panel for heater - A/C system.
51 45 315 REPLACING CENTER TRIM FOR INSTRUMENT PANEL (FRESH-AIR GRILL)
This operation is described under:
"Removing and installing/replacing center fresh-air grill", refer to 64 22 165 REMOVING AND
INSTALLING/REPLACING CENTER FRESH-AIR GRILL .
2005 BMW 645Ci
51 45 370 REMOVING AND INSTALLING DECORATIVE STRIP ON LEFT INSTRUMENT PANEL
 64 1 020
Partially fit special tool 64 1 020 as illustrated.
Lever out decorative strip on left instrument panel (1) at top and remove.
Fig. 323: Removing And Installing Decorative Strip On Left Instrument Panel
Installation:
Attach decorative strip to left instrument panel (1) at lower guides (2) first.
51 45 380 REMOVING AND INSTALLING (REPLACING) RIGHT DECORATIVE STRIP ON

INSTRUMENT PANEL
 00 9 317
Release screws (1).
Lever out right decorative strip on instrument panel (3) at retaining points (2) and pull back.
2005 BMW 645Ci
Fig. 324: Removing Right Decorative Strip On Instrument Panel At Retaining Points
Version up to MY 2004:
Lever out lock (1) towards front and detach Bowden cable (2).
Version from MY 2005:
Lever out lock (1) towards rear and detach Bowden cable (2) upwards.
Disengage Bowden cable nipple (3) and remove right decorative strip on instrument panel.
Fig. 325: Removing Right Decorative Strip On Instrument Panel (Version Up To My 2004)
Installation:
Clips (1) must be seated in associated mountings.
If necessary, remove clips (1) remaining on right decorative strip on instrument panel.
2005 BMW 645Ci
Replace damaged clips (1):
A. Turn clip (1) with screwdriver to left by approx. 60°.

B. Lever out clip (1) from below.
Fig. 326: Turning And Removing Clips

Replacement:
Release screws (1).
Remove glovebox button (2) from right decorative strip on instrument panel (3).
2005 BMW 645Ci
Fig. 327: Removing Glovebox Button From Right Decorative Strip On Instrument Panel
PARCEL SHELF TRIM PAN/ROLLER SUN BLIND

51 46 006 REMOVING AND INSTALLING/REPLACING TRIM FOR REAR PARCEL SHELF
 Remove panel for roof pillar at rear left/right

 Partially detach seat back
Release expander rivets (1) on rear parcel shelf (2).
Installation:
If necessary, replace faulty expander rivets (1).

2005 BMW 645Ci
Raise rear parcel shelf (2) and release plug connection on left/right mid-range speakers.
Feed out rear parcel shelf (2) over guides (3) in direction of arrow.
Fig. 328: Removing And Installing/Replacing Trim For Rear Parcel Shelf
NOTE: The operation "Removing trim for rear parcel shelf" ends here.
Replacement:
Remove left/right mid-range speakers.
51 46 050 REMOVING AND INSTALLING/REPLACING TOP TRIM ON REAR APRON

2005 BMW 645Ci
Release protective caps (1) and screws underneath.
Lever out expander rivets (2).
Lever out trim (3) inwards/upwards.
Fig. 329: Removing Top Trim On Rear Apron

Installation:
Replace damaged protective caps (1) and expander rivets (2).
Make sure rear lid seal is correctly seated.
Installation:
2005 BMW 645Ci
Fig. 330: Identifying Guides On Trim

FLOOR/LUGGAGE/ENG COMP TR. PANELS

51 47 ... REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT UNDERBODY PANELING
Unscrew nuts (1).
Remove underbody paneling (4) towards bottom.

2005 BMW 645Ci
Fig. 331: Removing And Installing/Replacing Left Or Right Underbody Paneling

51 47 000 REMOVING AND INSTALLING/REPLACING FRONT (INSIDE) LEFT OR RIGHT

ENTRANCE COVER STRIP
IMPORTANT: Risk of breakage to connecting lug on B-pillar trim panel. Do not raise entrance
cover strip (1) over entire length simultaneously.
Raise entrance cover strip (1) from front to rear. Detach with clips (2) from floor plate.
Detach entrance cover strip (1) from B-pillar trim panel at bottom in direction of arrow.
If necessary, lever out clips from floor plate.

2005 BMW 645Ci
Fig. 332: Removing Front (Inside) Left Or Right Entrance Cover Strip
Installation:

Connecting lug (3) of entrance cover strip (2) must not be damaged.
2005 BMW 645Ci
Fig. 333: Identifying Connecting Lug Of Entrance Cover Strip

51 47 065 REMOVING AND INSTALLING/REPLACING FINISHING STRIP AT FRONT LEFT OR

RIGHT ENTRANCE
 00 9 317
Unclip clips (1) for finishing strip (2) with special tool 00 9 317.
2005 BMW 645Ci
Fig. 334: Uncliping Clips (1) For Finishing Strip (2) With Special Tool 00 9 317
Remove finishing strip (2).
Installation:

2005 BMW 645Ci
Fig. 335: Identifying Finishing Strip Clips

51 47 101 REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT FLOOR

TRIM PANEL
Open rear lid.
Remove luggage compartment floor trim (1).

51 47 140 REMOVING AND INSTALLING/REPLACING PANEL FOR LUGGAGE COMPARTMENT

PARTITION
 00 9 317
2005 BMW 645Ci
 Remove left luggage compartment wheel arch trim

 Remove right luggage compartment wheel arch trim
Version with ski bag:
Lever out cover (1) with special tool 00 9 317 and remove.
Fig. 337: Levering Out Cover (1) With Special Tool 00 9 317
Lever out clip (1) and remove panel (2) in direction of arrow.
Fig. 338: Levering Out Clip (1) And Removing Panel (2)
Installation:
If necessary, replace clip (1).

2005 BMW 645Ci
51 47 151 REMOVING AND INSTALLING/REPLACING LEFT LUGGAGE COMPARTMENT

WHEEL ARCH TRIM
 Remove trim on rear apron
Release clip (1).
Lever out cover on lashing point (2) and remove.
Release screw underneath and remove lashing point (2) in direction of arrow.
If necessary, remove warning triangle.
Fig. 339: Removing Lashing Point Cover

Installation:
Clip (1) and cover on lashing point (2) must not be damaged.
Release mucket (1).
Feed out trim (2) in direction of arrow and remove.

2005 BMW 645Ci
Fig. 340: Removing Luggage Compartment Wheel Arch Trim

51 47 161 REMOVING AND INSTALLING/REPLACING RIGHT LUGGAGE COMPARTMENT

WHEEL ARCH TRIM
This operation is identical (apart from emergency pull strap actuator) to:
 Removing and installing/replacing left luggage compartment wheel arch trim, refer to 51 47 151
REMOVING AND INSTALLING/REPLACING LEFT LUGGAGE COMPARTMENT WHEEL
ARCH TRIM.
Unclip cover (1) on emergency pull strap actuator (2) in direction of arrow.
Fig. 341: Unclipping Emergency Pull Strap Actuator Cover

51 47 315 REMOVING AND INSTALLING/REPLACING FRONT CARPET FOR PASSENGER

COMPARTMENT

2005 BMW 645Ci
 Remove left/right front seat

 Remove side trim in footwell
 remove glovebox
 Remove accelerator pedal module
Cut out carpet (1) at marked cutting edges (2) on left/right.
IMPORTANT: If there are no marked cutting edges (2), align cuts as far as possible in
direction of middle of vehicle. This ensures that the cutting edges are covered
by the storage compartment/instrument panel. Pay attention to cables when
cutting (risk of damage).
If necessary, guide cable back through carpet (1).
Feed out carpet (1) towards rear/top.
Fig. 342: Removing Front Carpet For Passenger Compartment

Marked cutting edges (1) shown on removed carpet (2).
Replacement:
Cut out carpet at marked cutting edges (1).
If there are not marked cutting edges (1), place removed carpet over new piece and carry cuts over to new
carpet.
Installation:
2005 BMW 645Ci
Apertures (3) serve as alignment points for fitting the carpet (2).
Fig. 343: Identifying Alignment Points For Fitting Carpet

Replacement:
Detach stowage net (1).
Remove clips (2) for stowage net (1).
Fig. 344: Removing Stowage Net Clips

51 47 440 REMOVING AND INSTALLING/REPLACING REAR CARPET ON SEAT PAN
 Remove left/right front seat

 Remove handbrake lever
2005 BMW 645Ci
 Remove rear left/right side trim

 Remove front inside entrance cover strip
Lay cable (2) back.
Feed out cables (3 and 4) through carpet (5).
Remove carpet (5).
Fig. 345: Removing And Installing/Replacing Rear Carpet On Seat Pan

Installation:
Make sure openings for air duct and attachment points are correctly positioned.
Make sure all cables are in correct position.
51 47 490 REMOVING AND INSTALLING / REPLACING FRONT UNDERBODY PROTECTION
Not M5:
Release screws (1 and 2) and pull out underbody protection (3) from under bumper trim.
Installation:
Ensure that seals are correctly seated.
Center underbody protection (3) and tighten down screws (1) and (2).
2005 BMW 645Ci
Fig. 346: Removing And Installing / Replacing Front Underbody Protection (Not M5)
Replacement:
If necessary, remove catches (1) on cover (2).
Fig. 347: Removing Catches On Cover

M5 only:
Release screws (3) at side from wheel arch trim.
Pull underbody protection (4) forward under bumper trim.
Installation:

2005 BMW 645Ci
Center underside protection (4) and tighten down screws (1, 2 and 3).
Fig. 348: Removing And Installing / Replacing Front Underbody Protection (M5 Only)
51 47 491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION
 Remove front underbody protection
Release screws (1).
Press heat shield to one side.
Release screws (2) and remove rear underbody protection (3).
Fig. 349: Removing And Installing/Replacing Rear Underbody Protection

Installation:
2005 BMW 645Ci
Center rear underbody protection (3), secure with screws (2) and then insert screws (1).
FRONT LID INSULATION LINING

51 48 001 REMOVING AND INSTALLING/REPLACING INSULATION LINING ON
HOOD/BONNET
NOTE: Illustration created using the E87 as an example. There may be differences in
detail in the case of other vehicle models.
Release threaded rivets (1) on insulation lining (2).
Remove insulation lining (2).
Fig. 350: Removing And Installing/Replacing Insulation Lining On Hood/Bonnet

51 48 060 REMOVING AND INSTALLING/REPLACING SOUND INSULATION IN FRONT DOOR,

LEFT OR RIGHT
 00 9 317
Partial removal:
Complete removal:
2005 BMW 645Ci
 Remove control unit in front door
Using special tool 00 9 317, lever out sealing bead (1) of sound insulation (2) completely or if necessary
partially.
Feed wires (3) out of sound insulation (2).
Fig. 351: Removing Sealing Bead Of Sound Insulation With Special Tool 00 9 317
Installation:
In case of replacement or partial detachments, lay butylene tape depending on the conditions on inner door
panel or acoustic insulation.
Seal cable penetrations with butylene tape.
NOTE: Position of butylene tape (1) on inner door panel is identified by center punch
marks.
IMPORTANT: Do not damage Bowden cable (2) and lock knob control rod (3).
2005 BMW 645Ci
Fig. 352: Identifying Position Of Butylene Tape On Inner Door Panel

NOTE: Position of butylene tape (1) on acoustic insulation (2).
Fig. 353: Identifying Position Of Butylene Tape On Acoustic Insulation

NOTE: A marking (2) is provided all round on the acoustic insulation (1).
Butylene tape (3) rests on or inside the marking (2).

2005 BMW 645Ci
Fig. 354: Identifying Marking On Acoustic Insulation

Clean bonding area with adhesive remover.
Air drying time: 1 minute
IMPORTANT: Adhesive area must be dry and free from dust and grease. Once it has been
Lay single row of 6 mm dia. butylene tape or double row of 3 mm dia. tape in specified adhesive area.
Heat butylene tape (hot air blower) and press down firmly on sound insulation all round.
Contact pressure with hand roller: approx. 30 N/cm2
Manual contact pressure: approx. 10 N/cm2
REAR LID TRIM PANEL

51 49 000 REMOVING AND INSTALLING OR REPLACING TRIM FOR REAR LID
 Open trunk lid.
right side.
2005 BMW 645Ci
Version with manual rear lid unlocking:
Detach handle (1) from clip (2).
Disconnect Bowden cable (3) from handle (1).
Installation:
Guide Bowden cable (3) through clip (2) and connect correctly in handle (1).
Fig. 355: Detaching Handle From Clip

Release expansion rivets (1) and clip (2).
Remove trim (3).
Fig. 356: Identifying Expansion Rivets And Clip

Installation:
2005 BMW 645Ci
Replace damaged clips (1 and 2).
LOOSE BODY PARTS

51 13 115 REMOVING AND INSTALLING/REPLACING COWL PANEL COVER
 Remove both windshield wiper arms

 Remove lower microfilter housing section on left and right
Release clip on left/right.
NOTE: The fastener is closed if the arrow tips point to each other.
Unscrew bolt (1).
Remove cowl panel cover towards top.
Fig. 357: Removing And Installing/Replacing Cowl Panel Cover

Installation:
Tighten down screw (1) to tightening torque, refer to 51 13 5AZ in BODY EQUIPMENT - TIGHTENING
TORQUES - 645CI .
Check cover (3) for correct seating.
Tighten quick-release fasteners (2) from the middle.

2005 BMW 645Ci
51 71 ... REMOVING AND INSTALLING/REPLACING FRONT (BOTTOM) RIGHT WHEEL ARCH

TRIM
Turn steering wheel/front wheel to left.
Release screws (1).
Remove wheel arch trim (2) under assembly underside protection at side rear.
Fig. 358: Removing And Installing/Replacing Front (Bottom) Right Wheel Arch Trim
51 71 040 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH

COVER
 If necessary, remove left/right front wheel
Release screws (1) and (3).
Unscrew nuts (2).
Release screws (6).
If necessary, release screws (7).
If necessary, release expander rivets (4).
Carefully feed out front wheel arch cover (5) towards top.
2005 BMW 645Ci
Fig. 359: Removing And Installing/Replacing Front Left Or Right Wheel Arch Cover
Installation:
Make sure front wheel arch trim is correctly seated.
Replacement:
E63 and E64 only:
If necessary, remove cover of removed wheel arch cover and install in new part.
Right side only:
If necessary, remove bottom right wheel arch cover and install in new part.
51 71 041 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT WHEEL ARCH

COVER
 Remove rear wheel

 If necessary, disconnect and feed out plug from brake pad wear sensor
right side. Illustration created using E60 as an example. There may be
differences in detail in the case of other vehicle models.
Release screws (1, 3 and 5).
Unscrew nuts (2).

2005 BMW 645Ci
Carefully feed out rear wheel arch cover towards bottom.
Fig. 360: Removing And Installing/Replacing Rear Left Or Right Wheel Arch Cover
Installation:
Make sure rear wheel arch cover is correctly seated.
51 71 373 REMOVING AND INSTALLING/REPLACING TENSION STRUT ON SPRING STRUT

DOME
IMPORTANT: Vehicles must not be driven without their tension struts. Driving without
tension struts will result in bodywork damage.
 Remove lower microfilter housing section on left and right.
If necessary, remove cover on spring strut dome on left and right:
 Release expansion rivets (1)

 Remove cover (3),
 taking care not to damage retaining lug (2).
2005 BMW 645Ci
Fig. 361: Removing Cover On Spring Strut Dome On Left And Right
If necessary, remove tension strut panels:
 Release expansion rivets on panel (2).

 Remove panel (2) in direction of arrow.
Fig. 362: Removing Tension Strut Panels

Release screws (1).
Remove tension strut (2).

2005 BMW 645Ci
Fig. 363: Removing Tension Strut

Installation:
Tighten down self-tapping screws (2) to specified torque
51 71 387 REMOVING AND INSTALLING/REPLACING REAR WATER GUTTER TRIM (REAR

LID) ON LEFT OR RIGHT
E63 only:
Release clips (5).
Pull off rubber seal (6).
Remove trim (4) towards rear.
E64 only:
Slide stop spring (1) to end of gas strut (2) and lever out gas strut (2).
Release clips (5).
Pull off rubber seal (6).
Feed out cable guide (3) and remove trim (4) towards rear.
IMPORTANT: If clip mountings are removed during further operations (e.g. painting), always
replace these mounting to ensure watertightness.
2005 BMW 645Ci
Fig. 364: Removing And Installing/Replacing Rear Water Gutter Trim (Rear Lid) On Left Or Right
51 71 447 REMOVING AND INSTALLING OR REPLACING PANEL FOR COVER ON LEFT OR

RIGHT SIDE MEMBER
 Remove entrance cover strip

 Detach wheel arch cover from front/rear side member cover
Release expansion rivets (1).
Fig. 365: Releasing Expansion Rivets

Release screws (1).

2005 BMW 645Ci

Unclip panel (1) at front.
Unclip panel (1) at rear from holders (2) and remove in direction of arrow.
Fig. 367: Removing Panel At Rear From Holders

Installation:

2005 BMW 645Ci

Installation:
If necessary, detach holders (1) from body and fit on panel (2).
If necessary, replace faulty holders (1).

2005 BMW 645Ci
Fig. 369: Detaching Holders From Body And Fit On Panel

2006 BMW 650i
BRAKES Disc - 650i
BRAKES
Disc - 650i
00 BRAKE TESTING AND BLEEDING

34 00 ... GENERAL INFORMATION
The brake system is one of the most important safety systems on any motor vehicle. It is therefore essential to
act with utmost care when working on the brake system and to follow the instructions below.
General:
 Ensure cleanliness and only use rags which do not lose lint.
 Wash away or vacuum up brake dust, do not clear it away using compressed air. This dust is a health
hazard.
 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 cleaner (refer to BMW Parts Service), do not allow brake
cleaner to get into the brake system.
 Even the most minute traces of brake cleaner must be avoided.
Brake fluid:
 Replace brake fluid at least every two years.

 Never re-use drained brake fluid.
 Always use BMW-approved brake fluid, refer to BRAKES - 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.
Wheel brakes:
 Brake linings:
Brake linings must be replaced when the warning threshold of the brake lining wear indicator is reached.
2006 BMW 650i
BRAKES Disc - 650i
Refer to BRAKES - TECHNICAL DATA .
Brake linings must always be replaced on both sides of any axle.
The friction surfaces of the brake linings must not come into contact with oils or greases. The brake
linings must be replaced if they are fouled by such substances.
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 fitted on the relevant side of the vehicle.
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. Furthermore, minimum brake disk thickness, disk runout,
parallelism and surface roughness of the friction surfaces must not exceed or drop below the permitted
values.
Always strip preservative off new parts before installation. With the rear brake discs, also strip
preservative off brake drum on parking brake.
 Brake drums:
Brake drums must not be scored or cracked. Furthermore, the maximum drum inside 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 on brake calipers.
All moving parts on the brake caliper must move freely: note grease specifications.
Use only BMW-approved lubricants to grease caliper guides (refer to BRAKES - OPERATING
FLUIDS ).
Brake lines, brake hoses: brake lining wear indicator
 Brake lines and brake hoses must be correctly routed and must not abut with body or components in a
2006 BMW 650i
BRAKES Disc - 650i
 To prevent damage, release and tighten brake line couplings with a special brake line wrench only.
 The system must be bled each time any brake lines have been detached.
 All connection points must be checked for leaks.
 Only tighten down brake hoses on the front axle when wheels are in straight-ahead position.
 Close open connections on brake lines and individual components to prevent dirt from entering the brake
system.
 Observe tightening torques when tightening down brake line screw connections.
Tightening torque, 34 32 1AZ . See 34 32 BRAKE LINES
Wheel-slip control system:
The slip control system is basically maintenance-free.
However, be sure to adhere to the following:
 When carrying out welding work with electric welding equipment, be sure to disconnect the plug from
the electronic control unit (ignition turned off).
 During painting work, the control unit may be subjected for brief periods to loads of max. 95°C and for
long periods (approx. 2 hours) to loads of max. 85°C.
 Tighten down the battery terminals completely.
 The brake lines on the hydraulic unit must not be mixed up; if necessary, mark them before they are
removed and after completing repairs perform the mix-up check with the DIS Tester.
34 00 ... GENERAL INFORMATION ON BRAKING IN NEW BRAKE DISCS/BRAKE PADS
IMPORTANT: After completing work:
 Carry out function check on brake analyzer (test stand) to ensure that the
brakes complies with legal requirements.
 Carry out test braking while driving at low speed; the effectiveness of the
brakes may be reduced during the initial braking operations.
 Exaggerated drastic and continuous braking operations for faster braking
in are not permitted.
 Advise the customer not to perform any wilful drastic braking in the first
200 km after brake replacement.
 Attach mirror tag to interior rearview mirror.
34 00 009 CHECKING BRAKES ON TEST STAND

2006 BMW 650i
BRAKES Disc - 650i
 Check tire treads

 Check tire pressure
In the case of vehicles with ASC+T or DSC, the system must be deactivated with the switch. The ASC+T or
DSC telltale and warning light must light up in the instrument cluster!
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.
E65 and E66: Carry out parking brake function check . See 34 10 014 Adjusting Handbrake.
Fig. 1: Identifying Brake Test Stands

IMPORTANT: Only brake test stands (dynamic analyzers) with test speeds of 2.5-6 km/h may
be used.
You must follow without fail the guidelines contained in the operating
instructions of the relevant test stand manufacturer.
Failure to do so may result in damage to the vehicle and the system and also
personal injury.
34 00 010 CHECKING THICKNESS OF BRAKE PAD
 34 1 260
NOTE: The thickness of the outer brake pads can be determined without removing the
wheels.
2006 BMW 650i
BRAKES Disc - 650i
can be seen through rim styling.
Insert special tool 34 1 260 through rim into opening for brake pad wear indicator. See 34 1 260 BRAKE
LINING MEASURING GAUGE
Press special tool onto brake pad. Slide ring (1) in direction of arrow up to stop and read off measured value.
NOTE: A. Brake disk

B. Brake pad with backplate
Safe limit for lining wear, front brake . See 34 11 FRONT BRAKE E63
Safe limit for lining wear, rear brake . See 34 21 REAR BRAKE DISCS E63
Fig. 2: Identifying Special Tool (34 1 260)

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 released):
 Vehicles with manual transmission: Shift lever in neutral position.

 Vehicles with automatic transmission: Selector lever in "N" position.
 Without locking differential =150 N.
 With locking differential = 200 N (possibly odd display).

2006 BMW 650i
BRAKES Disc - 650i
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 00 017 CHECKING BRAKE BOOSTER (LOW-PRESSURE TEST)
 34 3 100
 Remove left microfilter housing. . See 64 31 061 REMOVING AND INSTALLING/REPLACING

LEFT OR RIGHT MICROFILTER HOUSING LOWER SECTION
 Detach hose from connection piece. Install vacuum tester 34 3 100 between connection piece and vacuum
hose of non-return valve. See 34 3 100 BRAKE BOOSTER TESTER
 Start engine.
 Check buildup of partial vacuum.
 Switch off engine.
 Press the brake pedal to set a vacuum pressure of not more than 0.8 bar and wait for the value to stabilize.
 When the brake pedal is not pressed, the vacuum pressure is permitted to drop over a test period of 1
minute by max. 0.06 bar.
2006 BMW 650i
BRAKES Disc - 650i

If specified values are not reached:
 Check line connections for vacuum seal.

 Replace non-return valve.
 Check seal between brake booster and brake master cylinder (sealing ring) for perfect condition and
correct seating.
 If the specified values are not achieved when the test is repeated, you must replace the brake booster.
34 00 025 REPLACING FLUID IN ABS/ASC+T BRAKE SYSTEM
 Read and comply with General Information . See 34 00 ... GENERAL INFORMATION
 Remove lower section of microfilter housing . See 64 31 061 REMOVING AND
INSTALLING/REPLACING LEFT OR RIGHT MICROFILTER HOUSING LOWER SECTION
IMPORTANT: When carrying out repairs to the brake system, follow the procedure set out in
Bleeding brake system with DSC. See 34 00 050 BLEEDING BRAKE SYSTEM
WITH DSC
Connect bleeder unit to expansion tank and switch on.
NOTE: Check relevant Operating Instructions for each device.
Charging pressure should not exceed 2 bar.

2006 BMW 650i
BRAKES Disc - 650i
Fig. 4: Identifying Bleeder Unit To Expansion Tank & Switch

Flushing Brake System Completely
Connect bleeder hose with collecting tray to bleeder valve on rear right brake caliper.
Open bleeder valve and purge until clear, bubble-free brake fluid emerges.
Close bleed valve.
Follow same procedure on rear left, front right and front left wheel brake.
Fig. 5: Connecting Bleeder Hose With Collecting Tray To Bleeder Valve On Rear Right Brake Caliper
NOTE: The clutch slave cylinder must also be scavenged in vehicles with manual
transmissions.
Switch off brake fluid changer and remove from expansion tank.
2006 BMW 650i
BRAKES Disc - 650i
Check brake fluid level.
Close expansion tank.
NOTE: Pay attention to rubber seal (1) in sealing cap.
Fig. 6: Locating Rubber Seal In Sealing Cap

34 00 050 BLEEDING BRAKE SYSTEM WITH DSC

Observe the filling and bleeding instructions when replacing or repairing:
 Brake master cylinder

 Hydraulic unit
 Components and connecting lines which are fitted between these assemblies.
Connect bleeder unit with max. 2 bar filling pressure.
A second person is needed to help carry out this work.
 Connect BMW Diagnosis and Information System (DIS).

 Select path: Service functions - Chassis/Suspension - Slip control systems - Bleeding procedure.
 Connect bleeder unit to expansion tank and switch on.
2006 BMW 650i
BRAKES Disc - 650i
IMPORTANT: Check relevant Operating Instructions for each device.
Charging pressure should not exceed 2 bar.
Fig. 7: Connecting BMW Diagnosis & Information System (DIS)

Close bleed valve.
2006 BMW 650i
BRAKES Disc - 650i
Close bleeder valve.
Run through bleeding routine with BMW Diagnosis and Information System (DIS) with bleeder valve open.
After completing routine, press brake pedal 5 times to floor, clear and bubble-free brake fluid must flow out.
Close bleed valve.
Repeat procedure at rear left.
Bleeding Front-Axle Brake Circuit
Connect bleeder hose with collecting tray to bleeder valve on front right brake caliper.
Close bleed valve.
Repeat procedure at front left.

2006 BMW 650i
BRAKES Disc - 650i
Fig. 10: Identifying Bleeding Front-Axle Brake Circuit

Switch off brake fluid changer and remove from expansion tank.
Check brake fluid level.
Fig. 11: Locating Rubber Seal In Sealing Cap

10 HANDBRAKE
34 10 014 ADJUSTING HANDBRAKE
NOTE: Perform inspection in the following manner:

2006 BMW 650i
BRAKES Disc - 650i
When 1st ratchet is engaged, no braking force should be exerted.
The difference in wheel circumferential forces between the left and right wheels
may deviate by max. 30 % from the greater value (measured on brake analyzer).
In event of larger deviations of wheel circumferential force: carry out

readjustment.
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.
 In event of excessive actuation stroke (10 teeth).
 When replacing parking brake Bowden cables.
1. Setting instruction for brake shoes (basic setting) Lock adjuster unit (ASZE). Actuate parking brake lever.
Screw in special tool 32 1 030 partially. Press stop (1) of adjusting spring back to such an extent that retaining
hook (2) engages in stop (1).
Fig. 12: Identifying Stop Of Adjusting Spring
Completely unscrew one wheel stud on each rear wheel. Installation: Tightening torque 36 10 1AZ. Turn wheel
until adjustment screw is visible in tapped hole.
2006 BMW 650i
BRAKES Disc - 650i
Fig. 13: Completely Unscrew One Wheel Stud On Each Rear Wheel
Turn adjusting screw with a screwdriver until the wheel is no longer able to turn. Then unfasten the adjusting
screw 8 notches.
Fig. 14: Turn Adjusting Screw With A Screwdriver Until Wheel Is Unable To Turn
Unlock adjuster unit (ASZE). Lever restraint hook (2) outwards with a suitable screwdriver (1). Restraint hook
(2) must disengage from stop of adjusting spring.
2006 BMW 650i
BRAKES Disc - 650i
Fig. 15: Lever Restraint Hook (2) Outwards Using Screwdriver
2. Setting instruction for parking brake Bowden cables
The parking brake lever must be applied 5 times to approx. 400 N actuating force
0th tooth (parking brake released):
Vehicles with manual transmission: Shift lever in neutral position.
Vehicles with automatic transmission: Selector lever position "N".
 Without locking differential < or =150 N.

 With locking differential < or = 200 N (possibly odd display).
1st tooth: No increase in braking force with regard to 0th tooth. Indicator lamp can be lit.
5th tooth: The brake force display must have reached > or = 400 N.
Apply parking brake until a wheel circumferential force (brake force display) of min. 1000 N is reached.
Max. permitted brake force differential right/left < or = 35 % (referred to greater brake value).
3. Braking in the duo-servo parking brake:
The following braking-in procedures are applicable in case of insufficient braking effect or after replacing brake
2006 BMW 650i
BRAKES Disc - 650i
3.1 On brake analyzer:
Apply parking brake lever until wheel circumferential force at first wheel is 800 N. Lock parking brake lever in
next lower tooth. Release parking brake lever after approx. 2 minutes.
3.2 When driving on road:
(If possible inside the company grounds or on an unused road) At approx. 40 km/h apply 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.
IMPORTANT: Allow brake to cool down sufficiently.
11 FRONT BRAKES
34 11 ... OVERVIEW OF FRONT BRAKE
2006 BMW 650i
BRAKES Disc - 650i
Fig. 16: Identifying Brake Disk, Brake Pad & Brake Caliper
34 11 000 REMOVING AND INSTALLING/REPLACING BRAKE LININGS ON BOTH FRONT DISC

BRAKES
 34 1 080
 34 1 280
 34 6 320
 Remove wheels . See 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL )
Observe safety instructions on raising the vehicle . See 00 .. ... LIFTING VEHICLE WITH A LIFTING
PLATFORM
If necessary, when replacing linings, reset CBS display in accordance with factory specification.
NOTE: After completing work:
 Fully depress brake pedal several times so that brake linings contact
brake discs.
 When installing new brake linings at front and rear axles, brake fluid level
must be brought up to "MAX" marking.
 Read and comply with notes on braking in new brake discs/brake pads .
See 34 00 ... GENERAL INFORMATION ON BRAKING IN NEW BRAKE
DISCS/BRAKE PADS
IMPORTANT: On the E60 M5 and E63 M6 the fault memory entry "Mastervac vacuum
pressure sensor" may be stored after the brake linings have been replaced.
The fault memory entry must be deleted. The vacuum pressure sensor only has
to be replaced if the fault is entered repeatedly.
Lever out retaining spring (1) in direction of arrow towards rear.
Installation:
Attach retaining spring (1) first at top and bottom and then allow retaining lug (2) to engage in recess of brake
caliper housing.
2006 BMW 650i
BRAKES Disc - 650i
Fig. 17: Identifying Retaining Spring & Retaining Lug

Remove plastic plugs (1).
Fig. 18: Identifying Plastic Plugs

Left:
Pull brake lining wear sensor (1) towards rear out of lining.
If necessary, replace brake lining wear sensor . See 34 35 001 REPLACING A BRAKE LINING SENSOR
Release guide screws (2) with special tool 34 1 080 . See 34 1 080 BIT INSERT
Withdraw brake caliper backwards.
Installation:
2006 BMW 650i
BRAKES Disc - 650i
Check threads.
Replace all guide screws which are not in perfect condition.
Tightening torque 34 11 3AZ . See 34 11 FRONT BRAKE
Fig. 19: Pulling Brake Lining Wear Sensor & Guide Screw
Press back brake linings and piston with special tool 34 6 320 . See 34 6 320 LEVER
IMPORTANT: When forcing piston back:
 Pay attention to brake fluid level in expansion tank; brake fluid that spills
over will damage paintwork.

Press brake linings inwards and remove.

2006 BMW 650i
BRAKES Disc - 650i
The two brake linings are seated with a spring in the piston or in the brake caliper housing and must not be
mixed up.
IMPORTANT: Mark any worn brake linings.
In the event of one-sided brake lining wear, do not change brake linings round.
Observe minimum thickness of brake linings . See 34 11 FRONT BRAKE E63
Clean brake linings.
Do not apply grease to brake pad backplate.
Fig. 21: Identifying Minimum Thickness Of Brake Linings

Check minimum brake disc thickness:
 Position special tool 34 1 280 at three measuring points in area (1) and measure. See 34 1 280 SLIDING
CALIPER
 Compare measurement result and lowest value with setpoint value . See 34 11 FRONT BRAKE E63
New brake linings may only be installed if the brake disc thickness is greater than or equal to the minimum
brake disc thickness (MIN TH) . See 34 11 FRONT BRAKE E63
2006 BMW 650i
BRAKES Disc - 650i

Check dust sleeve (1) for damage and replace if necessary.
Clean contact face (2) of brake piston and apply a thin coating of anti-squeak compound .
IMPORTANT: Dust sleeve must not come into contact with anti-squeak compound as this
may cause the dust sleeve to swell.
Fig. 23: Identifying Dust Sleeve & Contact Face

Clean mounting faces (1) and (2) of brake lining hammer heads/brake caliper housing and coat with anti-squeak
compound .
NOTE: Grease contact surfaces on brake caliper at top and bottom.

2006 BMW 650i
BRAKES Disc - 650i
Fig. 24: Identifying Mounting Faces

Clean mounting face (3) of brake caliper and apply a thin coating of anti-squeak compound .
Fig. 25: Identifying Mounting Face Of Brake Caliper

Clean brake caliper holder at hammerhead guides and apply a thin coating of anti-squeak compound.
Refer to BRAKES - OPERATING FLUIDS .

2006 BMW 650i
BRAKES Disc - 650i
Fig. 26: Locating Brake Caliper Holder & Hammerhead Guides

34 11 220 REMOVING AND INSTALLING/REPLACING BOTH FRONT BRAKE DISCS
 34 1 280
 Remove wheels . See 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL

 If necessary, remove and clean brake linings . See 34 11 000 REMOVING AND
INSTALLING/REPLACING BRAKE LININGS ON BOTH FRONT DISC BRAKES
After completing work, read and comply with notes on braking in new brake discs/brake pads . See 34 00 ...
GENERAL INFORMATION ON BRAKING IN NEW BRAKE DISCS/BRAKE PADS
PLATFORM
CALIPER
 Compare measurement result and lowest value with setpoint value . See 34 11 FRONT BRAKE E63
brake disc thickness (MIN TH) . See 34 11 FRONT BRAKE E63
Always replace brake discs in pairs.

2006 BMW 650i
BRAKES Disc - 650i

Release screws (1), remove brake caliper and tie up.
Installation:
NOTE: Brake hose remains connected.
If the brake hose was pulled from the mounting fixture during removal, make
sure it is positively attached when installed!
Fig. 28: Identifying Brake Caliper & Tie Up

Unscrew bolts and take off brake disc.
Installation:
2006 BMW 650i
BRAKES Disc - 650i
Clean contact surface of brake disc at wheel hub thoroughly and remove traces of corrosion if necessary.
Unevenness on contact surface may result in distortion of 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.
Fig. 29: Tightening Brake Disc Bolt

IMPORTANT: Internally ventilated brake discs are balanced.
Never remove or reposition balance clips.
Fig. 30: Locating Reposition Balance Clips

34 11 220 REMOVING AND INSTALLING/REPLACING BOTH FRONT BRAKE DISCS (S85)

2006 BMW 650i
BRAKES Disc - 650i
 34 1 280

 If necessary, remove and clean brake linings . See 34 11 000 REMOVING AND
INSTALLING/REPLACING BRAKE LININGS ON BOTH FRONT DISC BRAKES. After
completing work, read and comply with notes on braking in new brake discs/brake pads.
 Position special tool 34 1 280 at three measuring points in area (1) and measure.
 Compare measurement result and lowest value with setpoint value. See 11 - FRONT BRAKES .
Fig. 31: Checking Brake Thickness

IMPORTANT: 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)
Brake discs may only be replaced in pairs (on 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!

2006 BMW 650i
BRAKES Disc - 650i
Fig. 32: Release Screws (1), Remove Brake Caliper And Tie Up
NOTE: Brake hose remains connected. If the brake hose was pulled from the mounting
fixture during removal, make sure it is positively attached when installed!
Installation: Tightening torque, see 34 11 2AZ in 11 FRONT BRAKES .
Release screws (1) and remove brake disc (2).
Fig. 33: Release Screws (1) And Remove Brake Disc (2)
Installation: Thoroughly clean contact surface of brake disc on wheel hub and guide pins (3), remove traces of
corrosion if necessary.
2006 BMW 650i
BRAKES Disc - 650i
Brake disc can only be mounted in one position. Replace screws. Tightening torque, see 34 11 1AZ in 11
FRONT BRAKES .
34 11 250 REMOVING AND INSTALLING/REPLACING A BRAKE CARRIER/BRAKE GUARD

PLATE AT FRONT
 Remove front brake disks See 34 11 220 REMOVING AND INSTALLING/REPLACING BOTH
FRONT BRAKE DISCS
Release screws (1) and remove brake guard plate (2).
Installation:
Fig. 34: Identifying Brake Guard Plate & Screw

34 11 519 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT FRONT BRAKE

CALIPER
 Remove wheels . See 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL )
PLATFORM
After completing tasks, bleed brake system . See 34 00 025 REPLACING FLUID IN ABS/ASC+T BRAKE
SYSTEM
2006 BMW 650i
BRAKES Disc - 650i
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.
Fig. 35: Locating Pedal Prop & Brake Pedal

Left side: Disconnect plug connection for wear indicator.
Release brake hose on brake caliper.
Slacken connection for brake hose and brake line.
Installation:
Tighten brake hose on brake caliper.
Tightening torque 34 32 4AZ . See 34 32 BRAKE LINES
Move steering to straight-ahead position.
Screw brake hose to brake line, ensuring that brake hose is not twisted.
Unscrew bolts (1) and remove brake caliper.
Installation:

2006 BMW 650i
BRAKES Disc - 650i
Fig. 36: Removing Brake Caliper

34 11 552 OVERHAULING LEFT OR RIGHT FRONT BRAKE CALIPER (BRAKE CALIPER

REMOVED)
 34 1 133
NOTE: Use repair kit, refer to BMW Parts Service.
Bear in mind that guide sleeves and screws come in different lengths:
 16" brake system: two short guide sleeves with two short screws.
 17" brake system: one long guide sleeve and one short guide sleeve with one long screw and one short
screw.
 18" brake system: two long guide sleeves with two long screws.
Take off plastic caps (1).
Unscrew guide screws (2).
Installation:
Only clean guide screws; do not grease. Check guide bolts, replace if necessary.
E65 and E66:
Tightening torque: 34 11 3AZ . See 34 11 FRONT BRAKE

2006 BMW 650i
BRAKES Disc - 650i
Fig. 37: Identifying Plastic Caps & Guide Screws

Dismantle brake caliper and remove brake linings.
Installation:
Press brake lining fully outwards and insert spring (4).
Fig. 38: Identifying Brake Lining

In the following work step, large forces occur at the brake caliper piston
up to more than 2800 N.
Carefully force piston out through connection bore with compressed air.
To protect piston, place a protective plate (e.g. hard wood or hard felt) in caliper recess.
Do not grip piston with fingers - risk of trapping!

2006 BMW 650i
BRAKES Disc - 650i
Fig. 39: Locating Force Piston Out Connection Bore With Compressed Air
Check guide sleeves (5), fitting repair-kit guide sleeve if necessary.
IMPORTANT: Bear in mind that guide sleeves and screws come in different lengths.
Long guide sleeve with long screw is seated on disk inlet at bottom, short
sleeve with short screw is seated on disk outlet at top.
Fig. 40: Identifying Guide Sleeves

Remove sealing ring carefully with a plastic needle.
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.

2006 BMW 650i
BRAKES Disc - 650i
Fig. 41: Machining Of Cylinders And Pistons

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.
Press in piston with a hardwood board.
IMPORTANT: Do not tilt piston.
Fig. 42: Installing Sealing Cover In Rear Annular Groove Of Cylinder Bore
Press on dust protection sleeve evenly up to stop with special tool 34 1 133 .
Installation:
The area between dust protection sleeve and brake caliper housing must be kept dry so as to ensure correct
seating for the dust protection sleeve.
2006 BMW 650i
BRAKES Disc - 650i
Keep Ate brake cylinder paste or brake fluid away from this area.
Make sure dust protection sleeve is correctly seated on piston.
Fig. 43: Pressing On Dust Protection Sleeve With Special Tool (34 1 133)
34 11 667 PRECISION-TURNING BOTH FRONT BRAKE DISCS ON BOTH SIDES
IMPORTANT: Always precision-turn both sides of both brake discs on one axle.
Observe Max. machining dimension per friction ring side Minimum brake disc
thickness (MIN TH)
Brake discs of M models (Compound brake discs) must not be machined!
Only one brake pad set may be used up on brake discs which have been lathe-
turned to minimum thickness (MIN TH) .
Stationary brake disc lathe:
In the case of stationary brake disc lathes, the brake disc must be removed .
Please refer to the lathe manufacturer's instruction manual for the exact procedure.
IMPORTANT: Only BMW - approved brake disc lathes may be used!

2006 BMW 650i
BRAKES Disc - 650i
Fig. 44: Identifying Stationary Brake Disc Lathe

Mobile brake disc lathe:
In the case of mobile brake disc lathes, only the brake calliper has must be removed .
The brake discs remain on the car.
Please refer to the lathe manufacturer's instruction manual for the exact procedure.
IMPORTANT: Only BMW-approved brake disc lathes may be used!
Fig. 45: Identifying Mobile Brake Disc Lathe:

After fine-grinding the brake discs, measure the thickness difference inside the braking surfaces at 8 points with
an external micrometer.
2006 BMW 650i
BRAKES Disc - 650i
Fig. 46: Measuring Thickness Difference Inside Braking Surfaces

21 REAR BRAKES
34 21 ... OVERVIEW OF REAR BRAKE
2006 BMW 650i
BRAKES Disc - 650i
Fig. 47: Identifying Brake Disk, Brake Pad & Brake Caliper
34 21 171 REMOVING AND INSTALLING/REPLACING A BRAKE CARRIER/BRAKE GUARD AT

REAR
 Remove expander lock . See 34 41 250 REMOVING AND INSTALLING/REPLACING

EXPANDER LOCK FOR HANDBRAKE SHOES
 Remove wheel hub . See 33 41 151 REPLACING LEFT OR RIGHT WHEEL BEARING ON REAR
AXLE SHAFT
Release screws (1) and remove brake carrier (2).
Installation:
Tightening torque 34 21 6AZ . See 34 21 REAR BRAKE

2006 BMW 650i
BRAKES Disc - 650i
Fig. 48: Identifying Brake Carrier & Screw

34 21 200 REMOVING AND INSTALLING OR REPLACING BRAKE LININGS ON BOTH REAR

DISC BRAKES
 34 1 050
 34 1 080
 34 1 280
PLATFORM
brake discs.
 Read and comply with notes on braking in new brake discs / brake pads .
See 34 00 ... GENERAL INFORMATION ON BRAKING IN NEW BRAKE
DISCS/BRAKE PADS)
2006 BMW 650i
BRAKES Disc - 650i
pressure sensor" may be stored after the brake linings have been replaced.
The fault memory entry must be deleted. The vacuum pressure sensor only has
to be replaced if the fault is entered repeatedly.
Remove plastic plugs (1).
Right side:
Disconnect plug connection for brake lining wear sensor.
If necessary, replace brake lining wear sensor.
Fig. 49: Identifying Plastic Plugs

Release guide screws (2) with special tool 34 1 080 . See 34 1 080 BIT INSERT
Installation:
Only clean guide screws; do not grease.
Check threads.

2006 BMW 650i
BRAKES Disc - 650i

Lift out retaining spring (3).
Fig. 51: Lifting Out Retaining Spring

Turn piston fully back with special tool 34 1 050 . See 34 1 050 FIXTURE
2006 BMW 650i
BRAKES Disc - 650i
Fig. 52: Turning Piston Fully Back With Special Tool (34 1 050)
Remove outer brake lining.
Inner brake lining is located with its spring in the piston.
If the brake linings are worn on one side, they must not be mixed up!
Observe minimum thickness of brake linings .
Clean brake linings.
Fig. 53: Identifying Brake Linings

2006 BMW 650i
BRAKES Disc - 650i
CALIPER
 Compare measurement result and lowest value with setpoint value . See 34 21 REAR BRAKE DISCS
E63
brake disc thickness (MIN TH) . See 34 21 REAR BRAKE DISCS E63

Clean contact face (2) of brake piston and apply a thin coating of anti-squeak compound .
IMPORTANT: Dust sleeve must not come into contact with anti - squeak compound as this
2006 BMW 650i
BRAKES Disc - 650i
Fig. 55: Identifying Dust Sleeve & Contact Face

IMPORTANT: In E39/Touring models, make sure the insulating ring (1) is installed on the
brake piston.
Fig. 56: Identifying Insulating Ring

compound .
2006 BMW 650i
BRAKES Disc - 650i
Fig. 57: Identifying Mounting Faces

Clean contact face (3) of brake caliper and apply a thin coating of anti-squeak compound .
Fig. 58: Identifying Mounting Face Of Brake Caliper

Clean brake caliper mounting bracket at hammer head guides and apply a thin coating of anti-squeak
compound .
2006 BMW 650i
BRAKES Disc - 650i
Fig. 59: Locating Brake Caliper Holder & Hammerhead Guides

34 21 320 REMOVING AND INSTALLING OR REPLACING BOTH REAR BRAKE DISCS
 34 1 280

 If necessary, remove and clean brake linings . See 34 21 200 REMOVING AND INSTALLING OR
REPLACING BRAKE LININGS ON BOTH REAR DISC BRAKES
E65 and E66: Release parking brake (pushbutton to left of steering wheel).
After completing work:
 Adjust handbrake (not for E65 and E66)

 Read and comply with notes on braking in new brake discs/brake pads . See 34 00 ... GENERAL
INFORMATION ON BRAKING IN NEW BRAKE DISCS/BRAKE PADS
PLATFORM
CALIPER
 Compare measurement result and lowest value with setpoint value . See 34 21 REAR BRAKE DISCS
E63
2006 BMW 650i
BRAKES Disc - 650i
brake disc thickness (MIN TH) . See 34 21 REAR BRAKE DISCS E63
Always replace brake discs in pairs.
If the brake discs are replaced, you must also fit new brake linings.

Installation:
Fig. 61: Identifying Brake Caliper & Tie Up With Screw

2006 BMW 650i
BRAKES Disc - 650i
Unscrew bolts and take off brake disc.
Installation:
Clean contact surface of brake disc at wheel hub thoroughly and remove traces of corrosion if necessary.
Unevenness on contact surface may result in distortion of brake disc!
Fig. 62: Tightening Brake Disc Bolt

IMPORTANT: Internally ventilated brake discs are balanced.
Never remove or reposition balance clips.
Fig. 63: Locating Reposition Balance Clips

2006 BMW 650i
BRAKES Disc - 650i
34 21 320 REMOVING AND INSTALLING OR REPLACING BOTH REAR BRAKE DISCS (S85)
 34 1 280

 If necessary,remove and clean brake linings . After completing work, read and comply with notes on
braking in new brake discs/brake pads.
 Adjust parking brake.

 Read and comply with notes on braking in new brake discs / brake pads.
 Position special tool 34 1 280 at three measuring points in area (1) and measure.
 Compare measurement result and lowest value with setpoint value. See 21 - REAR BRAKES .
Fig. 64: Position Special Tool 34 1 280 At Three Measuring Points In Area (1) And Measure
IMPORTANT: 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). See 21 - REAR BRAKES .
Brake discs may only be replaced in pairs (on each axle).
If the brake discs are replaced, you must also fit new brake pads.
2006 BMW 650i
BRAKES Disc - 650i
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!
Fig. 65: Release Screws (1), Remove Brake Caliper And Tie Up
Installation: Tightening torque, see 34 21 3AZ in 34 21 REAR BRAKE .
Release screws (1) and remove brake disc (2).
Fig. 66: Release Screws (1) And Remove Brake Disc (2)
2006 BMW 650i
BRAKES Disc - 650i
Make sure contact surfaces between wheel hub and brake disc are absolutely clean. Replace screws. Tightening
torque, see 34 21 1AZ in 34 21 REAR BRAKE .
34 21 745 REMOVING AND INSTALLING OR REPLACING LEFT OR RIGHT REAR BRAKE

CALIPER
PLATFORM
SYSTEM
tank and air from entering the brake system when the brake lines are opened.

Right side: Disconnect plug connection for brake lining wear sensor.
Unfasten screws (1).
Installation:

2006 BMW 650i
BRAKES Disc - 650i
Release brake hose (2).
Installation:
Unfasten brake hose at connection point to brake line.
First tighten the brake hose on the brake cover, then tighten connection on brake line.
Install brake hose without torsional stress.
Pull off fist caliper towards rear of vehicle.
Fig. 68: Identifying Brake Hose & Screws

IMPORTANT: 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 21 812 OVERHAULING LEFT OR RIGHT REAR BRAKE CALIPER (BRAKE CALIPER

REMOVED)
 34 1 132
NOTE: Use original BMW repair kit.

2006 BMW 650i
BRAKES Disc - 650i
Installation:
Tightening torque: 34 21 5AZ . See 34 21 REAR BRAKE
Fig. 69: Identifying Plastic Caps & Screw

Installation:
Fig. 70: Identifying Brake Lining

In the following work step, large forces occur at the brake caliper piston
(up to more than 2800 N).
2006 BMW 650i
BRAKES Disc - 650i
Fig. 71: Locating Force Piston Out Connection Bore With Compressed Air
Fig. 72: Identifying Guide Sleeves

Thoroughly inspect cylinder bore, piston and flange surfaces.
Machining of cylinders and pistons is not permitted.

2006 BMW 650i
BRAKES Disc - 650i
Fig. 73: Machining Of Cylinders & Pistons

Installation:
Install sealing cover in rear annular groove of cylinder bore.
Press in piston with a hardwood board.
Fig. 74: Installing Sealing Cover In Rear Annular Groove Of Cylinder Bore
Press on dust protection sleeve evenly up to stop with special tool 34 1 132 .
Installation:
The area between dust protection sleeve and brake caliper housing must be kept dry so as to ensure correct
seating for the dust protection sleeve.
2006 BMW 650i
BRAKES Disc - 650i
Fig. 75: Pressing On Dust Protection Sleeve With Special Tool (34 1 133)
31 MASTER BRAKE CYLINDER

34 31 ... OVERVIEW OF BRAKE MASTER CYLINDER/BRAKE BOOSTER
2006 BMW 650i
BRAKES Disc - 650i
Fig. 76: Identifying Brake Booster, Expansion Tank & Brake Master Cylinder
34 31 181 REMOVING AND INSTALLING/REPLACING EXPANSION TANK FOR HYDRAULIC

BRAKE ACTUATION

Suck the brake fluid out of the expansion tank. Use suction bottle exclusively to draw off brake fluid.
IMPORTANT: Do not reuse drawn out brake fluid.

2006 BMW 650i
BRAKES Disc - 650i
Fig. 77: Sucking Brake Fluid Out Of Expansion Tank

Release retaining screw (2).
Installation:
Tightening torque 34 31 3AZ . See 34 31 BRAKE MASTER CYLINDER
Pull expansion tank vertically out of brake master cylinder.
Fig. 78: Identifying Plug Connection & Retaining Screw

Installation:
Check rubber plug in brake master cylinder for damage and replace if necessary.
2006 BMW 650i
BRAKES Disc - 650i
Fig. 79: Pushing Expansion Tank Vertically Onto Master Brake Cylinder
34 31 505 REMOVING AND INSTALLING/REPLACING MASTER BRAKE CYLINDER FOR DSC
 32 1 270
 Remove expansion tank . See 34 31 181 REMOVING AND INSTALLING/REPLACING

EXPANSION TANK FOR HYDRAULIC BRAKE ACTUATION
 Remove footwell trim . See 51 45 185 REMOVING AND INSTALLING/REPLACING PANEL FOR
PEDALS
 Read and comply with General Information . See 34 00 ... GENERAL INFORMATION)
After completing tasks, bleed brake system with DSC . See 34 00 050 BLEEDING BRAKE SYSTEM WITH
DSC
Remove locking clip (1) and disengage and pull out locking pin.
Slacken nuts (2).
Installation:
Tightening torque 35 11 1AZ . See 35 11 PEDAL ASSEMBLY CONSOLE

2006 BMW 650i
BRAKES Disc - 650i
Fig. 80: Identifying Locking Clip & Nuts

Unfasten brake lines (1).
Detach brake lines at junction (2) and remove short sections.
Seal off brake lines and brake master cylinder with plugs 32 1 270 . See 32 1 270 PLUGS (SET)
Installation:
Fit lines at both connection points and then tighten down.
Release nuts (3) and feed brake master cylinder out of brake booster.
Fig. 81: Identifying Brake Line, Brake Lines Junction & Nuts
2006 BMW 650i
BRAKES Disc - 650i
Installation:
Tightening torque 34 31 1AZ . See 34 31 BRAKE MASTER CYLINDER
Installation:
Replace sealing ring.
Fig. 82: Identifying Sealing Ring

IMPORTANT: Brake booster (1) must be loosely screwed into place so as not to jam brake
master cylinder (2) during installation.
Installation:
When inserting the brake master cylinder (2) into the brake booster (1), make sure the pressure rod of the brake
booster and that of the brake master cylinder meet each other on one level.
2006 BMW 650i
BRAKES Disc - 650i
Fig. 83: Identifying Brake Booster & Brake Master Cylinder

32 BRAKE LINES
34 32 ... OVERVIEW OF BRAKE LINES
2006 BMW 650i
BRAKES Disc - 650i
Fig. 84: Identifying Front Brake Hose, Brake Tubes & Rear Brake Hose
34 32 861 REPLACING ALL BRAKE PIPES
 34 5 100
NOTE: The brake lines are only supplied in the straight version and correct length with
connecting nipple.
Read and comply with General Information . See 34 00 ... GENERAL

INFORMATION
After completing work, bleed brake system . See 34 00 050 BLEEDING BRAKE
SYSTEM WITH DSC
2006 BMW 650i
BRAKES Disc - 650i
Observe safety instructions on raising the vehicle . See 00 .. ... LIFTING

VEHICLE WITH A LIFTING PLATFORM
New brake lines are bent into shape with bending tool 34 5 100 . See 34 5 100 BENDING FIXTURE
Removed brake pipes 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. Brake lines may not
make contact or rub.
 Tighten down brake line couplings with torque wrench.

Installation:
34 32 881 REPLACING FRONT LEFT OR RIGHT BRAKE HOSES
NOTE: After completing tasks, bleed brake system . See 34 00 025 REPLACING FLUID
IN ABS/ASC+T BRAKE SYSTEM
tank when the brake lines are opened.
2006 BMW 650i
BRAKES Disc - 650i
Fig. 86: Locating Pedal Prop And Brake Pedal

Pull brake hose out of holder (1).
Detach brake hose from brake line (2).
Installation:
IMPORTANT: Grip brake hose at square head (3) so that connecting piece cannot rotate in
retaining bracket.
Detach brake hose from brake caliper (4).
Fig. 87: Identifying Brake Hose, Brake Line & Brake Caliper
2006 BMW 650i
BRAKES Disc - 650i
Installation:
First tighten brake hose on brake caliper.
Move wheels into straight-ahead position.
Insert brake hose in bracket and screw onto brake pipe.
IMPORTANT: Never twist brake hose when installing it and avoid all contact with parts
attached rigidly to the body.
34 32 980 REPLACING REAR LEFT OR RIGHT BRAKE HOSES
NOTE: Read and comply with General Information . See 34 00 ... GENERAL
INFORMATION

After completing tasks, bleed brake system . See 34 00 025 REPLACING FLUID
IN ABS/ASC+T BRAKE SYSTEM
tank and air from entering the system when the brake lines are opened.

Disconnect brake hose from brake line (1).
Installation:
2006 BMW 650i
BRAKES Disc - 650i
retaining bracket.
Installation:
Fig. 89: Identifying Brake Line, Square Head & Brake Caliper
33 BRAKE BOOSTER
34 33 071 REPLACING VACUUM HOSE FOR BRAKE BOOSTER (S85)
 Remove lower section of microfilter housing. 64 31 061 REMOVING AND
IMPORTANT: Before starting work, press the brake pedal to the floor several times to reduce
the vacuum pressure in the brake booster. This makes it easier to detach the
lines.
Disconnect plug connection (1). Unscrew nuts (2). Unlock quick-release fastener (3) and detach vacuum hose.
2006 BMW 650i
BRAKES Disc - 650i
Fig. 90: Unlock Quick-Release Fastener (3) And Detach Vacuum Hose
Release clamp (1) and detach vacuum line.
Installation: Replace clamp (1).
Detach non-return valve (2) from brake booster and remove vacuum line (3).
Fig. 91: Detach Non-Return Valve (2) From Brake Booster And Remove Vacuum Line (3)
Installation: Check sealing ring in brake booster and replace if necessary.
When replacing vacuum line: Release screws (1) and convert differential pressure switch (2).
2006 BMW 650i
BRAKES Disc - 650i
Fig. 92: Release Screws (1) And Convert Differential Pressure Switch (2)
Important! Replace O-ring on differential pressure switch.
34 33 075 REMOVING AND INSTALLING/REPLACING VACUUM PUMP (S85)
 Remove lower section of microfilter housing. 64 31 061 REMOVING AND
the vacuum pressure in the brake booster. This makes it easier to detach the
lines.
Disconnect plug connection (1). Unlock quick-release fastener (2) and detach vacuum hose. Release nuts (3)
and remove vacuum pump.
2006 BMW 650i
BRAKES Disc - 650i
Fig. 93: Unlock Quick-Release Fastener (2) And Detach Vacuum Hose
34 33 505 REMOVING AND INSTALLING/REPLACING BRAKE BOOSTER
 Remove brake master cylinder . See 34 31 505 REMOVING AND INSTALLING/REPLACING
MASTER BRAKE CYLINDER FOR DSC
For cars with S85 engines:
 Remove vacuum pump

 Remove bracket for vacuum pump
 Remove vacuum line
Detach locking clip (1) from brake pedal, disengage and pull out locking pin.
Unscrew nuts (2).
Installation:
Tightening torque 35 11 1AZ . See 35 11 PEDAL ASSEMBLY CONSOLE
Fig. 94: Identifying Locking Clip From Brake Pedal

Remove non-return valve (1) from brake booster.

2006 BMW 650i
BRAKES Disc - 650i
Carefully pull brake booster (2) out of bulkhead and tilt out.
Installation:
Replace seal between brake booster and bulkhead.
IMPORTANT: Do not use any force when removing and installing the brake unit; the brake
unit can be damaged under certain circumstances.
Fig. 95: Removing Non-Return Valve From Brake Booster

35 ELECTRICAL COMPONENTS/WEAR INDICATOR

34 35 001 REPLACING A BRAKE LINING SENSOR
 Remove wheel . See 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL
IMPORTANT: If a brake lining sensor that has already been ground has to be replaced even
though the minimum brake lining thickness has not yet been reached, you
must observe the following: The new sliding contact must be filed down with a
file to the same length as the ground sliding contact. See 34 11 FRONT BRAKE
E63
Open cover (1) on plug housing (3).
Unclip lead of brake lining sensor (2) from plug housing (3).
Disconnect associated plug connection of lead from brake lining sensor (2).
2006 BMW 650i
BRAKES Disc - 650i
Fig. 96: Identifying Plug Housing & Brake Lining Sensor

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).
Fig. 97: Pressing Clip & Brake Lining Sensor

41 PARKING BRAKE
 32 1 030
2006 BMW 650i
BRAKES Disc - 650i
Perform inspection in the following manner:
When 1st ratchet is engaged, no braking force should be exerted.
The difference in wheel circumferential forces between the left and right wheels may deviate by max. 30% from
the greater value (measured on brake analyzer). In event of larger deviations of wheel circumferential force:
carry out readjustment.
It must be possible to brake with locked wheels with the handbrake.
The handbrake must be readjusted whenever the actuation stroke is greater than 10 teeth.
NOTE: The handbrake can only be adjusted correctly when the parking brake Bowden
cables and all moving handbrake parts are free to move and fully operational.
Basic handbrake adjustment is necessary:
 When replacing parking brake shoes.

 When replacing brake disks.
 In event of excessive actuation stroke (10 teeth).
 When replacing parking brake Bowden cables
1. Setting instruction for brake shoes (basic setting)
Lock adjuster unit (ASZE).
Using special tool 32 1 030 , press stop (1) of adjusting spring back to such an extent that retaining hook
(2) engages in stop (1). See 32 1 030 LEVER
Fig. 98: Identifying Retaining Hook With Special Tool (32 1 030)
2006 BMW 650i
BRAKES Disc - 650i
Completely unscrew one wheel stud on each rear wheel.
Installation:
Tightening torque 36 10 1AZ . See 36 10 WHEELS
Turn wheel until adjustment screw is visible in tapped hole.
Fig. 99: Identifying Wheel Stud On Rear Wheel

Turn adjusting screw with a screwdriver until the wheel is no longer able to turn.
Then unfasten the adjusting screw 8 notches.
Fig. 100: Turning Adjusting Screw

Unlock adjuster unit (ASZE).
Lever restraint hook (2) outwards with a suitable screwdriver (1).

2006 BMW 650i
BRAKES Disc - 650i
Restraint hook (2) must disengage from stop of adjusting spring.
Fig. 101: Identifying Restraint Hook & Screwdriver

The handbrake lever must be applied 5 times to approx. 400N actuating force.
2.1 On brake analyzer
0th tooth (handbrake released): Vehicles with manual transmission: Shift lever in neutral
position.
Vehicles with automatic transmission: Selector lever in "N" position.
 Without locking differential < or = 150 N.

 With locking differential < or = 200 N (possibly odd display).
5th tooth: The brake force display must have reached > or = 400 N.
Apply handbrake until a wheel circumferential force (brake force display) of min. 1000 N is
reached.
Max. permitted brake force differential right/left < or = 35% (referred to greater brake value).
2006 BMW 650i
BRAKES Disc - 650i
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 disks and/or brake shoes.
Apply handbrake lever until wheel circumferential force on first wheel is 800 N.
Lock lever in next lower tooth.
Release handbrake lever after approx. 2 minutes.
3.2 When driving on road
(If possible inside the company grounds or on an unused road)
At approx. 40 km/h, apply handbrake lever until braking action can be felt.
Pull up handbrake lever into next notch and drive on for approx. 400 m.
A basic requirement is that handbrake is adjusted uniformly.
34 41 ... OVERVIEW OF PARKING BRAKE

2006 BMW 650i
BRAKES Disc - 650i
Fig. 102: Identifying Handbrake Lever, Handbrake Show & Expander Lock
34 41 000 REMOVING AND INSTALLING/REPLACING HANDBRAKE LEVER
 32 1 030
 Remove center console . See 51 16 200 REMOVING AND INSTALLING STORAGE

COMPARTMENT
After completing tasks, adjust handbrake . See 34 10 014 ADJUSTING HANDBRAKE
Using special tool 32 1 030 , press stop (2) of adjusting spring back to such an extent that retaining hook (3)
engages in stop (2). See 32 1 030 LEVER
2006 BMW 650i
BRAKES Disc - 650i
Unclip mounting clip (1) upwards out of balance arm (2).
Fig. 104: Identifying Mounting Clip Upwards Out Of Balance Arm

Guide handbrake Bowden cables (1) with a screwdriver inwards and pull out of balance bar (2).
2006 BMW 650i
BRAKES Disc - 650i
Fig. 105: Identifying Guide Handbrake Bowden Cables & Balance Bar
Disconnect cable (1) from handbrake check switch.
Release screws (2) and remove handbrake lever (3).
Installation:
Tightening torque 34 41 1AZ . See 34 41 PARKING BRAKE
Handbrake lever and adjustment unit (ASZE) are only exchanged completely as a single unit.
Fig. 106: Removing Handbrake Lever & Screw

34 41 120 REMOVING AND INSTALLING/REPLACING BOTH HANDBRAKE BOWDEN CABLES

2006 BMW 650i
BRAKES Disc - 650i
 Remove center console . See 51 16 200 REMOVING AND INSTALLING STORAGE

COMPARTMENT
 Remove rear brake disks . See 34 21 320 REMOVING AND INSTALLING OR REPLACING BOTH
REAR BRAKE DISCS
 Remove exhaust system.
 Remove heat shield.
After completing tasks, adjust handbrake . See 34 10 014 ADJUSTING HANDBRAKE

2006 BMW 650i
BRAKES Disc - 650i
Fig. 108: Identifying Mounting Clip Upwards Out Of Balance Arm

Fig. 109: Identifying Guide Handbrake Bowden Cables & Balance Bar
Disconnect handbrake Bowden cables at expander locks.
Release screw (1) and remove bracket.
Installation:
Tightening torque 34 41 5AZ . See 34 41 PARKING BRAKE
Pull handbrake Bowden cables (2) out of wheel carrier.

2006 BMW 650i
BRAKES Disc - 650i
Fig. 110: Identifying Bowden Cables & Screw

Disconnect handbrake Bowden cables (1) out of mountings.
Pull handbrake Bowden cables (1) out of guide (2) and remove.
Fig. 111: Identifying Handbrake Bowden Cables Out Of Guide

34 41 220 REMOVING AND INSTALLING/REPLACING ALL HANDBRAKE SHOES
 32 1 030
 34 4 000
 Remove rear brake disk . See 34 21 320 REMOVING AND INSTALLING OR REPLACING BOTH
2006 BMW 650i
BRAKES Disc - 650i
REAR BRAKE DISCS)
 Adjusting handbrake . See 34 10 014 ADJUSTING HANDBRAKE
Release handbrake lever.
Using special tool 32 1 030, press stop (1) of adjusting spring back to such an extent that retaining hook (2)
Disconnect return spring (1) with brake spring pliers.
Installation:
Check and if necessary replace return spring (1).
Pay attention to installation position of adjustment screw (2).
Apply a thin coat of grease to bush and screw threads.

2006 BMW 650i
BRAKES Disc - 650i
Fig. 113: Identifying Return Spring With Brake Spring Pliers

Installation:
Fig. 114: Identifying Return Spring With Brake Spring Pliers

Turn clamping pins (1) with special tool 34 4 000 through 90° and disconnect. See 34 4 000 ALLEN KEY
Remove brake shoes (2).

2006 BMW 650i
BRAKES Disc - 650i

34 41 250 REMOVING AND INSTALLING/REPLACING EXPANDER LOCK FOR HANDBRAKE

SHOES
 32 1 030
 Remove handbrake shoes . See 34 41 220 REMOVING AND INSTALLING/REPLACING ALL

HANDBRAKE SHOES
 Adjust handbrake . See 34 10 014 ADJUSTING HANDBRAKE
2006 BMW 650i
BRAKES Disc - 650i
Pull expander lock (1) forwards, disconnect handbrake Bowden cable (2) and remove expander lock.
Fig. 117: Pulling Expander Lock

51 MECHANICAL/HYDRAULIC COMPONENTS
34 51 527 REMOVING AND INSTALLING/REPLACING HYDRAULIC UNIT FOR DSC (S85)
 Read and comply with General Information.

 Remove front left wheel arch trim. See 51 71 040 REMOVING AND INSTALLING/REPLACING
FRONT LEFT OR RIGHT WHEEL ARCH COVER .
 Remove front left support.
2006 BMW 650i
BRAKES Disc - 650i
After completing work: Bleed braking system.
Installation: After reinstalling the hydraulic unit, carry out the following tasks with the DIS (Diagnosis and
Information System):
 Mix-up check of brake lines

 Function check, hydraulic unit
Press clutch pedal down to floor and secure with pedal support.
NOTE: The pedal support may only be released when the brake lines are reconnected.
This prevents brake fluid from emerging from the expansion tank and air from entering the system when the
brake lines are opened.
IMPORTANT: Do not mix up brake lines.
If necessary, mark before removal.
Close off connection bores with plugs.
Fig. 118: Disconnect Plug Connection (1)

IMPORTANT: Do not bend brake lines.
Unfasten brake lines (2). Installation: Tightening torque, see 34 32 1AZ in 34 32 BRAKE LINES . Release
bolts (3) and remove hydraulic unit.
2006 BMW 650i
BRAKES Disc - 650i
 Release bolts (1) and modify bracket (2).

 Modify control unit.
Fig. 119: Release Bolts (1) And Modify Bracket (2)

52 ELECTRONIC COMPONENTS
34 52 ... OVERVIEW OF ELECTRONIC COMPONENTS
2006 BMW 650i
BRAKES Disc - 650i
Fig. 120: Identifying DSC Control Unit, Rear Pulse Generator & Front Pulse Generator
34 52 516 REMOVING AND INSTALLING/REPLACING DSC CONTROL UNIT
protection) . See 61 35 ... NOTES ON ESD PROTECTION (ELECTRO STATIC
DISCHARGE)
 Before removal, read out the control unit fault memory and if necessary print out the diagnostic trouble
code.
Installation:
2006 BMW 650i
BRAKES Disc - 650i
When replacing the control unit, carry out the following tasks with the DIS (Diagnosis and Information
System):
 Vehicle coding (performed by the vehicle itself)

 Adjustment of steering angle sensor (performed by the vehicle itself)
 Adjustment of brake pressure sensor (performed by the vehicle itself)
 Adjustment of lateral acceleration sensors (performed by the vehicle itself)
 Function check, hydraulic unit
Unfasten plug connection (1).
Release screws (2) and carefully detach control unit (3) towards front.
IMPORTANT: Risk of damage to the contacts when removing and installing the hydraulic
unit.
Fig. 121: Identifying Plug Connection, Control Unit & Screw

Installation:
Keep sealing faces clean.
Replace screws.
Observe tightening sequence (1-4).
Tightening torque 34 51 1AZ . See 34 51 SLIP CONTROL SYSTEM (ABS, ASC+T, DSC)
2006 BMW 650i
BRAKES Disc - 650i
Fig. 122: Identifying Plug Connection, Detach Control Unit & Screw
34 52 516 REMOVING AND INSTALLING/REPLACING DSC CONTROL UNIT (S85)
DISCHARGE)
 Remove hydraulic unit.
When replacing control unit:
 Carry out programming/coding.

 Adjustment of steering angle sensor.
 Mix-up check of brake lines.
 Function check, hydraulic unit.
2006 BMW 650i
BRAKES Disc - 650i
Fig. 123: Release Screws (1) And Carefully Detach Control Unit
unit.
Installation: Keep sealing faces clean. Replace screws. Observe tightening sequence (1-4). Tightening torque,
see 34 51 1AZ in 34 51 SLIP CONTROL SYSTEM (ABS, ASC+T, DSC)
Fig. 124: Control Unit Tightening Sequence

34 52 525 REPLACING ONE FRONT PULSE GENERATOR
DISCHARGE)
2006 BMW 650i
BRAKES Disc - 650i
INFORMATION

Open plug housing (1), pull plug connection (2) out of bracket and disconnect.
Pull cable with rubber grommet out of bracket on spring strut.
Installation:
Ensure proper locking of plug connector and proper seating of rubber grommets.
Fig. 125: Identifying Plug Housing & Plug Connection

Release hexagon socket head cap screw (1) and pull wheel speed sensor out of bore.
Installation:
Tightening torque 31 51 6AZ .
Clean bore hole for pulse generator and grease with Staburags NBU 12/K lubricating grease (refer to BRAKES
- OPERATING FLUIDS ).
2006 BMW 650i
BRAKES Disc - 650i
Fig. 126: Releasing Hexagon Socket Head Cap Screw

34 52 535 REPLACING A REAR PULSE GENERATOR
DISCHARGE)
 Remove rear wheel . See 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL
PLATFORM
Open plug housing (1).
Pull plug connection (2) out of mounting and disconnect.
Pull cable out of brackets on swinging arm.
Installation:
Ensure proper locking of the plug connector and proper seating of the cable in the brackets.
2006 BMW 650i
BRAKES Disc - 650i
Fig. 127: Pulling Plug Connection & Plug Housing

Installation:
Clean bore hole for pulse generator and grease with Staburags NBU 12/K lubricating grease (refer to BRAKES
- OPERATING FLUIDS ).
Fig. 128: Releasing Hexagon Socket Head Cap Screw

34 52 550 REMOVING AND INSTALLING/REPLACING DSC SENSOR
DISCHARGE)
2006 BMW 650i
BRAKES Disc - 650i
 Remove right front seat . See 52 14 000 REMOVING AND INSTALLING LEFT OR RIGHT
FRONT SEAT (NORMAL/ELECTRIC)
 Remove front inside entrance cover strip . See 51 47 000 REMOVING AND
INSTALLING/REPLACING FRONT (INSIDE) LEFT OR RIGHT ENTRANCE COVER STRIP
 Lift carpet and fold back to one side
NOTE: The yaw sensor comprises the function of the transversal-acceleration sensor
and the yaw sensor.
Unlock plug connection.
Installation:
Make sure plug connection locks correctly.
Release screws (1) and remove rotation rate sensor.
Installation:
Fig. 129: Identifying Rotation Rate Sensor Screw

34 52 550 REMOVING AND INSTALLING/REPLACING DSC SENSOR (S85)
DISCHARGE)

2006 BMW 650i
BRAKES Disc - 650i
 Remove right front seat. See 52 14 000 REMOVING AND INSTALLING LEFT OR RIGHT
FRONT SEAT (NORMAL/ELECTRIC) .
 Remove front inner entrance cover strip. See 51 47 000 REMOVING AND
Lift carpet (1) and fold to side. Release screws (2) and swing out DSC sensor (3). Installation: Tightening
torque, see 34 51 3AZ in 34 51 SLIP CONTROL SYSTEM (ABS, ASC+T, DSC) .
Fig. 130: Swing Out DSC Sensor

Unlock plug connection (1) and remove DSC sensor (2). Installation: Make sure plug connection locks
correctly.
Fig. 131: Removing DSC Sensor

34 52 575 REMOVING AND INSTALLING/REPLACING FRONT PRESSURE SENSOR FOR ACC

2006 BMW 650i
BRAKES Disc - 650i
 Remove front right wheel arch trim . See 51 71 040 REMOVING AND INSTALLING/REPLACING
FRONT LEFT OR RIGHT WHEEL ARCH COVER
SYSTEM

Release pressure sensor (2) and remove.
Installation:
2006 BMW 650i
BRAKES Disc - 650i
Fig. 133: Identifying Pressure Sensor & Plug Connection

34 52 580 REMOVING AND INSTALLING/REPLACING REAR PRESSURE SENSOR FOR ACC
NOTE: Read and comply with General Information . See 34 00 ... GENERAL
INFORMATION
Apply completing takes, bleed brake system. . See 34 00 025 REPLACING FLUID IN ABS/ASC+T BRAKE
SYSTEM

Vehicles with N52 engine:

2006 BMW 650i
BRAKES Disc - 650i
Installation:
Make sure heat shield is correctly seated.
If necessary, replace heat shield.
Fig. 135: Identifying Heat Shield

Installation:
Fig. 136: Identifying Pressure Sensor & Plug Connection

2005 BMW 645Ci
2004-05 BRAKES Disc - Repair Instructions - 6-Series (E63/64)
2004-05 BRAKES
Disc - Repair Instructions - 6-Series (E63/64)
BRAKES TESTING AND BLEEDING

34 00 ... GENERAL INFORMATION
The brake system is one of the most important safety systems on any motor vehicle. It is therefore essential to
act with utmost care when working on the brake system and to follow the instructions below.
General:
 Ensure cleanliness and only use rags which do not lose lint.
 Wash away or vacuum up brake dust, do not clear it away using compressed air. This dust is a health
hazard.
 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 cleaner, do not allow brake cleaner to get into the brake
system.
 Even the most minute traces of brake cleaner must be avoided.
Brake fluid:
 Replace brake fluid at least every two years.

 Never re-use drained brake fluid.
 Always use BMW-approved brake fluid.
 Always dispose of brake fluid in approved receptacles.
 Do not allow brake fluid to drain into drain pipes, into the outside environment or into unsuitable
facilities. This would create the risk of groundwater contamination since brake fluid is classed as a fluid
that is hazardous to water.
 Do not allow brake fluid to come into contact with paintwork as this will destroy the paint.
 Brake fluid must not be allowed to remain on bare skin too long in order to avoid skin problems. Wash
skin coated with brake fluid with water and soap.
 If brake fluid makes contact with eyes, immediately flush with large quantity of clean water and visit eye
doctor.
Wheel brakes:
 Brake linings:
Brake linings must be replaced when the warning threshold of the brake lining wear indicator is reached.
2005 BMW 645Ci
Brake linings must always be replaced on both sides of any axle.
The friction surfaces of the brake linings must not come into contact with oils or greases. The brake
linings must be replaced if they are fouled by such substances.
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 fitted on the relevant side of the vehicle.
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. Furthermore, minimum brake disk thickness, disk runout,
parallelism and surface roughness of the friction surfaces must not exceed or drop below the permitted
values.
Refer to BRAKES - TECHNICAL DATA - 645Ci .
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. Furthermore, the maximum drum inside diameter, radial
runout and surface roughness of the friction surfaces must not exceed or drop below the permitted values.
Refer to BRAKES - TECHNICAL DATA - 645Ci .
Always strip preservative off new parts before installation.
 Brake calipers:
Only approved pastes on the basis of glycine must be used for repairs on brake calipers.
All moving parts on the brake caliper must move freely: note grease specifications.
Use only BMW-approved lubricants to grease caliper guides (refer to OPERATING FLUIDS -
BRAKES - ALL MODELS ).
Brake Lines, Brake Hoses: Brake Lining Wear Indicator
 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.
2005 BMW 645Ci
 The system must be bled each time any brake lines have been detached.
 All connection points must be checked for leaks.
 Only tighten down brake hoses on the front axle when wheels are in straight-ahead position.
 Close open connections on brake lines and individual components to prevent dirt from entering the brake
system.
 Observe tightening torques when tightening down brake line screw connections.
Tightening torque, refer to 34 32 1AZ in BRAKES - TIGHTENING TORQUES - 645CI .
Wheel-slip control system:
The slip control system is basically maintenance-free. However, be sure to adhere to the following:
 When carrying out welding work with electric welding equipment, be sure to disconnect the plug from
the electronic control unit (ignition turned off).
 During painting work, the control unit may be subjected for brief periods to loads of max. 95°C and for
long periods (approx. 2 hours) to loads of max. 85°C.
 Tighten down the battery terminals completely.
 The brake lines on the hydraulic unit must not be mixed up; if necessary, mark them before they are
removed and after completing repairs perform the mix-up check with the DIS Tester.
34 00 009 CHECKING BRAKES ON TEST STAND
 Check tires for damage

 Check tire treads
 Check tire pressure
In the case of vehicles with ASC+T or DSC, the system must be deactivated with the switch. The ASC+T or
DSC telltale and warning light must light up in the instrument cluster!
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.
E65 and E66: Carry out parking brake function check.

2005 BMW 645Ci
Fig. 1: Identifying Brakes Testing Equipment

IMPORTANT: You should only use brake dynamometers whose test speed is less than equal
to 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.
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.
2005 BMW 645Ci
styling.
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 up to stop and read off measured value.
NOTE: A. Brake disk

B. Brake lining with backplate
Safe limit for lining wear, front brake, refer to BRAKES - TECHNICAL DATA .
Safe limit for lining wear, rear brake, refer to BRAKES - TECHNICAL DATA .
2005 BMW 645Ci
Fig. 2: Inserting Special Tool Through Rim Into Brake Lining Wear Indicator Opening
34 00 017 CHECKING BRAKE BOOSTER (LOW-PRESSURE TEST)
 34 3 100
 Remove left microfilter housing, refer to 64 31 061 REMOVING AND INSTALLING/REPLACING

LEFT OR RIGHT MICROFILTER HOUSING LOWER SECTION .
 Detach hose from connection piece. Install vacuum tester 34 3 100 between connection piece and vacuum
hose of non-return valve.
2005 BMW 645Ci
 Start engine.
 Check buildup of partial vacuum.
 Switch off engine.
 Press the brake pedal to set a vacuum pressure of not more than 0.8 bar and wait for the value to stabilize.
 When the brake pedal is not pressed, the vacuum pressure is permitted to drop over a test period of 1
minute by max. 0.06 bar.
If specified values are not reached:
 Check line connections for vacuum seal.

 Replace non-return valve.
 Check seal between brake booster and brake master cylinder (sealing ring) for perfect condition and
correct seating.
 If the specified values are not achieved when the test is repeated, you must replace the brake booster.
34 00 025 REPLACING FLUID IN ABS/ASC+T BRAKE SYSTEM
 Read and comply with General Information, refer to 34 00 ... GENERAL INFORMATION.
 Remove lower section of microfilter housing, refer to 64 31 061 REMOVING AND
INSTALLING/REPLACING LEFT OR RIGHT MICROFILTER HOUSING LOWER
SECTION .
IMPORTANT: When carrying out repairs to the brake system, follow the procedure set out in
Bleeding brake system with DSC, refer to 34 00 050 BLEEDING BRAKE
SYSTEM WITH DSC.
Connect bleeder unit to expansion tank and switch on.
NOTE: Check relevant Operating Instructions for each device. Charging pressure
should not exceed 2 bar.
2005 BMW 645Ci
Fig. 4: Connecting Bleeder Unit To Expansion Tank (ABS/ASC+T Brake System)

Close bleed valve.
2005 BMW 645Ci
Fig. 5: Connecting Bleeder Hose With Collecting Tray To Bleeder Valve (ABS/ASC+T Brake System)
NOTE: The clutch slave cylinder must also be scavenged in vehicles with manual
transmissions.
Switch off brake fluid changer and remove from expansion tank. Check brake fluid level. Close expansion tank.

2005 BMW 645Ci
Fig. 6: Locating Rubber Seal In Sealing Cap (ABS/ASC+T Brake System)

34 00 050 BLEEDING BRAKE SYSTEM WITH DSC

SECTION .
2005 BMW 645Ci
Observe the filling and bleeding instructions when replacing or repairing:
 Brake master cylinder

 Hydraulic unit
 Components and connecting lines which are fitted between these assemblies.
Connect bleeder unit with max. 2 bar filling pressure. A second person is needed to help carry out this work.
 Connect BMW Diagnosis and Information System (DIS).

 Select path: Service functions - Chassis/Suspension - Slip control systems - Bleeding procedure.
 Connect bleeder unit to expansion tank and switch on.
IMPORTANT: Check relevant Operating Instructions for each device. Charging pressure
should not exceed 2 bar.
Fig. 7: Connecting Bleeder Unit To Expansion Tank (Brake System With DSC)
2005 BMW 645Ci
Close bleed valve.
Fig. 8: Connecting Bleeder Hose To Bleeder Valve On Rear Right Brake Caliper (DSC) (1 Of 2)
Bleeding Rear-Axle Brake Circuit
2005 BMW 645Ci
Close bleed valve.
Repeat procedure at rear left.
Fig. 9: Connecting Bleeder Hose To Bleeder Valve On Rear Right Brake Caliper (DSC) (2 Of 2)
Bleeding Front-Axle Brake Circuit
Connect bleeder hose with collecting tray to bleeder valve on front right brake caliper.
Run through bleeding routine with BMW Diagnosis and

2005 BMW 645Ci
Information System (DIS) with bleeder valve open.
Close bleed valve.
Repeat procedure at front left.
Fig. 10: Connecting Bleeder Hose To Bleeder Valve On Front Right Brake caliper (DSC)
Switch off brake fluid changer and remove from expansion tank. Check brake fluid level.

2005 BMW 645Ci
Fig. 11: Locating Rubber Seal In Sealing Cap (DSC)

34 00 519 CHECKING SERVICE BRAKE: HIGH- AND LOWPRESSURE TESTS
IMPORTANT: The high/low-pressure test (leakage test) must be carried out with the engine
switched off.
Observe safety instructions on raising the vehicle, refer to 00 .. ... LIFTING VEHICLE WITH A LIFTING
PLATFORM .
2005 BMW 645Ci
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.
Fig. 12: Performing High-Pressure Test (Leakage Test)

Load brake pedal with a force and block brake pedal with pedal support, refer to BRAKES - TECHNICAL
DATA - 645CI .
2005 BMW 645Ci
Fig. 13: Blocking 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.
2005 BMW 645Ci
Fig. 14: Identifying Low-Pressure Test Measuring Apparatus

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.
FRONT BRAKES
34 11 ... OVERVIEW OF FRONT BRAKE
2005 BMW 645Ci
Fig. 15: Locating Front Brake Components

34 11 000 REMOVING AND INSTALLING/REPLACING BRAKE LININGS ON BOTH FRONT DISK

BRAKES
 34 1 080
 34 6 320
 Remove wheels, refer to 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL .
PLATFORM .
2005 BMW 645Ci
brake disks.
Lever out retaining spring (1) in direction of arrow towards rear.
Installation:
Attach retaining spring (1) first at top and bottom and then allow retaining lug (2) to engage in recess of brake
caliper housing.
Fig. 16: Removing Retaining Spring

2005 BMW 645Ci
Remove plastic plugs (1). Lift brake hose out of bracket.
Fig. 17: Removing Plastic Plugs

Left:
Pull brake lining wear sensor (1) towards rear out of lining. If necessary, replace brake lining wear sensor, refer
to 34 35 001 REPLACING A BRAKE LINING SENSOR.
Release guide screws (2) with special tool 34 1 080. Withdraw brake caliper backwards.
Installation:
Check threads.
2005 BMW 645Ci
Replace all guide screws which are not in perfect condition. Tightening torque, refer to 34 11 3AZ in BRAKES
- TIGHTENING TORQUES - 645CI .
Fig. 18: Removing Brake Lining Wear Sensor

Press back brake linings and piston with special tool 34 6 320.
2005 BMW 645Ci
Fig. 19: Pressing Brake Linings And Piston With Special Tool 34 6 320
Press brake linings inwards and remove.
The two brake linings are seated with a spring in the piston or in the brake caliper housing and must not be
mixed up.
In the event of one-sided brake lining wear, do not change brake linings round.
New brake linings may only be installed if the brake disk thickness is greater than or equal to the minimum
brake disk thickness (MIN TH).
Observe minimum brake disk thickness of brake linings, refer to BRAKES - TECHNICAL DATA .
2005 BMW 645Ci
ON BOTH FRONT DISK BRAKES.
Do not apply grease to brake pad backplate. Check dust sleeve (1) for damage and replace if necessary. Clean
contact face (2) of brake piston and apply a thin coating of anti-squeak compound.
Fig. 20: Identifying Dust Sleeve (1)

2005 BMW 645Ci
Fig. 21: Checking Dust Sleeve And Cleaning Contact Face

compound.
2005 BMW 645Ci
Fig. 22: Cleaning Brake Lining Hammer Heads/Brake Caliper Housing Mounting Face
NOTE: Grease contact surfaces on brake caliper at top and bottom.
Clean mounting face (3) of brake caliper and apply a thin coating of anti-squeak compound.
2005 BMW 645Ci
Fig. 23: Cleaning Brake Caliper Mounting Face

Clean brake caliper holder at hammerhead guides and apply a thin coating of anti-squeak compound.
Refer to OPERATING FLUIDS - BRAKES .

2005 BMW 645Ci
Fig. 24: Cleaning Brake Caliper Holder At Hammerhead Guides

34 11 220 REMOVING AND INSTALLING/REPLACING BOTH FRONT BRAKE DISKS

 If necessary, remove and clean brake linings, refer to 34 11 000 REMOVING AND
INSTALLING/REPLACING BRAKE LININGS ON BOTH FRONT DISK BRAKES.
PLATFORM .
IMPORTANT: If the thickness of the brake disks drops below the minimum brake disk
2005 BMW 645Ci
only be replaced in pairs (on each axle). If the brake disks are replaced, you
must also fit new brake linings.
Fig. 25: Releasing Screw And Removing Brake Caliper

Installation:
If the brake hose was pulled from the mounting fixture during removal, make sure it is positively attached when
installed!
2005 BMW 645Ci
Unscrew bolts and take off brake disk.
Fig. 26: Releasing Bolts And Removing Brake Disk

Installation:
Clean contact surface of brake disk at wheel hub thoroughly; remove traces of corrosion if necessary.
Unevenness on contact surface may result in distortion of brake disk!
2005 BMW 645Ci
a hammer or similar! If necessary, carefully tap on base of brake disk chamber

IMPORTANT: Internally ventilated brake disks are balanced. Never remove or reposition
balance clips.
Fig. 27: Locating Balance Clips

34 11 250 REMOVING AND INSTALLING / REPLACING A BRAKE CARRIER / BRAKE GUARD

PLATE AT FRONT
 Remove front brake disks, refer to 34 11 220 REMOVING AND INSTALLING/REPLACING BOTH
FRONT BRAKE DISKS.
2005 BMW 645Ci
Fig. 28: Releasing Screws And Removing Brake Guard Plate

Installation:
34 11 519 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT FRONT BRAKE

CALIPER
PLATFORM .
After completing tasks, bleed brake system, refer to 34 00 025 REPLACING FLUID IN ABS/ASC+T
2005 BMW 645Ci
BRAKE SYSTEM.
Fig. 29: Depressing Brake Pedal

Left side: Disconnect plug connection for wear indicator. Release brake hose on brake caliper.
Slacken connection for brake hose and brake line.
Installation:
Tighten brake hose on brake caliper. Tightening torque, refer to 34 32 4AZ in BRAKES - TIGHTENING
TORQUES - 645CI .
Move steering to straight-ahead position. Screw brake hose to brake line, ensuring that brake hose is not
twisted.

2005 BMW 645Ci
Unscrew bolts (1) and remove brake caliper.
Fig. 30: Releasing Bolts And Removing Brake Caliper

Installation:
34 11 552 OVERHAULING LEFT OR RIGHT FRONT BRAKE CALIPER (BRAKE CALIPER

REMOVED)
 34 1 133
NOTE: Use repair kit, refer to BMW Parts Service.

2005 BMW 645Ci
Bear in mind that guide sleeves and screws come in different lengths:
 16" brake system: two short guide sleeves with two short screws.
 17" brake system: one long guide sleeve and one short guide sleeve with one long screw and one short
screw.
 18" brake system: two long guide sleeves with two long screws.

2005 BMW 645Ci
Installation:
E65 and E66:
Installation:
Fig. 32: Removing Insert Spring

WARNING: Danger of injury! In the following work step, large forces occur at the
brake caliper piston up to more than 2800 N.
2005 BMW 645Ci
Fig. 33: Forcing Piston Out Through Connection Bore With Compressed Air
IMPORTANT: Bear in mind that guide sleeves and screws come in different lengths. Long
guide sleeve with long screw is seated on disk inlet at bottom, short sleeve
with short screw is seated on disk outlet at top.
2005 BMW 645Ci
Fig. 34: Checking Guide Sleeves

Thoroughly inspect cylinder bore, piston and flange surfaces. Machining of cylinders and pistons is not
permitted.
2005 BMW 645Ci
Fig. 35: Removing Sealing Ring

Installation:
Refer to OPERATING FLUIDS - BRAKES .
Install sealing cover in rear annular groove of cylinder bore. Press in piston with a hardwood board.

2005 BMW 645Ci
Fig. 36: Installing Sealing Cover In Cylinder Bore Rear Annular Groove
Press on dust protection sleeve evenly up to stop with special tool 34 1 133.
2005 BMW 645Ci
Fig. 37: Pressing Dust Protection Sleeve With Special Tool

Installation:
The area between dust protection sleeve and brake caliper housing must be kept dry so as to ensure
correct seating for the dust protection sleeve.
2005 BMW 645Ci
REMOVED)
IMPORTANT: Always fine-grind both sides of both brake disks on one axle. Observe Max.
machining dimension per friction ring side Minimum brake disk thickness (MIN
TH). Surface roughness of brake surfaces, refer to BRAKES - TECHNICAL
DATA . Brake disks of M models (Compound brake disks) must not be
machined!
NOTE: Only one brake lining set may be used up on brake disks which have been
lathe-turned to minimum thickness (MIN TH), refer to BRAKES - TECHNICAL
DATA .
Grinding machine, refer to BMW Service Workshop Equipment Planning documentation.
Follow the machine manufacturer's operating instructions.

2005 BMW 645Ci
Fig. 38: Identifying Brake Disks Grinding Machine

REAR BRAKES
34 21 ... OVERVIEW OF REAR BRAKE
2005 BMW 645Ci
Fig. 39: Locating Rear Brakes Components

34 21 171 REMOVING AND INSTALLING / REPLACING A BRAKE CARRIER / BRAKE GUARD

AT REAR
 Remove expander lock, refer to 34 41 250 REMOVING AND INSTALLING/REPLACING

EXPANDER LOCK FOR HANDBRAKE SHOES.
 Remove wheel hub
Release screws (1) and remove brake carrier (2).

2005 BMW 645Ci
Fig. 40: Releasing Screws And Removing Brake Carrier

Installation:
34 21 200 REMOVING AND INSTALLING OR REPLACING BRAKE LININGS ON BOTH REAR

DISK BRAKES
 34 1 050
 34 1 080

2005 BMW 645Ci
PLATFORM .
brake disks.
Remove plastic plugs (1). Right side: Disconnect plug connection for brake lining wear sensor.
Fig. 41: Removing Plastic Plugs

2005 BMW 645Ci
If necessary, replace brake lining wear sensor, refer to 34 35 001 REPLACING A BRAKE LINING
SENSOR.
Release guide screws (2) with special tool 34 1 080.
Fig. 42: Releasing Guide Screws With Special Tool 34 1 080

Installation:
Check threads.

2005 BMW 645Ci
Lift out retaining spring (3).
Fig. 43: Removing Retaining Spring

Turn piston fully back with special tool 34 1 050.
2005 BMW 645Ci
Fig. 44: Turning Piston Back With Special Tool 34 1 050

Remove outer brake lining.
Inner brake lining is located with its spring in the piston.
If the brake linings are worn on one side, they must not be mixed up!
New brake linings may only be installed if the brake disk thickness is greater than or equal to the minimum
brake disk thickness (MIN TH).
2005 BMW 645Ci
Clean brake linings, refer to 34 11 000 REMOVING AND INSTALLING/REPLACING BRAKE LININGS
ON BOTH FRONT DISK BRAKES.
Clean contact face (2) of brake piston and apply a thin coating of anti-squeak compound.
Fig. 45: Identifying Dust Sleeve And Contact Face (Rear Brake)
2005 BMW 645Ci
Fig. 46: Removing Outer Brake Lining

IMPORTANT: In E39/Touring models, make sure the insulating ring (1) is installed on the
brake piston.
2005 BMW 645Ci
Fig. 47: Locating Insulating Ring Position In Piston

compound.
2005 BMW 645Ci
Fig. 48: Cleaning Brake Lining Hammer Heads/Brake Caliper Housing Mounting Face (Rear Brake)
Clean contact face (3) of brake caliper and apply a thin coating of anti-squeak compound.
2005 BMW 645Ci
Fig. 49: Cleaning Brake Caliper Contact Face

Clean brake caliper mounting bracket at hammer head guides and apply a thin coating of anti-squeak
compound.
2005 BMW 645Ci
Fig. 50: Cleaning Brake Caliper Holder At Hammerhead Guides (Rear Brake)
34 21 320 REMOVING AND INSTALLING OR REPLACING BOTH REAR BRAKE DISKS

 If necessary, remove and clean brake linings, refer to 34 11 000 REMOVING AND
INSTALLING/REPLACING BRAKE LININGS ON BOTH FRONT DISK BRAKES
E65 and E66: Release parking brake (pushbutton to left of steering wheel).
After completing tasks, adjust handbrake. (Not for E65 and E66)! Refer to 34 10 014 ADJUSTING
HANDBRAKE.
2005 BMW 645Ci
PLATFORM .
IMPORTANT: If the thickness of the brake disks drops below the minimum brake disk
thickness (MIN TH), then the brake disks must be replaced, refer to BRAKES -
TECHNICAL DATA . Always replace brake disks in pairs. If the brake disks are
replaced, you must also fit new brake linings.
Fig. 51: Releasing Screws And Removing Brake Caliper (Rear Brake)

2005 BMW 645Ci
Unscrew bolts and take off brake disk.
Fig. 52: Releasing Bolts And Removing Brake Disk

Installation:
Clean contact surface of brake disk at wheel hub thoroughly; remove traces of corrosion if necessary.
2005 BMW 645Ci
IMPORTANT: To release brake disk: Do not under any circumstances strike friction ring with
a hammer or similar! If necessary, carefully tap on base of brake disk chamber
IMPORTANT: Internally ventilated brake disks are balanced. Never remove or reposition
balance clips.
Fig. 53: Locating Balance Clip (Rear Brake)

34 21 745 REMOVING AND INSTALLING OR REPLACING LEFT OR RIGHT REAR BRAKE

CALIPER

2005 BMW 645Ci
PLATFORM .
BRAKE SYSTEM.
tank and air from entering the brake system when the brake lines are opened.
Fig. 54: Depressing Brake Pedal (Rear Brake)

Right side: Disconnect plug connection for brake lining wear sensor.
Installation:
Release brake hose (2).
Installation:
2005 BMW 645Ci
Unfasten brake hose at connection point to brake line.
First tighten the brake hose on the brake cover, then tighten connection on brake line.
Install brake hose without torsional stress.
Pull off fist caliper towards rear of vehicle.
IMPORTANT: 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.
2005 BMW 645Ci
Fig. 55: Releasing Screws And Releasing Brake Hose

34 21 812 OVERHAULING LEFT OR RIGHT REAR BRAKE CALIPER (BRAKE CALIPER

REMOVED)
 34 1 132
NOTE: Use original BMW repair kit.
Take off plastic caps (1). Unscrew guide screws (2).

2005 BMW 645Ci
Fig. 56: Removing Plastic Caps (Rear Brake)

Installation:
Installation:
2005 BMW 645Ci
Fig. 57: Identifying Insert Spring (Rear Brake)

WARNING: Danger of injury! In the following work step, large forces occur at the
brake caliper piston (up to more than 2800 N).
2005 BMW 645Ci
Fig. 58: Forcing Piston Out Through Connection Bore With Compressed Air

2005 BMW 645Ci
Fig. 59: Checking Guide Sleeves (Rear Brake)

Remove sealing ring carefully with a plastic needle. Clean cylinder bores and parts with alcohol and dry with
compressed air.
2005 BMW 645Ci
Fig. 60: Removing Sealing Ring (Rear Brake)

Thoroughly inspect cylinder bore, piston and flange surfaces. Machining of cylinders and pistons is not
permitted.
Installation:
Apply a light coat of Ate brake cylinder paste to cylinder bore, piston and sealing sleeve, refer to
OPERATING FLUIDS - BRAKES .
Install sealing cover in rear annular groove of cylinder bore. Press in piston with a hardwood board.

2005 BMW 645Ci
Fig. 61: Installing Sealing Cover In Cylinder Bore Rear Annular Groove (Rear Brake)
Press on dust protection sleeve evenly up to stop with special tool 34 1 132.
2005 BMW 645Ci
Fig. 62: Pressing Dust Protection With Special Tool 34 1 132 (Rear Brake)
Installation:
The area between dust protection sleeve and brake caliper housing must be kept dry so as to ensure
correct seating for the dust protection sleeve.
2005 BMW 645Ci
REMOVED)
IMPORTANT: Always fine-grind both sides of both brake disks on one axle. machining
dimension per friction ring side, minimum brake disk thickness (MIN TH) and
Observe surface roughness of brake surfaces. Observe max. Only one brake
lining set may be used up on brake discs which have been lathe-turned to
minimum thickness (MIN TH). Brake disks of M models (Compound brake
disks) must not be machined! Refer to BRAKES - TECHNICAL DATA .
Grinding machine: refer to BMW Service
Workshop equipment/Planning documentation. Follow the machine manufacturer's operating instructions.
Fig. 63: Identifying Brake Disks Grinding Machine

2005 BMW 645Ci
MASTER BRAKE CYLINDER

34 31 ... OVERVIEW OF BRAKE MASTER CYLINDER / BRAKE BOOSTER
Fig. 64: Locating Brake Master Cylinder/Brake Booster Components

34 31 181 REMOVING AND INSTALLING / REPLACING EXPANSION TANK FOR HYDRAULIC

BRAKE ACTUATION

SECTION .
Suck the brake fluid out of the expansion tank. Use suction bottle exclusively to draw off brake fluid.
2005 BMW 645Ci
IMPORTANT: Do not reuse drawn out brake fluid.
Fig. 65: Draining Brake Fluid From Expansion Tank

Unfasten plug connection (1) and disconnect. Release retaining screw (2).
2005 BMW 645Ci

Installation:
Pull expansion tank vertically out of brake master cylinder.
Installation:
Check rubber plug in brake master cylinder for damage and replace if necessary. Push the expansion tank
vertically onto the master brake cylinder.
2005 BMW 645Ci
Fig. 67: Installing Expansion Tank Onto Master Brake Cylinder

34 31 505 REMOVING AND INSTALLING / REPLACING MASTER BRAKE CYLINDER FOR DSC
 32 1 270
 Remove expansion tank, refer to 34 31 181 REMOVING AND INSTALLING / REPLACING

EXPANSION TANK FOR HYDRAULIC BRAKE ACTUATION.
 Remove footwell trim.
After completing tasks, bleed brake system with DSC, refer to 34 00 050 BLEEDING BRAKE SYSTEM
2005 BMW 645Ci
WITH DSC.
Remove locking clip (1) and disengage and pull out locking pin. Slacken nuts (2).
Fig. 68: Removing Locking Clip

Installation:
Replace self-locking nuts. Tightening torque, refer to 35 11 1AZ in BRAKES - TIGHTENING TORQUES -
645CI .
Unfasten brake lines (1). Detach brake lines at junction (2) and remove short sections. Seal off brake lines and
brake master cylinder with plugs 32 1 270
2005 BMW 645Ci
Fig. 69: Detaching Brake Lines At Junction

Installation:
Fit lines at both connection points and then tighten down. Tightening torque, refer to 34 32 1AZ in
BRAKES - TIGHTENING TORQUES - 645CI .
Release nuts (3) and feed brake master cylinder out of brake booster.
Installation:
Replace self-locking nuts. Tightening torque, refer to 34 31 1AZ in BRAKES - TIGHTENING

TORQUES - 645CI .
Installation:
2005 BMW 645Ci
Fig. 70: Replacing Sealing Ring

IMPORTANT: Brake booster (1) must be loosely screwed into place so as not to jam brake
master cylinder (2) during installation.
Installation:
When inserting the brake master cylinder (2) into the brake booster (1), make sure the pressure rod of the brake
booster and that of the brake master cylinder meet each other on one level.
2005 BMW 645Ci
Fig. 71: identifying Brake Master Cylinder (2) And Brake Booster (1)
BRAKES LINES
34 32 ... OVERVIEW OF BRAKE LINES
2005 BMW 645Ci
Fig. 72: Locating Brakes Line Components

34 32 861 REPLACING ALL BRAKE PIPES
 34 5 100
NOTE: The brake lines are only supplied in the straight version and correct length with
connecting nipple. Read and comply with General Information, refer to 34 00 ...
GENERAL INFORMATION. After completing work, bleed brake system, refer to
34 00 025 REPLACING FLUID IN ABS/ASC+T BRAKE SYSTEM. Observe safety
instructions on raising the vehicle, refer to 00 .. ... LIFTING VEHICLE WITH A
LIFTING PLATFORM .
New brake lines are bent into shape with bending tool 34 5 100. Removed brake pipes can be used as templates
2005 BMW 645Ci

2005 BMW 645Ci
 Do not kink or bend back brake lines.

 Watch distances to rigid and movable vehicle parts. Brake lines may not
make contact or rub.
 Tighten down brake line couplings with torque wrench.
Installation:
34 32 881 REPLACING FRONT LEFT OR RIGHT BRAKE HOSES
NOTE: After completing tasks, bleed brake system, refer to 34 00 025 REPLACING
FLUID IN ABS/ASC+T BRAKE SYSTEM.
tank when the brake lines are opened.

2005 BMW 645Ci
Installation:
retaining bracket.
Detach brake hose from brake caliper (4). Tightening torque, refer to 34 32 4AZ in BRAKES - TIGHTENING
TORQUES - 645CI .
Installation:
Fig. 75: Detaching Brake Hose From Brake Caliper

First tighten brake hose on brake caliper. Move wheels into straight-ahead position. Insert brake hose in bracket
and screw onto brake pipe.
2005 BMW 645Ci
IMPORTANT: Never twist brake hose when installing it and avoid all contact with parts
attached rigidly to the body.
34 32 980 REPLACING REAR LEFT OR RIGHT BRAKE HOSES
NOTE: Read and comply with General Information, refer to 34 00 ... GENERAL
INFORMATION. Observe safety instructions on raising the vehicle, refer to 00 ..
... LIFTING VEHICLE WITH A LIFTING PLATFORM . After completing tasks,
bleed brake system, refer to 34 00 025 REPLACING FLUID IN ABS/ASC+T
BRAKE SYSTEM.
tank and air from entering the system when the brake lines are opened.
Fig. 76: Depressing Brake Pedal (Rear Left Or Right Brake Hoses)
Disconnect brake hose from brake line (1).
Installation:
2005 BMW 645Ci
retaining bracket.
Fig. 77: Disconnecting Brake Hose From Brake Line

Installation:
BRAKE BOOSTER
34 33 071 REPLACING VACUUM HOSE FOR BRAKE BOOSTER (N62)

2005 BMW 645Ci
SECTION .
 Remove engine acoustic cover.
 Remove intake filter housing, refer to 13 71 000 REMOVING AND INSTALLING/REPLACING
INTAKE FILTER HOUSING .
 Remove air intake hose with air-mass sensor.
the vacuum pressure in the brake booster. This makes it easier to remove the
PA pipe. Non-return valve and PA pipe are welded together and are replaced
together as a single unit.
Detach non-return valve (1) from brake booster.

2005 BMW 645Ci
Fig. 78: Detaching Non-Return From Brake Booster

Unclip vacuum line from fixture (1).
Unfasten hose clip (2).
Fig. 79: Removing Vacuum Line From Fixture

Installation:
Replace hose clip.
Release retaining clips (1) and feed out vacuum line (2).
2005 BMW 645Ci
Fig. 80: Releasing Retaining Clips And Removing Vacuum Line

34 33 505 REMOVING AND INSTALLING/REPLACING BRAKE BOOSTER
 Remove brake master cylinder, refer to 34 31 505 REMOVING AND INSTALLING / REPLACING
MASTER BRAKE CYLINDER FOR DSC.
Detach locking clip (1) from brake pedal, disengage and pull out locking pin.
Release nuts (2).

2005 BMW 645Ci
Fig. 81: Detaching Locking Clip From Brake Pedal

Installation:
Replace self-locking nuts. Tightening torque, refer to 35 11 1AZ in BRAKES - TIGHTENING

TORQUES - 645CI .
Remove non-return valve (1) from brake booster. Carefully pull brake booster (2) out of bulkhead and tilt out.
IMPORTANT: Do not use any force when removing and installing the brake unit; the brake
unit can be damaged under certain circumstances.
2005 BMW 645Ci
Fig. 82: Removing Non-Return From Brake Booster

ELECTRONIC COMPONENTS
 Remove wheel, refer to 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL .
though the minimum brake lining thickness has not yet been reached, refer to
BRAKES - TECHNICAL DATA , you must observe the following: The new
sliding contact must be filed down with a file to the same length as the ground
sliding contact.
2005 BMW 645Ci
Open cover (1) on plug housing (3). Unclip lead of brake lining sensor (2) from plug housing (3). Disconnect
associated plug connection of lead from brake lining sensor (2).
Fig. 83: Disconnecting Brake Lining Sensor Plug Connection

Feed lead from brake lining sensor (2) out of fixtures.
Installation:
2005 BMW 645Ci
Fig. 84: Detaching Brake Lining Sensor

PARKING BRAKE
 32 1 030
Perform inspection in the following manner: When 1st ratchet is engaged, no braking force should be exerted.
The difference in wheel circumferential forces between the left and right wheels may deviate by max. 30% from
the greater value (measured on brake analyzer).
In event of larger deviations of wheel circumferential force: carry out readjustment.

2005 BMW 645Ci
whenever the actuation stroke is greater than 10 teeth.
NOTE: The handbrake can only be adjusted correctly when the parking brake Bowden
cables and all moving handbrake parts are free to move and fully operational.
Basic handbrake adjustment is necessary:
 When replacing parking brake shoes.

 When replacing brake disks.
 In event of excessive actuation stroke (10 teeth).
 When replacing parking brake Bowden cables
1. Setting instruction for brake shoes (basic setting)
Lock adjuster unit (ASZE). Using special tool 32 1 030, press stop (1) of adjusting spring back to such an
extent that retaining hook (2) engages in stop (1).
2005 BMW 645Ci
Completely unscrew one wheel stud on each rear wheel.
Installation:
Turn wheel until adjustment screw is visible in tapped hole.
Fig. 86: Locating Adjusting Screw

Turn adjusting screw with a screwdriver until the wheel is no longer able to turn.
Then unfasten the adjusting screw 8 notches.

2005 BMW 645Ci
Fig. 87: Releasing Adjusting Screw

Unlock adjuster unit (ASZE).
Lever restraint hook (2) outwards with a suitable screwdriver (1).
Restraint hook (2) must disengage from stop of adjusting spring.

2005 BMW 645Ci
Fig. 88: Levering Restraint Hook Outwards With Tool

The handbrake lever must be applied 5 times to approx. 400N actuating force.
0th tooth (handbrake released): Vehicles with manual transmission: Shift lever in neutral position.
Vehicles with automatic transmission: Selector lever in "N" position.
 Without locking differential less than equal to 150 N.

 With locking differential less than equal to 200 N (possibly odd display).
2005 BMW 645Ci
5th tooth: The brake force display must have reached less than equal to 400 N.
Apply handbrake until a wheel circumferential force (brake force display) of min. 1000 N is reached.
Max. permitted brake force differential right/left less than equal to 35% (referred to greater brake value).
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 disks and/or brake shoes.
Apply handbrake lever until wheel circumferential force on first wheel is 800 N.
Lock lever in next lower tooth.
Release handbrake lever after approx. 2 minutes.
3.2 When driving on road
(If possible inside the company grounds or on an unused road) At approx. 40 km/h, apply
handbrake lever until braking action can be felt.
Pull up handbrake lever into next notch and drive on for approx. 400 m.
A basic requirement is that handbrake is adjusted uniformly.
34 41 ... OVERVIEW OF PARKING BRAKE

2005 BMW 645Ci
Fig. 89: Locating Parking Brake Components

34 41 000 REMOVING AND INSTALLING / REPLACING HANDBRAKE LEVER
 32 1 030

COMPARTMENT .
After completing tasks, adjust handbrake, refer to 34 10 014 ADJUSTING HANDBRAKE.

2005 BMW 645Ci
that retaining hook (3) engages in stop (2).
Fig. 90: Pressing Adjusting Spring With Special Tool 32 1 030


2005 BMW 645Ci
Fig. 91: Releasing Mounting Clip From Balance Arm

2005 BMW 645Ci
Fig. 92: Removing Handbrake Bowden Cables From Balance Bar

Disconnect cable (1) from handbrake check switch. Release screws (2) and remove handbrake lever (3).
2005 BMW 645Ci
Fig. 93: Disconnecting Cable From Handbrake Check Switch

Installation:
Handbrake lever and adjustment unit (ASZE) are only exchanged completely as a single unit.
34 41 120 REMOVING AND INSTALLING / REPLACING BOTH HANDBRAKE BOWDEN CABLES
 32 1 030

2005 BMW 645Ci
COMPARTMENT .
 Remove rear brake disks, refer to 34 21 320 REMOVING AND INSTALLING OR REPLACING
BOTH REAR BRAKE DISKS.
 Remove heat shield.
Using special tool 32 1 030, press stop (1) of adjusting spring back to such an extent that retaining hook (2)
engages in stop (1).


2005 BMW 645Ci
Fig. 95: Releasing Mounting Clip From Balance Arm

2005 BMW 645Ci
Fig. 96: Removing Handbrake Bowden Cables From Balance Bar

Disconnect handbrake Bowden cables at expander locks. Release screw (1) and remove bracket.
Installation:
Pull handbrake Bowden cables (2) out of wheel carrier.

2005 BMW 645Ci
Fig. 97: Removing Handbrake Bowden Cables From Wheel Carrier

Disconnect handbrake Bowden cables (1) out of mountings. Pull handbrake Bowden cables (1) out of guide (2)
and remove.
2005 BMW 645Ci
Fig. 98: Removing Handbrake Bowden Cables From Guide

34 41 220 REMOVING AND INSTALLING/REPLACING ALL HANDBRAKE SHOES
 32 1 030
 34 4 000
Installation:
 Remove rear brake disk, refer to 34 21 320 REMOVING AND INSTALLING OR REPLACING
BOTH REAR BRAKE DISKS

2005 BMW 645Ci

Installation:
Check and if necessary replace return spring (1). Figure illustrates right side: left side is mirror image of
this. Pay attention to installation position of adjustment screw (2).
2005 BMW 645Ci
Fig. 100: Identifying Return Spring And Adjustment Screw

Apply a thin coat of grease to bush and screw threads, Refer to OPERATING FLUIDS - BRAKES .

2005 BMW 645Ci
Fig. 101: Disconnecting Return Spring (1)

Installation:
Turn clamping pins (1) with special tool 34 4 000 through 90° and disconnect.
Remove brake shoes (2).

2005 BMW 645Ci
Fig. 102: Removing Brake Shoes

34 41 250 REMOVING AND INSTALLING/REPLACING EXPANDER LOCK FOR HANDBRAKE

SHOES
 32 1 030
 Remove handbrake shoes, refer to 34 41 220 REMOVING AND INSTALLING/REPLACING ALL

HANDBRAKE SHOES.

2005 BMW 645Ci

Pull expander lock (1) forwards, disconnect handbrake Bowden cable (2) and remove expander lock, refer to 34
41 250 REMOVING AND INSTALLING/REPLACING EXPANDER LOCK FOR HANDBRAKE
SHOES.
2005 BMW 645Ci
Fig. 104: Removing Expander Lock

MECHANICAL/HYDRAULIC COMPONENTS
34 51 527 REMOVING AND INSTALLING/REPLACING HYDRAULIC UNIT FOR DSC (M54 / N62 /
N52)
 Before removing hydraulic unit, read out control unit fault memory and if necessary print out diagnostic
trouble code.
BRAKE SYSTEM.
2005 BMW 645Ci
Installation:
System):

 Mix-up check of brake lines

IMPORTANT: Do not mix up brake pipes (mark if necessary). Seal off connection bores with
plugs.
2005 BMW 645Ci
Unfasten brake lines (2).
Installation:
IMPORTANT: Do not bend brake lines.
Release screw (3) and remove hydraulic unit.
Fig. 106: Removing Hydraulic Unit

When replacing hydraulic unit:

2005 BMW 645Ci
Fig. 107: Releasing Screws And Convert Holder

 Remove wheel, refer to 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL
though the minimum brake lining thickness has not yet been reached, you
must observe the following: The new sliding contact must be filed down with a
file to the same length as the ground sliding contact.
Open cover (1) on plug housing (3).

2005 BMW 645Ci
Unclip lead of brake lining sensor (2) from plug housing (3).
Disconnect associated plug connection of lead from brake lining sensor (2).
Feed lead from brake lining sensor (2) out of fixtures.
Fig. 108: Disconnecting Brake Lining Sensor Plug Connection

2005 BMW 645Ci
Fig. 109: Detaching Brake Lining

Installation:
34 52 ... OVERVIEW OF ELECTRONIC COMPONENTS

2005 BMW 645Ci
Fig. 110: Identifying Electronic Components

34 52 516 REMOVING AND INSTALLING / REPLACING DSC CONTROL UNIT
DISCHARGE) .
 Before removal, read out the control unit fault memory and if necessary print out the diagnostic trouble
code.
Installation:
2005 BMW 645Ci
System):

unit.
2005 BMW 645Ci
Installation:
Keep sealing faces clean.
Replace screws.
Observe tightening sequence (1-4).
Fig. 112: Tightening Screws In Sequence

34 52 525 REPLACING ONE FRONT PULSE GENERATOR

2005 BMW 645Ci

DISCHARGE) .
INFORMATION.
Observe safety instructions on raising the vehicle, refer to 00 .. ... LIFTING
VEHICLE WITH A LIFTING PLATFORM .
Open plug housing (1), pull plug connection (2) out of bracket and disconnect.

Pull cable with rubber grommet out of bracket on spring strut.
Installation:
2005 BMW 645Ci
Ensure proper locking of plug connector and proper seating of rubber grommets.
Fig. 114: Removing Wheel Speed Sensor

Installation:
Clean bore hole for pulse generator and grease with Staburags NBU 12/K lubricating grease (refer to
OPERATING FLUIDS - BRAKES ).
34 52 535 REPLACING A REAR PULSE GENERATOR
2005 BMW 645Ci

DISCHARGE) .
 Remove rear wheel, refer to 36 10 300 REMOVING OR INSTALLING FRONT OR REAR

WHEEL .
PLATFORM .
Open plug housing (1).
Pull plug connection (2) out of mounting and disconnect.

2005 BMW 645Ci
Pull cable out of brackets on swinging arm.
Installation:
Ensure proper locking of the plug connector and proper seating of the cable in the brackets.
Fig. 116: Removing Wheel Speed Sensor

Installation:

Clean bore hole for pulse generator and grease with Staburags NBU 12/K lubricating grease (refer to
2005 BMW 645Ci
34 52 550 REMOVING AND INSTALLING / REPLACING DSC SENSOR
DISCHARGE) .
 Remove right front seat, refer to 52 14 000 REMOVING AND INSTALLING LEFT OR RIGHT
FRONT SEAT (NORMAL/ELECTRIC) or 52 16 000 REMOVING AND INSTALLING FRONT
SEAT (SPORTS/ELECTRIC), LEFT OR RIGHT .
 Remove front inside entrance cover strip, refer to 51 47 000 REMOVING AND
 Lift carpet and fold back to one side
NOTE: The yaw sensor comprises the function of the transversal-acceleration sensor
and the yaw sensor.
Unlock plug connection.
Installation:
Make sure plug connection locks correctly.
Release screws (1) and remove rotation rate sensor.

2005 BMW 645Ci
Fig. 117: Releasing Screws And Removing Rotation Rate Sensor

Installation:
34 52 575 REMOVING AND INSTALLING/REPLACING FRONT PRESSURE SENSOR FOR ACC
 Remove front right wheel arch trim, refer to 51 71 040 REMOVING AND
INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH COVER .
BRAKE SYSTEM.
2005 BMW 645Ci


2005 BMW 645Ci
Fig. 119: Removing Pressure Sensor

Installation:
34 52 580 REMOVING AND INSTALLING / REPLACING REAR PRESSURE SENSOR FOR ACC
INFORMATION.
BRAKE SYSTEM.
2005 BMW 645Ci

Vehicles with N52 engine:
If necessary, remove heat shield (1).

2005 BMW 645Ci
Fig. 121: Removing Heat Shield

Installation:
Make sure heat shield is correctly seated.
If necessary, replace heat shield.

2005 BMW 645Ci
Fig. 122: Removing Pressure Sensor

Installation:

2005 BMW 645Ci
CABIN AIR FILTER Microfilter - 5 Series, 6 Series, M5 & M6 (E60, E61, E63 & E64 Chassis)
CABIN AIR FILTER
Microfilter - 5 Series, 6 Series, M5 & M6 (E60, E61, E63 & E64 Chassis)
NOTE: Manufacturer's terminology for this filter is Microfilter.
NOTE: Numbers in parenthesis refer to numbers in figures.
CABIN AIR FILTER
1. Open hood. If necessary, disconnect plug connection for engine hood contact switch.
2. Turn quick release fastener (1) approximately 90 degrees and open holder (2) in direction of arrow. See
Fig. 1.
2005 BMW 645Ci
Fig. 1: Removing Microfilter

3. Lever microfilter (1) in direction of arrow out of air duct (2) and remove. See Fig. 2.
4. To install microfilter, reverse removal procedure. Ensure microfilter (2) is correctly seated.
2005 BMW 645Ci
Fig. 2: Installing Microfilter

2005 BMW 645Ci
2004-09 GENERAL INFORMATION Car Communication Computer (CCC) - Overview - 5 & 6-Series (E60/E61/E63/E64)
2004-09 GENERAL INFORMATION
Car Communication Computer (CCC) - Overview - 5 & 6-Series (E60/E61/E63/E64)
CAR COMMUNICATION COMPUTER (CCC)

CAR COMMUNICATION COMPUTER
In principle, the structure of the car communication computer corresponds to that of a personal computer. In the
same way as a personal computer, the car communication computer contains a processor as well as RAM
modules and other peripheral components. Certain functions such as the voice input control system are
integrated in the form of software in the car communication computer.
The car communication computer is the central control module for all applications. It is always coupled with the
8.8" split-screen central information display. The car communication computer also features the high variant of
the controller with haptic feedback.
The car communication computer is based on a modular design, i.e. the main systems of the communication
network are integrated in the form of modules in the car communication computer. It can be configured and
expanded corresponding to requirements. At the time of market launch, the following modules/functions will be
integrated in the car communication computer:
 Radio double tuner

 DVD navigation system, Professional (map presentation)
 Voice control system
 ASK functions
 MOST-CAN gateway functions
2005 BMW 645Ci
The following advantages are achieved by combining several control units in one module:
 Increased functionality by combining several systems

 Easy to expand/upgrade by means of software with corresponding interfaces
 Fewer plug connections therefore fewer potential fault sources
 Reduced package space for control units
Components
2005 BMW 645Ci
Fig. 2: Identifying Control Unit Components

2005 BMW 645Ci
Fig. 3: Identifying Car Communication Computer Connectors And Connections

2005 BMW 645Ci
Fig. 4: Identifying Audio Board, Power Board And Main Board

SERVICE CONCEPT FOR THE CAR COMMUNICATION COMPUTER
The service concept is such that individual modules and parts of the car communication computer can be
2005 BMW 645Ci
replaced in the event of malfunction, thus serving to reduce repair costs. A differentiation is made between
electronic and mechanical parts.
Electronic Parts
Replacement of the following electronic parts is planned:
ELECTRONIC PARTS REPLACEMENT CHART

CD drive DVD drive Tuner module HIP module
Gyro Front panel Audio board Memory module
PMC cards Electric fan
Mechanical Parts
Following mechanical parts are available:
MECHANICAL PARTS SPECIFICATION

Top cover Bottom cover DVD drive retaining fixture
CD retaining fixture DVD drive holder CD drive holder
Cover PMC slot Cover PCMCIA slot Rubber mount for electric fan
Particular attention must be paid to electrostatic discharge ESD when working on the car communication
computer. Disregard of the safety requirements may result in damage to the electronic components in the car
communication computer.
Working On Electronic Components
Preparatory Work
The following points must be observed when working on electronic components of the car communication
computer corresponding to the service concept:
 All work must be carried out on a conductive and earthed workbench.

 The special tool 12 7 192 is additionally used for this purpose.
 The earthing cable must be connected to a secure and reliable earthing point (water pipe, heating pipe,
socket outlet earth). Before taking the parts out of their packaging, the person working on the components
must first put on the wrist cuff in order to discharge himself. The electronic components are placed on the
antistatic mat and also connected with the earthing cable.
Replacement
The electronic components must be replaced as described in the repair instructions and following the procedure
described on SIP Electrostatic Fundamentals, while observing ESD safety measures.
2005 BMW 645Ci
Fig. 5: Preparing For Parts Replacement

NOTE: The Antistatic Mat at your Center may look different than the one shown here or
at the training center. Remember the following when using the Antistatic Mat:
 Ground the Antistatic Mat to the workbench using the attached lead
 Attach the Grounding strap to the component being serviced
 Always wear the wrist cuff.
2005 BMW 645Ci
Fig. 6: Identifying Wrist Cuff

SYSTEM FUNCTIONS
The car communication computer comprises the following functions:
 Radio
 DVD navigation, Professional (map presentation)
 Voice control system
 Online platform
 Audio management
 ASK functions
 Driver for central information display
 MOST CAN gateway
Voice Control System
A voice control system High is integrated in the car communication computer. With this system, all functions
shown in the CID can be controlled by voice commands. This system has the advantage that the hands need not
be taken off the steering wheel while driving in order to change settings.
The SES can be used to control the following systems:

2005 BMW 645Ci
 Entertainment
 Communication
 Navigation
 Climate
 "5th Menu" setting
The voice control system makes use of specific voice commands. The voice control system sets up a dialogue
with the user. Repeat requests are issued if the system did not understand a command.
System Integration
The voice control system is loaded as pure software in the car communication computer. The voice control
system makes use of the memories and processors in the car communication computers as well as the hardware
of other systems (e.g. microphones).
The two hands-free microphones in the front roof console are used in connection with the voice control system.
The hands-free microphones are connected directly to the telematics control unit (TCU). The TCU sends the
microphone signals via MOST to the car communication computer where they are processed in the DSP in
order to execute the required functions.
Functional Principle Of Voice Control System
System Start/End
The voice control system is activated/deactivated via the push-to-talk button (PTT) on the multifunction
steering wheel or on the controller. For the first time, the PTT button on the controller makes it possible for the
passenger to use the voice control system (SES). The SES is activated for the driver by briefly pressing the
button and for the passenger by pressing and holding the button longer.
The SES is deactivated by again pressing one of the PTT buttons. Activation of the SES is indicated by a
graphic display (PTT logo) in the status line of the CID. The system is active for about 5 seconds. If no input
takes place during this period of time, the user is informed that no voice input was detected and the request for
voice input is repeated. The voice control system is deactivated if again no input is made within 5 seconds.
2005 BMW 645Ci
Fig. 7: Identifying Voice Control System Inputs/Outputs

2006 BMW 650i
ACCESSORIES AND EQUIPMENT Cellular Phone System - 650i
ACCESSORIES AND EQUIPMENT
Cellular Phone System - 650i
11 TRANSCEIVER, HANDSET
84 11 550 REMOVING AND INSTALLING/REPLACING HANDS-FREE MICROPHONE
 Remove front roofliner trim. See 51 44 ... REMOVING AND INSTALLING FRONT ROOFLINER
TRIM .
Unlock catch (1) and feed hands-free microphone (2) in direction of arrow out of front roofliner trim (3).
Installation:
Arrow on hands-free microphone (2) must point in direction of travel.
Fig. 1: Unlocking Catch

84 11 610 REMOVING AND INSTALLING/REPLACING EJECT BOX (CORDLESS KEYPAD

HANDSET)
 00 9 341
Unlock telephone mounting (1) and fold upwards.
Release catch (2) of cover (3) from telephone mounting (1).

2006 BMW 650i
Feed out centre console base (4) with cover (3) and remove.
Installation:
Make sure centre console base (4) and cover (3) are correctly seated.
Fig. 2: Releasing Catch Of Cover

Installation:
Make sure guide pins (1) of cover (3) are correctly seated in guide of centre console base (4).
Guide pins (1) and catches (2) of cover (3) must not be damaged or missing.
Fig. 3: Identifying Guide Pins, Catches And Cover

Turn plug connection (3) in direction of arrow and feed out.

2006 BMW 650i
If necessary, unlock antenna plug and disconnect.
Release screws (1).
Remove telephone mounting (2).
Installation:
Make sure cable guide is correctly laid.
Fig. 4: Unfastening Plug Connection

Unlock eject box (1) with special tool 00 9 341 and towards top rear out of telephone mounting (2).
Installation:
Make sure eject box (1) is correctly seated.
Fig. 5: Unlocking Eject Box

2006 BMW 650i
Installation:
Catches (1) on telephone mounting (2) must not be damaged or missing.
Fig. 6: Identifying Catches And Telephone Mounting

84 11 650 REMOVING AND INSTALLING/REPLACING TELEMATIC CONTROL UNIT (TCU)

(OPTION SA633/SA638/SA639/SA664)
IMPORTANT: Replacement with option SA638/SA664:
 Carry out programming/coding

 If necessary, carry out coupling procedure
Replacement with option SA633/SA639:
 Carry out programming/coding

 Via Diagnosis and Information System (DIS):
 Service functions
 Start subsequent assessment
IMPORTANT: Protect against electrostatic damage (ESD).
NOTE: Follow instructions for handling fibre optic cables. The minimum permitted
bending radius is 25 mm. Do not subject optical fibers to compressive and
tensile load. Protect optical fibers against the effects of heat (e.g. during
welding work, drying work with infrared heater or hot air blower). Optical fibers
are permitted to show only one junction point (bridge), replace optical fibers if
necessary. The optical fibers are colored differently as follows: Green=MOST
(Media Oriented Systems Transport) optical fibers. Yellow=ISIS (Intelligent
2006 BMW 650i
Safety and Integration System) optical fibers.

 Remove backrest for rear seat . See 52 24 010 REMOVING AND INSTALLING / REPLACING
BACKREST .
Disconnect antenna plug (3).
Installation:
Observe color coding of aerial/antenna plugs (3).
Release nuts (2) and remove TCU (4).
Fig. 7: Identifying Plug Connection, Antenna Plug And Nuts

31 HANDS-FREE SYSTEM, MICROPHONE

84 31 020 REMOVING AND INSTALLING/REPLACING HANDS-FREE SYSTEM SPEAKER
 Remove trim panel for pedal assembly . See 51 45 185 REMOVING AND
INSTALLING/REPLACING TRIM FOR PEDAL ASSEMBLY
Screw on threaded ring (1) in direction of arrow and remove hands-free system speaker (2) from trim for pedal
assembly (3).
2006 BMW 650i
Fig. 8: Removing Hands-Free System Speaker

41 CONTROL UNIT FOR VOICE

84 41 510 REMOVING AND INSTALLING/REPLACING CONTROL UNIT FOR VOICE INPUT
SYSTEM
NOTE: Follow instructions for handling fibre optic cables. The minimum permitted
bending radius is 25 mm. Do not subject optical fibers to compressive and
tensile load. Protect optical fibers against the effects of heat (e.g. during
welding work, drying work with infrared heater or hot air blower). Optical fibers
are permitted to show only one junction point (bridge), replace optical fibers if
necessary. The optical fibers are colored differently as follows: Green=MOST
(Media Oriented Systems Transport) optical fibers. Yellow=ISIS (Intelligent
Safety and Integration System) optical fibers.
Slacken nuts (2).
Unscrew nut (3).
Feed out control unit for voice input system (4) and remove.
2006 BMW 650i
Fig. 9: Identifying Plug Connection, Voice Input System And Nuts

2009 BMW 650i
GENERAL INFORMATION CIP Programming - Overview
GENERAL INFORMATION
CIP Programming - Overview
CIP PROGRAMMING
CIP PROGRAMMING SCREENS
Fig. 1: CIP Programming Screen

The opening screen when CIP is started.
Choose which vehicle you will be programming.

2009 BMW 650i
Fig. 2: Vehicle Selecting Programming Screen

2009 BMW 650i
Fig. 3: Programming Screen - Retrofit Select

Select depending upon programming required.
To retrofit select Load SW.
To update a vehicle select Vehicle.
Selecting Vehicle will ensure that complete encoding is performed.

2009 BMW 650i
Fig. 4: Programming Screen - Load Software

Regardless of whether you have selected Load SW or Vehicle, the VO will be determined.
2009 BMW 650i
Fig. 5: Programming Screen - Determine

A YES selection will lead you to choose which control module(s) have been replaced.
A NO selection will lead you to Retrofits .

2009 BMW 650i
Fig. 6: Programming Screen - Measure Plan

After selecting YES fitted control modules will be determined.

2009 BMW 650i
Fig. 7: Programming Screen - Control Modules

After determining the fitted modules, a measures plan will be made. At this point you will be notified if control
modules need to be replaced.
Control module replacement is required if the hardware level in a module can not be upgraded to a high enough
software level.
In the case above no modules need replacement, in fact on the DSC needs to be reprogrammed.
2009 BMW 650i
Fig. 8: Programming Screen - DSC Being

DSC programming is being carried out.

2009 BMW 650i
Fig. 9: Programming Screen - Retrofit Programming

If you selected no earlier (Have any control modules been replaced?) you would come to this screen.
Here selections to reprogram individual modules can be made or entry into retrofit programming.
2009 BMW 650i
Fig. 10: Programming Screen - Selecting Retrofit

Selecting retrofit on the previous screen brings you here.
More selections (such as mobile phone USA) are on the next page, accessed by pressing retrofits on bottom of
selection list.
2009 BMW 650i
Fig. 11: Programming Screen - Retrofit

Select the retrofit, in this case the Mobile phone USA.

2009 BMW 650i
Fig. 12: Programming Screen - Battery

You will be asked which battery the car has installed.

2009 BMW 650i
Fig. 13: Programming Screen - Measures Plan

A measures plan will be determined and displayed to accomplish the retrofit.
Press Accept.
2009 BMW 650i
Fig. 14: Programming Screen - Retrofit Being Carried Out

The retrofit is being carried out.

2009 BMW 650i
Fig. 15: Programming Screen - Vehicle Function

By selecting Vehicle initially when entering CIP, you will save time when updating the vehicle.
Updating through Load SW differs from Measures Plan determined through Vehicle.
When updating through Load SW only the module programmed is re-coded. You still need to come to this
screen and perform Complete Encoding.
By updating through Vehicle, the entire car is automatically encoded, after the programming is complete.
2009 BMW 650i
Fig. 16: Programming Screen - Pressing Start

Press start to begin the programming and encoding procedure.

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
2000-05 CLUTCHES
X3, X5 & 645Ci
APPLICATION
For manual transmission applications, see SERVICING article.
BLEEDING
1. Remove transmission underbody protection if necessary. Remove micro filter housing as necessary. See
CABIN AIR FILTERS - X3 , CABIN AIR FILTER - X5 or CABIN AIR FILTERS - 645Ci .
Unfasten nuts and remove clutch slave cylinder (pressure line remains connected). See Fig. 1 . Fit special
tool (21 5 030) on clutch slave cylinder (1). Press piston rod (2) with aid of spindle completely into clutch
slave cylinder. See Fig. 2 . Connect bleeder unit to brake fluid expansion tank.
NOTE: Check relevant operating instructions for each device.
2. Charging pressure should not exceed 2 bar. Connect bleeder hose to bleeder valve (1). See Fig. 3 . Hold
clutch slave cylinder in illustrated position with special tool (21 5 030). Open bleeder valve (1). If bubble-
free brake fluid emerges, retract piston rod (2) of clutch slave cylinder with aid of spindle a little and
press in again. If no air bubbles escape, close bleeder valve (1), otherwise repeat procedure.
3. Do not under any circumstances remove special tool (21 5 030) from clutch slave cylinder when brake
system is pressurized. Piston with push rod can jump out of clutch slave cylinder. Switch off bleeder unit
or remove from brake fluid expansion tank.
4. Slowly retract piston rod (2) of clutch slave cylinder (1) with special tool (21 5 030). See Fig. 4 . Remove
special tool (21 5 030) from clutch slave cylinder (1). Fit clutch slave cylinder to transmission. See Fig.
5 . During installation, replace self-locking nuts. Correct brake fluid level in expansion tank with DOT 4
brake fluid.
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 1: Unfastening Nuts & Removing Clutch Slave Cylinder

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 2: Pressing Piston Rod With Aid Of Spindle Completely Into Clutch Slave Cylinder
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 3: Connecting Bleeder Hose To Bleeder Valve

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 4: Slowly Retracting Piston Rod Of Clutch Slave Cylinder

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 5: Installing Clutch Slave Cylinder To Transmission

CHECKING/TOPPING OFF FLUID LEVEL IN HYDRAULIC SYSTEM

GS6S37BZ/GS6S53BZ/SMG
1. Method 1: Switch on ignition. Bleed hydraulic system. See BLEEDING . Open filler screw (1). Fill
expansion tank up to MAX marking with DOT 4 brake fluid. See Fig. 6 .
2. Method 2: Depressurize hydraulic system in accordance with BMW diagnosis system. Open filler screw
(1). Add BMW DOT 4 hydraulic fluid up to lower edge of filler cap. See Fig. 6 .
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 6: Identifying Filler Screw & MAX Mark

S6S420G/SMG
Turn on ignition. Press brake pedal. Move selector lever from position "0" to "R" or "0" to "E" until hydraulic
pump is activated. Wait until hydraulic pump shuts down. Open expansion tank (1). See Fig. 7 . Fill expansion
tank up to MAX marking (2) on dipstick (1). See Fig. 8 . Check with dipstick on cap by screwing in cap.
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 7: Identifying Expansion Tank

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 8: Identifying Dipstick Markings

ADJUSTMENTS
CLUTCH PEDAL
Clutch pedal stroke and free play are adjusted automatically.
BREAKING IN SELF-ADJUSTING CLUTCH (SAC)
Break in SAC clutches moderately to ensure correct operation, as 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 (such as 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 approximately 2000 RPM.
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
 Specific breaking-in program on gentle gradients.

 Starting speeds on a medium gradient up to approximately 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. See SELF-ADJUSTING CLUTCH BREAKING IN PROGRAM table.
Experience shows that approximately 800-1000 gearshifts are required for an optimally broken-in lining when a
car is driven normally.
SELF-ADJUSTING CLUTCH BREAKING IN PROGRAM

Application Specification
Shift Through Gears Often Starting Speed Maximum 200 RPM
Upshifts 1-2-3-4-5
Downshifts At 2000 RPM 5-4-3-2-1
Upshifts & Downshifts At 3000-
3-5 Times Starting On Gentle Gradient (Up To Starting Speed Maximum 2500 RPM
Approximately 12%)
TROUBLESHOOTING
1. If clutch is slipping, check for:
 Clutch pressure too low.
 Lining too heavily worn.
 Lining oiled.
 Engine:
a. Crankshaft Radial Seal At Front & Rear Including End Cover

b. Oil Sump
c. Cylinder Head Gasket At Cylinder Head
d. Oil Filler Cap
e. Timing Case Cover
f. Flywheel Mounting Bolts
 Cooling System:
a. Hoses & Connections

b. Heating Valves
c. Sealing Plugs On Engine Block
 Steering Unit:
a. Steering Gear
b. Servo Pump
c. Hydraulic Lines & Connections
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
a. Drive Shaft Radial Seal

b. Sealing Plugs Of Countershaft
 Release Bearing:
a. Clutch Was Overheated

b. Clutch Is Not An Original Equipment BMW Part
If problem is found, replace clutch and repair leaks as necessary.
2. If clutch sticks/slips, check for:
a. Lining not to specification.
b. Lining oiled.
c. Release unit presses on one side.
d. Clutch presses at an angle.
e. Crankshaft does not align with transmission input shaft.
f. Engine and transmission suspension defective.
g. Clutch plate not an original equipment BMW part.
If engine, speed characteristics not okay:
a. Engine management not okay.
b. Check engine control unit.
If problem is found, replace clutch, check engine/transmission contact face, adapter sleeves and cover
plate for damage, replace engine and transmission suspension, install original equipment BMW part as
necessary,
3. If clutch does not separate, check for:
a. Lining of clutch plate broken.
b. Lining rusted onto flywheel.
c. Guide bearing for transmission input shaft in crankshaft defective.
d. Leak in clutch hydraulic system.
e. Tangential leaf springs of clutch bent down.
f. Release unit binds on guide sleeve.
If problem is found, replace clutch plate, evenly sand flywheel with sandpaper and replace clutch plate,
replace guide bearing in crankshaft, replace faulty parts and bleed clutch hydraulics, replace clutch, or
clean guide sleeve, remove and install release unit.
4. If clutch makes noise, check for:
a. Imbalance of clutch and clutch plate too great.
b. Torsional-vibration damper defective.
c. Release unit defective.
d. Guide bearing for transmission input shaft in crankshaft defective.
e. Clutch rivet connection loose.
If problem is found, replace clutch plate or dual mass flywheel, release unit, guide bearing in crankshaft
or clutch as necessary.
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci

CLUTCH
Removal & Installation X3 & 6-Series
1. Remove transmission. See appropriate MANUAL TRANSMISSION removal article. On X3 6-cylinder,

block flywheel with special tools (11 9 260) and (11 9 265). See Fig. 9 . On 6-Series V8, block flywheel
with special tools (11 9 260, 11 9 263 and 11 9 264). See Fig. 10 .
Fig. 9: Blocking Flywheel (X3 6-Cylinder)

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 10: Blocking Flywheel (6-Series V8)

2. Release screws and remove clutch from flywheel. See Fig. 11 . During installation, clean flywheel and
check for wear and damage. Replace damaged flywheel. Always replace clutch plates fouled by oil,
cleaning agent or other materials. If installing removed clutch with new clutch plate, go to step 5 . If
installing a new clutch, go to step 7 . If installing a removed clutch and clutch plate, observe the following
procedure when installing the removed clutch and clutch plate. Insert special tool (21 2 180) in clutch.
Press special tool 212180 together at handles (1) as far as it will go and tighten down knurled screws (2).
See Fig. 12 .
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 11: Removing Clutch From Flywheel

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 12: Pressing Special Tool At Handles & Tightening Knurled Screws
3. Adjustment ring of clutch is now secured in its original position (wear position). Note that locking hooks
(1) of special tool (21 2 180) must engage in openings of pressure spring. See Fig. 13 . Fit special tool (21
2 170) and tighten down at knurled screw (1). Screw in spindle (2) until diaphragm spring (3) is tensioned
on stop. See Fig. 14 . Insert special tool (21 2 170) only in area of bores for dowel pins. Center clutch
plate (1) with special tool in dual-mass flywheel. See Fig. 15 .
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 13: Identifying Locking Hooks Of Special Tool

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 14: Screwing In Spindle Until Diaphragm Spring Is Tensioned On Stop

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 15: Centering Cutch Plate With Special Tools

4. Install clutch plate in correct position. Note designation for "engine side" and "transmission side". Handle
clutch plate with care. Do not touch surfaces of friction linings. Fit clutch (1) to flywheel. Clutch (1) must
be secured by way of dowel pins (2). See Fig. 16 . Release spindle (1) until load is fully removed from
diaphragm spring. See Fig. 17 . Remove special tools (21 2 170 and 21 2 180). Withdraw special tool
from clutch plate with aid of accompanying screw (1). See Fig. 18 .
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 16: Identifying Clutch & Dowel Pins

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 17: Releasing Spindle Until Load Is Fully Removed

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 18: Removing Special Tool From Clutch Plate Using Screw
5. When installing removed clutch with new clutch plate, always reset adjustment ring in new position. Set
clutch down on a clean surface. Insert special tool (21 2 180) in clutch (1). See Fig. 19 . Note that locking
hooks (1) of special tool (21 2 180) must engage in openings in clutch. See Fig. 20 . Fit special tool (21 2
170) and tighten down at knurled screw (1). See Fig. 16 . Insert special tool (21 2 170) only in area of
bores for dowel pins. Screw in spindle (1) until adjustment ring of clutch (2) can be turned with special
tool (21 2 180) at handles (3). Press special tool together at handles (3) as far as it will go and grip firmly.
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 19: Installing Special Tool In Clutch

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 20: Ensuring Locking Hooks Engage In Openings In Clutch

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 21: Screwing In Spindle Until Diaphragm Spring Is Tensioned On Stop

6. At same time, tighten down knurled screws (2). Adjustment ring of clutch is now secured in new position.
Screw in spindle (1) until diaphragm spring is tensioned on stop. See Fig. 21 . Center clutch plate (1) with
special tools. See Fig. 22 . Install clutch plate in correct position. Note designation for "engine side" and
"transmission side". Handle clutch plate with care. Do not touch surfaces of friction linings. Fit clutch (1)
to flywheel. Clutch (1) must be secured by way of dowel pins (2). See Fig. 16 . Release spindle (1) until
load is fully removed from diaphragm spring (2). Remove special tools (21 2 170 and 21 2 180). See Fig.
17 . Withdraw special tool from clutch plate with aid of accompanying screw (1). See Fig. 18 .
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci

7. If installing new clutch, locking piece may only be removed if clutch is screwed down. Center clutch
plate (1) with special tools. See Fig. 22 . It is important that clutch plate is installed in correct position.
Note designation for "engine side" and "transmission side". Handle clutch plate with care. Do not touch
surfaces of friction linings. Fit clutch to flywheel. It is important that clutch is secured by way of dowel
pins (1). See Fig. 23 . Carefully unscrew locking piece (1) clockwise or counterclockwise with a 14-mm
WAF hexagon socket wrench (2). See Fig. 24 . Note that a slight snapping of the plate spring while
unscrewing the lock is possible. Withdraw special tool (1) from clutch plate with aid of accompanying
screw (2). See Fig. 18 .
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 23: Fitting Clutch To Flywheel By Way Of Dowel Pins

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 24: Unscrewing Locking Piece

Removal & Installation (X5)
1. Remove transmission. See appropriate MANUAL TRANSMISSION removal article. To identify clutch,
note 3 openings each with a pressure piece (1) of a ring and a pressure spring (2).
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 25: Identifying Clutch

2. On 6-cylinder engine, block flywheel (1) with special tool 11 2 170. See Fig. 26 . On 8-cylinder engine,
lock flywheel with special tool 11 2 070. See Fig. 27 . Unfasten bolts and remove SAC from flywheel.
See Fig. 28 . Do not use a special tool to detach SAC clutch from flywheel. Remove clutch plate (1) from
flywheel. See Fig. 29 . 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. Always replace clutch plates fouled by oil or cleaning agent. Check clutch plate for damage
and friction rust in hub profile and replace if necessary. Check clutch disk for wear and measure lining
protrusion at lining rivets at closing head (A) in each case. Rivet connection: A = closing head, B = swage
head. See Fig. 30 . Replace clutch plate if lining protrusion at closing head (A) is less than 1 mm. Push
clutch disk onto the cleaned transmission input shaft and check for easy movability. Do not clean SAC
clutch with high pressure cleaner or washing machine as this may impair function of adjustment unit.
Clean friction surface only. Check SAC for wear and damage and replace if necessary.
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 26: Blocking Flywheel (6-Cylinder)

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 27: Blocking Flywheel (8-Cylinder)

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 28: Removing SAC From Flywheel

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 29: Removing Clutch Plate From Flywheel

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 30: Identifying Closing Head & Swage Head

3. To reinstall removed SAC clutch and clutch plate, set SAC clutch (1) down on a clean surface. See Fig.
31 . Install special tool 21 2 180 in SAC clutch (1). Locking hooks (1) of special tool 21 2 180 must
engage in openings in SAC clutch. See Fig. 32 . 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). See Fig. 33 . Adjustment ring
of SAC clutch is now secured in its original position (wear position). Do not reset adjustment ring to new
position. Insert special tool 21 2 170 only in area of bores for dowel pins. See Fig. 34 . Fit special tool 21
2 170 and tighten down at knurled screw (1). See Fig. 35 . Screw in spindle (1) until diaphragm spring (2)
is pretensioned up to stop. See Fig. 36 . Handle clutch disk carefully, using care to not touch surfaces of
friction pads. Install clutch plate in correct position. Note designation for "engine side" and "transmission
side". Center clutch plate (1) with special tool. See Fig. 37 . On vehicles manufactured from 4/03, note
color marking when fitting clutch with balance marking. Position color marking (1) on dual-mass
flywheel and color marking (2) on clutch pressure plate as closely as possible to each other. See Fig. 38 .
Maximum possible angle error is 60 degrees. On all vehicles, fit SAC clutch (1) on flywheel. Pay
attention to dowel pins (2). See Fig. 39 . SAC clutch (1) must be secured by way of dowel pins (2).
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 31: Setting SAC Clutch Down On A Clean Surface

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 32: Identifying Locking Hooks Of Special Tool

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 33: Pressing Special Tool At Handles & Tightening Knurled Screws
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 34: Identifying Area Of Bores For Dowel Pins

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 35: Installing Special Tool & Tightening At Knurled Screw

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 36: Screwing In Spindle Until Diaphragm Spring Is Pretensioned

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 37: Centering Clutch Plate With Special Tool

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 38: Positioning Color Marking

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 39: Identifying Clutch & Dowel Pins

4. Insert screws and tighten down. Release spindle (1) until tension is completely removed from diaphragm
spring (2). See Fig. 40 . Release knurled screw (1) and remove special tool (21 2 180). See Fig. 41 .
Release knurled screws (2) and remove special tool (21 2 180) from SAC clutch. See Fig. 42 . Withdraw
special tool from clutch plate with aid of accompanying screw (1). See Fig. 43 .
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 40: Releasing Spindle Until No Tension Is Present At Diaphragm Spring

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 41: Releasing Knurled Screw & Special Tool From Clutch
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 42: Releasing Knurled Screws & Special Tool

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 43: Removing Special Tool From Clutch Plate Using

5. Before installing an SAC clutch which has been in service with a new clutch plate, always reset
adjustment ring in new position. Set SAC clutch down on a clean surface. Install special tool (21 2 180)
in SAC clutch (1). See Fig. 44 .
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 44: Installing Special Tool In SAC Clutch

6. Locking hooks (1) of special tool (21 2 180) must engage in openings in SAC clutch. See Fig. 45 . Insert
special tool (21 2 170) only in area of bores for dowel pins. See Fig. 46 . Fit special tool (21 2 170) and
tighten down at knurled screw (1). See Fig. 47 . Screw in spindle (1) until adjustment ring of SAC clutch
(2) can be turned with special tool (21 2 180) at handles (3). Press special tool (21 2 180) together at
handles (3) as far as it will go and grip firmly. See Fig. 48 . At same time tighten down knurled screws
(2). Adjustment ring of SAC clutch is now secured in new position. See Fig. 49 . Screw in spindle (1)
until diaphragm spring (2) is tensioned to stop. See Fig. 50 . Handle clutch plate with care, do not touch
surfaces of friction linings. Install clutch plate in correct position. Pay attention to text "engine end" and
"transmission side".
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 45: Ensuring Locking Hooks Engage In Openings In SAC Clutch

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 46: Inserting Special Tool Only In Area Of Bores For Dowel Pins
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 47: Installing Special Tool & Tightening Down At Knurled Screw
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 48: Screwing In Spindle Until Adjustment Ring Of SAC Clutch Can Be Turned With Special
Tool At Handles
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 49: Securing Adjustment Ring Of SAC Clutch In New Position

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 50: Screwing In Spindle Until Diaphragm Spring Is Tensioned To Stop

7. Center clutch plate (1) with special tools. See Fig. 51 . On vehicles manufactured from 4/03, note color
marking when fitting clutch with balance marking. Position color marking (1) on dual-mass flywheel and
color marking (2) on clutch pressure plate as closely as possible to each other. See Fig. 38 . Maximum
possible angle error is 60 degrees. Fit SAC clutch (1) on flywheel. Pay attention to dowel pins (2). See
Fig. 52 . SAC clutch (1) must be secured by way of dowel pins (2). Install retaining screws of SAC clutch
and tighten down. Release spindle (1) until tension is completely removed from diaphragm spring (2).
See Fig. 53 . Release knurled screw (1) and remove special tool (21 2 170) from SAC clutch. See Fig.
54 . Release knurled screws (2) and remove special tool (21 2 180) from SAC clutch. See Fig. 55 .
Withdraw special tool from clutch plate with aid of accompanying screw (1). See Fig. 56 .
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 52: Fitting Clutch On Flywheel & Noting Location Of Dowel Pins
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 53: Releasing Spindle Until Tension Is Removed

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 54: Releasing Knurled Screw

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 55: Releasing Knurled Screws

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 56: Withdrawing Special Tool From Clutch Plate

8. When installing new SAC, handle clutch disk carefully. Do not touch surfaces of friction pads. Install
clutch plate (1) in correct position. Note designation for "engine side" and "transmission side". Center
clutch plate (1) with special tools. See Fig. 57 . Push SAC clutch onto dowel pins (1) located in flywheel
and screw down. See Fig. 58 . Locking piece (1) may only be removed with SAC screw-mounted clutch.
Carefully unscrew locking piece (1) clockwise or counterclockwise with a hexagon socket wrench (2).
See Fig. 59 . A slight snapping of the plate spring while unscrewing is possible. Withdraw special tool (1)
from clutch plate with aid of accompanying screw (2). See Fig. 60 .
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 57: Centering Clutch Plate With Special Tools

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 58: Pushing SAC Clutch Onto Dowel Pins

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 59: Unscrewing Locking Piece

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 60: Removing Special Tool From Clutch Plate

CLUTCH MASTER CYLINDER
NOTE: Numbers in text refer to numbers in figures. After completing work, bleed clutch
hydraulic system. See BLEEDING .
1. Remove trim panel for pedal assembly. See PEDAL ASSEMBLY TRIM . 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. See Fig. 61 . Press pin (1)
out of clutch pedal with a short screwdriver. See Fig. 62 .
2. During installation, pin is coded by a straight surface (1). See Fig. 63 . The coding points upwards. Screw
pin with coding upwards. Turn slightly until coding snaps into place. Press in pin until engaged (2).
Unfasten bolts. See Fig. 64 . Detach retainer (1) with a screwdriver (2). See Fig. 65 . Use care not to foul
carpet with brake fluid. Detach hydraulic line from clutch master cylinder. Detach supply hose (1) from
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
3. Do not pull supply hose completely into interior. Lever out shift element (1) from clutch master cylinder
(2) with screwdriver. Release plug connection (3) and disconnect plug (4) from shift element (1). See Fig.
67 . During installation, shift element is secured against incorrect installation. See Fig. 68 . Shift element
must snap audibly into place. See Fig. 68 .
Fig. 61: Detaching Supply Hose From Expansion Tank (X3 & 6-Series)
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 62: Pressing Pin Out Of Clutch Pedal (X3)

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 63: Identifying Pin Straight Surface & Pressing In Pin Until Engaged (X3)
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 64: Unfastening Bolts (X3)

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 65: Detaching Clutch Master Cylinder From Hydraulic Line (X3 & 6-Series)
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 66: Detaching Supply Hose From Clutch Master Cylinder (X3)
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 67: Levering Out Shift Element (All Models)

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 68: Shift Element Snapping Audibly Into Place (All Models)
1. Remove the cover (1). See Fig. 69 . Draw off brake fluid up to supply hose of clutch hydraulic system.
For this purpose, use only a vacuum pipe that is exclusively used for removing brake fluid. Remove the
supply hose (1) from the expansion tank. See Fig. 70 . Remove lower left trim panel from instrument
panel. Release screws (1). See Fig. 71 .
2. Release screw (1) and press clips (2) out of light switch. See Fig. 72 . Release screw (1) and remove
reinforcement plate. See Fig. 73 . Remove clutch pedal. Pull off retainer (1). Do not soil the footwell
carpet with brake fluid.
3. Disconnect clutch master cylinder (2) from hydraulic line and remove with supply hose. See Fig. 74 .
Lever switch module (1) out of clutch master cylinder (2) with a screwdriver. Release plug connection (3)
and disconnect plug (4) from switch module (1). See Fig. 67 . During installation, ensure switch module
is protected against incorrect installation. Switch module must audibly snap into place. See Fig. 68 .
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 70: Removing Supply Hose From Expansion Tank

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 72: Releasing Screw & Pressing Clips Out Of Light Switch
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 73: Releasing Screw & Removing Reinforcement Plate

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 74: Disconnecting Clutch Master Cylinder From Hydraulic Line

Removal & Installation (6-Series)
1. Remove trim panel for pedal assembly. See PEDAL ASSEMBLY TRIM . Remove microfilter housing
on left. See CABIN AIR FILTERS . Remove light module. See LIGHT MODULE . 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. See Fig. 61 .
Disconnect spring (1). Illustration shows component removed. See Fig. 75 .
2. Remove retainer (1) using screwdriver and press out pin. See Fig. 76 . Detach retainer (1) with a
screwdriver (2). See Fig. 65 . Do not foul carpet with brake fluid. Detach hydraulic line from clutch
master cylinder. Remove lock (1) from pin with aid of screwdriver (2). Lever out pin (3) with aid of
screwdriver. Remove clutch master cylinder. During installation, replace pin. Press in pin until lock (1)
can be seen to snap into place. See Fig. 77 . Detach supply hose (1) from clutch master cylinder. Do not
pull supply hose completely into interior. Lever out shift element (1) from clutch master cylinder (2) with
screwdriver. Release plug connection (3) and disconnect plug (4) from shift element (1). See Fig. 67 .
During installation, shift element is secured against incorrect installation. Shift element must snap audibly
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 75: Disconnecting Spring

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 76: Removing Retainer

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 77: Identifying Lock & Pin

CLUTCH RELEASE UNIT GUIDE TUBE
Removal & Installation (X3 & X5 6-Cylinder)
Remove clutch release bearing and release lever from tube. See CLUTCH RELEASE BEARING/LEVER .
Unfasten bolts. See Fig. 78 . Remove guide tube (1). When installing, clean thread. Install screws with Loctite
243. Remove sticker (1) and adhesive with a suitable solvent. See Fig. 79 .
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 78: Identifying Guide Tube Bolts

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 79: Identifying Sticker

LIGHT MODULE
Remove PEDAL ASSEMBLY TRIM . Unfasten plug connection (4) and disconnect. Unlock catch (1) and
feed out/remove light module (2) in direction of arrow. During installation, make sure light module (2) is
correctly seated in mounting (3) and catch (1). See Fig. 80 . Reprogram light module with BMW DIS.
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 80: Removing & Installing Light Module

PEDAL ASSEMBLY TRIM
Release screws (1). Unclip trim for pedal assembly (4) at retaining points (2). Remove rotary clip (3) and pull
back trim for pedal assembly (4) in direction of arrow. Disconnect associated plug connections and remove trim
for pedal assembly (3). See Fig. 81 . When installing, note that locator tabs (1) of trim for pedal assembly (2)
must not be damaged. Note location of gong (3) and footwell light (4). See Fig. 82 .
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 81: Removing Pedal Assembly Trim (X3)

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 82: Installing Pedal Trim (X3)

Release screws (1). Unclip trim for pedal assembly (3) at retaining points (2). Pull back panel for pedals (3) in
direction of arrow. Disconnect associated plug connections and remove trim for pedal assembly (3). During
installation, guides (1) and clips (2) of trim for pedal assembly (3) must not be damaged. See Fig. 83 . Note
location of speaker for hands-free system (4) and footwell light (5). See Fig. 84 .
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 83: Removing Pedal Assembly Trim (6-Series)

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 84: Installing Pedal Trim (6-Series)

CLUTCH RELEASE BEARING/LEVER
1. Remove transmission. See appropriate REMOVAL & INSTALLATION article. Remove release bearing
(1).
2. During installation, clean all sliding surfaces on clutch release bearing, check for damage and replace if
necessary. Do not grease clutch release lever. Sliding surfaces (2) of clutch release bearing must rest on
sliding surfaces (3) of release lever. Lightly grease sliding surfaces (2) of release bearing. See Fig. 85 . If
a new clutch release bearing is installed, go to next step.
3. New clutch release bearing: clutch release bearing with moving thrust plate (1) and swivel motion of
thrust plate (1) possible. See Fig. 86 . During installation, lightly grease sliding surfaces of release
bearing. A previously used clutch release bearing: clutch release bearing with rigidly positioned thrust
plate (1) and swivel motion of thrust plate (1) is not possible. See Fig. 87 . Withdraw release lever (4)
from spring wire clip (5) and remove. See Fig. 88 . Clean release lever. Do not grease release lever.
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
4. During installation, check spring wire clip (5) and ball pin (6) for damage and replace if necessary. See
Fig. 90 . Lightly grease ball pin (6). Note that spring wire clip and ball pin must always be replaced on
the S6S420G transmission. Clean guide sleeve (7). See Fig. 91 . Do not grease guide sleeve. It guide
sleeve is greased, the release lever can stick on the guide sleeve.
Fig. 85: Release Bearing, Sliding Surfaces Of Release Bearing & Release Lever
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 86: Clutch Release Bearing With Moving/Swivel Motion

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 87: Clutch Release Bearing With Rigid Thrust Plate & No Swivel Motion
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 88: Withdrawing Release Lever From Spring Wire Clip

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 89: Lightly Greasing Release Lever At Sliding Surfaces

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 90: Checking Spring Wire Clip & Ball Pin For Damage
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 91: Cleaning Guide Sleeve

CLUTCH SLAVE CYLINDER
1. Seal supply hose to clutch master cylinder with special tool (13 3 010). See Fig. 92 . Remove
transmission underbody protection if necessary. Release union screw (1) on hydraulic line. Release nut
(2) and remove hydraulic line (3) with bracket. See Fig. 93 .
2. Release nut and remove clutch slave cylinder. See Fig. 94 . During installation, clean thrust member (1)
and contact face on release lever (2). Lightly grease thrust member (1) on contact face (3). See Fig. 95 .
3. Bleed hydraulic system. See BLEEDING .
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 92: Sealing Supply Hose To Clutch Master Cylinder

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 93: Removing Union Screw, Nut & Hydraulic Line

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 94: Releasing Nut & Removing Clutch Slave Cylinder

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 95: Identifying Thrust Member, Release Lever & Contact Face
ROLLER BEARING FOR DUAL MASS FLYWHEEL
Remove flywheel. See ENGINE MECHANICAL article. Using hydraulic press (1) and special tool 212051,
press out dual-mass flywheel downwards on engine side. See Fig. 96 . Use care as there is a risk of damage:
roller bearing must not be driven out. Push roller bearing (2) onto special tool 212052. Using hydraulic press
(1), press roller bearing into dual-mass flywheel as far as it will go on clutch side. See Fig. 97 . Observe press-
in instruction.
a. Roller bearing must not be driven in.

b. Roller bearing mounting force/travel monitored:
 Minimum 2000N 1 mm before end of pressing in.
 Maximum 15000N during entire press-in procedure.

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 96: Pressing Out Dual-Mass Flywheel

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 97: Pressing In Dual-Mass Flywheel

SELECTOR SHAFT RADIAL SEAL (GS637BZ)
Remove transfer case. See TRANSFER CASE article. Shift transmission into 2nd gear. Drive out cylinder pin
(2). See Fig. 98 . Screw in special tool (23 0 210) until it is firmly connected with radial seal (1). See Fig. 99 .
Pullout radial seal with special tool (23 0 210). Coat sealing lips of radial seal and selector shaft with gear oil.
Drive in radial seal with special tool (23 0 220). See Fig. 100 .
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 98: Driving Out Cylinder Pin

2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
Fig. 99: Screwing In Tool Until It Is Firmly Connected With Radial Seal
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci

OVERHAUL
NOTE: Overhaul information is not provided.
Clutch Housing To Crankcase
M8 20 (27)
M10 38 (51)
M12 63 (86)
Clutch To Flywheel (X3 & X5)
M8/8.8 18 (25)
M8/10.9 25 (34)
2005 BMW 645Ci
2000-05 CLUTCHES X3, X5 & 645Ci
M8/8.8 11 (15) (1)

Clutch Master Cylinder To Bearing Block 16 (22)
Clutch Master Cylinder Fitting Screw 16 (22)
Clutch Master Cylinder To Pedal Assembly 88 (10)
Clutch Slave Cylinder To Clutch Housing/Transmission Case 16 (22)
Hydraulic Pipes Coupling Bolts 10 (14)
Hydraulic Unit Pressure Accumulator 30 (40)
(1) Tighten an additional 19-31 degrees.
2004 BMW 645Ci
2004 SPECIFICATIONS INDEX 645Ci
2004 SPECIFICATIONS INDEX
645Ci
SPECIFICATIONS INDEX
645Ci SPECIFICATIONS INDEX
System Specification/Procedure
Air Conditioning
Service TECHNICAL DATA
Torque TIGHTENING TORQUES
Axle Shaft Nut
Rear 310 Ft. Lbs. (420 N.m)
Battery BATTERY
Brakes
Bleeding Sequence BRAKES TESTING AND BLEEDING
Disc Brakes TECHNICAL DATA
Torque TIGHTENING TORQUES
Charging
Generator NA
Torque ALTERNATOR WITH DRIVE AND
MOUNTING
Drive Belts
Adjustment BELT ADJUSTMENT
Belt Routing DRIVE BELT ROUTING
Engine Cooling
General Service Specifications COOLING SYSTEM SPECIFICATIONS
Radiator Cap Pressure 21.75 psi (150 kPa)
Pressure is approximate and may vary slightly
by vehicle. See cap top for specification.
Thermostat R & I THERMOSTAT AND CONNECTIONS
Water Pump R & I WATER PUMP WITH DRIVE
Engine Mechanical
Compression ENGINE GENERAL
Oil pressure Oil pressure should be more than 14 psi (96
kPa) at idle and 58-87 psi (400-600 kPa)
control pressure.
Overhaul ENGINE - TECHNICAL DATA
Torque ENGINE - TIGHTENING TORQUES
Fluid Specifications See FLUIDS under MAINTENANCE tab. From
within Manager or Service Writer, click the
"30/60/90 Interval" or Maint." button.
2004 BMW 645Ci
2004 SPECIFICATIONS INDEX 645Ci
Flywheel/Flex Plate Torque FLYWHEEL

Fuel System
Fuel Filter Location In fuel tank, integral with sensor.
Fuel Filter R & I FUEL TRANSFER SENSOR FOR
GAUGE
Pressure Release Procedure NA
Pressure Specification 50 psi (344 kPa)
Fuel Pressure Test Procedure NOTES ON FUEL PRESSURE CHECK
Ignition
Firing Order & Cylinder Identification FIRING ORDER & CYLINDER
INDENTIFICATION
Ignition Wires (Routing) Coil on plug
Spark Plug
Type NGK BKR 6E QUP
Gap Spark plug gap is not adjustable.
Torque 23 Ft. Lbs. (31 N.m)
Starting
Starter STARTER SPECIFICATIONS
Torque TORQUE SPECIFICATIONS
Wheel Alignment
Adjustment Specifications WHEEL ALIGNMENT
SPECIFICATIONS
Torque TORQUE SPECIFICATIONS
Wheel & Tire
Wheel Lug Nut Torque 81-96 Ft. Lbs. (110-130 N.m)
2005 BMW 645Ci
2004-07 ACCESSORIES & BODY, CAB Cellular Phone System - Repair Instructions - 6-Series
Cellular Phone System - Repair Instructions - 6-Series
TRANSCEIVER, HANDSET
84 11 550 REMOVING AND INSTALLING/REPLACING HANDSFREE MICROPHONE
 Remove front roofliner trim, refer to 51 44 ... REMOVING AND INSTALLING FRONT
ROOFLINER TRIM .
Unlock catch (1) and feed hands-free microphone (2) in direction of arrow out of front roofliner trim (3).
Fig. 1: Unlocking Catch And Feed Hands-Free Microphone

2005 BMW 645Ci
Installation:
Arrow on hands-free microphone (2) must point in direction of travel.
84 11 610 REMOVING AND INSTALLING/REPLACING EJECT BOX (CORDLESS KEYPAD

HANDSET)
 00 9 341
Unlock telephone mounting (1) and fold upwards.
Release catch (2) of cover (3) from telephone mounting (1).
Release centre console base (4) in direction of arrow.
Feed out centre console base (4) with cover (3) and remove.
Fig. 2: Releasing Catch Of Cover From Telephone Mounting

Installation:
2005 BMW 645Ci
Installation:
Make sure guide pins (1) of cover (3) are correctly seated in guide of centre console base (4).
Guide pins (1) and catches (2) of cover (3) must not be damaged or missing.
Fig. 3: Identifying Guide Pins Of Cover And Centre Console Base

Turn plug connection (3) in direction of arrow and feed out.

2005 BMW 645Ci
Fig. 4: Turning Plug Connection In Direction Of Arrow

If necessary, unlock antenna plug and disconnect.
Release screws (1).
Remove telephone mounting (2).
Installation:
Make sure cable guide is correctly laid.
Unlock eject box (1) with special tool 00 9 341 and towards top rear out of telephone mounting (2).
2005 BMW 645Ci
Fig. 5: Unlocking Eject Box With Special Tool 00 9 341

Installation:
Make sure eject box (1) is correctly seated.
Installation:
Catches (1) on telephone mounting (2) must not be damaged or missing.

2005 BMW 645Ci
Fig. 6: Identifying Catches On Telephone Mounting

HANDS- FREE SYSTEM MICROPHONE, SPEAKER

84 31 020 REMOVING AND INSTALLING/REPLACING HANDSFREE SYSTEM SPEAKER
 Remove trim panel for pedal assembly refer to 51 45 185 REMOVING AND
INSTALLING/REPLACING TRIM FOR PEDAL ASSEMBLY .
Screw on threaded ring (1) in direction of arrow and remove hands-free system speaker (2) from trim for pedal
assembly (3).
2005 BMW 645Ci
Fig. 7: Removing Hands-Free System Speaker From Trim For Pedal Assembly
2009 BMW 650i
ACCESSORIES AND EQUIPMENT Slide/Tilt Sunroof and Convertible Top - SI Techniques - 6-Series
Slide/Tilt Sunroof and Convertible Top - SI Techniques - 6-Series
54 SLIDE TILT SUNROOF AND CONVERTIBLE TOP

SLIDE_TILT SUNROOF AND CONVERTIBLE TOP REFERENCE CHART
VS-22 es Baugruppe/Group: 54 54 01 04 (077) weltweit Datum/Date: 03/2004 Update: 08/2005
FULLY AUTOMATIC CONVERTIBLE TOP E64
Fig. 1: Identifying Fully Automatic Convertible Top (E64)

Introduction
The electrohydraulic convertible top can be opened and closed automatically. It takes approximately 20 seconds
to open or close the convertible top. The top is moved by hydraulic cylinders. An electric motor engages and
disengages the latching mechanism on the cowl panel. When the convertible top opens it retracts into the
convertible top compartment. The convertible top compartment lid is then automatically closed.
The convertible top can be opened and closed using 2 buttons in the centre console switch cluster.
2009 BMW 650i
Special features of the E64 convertible top:
 The convertible top includes a standing, heated rear glass window.

 The way the convertible top is actuated by the convertible top module (CVM) has been adapted.
 The rollover protection system has been adapted.
 The shape of the convertible top has been adapted to accommodate the standing rear window. The
convertible top tails off into two fins at the rear.
Benefits of the E64 convertible top:
 Heated rear window can be lowered

 Use of rear window as wind deflector, especially for rear-seat passengers
 Good ventilation when the convertible top is closed and the rear window and side windows are open
 Coupe-like design thanks to the fins and the lines of the convertible top dropping off to the rear
New for the E64 convertible top from 09/2005:
 The body gateway module (KGM) supersedes the safety and gateway module (SGM).
 The door modules on the driver's side (TMFA) and front-passenger side (TMBF) are discontinued
 The body gateway module (KGM) actuates the power windows in the front doors
Brief description of components
The components that supply input signals for the electrohydraulic convertible top are as follows:
 Hall sensor for cowl panel locked and Hall sensor for cowl panel unlocked
The two Hall sensors inform the convertible top module whether the convertible top is locked or unlocked
at the cowl panel.
 Hall sensor for convertible top compartment lid lock left and Hall sensor for convertible top
compartment lid lock right
The two Hall sensors inform the convertible top module whether the convertible top compartment lid is
locked or unlocked at the convertible top compartment.
 Hall sensor for convertible top compartment lid locked (left) and Hall sensor for convertible top
compartment lid open
The two Hall sensors inform the convertible top module which the position the convertible top
compartment lid is in.
 Sensor for main pillar and sensor for tensioning bar

2009 BMW 650i
For example, the convertible top compartment is unlocked when the main pillar is at an angle of 107 °.
The tensioning bar sensor supplies the position of the tensioning bar from the angle of rotation. This
allows the system to identify, for example, whether the fins are sufficiently raised.
 Hall sensor for rear window lowered
This Hall sensor monitors the position of the rear window. The convertible top can only be opened or
closed when the rear window has been fully lowered.
 Switch for convertible top compartment floor
The convertible top compartment floor switch informs the convertible top module whether the variable
convertible top compartment is in the lowered position.
 Rear window travel sensor in rear window drive
The rear window travel sensor informs the convertible top module of the position of the rear window.
The following control units are involved in the operation of the electrohydraulic convertible top:
 CVM: Convertible top module
The convertible top module (CVM) controls all electrical and hydraulic functions of the convertible top.
The convertible top module is connected to the K-CAN.
 TMFA, TMBF: Driver's door module, front-passenger door module

 up to 09/2005
The door modules (TMFA and TMBF) actuate the front power windows. Before the convertible top is
opened, the 4 side windows are automatically lowered a little.
The switch block in the driver's door is connected to the driver's door module (TMFA) via a LIN bus.
The power windows can be operated at the switch block in the driver's door.
 from 09/2005
The door modules are no longer fitted from 09/2005. The body gateway module (KGM) actuates the front
power windows. The switch block in the driver's door is connected to the body gateway module (KGM)
via the LIN bus.
The power windows can be operated at the switch block in the driver's door.
 KBM: Body basic module

2009 BMW 650i
The body basic module (KBM) actuates the rear power windows.
Before the convertible top is opened, the 4 side windows are automatically lowered a little.
The body basic module supplies the signal that the boot lid is closed.
The power windows and the lowering rear window can be operated from the switch block in the driver's
door.
 SZM: Centre console switch cluster
The buttons for opening/closing the convertible top and their control LED are located in the centre
console switch cluster (SZM).
The SZM is connected to the K-CAN. The control LED is actuated by the convertible top module via the
K-CAN.
 CAS: Car Access System
The Car Access System (CAS) controls the auto-remote opening of the convertible top.
The signals from the remote control are picked up by the remote control receiver and forwarded to the
CAS.
Auto-remote opening/closing via the lock barrel in the driver's door:
The CAS receives the signal from the driver's door module (TMFA).
 SGM: Safety and gateway module

 up to 09/2005
The safety and gateway module (SGM) is the interface between the door modules and the convertible top
module.
The SGM connects the byteflight, the PT-CAN and the K-CAN.
In addition, the SGM actuates the rollover protection system for the convertible. The rollover protection
system is a subfunction of the "Advanced Safety Electronics" (ASE) passive safety system.
 KGM: Body gateway module

 from 09/2005
The body gateway module (KGM) actuates the front power windows. The switch block in the driver's
door is connected to the body gateway module (KGM) via the LIN bus.
The KGM is the gateway between the PT-CAN and the K-CAN and diagnosis wire.
2009 BMW 650i
 KOMBI: Instrument cluster
The instrument cluster (KOMBI) supplies the following signals:
 Ambient temperature
 Road speed (recorded by the DSC control unit via the wheel-speed sensors)
The instrument cluster displays Check-Control messages concerning the convertible top via the variable
indicator lamp.
 HUD and CID: Head-up display and Central Information Display
The head-up display (HUD) uses the variable indicator lamp and the associated short text to indicate
Check-Control messages relating to the convertible top.
The detailed text that accompanies the short text with the Check-Control message can be called on the
Central Information Display (CID).
The following actuators are activated at the convertible top:
 Convertible top drive
There is a hydraulic cylinder at each of the left and right-hand main pillars. There is also a hydraulic
cylinder on each of the left and right-hand tensioning bars for the fins.
The convertible top drive (motor with hydraulic pump and valve block) controls all movements of the
convertible top via 3 pairs of cylinders.
One pair of cylinders works on each of the:
 Convertible top main pillars

 Convertible top tensioning bars (fins)
 Convertible top compartment lid
The direction of movement of the convertible top (OPEN or CLOSE) is controlled by 2 relays.
3 valves on the valve block execute the following functions:
 Raise the fins

 Lower the fins
 Open and close the convertible top compartment lid
Pressure can be applied to the hydraulic cylinders on both the piston side and the ram side. The direction
of movement of the hydraulic cylinders for the main pillars depends entirely on the direction of rotation
of the hydraulic pump.
2009 BMW 650i
 Cowl panel lock drive
The convertible top lock on the cowl panel is driven by an electric motor.
The catch hooks on the left and right are automatically locked in the cowl panel.
 Rear-window drive
The rear window is driven by an electric motor. The convertible top module actuates the rear-window
drive.
 The direction of movement of the rear window (lower or raise) is controlled by the convertible top
module via 2 relays.
The rear window can also be operated manually using a button on the switch block in the driver's door.
System functions
The electrohydraulic convertible top comprises the following functions:
 Automatic opening and closing of the convertible top with the two buttons in the centre console switch
cluster (SZM)
 Opening and closing of the convertible top with the key and opening the convertible top and the windows
with the remote control
 Emergency closure of the convertible top by hand
 Lowering and raising the rear window
Automatic opening and closing of convertible top with the two buttons in the centre console switch cluster (SZM)
For automatic opening and closing of the convertible top, the following conditions must be satisfied:
 On-board supply voltage greater than 10,5 volts

 Terminal R ON
 Ambient temperature between -20 °C and +80 °C
(signal from instrument cluster)
 Boot lid closed
(signal from boot lid lock via body basic module)
 Road speed lower than 30 km/h
(signal from instrument cluster)

2009 BMW 650i
 Convertible top compartment lowered
(signal from convertible top compartment floor switch)
 Rear window fully lowered
(signal from rear window Hall sensor at bottom of rear-window drive)
 Power window operation enabled
(signal from Car Access System)
To automatically open or close the convertible top, the corresponding button in the centre console switch cluster
must be pressed and held.
The control LED between the buttons in the centre console switch cluster lights up green to indicate that the
convertible top is moving.
Automatic opening runs as follows:
 The side windows are lowered slightly (to protect the window seals).
 The rear window is lowered fully.
 The convertible top is released at the cowl panel.
 The fins and the bow strut are raised (tensioning bar cylinders are retracted)
 The convertible top compartment lid is unlocked and opened.
 The convertible top is folded away into the convertible top compartment.
 The convertible top compartment lid is closed and locked.
 The side windows and the rear window are raised once the convertible top compartment lid has been
locked.
Automatic closing runs as follows:
 The side windows are lowered slightly (to protect the window seals).
 The rear window is lowered fully.
 The convertible top compartment lid is unlocked and opened.
 The convertible top is raised out of the convertible top compartment.
 The convertible top compartment lid is closed and locked.
 The fins are lowered.
 The front of the convertible top is lowered and locked onto the cowl panel.
 The side windows and the rear window are raised once the convertible top compartment lid has been
locked.
2009 BMW 650i
 Movement of the convertible top is interrupted due to a malfunction

 Button not pressed (released) and the convertible top has not reached a secure end position
The control LED in the switch cluster centre console lights up red if the convertible top compartment is raised
and the at the same time a button (OPEN/CLOSE) is pressed.
Check-Control messages are displayed for different malfunction causes.
Check-Control messages are displayed at the same time in the instrument cluster, the central information
display and the head-up display.
Opening and closing convertible top with key; opening convertible top and windows with remote control
There are two different ways of moving the convertible top:
 Opening and closing with the key in the driver's door lock barrel
 Convenience opening with the remote control
Opening and closing with key in driver's door lock barrel
While the convertible top is moving, the key must be held in the "open" or "close" position in the lock barrel.
Auto-remote opening with remote control
While the convertible top is moving, the "Open" button on the remote control must be pressed and held.
Difference to opening with the button in the centre console switch cluster (SZM):
The side windows and rear window are lowered fully and are not raised again.
As there is no anti-trap circuit, convenience closing with the remote control is not possible.
Emergency closure of convertible top by hand
If the electro-hydraulic system should fail, the convertible top can also be closed manually.
Emergency closure runs as follows:
 Fully lower all 4 side windows slightly and the rear window.
 Release the convertible top compartment lid from inside the boot (left and right) and open the convertible
top compartment lid.
 With the help of a second person, lift the convertible top out of the convertible top compartment and raise
the fins.
 Close the convertible top compartment lid.
2009 BMW 650i
 Remove the cover panel in the middle of the bow strut.

 Use the offset hexagon socket (from the on-board tool kit) at the bow strut to lock the convertible top.
Here, the hexagon socket is inserted into the drive for the cowl panel lock.
Lowering and raising the rear window
The convertible top module controls the automatic lowering and raising of the rear window (before and after the
convertible top is opened or closed).
The rear window can also be actuated by pressing the button above the switch block in the driver's door.
It is only possible to lower or raise the rear window under the following conditions:
 Convertible top completely closed

 Convertible top completely open
The rear window is not equipped with an anti-trap circuit.
In an emergency, the rear window can be manually opened or closed:
 Remove the cover panel between the rear-seat head restraints.

 Insert the offset hexagon socket wrench (from the on-board tool kit) in the screw and move the rear
window manually. Anticlockwise means close.
2005 BMW 645Ci
2004-05 ENGINE Cooing Systems - Repair Instructions - E63
2004-05 ENGINE
Cooing Systems - Repair Instructions - E63
COOLANT, CHECKING COOLING SYSTEM

17 00 ... INSTRUCTIONS FOR WORKING ON COOLING SYSTEM.
WARNING: Danger of scalding! Work on the cooling system should only be carried
out when the engine has cooled down.
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.
CAUTION: 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.
Recycling
Catch and dispose of drained coolant.
Instructions For Disassembly/Assembly Of Coolant Hose Fast-Release Couplings
Disassembly Of Fast-Release Coupling
Withdraw lock (1/2), disconnect hose.

2005 BMW 645Ci
Fig. 1: Releasing Lock And Disconnecting Hose

Installation:
Check O-rings (1).

Do not coat O-rings (1) with antiseize agent.
2005 BMW 645Ci
Fig. 2: Locating O-Rings

Assembly Of Fast-Release Coupling
Press in lock (1) before installing fast-release coupling.
Push on hose.
Fast-release coupling must audibly snap into place.

2005 BMW 645Ci
Fig. 3: Assembling Fast-Release Coupling

17 00 005 DRAINING AND ADDING COOLANT (N62)
WARNING: Danger of scalding!
Only carry out work on the cooling system after the engine has cooled
down!
Recycling
Follow instructions for working on cooling system.

2005 BMW 645Ci
Use only recommended coolant.
NOTE: Illustration shows E65:
Draining Coolant:
Open cap (1) on coolant expansion tank.
Fig. 4: Opening Coolant Expansion Tank

Remove front splash guard.
Drain, catch and dispose of coolant from radiator.

2005 BMW 645Ci
Fig. 5: Removing Coolant From Radiator

Remove reinforcement plate.
Open drain plug (1) on engine block.

2005 BMW 645Ci
Fig. 6: Opening Drain Plug On Engine Block

Drain, catch and dispose off coolant.
Installation:
Tightening torque, refer to 11 11 5AZ in COOLING SYSTEM - TIGHTENING TORQUES .
Adding Coolant:
Vent cooling system and check for leaks.
17 00 009 CHECKING COOLING SYSTEM FOR WATER LEAKS

2005 BMW 645Ci
NOTE: For special tools, refer to COOLING SYSTEM - SPECIAL TOOLS - 645CI .
 17 0 101
 17 0 113
 17 0 114
Only perform this work after engine has cooled down.
NOTE: Illustrations show M54:
Checking Pressure Drop In Cooling System:
Open cap on coolant expansion tank. Fit special tools 17 0 101 / 17 0 113.
Build up gauge pressure of 2 bar, wait approx. 2 minutes.
Cooling system is impervious to leaks if pressure drop is max.
0.1 bar.
2005 BMW 645Ci
Fig. 7: Checking Cooling System Pressure Drop

Checking Pressure Relief Valve In Cap:
NOTE: Coolant residue can cause the pressure relief valve in the cap to stick, therefore
repeat the check procedure on the cap 2-3 times.
Screw cap (1) onto special tool 17 0 114.
Build up pressure with special tool 17 0 101 (hand pump);
observe pressure gauge to ascertain when opening pressure is achieved.
Opening pressure of pressure relief valve.

2005 BMW 645Ci
Fig. 8: Installing Cap Onto Special Tool 17 0 114

17 00 039 VENTING COOLING SYSTEM AND CHECKING FOR LEAKS (N62)
Open sealing cap only after engine has cooled down.
No vent plugs on radiator and thermostat housing.
Cooling system is vented while it is filled and during subsequent idle operation.
NOTE: Before filling, turn on ignition. Set blower to low level. Seat heating controller to
maximum temperature. This ensures that the heater valves are fully opened and
the auxiliary water pump starts up.
2005 BMW 645Ci
IMPORTANT: The auxiliary water pump must deliver coolant in order to ensure fully venting!
Installation:
Use only recommended coolant.
Check cooling system for leaks.
Illustration Shows E65/E66:
Perform filling operation slowly.
Pour coolant into expansion tank (1) up to MAX mark.
Start engine and run at idle speed for approx. one minute (cap open). Then adjust coolant level to MAX.
Fig. 9: Locating Expansion Tank Coolant Filling Mark (E 65/E 66)

2005 BMW 645Ci
Close cap and run engine up to operating temperature until main thermostat opens. Check cooling circuit and
drain plug for leaks.
Illustration Shows E60/E61/E63/E64:
Perform filling operation slowly.
Pour coolant into expansion tank up to MAX mark.
Start engine and run at idle speed for approx. one minute (cap open). Then adjust coolant level to MAX.
Close cap and run engine up to operating temperature until main thermostat opens. Check cooling circuit and
drain plug for leaks.
Fig. 10: Locating Expansion Tank Coolant Filling Mark (E 60/E 61/E 63/E 64)
2005 BMW 645Ci
temperature must not exceed 30 °C. If ambient temperature is above 30°C,

allow engine to cool down to ambient temperature at least.
Check coolant level and adjust to MAX.
NOTE: Do not fill coolant expansion tank over MAX level as overfilling will cause the
coolant to overflow.
ENGINE RADIATOR WITH ATTACHMENT

REMOVING RADIATOR COVER
NOTE: Illustrations show N62:
Release screws along line.
Unclip Bowden cable (1).
Remove cover (2).
Fig. 11: Loosening Bowden Cable And Removing Cover

2005 BMW 645Ci
NOTE: Illustrations show N62:
Unclip line (1).
Unfasten screws.
Remove module carrier cover (2).
Fig. 12: Removing Module Carrier Cover

17 11 000 REMOVING AND INSTALLING RADIATOR (N62)
 Follow instructions for working on cooling system.

 Remove fan cowl
 Remove front engine underguard
 Drain coolant
2005 BMW 645Ci
 Detach heat exchanger for automatic transmission from radiator.

 Unlock and detach all coolant hoses on radiator.
Remove radiator (1) towards top.
Fig. 13: Removing Radiator

Installation:
Ensure correct seating in side guides.
Top up coolant.
17 11 035 REMOVING AND INSTALLING/REPLACING FAN COWL WITH ELECTRIC FAN (N62)
2005 BMW 645Ci
 Read out fault memory of DME control unit

 Switch off ignition
 Remove radiator cover
Unlock plug (1) on AUC sensor and disconnect.
Unlock plug (2) and remove.
NOTE: Modify AUC sensor when replacing fan cowl.
Fig. 14: Disconnecting And Removing AUC Sensor

Raise fan cowl (1) approx. 3 cm.

2005 BMW 645Ci
Fig. 15: Raising Fan Cowl

NOTE: For purposes of clarity, this work step is shown on the fan cowl after it has
been removed.
Fold in left retaining tab (1) in direction of arrow.

2005 BMW 645Ci
Fig. 16: Folding In Left Retaining Tab

Remove fan cowl (1) in direction of arrow.

2005 BMW 645Ci
Fig. 17: Removing Fan Cowl

Check stored fault messages.
Clear DME fault memory.
17 11 046 REMOVING AND INSTALLING/REPLACING MODULE CARRIER
 Remove radiator cover.

 Remove fan cowl with electric fan
 Drain coolant
 Remove radiator
 Draw off fluid from power steering
Installation:
Bleed power steering unit, refer to 32 13 006 BLEEDING POWER STEERING UNIT .
 Unlock hydraulic lines on cooling loop and disconnect

 Secure A/C condenser against damage and against falling down.
2005 BMW 645Ci
Press lock (1) and remove holder (2) downwards.
Fig. 18: Pressing Lock And Removing Holder

Illustration shows the left holder: The same procedure applies to the opposite side.
Installation:
Rubber mounts fall out easily, ensure correct installation position.
Remove module carrier (1) towards bottom.

2005 BMW 645Ci
Fig. 19: Removing Module Carrier

When replacing module carrier:
Convert power steering cooling loop.
17 11 100 REMOVING AND INSTALLING/REPLACING COOLANT EXPANSION TANK (N62)
 Drain coolant from radiator
Release and disconnect coolant hoses (1).
Unlock plug on coolant level sensor and disconnect.
Unfasten screws.
Remove coolant expansion tank (2).

2005 BMW 645Ci
Fig. 20: Removing Coolant Expansion Tank

Installation:
Insert locating pin in rubber grommet.
Check cooling system for leaks.
17 11 370 REMOVING AND INSTALLING/REPLACING COOLING LOOP FOR POWER

STEERING
 Remove module carrier
Recycling:
2005 BMW 645Ci
Catch and dispose of hydraulic fluid.
Fig. 21: Removing Cooling Loop

Release retaining clip (1) on left.
Unfasten screws.
IMPORTANT: Risk of damage to connecting pipes.
Carefully press cooling loop (2) on right towards front, then unclip on left and remove from module carrier (3).
OIL COOLER
2005 BMW 645Ci
17 21 500 FLUSHING OIL COOLER WITH LINES (AUTOMATIC TRANSMISSION)
 17 2 018
 17 2 019
NOTE: Carry out the work steps listed when:
Fitting a new or replacement transmission
Flushing can only be carried out with the automatic transmission removed.
Procedure:
Automatic transmission removed.
Connect appropriate adapters (see description below) to oil lines exiting from automatic transmission.
Connect the connecting line 17 2 019 from the oil collection unit with the quick-release coupling.
Connect drain line 17 2 018 using quick-release coupling.
Feed open end of drain line into a suitable collection container.
Using oil collection unit, flush approx. 1 liter of transmission fluid (refer to OPERATING FLUIDS -
AUTOMATIC TRANSMISSION ) through oil lines and oil cooler.
Reposition quick-release couplings.
Flush oil lines/oil cooler in opposite direction with approx. 1 liter of transmission fluid (refer to OPERATING
FLUIDS - AUTOMATIC TRANSMISSION ).
Disconnect quick-release couplings, remove adapters.
NOTE: Dispose of flushing oil properly; do not under any circumstances reuse it.
Arrangement of Flushing Device For Transmissions A5S 310Z, A5S 560Z, A5S 360R/390R, A4S 200R, A5S 325Z,
GA6HP26Z
2005 BMW 645Ci
Fig. 22: Identifying Transmission Flushing Device

Arrangement Of Flushing Device For Transmission A4S 310R

2005 BMW 645Ci
Fig. 23: Identifying Transmission Flushing Device (A4S 310R)

Arrangement Of Flushing Device For Transmission A4S 300J

2005 BMW 645Ci
Fig. 24: Identifying Transmission Flushing Device (A4S 300J)

Arrangement Of Flushing Device For Transmission A5S 440Z

2005 BMW 645Ci
Fig. 25: Identifying Transmission Flushing Device (A5S 440Z)

OIL COOLER LINES

17 21 500 FLUSHING OIL COOLER WITH LINES (AUTOMATIC TRANSMISSION)
2005 BMW 645Ci
 17 2 018
 17 2 019
NOTE: Carry out the work steps listed when:
Fitting a new or replacement transmission
Flushing can only be carried out with the automatic transmission removed.
Procedure:
Automatic transmission removed.
Connect appropriate adapters (see description below) to oil lines exiting from automatic transmission.
Connect the connecting line 17 2 019 from the oil collection unit with the quick-release coupling.
Connect drain line 17 2 018 using quick-release coupling.
Feed open end of drain line into a suitable collection container.
Using oil collection unit, flush approx. 1 liter of transmission fluid (refer to OPERATING FLUIDS -
AUTOMATIC TRANSMISSION ) through oil lines and oil cooler.
Reposition quick-release couplings.
Flush oil lines/oil cooler in opposite direction with approx. 1 liter of transmission fluid (refer to OPERATING
FLUIDS - AUTOMATIC TRANSMISSION ).
Disconnect quick-release couplings, remove adapters.
NOTE: Dispose of flushing oil properly; do not under any circumstances reuse it.
Arrangement Of Flushing Device For Transmissions A5S 310Z, A5S 560Z, A5S 360R/390R, A4S 200R, A5S 325Z,
GA6HP26Z
2005 BMW 645Ci
Fig. 26: Identifying Transmission Flushing Device

Arrangement Of Flushing Device For Transmission A4S 310R

2005 BMW 645Ci
Fig. 27: Identifying Transmission Flushing Device (A4S 310R)

Arrangement Of Flushing Device For Transmission A4S 300J

2005 BMW 645Ci
Fig. 28: Identifying Transmission Flushing Device (A4S 300J)

Arrangement Of Flushing Device For Transmission A5S 440Z

2005 BMW 645Ci
Fig. 29: Identifying Transmission Flushing Device (A5S 440Z)

17 22 010 REMOVING AND INSTALLING/REPLACING HEAT EXCHANGER FOR AUTOMATIC

TRANSMISSION
2005 BMW 645Ci
 17 0 030
 Follow instructions for working on cooling system

 Drain coolant from radiator
 Remove engine underbody protection
Recycling
Transmission fluid emerges when oil lines are detached from heat exchanger.
Catch and dispose of escaping transmission fluid.
Release catch (1) in direction of arrow.
Disengage mounting plate (2) in direction of arrow.

2005 BMW 645Ci
Fig. 30: Releasing Catch And Disengaging Mounting Plate

Installation:
Engage mounting plate (2) in mounting (3).
Unlock hydraulic lines (1 and 2) on heat exchanger (3) with special tool 17 0 030 and disconnect.
2005 BMW 645Ci
Fig. 31: Releasing Hydraulic Lines On Heat Exchanger With Special Tool
Installation:
Connect hydraulic line (2) with TOP marking to upper pipe of heat exchanger.
Release screws (1).
Remove heat exchanger (2) in direction of arrow.

2005 BMW 645Ci
Fig. 32: Removing Heat Exchanger

IMPORTANT: Check fluid level in automatic transmission.
Top up coolant and vent cooling system.

2005 BMW 645Ci
ACCESSORIES & BODY, CAB Distance & Cruise Control Systems - E60, E63, E65, & E66
ACCESSORIES & BODY, CAB
Distance & Cruise Control Systems - E60, E63, E65, & E66
ACTIVE CRUISE CONTROL E60, E61, E63, E64, E65, E66
Fig. 1: Identifying Active Cruise Control

INTRODUCTION
In 04/2000, Active Cruise Control (system supplier: BOSCH) was installed for the first time in a BMW as
special equipment for the E38.
Active cruise control is an extension of the conventional cruise-control system (FGR). A comfortable distance
and cruise control has been added to this. The distance from the vehicle ahead can be selected from 4 fixed
timed separations. (EURO version: 1.0 - 1.5 - 2.0 - 2.5 seconds) Thus the spatial distance from the vehicle in
front changes with the speed.
2005 BMW 645Ci
With Active Cruise Control activated, a speed in the range from 30 km/h to 180 km/h can be preselected.
IMPORTANT: Cruise control does not relieve the driver of his personal responsibility. The
Active Cruise Control option is a comfort system. Adjustments by the driver
will always have a higher priority (= importance) than cruise control. The driver
should decide whether (and how) the system is used based on road and traffic
conditions and visibility.
The 2nd generation (ACC 2) Active Cruise Control option 541 will be introduced for the first time in 09/2004
on the E63/E64.
With the model year measures in March 2005, Active Cruise Control (ACC 2) will be introduced in more
models: E60, E61, E65, E66.
 E60, E61, E63, E64 before 09/2005, for more information, refer to SYSTEM OVERVIEW FOR
ACTIVE CRUISE CONTROL: E60, E61, E63, E64 UP TO 09/2005:.
 E60, E61, E63, E64 from 09/2005, for more information, refer to SYSTEM OVERVIEW FOR
ACTIVE CRUISE CONTROL: E60, E61, E63, E64 FROM 09/2005.
 E65, E66 as from 03/2005, for more information, refer to SYSTEM OVERVIEW FOR ACTIVE
CRUISE CONTROL: E65, E66 FROM 03/2005.
Changes in ACC 2 compared to ACC 1 (in E38, E65 and E66 by 03/2005):
 Radar sensor now has 4 radar antennae instead of just 3
This means the area covered by the radar sensor is widened from +/-4° to +/-8°.
 The system is approximately 60 % smaller.
With the model year measures, the following changes to the Active Cruise Control option will be introduced in
March 2005:
> E60, E61, E63, E64 only
Additional scope of operation in combination of Car Communication Computer (CCC) with Professional
navigation system option 609.
The dynamics of the Active Cruise Control change according to the characteristics of the roads. (The roads are
split into road categories, e.g. motorways and highways. In addition, the general the number of bends on the
route ahead is analyzed, i.e. if there are a lot of bends ahead, or just a few, as well as the radii of the bends.)
The advantages:
In comparison with the previous ACC, ACC 2 offers the following advantages:
2005 BMW 645Ci
 The widened surveillance range of the radar sensor means that Active Cruise Control now works much
better when cornering.
 Vehicles in front are monitored earlier
 Longer, more stable monitoring when following a vehicle (even in cases of tight bends)
SYSTEM OVERVIEW FOR ACTIVE CRUISE CONTROL: E60, E61, E63, E64 UP TO 09/2005:
Inputs/outputs
Fig. 2: Identifying Active Cruise Control Inputs/Outputs: E60, E61, E63, E64 Up To 09/2005
System circuit diagram

2005 BMW 645Ci
Fig. 3: Identifying Active Cruise Control System Circuit Diagram: E60, E61, E63, E64 Up To 09/2005
SYSTEM OVERVIEW FOR ACTIVE CRUISE CONTROL: E60, E61, E63, E64 FROM 09/2005
Inputs/outputs
2005 BMW 645Ci
Fig. 4: Identifying Active Cruise Control Inputs/Outputs: E60, E61, E63, E64 From 09/2005

2005 BMW 645Ci
Fig. 5: Identifying Active Cruise Control System Circuit Diagram: E60, E61, E63, E64 From 09/2005
SYSTEM OVERVIEW FOR ACTIVE CRUISE CONTROL: E65, E66 FROM 03/2005
Inputs/outputs
2005 BMW 645Ci
Fig. 6: Identifying System Overview For Active Cruise Control Inputs/Outputs: E65, E66 From 03/2005

2005 BMW 645Ci
Fig. 7: Identifying System Overview For Active Cruise Control System Circuit Diagram: E65, E66 From
03/2005
The Active Cruise Control option consists of the following components:
 ACC sensor with control unit
The ACC sensor and control unit form a single unit.
The ACC sensor monitors the distance, angle and relative speed of vehicles driving ahead. (Relative
speed: The relative speed is the difference in speed between the two moving objects, i.e. relative to each
other.)
The ACC sensor is a radar sensor. The ACC sensor has a limited monitoring range (approximately 120
2005 BMW 645Ci
For more information, refer to ACC SENSOR WITH CONTROL UNIT: E60, E61, E63, E64, E65,
E66.
 Cruise control system steering-column stalk
Cruise control is set and called up using the Active Cruise Control system steering-column stalk.
For more information, refer to STEERING COLUMN STALK FOR ACTIVE CRUISE CONTROL:
E60, E61, E63, E64, E65, E66.
 2 brake pressure sensors
A brake pressure sensor is installed in each of the front and rear axle brake circuits. The signals from the
brake pressure sensors are evaluated by the Dynamic Stability Control.
If Active Cruise Control is in use, the vehicle will be braked as necessary by the Dynamic Stability
Control (DSC) (not DSC intervention). The brake pressure sensors regulate the brake pressure, which is
often only very slight, on the front and rear axles.
 Vehicles with DSC 8Plus:
The brake pressure sensors have been discontinued on vehicles with DSC 8Plus. DSC 8Plus is an
advanced development of the familiar DSC 8.
In addition, the ACC control unit communicates with the following control units:
 DME or DDE: Digital engine electronics or digital diesel electronics
The DME/DDE controls the engine intervention. The following data is transmitted by the ACC sensor to
the DME or DDE:
 Current torque request
The following data is transmitted from the DME or DDE to the ACC sensor:
Driver's command (signals from accelerator pedal module)

 SGM: Safety and gateway module
The SGM is the gateway (= data interface) between:
> E65, E66 as well as
E60, E61, E63, E64 up to 09/2005:
 PT-CAN
K-CAN
2005 BMW 645Ci
 Byteflight
The diagnostics cable is also connected at the SGM.
> E60, E61, E63, E64 from 09/2005
The body-gateway module replaces the safety and gateway module (SGM).
 KGM: Body-gateway module
> E60, E61, E63, E64 from 09/2005
The KGM is the gateway (= data interface) between:

 PT CAN
 K-CAN
The diagnosis lead is also connected at the KGM.
 DSC: Dynamic Stability Control
The current status of the vehicle is detected by the DSC, for example by evaluating the following sensor
signals:
 Yaw rate (measure of movement of the car about its vertical axis)
 Steering angle
 Information on the brake pressure
 Circumferential wheel speed
DSC then transmits data about current operating conditions to the ACC sensor.
The following data is transmitted by the ACC sensor to the DSC:
 Request for vehicle deceleration:
DSC receives the request for vehicle deceleration from the Active Cruise Control via the PT-CAN.
DSC reduces the speed. To do this, DSC intervenes in the brake system. (goal: comfortable vehicle
deceleration. No DSC intervention in the sense of enhanced operating stability.)
With automatic braking, the brake lights are actuated depending on the vehicle deceleration and the
gradient of the road (legally prescribed).
 FPM: Accelerator pedal module
The accelerator pedal module signals the driver's command. This signal is required to check the
2005 BMW 645Ci
By pressing the accelerator pedal, the speed setpoint of the Active Cruise Control can be overridden at
any time.
 Brake light switch
The brake light switch tells the Active Cruise Control when the brake pedal has been pressed. Active
Cruise Control is deactivated if braking actions are necessary.
 Clutch module (manual transmission only)
Clutch engagement/disengagement is recognized by the signal from the clutch module.
During the clutch engagement/disengagement process, the engine speed is maintained at an optimal speed
range by the DME or DDE.
After the clutch has been reengaged, the DME/DDE will adjust back to the current torque request from
the Active Cruise Control.
If the engine speed is too high or too low, an audible signal and a Check Control message prompt the
driver to change gear. The prompt to upshift when the engine speed is too high is only made during the
warm-up phase of the engine.
If no gearshift or change in engine speed is made within approximately 5 seconds of such a signal being
given, Active Cruise Control will be deactivated.
If the clutch is disengaged for longer than about 6 seconds, Active Cruise Control (ACC) will be
deactivated.
Active Cruise Control cannot be activated in 1st gear.
Active Cruise Control is automatically deactivated in the "neutral gate" (i.e. no gear engaged and clutch
not depressed).
IMPORTANT: Only install prescribed rear differential unit. Active Cruise Control has a variant
coding which is coordinated with the differential ratio. If a different rear
differential unit is installed, it may be the case that the Active Cruise Control
will deactivate itself in manual transmissions, particularly in the higher gears.
In this case, no fault is entered in the fault memory.
 EGS and SMG: electronic transmission control and sequential manual transmission
 Electronic transmission control
The electronic transmission control evaluates the data from the DME/DDE and ACC sensor.
The adaptive transmission control (constituent component of electronic transmission control)

adapts the shift characteristics of the driving program to the driver's commands and the driving
2005 BMW 645Ci
situation.
 Sequential manual transmission
No automatic upshift in manual mode.
In order to prevent excessively high engine speeds, an audible signal and Check-Control message
prompt the driver to change gear. The prompt to upshift when the engine speed is too high is only
made during the warm-up phase of the engine.
The following data is transmitted from the ESG or SMG to the ACC sensor:
 gear engaged
 status information about gearshifts
The ACC sensor transmits the following data to the EGS/SMG:
current operating status

 current torque request
 LM: Light module
When Active Cruise Control is in operation, the brake lights are actuated during automatic braking (legal
requirement). This requires a signal sent via the K-CAN to the light module.
Active Cruise Control uses the "turn signals" signal from the light module for assistance when changing
lanes. In other words, if a left turn signal is given before overtaking, the distance to the vehicle in front is
reduced. The vehicle to be overtaken is "ignored" more easily. Conversely, when you move back into the
right lane, vehicles being driven there will be monitored more quickly.
 SZL: Steering column switch cluster
The SZL processes all data from the cruise-control system steering-column stalk.
> E65, E66 as well as E60, E61, E63, E64 before 09/2005
The SZL is connected to the safety and gateway module (SGM) via the byteflight . The SGM creates the
connection to the bus system. The SGM connects the SZL with the remaining buses.
> E60, E61, E63, E64 from 09/2005
The SZL is connected to the bus system via the PT-CAN.
 Displays in the instrument cluster
For Active Cruise Control, the following displays are available in the instrument cluster:
2005 BMW 645Ci
 Set speed via an indicator disc
(Set speed = selected km/h of the cruise control system)
 Monitored vehicle
(Display through lit up icon)
 Request for action to driver
(Display through flashing icon. In addition, an audible warning is made.)
 Selected distance from vehicle driving ahead
(Display via icon)
 The LCD display briefly shows the newly selected set speed (approximately 6 seconds).
 Check-Control message in LCD display
For more information, refer to ACTIVE CRUISE CONTROL DISPLAYS IN INSTRUMENT

CLUSTER: E60, E61, E63, E64, E65, E66.
 M-ASK or CCC and CID: Multi-audio system controller/Car Communication Computer and
Central Information Display
> E60, E61, E63, E64 only
For the instrument cluster, the M-ASK and CCC serve as an interface to the Central Information Display
(CID).
Amongst other things, the CID displays detailed information about the Check-Control messages. To back
up the Check-Control message, the M-ASK /CCC emit audible warnings through the loudspeakers
(depending on national version). The instrument cluster assumes control over these warnings via the K-
CAN.
 CCC with Professional navigation system option 609:
Only in the combination of CCC with Professional navigation system option 609 are the additional scopes
of operation possible for the dynamics control behavior.
 CD: Control Display
> E65, E66 only
The Control Display is the central display for the information and communication system.
2005 BMW 645Ci
The Control Display is used as an interface between the MOST and K-CAN data buses. (MOST stands
for "Media Oriented System Transport"; K-CAN stands for "Body Controller Area Network".)
Amongst other things, the Control Display displays detailed information about the Check-Control
messages. The instrument cluster controls these warnings by means of the K-CAN.
 CAS: Car Access System
The CAS provides input signals relating to terminal status (e.g. terminal 15 ON).
 HUD: Head-up display
> E60, E61, E63, E64 only
The Head-up display (option 610) displays the following information:
 Set speed
 Object ahead monitored
 Request for action to driver
 Timed separation setting
 Check-Control messages
ACC Sensor With Control Unit: E60, E61, E63, E64, E65, E66
Installation location
The ACC sensor with control unit is installed in the front of the vehicle, under the bumper.
2005 BMW 645Ci
Fig. 8: Locating ACC Sensor With Control Unit: E60, E61, E63, E64, E65, E66
Design
2005 BMW 645Ci
Fig. 9: Identifying ACC Sensor With Control Unit Design: E60, E61, E63, E64, E65, E66
Pin assignments
PIN ASSIGNMENTS FOR CONNECTOR X1783, 8-PIN

1 M Terminal 31 (earth)
2 E/A PT CAN High
3 E/A PT CAN Low
4 E ACC control unit wake-up wire
5 --- ---
6 --- ---
7 --- ---
8 V Voltage supply, terminal 30g (active)
E = Input
2005 BMW 645Ci
E/A = Input/Output
M = Earth
V = Supply
For current specifications regarding pin assignments, please refer to BMW diagnosis system
How it works
The Active Cruise Control option can be activated from speeds of 30 km/h upwards.
The ACC sensor is always activated once a speed of approximately 15 km/h has been reached (standby for
activation). This means that cruise control is ready for immediate action when it is switched on.
Fig. 10: Identifying Radar Beams

The ACC sensor senses the monitoring range in front of the vehicle with 4 radar beams.
The monitoring range is between approx. 2-120 meters.
The transmission frequency of the ACC sensor is approx. 76 GHz. This means the sensor range is constantly
monitored.
2005 BMW 645Ci
 Horizontal opening angle: +/-8°

 Vertical opening angle: +/-4°
Each radar beam is emitted by an antenna which also receives the reflected radar beams.
Measurement of distance and relative speed
The ACC control unit determines the distance and relative speed from the frequency spectrums as follows:
 The distance is calculated from the time lag of the frequency spectrums.
 The relative speed is calculated using the Doppler effect.
The Doppler effect is a law of physics: if the object is moving towards the transmitter, the frequency of
the reflected radar wave will be higher.
If the object is moving away from the transmitter, the frequency of the reflected radar wave will be lower.
2005 BMW 645Ci
Fig. 11: Identifying Measurement Of Distance And Relative Speed

Determination of the angle
If an object is in the monitoring range, the reflected radar waves are received depending on the angle between
the wheel axis and the object:
The 4 antennae receive different amplitudes.
Example of how to determine the angle:
The diagram shows the vehicle with its 4 radar beams.
The vehicle ahead is in the range of radar beams 3 and 4.
Fig. 12: Determining Angle Of Radar Beams

2005 BMW 645Ci
Steering Column Stalk For Active Cruise Control: E60, E61, E63, E64, E65, E66
Active cruise control (ACC) is operated with the lower left-hand stalk on the steering column.
How it works
Fig. 13: Identifying Operation Of Steering Column Stalk For Active Cruise Control: E60, E61, E63, E64,
E65, E66
The signals from the steering-column stalk are processed by the steering column switch cluster (SZL).
The following signals are transmitted by the cruise-control system steering-column stalk to the SZL:
 Active cruise control activated/not activated

2005 BMW 645Ci
 Timed separation changed
The range of adjustments for Active Cruise Control are described in the Owner's Handbook.
Active Cruise Control Displays In Instrument Cluster: E60, E61, E63, E64, E65, E66
All relevant displays for Active Cruise Control are in the instrument cluster.
Fig. 14: Identifying Instrument Cluster Display (E60, E61, E63, E64)
2005 BMW 645Ci
Fig. 15: Identifying Instrument Cluster Display (E65 And E66)

How it works
The check control messages show information and warnings to Active Cruise Control.
The check control messages are displayed in the LC display.

2005 BMW 645Ci
Fig. 16: Identifying Check-Control Messages In Instrument Cluster (E60, E61, E63, E64)
2005 BMW 645Ci
Fig. 17: Identifying Check-Control Messages In Instrument Cluster (E65 And E66)
SYSTEM FUNCTIONS
The system functions of the Active Cruise Control option are described below:
 Monitor object ahead

 Cruise control
 Lens heating
 Low-voltage cutout and high-voltage protection for ACC sensor
 Self-diagnosis and compensation for minor horizontal adjustments
 Influence on the dynamics in connection with a navigation system
 System limits
Monitor object ahead

2005 BMW 645Ci
Objects are all vehicles in the same lane. The vehicles in other lanes are of no interest for the Active
Cruise Control option.
In the same lane, the vehicle immediately ahead is selected as the object.
With the calculated expected same lane, the lateral deviation of each monitored object to the same lane
can be determined.
The radar waves received cannot distinguish between animals, vehicles and traffic signs. In order to
prevent incorrect reactions, stationary objects and traffic in the other direction are ignored in the distance
control.
CRUISE CONTROL
The Active Cruise Control option differentiates between 2 driving conditions:
 Cruise control with specified set speed
A selected set speed (in the range 30 km/h - 180 km/h) is automatically maintained on open roads without
vehicles driving ahead.
 Cruise control with speed adapted to that of vehicle driving ahead
If a slower vehicle is detected in the vehicle's own lane, the vehicle's own speed will be adapted to that of
the vehicle driving ahead.
At the same time, a distance from this vehicle preset by the driver is established (4 fixed, timed
separations can be selected).
The timed separation from a vehicle driving ahead is no less than 1 second under stationary conditions. In
certain conditions (e.g. when a vehicle cuts in a short distance ahead), this timed separation may briefly
be less than 1 second.
LENS HEATING
The lens of the ACC sensor is made of plastic. The built-in lens heating ensures better availability of the Active
Cruise Control option in winter weather conditions.
The lens heating is activated by the ACC sensor. The heating is controlled via a pulse-width modulated signal
(PWM signal). The heating coil is integrated into the lens of the ACC sensor
The lens heating is only activated within a certain ambient temperature range (approximately +5 °C to -5 °C).
Reason: Only at temperatures around zero is snow wet or moist. At temperatures well below this, snow will be
dry. To prevent snow from thawing on the lens and creating an artificial coating, the heating is switched off
below a certain ambient temperature. The current ambient temperature value is transmitted by the instrument
cluster.
2005 BMW 645Ci
 Conditions for activation

 Engine ON
 ACC ON
 Ambient temperature between -5 °C and +5 °C
 Safety cutout
 Temperature in ACC sensor over 50 °C
(measured by interior temperature sensor in ACC sensor control unit)
 Voltage greater than 16 volts
The safety cutout shuts down the lens heating. The Active Cruise Control option remains activated.
(No fault memory entry)
 Monitoring
The lens heating is monitored for open and short circuits in the heating coil.
If the monitoring reports a fault, the Active Cruise Control option will be shut down. (Fault memory
entry)
LOW-VOLTAGE CUTOUT AND HIGH-VOLTAGE PROTECTION FOR ACC SENSOR
The ACC sensor works with a supply voltage of 9 to 16 volts.
 Low-voltage cutout
If the on-board supply voltage drops below about 9 volts, the ACC sensor will perform a low-voltage
cutout and a fault memory entry will be stored.
The ACC sensor will be reactivated when the on-board supply voltage exceeds 9.8 volts again.
 Overvoltage protection
If the on-board supply voltage exceeds about 17.5 volts, the ACC sensor will perform a cutout with a fault
memory entry.
The ACC sensor will be reactivated when the on-board supply voltage drops below 17.0 volts again.
SELF-DIAGNOSIS AND COMPENSATION FOR MINOR HORIZONTAL ADJUSTMENTS
External forces may change the alignment of the ACC sensor. A horizontal change leads to function limitations.
(Function limitations encountered are, e.g.: reaction to vehicles in the next lane or late reaction to vehicles in the
same lane).
2005 BMW 645Ci
Self-diagnosis allows the ACC sensor to compensate for minor horizontal adjustments of up to 1°.
If a horizontal adjustment of more than 1° is detected, the Active Cruise Control option will be deactivated and
a fault will be stored in the fault memory. A Check-Control message will be issued.
INFLUENCE ON THE DYNAMICS IN CONJUNCTION WITH A NAVIGATION SYSTEM
If the Active Cruise Control is coupled with a navigation system, this may have an influence on the dynamics.
(Only possible in combination of CCC with the Professional navigation system option 609.)
Navigation systems provide additional information, such as the course of the road and the road category.
The road category is split up as follows:
 Motorways and well finished fast roads
(faster acceleration)
 Main roads and highways
(average acceleration)
 Urban driving
(reduced acceleration)
On motorways and well finished fast roads, Active Cruise Control is expected to be highly dynamic. In other
words, faster acceleration if the driving mode changes from following a car ahead to clear road ahead. The set
speed is adjusted quickly.
On main roads and highways, Active Cruise Control is expected to be averagely dynamic. In other words,
comfortable acceleration if the driving mode changes from following a car ahead to clear road ahead. The set
speed is adjusted with an average acceleration behavior.
During urban driving, a reserved dynamic is expected of the Active Cruise Control. In other words, reduced
acceleration behavior if the driving mode changes from following a car ahead to clear road ahead. The set speed
is adjusted moderately.
The often difficult traffic situations during urban driving make reduced acceleration behavior necessary.
In addition, the number of bends on the road ahead is analyzed and the dynamic of the Active Cruise Control
adjusted accordingly.
SYSTEM LIMITS
If the limit of the functional range is reached, the driver is prompted to act (brake or swerve).
2005 BMW 645Ci
During operation, the following system functions requiring explanation (for the driver) can occur due to the
limits of the functional range:
 Limited range and deceleration:

 The range of the ACC sensor is limited (approximately 120 meters).
Rain, snow and fog absorb radar waves.
This will significantly reduce the range of the ACC sensor.
 The Active Cruise Control option is only able to effect limited deceleration via the DSC (dynamic
stability control) (a maximum of 2.5 m/s2 ; E65, E66: a maximum of 2.0 m/s2 ). This means that
cruise control is only able to compensate for a limited relative speed.
Operation of the Active Cruise Control is only possible in flowing traffic in a road speed range
from 30 km/h to 180 km/h.
 Lateral monitoring range
The lateral monitoring range of the ACC sensor is limited, meaning that a monitored vehicle ahead could
be lost due to a tight bend.
In such cases, cruise control will not accelerate to the set speed for approximately 2 seconds. This will
prevent the vehicle from accelerating too close to the vehicle ahead, which is possibly only briefly not
being monitored.
When driving straight ahead, this can cause a delayed reaction to another vehicle cutting in close in front.
The vehicle cutting in will not be monitored by the cruise control until it is clearly in the same lane as the
vehicle with the Active Cruise Control option.
 Display for monitored vehicle does not light up, the vehicle remains below the set speed and does
not accelerate further.
Causes:
 On sharp bends, the vehicle's speed will be controlled in such a way that lateral acceleration does
not exceed a maximum of 4.0 m/s2 to maintain driving comfort.
 Timed separation less than 1 second
The timed separation from a vehicle driving ahead is no less than 1 second in the adjusted status. In
certain conditions (e.g. when a vehicle cuts in a short distance ahead), this timed separation may briefly
be less than 1 second.
If the deceleration induced by the cruise control is not sufficient, the driver will have to intervene directly.
2005 BMW 645Ci
If the ACC sensor is blinded, the Active Cruise Control option shuts down. (Blinding, e.g. due to
extremely heavy snowfall, through a layer of ice on the sensor or through dirt)
Cruise control can be reactivated after the ACC sensor has been cleaned.
 Bends cannot be detected in an anticipatory manner
The cruise control is unable to work in an anticipatory manner when the vehicle is cornering. It is only
able to react to existing lateral acceleration when it is already on the bend. For this reason, the driver is
responsible for ensuring that an appropriate speed is being driven as the vehicle enters the bend.
 Active Cruise Control deactivated after DSC intervention or brake application by the driver
Cruise control will be deactivated following DSC intervention or a brake application by the driver. (DSC
intervention in the sense of enhanced operating stability.)
Cruise control will then have to be reactivated at the cruise control steering-column stalk.
OPERATION
Operation of the Active Cruise Control option is described in the Owner's Handbook.
NATIONAL VERSIONS
US and CDN national versions
Different timed separations encoded for following mode (1.5 - 1.8 - 2.2 - 2.5 seconds)
US and GB national versions
Active Cruise Control controls between 20 mph and 110 mph.
Speed preselections are possible in increments of 1 mph and 5 mph.
Subject to change.
PARK DISTANCE CONTROL E60, E61, E63, E64

2005 BMW 645Ci
Fig. 18: Identifying Park Distance Control

INTRODUCTION
Park Distance Control (PDC) is an item of special equipment (option 508). Park Distance Control (i.e.: parking-
aid) supports the driver in maneuvering in tight spaces.
For the BMW 5-Series (E60, E61) and the BMW 6-Series (E63, E64), the PDC was taken from the E65.
On the E60 PDC has the following new features:
 The PDC button is in the center console switch cluster. The signal from the PDC button is transferred to
the PDC control unit through the K-CAN.
 The signal from the reverse-light switch (reverse gear engaged) on vehicles with manual transmission is
transferred from the light module to the PDC control unit via the K-CAN.
 Display form of the optical warnings on the Central Information Display (display image).
2005 BMW 645Ci
The PDC measures the distance to objects within its range with ultrasonic sensors.
For more information, refer to E60, E61, E63, E64 - PARK DISTANCE CONTROL (PDC) SYSTEM
OVERVIEW.
The driver is warned of an object that could cause a collision as follows:
 Acoustic warning (via multi-audio system controller, M-ASK, and mid-range loudspeaker)
 Visual warning (via Central Information Display)
The PDC uses these two 2 warning functions to offer a degree of comfort for drivers who are hard of hearing or
physically impaired.
A fault in the PDC is indicated by a Check-Control message.
IMPORTANT: Responsibility remains with the driver at all times, PDC is unable to take the
place of the driver's personal assessment of obstacles. The ultrasonic sensors
have a blind spot. Objects in this blind spot cannot be detected. The ability to
detect objects can stretch the physical limits of ultrasonic measurements (no
or poor reflection of ultrasonic impulses, e.g. trailer tow bars or narrow
objects). Low objects that have already been indicated can "disappear", before
a continuous tone sounds (e.g. a high kerbstone). The evaluation of obstacles
is thus the responsibility of the driver, even with PDC.
E60, E61, E63, E64 - PARK DISTANCE CONTROL (PDC) SYSTEM OVERVIEW
Inputs/outputs
2005 BMW 645Ci
Fig. 19: Identifying Park Distance Control (PDC) System Inputs/Outputs (1 Of 2)

2005 BMW 645Ci
Fig. 20: Identifying Park Distance Control (PDC) System (2 Of 2)


2005 BMW 645Ci
Fig. 21: Identifying Park Distance Control (PDC) System Circuit Diagram
PDC consists of the following components:
 8 ultrasonic sensors
There are 4 ultrasonic sensors in each of the front and rear bumpers.
The ultrasonic sensors emit ultrasonic impulses. These ultrasonic impulses are reflected by obstacles
(echo impulses).
The ultrasonic sensors receive and amplify these echo impulses. The amplified echo impulses are then
converted into a digital signal. Each ultrasonic sensor has its own microprocessor, its own power supply
and its own data connection to the PDC control unit.
2005 BMW 645Ci
For more information, refer to E60, E61, E63, E64 - PARK DISTANCE CONTROL ULTRASONIC
SENSORS.
IMPORTANT: Measuring range of ultrasonic sensors. The measuring range of the ultrasonic
sensors is between approx. 25 centimeters and a maximum of approx. 200
centimeters. If the minimum distance that can be detected rises to an
impermissible level, a fault message is entered in the fault memory. Dirt
contamination, moisture, ice and snow can cause an impermissible rise in the
minimum distance that can be detected.
NOTE: Cleaning the ultrasonic sensors. To make sure the system remains fully
operational, keep the ultrasonic sensors clean and free from ice. Do not clean
by spraying high-pressure washers directly at the ultrasonic sensors. When
cleaning, always maintain a minimum distance of at least 10 centimeters.
 PDC button
The PDC button is in the center console switch cluster. The signal from the PDC button is transferred
through the K-CAN to the PDC control unit.
The PDC button is used to manually switch the Park Distance Control system on and off. When the PDC
is switched on, the function LED in the PDC button lights up.
If a fault develops in the PDC, the function LED in the PDC button flashes.
 PDC control unit
The PDC control unit controls the ultrasonic sensors for transmitting ultrasonic impulses. The PDC
control unit also receives the digital signals from the individual ultrasonic sensors. By comparing the
individual digital signals, the PDC control unit calculates the minimum distance between the ultrasonic
sensor and the object.
When an object is detected, an acoustic warning and a visual warning are given.
For more information, refer to E60, E61, E63, E64 - PDC CONTROL UNIT.
The PDC control unit is connected to various other control units via the bus systems:
 Multi-audio system controller / Car Communication Computer
The multi-audio system controller (M-ASK) or Car Communication Computer (CCC) emits the PDC
acoustic warning through the mid-range loudspeakers.
 Central Information Display

2005 BMW 645Ci
In addition, information regarding a Check-Control message that may be present is shown.
 Instrument cluster
A current Check-Control message is indicated by a symbol in the LCD display in the instrument cluster.
Moreover, the instrument cluster also provides the exterior temperature and the kilometer reading for the
PDC control unit.
Ice and frost can cause an unexpected response from the ultrasonic sensors. The response characteristics
of the ultrasonic sensors changes depending on the exterior temperature.
If a fault is stored in the fault memory, the kilometer reading and the exterior temperature are also stored.
 DSC control unit
The DSC control unit supplies the PDC with information about the roadspeed and distance travelled.
 Electronic transmission control
On vehicles with automatic transmission, the electronic transmission control (ESG) supplies the signal
that reverse gear is engaged.
 Light module
On vehicles with manual transmission, the light module (LM) supplies the signal that reverse gear is
engaged.
 Car Access System
The CAS control unit supplies the PDC with the terminal status (e.g.. terminal 15).
For vehicles from 03/2004, power is supplied to the PDC control unit through terminal 30g (active)
instead of terminal 15.
 Trailer module (AHM)
The trailer module sends a signal indicating whether or not the vehicle is towing a trailer. If a trailer is
recognized, the acoustic and visual warnings for the rear bumper are deactivated.
E60, E61, E63, E64 - Park Distance Control Ultrasonic Sensors
There are 4 ultrasonic sensors in each of the front and rear bumpers (illustration shows E60).
2005 BMW 645Ci
Fig. 22: Locating Park Distance Control Ultrasonic Sensors

Construction
Compared to earlier systems, the ultrasonic sensors have a circular membrane (larger effective range and lower
sensitivity to moisture). The membrane is always painted in the vehicle's body color.
The ultrasonic sensors in the front and rear bumpers are electrically identical. The difference between the front
and rear ultrasonic sensors is the arrangement of the plug connection, which is due to the specific installation
location.
How it works
The ultrasonic sensors are activated by the PDC control unit, either in combined transmit and receive mode or
in pure receive mode.
2005 BMW 645Ci
In combined transmit and receive mode, the 8 ultrasonic sensors first transmit a package of ultrasonic
impulses. Each ultrasonic sensor then receives the echo pulse reflected by an object within the effective
range. This echo pulse is amplified in the ultrasonic sensor and sent to the PDC control unit in the form of
a digital signal. The PDC control unit calculates the distance from the object from the time lag of the echo
pulse.
Receive mode
In receive mode, the ultrasonic sensor receives the echo pulses transmitted by the adjacent ultrasonic
sensors. The PDC control unit is then able to evaluate the signals of up to 3 ultrasonic sensors
(triangulation). The evaluation of these signals from several ultrasonic sensor is used to calculate the
minimum distance between the vehicle and the object.
E60, E61, E63, E64 - PDC Control Unit
On the BMW 5-Series, the PDC control unit is located under the spare wheel in the luggage compartment well.
The PDC control unit is fitted in the function carrier (illustration shows E60).
On the BMW 6-Series, the function carrier is in front of the battery in the luggage compartment well.
2005 BMW 645Ci
Fig. 23: Locating PDC Control Unit

Construction
The PDC control unit is connected to the rest of the vehicle electrical system by 3 plug connectors.
Pin assignment for X300, 12-pin
PIN ASSIGNMENT FOR X300, 12-PIN

1 V Power supply, terminal 15
For vehicles from 03/2004: terminal 30g (active)
2 E/A CAN high on K-CAN
3 --- ---
4 --- ---
2005 BMW 645Ci
6 M Earth, terminal 31
7 --- ---
8 E/A CAN low on K-CAN
9 --- ---
10 --- ---
11 --- ---
12 --- ---
E/A = Input and output
M = Earth
V = Supply
For current specifications regarding pin assignment, please refer to BMW diagnosis system

1 A Earth for ultrasonic sensor, rear right
2 A Earth for ultrasonic sensor, rear left
3 --- ---
4 --- ---
5 A Power supply for ultrasonic sensor, rear middle right
6 A Power supply for ultrasonic sensor, rear middle left
7 A Power supply for ultrasonic sensor, rear right
8 A Power supply for ultrasonic sensor, rear left
9 --- ---
10 A Earth for ultrasonic sensor, rear middle right
11 A Earth for ultrasonic sensor, rear middle left
12 E Signal from ultrasonic sensor, rear middle right
13 E Signal from ultrasonic sensor, rear middle left
14 E Signal from ultrasonic sensor, rear right
15 E Signal from ultrasonic sensor, rear left
16 --- ---
17 --- ---
18 --- ---
A = Output
E = Input

2005 BMW 645Ci
1 A Earth for ultrasonic sensor, front right

2 A Earth for ultrasonic sensor, front left
3 --- ---
4 --- ---
5 A Power supply for ultrasonic sensor, front middle right
6 A Power supply for ultrasonic sensor, front middle left
7 A Power supply for ultrasonic sensor, front right
8 A Power supply for ultrasonic sensor, front left
9 --- ---
10 A Earth for ultrasonic sensor, front middle right
11 A Earth for ultrasonic sensor, front middle left
12 E Signal from ultrasonic sensor, front middle right
13 E Signal from ultrasonic sensor, front middle left
14 E Signal from ultrasonic sensor, front right
15 E Signal from ultrasonic sensor, front left
16 --- ---
17 --- ---
18 --- ---
A = Output
E = Input
SYSTEM FUNCTIONS
PDC incorporates the following functions:
 Acoustic warnings
 Visual warnings
 Check Control
Acoustic warnings
The acoustic warnings are emitted by the M-ASK via the mid-range loudspeaker.
If an object is detected by 2 ultrasonic sensors, the loudspeaker closest to the object is actuated. The mid-
range loudspeaker in the left/right-hand front doors or the midrange loudspeaker on the left/right-hand
sides of the rear shelf can be actuated.
If an object is detected by 3 ultrasonic sensors, the mid-range loudspeakers on the left and right-hand
sides are actuated together.
The smaller the distance to the object, the faster the sequence of acoustic warning tones.
2005 BMW 645Ci
A distance of less than approx. 25 centimeters is indicated by a continuous tone.
The warning tone switches off as soon as the vehicle moves away from the object.
If the vehicle is moving directly towards a wall, the acoustic warning tone will be switched off after
approx. 3 seconds so that it does not distract the driver. If the vehicle continues to approach the wall, the
warning will be reactivated.
Effective range for acoustic warnings:
 approx. 60 centimeters for the ultrasonic sensors at the two corners of the front bumper
 approx. 70 centimeters for the two middle ultrasonic sensors in the front bumper
 approx. 60 centimeters for the ultrasonic sensors at the two corners of the rear bumper
 approx. 150 centimeters for the two middle ultrasonic sensors in the rear bumper
Visual warnings
The visual PDC warnings are given in the Central Information Display (CID). This is subject to the
display in the CID being active.
The visual warnings are given earlier than the acoustic warnings.
The effective range is approx. 2 meters at the front and approx. 2.5 meters at the rear.
The graphic display is shown on the CID. The PDC control unit supplies the distance between the
ultrasonic sensor and the object detected via the K-CAN.
The display on the CID is an overhead view of the vehicle with the effective ranges of the ultrasonic
sensors.
The distance to objects detected is shown in the colors of traffic lights:
 Distance down to 100 centimeters: green

 Distance between 100 an 50 centimeters: yellow
 Distance less than 50 centimeters: red
The display appears as soon as the PDC is switched on (manually or automatically). The display
overrides other displays in the CID. When the PDC is switched off again, the previous display
automatically appears again in the Central Information Display.
Check Control
If a fault develops in the PDC, the function LED in the PDC button flashes.
In this situation, PDC cannot be switched on.

2005 BMW 645Ci
At the same time, a Check-Control message is displayed in the following form
 Symbol in the LCD display in the instrument cluster

 The following text appears in the status line of the Central Information Display:
"PDC failure!"
In the menu "BMW Service", the following text can be called up in the submenu "Check-Control
messages":
"Park Distance Control
No acoustic warning available for Park Distance Control (PDC).
Have the problem checked by BMW Service as soon as possible."
CONDITIONS FOR SWITCHING ON AND OFF
PDC is switched on under the following conditions:
 PDC button pressed (PDC switched on manually)

 Reverse gear engaged (PDC switched on automatically)
PDC is switched off under the following conditions:
 PDC button pressed (PDC switched off manually)

 Ignition switched off (PDC switched off automatically
 After driving approx. 50 meters
 After exceeding a speed of 30 km/h
When a trailer is being towed, the acoustic and visual warnings for the rear bumper are deactivated.
For this to happen, the trailer must be electrically connected to the vehicle.
PROBLEMATIC CONDITIONS FOR SWITCHING ON AND OFF
In borderline situations, PDC may give a warning even though there is no object within the effective range
(reflection from the ground, e.g. on coarse gravel).
In borderline situations, it could happen that objects that are present are not detected (no or insufficient
reflection due to geometric form).
Under the following conditions, it could happen that the PDC gives a warning, even though there is no
object within the effective range:
2005 BMW 645Ci
 Ultrasonic sensor incorrectly located in its bracket

 Heavy rain
 Severe dirt contamination or icing of the ultrasonic sensors
 Ultrasonic sensors covered in snow
 Echo pulses caused by ground, e.g. extremely coarse road surface or high grass
 Very smooth walls in large, enclosed, rectangular spaces, e.g. in underground car parks (interference from
earlier, reflected echo impulses)
Under the following conditions, the PDC may not recognize an obstacle that is present:
 Low objects or objects with corners and sharp edges (no reflection)
 If you drive alongside a wall while you are parking, the acoustic warning will be deactivated so long as
you are moving parallel to the wall.
OPERATION
The visual warning (display) is switched on in the Central Information Display (CID) as follows:
 "Settings (i)" menu

 "Vehicle settings" menu
 "PDC" menu
 Activate "Display on"
JAPANESE NATIONAL VERSION
So long as reverse gear is engaged, an acoustic signal (reversing gong) is given via the multi-audio system
controller (M-ASK) and the mid-range loudspeaker. The reversing gong is deactivated immediately if the PDC
detects an object in the effective range and emits its own acoustic warning.
Subject to change.
2005 BMW 645Ci
2004 ENGINE COOLING Specifications & Drive Belt Routing - 645Ci
2004 ENGINE COOLING
Specifications & Drive Belt Routing - 645Ci
COOLING SYSTEM BLEEDING

Add coolant to expansion tank, and fill to level mark. Place A/C-heater control on WARM setting to ensure
heater valve is open. Start engine, and run it at fast idle speed. Open bleed screw on thermostat housing or
expansion tank, and continue to add coolant to expansion tank as coolant level drops. Tighten bleed screw as
soon as coolant is free of air bubbles.
BELT ADJUSTMENT
NOTE: All models use an automatic belt tensioner. Tensioner adjustment is not
required.
DRIVE BELT ROUTING

For drive belt routing, see V-RIBBED BELT WITH TENSIONER DEFLECT ELEMENT .
COOLING SYSTEM SPECIFICATIONS

FLUID CAPACITIES
Application Quantity
Cooling System (1) 14.8 Qts. (14.0L)
(1) Quantity is approximate.
2007 BMW 650i
AUTOMATIC TRANSMISSION Diagnostic Trouble Codes - 6-Speed ZF Transmission
Diagnostic Trouble Codes - 6-Speed ZF Transmission
DIAGNOSTIC TROUBLE CODES

A/T DIAGNOSTIC TROUBLE CODES
DTC (Diagnostic DTC Description
Trouble Code)
P0748 Pressure Control Solenoid 'A' Electrical
P0963 Pressure Control Solenoid 'A' Control Circuit High
P0962 Pressure Control Solenoid 'A' Control Circuit Low
P170A Pressure Control Solenoid 'A' Shunt Monitoring
P0745 Pressure Control Solenoid 'A'
P0778 Pressure Control Solenoid 'B' Electrical
P0967 Pressure Control Solenoid 'B' Control Circuit High
P0966 Pressure Control Solenoid 'B' Control Circuit Low
P170B Pressure Control Solenoid 'B' Shunt Monitoring
P0775 Pressure Control Solenoid 'B'
P0798 Pressure Control Solenoid 'C' Electrical
P0971 Pressure Control Solenoid 'C' Control Circuit High
P0970 Pressure Control Solenoid 'C' Control Circuit Low
P170C Pressure Control Solenoid 'C' Shunt Monitoring
P0795 Pressure Control Solenoid 'C'
P2716 Pressure Control Solenoid 'D' Electrical
P2721 Pressure Control Solenoid 'D' Control Circuit High
P2720 Pressure Control Solenoid 'D' Control Circuit Low
P170D Pressure Control Solenoid 'D' Shunt Monitoring
P2713 Pressure Control Solenoid 'D'
P2725 Pressure Control Solenoid 'E' Electrical
P2730 Pressure Control Solenoid 'E' Control Circuit High
P2729 Pressure Control Solenoid 'E' Control Circuit Low
P170E Pressure Control Solenoid 'E' Shunt Monitoring
P2759 Torque Converter Clutch Pressure Control Solenoid Control Circuit Electrical
P2763 Torque Converter Clutch Pressure Control Solenoid Control Circuit High
P2764 Torque Converter Clutch Pressure Control Solenoid Control Circuit Low
P170F Pressure Control Solenoid 'F' Shunt Monitoring
P1830 Pressure Control Solenoid Current Error in P/R/N
P0977 Shift Solenoid 'B' Control Circuit High
P0976 Shift Solenoid 'B' Control Circuit Low
P0755 Shift Solenoid 'B'
2007 BMW 650i
P0979 Shift Solenoid 'C' Control Circuit Low

P0982 Shift Solenoid 'D' Control Circuit Low
P1806 Shift Solenoid 'A' or 'B' Mechanically Stuck
P2815 Pressure Control Solenoid 'G' Control Circuit High
P2814 Pressure Control Solenoid 'G' Control Circuit Low
P173C Pressure Control Solenoid 'G' Shunt Monitoring
P0715 Input/Turbine Speed Sensor 'A' Circuit
P1811 Input/Turbine Speed Sensor Circuit Low
P0716 Input/Turbine Speed Sensor 'A' Circuit Range/Performance
P1812 Output Speed Sensor Circuit High Input
P1813 Output Speed Sensor Circuit Low Input
P0720 Output Speed Sensor Circuit
P0721 Output Speed Sensor Circuit Range/Performance
P1814 Output Speed Sensor Gradient Too High
P0710 Transmission Fluid Temperature Sensor 'A' Circuit
P1704 Transmission Fluid Temperature Sensor 'A' Circuit Shorted
P1718 Transmission Fluid Temperature Sensor 'A' Unpermitted Temperature Increase
P0711 Transmission Fluid Temperature Sensor 'A' Circuit Range/Performance
P0669 PCM/ECM/TCM Internal Temperature Sensor Circuit High
P0668 PCM/ECM/TCM Internal Temperature Sensor Circuit Low
P0666 PCM/ECM/TCM Internal Temperature Sensor Circuit
P0218 Transmission Fluid Over Temperature Condition
P171F Internal Transmission Control Module Component CG122 Error
P0741 Torque Converter Clutch Circuit Performance or Stuck Off
P173D CAN Message Monitoring Transmission Intake Torque
P1729 Engine High Rotational Irregularity
P1728 Engine Overspeed Condition
P1760 Engine Torque Request Plausibility
P17E1 Ratio Monitoring Clutch A
P17E2 Ratio Monitoring Clutch B
P17E3 Ratio Monitoring Clutch C
P17E4 Ratio Monitoring Clutch D
P17E5 Ratio Monitoring Clutch E
P17E6 Ratio Monitoring Shift 1-2
P17EA Ratio Monitoring Shift 5-6
P17EB Ratio Monitoring Shift 6-5
P17EC Ratio Monitoring Shift 5-4
2007 BMW 650i
Ratio Monitoring Shift 3-2

P17EF Ratio Monitoring Shift 2-1
P17F0 Ratio Monitoring Clutch A and D
P17F1 Ratio Monitoring Clutch A and C
P17F2 Ratio Monitoring Clutch A and B
P17F3 Ratio Monitoring Clutch A and E
P17F4 Ratio Monitoring Clutch B and E
P17F5 Ratio Monitoring Clutch C and E
P17F6 Ratio Monitoring Clutch B and D
P17F7 Ratio Monitoring Shift 6-4
P17FA Ratio Monitoring Shift 3-1
P1790 Internal Transmission Control Module Memory Check Sum/EPROM Error
P1791 Internal Transmission Control Module Memory Check Sum/EEPROM Error
P171A Internal Transmission Control Module Watchdog General Error
P171B Internal Transmission Control Module Watchdog Run Time Error
P171C Internal Transmission Control Module Watchdog Initialization Error
P171D Internal Transmission Control Module Watchdog Electrical Error
P171E Internal Transmission Control Module Watchdog Plausibility Error
P175A TCM Internal Error Shifting to D without Driver Command
P177A TCM Internal Error no Shifting despite of Driver Command
P175C Gear Shift Position 2/4 Circuit Wrong Frequency
P1798 Internal Transmission Control Module Writing Error EEPROM
P1798 Internal Transmission Control Module Monitoring Level 2 Error, Engine Torque
Up Request
P1712 Internal Transmission Control Module Monitoring Level 2 Error, Engine Torque
Up Request
P1713 Internal Transmission Control Module Monitoring Level 2 Error, Calculation
Engine Torque Up Request
P1723 Internal Transmission Control Module Severe QADC Error
P1722 Internal Transmission Control Module Minor QADC Error
P1724 Internal Transmission Control Module TPU AliveCounter Error
P1725 Internal Transmission Control Module TPU RAM Error Internal Transmission
Control Module Level 2 Error,
P172E Interference Counter above Threshold General Error Internal Transmission
P172A Interference Counter 1 above Threshold
Internal Transmission Control Module Level 2 Error,
P172B Interference Counter 2 above Threshold
2007 BMW 650i
P172C Interference Counter 3 above Threshold

P172D Interference Counter 4 above Threshold
P1754 Interference Counter below Threshold General Error Internal Transmission
P172F Interference Counter 1 below Threshold
P1733 Interference Counter 2 below Threshold
P1891 System Voltage High Input
P1892 System Voltage Low Input
P1890 System Voltage
P1893 Supply Voltage Pressure Control Solenoid/Shift Solenoid Circuit High
P1894 Supply Voltage Pressure Control Solenoid/Shift Solenoid Circuit Low
P1895 Supply Voltage Pressure Control Solenoid/Shift Solenoid No Signal
P1896 Supply Voltage Pressure Control Solenoid/Shift Solenoid
P1897 Supply Voltage Sensors High Input
P1898 Supply Voltage Sensors Low Input
P0705 Transmission Range Sensor 'A' Circuit (PRNDL Input)
P0706 Transmission Range Sensor 'A' Circuit Range/Performance
P1701 Double Error Position Information CAN / Serial Line
P1730 Pressure Control Solenoid Unpermitted Activation
P1702 Combination Substitute Function
P1727 CAN Engine Speed
P1771 CAN Torque Interface Plausibility
U0001 High Speed CAN Communication Bus
U114A Message Monitoring Engine Control Torque 1 Alive Check
U114B Lost Communication With Engine Control Torque 1
U114D Message Monitoring Engine Control Torque 2 Alive Check
U1163 Message Monitoring Engine Control Alive Check
U0100 Lost Communication With ECM/PCM 'A'
U1164 Message Monitoring Engine Control Check Sum Error
U1125 Message Monitoring DSC Status Alive Check
U1126 Lost Communication With DSC Status
U1127 Message Monitoring DSC Status Check Sum Error
U1149 Message Monitoring CAS Alive Check
2007 BMW 650i
U1150 Message Monitoring CAS Check Sum Error

U112A Message Monitoring Instrument Pack Status Alive Check
U112B Lost Communication With Instrument Pack Status
U112F Message Monitoring Instrument Pack Status Check Sum Error
2009 BMW 650i
DTC INDEX 550i, 650i, 750i, 750Li & X5
DTC INDEX
550i, 650i, 750i, 750Li & X5
SELF-DIAGNOSTICS DTCS
SELF-DIAGNOSTICS DIAGNOSTIC TROUBLE CODE (DTC) LIST
DTC Description
DTC P0010 'A' Camshaft Position - Actuator Circuit/Open (Bank 1) (SIG)
DTC P0011 'A' Camshaft Position - Timing Over-Advanced or System Performance (Bank 1)
(MIN)
DTC P0012 'A' Camshaft Position - Timing Over-Retarded (Bank 1) (PLAUS)
DTC P0013 'B' Camshaft Position - Actuator Circuit/Open (Bank 1) (SIG)
DTC P0014 'B' Camshaft Position - Timing Over-Advanced or System Performance (Bank 1)
(MIN)
DTC P0015 'B' Camshaft Position - Timing Over-Retarded (Bank 1) (PLAUS)
DTC P0016 Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor A) (MIN)
DTC P0017 Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor B) (MIN)
DTC P0018 Crankshaft Position - Camshaft Position Correlation (Bank 2 Sensor A) (MIN)
DTC P0019 Crankshaft Position - Camshaft Position Correlation (Bank 2 Sensor B) (MIN)
DTC P0020 'A' Camshaft Position - Actuator Circuit/Open (Bank 2) (SIG)
DTC P0021 'A' Camshaft Position - Timing Over-Advanced or System Performance (Bank 2)
(MIN)
DTC P0022 'A' Camshaft Position - Timing Over-Retarded (Bank 2) (PLAUS)
DTC P0023 'B' Camshaft Position - Actuator Circuit/Open (Bank 2) (SIG)
DTC P0024 'B' Camshaft Position - Timing Over-Advanced or System Performance (Bank 2)
(MIN)
DTC P0025 'B' Camshaft Position - Timing Over-Retarded (Bank 2) (PLAUS)
DTC P0030 HO2S Heater Control Circuit (Bank 1 Sensor 1) (SIG)
DTC P0031 HO2S Heater Control Circuit Low (Bank 1 Sensor 1) (MIN)
DTC P0032 HO2S Heater Control Circuit High (Bank 1 Sensor 1) (MAX)
DTC P0040 O2 Sensor Signals Swapped Bank 1 Sensor 1 / Bank 2 Sensor 1 (PLAUS)
2009 BMW 650i
DTC INDEX 550i, 650i, 750i, 750Li & X5
DTC P0071 Ambient Air Temperature Sensor Range/Performance (SIG)

DTC P0072 Ambient Air Temperature Sensor Circuit Low (MIN)
DTC P0073 Ambient Air Temperature Sensor Circuit High (MAX)
DTC P0100 Mass or Volume Air Flow 'A' Circuit (SIG)
DTC P0102 Mass or Volume Air Flow 'A' Circuit Low (MIN)
DTC P0103 Mass or Volume Air Flow 'A' Circuit High (MAX)
DTC P0110 Intake Air Temperature Sensor 1 Circuit (Bank 1) (PLAUS)
DTC P0111 Intake Air Temperature Sensor 1 Circuit Range/Performance (Bank 1) (PLAUS)
DTC P0112 Intake Air Temperature Sensor 1 Circuit Low (Bank 1) (MIN)
DTC P0113 Intake Air Temperature Sensor 1 Circuit High (Bank 1) (MAX)
DTC P0115 Engine Coolant Temperature Sensor 1 Circuit (SIG)
DTC P0116 Engine Coolant Temperature Sensor 1 Circuit Range/Performance (PLAUS)
DTC P0117 Engine Coolant Temperature Sensor 1 Circuit Low (MIN)
DTC P0118 Engine Coolant Temperature Sensor 1 Circuit High (MAX)
DTC P0119 Engine Coolant Temperature Sensor 1 Circuit Intermittent (PLAUS)
DTC P0120 Throttle/Pedal Position Sensor/Switch 'A' Circuit (PLAUS)
DTC P0121 Throttle/Pedal Position Sensor/Switch 'A' Circuit Range/Performance (PLAUS)
DTC P0122 Throttle/Pedal Position Sensor/Switch 'A' Circuit Low (MIN)
DTC P0123 Throttle/Pedal Position Sensor/Switch 'A' Circuit High (MAX)
DTC P0127 Intake Air Temperature Too High (MAX)
DTC P0128 Coolant Thermostat (Coolant Temperature Below Thermostat Regulating
Temperature) (PLAUS)
DTC P0130 O2 Sensor Circuit (Bank 1 Sensor 1) (MAX)
DTC P0131 O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) (MIN)
DTC P0132 O2 Sensor Circuit High Voltage (Bank 1 Sensor 1) (MAX)
DTC P0133 O2 Sensor Circuit Slow Response (Bank 1 Sensor 1) (MIN)
DTC P0135 O2 Sensor Heater Circuit (Bank 1 Sensor 1) (PLAUS)
DTC P0136 O2 Sensor Circuit (Bank 1 Sensor 2) (PLAUS)
DTC P0139 O2 Sensor Circuit Slow Response (Bank 1 Sensor 2) (SIG)
DTC P013A O2 Sensor Slow Response - Rich to Lean (Bank 1 Sensor 2) (MAX)
DTC P013C O2 Sensor Slow Response - Rich to Lean (Bank 2 Sensor 2) (MAX)
DTC P013E O2 Sensor Delayed Response - Rich to Lean (Bank 1 Sensor 2) (SIG)
DTC P0140 O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2) (SIG)
DTC P014A O2 Sensor Delayed Response - Rich to Lean (Bank 2 Sensor 2) (SIG)
DTC P0150 O2 Sensor Circuit (Bank 2 Sensor 1) (MAX)
2009 BMW 650i
DTC INDEX 550i, 650i, 750i, 750Li & X5
DTC P0153 O2 Sensor Circuit Slow Response (Bank 2 Sensor 1) (MIN)

DTC P0156 O2 Sensor Circuit (Bank 2 Sensor 2) (PLAUS)
DTC P0160 O2 Sensor Circuit No Activity Detected (Bank 2 Sensor 2) (SIG)
DTC P0201 Injector Circuit/Open - Cylinder 1 (SIG)
DTC P0221 Throttle/Pedal Position Sensor/Switch 'B' Circuit Range/Performance (PLAUS)
DTC P0222 Throttle/Pedal Position Sensor/Switch 'B' Circuit Low (MIN)
DTC P0223 Throttle/Pedal Position Sensor/Switch 'B' Circuit High (MAX)
DTC P0261 Cylinder 1 Injector Circuit Low (MIN)
DTC P0262 Cylinder 1 Injector Circuit High (MAX)
DTC P0298 Engine Oil Over Temperature (MAX)
DTC P0300 Random/Multiple Cylinder Misfire Detected (MAX)
DTC P0300 Random/Multiple Cylinder Misfire Detected (MIN)
DTC P0300 Random/Multiple Cylinder Misfire Detected (PLAUS)
2009 BMW 650i
DTC INDEX 550i, 650i, 750i, 750Li & X5
Cylinder 1 Misfire Detected (MIN)

DTC P0301 Cylinder 1 Misfire Detected (PLAUS)
DTC P0302 Cylinder 2 Misfire Detected (MAX)
DTC P0302 Cylinder 2 Misfire Detected (MIN)
DTC P0313 Misfire Detected With Low Fuel (MIN)
DTC P0325 Knock Sensor 1 Circuit (Bank 1 or Single Sensor) (PLAUS)
DTC P0327 Knock Sensor 1 Circuit Low (Bank 1 or Single Sensor) (MIN)
DTC P0328 Knock Sensor 1 Circuit High (Bank 1 or Single Sensor) (MAX)
DTC P0335 Crankshaft Position Sensor 'A' Circuit (SIG)
DTC P0336 Crankshaft Position Sensor 'A' Circuit Range/Performance (PLAUS)
DTC P033A Knock Sensor 4 Circuit (Bank 2) (PLAUS)
DTC P033C Knock Sensor 4 Circuit Low (Bank 2) (MIN)
DTC P033D Knock Sensor 4 Circuit High (Bank 2) (MAX)
DTC P0340 Camshaft Position Sensor 'A' Circuit (Bank 1 or Single Sensor) (PLAUS)
DTC P0341 Camshaft Position Sensor 'A' Circuit Range/Performance (Bank 1 or Single
Sensor) (SIG)
DTC P0342 Camshaft Position Sensor 'A' Circuit Low (Bank 1 or Single Sensor) (MIN)
DTC P0343 Camshaft Position Sensor 'A' Circuit High (Bank 1 or Single Sensor) (MAX)
DTC P0345 Camshaft Position Sensor 'A' Circuit (Bank 2) (PLAUS)
DTC P0346 Camshaft Position Sensor 'A' Circuit Range/Performance (Bank 2) (SIG)
DTC P0347 Camshaft Position Sensor 'A' Circuit Low (Bank 2) (MIN)
2009 BMW 650i
DTC INDEX 550i, 650i, 750i, 750Li & X5
DTC P0351 Ignition Coil 'A' Primary/Secondary Circuit (PLAUS)

DTC P0352 Ignition Coil 'B' Primary/Secondary Circuit (PLAUS)
DTC P0353 Ignition Coil 'C' Primary/Secondary Circuit (PLAUS)
DTC P0354 Ignition Coil 'D' Primary/Secondary Circuit (PLAUS)
DTC P0355 Ignition Coil 'E' Primary/Secondary Circuit (PLAUS)
DTC P0356 Ignition Coil 'F' Primary/Secondary Circuit (PLAUS)
DTC P0357 Ignition Coil 'G' Primary/Secondary Circuit (PLAUS)
DTC P0358 Ignition Coil 'H' Primary/Secondary Circuit (PLAUS)
DTC P0365 Camshaft Position Sensor 'B' Circuit (Bank 1) (PLAUS)
DTC P0366 Camshaft Position Sensor 'B' Circuit Range/Performance (Bank 1) (SIG)
DTC P0367 Camshaft Position Sensor 'B' Circuit Low (Bank 1) (MIN)
DTC P0368 Camshaft Position Sensor 'B' Circuit High (Bank 1) (MAX)
DTC P0370 Timing Reference High Resolution Signal 'A' (PLAUS)
DTC P0372 Timing Reference High Resolution Signal 'A' Too Few Pulses (SIG)
DTC P0373 Timing Reference High Resolution Signal 'A' Intermittent/Erratic Pulses (MAX)
DTC P0390 Camshaft Position Sensor 'B' Circuit (Bank 2) (PLAUS)
DTC P0391 Camshaft Position Sensor 'B' Circuit Range/Performance (Bank 2) (SIG)
DTC P0392 Camshaft Position Sensor 'B' Circuit Low Input (Bank 2) (MIN)
DTC P0393 Camshaft Position Sensor 'B' Circuit High Input (Bank 2) (MAX)
DTC P0420 Catalyst System Efficiency Below Threshold (Bank 1) (MIN)
DTC P0430 Catalyst System Efficiency Below Threshold (Bank 2) (MAX)
DTC P0430 Catalyst System Efficiency Below Threshold (Bank 2) (MIN)
DTC P0441 Evaporative Emission System Incorrect Purge Flow (MIN)
DTC P0442 Evaporative Emission System Leak Detected (Small Leak) (MAX)
DTC P0444 Evaporative Emission System Purge Control Valve Circuit Open (SIG)
DTC P0456 Evaporative Emission System Leak Detected (Very Small Leak) (MAX)
DTC P0456 Evaporative Emission System Leak Detected (Very Small Leak) (MIN)
DTC P0458 Evaporative Emission System Purge Control Valve Circuit Low (MIN)
DTC P0459 Evaporative Emission System Purge Control Valve Circuit High (MAX)
DTC P0460 Fuel Level Sensor 'A' Circuit (SIG)
DTC P0461 Fuel Level Sensor 'A' Circuit Range/Performance (PLAUS)
DTC P0462 Fuel Level Sensor 'A' Circuit Low (MIN)
DTC P0463 Fuel Level Sensor 'A' Circuit High (MAX)
DTC P0477 Exhaust Pressure Control Valve Low (MIN)
DTC P0478 Exhaust Pressure Control Valve High (MAX)
DTC P0479 Exhaust Pressure Control Valve Intermittent (SIG)
DTC P0480 Fan 1 Control Circuit (SIG)
DTC P0500 Vehicle Speed Sensor 'A' (MIN)
DTC P0501 Vehicle Speed Sensor 'A' Range/Performance (PLAUS)
DTC P0503 Vehicle Speed Sensor 'A' Intermittent/Erratic/High (MAX)
2009 BMW 650i
DTC INDEX 550i, 650i, 750i, 750Li & X5
Idle Air Control System RPM Higher Than Expected (MAX)

DTC P0512 Starter Request Circuit (SIG)
DTC P0520 Engine Oil Pressure Sensor/Switch Circuit (PLAUS)
DTC P0530 A/C Refrigerant Pressure Sensor 'A' Circuit (SIG)
DTC P0532 A/C Refrigerant Pressure Sensor 'A' Circuit Low (MIN)
DTC P0533 A/C Refrigerant Pressure Sensor 'A' Circuit High (MAX)
DTC P0560 System Voltage (PLAUS)
DTC P0561 System Voltage Unstable (SIG)
DTC P0562 System Voltage Low (MIN)
DTC P0563 System Voltage High (MAX)
DTC P0571 Brake Switch 'A' Circuit (PLAUS)
DTC P0597 Thermostat Heater Control Circuit/Open (SIG)
DTC P0598 Thermostat Heater Control Circuit Low (MIN)
DTC P0599 Thermostat Heater Control Circuit High (MAX)
DTC P0604 Internal Control Module Random Access Memory (RAM) Error (PLAUS)
DTC P0605 Internal Control Module Read Only Memory (ROM) Error (PLAUS)
DTC P0606 ECM/PCM Processor (MIN)
DTC P0606 ECM/PCM Processor (PLAUS)
DTC P0606 ECM/PCM Processor (SIG)
DTC P060A Internal Control Module Monitoring Processor Performance (MIN)
DTC P061F Internal Control Module Throttle Actuator Controller Performance (PLAUS)
DTC P0620 Generator Control Circuit (MAX)
DTC P0620 Generator Control Circuit (SIG)
DTC P0691 Fan 1 Control Circuit Low (MIN)
DTC P0692 Fan 1 Control Circuit High (MAX)
DTC P0704 Clutch Switch Input Circuit (SIG)
DTC P0A3B Generator Over Temperature (MAX)
DTC P0A3B Generator Over Temperature (MAX)
DTC P1000 VVT-System Min. Stroke Adaptation Number of Stops Exceeded (MAX)
DTC P1001 VVT-Limp Home Request High Input (MAX)
DTC P1002 VVT-Limp Home Request Low Input (MIN)
DTC P1003 VVT-Limp Home Request Open Circuit (SIG)
DTC P1004 VVT-Guiding Sensor Solenoid Loss (Bank 1) (MAX)
DTC P1005 VVT-Guiding Sensor Reset Error (Bank 1) (MIN)
DTC P1006 VVT-Guiding Sensor Parity Error (Bank 1) (SIG)
DTC P1007 VVT-Guiding Sensor Gradient Error (Bank 1) (PLAUS)
DTC P1008 VVT-Guiding Sensor Solenoid Loss (Bank 2) (MAX)
DTC P1009 VVT-Guiding Sensor Reset Error (Bank 2) (MIN)
DTC P1010 VVT-Guiding Sensor Parity Error (Bank 2) (SIG)
DTC P1011 VVT-Guiding Sensor Gradient Error (Bank 2) (PLAUS)
2009 BMW 650i
DTC INDEX 550i, 650i, 750i, 750Li & X5
VVT-Reference Sensor Reset Error (Bank 1) (MIN)

DTC P1014 VVT-Reference Sensor Parity Error (Bank 1) (SIG)
DTC P1015 VVT-Reference Sensor Gradient Error (Bank 1) (PLAUS)
DTC P1017 VVT-Sensors Plausibility (Bank 1) (PLAUS)
DTC P1018 VVT-Sensors Plausibility (Bank 2) (PLAUS)
DTC P1019 VVT-Supply Voltage Sensors High Input (Bank 1) (MAX)
DTC P1020 VVT-Supply Voltage Sensors Low Input (Bank 1) (MIN)
DTC P1021 VVT-Supply Voltage Sensors High Input (Bank 2) (MAX)
DTC P1022 VVT-Supply Voltage Sensors Low Input (Bank 2) (MIN)
DTC P1023 VVT-Self-Learning Function Faulty Adjustment Range (Bank 1) (MAX)
DTC P1024 VVT-Self-Learning Function Faulty Lower Learning Range (Bank 1) (MIN)
DTC P1025 VVT-Self-Learning Function No Positions Stored (Bank 1) (SIG)
DTC P1026 VVT-Self-Learning Function Faulty Adjustment Range (Bank 2) (MAX)
DTC P1027 VVT-Self-Learning Function Faulty Lower Learning Range (Bank 2) (MIN)
DTC P1028 VVT-Self-Learning Function No Positions Stored (Bank 2) (SIG)
DTC P1030 VVT-Actuator Monitoring Position Control, Control Deviation (Bank 1) (SIG)
DTC P1031 VVT-Actuator Monitoring Recognition of Direction of Rotation Plausibility
(Bank 1) (PLAUS)
DTC P1033 VVT-Actuator Monitoring Position Control, Control Deviation (Bank 2) (SIG)
DTC P1034 VVT-Actuator Monitoring Recognition of Direction of Rotation Plausibility
(Bank 2) (PLAUS)
DTC P1035 VVT-CAN-Message Monitoring Faulty Desired Message (Bank 1) (MAX)
DTC P1036 VVT-CAN-Timeout VVT-Desired Message (Bank 1) (SIG)
DTC P1037 VVT-CAN-Timeout VVT-Message (Bank 1) (PLAUS)
DTC P1038 VVT-CAN-Message Monitoring Faulty Desired Message (Bank 2) (MAX)
DTC P1039 VVT-CAN-Timeout VVT-Desired Message (Bank 2) (SIG)
DTC P1040 VVT-CAN-Timeout VVT-Message (Bank 2) (PLAUS)
DTC P1041 Internal VVT-Control Module EEPROM Error (Bank 1) (MAX)
DTC P1042 Internal VVT-Control Module Random Access Memory (RAM) Error (Bank 1)
(MIN)
DTC P1043 Internal VVT-Control Module Read Only Memory (ROM) Error (Bank 1)
(PLAUS)
DTC P1044 Internal VVT-Control Module EEPROM Error (Bank 2) (MAX)
DTC P1045 Internal VVT-Control Module Random Access Memory (RAM) Error (Bank 2)
(MIN)
DTC P1046 Internal VVT-Control Module Read Only Memory (ROM) Error (Bank 2)
(PLAUS)
DTC P1047 VVT-Control Circuit High Input (Bank 1) (MAX)
DTC P1048 VVT-Control Circuit Low Input (Bank 1) (MIN)
DTC P1049 VVT-Control Circuit Engine Cables Short Circuit (Bank 1) (SIG)
DTC P1050 VVT-Control Circuit (Bank 1) (PLAUS)
2009 BMW 650i
DTC INDEX 550i, 650i, 750i, 750Li & X5
DTC P1051 VVT-Control Circuit High Input (Bank 2) (MAX)

DTC P1052 VVT-Control Circuit Low Input (Bank 2) (MIN)
DTC P1053 VVT-Control Circuit Engine Cables Short Circuit (Bank 2) (SIG)
DTC P1054 VVT-Control Circuit (Bank 2) (PLAUS)
DTC P1055 VVT-Supply Voltage Control Motor High Input (Bank 1) (MAX)
DTC P1056 VVT-Supply Voltage Control Motor Low Input (Bank 1) (MIN)
DTC P1057 VVT-Supply Voltage Control Motor Electrical (Bank 1) (PLAUS)
DTC P1058 VVT-Supply Voltage Control Motor High Input (Bank 2) (MAX)
DTC P1059 VVT-Supply Voltage Control Motor Low Input (Bank 2) (MIN)
DTC P1060 VVT-Supply Voltage Control Motor Electrical (Bank 2) (PLAUS)
DTC P1061 VVT-Limp Home Request RPM and Charge Limitation (Bank 1) (MAX)
DTC P1062 VVT-Limp Home Request Full Stroke Position not Reached (Bank 1) (MIN)
DTC P1063 VVT-Limp Home Request Air Mass Plausibility (Bank 1) (SIG)
DTC P1064 VVT-Value Comparison Starting Position/Parking Position Plausibility (Bank 1)
(MAX)
DTC P1067 VVT-Reference Sensor Solenoid Loss (Bank 2) (MAX)
DTC P1068 VVT-Reference Sensor Reset Error (Bank 2) (MIN)
DTC P1069 VVT-Reference Sensor Parity Error (Bank 2) (SIG)
DTC P1070 VVT-Reference Sensor Gradient Error (Bank 2) (PLAUS)
DTC P1071 Internal VVT-Control Module Watchdog or Temperature Sensor Error (Bank 1)
(SIG)
DTC P1072 Internal VVT-Control Module Watchdog or Temperature Sensor Error (Bank 2)
(SIG)
DTC P1073 VVT-Sensors Data Conformity (Bank 1) (SIG)
DTC P1074 VVT-Sensors Data Conformity (Bank 2 (SIG)
DTC P1075 VVT-Overload Protection (Bank 1) (PLAUS)
DTC P1076 VVT-Overload Protection ECU-Temperature High Input (Bank 1) (SIG)
DTC P1078 VVT-Overload Protection Control Motor Current High Input (Bank 1) (MAX)
DTC P1079 VVT-Overload Protection (Bank 2) (PLAUS)
DTC P1080 VVT-Overload Protection ECU-Temperature High Input (Bank 2) (SIG)
DTC P1081 VVT-Overload Protection Control Motor Temperature High Input (Bank 2)
(MIN)
DTC P1082 VVT-Overload Protection Control Motor Current High Input (Bank 2) (MAX)
DTC P1104 Differential Pressure Sensor Intake Manifold Pressure Too Low (Bank 1) (MIN)
DTC P1104 Differential Pressure Sensor Intake Manifold Pressure Too Low (Bank 1) (MIN)
DTC P1105 Differential Pressure Sensor Intake Manifold Pressure Too High (Bank 1) (MAX)
DTC P1105 Differential Pressure Sensor Intake Manifold Pressure Too High (Bank 1) (MAX)
DTC P110F Ambient Air Temperature Sensor Faulty CAN Signal (SIG)
DTC P111E Intake Air Temperature Sensor 1 Maximum Temperature Implausible (Bank 1)
(MAX)
DTC P111F Intake Air Temperature Sensor 1 Minimum Temperature Implausible (Bank 1)
2009 BMW 650i
DTC INDEX 550i, 650i, 750i, 750Li & X5
(MIN)
DTC P112A Engine Coolant Temperature Sensor 1 Maximum Temperature Implausible
(MAX)
DTC P112B Engine Coolant Temperature Sensor 1 Minimum Temperature Implausible (MIN)
DTC P1130 O2 Sensor Circuit Dynamic Test (Bank 1 Sensor 2) (PLAUS)
DTC P1131 O2 Sensor Circuit Dynamic Test (Bank 2 Sensor 2) (PLAUS)
DTC P113A Mass or Volume Air Flow 1 Correction Signal Plausibility Period Too Long
(MAX)
DTC P113B Mass or Volume Air Flow 1 Correction Signal Plausibility Period Too Short
(MIN)
DTC P115A Mass or Volume Air Flow 'A' Maximum Exceeded (MAX)
DTC P115B Mass or Volume Air Flow 'A' Minimum Fallen Below (MIN)
DTC P115C Mass or Volume Air Flow 'A' Air Mass Too Low Compared to Model (SIG)
DTC P115D Mass or Volume Air Flow 'A' Air Mass Too High Compared to Model (PLAUS)
DTC P1197 Differential Pressure Sensor Intake Manifold High Input (Bank 1) (MAX)
DTC P1198 Differential Pressure Sensor Intake Manifold Low Input (Bank 1) (MIN)
DTC P1199 Differential Pressure Sensor Intake Manifold Pressure Plausibility (Bank 1)
(PLAUS)
DTC P1230 Fuel Pump Relay Primary Circuit (SIG)
DTC P1234 Fuel Pump Relay Primary Circuit Low (MIN)
DTC P1236 Fuel Pump Relay Primary Circuit High (MAX)
DTC P1327 Knock Sensor 2 Circuit Low Input (Bank 1) (MIN)
DTC P1328 Knock Sensor 2 Circuit High Input (Bank 1) (MAX)
DTC P1329 Knock Sensor 3 Circuit Low Input (MIN)
DTC P1330 Knock Sensor 3 Circuit High Input (MAX)
DTC P135C Knock Sensor 2 Circuit (Bank 1) (PLAUS)
DTC P1377 Camshaft Position Sensor Master Camshaft not Defined (SIG)
DTC P1381 Control Module Self-Test, Knock Control Offset (Bank 1) (PLAUS)
DTC P1382 Control Module Self-Test, Knock Control Test Pulse (Bank 1) (MAX)
DTC P1384 Knock Sensor 3 Circuit (PLAUS)
DTC P1386 Control Module Self-Test, Knock Control Circuit Baseline Test (Bank 1) (MIN)
DTC P1434 Diagnostic Module Tank Leakage (DM-TL) (SIG)
DTC P1447 Diagnostic Module Tank Leakage (DM-TL) Pump Current Too High During
Switching Solenoid Test (PLAUS)
DTC P1448 Diagnostic Module Tank Leakage (DM-TL) Pump Current Too Low (MIN)
DTC P1449 Diagnostic Module Tank Leakage (DM-TL) Pump Current Too High (MAX)
DTC P14C4 Radiator Shutter (Upper) Mechanical (MIN)
DTC P14C5 Radiator Shutter (Upper) Hardware Defect (MAX)
DTC P14C6 Radiator Shutter (Lower) Electrical (MAX)
DTC P150A Battery Sensor BSD (Bit Serial Data Interface) Extended Communication Circuit
(MAX)
2009 BMW 650i
DTC INDEX 550i, 650i, 750i, 750Li & X5
DTC P150B Battery Sensor BSD (Bit Serial Data Interface) Communication Circuit (SIG)
DTC P150C Battery Sensor Firmware Implausible (PLAUS)
DTC P150D Battery Sensor Temperature Error (MAX)
DTC P150E Battery Sensor Voltage Error (SIG)
DTC P150F Battery Sensor Current Error (PLAUS)
DTC P1511 DISA (Differentiated Intake Manifold) Control Circuit Electrical (PLAUS)
DTC P1512 DISA (Differentiated Intake Manifold) Control Circuit Signal Low (MIN)
DTC P1513 DISA (Differentiated Intake Manifold) Control Circuit Signal High (MAX)
DTC P1515 Engine Off Timer Plausibility (PLAUS)
DTC P1517 Rough Road Detection No Wheel Speed Signal (SIG)
DTC P1518 Rough Road Detection Wheel Speed Too High (MAX)
DTC P151A Battery Sensor Terminal 15/30 Wakeup Circuit (MAX)
DTC P151B Battery Sensor Wakeup Circuit (PLAUS)
DTC P151C Battery Sensor System Error (SIG)
DTC P151F CAN Message Monitoring Vehicle Speed Sensor Timeout (SIG)
DTC P1521 Engine Oil Quality Sensor Communication Error (SIG)
DTC P1521 Engine Oil Quality Sensor Communication Error (SIG)
DTC P152A Vehicle Speed Sensor, Speed Too Low Compared to Reference under Load
(MAX)
DTC P152B Vehicle Speed Sensor, Speed Too Low Compared to Reference in Coast Down
(MIN)
DTC P1535 DISA (Differentiated Intake Manifold) Coil Temperature Limit Value Exceeded
(PLAUS)
DTC P1536 DISA (Differentiated Intake Manifold) Controller Monitoring, Control Deviation
(SIG)
DTC P1537 DISA (Differentiated Intake Manifold) Potentiometer Voltage in Lower Diagnosis
Range (MIN)
DTC P1538 DISA (Differentiated Intake Manifold) Potentiometer Voltage in Upper Diagnosis
Range (MAX)
DTC P1539 DISA (Differentiated Intake Manifold) Coil Temperature Threshold Exceeded
(MAX)
(MIN)
(MIN)
DTC P1551 Engine Off Timer Timeout (SIG)
DTC P1561 Cold Start Idle Air Control System RPM Lower Than Expected (Bank 1) (MIN)
DTC P1562 Cold Start Idle Air Control System RPM Higher Than Expected (Bank 1) (MAX)
DTC P1577
2009 BMW 650i
DTC INDEX 550i, 650i, 750i, 750Li & X5
DTC P1578 Speed Indication Instrument Pack/ASC Signal Correlation (PLAUS)

DTC P1586 Engine Oil Quality Sensor Temperature Measurement (MAX)
DTC P1587 Engine Oil Quality Sensor Level Measurement (MIN)
DTC P1588 Engine Oil Quality Sensor Permeability Measurement (PLAUS)
DTC P1603 Control Module Self-Test, Torque Monitoring (PLAUS)
DTC P160A Powermanagement Exhaustive Discharge (MIN)
DTC P160B Powermanagement Defective (PLAUS)
DTC P160C Powermanagement Overvoltage (MAX)
DTC P160D Powermanagement Undervoltage (MIN)
DTC P160E Powermanagement Operation Without Battery (SIG)
DTC P160F Powermanagement No-Load Current Error (PLAUS)
DTC P1614 Serial Communication Link ACC (Adaptive Cruise Control) (SIG)
DTC P1631 Throttle Valve Actuator Spring Test (Bank 1) (MIN)
DTC P1633 Throttle Valve Adaptation Limp-Home Position Unknown (Bank 1) (PLAUS)
DTC P1634 Throttle Valve Adaptation Spring Test Failed (Bank 1) (MAX)
DTC P1635 Throttle Valve Adaptation Lower Mechanical Stop not Adapted (Bank 1)
(PLAUS)
DTC P1637 Throttle Valve Position Control, Control Deviation (Bank 1) (PLAUS)
DTC P1638 Throttle Valve Position Control Throttle Stuck Temporarily (Bank 1) (MIN)
DTC P1639 Throttle Valve Position Control Throttle Stuck Permanently (Bank 1) (MAX)
DTC P163C Voltage Monitoring Control Module Overvoltage (MAX)
DTC P163D Voltage Monitoring Control Module Cut-off Detected (MIN)
DTC P163E Voltage Monitoring Control Module Communication Error (SIG)
DTC P1641 Throttle Valve Adaptation Stop due to Environmental Conditions (MAX)
DTC P1642 Throttle Valve Adaptation Stop due to Environmental Values (MIN)
DTC P1643 Throttle Valve Actuator Start Test Amplifier Balancing Plausibility (PLAUS)
DTC P1644 Throttle Valve Adaptation Stop Relearning Lower Mechanical Stop (Bank 1)
(PLAUS)
DTC P1645 Internal Control Module Random Access Memory (RAM) Reading Error (MAX)
DTC P1649 Internal Control Module Random Access Memory (RAM) Writing Error (MIN)
DTC P1650 Start While Engine is Running (SIG)
DTC P1655 EWS (Electronic Immobilizer) Rolling Code Faulty Storage (MAX)
DTC P1660 EWS (Electronic Immobilizer) Telegram Error (MIN)
DTC P1661 Timeout EWS (Electronic Immobilizer)-Telegram (SIG)
DTC P1662 EWS (Electronic Immobilizer) Telegram Parity Error (PLAUS)
DTC P1663 EWS (Electronic Immobilizer) Rolling Code Faulty Storage in EEPROM (MIN)
DTC P1664 EWS (Electronic Immobilizer) Writing/Reading Error EEPROM (SIG)
DTC P1665 EWS (Electronic Immobilizer) Tampering via Rolling Code (PLAUS)
DTC P1666 EWS (Electronic Immobilizer) Tampering via KWP2000UE / Start Value not
Accepted (SIG)
DTC P1667 EWS (Electronic Immobilizer) Start Value not yet Programmed (MIN)
2009 BMW 650i
DTC INDEX 550i, 650i, 750i, 750Li & X5
DTC P1668 EWS (Electronic Immobilizer) Start Value Destroyed (MAX)

DTC P1676 ACC (Adaptive Cruise Control) Signal Plausibility (PLAUS)
DTC P1677 ACC (Adaptive Cruise Control) No Activity Detected (MIN)
DTC P1678 ACC (Adaptive Cruise Control) no Response to ACC Cut-Off (MAX)
DTC P1680 Electronic Throttle Control Monitor Level 2/3 ADC Processor Fault (SIG)
DTC P1681 Electronic Throttle Control Monitor Level 2/3 Engine Speed Calculation Error
(PLAUS)
DTC P1686 Electronic Throttle Control Monitor Level 2/3 Pedal Position Sensor Diagnostic
Error (PLAUS)
DTC P16A4 Timeout Control Module Knock Sensor SPI-Bus (PLAUS)
DTC P1721 CAN Timeout ASC/DSC (SIG)
DTC P2065 Fuel Level Sensor 'B' Circuit (SIG)
DTC P2067 Fuel Level Sensor 'B' Circuit Low (MIN)
DTC P2068 Fuel Level Sensor 'B' Circuit High (MAX)
DTC P2088 'A' Camshaft Position Actuator Control Circuit Low (Bank 1) (MIN)
DTC P2089 'A' Camshaft Position Actuator Control Circuit High (Bank 1) (MAX)
DTC P2090 'B' Camshaft Position Actuator Control Circuit Low (Bank 1) (MIN)
DTC P2091 'B' Camshaft Position Actuator Control Circuit High (Bank 1) (MAX)
DTC P2092 'A' Camshaft Position Actuator Control Circuit Low (Bank 2) (MIN)
DTC P2093 'A' Camshaft Position Actuator Control Circuit High (Bank 2) (MAX)
DTC P2094 'B' Camshaft Position Actuator Control Circuit Low (Bank 2) (MIN)
DTC P2095 'B' Camshaft Position Actuator Control Circuit High (Bank 2) (MAX)
DTC P2096 Post Catalyst Fuel Trim System Too Lean (Bank 1) (MIN)
DTC P2097 Post Catalyst Fuel Trim System Too Rich (Bank 1) (MAX)
DTC P2098 Post Catalyst Fuel Trim System Too Lean (Bank 2) (Min)
DTC P2099 Post Catalyst Fuel Trim System Too Rich (Bank 2) (MAX)
DTC P2100 Throttle Actuator 'A' Control Motor Circuit/Open (SIG)
DTC P2102 Throttle Actuator 'A' Control Motor Circuit Low (MIN)
DTC P2103 Throttle Actuator 'A' Control Motor Circuit High (MAX)
DTC P2120 Throttle/Pedal Position Sensor/Switch 'D' Circuit (PLAUS)
DTC P2122 Throttle/Pedal Position Sensor/Switch 'D' Circuit Low (MIN)
DTC P2123 Throttle/Pedal Position Sensor/Switch 'D' Circuit High (MAX)
DTC P2127 Throttle/Pedal Position Sensor/Switch 'E' Circuit Low (MIN)
DTC P2128 Throttle/Pedal Position Sensor/Switch 'E' Circuit High (MAX)
DTC P2138 Throttle/Pedal Position Sensor/Switch 'D' / 'E' Voltage Correlation (PLAUS)
DTC P2177 System Too Lean Off Idle (Bank 1) (MAX)
DTC P2178 System Too Rich Off Idle (Bank 1) (MIN)
2009 BMW 650i
DTC INDEX 550i, 650i, 750i, 750Li & X5

DTC P2183 Engine Coolant Temperature Sensor 2 Circuit Range/Performance (PLAUS)
DTC P2184 Engine Coolant Temperature Sensor 2 Circuit Low (MIN)
DTC P2185 Engine Coolant Temperature Sensor 2 Circuit High (MAX)
DTC P2187 System Too Lean at Idle (Bank 1) (MAX)
DTC P2187 System Too Lean at Idle (Bank 1) (SIG)
DTC P2188 System Too Rich at Idle (Bank 1) (MIN)
DTC P2188 System Too Rich at Idle (Bank 1) (PLAUS)
DTC P2189 System Too Lean at Idle (Bank 2) (MAX)
DTC P2189 System Too Lean at Idle (Bank 2) (SIG)
DTC P2190 System Too Rich at Idle (Bank 2) (MIN)
DTC P2190 System Too Rich at Idle (Bank 2) (PLAUS)
DTC P2191 System Too Lean at Higher Load (Bank 1) (MAX)
DTC P2192 System Too Rich at Higher Load (Bank 1) (MIN)
DTC P2193 System Too Lean at Higher Load (Bank 2) (MAX)
DTC P2194 System Too Rich At Higher Load (Bank 2) (MIN)
DTC P2195 O2 Sensor Signal Biased/Stuck Lean (Bank 1 Sensor 1) (PLAUS)
DTC P2196 O2 Sensor Signal Biased/Stuck Rich (Bank 1 Sensor 1) (SIG)
DTC P2197 O2 Sensor Signal Biased/Stuck Lean (Bank 2 Sensor 1) (PLAUS)
DTC P2198 O2 Sensor Signal Biased/Stuck Rich (Bank 2 Sensor 1) (SIG)
DTC P2228 Barometric Pressure Circuit Low (MIN)
DTC P2229 Barometric Pressure Circuit High (MAX)
DTC P2231 O2 Sensor Signal Circuit Shorted to Heater Circuit (Bank 1 Sensor 1) (SIG)
DTC P2234 O2 Sensor Signal Circuit Shorted to Heater Circuit (Bank 2 Sensor 1) (SIG)
DTC P2237 O2 Sensor Positive Current Control Circuit/Open (Bank 1 Sensor 1) (SIG)
DTC P2240 O2 Sensor Positive Current Control Circuit/Open (Bank 2 Sensor 1) (SIG)
DTC P2243 O2 Sensor Reference Voltage Circuit/Open (Bank 1 Sensor 1) (SIG)
DTC P2247 O2 Sensor Reference Voltage Circuit/Open (Bank 2 Sensor 1) (SIG)
DTC P2251 O2 Sensor Negative Current Control Circuit/Open (Bank 1 Sensor 1) (SIG)
DTC P2254 O2 Sensor Negative Current Control Circuit/Open (Bank 2 Sensor 1) (SIG)
DTC P2270 O2 Sensor Signal Biased/Stuck Lean (Bank 1 Sensor 2) (MAX)
DTC P2271 O2 Sensor Signal Biased/Stuck Rich (Bank 1 Sensor 2) (MIN)
DTC P2272 O2 Sensor Signal Biased/Stuck Lean (Bank 2 Sensor 2) (MAX)
DTC P2273 O2 Sensor Signal Biased/Stuck Rich (Bank 2 Sensor 2) (MIN)
DTC P2400 Evaporative Emission System Leak Detection Pump Control Circuit/Open (SIG)
DTC P2401 Evaporative Emission System Leak Detection Pump Control Circuit Low (MIN)
DTC P2402 Evaporative Emission System Leak Detection Pump Control Circuit High (MAX)
DTC P240A Evaporative Emission System Leak Detection Pump Heater Control Circuit/Open
(SIG)
2009 BMW 650i
DTC INDEX 550i, 650i, 750i, 750Li & X5
(MIN)
DTC P240C Evaporative Emission System Leak Detection Pump Heater Control Circuit High
(MAX)
DTC P2414 O2 Sensor Exhaust Sample Error (Bank 1 Sensor 1) (PLAUS)
DTC P2415 O2 Sensor Exhaust Sample Error (Bank 2 Sensor 1) (PLAUS)
DTC P2418 Evaporative Emission System Switching Valve Control Circuit/Open (SIG)
DTC P2419 Evaporative Emission System Switching Valve Control Circuit Low (MIN)
DTC P2420 Evaporative Emission System Switching Valve Control Circuit High (MAX)
DTC P250A Engine Oil Level Sensor Circuit (SIG)
DTC P250B Engine Oil Level Sensor Circuit Range/Performance (PLAUS)
DTC P250F Engine Oil Level Too Low (MIN)
DTC P2626 O2 Sensor Pumping Current Trim Circuit/Open (Bank 1 Sensor 1) (SIG)
DTC P2629 O2 Sensor Pumping Current Trim Circuit/Open (Bank 2 Sensor 1) (SIG)
DTC P300A Controlled Air Guiding Circuit High (MAX)
DTC P300B Controlled Air Guiding Circuit Low (MIN)
DTC P300C Controlled Air Guiding Circuit (SIG)
DTC P3012 O2 Sensor Signal Circuit Adaptation Value Too High (Bank 1 Sensor 1) (MAX)
DTC P3013 O2 Sensor Signal Circuit Adaptation Value Too High (Bank 2 Sensor 1) (MAX)
DTC P3014 O2 Sensor WRAF-IC Supply Voltage Too Low (Bank 1 Sensor 1) (MIN)
DTC P3015 O2 Sensor WRAF-IC Supply Voltage Too Low (Bank 2 Sensor 1) (MIN)
DTC P3016 O2 Sensor Calibration Resistance at WRAF-IC Plausibility (Bank 1 Sensor 1)
(SIG)
DTC P3017 O2 Sensor Calibration Resistance at WRAF-IC Plausibility (Bank 2 Sensor 1)
(SIG)
DTC P3018 O2 Sensor Lambda Controller Value Above Threshold Due To Open Pumping
Current Circuit (Bank 1 Sensor 1) (MAX)
DTC P3019 O2 Sensor Lambda Controller Value Above Threshold Due To Open Pumping
Current Circuit (Bank 2 Sensor 1) (MAX)
DTC P3020 O2 Sensor Signal Voltage Too Low during Coast Down Fuel Cut-Off due to Open
Pumping Current Circuit (Bank 1 Sensor 1) (PLAUS)
DTC P3021 O2 Sensor Signal Voltage Too Low during Coast Down Fuel Cut-Off due to Open
Pumping Current Circuit (Bank 2 Sensor 1) (PLAUS)
DTC P3022 O2 Sensor Disturbed SPI Communication to WRAF-IC (Bank 1 Sensor 1) (SIG)
DTC P3023 O2 Sensor Disturbed SPI Communication to WRAF-IC (Bank 2 Sensor 1) (SIG)
DTC P3024 O2 Sensor Initialization Error WRAF-IC (Bank 1 Sensor 1) (PLAUS)
DTC P3025 O2 Sensor Initialization Error WRAF-IC (Bank 2 Sensor 1) (PLAUS)
DTC P3026 O2 Sensor Operating Temperature Not Reached (Bank 1 Sensor 1) (MAX)
DTC P3027 O2 Sensor Operating Temperature Not Reached (Bank 2 Sensor 1) (MAX)
DTC P3028 O2 Sensor Heater Control No Activity Detected (Bank 1 Sensor 1) (MIN)
DTC P3029 O2 Sensor Heater Control No Activity Detected (Bank 2 Sensor 1) (MIN)
DTC P316C Radiator Coolant Temperature Sensor Maximum Temperature Implausible
2009 BMW 650i
DTC INDEX 550i, 650i, 750i, 750Li & X5
DTC P3200 Powertrain CAN, CAN Chip Defective (MAX)

DTC P3201 Powertrain CAN, DPRAM-CAN Chip Defective (MIN)
DTC P3202 Powertrain CAN, CAN Chip Cut-Off (SIG)
DTC P3203 Local CAN, LoCAN Chip Defective (MAX)
DTC P3204 Local CAN, DPRAM-LoCAN Chip Defective (MIN)
DTC P3205 Local CAN, CAN Chip Cut-Off (MAX)
DTC P3205 Local CAN, CAN Chip Cut-Off (MIN)
DTC P3205 Local CAN, CAN Chip Cut-Off (SIG)
DTC P3206 CAN Timeout ARS (MIN)
DTC P3207 CAN Message Monitoring ARS No Signal (SIG)
DTC P3208 CAN Message Monitoring ARS Plausibility (PLAUS)
DTC P3209 CAN Message Monitoring ASC/DSC Alive Check (MIN)
DTC P3210 CAN Message Monitoring ASC/DSC Plausibility (PLAUS)
DTC P3212 CAN Message Monitoring CAS Plausibility (PLAUS)
DTC P3215 CAN Message Monitoring IHKA (Automatic Heating and Air Conditioning) No
Signal (SIG)
DTC P3217 CAN Message Monitoring Instrument Pack Plausibility (PLAUS)
DTC P3219 CAN Message Monitoring SZL (Switch Cluster Steering Column) Alive Check
(MIN)
DTC P321E Ambient Pressure Sensor Maximum Pressure Implausible (MAX)
DTC P321F Ambient Pressure Sensor Minimum Pressure Implausible (MIN)
DTC P3220 CAN Message Monitoring SZL (Switch Cluster Steering Column) No Signal
(SIG)
DTC P3221 CAN Message Monitoring SZL (Switch Cluster Steering Column) Plausibility
(PLAUS)
DTC P3223 Generator Mechanical (MAX)
DTC P3223 Generator Mechanical (PLAUS)
DTC P3225 Generator Communication Error (MIN)
DTC P3226 E-Box Control Circuit Fan High Input (MAX)
DTC P3227 E-Box Control Circuit Fan Low Input (MIN)
DTC P3228 E-Box Control Circuit Fan Open Circuit (SIG)
DTC P322A Ambient Pressure Sensor Continuity Error (SIG)
DTC P3231 Control Module Monitoring Error Response Plausibility (PLAUS)
DTC P3232 Control Module Monitoring Ignition Timing Plausibility (MIN)
DTC P3233 Control Module Monitoring Relative Charge Plausibility (MAX)
DTC P3234 Control Module Monitoring Throttle Valve Actuator Stop Test (PLAUS)
DTC P3235 Control Module Monitoring Version Coding Plausibility (SIG)
DTC P3236 Control Module Monitoring Injection Time Relative Fuel Quantity Plausibility
(MIN)
DTC P3237 Control Module Monitoring Fuel Correction Error (MAX)
DTC P3238 Control Module Monitoring TPU Chip Defective (MAX)
2009 BMW 650i
DTC INDEX 550i, 650i, 750i, 750Li & X5
DTC P3239 Control Module Coding Process No Coding (MIN)

DTC P3239 Control Module Coding Process No Coding (PLAUS)
DTC P323C Ambient Pressure Sensor Comparison Current to Last Driving Cycle Implausible
(PLAUS)
DTC P323D Control Module Monitoring Air Mass Flow Balancing, Control Range Monitoring
(PLAUS)
DTC P3247 Internal Control Module NVRAM Backup Error (PLAUS)
DTC P324A Generator Type Implausible (MAX)
DTC P324A Generator Type Implausible (PLAUS)
DTC P324C Generator Over Temperature Calculated (MAX)
DTC P324E Generator Regulator Type Implausible (MAX)
DTC P3258 No Info (PLAUS)
DTC P325A Generator Electrical Error Calculated (MAX)
DTC P3400 Cylinder Deactivation System (Bank 1) (PLAUS)
DTC P3497 Cylinder Deactivation System (Bank 2) (PLAUS)
DTC U0101 Lost Communication With TCM (SIG)
DTC U0101 Lost Communication With TCM (SIG)
DTC U0137 Lost Communication With Trailer Brake Control Module (PLAUS)
DTC U0137 Lost Communication With Trailer Brake Control Module (PLAUS)
DTC U0137 Lost Communication With Trailer Brake Control Module (SIG)
DTC U0155 Lost Communication With Instrument Panel Cluster (IPC) Control Module (SIG)
DTC U0155 Lost Communication With Instrument Panel Cluster (IPC) Control Module (SIG)
DTC U1108 Message Monitoring Torque Request Steering Alive Check (PLAUS)
DTC U1108 Message Monitoring Torque Request Steering Alive Check (PLAUS)
DTC U1109 Lost Communication With Torque Request Steering (SIG)
DTC U1109 Lost Communication With Torque Request Steering (SIG)
DTC U1115 Lost Communication With Vehicle Mode Status (SIG)
DTC U1116 Message Monitoring Vehicle Mode Status Check Sum Error (PLAUS)
DTC U1120 Lost Communication With Steering Wheel Angle (SIG)
DTC U1121 Lost Communication With Power Management Battery Voltage (SIG)
DTC U1122 Lost Communication With Power Management Charge Voltage (SIG)
DTC U1129 Lost Communication With Reverse Status (SIG)
DTC U112A Message Monitoring Instrument Pack Status Alive Check (MIN)
DTC U112D Lost Communication With Control Crash Cut - Off EKP (Electrical Fuel Pump)
(SIG)
DTC U1130 Lost Communication With Radiator Shutter (Upper) (PLAUS)
DTC U1131 Lost Communication With CAS (SIG)
DTC U1132 Lost Communication With Generator via BSD (Bit Serial Data Interface) (MAX)
DTC U1132 Lost Communication With Generator via BSD (Bit Serial Data Interface) (SIG)
2009 BMW 650i
DTC INDEX 550i, 650i, 750i, 750Li & X5
DTC U1132 Lost Communication With Generator via BSD (Bit Serial Data Interface) (SIG)
DTC U1133 Lost Communication With Generator 2 via BSD (Bit Serial Data Interface) (SIG)
DTC U1134 Lost Communication With Lamp Status (MAX)
DTC U1134 Lost Communication With Lamp Status (SIG)
DTC U1135 Lost Communication With Status Water Valve (SIG)
DTC U113C Lost Communication With Time/Date (SIG)
DTC U113D Lost Communication With Wheel Torque Management Request/Driveline (SIG)
DTC U113E Lost Communication With Display Transmission Data (MAX)
DTC U113E Lost Communication With Display Transmission Data (MIN)
DTC U113E Lost Communication With Display Transmission Data (SIG)
DTC U1165 Message Monitoring Wheel Torque Management Request/Driveline Alive
Check/Check Sum Error (PLAUS)
DTC U1172 Lost Communication With VVT-Control Module (SIG)
DTC U1174 Message Monitoring VVT - Control Module Alive Check/Check Sum Error
(PLAUS)
DTC U1200 Message Monitoring TCM Check Sum Error (PLAUS)
DTC U1202 Message Monitoring TCM Alive Check (MIN)
DTC U1202 Message Monitoring TCM Alive Check (PLAUS)
2004 BMW 645Ci
DTC INDEX BMW (TRANSMISSION)
DTC INDEX
BMW (TRANSMISSION)
SELF-DIAGNOSTICS (TRANSMISSION) DTCS

DIAGNOSTIC TROUBLE CODES Z3, 318I & 318TI (1/96-8/96)
DIAGNOSTIC TROUBLE CODES Z3, 318i & 318ti (1/96-8/96)

PCode BMW Code Possible Problem Diagnostic Parameters
P0705 8 Transmission Range Sensor "A" Circuit See 1996 4-CYLINDER
Malfunction (PRNDL Input) DIAGNOSIS: Z3, 318i &
318ti (1/96-8/96) .
P0720 42 Output Speed Sensor Circuit See 1996 4-CYLINDER
DIAGNOSIS: Z3, 318i &
318ti (1/96-8/96) .
P0730 100 Incorrect Gear Ratio See 1996 4-CYLINDER
318ti (1/96-8/96) .
P0740 111 Torque Converter Clutch Circuit/Open See 1996 4-CYLINDER
318ti (1/96-8/96) .
P0743 32 Torque Converter Clutch Circuit See 1996 4-CYLINDER
Electrical DIAGNOSIS: Z3, 318i &
318ti (1/96-8/96) .
P0748 5 Pressure Control Solenoid "A" Electrical See 1996 4-CYLINDER
318ti (1/96-8/96) .
P0753 30 Shift Solenoid "A" Electrical See 1996 4-CYLINDER
318ti (1/96-8/96) .
P0758 33 Shift Solenoid "B" Electrical See 1996 4-CYLINDER
318ti (1/96-8/96) .
P1743 4 Pressure Control Solenoid "E" Electrical See 1996 4-CYLINDER
(M44/M52: Brake Band Electrical) DIAGNOSIS: Z3, 318i &
318ti (1/96-8/96) .
P1746 104 Transmission Control Module Output See 1996 4-CYLINDER
Stage DIAGNOSIS: Z3, 318i &
318ti (1/96-8/96) .
P1747 150 CAN-Bus Monitoring See 1996 4-CYLINDER
318ti (1/96-8/96) .
2004 BMW 645Ci
318ti (1/96-8/96) .
318ti (1/96-8/96) .
P1748 103 Transmission Control Module Self-Test See 1996 4-CYLINDER
318ti (1/96-8/96) .
318ti (1/96-8/96) .
318ti (1/96-8/96) .
P1749 108 Secondary Pressure Solenoid No Diagnosis Available
Communication Error (M52: Internal
Transmission Control Module Memory
Error)
P1750 54 Secondary Pressure Solenoid Circuit No Diagnosis Available
Range/Performance
(M44/M52/S52/M62/M73: System
Voltage Input Low)
P1761 2 Shiftlock Solenoid No Diagnosis Available
P1765 154 CAN Throttle Valve No Diagnosis Available
P1780 152 CAN Torque Reduction No Diagnosis Available
DIAGNOSTIC TROUBLE CODES Z3, 318I & 318TI (9/96-8/97)
DIAGNOSTIC TROUBLE CODES Z3, 318i & 318ti (9/96-8/97)

PCode BMW Code Possible Cause Diagnostic Parameters
P0705 8 Transmission Range Sensor "A" See 1997 4-CYLINDER
Circuit Malfunction (PRNDL Input) DIAGNOSIS: Z3, 318i &
318ti (9/96-8/97) .
318ti (9/96-8/97) .
P0731 100 Gear 1 Incorrect Ratio See 1997 4-CYLINDER
318ti (9/96-8/97) .
P0732 ..... Gear 2 Incorrect Ratio See 1997 4-CYLINDER
318ti (9/96-8/97) .
2004 BMW 645Ci

318ti (9/96-8/97) .
318ti (9/96-8/97) .
P0740 111 Torque Converter Clutch See 1997 4-CYLINDER
Circuit/Open DIAGNOSIS: Z3, 318i &
318ti (9/96-8/97) .
318ti (9/96-8/97) .
P0748 5 Pressure Control Solenoid "A" See 1997 4-CYLINDER
318ti (9/96-8/97) .
318ti (9/96-8/97) .
318ti (9/96-8/97) .
P1743 4 Pressure Control Solenoid "E" See 1997 4-CYLINDER
Electrical (M44/M52: Brake Band DIAGNOSIS: Z3, 318i &
Electrical) 318ti (9/96-8/97) .
Stage DIAGNOSIS: Z3, 318i &
318ti (9/96-8/97) .
318ti (9/96-8/97) .
318ti (9/96-8/97) .
318ti (9/96-8/97) .
P1748 103 Transmission Control Module Self- See 1997 4-CYLINDER
Test DIAGNOSIS: Z3, 318i &
318ti (9/96-8/97) .
318ti (9/96-8/97) .
318ti (9/96-8/97) .
2004 BMW 645Ci

Transmission Control Module
Memory Error)
Range/Performance
(M44/M52/S52/M62/M73: System
Voltage Input Low)
DIAGNOSTIC TROUBLE CODES Z3 (10/97-8/98), 318I (9/97-6/98) & 318TI (9/97-6/98)
TABLE 3: Z3 (10/97-8/98), 318i (9/97-6/98) & 318ti (9/97-6/98)

P0705 8 Transmission Range Sensor "A" See 1998 4-CYLINDER
Circuit Malfunction (PRNDL Input) DIAGNOSIS: Z3 (10/97-
8/98), 318i (9/97-6/98) &
318ti (9/97-6/98) .
DIAGNOSIS: Z3 (10/97-
8/98), 318i (9/97-6/98) &
318ti (9/97-6/98) .
8/98), 318i (9/97-6/98) &
318ti (9/97-6/98) .
8/98), 318i (9/97-6/98) &
318ti (9/97-6/98) .
8/98), 318i (9/97-6/98) &
318ti (9/97-6/98) .
8/98), 318i (9/97-6/98) &
318ti (9/97-6/98) .
P0740 111 Torque Converter Clutch See 1998 4-CYLINDER
Circuit/Open DIAGNOSIS: Z3 (10/97-
8/98), 318i (9/97-6/98) &
2004 BMW 645Ci

Electrical DIAGNOSIS: Z3 (10/97-
8/98), 318i (9/97-6/98) &
318ti (9/97-6/98) .
Electrical DIAGNOSIS: Z3 (10/97-
8/98), 318i (9/97-6/98) &
318ti (9/97-6/98) .
8/98), 318i (9/97-6/98) &
318ti (9/97-6/98) .
8/98), 318i (9/97-6/98) &
318ti (9/97-6/98) .
Electrical (M44/M52: Brake Band DIAGNOSIS: Z3 (10/97-
Electrical) 8/98), 318i (9/97-6/98) &
318ti (9/97-6/98) .
P1746 104 Transmission Control Module See 1998 4-CYLINDER
Output Stage DIAGNOSIS: Z3 (10/97-
8/98), 318i (9/97-6/98) &
318ti (9/97-6/98) .
8/98), 318i (9/97-6/98) &
318ti (9/97-6/98) .
8/98), 318i (9/97-6/98) &
318ti (9/97-6/98) .
8/98), 318i (9/97-6/98) &
318ti (9/97-6/98) .
Test DIAGNOSIS: Z3 (10/97-
8/98), 318i (9/97-6/98) &
318ti (9/97-6/98) .
Test DIAGNOSIS: Z3 (10/97-
8/98), 318i (9/97-6/98) &
318ti (9/97-6/98) .
P1748 110 Transmission Control Module Self- No Diagnosis Available
2004 BMW 645Ci

Memory Error)
Range/Performance
(M44/M52/S52/M62/M73: System
Voltage Input Low)
DIAGNOSTIC TROUBLE CODES DIAGNOSTIC TROUBLE CODES 318TI (9/98-12/98)
TABLE 4: DIAGNOSTIC TROUBLE CODES 318ti (9/98-12/98)

P0705 8 Transmission Range Sensor "A" Circuit See 1999 4-CYLINDER
Malfunction (PRNDL Input) DIAGNOSIS: 318ti (9/98-
12/98) .
DIAGNOSIS: 318ti (9/98-
12/98) .
12/98) .
12/98) .
12/98) .
12/98) .
P0740 111 Torque Converter Clutch Circuit/Open See 1999 4-CYLINDER
12/98) .
Electrical DIAGNOSIS: 318ti (9/98-
12/98) .
Electrical DIAGNOSIS: 318ti (9/98-
2004 BMW 645Ci
12/98) .
12/98) .
12/98) .
Electrical (M44/M52: Brake Band DIAGNOSIS: 318ti (9/98-
Electrical) 12/98) .
Stage DIAGNOSIS: 318ti (9/98-
12/98) .
12/98) .
12/98) .
12/98) .
12/98) .
12/98) .
12/98) .
Transmission Control Module Memory
Error)
Range/Performance
(M44/M52/S52/M62/M73: System
Voltage Input Low)
2004 BMW 645Ci
DIAGNOSTIC TROUBLE CODES 6-CYLINDER : M52 - 2.8L (11/95-8/96)
DIAGNOSTIC TROUBLE CODES 6-CYLINDER : M52 - 2.8L (11/95-8/96)

PCode BMW Code Possible Cause Diagnosis Parameters
P0412 ..... Secondary Air System Solenoid No Diagnosis Available
Valve
P0705 8 Transmission Range Sensor "A" See 6-CYLINDER
Circuit Malfunction (PRNDL Input) DIAGNOSIS: M52 - 2.8L
(11/95-8/96) .
P0715 ..... Input Speed Sensor No Diagnosis Available
P0720 42 Output Speed Sensor Circuit See 6-CYLINDER
DIAGNOSIS: M52 - 2.8L
(11/95-8/96) .
P0730 100 Incorrect Gear Ratio See 6-CYLINDER
(11/95-8/96) .
P0740 111 Torque Converter Clutch See 6-CYLINDER
Circuit/Open DIAGNOSIS: M52 - 2.8L
(11/95-8/96) .
P0743 32 Torque Converter Clutch Circuit See 6-CYLINDER
Electrical DIAGNOSIS: M52 - 2.8L
(11/95-8/96) .
P0748 5 Pressure Control Solenoid "A" See 6-CYLINDER
Electrical DIAGNOSIS: M52 - 2.8L
(11/95-8/96) .
P0753 30 Shift Solenoid "A" Electrical See 6-CYLINDER
(11/95-8/96) .
P0758 33 Shift Solenoid "B" Electrical See 6-CYLINDER
(11/95-8/96) .
P1453 ..... Secondary Air System Relay No Diagnosis Available
P1743 4 Pressure Control Solenoid "E" See 6-CYLINDER
Electrical (M44/M52: Brake Band DIAGNOSIS: M52 - 2.8L
Electrical) (11/95-8/96) .
P1746 104 Transmission Control Module See 6-CYLINDER
Output Stage DIAGNOSIS: M52 - 2.8L
(11/95-8/96) .
P1747 150 CAN-Bus Monitoring See 6-CYLINDER
(11/95-8/96) .
(11/95-8/96) .
2004 BMW 645Ci

(11/95-8/96) .
P1748 103 Transmission Control Module Self- See 6-CYLINDER
Test DIAGNOSIS: M52 - 2.8L
(11/95-8/96) .
(11/95-8/96) .
(11/95-8/96) .
Memory Error)
P1750 54 Secondary Pressure Solenoid Circuit See 6-CYLINDER
Range/Performance DIAGNOSIS: M52 - 2.8L
(M44/M52/S52/M62/M73: System (11/95-8/96) .
Voltage Input Low)
DIAGNOSTIC TROUBLE CODES 6-CYLINDER (3-SERIES - 9/96-8/97) & 5-SERIES (3/96-8/97)
DIAGNOSTIC TROUBLE CODES 6-CYLINDER (3-SERIES - 9/96-8/97) & 5-SERIES (3/96-8/97)

Circuit Malfunction (PRNDL Input) DIAGNOSIS: M52 - 2.8L 3-
SERIES (9/96-8/97) & 5-
SERIES (3/96-8/97) .
DIAGNOSIS: M52 - 2.8L 3-
SERIES (9/96-8/97) & 5-
SERIES (3/96-8/97) .
P0731 100 Gear 1 Incorrect Ratio See 6-CYLINDER
SERIES (9/96-8/97) & 5-
SERIES (3/96-8/97) .
P0732 ..... Gear 2 Incorrect Ratio See 6-CYLINDER
SERIES (9/96-8/97) & 5-
2004 BMW 645Ci

SERIES (9/96-8/97) & 5-
SERIES (3/96-8/97) .
SERIES (9/96-8/97) & 5-
SERIES (3/96-8/97) .
Circuit/Open DIAGNOSIS: M52 - 2.8L 3-
SERIES (9/96-8/97) & 5-
SERIES (3/96-8/97) .
Electrical DIAGNOSIS: M52 - 2.8L 3-
SERIES (9/96-8/97) & 5-
SERIES (3/96-8/97) .
Electrical DIAGNOSIS: M52 - 2.8L 3-
SERIES (9/96-8/97) & 5-
SERIES (3/96-8/97) .
SERIES (9/96-8/97) & 5-
SERIES (3/96-8/97) .
SERIES (9/96-8/97) & 5-
SERIES (3/96-8/97) .
Electrical (M44/M52: Brake Band DIAGNOSIS: M52 - 2.8L 3-
Electrical) SERIES (9/96-8/97) & 5-
SERIES (3/96-8/97) .
P1746 104 Transmission Control Module Output See 6-CYLINDER
Stage DIAGNOSIS: M52 - 2.8L 3-
SERIES (9/96-8/97) & 5-
SERIES (3/96-8/97) .
SERIES (9/96-8/97) & 5-
SERIES (3/96-8/97) .
SERIES (9/96-8/97) & 5-
SERIES (3/96-8/97) .
2004 BMW 645Ci
SERIES (9/96-8/97) & 5-

SERIES (3/96-8/97) .
Test DIAGNOSIS: M52 - 2.8L 3-
SERIES (9/96-8/97) & 5-
SERIES (3/96-8/97) .
SERIES (9/96-8/97) & 5-
SERIES (3/96-8/97) .
SERIES (9/96-8/97) & 5-
SERIES (3/96-8/97) .
Memory Error)
Range/Performance
(M44/M52/S52/M62/M73: System
Voltage Input Low)
DIAGNOSTIC TROUBLE CODES 6-CYLINDER (M3 - 4/96-8/97)
DIAGNOSTIC TROUBLE CODES 6-CYLINDER (M3 - 4/96-8/97)

P0705 8 Transmission Range Sensor "A" See 6-CYLINDER DIAGNOSIS -
Circuit Malfunction (PRNDL M3, 3.2L (4/96-8/97) .
Input)
Input)
Input)
P0715 16 Input/Turbine Speed Sensor "A" See 6-CYLINDER DIAGNOSIS -
Circuit M3, 3.2L (4/96-8/97) .
P0720 42 Output Speed Sensor Circuit See 6-CYLINDER DIAGNOSIS -
2004 BMW 645Ci
M3, 3.2L (4/96-8/97) .

P0720 106 Output Speed Sensor Circuit See 6-CYLINDER DIAGNOSIS -
M3, 3.2L (4/96-8/97) .
P0732 100 Gear 2 Incorrect Ratio See 6-CYLINDER DIAGNOSIS -
M3, 3.2L (4/96-8/97) .
P0733 ..... Incorrect Gear Ratio See 6-CYLINDER DIAGNOSIS -
M3, 3.2L (4/96-8/97) .
M3, 3.2L (4/96-8/97) .
M3, 3.2L (4/96-8/97) .
P0740 111 Torque Converter Clutch See 6-CYLINDER DIAGNOSIS -
Circuit/Open M3, 3.2L (4/96-8/97) .
P0743 4 Torque Converter Clutch Circuit See 6-CYLINDER DIAGNOSIS -
Electrical M3, 3.2L (4/96-8/97) .
P0748 5 Pressure Control Solenoid "A" See 6-CYLINDER DIAGNOSIS -
Electrical M3, 3.2L (4/96-8/97) .
P0753 30 Shift Solenoid "A" Electrical See 6-CYLINDER DIAGNOSIS -
M3, 3.2L (4/96-8/97) .
P0758 33 Shift Solenoid "B" Electrical See 6-CYLINDER DIAGNOSIS -
M3, 3.2L (4/96-8/97) .
P0763 32 Shift Solenoid "C" Electrical See 6-CYLINDER DIAGNOSIS -
M3, 3.2L (4/96-8/97) .
P0768 31 Shift Solenoid "D" Electrical See 6-CYLINDER DIAGNOSIS -
M3, 3.2L (4/96-8/97) .
P0773 3 Shift Solenoid "E" Electrical See 6-CYLINDER DIAGNOSIS -
M3, 3.2L (4/96-8/97) .
P1746 104 Transmission Control Module See 6-CYLINDER DIAGNOSIS -
Output Stage M3, 3.2L (4/96-8/97) .
P1747 150 CAN-Bus Monitoring See 6-CYLINDER DIAGNOSIS -
M3, 3.2L (4/96-8/97) .
M3, 3.2L (4/96-8/97) .
M3, 3.2L (4/96-8/97) .
Self-Test M3, 3.2L (4/96-8/97) .
Self-Test M3, 3.2L (4/96-8/97) .
Self-Test M3, 3.2L (4/96-8/97) .
P1750 54 Secondary Pressure Solenoid See 6-CYLINDER DIAGNOSIS -
Circuit Range/Performance M3, 3.2L (4/96-8/97) .
2004 BMW 645Ci
System Voltage Input Low)

DIAGNOSTIC TROUBLE CODES 6-CYLINDER (9/97-8/98)

Circuit Malfunction (PRNDL Input) DIAGNOSIS: 6-
CYLINDER (9/97-8/98) .
P0715 ..... Input Speed Signal See 6-CYLINDER
DIAGNOSIS: 6-
CYLINDER (9/97-8/98) .
DIAGNOSIS: 6-
CYLINDER (9/97-8/98) .
DIAGNOSIS: 6-
CYLINDER (9/97-8/98) .
DIAGNOSIS: 6-
CYLINDER (9/97-8/98) .
DIAGNOSIS: 6-
CYLINDER (9/97-8/98) .
DIAGNOSIS: 6-
CYLINDER (9/97-8/98) .
DIAGNOSIS: 6-
CYLINDER (9/97-8/98) .
Circuit/Open DIAGNOSIS: 6-
CYLINDER (9/97-8/98) .
Electrical DIAGNOSIS: 6-
CYLINDER (9/97-8/98) .
Electrical DIAGNOSIS: 6-
CYLINDER (9/97-8/98) .
2004 BMW 645Ci
DIAGNOSIS: 6-
CYLINDER (9/97-8/98) .
DIAGNOSIS: 6-
CYLINDER (9/97-8/98) .
Electrical (M44/M52: Brake Band DIAGNOSIS: 6-
Electrical) CYLINDER (9/97-8/98) .
P1746 104 Transmission Control Module Output See 6-CYLINDER
Stage DIAGNOSIS: 6-
CYLINDER (9/97-8/98) .
DIAGNOSIS: 6-
CYLINDER (9/97-8/98) .
DIAGNOSIS: 6-
CYLINDER (9/97-8/98) .
DIAGNOSIS: 6-
CYLINDER (9/97-8/98) .
Test DIAGNOSIS: 6-
CYLINDER (9/97-8/98) .
Test DIAGNOSIS: 6-
CYLINDER (9/97-8/98) .
Test DIAGNOSIS: 6-
CYLINDER (9/97-8/98) .
Memory Error)
Range/Performance DIAGNOSIS: 6-
(M44/M52/S52/M62/M73: System CYLINDER (9/97-8/98) .
Voltage Input Low)
DIAGNOSTIC TROUBLE CODES 6-CYLINDER (323I, 328I & 528I - 9/98-5/99)

2004 BMW 645Ci
DIAGNOSTIC TROUBLE CODES 6-CYLINDER (323i, 328i & 528i - 9/98-5/99)

Circuit Malfunction (PRNDL DIAGNOSIS (323i, 328i, 528i
Input) - 9/98-5/99) .
P0715 ..... Input Speed Signal See 6-CYLINDER
DIAGNOSIS (323i, 328i, 528i
- 9/98-5/99) .
- 9/98-5/99) .
- 9/98-5/99) .
- 9/98-5/99) .
- 9/98-5/99) .
- 9/98-5/99) .
- 9/98-5/99) .
Circuit/Open DIAGNOSIS (323i, 328i, 528i
- 9/98-5/99) .
Electrical DIAGNOSIS (323i, 328i, 528i
- 9/98-5/99) .
Electrical DIAGNOSIS (323i, 328i, 528i
- 9/98-5/99) .
- 9/98-5/99) .
- 9/98-5/99) .
P0763 ..... Shift Solenoid "C" Electrical See 6-CYLINDER
- 9/98-5/99) .
2004 BMW 645Ci
Electrical (M44/M52: Brake Band DIAGNOSIS (323i, 328i, 528i

Electrical) - 9/98-5/99) .
P1746 104 Transmission Control Module No Diagnosis Available
Output Stage
- 9/98-5/99) .
- 9/98-5/99) .
- 9/98-5/99) .
Self-Test DIAGNOSIS (323i, 328i, 528i
- 9/98-5/99) .
- 9/98-5/99) .
- 9/98-5/99) .
P1749 108 Secondary Pressure Solenoid See 6-CYLINDER
Communication Error (M52: DIAGNOSIS (323i, 328i, 528i
Internal Transmission Control - 9/98-5/99) .
Module Memory Error)
Circuit Range/Performance DIAGNOSIS (323i, 328i, 528i
(Voltage Input Low) - 9/98-5/99) .
Circuit Range/Performance DIAGNOSIS (323i, 328i, 528i
(Voltage Input High) - 9/98-5/99) .
P1765 154 CAN Throttle Valve See 6-CYLINDER
- 9/98-5/99) .
- 9/98-5/99) .
DIAGNOSTIC TROUBLE CODES 6-CYLINDER (M COUPE, M ROADSTER, M3, Z3, 328IS, 528I -
9/98-5/99)
2004 BMW 645Ci
9/98-5/99)
Circuit Malfunction (PRNDL Input) DIAGNOSIS (M COUPE,
M ROADSTER, M3, Z3,
328IS, 528i - 9/98-5/99) .
DIAGNOSIS (M COUPE,
M ROADSTER, M3, Z3,
328IS, 528i - 9/98-5/99) .
DIAGNOSIS (M COUPE,
M ROADSTER, M3, Z3,
328IS, 528i - 9/98-5/99) .
DIAGNOSIS (M COUPE,
M ROADSTER, M3, Z3,
328IS, 528i - 9/98-5/99) .
DIAGNOSIS (M COUPE,
M ROADSTER, M3, Z3,
328IS, 528i - 9/98-5/99) .
DIAGNOSIS (M COUPE,
M ROADSTER, M3, Z3,
328IS, 528i - 9/98-5/99) .
Circuit/Open DIAGNOSIS (M COUPE,
M ROADSTER, M3, Z3,
328IS, 528i - 9/98-5/99) .
Electrical DIAGNOSIS (M COUPE,
M ROADSTER, M3, Z3,
328IS, 528i - 9/98-5/99) .
Electrical DIAGNOSIS (M COUPE,
M ROADSTER, M3, Z3,
328IS, 528i - 9/98-5/99) .
DIAGNOSIS (M COUPE,
M ROADSTER, M3, Z3,
328IS, 528i - 9/98-5/99) .
DIAGNOSIS (M COUPE,
M ROADSTER, M3, Z3,
2004 BMW 645Ci

Electrical (M44/M52: Brake Band DIAGNOSIS (M COUPE,
Electrical) M ROADSTER, M3, Z3,
328IS, 528i - 9/98-5/99) .
Output Stage DIAGNOSIS (M COUPE,
M ROADSTER, M3, Z3,
328IS, 528i - 9/98-5/99) .
DIAGNOSIS (M COUPE,
M ROADSTER, M3, Z3,
328IS, 528i - 9/98-5/99) .
DIAGNOSIS (M COUPE,
M ROADSTER, M3, Z3,
328IS, 528i - 9/98-5/99) .
DIAGNOSIS (M COUPE,
M ROADSTER, M3, Z3,
328IS, 528i - 9/98-5/99) .
Test DIAGNOSIS (M COUPE,
M ROADSTER, M3, Z3,
328IS, 528i - 9/98-5/99) .
M ROADSTER, M3, Z3,
328IS, 528i - 9/98-5/99) .
M ROADSTER, M3, Z3,
328IS, 528i - 9/98-5/99) .
Memory Error)
Range/Performance
(M44/M52/S52/M62/M73: System
Voltage Input Low)
P1761 2 Shiftlock Solenoid See 6-CYLINDER
DIAGNOSIS (M COUPE,
M ROADSTER, M3, Z3,
328IS, 528i - 9/98-5/99) .
2004 BMW 645Ci
M ROADSTER, M3, Z3,

328IS, 528i - 9/98-5/99) .
DIAGNOSIS (M COUPE,
M ROADSTER, M3, Z3,
328IS, 528i - 9/98-5/99) .
DIAGNOSTIC TROUBLE CODES 6-CYLINDER (Z3 - 6/99-5/00)
DIAGNOSTIC TROUBLE CODES 6-CYLINDER (Z3 - 6/99-5/00)

P0705 8 Transmission Range Sensor "A" See 6-CYLINDER DIAGNOSIS
Circuit Malfunction (PRNDL (Z3 - 6/99-5/00) .
Input)
P0720 42 Output Speed Sensor Circuit See 6-CYLINDER DIAGNOSIS
(Z3 - 6/99-5/00) .
P0731 100 Gear 1 Incorrect Ratio See 6-CYLINDER DIAGNOSIS
(Z3 - 6/99-5/00) .
(Z3 - 6/99-5/00) .
(Z3 - 6/99-5/00) .
(Z3 - 6/99-5/00) .
P0740 111 Torque Converter Clutch See 6-CYLINDER DIAGNOSIS
Circuit/Open (Z3 - 6/99-5/00) .
P0743 32 Torque Converter Clutch Circuit See 6-CYLINDER DIAGNOSIS
Electrical (Z3 - 6/99-5/00) .
P0748 5 Pressure Control Solenoid "A" See 6-CYLINDER DIAGNOSIS
Electrical (Z3 - 6/99-5/00) .
P0753 30 Shift Solenoid "A" Electrical See 6-CYLINDER DIAGNOSIS
(Z3 - 6/99-5/00) .
P0758 33 Shift Solenoid "B" Electrical See 6-CYLINDER DIAGNOSIS
(Z3 - 6/99-5/00) .
P1743 4 Pressure Control Solenoid "E" See 6-CYLINDER DIAGNOSIS
Electrical (M44/M52: Brake Band (Z3 - 6/99-5/00) .
Electrical)
P1746 104 Transmission Control Module See 6-CYLINDER DIAGNOSIS
Output Stage (Z3 - 6/99-5/00) .
P1747 150 CAN-Bus Monitoring See 6-CYLINDER DIAGNOSIS
(Z3 - 6/99-5/00) .
2004 BMW 645Ci
(Z3 - 6/99-5/00) .
P1747 156 CAN-Bus Monitoring See 6-CYLINDER DIAGNOSIS
(Z3 - 6/99-5/00) .
Self-Test (Z3 - 6/99-5/00) .
Self-Test (Z3 - 6/99-5/00) .
Self-Test (Z3 - 6/99-5/00) .
Communication Error (M52:
Internal Transmission Control
Module Memory Error)
Circuit Range/Performance
(M44/M52/S52/M62/M73: System
Voltage Input Low)
P1761 2 Shiftlock Solenoid See 6-CYLINDER DIAGNOSIS
(Z3 - 6/99-5/00) .
P1765 154 CAN Throttle Valve See 6-CYLINDER DIAGNOSIS
(Z3 - 6/99-5/00) .
P1765 158 CAN Throttle Valve See 6-CYLINDER DIAGNOSIS
(Z3 - 6/99-5/00) .
DIAGNOSTIC TROUBLE CODES 6-CYLINDER (323I, 328I & 528I - 6/99-8/00)
DIAGNOSTIC TROUBLE CODES 6-CYLINDER (323i, 328i & 528i - 6/99-8/00)

Circuit Malfunction (PRNDL Input) DIAGNOSIS (323i, 328i
& 528i - 6/99-8/00) .
P0715 33 Input/Turbine Speed Sensor "A" See 6-CYLINDER
Circuit DIAGNOSIS (323i, 328i
& 528i - 6/99-8/00) .
DIAGNOSIS (323i, 328i
& 528i - 6/99-8/00) .
P0727 150 Engine Speed Input Circuit No Signal See 6-CYLINDER
& 528i - 6/99-8/00) .
2004 BMW 645Ci
& 528i - 6/99-8/00) .

& 528i - 6/99-8/00) .
& 528i - 6/99-8/00) .
& 528i - 6/99-8/00) .
& 528i - 6/99-8/00) .
P0740 48 Torque Converter Clutch Circuit/Open See 6-CYLINDER
& 528i - 6/99-8/00) .
Electrical DIAGNOSIS (323i, 328i
& 528i - 6/99-8/00) .
& 528i - 6/99-8/00) .
& 528i - 6/99-8/00) .
P0763 18 Shift Solenoid "C" Electrical See 6-CYLINDER
& 528i - 6/99-8/00) .
& 528i - 6/99-8/00) .
& 528i - 6/99-8/00) .
Test DIAGNOSIS (323i, 328i
& 528i - 6/99-8/00) .
Communication Error (M52: Internal DIAGNOSIS (323i, 328i
Transmission Control Module Memory & 528i - 6/99-8/00) .
Error)
Range/Performance (System Voltage DIAGNOSIS (323i, 328i
Input Low) & 528i - 6/99-8/00) .
2004 BMW 645Ci
Range/Performance (System Voltage DIAGNOSIS (323i, 328i

Input High) & 528i - 6/99-8/00) .
& 528i - 6/99-8/00) .

P0560 96 System Voltage See 6-CYLINDER
DIAGNOSIS (4/00-9/01) .
P0600 129 Serial Communication Link See 6-CYLINDER
DIAGNOSIS (4/00-9/01) .
P0600 144 Serial Communication Link See 6-CYLINDER
DIAGNOSIS (4/00-9/01) .
P0601 80 Internal Control Module Memory See 6-CYLINDER
Check Sum Error DIAGNOSIS (4/00-9/01) .
P0603 81 Internal Control Module Keep No Diagnosis Available
Alive Memory (KAM) Error
Circuit Malfunction (PRNDL DIAGNOSIS (4/00-9/01) .
Input)
P0715 33 Input/Turbine Speed Sensor "A" See 6-CYLINDER
Circuit DIAGNOSIS (4/00-9/01) .
DIAGNOSIS (4/00-9/01) .
P0727 150 Engine Speed Input Circuit No See 6-CYLINDER
Signal DIAGNOSIS (4/00-9/01) .
DIAGNOSIS (4/00-9/01) .
DIAGNOSIS (4/00-9/01) .
DIAGNOSIS (4/00-9/01) .
DIAGNOSIS (4/00-9/01) .
DIAGNOSIS (4/00-9/01) .
P0741 ..... Torque Converter Clutch See 6-CYLINDER
Functional Check DIAGNOSIS (4/00-9/01) .
Electrical DIAGNOSIS (4/00-9/01) .
2004 BMW 645Ci
DIAGNOSIS (4/00-9/01) .
DIAGNOSIS (4/00-9/01) .
P0763 18 Shift Solenoid "C" Electrical See 6-CYLINDER
DIAGNOSIS (4/00-9/01) .
P1748 ..... Transmission Control Module See 6-CYLINDER
Internal Module DIAGNOSIS (4/00-9/01) .
DIAGNOSIS (4/00-9/01) .
DIAGNOSTIC TROUBLE CODES 6-CYLINDER: ZF TRANSMISSION (9/01-8/02)
DIAGNOSTIC TROUBLE CODES 6-CYLINDER: ZF TRANSMISSION (9/01-8/02)

P Code BMW Code Possible Cause Diagnostic Parameters
P0709 60 Transmission Range Sensor "A" See 6-CYLINDER: ZF
Circuit Intermittent TRANSMISSION DIAGNOSIS
(9/01-8/02 - 1 OF 4) .
P0715 33 Input/Turbine Speed Sensor "A" See 6-CYLINDER: ZF
Circuit TRANSMISSION DIAGNOSIS
(9/01-8/02 - 1 OF 4) .
P0716 33 Input/Turbine Speed Sensor "A" See 6-CYLINDER: ZF
Circuit Range/Performance TRANSMISSION DIAGNOSIS
(9/01-8/02 - 1 OF 4) .
P0720 32 Output Speed Sensor Circuit See 6-CYLINDER: ZF
TRANSMISSION DIAGNOSIS
(9/01-8/02 - 1 OF 4) .
P0721 59 Output Speed Sensor Circuit See 6-CYLINDER: ZF
Range/Performance TRANSMISSION DIAGNOSIS
(9/01-8/02 - 1 OF 4) .
P0731 50 Gear 1 Incorrect Ratio See 6-CYLINDER: ZF
(9/01-8/02 - 1 OF 4) .
(9/01-8/02 - 1 OF 4) .
(9/01-8/02 - 1 OF 4) .
(9/01-8/02 - 1 OF 4) .
(9/01-8/02 - 1 OF 4) .
2004 BMW 645Ci
P0740 4 Torque Converter Clutch See 6-CYLINDER: ZF

Circuit/Open TRANSMISSION DIAGNOSIS
(9/01-8/02 - 2 OF 4) .
P0741 48 Torque Converter Clutch Circuit See 6-CYLINDER: ZF
Performance or Stuck Off TRANSMISSION DIAGNOSIS
(9/01-8/02 - 1 OF 4) .
P0745 1 Pressure Control Solenoid "A" See 6-CYLINDER: ZF
(9/01-8/02 - 2 OF 4) .
P0750 16 Shift Solenoid "A" See 6-CYLINDER: ZF
(9/01-8/02 - 2 OF 4) .
P0751 16 Shift Solenoid "A" Performance See 6-CYLINDER: ZF
or Stuck Off TRANSMISSION DIAGNOSIS
(9/01-8/02 - 2 OF 4) .
P0752 16 Shift Solenoid "A" Stuck On See 6-CYLINDER: ZF
(9/01-8/02 - 2 OF 4) .
P0753 16 Shift Solenoid "A" Electrical See 6-CYLINDER: ZF
(9/01-8/02 - 2 OF 4) .
P0755 17 Shift Solenoid "B" See 6-CYLINDER: ZF
(9/01-8/02 - 2 OF 4) .
P0756 17 Shift Solenoid "B" Performance See 6-CYLINDER: ZF
(9/01-8/02 - 2 OF 4) .
P0757 17 Shift Solenoid "B" Stuck On See 6-CYLINDER: ZF
(9/01-8/02 - 2 OF 4) .
P0758 17 Shift Solenoid "B" Electrical See 6-CYLINDER: ZF
(9/01-8/02 - 2 OF 4) .
P0760 18 Shift Solenoid "C" See 6-CYLINDER: ZF
(9/01-8/02 - 3 OF 4) .
P0761 18 Shift Solenoid "C" Performance See 6-CYLINDER: ZF
(9/01-8/02 - 3 OF 4) .
P0762 18 Shift Solenoid "C" Stuck On See 6-CYLINDER: ZF
(9/01-8/02 - 3 OF 4) .
P0763 18 Shift Solenoid "C" Electrical See 6-CYLINDER: ZF
(9/01-8/02 - 3 OF 4) .
2004 BMW 645Ci
P0775 2 Pressure Control Solenoid "B" See 6-CYLINDER: ZF

(9/01-8/02 - 2 OF 4) .
P0782 57 2-3 Shift See 6-CYLINDER: ZF
(9/01-8/02 - 3 OF 4) .
P0783 58 3-4 Shift See 6-CYLINDER: ZF
(9/01-8/02 - 3 OF 4) .
P0795 3 Pressure Control Solenoid "C" See 6-CYLINDER: ZF
(9/01-8/02 - 2 OF 4) .
P1700 62 Double Error Output Speed and See 6-CYLINDER: ZF
Input/Turbine Speed TRANSMISSION DIAGNOSIS
(9/01-8/02 - 1 OF 4) .
P1719 144 CAN Version Error See 6-CYLINDER: ZF
(9/01-8/02 - 3 OF 4) .
P1720 129 CAN Timeout Control Module See 6-CYLINDER: ZF
(9/01-8/02 - 3 OF 4) .
P1731 51 Gear 1 manual Incorrect Ratio See 6-CYLINDER: ZF
(9/01-8/02 - 1 OF 4) .
P1747 128 CAN-Bus Monitoring See 6-CYLINDER: ZF
(9/01-8/02 - 3 OF 4) .
P1761 19 Shiftlock Solenoid See 6-CYLINDER: ZF
(9/01-8/02 - 3 OF 4) .
P1762 19 Shiftlock Solenoid High Input See 6-CYLINDER: ZF
(9/01-8/02 - 3 OF 4) .
P1763 19 Shiftlock Solenoid Low Input See 6-CYLINDER: ZF
(9/01-8/02 - 3 OF 4) .
P1764 19 Shiftlock Solenoid Open Circuit See 6-CYLINDER: ZF
(9/01-8/02 - 3 OF 4) .
P1765 147 CAN Throttle Valve See 6-CYLINDER: ZF
(9/01-8/02 - 3 OF 4) .
P1791 81 Internal Transmission Control See 6-CYLINDER: ZF
Module Memory TRANSMISSION DIAGNOSIS
Checksum/EEPROM Error (9/01-8/02 - 3 OF 4) .
2004 BMW 645Ci

Module Watchdog Error TRANSMISSION DIAGNOSIS
(9/01-8/02 - 3 OF 4)
Module Memory Checksum TRANSMISSION DIAGNOSIS
Error (9/01-8/02 - 3 OF 4) .
Circuit High TRANSMISSION DIAGNOSIS
(9/01-8/02 - 2 OF 4) .
(9/01-8/02 - 2 OF 4) .
(9/01-8/02 - 2 OF 4) .
P1834 4 Pressure Control Solenoid "D" See 6-CYLINDER: ZF
(9/01-8/02 - 2 OF 4) .
Circuit Low TRANSMISSION DIAGNOSIS
(9/01-8/02 - 2 OF 4) .
(9/01-8/02 - 2 OF 4) .
(9/01-8/02 - 2 OF 4) .
P1844 4 Pressure Control Solenoid "D" See 6-CYLINDER: ZF
(9/01-8/02 - 2 OF 4) .
P1882 57 2-3 Shift Circuit High See 6-CYLINDER: ZF
(9/01-8/02 - 3 OF 4) .
P1883 58 3-4 Shift Circuit High See 6-CYLINDER: ZF
(9/01-8/02 - 3 OF 4) .
P1889 96 System Voltage - Electrical See 6-CYLINDER: ZF
(9/01-8/02 - 3 OF 4) .
P1892 96 System Voltage Low Input See 6-CYLINDER: ZF
(9/01-8/02 - 3 OF 4) .
P1893 83 Supply Voltage Pressure Control See 6-CYLINDER: ZF
Solenoid/Shift Solenoid Circuit TRANSMISSION DIAGNOSIS
High (9/01-8/02 - 4 OF 4) .
2004 BMW 645Ci

Solenoid/Shift Solenoid Circuit TRANSMISSION DIAGNOSIS
Low (9/01-8/02 - 4 OF 4) .
Solenoid/Shift Solenoid No TRANSMISSION DIAGNOSIS
Signal (9/01-8/02 - 4 OF 4) .
DIAGNOSTIC TROUBLE CODES 6-CYLINDER: GM TRANSMISSION (9/01-8/02)
DIAGNOSTIC TROUBLE CODES 6-CYLINDER: GM TRANSMISSION (9/01-8/02)

P0705 8 Transmission Range Sensor "A" See 6-CYLINDER: GM5
Circuit Malfunction (PRNDL Input) TRANSMISSION
DIAGNOSIS (9/01-8/02 - 1
OF 3) .
DIAGNOSIS (9/01-8/02 - 1
OF 3) .
DIAGNOSIS (9/01-8/02 - 1
OF 3) .
P0709 ..... Range Switch Transitional Signal See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 1
OF 3) .
P0715 16 Input/Turbine Speed Sensor "A" See 6-CYLINDER: GM5
Circuit TRANSMISSION
DIAGNOSIS (9/01-8/02 - 1
OF 3) .
P0717 ..... Input Speed Less Than 100 RPM See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 1
OF 3) .
P0720 42 Output Speed Sensor Circuit See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 1
OF 3) .
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 1
OF 3) .
P0722 ..... Output Speed Less Than 100 RPM See 6-CYLINDER: GM5
TRANSMISSION
2004 BMW 645Ci
DIAGNOSIS (9/01-8/02 - 1
OF 3) .
P0727 ..... CAN Engine Speed Invalid Signal See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 3
OF 3) .
P0731 ..... Gear 1 Incorrect Ratio See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 1
OF 3) .
P0732 100 Gear 2 Incorrect Ratio See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 1
OF 3) .
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 1
OF 3) .
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 1
OF 3) .
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 1
OF 3) .
P0741 ..... TCC Stuck Off See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 2
OF 3) .
P0742 ..... TCC Stuck On See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 2
OF 3) .
P0743 4 Torque Converter Clutch Circuit See 6-CYLINDER: GM5
Electrical TRANSMISSION
DIAGNOSIS (9/01-8/02 - 2
OF 3) .
P0753 30 Shift Solenoid "A" Electrical See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 2
OF 3) .
P0758 33 Shift Solenoid "B" Electrical See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 2
2004 BMW 645Ci
P0763 32 Shift Solenoid "C" Electrical See 6-CYLINDER: GM5

TRANSMISSION
DIAGNOSIS (9/01-8/02 - 2
OF 3) .
P1719 ..... CAN Level Bus Check See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 3
OF 3) .
P1720 ..... CAN Messages/Time Out See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 3
OF 3) .
P1765 154 CAN Throttle Valve See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 3
OF 3) .
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 3
OF 3) .
P1780 152 CAN Torque Reduction See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 3
OF 3) .
P1790 ..... RAM & ROM Check See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 3
OF 3) .
P1791 ..... Internal Error (NVM/RAM) See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 3
OF 3) .
P1794 ..... ROM Check See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 3
OF 3) .
P1801 ..... Shift Solenoid "A" Short To See 6-CYLINDER: GM5
Ground TRANSMISSION
DIAGNOSIS (9/01-8/02 - 2
OF 3) .
P1802 ..... Shift Solenoid "B" Short To Ground See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 2
OF 3) .
P1803 ..... Shift Solenoid "C" Short To Ground See 6-CYLINDER: GM5
2004 BMW 645Ci
DIAGNOSIS (9/01-8/02 - 2
OF 3) .
P1891 ..... Power Supply Fault See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 3
OF 3) .
P1892 ..... Power Supply Fault See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/01-8/02 - 3
OF 3) .
DIAGNOSTIC TROUBLE CODES 6-CYLINDER: 5HP19 TRANSMISSION (9/02-2003)
DIAGNOSTIC TROUBLE CODES 6-CYLINDER: 5HP19 TRANSMISSION (9/02-2003)

P0709 60 Transmission Range Sensor "A" See 6-CYLINDER: 5HP19
Circuit Intermittent TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
P0715 33 Input/Turbine Speed Sensor "A" See 6-CYLINDER: 5HP19
DIAGNOSIS (9/02-2003 - 1
OF 3) .
Circuit Range/Performance TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
P0720 32 Output Speed Sensor Circuit See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
Range/Performance TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
P0731 50 Gear 1 Incorrect Ratio See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
TRANSMISSION
2004 BMW 645Ci
DIAGNOSIS (9/02-2003 - 1
OF 3) .
TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
P0741 48 Torque Converter Clutch Circuit See 6-CYLINDER: 5HP19
Performance or Stuck Off TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
P0745 1 Pressure Control Solenoid "A" See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 2
OF 3) .
P0750 16 Shift Solenoid "A" See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 2
OF 3) .
P0751 16 Shift Solenoid "A" Performance or See 6-CYLINDER: 5HP19
Stuck Off TRANSMISSION
DIAGNOSIS (9/02-2003 - 2
OF 3) .
P0752 16 Shift Solenoid "A" Stuck On See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 2
OF 3) .
P0753 16 Shift Solenoid "A" Electrical See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 2
OF 3) .
P0755 17 Shift Solenoid "B" See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 2
OF 3) .
P0756 17 Shift Solenoid "B" Performance or See 6-CYLINDER: 5HP19
DIAGNOSIS (9/02-2003 - 2
OF 3) .
P0757 17 Shift Solenoid "B" Stuck On See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 2
2004 BMW 645Ci
P0758 17 Shift Solenoid "B" Electrical See 6-CYLINDER: 5HP19

TRANSMISSION
DIAGNOSIS (9/02-2003 - 2
OF 3) .
P0760 18 Shift Solenoid "C" See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P0761 18 Shift Solenoid "C" Performance or See 6-CYLINDER: 5HP19
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P0762 18 Shift Solenoid "C" Stuck On See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P0763 18 Shift Solenoid "C" Electrical See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P0775 2 Pressure Control Solenoid "B" See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 2
OF 3) .
P0782 57 2-3 Shift See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P0795 3 Pressure Control Solenoid "C" See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 2
OF 3) .
Control Circuit Low TRANSMISSION
DIAGNOSIS (9/02-2003 - 2
OF 3) .
Control Circuit High TRANSMISSION
DIAGNOSIS (9/02-2003 - 2
OF 3) .
2004 BMW 645Ci
DIAGNOSIS (9/02-2003 - 2
OF 3) .
DIAGNOSIS (9/02-2003 - 2
OF 3) .
DIAGNOSIS (9/02-2003 - 2
OF 3) .
DIAGNOSIS (9/02-2003 - 2
OF 3) .
P1700 62 Double Error Output Speed and See 6-CYLINDER: 5HP19
Input/Turbine Speed TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
P1719 144 CAN Version Error See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P1720 129 CAN Timeout Control Module See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P1731 51 Gear 1 manual Incorrect Ratio See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
P1732 65 Gear Monitoring 4 at Electrical See 6-CYLINDER: 5HP19
Substitute Program TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
P1747 128 CAN-Bus Monitoring See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P1761 19 Shiftlock Solenoid See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P1762 19 Shiftlock Solenoid High Input See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
2004 BMW 645Ci
P1763 19 Shiftlock Solenoid Low Input See 6-CYLINDER: 5HP19

TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P1764 19 Shiftlock Solenoid Open Circuit See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P1765 147 CAN Throttle Valve See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P1791 81 Internal Transmission Control See 6-CYLINDER: 5HP19
Module Memory TRANSMISSION
Checksum/EEPROM Error DIAGNOSIS (9/02-2003 - 3
OF 3) .
Module Watchdog Error TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
Module Memory Checksum Error TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P1882 57 2-3 Shift Circuit High See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P1889 96 System Voltage - Electrical See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P1892 96 System Voltage Low Input See 6-CYLINDER: 5HP19
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P1893 83 Supply Voltage Pressure Control Diagnosis Not Available
Solenoid/Shift Solenoid Circuit
High
Solenoid/Shift Solenoid Circuit
2004 BMW 645Ci

Solenoid/Shift Solenoid No Signal
P2761 4 Torque Converter Clutch Pressure See 6-CYLINDER: 5HP19
Control Solenoid Control TRANSMISSION
Circuit/Open DIAGNOSIS (9/02-2003 - 2
OF 3) .
Control Solenoid Control Circuit TRANSMISSION
High DIAGNOSIS (9/02-2003 - 2
OF 3) .
Control Solenoid Control Circuit TRANSMISSION
Low DIAGNOSIS (9/02-2003 - 2
OF 3) .
DIAGNOSTIC TROUBLE CODES 6-CYLINDER: GM5 TRANSMISSION (9/02-2003)
DIAGNOSTIC TROUBLE CODES 6-CYLINDER: GM5 TRANSMISSION (9/02-2003)

Circuit Malfunction (PRNDL TRANSMISSION
Input) DIAGNOSIS (9/02-2003 - 1
OF 3) .
Circuit Intermittent TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
DIAGNOSIS (9/02-2003 - 1
OF 3) .
Circuit No Signal TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
P0722 32 Output Speed Sensor Circuit No See 6-CYLINDER: GM5
Signal TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
P0727 150 Engine Speed Input Circuit No See 6-CYLINDER: GM5
Signal TRANSMISSION
2004 BMW 645Ci
DIAGNOSIS (9/02-2003 - 3
OF 3) .
TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
TRANSMISSION
DIAGNOSIS (9/02-2003 - 1
OF 3) .
DIAGNOSIS (9/02-2003 - 2
OF 3) .
Stuck On TRANSMISSION
DIAGNOSIS (9/02-2003 - 2
OF 3) .
TRANSMISSION
DIAGNOSIS (9/02-2003 - 2
OF 3) .
TRANSMISSION
DIAGNOSIS (9/02-2003 - 2
OF 3) .
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P0973 16 Shift Solenoid "A" Control Circuit See 6-CYLINDER: GM5
Low TRANSMISSION
DIAGNOSIS (9/02-2003 - 2
2004 BMW 645Ci
P0976 17 Shift Solenoid "B" Control Circuit See 6-CYLINDER: GM5

Low TRANSMISSION
DIAGNOSIS (9/02-2003 - 2
OF 3) .
P0979 18 Shift Solenoid "C" Control Circuit See 6-CYLINDER: GM5
Low TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P1719 144 CAN Version Error See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P1720 129 CAN Timeout Control Module See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P1780 ..... CAN Throttle Valve See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P1790 80 Internal Transmission Control See 6-CYLINDER: GM5
Checksum/EPROM Error DIAGNOSIS (9/02-2003 - 3
OF 3) .
OF 3) .
Module Memory Checksum Error TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P1891 96 System Voltage High Input See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P1892 96 System Voltage Low Input See 6-CYLINDER: GM5
TRANSMISSION
DIAGNOSIS (9/02-2003 - 3
OF 3) .
P2759 4 Torque Converter Clutch Pressure See 6-CYLINDER: GM5
2004 BMW 645Ci
Electrical DIAGNOSIS (9/02-2003 - 2

OF 3) .
DIAGNOSTIC TROUBLE CODES 6-CYLINDER: SMG TRANSMISSION (3/03-2003)
DIAGNOSTIC TROUBLE CODES 6-CYLINDER: SMG TRANSMISSION (3/03-2003)

P0932 20215 Hydraulic Pressure Sensor Circuit See 6-CYLINDER: SMG
TRANSMISSION
DIAGNOSIS (3/03-2003 - 1
OF 5) .
Low TRANSMISSION
DIAGNOSIS (3/03-2003 - 1
OF 5) .
High TRANSMISSION
DIAGNOSIS (3/03-2003 - 1
OF 5) .
P1720 20800 CAN Timeout Control Module See 6-CYLINDER: SMG
TRANSMISSION
DIAGNOSIS (3/03-2003 - 1
OF 5) .
P1721 20801 CAN Timeout ASC/DSC See 6-CYLINDER: SMG
TRANSMISSION
DIAGNOSIS (3/03-2003 - 1
OF 5) .
P1747 52999 CAN-Bus Monitoring See 6-CYLINDER: SMG
TRANSMISSION
DIAGNOSIS (3/03-2003 - 1
OF 5) .
P1765 20904 CAN Throttle Valve See 6-CYLINDER: SMG
TRANSMISSION
DIAGNOSIS (3/03-2003 - 1
OF 5) .
P1766 20702 Double Error Engine Speed See 6-CYLINDER: SMG
CAN/Direct Wiring TRANSMISSION
DIAGNOSIS (3/03-2003 - 1
OF 5) .
P1767 20913 CAN Wheel Speeds Rear Axle See 6-CYLINDER: SMG
TRANSMISSION
DIAGNOSIS (3/03-2003 - 3
OF 5) .
P1771 20901 CAN Torque Interface Plausibility See 6-CYLINDER: SMG
TRANSMISSION
2004 BMW 645Ci
DIAGNOSIS (3/03-2003 - 4
OF 5) .
P1782 20910 CAN Brake Signal See 6-CYLINDER: SMG
TRANSMISSION
DIAGNOSIS (3/03-2003 - 2
OF 5) .
P1791 20401 Internal Transmission Control See 6-CYLINDER: SMG
OF 5) .
Module Error 7 (High Side TRANSMISSION
Driver) DIAGNOSIS (3/03-2003 - 4
OF 5) .
P1817 20606 Gear Selector Lever GSL0 Cable See 6-CYLINDER: SMG
High Input TRANSMISSION
DIAGNOSIS (3/03-2003 - 4
OF 5) .
Low Input TRANSMISSION
DIAGNOSIS (3/03-2003 - 4
OF 5) .
Plausibility TRANSMISSION
DIAGNOSIS (3/03-2003 - 4
OF 5) .
DIAGNOSIS (3/03-2003 - 4
OF 5) .
DIAGNOSIS (3/03-2003 - 4
OF 5) .
DIAGNOSIS (3/03-2003 - 4
OF 5) .
P1823 20611 Gear Selector Lever Digital Cable See 6-CYLINDER: SMG
DIAGNOSIS (3/03-2003 - 3
OF 5) .
P1850 20213 Shift Angle Sensor High Input See 6-CYLINDER: SMG
TRANSMISSION
DIAGNOSIS (3/03-2003 - 2
2004 BMW 645Ci
P1851 20213 Shift Angle Sensor Low Input See 6-CYLINDER: SMG
TRANSMISSION
DIAGNOSIS (3/03-2003 - 2
OF 5) .
P1852 20213 Shift Angle Sensor Plausibility See 6-CYLINDER: SMG
TRANSMISSION
DIAGNOSIS (3/03-2003 - 2
OF 5) .
P1859 20217 Clutch Speed Sensor Plausibility See 6-CYLINDER: SMG
TRANSMISSION
DIAGNOSIS (3/03-2003 - 5
OF 5) .
P1860 20612 Gear Selector Lever Hall Sensor See 6-CYLINDER: SMG
Error 1 TRANSMISSION
DIAGNOSIS (3/03-2003 - 5
OF 5) .
DIAGNOSIS (3/03-2003 - 4
OF 5) .
DIAGNOSIS (3/03-2003 - 4
OF 5) .
DIAGNOSIS (3/03-2003 - 4
OF 5) .
DIAGNOSIS (3/03-2003 - 4
OF 5) .
DIAGNOSIS (3/03-2003 - 4
OF 5) .
DIAGNOSIS (3/03-2003 - 4
OF 5) .
P1887 20335 Hydraulic Pump See 6-CYLINDER: SMG
TRANSMISSION
DIAGNOSIS (3/03-2003 - 2
OF 5) .
2004 BMW 645Ci

Circuit Intermittent NON-AWD TRANSMISSION
DIAGNOSIS (2004 - 1 OF 4) .
Circuit NON-AWD TRANSMISSION
Circuit Range/Performance NON-AWD TRANSMISSION
NON-AWD TRANSMISSION
Range/Performance NON-AWD TRANSMISSION
Performance or Stuck Off NON-AWD TRANSMISSION
P0751 16 Shift Solenoid "A" Performance See 6-CYLINDER: 5HP19
or Stuck Off NON-AWD TRANSMISSION
2004 BMW 645Ci
P0756 17 Shift Solenoid "B" Performance See 6-CYLINDER: 5HP19
P0761 18 Shift Solenoid "C" Performance See 6-CYLINDER: 5HP19
Control Circuit Low NON-AWD TRANSMISSION
2004 BMW 645Ci
Control Circuit High NON-AWD TRANSMISSION
Control Circuit High NON-AWD TRANSMISSION
Input/Turbine Speed NON-AWD TRANSMISSION
Substitute Program NON-AWD TRANSMISSION
2004 BMW 645Ci
Module Memory NON-AWD TRANSMISSION
Checksum/EEPROM Error DIAGNOSIS (2004 - 4 OF 4) .
Module Watchdog Error NON-AWD TRANSMISSION
Module Memory Checksum Error NON-AWD TRANSMISSION
P1893 83 Supply Voltage Pressure Control See 6-CYLINDER: 5HP19
Solenoid/Shift Solenoid Circuit NON-AWD TRANSMISSION
High DIAGNOSIS (2004 - 4 OF 4) .
Solenoid/Shift Solenoid Circuit NON-AWD TRANSMISSION
Low DIAGNOSIS (2004 - 4 OF 4) .
Solenoid/Shift Solenoid No NON-AWD TRANSMISSION
Signal DIAGNOSIS (2004 - 4 OF 4) .
P2761 4 Torque Converter Clutch See 6-CYLINDER: 5HP19
Pressure Control Solenoid NON-AWD TRANSMISSION
Control Circuit/Open DIAGNOSIS (2004 - 2 OF 4) .
Control Circuit High DIAGNOSIS (2004 - 2 OF 4) .
Control Circuit Low DIAGNOSIS (2004 - 2 OF 4) .
DIAGNOSTIC TROUBLE CODES 6-CYLINDER: 5HP19 (5-SPEED) - AWD TRANSMISSION (2004)

2004 BMW 645Ci

Circuit Intermittent AWD TRANSMISSION
P0710 ..... Transmission Fluid Check See 6-CYLINDER: 5HP19
AWD TRANSMISSION
P0711 ..... Transmission Temperature Sensor See 6-CYLINDER: 5HP19
AWD TRANSMISSION
AWD TRANSMISSION
AWD TRANSMISSION
AWD TRANSMISSION
Circuit AWD TRANSMISSION
Circuit Range/Performance AWD TRANSMISSION
AWD TRANSMISSION
Range/Performance AWD TRANSMISSION
AWD TRANSMISSION
AWD TRANSMISSION
AWD TRANSMISSION
AWD TRANSMISSION
AWD TRANSMISSION
2004 BMW 645Ci

Performance or Stuck Off AWD TRANSMISSION
AWD TRANSMISSION
AWD TRANSMISSION
P0751 16 Shift Solenoid "A" Performance or See 6-CYLINDER: 5HP19
Stuck Off AWD TRANSMISSION
AWD TRANSMISSION
AWD TRANSMISSION
AWD TRANSMISSION
P0756 17 Shift Solenoid "B" Performance or See 6-CYLINDER: 5HP19
AWD TRANSMISSION
AWD TRANSMISSION
AWD TRANSMISSION
P0761 18 Shift Solenoid "C" Performance or See 6-CYLINDER: 5HP19
AWD TRANSMISSION
AWD TRANSMISSION
AWD TRANSMISSION
2004 BMW 645Ci

AWD TRANSMISSION
AWD TRANSMISSION
AWD TRANSMISSION
Control Circuit Low AWD TRANSMISSION
Control Circuit High AWD TRANSMISSION
Input/Turbine Speed AWD TRANSMISSION
AWD TRANSMISSION
AWD TRANSMISSION
AWD TRANSMISSION
Substitute Program AWD TRANSMISSION
AWD TRANSMISSION
2004 BMW 645Ci

AWD TRANSMISSION
AWD TRANSMISSION
AWD TRANSMISSION
AWD TRANSMISSION
AWD TRANSMISSION
Module Memory AWD TRANSMISSION
Module Watchdog Error AWD TRANSMISSION
Module Memory Checksum Error AWD TRANSMISSION
AWD TRANSMISSION
AWD TRANSMISSION
AWD TRANSMISSION
AWD TRANSMISSION
Solenoid/Shift Solenoid Circuit AWD TRANSMISSION
Solenoid/Shift Solenoid Circuit AWD TRANSMISSION
Solenoid/Shift Solenoid No Signal AWD TRANSMISSION
2004 BMW 645Ci

Control Solenoid Control AWD TRANSMISSION
Circuit/Open DIAGNOSIS (2004 - 2 OF 3) .
Control Solenoid Control Circuit AWD TRANSMISSION
Control Solenoid Control Circuit AWD TRANSMISSION

PCode Possible Cause Diagnostic Parameters
P0705 Range Position Switch See 6-CYLINDER: 6HP19
(2004 - 4 OF 5) .
P0710 Oil Temperature Sensor Plausibility See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P0711 Oil Temperature Sensor General See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P0712 Oil Temperature Sensor Lower See 6-CYLINDER: 6HP19
Threshold TRANSMISSION DIAGNOSIS
(2004 - 1 OF 5) .
P0713 Oil Temperature Sensor Upper Threshold See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P0714 Oil Temperature Sensor No Signal See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P0715 Input/Turbine Speed Sensor "A" Circuit See 6-CYLINDER: 6HP19
(2004 - 4 OF 5) .
P0720 Output Speed Sensor Circuit See 6-CYLINDER: 6HP19
(2004 - 4 OF 5) .
P0721 Output Speed Sensor Circuit See 6-CYLINDER: 6HP19
Range/Performance TRANSMISSION DIAGNOSIS
(2004 - 4 OF 5) .
P0731 Gear 1 Incorrect Ratio See 6-CYLINDER: 6HP19
(2004 - 2 OF 5) .
2004 BMW 645Ci
(2004 - 2 OF 5) .
(2004 - 2 OF 5) .
P0734 Gear 4 Incorrect Ratio See6-CYLINDER: 6HP19
(2004 - 2 OF 5) .
(2004 - 2 OF 5) .
P0741 Torque Converter Clutch Circuit See 6-CYLINDER: 6HP19
(2004 - 2 OF 5) .
P0745 Pressure Control Solenoid "A" See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P0748 Pressure Control Solenoid "A" No Signal See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P0751 Shift Solenoid "A" Performance or Stuck See 6-CYLINDER: 6HP19
Off TRANSMISSION DIAGNOSIS
(2004 - 1 OF 5) .
P0753 Solenoid Valve Upper Threshold See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P0775 Pressure Control Solenoid "B" See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P0778 Pressure Control Solenoid "B" No Signal See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P0781 Range Shift Monitoring General See 6-CYLINDER: 6HP19
(2004 - 2 OF 5) .
P0782 Range Shift Monitoring General See 6-CYLINDER: 6HP19
(2004 - 2 OF 5) .
P0783 3-4 Shift See 6-CYLINDER: 6HP19
(2004 - 3 OF 5) .
(2004 - 3 OF 5) .
2004 BMW 645Ci
(2004 - 1 OF 5) .
P0798 Pressure Control Solenoid "C" No Signal See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
(2004 - 3 OF 5) .
P0962 Pressure Control Solenoid "A" Control See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P0963 Pressure Control Solenoid "A" Control See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P0966 Pressure Control Solenoid "B" Control See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P0967 Pressure Control Solenoid "B" Control See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P0970 Pressure Control Solenoid "C" Control See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P0971 Pressure Control Solenoid "C" Control See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P0973 Solenoid Valve Lower Threshold See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P0979 Solenoid Valve Lower Threshold See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P1702 Double Error Output Or Not Allowed See 6-CYLINDER: 6HP19
Actuation Of Valves TRANSMISSION DIAGNOSIS
(2004 - 5 OF 5) .
P1720 CAN Timeout Control Module See 6-CYLINDER: 6HP19
(2004 - 5 OF 5) .
P1721 CAN Timeout Control Module See 6-CYLINDER: 6HP19
(2004 - 5 OF 5) .
P1727 Engine Speed Signal See 6-CYLINDER: 6HP19
(2004 - 4 OF 5) .
2004 BMW 645Ci
(2004 - 4 OF 5) .
P1736 Gear Ratio Monitoring See 6-CYLINDER: 6HP19
(2004 - 2 OF 5) .
P1747 CAN-Bus Monitoring See 6-CYLINDER: 6HP19
(2004 - 4 OF 5) .
P1771 Engine Torque Plausibility See 6-CYLINDER: 6HP19
(2004 - 3 OF 5) .
P1790 Internal Transmission Control Module See 6-CYLINDER: 6HP19
Memory Checksum/EEPROM Error TRANSMISSION DIAGNOSIS
(2004 - 5 OF 5) .
(2004 - 5 OF 5) .
Watchdog Error TRANSMISSION DIAGNOSIS
(2004 - 5 OF 5) .
P1793 TCM Hot Disabling See 6-CYLINDER: 6HP19
(2004 - 5 OF 5) .
(2004 - 5 OF 5) .
P1804 Solenoid Valve Shiftlock See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P1810 Turbine Speed Sensor Upper Threshold See 6-CYLINDER: 6HP19
(2004 - 4 OF 5) .
P1811 Turbine Speed Sensor Lower Threshold See 6-CYLINDER: 6HP19
(2004 - 4 OF 5) .
P1812 Output Speed Sensor Upper Threshold See 6-CYLINDER: 6HP19
(2004 - 4 OF 5) .
P1813 Output Speed Sensor Lower Threshold See 6-CYLINDER: 6HP19
(2004 - 4 OF 5) .
P1814 Output Speed Sensor Plausibility See 6-CYLINDER: 6HP19
(2004 - 4 OF 5) .
2004 BMW 645Ci
(2004 - 3 OF 5) .
P1862 3-2 Shift Circuit General See 6-CYLINDER: 6HP19
(2004 - 3 OF 5) .
(2004 - 3 OF 5) .
(2004 - 3 OF 5) .
(2004 - 3 OF 5) .
P1881 Range Shift (1-2) Monitoring Upper See 6-CYLINDER: 6HP19
(2004 - 2 OF 5) .
P1882 Range Shift (2-3) Monitoring Upper See6-CYLINDER: 6HP19
(2004 - 2 OF 5) .
P1883 3-4 Shift Circuit High See 6-CYLINDER: 6HP19
(2004 - 3 OF 5) .
(2004 - 3 OF 5) .
(2004 - 3 OF 5) .
P1890 Power Supply General See 6-CYLINDER: 6HP19
(2004 - 2 OF 5) .
P1891 Power Supply Upper Threshold See 6-CYLINDER: 6HP19
(2004 - 2 OF 5) .
P1892 System Voltage Low Input See 6-CYLINDER: 6HP19
(2004 - 2 OF 5) .
P1893 Supply Voltage Pressure Control See 6-CYLINDER: 6HP19
Solenoid/Shift Solenoid Circuit High TRANSMISSION DIAGNOSIS
(2004 - 5 OF 5) .
P1894 Supply Voltage Pressure Control See 6-CYLINDER: 6HP19
Solenoid/Shift Solenoid Circuit Low TRANSMISSION DIAGNOSIS
(2004 - 5 OF 5) .
2004 BMW 645Ci
Solenoid/Shift Solenoid No Signal TRANSMISSION DIAGNOSIS

(2004 - 5 OF 5) .
P1896 Valve Voltage Supply See 6-CYLINDER: 6HP19
(2004 - 5 OF 5) .
P1897 Valve Voltage Supply Upper Threshold See 6-CYLINDER: 6HP19
(2004 - 5 OF 5) .
P1898 Sensor Voltage Supply Lower Threshold See 6-CYLINDER: 6HP19
(2004 - 5 OF 5) .
P2713 Pressure Regulator Valve Plausibility See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P2716 Pressure Regulator No Signal See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P2720 Pressure Regulator Valve Lower See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P2721 Pressure Regulator Valve Upper See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P2722 Pressure Regulator Valve Plausibility See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P2725 Pressure Regulator Valve No Signal See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P2729 Pressure Regulator Valve Lower See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P2730 Pressure Regulator Valve Upper See 6-CYLINDER: 6HP19
(2004 - 1 OF 5) .
P2759 Torque Converter Clutch No Signal See 6-CYLINDER: 6HP19
(2004 - 2 OF 5) .
P2761 Torque Converter Clutch Pressure See 6-CYLINDER: 6HP19
Control Solenoid Control Circuit/Open TRANSMISSION DIAGNOSIS
(2004 - 2 OF 5) .
P2763 Torque Converter Clutch Pressure See 6-CYLINDER: 6HP19
Control Solenoid Control Circuit High TRANSMISSION DIAGNOSIS
(2004 - 2 OF 5) .
2004 BMW 645Ci
Control Solenoid Control Circuit Low TRANSMISSION DIAGNOSIS

(2004 - 2 OF 5) .
DIAGNOSTIC TROUBLE CODES 6-CYLINDER: NON-AWD TRANSMISSION (2004)
DIAGNOSTIC TROUBLE CODES 6-CYLINDER: NON-AWD TRANSMISSION (2004)

Circuit Malfunction (PRNDL NON-AWD TRANSMISSION
Input) DIAGNOSIS (2004 - 1 OF 3) .
Circuit Intermittent NON-AWD TRANSMISSION
Circuit NON-AWD TRANSMISSION
Circuit No Signal NON-AWD TRANSMISSION
P0722 32 Output Speed Sensor Circuit No See 6-CYLINDER: GM5
Signal NON-AWD TRANSMISSION
P0727 150 Engine Speed Input Circuit No See 6-CYLINDER: GM5
Signal NON-AWD TRANSMISSION
2004 BMW 645Ci
Stuck On NON-AWD TRANSMISSION
P0973 16 Shift Solenoid "A" Control Circuit See 6-CYLINDER: GM5
Low NON-AWD TRANSMISSION
P0976 17 Shift Solenoid "B" Control Circuit See 6-CYLINDER: GM5
P0979 18 Shift Solenoid "C" Control Circuit See 6-CYLINDER: GM5
P1719 144 CAN Version Error See 6-CYLINDER: GM5
P1720 129 CAN Timeout Control Module See 6-CYLINDER: GM5
P1780 ..... CAN Throttle Valve See 6-CYLINDER: GM5
Checksum/EPROM Error DIAGNOSIS (2004 - 3 OF 3) .
Module Memory Checksum Error NON-AWD TRANSMISSION
P1891 96 System Voltage High Input See 6-CYLINDER: GM5
2004 BMW 645Ci
P1892 96 System Voltage Low Input See 6-CYLINDER: GM5
P2759 4 Torque Converter Clutch Pressure See 6-CYLINDER: GM5
Control Solenoid Control Circuit NON-AWD TRANSMISSION
Electrical DIAGNOSIS (2004 - 2 OF 3) .
DIAGNOSTIC TROUBLE CODES 6-CYLINDER: GM5 - AWD (2004)
DIAGNOSTIC TROUBLE CODES 6-CYLINDER: GM5 - AWD (2004)

P0705 60 Transmission Range Sensor "A" See 6-CYLINDER: GM5 AWD
Circuit Malfunction (PRNDL TRANSMISSION DIAGNOSIS
Input) (2004 - 1 OF 3) .
P0709 60 Transmission Range Sensor "A" See 6-CYLINDER: GM5 AWD
Circuit Intermittent TRANSMISSION DIAGNOSIS
(2004 - 1 OF 3) .
P0710 ..... Transmission Fluid Temperature See 6-CYLINDER: GM5 AWD
Sensor TRANSMISSION DIAGNOSIS
(2004 - 1 OF 3) .
(2004 - 1 OF 3) .
(2004 - 1 OF 3) .
P0715 33 Input/Turbine Speed Sensor "A" See 6-CYLINDER: GM5 AWD
Circuit TRANSMISSION DIAGNOSIS
(2004 - 1 OF 3) .
P0717 33 Input/Turbine Speed Sensor "A" See 6-CYLINDER: GM5 AWD
Circuit No Signal TRANSMISSION DIAGNOSIS
(2004 - 1 OF 3) .
P0720 32 Output Speed Sensor Circuit See 6-CYLINDER: GM5 AWD
(2004 - 1 OF 3) .
P0722 32 Output Speed Sensor Circuit No See 6-CYLINDER: GM5 AWD
Signal TRANSMISSION DIAGNOSIS
(2004 - 1 OF 3) .
P0727 150 Engine Speed Input Circuit No See 6-CYLINDER: GM5 AWD
Signal TRANSMISSION DIAGNOSIS
(2004 - 3 OF 3) .
P0731 50 Gear 1 Incorrect Ratio See 6-CYLINDER: GM5 AWD
2004 BMW 645Ci

(2004 - 2 OF 3) .
(2004 - 2 OF 3) .
(2004 - 2 OF 3) .
(2004 - 2 OF 3) .
P0741 48 Torque Converter Clutch Circuit See 6-CYLINDER: GM5 AWD
(2004 - 2 OF 3) .
P0742 48 Torque Converter Clutch Circuit See 6-CYLINDER: GM5 AWD
Stuck On TRANSMISSION DIAGNOSIS
(2004 - 2 OF 3) .
P0753 16 Shift Solenoid "A" Electrical See 6-CYLINDER: GM5 AWD
(2004 - 2 OF 3) .
P0758 17 Shift Solenoid "B" Electrical See 6-CYLINDER: GM5 AWD
(2004 - 2 OF 3) .
P0763 18 Shift Solenoid "C" Electrical See 6-CYLINDER: GM5 AWD
(2004 - 3 OF 3) .
P0973 16 Shift Solenoid "A" Control Circuit See 6-CYLINDER: GM5 AWD
Low TRANSMISSION DIAGNOSIS
(2004 - 2 OF 3) .
P0976 17 Shift Solenoid "B" Control Circuit See 6-CYLINDER: GM5 AWD
(2004 - 2 OF 3) .
P0979 18 Shift Solenoid "C" Control Circuit See 6-CYLINDER: GM5 AWD
(2004 - 3 OF 3) .
P1719 144 CAN Version Error See 6-CYLINDER: GM5 AWD
(2004 - 3 OF 3) .
P1720 129 CAN Timeout Control Module See 6-CYLINDER: GM5 AWD
(2004 - 3 OF 3) .
P1765 147 CAN Throttle Valve See 6-CYLINDER: GM5 AWD
(2004 - 3 OF 3) .
2004 BMW 645Ci
P1790 80 Internal Transmission Control See 6-CYLINDER: GM5 AWD

Checksum/EPROM Error (2004 - 3 OF 3) .
Checksum/EEPROM Error (2004 - 3 OF 3) .
Module Memory Checksum Error TRANSMISSION DIAGNOSIS
(2004 - 3 OF 3) .
P1891 96 System Voltage High Input See 6-CYLINDER: GM5 AWD
(2004 - 3 OF 3) .
P1892 96 System Voltage Low Input See 6-CYLINDER: GM5 AWD
(2004 - 3 OF 3) .
DIAGNOSTIC TROUBLE CODES 6-CYLINDER: SMG TRANSMISSION (2004)
DIAGNOSTIC TROUBLE CODES 6-CYLINDER: SMG TRANSMISSION (2004)

P0932 20215 Hydraulic Pressure Sensor See 6-CYLINDER: SMG
Circuit Low TRANSMISSION
Circuit High TRANSMISSION
P1720 20800 CAN Timeout Control Module See 6-CYLINDER: SMG
TRANSMISSION
P1721 20801 CAN Timeout ASC/DSC See 6-CYLINDER: SMG
TRANSMISSION
P1747 52999 CAN-Bus Monitoring See 6-CYLINDER: SMG
TRANSMISSION
P1765 20904 CAN Throttle Valve See 6-CYLINDER: SMG
TRANSMISSION
P1766 20702 Double Error Engine Speed See 6-CYLINDER: SMG
2004 BMW 645Ci
TRANSMISSION
P1771 20901 CAN Torque Interface See 6-CYLINDER: SMG
P1782 20910 CAN Brake Signal See 6-CYLINDER: SMG
TRANSMISSION
Module Error 7 (High Side TRANSMISSION
Driver) DIAGNOSIS (2004 - 4 OF 5) .
P1817 20606 Gear Selector Lever GSL0 See 6-CYLINDER: SMG
Cable High Input TRANSMISSION
Cable Low Input TRANSMISSION
Cable Plausibility TRANSMISSION
P1823 20611 Gear Selector Lever Digital See 6-CYLINDER: SMG
P1850 20213 Shift Angle Sensor High Input See 6-CYLINDER: SMG
TRANSMISSION
P1851 20213 Shift Angle Sensor Low Input See 6-CYLINDER: SMG
TRANSMISSION
P1852 20213 Shift Angle Sensor Plausibility See 6-CYLINDER: SMG
TRANSMISSION
2004 BMW 645Ci
P1860 20612 Gear Selector Lever Hall See 6-CYLINDER: SMG
Sensor Error 1 TRANSMISSION
P1887 20335 Hydraulic Pump See 6-CYLINDER: SMG
TRANSMISSION
DIAGNOSTIC TROUBLE CODES V8: TRANSMISSION (1/96-8/97)
DIAGNOSTIC TROUBLE CODES V8: TRANSMISSION (1/96-8/97)

P0705 8 Transmission Range Sensor "A" See V8 TRANSMISSION
Circuit Malfunction (PRNDL DIAGNOSIS (1996-8/97) .
Input)
P0715 16 Input/Turbine Speed Sensor "A" See V8 TRANSMISSION
Circuit DIAGNOSIS (1996-8/97) .
P0720 42 Output Speed Sensor Circuit SeeV8 TRANSMISSION
DIAGNOSIS (1996-8/97) .
P0730 102 Incorrect Gear Ratio See V8 TRANSMISSION
DIAGNOSIS (1996-8/97) .
P0731 ..... Incorrect Gear Ratio See V8 TRANSMISSION
DIAGNOSIS (1996-8/97) .
P0732 100 Gear 2 Incorrect Ratio See V8 TRANSMISSION
DIAGNOSIS (1996-8/97) .
2004 BMW 645Ci
P0733 ..... Gear 2 Incorrect Ratio See V8 TRANSMISSION

DIAGNOSIS (1996-8/97) .
P0734 ..... Gear 2 Incorrect Ratio See V8 TRANSMISSION
DIAGNOSIS (1996-8/97) .
DIAGNOSIS (1996-8/97) .
P0740 111 Torque Converter Clutch See V8 TRANSMISSION
Circuit/Open DIAGNOSIS (1996-8/97) .
P0743 4 Torque Converter Clutch Circuit See V8 TRANSMISSION
Electrical DIAGNOSIS (1996-8/97) .
P0748 5 Pressure Control Solenoid "A" See V8 TRANSMISSION
P0753 30 Shift Solenoid "A" Electrical See V8 TRANSMISSION
DIAGNOSIS (1996-8/97) .
P0758 33 Shift Solenoid "B" Electrical See V8 TRANSMISSION
DIAGNOSIS (1996-8/97) .
P0763 32 Shift Solenoid "C" Electrical See V8 TRANSMISSION
DIAGNOSIS (1996-8/97) .
P1734 1 Pressure Control Solenoid "B" See V8 TRANSMISSION
P1738 29 Pressure Control Solenoid "C" See V8 TRANSMISSION
P1743 51 Pressure Control Solenoid "E" See V8 TRANSMISSION
P1746 104 Transmission Control Module See V8 TRANSMISSION
Output Stage DIAGNOSIS (1996-8/97) .
P1747 150 CAN-Bus Monitoring See V8 TRANSMISSION
DIAGNOSIS (1996-8/97) .
DIAGNOSIS (1996-8/97) .
DIAGNOSIS (1996-8/97) .
P1748 103 Transmission Control Module Self- See V8 TRANSMISSION
Test DIAGNOSIS (1996-8/97) .
P1750 54 Secondary Pressure Solenoid See V8 TRANSMISSION
Circuit Range/Performance System DIAGNOSIS (1996-8/97) .
Voltage Input Low)
DIAGNOSTIC TROUBLE CODES V8 TRANSMISSION (9/97-8/00)

2004 BMW 645Ci

Input)
P0720 42 Output Speed Sensor Circuit See V8 TRANSMISSION
DIAGNOSIS (9/97-8/00) .
DIAGNOSIS (9/97-8/00) .
DIAGNOSIS (9/97-8/00) .
Circuit/Open DIAGNOSIS (9/97-8/00) .
DIAGNOSIS (9/97-8/00) .
DIAGNOSIS (9/97-8/00) .
DIAGNOSIS (9/97-8/00) .
Output Stage DIAGNOSIS (9/97-8/00) .
DIAGNOSIS (9/97-8/00) .
DIAGNOSIS (9/97-8/00) .
DIAGNOSIS (9/97-8/00) .
Test DIAGNOSIS (9/97-8/00) .
2004 BMW 645Ci

Circuit Range/Performance DIAGNOSIS (9/97-8/00) .
P1761 2 Shiftlock Solenoid See V8 TRANSMISSION
DIAGNOSIS (9/97-8/00) .
P1765 ..... TCM Rationality See V8 TRANSMISSION
DIAGNOSIS (9/97-8/00) .

P0560 96 System Voltage See V8 TRANSMISSION
DIAGNOSIS (9/00-8/01) .
P0600 129 Serial Communication Link See V8 TRANSMISSION
DIAGNOSIS (9/00-8/01) .
DIAGNOSIS (9/00-8/01) .
P0603 81 Internal Control Module Keep See V8 TRANSMISSION
Alive Memory (KAM) Error DIAGNOSIS (9/00-8/01) .
P0606 82 ECM/PCM Processor See V8 TRANSMISSION
DIAGNOSIS (9/00-8/01) .
Input)
DIAGNOSIS (9/00-8/01) .
DIAGNOSIS (9/00-8/01) .
DIAGNOSIS (9/00-8/01) .
DIAGNOSIS (9/00-8/01) .
DIAGNOSIS (9/00-8/01) .
DIAGNOSIS (9/00-8/01) .
DIAGNOSIS (9/00-8/01) .
DIAGNOSIS (9/00-8/01) .
2004 BMW 645Ci
DIAGNOSIS (9/00-8/01) .
DIAGNOSIS (9/00-8/01) .
Performance or Stuck Off DIAGNOSIS (9/00-8/01) .
DIAGNOSIS (9/00-8/01) .
DIAGNOSIS (9/00-8/01) .
DIAGNOSIS (9/00-8/01) .
Electrical (M44/M52: Brake Band DIAGNOSIS (9/00-8/01) .
Electrical)
Output Stage DIAGNOSIS (9/00-8/01) .
DIAGNOSIS (9/00-8/01) .
Self-Test DIAGNOSIS (9/00-8/01) .
P1765 147 CAN Throttle Valve See V8 TRANSMISSION
DIAGNOSIS (9/00-8/01) .

Circuit Intermittent DIAGNOSIS (9/01-8/02 - 1
OF 5) .
Circuit DIAGNOSIS (9/01-8/02 - 1
OF 5) .
Circuit Range/Performance DIAGNOSIS (9/01-8/02 - 1
OF 5) .
2004 BMW 645Ci

DIAGNOSIS (9/01-8/02 - 1
OF 5) .
Range/Performance DIAGNOSIS (9/01-8/02 - 1
OF 5) .
DIAGNOSIS (9/01-8/02 - 1
OF 5) .
DIAGNOSIS (9/01-8/02 - 1
OF 5) .
DIAGNOSIS (9/01-8/02 - 1
OF 5) .
DIAGNOSIS (9/01-8/02 - 1
OF 5) .
DIAGNOSIS (9/01-8/02 - 1
OF 5) .
Circuit/Open DIAGNOSIS (9/01-8/02 - 2
OF 5) .
Performance or Stuck Off DIAGNOSIS (9/01-8/02 - 2
OF 5) .
DIAGNOSIS (9/01-8/02 - 2
OF 5) .
P0750 16 Shift Solenoid "A" See V8 TRANSMISSION
DIAGNOSIS (9/01-8/02 - 3
OF 5) .
P0751 16 Shift Solenoid "A" Performance or See V8 TRANSMISSION
Stuck Off DIAGNOSIS (9/01-8/02 - 3
OF 5) .
P0752 16 Shift Solenoid "A" Stuck On See V8 TRANSMISSION
DIAGNOSIS (9/01-8/02 - 3
OF 5) .
DIAGNOSIS (9/01-8/02 - 3
OF 5) .
P0755 17 Shift Solenoid "B" See V8 TRANSMISSION
DIAGNOSIS (9/01-8/02 - 3
OF 5) .
2004 BMW 645Ci
P0756 17 Shift Solenoid "B" Performance or See V8 TRANSMISSION

OF 5) .
P0757 17 Shift Solenoid "B" Stuck On See V8 TRANSMISSION
DIAGNOSIS (9/01-8/02 - 3
OF 5) .
DIAGNOSIS (9/01-8/02 - 3
OF 5) .
P0760 18 Shift Solenoid "C" See V8 TRANSMISSION
DIAGNOSIS (9/01-8/02 - 3
OF 5) .
P0761 18 Shift Solenoid "C" Performance or See V8 TRANSMISSION
OF 5) .
P0762 18 Shift Solenoid "C" Stuck On See V8 TRANSMISSION
DIAGNOSIS (9/01-8/02 - 3
OF 5) .
DIAGNOSIS (9/01-8/02 - 3
OF 5) .
DIAGNOSIS (9/01-8/02 - 2
OF 5) .
P0782 57 2-3 Shift See V8 TRANSMISSION
DIAGNOSIS (9/01-8/02 - 4
OF 5) .
P0783 58 3-4 Shift See V8 TRANSMISSION
DIAGNOSIS (9/01-8/02 - 4
OF 5) .
DIAGNOSIS (9/01-8/02 - 2
OF 5) .
P1719 144 CAN Version Error See V8 TRANSMISSION
DIAGNOSIS (9/01-8/02 - 5
OF 5) .
P1720 129 CAN Timeout Control Module See V8 TRANSMISSION
DIAGNOSIS (9/01-8/02 - 5
OF 5) .
P1731 51 Gear 1 manual Incorrect Ratio See V8 TRANSMISSION
DIAGNOSIS (9/01-8/02 - 1
OF 5) .
DIAGNOSIS (9/01-8/02 - 3
OF 5) .
2004 BMW 645Ci

DIAGNOSIS (9/01-8/02 - 5
OF 5) .
Test DIAGNOSIS (9/01-8/02 - 3
OF 5) .
DIAGNOSIS (9/01-8/02 - 4
OF 5) .
P1762 19 Shiftlock Solenoid High Input See V8 TRANSMISSION
DIAGNOSIS (9/01-8/02 - 4
OF 5) .
P1763 19 Shiftlock Solenoid Low Input See V8 TRANSMISSION
DIAGNOSIS (9/01-8/02 - 4
OF 5) .
P1764 19 Shiftlock Solenoid Open Circuit See V8 TRANSMISSION
DIAGNOSIS (9/01-8/02 - 4
OF 5) .
DIAGNOSIS (9/01-8/02 - 5
OF 5) .
P1791 81 Internal Transmission Control See V8 TRANSMISSION
Module Memory DIAGNOSIS (9/01-8/02 - 5
Checksum/EEPROM Error OF 5) .
Module Watchdog Error DIAGNOSIS (9/01-8/02 - 5
OF 5) .
Module Memory Checksum Error DIAGNOSIS (9/01-8/02 - 5
OF 5) .
Circuit High DIAGNOSIS (9/01-8/02 - 2
OF 5) .
OF 5) .
OF 5) .
P1834 4 Pressure Control Solenoid "D" See V8 TRANSMISSION
OF 5) .
OF 5) .
2004 BMW 645Ci

Circuit Low DIAGNOSIS (9/01-8/02 - 2
OF 5) .
OF 5) .
OF 5) .
P1844 4 Pressure Control Solenoid "D" See V8 TRANSMISSION
OF 5) .
OF 5) .
P1882 57 2-3 Shift Circuit High See V8 TRANSMISSION
DIAGNOSIS (9/01-8/02 - 4
OF 5) .
P1883 58 3-4 Shift Circuit High See V8 TRANSMISSION
DIAGNOSIS (9/01-8/02 - 4
OF 5) .
P1889 96 System Voltage - Electrical See V8 TRANSMISSION
DIAGNOSIS (9/01-8/02 - 4
OF 5) .
P1892 96 System Voltage Low Input See V8 TRANSMISSION
DIAGNOSIS (9/01-8/02 - 4
OF 5) .
P1893 83 Supply Voltage Pressure Control See V8 TRANSMISSION
Solenoid/Shift Solenoid Circuit DIAGNOSIS (9/01-8/02 - 5
High OF 5) .
Solenoid/Shift Solenoid Circuit DIAGNOSIS (9/01-8/02 - 5
Low OF 5) .
Solenoid/Shift Solenoid No Signal DIAGNOSIS (9/01-8/02 - 5
OF 5) .
DIAGNOSTIC TROUBLE CODES V8 TRANSMISSION (5-SPEED - 9/02-2003)
DIAGNOSTIC TROUBLE CODES V8 TRANSMISSION (5-SPEED - 9/02-2003)

P0709 60 Transmission Range Sensor "A" See V8 TRANSMISSION 5-
Circuit Intermittent SPEED DIAGNOSIS (9/02-2003
- 1 OF 5) .
2004 BMW 645Ci
Circuit SPEED DIAGNOSIS (9/02-2003

- 1 OF 5) .
P0716 33 Input/Turbine Speed Sensor "A" See V8 TRANSMISSION 5-
Circuit Range/Performance SPEED DIAGNOSIS (9/02-2003
- 1 OF 5) .
P0720 32 Output Speed Sensor Circuit See V8 TRANSMISSION 5-
SPEED DIAGNOSIS (9/02-2003
- 1 OF 5) .
P0721 59 Output Speed Sensor Circuit See V8 TRANSMISSION 5-
Range/Performance SPEED DIAGNOSIS (9/02-2003
- 1 OF 5) .
P0731 50 Gear 1 Incorrect Ratio See V8 TRANSMISSION 5-
- 1 OF 5) .
- 1 OF 5) .
- 1 OF 5) .
- 1 OF 5) .
- 1 OF 5) .
P0741 48 Torque Converter Clutch Circuit See V8 TRANSMISSION 5-
Performance or Stuck Off SPEED DIAGNOSIS (9/02-2003
- 2 OF 5) .
P0745 1 Pressure Control Solenoid "A" See V8 TRANSMISSION 5-
- 2 OF 5) .
P0750 16 Shift Solenoid "A" See V8 TRANSMISSION 5-
- 3 OF 5) .
P0751 16 Shift Solenoid "A" Performance See V8 TRANSMISSION 5-
or Stuck Off SPEED DIAGNOSIS (9/02-2003
- 3 OF 5) .
P0752 16 Shift Solenoid "A" Stuck On See V8 TRANSMISSION 5-
- 3 OF 5) .
P0753 16 Shift Solenoid "A" Electrical See V8 TRANSMISSION 5-
- 3 OF 5) .
2004 BMW 645Ci

- 3 OF 5) .
P0756 17 Shift Solenoid "B" Performance See V8 TRANSMISSION 5-
- 3 OF 5) .
P0757 17 Shift Solenoid "B" Stuck On See V8 TRANSMISSION 5-
- 3 OF 5) .
P0758 17 Shift Solenoid "B" Electrical See V8 TRANSMISSION 5-
- 3 OF 5) .
P0760 18 Shift Solenoid "C" See V8 TRANSMISSION 5-
- 3 OF 5) .
P0761 18 Shift Solenoid "C" Performance See V8 TRANSMISSION 5-
- 3 OF 5) .
P0762 18 Shift Solenoid "C" Stuck On See V8 TRANSMISSION 5-
- 3 OF 5) .
P0763 18 Shift Solenoid "C" Electrical See V8 TRANSMISSION 5-
- 3 OF 5) .
P0775 2 Pressure Control Solenoid "B" See V8 TRANSMISSION 5-
- 2 OF 5) .
P0782 57 2-3 Shift See V8 TRANSMISSION 5-
- 4 OF 5) .
P0783 58 3-4 Shift See V8 TRANSMISSION 5-
- 4 OF 5) .
P0795 3 Pressure Control Solenoid "C" See V8 TRANSMISSION 5-
- 2 OF 5) .
Control Circuit Low SPEED DIAGNOSIS (9/02-2003
- 2 OF 5) .
Control Circuit High SPEED DIAGNOSIS (9/02-2003
- 2 OF 5) .
P0966 2 Pressure Control Solenoid "B" See V8 TRANSMISSION 5-
- 2 OF 5) .
2004 BMW 645Ci

- 2 OF 5) .
- 2 OF 5) .
- 2 OF 5) .
P1719 144 CAN Version Error See V8 TRANSMISSION 5-
- 5 OF 5) .
P1720 129 CAN Timeout Control Module See V8 TRANSMISSION 5-
- 5 OF 5) .
P1731 51 Gear 1 manual Incorrect Ratio See V8 TRANSMISSION 5-
- 1 OF 5) .
P1747 128 CAN-Bus Monitoring See V8 TRANSMISSION 5-
- 5 OF 5) .
P1748 15 Transmission Control Module See V8 TRANSMISSION 5-
Self-Test SPEED DIAGNOSIS (9/02-2003
- 3 OF 5) .
P1761 19 Shiftlock Solenoid See V8 TRANSMISSION 5-
- 4 OF 5) .
P1762 19 Shiftlock Solenoid High Input See V8 TRANSMISSION 5-
- 4 OF 5) .
P1763 19 Shiftlock Solenoid Low Input See V8 TRANSMISSION 5-
- 4 OF 5) .
P1764 19 Shiftlock Solenoid Open Circuit See V8 TRANSMISSION 5-
- 4 OF 5) .
P1765 147 CAN Throttle Valve See V8 TRANSMISSION 5-
- 5 OF 5) .
P1791 81 Internal Transmission Control See V8 TRANSMISSION 5-
Module Memory SPEED DIAGNOSIS (9/02-2003
Checksum/EEPROM Error - 5 OF 5) .
P1792 82 Internal Transmission Control See V8 TRANSMISSION 5-
Module Watchdog Error SPEED DIAGNOSIS (9/02-2003
- 5 OF 5) .
2004 BMW 645Ci
Module Memory Checksum SPEED DIAGNOSIS (9/02-2003

Error - 5 OF 5) .
P1882 57 2-3 Shift Circuit High See V8 TRANSMISSION 5-
- 4 OF 5) .
P1883 58 3-4 Shift Circuit High See V8 TRANSMISSION 5-
- 4 OF 5) .
P1889 96 System Voltage - Electrical See V8 TRANSMISSION 5-
- 4 OF 5) .
P1892 96 System Voltage Low Input See V8 TRANSMISSION 5-
- 4 OF 5) .
P1893 83 Supply Voltage Pressure Control See V8 TRANSMISSION 5-
Solenoid/Shift Solenoid Circuit SPEED DIAGNOSIS (9/02-2003
High - 5 OF 5) .
Solenoid/Shift Solenoid Circuit SPEED DIAGNOSIS (9/02-2003
Low - 5 OF 5) .
Solenoid/Shift Solenoid No SPEED DIAGNOSIS (9/02-2003
Signal - 5 OF 5) .
P2722 5 Pressure Control Solenoid "E" See V8 TRANSMISSION 5-
- 3 OF 5) .
- 3 OF 5) .
- 3 OF 5) .
P2761 4 Torque Converter Clutch See V8 TRANSMISSION 5-
Pressure Control Solenoid SPEED DIAGNOSIS (9/02-2003
Control Circuit/Open - 2 OF 5) .
Control Circuit High - 2 OF 5) .
Control Circuit Low - 2 OF 5) .
DIAGNOSTIC TROUBLE CODES V8: TRANSMISSION (SMG - 2004)

2004 BMW 645Ci

P1765 20904 CAN Throttle Valve See V8 SMG
TRANSMISSION
P1766 20702 Double Error Engine Speed See V8 SMG
P1767 20913 CAN Wheel Speeds Rear See V8 SMG
Axle TRANSMISSION
P1771 20901 CAN Torque Interface See V8 SMG
P1782 20910 CAN Brake Signal See V8 SMG
TRANSMISSION
P1791 20401 Internal Transmission See V8 SMG
Control Module Memory TRANSMISSION
P1796 20406 Internal Transmission See V8 SMG
Control Module Error 7 TRANSMISSION
(High Side Driver) DIAGNOSIS (2004 - 2 OF 4) .
P1817 20606 Gear Selector Lever GSL0 See V8 SMG
P1823 20611 Gear Selector Lever Digital See V8 SMG
P1850 20213 Shift Angle Sensor High See V8 SMG
2004 BMW 645Ci
P1851 20213 Shift Angle Sensor Low See V8 SMG
Input TRANSMISSION
P1852 20213 Shift Angle Sensor See V8 SMG
P1859 20217 Clutch Speed Sensor See V8 SMG
P1860 20612 Gear Selector Lever Hall See V8 SMG
Sensor Error 1 TRANSMISSION
P1887 20335 Hydraulic Pump See V8 SMG
TRANSMISSION
DIAGNOSTIC TROUBLE CODES V8 & V12 TRANSMISSION (6-SPEED - 2003)

P0715 20200 Input/Turbine Speed Sensor "A" See V8 & V12 6-SPEED
P0720 20201 Output Speed Sensor Circuit See V8 & V12 6-SPEED
TRANSMISSION
2004 BMW 645Ci
P0729 20306 Gear 6 Incorrect Ratio See V8 & V12 6-SPEED

TRANSMISSION
TRANSMISSION
TRANSMISSION
TRANSMISSION
TRANSMISSION
TRANSMISSION
P0741 20307 Torque Converter Clutch Circuit See V8 & V12 6-SPEED
P0745 20000 Pressure Control Solenoid "A" See V8 & V12 6-SPEED
TRANSMISSION
P0751 20100 Shift Solenoid "A" Performance See V8 & V12 6-SPEED
or Stuck Off TRANSMISSION
P0753 20100 Shift Solenoid "A" Electrical See V8 & V12 6-SPEED
TRANSMISSION
P0756 20101 Shift Solenoid "B" Performance See V8 & V12 6-SPEED
P0758 20101 Shift Solenoid "B" Electrical See V8 & V12 6-SPEED
TRANSMISSION
P0761 20102 Shift Solenoid "C" Performance See V8 & V12 6-SPEED
P0763 20102 Shift Solenoid "C" Electrical See V8 & V12 6-SPEED
TRANSMISSION
2004 BMW 645Ci
P0766 ...... Reserved For Later Versions See V8 & V12 6-SPEED
TRANSMISSION
P0768 ..... Reserved For Later Versions See V8 & V12 6-SPEED
TRANSMISSION
P0775 20001 Pressure Control Solenoid "B" See V8 & V12 6-SPEED
TRANSMISSION
P0781 20311 1-2 Shift See V8 & V12 6-SPEED
TRANSMISSION
TRANSMISSION
TRANSMISSION
TRANSMISSION
P0795 20002 Pressure Control Solenoid "C" See V8 & V12 6-SPEED
TRANSMISSION
TRANSMISSION
2004 BMW 645Ci
P0973 20100 Shift Solenoid "A" Control See V8 & V12 6-SPEED
P0976 20101 Shift Solenoid "B" Control See V8 & V12 6-SPEED
P0979 20102 Shift Solenoid "C" Control See V8 & V12 6-SPEED
P1701 20700 Double Error Position See V8 & V12 6-SPEED
Information CAN/Serial Line TRANSMISSION
P1702 20701 Combination Substitute Function See V8 & V12 6-SPEED
TRANSMISSION
P1720 20800 CAN Timeout Control Module See V8 & V12 6-SPEED
TRANSMISSION
P1721 20801 CAN Timeout ASC/DSC See V8 & V12 6-SPEED
TRANSMISSION
P1727 20903 CAN Engine Speed See V8 & V12 6-SPEED
TRANSMISSION
P1728 20336 Engine Overspeed Condition See V8 & V12 6-SPEED
TRANSMISSION
P1747 52999 CAN-Bus Monitoring See V8 & V12 6-SPEED
TRANSMISSION
P1765 ..... Throttle Valve Signal See V8 & V12 6-SPEED
TRANSMISSION
P1771 20901 CAN Torque Interface See V8 & V12 6-SPEED
P1782 ..... Brake Pedal Signal See V8 & V12 6-SPEED
TRANSMISSION
2004 BMW 645Ci
P1790 20400 Internal Transmission Control See V8 & V12 6-SPEED

Checksum/EPROM Error DIAGNOSIS (2003 - 6 OF 6) .
P1793 20330 ETC Cut-Off Due To See V8 & V12 6-SPEED
Overtemperature Condition TRANSMISSION
P1804 ..... Reserved For Later Versions See V8 & V12 6-SPEED
TRANSMISSION
P1806 20105 Shift Solenoid "A" or "B" See V8 & V12 6-SPEED
Mechanically Stuck TRANSMISSION
P1810 20200 Input/Turbine Speed Sensor See V8 & V12 6-SPEED
P1813 20201 Output Speed Sensor Circuit Low See V8 & V12 6-SPEED
Input TRANSMISSION
P1814 20203 Output Speed Sensor Gradient See V8 & V12 6-SPEED
Too High TRANSMISSION
P1830 20006 Pressure Control Solenoid See V8 & V12 6-SPEED
Current Error in P/R/N TRANSMISSION
High TRANSMISSION
Low TRANSMISSION
TRANSMISSION
2004 BMW 645Ci

TRANSMISSION
TRANSMISSION
TRANSMISSION
TRANSMISSION
P1871 20316 2-1 Shift Circuit High See V8 & V12 6-SPEED
TRANSMISSION
TRANSMISSION
TRANSMISSION
TRANSMISSION
TRANSMISSION
TRANSMISSION
TRANSMISSION
TRANSMISSION
TRANSMISSION
TRANSMISSION
P1888 20337 CAN Timeout Instrument Pack See V8 & V12 6-SPEED
during Operation Parking TRANSMISSION
Interlock Emergency Release DIAGNOSIS (2003 - 5 OF 6) .
2004 BMW 645Ci
P1890 20500 System Voltage See V8 & V12 6-SPEED

TRANSMISSION
P1891 20500 System Voltage High Input See V8 & V12 6-SPEED
TRANSMISSION
P1892 20500 System Voltage Low Input See V8 & V12 6-SPEED
TRANSMISSION
P1893 20501 Supply Voltage Pressure Control See V8 & V12 6-SPEED
Solenoid/Shift Solenoid Circuit TRANSMISSION
Solenoid/Shift Solenoid Circuit TRANSMISSION
Solenoid/Shift Solenoid No TRANSMISSION
Signal DIAGNOSIS (2003 - 6 OF 6) .
Solenoid/Shift Solenoid TRANSMISSION
P1897 20502 Supply Voltage Sensors High See V8 & V12 6-SPEED
Input TRANSMISSION
P1898 20502 Supply Voltage Sensors Low See V8 & V12 6-SPEED
Input TRANSMISSION
P2713 20003 Pressure Control Solenoid "D" See V8 & V12 6-SPEED
TRANSMISSION
P2722 20004 Pressure Control Solenoid "E" See V8 & V12 6-SPEED
TRANSMISSION
2004 BMW 645Ci
P2759 20005 Torque Converter Clutch See V8 & V12 6-SPEED
Pressure Control Solenoid TRANSMISSION
Control Circuit Electrical DIAGNOSIS (2003 - 3 OF 6) .
Pressure Control Solenoid TRANSMISSION
Control Circuit/Open DIAGNOSIS (2003 - 3 OF 6) .

PCode BMW Code Possible Cause Diagnostic Parameter
P0668 ..... Chip Temp See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 10 OF 10)
P0669 ..... Chip Temp See V8 & V12 6-SPEED
TRANSMISSION
P0701 ..... Range Position Switch See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 9 OF 10) .
P0702 ..... Watchdog See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 9 OF 10) .
P0705 ..... Range Position Switch See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 9 OF 10) .
P0710 ..... Oil Temperature Sensor See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 2 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 2 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 2 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 2 OF 10) .
2004 BMW 645Ci
TRANSMISSION
DIAGNOSIS (2004 - 2 OF 10) .
"A" Circuit TRANSMISSION
DIAGNOSIS (2004 - 1 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 2 OF 10) .
P0721 ..... Output Speed Sensor Circuit SeeV8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 1 OF 10) .
P0729 ..... Gear Ratio Monitoring See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 6 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 6 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 6 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 6 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 6 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 6 OF 10) .
P0736 ..... Gear Ratio Monitoring See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 6 OF 10) .
Circuit Performance or Stuck TRANSMISSION
Off DIAGNOSIS (2004 - 5 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
DIAGNOSIS (2004 - 3 OF 10) .
P0751 20100 Shift Solenoid "A" See V8 & V12 6-SPEED
DIAGNOSIS (2004 - 4 OF 10) .
2004 BMW 645Ci
TRANSMISSION
DIAGNOSIS (2004 - 4 OF 10) .
P0756 20101 Shift Solenoid "B" Performance See V8 & V12 6-SPEED
DIAGNOSIS (2004 - 5 OF 10) .
P0758 20101 Shift Solenoid "B" Electrical See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 4 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
DIAGNOSIS (2004 - 3 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 6 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 6 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 6 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 7 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
DIAGNOSIS (2004 - 3 OF 10) .
P0829 ..... Range Shift Monitoring See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
P0962 ..... Pressure Regulator Valve See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
2004 BMW 645Ci
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
P0973 ..... Solenoid Valve See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
P0979 ..... Interlock Lower Threshold See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 5 OF 10) .
P0982 ..... Shiftlock Interruption Or Short See V8 & V12 6-SPEED
To Ground TRANSMISSION
DIAGNOSIS (2004 - 5 OF 10) .
P1720 20800 CAN Timeout Control Module See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 8 OF 10) .
P1721 20801 CAN Timeout ASC/DSC See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 8 OF 10) .
P1727 20903 CAN Engine Speed See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 8 OF 10) .
P1728 20336 Engine Overspeed Condition See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 8 OF 10) .
P1747 52999 CAN-Bus Monitoring See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 9 OF 10) .
P1771 20901 CAN Torque Interface See V8 & V12 6-SPEED
DIAGNOSIS (2004 - 8 OF 10) .
Checksum/EPROM Error DIAGNOSIS (2004 - 10 OF
10) .
Checksum/EEPROM Error DIAGNOSIS (2004 - 10 OF
10) .
2004 BMW 645Ci
DIAGNOSIS (2004 - 9 OF 10) .

P1793 20330 ETC Cut-Off due to See V8 & V12 6-SPEED
Overtemperature Condition TRANSMISSION
DIAGNOSIS (2004 - 9 OF 10) .
P1798 ..... EPROM Plausibility See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 10 OF
10) .
DIAGNOSIS (2004 - 1 OF 10) .
DIAGNOSIS (2004 - 1 OF 10) .
DIAGNOSIS (2004 - 2 OF 10) .
DIAGNOSIS (2004 - 2 OF 10) .
P1814 20203 Output Speed Sensor Gradient See V8 & V12 6-SPEED
Too High TRANSMISSION
DIAGNOSIS (2004 - 2 OF 10) .
P1861 20316 2-1 Shift See .V8 & V12 6-SPEED
TRANSMISSION
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 8 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 6 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 6 OF 10) .
2004 BMW 645Ci
TRANSMISSION
DIAGNOSIS (2004 - 6 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 7 OF 10) .
TRANSMISSION
P1888 20337 CAN Timeout Instrument Pack See V8 & V12 6-SPEED
during Operation Parking TRANSMISSION
Interlock Emergency Release DIAGNOSIS (2004 - 9 OF 10) .
P1890 20500 System Voltage See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 5 OF 10) .
P1891 20500 System Voltage High Input See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 5 OF 10) .
P1892 20500 System Voltage Low Input See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 5 OF 10) .
P1893 20501 Supply Voltage Pressure See V8 & V12 6-SPEED
Control Solenoid/Shift TRANSMISSION
Solenoid Circuit High DIAGNOSIS (2004 - 10 OF
10) .
Solenoid Circuit Low DIAGNOSIS (2004 - 10 OF
10) .
Solenoid No Signal DIAGNOSIS (2004 - 10 OF
10) .
Solenoid DIAGNOSIS (2004 - 10 OF
10) .
P1897 20502 Supply Voltage Sensors High See V8 & V12 6-SPEED
Input TRANSMISSION
10) .
P1898 20502 Supply Voltage Sensors Low See V8 & V12 6-SPEED
Input TRANSMISSION
10) .
2004 BMW 645Ci
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 3 OF 10) .
P2759 ..... TCC Valve See V8 & V12 6-SPEED
TRANSMISSION
DIAGNOSIS (2004 - 5 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 5 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 5 OF 10) .
TRANSMISSION
DIAGNOSIS (2004 - 5 OF 10) .
DIAGNOSTIC TROUBLE CODES V12 TRANSMISSION (1996)

Circuit Malfunction (PRNDL DIAGNOSIS (1996) .
Input)
Circuit DIAGNOSIS (1996) .
DIAGNOSIS (1996) .
2004 BMW 645Ci
DIAGNOSIS (1996) .
P0730 102 Incorrect Gear Ratio See V12 TRANSMISSION
DIAGNOSIS (1996) .
DIAGNOSIS (1996) .
Circuit/Open DIAGNOSIS (1996) .
Electrical DIAGNOSIS (1996) .
DIAGNOSIS (1996) .
DIAGNOSIS (1996) .
DIAGNOSIS (1996) .
P1734 1 Pressure Control Solenoid "B" SeeV12 TRANSMISSION
Output Stage DIAGNOSIS (1996) .
DIAGNOSIS (1996) .
DIAGNOSIS (1996) .
DIAGNOSIS (1996) .
Self-Test DIAGNOSIS (1996) .
Circuit Range/Performance DIAGNOSIS (1996) .
DIAGNOSIS (1996) .

2004 BMW 645Ci

Circuit Malfunction (PRNDL DIAGNOSIS (1997) .
Input)
DIAGNOSIS (1997) .
DIAGNOSIS (1997) .
DIAGNOSIS (1997) .
DIAGNOSIS (1997) .
DIAGNOSIS (1997) .
Circuit/Open DIAGNOSIS (1997) .
DIAGNOSIS (1997) .
DIAGNOSIS (1997) .
DIAGNOSIS (1997) .
DIAGNOSIS (1997) .
DIAGNOSIS (1997) .
DIAGNOSIS (1997) .
2004 BMW 645Ci

Circuit Range/Performance DIAGNOSIS (1997) .
DIAGNOSTIC TROUBLE CODES V12 TRANSMISSION (1998-2000)
DIAGNOSTIC TROUBLE CODES V12 TRANSMISSION (1998-2000)

Circuit Malfunction (PRNDL DIAGNOSIS (1998-2000) .
Input)
Circuit DIAGNOSIS (1998-2000) .
DIAGNOSIS (1998-2000) .
DIAGNOSIS (1998-2000) .
DIAGNOSIS (1998-2000) .
DIAGNOSIS (1998-2000) .
DIAGNOSIS (1998-2000) .
Circuit/Open DIAGNOSIS (1998-2000) .
Electrical DIAGNOSIS (1998-2000) .
DIAGNOSIS (1998-2000) .
DIAGNOSIS (1998-2000) .
DIAGNOSIS (1998-2000) .
2004 BMW 645Ci

Output Stage DIAGNOSIS (1998-2000) .
DIAGNOSIS (1998-2000) .
DIAGNOSIS (1998-2000) .
DIAGNOSIS (1998-2000) .
Self-Test DIAGNOSIS (1998-2000) .
Circuit Range/Performance DIAGNOSIS (1998-2000) .
P1761 ..... Transmission Control Module See V12 TRANSMISSION
DIAGNOSIS (1998-2000) .
P1765 ..... Transmission Control Module See V12 TRANSMISSION
DIAGNOSIS (1998-2000) .

P0560 96 System Voltage See V12 TRANSMISSION
DIAGNOSIS (2001) .
DIAGNOSIS (2001) .
P0603 81 Internal Control Module Keep See V12 TRANSMISSION
Alive Memory (KAM) Error DIAGNOSIS (2001) .
P0606 82 ECM/PCM Processor See V12 TRANSMISSION
DIAGNOSIS (2001) .
Circuit Malfunction (PRNDL DIAGNOSIS (2001)
Input)
DIAGNOSIS (2001) .
DIAGNOSIS (2001) .
2004 BMW 645Ci
DIAGNOSIS (2001) .
DIAGNOSIS (2001) .
DIAGNOSIS (2001) .
DIAGNOSIS (2001) .
DIAGNOSIS (2001) .
DIAGNOSIS (2001) .
Performance or Stuck Off DIAGNOSIS (2001) .
DIAGNOSIS (2001) .
DIAGNOSIS (2001) .
DIAGNOSIS (2001) .
DIAGNOSIS (2001) .
DIAGNOSIS (2001) .
2004 BMW 645Ci
2004 DTC INDEX BMW - 545i, 645Ci, 745i, X5
2004 DTC INDEX
BMW - 545i, 645Ci, 745i, X5
SELF-DIAGNOSTICS DTCS
ENGINE PERFORMANCE & TRANSMISSION DIAGNOSTIC TROUBLE CODES LIST - V8
Diagnostic Trouble Diagnosis
Code
P140B See DTC CHART (4BMXV04.4LEV, 4BMXT04.4N62, 4BMXT04.8NHP) - 4
OF 30 .
P140C See DTC CHART (4BMXV04.4LEV, 4BMXT04.4N62, 4BMXT04.8NHP) - 4
OF 30 .
P320D See DTC CHART (4BMXV04.4LEV, 4BMXT04.4N62, 4BMXT04.8NHP) - 15
OF 30 .
P0010 See DTC CHART (4BMXV04.4LEV, 4BMXT04.4N62, 4BMXT04.8NHP) - 13
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
2004 BMW 645Ci
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
2004 BMW 645Ci
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
2004 BMW 645Ci
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
2004 BMW 645Ci
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
2004 BMW 645Ci
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
2004 BMW 645Ci
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
2004 BMW 645Ci
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
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OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
2004 BMW 645Ci
OF 30 .
OF 30 .
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OF 30 .
OF 30 .
OF 30 .
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OF 30 .
OF 30 .
OF 30 .
OF 30 .
OF 30 .
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OF 30 .
2004 BMW 645Ci
OF 30 .
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2004 BMW 645Ci
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See DTC CHART (4BMXV04.4LEV, 4BMXT04.4N62, 4BMXT04.8NHP) - 23
OF 30 .
P1720
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2004 BMW 645Ci
OF 30 .
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P1747
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2004 BMW 645Ci
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2004 BMW 645Ci
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2004 BMW 645Ci
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2004 BMW 645Ci
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2004 BMW 645Ci
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2004 BMW 645Ci
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2009 BMW 650i
2009 BMW 650i & M6
2009 BMW
650i & M6
BUZZERS, RELAYS & TIMERS

BUZZERS, RELAYS & TIMERS LOCATION
Component Location
Convertible Top 1 Relay (K18363) Below center of rear window. See Fig. 65.
Convertible Top 2 Relay (K18364) Below center of rear window. See Fig. 65.
DME Relay (K6300) Right rear of engine compartment. See Fig. 47.
Electric Vacuum Pump Relay (K213) Top right side of dash. See Fig. 63.
Fuel Pump Relay (K96) Under right side of dash. See Fig. 5.
Headlight Washer Relay (K6) Center of rear compartment. See Fig. 61.
Hydraulic Pump Relay (SMG) (K6318) Right rear of engine compartment. See Fig. 29.
Lowering Rear Window Relay (K89) Center of rear compartment. See Fig. 62.
Power Saving Relay, Terminal 15 (K6326) Right rear of engine compartment. See Fig. 47.
Raising Rear Window Relay (I01113) Center of rear compartment.
Rear Defroster Relay (I01061) In center of rear compartment. See Fig. 44.
Secondary Air Pump Relay (K6304a) Right rear of engine compartment. See Fig. 46.
Terminal 15 Relay (I01069) In center of rear compartment. See Fig. 44.
Terminal 30G Relay (I01068) In center of rear compartment. See Fig. 44.
Transmission Fluid Pump Relay (K63831) Right rear of engine compartment. See Fig. 66.
Windshield Wiper Relay (K11) Right rear of engine compartment. See Fig. 46.
CIRCUIT PROTECTION DEVICES

CIRCUIT PROTECTION DEVICES LOCATION
Component Location
B+ Potential Distributor (A2076) Right rear of engine compartment. See Fig. 64.
E Box Right rear of engine compartment.
Fuse Holder (Front) (A41a) Behind glove box. See Fig. 5.
Fuse Holder (Rear) (A46) In luggage compartment. See Fig. 6.
CONTROL UNITS
CONTROL UNITS LOCATION
Component Location
Accelerator Pedal Module At accelerator pedal. See Fig. 31.
Active Cruise Control (A144a) Front of vehicle. See Fig. 11.
Active Steering Module (A467) Right front floor. See Fig. 23.
2009 BMW 650i
2009 BMW 650i & M6
Adaptive Headlight (A214) Under right side of dash. See Fig. 69.
Basic Body Module (A1a) Behind glove box. See Fig. 1.
Body-Gateway Module (A16760) Under right side of dash. See Fig. 85.
Car Access Module (A149a) Behind left side of dash. See Fig. 13.
Comfort Access Control Module (A215) Under right side of dash. See Fig. 69.
Convertible Top Module (A96) Near left "C" pillar. See Fig. 9.
Crash Safety Module (A12a) Left side of center console. See Fig. 68.
Digital Motor Electronics (DME) Control Module
Right rear engine compartment. See Fig. 24.
(A6000)
Driver's Door Module (A23a) In driver's door. See Fig. 3.
Driver's Seat Module (Convertible) (A187) Under driver's seat. See Fig. 19.
Driver's Seat Module (Coupe) (A187) Side of driver's seat. See Fig. 18.
Dynamic Drive Control Module (A148a) Right kick panel. See Fig. 12.
Dynamic Stability Control (DSC) (A65a) Right front of engine compartment. See Fig. 7.
Electronically Controlled Fuel Pump (A13663) Front of center console. See Fig. 83.
Electronic Steering Wheel Module (I01004) Part of steering wheel. See Fig. 143.
Fuel Tank Leakage Diagnosis Module (M119) Under rear of vehicle. See Fig. 51.
Heating/Air Conditioning System (A11a) Center of dash. See Fig. 67.
Integrated Supply Module (IVM) (A6009) Right rear of engine compartment. See Fig. 25.
Ionic Current Control Module 1 (A6180) Right front of engine. See Fig. 26.
Ionic Current Control Module 2 (A6190) Left front of engine. See Fig. 27.
Light Module (A3) Near left kick panel. See Fig. 2.
Micro-Power Module (A16021) In luggage compartment. See Fig. 8.
Night Vision Control (A859) Under right side of dash. See Fig. 82.
Park Distance Control (PDC) (A81a) In luggage compartment. See Fig. 8.
Passenger's Door Module (A24a) In passenger's door. See Fig. 4.
Passenger's Seat Module (Convertible) (A186) Under passenger's seat. See Fig. 16.
Passenger's Seat Module (Coupe) (A186) Side of passenger's seat. See Fig. 17.
Safety & Gateway Module (A220) Behind glove box. See Fig. 1.
Sequential Manual Transmission (SMG) (A70010) Right rear of engine compartment. See Fig. 30.
Sunroof Module (A33b) Front of roof. See Fig. 69.
Tire Pressure Control (RDC) (A85a) Under right side of dash. See Fig. 69.
Transmission Control Module (A/T) Rear of transmission. See Fig. 28.
Variable Valve Timing Gear Control Module
Right rear of engine compartment. See Fig. 24.
(A60210)
Video Module (A197) Left side of luggage compartment. See Fig. 20.
MOTORS
MOTORS LOCATION
Component Location
2009 BMW 650i
2009 BMW 650i & M6
Auxiliary Water Pump (M37) Front of engine compartment. See Fig. 50.
Circulation Pump (Independent Heater) (I01008) Left front wheelwell. See Fig. 41.
Cold Air Flap Motor (I01057) Behind right side of dash. See Fig. 42.
Convertible Top Drive (M101) Top center of rear compartment. See Fig. 145.
Cowl Panel Locking Drive (M132) Left front side of roof. See Fig. 149.
Defroster Flap Motor (M35a) Behind left side of dash. See Fig. 43.
Driver's Door System Lock (S246) Rear of driver's door. See Fig. 137.
Driver's Seat Angle Adjustment Drive (Convertible)
Under driver's seat. See Fig. 157.
(M50a)
Driver's Seat Angle Adjustment Drive (Coupe)
(M50a)
Driver's Seat Backrest Angle Adjustment Drive
(Convertible) (M53a)
Driver's Seat Backrest Angle Adjustment Drive
(Coupe) (M53a)
Driver's Seat Forward/Backward Adjustment Drive
Driver's Seat Forward/Backward Adjustment Drive
(Coupe) (M51a)
Driver's Seat Head Restraint Adjustment Drive
Top left side of driver's seat back. See Fig. 160.
(M54a)
Driver's Seat Height Adjustment Drive
Driver's Seat Height Adjustment Drive (Coupe)
(M52a)
Driver's Seat Lumbar Support Drive (M55a) Under driver's seat. See Fig. 159.
Driver's Window Motor (M21) Center front of driver's door. See Fig. 154.
Electrical Fuel Pump (M2) Below right rear seat. See Fig. 48.
Electric Fan (M135) Front of engine. See Fig. 165.
Electronic Throttle Valve Actuator (Y5392) On top of engine. See Fig. 55.
Electronic Throttle Valve Actuator 2 (Y5393) On top of engine. See Fig. 55.
Footwell Flap Motor (Left) (M13734a) Behind left side of dash. See Fig. 43.
Footwell Flap Motor (Right) (M13735a) Behind right side of dash. See Fig. 42.
Fresh Air-Recirculation Air Flap Motor (Left)
Behind left side of dash. See Fig. 43.
(M36a)
Fresh Air-Recirculation Air Flap Motor (Right)
Behind right side of dash. See Fig. 42.
(M40a)
Fuel Filler Flap Central Locking Drive (M16) Right side of rear compartment. See Fig. 70.
Fuel Metering Pump (Y7) Under left center side of vehicle. See Fig. 191.
Glass Roof Motor (M14105) Center rear of roof. See Fig. 73.
Headlight Washer Pump (M7) Left front wheelwell. See Fig. 49.
Hydraulic Pump (Y6975) Bottom of transmission. See Fig. 208.
2009 BMW 650i
2009 BMW 650i & M6
Independent Heater Combustion Air Blower

Behind left front wheel. See Fig. 146.
(I01009)
Left Rear Window Regulator Motor (M98) Center of left rear interior panel. See Fig. 162.
Left Rollover Protection Actuator (Y85) Behind left side of left rear seat. See Fig. 212.
M-ASK/CC Fan (M455) Center of dash. See Fig. 167.
Passenger's Backrest Angle Adjustment Drive
Under front passenger's seat. See Fig. 81.
Passenger's Backrest Angle Adjustment Drive
(Coupe) (M58a)
Passenger's Door System Lock (S254) Rear of front passenger's door. See Fig. 138.
Passenger's Head Restraint Adjustment Drive Top right side of front passenger's seat back. See
(M57a) Fig. 161.
Passenger's Seat Angle Adjustment Drive
Under passenger's seat. See Fig. 16.
Passenger's Seat Angle Adjustment Drive (Coupe)
(M61a)
Passenger's Seat Forward/Backward Adjustment
Drive (Convertible) (M60a)
Passenger's Seat Forward/Backward Adjustment
Drive (Coupe) (M60a)
Passenger's Seat Height Adjustment Drive
Under front passenger's seat.
Passenger's Seat Height Adjustment Drive (Coupe)
(M59a)
Passenger's Seat Lumbar Support Drive (M56a) Under front passenger's seat. See Fig. 81.
Bottom front of front passenger's door. See Fig.
Passenger's Window Motor (M23)
155.
Rear Compartment Mixing Flap Motor (I01060) Behind left side of dash. See Fig. 34.
Rear Lid Central Locking Drive (M17b)
Center of rear compartment door. See Fig. 153.
(Convertible)
Rear Lid Central Locking Drive (M17b) (Coupe) Center of rear compartment door. See Fig. 152.
Rear Window Drive (I01112) Top center of rear compartment. See Fig. 147.
Right Rear Window Regulator Motor (M99) Center of right rear interior panel. See Fig. 163.
Right Rollover Protection Actuator (Y86) Behind right side of right rear seat. See Fig. 194.
Secondary Air Injection Pump (M63) Right front wheelwell. See Fig. 40.
Steering Column Adjustment Motor (M137) Under left side of dash. See Fig. 164.
Steering Gear (M179) Under right front of vehicle. See Fig. 166.
Valvetronic Actuator Motor (M6351) Right side of engine. See Fig. 168.
Valvetronic Actuator Motor 2 (M6352) Left side of engine. See Fig. 169.
Ventilation Flap Motor (Left) (I01058) Behind left side of dash. See Fig. 43.
Ventilation Flap Motor (Right) (I01059) Behind right side of dash. See Fig. 42.
Visor Motor (M14104) In overhead console. See Fig. 71.
2009 BMW 650i
2009 BMW 650i & M6
Windshield Washer Pump (M4) Left front wheelwell. See Fig. 49.
Wiper Motor (M3a) Left rear of engine compartment. See Fig. 36.
SENDING UNITS & SENSORS

SENDING UNITS & SENSORS LOCATION
Component Location
Air Mass Sensor 1 (B6217) Right front side of engine. See Fig. 116.
Air Mass Sensor 2 (B6227) Left front side of engine. See Fig. 116.
Automatic Air Recirculation Sensor (B414) Front of engine compartment. See Fig. 107.
Battery Sensor (B895) In center of rear compartment. See Fig. 39.
Camshaft Sensor - Exhaust (4.8L) (B62142) Right rear side of engine. See Fig. 125.
Camshaft Sensor - Exhaust (5.0L) (B62142) Left rear side of engine. See Fig. 126.
Camshaft Sensor - Intake (4.8L) (B62141) Right rear side of engine. See Fig. 125.
Camshaft Sensor - Intake (5.0L) (B62141) Left rear side of engine. See Fig. 126.
Camshaft Sensor 2 - Exhaust (4.8L) (B62242) Left rear side of engine. See Fig. 127.
Camshaft Sensor 2 - Exhaust (5.0L) (B62242) Left front side of engine. See Fig. 128.
Camshaft Sensor 2 - Intake (4.8L) (B62241) Left rear side of engine. See Fig. 127.
Camshaft Sensor 2 - Intake (5.0L) (B62241) Left front side of engine. See Fig. 128.
Characteristic Map Thermostat (Y6279) Front of engine. See Fig. 117.
Clutch Position Sensor (B6574) Left side of transmission. See Fig. 121.
Condensation Sensor (B100) Center of windshield. See Fig. 74.
Convertible Top Lid Open Hall Sensor (S188) Left top side of rear compartment. See Fig. 176.
Coolant Pressure Sensor (B97) Top of right front wheel. See Fig. 103.
Cowl Panel Locked Hall Sensor (I01117) Left front of headliner. See Fig. 149.
Cowl Panel Release Hall Sensor (I01116) Left front of headliner. See Fig. 149.
Crankshaft Position Sensor (4.8L) (B6203) Right side of engine. See Fig. 113.
Crankshaft Position Sensor (5.0L) (B6203) Under left center of vehicle. See Fig. 114.
Driver's Side Door Airbag Sensor (B78a) Front of driver's door. See Fig. 101.
DSC Sensor (B75) Under right side of driver's seat. See Fig. 10.
DSC Sensor 2 (B105) Under driver's seat. See Fig. 104.
Dynamic Drive Lateral-Acceleration Sensor (A139) Under right side of driver's seat. See Fig. 10.
Eccentric Shaft Sensor (B60213) Rear of engine. See Fig. 125.
Eccentric Shaft Sensor 2 (B60223) Left rear of engine. See Fig. 127.
Engine Coolant Temperature Sensor (B6236) Front of engine. See Fig. 117.
Evaporator Temperature Sensor (B14a) Behind left side of dash. See Fig. 34.
Exhaust Temperature Sensor 1 (B62301) Right side of transmission. See Fig. 129.
Exhaust Temperature Sensor 2 (B62302) Left side of transmission. See Fig. 129.
Front Axle Brake Pressure Sensor (B112a) Top of right front wheel. See Fig. 103.
Gearbox Temperature Sensor (B6950) Under right center of vehicle. See Fig. 122.
2009 BMW 650i
2009 BMW 650i & M6
Heat Exchanger Temperature Sensor (Basic) (B11b) Behind center of dash. See Fig. 33.
Heat Exchanger Temperature Sensor (Left) (IHKA
Behind center of dash. See Fig. 32.
High) (B11a)
Heat Exchanger Temperature Sensor (Right) (IHKA
Behind center of dash. See Fig. 32.
High) (B12a)
Hot Film Mass Air Flow Sensor (B6207) Right side of engine. See Fig. 115.
Hydraulic Pressure Sensor (B6571) Rear of transmission. See Fig. 119.
Intake Pipe Pressure Sensor (B6239) Front of engine. See Fig. 110.
Knock Sensor (B6257) Under intake manifold. See Fig. 118.
Knock Sensor 2 (B6258) Under intake manifold.
Latch Fastener Sensor (I01115) Left top side of rear compartment. See Fig. 148.
Left Convertible Top Compartment Lock Hall
Left top side of rear compartment. See Fig. 148.
Sensor (S158)
Left Front Brake Pad Wear Sensor (B16a) Behind left front wheel. See Fig. 90.
Left Front Center Ultrasonic Sensor (B31a) Front bumper. See Fig. 92.
Left Front Ultrasonic Sensor (B30a) Front bumper. See Fig. 92.
Left Front Wheel Speed Sensor (B2) Front of left front wheel. See Fig. 87.
Left Rear Center Ultrasonic Sensor (B35a) Rear bumper. See Fig. 93.
Left Rear Level Sensor (B70) Front of left rear wheel. See Fig. 100.
Left Rear Microwave Sensor (B14145) Left side of left "B" pillar. See Fig. 123.
Left Rear Ultrasonic Sensor (B34a) Rear bumper. See Fig. 93.
Left Rear Wheel Speed Sensor (B4) Front of left rear wheel. See Fig. 89.
Level Sensor (Right Front) (B42) On right front suspension. See Fig. 37.
Level Sensor (Right Rear) (B69) On right rear suspension. See Fig. 38.
Main Pillar Sensor (I01114) Left top side of rear compartment. See Fig. 148.
Mainshaft Speed Sensor (Y8616) Right side of transmission. See Fig. 120.
Microwave Sensor (Driver's Door) (B14143) In driver's door. See Fig. 3.
Microwave Sensor (Passenger's Door) (B14144) In passenger's door. See Fig. 4.
Neutral Sensor (B456) Top of transmission. See Fig. 108.
Oil Quality Sensor (B62540) Right side of engine. See Fig. 113.
Outside Temperature Sensor (B21a) Front of vehicle. See Fig. 11.
Oxygen Sensor 2 (4.8L) (B62201) Left rear side of engine. See Fig. 131.
Oxygen Sensor 2 (4.8L) (B62202) Behind catalytic converter. See Fig. 130.
Oxygen Sensor 2 (5.0L) (B62201) Left rear side of engine. See Fig. 129.
Oxygen Sensor 2 (5.0L) (B62202) Behind catalytic converter. See Fig. 129.
Oxygen Sensor (4.8L) (B62101) Right rear side of engine. See Fig. 130.
Oxygen Sensor (4.8L) (B62102) Behind catalytic converter. See Fig. 131.
Oxygen Sensor (5.0L) (B62101) Right rear side of engine. See Fig. 129.
Oxygen Sensor (5.0L) (B62102) Behind catalytic converter. See Fig. 129.
Passenger's Seat Occupancy Detection (Convertible)
(A222a)
2009 BMW 650i
2009 BMW 650i & M6
Passenger's Seat Occupancy Detection (Coupe)

(A222a)
Passenger's Side Door Airbag Sensor (B79a) Front of passenger's door. See Fig. 102.
Radiator Outlet Temperature Sensor (B604a) Front of engine compartment. See Fig. 107.
Rain/Headlight Sensor (B57b) Center of windshield. See Fig. 74.
Rear Axle Brake Pressure Sensor (B114a) Right side of engine compartment. See Fig. 105.
Right Convertible Top Compartment Lock Hall
Right top side of rear compartment. See Fig. 175.
Sensor (S161)
Right Front Brake Pad Wear Sensor (B118) Behind right front wheel. See Fig. 106.
Right Front Center Ultrasonic Sensor (B32a) Front bumper. See Fig. 92.
Right Front Ultrasonic Sensor (B33a) Front bumper. See Fig. 92.
Right Front Wheel Speed Sensor (B1) Front of right front wheel. See Fig. 86.
Right Rear Brake Pad Wear Sensor (B17a) Behind right rear wheel. See Fig. 91.
Right Rear Center Ultrasonic Sensor (B36a) Rear bumper. See Fig. 93.
Right Rear Microwave Sensor (B14146) Right side of right "B" pillar. See Fig. 124.
Right Rear Ultrasonic Sensor (B37a) Rear bumper. See Fig. 93.
Right Rear Wheel Speed Sensor (B3) Front of right rear wheel. See Fig. 88.
Selector Angle Sensor (B6573) Top of transmission. See Fig. 120.
Siren & Tilt Alarm Sensor (A14147) Behind right rear wheel. See Fig. 84.
Solar Sensor (B66) Top center of dash. See Fig. 99.
Speed (RPM) Sensor (B2013) Left side of engine. See Fig. 109.
Throttle Valve Sensor (R62521) Right rear of engine. See Fig. 54.
Throttle Valve Sensor 2 (R62522) Top of engine. See Fig. 55.
SOLENOIDS & SOLENOID VALVES

SOLENOIDS & SOLENOID VALVES LOCATION
Component Location
Brake Solenoid Valve (Y6563) Rear of transmission. See Fig. 208.
Charcoal Filter Valve (Y6121) At rear top of engine. See Fig. 54.
Clutch Solenoid Valve (Y6564) Bottom of transmission. See Fig. 119.
Convertible Top Lid Opening Valve (I01111) Rear center of rear compartment. See Fig. 145.
Coolant Changeover Valve (Y12) Behind left front wheel. See Fig. 192.
DISA Controller 1 (Y6540) Front of engine. See Fig. 110.
DISA Controller 2 (Y6541) Front of engine. See Fig. 110.
Driver's Lumbar Support Valve Block (Y193) Top of driver's seat back. See Fig. 160.
Dynamic Drive Valve Block (Y40) Behind right front wheel. See Fig. 193.
Electric Throttle Valve (Y6390) Front of engine. See Fig. 203.
Evaporative Emission Valve (Y6120) Front of engine. See Fig. 203.
Fuel Injector 1 (4.8L) (Y6101) Right front of engine. See Fig. 199.
Fuel Injector 1 (5.0L) (Y6101) Left side of engine. See Fig. 202.
2009 BMW 650i
2009 BMW 650i & M6
Fuel Injector 2 (4.8L) (Y6102) Right center side of engine. See Fig. 199.
Fuel Injector 3 (4.8L) (Y6103) Right center side of engine. See Fig. 199.
Fuel Injector 4 (4.8L) (Y6104) Right rear side of engine. See Fig. 199.
Fuel Injector 5 (4.8L) (Y6105) Left front side of engine. See Fig. 200.
Fuel Injector 6 (4.8L) (Y6106) Left center side of engine. See Fig. 200.
Fuel Injector 6 (5.0L) (Y6106) Right side of engine. See Fig. 201.
Fuel Injector 7 (4.8L) (Y6107) Left center side of engine. See Fig. 200.
Fuel Injector 8 (4.8L) (Y6108) Left rear side of engine. See Fig. 200.
Fuel Tank Vent Valve 2 (Y6122) Top rear of engine. See Fig. 54.
Gear Solenoid Valve 1 (Y6561) Rear of transmission. See Fig. 208.
Gear Solenoid Valve 2 (Y6562) Bottom of transmission. See Fig. 119.
Idle Actuator (Y6939) Top rear of engine. See Fig. 209.
Idle Actuator 2 (Y6938) Top rear of engine. See Fig. 209.
Left Front Damper Valve (Y401) Left side of engine compartment. See Fig. 195.
Left Rear Damper Valve (Y403) Behind left rear seat. See Fig. 197.
Lifting Latch Fastener Valve (I01123) Top center of rear compartment. See Fig. 65.
Lowering Latch Fastener Valve (I01124) Top center of rear compartment. See Fig. 65.
Passenger's Lumbar Support Valve Block (Y194) Top of front passenger's seat back. See Fig. 161.
Right Front Damper Valve (Y402) Right side of engine compartment. See Fig. 196.
Right Rear Damper Valve (Y404) Behind right rear seat. See Fig. 198.
Secondary Air Injection Pump Valve (Y6163) Front of engine. See Fig. 205.
Servotronic Valve (B15a) Near left rear wheel, under vehicle. See Fig. 35.
VANOS Pressure Accumulator Valve (Y13041) Near starter. See Fig. 210.
VANOS Solenoid Valve - Exhaust (4.8L) (Y6282) Front of engine. See Fig. 204.
VANOS Solenoid Valve - Exhaust (5.0L) (Y6282) Front of engine. See Fig. 205.
VANOS Solenoid Valve - Intake (4.8L) (Y6281) Front of engine. See Fig. 204.
VANOS Solenoid Valve - Intake (5.0L) (Y6281) Front of engine. See Fig. 205.
VANOS Solenoid Valve 2 - Exhaust (4.8L)
Front of engine. See Fig. 207.
(Y6284)
VANOS Solenoid Valve 2 - Exhaust (5.0L)
Front of engine. See Fig. 206.
(Y6284)
VANOS Solenoid Valve 2 - Intake (4.8L) (Y6283) Front of engine. See Fig. 207.
2009 BMW 650i
2009 BMW 650i & M6
Volume Control Valve (B2382) Left side of engine. See Fig. 111.
Water Valve Assembly (Y4) Left rear of engine compartment. See Fig. 56.
SWITCHES
SWITCHES LOCATION
Component Location
Back-Up Light Switch (S8511) Right rear side of transmission. See Fig. 178.
Brake Fluid Level Switch (B18a) Left rear engine compartment. See Fig. 36.
Brake Light Switch (S29) Under left side of dash. See Fig. 2.
Clutch Switch Module (S805a) Under left side of dash. See Fig. 177.
Coolant Level Switch (S63b) Right side of engine compartment. See Fig. 174.
Hood Contact Switch (S19) Right rear of engine compartment. See Fig. 105.
Oil Level Switch (S65) Right side of engine compartment. See Fig. 174.
Oil Pressure Switch (B6231) Left side of engine. See Fig. 117.
Park Brake Switch (S31) Left side of center console. See Fig. 79.
Park/Neutral Position Switch (W/O SMG) (Y19) Part of shifter assembly. See Fig. 57.
Park/Neutral Position Switch (W/ SMG) (Y19) Part of shifter assembly. See Fig. 58.
Radiator Blind Solenoid Switch (Y13864) Center of front bumper. See Fig. 11.
Selector Lever Position Switch (S227) In center console. See Fig. 57.
Steptronic Switch (S224) In center console. See Fig. 57.
Washer Fluid Level Switch (S136) In left front wheelwell. See Fig. 49.
MISCELLANEOUS
MISCELLANEOUS LOCATION
Component Location
Amplifier TV2 Top of right "C" pillar. See Fig. 132.
Auxiliary Battery (G402) Behind left rear seat. See Fig. 141.
Battery (G1) In center of rear compartment. See Fig. 6.
Bluetooth Antenna (W18) Bottom right side of rear window. See Fig. 189.
Compensator (N27) Behind left rear seat. See Fig. 173.
Crankcase Breather Heating (B2394) Right side of engine. See Fig. 112.
Driver's Airbag Inflator Assemblies (G5) Part steering wheel. See Fig. 135.
Driver Side Airbag Inflator Assembly (G14b) Top rear of driver's door. See Fig. 137.
Driver's Seat Backrest Heating Element (E56a) In driver's seat back. See Fig. 133.
Driver's Seat Cushion Heating Element (E57a) In driver's seat cushion. See Fig. 133.
Electric Auxiliary Heater (I01062) Top left side of dash. See Fig. 34.
Emergency Antenna (W19) Bottom left side of rear window. See Fig. 190.
Front Center Console Interior Antenna (W10b) Center of dash. See Fig. 187.
2009 BMW 650i
2009 BMW 650i & M6
Heated Windshield Washer Jet, Right (E52a) Rear of hood. See Fig. 59.
Hi-Fi Amplifier (N40a) Left side of luggage compartment. See Fig. 52.
Horn (High) (H3) Right front wheelwell. See Fig. 40.
Horn (Low) (H2) Right front wheelwell. See Fig. 40.
Ignition Coil 1 (4.8L) (T6151) Right front side of engine. See Fig. 179.
Ignition Coil 1 (5.0L) (T6151) Left side of engine. See Fig. 183.
Ignition Coil 2 (4.8L) (T6152) Right side of engine. See Fig. 180.
Ignition Coil 4 (4.8L) (T6154) Right rear of engine. See Fig. 180.
Ignition Coil 5 (4.8L) (T6155) Left front side of engine. See Fig. 181.
Ignition Coil 8 (4.8L) (T6158) Left rear side of engine. See Fig. 182.
Independent Auxiliary Heater (A14a) Left front wheelwell. See Fig. 41.
Independent Heater Plug (I01010) Behind left front wheel. See Fig. 146.
Interference Suppression Coil 1 (I01119) Top center of dash. See Fig. 150.
Interference Suppression Coil 2 (I01120) Top center of dash. See Fig. 150.
Jump Start Terminal Point (G6430) Left side of engine compartment. See Fig. 142.
Left "B" Pillar Satellite (Convertible) (A157) Bottom of left "B" pillar. See Fig. 76.
Left "B" Pillar Satellite (Coupe) (A157) Bottom of left "B" pillar. See Fig. 14.
Left Front Knee Airbag Inflator Assembly (G30) Left kick panel. See Fig. 139.
Left Front RDC Transmitter (B43a) Behind left front wheel. See Fig. 94.
Left Rear RDC Transmitter (B45a) Behind left rear wheel. See Fig. 96.
Microphone (Convertible) (B400) Behind left side of steering wheel. See Fig. 72.
Microphone (Coupe) (B400) In overhead console. See Fig. 71.
MOST-Bus Connector (I14255) Behind left rear seat. See Fig. 151.
Noise Suppressor Filter (Convertible) (Z13) Right side of rear compartment. See Fig. 172.
Noise Suppressor Filter (Coupe) (Z13) Bottom of left "C" pillar. See Fig. 171.
OBDII Socket (X19527) Near left kick panel. See Fig. 60.
Passenger's Airbag Inflator Assemblies (G6) Top right side of dash. See Fig. 136.
Passenger Side Airbag Inflator Assembly (G15b) Top rear of front passenger's door.
2009 BMW 650i
2009 BMW 650i & M6
In front passenger's seat cushion. See Fig. 134.

RDC Antenna (B46a) Under right center of vehicle. See Fig. 98.
Rear Center Console Interior Antenna (W11b) Rear of center console. See Fig. 188.
Remote Control Receiver (Convertible) (N8a) Left side of rear compartment door. See Fig. 170.
Remote Control Receiver (Coupe) (N8a) Middle of left "C" pillar. See Fig. 171.
Right "B" Pillar Satellite (Convertible) (A158) Bottom of right "B" pillar. See Fig. 77.
Right "B" Pillar Satellite (Coupe) (A158) Bottom of right "B" pillar. See Fig. 78.
Right Front Knee Airbag Inflator Assembly (G31) Right kick panel. See Fig. 140.
Right Front RDC Transmitter (B47a) Behind right front wheel. See Fig. 97.
Right Rear RDC Transmitter (B44a) Behind right rear wheel. See Fig. 95.
Right Side TV Amplifier (A453a) Middle of right "C" pillar. See Fig. 132.
Safety Battery Terminal (Generator) (G19a) In luggage compartment. See Fig. 6.
Satellite Receiver (N47) Left side of luggage compartment. See Fig. 53.
SDARS Antenna (Convertible) (I01106) In luggage compartment lid. See Fig. 45.
SDARS Antenna (Coupe) (I01106) Left side of rear compartment door. See Fig. 144.
Telephone & GPS Antenna (Convertible) (I01105) In luggage compartment lid. See Fig. 45.
Telephone & GPS Antenna (Coupe) (I01105) Right side of rear compartment door. See Fig. 144.
Telephone Transceiver (U400a) Behind left rear seat. See Fig. 186.
Vehicle Center Satellite (A161) Center console. See Fig. 15.
Voice Control Microphone (Convertible) (B429a) Behind right side of steering wheel. See Fig. 72.
Voice Control Microphone (Coupe) (B429a) In overhead console. See Fig. 71.
Wave Trap 1 (I01101) Bottom of right "C" pillar. See Fig. 132.
CONNECTORS
CONNECTORS LOCATION
Component Location
X275 Under driver's seat. See Fig. 19.
X14256 Left side of rear compartment. See Fig. 52.
X60532 Bottom of transmission. See Fig. 121.
GROUNDS
GROUNDS LOCATION
Component Location
X6 Right rear of engine compartment. See Fig. 46.
X13782 Right kick panel. See Fig. 12.
X13783 Left kick panel. See Fig. 60.
X13784 Right kick panel. See Fig. 12.
2009 BMW 650i
2009 BMW 650i & M6

X13788 Right front floor. See Fig. 23.
X13789 Under front passenger's seat. See Fig. 211.
X13790 Right side of right "B" pillar. See Fig. 124.
X13793 Left side of left "B" pillar. See Fig. 123.
X13795 Left side of rear compartment. See Fig. 52.
SPLICES
SPLICES LOCATION
Component Location
X183 Behind right side of dash. See Fig. 75.
X6453 Right rear engine compartment. See Fig. 46.
X6462 Right front side of engine. See Fig. 26.
X6463 Left front side of engine. See Fig. 27.
X10551 Behind right rear seat. See Fig. 194.
X10554 Center of front bumper. See Fig. 11.
X10555 Center of front bumper. See Fig. 11.
X13724 (Except M6) Right front footwell. See Fig. 12.
X13724 (M6) Under right side of dash. See Fig. 75.
X13725 (Except M6) Right front footwell. See Fig. 12.
X13725 (M6) Under right side of dash. See Fig. 75.
X14218 Right side of engine compartment. See Fig. 105.
X14219 Right side of engine compartment. See Fig. 105.
COMPONENT LOCATION GRAPHICS

2009 BMW 650i
2009 BMW 650i & M6
proper figure references.
Fig. 1: Behind Glove Box

Fig. 2: Under Left Side Of Dash

2009 BMW 650i
2009 BMW 650i & M6
Fig. 3: Driver's Door

Fig. 4: Passenger's Door

2009 BMW 650i
2009 BMW 650i & M6
Fig. 5: Behind Glove Box

Fig. 6: Luggage Compartment

2009 BMW 650i
2009 BMW 650i & M6
Fig. 7: Right Side Of Engine Compartment


2009 BMW 650i
2009 BMW 650i & M6
Fig. 9: Left "B" Pillar (Convertible)

Fig. 10: Under Front Passenger's Seat

2009 BMW 650i
2009 BMW 650i & M6
Fig. 11: Front Of Vehicle

Fig. 12: Right Kick Panel

2009 BMW 650i
2009 BMW 650i & M6
Fig. 13: Left Side Of Dash

Fig. 14: Left "B" Pillar (Coupe)

2009 BMW 650i
2009 BMW 650i & M6
Fig. 15: Center Console

Fig. 16: Front Passenger's Seat (Convertible)

2009 BMW 650i
2009 BMW 650i & M6
Fig. 17: Front Passenger's Seat (Coupe)

Fig. 18: Driver's Seat (Coupe)

2009 BMW 650i
2009 BMW 650i & M6
Fig. 19: Driver's Seat (Convertible)

Fig. 20: Left Side Of Luggage Compartment

2009 BMW 650i
2009 BMW 650i & M6
Fig. 21: Passenger's Seat (Coupe)

Fig. 22: Passenger's Seat (Convertible)

2009 BMW 650i
2009 BMW 650i & M6
Fig. 23: Right Front Floor

Fig. 24: Right Rear Of Engine Compartment

2009 BMW 650i
2009 BMW 650i & M6

Fig. 26: Engine (M6)

2009 BMW 650i
2009 BMW 650i & M6
Fig. 27: Engine (M6)

Fig. 28: Transmission (A/T)

2009 BMW 650i
2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6

Fig. 32: Behind Center Of Dash

2009 BMW 650i
2009 BMW 650i & M6
Fig. 33: Behind Center Of Dash


2009 BMW 650i
2009 BMW 650i & M6
Fig. 35: Lower Left Side Of Engine Compartment

Fig. 36: Left Rear Of Engine Compartment

2009 BMW 650i
2009 BMW 650i & M6
Fig. 37: Right Front Wheelwell

Fig. 38: Right Rear Wheelwell

2009 BMW 650i
2009 BMW 650i & M6

Fig. 40: Right Front Wheelwell

2009 BMW 650i
2009 BMW 650i & M6
Fig. 41: Left Front Wheelwell

Fig. 42: Right Side Of Dash

2009 BMW 650i
2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6
Fig. 45: Luggage Compartment Lid


2009 BMW 650i
2009 BMW 650i & M6

Fig. 48: Under Rear Seat

2009 BMW 650i
2009 BMW 650i & M6
Fig. 49: Left Front Wheelwell

Fig. 50: Front Of Engine Compartment

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2009 BMW 650i & M6
Fig. 51: Rear Of Vehicle


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2009 BMW 650i & M6

Fig. 54: Top Of Engine

2009 BMW 650i
2009 BMW 650i & M6

Fig. 56: Left Side Of Engine Compartment

2009 BMW 650i
2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6
Fig. 59: Rear Of Hood

Fig. 60: Left Kick Panel

2009 BMW 650i
2009 BMW 650i & M6
Fig. 61: Center Of Rear Compartment

Fig. 62: Center Of Rear Compartment

2009 BMW 650i
2009 BMW 650i & M6
Fig. 63: Top Right Side Of Dash

Fig. 64: Right Rear Side Of Engine Compartment

2009 BMW 650i
2009 BMW 650i & M6
Fig. 65: Rear Compartment


2009 BMW 650i
2009 BMW 650i & M6
Fig. 67: Center Of Dash


2009 BMW 650i
2009 BMW 650i & M6
Fig. 69: Under Right Side Of Dash

Fig. 70: Right Side Of Rear Compartment

2009 BMW 650i
2009 BMW 650i & M6
Fig. 71: Overhead Console

Fig. 72: Behind Steering Wheel Column

2009 BMW 650i
2009 BMW 650i & M6
Fig. 73: Rear Of Roof

Fig. 74: Center Of Windshield

2009 BMW 650i
2009 BMW 650i & M6

Fig. 76: Left "B" Pillar

2009 BMW 650i
2009 BMW 650i & M6
Fig. 77: Right "B" Pillar

Fig. 78: Bottom Of Right "B" Pillar

2009 BMW 650i
2009 BMW 650i & M6

Fig. 80: Under Front Passenger's Seat (Coupe)

2009 BMW 650i
2009 BMW 650i & M6
Fig. 81: Under Front Passenger's Seat (Convertible)


2009 BMW 650i
2009 BMW 650i & M6
Fig. 83: Front Of Center Console

Fig. 84: Behind Right Rear Wheel

2009 BMW 650i
2009 BMW 650i & M6

Fig. 86: Front Of Right Front Wheel

2009 BMW 650i
2009 BMW 650i & M6
Fig. 87: Front Of Left Front Wheel

Fig. 88: Front Of Right Rear Wheel

2009 BMW 650i
2009 BMW 650i & M6
Fig. 89: Front Of Left Rear Wheel

Fig. 90: Behind Left Front Wheel

2009 BMW 650i
2009 BMW 650i & M6

Fig. 92: Front Bumper

2009 BMW 650i
2009 BMW 650i & M6
Fig. 93: Rear Bumper


2009 BMW 650i
2009 BMW 650i & M6

Fig. 96: Behind Left Rear Wheel

2009 BMW 650i
2009 BMW 650i & M6
Fig. 97: Behind Right Front Wheel

Fig. 98: Under Vehicle

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2009 BMW 650i & M6
Fig. 99: Top Center Of Dash

Fig. 100: Front Of Left Rear Wheel

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2009 BMW 650i & M6

Fig. 102: Front Passenger's Door

2009 BMW 650i
2009 BMW 650i & M6
Fig. 103: Top Of Right Front Wheel

Fig. 104: Under Driver's Seat

2009 BMW 650i
2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6
Fig. 107: Front Of Engine Compartment


2009 BMW 650i
2009 BMW 650i & M6
Fig. 109: Starter

Fig. 110: Front Of Engine

2009 BMW 650i
2009 BMW 650i & M6
Fig. 111: Left Side Of Engine

Fig. 112: Right Side Of Engine

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2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6

Fig. 118: Left Side Of Engine

2009 BMW 650i
2009 BMW 650i & M6
Fig. 119: Rear Of Transmission

Fig. 120: Top Of Transmission

2009 BMW 650i
2009 BMW 650i & M6
Fig. 121: Left Side Of Transmission


2009 BMW 650i
2009 BMW 650i & M6
Fig. 123: Left Side Of Left "B" Pillar

Fig. 124: Right Side Of Right "B" Pillar

2009 BMW 650i
2009 BMW 650i & M6
Fig. 125: Rear Of Engine


2009 BMW 650i
2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6
Fig. 129: Front Of Transmission


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2009 BMW 650i & M6

Fig. 132: Top Of Right "C" Pillar

2009 BMW 650i
2009 BMW 650i & M6
Fig. 133: Driver's Seat

Fig. 134: Front Passenger's Seat

2009 BMW 650i
2009 BMW 650i & M6
Fig. 135: Steering Wheel

Fig. 136: Top Right Side Of Dash

2009 BMW 650i
2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6
Fig. 139: Left Kick Panel

Fig. 140: Right Kick Panel

2009 BMW 650i
2009 BMW 650i & M6
Fig. 141: Behind Left Rear Seat


2009 BMW 650i
2009 BMW 650i & M6
Fig. 143: Steering Wheel

Fig. 144: Rear Compartment Door

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2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6
Fig. 149: Left Side Of Roof

Fig. 150: Top Center Of Dash

2009 BMW 650i
2009 BMW 650i & M6

Fig. 152: Rear Compartment Door (Coupe)

2009 BMW 650i
2009 BMW 650i & M6
Fig. 153: Rear Compartment Door (Convertible)


2009 BMW 650i
2009 BMW 650i & M6

Fig. 156: Under Driver's Seat (Coupe)

2009 BMW 650i
2009 BMW 650i & M6
Fig. 157: Under Driver's Seat (Convertible)

Fig. 158: Under Driver's Seat (Coupe)

2009 BMW 650i
2009 BMW 650i & M6
Fig. 159: Under Driver's Seat (Convertible)

Fig. 160: Driver's Seat Back

2009 BMW 650i
2009 BMW 650i & M6
Fig. 161: Front Passenger's Seat Back

Fig. 162: Left Of Left "B" Pillar

2009 BMW 650i
2009 BMW 650i & M6
Fig. 163: Right Of Right "B" Pillar


2009 BMW 650i
2009 BMW 650i & M6
Fig. 165: Front Engine Compartment


2009 BMW 650i
2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6

Fig. 170: Rear Compartment Door

2009 BMW 650i
2009 BMW 650i & M6
Fig. 171: Left "C" Pillar

Fig. 172: Right Side Of Rear Compartment

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2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6

Fig. 178: Right Rear Of Transmission

2009 BMW 650i
2009 BMW 650i & M6
Fig. 179: Right Side Of Engine (4.8L)

Fig. 180: Right Side Of Engine (4.8L)

2009 BMW 650i
2009 BMW 650i & M6
Fig. 181: Left Side Of Engine (4.8L)

Fig. 182: Left Side Of Engine (4.8L)

2009 BMW 650i
2009 BMW 650i & M6
Fig. 183: Top Of Engine (5.0L)


2009 BMW 650i
2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6

Fig. 188: Rear Of Center Console

2009 BMW 650i
2009 BMW 650i & M6
Fig. 189: Behind Right Rear Seat


2009 BMW 650i
2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6

Fig. 204: Front Of Engine (4.8L)

2009 BMW 650i
2009 BMW 650i & M6


2009 BMW 650i
2009 BMW 650i & M6

Fig. 208: Left Side Of Transmission

2009 BMW 650i
2009 BMW 650i & M6

Fig. 210: Top Rear Of Engine

2009 BMW 650i
2009 BMW 650i & M6
Fig. 211: Front Of Front Passenger's Seat


2006 BMW 650i
ACCESSORIES AND EQUIPMENT Electrical Drive Units - 650i, M6
Electrical Drive Units - 650i, M6
11 CENTRAL LOCKING UNIT

67 11 510 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR FRONT LEFT OR
RIGHT DOOR LOCKING MECHANISM
NOTE: Servodrive for door locking mechanism is integrated in door lock in front door.
Procedure is described in the document 51 21 090 REMOVING AND INSTALLING/REPLACING DOOR

LOCK IN LEFT OR RIGHT FRONT DOOR .
67 11 555 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR TANK FILLER FLAP
 Remove luggage compartment floor trim panel. See 51 47 101 REMOVING AND
 Disconnect battery negative lead. See THE BATTERY - OVERVIEW - ALL MODELS .
 Remove right luggage compartment wheel arch trim. See 51 47 161 REMOVING AND
INSTALLING/REPLACING RIGHT LUGGAGE COMPARTMENT WHEEL ARCH TRIM .
Release screws (1) and remove servodrive for tank filler flap (2) from retaining plate.
Installation:
If necessary, carry out adjustment of servodrive for tank filler flap (2) via elongated holes (3). It must be
possible to lock or unlock the fuel filler flap completely.
Fig. 1: Identifying Tank Filler Flap And Screws

2006 BMW 650i
Unclip tank filler flap Bowden cable (2) in direction of arrow from servodrive for tank filler flap (3).
Unhook emergency actuation pull strap (4) from clip (5).
Remove servodrive for fuel filler flap (3).
Fig. 2: Uncliping Tank Filler Flap Bowden Cable

67 11 560 REPLACING SERVODRIVE FOR REAR LID LOCK
"Removing rear lid lock" See 51 24 100 REMOVING AND INSTALLING/REPLACING REAR LID
LOCK (UPPER SECTION) .
67 11 610 REMOVING AND INSTALLING/REPLACING SERVODRIVE IN STORAGE

COMPARTMENT
 Disconnect battery negative lead . See THE BATTERY - OVERVIEW - ALL MODELS .
Disconnect plug connections (1)
Press in button (3) and lift storage compartment (4) out of centre armrest.
2006 BMW 650i
Fig. 3: Identifying Plug Connections, Bowden Cable And Lift Storage Compartment
Installation:
Fig. 4: Identifying Bowden Cable

Release screws (1).
Pull servodrive (2) with locator (3) forwards from guide.

2006 BMW 650i
Fig. 5: Identifying Screws, Servodrive And Locator

13 MIRROR ADJUSTMENT
67 13 001 REPLACING DRIVE UNIT FOR ELECTRICALLY OPERATED LEFT OR RIGHT DOOR
MIRROR
 Remove mirror glass for rearview mirror.
Release screws (1).
Remove drive unit for electrically operated door mirror (2) slightly in direction of arrow.
Remove drive for electrically adjustable door mirror (2).
Fig. 6: Removing Drive Unit

2006 BMW 650i
Build date from 03/2007:
Release screw (1) and remove drive (2).
Fig. 7: Identifying Drive And Screws

31 DRIVE, SEAT ADJUSTMENT

67 31 501 REMOVING AND INSTALLING/REPLACING DRIVE FOR LONGITUDINAL SEAT
ADJUSTMENT (FRONT SEAT REMOVED)
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).
2006 BMW 650i
Fig. 8: Uncliping Plug Housing

Installation:
Make sure drive shaft (1) is correctly seated.
Make sure drive for longitudinal seat adjustment (2) is correctly seated on flange (3).
Fig. 9: Identifying Drive Shaft, Seat Adjustment And Flange

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).

2006 BMW 650i
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).
Fig. 10: Removing Inner Drive Shaft From Drive

Installation:
Ensure fixture for plug connection (3) and drive for seat tilt adjustment (4) on flange (2) are correctly seated.
Fig. 11: Identifying Drive Shaft, Plug Connection And Flange

67 31 521 REMOVING AND INSTALLING/REPLACING DRIVE FOR SEAT HEIGHT


2006 BMW 650i
NOTE: Secure drive for seat height adjustment (3) against falling out.
Release screws (1).
Remove drive for seat height adjustment (3) with fixture for plug connection (4) in direction of arrow from
flange (5).
If necessary, remove inner drive shaft from drive for seat height adjustment (3).
Fig. 12: Removing Inner Drive Shaft From Drive For Seat Height Adjustment
Installation:
Make sure drive shaft (1) is exactly seated.
Ensure fixture for plug connection (2) and drive for seat height adjustment (3) on flange (4) are correctly seated.
Fig. 13: Identifying Drive Shaft, Plug Connection And Flange

2006 BMW 650i
67 31 531 REMOVING AND INSTALLING/REPLACING DRIVE FOR BACKREST ANGLE

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).
Fig. 14: Removing Inner Drive Shaft From Drive For Backrest Angle Adjustment
Installation:
Ensure fixture for plug connection (3) and drive for backrest angle adjustment (4) on flange (2) are correctly
seated.
2006 BMW 650i
Fig. 15: Identifying Drive Shaft, Angle Adjustment And Plug Connection
61 DRIVE, SLIDE-TILT SUNROOF/CONVERTIBLE TOP

67 61 005 REMOVING AND INSTALLING/REPLACING DRIVE WITH GEAR (FRONT) FOR
ACTUATING SLIDE/TILT SUNROOF
protection). See 61 35 ... NOTES ON ESD PROTECTION (ELECTRO STATIC
DISCHARGE) .
Necessary preliminary tasks: Remove front roofliner trim. See 51 44 ... REMOVING AND INSTALLING
FRONT ROOFLINER TRIM .
NOTE: Secure drive with gear for actuating slide/tilt sunroof (3) against falling out.
Unfasten plug connection (1) and disconnect. Release screws (2), tightening torque 3.5 Nm.
NOTE: Screws (1) are microencapsulated.
Feed drive with gear for actuating slide/tilt sunroof (3) out of roofliner (4) and remove.
2006 BMW 650i
Fig. 16: Feed Drive With Gear For Actuating Slide/Tilt Sunroof Out Of Roofliner
Installation: Insert gear wheel (1) of drive with gear for actuating slide/tilt sunroof (2) exactly in gear teeth (3).
Fig. 17: Insert Gear Wheel Of Drive With Gear For Actuating Slide/Tilt Sunroof
Installation: Initialise slide/tilt sunroof.
67 61 007 REMOVING AND INSTALLING/REPLACING DRIVE WITH GEAR (REAR) FOR

SLIDE/TILT SUNROOF
DISCHARGE) .
Detach cover for auxiliary brake light (1) on both sides in direction of arrow and unclip at points (2). Feed cover
for auxiliary brake light (1) in direction of arrow out of roofliner (3) and remove.
2006 BMW 650i
Fig. 18: Detach Cover For Auxiliary Brake Light
Installation: Retaining bar (1), clips (2) and guides (3) must not be damaged. Make sure cover for auxiliary
brake light (4) is correctly seated.
Fig. 19: Make Sure Cover For Auxiliary Brake Light (4) Is Correctly Seated
Unfasten plug connection (1) and disconnect. Release screws (2), tightening torque 54 13 1AZ.
2006 BMW 650i
Fig. 20: Unfasten Plug Connection (1) And Disconnect
Installation: Insert gear wheel (1) of drive with gear for actuating slide/tilt sunroof (2) exactly in gear teeth (3).
Fig. 21: Insert Gear Wheel (1) Of Drive With Gear For Actuating Slide/Tilt Sunroof
Installation: Initialize slide/tilt sunroof
67 61 531 REMOVING AND INSTALLING/REPLACING DRIVE FOR CONVERTIBLE TOP

FASTENER
Necessary preliminary tasks: Move convertible top compartment lid into service position. Remove cowl panel
trim.
Unhook drive shafts (1) and (3) from mounts (5) and (4). Pull off drive shafts (1) and (3) in direction of arrow
from drive for convertible top fastener (2).
2006 BMW 650i
Fig. 22: Unhook Drive Shafts (1) And (3) From Mounts (5) And (4) And Convertible Top Fastener (2)
Installation: Do not mix up drive shafts (1) and (3), pay attention to relevant markings.
Installation: Turn relevant drive shaft (1) to open convertible top lock (2) completely to outer side of car.
Fig. 23: Turn Relevant Drive Shaft (1) To Open Convertible Top Lock (2) Completely To Outer Side Of
Car
Pull out wiring harness (1) in direction of arrow.
Installation: Ensure wiring harness (1) is laid correctly.
Turn plug connections (2) completely in direction of arrow and unclip from fixture (3). Unlock plug
connections (2) and disconnect.
2006 BMW 650i
Fig. 24: Turn Plug Connections (2) Completely In Direction Of Arrow And Unclip From Fixture (3)
Unlock plug housing (3) and disconnect in direction of arrow from plug housing (4).
Release nuts (1) and remove drive for convertible top lock (2). Tightening torque (54 34 1AZ) 10 N.m.
Installation: Screws for nuts (1) are microencapsulated.
Fig. 25: Removing Drive For Convertible Top Lock (2)

67 61 541 REMOVING AND INSTALLING/REPLACING DRIVE FOR REAR WINDOW
Necessary preliminary tasks: Remove rear window.
Release screws (1) and remove cap (2).

2006 BMW 650i
Fig. 26: Release Screws (1) And Remove Cap (2)

Note: If necessary, mark drive shafts (1). Detach drive shafts (1) in each case in direction of arrow.
Fig. 27: Detach Drive Shafts (1) In Each Case In Direction Of Arrow
Installation: Do not mix up drive shafts (1), pay attention to relevant markings.
Unfasten plug connection (5) and disconnect. Release screws (2), tightening torque 54 34 6AZ (4.25-5.75 N.m).
Remove plate (3) together with drive for rear window (4).
62 DRIVE, WINDOW REGULATOR

67 62 000 REMOVING AND INSTALLING/REPLACING FLAT MOTOR FOR FRONT LEFT OR
RIGHT POWER WINDOW UNIT

2006 BMW 650i
 Release sound insulation on front door . See 51 48 060 REMOVING AND

Release screws (2).
Detach flat motor for power window unit (3) in direction of arrow from power window unit (4) and remove.
Fig. 28: Detaching Flat Motor

Replacement:
A normalization must be carried out in order to activate anti - trapping protection.
Operating sequence for normalization:
 Open corresponding window completely.

 Operate corresponding power window switch in "Close" position (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: Carry out function check (one-touch function, anti-trapping protection and, if
necessary, comfort function).
64 DRIVE, STEERING COLUMN

67 64 010 REMOVING AND INSTALLING/REPLACING DRIVE UNIT FOR ELECTRIC STEERING
COLUMN ADJUSTMENT
2006 BMW 650i
 Move steering wheel into maximum "lower" and "extended" position

 US only: Remove panel for active knee protection, left . See 67 64 010 REMOVING AND
INSTALLING/REPLACING DRIVE UNIT FOR ELECTRIC STEERING COLUMN
ADJUSTMENT .
Unlock plug connections (1) and (2) of drive unit for electric steering column adjustment (3) and disconnect.
Fig. 29: Identifying Plug Connections And Drive Unit

NOTE: For purposes of clarity, illustrations show steering column removed.
Installation:
Replace screws (1) and (2).
Tightening torque 32 31 12AZ. See STEERING AND WHEEL ALIGNMENT - TIGHTENING

TORQUES .
2006 BMW 650i

IMPORTANT: Pay attention to drive shafts (1) and (3) when removing and installing drive unit
for electric steering column adjustment (4). Do not bend or twist.
Drive shafts (1) and (3) must be exactly inserted in associated mountings (2).
Detach drive shafts (1) and (3) from associated mountings (2) and remove drive unit for electric steering
column adjustment (4).
Fig. 31: Detaching Drive Shafts

Installation:
Longer drive shaft (1) is located in installation position under shorter drive shaft (2).
If necessary, replace plastic mount (3).

2006 BMW 650i
Fig. 32: Identifying Drive Shafts, Associated Mountings And Plastic Mount
66 DRIVE, SEAT ADJUSTMENT

67 66 010 REMOVING AND INSTALLING/REPLACING LUMBAR SUPPORT DRIVE MECHANISM
ON FRONT SEAT, LEFT OR RIGHT
 Remove rear panel on front seat backrest . See 52 14 198 REMOVING AND
INSTALLING/REPLACING REAR PANEL ON LEFT OR RIGHT FRONT SEAT BACKREST
(NORMAL/ELECTRIC) .
Detach backrest cover (1) in direction of arrow from backrest frame (2).
Fig. 33: Detaching Backrest Cover


2006 BMW 650i
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.
Fig. 34: Detaching Fabric Adhesive Tape

Installation:
Clean adhesive area (1) on backrest frame (2).
Fig. 35: Identifying Adhesive Area And Backrest Frame

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.
2006 BMW 650i
If necessary, secure jacket (2) with cable strap.
Fig. 36: Identifying Transparent Hose, Protective Film And Jacket

2005 BMW 645Ci
2004-08 ACCESSORIES & BODY, CAB Electrical Drive Units - Repair Instructions - 6-Series
Electrical Drive Units - Repair Instructions - 6-Series
CENTRAL LOCKING UNIT/UNLOCKING

67 11 510 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR FRONT LEFT OR
RIGHT DOOR LOCKING MECHANISM
NOTE: Servodrive for door locking mechanism is integrated in door lock in front door.
Procedure is described in the "Door lock in front door ..", refer to 51 21 090 REMOVING AND
INSTALLING/REPLACING DOOR LOCK IN LEFT OR RIGHT FRONT DOOR .
67 11 555 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR TANK FILLER FLAP
 Remove luggage compartment floor trim panel, refer to 51 47 101 REMOVING AND
 Remove right luggage compartment wheel arch trim, refer to 51 47 161 REMOVING AND
Release screws (1) and remove servodrive for tank filler flap (2) from retaining plate.
Fig. 1: Removing Servodrive For Tank Filler Flap From Retaining Plate
Installation:
2005 BMW 645Ci
If necessary, carry out adjustment of servodrive for tank filler flap (2) via elongated holes (3). It must be
possible to lock or unlock the fuel filler flap completely.
Unclip tank filler flap Bowden cable (2) in direction of arrow from servodrive for tank filler flap (3).
Unhook emergency actuation pull strap (4) from clip (5).
Remove servodrive for fuel filler flap (3).
Fig. 2: Unclipping Tank Filler Flap Bowden Cable

67 11 560 REPLACING SERVODRIVE FOR REAR LID LOCK
"Removing rear lid lock", refer to 51 24 100 REMOVING AND INSTALLING/REPLACING REAR LID
LOCK (UPPER SECTION) .
67 11 610 REMOVING AND INSTALLING/REPLACING SERVODRIVE IN STORAGE

COMPARTMENT
Disconnect battery negative lead, refer to 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND
Disconnect plug connections (1)

2005 BMW 645Ci
Press in button (3) and lift storage compartment (4) out of centre armrest.
Fig. 3: Pressing In Button (3) And Lifting Storage Compartment (4) Out Of Centre Armrest
Fig. 4: Disconnecting Bowden Cable

Installation:
Release screws (1).
Pull servodrive (2) with locator (3) forwards from guide.

2005 BMW 645Ci
Fig. 5: Identifying Servo Drive With Locator

MIRROR ADJUSTMENT
67 13 001 REPLACING DRIVE UNIT FOR ELECTRICALLY OPERATED LEFT OR RIGHT DOOR
MIRROR
 Remove mirror glass for rearview mirror, refer to 51 16 026 REPLACING MIRROR GLASS .
Release screws (1).
Remove drive unit for electrically operated door mirror (2) slightly in direction of arrow.
Remove drive unit for electrically operated door mirror (2).

2005 BMW 645Ci
Fig. 6: Removing Drive Unit For Electrically Operated Door Mirror

DRIVE, SEAT ADJUSTMENT

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).
2005 BMW 645Ci
Installation:
Make sure drive shafts (1) is correctly seated.
Make sure drive for longitudinal seat adjustment (2) is correctly seated on flange (3).
Fig. 8: Identifying Drive Shaft And Flange

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).
2005 BMW 645Ci
Fig. 9: Removing Drive For Seat Tilt Adjustment With Fixture For Plug Connection
Installation:
Ensure fixture for plug connection (3) and drive for seat tilt adjustment (4) on flange (2) are correctly seated.
Fig. 10: Identifying Plug Connection And Drive For Seat Tilt Adjustment On Flange
67 31 521 REMOVING AND INSTALLING/REPLACING DRIVE FOR SEAT HEIGHT

NOTE: Secure drive for seat height adjustment (3) against falling out.
2005 BMW 645Ci
Release screws (1).
Remove drive for seat height adjustment (3) with fixture for plug connection (4) in direction of arrow from
flange (5).
If necessary, remove inner drive shaft from drive for seat height adjustment (3).
Fig. 11: Removing Drive For Seat Height Adjustment

Installation:
Ensure fixture for plug connection (2) and drive for seat height adjustment (3) on flange (4) are correctly seated.
Fig. 12: Identifying Drive Shaft And Drive For Seat Height Adjustment On Flange
2005 BMW 645Ci
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).
Fig. 13: Removing Inner Drive Shaft From Drive For Backrest Angle Adjustment
Installation:
Ensure fixture for plug connection (3) and drive for backrest angle adjustment (4) on flange (2) are correctly
seated.
2005 BMW 645Ci
Fig. 14: Identifying Drive For Backrest Angle Adjustment On Flange

DRIVE, SLIDE TILT SUNROOF CONV. TOP

67 61 005 REMOVING AND INSTALLING/REPLACING DRIVE WITH GEAR (FRONT) FOR
ACTUATING SLIDE/TILT SUNROOF
DISCHARGE) .
ROOFLINER TRIM .
Release screws (2), tightening torque 3.5 N.m.
2005 BMW 645Ci
Fig. 15: Feeding Drive With Gear For Actuating Slide/Tilt Sunroof Out Of Roofliner
Installation:
Insert gear wheel (1) of drive with gear for actuating slide/tilt sunroof (2) exactly in gear teeth (3).
2005 BMW 645Ci
Fig. 16: Inserting Gear Wheel Of Drive With Gear For Actuating Slide/Tilt Sunroof
Installation:
 Initialise slide/tilt sunroof, refer to 54 0 ... NOTES ON PANORAMA GLASS ROOF

(INITIALIZATION/NORMALIZATION/LEARNING OF CHARACTERISTIC CURVE) .
67 61 007 REMOVING AND INSTALLING/REPLACING DRIVE WITH GEAR (REAR) FOR

SLIDE/TILT SUNROOF
DISCHARGE) .
Detach cover for auxiliary brake light (1) on both sides in direction of arrow and unclip at points (2).
Feed cover for auxiliary brake light (1) in direction of arrow out of roofliner (3) and remove.
2005 BMW 645Ci
Fig. 17: Feeding Cover For Auxiliary Brake Light Out Of Roofliner
Installation:
Retaining bar (1), clips (2) and guides (3) must not be damaged.
Make sure cover for auxiliary brake light (4) is correctly seated.
2005 BMW 645Ci
Fig. 18: Identifying Retaining Bar, Clips And Guides

2005 BMW 645Ci
Fig. 19: Feeding Drive With Gear For Actuating Slide/Tilt Sunroof Out Of Roofliner
Installation:
Insert gear wheel (1) of drive with gear for actuating slide/tilt sunroof (2) exactly in gear teeth (3).
2005 BMW 645Ci
Fig. 20: Inserting Gear Wheel Of Drive With Gear For Actuating Slide/Tilt Sunroof
Installation:
 Initialize slide/tilt sunroof, refer to 54 0 ... NOTES ON PANORAMA GLASS ROOF

DRIVE, WINDOW REGULATOR

67 62 000 REMOVING AND INSTALLING/REPLACING FLAT MOTOR FOR FRONT LEFT OR
RIGHT POWER WINDOW UNIT
 Release sound insulation on front door, refer to 51 48 060 REMOVING AND

2005 BMW 645Ci
Unfasten plug connection (1) and disconnect. Release screws (2).
Detach flat motor for power window unit (3) in direction of arrow from power window unit (4) and remove.
Fig. 21: Detaching Flat Motor For Power Window Unit

Replacement:
A normalization must be carried out in order to activate anti-trapping protection.
Operating sequence for normalization:
 Open corresponding window completely.

 Operate corresponding power window switch in "Close" position (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.
2005 BMW 645Ci
NOTE: Carry out function check (one-touch function, anti-trapping protection and, if
necessary, comfort function).
DRIVE, STEERING COLUMN

67 64 010 REMOVING AND INSTALLING/REPLACING DRIVE UNIT FOR ELECTRIC STEERING
COLUMN ADJUSTMENT
 Move steering wheel into maximum "lower" and "extended" position

 EUR only: Remove trim panel for pedal assembly.
 US only: Remove panel for active knee protection, left, refer to 51 45 177 REMOVING AND
INSTALLING/REPLACING PANEL FOR ACTIVE KNEE PROTECTOR ON LEFT .
Unlock plug connections (1) and (2) of drive unit for electric steering column adjustment (3) and disconnect.
2005 BMW 645Ci
Fig. 22: Identifying Plug Connections And Of Drive Unit For Electric Steering Column Adjustment
NOTE: For purposes of clarity, illustrations show steering column removed.
Installation:
Replace screws (1) and (2).
Tightening torque 6. N.m.
Fig. 23: Identifying Screws On Steering Column

IMPORTANT: Pay attention to drive shafts (1) and (3) when removing and installing drive unit
2005 BMW 645Ci
for electric steering column adjustment (4). Do not bend or twist. Drive shafts
(1) and (3) must be exactly inserted in associated mountings (2).
Detach drive shafts (1) and (3) from associated mountings (2) and remove drive unit for electric steering
column adjustment (4).
Fig. 24: Removing Drive Unit For Electric Steering Column Adjustment
Installation:
Longer drive shaft (1) is located in installation position under shorter drive shaft (2).
If necessary, replace plastic mount (3).

2005 BMW 645Ci
Fig. 25: Identifying Longer Drive Shaft, Shorter Drive Shaft And Replace Plastic Mount
DRIVE SEAT ADJUSTMENT

67 66 010 REMOVING AND INSTALLING/REPLACING LUMBAR SUPPORT DRIVE MECHANISM
ON FRONT SEAT, LEFT OR RIGHT
 Remove rear panel on front seat backrest, refer to 52 14 198 REMOVING AND
INSTALLING/REPLACING REAR PANEL ON LEFT OR RIGHT FRONT SEAT BACKREST
(NORMAL/ELECTRIC) .
E53 comfort seat:
 Remove rear panel at bottom

2005 BMW 645Ci

Detach transparent hose (2) from valve housing (3).
If necessary, detach fabric adhesive tape (4).
Detach drive unit for lumbar support (5) with jacket in direction of arrow.
2005 BMW 645Ci
Fig. 27: Detaching Drive Unit For Lumbar Support

Installation:
Clean adhesive area (1) on backrest frame (2).
Fig. 28: Identifying Adhesive Area On Backrest Frame

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.

2005 BMW 645Ci
Fig. 29: Identifying Protective Film On Jacket

2005 BMW 645Ci
2004-05 ENGINE Engine And Gearbox Suspension - Repair Instructions - 645Ci
2004-05 ENGINE
Engine And Gearbox Suspension - Repair Instructions - 645Ci
ENGINE SUSPENSION
22 11 001 REPLACING RIGHT ENGINE MOUNT (N62)
 Remove both front wheels.

 Remove underbody protection.
 Remove reinforcement plate.
Observe safety instructions on raising the vehicle.
Unscrew nut (1).
Tightening torque, refer to 22 11 2AZ in ENGINE & GEARBOX SUSPENSION - TIGHTENING

TORQUE - 645CI .
Secure engine in installation position.
Release screws (2) and remove engine mount.

TORQUE - 645CI .
2005 BMW 645Ci
Fig. 1: Removing Engine Mount

NOTE: To remove engine mount, lower front axle carrier.
IMPORTANT: Note installation position.
22 11 011 REPLACING LEFT ENGINE MOUNT (N62)
This task is identical to Replacing right engine mount.
NOTE: Remove engine mount towards rear.
22 11 100 REPLACING RIGHT ENGINE SUPPORT ARM (N62)

2005 BMW 645Ci
 Remove both front wheels.

Observe safety instructions on raising the vehicle.
Release grounding strap (1) from engine support arm.
NOTE: Clean contact surfaces to ensure a safe ground connection.
Fig. 2: Releasing Grounding Strap From Engine Support Arm

Unscrew nut (3).

2005 BMW 645Ci
Secure engine in installation position.
Release bolts (2) and remove engine support arm.

TORQUE - 645CI .
NOTE: To remove engine mount, lower front axle carrier.
22 11 110 REPLACING LEFT ENGINE SUPPORT ARM (N62)
This task is identical to Replacing right engine support arm.
Installation:
Fit M10x60 screws in direction of travel at front.
TRANSMISSION SUSPENSION
22 31 001 REPLACING RUBBER MOUNT FOR TRANSMISSION MOUNTING

 Remove complete exhaust system.
 Support transmission with hydraulic lifter.
If necessary, remove heat shield (1) on left and right.

2005 BMW 645Ci
Fig. 3: Removing Heat Shield On Left And Right

Release screws (1) and nuts (2) and remove transmission cross-member.
Remove transmission mount from transmission cross-member.
Tightening torque, refer to 23 71 2AZ/5AZ in ENGINE & GEARBOX SUSPENSION - TIGHTENING

TORQUE - 645CI .
2005 BMW 645Ci
Fig. 4: Removing Transmission Mount From Transmission Cross-Member

TRANSMISSION - SUSPENSION
22 32 001 REPLACING RUBBER MOUNT FOR TRANSMISSION MOUNTING
 Remove rear underbody protection.

 Support transmission with lifter.
If necessary, remove heat shield (1) on left and right.

2005 BMW 645Ci
Fig. 5: Removing Heat Shield On Left And Right

M57 only:
Release screws (1) and nut (2) and remove transmission cross-member.
2005 BMW 645Ci
Fig. 6: Removing Rubber Mount From Transmission Cross-Member (1 Of 2)

Remove rubber mount from transmission cross-member.

TORQUE - 645CI .
M54/N52/N62 only:
Release screws (1) and nut (2) and remove transmission cross-member.
Remove rubber mount from transmission cross-member.

2005 BMW 645Ci
Fig. 7: Remove Rubber Mount From Transmission Cross-Member (2 Of 2)


TORQUE - 645CI .
2006 BMW 650i
ENGINE Engine Electrical System - Repair Instructions - V8 (N62TU)
ENGINE
Engine Electrical System - Repair Instructions - V8 (N62TU)
00 TROUBLESHOOTING
12 00 CONTENTS OF ENGINE ELECTRICAL SYSTEM GENERAL
General Information
 Working on ignition system

 Removing and installing electronic control units
 Welding work (overload protection of control units)
 Disconnecting and connecting battery
 Disconnecting and connecting test equipment
 Component inspection:
 External jump-starting aid
 Compression testing
12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY
Observe safety instructions for handling vehicle battery.
Before disconnecting battery:
Turn off the ignition and other electrical loads/consumers to prevent sparking when reconnecting.
NOTE: If the ignition is not turned off when the battery is disconnected, fault memories
may be set in some control units.
IMPORTANT:  There is a danger of mixing up battery leads: If the battery positive and
negative leads are the same color and you are in doubt, follow the polarity
to the battery, then mark and cover the leads.
 On vehicles with radio code: After disconnecting the battery, the radio
code must be re-entered. Therefore obtain the radio code card from the
customer beforehand. Note stored stations and restore them after
connecting the battery.
 Stored settings of the on-board computer and clock will also be lost.
 All available central keys must be recoded for cars with first generation
infrared transmitter locking systems.
General notes on disconnecting battery:

2006 BMW 650i
 Do not disconnect battery leads and leads from alternator and starter motor while engine is running.
 Cars with IBS on battery negative terminal:
Do not under any circumstances pull/lever off pole shoes by force.
Do not under any circumstances release socket-head cap screw of IBS.
 Detach terminal of battery negative lead from car battery and second battery if fitted. Cover battery
negative terminal(s) and secure.
 When work is carried out on the electrical system, faults may be caused in the fault memories of some
control units when the battery is connected.
 When installing battery terminal: See tightening torque 61 21 1AZ in 61 21 BATTERY WITH
TERMINAL .
After connecting battery:
IMPORTANT: After a power supply interruption some equipment is disabled and must be
reactivated.
Likewise, individual settings are lost and must be activated.
Example:
 Vehicles with build date from 03/2007:
Teach-in mid-position for power steering
 If necessary, activate sliding sunroof

 If necessary, carry out adjustment of active front steering
 If necessary, activate power windows
 If necessary, activate mirror with compass
Vehicles with a two-battery system
Starter and equipment batteries
A two-battery system has a starter battery circuit and an equipment battery circuit. A secondary control unit
monitors both battery circuits. Depending on the situation, the battery circuits are connected to or isolated from
the secondary control unit via an isolating relay.
Two AGM batteries, whose design and properties are described in AGM batteries, are used as a storage battery.
IMPORTANT: These batteries must not under any circumstances be charged with a voltage in
excess of 14.8 V. Rapid programs must not be used either.
2006 BMW 650i
Receiving/giving starting assistance via jump start terminal
The engine can be jump-started with an external voltage supply via the jump start terminal on the right side of
the engine compartment.
NOTE: The starter battery is isolated from the alternators when the engine hood/bonnet
is open.
Giving starting assistance via the jump start terminal is thus limited by the capacity of the starter battery when
the engine hood/bonnet is open.
Charging starter and equipment batteries via jump start terminal
The starter battery is charged as a matter of priority with a charger connected to the jump start terminal. The
voltage at the starter battery is the decisive factor in determining whether the equipment battery is also included
in the charging operation. The secondary control unit automatically detects a charging operation at a charging
voltage at the starter battery of > or = 13.5 V. The isolating relay is closed and thus the equipment battery is
connected in parallel. Both batteries are now charged.
Prerequisite:
 Terminal 61 inactive
If terminal 15 becomes "active" during the charging operation, the isolating relay is opened immediately and
again only the starter battery is charged.
NOTE: When the engine hood is open, the isolating relay is also opened in normal
operation when the engine is running.
A special mode can be set by means of diagnosis for workshop/garage

operation. The isolating relay is closed from terminal R in this operating mode.
This mode is automatically reset once a distance of 5 km has been driven.
Trickle charging
The increased closed-circuit current consumption can be compensated for via the jump-start connection point
with the aid of the "Acctiva easy" battery trickle charger.
IMPORTANT: The cigarette lighter is isolated from the electrical system after terminal R
"OFF" on a timed basis (60 mins.), thereby interrupting charging of the
equipment battery via the cigarette lighter. This is prevented if the battery
master switch (on the right side of the luggage compartment behind the panel)
is turned on and off again twice within 2 seconds. (Cigarette light battery
charging function).
2006 BMW 650i
12 00 ... INSTRUCTIONS FOR REMOVING AND INSTALLING ELECTRONIC CONTROL UNITS
IMPORTANT:  Disconnecting the vehicle battery will cancel the fault memories of control
units. Consequently, before disconnecting the car's battery, always
interrogate the fault memories. Investigate stored faults and, once any
faults have been remedied, cancel the fault memory.
 Control unit plugs should only ever be connected and disconnected while
the ignition is turned off.
 The removal and installation of components, relays, fuses etc. can cause
faults to be stored in fault memories capable of self diagnosis. Always
interrogate the fault memories after completing work on the electrical
system.
 Investigate stored faults and, once any faults have been remedied, cancel
the fault memory.
Comply with the following when replacing the DME/DDE (Digital Motor Electronics/Digital Diesel
Electronics):
 Always read out hardware/software version of the corresponding control unit with DIS tester.
Comply with the instructions of the DIS tester on the steps coding and programming.
On vehicles with electronic vehicle immobilization, comply with the instructions of the DIS tester.
 Each control unit is programmed with certain basic values, which serve as mean values. The control unit
receives different input values, depending on engine condition, which are compared with the stored
values. The adaptive system compares the input values with the stored map values. The control
commands are routed to the relevant actuators.
 If, for example, the DME control unit would be without current for a long time (more than an hour), its
adaptive system would lose the stored values. When a cleared control unit is restarted or a new control
unit is installed, the adaptive system must read in and store the input values of the associated engine as
new basic values itself.
 This procedure could lead to erratic idling and disturbed overrunning of the engine after starting.
Depending on the engine it could require some time before all values are adapted to the engine condition.
 Therefore observe the following procedure before replacing or reinstalling a DME/DDE control unit:
1. If possible before exchanging control unit, run engine up to operating temperature.
2. Remove the control unit, install a new control unit and operate vehicle at different engine speeds.
12 13 NOTES ON CHECKING IGNITION SYSTEM
Troubleshooting
 Fault in fuel injection system

2006 BMW 650i
 Ignition coil faults

 Further fault patterns with evaluation
 Additional fault notes for troubleshooting
Oscillograms
 Normal oscillogram
 Oscillograms of ignition coils from different manufacturers
Check
 Secondary signal for stationary ignition distribution
12 REMOVING AND INSTALLING ENGINE COMPARTMENT SUPPRESSION LINES

(GROUNDING CABLES) (N62/TU)
 Read out fault memory of DME control unit; if necessary, work through test schedules
 If necessary, remove acoustic cover
 REMOVE INTAKE HOSE
 Remove intake filter housing
Release screw connection (1) of intake filter mounting.
Pull ignition coil covers (2) out of rubber grommets.
Fig. 1: Identifying Holder And Ignition Coil Covers

2006 BMW 650i
Release front screw connection of fuel injector wiring harness, screw down grounding strap with crimp
connection again in upward direction.
Release ignition coil ground screw connection and screw other end of grounding strap to ignition coil ground
again.
Installation:
Tightening torque: 12 52 3AZ . See CONNECTIONS, TERMINALS, LOOSE PARTS for specs.
The picture shows the right cylinder bank, the procedure for the left cylinder bank is identical.
Add final details to vehicle, read out fault memory.
Fig. 2: Identifying Ignition Coil Ground Wire

12 IGNITION WIRES, SPARK PLUGS

FIRING ORDER
FIRING ORDER
Application Firing Order
V8 1-5-4-8-6-3-7-2
2006 BMW 650i
2006 BMW 650i
Fig. 3: Firing Order (V8)

12 12 011 REPLACING ALL SPARK PLUGS (N62, N62TU)
 12 1 171
 12 1 172

 Remove all IGNITION COILS.
Unscrew spark plugs with special tool 12 1 171.
Installation:
Tighten down spark plugs with special tool 12 1 171 and special tool 12 1 172 (torque limiter).
Without special tool 12 1 172, observe tightening torque.
Tightening torque 12 12 1AZ. See ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .
Fig. 4: Tightening Down Spark Plugs With Special Tool 12 1 171 And 12 1 172
13 IGNITION COIL
Troubleshooting
2006 BMW 650i

 Spark plug faults
Oscillograms
Check
12 13 ... ADDITIONAL FAULT NOTES FOR TROUBLESHOOTING
 Connect diagnosis system
Fig. 5: Identifying Diagnosis Information System

12 13 ... CHECKING SECONDARY SIGNAL FOR STATIONARY IGNITION DISTRIBUTION
 12 7 030
Remove ignition coil. Clip special tool 12 7 030 on relevant ignition coil to be tested. Clip high tension clip
2006 BMW 650i
Fig. 6: Removing Ignition Coil

Connect earth lead of adapter to vehicle earth and ignition coil. Connect up diagnosis connector.
If trigger signal is not present (terminal 1), connect black clip of universal adapter cable to pin 1 of primary
adapter cable.
Fig. 7: Connecting Earth Lead Of Adapter To Vehicle Earth And Ignition Coil
Produce a stationary signal by pressing key R on the tester.
NOTE: Neighboring ignition leads could produce interference on the screen of the
oscilloscope.
Interrogate fault memory and its fault reports.

2006 BMW 650i
Fig. 8: Identifying Waveform

12 13 ... FURTHER FAULT PATTERNS WITH EVALUATION
Fig. 9: Identifying Diagnosis And Information System

12 13 009 CHECKING ROD-TYPE IGNITION COILS (M54, M56, N40, N42, N43, N45, N46, N52, N62,
N62TU, N73)
 12 1 301
 12 7 050

2006 BMW 650i
 N40: Remove sound absorption hood

 N62/N62TU: Remove sound absorption hood
 N62/N62TU: Remove ignition coil cover Open control unit box
 Remove M54/56 ignition coil cover
Unlock plug fastener (1) of ignition coil.
Fig. 10: Unlocking Plug Fastener Of Ignition Coil

Detach plug (1) in direction of arrow.
Pull out ignition coil (2) towards top.
NOTE: Procedure applies to all rod-type ignition coils.

2006 BMW 650i
Fig. 11: Detaching Ignition Coil Connector

Install special tool 12 7 050.
Installation:
Special tool 12 7 050 is attached between spark plug and rod-type ignition coil.

Secondary measurement:
Connect KV clip-on probe (1) of DIS Tester to special tool 12 7 050.
Procedure on DIS Tester:
 Select < Measurement >.

 Select < Preset measurement >.
2006 BMW 650i
 Select < Secondary ignition signal >.

 Connect < TD cable to diagnostic head >.
 Select < static ignition distribution >.
 Select < Number of cylinders >.
For subsequent procedure, follow DIS instructions.
Fig. 13: Identifying KV Clip-On Probe

NOTE: Illustration shows: KV clip-on probe (1) US version.
Primary measurement:
Connect 26-pin pin box with special tool 12 1 301 to connector (1) DME module 5.

 Select < Ignition signal term.1 >.
IMPORTANT: Ignition signal is a multiple spark ignition .

2006 BMW 650i
Fig. 14: Identifying Connector

Illustration of multiple spark ignition
1. Start of ignition peak.

2. Level of ignition voltage.
3. Level of sparking voltage.
4. Spark duration.
5. Sparking voltage curve.
6. Start of decay process.
7. Decay process.
Fig. 15: Multiple Spark Ignition Graph

M54 / M56 / N40 / N42 / N45 / N46 / N62 / N73:
The following ignition oscillogram applies to engines with multiple spark ignition from a production date of
2006 BMW 650i
Depending on engine temperature (approx. -20° to 100°) and engine speed (< 2000 rpm.), some ignition voltage
peaks (approx. 1-5 ignition peaks) can occur before the typical ignition voltage characteristic.
The additional ignition peaks play no role in diagnosis.
The last ignition peak (1) on the oscillogram is decisive.
Fig. 16: Identifying Waveform Of Ignition Peak

NOTE: The display of the ignition voltage peak is approx. 20-25 % lower than the real
value.
It is not the height of the ignition voltage peaks but rather the uniformity of all
the cylinders that is important.
Differences of 3000 to 4000 volts are permitted.
12 13 511 REPLACING IGNITION COIL (N62TU)

 Remove INTAKE FILTER HOUSING
Release screws and remove holder (1).

2006 BMW 650i
Fig. 17: Locating Holder And Screws


Detach ignition coil connector in direction of arrow.
Pull out ignition coil (2).
This procedure is applicable to all ignition coils.

2006 BMW 650i

Installation:
Insert rubber seal on ignition coils (2) between guides.
Fig. 20: Inserting Rubber Seal On Ignition Coils Between Guides

Assemble engine.
NOTE: Read out DME fault memory.
Check function of DME.
14 ELECTRONIC SWITCHING OR CONTROL UNIT

11 37 700 REPLACING CONTROL UNIT (VALVETRONIC)
2006 BMW 650i
Switch off ignition.
Follow instructions for disconnecting and connecting battery.
Disconnect battery.
CAUTION: Follow instructions for removing and installing electronic control units.
See INSTRUCTIONS FOR REMOVING AND INSTALLING ELECTRONIC
CONTROL UNITS.
Observe following instructions before replacing control unit:
PROGRAM CONTROL UNIT.
Remove right fresh air duct.
Release screw and remove holder (1).
Release screws and remove cover (2) from control unit box.
NOTE: Release screws on seal (3) only when removing wiring harness.
Fig. 21: Locating Holder And Cover

Installation:
Insert tabs (1) in openings (2) and close cover.

2006 BMW 650i
Fig. 22: Identifying Tabs And Cover

Unlock and detach plug connections on Valvetronic control unit (1).
Remove Valvetronic control unit (1).
Fig. 23: Identifying Valvetronic Control Unit

NOTE: Interrogate fault memory of DME control unit.
Rectify faults.
Then clear fault memory.
12 14 512 REPLACING PULSE GENERATOR ON LEFT EXHAUST CAMSHAFT (N62, N62TU)

2006 BMW 650i
(cylinder bank 5 to 8)
 Switch off ignition.
 Remove ACOUSTIC COVER
 Remove left ignition coil cover
Release plug connector (1) and pull off.
Fig. 24: Identifying Plug Connector

Release screw.
Remove pulse generator (2).
Installation:
Replace sealing ring and coat with antiseize agent.

2006 BMW 650i
Fig. 25: Identifying Pulse Generator

NOTE: Now clear the fault memory.
12 14 513 REPLACING PULSE GENERATOR ON RIGHT EXHAUST CAMSHAFT (N62, N62TU)
 Remove right ignition coil cover

2006 BMW 650i
Release screw.
Installation:

12 14 521 REPLACING CRANKSHAFT PULSE GENERATOR (N62, N62TU)
 If necessary, remove underbody protection.
Installation location:
On transmission housing at bottom right.
Release screw.
Withdraw pulse generator (2) from transmission housing.
Installation:
2006 BMW 650i
Replace screw.
Fig. 28: Locating Pulse Generator

Installation:
Now clear the fault memory.
12 14 522 REPLACING PULSE GENERATOR ON LEFT INLET CAMSHAFT (N62, N62TU)

2006 BMW 650i

Release screw.
Installation:

12 14 526 REPLACING PULSE GENERATOR ON RIGHT INLET CAMSHAFT (N62, N62TU)
2006 BMW 650i

Release screw.
Installation:

2006 BMW 650i

12 14 550 REPLACING CONTROL UNIT (DME) (N62, N62TU)
 Read fault memory

 Disconnect battery
 Remove LOWER SECTION OF MICROFILTER HOUSING ON RIGHT .
IMPORTANT: Follow instructions for removing and installing electronic control units. See
Instructions For Removing And Installing Electronic Control Units.
IMPORTANT: Read and comply with notes on PROTECTION AGAINST ELECTROSTATIC

DAMAGE (ESD PROTECTION) .
Replacement:
 PROGRAM CONTROL UNIT

 CODE CONTROL UNIT
Unlock stopper (1) in direction of arrow.
Unfasten screws.
Lift out cover (2).
Security version:
Remove DME ARMOUR PLATING

2006 BMW 650i
Fig. 33: Locating Screws And Stopper

Unlock and detach all plug connections on DME control unit (1).
Unlock DME control unit (1) and remove towards top.
Fig. 34: Identifying DME Control Unit

12 14 610 REPLACING RIGHT KNOCK SENSORS (N62, N62TU)

 Check stored fault messages
2006 BMW 650i
IMPORTANT: Mixing up the knock sensor plug connections will result in engine damage!
Routing of wires and plug connections must conform to the original routing.
This eliminates the risk of confusion and mix-ups.
Release bolts.
Tightening torque 12 14 1AZ. See ENGINE - TIGHTENING TORQUES .
Remove knock sensors (1).
Fig. 35: Locating Knock Sensors

12 14 611 REPLACING LEFT KNOCK SENSORS (N62, N62TU)

 Remove INTAKE AIR MANIFOLD
2006 BMW 650i
Release bolts.

12 14 700 CODING CONTROL MODULE (DME / DDE)
Connect MoDiC or DIS/GT1 Tester.
Switch on ignition.
Select "Coding" program.
For subsequent procedure, follow instructions in MoDiC or DIS/GT1 Tester.
Carry out adjustment of following control units:
 EWS (electronic immobilizer)

 DME (Digital Motor Electronics) or
 DDE (Digital Diesel Electronics)
12 14 705 PROGRAMMING CONTROL UNIT (DME / DDE)

2006 BMW 650i
Switch on ignition.
Select "Programming".

31 ALTERNATOR WITH DRIVE AND MOUNT

12 31 ... REPLACING ALTERNATOR BELT PULLEY
 12 7 110
Remove and install alternator drive belt.
Depending on alternator type, grip shaft with:
 hexagon socket
 multi-tooth socket or
 Torx socket wrench
Release nut with special tool 12 7 110.
Installation:
Tightening torque, 12 31 2AZ / 12 31 3AZ. See ENGINE - TIGHTENING TORQUES .

2006 BMW 650i

12 31 ... REPLACING ALTERNATOR BELT PULLEY (WITH OVERRUNNING CLUTCH)
 12 7 120
Grip alternator shaft with:
 internal serration
Release nut with special tools 12 7 120.
Installation:
Tightening torque: 12 31 3AZ. See ENGINE - TIGHTENING TORQUES .

2006 BMW 650i
Fig. 38: Special Tools (12 7 122) And (12 7 121)

12 31 009 CHECKING ALTERNATOR (BSD)
 Correct connections on charged battery

 Correct connections on alternator and starter motor
 Good ground connection between engine and body
 Tensioned ribbed V-belt
 Read out DME/DDE fault memory.
NOTE: The alternator with BSD interface can communicate with the engine control unit
(DME/DDE).
The alternator is not connected to the charge telltale light.
The alternator can identify various faults.
BSD alternator can be recognized by the plug connection on the alternator.
Connect diagnosis tester.
 Function selection
 Complete vehicle
 Drive
 Voltage and current regulation
 Voltage and current generation
 Alternator
 Follow instruction in diagnostic program
Oscillogram for a fault-free alternator:

2006 BMW 650i
Fig. 39: Identifying Waveform - Fault-Free Alternator

Oscillogram for a faulty alternator:
One phase interrupted.
Repair/exchange alternator.
Fig. 40: Identifying Waveform - Faulty Alternator (1 Of 6)

Interturn fault.
2006 BMW 650i

Open circuit in negative diode.

Short circuit in positive diode.
2006 BMW 650i

Open circuit in positive diode.

Open circuit in exciter diode.
2006 BMW 650i

Assemble engine.
Check function of DME/DDE.
12 31 020 REMOVING AND INSTALLING/REPLACING ALTERNATOR (N62) (VERSION 1)
 Disconnect battery negative lead.

 Remove SUCTION FILTER HOUSING .
 Remove ELECTRIC FAN with cowl.
 Remove alternator DRIVE BELT .
Disconnect plug (3) from alternator.
Unscrew nut (1).
Lay B+ line (2) to one side.

2006 BMW 650i
Fig. 46: Identifying Plug And Nut

Release screws (1).
Remove alternator (2).
Installation:
Modify guide pulley (3) to new alternator (replace if necessary).
Fig. 47: Identifying Alternator, Guide Pulley And Screws

Check DME (alternator) for correct operation.
12 31 020 REMOVING AND INSTALLING OR REPLACING ALTERNATOR (N62)

2006 BMW 650i
 Disconnect battery negative lead. See 12 00... INSTRUCTIONS FOR DISCONNECTING AND
 Remove fan cowl with electric fan.
 Remove alternator drive belt.
IMPORTANT: Risk of damage Cover radiator.
If fitted: Unscrew nuts. Place holder (1) for refrigerant line (2) to one side. Release screw. Place holder (3) for
hydraulic line (4) to one side.
Fig. 48: Place Holder (1) For Refrigerant Line (2) To One Side
Remove cover (1) and release screw underneath. Remove deflecting element (2).
Fig. 49: Remove Cover (1) And Release Screw Underneath

2006 BMW 650i
MOUNTING PARTS . Pull alternator (1) forwards until connections are accessible.
Fig. 50: Pull Alternator (1) Forwards Until Connections Are Accessible
Unlock plug (1) and remove. Remove cover (2) and release nut underneath. Tightening torque, see 12 42 1AZ
in 12 42 STARTER LINE . Disconnect battery positive lead from alternator. Remove alternator.
Fig. 51: Unlock Plug (1) And Remove

32 REGULATOR
12 32 501 REPLACING CONTROLLER SWITCH FOR ALTERNATOR (N62, N62TU)

 Remove ALTERNATOR
2006 BMW 650i
Carefully insert a screwdriver between cover (1) and threaded pin.
Lever out cover (1) towards top.
Fig. 52: Inserting Screwdriver Between Cover And Threaded Pin

Release contact screws (1).
Slacken nut (2).
Remove controller switch (3).
Fig. 53: Identifying Contact Screws, Nut And Controller Switch

Check contact surfaces (1) of slip rings for wear and recondition if necessary.
2006 BMW 650i
Fig. 54: Identifying Contact Surfaces

Press in carbon brushes (1) of controller switch (2) in direction of arrow.
Install controller switch (2).
Fig. 55: Pressing Carbon Brushes Of Controller Switch

Insert and tighten down contact screws (1).
Insert nut (2) and tighten down.

2006 BMW 650i
Fig. 56: Identifying Contact Screws And Nut

Assemble alternator.
Carry out alternator test with diagnostic system.
12 32 501 REPLACING VOLTAGE REGULATOR

 Notes on removing and installing electronic control units
 Remove alternator
Bosch:
Release protective caps (1).

2006 BMW 650i
Fig. 57: Identifying Protective Caps

Bosch:
Release screw (1) and nuts (2), remove cover.
Fig. 58: Identifying Cover Screw And Nuts

Bosch:
Release screws and remove regulator switch (1) in direction of arrow.
Fig. 59: Removing Regulator Switch

Bosch:
Installation:
2006 BMW 650i
Clean contact surfaces and check pretension of contact spring, replace regulator switch if necessary.
Measurement A = min. 5 mm.
Check collector ring for wear and recondition if necessary.
Fig. 60: Identifying Pretension Of Contact Spring

Valeo:
Slacken nut (1).
Slacken nut (2).
Release screws (3).
Release cover (4).
Fig. 61: Identifying Cover, Nuts And Screws

2006 BMW 650i
Valeo:
Release screws.
Remove regulator switch (1) towards top.
Fig. 62: Locating Regulator Switch Screws

Valeo:
Installation:

2006 BMW 650i
Installation:
Fit new regulator (1) with attached mounting sleeve (2) or locked carbon brush.
Pull off mounting sleeve (2) and replace with cover (3).
Fig. 64: Identifying Regulator, Mounting Sleeve And Cover

41 STARTER WITH MOUNTING

12 41 020 REMOVING AND INSTALLING/REPLACING STARTER MOTOR (N62)
 Disconnect battery ground terminal.

 Remove right exhaust manifold.
Release screws and nut on heat shield (1) (see arrows).
Remove heat shield (1).
Installation:
Tightening torque: 12 41 6AZ. See ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

2006 BMW 650i
Fig. 65: Locating Heat Shield

Disconnect plug connection (1) term.50.
Unscrew nut (2).
Installation:
Remove starter cable (3) term.30.
Fig. 66: Identifying Plug Connection, Nut And Starter Cable

Release screws on transmission (see arrows).
Installation:
2006 BMW 650i
Fig. 67: Locating Screws On Transmission

Assemble vehicle.
12 41 020 REMOVING AND INSTALLING/REPLACING STARTER MOTOR (N62, N62TU)

 Follow instructions for disconnecting and connecting battery
Disconnect battery negative lead and cover
 Remove REINFORCEMENT PLATE

 E60/E63/64/E65/E66 only: Remove RIGHT EXHAUST MANIFOLD
Release screw and nut.

2006 BMW 650i

Unfasten nut.

Release screws and pull starter motor out of transmission mounting and remove.

2006 BMW 650i

Installation:
Check starter pinion and ring gear for damage, replace damaged parts if necessary.
12 41 041 REPLACING SOLENOID SWITCH
Turn off ignition.
Remove starter motor.
Release nut (1).
Remove cable lug (2).
Fig. 71: Identifying Cable Lug And Nut

2006 BMW 650i
CAUTION: Do not turn cable lug (2) while tightening down - risk of short circuit to
starter motor housing.
Tightening torque, 12 41 4AZ. See ENGINE ELECTRICAL SYSTEM -

TIGHTENING TORQUES .
Release screws (1).

Remove solenoid switch (1) and spring (2).
Unhook pin (3).
Installation:
Check pin (3) for wear and apply grease.
Fig. 73: Identifying Solenoid Switch, Spring And Pin

2006 BMW 650i
42 STARTER LEAD
12 42 500 REMOVING AND INSTALLING OR REPLACING BATTERY POSITIVE LEAD
(BETWEEN ALTERNATOR, STARTER MOTOR AND JUMP START CONNECTION POINT) (N62,
N62TU)
REFERENCE CHART
Work step Note:
Switch off ignition
Disconnect battery negative lead Follow instructions for disconnecting and connecting battery
Disconnect battery positive lead at jump Tightening torque: 12 42 1AZ . See WIRES TO
start connection point STARTER for specs.
Remove INTAKE AIR MANIFOLD
Remove FAN COWL
Detach battery positive lead from alternator
Release expansion tank
Secure engine in installation position with
special tool
Release both engine mounts from above
Lower front axle
Remove right exhaust manifold
Remove HEAT SHIELD FROM
STARTER MOTOR
Detach battery positive lead from starter Tightening torque: 12 41 4AZ . See STARTER AND
motor MOUNTING PARTS for specs.
Remove battery positive lead

(BETWEEN ALTERNATOR, STARTER AND BATTERY POSITIVE TERMINAL) (N62)
REFERENCE CHART (N62)

Work step Note:
Switch off ignition
Disconnect battery negative lead Follow instructions for disconnecting and
connecting battery
Disconnect battery positive lead at jump start Tightening torque: 12 42 1AZ . See WIRES TO
connection point STARTER for specs.
REMOVE SUCTION FILTER HOUSING .
REMOVE RIGHT FRESH AIR DUCT .
Remove centre equipment compartment heater
bulkhead.
2006 BMW 650i

REMOVE A/C COMPRESSOR DRIVE BELT .
Detach battery positive lead from alternator Tightening torque: 12 31 1AZ . See
ALTERNATOR WITH DRIVE AND
MOUNTING PARTS for specs.
LIFT ENGINE HOOD INTO ASSEMBLY
POSITION .
SECURE ENGINE IN INSTALLATION
POSITION WITH SPECIAL TOOL
Release grounding strap on engine support arm.
RELEASE A/C COMPRESSOR AND PLACE
TO ONE SIDE .
Remove EXHAUST SYSTEM
Lower front axle
Remove STARTER MOTOR. Tightening torque: 12 41 4AZ . See STARTER
AND MOUNTING PARTS for specs.
Detach battery positive lead from support Tightening torque: 12 42 1AZ . See WIRES TO
point/terminal STARTER for specs.
Unclip battery positive lead (2) from holders (1).
Installation:
Make sure battery positive lead is in correct installation position.
Danger of short circuits.
Fig. 74: Identifying Positive Battery Lead And Holders

2006 BMW 650i
51 ENGINE WIRING LOOM

12 51 001 REPLACING WIRING HARNESS SECTION FOR ENGINE (N62)
 Read out DME fault memory

 ENGINE BONNET/HOOD in assembly position
 Remove FRESH AIR DUCT on right and if necessary on left
 Remove center of ASSEMBLY PARTITION WALL
 Remove intake air manifold
 Remove underbody protection at front/rear
 Remove ELECTRIC FAN with fan cowl
 Remove right exhaust manifold
 Remove STARTER MOTOR
Release screws (2).
Detach electronics box cover (1) from fixture (3) in direction of arrow towards right.
Installation:
Secure electronics box cover (1) in direction of arrow on left in fixture (3).
Fig. 75: Detaching Electronics Box Cover From Fixture

2006 BMW 650i
Unfasten following plug connections:
Fig. 76: Identifying Plug Connections (1 Of 4)


2006 BMW 650i


2006 BMW 650i


2006 BMW 650i

Installation:
Fit profile seals correctly.
Check for water leaks.
Assemble engine.
NOTE: Check function of DME.
Check electronics box cover and rubber grommets on equipment carrier for
watertightness.
12 51 100 REPLACING WIRING HARNESS SECTION FOR IGNITION COIL (N62, N62TU)
2006 BMW 650i
 Remove RIGHT FRESH AIR DUCT
Installation:
Make sure seal of wiring harness section for ignition coils is correctly installed in electronics box.
Unfasten screws.
Lift out cover (2).
Fig. 80: Unlocking Stopper

REFERENCE CHART
Work step Note:
Remove ACOUSTIC COVER
Unlock and detach plug connections on Only plug connections of wiring harness section for ignition
DME control unit. coils
This work step is described in the article "REPLACING
Remove ignition coil cover
IGNITION COIL".
Detach grounding cable from cylinder head Pay attention to INTERFERENCE SUPPRESSION
cover. LINE
Unclip cable duct.
Do not remove ignition coils
Unlock plug connections on ignition coils
and disconnect
IGNITION COIL".
2006 BMW 650i
Remove engine vent hose

Unclip and remove wiring harness.
12 51 150 REMOVING AND INSTALLING/REPLACING WIRING HARNESS SECTION FOR FUEL

INJECTORS ON LEFT OR RIGHT (N62, N62TU)

 Remove ignition coil cover
NOTE: The procedure is identical for both sides.
Unfasten screws.
Remove positioning motor for eccentric shaft. See REMOVING AND INSTALLING/REPLACING
SERVOMOTOR FOR LEFT ECCENTRIC SHAFT (N62/N62TU) and REMOVING AND
INSTALLING/REPLACING SERVOMOTOR FOR RIGHT ECCENTRIC SHAFT (N62/N62TU) .
Unlock plugs on fuel injectors and disconnect.
Remove wiring harness.
Fig. 81: Locating Plug And Screws

2006 BMW 650i
61 OIL PRESSURE/OIL TEMPERATURE GAUGE

12 61 280 REMOVING AND INSTALLING/REPLACING OIL PRESSURE SWITCH (N62, N62TU)

 E65/E66 only: Remove intake filter housing
 E53 only: Remove intake hood with air intake hose
Only perform this task on an engine that has cooled down.
Cylinder bank 1 to 4 on cylinder head, front right.
Engine oil may emerge when oil pressure switch is replaced; have a cleaning cloth ready.
Unscrew oil pressure switch (2).
Tightening torque: 12 61 1AZ . See ENGINE - TIGHTENING TORQUES .
Installation:
Check engine oil level, top up engine oil if necessary.
Fig. 82: Identifying Plug Connector And Oil Pressure Switch

2006 BMW 650i
12 61 285 REPLACING ENGINE OIL LEVEL SWITCH (N62, N62TU)

 DRAIN OFF ENGINE OIL
Illustration shows E65:
Unscrew nuts.
Remove level switch (2).
Installation:
Clean sealing face on oil sump.
Replace seal on level switch.
An excessively low torque value will result in oil leakage, an excessively high torque value will result in
damage to the level switch.
Top up engine oil.
Fig. 83: Locating Plug Connector, Level Switch And Nuts

2006 BMW 650i
12 90 ... REMOVING AND INSTALLING/REPLACING ELECTRONICS BOX

NOTE: Follow instructions for removing and installing electronic control units. See
INSTRUCTIONS FOR REMOVING AND INSTALLING ELECTRONIC CONTROL
UNITS.
 Read fault memory.

 Disconnect negative battery cable
 Remove ELECTRONICS BOX FAN
 Remove DISTRIBUTION BOX (PASSENGER COMPARTMENT)
 Release control unit holder; if necessary, release CD changer
Release screws (arrows) behind sound insulation.
Disconnect wiring harness on engine compartment side on right.
Remove electronics box.
Fig. 84: Locating Electronics Box

Installation:
Make sure gasket (1) is correctly seated on electronics box.
Read fault memory.

2006 BMW 650i
Fig. 85: Identifying Gasket

12 90 100 REPLACING FAN FOR ELECTRONICS BOX (N62)


 Follow instructions for disconnecting and connecting battery.
 Remove right fresh air duct.
UNITS.
Release screw (2).
Remove cover (1) of equipment box in direction of arrow towards right.
Installation:
Push on cover (1) of equipment box in direction of arrow towards left into holder (3).
2006 BMW 650i
Fig. 86: Detaching Cover Of Equipment Box

Disconnect plug connections (1 to 6).
Remove Valvetronic control unit, DME and integrated supply module.
Fig. 87: Identifying Plug Connection

Unlock plug connection (3) on fan for electronics box and disconnect.
Release screws (1) on control unit carrier (2).
Remove control unit carrier (2) towards top.

2006 BMW 650i
Fig. 88: Identifying Plug Connection And Control Unit Carrier

Release screws (1).
Remove fan (2) in direction of arrow.
Fig. 89: Removing Fan And Screws


2006 BMW 650i
ENGINE
Engine Electrical System - Repair Instructions - V8 (N62TU)
00 TROUBLESHOOTING
General Information
 Working on ignition system

 Removing and installing electronic control units
 Welding work (overload protection of control units)
 Disconnecting and connecting battery
 Disconnecting and connecting test equipment
 Component inspection:
 External jump-starting aid
 Compression testing
Observe safety instructions for handling vehicle battery.
Turn off the ignition and other electrical loads/consumers to prevent sparking when reconnecting.

2006 BMW 650i
 When installing battery terminal: See tightening torque 61 21 1AZ in 61 21 BATTERY WITH
TERMINAL .
reactivated.
Example:
 Vehicles with build date from 03/2007:
Teach-in mid-position for power steering
 If necessary, activate sliding sunroof

 If necessary, carry out adjustment of active front steering
 If necessary, activate power windows
Two AGM batteries, whose design and properties are described in AGM batteries, are used as a storage battery.
2006 BMW 650i
is open.
voltage at the starter battery of > or = 13.5 V. The isolating relay is closed and thus the equipment battery is
connected in parallel. Both batteries are now charged.
Prerequisite:
operation when the engine is running.
A special mode can be set by means of diagnosis for workshop/garage

operation. The isolating relay is closed from terminal R in this operating mode.
This mode is automatically reset once a distance of 5 km has been driven.
Trickle charging
The increased closed-circuit current consumption can be compensated for via the jump-start connection point
with the aid of the "Acctiva easy" battery trickle charger.
charging function).
2006 BMW 650i
12 00 ... INSTRUCTIONS FOR REMOVING AND INSTALLING ELECTRONIC CONTROL UNITS
IMPORTANT:  Disconnecting the vehicle battery will cancel the fault memories of control
units. Consequently, before disconnecting the car's battery, always
interrogate the fault memories. Investigate stored faults and, once any
faults have been remedied, cancel the fault memory.
 Control unit plugs should only ever be connected and disconnected while
the ignition is turned off.
 The removal and installation of components, relays, fuses etc. can cause
faults to be stored in fault memories capable of self diagnosis. Always
interrogate the fault memories after completing work on the electrical
system.
 Investigate stored faults and, once any faults have been remedied, cancel
the fault memory.
Comply with the following when replacing the DME/DDE (Digital Motor Electronics/Digital Diesel
Electronics):
Comply with the instructions of the DIS tester on the steps coding and programming.
On vehicles with electronic vehicle immobilization, comply with the instructions of the DIS tester.
 Each control unit is programmed with certain basic values, which serve as mean values. The control unit
receives different input values, depending on engine condition, which are compared with the stored
values. The adaptive system compares the input values with the stored map values. The control
commands are routed to the relevant actuators.
 If, for example, the DME control unit would be without current for a long time (more than an hour), its
adaptive system would lose the stored values. When a cleared control unit is restarted or a new control
unit is installed, the adaptive system must read in and store the input values of the associated engine as
new basic values itself.
Depending on the engine it could require some time before all values are adapted to the engine condition.
 Therefore observe the following procedure before replacing or reinstalling a DME/DDE control unit:
2. Remove the control unit, install a new control unit and operate vehicle at different engine speeds.
Troubleshooting

2006 BMW 650i

Oscillograms
Check
12 REMOVING AND INSTALLING ENGINE COMPARTMENT SUPPRESSION LINES

(GROUNDING CABLES) (N62/TU)
 If necessary, remove acoustic cover
 REMOVE INTAKE HOSE
Release screw connection (1) of intake filter mounting.

2006 BMW 650i
Release front screw connection of fuel injector wiring harness, screw down grounding strap with crimp
connection again in upward direction.
Release ignition coil ground screw connection and screw other end of grounding strap to ignition coil ground
again.
Installation:
Tightening torque: 12 52 3AZ . See CONNECTIONS, TERMINALS, LOOSE PARTS for specs.
The picture shows the right cylinder bank, the procedure for the left cylinder bank is identical.
Add final details to vehicle, read out fault memory.
Fig. 2: Identifying Ignition Coil Ground Wire

12 IGNITION WIRES, SPARK PLUGS

FIRING ORDER
FIRING ORDER
V8 1-5-4-8-6-3-7-2
2006 BMW 650i
2006 BMW 650i

12 12 011 REPLACING ALL SPARK PLUGS (N62, N62TU)
 12 1 171
 12 1 172

 Remove all IGNITION COILS.
Installation:
Fig. 4: Tightening Down Spark Plugs With Special Tool 12 1 171 And 12 1 172
13 IGNITION COIL
Troubleshooting
2006 BMW 650i

 Spark plug faults
Oscillograms
Check
Fig. 5: Identifying Diagnosis Information System

 12 7 030
2006 BMW 650i

Connect earth lead of adapter to vehicle earth and ignition coil. Connect up diagnosis connector.
adapter cable.
Fig. 7: Connecting Earth Lead Of Adapter To Vehicle Earth And Ignition Coil
oscilloscope.

2006 BMW 650i
Fig. 8: Identifying Waveform


12 13 009 CHECKING ROD-TYPE IGNITION COILS (M54, M56, N40, N42, N43, N45, N46, N52, N62,
N62TU, N73)
 12 1 301
 12 7 050

2006 BMW 650i

 N62/N62TU: Remove sound absorption hood
 N62/N62TU: Remove ignition coil cover Open control unit box


2006 BMW 650i

Installation:


2006 BMW 650i
 Select < Secondary ignition signal >.

 Connect < TD cable to diagnostic head >.
 Select < static ignition distribution >.
 Select < Number of cylinders >.
Fig. 13: Identifying KV Clip-On Probe

Primary measurement:

 Select < Ignition signal term.1 >.
IMPORTANT: Ignition signal is a multiple spark ignition .

2006 BMW 650i
Fig. 14: Identifying Connector

Illustration of multiple spark ignition
1. Start of ignition peak.

2. Level of ignition voltage.
3. Level of sparking voltage.
4. Spark duration.
5. Sparking voltage curve.
6. Start of decay process.
7. Decay process.
Fig. 15: Multiple Spark Ignition Graph

M54 / M56 / N40 / N42 / N45 / N46 / N62 / N73:
2006 BMW 650i
Fig. 16: Identifying Waveform Of Ignition Peak

value.
It is not the height of the ignition voltage peaks but rather the uniformity of all
the cylinders that is important.


2006 BMW 650i
Fig. 17: Locating Holder And Screws



2006 BMW 650i

Installation:

Assemble engine.
14 ELECTRONIC SWITCHING OR CONTROL UNIT

2006 BMW 650i
Follow instructions for disconnecting and connecting battery.
Disconnect battery.
See INSTRUCTIONS FOR REMOVING AND INSTALLING ELECTRONIC
CONTROL UNITS.
PROGRAM CONTROL UNIT.
Fig. 21: Locating Holder And Cover

Installation:

2006 BMW 650i
Fig. 22: Identifying Tabs And Cover


Rectify faults.
12 14 512 REPLACING PULSE GENERATOR ON LEFT EXHAUST CAMSHAFT (N62, N62TU)

2006 BMW 650i

Release screw.
Installation:

2006 BMW 650i

12 14 513 REPLACING PULSE GENERATOR ON RIGHT EXHAUST CAMSHAFT (N62, N62TU)

2006 BMW 650i
Release screw.
Installation:

12 14 521 REPLACING CRANKSHAFT PULSE GENERATOR (N62, N62TU)
 If necessary, remove underbody protection.
On transmission housing at bottom right.
Release screw.
Withdraw pulse generator (2) from transmission housing.
Installation:
2006 BMW 650i
Replace screw.

Installation:
12 14 522 REPLACING PULSE GENERATOR ON LEFT INLET CAMSHAFT (N62, N62TU)

2006 BMW 650i

Release screw.
Installation:

12 14 526 REPLACING PULSE GENERATOR ON RIGHT INLET CAMSHAFT (N62, N62TU)
2006 BMW 650i

Release screw.
Installation:

2006 BMW 650i

12 14 550 REPLACING CONTROL UNIT (DME) (N62, N62TU)
 Read fault memory

 Remove LOWER SECTION OF MICROFILTER HOUSING ON RIGHT .
Instructions For Removing And Installing Electronic Control Units.

Replacement:
 PROGRAM CONTROL UNIT

 CODE CONTROL UNIT
Unfasten screws.
Lift out cover (2).
Security version:
Remove DME ARMOUR PLATING

2006 BMW 650i
Fig. 33: Locating Screws And Stopper

Fig. 34: Identifying DME Control Unit

12 14 610 REPLACING RIGHT KNOCK SENSORS (N62, N62TU)

2006 BMW 650i
Release bolts.

12 14 611 REPLACING LEFT KNOCK SENSORS (N62, N62TU)

 Remove INTAKE AIR MANIFOLD
2006 BMW 650i
Release bolts.

Switch on ignition.


2006 BMW 650i
Switch on ignition.

31 ALTERNATOR WITH DRIVE AND MOUNT

 12 7 110
 hexagon socket
Installation:
Tightening torque, 12 31 2AZ / 12 31 3AZ. See ENGINE - TIGHTENING TORQUES .

2006 BMW 650i

12 31 ... REPLACING ALTERNATOR BELT PULLEY (WITH OVERRUNNING CLUTCH)
 12 7 120
Grip alternator shaft with:
 internal serration
Release nut with special tools 12 7 120.
Installation:
Tightening torque: 12 31 3AZ. See ENGINE - TIGHTENING TORQUES .

2006 BMW 650i
Fig. 38: Special Tools (12 7 122) And (12 7 121)


(DME/DDE).
 Drive
 Alternator

2006 BMW 650i
Fig. 39: Identifying Waveform - Fault-Free Alternator


Interturn fault.
2006 BMW 650i


2006 BMW 650i


2006 BMW 650i

Assemble engine.
12 31 020 REMOVING AND INSTALLING/REPLACING ALTERNATOR (N62) (VERSION 1)

 Remove SUCTION FILTER HOUSING .
 Remove ELECTRIC FAN with cowl.
 Remove alternator DRIVE BELT .
Disconnect plug (3) from alternator.
Unscrew nut (1).
Lay B+ line (2) to one side.

2006 BMW 650i

Release screws (1).
Remove alternator (2).
Installation:
Modify guide pulley (3) to new alternator (replace if necessary).
Fig. 47: Identifying Alternator, Guide Pulley And Screws

Check DME (alternator) for correct operation.

2006 BMW 650i
 Disconnect battery negative lead. See 12 00... INSTRUCTIONS FOR DISCONNECTING AND
 Remove fan cowl with electric fan.
 Remove alternator drive belt.
IMPORTANT: Risk of damage Cover radiator.
If fitted: Unscrew nuts. Place holder (1) for refrigerant line (2) to one side. Release screw. Place holder (3) for
hydraulic line (4) to one side.
Fig. 48: Place Holder (1) For Refrigerant Line (2) To One Side
Remove cover (1) and release screw underneath. Remove deflecting element (2).
Fig. 49: Remove Cover (1) And Release Screw Underneath

2006 BMW 650i
MOUNTING PARTS . Pull alternator (1) forwards until connections are accessible.
Fig. 50: Pull Alternator (1) Forwards Until Connections Are Accessible
Unlock plug (1) and remove. Remove cover (2) and release nut underneath. Tightening torque, see 12 42 1AZ
in 12 42 STARTER LINE . Disconnect battery positive lead from alternator. Remove alternator.
Fig. 51: Unlock Plug (1) And Remove

32 REGULATOR
12 32 501 REPLACING CONTROLLER SWITCH FOR ALTERNATOR (N62, N62TU)

2006 BMW 650i
Fig. 52: Inserting Screwdriver Between Cover And Threaded Pin

Slacken nut (2).
Fig. 53: Identifying Contact Screws, Nut And Controller Switch

2006 BMW 650i
Fig. 54: Identifying Contact Surfaces

Fig. 55: Pressing Carbon Brushes Of Controller Switch


2006 BMW 650i
Fig. 56: Identifying Contact Screws And Nut

12 32 501 REPLACING VOLTAGE REGULATOR

 Notes on removing and installing electronic control units
Bosch:
Release protective caps (1).

2006 BMW 650i
Fig. 57: Identifying Protective Caps

Bosch:
Release screw (1) and nuts (2), remove cover.
Fig. 58: Identifying Cover Screw And Nuts

Bosch:
Release screws and remove regulator switch (1) in direction of arrow.
Fig. 59: Removing Regulator Switch

Bosch:
Installation:
2006 BMW 650i

Valeo:
Slacken nut (1).
Slacken nut (2).
Release screws (3).
Release cover (4).
Fig. 61: Identifying Cover, Nuts And Screws

2006 BMW 650i
Valeo:
Release screws.
Remove regulator switch (1) towards top.
Fig. 62: Locating Regulator Switch Screws

Valeo:
Installation:

2006 BMW 650i
Installation:
Fit new regulator (1) with attached mounting sleeve (2) or locked carbon brush.
Pull off mounting sleeve (2) and replace with cover (3).
Fig. 64: Identifying Regulator, Mounting Sleeve And Cover

41 STARTER WITH MOUNTING


 Remove right exhaust manifold.
Release screws and nut on heat shield (1) (see arrows).
Installation:
Tightening torque: 12 41 6AZ. See ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

2006 BMW 650i

Disconnect plug connection (1) term.50.
Unscrew nut (2).
Installation:
Remove starter cable (3) term.30.
Fig. 66: Identifying Plug Connection, Nut And Starter Cable

Release screws on transmission (see arrows).
Installation:
2006 BMW 650i

Assemble vehicle.
12 41 020 REMOVING AND INSTALLING/REPLACING STARTER MOTOR (N62, N62TU)

Disconnect battery negative lead and cover

 E60/E63/64/E65/E66 only: Remove RIGHT EXHAUST MANIFOLD
Release screw and nut.

2006 BMW 650i

Unfasten nut.

Release screws and pull starter motor out of transmission mounting and remove.

2006 BMW 650i

Installation:
Turn off ignition.
Release nut (1).
Remove cable lug (2).
Fig. 71: Identifying Cable Lug And Nut

2006 BMW 650i
Tightening torque, 12 41 4AZ. See ENGINE ELECTRICAL SYSTEM -

Release screws (1).

Unhook pin (3).
Installation:
Fig. 73: Identifying Solenoid Switch, Spring And Pin

2006 BMW 650i
42 STARTER LEAD
(BETWEEN ALTERNATOR, STARTER MOTOR AND JUMP START CONNECTION POINT) (N62,
N62TU)
REFERENCE CHART
Work step Note:
Switch off ignition
Disconnect battery negative lead Follow instructions for disconnecting and connecting battery
Disconnect battery positive lead at jump Tightening torque: 12 42 1AZ . See WIRES TO
start connection point STARTER for specs.
Remove FAN COWL
Secure engine in installation position with
special tool
Lower front axle
Remove HEAT SHIELD FROM
STARTER MOTOR
Detach battery positive lead from starter Tightening torque: 12 41 4AZ . See STARTER AND
motor MOUNTING PARTS for specs.

(BETWEEN ALTERNATOR, STARTER AND BATTERY POSITIVE TERMINAL) (N62)
REFERENCE CHART (N62)

Work step Note:
Switch off ignition
connecting battery
Disconnect battery positive lead at jump start Tightening torque: 12 42 1AZ . See WIRES TO
connection point STARTER for specs.
REMOVE SUCTION FILTER HOUSING .
REMOVE RIGHT FRESH AIR DUCT .
Remove centre equipment compartment heater
bulkhead.
2006 BMW 650i

REMOVE A/C COMPRESSOR DRIVE BELT .
Detach battery positive lead from alternator Tightening torque: 12 31 1AZ . See
ALTERNATOR WITH DRIVE AND
MOUNTING PARTS for specs.
LIFT ENGINE HOOD INTO ASSEMBLY
POSITION .
SECURE ENGINE IN INSTALLATION
POSITION WITH SPECIAL TOOL
Release grounding strap on engine support arm.
RELEASE A/C COMPRESSOR AND PLACE
TO ONE SIDE .
Remove EXHAUST SYSTEM
Lower front axle
Remove STARTER MOTOR. Tightening torque: 12 41 4AZ . See STARTER
AND MOUNTING PARTS for specs.
Detach battery positive lead from support Tightening torque: 12 42 1AZ . See WIRES TO
point/terminal STARTER for specs.
Unclip battery positive lead (2) from holders (1).
Installation:
Make sure battery positive lead is in correct installation position.
Danger of short circuits.
Fig. 74: Identifying Positive Battery Lead And Holders

2006 BMW 650i
51 ENGINE WIRING LOOM

 Read out DME fault memory

 ENGINE BONNET/HOOD in assembly position
 Remove FRESH AIR DUCT on right and if necessary on left
 Remove center of ASSEMBLY PARTITION WALL
 Remove intake air manifold
 Remove underbody protection at front/rear
 Remove ELECTRIC FAN with fan cowl
 Remove STARTER MOTOR
Release screws (2).
Detach electronics box cover (1) from fixture (3) in direction of arrow towards right.
Installation:
Secure electronics box cover (1) in direction of arrow on left in fixture (3).
Fig. 75: Detaching Electronics Box Cover From Fixture

2006 BMW 650i


2006 BMW 650i


2006 BMW 650i


2006 BMW 650i

Installation:
Fit profile seals correctly.
Check for water leaks.
Assemble engine.
NOTE: Check function of DME.
Check electronics box cover and rubber grommets on equipment carrier for
watertightness.
12 51 100 REPLACING WIRING HARNESS SECTION FOR IGNITION COIL (N62, N62TU)
2006 BMW 650i
 Remove RIGHT FRESH AIR DUCT
Installation:
Unfasten screws.
Lift out cover (2).
Fig. 80: Unlocking Stopper

REFERENCE CHART
Work step Note:
Unlock and detach plug connections on Only plug connections of wiring harness section for ignition
DME control unit. coils
Remove ignition coil cover
IGNITION COIL".
Detach grounding cable from cylinder head Pay attention to INTERFERENCE SUPPRESSION
cover. LINE
Unclip cable duct.
Do not remove ignition coils
Unlock plug connections on ignition coils
and disconnect
IGNITION COIL".
2006 BMW 650i
Remove engine vent hose

Unclip and remove wiring harness.

INJECTORS ON LEFT OR RIGHT (N62, N62TU)

Unfasten screws.
Remove positioning motor for eccentric shaft. See REMOVING AND INSTALLING/REPLACING
SERVOMOTOR FOR LEFT ECCENTRIC SHAFT (N62/N62TU) and REMOVING AND
INSTALLING/REPLACING SERVOMOTOR FOR RIGHT ECCENTRIC SHAFT (N62/N62TU) .
Fig. 81: Locating Plug And Screws

2006 BMW 650i
61 OIL PRESSURE/OIL TEMPERATURE GAUGE

12 61 280 REMOVING AND INSTALLING/REPLACING OIL PRESSURE SWITCH (N62, N62TU)

 E65/E66 only: Remove intake filter housing
 E53 only: Remove intake hood with air intake hose
Installation:
Fig. 82: Identifying Plug Connector And Oil Pressure Switch

2006 BMW 650i
12 61 285 REPLACING ENGINE OIL LEVEL SWITCH (N62, N62TU)

 DRAIN OFF ENGINE OIL
Unscrew nuts.
Installation:
Top up engine oil.
Fig. 83: Locating Plug Connector, Level Switch And Nuts

2006 BMW 650i
12 90 ... REMOVING AND INSTALLING/REPLACING ELECTRONICS BOX

NOTE: Follow instructions for removing and installing electronic control units. See
UNITS.
 Read fault memory.

 Disconnect negative battery cable
 Remove ELECTRONICS BOX FAN
 Remove DISTRIBUTION BOX (PASSENGER COMPARTMENT)
 Release control unit holder; if necessary, release CD changer
Release screws (arrows) behind sound insulation.
Disconnect wiring harness on engine compartment side on right.
Remove electronics box.
Fig. 84: Locating Electronics Box

Installation:
Make sure gasket (1) is correctly seated on electronics box.
Read fault memory.

2006 BMW 650i



 Remove right fresh air duct.
UNITS.
Release screw (2).
Remove cover (1) of equipment box in direction of arrow towards right.
Installation:
Push on cover (1) of equipment box in direction of arrow towards left into holder (3).
2006 BMW 650i
Fig. 86: Detaching Cover Of Equipment Box

Disconnect plug connections (1 to 6).
Remove Valvetronic control unit, DME and integrated supply module.

Unlock plug connection (3) on fan for electronics box and disconnect.
Release screws (1) on control unit carrier (2).
Remove control unit carrier (2) towards top.

2006 BMW 650i
Fig. 88: Identifying Plug Connection And Control Unit Carrier

Release screws (1).
Remove fan (2) in direction of arrow.
Fig. 89: Removing Fan And Screws


2005 BMW 645Ci
2004-05 ENGINE Engine Electrical - Repair Instructions - E63
2004-05 ENGINE
Engine Electrical - Repair Instructions - E63
TROUBLESHOOTING
General Information -> Working on ignition system, refer to WORKING ON IGNITION SYSTEM.
-> Removing and installing electronic control units, refer to REMOVING AND INSTALLING
ELECTRONIC CONTROL UNITS.
-> Welding work (overload protection of control units), refer to WELDING WORK (OVERLOAD
PROTECTION OF CONTROL UNITS).
-> Disconnecting and connecting battery, refer to DISCONNECTING AND CONNECTING BATTERY.
-> Disconnecting and connecting test equipment, refer to DISCONNECTING AND CONNECTING TEST
EQUIPMENT.
-> Component inspection:, refer to COMPONENT INSPECTION.
-> External jump-starting aid, refer to EXTERNAL JUMP-STARTING AID.
-> Compression testing, refer to COMPRESSION TESTING.
Observe safety instructions for handling vehicle battery. Refer to 61 00 ... SAFETY INSTRUCTIONS FOR
HANDLING VEHICLE BATTERY .
2005 BMW 645Ci

 When fitting terminal for battery negative lead: refer to tightening torque 61 21 1AZ in ENGINE
ELECTRICAL SYSTEM - TIGHTENING TORQUES .
reactivated. Likewise, individual settings are lost and must be activated.
Example:
 Activate sliding sunroof, refer to 54 0 ... NOTES ON PANORAMA GLASS

ROOF (INITIALIZATION/NORMALIZATION/LEARNING OF
CHARACTERISTIC CURVE) .
 Vehicles with AFS only: Activate steering angle, refer to 61 00 VERSION
WITH AFS: SETTING STEERING ANGLE (AFTER RECONNECTING
VEHICLE BATTERY) .
 If necessary, activate mirror with compass.
Two AGM batteries are used as a storage battery.

2005 BMW 645Ci
is open.
voltage at the starter battery of GRATER THAN EQUAL TO ace;13.5 V. The isolating relay is closed and thus
the equipment battery is connected in parallel. Both batteries are now charged.
Prerequisite:
operation when the engine is running. A special mode can be set by means of
diagnosis for workshop/garage operation. The isolating relay is closed from
terminal R in this operating mode. This mode is automatically reset once a
distance of 5 km has been driven.
Trickle charging
Increased closed-circuit current consumption can be compensated with the aid of the battery trickle charger
(special tool 61 2 410) via the jump start terminal.
2005 BMW 645Ci
charging function).
Troubleshooting
-> Fault in fuel injection system. Refer to 12 13 ... FAULT IN FUEL INJECTION SYSTEM.
-> Spark-plug faults. Refer to 12 13 ... SPARK-PLUG FAULTS.
-> Ignition coil faults. Refer to 12 13 ... IGNITION COIL FAULTS.
-> Further fault patterns with evaluation. Refer to 12 13 ... FURTHER FAULT PATTERNS WITH
EVALUATION.
-> Additional fault notes for troubleshooting. Refer to 12 13 ... ADDITIONAL FAULT NOTES FOR
TROUBLESHOOTING.
Oscillograms
-> Normal oscillogram, refer to 12 13 ... NORMAL OSCILLOGRAM (N42, N62).
Check
-> Secondary signal for stationary ignition distribution, refer to 12 13 ... CHECKING SECONDARY
SIGNAL FOR STATIONARY IGNITION DISTRIBUTION.
Working On Ignition System
Safety instructions:
Always switch off ignition before working on ignition system.

Use only test leads which have been approved and belong to the testing instruments (e.g. DIS Tester).
Comply with operating instructions of the respective testing instrument used.
Comply with the country-specific safety regulations.
Never touch components conducting current with engine running!
Comply with instructions of DIS tester.
Do not connect any suppression capacitors or inspection lamps to terminal 1 on the ignition coil.
Terminal 1 of ignition coil must not be connected to ground or battery positive lead.
If an alarm system is subsequently installed, lead of terminal 1 must not be used for start prevention.
When working on ignition system, always disconnect supply leads to ignition coils.
CAUTION: High voltage! - Mortal danger! Caution! Hazardous voltages occur at:
2005 BMW 645Ci
 Ignition lead
 Spark-plug connector
 Spark plug
 Ignition coil (high voltage at terminal 4 is approx. 40 kV)
 Lead of terminal 1 from ignition coil to DME control unit (high voltage
approx. 350 V)
Removing And Installing Electronic Control Units
Instructions for removing and installing electronic control units:
 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.
 Comply with the following when replacing the DME/DDE (Digital Motor Electronics/Digital Diesel
Electronics):
Comply with the instructions of the DIS tester on the steps coding and programming. On vehicles
with electronic vehicle immobilization, comply with the instructions of the DIS tester.
 Each control unit is programmed with certain basic values, which serve as mean values. The
control unit receives different input values, depending on engine condition, which are compared
with the stored values. The adaptive system compares the input values with the stored map values.
The control commands are routed to the relevant actuators.
 If, for example, the DME control unit were without current for a long time (more than an hour), its
adaptive system would lose the stored values. When a cleared control unit is restarted or a new
control unit is installed, the adaptive system must read in and store the input values of the
associated engine as new basic values itself.
Depending on the engine it could require some time before all values are adapted to the engine
condition.
 Therefore observe the following procedure before replacing or reinstalling a DME/DDE control
unit:
2. Remove the control unit, install a new control unit and operate vehicle at different engine
speeds.
Welding Work (Overload Protection Of Control Units)

2005 BMW 645Ci
When performing welding work on installed control units, to avoid any defects in the electronic control units,
observe the following steps:
 Observe instructions for disconnecting and connecting battery. See DISCONNECTING AND
CONNECTING BATTERY.
 Detach terminal of battery negative lead from car battery and second battery if fitted. Cover negative
terminal posts.
 If welding is to be performed near the battery/batteries, first remove battery/batteries from vehicle (flying
sparks - combustion of explosive gas).
 Fit return clamp on welding unit as close as possible to welding point (maximum distance approx. 1 m).
 Never connect return clamp to ground pin on body which has ground wires attached!
Disconnecting And Connecting Battery
See 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY.
Disconnecting And Connecting Test Equipment
When connecting and disconnecting:
 Service Tester
 Testing Devices
 Test Leads
 When Replacing Control Units
it is essential to turn off the ignition.
Follow instructions for removing and installing electronic control units. See REMOVING AND
INSTALLING ELECTRONIC CONTROL UNITS.
Follow operating instructions for testing devices.
Make sure that connected test leads cannot make contact with rotating parts (e.g.: fans, ribbed V-belts, etc.).
Component Inspection
Instructions On Component Testing:
 During all inspections and work on engine electrics and electronics, always observe safety regulations
and accident prevention specifications.
 Always disconnect connectors of control units or components before checking electric wires.
Testing Aids:
2005 BMW 645Ci
 Only ever use test lines, adapters, terminals and test tips manufactured by specialists, refer to Diagnosis
Information System.
 The inspection values for component testing are located in the Diagnosis Information System (DIS).
External Jump-Starting Aid
Instructions On Starting Aid Do not start the engine with help of starting sprays.
Preparation
Conform with the following when starting engine with starting cable:
 Ensure that jump lead wires are to appropriate cross-section size.

 Only use fuse-protected jump leads.
 Check whether the current supplying battery has 12 V voltage.
 If engine is started from battery of another vehicle, ensure that there is no contact between the bodies of
both vehicles.
Carrying Out
CAUTION: Never touch ignition system components and current - dangerous high
tension!
If the battery in the vehicle supplying power is weak, start the engine of this vehicle and let it run at idling
speed.
Always conform with the procedures to avoid injury to persons or damage to parts:
 On automatic transmission, select "P" setting, apply handbrake.

 Move the shift lever of vehicles with manual transmission into neutral and apply the parking brake.
 Ensure that the jump leads cannot get caught in rotating parts, e.g. fan.
 First connect positive terminals of both batteries with one jump lead (red).
 Use positive connection point in engine compartment for vehicles with one battery in trunk.
 Then attach second jump lead (black) to negative terminal of donor battery and to engine ground or body
ground on vehicle to be started.
CAUTION: Never connect second jump lead (black) to negative terminal of battery in
vehicle to be started. This would produce explosive gas which could be
ignited by sparks.
Danger of explosion! After engine of vehicle to be started has started up,

first disconnect the jump lead on the negative terminal/ground connection.
Then remove jump lead from positive terminals.
2005 BMW 645Ci
Compression Testing
See 11 00 045 CHECKING ABSOLUTE COMPRESSION OF ALL CYLINDERS .
IGNITION WIRES, SPARK PLUGS

FIRING ORDER
FIRING ORDER
V8 1-5-4-8-6-3-7-2
2005 BMW 645Ci
2005 BMW 645Ci

12 12 011 REPLACING ALL SPARK PLUGS (N62)
NOTE: For special tools, refer to ENGINE ELECTRICAL SYSTEM - SPECIAL TOOLS -
645CI .
 12 1 171
 12 1 172

 Remove all ignition coils. Refer to 12 13 511 REPLACING IGNITION COIL (N62).

2005 BMW 645Ci
Fig. 2: Unscrewing Spark Plugs With Special Tool

Installation:
Refer to tightening torque 12 12 1AZ, in ENGINE ELECTRICAL SYSTEM - TIGHTENING
TORQUES .
IGNITION COIL
For procedures, refer to 12 13 NOTES ON CHECKING IGNITION SYSTEM.

2005 BMW 645Ci
Fig. 3: Identifying DIS Tester

645CI .
 12 7 030
Engine Test Step 10

2005 BMW 645Ci
around ignition lead.
Fig. 4: Connecting Test Equipment

Connect earth lead of adapter to vehicle earth and ignition coil.

2005 BMW 645Ci
Fig. 5: Connecting Earth Lead

Connect up diagnosis connector.
adapter cable.

2005 BMW 645Ci
Fig. 6: Identifying Stationary Signal

oscilloscope.
Refer to the fault memories of engine control units for additional troubleshooting.

2005 BMW 645Ci
Fig. 7: Identifying DIS Tester

12 13 ... NORMAL OSCILLOGRAM (N42, N62)

2005 BMW 645Ci
2005 BMW 645Ci
Fig. 8: Identifying Combustion Period Graph

N42 / N62:
The following normal oscillogram is applicable to engines with multiple-spark ignition from the production date
of April 2001:
Depending on the engine temperature/speed, some ignition voltage peaks can occur before the typical ignition
voltage curve.
These peaks do not play any role for diagnostics.
The last ignition voltage peak (1) before the ignition voltage curve is the decisive factor for the test.
Fig. 9: Identifying Last Ignition Voltage Peak

2005 BMW 645Ci
NOTE: The indication of the ignition voltage needle is approx. 20-25 % lower than the
real value.
The uniformity of all cylinders to each other is more important than the height of ignition voltage peaks.
12 13 ... FAULT IN FUEL INJECTION SYSTEM
Evaluation of ignition voltage peaks in response to sudden accelerator loads.
Fig. 10: Evaluation Of Ignition Voltage Peaks

1. Beginning of dying-out process is not much higher than ignition voltage peak. Ignition system is OK.
2. Beginning of dying-out process is considerably higher than ignition voltage peak. Fault in injection
system:
 lean mixture
2005 BMW 645Ci
 defective injection valve

 low compressions
12 13 ... SPARK-PLUG FAULTS
Evaluation of sparking period at idling speed.
1. Normal ignition voltage peak Spark plug is OK.

2. Low ignition voltage peak Small electrode gap.
3. High ignition voltage peak Large electrode gap.
Fig. 11: Evaluation Of Sparking Period During Idling Period

Evaluation of sparking period at idling speed:
Normal combustion period:

2005 BMW 645Ci
Fig. 12: Evaluation Of Sparking Period - Normal Combustion

Long combustion period:
 Small electrode gap.

2005 BMW 645Ci
Fig. 13: Evaluation Of Sparking Period - Long Combustion Period

Short sparking period:
 Large electrode gap.

2005 BMW 645Ci
Fig. 14: Evaluation Of Sparking Period - Short Sparking Period

12 13 ... IGNITION COIL FAULTS
Evaluation of ignition voltage peaks and attenuation process at idling speed:
1. Beginning of attenuation processes with normal peaks upwards and downwards.

2. Beginning of attenuation processes strongly shortened Ignition coil is defective.
3. Absence of initial downwards attenuation Ignition coil is defective.
NOTE: Higher ignition voltage peak is not always available.

2005 BMW 645Ci
Fig. 15: Evaluation Of Ignition Voltage Peaks & Attenuation Process

Evaluation of sparking voltage line at idling speed:
1. Normal combustion period.

2. Normal attenuations to sparking voltage line. Ignition coil is OK.
2005 BMW 645Ci
Fig. 16: Evaluation Of Sparking Voltage - Normal Combustion Period

1. Shorter sparking period.

2. Attenuation to sparking voltage line is only slight. Ignition coil is defective.
2005 BMW 645Ci
Fig. 17: Evaluation Of Sparking Voltage - Shorter Period

1. Much shorter sparking period.

2. Attenuations to sparking voltage line absent. Ignition coil is defective.
2005 BMW 645Ci
Fig. 18: Evaluation Of Sparking Voltage - Much Shorter Period

No sparking voltage line. Ignition coil is defective.

2005 BMW 645Ci
Fig. 19: Evaluation Of Sparking Voltage - No Sparking Voltage Line

Evaluation of combustion voltage line at raised engine speeds approx. 1500 Min (1):

2. Normal attenuations to sparking voltage line. Ignition coil is OK.
2005 BMW 645Ci
Fig. 20: Evaluation Of Combustion Voltage Line - Normal Combustion Period

1. Shorter sparking period.

2. Attenuation to sparking voltage line is only slight. Ignition coil is defective.
2005 BMW 645Ci
Fig. 21: Evaluation Of Combustion Voltage Line - Shorter Sparking Period


2. Attenuations to sparking voltage line absent. Ignition coil is defective.
2005 BMW 645Ci
Fig. 22: Evaluation Of Combustion Voltage Line - Normal Combustion Period

12 13 009 CHECKING ROD-TYPE IGNITION COILS (M54, M56, N40, N42, N45, N46, N52, N62, N73)
645CI .
 12 1 301
 12 7 050
 Read out fault memory in DME (Digital Motor Electronics)

2005 BMW 645Ci

 N62: Remove ignition coil cover
Open control unit box
Fig. 23: Releasing Ignition Coil Plug Fasteners

2005 BMW 645Ci

Installation:
2005 BMW 645Ci
Fig. 25: Attaching Special Tool Between Spark Plug And Rod-Type Ignition Coil

2005 BMW 645Ci
Fig. 26: Connecting KV Clip-On Probe Of DIS Tester To Special Tool

 Select < Measurement>.

 Select < Preset measurement>.
 Select < Secondary ignition signal>.
 Connect < TD cable to diagnostic head>.
 Select < static ignition distribution>.
 Select < Number of cylinders>.

2005 BMW 645Ci
Primary Measurement:
Fig. 27: Connecting Pin Box With Special Tool To Connector DME Module
 Select < Measurement>.

 Select < Preset measurement>.
 Select < Ignition signal term. 1>.
NOTE: Pin assignment acc. to connection scheme. Illustration N42.

2005 BMW 645Ci
IMPORTANT: Ignition signal is a multiple spark ignition.

2005 BMW 645Ci
2005 BMW 645Ci
Fig. 28: Identifying Multiple Spark Ignition

M54 / M56 / N40 / N42 / N45 / N46 / N62 / N73:
April 2001:
Fig. 29: Identifying Ignition Oscillogram

2005 BMW 645Ci
value.
It is not the height of the ignition voltage peaks but rather the uniformity of all the cylinders that is important.
12 13 511 REPLACING IGNITION COIL (N62)
Remove acoustic cover.
Fig. 30: Removing Ignition Coil Covers

2005 BMW 645Ci
Fig. 31: Releasing Ignition Coil Plug Fastener

Disconnect plug.
2005 BMW 645Ci

Installation:

2005 BMW 645Ci

NOTE: Interrogate fault memory of DME control unit. Check stored fault messages.
Rectify faults. Now clear the fault memory.
ELECTRONIC SWITCHING OR CONTROL UNIT

Follow instructions for disconnecting and connecting battery. Refer to 12 00 ... INSTRUCTIONS FOR
DISCONNECTING AND CONNECTING BATTERY.
Disconnect battery.
2005 BMW 645Ci
Refer to REMOVING AND INSTALLING ELECTRONIC CONTROL UNITS.
Program control unit. Refer to 12 14 705 PROGRAMMING CONTROL UNIT (DME / DDE).
Fig. 34: Releasing Screws And Removing Cover From Control Unit Box
Installation:

2005 BMW 645Ci
Fig. 35: Inserting Tabs In Openings And Closing Cover


2005 BMW 645Ci
Fig. 36: Removing Valvetronic Control Unit

Rectify faults. Then clear fault memory.
12 14 512 REPLACING PULSE GENERATOR ON LEFT EXHAUST CAMSHAFT (N62)
Remove left ignition coil cover.
Unlock and detach plug connection (1).

2005 BMW 645Ci
Fig. 37: Unlocking And Detaching Plug Connection

Release screw.

2005 BMW 645Ci
Fig. 38: Removing Pulse Generator

Installation:
Replace sealing ring and coat with anti-friction rubber coating.
Rectify faults. Then clear fault memory.
12 14 513 REPLACING PULSE GENERATOR ON RIGHT EXHAUST CAMSHAFT (N62)

2005 BMW 645Ci
Remove right ignition coil cover.

Release screw.

2005 BMW 645Ci

Installation:
12 14 521 REPLACING CRANKSHAFT PULSE GENERATOR (N62)
On transmission bell housing at bottom right.
Unlock plug and detach from crankshaft pulse generator.
Release screw.
Tightening torque, refer to 12 14 3AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

2005 BMW 645Ci
Withdraw pulse generator (1) from transmission bell housing.
Installation:
Replace screw.
Fig. 41: Unlocking Plug And Detaching From Crankshaft Pulse Generator
Installation:
Read out fault memory of control unit of Digital Motor Electronics (DME).

2005 BMW 645Ci
12 14 522 REPLACING PULSE GENERATOR ON LEFT INLET CAMSHAFT (N62)
Interrogate fault memory of DME control unit.
Remove left ignition coil cover.

2005 BMW 645Ci
Release screw.

Installation:
12 14 526 REPLACING PULSE GENERATOR ON RIGHT INLET CAMSHAFT (N62)
2005 BMW 645Ci
Remove right ignition coil cover.

Release screw.

2005 BMW 645Ci

Installation:
12 14 550 REPLACING CONTROL UNIT (DME N62)
 Observe instructions for disconnecting and connecting battery, refer to 12 00 ... INSTRUCTIONS FOR
 Remove right fresh air duct
Replacement:
 Program control unit. Refer to 12 14 705 PROGRAMMING CONTROL UNIT (DME / DDE).
 Code control unit. Refer to 12 14 700 CODING CONTROL MODULE (DME / DDE).
2005 BMW 645Ci
Unfasten screws.
Lift out cover (2).
Fig. 46: Lifting Out Cover

2005 BMW 645Ci
Fig. 47: Unlocking And Detaching All Plug Connections On DME Control Unit
12 14 610 REPLACING RIGHT KNOCK SENSORS (N62)
Remove intake air manifold, refer to 11 61 050 REMOVING AND INSTALLING INTAKE AIR
MANIFOLD (N62) .
CAUTION: Mixing up the knock sensor plug connections will result in engine
damage! Routing of wires and plug connections must conform to the
original routing. This eliminates the risk of confusion and mix-ups.
Unfasten screws.

2005 BMW 645Ci
Fig. 48: Removing Knock Sensors

12 14 611 REPLACING LEFT KNOCK SENSORS (N62)
Remove intake air manifold, refer to 11 61 050 REMOVING AND INSTALLING INTAKE AIR
MANIFOLD (N62) .
CAUTION: Mixing up the knock sensor plug connections will result in engine
damage! Routing of wires and plug connections must conform to the
original routing. This eliminates the risk of confusion and mix-ups.
2005 BMW 645Ci
Fig. 49: Removing Knock Sensors

Switch on ignition.

2005 BMW 645Ci

Switch on ignition.

12 52 005 REMOVING AND INSTALLING/REPLACING INTEGRATED SUPPLY MODULE (N62)
 Read and print out fault memory with MoDiC or BMW DIS
Disconnect battery, refer to 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND

CONNECTING BATTERY.
 Remove right fresh air duct, refer to 64 31 053 REMOVING AND INSTALLING OR REPLACING
FRESH AIR DUCT .
IMPORTANT: Follow instructions for removing and installing control units, refer to
REMOVING AND INSTALLING ELECTRONIC CONTROL UNITS.
Unfasten screws.
Lift out cover (2).

2005 BMW 645Ci

Unlock and detach plug connections on supply module.
Unlock supply module (1) and remove towards top.

2005 BMW 645Ci
Fig. 51: Unlocking Supply Module And Removing Towards Top

Read out fault memory of control unit of Digital Motor
Electronics (DME).
 Follow instructions for disconnecting and connecting battery, refer to 12 00 ... INSTRUCTIONS FOR
Disconnect battery
FRESH AIR DUCT .
2005 BMW 645Ci
IMPORTANT: Follow instructions for removing and installing control units
Unfasten screws.
Lift out cover (2).

Unlock and detach plug connections (2) on supply module (1).
Unlock and detach plug connections (3) on DME control unit (4).
Unlock and detach plug connections (6) on Valvetronic control unit (5).
2005 BMW 645Ci
Fig. 53: Unlocking And Detaching Plug Connections On Supply Module

Unlock and detach plug (1) on device holder (2).

2005 BMW 645Ci
Fig. 54: Unlocking And Detaching Plug On Device Holder

Unfasten screws.
Lift out device holder (2).
Unlock plug connection on fan for electronics box and detach.
Unfasten screws.
Remove fan (1) for electronics box.

2005 BMW 645Ci
Fig. 55: Removing Fan Electronics Box

Electronics (DME).
ALTERNATOR WITH DRIVE AND MOUNT


2005 BMW 645Ci
645CI .
 12 7 110
 hexagon socket
Fig. 56: Releasing Nut With Special Tool

2005 BMW 645Ci
Installation:
Tightening torque, refer to 12 31 2AZ / 12 31 3AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING

TORQUES .

(DME/DDE).
 Drive
 Alternator

2005 BMW 645Ci
Fig. 57: Oscillogram Graph For Fault-Free Alternator

2005 BMW 645Ci
Fig. 58: Oscillogram Graph For Faulty Alternator

Interturn fault.
2005 BMW 645Ci
Fig. 59: Identifying Interturn Fault

2005 BMW 645Ci
Fig. 60: Identifying Open Circuit In Negative Diode

2005 BMW 645Ci
Fig. 61: Identifying Short Circuit In Positive Diode

2005 BMW 645Ci
Fig. 62: Identifying Open Circuit In Positive Diode

2005 BMW 645Ci
Fig. 63: Identifying Open Circuit In Exciter Diode

Assemble engine.
Disconnect and cover battery negative lead.
WARNING: Danger of scalding! Only perform these tasks on an engine that has
2005 BMW 645Ci
Remove radiator.
Remove alternator drive belt.
Remove A/C compressor drive belt.
Release screws on antifriction bearing on left and right of stabilizer bar.
Hydraulic lines on oscillating motor remain connected. Do not release screws on stabilizer link. Remove
stabilizer bar with antifriction bearing from threaded pins and secure against falling down.
Release holder from hydraulic lines for power steering. Hydraulic lines on power steering pump remain
connected.
NOTE: For purposes of clarity, the following work steps are shown on the engine after
it has been removed.
Release screws and remove guide pulley (1).

2005 BMW 645Ci
Fig. 64: Releasing Screws And Removing Guide Pulley

Unscrew nut (2).
Remove battery positive lead from alternator (3).

2005 BMW 645Ci
Fig. 65: Removing Battery Positive Lead From Alternator

Recycling
A residual quantity of coolant emerges when the alternator is removed from the housing.
Catch and dispose of escaping coolant.
Release screws on alternator (3).

2005 BMW 645Ci
Fig. 66: Releasing Screws On Alternator

Pull out alternator towards front.
Installation:
Replace sealing ring (1) on alternator.

2005 BMW 645Ci
Fig. 67: Replacing Sealing Ring On Alternator

NOTE: If necessary, replace alternator belt pulley.
Top up coolant.

 Disconnect battery negative lead and cover
 Remove fan cowl with electric fan
2005 BMW 645Ci
IMPORTANT: Risk of damage! Cover radiator.
Remove cover (1) and release screw underneath.
Remove deflecting element (2).
Fig. 68: Removing Deflecting Element

Unfasten screws.
2005 BMW 645Ci
Fig. 69: Unfastening Alternator Screws

Pull alternator (1) forwards until connections are accessible.
Remove cover (2) and release nut underneath.

2005 BMW 645Ci
Fig. 70: Removing Cover And Releasing Nut Underneath

Disconnect battery positive lead from alternator.
REGULATOR
12 32 501 REPLACING CONTROLLER SWITCH FOR ALTERNATOR (N62)

 Remove alternator.

2005 BMW 645Ci
Fig. 71: Levering Out Cover Towards Top

Unscrew nut (2).

2005 BMW 645Ci
Fig. 72: Removing Controller Switch

2005 BMW 645Ci
Fig. 73: Checking Contact Surfaces Of Slip Rings


2005 BMW 645Ci
Fig. 74: Installing Controller Switch


2005 BMW 645Ci
Fig. 75: Tightening Down Contact Screws

Assemble engine.
STARTER WITH MOUNTING


 Disconnect battery negative lead and cover
 Remove reinforcement plate
 E60/E63/64/E65/E66 only: Remove right exhaust manifold
2005 BMW 645Ci

Unfasten nut.

2005 BMW 645Ci

Release screws and pull release out of transmission mounting and remove.
2005 BMW 645Ci

Installation:
Turn off ignition.
Release nut (1).

2005 BMW 645Ci
Fig. 79: Removing Cable Lug

Release screws (1).

2005 BMW 645Ci

Unhook pin (3).

2005 BMW 645Ci
Fig. 81: Removing Solenoid Switch And Spring

Installation:
STARTER LEAD
(BETWEEN ALTERNATOR, STARTER MOTOR AND BATTERY POSITIVE SUPPORT POINT)
(N62)
STARTER LEAD
Work step Note:
Switch off ignition
2005 BMW 645Ci
connecting battery, refer to 12 00 ...

INSTRUCTIONS FOR DISCONNECTING
AND CONNECTING BATTERY.
Detach battery positive lead from support point Tightening torque, refer to 12 42 1AZ in ENGINE
ELECTRICAL SYSTEM - TIGHTENING
TORQUES .
Remove intake air manifold, refer to 11 61 050
REMOVING AND INSTALLING INTAKE AIR
MANIFOLD (N62) .
Remove fan cowl
Secure engine in installation position with special
tool
Lower front axle
Remove heat shield from starter motor
Detach battery positive lead from starter motor Tightening torque, refer to 12 41 4AZ in ENGINE
ELECTRICAL SYSTEM - TIGHTENING
TORQUES .
ENGINE WIRING LOOM


 Remove acoustic cover
 Remove fan cowl
 Remove ignition coil cover on left and right
 Release cable duct from intake air manifold
 Remove transmission underbody protection
 Remove heat shield from starter motor
ENGINE WIRING LOOM

2005 BMW 645Ci
Unlock plug on monitor sensor on left and right and

disconnect
Unlock plug on control sensor on left and right and
disconnect
Unclip cable duct of oxygen sensors Fitted to underside of transmission.
Unlock plug on oil level sensor and disconnect
Unlock plug of crankshaft pulse generator and
disconnect
Unlock plug on tank venting valve and disconnect
Unlock plug on coolant temperature sensor and
disconnect
Unlock plug on coolant thermostat and disconnect
Unlock plug on oil pressure switch and disconnect
Unlock plug of knock sensors on left and right on
cable duct and disconnect
Release control lines on starter motor
Unlock plugs of fuel injectors on cable duct and
disconnect
Unlock plug on pulse generator of left and right
inlet camshafts and disconnect
Unlock plug on pulse generator of left and right
exhaust camshafts and disconnect
Unlock plugs on both solenoid valves on left side
and disconnect
Unlock plugs on both solenoid valves on right side
and disconnect
Unlock plugs on left and right Valvetronic
servomotors and disconnect
Unlock plugs on left and right eccentric shaft
sensors and disconnect
Unlock plug on throttle valve potentiometer and
disconnect
Unlock plug on differential pressure sensor and
disconnect
Unlock plug on air-mass flow sensor and disconnect
Unlock plug on DISA servomotor and disconnect
Release negative lead on spring strut dome
Unlock plug connections in electronics box and
disconnect:
 at DME control unit

 at Valvetronic control unit
2005 BMW 645Ci
Installation:
12 51 100 REPLACING WIRING HARNESS SECTION FOR IGNITION COIL (N62)

FRESH AIR DUCT .
Installation:
Unfasten screws.
Lift out cover (2).

2005 BMW 645Ci

PRELIMINARY TASKS
Work step Note:
Remove acoustic cover -
Unlock and detach plug connections on DME Only plug connections of wiring harness section for
control unit. ignition coils
Remove ignition coil cover This work step is described in the section
"Replacing ignition coil".
Detach grounding cable from cylinder head cover. -
Unclip cable duct. -
Unlock plug connections on ignition coils and Do not remove ignition coils
disconnect. This work step is described in the section
"Replacing ignition coil".
Remove engine vent hose -
2005 BMW 645Ci
NOTE: Read out fault memory of DME control unit. Check stored fault messages. Now
clear the fault memory.

INJECTORS ON LEFT OR RIGHT (N62)
Disconnect battery negative lead from battery and lay to one side

Illustrations show and descriptions refer to the left side.
Unfasten screws.

2005 BMW 645Ci

Remove positioning motor for eccentric shaft.
CONNECTOR, PLUGS
12 52 005 REMOVING AND INSTALLING/REPLACING INTEGRATED SUPPLY MODULE (N62)

2005 BMW 645Ci

Disconnect battery
Unfasten screws.
Lift out cover (2).

2005 BMW 645Ci
Unlock and detach plug connections on supply module.
Unlock supply module (1) and remove towards top.
Fig. 85: Unlocking Supply Module

Electronics (DME).
OIL PRESSURE - OIL TEMPERATURE GAUGE

12 61 280 REMOVING AND INSTALLING/REPLACING OIL PRESSURE SWITCH (N62)

2005 BMW 645Ci
WARNING: Scalding hazard! Only perform this task on an engine that has cooled
down.

ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES

2005 BMW 645Ci
Installation:
12 61 285 REPLACING ENGINE OIL LEVEL SWITCH (N62)
Switch off ignition
Remove reinforcement plate
Drain off engine oil

2005 BMW 645Ci
Unscrew nuts.
Installation:
Top up engine oil.
CONTROL UNIT BOX

Disconnect battery
Unfasten screws.
Lift out cover (2).

2005 BMW 645Ci

Unlock and detach plug connections (2) on supply module (1).
Unlock and detach plug connections (3) on DME control unit (4).
Unlock and detach plug connections (6) on Valvetronic control unit (5).
2005 BMW 645Ci
Fig. 89: Unlocking And Detach Plug Connections On Valvetronic Control Unit
Place wiring harness to one side.
Unlock and detach plug (1) on device holder (2).
Unfasten screws.
Lift out device holder (2).

2005 BMW 645Ci
Fig. 90: Lifting Out Device Holder

Unlock plug connection on fan for electronics box and detach.
Unfasten screws.
Remove fan (1) for electronics box.

2005 BMW 645Ci
Fig. 91: Removing Fan Electronics Box

Electronics (DME).

2005 BMW 645Ci
2004-2005 ENGINE Engine Mechanical - Repair Instructions - 645Ci (4.4L) E63/N62
2004-2005 ENGINE
Engine Mechanical - Repair Instructions - 645Ci (4.4L) E63/N62
ENGINE, GENERAL
SECURING ENGINE IN INSTALLATION POSITION WITH SPECIAL TOOL (N62)
NOTE: For Special Tool identification, refer to ENGINE - SPECIAL TOOLS - 645CI .
Special Tools Required:
 00 0 200
 00 0 201
 00 0 202
 00 0 203
 00 0 204
 00 0 208
 11 0 020
Necessary Preliminary Tasks:
 Remove acoustic cover.

 Move engine hood into service position. Refer to 51 00 ... SERVICE POSITION OF ENGINE
HOOD .
 Remove air filter housing.
 Remove microfilter. Refer to 64 31 061 REMOVING AND INSTALLING/REPLACING LEFT OR
RIGHT MICROFILTER HOUSING LOWER SECTION .
 Remove tension strut on spring strut dome. Refer to 51 71 373 REMOVING AND
INSTALLING/REPLACING TENSION STRUT ON SPRING STRUT DOME .
 Release servo fluid reservoir and place to one side.
Assemble special tool 00 0 200 with special tools 00 0 201 / 00 0 202 / 00 0 203 / 00 0 204 / 00 0 208 and fit.
Secure special tool 11 0 020 to front and rear lifting eyes (1) and to special tool 00 0 200.
2005 BMW 645Ci
Fig. 1: Assembling Cross Member With Special Tools

NOTE: Supports (1) of special tool 00 0 208 must rest on screw connection (2) of both
side panels (risk of damage).
2005 BMW 645Ci
Fig. 2: Supporting Cross Member On Screw Connection

Tighten the screws (1 and 2).

2005 BMW 645Ci
Fig. 3: Tightening Screws On Cross Member

Release engine mounts at top left and right.
Raise engine with special tool 00 0 200 approx. 10 mm.

2005 BMW 645Ci
Fig. 4: Raising Engine With Cross Member

00 00 610 ENGINE OIL SERVICE (N62/N62TU)
Recycling:
Catch and dispose of used oil.
NOTE: For purposes of clarity, this work step is shown without the reinforcement plate.
Remove drain plug (1) in oil sump.
Remove drain plug (2) on oil filter cover (3).
Release oil filter cover (3).

2005 BMW 645Ci
Fig. 5: Removing Drain Plug In Filter Cover

Installation:
Replace and lubricate sealing rings (1 and 2).

Replace oil filter element (3) and slide into oil filter cover.
Oil filter element (3) must snap audibly into place.
2005 BMW 645Ci
Fig. 6: Replacing Oil Filter Element

Installation:
Insert and tighten down drain plug (1).
Tightening torque, refer to 11 13 1AZ in ENGINE - TIGHTENING TORQUES .
Insert and tighten down oil filter cover (3).
Insert drain plug (2) on oil filter cover (3) and tighten down.
2005 BMW 645Ci
Fig. 7: Installing Drain Plug

Pour in engine oil.
Start engine and run at idle 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.
SECURING ENGINE IN INSTALLATION POSITION WITH SPECIAL TOOL (N62)

2005 BMW 645Ci
 00 0 201
 00 0 202
 00 0 203
 00 0 204
 00 0 208
 11 0 020
 51 2 180
Using special tool 51 2 180, secure engine hood in service position, refer to 51 00 ... SERVICE POSITION
OF ENGINE HOOD .
Assemble special tool 00 0 200 with special tools 00 0 201 / 00 0 202 / 00 0 203 / 00 0 204 / 00 0 208 and fit.
Secure special tool 11 0 020 to front and rear lifting eyes and to special tool 00 0 200.
2005 BMW 645Ci
Fig. 8: Fitting Special Tools To Lifting Eyes

NOTE: The supports (1) of special tool 00 0 208 must rest on the bolt connection of
both side walls.
Tighten the screws (1 and 2).
Fig. 9: Tightening Screws (1 And 2)

Release engine mounts at top left and right.
Raise engine with special tool 00 0 200 approx. 10 mm.

2005 BMW 645Ci
Fig. 10: Raising Engine With Special Tool 00 0 200

11 00 045 CHECKING ABSOLUTE COMPRESSION OF ALL CYLINDERS

2005 BMW 645Ci
Fig. 11: Identifying Diagnosis And Information System (DIS) Machine


2005 BMW 645Ci

 Remove right ignition coil cover.
 Connect DIS Tester.
Test:
 Call up Diagnosis.
 Select car > right arrow key.
 Function selection.
 Complete vehicle.
 Drive.
 Engine management.
 Valve gear.
 Valvetronic variable valve gear.
 Mechanical components / function.
 Test schedule > right arrow key.

 Compression test > right arrow key.
 Follow DIS Tester instructions.
NOTE: Clear fault memory.
11 00 050 REMOVING AND INSTALLING ENGINE (N62 / N62TU)
 11 0 000
Follow instructions for disconnecting and connecting battery, refer to 12 00 ... INSTRUCTIONS FOR
Disconnect negative battery lead.
Both exhaust manifolds remain on engine during removal.
Observe specified tightening torque and safety precautions in all work steps.
REMOVING AND INSTALLING ENGINE (N62 / N62TU)

Work step Note:
Lift engine hood into assembly position After removing transmission, secure engine
2005 BMW 645Ci
tool, refer to SECURING ENGINE IN

INSTALLATION POSITION WITH SPECIAL
TOOL
Remove gearbox
Remove intake filter housing, refer to 13 62 010
REMOVING AND INSTALLING/REPLACING
DIFFERENTIAL PRESSURE SENSOR (N62) .
Remove radiator
Remove radiator lines.
Remove expansion tank.
Remove intake air manifold, refer to 11 61 050
REMOVING AND INSTALLING INTAKE AIR
MANIFOLD (N62).
Remove heater radiator line.
Unlock engine wiring harness section on control unit Wiring harness remains on engine.
and detach.
Unlock spark plug wiring harness section on control Wiring harness remains on engine.
unit and detach.
Release negative lead on spring strut dome.
Release battery positive lead at positive terminal.
Detach vacuum line and vacuum hose from vacuum
pump, refer to 11 66 000 REMOVING AND
INSTALLING/REPLACING VACUUM PUMP
(N62).
Unlock line on tank venting valve and disconnect,
refer to 11 66 000 REMOVING AND
INSTALLING/REPLACING VACUUM PUMP
(N62).
Remove both oxygen monitor sensors, refer to 11 78
540 REPLACING LEFT OXYGEN MONITOR
SENSOR (N62) and 11 78 543 REPLACING
RIGHT OXYGEN MONITOR SENSOR (N62).
Remove both oxygen control sensors, refer to 11 78
530 REPLACING LEFT OXYGEN CONTROL
SENSOR (N62) and 11 78 533 REPLACING
RIGHT OXYGEN CONTROL SENSOR (N62).
Release negative lead on engine support arm.
Remove vibration damper and tensioning pulley from
A/C compressor drive belt, refer to 11 23 010
VIBRATION DAMPER (N62).
Release power steering pump on bracket, hydraulic Do not remove power steering pump, secure
lines remain connected. against falling down.
Release A/C compressor on bracket, lines remain Do not remove A/C compressor, secure against
2005 BMW 645Ci
connected, do not evacuate A/C system. falling down.

Release ABS control unit on bracket, lines remain Do not remove ABS control unit, secure against
connected. falling down.
Remove lower universal joint of steering spindle
Vehicles with Dynamic Drive only:
Unlock and detach hydraulic line (1).
Fig. 12: Unlocking And Detaching Hydraulic Line (1)

Suspend engine off-center from special tool 11 0 000.

2005 BMW 645Ci
Fig. 13: Suspending Engine Off-Center From Special Tool 11 0 000

Release engine mounts on left and right from above.
Protect assembly compartment and hydraulic lines against damage.
Installation:
11 00 050 REMOVING AND INSTALLING ENGINE (N62)
11 0 020
2005 BMW 645Ci
 Disconnect battery negative lead. Refer to 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND
 Lift engine hood into assembly position. Refer to 51 00 ... SERVICE POSITION OF ENGINE
HOOD .
 Remove radiator design cover.
 Remove air cleaner housing. Refer to 13 71 000 REMOVING AND INSTALLING/REPLACING
 Remove tension strut. Refer to 51 71 373 REMOVING AND INSTALLING/REPLACING TENSION
STRUT ON SPRING STRUT DOME .
 Remove fresh air duct. Refer to 64 31 053 REMOVING AND INSTALLING OR REPLACING
FRESH AIR DUCT .
 Detach steering spindle from steering gear.
 Release engine wiring harness from electronics box.
 Drain coolant.
 Remove coolant expansion tank.
 Remove radiator.
 Remove A/C compressor drive belt.
 Remove alternator drive belt. Refer to 11 28 010 REPLACING ALTERNATOR DRIVE BELT
(N62/N62TU).
 Disconnect fuel line.
 Remove front/middle underbody protection.
 Remove all lambda oxygen sensors.
 Remove transmission.
NOTE: Do not detach oil lines from automatic transmission to heat exchanger at oil
sum.
IMPORTANT: Risk of damage to oil lines on steering gear.
Secure starter motor (1) with transmission screw (2) against falling out.
2005 BMW 645Ci
Fig. 14: Securing Starter Motor With Transmission Screw

Detach oil line (1) at screw connection (2).
Set oil line (1) down in engine compartment at front and secure against falling out.
2005 BMW 645Ci
Fig. 15: Detaching Oil Line At Screw Connection

Release power steering pump (1).
Secure against falling out by applying a cable tie (2) to stabilizer bar (3).
2005 BMW 645Ci
Fig. 16: Applying Cable Tie To Stabilizer Bar

Release A/C compressor (1).
NOTE: Secure all connecting leads with cable ties (3) against falling down.
2005 BMW 645Ci
Fig. 17: Securing Connecting Leads With Cable Ties

Release and disconnect coolant hoses (1).
Unlock heater hose (2) and detach in direction of arrow.

2005 BMW 645Ci
Fig. 18: Removing Heater Hose

Installation:
Plug-in connections of coolant hoses are correctly fitted when they snap into place with a clearly audible click.
Unlock coolant hose (1) on auxiliary water pump and detach in direction of arrow.
2005 BMW 645Ci
Fig. 19: Unlocking Coolant Hose On Auxiliary Water Pump

Remove auxiliary water pump.
Unlock hose (1) and detach from secondary air pump.
Secure automatic transmission heat exchanger (2) with cable tie (3) against falling down.
NOTE: Engine removed for purposes of clarity.

2005 BMW 645Ci
Fig. 20: Securing A/T Heat Exchanger With Cable Tie

Secure engine wiring harness (2) with cable tie (3) on suction bridge against falling out.
Mount special tool 11 0 020 on engine.

2005 BMW 645Ci
Fig. 21: Mounting Special Tool 11 0 020 On Engine

Release nut (1) on left and right engine brackets.
Unfasten ground strap (2).

2005 BMW 645Ci
Fig. 22: Releasing Nut (1) On Left And Right Engine Brackets And Unfastening Ground Strap (2)
Remove engine.
Assemble engine.
Vent cooling system and check for leaks. Refer to 17 00 039 VENTING COOLING SYSTEM AND
CHECKING FOR LEAKS .
Installation:
Risk of damage to automatic fluid lines and servo fluid lines.
CYLINDER HEAD WITH COVER

11 12 005 REMOVING AND INSTALLING/SEALING LEFT CYLINDER HEAD COVER
2005 BMW 645Ci
(Cylinder Bank 5 To 8)
Remove design cover.
Remove center engine compartment partition wall.
Remove ignition coil cover.
Unclip cable holder (1) with cables.
Pull tank venting valve (2) off holder.
Fig. 23: Locating Tank Venting Valve And Cable Holder


2005 BMW 645Ci
Fig. 24: Unlocking And Removing Plug

Release screws and remove sealing element (2).
Remove sensors (3 and 4).
Installation:
Replace sealing element (2).
Replace sealing rings on sensors (3 and 4).

2005 BMW 645Ci
Fig. 25: Identifying Sensors And Sealing Rings

Removing ignition coils.
Release both grounding cables.
Unlock and detach vent hose.
Unclip cable duct (1) and remove cable from holder.

2005 BMW 645Ci
Fig. 26: Locating Cable Duct

Remove servomotor for left eccentric shaft. Refer to 11 37 022 REMOVING AND
INSTALLING/REPLACING SERVOMOTOR FOR LEFT ECCENTRIC SHAFT (N62).
Unfasten screws.
Remove spacer (3) upwards.

2005 BMW 645Ci
Fig. 27: View Of Spacer And Retaining Screws

Installation:
Remove injection pipe. Refer to 13 53 240 REPLACING COMPLETE INJECTION PIPE (N62) .
Release screw connections (1, 2, 3 and 4).
If necessary, pull out oil dipstick.
Remove cylinder-head cover.

2005 BMW 645Ci
Fig. 28: Releasing Screw Connections

Installation:
Note installation direction of sealing ring (1).
Groove in sealing ring (1) points outwards.

2005 BMW 645Ci
Fig. 29: Aligning Groove In Sealing Ring

Replace sealing ring (1) and press into cylinder head cover until flush.
2005 BMW 645Ci
Fig. 30: Installing Sealing Ring Into Cylinder Head Cover

Installation:
Replace seal (1).
Align gasket (1) loosely in cover groove. Starting at corner radii, secure gasket (1) in cover groove and press
into groove so that it is free of tension.
2005 BMW 645Ci
Fig. 31: Aligning Gasket In Groove

Installation:
Replace spark plug domes.
Coat rubber seals on spark plug dome (1) with anti-friction rubber coating.
2005 BMW 645Ci
Fig. 32: Identifying Spark Plug Dome

Installation:
Install spark plug domes in cylinder head.
When Fitting Cylinder Head Cover:
Align spark plug domes to cylinder head cover.

2005 BMW 645Ci
Fig. 33: Aligning Spark Plug Domes To Cylinder Head Cover

Installation:
Clean seal residue from sealing surfaces.
Coat contact surfaces of joint with Drei Bond 1209.

2005 BMW 645Ci
Fig. 34: View Of Contact Surfaces Of Joint

Installation:
Apply a thin, uniform bead of Drei Bond 1209 sealing agent to transition area of half-moon sections.
2005 BMW 645Ci
Fig. 35: Locating Transition Area Of Half-Moon Sections

Replace sealing elements (1).

2005 BMW 645Ci
Fig. 36: Replacing Sealing Elements

Installation:
Make sure gasket is correctly seated at sides and on rear side of cylinder head.
2005 BMW 645Ci
Fig. 37: Identifying Gasket Seating Position

Installation:
Screw connections (1, 2, 3 and 4) of cylinder head cover are different.
Replace screw connections (3).
Insert screw connections (1, 2 and 3) without pretension and align cover.
Tighten down screw connections (1, 2 and 3) in diagonal sequence from inside to outside.
2005 BMW 645Ci
Fig. 38: View Of Tightening Sequence Of Screw Connections

11 12 006 REMOVING AND INSTALLING / SEALING RIGHT CYLINDER HEAD COVER (N62 /
N62TU)
Remove center of assembly partition wall.
Remove electronics box cover.
Remove electronics box seal.
These work steps are described in Replacing control unit.
Remove intake filter housing (without raw air housing).

2005 BMW 645Ci
Remove intake hose with air-mass flow sensor
Installation:

Release screws and remove sealing element (2). Remove sensors (3 and 4).
Installation:

2005 BMW 645Ci
Fig. 40: Replacing Sealing Element


2005 BMW 645Ci
Fig. 41: Unclipping Cable Duct

Remove servomotor for right eccentric shaft. Refer to 11 37 024 REMOVING AND
INSTALLING/REPLACING SERVOMOTOR FOR RIGHT ECCENTRIC SHAFT (N62).
Unfasten screws.
Replace seal.
2005 BMW 645Ci
Fig. 42: Identifying Spacer And Retaining Screws

Remove injection pipe. Refer to 13 53 240 REPLACING COMPLETE INJECTION PIPE (N62) .
Remove cylinder-head cover.

2005 BMW 645Ci
Fig. 43: Releasing Screw Connections

Installation:

2005 BMW 645Ci
Fig. 44: Aligning Groove In Sealing Ring

2005 BMW 645Ci

Installation:
Replace seal (1).
2005 BMW 645Ci
Fig. 46: Aligning Gasket In Cover Groove

Installation:
Make sure sliding rails are correctly seated when mounting on cylinder head.
Installation:
Coat rubber seals on spark plug dome (1) with anti-friction rubber coating.
2005 BMW 645Ci
Fig. 47: View Of Spark Plug Dome

Installation:
When fitting cylinder head cover:

2005 BMW 645Ci
Fig. 48: Aligning Spark Plug Domes To Cylinder Head Cover

Installation:

2005 BMW 645Ci
Fig. 49: Identifying Contact Surfaces Of Joint

Installation:
2005 BMW 645Ci
Fig. 50: View Of Transition Area Of Half-Moon Sections


2005 BMW 645Ci
Fig. 51: Replacing Sealing Elements

Installation:
2005 BMW 645Ci
Fig. 52: Identifying Gasket Seating Position

Installation:
Screw connections (1, 2, 3 and 4) of cylinder head cover are different .
Move cylinder head cover with gasket into assembly position.
Secure cylinder head cover, starting with screw connection (4) from front .
2005 BMW 645Ci
Fig. 53: Identifying Tightening Sequence Of Screw Connections

11 12 105 REMOVING AND INSTALLING LEFT CYLINDER HEAD (N62 FROM 9/03 AND N62TU)
NOTE: To remove the exhaust manifolds, the engine must be secured in the
installation position with the special tool and then the front axle bracket
lowered.
Remove left exhaust manifold.
After Removing Exhaust Manifolds:
Reinstall front axle bracket provisionally and remove special tool for securing engine in installation position.
Open drain plug for coolant on left side of engine block.
Drain off coolant and dispose of correctly.
Installation:

2005 BMW 645Ci
Tightening torque of drain plug, (25 N.m.).
Top up coolant. Vent cooling system and check for leaks. Refer to 17 00 039 VENTING COOLING
SYSTEM AND CHECKING FOR LEAKS .
Remove ignition coils on cylinder bank 5 to 8.
Remove left cylinder head cover. Refer to 11 12 005 REMOVING AND INSTALLING/SEALING LEFT
CYLINDER HEAD COVER (N62/N62TU).
Remove intake air manifold. Refer to 11 61 050 REMOVING AND INSTALLING INTAKE AIR
MANIFOLD (N62).
Remove left timing case cover. Refer to 11 14 080 REMOVING AND INSTALLING TOP LEFT TIMING
CASE COVER (N62).
Disconnect plug connections and lay engine wiring harness to one side.
Remove spark plugs on cylinder bank 5 to 8.
Remove vent hose on cylinder head.
NOTE: Illustration with engine removed.
Detach hose (1) on check valve (2).

2005 BMW 645Ci
Fig. 54: Locating Tube With Check Valve

NOTE: Do not remove guide tube (5) for oil dipstick.
Installation:
Replace sealing ring on tube (4) and coat with antiseize agent.
Removal:
Removal of cylinder head is described separately from installation.
Remove inlet and exhaust adjustment unit on left side. Refer to 11 36 047 REMOVING AND
INSTALLING/REPLACING INLET AND EXHAUST ADJUSTMENT UNITS ON LEFT SIDE (N62).

2005 BMW 645Ci
Remove eccentric shaft sensor (2).
Fig. 55: View Of Eccentric Shaft Sensor

Detach guide rail from cylinder head.

2005 BMW 645Ci
Fig. 56: Identifying Guide Rail From Cylinder Head

Release screws between cylinder head and timing case cover.

2005 BMW 645Ci
Fig. 57: Locating Screws Between Cylinder Head And Timing Case Cover
NOTE: At narrow points, use a socket with 3/8" drive and a short extension.
Release cylinder-head bolts in sequence 10-1.
Lift off cylinder head.
Lift off cylinder head gasket.

2005 BMW 645Ci
Fig. 58: Identifying Cylinder Head Bolt Releasing Sequence

Installation:
Installation of cylinder head is described separately from removal.
Clean sealing faces of cylinder head and crankcase; if necessary, remove gasket debris with wooden scraper.
Make sure no gasket debris drops into the oil and coolant ducts.
Threaded bores in engine block must be free of dirt and oil (risk of cracking).
Coat joint between engine block and timing case cover with Drei Bond 1209.
2005 BMW 645Ci
Fig. 59: Locating Joint Between Engine Block And Timing Case Cover
Check dowel sleeves (1) for damage and correct installation position.
Fit new cylinder-head seal.

2005 BMW 645Ci
Fig. 60: View Of Dowel Sleeves

Put the cylinder head on.
NOTE: Do not wash off bolt coating. Insert new cylinder head bolts and initially tighten
so that they are free of play.
At narrow points, use a socket with 3/8" drive and a short extension.
Tighten down the cylinder-head bolts in order 1-10.

2005 BMW 645Ci
Fig. 61: Identifying Cylinder-Head Bolts Tightening Sequence

Insert and tighten down screws between cylinder head and timing case cover.
2005 BMW 645Ci
Fig. 62: Locating Screws Between Cylinder Head And Timing Case Cover
Replacement:
Insert screw plug (1).

2005 BMW 645Ci
Fig. 63: Inserting Screw Plug

Installation:
Failure to install the screw (1) will result in a malfunction in the VANOS control.
Insert and tighten down guide rail screw.

2005 BMW 645Ci
Fig. 64: Tightening Down Guide Rail Screw

Install eccentric shaft sensor (2).

2005 BMW 645Ci
Fig. 65: Installing Eccentric Shaft Sensor

Install inlet and exhaust adjustment unit on left side. Refer to 11 36 047 REMOVING AND
Assemble engine.
11 12 106 REMOVING AND INSTALLING RIGHT CYLINDER HEAD (N62 FROM 9/03 AND N62TU)
lowered.
Remove right exhaust manifold. 18 40 020 REMOVING AND INSTALLING/REPLACING RIGHT

EXHAUST MANIFOLD (N62) .
After Removing Exhaust Manifolds:
2005 BMW 645Ci
Open drain plug for coolant on right side of engine block.
Installation:

Tightening torque of drain plug, (25 N.m.).
Top up coolant. Vent cooling system and check for leaks. Refer to 17 00 039 VENTING COOLING
SYSTEM AND CHECKING FOR LEAKS .
Remove servomotor for right eccentric shaft.
Remove intake air manifold. Refer to 11 61 050 REMOVING AND INSTALLING INTAKE AIR
MANIFOLD (N62).
Remove right cylinder head cover. Refer to 11 12 006 REMOVING AND INSTALLING / SEALING
RIGHT CYLINDER HEAD COVER (N62 / N62TU).
Remove right timing case cover. Refer to 11 14 085 REMOVING AND INSTALLING TOP RIGHT
TIMING CASE COVER (N62 / N62TU).
Release screws (2).

2005 BMW 645Ci
Fig. 66: Detaching Hose On Check Valve

IMPORTANT: A spacer bushing is secured with screw (3) behind tube (5).
Release screw (3) and remove check valve (4), tube (5) and spacer bushing.
Unclip cables (6 and 7).
Installation:
Removal:
Remove inlet and exhaust adjustment unit on right side. Refer to 11 36 048 REMOVING AND
INSTALLING/REPLACING INLET AND EXHAUST ADJUSTMENT UNITS ON RIGHT SIDE (N62).
Slacken off chain tensioning piston (1) by approx. one turn.

2005 BMW 645Ci
Fig. 67: Locating Chain Tensioning Piston


2005 BMW 645Ci
Fig. 68: Removing Eccentric Shaft Sensor


2005 BMW 645Ci
Fig. 69: Detaching Guide Rail From Cylinder Head


2005 BMW 645Ci
Fig. 70: Releasing Screws Between Cylinder Head And Timing Case Cover
Release cylinder-head bolts in sequence 10-1.

2005 BMW 645Ci
Fig. 71: Releasing Cylinder-Head Bolts In Sequence

Remove chain tensioning piston (1).

2005 BMW 645Ci
Fig. 72: Removing Chain Tensioning Piston

Place chain tensioning piston (1) on a level surface and compress slowly and carefully.
Repeat this procedure twice.

2005 BMW 645Ci
Fig. 73: Compressing Chain Tensioning Piston

Installation:
Install chain tensioning piston (1) and initially tighten screw connection without play.
2005 BMW 645Ci
Fig. 74: Installing Chain Tensioning Piston

2005 BMW 645Ci
Fig. 75: Locating Joint Between Engine Block And Timing Case Cover
2005 BMW 645Ci

Tighten down the cylinder-head bolts in order 1 ... 10.

2005 BMW 645Ci
Fig. 77: Identifying Cylinder-Head Bolts Tightening Sequence

2005 BMW 645Ci
Fig. 78: Inserting Screws Between Cylinder Head And Timing Case Cover
Replacement:

2005 BMW 645Ci

Installation:

2005 BMW 645Ci


2005 BMW 645Ci
Fig. 81: Inserting And Tightening Guide Rail Screw

Tighten down chain tensioning piston (1).

2005 BMW 645Ci
Fig. 82: Installing Eccentric Shaft Sensor

Install inlet and exhaust adjustment unit on right side. Refer to 11 36 048 REMOVING AND
Assemble engine.
11 12 503 DISASSEMBLING AND ASSEMBLING CYLINDER HEAD (N62/N62TU)
 11 9 000
 11 9 001
2005 BMW 645Ci
 11 9 005
 11 9 006
 11 9 007
 11 9 008
 11 9 009
 11 9 011
 11 9 015
Have special tool 11 9 000 ready for removing valve springs.
Secure cylinder head (1) on special tool 11 9 001.
NOTE: Secure cylinder head from above with screws contained in scope of delivery on
special tool 11 9 001.
Turn special tool 11 9 001 through 180°.

2005 BMW 645Ci
Fig. 83: Securing Cylinder Head On Special Tool 11 9 001

Align special tool 11 9 008 in conjunction with special tool 11 9 007 on special tool 11 9 006 to relevant
combustion chamber.
Place special tool 11 9 006 on cylinder head.

2005 BMW 645Ci
Fig. 84: Placing Special Tool 11 9 006 On Cylinder Head

Slide both special tools 11 9 005 in direction of arrow as far as they will go.
2005 BMW 645Ci
Fig. 85: Sliding Both Special Tools 11 9 005

Turn lever of special tools 11 9 005.

2005 BMW 645Ci
Fig. 86: Turning Lever Of Special Tool 11 9 001

Assemble clamping device with:
 Special tool 11 9 002

2005 BMW 645Ci
Fig. 87: Assembling Clamping Device With Special Tools

Remove all valve springs. Refer to 11 34 715 REPLACING ALL VALVE SPRINGS (N62).
Remove all valve stem seals. Refer to 11 34 560 REPLACING ALL VALVE STEM SEALS (N62).
Remove all valves. Refer to 11 34 552 REMOVING AND INSTALLING/REPLACING ALL VALVES
(N62).
11 12 527 REMACHINING A VALVE SEAT - CYLINDER HEAD DISASSEMBLED (N62)
 00 3 520
2005 BMW 645Ci
 00 3 580
Machine valve seat surface with special tool 00 3 520 or with 00 3 580 in accordance with tool manufacturer's
instructions.
Fig. 88: Identifying Valve Seat Turning Tool

NOTE: After machining valve-seat surface: Remachine outside and inside diameters
with correction milling tool to the specified diameters until you obtain valve
seat width (5).
1. Valve-seat angle.
2. Correction angle, external diameter.
3. Correction angle, internal diameter.
4. Valve seat, external diameter.
2005 BMW 645Ci
5. Valve seat width.
Items (1) to (5), refer to ENGINE - TECHNICAL DATA - 645CI .
Fig. 89: Identifying Valve-Seat Angle, External/Internal Diameter And Valve Seat Width
11 12 595 CHECKING A VALVE GUIDE FOR WEAR (N62)
(Valve removed)
2005 BMW 645Ci
To measure tilt clearance, install a new valve so that end of valve stem is flush with valve guide.
Attach dial gauge and measure tilt clearance.
NOTE: Max. permissible tilt clearance, refer to ENGINE - TECHNICAL DATA - 645CI .
Fig. 90: Attaching Dial Gauge And Measuring Tilt Clearance

11 12 719 MILLING CYLINDER HEAD SEALING SURFACE (N62/N62TU)
(Cylinder head dismantled)
Check evenness of cylinder head sealing surface with a standard straight-edge (1).
NOTE: Maximum plane deviation: longitudinal 0.10 mm.

2005 BMW 645Ci
Fig. 91: Checking Cylinder Head Longitudinal Plane Using Straight-Edge

NOTE: Maximum plane deviation: transversal 0.05 mm.
Machining limit, refer to ENGINE - TECHNICAL DATA - 645CI .

2005 BMW 645Ci
Fig. 92: Checking Cylinder Head Transversal Plane Using Straight-Edge

NOTE: A cylinder head seal 0.3 mm thicker than usual can be obtained for machined
(milled) cylinder heads.
2005 BMW 645Ci
Fig. 93: Identifying 0.3 mm Thicker Cylinder Head Seal

11 12 729 CHECKING CYLINDER HEAD FOR LEAKS (N62/N62TU)
 11 9 430
 11 9 431
 11 9 432
 11 9 433
(Cylinder head dismantled)

2005 BMW 645Ci
NOTE: Special tool kit 11 9 430 can be used for cylinder bank 1 to 4 and cylinder bank 5
to 8.
Place special tool 11 9 431 on cylinder head sealing surface, insert screws (special tool 11 9 433) and tighten
down.
Seal coolant opening with special tool 11 9 432 and tighten down.
Fig. 94: Cylinder Head Pressure Tester

Connect compressed air hose (1) to pressure gauge.

2005 BMW 645Ci
Fig. 95: Connecting Compressed Air Hose To Pressure Gauge

Immerse cylinder head in a water bath. Inspection pressure 4.5 bar.
Check cylinder head for escaping air (cracks).
NOTE: If necessary, soften the bath water with a cleaning agent.
OIL SUMP
11 13 010 REMOVING AND INSTALLING/REPLACING OIL SUMP TOP SECTION (N62)

2005 BMW 645Ci
 17 0 030
OIL SUMP TOP SECTION (N62) WORK STEPS

Work Step Note:
Remove center of front wall.
Remove fan clutch. (E65 only).
Remove fan cowl. (E65 only).
Remove electric fan. (E60 only).
Remove alternator drive belt. Refer to 11 28 010
REPLACING ALTERNATOR DRIVE BELT
(N62).
Secure engine in installation position with special
tool. Refer to SECURING ENGINE IN
INSTALLATION POSITION (N62/N62TU) .
Release nuts on left and right engine mounts at top.
Drain engine oil. Refer to 00 00 ... ENGINE OIL
SERVICE (N62/N62TU)
Remove lower oil sump section. Refer to 11 13 020
OIL SUMP BOTTOM SECTION (N62).
Lower front axle support. To remove the oil sump, you must lower the front
axle support. There is no need to perform a front
axle alignment check.
Release power steering pump on bracket, hydraulic
lines remain connected. Secure power steering pump
against falling down.
Unlock and disconnect hydraulic lines from heat Installation location: on radiator at bottom left.
exchanger with special tool 17 0 030. Transmission fluid emerges when hydraulic lines
Release hydraulic lines on automatic transmission. are released. Catch and dispose of escaping
Release holder for hydraulic lines. Remove hydraulic transmission fluid.
lines. Installation:
Check fluid level in automatic transmission; top
up if necessary.
Unclip cable duct of oxygen sensors from automatic
transmission.
Unfasten screws.
2005 BMW 645Ci
Fig. 96: Unfastening Screws

Release screws and remove oil sump top section.

2005 BMW 645Ci
Fig. 97: Releasing Screws From Oil Sump Top Section

Installation:
Replace sealing ring on dipstick guide tube.

Free sealing faces of seal debris and clean.
1. Replace seal.
2. Install oil sump.
3. Insert all screws on transmission end,
4. Tighten down all screws on oil sump.
11 13 020 REMOVING AND INSTALLING/REPLACING OIL SUMP BOTTOM SECTION (N62)

2005 BMW 645Ci
Remove oil drain plug and drain engine oil. Refer to 00 00 610 ENGINE OIL SERVICE (N62/N62TU).
Unlock and detach plug connection (1) from oil level switch.
Release screws and remove oil sump bottom section (2).
Fig. 98: Removing Oil Sump Bottom Section

Installation:
Clean sealing surfaces.

Replace seal.
Replace screws.
When replacing oil sump bottom section:
Convert oil level sensor.

2005 BMW 645Ci
12 13 511 REPLACING IGNITION COIL (N62)

 Release A/C line (intake line) in area of cyl. 4 and remove from mounting.
Fig. 99: Pulling Ignition Coil Covers Out Of Rubber Grommets


2005 BMW 645Ci


2005 BMW 645Ci
Fig. 101: Pulling Out Ignition Coil

Installation:

2005 BMW 645Ci

Assemble engine.
NOTE: Read out DME fault memory. Check function of DME.
HOUSING COVER
11 14 080 REMOVING AND INSTALLING TOP LEFT TIMING CASE COVER (N62)
(Cylinder bank 5 to 8)
Remove both solenoid valves on left side. Refer to 11 36 715 REMOVING AND
2005 BMW 645Ci
INSTALLING/REPLACING BOTH SOLENOID VALVES ON LEFT SIDE (N62).
Release alternator (air-cooled).
Release screw, remove holder (1).
Remove line (2) from holder.
Fig. 103: Removing Line From Holder

Release screws (1 and 2).
Remove timing case cover (3).

2005 BMW 645Ci
Fig. 104: Locating Timing Case Cover Screws

Installation:
Free sealing face (2) on timing case cover (3) of seal debris and clean.
2005 BMW 645Ci
Fig. 105: Identifying Timing Case Cover

Installation:
Check adapter sleeves (1) for damage and correct installation position; replace if necessary.
Free sealing face (2) of seal debris and clean.
2005 BMW 645Ci
Fig. 106: View Of Adapter Sleeves

Installation:
Replace gasket (1) and check for correct installation position.

2005 BMW 645Ci
Fig. 107: Identifying Cover Gasket

11 14 085 REMOVING AND INSTALLING TOP RIGHT TIMING CASE COVER (N62 / N62TU)
 Remove right cylinder head cover. Refer to 11 12 006 REMOVING AND INSTALLING / SEALING
 Remove vacuum pump. Refer to 11 66 000 REMOVING AND INSTALLING/REPLACING
VACUUM PUMP (N62).
 Remove both solenoid valves on right side. Refer to 11 36 720 REMOVING AND
INSTALLING/REPLACING BOTH SOLENOID VALVES ON RIGHT SIDE (N62).
Remove cable from holder.

2005 BMW 645Ci
Fig. 108: Removing Cable From Holder


2005 BMW 645Ci
Fig. 109: Removing Timing Case Cover

Installation:
2005 BMW 645Ci
Fig. 110: View Of Timing Case Cover

Installation:

2005 BMW 645Ci
Fig. 111: Locating Adapter Sleeves

Installation:

2005 BMW 645Ci
Fig. 112: Identifying Cover Gasket

11 14 110 REMOVING AND INSTALLING BOTTOM TIMING CASE COVER (N62/N62TU)
 23 1 040
 Remove engine.
 Remove both cylinder heads. Refer to 11 12 105 REMOVING AND INSTALLING LEFT
CYLINDER HEAD (N62 FROM 9/03 AND N62TU) and 11 12 106 REMOVING AND
INSTALLING RIGHT CYLINDER HEAD (N62 FROM 9/03 AND N62TU).
 Remove lower oil sump section. Refer to 11 13 020 REMOVING AND INSTALLING/REPLACING
OIL SUMP BOTTOM SECTION (N62).
 Remove upper oil sump section. Refer to 11 13 010 REMOVING AND INSTALLING/REPLACING
OIL SUMP TOP SECTION (N62).
 Remove vibration damper. Refer to 11 23 010 REMOVING AND INSTALLING/REPLACING
2005 BMW 645Ci
 Remove water pump. Refer to 11 51 000 REMOVING AND INSTALLING WATER PUMP (N62).
 Remove tensioner from poly-V-belt.
 Remove alternator with housing.
 Remove hub for vibration damper. Refer to 11 23 031 REMOVING AND INSTALLING /
REPLACING VIBRATION DAMPER HUB (N62 / N62TU).
 Remove flywheel. Refer to 11 22 000 REMOVING AND INSTALLING/REPLACING FLYWHEEL
(N62).
 Remove rear coolant cap.
Release screws along lines (1).
Remove timing case cover (2) towards front.
Fig. 113: Identifying Timing Case Cover Screws

2005 BMW 645Ci
Drive out water pipe (1) with special tool 23 1 040 at cutout (2) towards front.
Installation:
Replace water pipe (1) and sealing ring (3).
Fig. 114: Replacing Water Pipe And Sealing Ring

Installation:
Clean sealing surfaces and replace seal.
Install timing case cover, insert all screws and initially tighten to approx. 5 Nm.
Fully tighten all screws in alternate sequence.

2005 BMW 645Ci
IMPORTANT: Once all screws have been tightened down, retighten them in a second
operation.
Replace radial seal in timing case at bottom. Refer to 11 14 141 REPLACING RADIAL SHAFT SEAL IN
TIMING CASE COVER AT BOTTOM (N62 / N62TU).
11 14 141 REPLACING RADIAL SHAFT SEAL IN TIMING CASE COVER AT BOTTOM

(N62/N62TU)
 11 9 410
 11 9 420
 Removing hub for vibration damper. Refer to 11 23 031 REMOVING AND INSTALLING /
REPLACING VIBRATION DAMPER HUB (N62 / N62TU).
Position lever (2) for removing radial shaft seal (1) horizontally and install special tool 11 9 410.
2005 BMW 645Ci
Turn lever (2) so that it grips behind radial shaft seal (1).
Turn bolt (3) on special tool 11 9 410 to remove radial shaft seal (1).
Fig. 116: Locating Bolt On Radial Shaft Seal Puller

NOTE: Radial shaft seal may only be supported with a "support sleeve".
If the radial shaft seal (1) is stored for longer than six months without the support sleeve (2), its operational
reliability can no longer be guaranteed and it must not be reused.
2005 BMW 645Ci
Fig. 117: Identifying Support Sleeve On Radial Shaft Seal

IMPORTANT: The sealing lip of the radial shaft seal is highly sensitive and must not be
kinked under any circumstances. Do not touch the sealing lip with your fingers.
Remove support sleeve (2) from radial shaft seal (1).
Fit radial shaft seal (1) on timing case cover.

2005 BMW 645Ci
Fig. 118: Fitting Radial Shaft Seal On Timing Case Cover

Using special tool 11 9 420 and central bolt (3), install radial shaft seal flush with timing case cover.
2005 BMW 645Ci
Fig. 119: Installing Radial Shaft Seal Flush With Timing Case Cover
11 14 151 REPLACING CRANKSHAFT RADIAL SHAFT SEAL (N62/N62TU)
 11 2 390
(Transmission side)
 Remove transmission.
 Drain off engine oil. Refer to 00 00 610 ENGINE OIL SERVICE (N62/N62TU).
2005 BMW 645Ci
 Remove flywheel. Refer to 11 22 000 REMOVING AND INSTALLING/REPLACING FLYWHEEL

(N62).
Release screws (2).
Release screws (1).
Fig. 120: Identifying End Cover Screws

Carefully remove end cover.
kinked. Do not touch the sealing lip with your fingers.
2005 BMW 645Ci
Fig. 121: View Of Sealing Lip

NOTE: Support sleeve (2) is included in scope of delivery.
The support sleeve (2) remains in the radial shaft seal and is used as a slip sleeve in the installation described
later.
IMPORTANT: Special tool 11 2 390 must not be used.
When the radial shaft seal is installed, only the support sleeve included in the scope of delivery may be used as
a slip sleeve.
2005 BMW 645Ci
Fig. 122: View Of Special Tool 11 2 390

NOTE: The radial shaft seal can only be replaced completely with the end cover.
The gasket is an integral part of the end cover and cannot be replaced individually.
Installation:
Keep sealing faces clean and free of oil.
Coat contact points on joint along oil sump with Drei Bond 1209.
2005 BMW 645Ci
Fig. 123: Locating Dowel Sleeves

Installation:
Lightly oil running surface of crankshaft.
Fit end cover (1) with support sleeve (2) on crankshaft and push on carefully.
2005 BMW 645Ci
Fig. 124: Fitting End Cover With Support Sleeve On Crankshaft

Insert screws (1) and initially tighten without play.
Tighten down screws (1).

2005 BMW 645Ci
Fig. 125: Inserting Screws

CRANKSHAFT WITH BEARING

11 21 500 REPLACING CRANKSHAFT (N62/N62TU)
CRANKSHAFT OPERATION (N62/N62TU)

Operation: Note:
Remove engine
Remove cylinder head (cylinder bank 1 to 4), refer to 11 12 106
REMOVING AND INSTALLING RIGHT CYLINDER HEAD (N62
FROM 9/03 AND N62TU).
Remove cylinder head (cylinder bank 5 to 8), refer to 11 12 105
REMOVING AND INSTALLING LEFT CYLINDER HEAD (N62
Remove hub for vibration damper. Refer to 11 23 031 REMOVING AND
INSTALLING / REPLACING VIBRATION DAMPER HUB (N62 /
N62TU).
Removing lower timing case cover.
Removing oil pan. Refer to 11 13 010 REMOVING AND
INSTALLING/REPLACING OIL SUMP TOP SECTION (N62) and
11 13 020 REMOVING AND INSTALLING/REPLACING OIL
2005 BMW 645Ci
Remove oil pump. Refer to 11 41 000 REMOVING AND

INSTALLING/REPLACING OIL PUMP (N62).
Removing piston. Refer to 11 25 530 REMOVING AND
INSTALLING/REPLACING ALL PISTONS (N62).
Remove flywheel. Refer to 11 22 000 REMOVING AND
INSTALLING/REPLACING FLYWHEEL (N62).
Release main bearing inclined screw connection (1).
Installation:
Fig. 126: Locating Main Bearing Inclined Screw Connection

Release spacer bolt (2).

2005 BMW 645Ci
Fig. 127: Identifying Spacer Bolt

Release main bearing screws.
Remove main bearing caps 1 to 5.

2005 BMW 645Ci
Fig. 128: View Of Main Bearing Caps

Lever out crankshaft.
Replace main crankshaft bearing shells. Refer to 11 21 531 REPLACING ALL MAIN CRANKSHAFT
BEARING SHELLS (N62).
Replace conrod bearing shells. Refer to 11 24 571 REPLACING ALL CONROD BEARINGS (N62).
11 21 531 REPLACING ALL MAIN CRANKSHAFT BEARING SHELLS (N62)
 00 2 590
 00 9 120
(Engine dismantled)
2005 BMW 645Ci
Preparatory tasks are described in 11 21 500 REPLACING CRANKSHAFT (N62/N62TU).
NOTE: Install main bearing shells (1) with lubrication groove in crankcase. Install main
bearing shells (2) without lubrication groove in the main bearing caps.
Fig. 129: Identifying Main Bearing Shell Types

The letter (1) denotes the crankshaft construction stage.
S= Series.
B= Construction stage 1.
C= Construction stage 2.
The numbers (2) denote the bearing shell classification for the relevant bearing position from 1 to 5 (main
2005 BMW 645Ci
1= yellow.
2= green.
3= violet.
Fig. 130: Locating Crankshaft Construction Stage

The letters (1) denote the bearing shell classification for the relevant bearing position from 1 to 5 in the
crankcase and is located on the transmission side in the Vee. The first letter on the left applies to the first
bearing position at the front.
Y= yellow.
G= green.
2005 BMW 645Ci
Fig. 131: Identifying Bearing Shell Classification

NOTE: Main bearing caps (1, 2 and 3) are identified with punch numbers. Main bearing
caps (4 and 5) are not identified.
2005 BMW 645Ci
Fig. 132: Identifying Main Bearing Caps With Punch Numbers

NOTE: Main bearing cap number 5 can be identified by the surfaces (1) for the stop
disks of the thrust bearing.
2005 BMW 645Ci
Fig. 133: Identifying Main Bearing Cap Number 5

Unscrew thread support bushings in main bearing caps.

2005 BMW 645Ci
Fig. 134: Unscrewing Thread Support Bushings In Main Bearing Caps

Checking Main Bearing Clearance:
To check crankshaft bearing clearance, use old main bearing screws.
There must be no oil in the blind holes (risk of cracking).
Do not rotate crankshaft.
Fit special tool 00 2 590 (Plastigage Type PG 1) to the oil-free crankshaft.

2005 BMW 645Ci
Fig. 135: Checking Crankshaft Bearing Clearance

1. Tighten all screws on main bearing cover with jointing torque.

2. Tighten down all screws on main bearing caps with special tool 00 9 120 and torsion angle.

2005 BMW 645Ci
Fig. 136: Identifying Torque Angle Measuring Dial

Remove main bearing cap.
Read off main bearing play at width of flattened plastic thread with assistance of measurement scale.
Main bearing play, refer to ENGINE - TECHNICAL DATA - 645Ci .
 Remove plastic thread.

 Lubricate bearing shells and bearing shells.
2005 BMW 645Ci
Fig. 137: Measuring Main Bearing Play Using Measurement Scale

NOTE: Always replace main bearing bolts of main bearing caps with new bolts. Do not
wash off bolt coating. No oil is permitted in the blind bores! (Danger of
cracking).
Tightening specifications for main bearing:

2. Unfasten screws on main bearing cover 5.
3. Strike back and front of crankshaft with plastic hammer to center guide bearing (do not damage
crankshaft).
Check axial play. Refer to ENGINE - TECHNICAL DATA - 645CI .

2005 BMW 645Ci
Check guide bearing shell, crankshaft and crankcase if necessary.
4. Tighten screws of main bearing cover 5 with jointing torque.

5. Tightening torque, refer to 11 11 2AZ in ENGINE - TIGHTENING TORQUES .
Fig. 138: Checking Axial Using Dial Gauge

Tighten down all screws on main bearing caps with special tool 00 9 120 and torsion angle.
Tighten down thread support bushings (2).

2005 BMW 645Ci
Fig. 139: Locating Thread Support Bushings

Replace flanged head screws (1) and tighten down.

2005 BMW 645Ci
Fig. 140: Identifying Flanged Head Screws

FLYWHEEL
11 22 000 REMOVING AND INSTALLING/REPLACING FLYWHEEL (N62)
 11 4 180
 11 9 260
 11 9 262
 11 9 263
 11 9 264
2005 BMW 645Ci
 Remove automatic transmission. AUTOMATIC TRANSMISSION .

 Remove manual transmission. Refer to REMOVAL & INSTALLATION - 545I & 645CI (GS6-53BZ)
or REMOVAL & INSTALLATION - 545I & 645CI (GS6S53BZ SMG) .
 Remove clutch. Refer to CLUTCH .
Automatic Transmissions Only:
Block flywheel (1) with special tools 11 9 260 / 11 9 263 / 11 9 264.
Unfasten flywheel screws.
Remove flywheel (1). Refer to 11 22 000 REMOVING AND INSTALLING/REPLACING FLYWHEEL

(N62).
Fig. 141: Identifying Flywheel Secured With Special Tools

Installation:
Clean threads on flywheel screws in crankshaft.

2005 BMW 645Ci
Flywheel (1) is secured with an alignment pin.
Fit flywheel (1).
Fit new flywheel screws.
Manual Transmissions Only:
Block flywheel (dual-mass) with special tools 11 9 260 / 11 9 262 / 11 9 263.
Release flywheel screws with special tool 11 4 180.
Installation:
IMPORTANT: Do not use screw locking varnish.
Fig. 142: View Of Dual-Mass Flywheel Secured With Special Tools

2005 BMW 645Ci
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.
Fig. 143: Pressing Out Dual-Mass Flywheel Downwards On Engine Side

2005 BMW 645Ci
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.
Fig. 144: Pressing Roller Bearing Into Dual-Mass Flywheel

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.

2005 BMW 645Ci
11 23 010 REMOVING AND INSTALLING/REPLACING VIBRATION DAMPER (N62)
Remove alternator drive belt. Refer to 11 28 010 REPLACING ALTERNATOR DRIVE BELT
(N62/N62TU).
Remove fan cowl. 17 11 035 REMOVING AND INSTALLING/REPLACING FAN COWL WITH
ELECTRIC FAN (N62) .
Release screws and remove vibration damper (1). Refer to 11 23 010 REMOVING AND
INSTALLING/REPLACING VIBRATION DAMPER (N62).
Fig. 145: Locating Vibration Damper Retaining Screws

Installation:
2005 BMW 645Ci
Vibration damper is secured on hub with an alignment pin (4).
Fig. 146: Identifying Alignment Pin

Installation:
Fit bore (2) in vibration damper (1) on alignment pin in hub.
Fit washer (3).
Replace screws.

2005 BMW 645Ci
Fig. 147: Fitting Bore In Vibration Damper On Alignment Pin In Hub

11 23 031 REMOVING AND INSTALLING/REPLACING VIBRATION DAMPER HUB (N62/N62TU)
 11 3 454
 11 3 460
 11 9 451
 11 9 452
 11 9 453

2005 BMW 645Ci
 Remove design cover.

 Remove drive belt for alternator, refer to 11 28 010 REPLACING ALTERNATOR DRIVE BELT
(N62).
 Remove drive belt for A/C compressor.
 Remove front engine underguard.
 Remove vibration damper. Refer to 11 23 010 REMOVING AND INSTALLING/REPLACING
Screw special tool 11 9 451 in conjunction with special tool 11 9 452 to vibration damper hub and to oil sump.
Release central bolt (1).
Remove special tools.
Remove hub for vibration damper. Refer to 11 23 031 REMOVING AND INSTALLING / REPLACING
VIBRATION DAMPER HUB (N62 / N62TU).
2005 BMW 645Ci
Fig. 148: Removing Central Bolt From Vibration Damper Hub

Installation:
Check vibration damper hub and radial seal, replace if necessary.

Align groove in vibration damper hub to parallel key and install vibration damper hub.
Replace central bolt (1).
Tighten down central bolt (1) to joining torque.
Installation:
Fit special tool 11 3 460 on special tool 11 9 451.
NOTE: Special tool 11 3 460 is magnetic.
Fig. 149: Installing Central Bolt Using Counter Holder

Installation:
Select 0° position and secure special tool 11 9 453 with clamping screw on socket (special tool 11 3 454).
2005 BMW 645Ci
Tighten the central screw with torsion angle.
Fig. 150: Tightening Central Screw With Torsion Angle

Assemble engine.
CONNECTING ROD WITH BEARING

11 24 571 REPLACING ALL CONROD BEARINGS (N62)

2005 BMW 645Ci
 00 2 590
 00 9 120
 11 2 110
(Piston removed)
CAUTION: Note grinding stages on crankshaft, refer to ENGINE - TECHNICAL DATA -

645CI
bearing cap).
Fig. 151: Identifying Letter And Numbers Denoting Crankshaft Construction Stage And Bearing Shell
Classification
2005 BMW 645Ci
Install new conrod bearing shells.
Fig. 152: Installing Conrod Bearing Shells

Insert one red and one blue bearing shell for each conrod.
Install piston. Refer to 11 25 530 REMOVING AND INSTALLING/REPLACING ALL PISTONS (N62).
Check Connecting-Rod Bearing Clearance:
Piston in BDC position.
Fit special tool 00 2 590 (Plastigage Type PG 1) to the oil-free crankshaft.

2005 BMW 645Ci
Fig. 153: Aligning Bearing Caps

CAUTION: Do not distort conrods or crankshaft.
Use the old connecting-rod bolts to check connecting-rod clearance.
Tighten down conrod bolts with special tool 00 9 120 or special tool 11 2 110.

2005 BMW 645Ci
Fig. 154: Identifying Torque Angle Measuring Dial

Remove bearing cap and read off bearing play at width of flattened plastic thread with assistance of
measurement scale.
2005 BMW 645Ci
Fig. 155: Measuring Bearing Play Using Measurement Scale

Conrod bearing clearance. Refer to ENGINE - TECHNICAL DATA - 645CI .

 Lubricate crankshaft and bearing shells.
 Install new connecting-rod screws.

2005 BMW 645Ci
Fig. 156: View Of Torque Angle Measuring Dial

PISTONS WITH RINGS AND PIN

11 25 530 REMOVING AND INSTALLING/REPLACING ALL PISTONS (N62)
 00 9 120
 11 8 141
 11 8 151
 11 8 152
 11 9 500
(Engine removed)
2005 BMW 645Ci
Removal
Removal of pistons is described separately from installation. Assembly sequence for removal and installation is
different.
Mount engine on assembly stand.
Remove both cylinder heads. Refer to 11 12 105 REMOVING AND INSTALLING LEFT CYLINDER
HEAD (N62 FROM 9/03 AND N62TU) and 11 12 106 REMOVING AND INSTALLING RIGHT
CYLINDER HEAD (N62 FROM 9/03 AND N62TU).
Unscrew oil sump.
Remove oil pump. Refer to 11 41 000 REMOVING AND INSTALLING/REPLACING OIL PUMP (N62).
CAUTION: Re-install piston, connecting rod and bearing shells back in the same
position and in the same installation location. Conrods and conrod
bearing caps are denoted with the same pairing letters, do not mix them
up.
In event of heavy oil carbon residue:
Carefully remove oil carbon residue from cylinder wall.

2005 BMW 645Ci
Fig. 157: Identifying Oil Carbon Residue On Cylinder Wall

CAUTION: When removing and installing pistons, make sure piston cooling spray
nozzles (1) are not damaged.
2005 BMW 645Ci
Fig. 158: Locating Piston Cooling Spray Nozzles

Remove connecting-rod cover.
NOTE: Conrods and conrod bearing caps are denoted with the same pairing letters.
Set down conrod bearing caps in order.

2005 BMW 645Ci
Fig. 159: Removing Connecting-Rod Cover

Insert special tools 11 8 151 and 11 8 152 in conrod.

2005 BMW 645Ci
Fig. 160: Inserting Special Tools 11 8 151 And 11 8 152 In Conrod

Remove connecting rod with piston from cylinder-head side.
CAUTION: Piston and piston bolts are paired and must not be fitted individually.
Lift out retaining ring and press out piston pin.

2005 BMW 645Ci
Fig. 161: Removing Piston Pin Retaining Ring

Installation
Installation of pistons is described separately from removal. The assembly sequence for removal and installation
is different.
If necessary, replace connecting rods.
NOTE: The Conrods can also be replaced individually.
The piston pin must be able to be pressed through the liner by hand with little force and must not display any
significant play.
2005 BMW 645Ci
Fig. 162: Identifying Piston Pin

Prior to installation, measure piston installation clearance:
Measure piston diameter with micrometer at measuring point A from lower edge of piston and offset by 90° to
piston pin axis.
Measuring point A. Refer to ENGINE - TECHNICAL DATA - 645CI .

2005 BMW 645Ci
Fig. 163: Measuring Piston Installation Clearance

Adjust micrometer to cylinder bore of engine block. Set internal caliper on micrometer to zero. Measure
bottom, center and top of cylinder bore in direction of travel and direction of engine rotation.
Diameter of cylinder bore.
Piston installation clearance. Refer to ENGINE - TECHNICAL DATA - 645CI .
Total permissible wear tolerance. Refer to ENGINE - TECHNICAL DATA - 645CI .

2005 BMW 645Ci
Fig. 164: Measuring Cylinder Bore

NOTE: The pistons and conrods of cylinders 1 to 8 are identical.
CAUTION: The conrods of cylinder banks 1 to 4 and 5 to 8 are mounted to the pistons
differently.
Cylinder Bank 1 To 4
Fit conrod with piston pin to piston in such a way that arrow on piston points to front and flat end of conrod
points to rear.
2005 BMW 645Ci
Fig. 165: Fitting Conrod With Piston Pin To Piston (Cylinder Bank 1 To 4)
Cylinder Bank 5 To 8
Fit conrod with piston pin to piston in such a way that arrow on piston points to front and flat end of conrod
points to rear.
Install conrod bearing. Refer to ENGINE - TECHNICAL DATA - 645CI .

2005 BMW 645Ci
Fig. 166: Aligning Arrow On Piston And End Of Conrod

Install retaining ring.

2005 BMW 645Ci
Fig. 167: Installing Piston Pin Retaining Ring

Insert special tools 11 8 151 and 11 8 152 in conrod.

2005 BMW 645Ci
Fig. 168: Inserting Special Tools 11 8 151 And 11 8 152 In Conrod

N62 B44
Lightly coat pistons and piston rings with oil.
Offset the contact points of the piston rings by approx. 120° to each other but do not position above the piston
pin boss.
Compress piston rings with special tool 11 9 500.

2005 BMW 645Ci
Fig. 169: Compressing Piston Rings With Special Tool 11 9 500

Keep piston rings compressed with special tool 11 9 500.

2005 BMW 645Ci
Fig. 170: Keeping Piston Rings Compressed With Special Tool 11 9 500
Install piston so that arrow points to camshaft drive.
CAUTION: Danger of piston ring failure.
Only press pistons into place with finger force - do not knock in!
N62 B36
Lightly coat pistons and piston rings with oil. Offset the contact points of the piston rings by approx. 120° to
each other but do not position above the piston pin boss.
Slide special tool 11 8 141 over piston (1).

2005 BMW 645Ci
Fig. 171: Sliding Special Tool 11 8 141 Over Piston (1)

CAUTION: Danger of piston ring failure.
Only press pistons into place with finger force - do not knock in!
Attach crankpin to connecting rod.
Remove special tools 11 8 151 and 11 8 152.

2005 BMW 645Ci
Fig. 172: Removing Special Tools 11 8 151 And 11 8 152

NOTE: For purposes of clarity, the pairing letters (1) are shown on the removed
conrod.
CAUTION: Conrods and conrod bearing caps are denoted with the same pairing
letters (1), do not mix them up.
2005 BMW 645Ci
Fig. 173: Identifying Pairing Letters On Conrod

Apply light coat of oil to connecting-rod bearing shells.
Fit bearing cap so that pairing letters match up.
Install new connecting-rod screws.

2005 BMW 645Ci
Fig. 174: Installing Connecting-Rod Screws

Secure conrod with special tool 00 9 120.

2005 BMW 645Ci
Fig. 175: Securing Conrod With Special Tool 00 9 120

11 25 671 REPLACING PISTON RINGS ON ALL PISTONS (N62)
(Piston removed)
Measuring axial clearance of piston rings in piston ring groove (1 and 2):
Refer to ENGINE - TECHNICAL DATA - 645CI
NOTE: It is not possible to measure the axial clearance of the oil scraper rings.
2005 BMW 645Ci
Fig. 176: Measuring Axial Clearance Of Piston Rings In Piston Ring Groove
Remove piston rings (1 and 2) with piston ring compressing pliers.
NOTE: It might not be possible to find the identification on used piston rings
2005 BMW 645Ci
Fig. 177: Removing Piston Rings With Piston Ring Compressing Pliers
Put aside piston rings in correct sequence and installation position.
New pistons may only be installed together with new piston rings.
Measure end clearance. Refer to ENGINE - TECHNICAL DATA - 645CI

2005 BMW 645Ci
Fig. 178: Measuring End Clearance

NOTE: Picture shows a schematic representation.
Installation:
Install piston rings with "TOP" to piston top.
1. Plain compression ring.

2. Stepped compression ring "Top".
3. Steel band ring with support spring.
2005 BMW 645Ci
Fig. 179: Identifying Piston Rings

pin boss.
Installation:
Oil control ring comprises two steel band rings (1) and a support spring (2).
2005 BMW 645Ci
Fig. 180: Identifying Oil Control Ring Components

Insert support spring (2) into piston ring groove.
CAUTION: Incorrect installation possible. Contact points of support spring (2) slip
very easily over each other when fitted. Contact points must be positioned
exactly on each other. If the contact points overlap, the oil scraper ring will
be damaged when the piston is installed.
Then fit steel band rings (1) so that contact joints are offset approx. 120°.
V RIBBED BELT W/TENS. DEFLECT ELEMENT

11 28 010 REPLACING ALTERNATOR DRIVE BELT (N62)
2005 BMW 645Ci
 11 3 340
NOTE: If the drive belt is to be reused: Mark direction of travel and reinstall drive belt in
same direction of travel.
Pretension belt tensioner slowly and carefully with a Torx socket as far as it will go and secure with special tool
11 3 340.
Remove drive belt.
IMPORTANT: If contaminated with hydraulic fluid: Replace drive belt.
Fig. 181: Pretensioning Belt Tensioner With A Torx Socket And Securing With Special Tool 11 3 340
Put on the drive belt.
Remove special tool 11 3 340.
Installation:
2005 BMW 645Ci
Check that drive belt is correctly positioned on pulleys.
Fig. 182: Identifying Correctly Positioned Drive Belt

CAMSHAFT
11 31 032 REMOVING AND INSTALLING/REPLACING LEFT INLET CAMSHAFT (N62 FROM
9/03)
 11 9 470
 11 9 472
 11 9 473
 11 9 474
 11 9 475
 11 9 480
 11 9 490
2005 BMW 645Ci
Removal
Removal of inlet camshaft is described separately from installation.
IMPORTANT: The inlet camshaft must first be rotated so that when the bearing bracket is
removed the intermediate levers do not slip out and damage the camshaft.
Rotate inlet camshaft against direction of rotation until lettering (1) on 8th cylinder points upwards in cylinder
axis and cam is horizontal.
Fig. 183: Aligning Lettering On 8th Cylinder

2005 BMW 645Ci
IMPORTANT: Do not mix up the camshaft bearing covers of cylinders 1 to 4 and 5 to 8.
NOTE: Bearing caps of inlet camshaft are marked on cylinder bank 5 to 8 with R E1 to
R E5 from inlet side.
Release nuts and remove bearing cap R E1.
Fig. 184: Identifying Marked Bearing Caps Of Inlet Camshaft

Release 8 nuts of bearing bracket (1) from outside to inside.

2005 BMW 645Ci
Fig. 185: Identifying Nuts Of Bearing Bracket

NOTE: Rocker arms are freely accessible after bearing bracket has been removed.
Do "not" remove rocker arm (1) on inlet side.
IMPORTANT: Rockers arms (1) are divided into individual tolerance classes. The tolerance
classes are designated as illustrated with the numbers from 1 to 4. Used rocker
arms (1) may only be reused in the same position.
2005 BMW 645Ci
Fig. 186: Identifying Rocker Arm

When replacing rocker arms (1) on inlet side: install rocker arms of the same tolerance class in the same
position.
Clamp special tool 11 9 470 as illustrated in a vise.

2005 BMW 645Ci
Fig. 187: Clamping Special Tool 11 9 470 In A Vise

IMPORTANT: Do not tilt bearing bracket (1).
Carefully lift out bearing bracket (1).

2005 BMW 645Ci
Fig. 188: Identifying Bearing Bracket

Place bearing bracket (1) with inlet camshaft and eccentric shaft as illustrated on special tool 11 9 470.
Secure bearing bracket (1) with a nut (special tool 11 9 473).

2005 BMW 645Ci
Fig. 189: Securing Bearing Bracket With Nut

IMPORTANT: The lower section of the bearing bracket (1) is machined with the cylinder head
and must not be mixed up.
NOTE: Lower section of bearing bracket (1) remains on cylinder head.

2005 BMW 645Ci
Fig. 190: Identifying Lower Section Of Bearing Bracket

NOTE: This work step will only be necessary if after the inlet camshaft has been
removed the eccentric shaft is also to be removed.
If necessary, remove eccentric shaft sensor (2).

2005 BMW 645Ci
Fig. 191: Locating Eccentric Shaft Sensor Retaining Screws

NOTE: Removal of the intermediate levers and torsion springs is described on the 8th
cylinder. The same procedure is applicable to cylinders 5 to 7.
Raise one end of torsion spring (1) with special tool 11 9 480.
Lift out intermediate lever (2) and set down in an orderly fashion.
IMPORTANT: Keep holding torsion spring (1) with special tool 11 9 480.
2005 BMW 645Ci
Fig. 192: Raising Torsion Spring Using Lever

Attach special tool 11 9 490 to end of torsion spring.
Support end of torsion spring protected with special tool 11 9 490 on inlet camshaft.
2005 BMW 645Ci
Fig. 193: Attaching Special Tool To End Of Torsion Spring

IMPORTANT: Intermediate levers (2) are divided into individual tolerance classes. Only
intermediate levers of the same tolerance class may be fitted in a single
cylinder head. The tolerance classes are designated as illustrated with the
numbers from 1 to 5. Used intermediate levers (2) may only be reused in the
same position.
2005 BMW 645Ci
Fig. 194: Identifying Intermediate Lever Tolerance Class Number

Raise second end of torsion spring (1) with special tool 11 9 480.
2005 BMW 645Ci
Fig. 195: Holding Torsion Spring With Lever

Attach special tool 11 9 490 to second end of torsion spring.
2005 BMW 645Ci
Fig. 196: Attaching Lever To Second End Of Torsion Spring

Release screw (1).

2005 BMW 645Ci
Fig. 197: Releasing Screw

Remove torsion spring (1) and special tool 11 9 490.

2005 BMW 645Ci
Fig. 198: Removing Torsion Spring (1) And Special Tool 11 9 490
Remove the intermediate levers and torsion springs of cylinders 5 to 7 according to the same procedure and set
down in an orderly fashion.
Unscrew nut (special tool 11 9 473).

2005 BMW 645Ci
Fig. 199: Unscrewing Knurled Nut

NOTE: Bearing caps are marked as illustrated with R E2 to R E5.
Remove bearing caps R E2 to R E5 and place to one side in order.

2005 BMW 645Ci
Fig. 200: Identifying Bearing Caps

Lift out inlet camshaft (1).

2005 BMW 645Ci
Fig. 201: View Of Inlet Camshaft

NOTE: Further tasks: The article 11 37 006 REMOVING AND INSTALLING/REPLACING

LEFT ECCENTRIC SHAFT (N62 FROM 9/03) contains important installation
instructions.
If necessary, replace plain compression rings (1).
IMPORTANT: Plain compression rings (1) can easily break.
Plain compression rings (1) are engaged at joint.
Press compression ring (1) on one side into groove, pull up on other side and remove catch.
Carefully pull compression ring (1) apart and remove towards front.
2005 BMW 645Ci
Fig. 202: Identifying Plain Compression Rings

NOTE: Inlet camshaft of cylinder bank 5 to 8 is marked with "EIN 58".
If necessary, replace sensor gear (1).
Release screw (2) and remove sensor gear (1).

2005 BMW 645Ci
Fig. 203: Locating Sensor Gear And Retaining Screw

Installation
Installation of inlet camshaft is described separately from removal.
Clean all bearings and cams of inlet camshaft and lubricate with engine oil.
NOTE: Camshaft has a groove and sensor gear has a lug for fastening purposes.
2005 BMW 645Ci
Fig. 204: Identifying Camshaft Groove

Fit sensor gear (1) and align to groove in camshaft.
Insert screw (2) and tighten down.
Tightening torque of screw (2), refer to 11 31 14AZ in ENGINE - TIGHTENING TORQUES .

2005 BMW 645Ci
Fig. 205: Aligning Sensor Gear To Groove In Camshaft

Installing compression rings (1):
Carefully pull compression ring (1) apart and install from front.
Press compression ring (1) on one side into groove, install catch on other side.
2005 BMW 645Ci
Fig. 206: Installing Compression Rings

Insert inlet camshaft (1) so that cams point upwards at cylinder 5 as shown in illustration.
2005 BMW 645Ci
Fig. 207: Inserting Inlet Camshaft

Make sure bearing shells (1) of eccentric shaft are engaged in bearing bracket.
NOTE: Bearing shell (1) is guided in a groove in bearing cap.

2005 BMW 645Ci
Fig. 208: Identifying Bearing Shells Position

2005 BMW 645Ci

NOTE: Bearing caps are marked as illustrated with R E2 to R E5.
Fit bearing caps R E2 to R E5.

2005 BMW 645Ci
Fig. 210: Installing Bearing Caps R E2 To R E5

NOTE: Initially tighten special tool 11 9 473 without play only.
Secure bearing bracket and bearing cap with nut (special tool 11 9 473).
2005 BMW 645Ci
Fig. 211: Installing Knurled Nut

NOTE: The mounting of the bearing bracket described later can only be performed if
the first bearing of the inlet camshaft is aligned with special tool 11 9 472.
Fit special tool 11 9 472 as shown in illustration and align inlet camshaft.
2005 BMW 645Ci
Fig. 212: Aligning Inlet Camshaft

Fit centering sleeves (special tool 11 9 475) and align special tool 11 9 472 to bearing caps 2 and 3.
2005 BMW 645Ci
Fig. 213: Identifying Centering Sleeves

Insert special tool 11 9 474 and initially tighten without play.
NOTE: Special tools 11 9 472 / 11 9 474 and 11 9 475 remain fitted until all torsion
springs and intermediate levers have been installed.
2005 BMW 645Ci
Fig. 214: Locating Guide Bushes And Retaining Screws

NOTE: Installation of the intermediate levers and torsion springs is described on the
8th cylinder. The same procedure is applicable to cylinders 5 to 7.
Attach special tool 11 9 490 to ends of torsion spring.

2005 BMW 645Ci
Fig. 215: Attaching Special Tool 11 9 490 To Ends Of Torsion Spring

Install torsion spring (1).

2005 BMW 645Ci
Fig. 216: Installing Screw

intermediate levers of the same tolerance class may be fitted in a single engine.
The tolerance classes are designated as illustrated with the numbers from 1 to
5. Used intermediate levers (2) may only be reused in the same position.
Lubricate all sliding surfaces on intermediate lever (2) with engine oil.
2005 BMW 645Ci

Raise torsion spring (1) with special tool 11 9 480.
Detach special tool 11 9 490.

2005 BMW 645Ci
Fig. 218: Detaching Holder Sleeve

Hold torsion spring (1) with special tool 11 9 480.
Install intermediate lever (2) from above.
Insert end of torsion spring (1) into guide on intermediate lever (2).
2005 BMW 645Ci
Fig. 219: Holding Torsion Spring With Lever

Raise second end of torsion spring with special tool 11 9 480.

2005 BMW 645Ci
Fig. 220: Removing Holder Sleeve

2005 BMW 645Ci
Fig. 221: Installing Intermediate Lever

Insert screws and tighten down eccentric shaft sensor (2).

2005 BMW 645Ci
Fig. 222: Identifying Eccentric Shaft Sensor And Retaining Screws


2005 BMW 645Ci
Fig. 223: Removing Special Tool 11 9 474

Remove special tool 11 9 472 and special tool 11 9 475.

2005 BMW 645Ci
Fig. 224: Removing Special Tool 11 9 472 And Special Tool 11 9 475
Ends of compression rings (1) point upwards.
Make sure compression rings (1) are engaged at ends.

2005 BMW 645Ci
Fig. 225: Identifying Ends Of Compression Rings

IMPORTANT: Rocker arms (1) slip slightly when bearing bracket is fitted. Make sure rocker
arms (1) are secured as illustrated on hydraulic valve clearance compensating
elements and on valves.
Align rocker arms (1) straight.

2005 BMW 645Ci
Fig. 226: Identifying Rocker Arms

Remove bearing bracket (1) from special tool 11 9 470.

2005 BMW 645Ci
Fig. 227: Removing Bearing Bracket From Support

Lower bearing bracket (1) from above and carefully bring into contact with cylinder head.
Insert nuts and tighten by hand without play.
IMPORTANT: Make sure none of the intermediate levers or rocker arms have slipped out.
Tighten down nuts from inside to outside.

2005 BMW 645Ci
Fig. 228: Locating Bearing Bracket Nuts

Fit bearing cap R E1 in such a way that marking is legible from inlet side.
Install nuts and tighten down.

2005 BMW 645Ci
Fig. 229: View Of Bearing Cap Marking

Rotate inlet camshaft in direction of rotation until cam on 5th cylinder points upwards at an angle as shown in
illustration.
NOTE: The marking (1) on the hexagon drive of the inlet camshaft faces upwards.
2005 BMW 645Ci
Fig. 230: Aligning Marking On Hexagon Drive Of Inlet Camshaft

Install spark plugs on cylinder bank 5 to 8.
Install left cylinder head cover. Refer to 11 12 005 REMOVING AND INSTALLING/SEALING LEFT
Install ignition coils on cylinder bank 5 to 8.
Install servomotor for left eccentric shaft. Refer to 11 37 022 REMOVING AND
Assemble engine.
2005 BMW 645Ci
11 31 034 REMOVING AND INSTALLING/REPLACING RIGHT INLET CAMSHAFT (N62 FROM

9/03 AND N62TU)
 11 9 470
 11 9 472
 11 9 473
 11 9 474
 11 9 475
 11 9 480
 11 9 490
Removal
Removal of inlet camshaft is described separately from installation.
Rotate inlet camshaft in direction of rotation until cam on 1st cylinder is positioned horizontally as shown in
illustration.
2005 BMW 645Ci
Fig. 231: Aligning Cam For 1st Cylinder Horizontally

NOTE: Bearing caps of inlet camshaft are marked on cylinder bank 1 to 4 with L E1 to L
E5 from inlet side.
Release nuts and remove bearing cap L E1.

2005 BMW 645Ci
Fig. 232: Identifying Bearing Cap L E1


2005 BMW 645Ci
Fig. 233: Locating Nuts Of Bearing Bracket


2005 BMW 645Ci

position.

2005 BMW 645Ci
Fig. 235: Clamping Support In Vise


2005 BMW 645Ci
Fig. 236: View Of Bearing Bracket


2005 BMW 645Ci
Fig. 237: Securing Bearing Bracket With Nut


2005 BMW 645Ci


2005 BMW 645Ci
Fig. 239: Locating Eccentric Shaft Sensor And Retaining Screws

2005 BMW 645Ci
Fig. 240: Raising One End Of Torsion Spring With Lever

2005 BMW 645Ci
Fig. 241: Attaching Holder Sleeve To End Of Torsion Spring

same position.
2005 BMW 645Ci

2005 BMW 645Ci
Fig. 243: Raising Second End Of Torsion Spring With Lever

2005 BMW 645Ci
Fig. 244: Attaching Holder Sleeve To Second End Of Torsion Spring

Release screw (1).

2005 BMW 645Ci


2005 BMW 645Ci
Fig. 246: Removing Torsion Spring And Holder Sleeve

Remove the intermediate levers and torsion springs of cylinders 1 to 3 according to the same procedure and set

2005 BMW 645Ci
Fig. 247: Unscrewing Knurled Nut

NOTE: Bearing caps are marked as illustrated with L E2 to L E5.
Remove bearing caps L E2 to L E5 and place to one side in order.

2005 BMW 645Ci
Fig. 248: Identifying Bearing Caps L E2 To L E5


2005 BMW 645Ci
Fig. 249: View Of Inlet Camshaft

NOTE: Further tasks: The article 11 37 008 REMOVING AND INSTALLING/REPLACING

RIGHT ECCENTRIC SHAFT (N62 FROM 9/03) contains important installation
instructions.
2005 BMW 645Ci
Fig. 250: Removing Compression Ring


2005 BMW 645Ci
Fig. 251: Removing Sensor Gear And Retaining Screw

Installation
2005 BMW 645Ci


2005 BMW 645Ci

2005 BMW 645Ci

Insert inlet camshaft (1) so that cams point upwards at 4th cylinder as shown in illustration.
2005 BMW 645Ci
Fig. 255: Aligning Inlet Camshaft


2005 BMW 645Ci
Fig. 256: Identifying Bearing Shells Alignment

2005 BMW 645Ci

NOTE: Bearing caps are marked as illustrated with L E2 to L E5.
Fit bearing caps L E2 to L E5.

2005 BMW 645Ci
Fig. 258: View Of Bearing Caps L E2 to L E5

2005 BMW 645Ci
Fig. 259: Tightening Knurled Nut

Fit special tool 11 9 472 as shown in illustration and align inlet camshaft.
2005 BMW 645Ci
Fig. 260: Aligning Inlet Camshaft In Support

2005 BMW 645Ci
Fig. 261: Locating Centering Sleeves

NOTE: Special tools 11 9 472 / 11 9 474 and 11 9 475 remain fitted until all torsion
2005 BMW 645Ci
Fig. 262: View Of Guide Bushes


2005 BMW 645Ci
Fig. 263: Installing Torsion Spring


2005 BMW 645Ci
Fig. 264: Inserting Screw

intermediate levers of the same tolerance class may be fitted in a single engine.
5. Used intermediate levers (2) may only be reused in the same position.
2005 BMW 645Ci


2005 BMW 645Ci
Fig. 266: Raising Torsion Spring With Holder Sleeve

2005 BMW 645Ci
Fig. 267: Installing Intermediate Lever


2005 BMW 645Ci
Fig. 268: Detaching Holder Sleeve

2005 BMW 645Ci
Fig. 269: Inserting End Of Torsion Spring Into Guide On Intermediate Lever

2005 BMW 645Ci
Fig. 270: Identifying Eccentric Shaft Sensor And Retaining Screws


2005 BMW 645Ci
Fig. 271: Removing Retaining Screws


2005 BMW 645Ci
Fig. 272: Removing Special Tool 11 9 472 And Special Tool 11 9 475

2005 BMW 645Ci
Fig. 273: Identifying Compression Rings Engaged Ends


2005 BMW 645Ci
Fig. 274: Aligning Rocker Arms


2005 BMW 645Ci
Fig. 275: Removing Knurled Nut

2005 BMW 645Ci
Fig. 276: Locating Bearing Bracket Nuts

Fit bearing cap L E1 in such a way that marking is legible from inlet side.
2005 BMW 645Ci
Fig. 277: View Of Bearing Cap L E1

Rotate inlet camshaft at hexagon head against direction of rotation until cam on 1st cylinder points downwards
at an angle as shown in illustration.
2005 BMW 645Ci
Fig. 278: Identifying Marking On Hexagon Drive Of Inlet Camshaft

Install right cylinder head cover. Refer to 11 12 006 REMOVING AND INSTALLING / SEALING RIGHT
CYLINDER HEAD COVER (N62 / N62TU).
Install servomotor for right eccentric shaft. Refer to Refer to 11 37 024 REMOVING AND
Assemble engine.
2005 BMW 645Ci
11 31 036 REMOVING AND INSTALLING/REPLACING LEFT EXHAUST CAMSHAFT (N62)
Removal
Removal of exhaust camshaft is described separately from installation.
Remove slide rail (1).
Fig. 279: Removing Slide Rail

2005 BMW 645Ci
Rotate exhaust camshaft at hexagon head until exhaust cam on cylinder (6) is facing upwards.
Fig. 280: Aligning Exhaust Cam On Cylinder 6 Upwards

CAUTION: Do not mix up the camshaft bearing covers of cylinders 1 to 4 and 5 to 8.
NOTE: Bearing caps of exhaust camshaft are marked on cylinder bank 5 to 8 with R A1
to R A5 from inlet side.
Release nuts and remove bearing cap R A1.

2005 BMW 645Ci
Fig. 281: Locating Bearing Cap R A1

NOTE: Retaining clips (1) for oil line are fitted on bearing caps 3 and 5.
Release nuts on bearing caps R A2 to R A5.

2005 BMW 645Ci
Fig. 282: Identifying Retaining Clips For Oil Line

Remove bearing caps R A2 to R A5.

2005 BMW 645Ci
Fig. 283: View Of Bearing Caps R A2 To R A5

Remove exhaust camshaft (1).

2005 BMW 645Ci
Fig. 284: Locating Exhaust Camshaft

CAUTION: Plain compression rings (1) can easily break.
2005 BMW 645Ci
Fig. 285: Removing Compression Ring


2005 BMW 645Ci
Fig. 286: Releasing Screw And Removing Sensor Gear

Installation
Installation of exhaust camshaft is described separately from removal.
Clean all bearings and cams of exhaust camshaft and lubricate with engine oil.
2005 BMW 645Ci


2005 BMW 645Ci

2005 BMW 645Ci

NOTE: Rocker arms (1) of exhaust camshaft are of same design as rocker arms of inlet
camshaft.
The classification 3 shown in the illustration has no affect on the function on the exhaust camshaft.
2005 BMW 645Ci
Fig. 290: Identifying Exhaust Rocker Arm

CAUTION: Rocker arms (1) slip slightly when exhaust camshaft is fitted. Make sure
rocker arms (1) are secured as illustrated on hydraulic valve clearance
compensating elements and on valves.
Used rocker arms (1) may only be reused in the same position.

2005 BMW 645Ci

Lubricate exhaust camshaft and bearing caps with engine oil.
Install exhaust camshaft (1).
Rotate exhaust camshaft (1) until exhaust cam on cylinder 2 is facing upwards.
2005 BMW 645Ci
Fig. 292: Installing Exhaust Camshaft

Check adapter sleeves (2) for damage and correct installation position.

2005 BMW 645Ci
Fig. 293: Identifying Adapter Sleeves

Fit bearing caps R A2 to R A5.

2005 BMW 645Ci
Fig. 294: Identifying Bearing Caps R A2 To R A5

2005 BMW 645Ci
Fig. 295: Locating Retaining Clips For Oil Line

Tighten down nuts on bearing caps R A2 to R A5 in 1/2 turn increments evenly from inside to outside.
Fit bearing cap R A1 in such a way that marking is legible from inlet side.

2005 BMW 645Ci
Fig. 296: Installing Bearing Cap Nuts

NOTE: A gasket (2) is installed between cylinder head and slide rail (1).
Replace gasket (2) and preinstall on slide rail (1).

2005 BMW 645Ci
Fig. 297: Identifying Gasket On Slide Rail

Install slide rail (1) with gasket, insert screw and tighten down.
2005 BMW 645Ci
Fig. 298: Installing Slide Rail With Gasket

Rotate exhaust camshaft against direction of rotation until cam on 1st cylinder points upwards at an angle as
shown in illustration.
2005 BMW 645Ci
Fig. 299: Aligning Cam On 1st Cylinder Upwards

Assemble engine.
11 31 038 REMOVING AND INSTALLING/REPLACING RIGHT EXHAUST CAMSHAFT (N62)

2005 BMW 645Ci
Removal
Removal of exhaust camshaft is described separately from installation.
Fig. 300: Removing Slide Rail

Rotate exhaust camshaft at hexagon head against direction of rotation until exhaust cam on cylinder (2) faces
upwards.
2005 BMW 645Ci
Fig. 301: Aligning Exhaust Cam On Cylinder Upwards

NOTE: Bearing caps of exhaust camshaft are marked on cylinder bank 1 to 4 with L A1
to L A5 from inlet side.
Release nuts and remove bearing cap L A1.

2005 BMW 645Ci
Fig. 302: Identifying Bearing Cap L A1 And Retaining Nuts

Release nuts on bearing caps L A2 to L A5.

2005 BMW 645Ci
Fig. 303: Locating Retaining Clips For Oil Line

Remove bearing caps L A2 to L A5.

2005 BMW 645Ci
Fig. 304: Removing Bearing Caps L A2 To L A5


2005 BMW 645Ci
Fig. 305: Removing Exhaust Camshaft

2005 BMW 645Ci
Fig. 306: Identifying Plain Compression Rings


2005 BMW 645Ci
Fig. 307: Removing Sensor Gear And Releasing Screw

Installation
2005 BMW 645Ci
Fig. 308: Locating Camshaft Groove


2005 BMW 645Ci

2005 BMW 645Ci

camshaft.
The classification 3 shown in the illustration has no affect on the function on the exhaust camshaft.
2005 BMW 645Ci
Fig. 311: Identifying Exhaust Rocker Arm Classification 3

CAUTION: Rocker arms (1) slip slightly when exhaust camshaft is fitted. Make sure
rocker arms (1) are secured as illustrated on hydraulic valve clearance
compensating elements and on valves.

2005 BMW 645Ci

2005 BMW 645Ci
Fig. 313: Installing Exhaust Camshaft

Check adapter sleeves (2) for damage and correct installation position.

2005 BMW 645Ci
Fig. 314: Locating Adapter Sleeves

Fit bearing caps L A2 to L A5.

2005 BMW 645Ci
Fig. 315: Identifying Bearing Caps L A2 To L A5

Tighten down nuts on bearing caps L A2 to L A5 in 1/2 turn increments evenly from inside to outside.

2005 BMW 645Ci
Fig. 316: Identifying Retaining Clips For Oil Line

Fit bearing cap L A1 in such a way that marking is legible from inlet side.

2005 BMW 645Ci
Fig. 317: Identifying Bearing Cap L A1


2005 BMW 645Ci
Fig. 318: Identifying Slide Rail Gasket

2005 BMW 645Ci
Fig. 319: Installing Slide Rail With Gasket

2005 BMW 645Ci
Fig. 320: Identifying Exhaust Camshaft Position

Assemble engine.
11 31 052 REPLACING BOTH TIMING CHAINS (N62/N62TU)

2005 BMW 645Ci
 11 2 001
 11 2 002
 11 2 003
 11 2 007
 Remove lower timing case cover, refer to 11 14 110 REMOVING AND INSTALLING BOTTOM
TIMING CASE COVER (N62/N62TU).
Remove timing chain (1).
Fig. 321: Removing Timing Chains


2005 BMW 645Ci
Release screws (7).
Remove guide rails (3 and 6).
Remove tensioning rails (2 and 4).
Installation:
Maintain tension of timing chains when installing timing case cover.
Observe sparking protection on timing case cover.
Make sure timing chain (1) is correctly installed when placing it in guide rail (3).
Attach special tools 11 2 001 and 11 2 002 to crankshaft.
Fig. 322: Removing Sprocket Wheel

2005 BMW 645Ci
Insert special tool 11 2 007 and remove sprocket wheel with special tool 11 2 003.
Installation:
Check sprocket wheels for wear, replace if necessary. Heat sprocket wheel to 60 °C.
WARNING: Burning hazard! Wear gloves.
Assemble engine.
11 31 070 CHECKING CAMSHAFT TIMING ON LEFT SIDE (N62)
 11 9 190
 11 9 461
 11 9 462
Remove all spark plugs on cylinder bank 5 to 8.
If necessary, remove fan cowl.
CAUTION: Screw (1) is a special screw and must not be replaced with a normal M8
screw.
Release screw (1).
Unclip oil line (3) from retainers (2) and remove.

2005 BMW 645Ci
Fig. 323: Unclipping And Removing Oil Line From Retainers

Crank engine at central bolt in direction of rotation to firing TDC position of 1st cylinder.
NOTE: With 1st cylinder in firing TDC position, cams of inlet and exhaust camshafts at
5th cylinder point upwards at an angle as shown in illustration.
2005 BMW 645Ci
Fig. 324: Identifying Inlet And Exhaust Camshafts

NOTE: Alignment hole for TDC position is at front on timing case cover.
Crank engine at central bolt and secure vibration damper with special tool 11 9 190 in firing TDC position of
1st cylinder.
2005 BMW 645Ci
Fig. 325: Securing Vibration Damper With Special Tool 11 9 190

CAUTION: When the engine is shut down, the inlet and exhaust adjustment unit is
normally locked in its initial position.
The situation may arise in some individual cases where this initial position is not reached and the camshaft can
continue to be rotated in the adjustment range of the adjustment unit.
In order to avoid incorrect timing adjustment, it is essential to check the locking of the adjustment unit and if
necessary perform locking by rotating the camshafts.
Checking locking of inlet adjustment unit in initial position:
Engage hexagon head of inlet camshaft and attempt to rotate inlet camshaft carefully against direction of
rotation.
2005 BMW 645Ci
If there is no fixed connection between inlet camshaft and inlet adjustment unit, rotate inlet camshaft against
direction of rotation as far as it will go.
The inlet adjustment unit is locked in the initial position when the inlet camshaft is non-positively connected to
the inlet adjustment unit.
Fig. 326: Checking Locking Of Inlet Adjustment Unit In Initial Position

Checking locking of exhaust adjustment unit in initial position:
Engage hexagon head of exhaust camshaft and attempt to rotate exhaust camshaft carefully in direction of
rotation.
If there is no fixed connection between exhaust camshaft and exhaust adjustment unit, rotate exhaust camshaft
in direction of rotation as far as it will go.
The exhaust adjustment unit is locked in the initial position when the exhaust camshaft is non-positively
connected to the exhaust adjustment unit.
2005 BMW 645Ci
Fig. 327: Checking Locking Of Exhaust Adjustment Unit In Initial Position

CAUTION: If the inlet or exhaust adjustment unit of the camshafts "cannot" be locked
as described, the adjustment unit is faulty and must be replaced.
Place special tool 11 9 461 on inlet camshaft and check timing.
NOTE: The timing is correctly adjusted when special tool 11 9 461 rests flat on the
cylinder head or protrudes by up to 0.5 mm to the exhaust side.
Remove special tool 11 9 461 from inlet camshaft.

2005 BMW 645Ci
Fig. 328: Placing Special Tool 11 9 461 On Inlet Camshaft And Checking Timing
Place special tool 11 9 462 on exhaust camshaft and check timing.
If necessary, adjust camshaft timing on left side.

2005 BMW 645Ci
Fig. 329: Placing Special Tool 11 9 462 On Exhaust Camshaft And Checking Timing
Remove all special tools.
screw.
Clip oil line (3) into retainers (2).

2005 BMW 645Ci
Fig. 330: Clipping Oil Line Into Retainers

Assemble engine.
11 31 071 CHECKING CAMSHAFT TIMING ON RIGHT SIDE (N62)
 11 9 190
 11 9 461
 11 9 462
 Remove servomotor fro right eccentric shaft

 Remove all spark plugs on cylinder bank 1 to 4
2005 BMW 645Ci
 If necessary, remove fan cowl
IMPORTANT: Screw (1) is a special screw and must not be replaced with a normal M8 screw.
Release screw (1).
Fig. 331: Unclipping Oil Line From Retainers

NOTE: In firing TDC position, cam of exhaust camshaft at 1st cylinder points upwards
at an angle.
Cam of inlet camshaft points downwards at an angle:

2005 BMW 645Ci
Fig. 332: Identifying Cam Of Inlet Camshaft Points Angle

1st cylinder.
2005 BMW 645Ci

IMPORTANT: When the engine is shut down, the inlet and exhaust adjustment unit is
normally locked in its initial position. The situation may arise in some
individual cases where this initial position is not reached and the camshaft can
continue to be rotated in the adjustment range of the adjustment unit. In order
to avoid incorrect timing adjustment, it is essential to check the locking of the
adjustment unit and if necessary perform locking by rotating the camshafts.
rotation.
2005 BMW 645Ci
Fig. 334: Checking Locking Of Inlet Adjustment

rotation.
2005 BMW 645Ci
Fig. 335: Locking Exhaust Adjustment Unit In Initial Position

IMPORTANT: If the inlet or exhaust adjustment unit of the camshafts "cannot" be locked as
described, the adjustment unit is faulty and must be replaced.

2005 BMW 645Ci
Fig. 336: Placing Special Tool 11 9 461 On Inlet Camshaft

2005 BMW 645Ci
Fig. 337: Placing Special Tool 11 9 462 On Exhaust Camshaft

If necessary, adjust camshaft timing on right side, refer to 11 31 574 ADJUSTING CAMSHAFT TIMING
ON RIGHT SIDE (N62 / N62TU).
Assemble engine.
2005 BMW 645Ci

11 31 573 ADJUSTING CAMSHAFT TIMING ON LEFT SIDE (N62 / N62TU)
 11 9 190
 11 9 460
 11 9 461
 11 9 462
 11 9 463
 Check camshaft timing on left side

 Remove left timing case cover. Refer to 11 14 080 REMOVING AND INSTALLING TOP LEFT
TIMING CASE COVER (N62).
2005 BMW 645Ci
NOTE: When slackening screws, grip camshafts at hexagon head.
Slacken screws of exhaust and inlet adjustment unit.
Fig. 339: Identifying Screws Of Exhaust And Inlet Adjustment Unit

Get special tool kit 11 9 460 ready for securing camshafts.
NOTE: Special tool 11 9 461 for securing inlet camshaft.
Special tool 11 9 462 for securing exhaust camshaft.
Special tool 11 9 463 (holder with screw).

2005 BMW 645Ci
Fig. 340: Identifying Special Tool Kit 11 9 460 For Securing Camshafts
Place special tool 11 9 461 on inlet camshaft and align inlet camshaft so that special tool 11 9 461 rests without
a gap on cylinder head.
2005 BMW 645Ci
Fig. 341: Placing Special Tool 11 9 461 On Inlet Camshaft And Aligning Inlet Camshaft
Fit special tool 11 9 463, secure screw (1) in thread for oil line and tighten down by hand.
2005 BMW 645Ci
Fig. 342: Fitting Special Tool 11 9 463, Securing Screw In Thread For Oil Line
NOTE: When tightening down screw (1), grip camshaft at hexagon head.
Tighten down screw (1) of inlet adjustment unit.

2005 BMW 645Ci
Fig. 343: Tightening Down Screw Of Inlet Adjustment Unit

Release screw (1), remove special tools 11 9 463 and 11 9 461 from inlet camshaft.
2005 BMW 645Ci
Fig. 344: Releasing Screw And Removing Special Tools 11 9 463 And 11 9 461 From Inlet Camshaft
Place special tool 11 9 462 on exhaust camshaft and align exhaust camshaft so that special tool 11 9 462 rests
without a gap on cylinder head.
2005 BMW 645Ci
Fig. 345: Placing Special Tool 11 9 462 On Exhaust Camshaft And Aligning Exhaust Camshaft
2005 BMW 645Ci
Tighten down screw (2) of exhaust adjustment unit.

2005 BMW 645Ci
Fig. 347: Tightening Screw Of Exhaust Adjustment Unit

Release screw (1), remove special tools 11 9 463 and 11 9 462 from exhaust camshaft.
2005 BMW 645Ci
Fig. 348: Identifying Special Tools 11 9 463 and 11 9 462

Crank engine at central bolt twice in direction of rotation until engine returns to firing TDC position of 1st
cylinder.
Secure vibration damper with special tool 11 9 190 in firing TDC position of 1st cylinder.
2005 BMW 645Ci
Fig. 349: Securing Vibration Damper With Special Tool 11 9 190 In Firing TDC Position Of 1st Cylinder

2005 BMW 645Ci

2005 BMW 645Ci
Assemble engine.
11 31 574 ADJUSTING CAMSHAFT TIMING ON RIGHT SIDE (N62 / N62TU)
 11 9 190
 11 9 460
 11 9 461
2005 BMW 645Ci
 11 9 463
 Are described in the operation "Checking camshaft timing on right side".

 Remove right timing case cover


2005 BMW 645Ci
2005 BMW 645Ci
2005 BMW 645Ci
Fig. 355: Fitting Special Tool, Securing Screw In Thread For Oil Line And Tightening Down By Hand

2005 BMW 645Ci
Fig. 356: Identifying Screw Of Inlet Adjustment Unit

2005 BMW 645Ci
Fig. 357: Releasing Screw, Removing Special Tools 11 9 463 And 11 9 461 From Inlet Camshaft
2005 BMW 645Ci
2005 BMW 645Ci

2005 BMW 645Ci
Fig. 360: Tightening Screw Of Exhaust Adjustment Unit

2005 BMW 645Ci
Fig. 361: Releasing Screw And Removing Special Tools 11 9 463 And 11 9 462 From Exhaust Camshaft

2005 BMW 645Ci

cylinder.

2005 BMW 645Ci

2005 BMW 645Ci
Fig. 364: Identifying Placing Special Tool 11 9 462

Assemble engine.
11 33 516 REMOVING AND INSTALLING/REPLACING ROCKER ARMS ON LEFT INLET SIDE

(N62 FROM 9/03)
 11 9 470
 11 9 473
2005 BMW 645Ci
Removal
Removal of rocker arms is described separately from installation.
2005 BMW 645Ci
Fig. 365: Identifying Lettering On 8th Cylinder Of Camshaft

Fig. 366: Releasing Nuts And Removing Bearing Cap R E1


2005 BMW 645Ci
Fig. 367: Releasing Nuts Of Bearing Bracket From Outside To Inside


2005 BMW 645Ci


2005 BMW 645Ci
Fig. 369: Lifting Out Bearing Bracket


2005 BMW 645Ci
Fig. 370: Securing Bearing Bracket With Nut (Special Tool 11 9 473)

2005 BMW 645Ci

position.
Remove rocker arms (1) on inlet side and set aside in neat order.
2005 BMW 645Ci
Fig. 372: Removing Rocker Arms On Inlet Side

Installation
Installation of rocker arms is described separately from removal.

2005 BMW 645Ci
Fig. 373: Identifying Compression Rings (1)

Install rocker arms (1) on inlet side.

2005 BMW 645Ci
Fig. 374: Identifying Rocker Arms (1)


2005 BMW 645Ci
Fig. 375: Identifying Bearing Bracket (1) And Special Tools 11 9 470 And 11 9 473

2005 BMW 645Ci
Fig. 376: Tighten Down 8 Nuts Of Bearing Bracket (1) From Inside To Outside
2005 BMW 645Ci
Fig. 377: Fit Bearing Cap R E1

illustration.
2005 BMW 645Ci
Fig. 378: Rotate Cam Until 5th Cylinder Points Upwards At An Angle
Assemble engine.
2005 BMW 645Ci
11 33 517 REMOVING AND INSTALLING/REPLACING ROCKER ARMS ON RIGHT INLET SIDE

(N62 FROM 9/03)
 11 9 470
 11 9 473
Removal
illustration.
2005 BMW 645Ci
Fig. 379: Rotating Inlet Camshaft Until Cam On 1st Cylinder Is Positioned Horizontally
E5 from inlet side.

2005 BMW 645Ci
Fig. 380: Releasing Nuts And Removing Bearing Cap L E1


2005 BMW 645Ci


2005 BMW 645Ci


2005 BMW 645Ci


2005 BMW 645Ci

2005 BMW 645Ci
Fig. 385: Identifying Lowering Section Of Bearing Bracket Remaining On Cylinder Head
2005 BMW 645Ci
Fig. 386: Identifying Tolerance Classes On Rocker Arms

position.
Installation

2005 BMW 645Ci


2005 BMW 645Ci
Fig. 388: Identifying Correct Installation Of Rocker Arm On Inlet Side


2005 BMW 645Ci
Fig. 389: Removing Special Tool 11 9 473 And Bearing Bracket (1) From Special Tool 11 9 470

2005 BMW 645Ci
Fig. 390: Tighten Down Nuts From Inside To Outside


2005 BMW 645Ci
Fig. 391: Installing Camshaft Bearing Cover Nuts

2005 BMW 645Ci

Install servomotor for right eccentric shaft.
Assemble engine.
2005 BMW 645Ci

(N62 FROM 9/03)
 11 9 470
 11 9 473
Removal
2005 BMW 645Ci
Fig. 393: Identifying Inlet Camshaft Position


2005 BMW 645Ci
Fig. 394: Removing Bearing Cap R E1


2005 BMW 645Ci


2005 BMW 645Ci
Fig. 396: Clamping Special Tool 11 9 470


2005 BMW 645Ci
Fig. 397: Lifting Out Bearing Bracket (1)


2005 BMW 645Ci
Fig. 398: Securing Bearing Bracket (1) With A Nut (Special Tool 11 9 473)

2005 BMW 645Ci
Fig. 399: Identifying Lower Section Of Bearing Bracket Position

position.
2005 BMW 645Ci

Installation

2005 BMW 645Ci


2005 BMW 645Ci


2005 BMW 645Ci
Fig. 403: Removing Special Tools 11 9 473/11 9 470


2005 BMW 645Ci
Fig. 404: Tightening Down Nuts From Inside To Outside


2005 BMW 645Ci
Fig. 405: Fitting Bearing Cap

illustration.
2005 BMW 645Ci

Assemble engine.
2005 BMW 645Ci

(N62 FROM 9/03)
 11 9 470
 11 9 473
Removal
illustration.
2005 BMW 645Ci
Fig. 407: Identifying Inlet Camshaft Position

E5 from inlet side.

2005 BMW 645Ci
Fig. 408: Removing Bearing Cap L E1


2005 BMW 645Ci


2005 BMW 645Ci
Fig. 410: Clamping Special Tool 11 9 470


2005 BMW 645Ci
Fig. 411: Lifting Out Bearing Bracket (1)


2005 BMW 645Ci
Fig. 412: Placing Bearing Bracket With Inlet Camshaft And Eccentric Shaft On Special Tool 11 9 470

2005 BMW 645Ci

position.
2005 BMW 645Ci

Installation

2005 BMW 645Ci


2005 BMW 645Ci
Fig. 416: Aligning Rocker Arms (1)


2005 BMW 645Ci
Fig. 417: Removing Special Tool 11 9 473/11 9 470


2005 BMW 645Ci


2005 BMW 645Ci
Fig. 419: Fitting Bearing Cap L E1

2005 BMW 645Ci
Fig. 420: Identifying Marking On Hexagon Drive Of Inlet Camshaft Position

Install servomotor for right eccentric shaft. Refer to 11 37 024 REMOVING AND
Assemble engine.
2005 BMW 645Ci
VALVES WITH SPRINGS

11 34 552 REMOVING AND INSTALLING/REPLACING ALL VALVES (N62)
(cylinder head removed)
Preliminary tasks are described in Disassembling and assembling cylinder head, refer to 11 12 503
DISASSEMBLING AND ASSEMBLING CYLINDER HEAD (N62/N62TU).
Remove valve springs, refer to 11 34 715 REPLACING ALL VALVE SPRINGS (N62).
Remove valve stem seals, refer to 11 34 560 REPLACING ALL VALVE STEM SEALS (N62).
Remove valves from cylinder head.
Installation:
If necessary, check valve guide for wear, refer to 11 12 595 CHECKING A VALVE GUIDE FOR WEAR
(N62).
If necessary, remachine valve seat, refer to 11 12 527 REMACHINING A VALVE SEAT - CYLINDER
HEAD DISASSEMBLED (N62).
IMPORTANT: Incorrect installation possible. Valve springs of exhaust and inlet camshafts
are different. Incorrect installation will result in engine damage.
NOTE: Valve springs for exhaust valves are approx. 4 mm longer.
1. Valve springs of inlet valves

2. Valve springs of exhaust valves
2005 BMW 645Ci
Fig. 421: Identifying Difference Between Dimensions Of Inlet And Exhaust valves
IMPORTANT: Incorrect installation possible. Incorrect installation will result in valve spring
breakage. Color marking (1) is normally on lower end of valve spring. Only the
diameter is decisive for the correct installation of the valve springs. Install
valve spring so that larger diameter points to spring plate at bottom.
2005 BMW 645Ci
Fig. 422: Identifying Color Marking On Lower End Of Valve Spring

Arrangement:
2005 BMW 645Ci
Fig. 423: Identifying Arrangement Of valve

11 34 560 REPLACING ALL VALVE STEM SEALS (N62)
 11 1 380
2005 BMW 645Ci
 11 6 380
Press special tool 11 6 370 onto valve stem seal.
Withdraw valve stem seal by turning and simultaneously unscrewing special tool 11 6 370.
Fig. 424: Pressing Special Tool 11 6 370 Onto Valve Stem Seal
Installation:
Lubricate valve stem with oil and insert valve.
Fit special tool 11 1 380.

2005 BMW 645Ci
Fig. 425: Fit Special Tool 11 1 380

Coat new valve stem seal (1) with oil and install.
NOTE: For use on the N62 engine, special tool 11 6 380 must be remachined in
accordance with the illustration with a 6.2 mm dia. drill bit to a depth of A =
approx. 45 mm.
This modification has already been taken into account for reordering.
2005 BMW 645Ci
Fig. 426: Identifying Dimension Of Remachined Tool

Press on valve stem seal with special tool 11 6 380 by hand as far as it will go.
2005 BMW 645Ci
Fig. 427: Pressing On Valve Stem Seal With Special Tool 11 6 380
11 34 715 REPLACING ALL VALVE SPRINGS (N62)
 11 0 346
 11 9 470
2005 BMW 645Ci
Remove bearing bracket (1) with inlet camshaft and stow in special tool 11 9 470. The procedure is described in
9/03) and 11 31 034 REMOVING AND INSTALLING/REPLACING RIGHT INLET CAMSHAFT (N62
Removing and installing inlet camshaft.
Fig. 428: Removing Bearing Bracket With Inlet Camshaft

Remove exhaust camshaft.
Align special tool 11 0 346 in direction of valve shaft.

2005 BMW 645Ci
Fig. 429: Aligning Special Tool 11 0 346 In Direction Of Valve Shaft

Press down valve spring on spring cap, top, and remove valve keys.
2005 BMW 645Ci
Fig. 430: Pressing Down Valve Spring On Spring Cap, Top, And Removing Valve Keys
CAUTION: Incorrect installation possible. Valve springs of exhaust and inlet

camshafts are different. Incorrect installation will result in engine damage.
2005 BMW 645Ci

Fig. 431: Identifying Difference Between Dimensions Of Inlet And Exhaust valves
CAUTION: Incorrect installation possible. Incorrect installation will result in valve

spring breakage. The color coding (1) is normally located on the lower end
of the valve spring. Only the diameter is decisive for the correct
installation of the valve springs. Install valve spring so that larger diameter
points to spring plate at bottom.
2005 BMW 645Ci

Arrangement:
2005 BMW 645Ci
Fig. 433: Identifying Arrangement Of Valve

VARIABLE CAMSHAFT TIMING

11 31 070 CHECKING CAMSHAFT TIMING ON LEFT SIDE (N62)

2005 BMW 645Ci
 11 9 190
 11 9 461
 11 9 462
screw.
Release screw (1).

2005 BMW 645Ci
Fig. 434: Unclipping Oil Line From Retainers

Fig. 435: Identifying Cams Of Inlet And Exhaust Camshafts 5th Cylinder Point
1st cylinder.
2005 BMW 645Ci

individual cases where this initial position is not reached and the camshaft
can continue to be rotated in the adjustment range of the adjustment unit.
In order to avoid incorrect timing adjustment, it is essential to check the
locking of the adjustment unit and if necessary perform locking by rotating
the camshafts.
rotation.
2005 BMW 645Ci

rotation.
2005 BMW 645Ci


2005 BMW 645Ci
Fig. 439: Placing Special Tool On Inlet Camshaft 11 9 461

2005 BMW 645Ci
Fig. 440: Placing Special Tool On Exhaust Camshaft 11 9 462

If necessary, adjust camshaft timing on left side.
screw.

2005 BMW 645Ci

Assemble engine.
11 31 071 CHECKING CAMSHAFT TIMING ON RIGHT SIDE (N62)
 11 9 190
 11 9 461
 11 9 462
 Remove servomotor for right eccentric shaft, refer to 11 37 024 REMOVING AND
2005 BMW 645Ci

Release screw (1).

at an angle.

2005 BMW 645Ci
Fig. 443: Identifying Cam Of Inlet Camshaft Pointing Downwards

1st cylinder.
2005 BMW 645Ci

individual cases where this initial position is not reached and the camshaft can
continue to be rotated in the adjustment range of the adjustment unit. In order
to avoid incorrect timing adjustment, it is essential to check the locking of the
adjustment unit and if necessary perform locking by rotating the camshafts.
rotation.
2005 BMW 645Ci

rotation.
2005 BMW 645Ci

2005 BMW 645Ci
Fig. 447: Placing Special Tool 11 9 461 On Inlet Camshaft And Check Timing
2005 BMW 645Ci
Fig. 448: Placing Special Tool 11 9 462 On Exhaust Camshaft And Check Timing
If necessary, adjust camshaft timing on right side, refer to 11 31 574 ADJUSTING CAMSHAFT TIMING
ON RIGHT SIDE (N62 / N62TU).

2005 BMW 645Ci

Assemble engine.
 11 9 190
 11 9 460
 11 9 461
 11 9 462
 11 9 463
 Check camshaft timing on left side, refer to 11 31 070 CHECKING CAMSHAFT TIMING ON LEFT
SIDE (N62).
2005 BMW 645Ci
 Remove left timing case cover. Refer to 11 14 080 REMOVING AND INSTALLING TOP LEFT
TIMING CASE COVER (N62).


2005 BMW 645Ci
Fig. 451: Identifying Special Tools 11 9 461/11 9 461/11 9 463

2005 BMW 645Ci

2005 BMW 645Ci
Fig. 453: Fitting Special Tool 11 9 463


2005 BMW 645Ci
Fig. 454: Identifying Screw Of Inlet Adjustment Unit

2005 BMW 645Ci
Fig. 455: Removing Special Tools 11 9 463/11 9 461 From Inlet Camshaft
2005 BMW 645Ci

2005 BMW 645Ci


2005 BMW 645Ci
Fig. 458: Tightening Down Screw (2) Of Exhaust Adjustment Unit

2005 BMW 645Ci
Fig. 459: Removing Special Tools 11 9 463/11 9 462 And From Exhaust Camshaft
cylinder.
2005 BMW 645Ci


2005 BMW 645Ci
2005 BMW 645Ci

Assemble engine.
 11 9 190
 11 9 460
 11 9 461
2005 BMW 645Ci
 11 9 463
 Are described in the operation "Checking camshaft timing on right side", refer to 11 31 071 CHECKING
CAMSHAFT TIMING ON RIGHT SIDE (N62).
 Remove right timing case cover, refer to 11 14 085 REMOVING AND INSTALLING TOP RIGHT
Fig. 463: Slackening Screws Of Exhaust And Inlet Adjustment Unit

NOTE: Special tool 11 9 461 for securing inlet camshaft. Special tool 11 9 462 for
securing exhaust camshaft. Special tool 11 9 463 (holder with screw).
2005 BMW 645Ci
Fig. 464: Identifying Special Tools 11 9 461/11 9 462/11 9 463

2005 BMW 645Ci

2005 BMW 645Ci


2005 BMW 645Ci
Fig. 467: Identifying Screw (1) Of Inlet Adjustment Unit

2005 BMW 645Ci
Fig. 468: Removing Special Tools 11 9 463/11 9 461 From Inlet Camshaft
2005 BMW 645Ci

2005 BMW 645Ci


2005 BMW 645Ci
Fig. 471: Identifying Screw (2) Of Exhaust Adjustment Unit

2005 BMW 645Ci
Fig. 472: Removing Special Tools From Exhaust Camshaft

cylinder.
2005 BMW 645Ci


2005 BMW 645Ci

2005 BMW 645Ci

Assemble engine.
11 36 047 REMOVING AND INSTALLING/REPLACING INLET AND EXHAUST ADJUSTMENT

UNITS ON LEFT SIDE (N62)
 11 9 190
 11 9 460
2005 BMW 645Ci
 11 9 462
 11 9 463
Read fault memory and make a documentary record.
Remove left timing case cover. Refer to 11 14 080 REMOVING AND INSTALLING TOP LEFT TIMING
CASE COVER (N62).
Removal
Removal of inlet and exhaust adjustment units is described separately from installation.
screw.
Release screw (1).

2005 BMW 645Ci

2005 BMW 645Ci
Fig. 477: Identifying Cams Of Inlet And Exhaust Camshafts At 5th Cylinder
1st cylinder.
2005 BMW 645Ci

the camshafts.
rotation.
2005 BMW 645Ci

rotation.
2005 BMW 645Ci

Crank engine at central bolt against direction of rotation to 45° before TDC position.
2005 BMW 645Ci
Fig. 481: Cranking Engine At Central Bolt Against Direction Of Rotation To 45° Before TDC Position

2005 BMW 645Ci

Remove screw on exhaust adjustment unit.

2005 BMW 645Ci
Fig. 483: Identifying Screw On Exhaust Adjustment Unit

Vigorously press back tensioner rail (3) several times to remove oil in chain tensioner.
Feed out exhaust adjustment unit (2).

2005 BMW 645Ci
Fig. 484: Feeding Out Exhaust Adjustment Unit

Remove screw on inlet adjustment unit.

2005 BMW 645Ci
Fig. 485: Identifying Screw On Inlet Adjustment Unit

Feed out inlet adjustment unit (1).
Secure timing chain against slipping down.

2005 BMW 645Ci
Fig. 486: Identifying Inlet Adjustment Unit

Installation
Installation of inlet and exhaust adjustment units is described separately from removal.
CAUTION: Risk of mixing up parts.
The inlet and exhaust adjustment units are different.
Mixing up the inlet and exhaust adjustment units will cause damage to the engine.
1. Inlet adjustment unit (1) is marked with EIN and IN

2. Exhaust adjustment unit (2) is marked with AUS and EX
2005 BMW 645Ci
Fig. 487: Identifying Inlet Adjustment Unit And Exhaust Adjustment Unit
NOTE: Position of inlet adjustment unit (1) to timing chain can be freely selected.
Pull timing chain up.
Feed inlet adjustment unit (1) into timing chain and fit onto inlet camshaft.
2005 BMW 645Ci

Replace screw.
Install screw on inlet adjustment unit.
Tighten screw without play and then slacken off again by half a turn.
2005 BMW 645Ci
Fig. 489: Tightening Inlet Adjustment Unit Screw

NOTE: Position of exhaust adjustment unit (2) to timing chain can be freely selected.
Feed exhaust adjustment unit (2) into timing chain.
Press tensioner rail (3) back and fit exhaust adjustment unit (2) onto exhaust camshaft.
NOTE: If tensioner rail (3) cannot be pressed back far enough to enable fitting of
exhaust adjustment unit (2):
Remove chain tensioner. Place chain tensioner on a level surface and compress slowly and carefully. Repeat
this procedure twice.
2005 BMW 645Ci
Fig. 490: Pressing Tensioner Rail Back And Fitting Exhaust Adjustment Unit Onto Exhaust Camshaft
Installation:
Replace sealing ring. Install chain tensioner and tighten down.
Tightening torque, of chain tensioner, refer to 11 31 8AZ in ENGINE - TIGHTENING TORQUES .
Fit exhaust adjustment unit (2).
Replace screw.
Install screw on exhaust adjustment unit.
2005 BMW 645Ci
Fig. 491: Installing Screw On Exhaust Adjustment Unit

2005 BMW 645Ci
2005 BMW 645Ci
2005 BMW 645Ci
Fig. 494: Fitting Special Tool 11 9 463 And Securing Screw In Thread For Oil Line And Tightening
Down By Hand
CAUTION: Make sure screws of inlet and exhaust adjustment units have been
slackened off by a half turn.
Crank engine at central bolt from 45° before TDC position in direction of rotation to firing TDC position.
2005 BMW 645Ci

Tightening torque, refer to, 11 36 16AZ in ENGINE - TIGHTENING TORQUES .

2005 BMW 645Ci
Fig. 496: Tightening Down Screw Of Inlet Adjustment Unit

2005 BMW 645Ci
Fig. 497: Releasing Screw And Removing Special Tools 11 9 463/11 9 461 From Inlet Camshaft
2005 BMW 645Ci
2005 BMW 645Ci
Down By Hand
Tightening torque, refer to, 11 36 16AZ in ENGINE - TIGHTENING TORQUES .

2005 BMW 645Ci
Fig. 500: Tightening Down Screw Of Exhaust Adjustment Unit

2005 BMW 645Ci
Fig. 501: Releasing Screw And Removing Special Tools 11 9 463/11 9 462 From Exhaust Camshaft
cylinder.
2005 BMW 645Ci


2005 BMW 645Ci
Fig. 503: Placing Special Tool 11 9 461 On Inlet Camshaft And Checking Timing
2005 BMW 645Ci
screw.
Assemble engine.
2005 BMW 645Ci


UNITS ON RIGHT SIDE (N62)
 11 9 190
 11 9 460
 11 9 461
 11 9 462
 11 9 463
Read fault memory and make a documentary record.
2005 BMW 645Ci
Remove right timing case cover, refer to 11 14 085 REMOVING AND INSTALLING TOP RIGHT
Removal
screw.
Release screw (1).

2005 BMW 645Ci
at an angle.
Fig. 507: Identifying Cam Of Inlet Camshaft Points Downwards At An Angle

1st cylinder.
2005 BMW 645Ci

the camshafts.
rotation.
2005 BMW 645Ci

rotation.
2005 BMW 645Ci

2005 BMW 645Ci
Fig. 511: Cranking Engine At Central Bolt Against Direction Of Rotation To 45° Before TDC Position

2005 BMW 645Ci
Fig. 512: Slackening Screws Of Exhaust And Inlet Adjustment Unit


2005 BMW 645Ci
Fig. 513: Removing Screw On Inlet Adjustment Unit


2005 BMW 645Ci
Fig. 514: Feeding Out Inlet Adjustment Unit


2005 BMW 645Ci
Fig. 515: Removing Screw On Exhaust Adjustment Unit


2005 BMW 645Ci
Fig. 516: Feeding Out Exhaust Adjustment Unit

Secure timing chain against slipping down.
Installation
CAUTION: Risk of mixing up parts.
The inlet and exhaust adjustment units are different.
1. Inlet adjustment unit (1) is marked with EIN and IN

2. Exhaust adjustment unit (2) is marked with AUS and EX
2005 BMW 645Ci
Fig. 517: Identifying Inlet Adjustment Unit And Exhaust Adjustment Unit
NOTE: The exhaust adjustment unit on cylinder bank 1 to 4 also has a metal clip (3) for
driving the vacuum pump.
2005 BMW 645Ci
Fig. 518: Identifying Metal Clip For Driving Vacuum Pump

Feed exhaust adjustment unit (2) into timing chain and fit onto exhaust camshaft.
2005 BMW 645Ci
Fig. 519: Feeding Exhaust Adjustment Unit Into Timing Chain And Fitting Onto Exhaust Camshaft
Replace screw.

2005 BMW 645Ci
Fig. 520: Installing Screw On Exhaust Adjustment Unit

Feed inlet adjustment unit (1) into timing chain.
Press tensioner rail (3) back and fit inlet adjustment unit (1) onto inlet camshaft.
2005 BMW 645Ci
Fig. 521: Pressing Tensioner Rail Back And Fitting Inlet Adjustment Unit Onto Inlet Camshaft
NOTE: If tensioner rail (3) cannot be pressed back far enough to enable fitting of inlet
adjustment unit (1):
Slacken off chain tensioner by approx. three turns.
Fit inlet adjustment unit (1).
Replace and insert screw on inlet adjustment unit (1).
Tighten down chain tensioner.
Tightening torque, of chain tensioner, refer to 11 31 8AZ in ENGINE - TIGHTENING TORQUES .
Tighten screw on inlet adjustment unit without play and then slacken off again by a half turn.
2005 BMW 645Ci
Fig. 522: Tightening Screw On Inlet Adjustment Unit Without Play And Slacken Off Again By Half Turn
2005 BMW 645Ci
2005 BMW 645Ci
2005 BMW 645Ci
Down By Hand
CAUTION: Make sure screws of inlet and exhaust adjustment units have been
slackened off.
2005 BMW 645Ci


2005 BMW 645Ci
Fig. 527: Tightening Screw (1) Of Inlet Adjustment Unit

2005 BMW 645Ci
Fig. 528: Releasing Screw And Removing Special Tools 11 9 463/11 9 461 From Inlet Camshaft
2005 BMW 645Ci
2005 BMW 645Ci
Fig. 530: Fitting Special Tool And Securing Screw In Thread For Oil Line

2005 BMW 645Ci
Fig. 531: Tightening Screw (2) Of Exhaust Adjustment Unit

2005 BMW 645Ci
Fig. 532: Releasing Screw And Removing Special Tools 11 9 463/11 9 462 From Exhaust Camshaft
cylinder.
2005 BMW 645Ci

2005 BMW 645Ci
2005 BMW 645Ci
Fig. 535: Placing Special Tool 11 9 462 On Exhaust Camshaft And Check Timing
screw.

2005 BMW 645Ci

Assemble engine.
11 36 715 REMOVING AND INSTALLING/REPLACING BOTH SOLENOID VALVES ON LEFT

SIDE (N62)
 Read out fault memory of control unit of Digital Motor Electronics (DME).
 Unlock hose on tank venting valve and disconnect.
NOTE: Solenoid valve (1) controls adjusting unit on inlet side.
Solenoid valve (2) controls adjusting unit on exhaust side.

2005 BMW 645Ci
Fig. 537: Unlocking Plug Of Solenoid Valves (1 And 2)

Pull out solenoid valves (1 and 2).
Installation:
Check holder (3) for deformation; replace if necessary.
Installation:
Clean sealing faces (1) on cylinder head.

2005 BMW 645Ci
Fig. 538: Cleaning Sealing Faces On Cylinder Head

Installation:
Replace O-rings (1 and 2) on solenoid valve (3) and lubricate.

2005 BMW 645Ci
Fig. 539: Replacing O-Rings (1 And 2) On Solenoid Valve

Installation:
Press in solenoid valve as far as it will go.

2005 BMW 645Ci
Fig. 540: Pressing In Solenoid Valve

Make sure holders are in correct installation positions.
Install and tighten down screws.
11 36 720 REMOVING AND INSTALLING/REPLACING BOTH SOLENOID VALVES ON RIGHT

SIDE (N62)
 Read out fault memory of control unit of Digital Motor Electronics (DME).
2005 BMW 645Ci

 Remove upper section of intake filter housing with air-mass flow sensor and intake hose.
NOTE: Solenoid valve (1) controls adjusting unit on inlet side.
Solenoid valve (2) controls adjusting unit on exhaust side.
Unlock plug of solenoid valves (1 and 2) and disconnect.
Fig. 541: Pulling Out Solenoid Valves (1 And 2)

2005 BMW 645Ci
Installation:
Installation:
Fig. 542: Cleaning Sealing Faces On Cylinder Head

Installation:

2005 BMW 645Ci
Fig. 543: Replacing O-Rings On Solenoid Valve

Installation:
Press in solenoid valves as far as they will go.

2005 BMW 645Ci
Fig. 544: Pressing In Solenoid Valves

VARIABLE VALVE GEAR

11 37 006 REMOVING AND INSTALLING/REPLACING LEFT ECCENTRIC SHAFT (N62 FROM
9/03)
2005 BMW 645Ci
Remove left inlet camshaft.
Eccentric shafts from 2/2003:
NOTE: Eccentric shafts of cylinders 1 to 4 and 5 to 8 are identical parts.
IMPORTANT: Note installation direction of eccentric shafts. Depending on the side on which
the magnet wheel is fitted, the eccentric shafts are used for cylinders 1 to 4 or 5
to 8. Incorrect assembly will result in engine damage.
Removal
Removal of eccentric shaft is described separately from installation.
NOTE: The work steps are only described on one bearing position. The procedure is
identical for the other bearing positions.
Carefully tilt bearing shell (1) to one side and simultaneously remove towards top.
2005 BMW 645Ci
Fig. 545: Tilting Bearing Shell To One Side And Removing Towards Top
Lift out eccentric shaft (1).

2005 BMW 645Ci
Fig. 546: Lifting Out Eccentric Shaft

Removal of magnet wheel (if necessary):
NOTE: Carefully clamp eccentric shaft (1) as illustrated with protective jaws (2) in a
vice.
2005 BMW 645Ci
Fig. 547: Clamping Eccentric Shaft With Protective Jaws In Vice

IMPORTANT: Danger of mix-up:
It is very easy to mix up left and right or front and rear on the eccentric shaft.
If necessary, mark the side on which the magnet wheel is fitted.
NOTE: Magnet wheel (1) is extremely magnetic.
After removal, place magnet wheel in a plastic bag to protect it against metal chips.
Release screw and remove magnet wheel (1).

2005 BMW 645Ci
Fig. 548: Identifying Magnet Wheel (1)

IMPORTANT: Needle bearings (1) break off very easily when removed and installed.
Carefully press needle bearings (1) apart at split position only to such an extent that they can be removed from
eccentric shaft.
2005 BMW 645Ci
Fig. 549: Identifying Needle Bearings (1)

NOTE: If the needle-roller bearings are replaced, the bearing shells must be replaced
as well.
Carefully press bearing shell (1) to one side and simultaneously remove towards top.
2005 BMW 645Ci
Fig. 550: Pressing Bearing Shell To One Side And Removing Towards Top
Installation
Installation of eccentric shaft is described separately from removal.
NOTE: Lubricate eccentric shaft at bearing positions.
Replace needle bearing (1).
IMPORTANT: Needle bearings break off very easily when installed.
Carefully press needle bearings (1) apart at split position only to such an extent that they can be fitted over
eccentric shaft.
2005 BMW 645Ci
Fig. 551: Pressing Needle Bearings Apart At Split Position

to 8.
Incorrect assembly will result in engine damage.
Installation of magnet wheel:
vice.
2005 BMW 645Ci
Fig. 552: Installing Clamp Eccentric Shaft With Protective Jaws

IMPORTANT: Incorrect assembly will result in engine damage.
Assemble eccentric shaft for cylinder bank 5 to 8:
The machined curvature (3) and the groove in the eccentric shaft must point forwards as illustrated.
The unmachined surface on the eccentric points to the left.
Secure magnet wheel (1) with lug in eccentric shaft groove.
IMPORTANT: Only install original antimagnetic screw (2).

2005 BMW 645Ci
Tightening torque 11 37 1AZ in ENGINE - TIGHTENING TORQUES .
Fig. 553: Securing Magnet Wheel With Lug In Eccentric Shaft Groove
NOTE: Replace bearing shells (1) of needle bearings.
IMPORTANT: Bearing shells (1) must be installed in such a way that ends of bearing shells
(1) face each other as shown in illustration.
2005 BMW 645Ci
Fig. 554: Replacing Bearing Shells Of Needle Bearings

Insert bearing shells (1) into bearing bracket so that it is secured in bore (2).
2005 BMW 645Ci
Fig. 555: Inserting Bearing Shells Into Bearing Bracket

Lubricate bearing shells (1) with engine oil.

2005 BMW 645Ci
Fig. 556: Lubricating Bearing Shells With Engine Oil

Cylinder bank 5 to 8:
IMPORTANT: The machined curvature (1) of the eccentric points inwards.
Install eccentric shaft as shown in illustration.

2005 BMW 645Ci
Fig. 557: Installing Eccentric Shaft

Install bearing shells (1).

2005 BMW 645Ci
Fig. 558: Installing Bearing Shells

Bearing shells (1) must snap audibly into place.
Check correct position of bearing shells (1).

2005 BMW 645Ci
Fig. 559: Identifying Bearing Shells

Install left inlet camshaft.
Assemble engine.
11 37 008 REMOVING AND INSTALLING/REPLACING RIGHT ECCENTRIC SHAFT (N62 FROM

9/03)

2005 BMW 645Ci
Remove right inlet camshaft.
Removal
2005 BMW 645Ci
Fig. 560: Tilting Bearing Shell To One Side And Removing Towards Top

2005 BMW 645Ci
Fig. 561: Lifting Out Eccentric Shaft

vice.
2005 BMW 645Ci
Fig. 562: Clamping Eccentric Shaft With Protective Jaws In Vice

After removal, place magnet wheel in a plastic bag to protect it against metal chips.

2005 BMW 645Ci
Fig. 563: Releasing Screw And Removing Magnet Wheel

eccentric shaft.
2005 BMW 645Ci

as well.
2005 BMW 645Ci
Fig. 565: Pressing Bearing Shell To One Side And Removing Towards Top
Installation
eccentric shaft.
2005 BMW 645Ci

vice.
2005 BMW 645Ci
Fig. 567: Clamping Eccentric Shaft With Protective Jaws

Assemble eccentric shaft for cylinder bank 1 to 4:
The machined curvature (3) and the groove in the eccentric shaft must point forwards as illustrated.
The unmachined surface on the eccentric points to the right.

2005 BMW 645Ci
Tightening torque 11 37 1AZ in ENGINE - TIGHTENING TORQUES .
Fig. 568: Identifying Magnet Wheel With Lug In Eccentric Shaft Groove
2005 BMW 645Ci
Fig. 569: Replacing Bearing Shells Of Needle Bearings

2005 BMW 645Ci


2005 BMW 645Ci
Fig. 571: Lubricating Bearing Shells With Engine Oil

The magnet wheel (2) is at the rear.
Install eccentric shaft as shown in illustration.

2005 BMW 645Ci


2005 BMW 645Ci


2005 BMW 645Ci
Fig. 574: Checking Correct Position Of Bearing Shells

Install right inlet camshaft.
Assemble engine.
11 37 012 REMOVING AND INSTALLING/REPLACING LEFT INTERMEDIATE LEVER (N62

FROM 9/03)
 11 9 470
 11 9 472
2005 BMW 645Ci
 11 9 474
 11 9 475
 11 9 480
 11 9 490
Removal
Removal of intermediate levers is described separately from installation.
2005 BMW 645Ci
Fig. 575: Identifying Lettering On 8th Cylinder Points Upwards In Cylinder Axis

2005 BMW 645Ci
Fig. 576: Releasing Nuts And Removing Bearing Cap R E1


2005 BMW 645Ci

2005 BMW 645Ci
Fig. 578: Identifying Rocker Arm Tolerance Class

position.

2005 BMW 645Ci


2005 BMW 645Ci


2005 BMW 645Ci
Fig. 581: Placing Bearing Bracket With Inlet Camshaft And Eccentric Shaft On Special Tool

2005 BMW 645Ci
Fig. 582: Identifying Lower Section Of Bearing Bracket Remaining On Cylinder Head
NOTE: The mounting of the bearing bracket described later can only be carried out if
the inlet camshaft has not been axially displaced.
Special tools 11 9 472 and 11 9 475 prevent the inlet camshaft from rotating and moving while the intermediate
levers are installed.
Fit special tool 11 9 472 and secure with special tool 11 9 475.
2005 BMW 645Ci
Fig. 583: Fitting Special Tool 11 9 472 And Securing With Special Tool 11 9 475

2005 BMW 645Ci
Fig. 584: Inserting Special Tool 11 9 474

NOTE: Removal of intermediate levers is described on 8th cylinder.
The same procedure is applicable to cylinders 5 to 7.
2005 BMW 645Ci
Fig. 585: Raising One End Of Torsion Spring With Special Tool 11 9 480
2005 BMW 645Ci
Fig. 586: Attaching Special Tool 11 9 490 To End Of Torsion Spring

same position.
2005 BMW 645Ci
Fig. 587: Identifying Intermediate Lever Tolerance Class

2005 BMW 645Ci
Fig. 588: Holding Torsion Spring With Special Tool 11 9 480

2005 BMW 645Ci
Fig. 589: Attaching Special Tool 11 9 490 To Second End Of Torsion Spring
Installation
same position.
2005 BMW 645Ci
Fig. 590: Identifying Intermediate Lever Tolerance Class


2005 BMW 645Ci
Fig. 591: Raising Torsion Spring (1) With Special Tool 11 9 480

2005 BMW 645Ci
Fig. 592: Holding Torsion Spring (1) With Special Tool 11 9 480

2005 BMW 645Ci
Fig. 593: Raising Second End Of Torsion Spring With Special Tool 11 9 480

2005 BMW 645Ci
Fig. 594: Installing Intermediate Lever (2) From Above


2005 BMW 645Ci

Remove special tools 11 9 472 and special tools 11 9 475.

2005 BMW 645Ci
Fig. 596: Removing Special Tools 11 9 472/11 9 475


2005 BMW 645Ci
Fig. 597: Ensuring Ends Of Compression Rings (1) Point Upwards

IMPORTANT: Rocker arms (1) slip slightly when bearing bracket is fitted.
Make sure rocker arms (1) are secured as illustrated on hydraulic valve clearance compensating elements and on
valves.

2005 BMW 645Ci
Fig. 598: Ensuring Rocker Arms (1) Are Secured On Hydraulic Valve Clearance Compensating Elements
And On Valves

2005 BMW 645Ci
Fig. 599: Remove Special Tools 11 9 473/11 9 470


2005 BMW 645Ci
Fig. 600: Tightening Down Nuts From Inside To Outside

2005 BMW 645Ci
Fig. 601: Fitting Bearing Cap R E1

illustration.
2005 BMW 645Ci
Fig. 602: Identifying Marking (1) On Hexagon Drive Of The Inlet Camshaft Faces
Assemble engine.
2005 BMW 645Ci
11 37 014 REMOVING AND INSTALLING/REPLACING RIGHT INTERMEDIATE LEVER (N62

FROM 9/03)
 11 9 470
 11 9 472
 11 9 473
 11 9 474
 11 9 475
 11 9 480
 11 9 490
Removal
illustration.
2005 BMW 645Ci
Fig. 603: Rotating Inlet Camshaft Until Cam On 1st Cylinder Is Positioned Horizontally
E5 from inlet side.

2005 BMW 645Ci
Fig. 604: Releasing Nuts And Removing Bearing Cap L E1


2005 BMW 645Ci
Fig. 605: Identifying Nuts Of Bearing Bracket

2005 BMW 645Ci
Fig. 606: Identifying Tolerance Class On Rocker Arm

position.

2005 BMW 645Ci


2005 BMW 645Ci


2005 BMW 645Ci

2005 BMW 645Ci
Fig. 610: Identifying Lowering Section Of Bearing Bracket Remains On Cylinder Head
Special tools 11 9 472 and 11 9 475 prevent the inlet camshaft from rotating and moving while the intermediate
levers are installed.
2005 BMW 645Ci
Fig. 611: Fitting Special Tool 11 9 472 And Securing With Special Tool 11 9 475

2005 BMW 645Ci
Fig. 612: Inserting Special Tool 11 9 474 And Initially Tightening Without Play
NOTE: Removal of intermediate levers is described on 4th cylinder.
2005 BMW 645Ci
Fig. 613: Raising One End Of Torsion Spring With Special Tool 11 9 480
2005 BMW 645Ci
Fig. 614: Attaching Special Tool 11 9 490 To End Of Torsion Spring

same position.
2005 BMW 645Ci
Fig. 615: Identifying Tolerance Classes On Intermediate Levers

2005 BMW 645Ci
Fig. 616: Raising Second End Of Torsion Spring (1) With Special Tool 11 9 480
2005 BMW 645Ci
Fig. 617: Attaching Special Tool 11 9 490 To Second End Of Torsion Spring
Installation
same position.
2005 BMW 645Ci
Fig. 618: Identifying Intermediate Lever (2) Tolerance Class


2005 BMW 645Ci
Fig. 619: Raising Torsion Spring (1) With Special Tool 11 9 480

2005 BMW 645Ci

2005 BMW 645Ci
Fig. 621: Raising Second End Of Torsion Spring With Special Tool 11 9 480

2005 BMW 645Ci

2005 BMW 645Ci


2005 BMW 645Ci
Fig. 624: Removing Special Tools 11 9 472 /11 9 475.


2005 BMW 645Ci
Fig. 625: Ensuring Ends Of Compression Rings (1) Point Upwards


2005 BMW 645Ci
Fig. 626: Aligning Rocker Arm (1)


2005 BMW 645Ci
Fig. 627: Removing Bearing Bracket (1) From Special Tool 11 9 470

2005 BMW 645Ci

2005 BMW 645Ci
Fig. 629: Fitting Bearing Cap L E1

2005 BMW 645Ci
Fig. 630: Identifying Intermediate Levers

Install servomotor for right eccentric shaft. Refer to Refer to 11 37 024 REMOVING AND
Assemble engine.
2005 BMW 645Ci
11 37 022 REMOVING AND INSTALLING/REPLACING SERVOMOTOR FOR LEFT ECCENTRIC

SHAFT (N62)
Unlock plug (1) on servomotor (2) and disconnect.
Fig. 631: Unlocking And Disconnecting Plug On Servomotor

Unfasten screws.
Rotate servomotor (2) until no longer engaged in spline teeth of eccentric shaft.
2005 BMW 645Ci
Fig. 632: Rotating Servomotor Until No Longer Engaged In Spline Teeth Of Eccentric Shaft
Installation:
Replace sealing ring on spacer.
Install servomotor (1) and screw in up to spacer.
Rotate servomotor (1) into correct installation position.

2005 BMW 645Ci
Fig. 633: Replacing Sealing Ring On Spacer

Installation:
Rectify faults.
11 37 024 REMOVING AND INSTALLING/REPLACING SERVOMOTOR FOR RIGHT ECCENTRIC

SHAFT (N62/N62TU)
2005 BMW 645Ci
Fig. 634: Unlocking And Disconnecting Plug On Servomotor

Unfasten screws.
2005 BMW 645Ci
Fig. 635: Rotating Servomotor Until No Longer Engaged In Spline Teeth Of Eccentric Shaft
Installation:

2005 BMW 645Ci
Fig. 636: Installing Servomotor And Screwing In Spacer

Installation:
Rectify faults.
11 37 035 REMOVING AND INSTALLING/REPLACING LEFT ECCENTRIC SHAFT SENSOR

(N62/N62TU)
2005 BMW 645Ci
Unfasten screws.

Installation:
Rectify faults.
2005 BMW 645Ci
11 37 040 REMOVING AND INSTALLING/REPLACING RIGHT ECCENTRIC SHAFT SENSOR

(N62/N62TU)
Unfasten screws.

2005 BMW 645Ci
Rectify faults.
Follow instructions for disconnecting and connecting battery, refer to 12 00 ... INSTRUCTIONS FOR
Disconnect battery.
CAUTION: Follow instructions for removing and installing electronic control units,
refer to REMOVING AND INSTALLING ELECTRONIC CONTROL UNITS .
Program control unit, refer to 12 14 705 PROGRAMMING CONTROL UNIT (DME / DDE) .
2005 BMW 645Ci
Fig. 639: Releasing Screw And Removing Holder

Installation:

2005 BMW 645Ci
Fig. 640: Inserting Tabs In Openings And Closing Cover


2005 BMW 645Ci
Fig. 641: Removing Valvetronic Control Unit

Rectify faults.
OIL SUPPLY
11 40 000 CHECKING ENGINE OIL PRESSURE
 11 4 050
 13 3 061
 13 3 063
2005 BMW 645Ci
 13 6 054
NOTE: To check the engine oil pressure, the oil pressure switch must be removed and
the special tools installed and connected.
NOTE: A small amount of oil will emerge when the oil pressure switch is removed.
Have a cleaning cloth ready.
Make sure no oil runs onto belt drive.
Remove any remnants of oil immediately with cleaning cloth.
Remove oil pressure switch.
Installation:
Tightening torque, 12 61 1AZ in ENGINE - TIGHTENING TORQUES .
Install special tool 11 4 050 with sealing ring (1) in place of oil pressure switch.
2005 BMW 645Ci
Fig. 642: Identifying Special Tool 11 4 050 With Sealing Ring (1)
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).
Start engine and check engine oil pressure.
Specified value.
2005 BMW 645Ci
Fig. 643: Checking Engine Oil Pressure With DIS Tester

OIL PUMP WITH FILTER AND DRIVE

11 41 000 REMOVING AND INSTALLING/REPLACING OIL PUMP (N62)
 Drain engine oil. Refer to 00 00 610 ENGINE OIL SERVICE (N62/N62TU).

 Remove upper oil sump section. Refer to 11 13 010 REMOVING AND INSTALLING/REPLACING
OIL SUMP TOP SECTION (N62).
Unscrew nut (1).
ENGINE - TIGHTENING TORQUES

2005 BMW 645Ci
Remove oil pump sprocket wheel (2).
Fig. 644: Removing Oil Pump Sprocket Wheel

Release screws, remove oil pump (1) with aid of a second person.
2005 BMW 645Ci
Fig. 645: Releasing Screws And Removing Oil Pump

Installation:
Replace screws.
Installation:
Apply light coat of oil to sealing ring (1).

2005 BMW 645Ci

Installation:
Insert oil line (2) in crankcase.
Do not damage sealing ring.

2005 BMW 645Ci
Fig. 647: Inserting Oil Line

Installation:
Insert oil line (2) in bore hole in oil pump.
Do not damage sealing rings.

2005 BMW 645Ci
Fig. 648: Inserting Oil Line In Bore Hole In Oil Pump

Install oil pump with aid of a second person.
Assemble engine.
OIL FILLING, DIPSTICK

11 43 000 REMOVING AND INSTALLING/SEALING GUIDE TUBE FOR OIL DIPSTICK (N62)
 Remove intake air manifold. Refer to 11 61 050 REMOVING AND INSTALLING INTAKE AIR
MANIFOLD (N62).
 Drain engine oil. Refer to 00 00 610 ENGINE OIL SERVICE (N62/N62TU).
2005 BMW 645Ci
NOTE: For purposes of clarity, this work step is shown on the engine after it has been
removed.
Unlock and detach vacuum line (1).
Release screws and remove check valve (2).
Remove guide tube (3) upwards.
Fig. 649: Installing Guide Tube For Oil Dipstick (N62)

Installation:
Replace sealing ring on guide tube.
Apply light coat of oil to seal.

2005 BMW 645Ci
Replacing sealing ring on check valve pipe.
Assemble engine.
Check engine for leaks.
WATER PUMP WITH DRIVE

11 51 000 REMOVING AND INSTALLING/REPLACING WATER PUMP (N62/N62TU)
WARNING: Only carry out work on the cooling system after the engine has cooled
down (risk of scalding).
Follow instructions for working on cooling system, refer to 17 00 ... INSTRUCTIONS FOR WORKING ON
COOLING SYSTEM. .
Drain and dispose of coolant from radiator.
Installation:
Remove fan cowl.
Remove electric fan, refer to 17 11 035 REMOVING AND INSTALLING/REPLACING FAN COWL
WITH ELECTRIC FAN (N62) .
Remove alternator drive belt. Refer to 11 28 010 REPLACING ALTERNATOR DRIVE BELT
(N62/N62TU).
Unlock and detach plug connections (1).
Release screw and remove vacuum line holder.
Unlock and detach all coolant hoses on water pump.
Release screws and remove belt pulley (2).

2005 BMW 645Ci
Fig. 650: Releasing Screws And Removing Belt Pulley

Remove vibration damper. Refer to 11 23 010 REMOVING AND INSTALLING/REPLACING

Release screws and remove water pump (1). Refer to 11 51 000 REMOVING AND INSTALLING WATER
PUMP (N62).
2005 BMW 645Ci
Fig. 651: Releasing Screws And Removing Water Pump

Installation:
Check adapter sleeve (1) for correct seating and damage; replace if necessary.
Clean sealing faces (2).
2005 BMW 645Ci
Fig. 652: Cleaning Sealing Faces

Installation:
Replace sealing rings (1 and 2).

2005 BMW 645Ci
Fig. 653: Replacing Sealing Rings

Installation:
Replace both coolant pipes (1) and coat sealing surfaces with anti-friction rubber coating.
Thin coolant pipe (1) only with water-cooled alternator.

2005 BMW 645Ci
Fig. 654: Replacing Both Coolant Pipes

NOTE: When replacing water pump:
1. Convert coolant thermostat.

2. Modify coolant temperature sensor.
Assemble engine.
Check cooling system for leaks and correct operation.
FAN
11 52 020 REMOVING AND INSTALLING OR REPLACING FAN CLUTCH (N62)
2005 BMW 645Ci
 11 5 040
 11 5 050
CAUTION: Left-hand threads.
Using special tool 11 5 050 brace against pulley and unfasten cap nut from water pump using special tool 11 5
040.
Fig. 655: Unfastening Cap Nut From Water Pump

Remove fan wheel with fan coupling from water pump.
Installation:
Tighten down fan impeller using special tool 11 5 040.

2005 BMW 645Ci
NOTE: When using special tool 11 5 040, 30 Nm on the torque wrench scale are
equivalent to a tightening torque of 40 Nm.

Release screws, detach fan from fan clutch.

2005 BMW 645Ci
Fig. 657: Releasing Fan Screws

THERMOSTAT AND CONNECTIONS

11 53 000 REMOVING AND INSTALLING/REPLACING COOLANT THERMOSTAT (N62)
WARNING: Danger of scalding! Only perform these tasks on an engine that has
cooled down.
Recycling:
COOLING SYSTEM. .
2005 BMW 645Ci
Remove front underbody protection.
Remove coolant drain plug on radiator. Drain and dispose of coolant.
Unlock and detach water hose (2).
Unfasten nut.
Release screws and remove coolant thermostat (3).
Fig. 658: Releasing Screws And Removing Coolant Thermostat

NOTE: Coolant thermostat is integrated in cover and can only be replaced as a

complete unit.

2005 BMW 645Ci

Installation:
Top up coolant17 00 039 VENTING COOLING SYSTEM AND CHECKING FOR LEAKS (N62) .
INTAKE MANIFOLD
11 61 050 REMOVING AND INSTALLING INTAKE AIR MANIFOLD (N62)

2005 BMW 645Ci
Remove center of bulkhead.
Remove intake hose.
Remove injection pipe, refer to 13 53 240 REPLACING COMPLETE INJECTION PIPE (N62) .
On rear side of manifold, unlock and disconnect plug on differential pressure sensor and on servomotor.
Fig. 660: Detaching Vent Hose

Unlock and detach vent hose (1).
Unfasten screws.
2005 BMW 645Ci
INSTALLING INTAKE AIR MANIFOLD (N62).
Fig. 661: Removing Intake Air Manifold Upwards

Installation:
Clean sealing faces (1) on intake air manifold (2).

2005 BMW 645Ci
Fig. 662: Cleaning Sealing Faces On Intake Air Manifold

Installation:
Clean sealing face (1) on left and right.

2005 BMW 645Ci
Fig. 663: Cleaning Sealing Face On Left And Right

Replace gasket on left and right.
Assemble engine.
Check air intake system for leaks.
11 61 095 REMOVING AND INSTALLING/REPLACING DISA ADJUSTMENT UNIT
WORK STEP
Work step Note:
Remove engine cover.
Remove cover for ignition coils on left and right.
Remove bulkhead, equipment compartment, center.
Unlock plug on throttle and disconnect.
Unlock plug on knock sensor on left and right and disconnect.
Unlock plug on oil pressure switch and disconnect.
Unlock plug on thermostat and disconnect.
Unlock plug on water temperature sensor and disconnect.
2005 BMW 645Ci
Unlock plug on exhaust solenoid valve on left and right and

disconnect.
Unlock plug on inlet solenoid valve on left and right and disconnect.
Unlock plug on tank venting valve and disconnect.
Unlock plug on alternator and disconnect.
Unlock plug on injection pipe on left and right and disconnect.
Unlock plug on Valvetronic servomotor on left and right and
disconnect.
Unlock plug on exhaust camshaft sensor on left and right and
disconnect.
Unlock plug on inlet camshaft sensor on left and right and
disconnect.
Unlock plug on eccentric shaft sensor on left and right and
disconnect.
Unlock plug on differential pressure sensor and disconnect.
Remove engine wiring harness from guides.
Release engine wiring harness screw connection to intake air
manifold on left and right.
The tasks listed above are described in the section "Wiring harness
section for engine".
Reverse side, intake air manifold.
Unlock plug (1) and disconnect from DISA adjustment unit (2) (DISA = differentiated air intake system).
Unfasten screws.
2005 BMW 645Ci
Fig. 664: Unlocking Plug (1), Disconnect From Disa Adjustment Unit (2) And Remove Screws
Installation:
Replace screws.
Withdraw DISA adjustment unit (2) from intake air manifold.
Installation:
Rotate drive shaft on adjustment unit (2) into correct position.
VACUUM PUMP
11 66 000 REMOVING AND INSTALLING/REPLACING VACUUM PUMP (N62/N62TU)
2005 BMW 645Ci
NOTE: Press brake pedal several times in order to reduce vacuum pressure in brake
booster.
Vacuum pump is fitted on cylinder head 1 to 4 at front on exhaust camshaft.
Remove intake hose with air-mass flow sensor and upper section of intake filter housing.
IMPORTANT: Installation: Due to the risk of damage to the engine gaskets/seals and the lack
of brake boosting, make sure before starting the engine that all the vacuum
lines are connected.
Open hose clip (1) and pull off vacuum line.
Fig. 665: Opening Hose Clip And Pulling Off Vacuum Line
Release nuts on hose holders.

2005 BMW 645Ci
Remove vacuum hose.
Remove vacuum pump (2). Refer to 11 66 000 REMOVING AND INSTALLING/REPLACING VACUUM
PUMP (N62).
Fig. 666: Removing Holder And Vacuum Pump

Installation:
Replace sealing ring (1) and secure with grease.
Drive (2) must be rotated into correct position prior to installation.

2005 BMW 645Ci
Fig. 667: Replacing Sealing Ring And Securing With Grease

Installation:
Align vacuum pump drive to groove (3) on exhaust camshaft.
Vacuum pump can best be installed when groove (3) is vertically aligned.
If vacuum pump cannot be installed, crank engine if necessary at central bolt into correct position.
2005 BMW 645Ci
Fig. 668: Aligning Vacuum Pump Drive To Groove On Exhaust Camshaft

AIR PUMP, LINES

11 72 000 REMOVING AND INSTALLING/REPLACING AIR PUMP (N62)
Remove upper section of intake filter housing.
Release retaining screws on coolant expansion tank.
Remove suction filter housing.
Remove raw air housing.
Unlock and disconnect pressure and suction lines (1).

2005 BMW 645Ci
Loosen screw (3).
Fig. 669: Unlocking And Disconnecting Pressure And Suction Lines (1) and Loosen screws (2 And 3)
Remove trim panel at bottom right.
Unscrew bolt (3).
Remove air pump (2).

2005 BMW 645Ci
Fig. 670: Unlocking Plug (1), Unscrewing Bolt (3) And Removing Air Pump (2)
Unscrew nuts.
Unclip plug (1).
Remove holder from air pump.

2005 BMW 645Ci
Fig. 671: Releasing Nuts From Air Pump

EMISSION CONTROL OXYGEN SENSOR

11 78 530 REPLACING LEFT OXYGEN CONTROL SENSOR (N62/N62TU)
 11 7 030
 11 9 150
2005 BMW 645Ci

down.
Unclip oxygen control sensor cable.

Release oxygen control sensor (4) with special tool 11 7 030 in conjunction with 11 9 150.
2005 BMW 645Ci
Fig. 673: Releasing Oxygen Control Sensor With Special Tool 11 7 030 In Conjunction With 11 9 150
Installation:
Threads of new oxygen sensors are already coated with Never Seez compound.
If an oxygen sensor is reused, only apply a thin and uniform coat of Never Seez compound to thread.
Oxygen sensor section projecting into exhaust system branch must not be cleaned or come into contact
with lubricant.
Installation:
When using special tool 11 9 150 in conjunction with special tool 11 7 030, 47 Nm on torque wrench
scale corresponds to an actual tightening torque of 50 Nm.
Tighten down oxygen control sensor (4) with special tool 11 7 030 in conjunction with 11 9 150.
2005 BMW 645Ci
Fig. 674: Tightening Down Oxygen Control Sensor With Special Tool In Conjunction
Pay attention to cable routing of oxygen control sensor.
Installation:
Rectify faults.

2005 BMW 645Ci
 11 7 030
down.
Unclip oxygen control sensor cable.
Fig. 675: Unlocking Plug Connection

Release oxygen control sensor (2) with special tool 11 7 030.

2005 BMW 645Ci
Fig. 676: Releasing Oxygen Control Sensor

Installation:
with lubricant.
Installation:
Tighten down oxygen control sensor (2) with special tool 11 7 030.
2005 BMW 645Ci
Fig. 677: Tightening Down Oxygen Control Sensor With Special Tool
Pay attention to cable routing of oxygen control sensor.
Installation:
Rectify faults.
11 78 540 REPLACING LEFT OXYGEN MONITOR SENSOR (N62 / N62TU)

2005 BMW 645Ci
 11 7 030
down.
Unlock and detach plug connection (1) for oxygen monitor sensor (2).
Fig. 678: Unlocking Plug Connection For Oxygen Monitor Sensor

2005 BMW 645Ci
Release oxygen monitor sensor (2) with special tool 11 7 030.
Installation:
with lubricant.
Installation:
Tighten down oxygen monitor sensor (2) with special tool 11 7 030.
Fig. 679: Tightening Down Oxygen Monitor Sensor With Special Tool 11 7 030
Pay attention to cable routing of oxygen monitor sensor.
Installation:
2005 BMW 645Ci
Rectify faults.
11 78 543 REPLACING RIGHT OXYGEN MONITOR SENSOR (N62/N62TU)
 11 7 030
down.
Unlock and detach plug connection (1) for oxygen monitor sensor (2).
2005 BMW 645Ci
Fig. 680: Unlocking Plug Connection For Oxygen Monitor Sensor

Unclip oxygen monitor sensor cable.
Release oxygen monitor sensor (2) with special tool 11 7 030.
Installation:
with lubricant.
Installation:
Tighten down oxygen monitor sensor (2) with special tool 11 7 030.
2005 BMW 645Ci
Fig. 681: Tightening Down Oxygen Monitor Sensor With Special Tool 11 7 030
Pay attention to cable routing of oxygen monitor sensor.
Installation:
Rectify faults.
CRANKCASE VENT VALVE/POSITIVE CRANKCASE VENTILATION (PCV)

2005 BMW 645Ci
Fig. 682: Crankcase Vent Valve Components And Location

1. Vent Valve Cover

2. Diaphragm
3. Spring
2006 BMW 650i
ENGINE Engine - Repair Instructions - V8 (N62, N62TU)
ENGINE
Engine - Repair Instructions - V8 (N62, N62TU)
00 ENGINE, GENERAL
 Headaches
 Dizziness
 Stomach aches
 Vomiting
 Diarrhoea
 Cramps/fits
 Unconsciousness

First aid measures:
Danger of injury!

2006 BMW 650i
 Impaired sight

First aid measures:
 Eye contact: Rinse eyes immediately with plenty of water for at least 15 minutes; if available, use an eye-
 Skin contact: Wash off with soap and water immediately. If irritation persists, consult a doctor.
Recycling:
 Personal precautionary measures: Danger of slipping! Keep non-involved persons away from the work
 Environmental protection measures: Prevent oil from draining into drain channels, sewerage systems,
 Limiting spread: Use oil blocks to prevent the surface spread of oil.
 Cleaning procedure: Bind and dispose of escaped oil with nonflammable absorbents.
00 00 610 ENGINE OIL SERVICE (N62/N62TU)

2006 BMW 650i
Recycling:
Catch and dispose of used oil.
NOTE: For purposes of clarity, this work step is shown without the reinforcement plate.
Open oil drain plug (1) in oil sump.
Remove oil drain plug (2) on oil filter cap (3).
Release oil filter cover (3).
Fig. 1: Identifying Oil Drain Plug, Oil Filter Cap And Oil Filter Cover
Installation:
Replace and lubricate sealing rings (1 and 2).
Replace oil filter element (3) and slide into oil filter cover.
Oil filter element (3) must snap audibly into place.

2006 BMW 650i
Fig. 2: Replacing Oil Filter Element

Installation:
Install oil drain plug (1) and tighten down.
Tightening torque: 11 13 1AZ . See OIL PAN for specs.
Insert and tighten down oil filter cover (3).
Tightening torque: 11 42 2AZ . See OIL FILTER AND PIPES for specs.
Insert oil drain plug (2) on oil filter cap (3) and tighten down.
Tightening torque: 10 Nm.
Fig. 3: Identifying Oil Drain Plug, Oil Filter Cover And Oil Filter Cap
2006 BMW 650i
Pour in engine oil.
Start engine and run at idle 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.
11 00 045 CHECKING ABSOLUTE COMPRESSION OF ALL CYLINDERS
Diagnosis and Information System (DIS)
Fig. 4: Diagnosis And Information System (DIS) Tester

 Remove ACOUSTIC COVER.

 Remove right ignition coil cover.
 Connect DIS Tester.
2006 BMW 650i
Test:
 Call up Diagnosis
 Select car > right arrow key
 Complete vehicle
 Drive
 Engine management
 Valve gear
 Valvetronic variable valve gear
 Mechanical components / function
 Test schedule > right arrow key

 Compression test > right arrow key
 Follow DIS Tester instructions.
NOTE: Clear fault memory
11 00 050 REMOVING AND INSTALLING ENGINE (N62 / N62TU)
 11 0 000
 Disconnect negative battery lead.

 Both exhaust manifolds remain on engine during removal.
 BMW ALPINA B7 vehicles:
 Order parts in accordance with BMW ALPINA
 If necessary, modify ALPINA-specific parts
WORK STEP REFERENCE CHART

Work step Note:
Lift engine hood into assembly position
After removing transmission,
Secure engine in installation position with special tool
secure engine against tilting.
Remove gearbox
Remove INTAKE FILTER HOUSING
Remove radiator
2006 BMW 650i
Remove radiator lines.

Remove expansion tank.
Remove heater radiator line.
Wiring harness remains on
Unlock engine wiring harness section on control unit and detach.
engine.
Wiring harness remains on
Unlock spark plug wiring harness section on control unit and detach.
engine.
Release negative lead on spring strut dome.
Release battery positive lead at positive terminal.
DETACH VACUUM LINE AND VACUUM HOSE FROM
VACUUM PUMP.
UNLOCK LINE ON TANK VENTING VALVE AND
DISCONNECT .
Remove both oxygen monitor sensors. See REPLACING LEFT
OXYGEN MONITOR SENSOR (N62 / N62TU) and REPLACING
RIGHT OXYGEN MONITOR SENSOR (N62/N62TU).
Remove both oxygen control sensors. See REPLACING LEFT
OXYGEN CONTROL SENSOR (N62/N62TU) and REPLACING
RIGHT OXYGEN CONTROL SENSOR (N62/N62TU).
Release negative lead on engine support arm.
REMOVE VIBRATION DAMPER AND TENSIONING PULLEY
FROM A/C COMPRESSOR DRIVE BELT
Do not remove power
Release power steering pump on bracket, hydraulic lines remain
steering pump, secure against
connected.
falling down.
Do not remove A/C
Release A/C compressor on bracket, lines remain connected, do not
compressor, secure against
evacuate A/C system.
falling down.
Do not remove ABS control
Release ABS control unit on bracket, lines remain connected. unit, secure against falling
down.
Remove lower universal joint of steering spindle
Vehicles with Dynamic Drive only:
Unlock and detach hydraulic line (1).

2006 BMW 650i
Fig. 5: Identifying Hydraulic Line

Suspend engine off-center from special tool 11 0 000 .
Release engine mounts on left and right from above.
Fig. 6: Identifying Special Tool

Protect assembly compartment and hydraulic lines against damage.
Installation:
11 00 670 SECURING ENGINE IN INSTALLATION POSITION (N62, N62TU)

2006 BMW 650i
 00 0 202
 00 0 204
 00 0 208
 11 0 000
Observe following instructions relating to special tool:
 Secure ENGINE BONNET/HOOD IN SERVICE POSITION

 Detach COOLANT EXPANSION TANK and place to one side
 Remove tension strut (on spring strut dome)
Assemble transverse member 00 0 200 with special tools 00 0 202, 00 0 204, 00 0 208.

IMPORTANT: Avoid a change of engine position in the transversal or longitudinal direction.

2006 BMW 650i
Always make sure there is sufficient clearance between the engine (or its
attachment parts) and the body.
Position transverse member 00 0 200 with a 2nd person helping by way of rests
(1) on bolt connections of side panels.
Secure special tool 11 0 000 to spindle 00 0 202.
Attach suitable chains to special tool 11 0 000 and suspend from both engine suspension eyes.

Tighten down all adjusting screws and nuts on transverse member 00 0

200.
2006 BMW 650i

Unscrew nuts (1).
Raise engine approx. 10 mm with transverse member.
Installation:
Tightening torque: 22 11 2AZ . See ENGINE SUSPENSION for specs.

ENGINE IDENTIFICATION
Drive in engine numbers at marked surface with impact tool.
M47 / M47TU / M47T2

2006 BMW 650i
Fig. 11: Identifying Engine Identification Number - M47 / M47TU / M47T2

M57 / M57TU / M57T2
Fig. 12: Identifying Engine Identification Number - M57

M67 / M67TU
2006 BMW 650i

N47
Fig. 14: Identifying Engine Identification Number - N47

M52 / M52TU
2006 BMW 650i

M54

M56
2006 BMW 650i

N40 / N45
Fig. 18: Identifying Engine Identification Number - N40 / N45

N42 / N46 / N46T

2006 BMW 650i
Fig. 19: Identifying Engine Identification Number - N42 / N46 / N46T

N51 / N52 / N52K / N53 / N54
Fig. 20: Identifying Engine Identification Number - N51 / N52K

N62
2006 BMW 650i

N73

S54
2006 BMW 650i
Fig. 23: Identifying Engine Identification Number - S54

S85
Fig. 24: Identifying Engine Identification Number - S85

W10 / W11
2006 BMW 650i
Fig. 25: Identifying Engine Identification Number - W10 / W11

W17
Fig. 26: Identifying Engine Identification Number - W17

Assemble engine.
12 CYLINDER HEAD WITH COVER

11 12 005 REMOVING AND INSTALLING/SEALING LEFT CYLINDER HEAD COVER
(N62/N62TU)
 Remove design cover

2006 BMW 650i

 Remove centre engine compartment partition wall
 Remove radial compressor
Unclip cable holder (1) with cables.
Pull tank venting valve (2) off holder.
Fig. 27: Identifying Tank Venting Valve And Cable Holder


2006 BMW 650i
Installation:
Fig. 29: Identifying Sealing Element And Sealing Rings


2006 BMW 650i
Fig. 30: Identifying Cable Duct

Remove SERVOMOTOR FOR LEFT ECCENTRIC SHAFT.
Unfasten screws.
Installation:

Remove INJECTION PIPE

2006 BMW 650i
Remove cylinder head cover.
Fig. 32: Identifying Screw Connections

Installation:

2006 BMW 650i

Installation:
Replace seal (1).

Installation:
Coat rubber seals on spark plug dome (1) with antifriction rubber coating.
2006 BMW 650i

Installation:
Fig. 37: Installing Spark Plug Domes In Cylinder Head

Installation:

2006 BMW 650i
Fig. 38: Locating Sealing Surface

Installation:


2006 BMW 650i
Fig. 40: Identifying Sealing Elements

Installation:
Fig. 41: Locating Gasket Seated Position

Installation:
Insert screw connections (1, 2 and 3) without pretension and align cover.
2006 BMW 650i

11 12 006 REMOVING AND INSTALLING/SEALING RIGHT CYLINDER HEAD COVER

(N62/N62TU)
Remove design cover
Remove acoustic cover
Remove centre of assembly partition wall
Remove electronics box cover.
Remove electronics box seal.
These work steps are described in the section REPLACING CONTROL UNIT.
Remove intake filter housing (without raw air housing).
Remove intake hose with air-mass flow sensor

2006 BMW 650i
Fig. 43: Identifying Plug

Installation:
Fig. 44: Identifying Sealing Element, Sensors And Sealing Rings


2006 BMW 650i
Fig. 45: Identifying Cable Duct

Remove SERVOMOTOR FOR RIGHT ECCENTRIC SHAFT.
Unfasten screws.
Replace seal.
Fig. 46: Identifying Spacer

Remove INJECTION PIPE .

2006 BMW 650i

Installation:

2006 BMW 650i

Installation:
Replace seal (1).
Installation:
Make sure sliding rails are correctly seated when mounting on cylinder head.

Installation:

2006 BMW 650i
Coat rubber seals on spark plug dome (1) with antifriction rubber coating.

Installation:
Fig. 52: Installing Spark Plug Domes In Cylinder Head

Installation:

2006 BMW 650i

Installation:


2006 BMW 650i
Fig. 55: Identifying Sealing Element

Installation:
Fig. 56: Locating Gasket Seated Position

Installation:
Move cylinder head cover with gasket into assembly position.
Secure cylinder head cover, starting with screw connection (4) from front.
2006 BMW 650i

11 12 105 REMOVING AND INSTALLING LEFT CYLINDER HEAD (N62 FROM 9/03 AND N62TU)
lowered.
Remove left exhaust manifold.
After removing exhaust manifolds:
Open drain plug for coolant on left side of engine block.
Installation:
Tightening torque of drain plug 11 11 5AZ . See ENGINE BLOCK for specs.
Top up coolant. Vent cooling system and check for leaks. See VENTING COOLING SYSTEM AND
CHECKING FOR LEAKS (N62) or VENTING COOLING SYSTEM AND CHECKING FOR LEAKS
(N62, N62TU) .

2006 BMW 650i
Remove SERVOMOTOR FOR LEFT ECCENTRIC SHAFT.
Remove INTAKE AIR MANIFOLD.
Remove LEFT CYLINDER HEAD COVER.
Remove LEFT TIMING CASE COVER.
E65 only:
Release screws (3).
Remove tube (4) with check valve (2).
Fig. 58: Identifying Hose, Check Valve, Tube And Sealing Ring
NOTE: Do not remove guide tube (5) for oil dipstick.
Installation:
2006 BMW 650i
Removal:
Remove INLET AND EXHAUST ADJUSTMENT UNIT ON LEFT SIDE.
Fig. 59: Identifying Eccentric Shaft Sensor

Fig. 60: Locating Guide Rail Screw


2006 BMW 650i
Fig. 61: Locating Timing Case Cover Screw

Release cylinder-head bolts in sequence 10 ... 1.
Fig. 62: Releasing Cylinder-Head Bolts In Reverse Order

Installation:
2006 BMW 650i
Fig. 63: Locating Coat Joint Between Engine Block And Timing Case Cover
Fig. 64: Identifying Dowel Sleeves

2006 BMW 650i
Tightening torque: 11 12 8AZ . See CYLINDER HEAD WITH COVER for specs.
Fig. 65: Tightening Sequence Of Cylinder-Head Bolts


Replacement:
Installation:
2006 BMW 650i
Fig. 67: Identifying Screw Plug

Fig. 68: Locating Guide Rail Screw


2006 BMW 650i

Install INLET AND EXHAUST ADJUSTMENT UNIT ON LEFT SIDE.
Assemble engine.
11 12 106 REMOVING AND INSTALLING RIGHT CYLINDER HEAD (N62 FROM 9/03 AND N62TU)
lowered.
Remove right exhaust manifold.
After removing exhaust manifolds:
Open drain plug for coolant on right side of engine block.
Installation:
Tightening torque of drain plug 11 11 5AZ . See ENGINE BLOCK for specs.
Top up coolant. Vent cooling system and check for leaks.

2006 BMW 650i
Remove servomotor for right eccentric shaft.
Remove INTAKE AIR MANIFOLD.
Remove RIGHT CYLINDER HEAD COVER.
Remove RIGHT TIMING CASE COVER.
IMPORTANT: A spacer bushing is secured with screw (3) behind tube (5).
Release screw (3) and remove check valve (4), tube (5) and spacer bushing.
Unclip cables (6 and 7).
Fig. 70: Identifying Hose, Check Valve, Tube, Cable And Screws
Installation:
2006 BMW 650i
Removal:
Remove INLET AND EXHAUST ADJUSTMENT UNIT ON RIGHT SIDE.
Slacken off chain tensioning piston (1) by approx. one turn.
Fig. 71: Identifying Chain Tensioning Piston


2006 BMW 650i
Fig. 73: Identifying Guide Rail Screw


Release cylinder-head bolts in sequence 10 ... 1.

2006 BMW 650i
Fig. 75: Releasing Cylinder-Head Bolts In Reverse Order

Remove chain tensioning piston (1).

Place chain tensioning piston (1) on a level surface and compress slowly and carefully.

2006 BMW 650i
Fig. 77: Compressing Chain Tensioning Piston On Level Surface

Installation:
Install chain tensioning piston (1) and initially tighten screw connection without play.

2006 BMW 650i
Fig. 79: Coat Joint Between Engine Block And Timing Case Cover

Tightening torque: 11 12 8AZ . See CYLINDER HEAD WITH COVER for specs.
2006 BMW 650i
Fig. 81: Tightening Sequence Of Cylinder-Head Bolts

Fig. 82: Locating Timing Case Cover Screw

Replacement:
Installation:
2006 BMW 650i
Fig. 83: Identifying Screw Plug

Fig. 84: Identifying Guide Rail Screw


2006 BMW 650i

Tighten down chain tensioning piston (1).
Tightening torque: 11 31 8AZ . See CAMSHAFT for specs.

Install INLET AND EXHAUST ADJUSTMENT UNIT ON RIGHT SIDE.
Assemble engine.
11 12 503 DISASSEMBLING AND ASSEMBLING CYLINDER HEAD (N62/N62TU)
 11 9 000
 11 9 001
2006 BMW 650i
 11 9 002
 11 9 005
 11 9 006
 11 9 007
 11 9 008
 11 9 009
 11 9 011
 11 9 015
Have special tool 11 9 000 ready for removing valve springs.
Secure cylinder head (1) on special tool 11 9 001 .
NOTE: Secure cylinder head from above with screws contained in scope of delivery on

Align special tool 11 9 008 in conjunction with special tool 11 9 007 on special tool 11 9 006 to relevant
combustion chamber.
Place special tool 11 9 006 on cylinder head.

2006 BMW 650i

Slide both special tools 11 9 005 in direction of arrow as far as they will go.

Turn lever of special tools 11 9 005 .

2006 BMW 650i

Assemble clamping device with
 special tool 11 9 002


Remove all valve springs.
Remove all VALVE STEM SEALS.
Remove ALL VALVES.

2006 BMW 650i
 00 3 520
 00 3 580
Machine valve seat surface with special tool 00 3 520 or with 00 3 580 in accordance with tool manufacturer's
instructions.
Fig. 92: Machining Valve Seat

NOTE: After machining valve-seat surface: Remachine outside and inside diameters
with correction milling tool to the specified diameters until you obtain valve
seat width (5).
1. Valve-seat angle
2. Correction angle, external diameter
3. Correction angle, internal diameter
4. Valve seat, external diameter
5. Valve seat width
Items (1) to (5).
See CYLINDER HEAD WITH COVER

2006 BMW 650i
Fig. 93: Identifying Valve-Seat Surface

11 12 719 MILLING CYLINDER HEAD SEALING FACE (N62/N62TU)
(cylinder head dismantled)
Check evenness of cylinder head sealing face with a standard straight-edge (1).
NOTE: Maximum plane deviation: longitudinal 0.10 mm.
Fig. 94: Checking Evenness Of Cylinder Head Sealing Face

NOTE: Maximum plane deviation: transversal 0.05 mm.
 MACHINING LIMIT
2006 BMW 650i
Fig. 95: Checking Plane Deviation

NOTE: A cylinder head seal 0.3 mm thicker than usual can be obtained for machined
(milled) cylinder heads.
Fig. 96: Identifying Cylinder Head Seal

11 12 729 CHECKING CYLINDER HEAD FOR WATER LEAKS (N62/N62TU)
 11 9 430
 11 9 431
 11 9 432
 11 9 433
(cylinder head dismantled)

2006 BMW 650i
Prepare special tool kit 11 9 430.
NOTE: Special tool kit 11 9 430 can be used for cylinder bank 1 to 4 and cylinder bank 5
to 8.
Place special tool 11 9 431 on cylinder head sealing surface, insert screws (special tool 11 9 433) and tighten
down.
Seal coolant aperture with special tool 11 9 432 and tighten down.
Fig. 97: Identifying Special Tools On Cylinder Head Sealing Surface

Connect compressed air hose (1) to pressure gauge.
Immerse cylinder head in a water bath. Inspection pressure 4.5 bar.
Check cylinder head for escaping air (cracks).
NOTE: If necessary, add cleaning agent to water bath.

2006 BMW 650i
Fig. 98: Identifying Air Hose

13 OIL SUMP
11 13 010 REMOVING AND INSTALLING/REPLACING OIL SUMP TOP SECTION (N62/N62TU)
 17 0 030
WORK REFERENCE CHART

Work step Note:
Remove design cover
Remove center front panel
Remove FAN CLUTCH (E65 only)
Remove fan cowl (E65 only)
Remove ELECTRIC FAN (E60 only)
Remove ALTERNATOR DRIVE BELT
Remove A/C COMPRESSOR DRIVE BELT
Secure engine in installation position with special tool
Release nuts on left and right engine mounts at top
Remove REINFORCEMENT PLATE
Drain off engine oil
Remove LOWER OIL SUMP SECTION
NOTE:
To remove the oil sump, you must
Lower FRONT AXLE SUPPORT lower the front axle support.
There is no need to perform a
front axle alignment check.
2006 BMW 650i
Release power steering pump on bracket, hydraulic lines remain

connected. Secure power steering pump against falling down.
Unlock and disconnect hydraulic lines from heat exchanger with Installation location: on radiator at
special tool 17 0 030. bottom left.
Transmission fluid emerges when
Release hydraulic lines on automatic transmission.
hydraulic lines are released.
Catch and dispose of escaping
transmission fluid.
Release holder for hydraulic lines. Remove hydraulic lines. Installation:
Check fluid level in automatic
transmission; top up if necessary.
Unclip cable duct of oxygen sensors from automatic transmission.
Release screw, remove tensioner (1) from A/C compressor drive belt (E65 only).
Fig. 99: Identifying A/C Compressor Drive Belt Tensioner

Unfasten screws.
2006 BMW 650i

Release screws and remove oil sump top section.
Installation:
Replace sealing ring on dipstick guide tube.
Free sealing faces of seal debris and clean.
1. Replace gasket.
2. Install oil sump.
3. Insert all screws on transmission end,
4. Tighten down all screws on oil sump.
Fig. 101: Locating Oil Sump Top Section Screws

11 13 020 REMOVING AND INSTALLING/REPLACING OIL SUMP BOTTOM SECTION

(N62/N62TU)

 Remove oil drain plug and drain engine oil.
Unlock plug connection (1) on oil level sensor and disconnect.
Release screws and remove oil sump bottom section (2).

2006 BMW 650i
Installation:
Replace seal.
Replace screws.
When replacing oil sump bottom section:
Convert oil level sensor.
Fig. 102: Locating Oil Sump Bottom Section Screws



2006 BMW 650i

Fig. 104: Identifying Plug Fastener


2006 BMW 650i
Fig. 105: Pulling Out Ignition Coil

Installation:

Assemble engine.
14 HOUSING COVER
REMOVING ACOUSTIC COVER (N62/N62TU)
2006 BMW 650i
Unfasten screws.
Raise acoustic cover (1) and remove towards front.
Fig. 107: Identifying Acoustic Cover

11 14 080 REMOVING AND INSTALLING TOP LEFT TIMING CASE COVER (N62/N62TU)
 Remove LEFT CYLINDER HEAD COVER.

 Remove BOTH SOLENOID VALVES ON LEFT SIDE
 Release ALTERNATOR (air-cooled)
 Remove support block for radial compressor
Release screw, remove holder (1).

2006 BMW 650i
Remove line (2) from holder.
Fig. 108: Identifying Holder And Line


Installation:
2006 BMW 650i
Fig. 110: Identifying Sealing Face And Timing Case Cover

Installation:
Fig. 111: Identifying Adapter Sleeves And Sealing Face

Installation:

2006 BMW 650i

11 14 085 REMOVING AND INSTALLING TOP RIGHT TIMING CASE COVER (N62 / N62TU)
 Remove RIGHT CYLINDER HEAD COVER

 Remove VACUUM PUMP
 Remove BOTH SOLENOID VALVES ON RIGHT SIDE
Fig. 113: Removing Cable From Holder


2006 BMW 650i

Installation:
Fig. 115: Identifying Timing Case Cover And Sealing Face

Installation:

2006 BMW 650i
Fig. 116: Identifying Adapter Sleeves And Seal

Installation:

11 14 110 REMOVING AND INSTALLING BOTTOM TIMING CASE COVER (N62 / N62TU)
 23 1 040
 Remove ENGINE
 Remove both cylinder heads. See REMOVING AND INSTALLING LEFT CYLINDER HEAD (N62
2006 BMW 650i
FROM 9/03 AND N62TU) and REMOVING AND INSTALLING RIGHT CYLINDER HEAD (N62
FROM 9/03 AND N62TU)
 Remove LOWER OIL SUMP SECTION
 Remove UPPER OIL SUMP SECTION
 Remove VIBRATION DAMPER
 Remove WATER PUMP
 Remove tensioner from poly-V-belt
 Remove alternator with housing
 Remove HUB FOR VIBRATION DAMPER
 Remove FLYWHEEL
 Remove rear coolant cap
Release screws along lines (1).
Remove timing case cover (2) towards front.

Drive out water pipe (1) with special tool 23 1 040 at cutout (2) towards front.
Installation:
Replace water pipe (1) and sealing ring (3).

2006 BMW 650i
Fig. 119: Identifying Water Pipe And Sealing Ring

Installation:
Clean sealing surfaces and replace seal.
Install timing case cover, insert all screws and initially tighten to approx. 5 Nm.
Fully tighten all screws in alternate sequence.
Tightening torque: 11 14 1AZ . See CASE COVERS for specs.
IMPORTANT: Once all screws have been tightened down, retighten them in a second
operation.
Replace RADIAL SEAL in timing case at bottom.
11 14 141 REPLACING RADIAL SHAFT SEAL IN TIMING CASE COVER AT BOTTOM

(N62/N62TU)
 11 9 410
 11 9 420
 REMOVING HUB FOR VIBRATION DAMPER
Position lever (2) for removing radial shaft seal (1) horizontally and install special tool 11 9 410.
2006 BMW 650i
Fig. 120: Identifying Lever And Radial Shaft Seal

Turn lever (2) so that it grips behind radial shaft seal (1).
Turn bolt (3) on special tool 11 9 410 to remove radial shaft seal (1).
Fig. 121: Identifying Radial Shaft Seal

NOTE: Radial shaft seal may only be supported with a "support sleeve".
kinked under any circumstances.
Do not touch the sealing lip with your fingers.

2006 BMW 650i
Fig. 122: Identifying Support Sleeve

Remove support sleeve (2) from radial shaft seal (1).
Fit radial shaft seal (1) on timing case cover.

Using special tool 11 9 420 and central bolt (3), install radial shaft seal flush with timing case cover.
2006 BMW 650i
Fig. 124: Identifying Central Bolt

11 14 151 REPLACING CRANKSHAFT RADIAL SHAFT SEAL (N62 / N62TU)
 11 2 390
(transmission side)
 Remove transmission
 Drain off engine oil
 Remove FLYWHEEL
Release screws (2).
Release screws (1).
Carefully remove end cover.

2006 BMW 650i
Fig. 125: Identifying Cover Screws

kinked.
Do not touch the sealing lip with your fingers.

NOTE: Support sleeve (2) is included in scope of delivery. If the radial shaft seal (1) is
stored for longer than six months without the support sleeve (2), its operational
The support sleeve (2) remains in the radial shaft seal and is used as a slip
sleeve in the installation described later.
IMPORTANT: Special tool 11 2 390 must not be used.

2006 BMW 650i
a slip sleeve.
Fig. 127: Identifying Support Sleeve

NOTE: The radial shaft seal can only be replaced completely with the end cover.
The gasket is an integral part of the end cover and cannot be replaced
individually.
Installation:
Keep sealing faces clean and free of oil.
Coat contact points on joint along oil sump with Drei Bond 1209.

2006 BMW 650i
Installation:
Lightly oil running surface of crankshaft.
Fit end cover (1) with support sleeve (2) on crankshaft and push on carefully.
Fig. 129: Identifying Support Sleeve And Cover

Fig. 130: Identifying Down Screws

2006 BMW 650i
21 CRANKSHAFT WITH BEARING

11 21 500 REPLACING CRANKSHAFT (N62 / N62TU)
CRANKSHAFT REFERENCE
Operation: Note:
Remove ENGINE
Remove cylinder head (cylinder bank 1 to 4)
Remove cylinder head (cylinder bank 5 to 8)
Remove HUB FOR VIBRATION DAMPER
Removing lower timing case cover
Removing oil pan. See REMOVING AND INSTALLING/REPLACING OIL SUMP TOP
SECTION (N62/N62TU) and REMOVING AND INSTALLING/REPLACING OIL SUMP
BOTTOM SECTION (N62/N62TU)
Remove OIL PUMP
Removing piston
Remove FLYWHEEL
Release main bearing inclined screw connection (1).
Installation:
Tightening torque: 11 11 3AZ . See ENGINE BLOCK for specs.
Fig. 131: Identifying Main Bearing Inclined Screw Connection

Release spacer bolt (2).

2006 BMW 650i
Tightening torque: 11 11 2AZ . See ENGINE BLOCK, CYLINDER CRANKCASE for specs.
Fig. 132: Identifying Spacer Bolt

Remove main bearing caps 1 to 5.
Lever out crankshaft.
Fig. 133: Identifying Main Bearing Caps

Replace MAIN CRANKSHAFT BEARING SHELLS.
Replace CONROD BEARING SHELLS.
11 21 531 REPLACING ALL MAIN CRANKSHAFT BEARING SHELLS (N62/N62TU)

2006 BMW 650i
 00 9 120
 (engine dismantled)
 Clean components before installing.
 Preparatory tasks are described in the section REPLACING CRANKSHAFT.
NOTE: Install main bearing shells (1) with lubrication groove in crankcase.
Install main bearing shells (2) without lubrication groove in the main bearing
caps.
Fig. 134: Identifying Main Bearing Shells

S= Series
B= Construction stage 1
C= Construction stage 2
bearing cap).
1= yellow
2= green
3= violet
2006 BMW 650i
Fig. 135: Identifying Crankshaft Construction Stage And Bearing Shell Classification
The letters (1) denote the bearing shell classification for the relevant bearing position from 1 to 5 in the
crankcase and is located on the transmission side in the Vee. The first letter on the left applies to the first
bearing position at the front.
Y= yellow
G= green
V= violet
Fig. 136: Identifying Bearing Shell Classification Letters

NOTE: Main bearing caps (1, 2 and 3) are identified with punch numbers.
Main bearing caps (4 and 5) are not identified.

2006 BMW 650i
Fig. 137: Identifying Main Bearing Caps

NOTE: Main bearing cap number 5 can be identified by the surfaces (1) for the stop
disks of the thrust bearing.
Fig. 138: Identifying Thrust Bearing Stop Disk Surface

Unscrew thread support bushings in main bearing caps.

2006 BMW 650i
Fig. 139: Identifying Main Bearing Cap

Checking main bearing clearance:
To check crankshaft bearing clearance, use old main bearing screws.
There must be no oil in the blind holes (risk of cracking).
Do not twist crankshaft.
Fit special tool 00 2 590 (Plastigage Type PG 1) to the oilfree crankshaft.
Fig. 140: Identifying Crankshaft Holes


2. Tighten down all screws on main bearing caps with special tool 00 9 120 and torsion angle.
2006 BMW 650i
Remove main bearing cap.
Read off main bearing play at width of flattened plastic thread with assistance of measurement scale.
MAIN BEARING PLAY .

 Lubricate bearing shells and bearing shells.
Fig. 142: Checking Main Bearing Play

NOTE: Always replace main bearing bolts of main bearing caps with new bolts.
Do not wash off bolt coating.
No oil is permitted in the blind bores! (Danger of cracking).
Tightening specifications for main bearing:

2. Unfasten screws on main bearing cover 5.
3. Strike back and front of crankshaft with plastic hammer to center thrust bearing (do not damage
crankshaft).
CHECK AXIAL PLAY .
Check guide bearing shell, crankshaft and crankcase if necessary.
4. Tighten screws of main bearing cover 5 with jointing torque.

2006 BMW 650i
5. Tightening torque: 11 11 2AZ . See ENGINE BLOCK, CYLINDER CRANKCASE for specs.
Fig. 143: Checking Axial Play

Tighten down all screws on main bearing caps with special tool 00 9 120 and torsion angle.
Tighten down thread support bushings (2).
Fig. 144: Identifying Main Bearing Cap Screws

Replace flanged head screws (1) and tighten down.

2006 BMW 650i
Fig. 145: Identifying Head Screws

22 FLYWHEEL
11 22 000 REMOVING AND INSTALLING/REPLACING FLYWHEEL (N62/N62TU)
 11 4 180
 11 9 260
 11 9 262
 11 9 263
 11 9 264
 Remove automatic transmission. See REMOVING AND INSTALLING AUTOMATIC

TRANSMISSION (6HP26Z/N62) or REMOVING AND INSTALLING AUTOMATIC
TRANSMISSION (6HP26Z/N62TU) FROM 03/07 .
 Remove manual transmission. See REMOVING AND INSTALLING TRANSMISSION (GS6-53BZ)
or REMOVING AND INSTALLING TRANSMISSION (GS6S53BZ SMG) .
 Remove CLUTCH .
Automatic transmissions only:
Block flywheel (1) with special tools 11 9 260 / 11 9 263 / 11 9 264.
Unfasten flywheel screws.
Remove flywheel (1).

2006 BMW 650i
Installation:
Clean threads on flywheel screws in crankshaft.
Fit flywheel (1).
Fit new flywheel screws.
Tightening torque: 11 22 1AZ . See FLYWHEEL for specs.
Fig. 146: Identifying Special Tools For Flywheel

Manual transmissions only:
Block flywheel (dual-mass) with special tools 11 9 260 / 11 9 262 / 11 9 263.
Release flywheel screws with special tool 11 4 180.
Installation:
IMPORTANT: Do not use screw locking varnish .
Tightening torque: 11 22 1AZ . See FLYWHEEL for specs.

2006 BMW 650i
Fig. 147: Identifying Special Tools For Flywheel (Manual Transmission)

23 VIBRATION DAMPER
11 23 010 REMOVING AND INSTALLING/REPLACING VIBRATION DAMPER (N62/N62TU)
 Remove ALTERNATOR DRIVE BELT

 Remove A/C compressor drive belt. See REPLACING A/C COMPRESSOR DRIVE BELT (N62) or
REPLACING A/C COMPRESSOR DRIVE BELT WITH BELT TENSIONER (N62/N62TU).
 Remove REMOVING AND INSTALLING/REPLACING FAN COWL WITH ELECTRIC FAN
(N62, N62TU)
Release bolts and remove vibration damper (1).
NOTE: On BMW ALPINA B7 vehicles, the additional radial compressor belt pulley must
be removed as well.
When replacing the bolts, bear in mind the altered bolt length in BMW ALPINA
B7 vehicles.
2006 BMW 650i
Fig. 148: Identifying Vibration Damper

Installation:
Vibration damper is secured on hub with an alignment pin (4).
Fig. 149: Identifying Vibration Damper Alignment Pin

Installation:
Fit bore (2) in vibration damper (1) on alignment pin in hub.
Fit disk (3).
Replace screws.
Tightening torque: 11 23 3AZ . See VIBRATION DAMPER for specs.

2006 BMW 650i
Fig. 150: Identifying Disk And Vibration Damper

11 23 031 REMOVING AND INSTALLING/REPLACING VIBRATION DAMPER HUB (N62/N62TU)
 11 3 460
 11 9 451
 11 9 452
 11 9 453
 11 9 454

 Remove FAN CLUTCH (E65)
 Remove fan cowl (E65)
 Remove ELECTRIC FAN (E60)
 Remove DRIVE BELT for alternator
 Remove drive belt for A/C compressor. See REPLACING A/C COMPRESSOR DRIVE BELT (N62)
or REPLACING A/C COMPRESSOR DRIVE BELT WITH BELT TENSIONER (N62/N62TU).
 Remove front engine underguard
 Remove tensioner from A/C compressor drive belt (E65)
 Remove VIBRATION DAMPER
Screw special tool 11 9 451 in conjunction with special tool 11 9 452 to vibration damper hub and to oil sump.
Release central bolt (1).

2006 BMW 650i
Remove hub for vibration damper.

Installation:
Check vibration damper hub and radial seal, replace if necessary.
Align groove in vibration damper hub to parallel key and install vibration damper hub.
Replace central bolt (1).
Tighten down central bolt (1) to joining torque.
Installation:
Fit special tool 11 3 460 on special tool 11 9 451.
NOTE: Special tool 11 3 460 is magnetic.

2006 BMW 650i

Installation:
Select 0° position and secure special tool 11 9 453 with clamping screw on socket (special tool 11 9 454).
Tighten the central screw with torsion angle.
Fig. 153: Identifying Special Tool With Clamping Screw On Socket

Assemble engine.
24 CONNECTING ROD WITH BEARING

11 24 571 REPLACING ALL CONROD BEARINGS (N62/N62TU)
2006 BMW 650i
 00 2 590
 00 9 120
 11 2 110
(piston removed)
IMPORTANT: Note GRINDING STAGES ON CRANKSHAFT
bearing cap).
Fig. 154: Identifying Crankshaft Construction Stage And Bearing Shell Classification
Install new conrod bearing shells.
Insert one red and one blue bearing shell for each conrod.
Install piston.
2006 BMW 650i
Fig. 155: Inserting Bearing Shell In Conrod

Check connecting-rod bearing clearance:
Piston in BDC position.
Fit special tool 00 2 590 (Plastigage Type PG 1) to the oilfree crankshaft.
Fit bearing caps so that pair numbers match up.
Fig. 156: Locating Bearing Caps

IMPORTANT: Do not distort conrods or crankshaft.
Use conrod bolts to check conrod bearing clearance.
2006 BMW 650i
Tightening torque: 11 24 1AZ . See CONNECTING RODS AND BEARINGS for specs.

Remove bearing cap and read off bearing play at width of flattened plastic thread with assistance of
measurement scale.
CONROD BEARING CLEARANCE .

 Lubricate crankshaft and bearing shells.
 Install new conrod bolts.
Fig. 158: Checking Conrod Bearing Clearance

2006 BMW 650i

25 PISTON WITH RINGS AND PIN

11 25 530 REMOVING AND INSTALLING/REPLACING ALL PISTONS (N62TU)
 00 9 120
 11 5 430
 11 5 440
 11 5 450
IMPORTANT: Re-install piston, conrod and bearing shells back in the same position and in
the same installation location.
Conrods and conrod bearing caps are denoted with the same pairing letters, do
not mix them up.
 (engine removed)
 Install engine on assembly stand
 Remove both cylinder heads. See REMOVING AND INSTALLING LEFT CYLINDER HEAD (N62
FROM 9/03 AND N62TU) and REMOVING AND INSTALLING RIGHT CYLINDER HEAD (N62
 Removing oil pan. See REMOVING AND INSTALLING/REPLACING OIL SUMP TOP
SECTION (N62/N62TU) and REMOVING AND INSTALLING/REPLACING OIL SUMP
BOTTOM SECTION (N62/N62TU).
 Remove OIL PUMP
In event of heavy oil carbon residue:

2006 BMW 650i
Carefully remove oil carbon residue from cylinder wall.
Fig. 160: Removing Oil Carbon Residue From Cylinder Wall

IMPORTANT: When removing and installing pistons, make sure piston cooling spray nozzles
(1) are not damaged.
Fig. 161: Identifying Piston Cooling Spray Nozzle

Unscrew conrod bearing cover.
IMPORTANT: Conrods and conrod bearing caps are denoted with the same pairing letters.
Set down conrod bearing caps in order.

2006 BMW 650i
Fig. 162: Identifying Conrod Bearing Caps

Insert special tool 11 5 440 in conrod.
Screw special tool 11 5 440 into conrod with screw (1).
Remove conrod with piston from cylinder head side.

IMPORTANT: Piston and piston pin are matched to each other.
Mixing up the components will result in engine damage.
Lever out circlip with special tool 11 4 492 in direction of arrow and press out piston pin.
2006 BMW 650i

If necessary, replace connecting rods.
NOTE: The conrods can also be replaced individually.
The piston pin must be able to be pressed through the liner by hand with little
force and must not display any significant play.
Fig. 165: Pressing Piston Pin

Prior to installation, measure piston installation clearance:
Measure piston diameter with micrometer at measuring point A from lower edge of piston and offset by 90° to
piston pin axis.
MEASURING POINT A .
2006 BMW 650i
Fig. 166: Checking Piston Diameter With Micrometer

Adjust micrometer to cylinder bore of engine block. Set internal caliper on micrometer to zero. Measure
bottom, center and top of cylinder bore in direction of travel and direction of engine rotation.
DIAMETER OF CYLINDER BORE .
PISTON INSTALLATION CLEARANCE .
TOTAL PERMISSIBLE WEAR TOLERANCE .
Fig. 167: Checking Cylinder Bore Diameter

NOTE: The pistons and conrods of cylinders 1 to 8 are identical.
IMPORTANT: The conrods of cylinder banks 1 to 4 and 5 to 8 are mounted to the pistons
differently.
Cylinder bank 1 to 4
Mount conrod on piston in such a way that arrow on piston points upwards and marking on conrod points
2006 BMW 650i
upwards.
Fig. 168: Identifying Piston Points

Cylinder bank 5 to 8
Mount conrod on piston in such a way that arrow on piston points downwards and marking on conrod points
upwards.
INSTALL CONROD BEARING.
Fig. 169: Identifying Conrod Bearing

Install retaining ring.

2006 BMW 650i

Offset the contact points (1) of the piston rings by approx. 120° to each other but do not position above the
piston pin boss.
NOTE: Illustration shows N52.
Fig. 171: Identifying Contact Points

Installation:
B40 and B48:
Insert special tools 11 5 440 in conrod.
Installation:
B40:
2006 BMW 650i
Prepare piston with rings with special tool 11 5 450.

B40:
Lightly coat pistons and piston rings with oil. Offset the contact points of the piston rings by approx. 120° to
each other but do not position above the piston pin boss.
Slide in special tool 11 5 450 with piston (1).
IMPORTANT: Danger of piston ring failure.
Press in piston with finger force only.

2006 BMW 650i
B48:
Keep piston rings compressed with special tool 11 5 430.
IMPORTANT: Danger of piston ring failure.
Press in piston with finger force only.
Fig. 174: Identifying Special Tool For Piston Rings

Attach crankpin to connecting rod.
Remove special tools 11 5 450.

2006 BMW 650i
NOTE: For purposes of clarity, the pairing letters (1) are shown on the removed
conrod.
IMPORTANT: Conrods and conrod bearing caps are denoted with the same pairing letters (1),
do not mix them up.
Fig. 176: Identifying Pairing Letters

IMPORTANT: Conrod of cylinder 1 to 4 is installed in direction of travel, see arrow (1), front.
Conrod of cylinder 5 to 8 is installed in direction of travel, see arrow (1), rear.
Markings on conrod must be situated on the outside (see arrows)
Apply light coat of oil to connecting-rod bearing shells.
Fit bearing cap so that pairing letters match up.
Install new conrod bolts.

2006 BMW 650i
Fig. 177: Identifying Conrod Marking

Secure conrod with special tool 00 9 120.

Assemble engine.
11 25 671 REPLACING PISTON RINGS ON ALL PISTONS (N62)
(piston removed)
Measuring axial clearance of piston rings in piston ring groove (1 and 2):
TECHNICAL DATA .
NOTE: It is not possible to measure the axial clearance of the oil scraper rings.
2006 BMW 650i
Fig. 179: Checking Piston Ring Axial Clearance

Remove piston rings (1 and 2) with 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.
New pistons may only be installed together with new piston rings.
Fig. 180: Removing Piston Rings With Piston Ring Compressing Pliers
MEASURE END CLEARANCE .

2006 BMW 650i
Fig. 181: Checking End Clearance

NOTE: Picture shows a schematic representation.
Installation:
Install piston rings with "TOP" to piston top.
1. Plain compression ring

2. Stepped compression ring "Top"
3. Steel band ring with support spring
pin boss.
Fig. 182: Identifying Piston Rings Position

Installation:
2006 BMW 650i
Insert support spring (2) into piston ring groove.
CAUTION: Incorrect installation possible.
Contact points of support spring (2) slip very easily over each other when
fitted.
Contact points must be positioned exactly on each other.
If the contact points overlap, the oil scraper ring will be damaged when the
piston is installed.
Fig. 183: Identifying Support Spring

Then fit steel band rings (1) so that contact joints are offset approx. 120°.
28 V-RIBBED BELT WITH TENSIONER, DEFLECTION ELEMENT

11 28 010 REPLACING ALTERNATOR DRIVE BELT (N62/N62TU)
 11 3 340
 Remove FAN CLUTCH WITH FAN IMPELLER (E65/66)

 Remove radial compressor drive belt
NOTE: If the drive belt is to be reused:
Mark direction of travel and reinstall drive belt in same direction of travel.
2006 BMW 650i
11 3 340.
Remove drive belt.
Fig. 184: Identifying Drive Belt Travel Direction

Installation:
Fig. 185: Identifying Drive Belt Position

2006 BMW 650i
11 28 050 REPLACING A/C COMPRESSOR DRIVE BELT (N62)
 64 1 040
 Remove ALTERNATOR DRIVE BELT.

 Remove engine splash guard.
Installation:
If reusing the drive belt, mark the direction of rotation and reinstall in the same direction.
Check drive belt for coolant and oil residues, replace if necessary.
Rotate engine at central bolt in direction of engine rotation.
At the same time, pull off drive belt (1) towards front in direction of arrow using a clean cloth (2).
Remove drive belt (1) towards front.
Fig. 186: Pulling Off Drive Belt

Place drive belt (1) in position.
Clamp drive belt (1) with special tool 64 1 040 on belt pulley.
2006 BMW 650i
damage) .
Fig. 187: Clamping Drive Belt With Special Tool

Crank engine at central bolt in direction of rotation until drive belt is fully guided in belt pulley.

Installation:
Check installation position of drive belt.
Assemble vehicle.
11 28 050 REPLACING A/C COMPRESSOR DRIVE BELT WITH BELT TENSIONER (N62/N62TU)
2006 BMW 650i
 11 3 340
 Remove ALTERNATOR DRIVE BELT

 Remove engine splash guard.
NOTE: If the drive belt is to be reused:
Mark direction of travel and reinstall drive belt in same direction of travel.
11 3 340.
Remove drive belt.
Fig. 189: Securing Drive Belt With Special Tool

Installation:

2006 BMW 650i
Fig. 190: Identifying Drive Belt Position

31 CAMSHAFT
9/03 AND N62TU)
 11 9 470
 11 9 472
 11 9 473
 11 9 474
 11 9 475
 11 9 480
 11 9 490
 Remove SERVOMOTOR FOR LEFT ECCENTRIC SHAFT

 Remove ignition coils on cylinder bank 5 to 8
 Remove LEFT CYLINDER HEAD COVER
 Remove spark plugs on cylinder bank 5 to 8
 Remove LEFT INLET AND EXHAUST ADJUSTMENT UNITS
2006 BMW 650i
Fig. 191: Locating Inlet Camshaft Position

IMPORTANT: Camshaft bearing caps of cylinders 1 to 4 and 5 to 8 must not be mixed up.
Fig. 192: Locating Camshaft Bearing Caps Of Cylinders


2006 BMW 650i
Fig. 193: Locating Bearing Bracket

IMPORTANT: Rocker arms (1) are divided into individual tolerance classes.
4.
Fig. 194: Locating Rocker Arms On Inlet Side

position.
2006 BMW 650i
Clamp special tool 11 9 470 as illustrated in a vice.



2006 BMW 650i
Fig. 197: Identifying Special Tools (11 9 470) And (11 9 473)


2006 BMW 650i
Fig. 199: Locating Eccentric Shaft Sensor

Fig. 200: Identifying Torsion Spring And Intermediate Lever

Attach special tool 11 9490 to end of torsion spring.
Support end of torsion spring protected with special tool 11 9490 on inlet camshaft.
2006 BMW 650i
Fig. 201: Identifying Special Tool For Torsion Spring

IMPORTANT: Intermediate levers (2) are divided into individual tolerance classes.
Only intermediate levers of the same tolerance class may be fitted in a single
cylinder head.
5.
Used intermediate levers (2) may only be reused in the same position.
Fig. 202: Locating Intermediate Levers

2006 BMW 650i

Attach special tool 11 9490 to second end of torsion spring.
Fig. 204: Identifying Special Tool (11 9 480) And (11 9 490)
Release screw (1).

2006 BMW 650i
Fig. 205: Identifying Screw

Fig. 206: Identifying Torsion Spring And Special Tool

Remove intermediate levers and torsion springs of cylinders 5 to 7 according to the same procedure and set

2006 BMW 650i

NOTE: Bearing caps are marked in graphic with R E2 to R E5.
Remove bearing caps R E2 to R E5 and place to one side in order.
Fig. 208: Identifying Bearing Caps Marks


2006 BMW 650i
Fig. 209: Identifying Inlet Camshaft

NOTE: Further tasks:
The article REMOVING AND INSTALLING LEFT ECCENTRIC SHAFT contains

important installation instructions.
2006 BMW 650i
Fig. 211: Identifying Sensor Gear And Screw

Installation:
2006 BMW 650i
Fig. 213: Aligning Sensor Gear With Camshaft Groove

Installing plain compression rings (1):
Fig. 214: Pulling Compression Ring

2006 BMW 650i
Insert inlet camshaft (1) so that cams point upwards at cylinder 5 as shown in graphic.

Fig. 216: Identifying Bearing Shell

2006 BMW 650i

NOTE: Bearing caps are marked in graphic with R E2 to R E5.
Fit bearing caps R E2 to R E5.
Fig. 218: Identifying Bearing Cap Marks

2006 BMW 650i

Fit special tool 11 9 472 as shown in graphic and align inlet camshaft.
Fig. 220: Fitting Special Tools

2006 BMW 650i
Fig. 221: Aligning Special Tool To Bearing Caps

NOTE: Special tools 11 9 472, 11 9 474 and 11 9 475 remain fitted until all torsion


2006 BMW 650i
Fig. 223: Identifying Torsion Spring

Fig. 224: Identifying Torsion Spring Screw

engine.
5.
2006 BMW 650i

2006 BMW 650i


2006 BMW 650i



2006 BMW 650i


2006 BMW 650i
Fig. 233: Identifying Compression Rings

Make sure rocker arms (1) are secured as illustrated on hydraulic valve
clearance compensating elements and on valves.
Align rockers (1) straight.
Fig. 234: Identifying Rocker Arms On Inlet Side


2006 BMW 650i

2006 BMW 650i

illustration.


2006 BMW 650i
Install LEFT CYLINDER HEAD COVER.
Install SERVOMOTOR FOR LEFT ECCENTRIC SHAFT.
Assemble engine.
11 31 034 REMOVING AND INSTALLING/REPLACING RIGHT INLET CAMSHAFT (N62 FROM

9/03 AND N62TU)
 11 9 470
 11 9 472
 11 9 473
 11 9 474
 11 9 475
 11 9 480
 11 9 490
 Remove SERVOMOTOR FOR RIGHT ECCENTRIC SHAFT

 Remove RIGHT INLET AND EXHAUST ADJUSTMENT UNITS
illustration.
2006 BMW 650i

E5 from inlet side.
Fig. 240: Locating Bearing Cap Marks


2006 BMW 650i

4.

position.
2006 BMW 650i

Fig. 244: Identifying Tilt Bearing Bracket


2006 BMW 650i
Fig. 246: Identifying Bearing Bracket Lower Section


2006 BMW 650i


2006 BMW 650i
cylinder head.
5.

2006 BMW 650i
Fig. 251: Holding Torsion Spring With Special Tool (11 9 480)
Release screw (1).

2006 BMW 650i

Fig. 254: Identifying Torsion Spring And Special Tool

Remove intermediate levers and torsion springs of cylinders 1 to 3 according to the same procedure and set

2006 BMW 650i

NOTE: Bearing caps are marked in graphic with L E2 to L E5.
Remove bearing caps L E2 to L E5 and place to one side in order.
Fig. 256: Identifying Bearing Cap Marks


2006 BMW 650i

NOTE: Further tasks:
The section REMOVING AND INSTALLING RIGHT ECCENTRIC SHAFT contains

important installation instructions.

2006 BMW 650i

Installation
Fig. 260: Locating Sensor Lug

2006 BMW 650i

Fig. 262: Identifying Compression Ring

2006 BMW 650i
Insert inlet camshaft (1) so that cams point upwards at 4th cylinder as shown in graphic.

Fig. 264: Identifying Bearing Shell

2006 BMW 650i

NOTE: Bearing caps are marked in graphic with L E2 to L E5.
Fit bearing caps L E2 to L E5.
Fig. 266: Identifying Bearing Caps Marks

2006 BMW 650i

Fit special tool 11 9 472 as shown in graphic and align inlet camshaft.

2006 BMW 650i

NOTE: Special tools 11 9 472, 11 9 474 and 11 9 475 remain fitted until all torsion
Fig. 270: Identifying Special Tools For Torsion Springs

4th cylinder.

2006 BMW 650i
Fig. 271: Identifying Torsion Spring


engine.
5.
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
Fig. 277: Identifying Intermediate Lever And Torsion Spring



2006 BMW 650i

2006 BMW 650i



2006 BMW 650i

2006 BMW 650i
Fig. 285: Locating Bearing Cap Nut

at an angle as shown in graphic.
Fig. 286: Identifying Inlet Camshaft Marking


2006 BMW 650i
Install RIGHT CYLINDER HEAD COVER.
Install SERVOMOTOR FOR RIGHT ECCENTRIC SHAFT.
Assemble engine.
11 31 036 REMOVING AND INSTALLING/REPLACING LEFT EXHAUST CAMSHAFT

(N62/N62TU)

Fig. 287: Identifying Slide Rail

Rotate exhaust camshaft at hexagon head until exhaust cam on cylinder (6) is facing upwards.
2006 BMW 650i
Fig. 288: Identifying Exhaust Cam On Cylinder

Release nuts and remove bearing cap R A1.
Fig. 289: Identifying Camshaft Bearing Caps

Release nuts on bearing caps R A2 to R A5.

2006 BMW 650i
Fig. 290: Identifying Retaining Clips

Remove bearing caps R A2 to R A5.


2006 BMW 650i
Fig. 292: Identifying Exhaust Camshaft



2006 BMW 650i

Installation:
Fig. 295: Identifying Sensor Gear Lug


2006 BMW 650i
Fig. 296: Identifying Sensor Gear And Gear


camshaft.
The classification 3 shown in the graphic has no effect on the function on the
exhaust camshaft.
2006 BMW 650i

IMPORTANT: Rocker arms (1) slip slightly when exhaust camshaft is fitted.

2006 BMW 650i

Fig. 301: Identifying Compression Rings And Dowel Sleeves

Fit bearing caps R A2 to R A5.

2006 BMW 650i

Tighten down nuts on bearing caps R A2 to R A5 in 1/2 turn increments evenly from inside to outside.

Fit bearing cap R A1 in such a way that marking is legible from inlet side.

2006 BMW 650i
Fig. 304: Identifying Bearing Cap Mark

Fig. 305: Identifying Gasket And Slide Rail

2006 BMW 650i
Fig. 306: Identifying Slide Rail With Gasket

Rotate exhaust camshaft against direction of rotation until cam on 5th cylinder points upwards at an angle as
Fig. 307: Locating Exhaust Camshaft

INSTALL INLET AND EXHAUST ADJUSTMENT UNIT ON LEFT SIDE.
INSTALL LEFT CYLINDER HEAD COVER.
Assemble engine.
11 31 038 REMOVING AND INSTALLING/REPLACING RIGHT EXHAUST CAMSHAFT

2006 BMW 650i

Fig. 308: Identifying Slide Rail

Rotate exhaust camshaft at hexagon head against direction of rotation until exhaust cam on cylinder (2) faces
upwards.
Fig. 309: Identifying Exhaust Cam Position

2006 BMW 650i
Release nuts and remove bearing cap L A1.

Release nuts on bearing caps L A2 to L A5.

Remove bearing caps L A2 to L A5.

2006 BMW 650i


2006 BMW 650i


Installation:
2006 BMW 650i
Fig. 316: Identifying Sensor Gear Lug


2006 BMW 650i

camshaft.
The classification 3 shown in the graphic has no effect on the function on the
exhaust camshaft.

IMPORTANT: Rocker arms (1) slip slightly when exhaust camshaft is fitted.
2006 BMW 650i
Fig. 320: Identifying Rocker Arm Position



2006 BMW 650i

Fit bearing caps L A2 to L A5.
Fig. 323: Identifying Bearing Caps Mark

Tighten down nuts on bearing caps L A2 to L A5 in 1/2 turn increments evenly from inside to outside.
2006 BMW 650i

Fit bearing cap L A1 in such a way that marking is legible from inlet side.
Fig. 325: Identifying Bearing Cap Mark


2006 BMW 650i
Fig. 326: Identifying Gasket And Slide Rail

Fig. 327: Identifying Slide Rail With Gasket

shown in graphic.
2006 BMW 650i
Fig. 328: Identifying Exhaust Camshaft Cam

Assemble engine.
11 31 052 REPLACING BOTH TIMING CHAINS (N62/N62TU)
 11 2 001
 11 2 002
 11 2 003
 11 2 007
 Remove lower TIMING CASE COVER
Release screws (7).

2006 BMW 650i
Remove tensioning rails (2 and 4).
Installation:
Maintain tension of timing chains when installing timing case cover.
Observe sparking protection on timing case cover.
Make sure timing chain (1) is correctly installed when placing it in guide rail (3).
Fig. 329: Identifying Timing Chain And Guide Rail

Attach special tools 11 2 001 and 11 2 002 to crankshaft.
Insert special tool 11 2 007 and remove sprocket wheel with special tool 11 2 003.
Installation:
Check sprocket wheels for wear, replace if necessary.
Heat sprocket wheel to 60 °C.
WARNING: Burning hazard! Wear gloves.

2006 BMW 650i
Fig. 330: Identifying Special Tools For Crankshaft

Assemble engine.
11 31 070 CHECKING CAMSHAFT TIMING ON LEFT SIDE (N62/N62TU)
 11 9 190
 11 9 461
 11 9 462

Release screw (1).

2006 BMW 650i
Fig. 331: Identifying Oil Line And Retainers

Fig. 332: Locating Camshaft Cam

1st cylinder.
2006 BMW 650i

The situation may arise in some individual cases where this initial position is
not reached and the camshaft can continue to be rotated in the adjustment
range of the adjustment unit.

locking of the adjustment unit and if necessary perform locking by rotating the
camshafts.
rotation.
2006 BMW 650i
Fig. 334: Rotating Inlet Camshaft

rotation.
Fig. 335: Rotating Exhaust Camshaft

2006 BMW 650i

IF NECESSARY, ADJUST CAMSHAFT TIMING ON LEFT SIDE.

2006 BMW 650i
Assemble engine.
Fig. 338: Identifying Clip Oil Line, Retainers And Screw

11 31 071 CHECKING CAMSHAFT TIMING ON RIGHT SIDE (N62/N62TU)
 11 9 190
 11 9 461
 11 9 462

2006 BMW 650i
Release screw (1).
Fig. 339: Identifying Oil Line, Retainers And Screw

at an angle.
Fig. 340: Crank Engine At Central Bolt In Direction Of Rotation To Firing TDC Position
2006 BMW 650i
1st cylinder.


camshafts.
rotation. If there is no fixed connection between inlet camshaft and inlet adjustment unit, rotate inlet camshaft
against direction of rotation as far as it will go.
2006 BMW 650i

rotation.
Fig. 343: Rotating Exhaust Camshaft

2006 BMW 650i

If necessary, adjust CAMSHAFT TIMING ON RIGHT SIDE
Fig. 345: Identifying Special Tool (R11 2621)


2006 BMW 650i
Assemble engine.

 11 9 190
 11 9 460
 11 9 461
 11 9 462
 11 9 463
 Check CAMSHAFT TIMING ON LEFT SIDE

 Remove LEFT TIMING CASE COVER

2006 BMW 650i
Fig. 347: Identifying Special Tool (11 9 461), (11 9 463) And (11 9 462)

2006 BMW 650i
Tightening torque: 11 36 16AZ . See VARIABLE CAMSHAFT CONTROL or specs.

2006 BMW 650i

2006 BMW 650i

2006 BMW 650i
cylinder.


2006 BMW 650i


Assemble engine.
 11 9 190
2006 BMW 650i
 11 9 460
 11 9 461
 11 9 462
 11 9 463
 Are described in the operation "CHECKING CAMSHAFT TIMING ON RIGHT SIDE".

 Remove RIGHT TIMING CASE COVER
Fig. 359: Slacken Screws Of Exhaust And Inlet


2006 BMW 650i

2006 BMW 650i

2006 BMW 650i

2006 BMW 650i

2006 BMW 650i
cylinder.


2006 BMW 650i


Assemble engine.
33 ROCKER ARM WITH BEARING MOUNT

(N62 FROM 9/03 AND N62TU)
2006 BMW 650i
 11 9 470
 11 9 473


2006 BMW 650i



2006 BMW 650i



2006 BMW 650i

4.
2006 BMW 650i

Replacement only:
When replacing rocker arms (1) on inlet side:
Rocker arms have new tolerance classes and must be assigned to the old tolerance classes and fitted in the same
position.
Old 1 = new 2A
Old 2 = new 2A
Old 3 = new 2B
Old 4 = new 2B

2006 BMW 650i
Installation:


2006 BMW 650i


2006 BMW 650i


illustration.
2006 BMW 650i

INSTALL INLET AND EXHAUST ADJUSTMENT UNIT ON LEFT SIDE.
INSTALL LEFT CYLINDER HEAD COVER.
Assemble engine.

(N62 FROM 9/03 AND N62TU)
 11 9 470
 11 9 473
 Removal of rocker arms is described separately from installation.

2006 BMW 650i
illustration.

E5 from inlet side.

2006 BMW 650i



2006 BMW 650i


2006 BMW 650i


4.
position.
2006 BMW 650i

Replacement only:
When replacing rocker arms (1) on inlet side:
Rocker arms have new tolerance classes and must be assigned to the old tolerance classes and fitted in the same
position.
Old 1 = new 2A
Old 2 = new 2A
Old 3 = new 2B
Old 4 = new 2B
Installation:

2006 BMW 650i



2006 BMW 650i

2006 BMW 650i



2006 BMW 650i
Assemble engine.
34 VALVES WITH SPRINGS

11 34 552 REMOVING AND INSTALLING/REPLACING ALL VALVES (N62)
Preliminary tasks are described in DISASSEMBLING AND ASSEMBLING CYLINDER HEAD.
Remove valve springs.
REMOVE VALVE STEM SEALS.
Remove valves from cylinder head.
Installation:
If necessary, check valve guide for wear.
IF NECESSARY, REMACHINE VALVE SEAT.
IMPORTANT: Incorrect installation possible.
Valve springs of exhaust and inlet camshafts are different. Incorrect installation
will result in engine damage.

2006 BMW 650i
Fig. 402: Identifying Valve Springs Of Inlet Valves And Exhaust Valves
Incorrect installation will result in valve spring breakage.
Color marking (1) is normally on lower end of valve spring.
Only the diameter is decisive for the correct installation of the valve springs.
Install valve spring so that larger diameter points to spring plate at bottom.

Arrangement:
1. Valve
2006 BMW 650i
3. Valve spring
4. Top plate spring
5. Valve tapers
Fig. 404: Identifying Valve, Valve Spring And Top Plate Spring
11 34 560 REPLACING ALL VALVE STEM SEALS (N62)
 11 1 380
 11 6 370
 11 6 380
Press special tool 11 6 370 onto valve stem seal.
Withdraw valve stem seal by turning and simultaneously unscrewing special tool 11 6 370.
2006 BMW 650i

Installation:
Lubricate valve stem with oil and insert valve.
Fit special tool 11 1 380.
Coat new valve stem seal (1) with oil and install.

NOTE: For use on the N62 engine, special tool 11 6 380 must be remachined in
accordance with the illustration with a 6.2 mm dia. drill bit to a depth of A =
approx. 45 mm. This modification has already been taken into account for
reordering.

2006 BMW 650i
Press on valve stem seal with special tool 11 6 380 by hand as far as it will go.

11 34 715 REPLACING ALL VALVE SPRINGS (N62TU)
 11 0 346
 11 9 470
Remove bearing bracket (1) with inlet camshaft and stow in special tool 11 9 470.
2006 BMW 650i
Remove exhaust camshaft.
Using special tool (11 0 346), press down valve spring on spring cap, top, and remove valve keys.
Fig. 410: Removing Valve Spring On Spring Cap

Incorrect installation will result in valve spring breakage.
The color coding (1) is normally located on the lower end of the valve spring.
2006 BMW 650i
Install valve spring so that larger diameter points to spring plate at bottom.

Arrangement:
1. Valve
2. Valve stem seal with spring plate, bottom
3. Valve spring
4. Top plate spring
5. Valve tapers
Fig. 412: Identifying Valve, Valve Spring And Top Plate Spring
36 VARIABLE CAMSHAFT TIMING

UNITS ON LEFT SIDE (N62/N62TU)
2006 BMW 650i
 11 9 190
 11 9 460
 11 9 461
 11 9 462
 11 9 463
 Read fault memory and make a documentary record

 Remove LEFT TIMING CASE COVER
Removal:
Release screw (1).

2006 BMW 650i
5th cylinder point upwards at an angle as shown in graphic.
Fig. 414: Identifying Inlet And Exhaust Camshafts Upwards Positions

1st cylinder.

2006 BMW 650i

camshafts.
rotation.
Fig. 416: Rotating Inlet Camshaft Against Direction

rotation.
2006 BMW 650i
Fig. 417: Rotating Exhaust Camshaft Against Direction

Fig. 418: Identifying Rotation To 45° Before TDC Position


2006 BMW 650i
Fig. 419: Locating Slackening Screws

Fig. 420: Locating Exhaust Adjustment Unit Screw


2006 BMW 650i
Fig. 421: Identifying Back Tensioner Rail

Fig. 422: Locating Inlet Adjustment Unit Screw

Secure timing chain to prevent it from sliding down.

2006 BMW 650i

Installation:
Inlet and exhaust adjustment units are different.
1. Inlet adjustment unit (1) is marked with EIN and IN.

2. Exhaust adjustment unit (2) is marked with AUS and EX.
Fig. 424: Identifying Inlet And Exhaust Adjustment Unit Mark

2006 BMW 650i
Feed inlet adjustment unit (1) into timing chain and fit onto inlet camshaft.
Fig. 425: Identifying Inlet Adjustment Unit Positions

Replace screw.
Install screw on inlet adjustment unit.
Fig. 426: Locating Screw On Inlet Adjustment Unit


2006 BMW 650i
Feed exhaust adjustment unit (2) into timing chain.
Press tensioner rail (3) back and fit exhaust adjustment unit (2) onto exhaust camshaft.
NOTE: If tensioner rail (3) cannot be pressed back far enough to enable fitting of
exhaust adjustment unit (2):
Remove chain tensioner.
Place chain tensioner on a level surface and compress slowly and carefully.
Fig. 427: Identifying Exhaust Adjustment Unit And Tensioner Rail

Installation:
Install chain tensioner and tighten down.
Fit exhaust adjustment unit (2).
Replace screw.
2006 BMW 650i
Fig. 428: Locating Adjustment Unit

2006 BMW 650i

IMPORTANT: Make sure screws of inlet and exhaust adjustment units have been slackened
off by a half turn.
2006 BMW 650i

Tightening torque: 11 36 16AZ . See VARIABLE CAMSHAFT CONTROL for specs.

Release screw (1) and remove special tools 11 9 463 / 11 9 461 from inlet camshaft.
2006 BMW 650i

2006 BMW 650i

Release screw (1) and remove special tools 11 9 463 / 11 9 462 from exhaust camshaft.
2006 BMW 650i
cylinder.


2006 BMW 650i



2006 BMW 650i


UNITS ON RIGHT SIDE (N62/N62TU)
 11 9 190
 11 9 460
 11 9 461
 11 9 462
 11 9 463
 Read fault memory and make a documentary record

 Remove RIGHT TIMING CASE COVER
Removal:
2006 BMW 650i
Release screw (1).

at an angle.
Cam of inlet camshaft points downwards at an angle.
Fig. 444: Locating Crank Engine Central Bolt In Direction Of Rotation To Firing TDC Position
2006 BMW 650i
1st cylinder.


camshafts.
rotation.
2006 BMW 650i

rotation.
Fig. 447: Identifying Central Bolt Rotation To 45° Before TDC Position
IMPORTANT: If the inlet or exhaust adjustment unit or the camshafts "cannot" be locked as
2006 BMW 650i
Fig. 448: Locating Slackening Screws

Fig. 449: Locating Slacken Screws Of Exhaust And Inlet


2006 BMW 650i

Fig. 451: Identifying Back Tensioner Rail And Inlet Adjustment Unit

2006 BMW 650i
Fig. 452: Identifying Exhaust Adjustment Unit Screw

Secure timing chain to prevent it from sliding down.
Fig. 453: Identifying Exhaust Adjustment Unit

Installation:
Inlet and exhaust adjustment units are different.
2006 BMW 650i
1. Inlet adjustment unit (1) is marked with EIN and IN.

2. Exhaust adjustment unit (2) is marked with AUS and EX.
Fig. 454: Identifying Inlet And Exhaust Adjustment Unit Mark

NOTE: The exhaust adjustment unit on cylinder bank 1 to 4 also has a metal clip (3) for
driving the vacuum pump.
Fig. 455: Identifying Metal Clip

Feed exhaust adjustment unit (2) into timing chain and fit onto exhaust camshaft.
2006 BMW 650i
Fig. 456: Identifying Exhaust Adjustment Unit Into Timing Chain

Replace screw.

Feed inlet adjustment unit (1) into timing chain.
Press tensioner rail (3) back and fit inlet adjustment unit (1) onto inlet camshaft.
2006 BMW 650i
NOTE: If tensioner rail (3) cannot be pressed back far enough to enable fitting of inlet
adjustment unit (1):
Slacken off chain tensioner by approx. three turns.
Fit inlet adjustment unit (1).
Replace and insert screw on inlet adjustment unit (1).
Tighten down chain tensioner.
Tightening torque of chain tensioner, 11 31 8AZ . See CAMSHAFT for specs.
Fig. 458: Pressing Tensioner Rail Back And Inlet Adjustment Unit
Tighten screw on inlet adjustment unit without play and then slacken off again by a half turn.

2006 BMW 650i

2006 BMW 650i
IMPORTANT: Make sure screws of inlet and exhaust adjustment units have been slackened
off.


2006 BMW 650i
Fig. 464: Identifying Inlet Adjustment Unit Screw

Release screw (1) and remove special tools 11 9 463/11 9 461 from inlet camshaft.
2006 BMW 650i


2006 BMW 650i

Release screw (1) and remove special tools 11 9 463/11 9 462 from exhaust camshaft.
cylinder.
2006 BMW 650i


2006 BMW 650i

Assemble engine.

11 36 715 REMOVING AND INSTALLING/REPLACING BOTH LEFT SOLENOID VALVES

(N62/N62TU)
2006 BMW 650i
 Read out fault memory of control unit of Digital Motor Electronics (DME)
 Unlock hose on tank venting valve and disconnect.
NOTE: Solenoid valve (1) controls adjustment unit on inlet side.
Solenoid valve (2) controls adjustment unit on exhaust side.
Installation:
Fig. 474: Locating Solenoid Valves And Holder

Installation:

2006 BMW 650i
Fig. 475: Identifying Sealing Faces On Cylinder Head

Installation:
Fig. 476: Identifying O-Rings On Solenoid Valve

Installation:
Press in solenoid valve as far as it will go.

2006 BMW 650i
Fig. 477: Locating Solenoid Valve

11 36 720 REMOVING AND INSTALLING/REPLACING BOTH RIGHT SOLENOID VALVES

(N62/N62TU)
 Read out fault memory of control unit of Digital Motor Electronics (DME)
 Remove upper section of intake filter housing with air-mass flow sensor and intake hose
NOTE: Solenoid valve (1) controls adjustment unit on inlet side.
Solenoid valve (2) controls adjustment unit on exhaust side.
Installation:

2006 BMW 650i
Fig. 478: Locating Solenoid Valves And Holder

Installation:
Fig. 479: Identifying Sealing Faces On Cylinder Head

Installation:

2006 BMW 650i
Fig. 480: Identifying O-Rings On Solenoid Valve

Installation:
Press in solenoid valves as far as they will go.
Fig. 481: Locating Solenoid Installation Positions

37 VARIABLE VALVE GEAR

11 37 006 REMOVING AND INSTALLING/REPLACING LEFT ECCENTRIC SHAFT (N62 FROM
9/03 AND N62TU)
2006 BMW 650i
 Remove servomotor for left eccentric shaft

 Remove left cylinder head cover
 Remove left inlet and exhaust adjustment units
 Remove LEFT INLET CAMSHAFT
IMPORTANT: Note installation direction of eccentric shafts.
Depending on the side on which the magnet wheel is fitted, the eccentric shafts
are used for cylinders 1 to 4 or 5 to 8.
Fig. 482: Removing Bearing Shell


2006 BMW 650i
Fig. 483: Identifying Eccentric Shaft

vice.
Fig. 484: Clamping Eccentric Shaft Illustrated With Protective Jaws In Vice

2006 BMW 650i
Fig. 485: Placing Magnet Wheel In Plastic Bag

After removal, place magnet wheel in a plastic bag to protect it against metal
chips.
Fig. 486: Removing Needle Bearings

eccentric shaft.
2006 BMW 650i

as well.
Installation
eccentric shaft.
2006 BMW 650i

vice.
2006 BMW 650i
Assembling eccentric shaft for cylinder bank 5 to 8:
The machined curvature (3) and the groove in the eccentric shaft must point forwards as illustrated. The
unmachined surface on the eccentric points to the left.
Tightening torque: 11 37 1AZ . See VARIABLE VALVE GEAR for specs.
Fig. 490: Locating Machined Curvature

2006 BMW 650i



2006 BMW 650i
Fig. 493: Identifying Bearing Shells With Engine Oil

Install eccentric shaft as shown in graphic.
Fig. 494: Identifying Machined Curvature Of Eccentric Points

Lubricate bearing shells (1) with engine oil. Install bearing shells (1).
2006 BMW 650i

Bearing shells (1) must snap audibly into place. Check correct position of bearing shells (1).
Fig. 496: Identifying Bearing Shells Installation Positions

Install LEFT INLET CAMSHAFT.
Assemble engine.
11 37 008 REMOVING AND INSTALLING/REPLACING RIGHT ECCENTRIC SHAFT (N62 FROM

9/03 AND N62TU)
 Remove servomotor for right eccentric shaft

2006 BMW 650i

 Remove right cylinder head cover
 Remove right inlet and exhaust adjustment units
 Remove RIGHT INLET CAMSHAFT
to 8.
Removal:
Fig. 497: Locating Bearing Shells Installation Positions


2006 BMW 650i
Fig. 498: Identifying Eccentric Shaft

vice.
Fig. 499: Clamping Eccentric Shaft Installation With Protective Jaws In Vice

2006 BMW 650i
Fig. 500: Identifying Magnet Wheel

After removal, place magnet wheel in a plastic bag to protect it against metal
chips.
eccentric shaft.

2006 BMW 650i
Fig. 502: Installing Bearing Shell

Installation:
eccentric shaft.
2006 BMW 650i
vice.
Fig. 504: Clamping Eccentric Shaft In Vice

Assemble eccentric shaft for cylinder bank 1 to 4: The machined curvature (3) and the groove in the eccentric
shaft must point forwards as illustrated.
The unmachined surface on the eccentric points to the right.

2006 BMW 650i
Fig. 505: Locating Machined Curvature

Tightening torque: 11 37 1AZ . See VARIABLE VALVE GEAR for specs.
Fig. 506: Identifying Bearing Shells Face Installation Positions

2006 BMW 650i

Fig. 508: Identifying Bearing Shells With Engine Oil

The magnet wheel (2) is at the rear.
Install eccentric shaft as shown in graphic.

2006 BMW 650i



2006 BMW 650i
Fig. 511: Identifying Bearing Shells Installation Positions

Install RIGHT INLET CAMSHAFT.
Assemble engine.
11 37 012 REMOVING AND INSTALLING/REPLACING LEFT INTERMEDIATE LEVERS (N62

 11 9 470
 11 9 472
 11 9 473
 11 9 474
 11 9 475
 11 9 480
 11 9 490

LEFT INLET AND EXHAUST ADJUSTMENT UNITS
2006 BMW 650i


2006 BMW 650i

4.

position.
2006 BMW 650i

carefully lift out bearing bracket (1).


2006 BMW 650i

Special tools 11 9 472 and 11 9 475 prevent the inlet camshaft from rotating and
moving while the intermediate levers are installed.
2006 BMW 650i

NOTE: Removal of intermediate levers is described on 8th cylinder. The same

procedure is applicable to cylinders 5 to 7.
2006 BMW 650i

Attach special tool 11 9 490 to end of torsion spring. Support end of torsion spring protected with special tool
11 9 490 on inlet camshaft.

cylinder head.
5.
2006 BMW 650i


2006 BMW 650i
Installation:
Installation of intermediate levers is described separately from removal.
cylinder head.
5.
2006 BMW 650i

2006 BMW 650i


2006 BMW 650i



2006 BMW 650i


2006 BMW 650i


2006 BMW 650i


illustration.
2006 BMW 650i

Install LEFT CYLINDER HEAD COVER.
Assemble engine.
11 37 014 REMOVING AND INSTALLING/REPLACING RIGHT INTERMEDIATE LEVERS (N62

 11 9 470
 11 9 472
 11 9 473
 11 9 474
 11 9 475
 11 9 480
 11 9 490

2006 BMW 650i

illustration.

E5 from inlet side.

2006 BMW 650i


4.
2006 BMW 650i

position.


2006 BMW 650i


2006 BMW 650i

Special tools 11 9 472 and 11 9 475 prevent the inlet camshaft from rotating and
moving while the intermediate levers are installed.

2006 BMW 650i

NOTE: Removal of intermediate levers is described on 4th cylinder. The same

procedure is applicable to cylinders 1 to 3.

2006 BMW 650i
cylinder head.
5.

2006 BMW 650i
Installation
2006 BMW 650i
cylinder head.
5.

2006 BMW 650i

2006 BMW 650i


2006 BMW 650i


2006 BMW 650i


2006 BMW 650i


2006 BMW 650i

Assemble engine.
11 37 022 REMOVING AND INSTALLING/REPLACING SERVOMOTOR FOR LEFT ECCENTRIC

SHAFT (N62/N62TU)
IMPORTANT: Follow instructions issued by diagnosis tester.
Risk of damage to intermediate shaft.
 Connect diagnosis tester.


2006 BMW 650i
Fig. 568: Identifying Unlock Plug On Servomotor

Unfasten screws.
Fig. 569: Rotating Servomotor Until

Installation:

2006 BMW 650i
Fig. 570: Rotating Servomotor Into Correct Installation Position

Installation:
Rectify faults.
11 37 024 REMOVING AND INSTALLING/REPLACING SERVOMOTOR FOR RIGHT ECCENTRIC

SHAFT (N62/N62TU)
Risk of damage to intermediate shaft.
 Connect diagnosis tester


2006 BMW 650i
Fig. 571: Identifying Unlock Plug On Servomotor

Unfasten screws.
Fig. 572: Rotating Servomotor

Installation:

2006 BMW 650i
Fig. 573: Rotating Servomotor Into Correct Installation Position

Installation:
Rectify faults.
11 37 035 REMOVING AND INSTALLING/REPLACING LEFT ECCENTRIC SHAFT SENSOR

(N62/N62TU)
Unfasten screws.

2006 BMW 650i

Installation:
Rectify faults.
11 37 040 REMOVING AND INSTALLING/REPLACING RIGHT ECCENTRIC SHAFT SENSOR

(N62/N62TU)
Unfasten screws.

2006 BMW 650i

Installation:
Rectify faults.
FOLLOW INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .
Disconnect battery.
CAUTION: Follow INSTRUCTIONS FOR REMOVING AND INSTALLING ELECTRONIC

CONTROL UNITS .
PROGRAM CONTROL UNIT .

2006 BMW 650i
Fig. 576: Identifying Holder And Seal

Installation:
Fig. 577: Identifying Cover And Tabs


2006 BMW 650i

Rectify faults.
40 OIL SUPPLY
11 40 000 CHECKING ENGINE OIL PRESSURE
 11 4 050
 13 3 061
 13 3 063
 13 6 051
 13 6 054
NOTE: To check the engine oil pressure, the oil pressure switch must be removed and
the special tools installed and connected.
NOTE: A small amount of oil will emerge when the oil pressure switch is removed.
Have a cleaning cloth ready.
Make sure no oil runs onto belt drive.

2006 BMW 650i
Remove any remnants of oil immediately with cleaning cloth.
Remove oil pressure switch.
Installation:
Tightening torque: 12 61 1AZ . See OIL PRESSURE, OIL TEMPERATURE, OIL LEVEL DISPLAY for
specs.
Install special tool 11 4 050 with sealing ring (1) in place of oil pressure switch.
Fig. 579: Identifying Special Tool (11 4 050) With Sealing Ring
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).
Start engine and check engine oil pressure.
SPECIFIED VALUE .
2006 BMW 650i
Fig. 580: Identifying Special Tool (13 3 063) And (13 3 061) (Pressure Gauge)
41 OIL PUMP WITH FILTER AND DRIVE

11 41 000 REMOVING AND INSTALLING/REPLACING OIL PUMP (N62)
 Drain engine oil.

 Remove upper oil sump section. See REMOVING AND INSTALLING/REPLACING OIL SUMP
TOP SECTION (N62/N62TU) and REMOVING AND INSTALLING/REPLACING OIL SUMP
BOTTOM SECTION (N62/N62TU).
 Remove REINFORCEMENT PLATE .
Unscrew nut (1).
Tightening torque: 11 41 4AZ . See OIL PUMP WITH STRAINER AND DRIVE for specs.
Remove oil pump sprocket wheel (2).

2006 BMW 650i
Fig. 581: Identifying Oil Pump Sprocket Wheel And Nut

Release screws, remove oil pump (1) with aid of a second person.
Installation:
Replace screws.
Tightening torque: 11 41 2AZ . See OIL PUMP WITH STRAINER AND DRIVE for specs.
Fig. 582: Identifying Oil Pump

Installation:

2006 BMW 650i

Installation:
Insert oil line (2) in crankcase.
Do not damage sealing ring.
Fig. 584: Identifying Oil Line In Crankcase

Installation:
Insert oil line (2) in bore hole in oil pump.

2006 BMW 650i
Do not damage sealing rings.
Make sure oil lines are correctly seated.
Fig. 585: Identifying Sealing Ring And Oil Lines

Install oil pump with aid of a second person.
Assemble engine.
43 OIL FILLING, DIPSTICK

11 43 000 REMOVING AND INSTALLING/SEALING GUIDE TUBE FOR OIL DIPSTICK (N62)
 Remove INTAKE AIR MANIFOLD.

 Drain engine oil.
NOTE: For purposes of clarity, this work step is shown on the engine after it has been
removed.
Unlock and detach vacuum line (1).
Release screws and remove check valve (2).
Remove guide tube (3) upwards.
Installation:
2006 BMW 650i
Replace sealing ring on guide tube.
Replacing sealing ring on check valve pipe.
Assemble engine.
Check engine for leaks.
Fig. 586: Identifying Vacuum Line And Guide Tube

51 WATER PUMP WITH DRIVE

11 51 000 REMOVING AND INSTALLING/REPLACING WATER PUMP (N62/N62TU)
WARNING: Only carry out work on the cooling system after the engine has cooled
down (risk of scalding ).
Follow INSTRUCTIONS FOR WORKING ON COOLING SYSTEM .
 Drain and dispose of coolant from radiator.

 Remove fan cowl.
 Remove ELECTRIC FAN .
 Remove ALTERNATOR DRIVE BELT.
Unlock and detach plug connections (1).

2006 BMW 650i
Release screw and remove vacuum line holder.
Unlock and detach all coolant hoses on water pump.
Release screws and remove belt pulley (2).
Fig. 587: Identifying Plug Connections And Belt Pulley Screws

Remove VIBRATION DAMPER.
Release screws and remove water pump (1).
Fig. 588: Identifying Water Pump And Screws

Installation:
Check adapter sleeve (1) for correct seating and damage; replace if necessary.
2006 BMW 650i
Fig. 589: Identifying Sealing Faces

Installation:
Replace sealing rings (1 and 2).
Fig. 590: Identifying Sealing Rings

Installation:
Replace both coolant pipes (1) and coat sealing surfaces with anti-friction rubber coating.
Thin coolant pipe (1) only with water-cooled alternator.

2006 BMW 650i
Fig. 591: Identifying Coolant Pipe

NOTE: Remove coolant thermostat and coolant sensor of faulty water pump.
Check coolant thermostat and coolant sensor for damage and replace if
necessary.
Install coolant thermostat and coolant sensor in new water pump.
Assemble engine.
VENT COOLING SYSTEM AND CHECK FOR LEAKS .
52 FAN
11 52 020 REMOVING AND INSTALLING OR REPLACING FAN CLUTCH (N62)
 11 5 040
 11 5 050
CAUTION: Left-hand threads.
Using special tool 11 5 050 brace against pulley and unfasten cap nut from water pump using special tool 11 5
040.
Remove fan wheel with fan coupling from water pump.

2006 BMW 650i
Fig. 592: Identifying Special Tool (11 5 050 And 11 5 040) On Water Pump
Installation:
Tighten down fan impeller using special tool 11 5 040.
Tightening torque: 11 52 1AZ . See FAN for specs.
NOTE: When using special tool 11 5 040, 30 Nm on the torque wrench scale are
equivalent to a tightening torque of 40 Nm.

Release screws, detach fan from fan clutch.

2006 BMW 650i
Fig. 594: Identifying Clutch Fan Screws

53 THERMOSTAT AND CONNECTIONS

11 53 000 REMOVING AND INSTALLING/REPLACING COOLANT THERMOSTAT (N62)
Only perform these tasks on an engine that has cooled down.
Recycling:
Follow instructions for working on cooling system.
Remove front underbody protection.
Remove coolant drain plug on radiator. Drain and dispose of coolant.
Unlock and detach water hose (2).
Unfasten nut.
Release screws and remove coolant thermostat (3).

2006 BMW 650i
Fig. 595: Locating Coolant Thermostat, Water Hose And Unlock Plug
NOTE: Coolant thermostat is integrated in cover and can only be replaced as a

complete unit.
Installation:
TOP UP COOLANT .
VENT COOLING SYSTEM AND CHECK FOR LEAKS .

2006 BMW 650i
11 61 050 REMOVING AND INSTALLING INTAKE AIR MANIFOLD (N62)
Remove ACOUSTIC COVER.
Remove center of bulkhead.
Remove intake hose.
Remove INJECTION PIPE .
On rear side of manifold, unlock and disconnect plug on differential pressure sensor and on servomotor.
Unlock and detach vent hose (1).
Fig. 597: Identifying Vent Hose

Unfasten screws.
Remove intake air manifold (2) upwards with aid of a second person.
2006 BMW 650i
Fig. 598: Identifying Intake Air Manifold

Installation:
Clean sealing faces (1) on intake air manifold (2).
Fig. 599: Identifying Sealing Faces On Intake Air Manifold

Installation:
Clean sealing face (1) on left and right.
Replace gasket on left and right.

2006 BMW 650i
Fig. 600: Identifying Sealing Face On Left And Right

Assemble engine.
Check air intake system for leaks.
66 VACUUM PUMP
11 66 000 REMOVING AND INSTALLING/REPLACING VACUUM PUMP (N62/N62TU)
NOTE: Press brake pedal several times in order to reduce vacuum pressure in brake
booster.
Vacuum pump is fitted on cylinder head 1 to 4 at front on exhaust camshaft.
Remove ACOUSTIC COVER.
Remove intake hose with air-mass flow sensor and upper section of intake filter housing.
IMPORTANT: Installation:
Due to the risk of damage to the engine gaskets/seals and the lack of brake
boosting, make sure before starting the engine that all the vacuum lines are
connected.
Open hose clip (1) and pull off vacuum line.

2006 BMW 650i
Remove vacuum hose.
Fig. 601: Identifying Hose Clip

Remove vacuum pump (2).
Fig. 602: Identifying Vacuum Pump

Installation:
Replace sealing ring (1) and secure with grease.
Drive (2) must be rotated into correct position prior to installation.

2006 BMW 650i

Installation:
Align vacuum pump drive to groove (3) on exhaust camshaft.
Vacuum pump can best be installed when groove (3) is vertically aligned.
If vacuum pump cannot be installed, crank engine if necessary at central bolt into correct position.
Fig. 604: Aligning Vacuum Pump Drive To Groove On Exhaust Camshaft

72 AIR PUMP, LINES AND CONNECTIONS

11 72 000 REMOVING AND INSTALLING/REPLACING AIR PUMP (N62)
Remove upper section of intake filter housing.

2006 BMW 650i
Release retaining screws on coolant expansion tank.
Remove suction filter housing.
Remove raw air housing.
Unlock and disconnect pressure and suction lines (1).
Loosen screws (2).
Loosen screw (3).
Fig. 605: Identifying Suction Lines And Screws

Remove trim panel at bottom right.
Unscrew bolt (3).
Remove air pump (2).

2006 BMW 650i
Fig. 606: Identifying Air Pump Bolt

Unscrew nuts.
Unclip plug (1).
Remove holder from air pump.
Fig. 607: Locating Air Pump Nut

78 EMISSION CONTROL, OXYGEN SENSOR

11 78 530 REPLACING LEFT OXYGEN CONTROL SENSOR (N62/N62TU)
 11 7 030
11 9 150
2006 BMW 650i

Unclip control sensor cable.

Release control sensor (4) with special tool 11 7 030 in conjunction with 11 9 150.
2006 BMW 650i
Fig. 609: Identifying Control Sensor

Installation:
Threads of new oxygen sensors are already coated with Never Seez Compound.
If the oxygen sensor is reused, only apply a thin and uniform coat of Never Seez Compound to thread.
Oxygen sensor section projecting into exhaust system branch must not be cleaned or come into contact with
lubricant.
Installation:
When special tool 11 9 150 is used in conjunction with special tool 11 7 030, 47 Nm on the torque wrench dial
corresponds to an actual tightening torque of 50 Nm.
Tighten down control sensor (4) with special tool 11 7 030 in conjunction with 11 9 150.
Tightening torque: 11 78 1AZ . See EMISSIONS-CONTROL, LAMBDA OXYGEN SENSOR for specs.
Pay attention to cable routing of control sensor.
Installation:
Rectify faults.
2006 BMW 650i
11 78 533 REPLACING RIGHT OXYGEN CONTROL SENSOR (N62/N62TU)
 11 7 030

Unclip control sensor cable.

Release control sensor (2) with special tool 11 7 030.

2006 BMW 650i
Fig. 612: Identifying Control Sensor

Installation:
If the oxygen sensor is reused, only apply a thin and uniform coat of Never Seez Compound.
lubricant.
Installation:
Tighten down control sensor (2) with special tool 11 7 030.
Pay attention to cable routing of control sensor.

2006 BMW 650i
Installation:
Different heat shields!
To prevent fraying, make sure that wiring harness (1) is correctly laid on heat shield (2).
Fig. 614: Identifying Wiring Harness And Heat Shield

Installation:
Rectify faults.
11 78 540 REPLACING LEFT OXYGEN MONITOR SENSOR (N62 / N62TU)
 11 7 030

 Remove REAR UNDERBODY PROTECTION
2006 BMW 650i
Unlock and detach plug connection (1) for monitor sensor (2).
Unclip monitor sensor cable.
Release monitor sensor (2) with special tool 11 7 030.
Fig. 615: Identifying Plug Connection And Monitor Sensor

Installation:
lubricant.
Installation:
Tighten down monitor sensor (2) with special tool 11 7 030.
Pay attention to cable routing of monitor sensor.

2006 BMW 650i
Fig. 616: Identifying Special Tool (11 7 030) On Monitor Sensor

Installation:
Rectify faults.
11 78 543 REPLACING RIGHT OXYGEN MONITOR SENSOR (N62/N62TU)
 11 7 030

 Remove REAR UNDERBODY PROTECTION
Unlock and detach plug connection (1) for monitor sensor (2).
2006 BMW 650i
Release monitor sensor (2) with special tool 11 7 030.
Fig. 617: Identifying Monitor Sensor

Installation:
lubricant.
Installation:
Tighten down monitor sensor (2) with special tool 11 7 030.
Pay attention to cable routing of monitor sensor.

2006 BMW 650i
Fig. 618: Identifying Special Tool (11 7 030) On Monitor Sensor

Installation:
Rectify faults.
CRANKCASE VENT VALVE/POSITIVE CRANKCASE VENTILATION (PCV)
Fig. 619: Crankcase Vent Valve Components And Location

1. Vent Valve Cover

2. Diaphragm
3. Spring
2005 BMW 645Ci
2005-06 GENERAL INFORMATION 4.4L N62 Engine - Overview - 5, 6 & 7-Series
2005-06 GENERAL INFORMATION
4.4L N62 Engine - Overview - 5, 6 & 7-Series
N62 ENGINE UPDATE

INTRODUCTION
Since the initial introduction of the N62 in the 2002 E65, there have been several new modifications to the
original design. The N62B44 was also subsequently installed in the 5, 6 and X5 series vehicles beginning with
9/03 production.
The X5 4.6is, which uses the M62TUB44, has been replaced by the X5 4.8is from 4/04. The new E53 4.8is
variant uses the modified N62 with a displacement of 4.8 liters. The power output and torque figures were also
increased as well.
For the 2005 model year, the new N62B48TU has been added to the model line. The 5, 6 and 7 series vehicles
have been re-named to reflect these changes. Beginning with May of 2005, the 550i, 650i and 750i/Li will be
available with the new engine variant.
2005 BMW 645Ci
Fig. 1: Identifying Engine

ENGINE TORQUE SPECIFICATIONS CHART

Model/Series Engine Output (HP - US) Torque Introduction
E65/E66 745i/Li N62B44 325 at 6100 RPM 450 N.m at 3600 11/01
RPM
E60 545i N62B44 325 at 6100 RPM 450 N.m at 9/03
3600 RPM
E63/E64 645Ci N62B44 325 at 6100 RPM 450 N.m at 3600 9/03
RPM
E53 4.4 N62B44 315 at 6100 RPM 440 N.m at 3600 9/03
2005 BMW 645Ci
E53 4.8is N62B48 355 at 6200 RPM 490 N.m at 3600 4/04
RPM
E65/E66 750i/Li N62B48TU 360 at 6300 RPM 490 N.m at 3400 5/05
RPM
E63/E64 650Ci N62B48TU 360 at 6300 RPM 490 N.m at 3400 5/05
RPM
E60 550i N62B48TU 360 at 6300 RPM 490 N.m at 3400 5/05
RPM
Power Output
2005 BMW 645Ci
Fig. 2: Identifying Power Output Graph

N62B48
2005 BMW 645Ci
The N62B48 engine is an increased displacement variant of the N62B44. The following components have been
modified for use in the E53 X5 4.8is:
 Intake Silencer
 Cylinder Head
 Engine Block
 Crankshaft
 Pistons and connecting rods
 Lubrication System
 Exhaust System
 Engine wiring harness
Intake Silencer
On account of the higher intake capacity at high engine speeds the flow characteristics of the intake silencer
have been optimized for the N62B48 and the silencer has been additionally equipped with a second intake
snorkel. This intake snorkel is active in the area of the righthand fog light. The second intake snorkel does not
have a negative effect on the fording depth. The second intake snorkel draws in additional air only when the
engine is running at high load and speed. The main volume of air is drawn in via the sound absorption cover (3).
Fig. 3: Identifying Intake Silencer Components

Cylinder Head
2005 BMW 645Ci
The cylinder heads of the N62B48 are variants of the N62B44. Due to the higher stress load, the cylinder heads
on the N62B48 are made from a stronger aluminum-silicon alloy. The combustion chamber diameter in the
cylinder head has been adapted to the larger cylinder bore of the N62B48. The flange pattern of the exhaust
manifolds on the cylinder heads has been changed in line with the new exhaust manifolds. Due to the close
proximity to the hood, a heat shield has been mounted over the new exhaust manifolds on the cylinder heads.
Secondary Air System
The N62B48 is no longer equipped with a secondary air system so that the secondary air duct in the cylinder
head is also rendered unnecessary. This modification has been made possible by using an optimized catalytic
converter coating.
Cylinder Head Gasket
The cylinder head gasket has been adapted to the larger combustion chamber diameter. For the N62B48 it is
identified by two 6 mm holes on the left next to the BMW part number.
Engine Block
Compared to the N62B44, the diameter of the cylinder bores in the N62B48 have been increased by 1 mm to 93
mm.
The crankshaft bearing caps feature apertures (1) for the purpose of improving ventilation lengthways in the
crankcase and reducing pump and splashing losses in the crankcase.
2005 BMW 645Ci
Fig. 4: Identifying Crankshaft Bearing Cap

Crankshaft
For strength reasons, the crankshaft material in the N62B48 has been changed from lamellar graphite to steel.
The journal width of the crankshaft has been adapted to the modified connecting rods and therefore reduced
from 42 mm (N62B44) to 36 mm (N62B48). To increase the displacement, the stroke of the crankshaft journals
has been increased from 82.7 mm to 88.3 mm.
Pistons and Connecting Rods
The pistons have been adapted to the increased cylinder bore diameter. The connecting rods of the N62B44
feature an asymmetric form. The connecting rods are symmetrically formed on the N62B48. The symmetrically
formed connecting rods permit a more uniform force application.
Consequently, it has been possible to reduce the width of the connecting rods from 21 mm (N62B44) to 18 mm
(N62B48), matching the width of the crankshaft journals. In view of the higher mechanical loads in the big-end
bearing, different bearing shells are used on the bearing cap and rod sides in the N62B48. Glyco 199 (sputter
bearings) are used on the connecting rod end in the N62B48. These bearings are very important as the bearing
shells on the connecting rod end are subject to high pressure loads.
Glyco 81 (three-component bearings) are fitted on the bearing cap end to withstand the tensile loads that occur
2005 BMW 645Ci
Lubrication System
Shorter oil spray nozzles are used on the N62B48. They have been adapted to the longer stroke of the piston and
must not be confused with the oil spray nozzles of the N62B44.
The N62B48 is equipped with a modified oil pan. The bottom section of the oil pan has been lowered by 16mm
to accommodate the increased displacement of the N62B48. This modification minimizes power losses that
occur in the crankcase as the result of pumping and splashing movements. By lowering the bottom section of
the oil pan it was necessary to open up the thrust panel in this area. As a result, the bottom section of the oil pan
on the N62B48 was no longer supported by the thrust panel and lies freely on the underbody. For this reason,
the oil pan material has been changed from cast aluminum to sheet steel. The bottom section of the oil pan is
made from 2 mm thick sheet steel and is less susceptible to mechanical influences compared to the B44 (cast
aluminum).
The dipstick has been lengthened in line with lowering the bottom section of the oil pan. Due to the lowered
bottom section of the oil pan in the N62B48, an extended intake snorkel is installed on the oil pump.
The N62B48 features an oil cooler with increased cooling capacity. It is located in front of the radiator under
the A/C condenser in the cooling module. The function and design are identical to those of the oil coolers
already used in the N62 for the Hot Climate variants.
Exhaust System
The flow characteristics of the exhaust system have been optimized for the N62B48. The pipe diameter has
been widened.
Exhaust Manifold
The exhaust manifolds have been newly developed for the N62B48 and are designed as 4-2-1 exhaust
manifolds. The newly developed form prevents residual gasses entering the combustion chamber, thus
improving the cylinder charge and the torque progression in the lower engine speed range.
2005 BMW 645Ci
Fig. 5: Identifying Exhaust Manifold

Catalytic Converters
The catalytic converters feature an optimized catalytic coating. This coating has a faster response characteristic
and higher temperature resistance. The faster response characteristic of the catalytic converters renders the
secondary air injection after starting the engine unnecessary on the N62B48.
Engine Wiring Harness
The engine wiring harness has been lengthened for the oil level sensor due to the lowered bottom section of the
oil pan. As from the launch of the N62B48, the same wiring harness will also be installed in the N62B44.
N62TU
The N62 engine is replaced by the N62TU engine as of April 2005. The N62TU engine features changes from
its predecessor in the following areas:
2005 BMW 645Ci
 Air intake duct

 Differentiated intake system (DISA)
 Crankshaft
 Oil dipstick
 Oil pump
 Inlet and exhaust valves
 Spark plugs
 DME 9.2.2
 Secondary Air System
Air Intake Duct
The N62B48TU engine has a greater displacement and thus a larger air requirement. Due to the new lower
profile hood design of the 7 series, a new air intake ducting is required. A larger, two-channel air intake duct is
therefore used.
Fig. 6: Identifying Air Intake Duct Components

Differential Intake Air System (DISA)

2005 BMW 645Ci
system (DISA) is used instead. The previous intake manifold was made from magnesium, the new intake is
manufactured from glass fiber reinforced plastic.
There are two servomotors which provides a 2-stage (long/short) function of the intake manifold runners. Due
to the increased displacement and engine power, the fully variable intake system is no longer needed.
Fig. 7: Identifying Differential Intake Air System (DISA) Components

2-Stage DISA (Functional Principle)

2005 BMW 645Ci
Fig. 8: Identifying 2-Stage DISA (Functional Principle) Components

In the intake system a sliding sleeve (3) is located at the intake manifold for each cylinder. The displacement of
the sleeves determines whether the intake passage is long (1) or short (2). At idle a long intake passage is set
(torque setting).
From 4700 RPM, the sleeves are pushed back and a short intake passage is thereby set (power setting). When
there is no flow, the sliding sleeves remain in their respective position.
Varying the intake passages controls the pressure wave in the intake manifold in such a way as to produce a
boost effect in the high RPM range. The sliding sleeves are driven by a servomotor assigned to each cylinder
bank. The two servomotors together with the differential pressure sensor form a single component.
The 12V servomotors are actuated by the ECM via a PWM signal. While the sliding sleeves are open (power
setting), the servomotors are actuated with a 5 % PWM signal in order to hold the sleeves in their open position.
The servomotors do not have position feedback. The sleeves can be inspected visually through the throttle valve
opening. The sleeves are opened and closed once when the ignition is turned on. This prevents the sleeves from
seizing during extended operation in the torque setting.
The bores for the fuel injectors and the connections for crankcase and tank ventilation are located on the intake
system as well.
The following illustrations show the sliding sleeves of the intake runner in their respective positions. The first
2005 BMW 645Ci
illustration (1) shows the intake sleeves closed (long runner). This setting is for low RPM to create higher
torque.
The second illustration (2) shows the intake sleeves open (short runner). This setting is for high RPM which
takes advantage of the pressure wave effect for increased power.
Fig. 9: Identifying Intake Sleeves Closed (Long Runner)

2005 BMW 645Ci
Fig. 10: Identifying Intake Sleeves Open (Short Runner)

Crankshaft
Due to the increased demands, the N62B48TU engine has a steel crankshaft. In the interests of reducing power
loss (oil churning losses in the crankcase), the crankpin width has been reduced from 42 mm to 36 mm. The
connecting rods are adapted accordingly.
Oil Pump
The geometry of the oil pump is specifically adapted. Oil churning losses in the crankcase are further reduced
by the modified design of the oil deflector.
Oil Dipstick
The E65 Facelift model series is equipped with an electronic oil level display. The engine oil dipstick has a
modified handle in black. This eliminates the need for the customer to check the engine oil level twice.
2005 BMW 645Ci
Fig. 11: Displaying Engine Oil Level

Inlet and Exhaust Valves
The stem diameter has been reduced from 6 mm to 5 mm. The moving masses reduced in this way result in a
higher RPM capability.
Spark Plugs
The previous surface-gap spark plugs with 2 ground electrodes have been replaced by spark plugs with the
spark position brought forward and a hook electrode.
This enables better ignition of the fuel/air mixture. In the new spark plugs the center electrode is made of
platinum (replacement interval: every 100,000 miles).
Digital Motor Electronics (DME)
The N62TU engine is equipped with DME ME9.2.2. The functions of the ME 9.2.2 are carried over from the
previous ME 9.2 of the N62 engine.
The pin assignment of the ME 9.2.2 has not changed in relation to the ME 9.2.1. An ME9.2.2 control unit and a
VALVETRONIC control unit are used to run the N62TU.
The following changes have been made:
 New processor (clock frequency 56 MHz)

 Lambda oxygen sensor LSU 4.9
 Hot-film air-mass meter HFM 6
 Software for electronic oil level measurement.
2005 BMW 645Ci
An LSU 4.9 oxygen sensor is used as the control sensor for each cylinder bank. Compared with the LSU 4.2
oxygen sensor previously used, the LSU 4.9 oxygen sensor reaches operational readiness twice as fast.
Full operational readiness is reached after 10 seconds (LSU 4.2 = 20 seconds). This rapid starting capability is
made possible by the use of a smaller ceramic element. The outer dimensions of the oxygen sensor remain
unchanged.
The previous opening for the supply of ambient air (reference air measurement) has been dispensed with. The
new sensor differs from the LSU 4.2 in that a porous layer permeable by air is used instead of a reference air
channel. The function stays the same. The ambient air is directed to the measuring element via the connecting
cable.
Hot-film Air-mass Meter (HFM)
The HFM 6.4 is used in the N62TU engine. The sensor signal is already digitized in the HFM 6.4. The digitized
signal is sent to the ECM (DME).
2006 BMW 650i
ENGINE Engine - Technical Data - V8 (N62TU)
ENGINE
Engine - Technical Data - V8 (N62TU)
ENGINE, GENERAL
11 00 ENGINE IN GENERAL B40
ENGINE IN GENERAL SPECIFICATION B40

Cylinder 8
Bore mm 87
Stroke mm 84.1
Effective displacement cm3 4000
Compression ratio :1 10.5
Max. permissible engine speed rpm 6500
Permissible constant speed rpm 6500
11 00 ENGINE IN GENERAL B48
ENGINE IN GENERAL SPECIFICATION B48

Cylinder 8
Bore mm 93
Stroke mm 88.3
Effective displacement cm3 4799
Compression ratio :1 10.5
Max. permissible engine speed rpm 6500 +/-50
Permissible constant speed rpm 6500
ENGINE BLOCK
11 11 ENGINE BLOCK, CYLINDER CRANKCASE
ENGINE BLOCK, CYLINDER CRANKCASE B40 SPECIFICATION

Bore diameter stage 0 a) mm 87.000 +0.014
Permitted out-of-round of cylinder mm 0.007
bore a)
Permitted conicity of cylinder bore mm 0.01
a)
Permissible total wear tolerance mm 0.10
2006 BMW 650i
(engine operated)
a. new status or recondition
11 11 ENGINE BLOCK, CYLINDER CRANKCASE
ENGINE BLOCK, CYLINDER CRANKCASE B48 SPECIFICATION

Permitted out-of-round of cylinder mm 0.007
bore a)
Permitted conicity of cylinder bore mm 0.01
a)
between piston and cylinder
(engine operated)
a. new status or recondition
CYLINDER HEAD WITH COVER

11 12 CYLINDER HEAD WITH COVER
CYLINDER HEAD WITH COVER N62TU SPECIFICATION

Cylinder head height: Original mm 133.0 +/- 0.07
dimension
Machining limit mm 132.7 +/- 0.07
Valve guides are not available as
replacement parts.
Inside diameter of installed valve
guide
Standard mm 6.0 H7
Tilt clearance, maximum (wear mm 0.5
between valve and valve guide)
Bearing of camshaft
Guide bearing (width) mm 14.035-13.993
11 12 CYLINDER HEAD WITH VALVE SEAT COVER B40
CYLINDER HEAD WITH VALVE SEAT COVER N62TU B40 SPECIFICATION

Valve seat angle ° 45
2006 BMW 650i
Correction angle: inner ° 60

Valve seat width: Inlet mm 1.25+/-0.25
Valve seat width: Exhaust mm 1.65+/-0.25
11 12 CYLINDER HEAD WITH VALVE SEAT COVER B48
CYLINDER HEAD WITH VALVE SEAT COVER B48 SPECIFICATION

Valve seat angle ° 45
Correction angle: outer ° 15
Correction angle: inner ° 60
Valve seat width: Inlet mm 1.25+/-0.25
Valve seat width: Exhaust mm 1.65+/-0.25
CRANKSHAFT WITH BEARING

11 21 CRANKSHAFT AND BEARINGS N62TU
CRANKSHAFT AND BEARINGS N62TU SPECIFICATION

Ground sizes of main bearing Bearing point 1
journals
Standard yellow mm 69.974 +0.006
Standard green mm 69.967 +0.006
Original violet mm 69.961 +0.005
Undersize 1 (U 0.25) yellow mm 69.724 +0.006
Undersize 1 (U 0.25) green mm 69.717 +0.006
Stage 1 (U 0.25) violet mm 69.711 +0.005
Stage 2 (U 0.50) violet mm 69.461 +0.005
Crankshaft bearing clearance, mm 0.024-0.052
radial
Maximum permitted runout on mm 0.15
central crankshaft journal
(crankshaft supported at bearing
journals 1 and 5).

Ground sizes of main bearing Bearing points 2 to 7
2006 BMW 650i
Standard yellow mm 69.984 +0.006

Standard green mm 69.977 +0.006
Original violet mm 69.971 +0.005
Stage 1 (U 0.25) violet mm 69.721 +0.005
Stage 2 (U 0.50) violet mm 69.471 +0.005
Crankshaft bearing clearance, mm 0.024-0.052
radial
Maximum permitted runout on mm 0.15
central crankshaft journal
(crankshaft supported at bearing
journals 1 and 5).
11 21 INSPECTING

Grinding stages, crankshaft guide
bearing
Standard mm 28.0 F8
Size 1 mm 28.2 F8
Size 2 mm 28.4 F8
Crankshaft axial play mm 0.080-0.246

Ground sizes of conrod bearing
journals
Standard mm 54.00 -0.009 -0.025
Size 1 mm 53.75 -0.009 -0.025
Size 2 mm 53.50 -0.009 -0.025
Radial conrod bearing play mm 0.028-0.070
VIBRATION DAMPER
11 23 VIBRATION DAMPER N62TU
2006 BMW 650i
VIBRATION DAMPER N62TU SPECIFICATION

Max. permitted radial runout mm 0.25
(drive levels)
Max. permitted axial runout (drive mm 0.25
levels)
CONNECTING ROD WITH BEARING

11 24 CONNECTING RODS AND BEARINGS N62TU
CONNECTING RODS AND BEARINGS N62TU SPECIFICATION

Large connecting rod eye bore mm 57.600 +0.016
diameter (without bearing shells)
Conrod bushing: Inside diameter mm 21 +0.014 +0.006
Permissible total deviation of g +/-4
connecting rods in one engine
(without bearing shells)
PISTON WITH RINGS AND PIN

11 25 PISTONS WITH RINGS AND PINS N62TU
PISTONS WITH RINGS AND PINS N62TU SPECIFICATION

1st groove
Height mm 1.2 -0.010 -0.030
End clearance mm 0.1-0.3
Axial play mm 0.020-0.070
2nd groove
Height mm 1.5 -0.010 -0.030
3rd groove
Height mm cannot be measured
Axial play mm cannot be measured
11 25 PISTONS WITH RINGS AND PINS N62TU B40
PISTONS WITH RINGS AND PINS B40 SPECIFICATION

Piston and pin are paired to each
other - replace together only.
2006 BMW 650i
Measuring point "A" (position) mm 11

Piston diameter at measuring point
"A"
Original, stage 0 (new dimension) mm 86.985 +/- 0.014
Oversize, stage 1 (new dimension) mm 86.235 +/- 0.014
Piston installation clearance mm 0.001-0.044
(piston new)
(piston worn)
(engine operated)
11 25 PISTONS WITH RINGS AND PINS N62TU
PISTONS WITH RINGS AND PINS N62TU B48 SPECIFICATION

Piston and pin are paired to each
other - replace together only.
Measuring point "A" (position) mm 18
Piston diameter at measuring point
"A"
Original, stage 0 (new dimension) mm 93.986 +/- 0.016
(piston new)
(piston worn)
(engine operated)
CAMSHAFT
11 31 CAMSHAFT N62TU
CAMSHAFT N62TU SPECIFICATION

Guide bearing (width) mm 14.100 +0.043
Radial runout mm 0.040-0.082
2006 BMW 650i
11 34 VALVES WITH SPRINGS N62TU
VALVES WITH SPRINGS N62TU B40 SPECIFICATION

Plate dia.
Inlet mm 35.0
Exhaust mm 29.0
Stem bore diameter
Inlet mm 6.0 -0.025 -0.040
Exhaust mm 6.0 -0.033 -0.047
11 34 VALVES WITH SPRINGS N62TU B44
VALVES WITH SPRINGS N62TU B48 SPECIFICATION

Plate dia.
Inlet mm 35.0
Exhaust mm 29.0
Stem bore diameter
Inlet mm 6.0 -0.025 -0.040
Exhaust mm 6.0 -0.033 -0.047
VARIABLE VALVE GEAR

11 37 VARIABLE VALVE GEAR N62TU
VARIABLE VALVE GEAR N62TU SPECIFICATION

Axial clearance of eccentric shaft mm 0.100-0.200
OIL SUPPLY
11 40 OIL SUPPLY N62TU
OIL SUPPLY SPECIFICATION

Oil grades and consumption: refer
to BMW SERVICE OPERATING
FLUIDS .
Oil change volume with oil filter ltr. 8.0
OIL PUMP WITH FILTER AND DRIVE

11 41 OIL PUMP WITH STRAINER AND DRIVE N62TU
2006 BMW 650i
OIL PUMP WITH STRAINER AND DRIVE N62TU SPECIFICATION

Oil pressure at idle speed with min bar 1.0
engine at operating temperature
Control pressure with engine at bar 4.0-6.0
operating temperature
2005 BMW 645Ci
2004-05 ENGINE Exhaust Systems - Repair Instructions - 645Ci
2004-05 ENGINE
Exhaust Systems - Repair Instructions - 645Ci
EXHAUST SYSTEM COMPLETE

18 00 020 REMOVING AND INSTALLING COMPLETE EXHAUST SYSTEM (N62)
 31 2 220

WARNING: Scalding hazard! Only perform this work after engine has cooled down.
Danger of injury! Removal of the exhaust system must be carried out with
2005 BMW 645Ci
the assistance of a second person. Weight of exhaust system is approx.

50kg.
 E64 only:
Remove tension struts on left and right
Support exhaust system with special tool 31 2 220.
Unscrew nuts (1).
Unscrew nuts (2).
Fig. 2: Releasing Nuts (1 Of 4)

2005 BMW 645Ci
NOTE: Illustrations depict the left side - proceed in the same way for the right side.
Unscrew nut (1).

Unscrew nuts.
2005 BMW 645Ci

Unscrew nuts.
2005 BMW 645Ci

Unfasten screws.
Remove reinforcement plate (1).

2005 BMW 645Ci
Fig. 6: Removing Reinforcement Plate (N62)

Lower exhaust system carefully.
18 10 031 REPLACING REAR MUFFLER (LEFT OR RIGHT) (N62)
 00 2 210
 31 2 220
WARNING: Scalding hazard! Only perform these tasks on an engine that has cooled
down.
Support rear muffler with special tool 31 2 220.

2005 BMW 645Ci
Fig. 7: Supporting Rear Muffler With Special Tool 31 2 220 (Left Or Right - N62)
While installed, mark cutting line with aid of replacement muffler on faulty rear muffler.
Cut exhaust pipes with special tool 00 2 210 at marked points and deburr.
2005 BMW 645Ci
Fig. 8: Cutting Exhaust Pipes With Special Tool 00 2 210 At Marked Points (Left Or Right - N62)
Unscrew nuts.
2005 BMW 645Ci
Fig. 9: Releasing Nuts (Left Or Right - N62)

Release nuts and remove rear muffler.

2005 BMW 645Ci
Fig. 10: Releasing Nuts And Removing Rear Muffler (Left Or Right - N62)
Connect final muffler to center muffler.

2005 BMW 645Ci
Fig. 11: Connecting Final Muffler To Center Muffler (Left Or Right - N62)
Align clamp and tighten down.
18 12 040 REMOVING AND INSTALLING/REPLACING FRONT MUFFLER (N62)
 00 2 210
 31 2 220
WARNING: Scalding hazard! Only perform these tasks after exhaust system has
cooled down.
Support front muffler with lifter and special tool 31 2 220 and secure against falling out.
2005 BMW 645Ci
Fig. 12: Supporting Front Muffler With Lifter And Special Tool 31 2 220 (Front Muffler - N62)
While installed, mark length (A) with aid of replacement muffler on faulty front muffler.
2005 BMW 645Ci
Fig. 13: Identifying Front Muffler Replacement Marks (Front Muffler - N62)
Cut both exhaust pipes with special tool 00 2 210 at marked points and deburr.
2005 BMW 645Ci
Fig. 14: Cutting Exhaust Pipes With Special Tool 00 2 210 At Marked Points (Front Muffler - N62)
Release nuts on holder (1).
Unscrew nuts (2).
Remove primary muffler.

2005 BMW 645Ci
Fig. 15: Removing Primary Muffler (Front Muffler - N62)

Connect new front muffler with central muffler using clamping sleeves.
2005 BMW 645Ci
Fig. 16: Connecting Front Muffler With Central Muffler (Front Muffler - N62)
Installation:
Nuts point downwards.
Align clamping sleeves so that:
Cutting line is in middle of clamping sleeve.

There is sufficient spacing to adjoining components.
18 12 045 REMOVING AND INSTALLING/REPLACING CENTRAL MUFFLER (N62)
 00 2 210
2005 BMW 645Ci
cooled down.
Fig. 17: Cutting Exhaust Pipes With Special Tool At Marked Points (Central Muffler - N62)
Replace center muffler (2).
Connect center muffler and front muffler by means of clamping sleeves.

2005 BMW 645Ci
Fig. 18: Connecting Center Muffler And Front Muffler (Central Muffler - N62)
Connect center muffler to rear muffler by means of clamping sleeve.

2005 BMW 645Ci
Fig. 19: Connecting Center Muffler To Rear Muffler (Central Muffler - N62)
MUFFLERS DIESEL
 00 2 210
 31 2 220
down.

2005 BMW 645Ci
Fig. 20: Supporting Rear Muffler With Special Tool 31 2 220 (Left Or Right - N62 - Diesel)
2005 BMW 645Ci
Fig. 21: Cutting Exhaust Pipes With Special Tool At Marked Points (Left Or Right - N62 - Diesel)
Unscrew nuts.
2005 BMW 645Ci
Fig. 22: Releasing Nuts (Left Or Right - N62 - Diesel)


2005 BMW 645Ci
Fig. 23: Releasing Nuts And Removing Rear Muffler (Left Or Right - N62 - Diesel)

2005 BMW 645Ci
Fig. 24: Connecting Final Muffler To Center Muffler (Left Or Right - N62 - Diesel)
MUFFLERS PETROL
 00 2 210
 31 2 220
down.
2005 BMW 645Ci
Fig. 25: Supporting Rear Muffler With Special 31 2 220 (Left Or Right - N62 - Petrol)
2005 BMW 645Ci
Fig. 26: Cutting Exhaust Pipes With Special Tool 00 2 210 At Marked Points (Left Or Right - N62 -
Petrol)
Unscrew nuts.
2005 BMW 645Ci
Fig. 27: Releasing Nuts (Left Or Right - N62 - Petrol)


2005 BMW 645Ci
Fig. 28: Releasing Nuts And Removing Rear Muffler (Left Or Right - N62 - Petrol)

2005 BMW 645Ci
Fig. 29: Connecting Final Muffler To Center Muffler (Left Or Right - N62 - Petrol)
18 12 040 REMOVING AND INSTALLING/REPLACING FRONT MUFFLER (N62)
 00 2 210
 31 2 220
cooled down.
Support front muffler with lifter and special tool 31 2 220 and secure against falling out.
2005 BMW 645Ci
Fig. 30: Supporting Front Muffler With Lifter And Special Tool 31 2 220 (Front Muffler - N62)
While installed, mark length (A) with aid of replacement muffler on faulty front muffler.
2005 BMW 645Ci
Fig. 31: Identifying Front Muffler Replacement Marks (Front Muffler - N62)
Cut both exhaust pipes with special tool 00 2 210 at marked points and deburr.
2005 BMW 645Ci
Fig. 32: Cutting Exhaust Pipes With Special Tool 00 2 210 At Marked Points (Front Muffler - N62)
Release nuts on holder (1).
Unscrew nuts (2).
Remove primary muffler.

2005 BMW 645Ci
Fig. 33: Releasing Nuts And Removing Primary Muffler (Front Muffler - N62)
Connect new front muffler with central muffler using clamping sleeves.
2005 BMW 645Ci
Fig. 34: Connecting Front Muffler With Central Muffler (Front Muffler - N62)
Installation:
Nuts point downwards.
Align clamping sleeves so that:
Cutting line is in middle of clamping sleeve.

There is sufficient spacing to adjoining components.
18 12 045 REMOVING AND INSTALLING/REPLACING CENTRAL MUFFLER (N62)
 00 2 210
2005 BMW 645Ci
cooled down.
Replace center muffler (2).
Fig. 35: Cutting Exhaust Pipes With Special Tool 00 2 210 At Marked Points (Central Muffler - N62)
Connect center muffler and front muffler by means of clamping sleeves.

2005 BMW 645Ci
Fig. 36: Connecting Center Muffler And Front Muffler (Central Muffler - N62)
Connect center muffler to rear muffler by means of clamping sleeve.

2005 BMW 645Ci
Fig. 37: Connecting Center Muffler To Rear Muffler (Central Muffler - N62)
EXHAUST MANIFOLD
18 40 020 REMOVING AND INSTALLING/REPLACING RIGHT EXHAUST MANIFOLD (N62)
down.
 Remove right control sensor

 Remove right monitor sensor
 Remove complete exhaust system
 Secure engine in installation position with special tool
2005 BMW 645Ci
 E65 only:
Remove intake filter housing
 Lower front axle support

 E65 only:
Remove A/C compressor drive belt
 Remove right engine support arm
Release screw connection of A/C compressor.
Place A/C compressor to one side and secure A/C system line so as to improve accessibility to nuts on exhaust
manifold.
For purposes of clarity, nuts are shown on removed engine.
Release nuts on exhaust manifold.
Remove exhaust manifold towards bottom and pull out towards rear.
2005 BMW 645Ci
Fig. 38: Removing Exhaust Manifold

Installation:
Replace seals.
Beads of seals face the exhaust manifold.

2005 BMW 645Ci
Fig. 39: Identifying Exhaust Manifold Seals Beads Position

Coat threads with copper paste.
Replace nuts.
Tightening torque, refer to 11 62 1AZ in EXHAUST SYSTEM - TIGHTENING TORQUES - 645CI .

2009 BMW 650i
SUSPENSION Front Suspension - 650i, M6
SUSPENSION
Front Suspension - 650i, M6
00 GENERAL
 Headaches
 Dizziness
 Stomach aches
 Vomiting
 Diarrhoea
 Cramps/fits
 Unconsciousness

First aid measures:
Danger of injury!

2009 BMW 650i
 Impaired sight

First aid measures:

Recycling:

2009 BMW 650i

contact points.
necessary.

points!

Risk of damage: It is not permitted to raise the vehicle at the rear differential cover!
2009 BMW 650i

31 ... . FRONT AXLE OVERVIEW

2009 BMW 650i
Fig. 3: Identifying Front Axle Components

31 .. .. LAYOUT OF SPRING STRUT SHOCK ABSORBER

2009 BMW 650i
Fig. 4: Identifying Spring Strut Shock Absorber Components

31 00 ... FRONT AXLE + STEERING: WHEEL/CHASSIS ALIGNMENT CHECK MUST BE

CARRIED OUT AFTER THE FOLLOWING WORK
2009 BMW 650i


 Steering gear to front axle carrier
 Control arm to front axle carrier
 Support bearing to body (if centering pin is missing)
 Tie rod end to tie rod

1. Front axle carrier
2. Steering gear
3. Gaiter (if the tie rod end has to be screwed off)
4. Control arm
5. Support bearing (if centering pin is missing)
6. Swivel bearing
7. Tie rod end
8. Tie rod
2009 BMW 650i
Facts:
Consequence:
Procedure:
Exception: On all M-models, when a limit value is exceeded on one side, it is still necessary always to replace

bristles!
31 00 ... INSTRUCTIONS (DAMAGE TO SUSPENSION)
Substandard roadholding, atypical noises, tires worn on one side, camber and toe-in values which deviate from
nominal value and mis-shaped components are all indicators of damage to the suspension caused by road traffic
accidents or similar impacts.
To repair vehicle correctly, depending on condition of vehicle, perform the following troubleshooting
procedure:
You must also follow the rules and guidelines for accident-related repairs to the steering gear.
Troubleshooting
2009 BMW 650i
TROUBLESHOOTING CHART
Vehicle condition Possible cause Remedy
a. Check screw connections:
Tie rod end to swivel bearing
Tie rod to power steering gear
a. Screw connection not Power steering gear to front axle

OK carrier
b. Tie rod or journal of
1 Camber inside/toe-in outside b. Replace tie rod, tension strut and
tie rod end is
the nominal value, adjustment of swivel bearing
deformed
track alignment possible
c. One or both tension IMPORTANT:
struts is/are deformed
If the journal of the tie rod end is
d. Control arm deformed deformed, the power steering
gear must also be replaced
c. Replace tension strut and swivel

bearing
d. Replace control arm, tension strut
and swivel bearing
Replace tie rods
2 Camber inside/toe-in outside Powerful forces acting on Replace swivel bearing
the nominal value, adjustment of steering/front axle Replace power steering gear
track alignment possible components Replace tension strut
Replace control arms
3 Camber/toe-in outside the
Powerful forces acting on
nominal value, adjustment of
front axle with distortion of:
track alignment not possible
a. Check screw connections, replace
a. Screw connections
the relevant part if necessary
b. Front axle support
b. Replace front axle carrier
c. See Pt. 1b) to d)
d. Spring strut/piston rod
d. Replace spring strut
NOTE: Damaged threads in engine carrier may be repaired with Helicoil thread inserts.
Comply with the procedure described in the example.
2009 BMW 650i
Fig. 6: Identifying Damaged Threads

Procedure:
1. Create a clean core hole; if necessary, drill out screw remnants
Fig. 7: Drilling Out Screw Remnants

2. Create locating thread for Helicoil thread insert

2009 BMW 650i
Fig. 8: Creating 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
Fig. 9: Screwing Helicoil Thread Insert Into Locating Thread

4. Break drive pin and remove

2009 BMW 650i
Fig. 10: Removing Drive Pin

10 FRONT AXLE SUSPENSION

31 10 000 REMOVING AND INSTALLING COMPLETE FRONT AXLE (WITH SPRING STRUT
SHOCK ABSORBER)
WARNING: Danger to life!

Secure engine in installation position to prevent it from falling down.
system.
Seal off hydraulic lines with plugs.

 Draw off and dispose off hydraulic fluid from fluid reservoir
 Secure engine in installation position
 Remove front wheels
 Disconnect plug connection of both pulse generators
 Remove and tie back brake caliper on both sides
 If necessary, remove steering gear cover on both sides
 Remove wheel suspension cover on both sides
 Remove lower steering spindle from power steering gear
 If necessary, disconnect plug connection on EH converter and expose line up to engine carrier
 If necessary, disconnect plug connection on ride-height sensor and expose line up to engine carrier
2009 BMW 650i
support arm
 Except M5, M6: Remove pressure line and if necessary Dynamic Drive pressure line from vane pump
 M5, M6: Disconnect pressure line from power steering gear
 Disconnect return line from power steering cooler
 Remove stabilizer link on both sides from bracket/spring strut
Remove bottom right wheel arch trim.
Release nuts (1, 2).
Tightening torque (1): 32 41 3AZ. See STEERING AND WHEEL ALIGNMENT - TIGHTENING
TORQUES .
Tightening torque (2): 37 14 13AZ. See INTEGRATED SUSPENSION SYSTEMS - TIGHTENING

TORQUES -- 650I .

Version with active steering:
Disconnect plug connections (1, 2).
Expose wiring harness (3) up to front axle carrier.

2009 BMW 650i
Fig. 12: Identifying Plug Connections And Wiring Harness

IMPORTANT: Guide spring struts with your hand when lowering and raising in order to avoid
damaging the wheel arches.
After lowering, the spring struts must be aligned to the front axle carrier and
secured in such a way that the ball joints of the control arms, tension struts
and tie rod ends are not damaged.
Remove spring strut from spring strut dome.
Support front axle carrier, release from engine carrier and carefully lower with spring struts.
Fig. 13: Identifying Front Axle Carrier

After installation:
 Fill and bleed hydraulic system

 Check pipe connections for leaks
2009 BMW 650i
 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/adjustment for active front steering
 If necessary, carry out initial Dynamic Drive operation
31 10 010 REMOVING AND INSTALLING/REPLACING REINFORCEMENT PLATE

Driving without reinforcement plate is not permitted!
 Remove underbody protective plate
Release screws (1) and remove reinforcement plate.
Installation:
Replace screws and insertion nuts.
Tightening torque 31 10 9AZ. See FRONT AXLE - TIGHTENING TORQUES -- 650I
Fig. 14: Identifying Reinforcement Plate Screws

Replacement:
If applicable, remove heat shield.
All except M5:

2009 BMW 650i
Installation:
Fig. 15: Pulling Out Underbody Protection From Under Bumper Trim
Replacement:
Fig. 16: Removing Catches

Version with rough road package:

2009 BMW 650i
Feed out underbody protection (3) towards rear.
Installation:
Replace screws (1).
Tightening torque 51 71 20AZ. See BODY EQUIPMENT - TIGHTENING TORQUES .
Fig. 17: Feeding Out Underbody Protection Towards Rear

M5 only:
Installation:
2009 BMW 650i
Fig. 18: Pulling Underbody Protection Forward Under Bumper Trim

Release screws (1).
Installation:
Fig. 19: Removing Rear Underbody Protection

2009 BMW 650i
11 FRONT SUB-FRAME
31 11 001 REPLACING FRONT AXLE CARRIER

system.

 Remove stabilizer
 Remove pressure line and if necessary Dynamic Drive pressure line from vane pump
 Remove tension strut on both sides from front axle carrier
 Remove jointed rod of ride-height sensor from control arm
 Remove control arm on both sides from front axle carrier
 Remove tie rod end on both sides from swivel bearing
 Lower front axle carrier
Remove pressure lines for oscillating motor of front axle with hose/pipe holders.
Remove vent hose with filter.
Remove heat shield(s).
Disconnect hydraulic lines from power steering gear and front axle carrier.
Remove left engine mount/bracket and right engine mount and if necessary remove with vacuum lines from
front axle carrier.
Remove power steering gear.
Remove vehicle jack support.

2009 BMW 650i
Take front axle subframe down and set down on a suitable surface.
Installation:
Use previous front axle subframe as a template for modifying or replacing small parts.

After installation:

31 11 506 LOWERING/RAISING FRONT AXLE CARRIER
 00 2 030
 00 2 040
 31 4 012
 33 3 274

system.
2009 BMW 650i

 Remove steering gear cover on both sides
Draw off and dispose off hydraulic fluid from fluid reservoir.
Release nut (1) for Dynamic Drive return line.
Tightening torque 37 14 21AZ. See INTEGRATED SUSPENSION SYSTEMS - TIGHTENING

TORQUES -- 650I .
Release nut (2) for Dynamic Drive pressure line.

TORQUES -- 650I .
Release nuts (3) for pressure lines to front axle oscillating motor.
Fig. 21: Identifying Nuts For Dynamic Drive Return Line And Pressure Line
2009 BMW 650i

TORQUES -- 650I .



If necessary, position special tool 00 2 040 with a 2nd person helping on workshop jack 00 2 030.
Insert special tools 31 4 012 into corresponding receptacles of special tool 00 2 040.
Align special tool 00 2 040 to front axle subframe.
NOTE: Make sure when raising that the special tools 31 4 012 are correctly inserted in
the rear recesses on the front axle carrier.
Support front axle carrier in rear area by raising special tool 00 2 040.
2009 BMW 650i
Position special tool 33 3 274 on floor jack mounting.

IMPORTANT: Pay attention to power steering hoses and lines when lowering and raising.
Hoses/lines must not be kinked/tensioned/bent!
Release screws (1, 2).
Installation:
Check threads for damage; if necessary, repair with Helicoil thread inserts.
Tighten down screws (1) and then screws (2).
Lower front axle carrier.
NOTE: If necessary, perform the following work steps if the front axle carrier has to be
lowered by more than 10 cm.
2009 BMW 650i

Detach pressure lines from oscillating motor of front axle.
Release screw.

TORQUES -- 650I .
Move pipe holder towards rear.

After installation:

2009 BMW 650i

 Carry out steering angle sensor adjustment/adjustment for active steering
 Carry out initial Dynamic Drive operation
12 STRUTS WITH RUBBER MOUNTS

31 12 000 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT CONTROL ARM
NOTE: If the control arm is detached from the front axle carrier, it is necessary after
 If necessary, remove steering gear cover at side
Right side only on version with xenon headlight:
Release nut (jointed rod on control arm).
Remove jointed rod (1) from control arm.
Disconnect plug connection (2) on ride-height sensor.
Fig. 26: Identifying Jointed Rod And Plug Connection

Unscrew nut (1).
Remove screw towards rear.
Only on right side: If necessary, remove holder with ride-height sensor.

2009 BMW 650i
Take off control arm.
Installation:
Keep control arm to swivel bearing connection clean and free from oil and grease.

After installation:

31 12 080 REMOVING AND INSTALLING/REPLACING BOTH TENSION STRUTS
 Remove front wheel

 Remove front assembly underside protection
 Remove steering gear cover at side
 If necessary, remove wheel suspension cover
2009 BMW 650i
Release nuts (1) and pull out screw (3).
Installation:
Tightening torque 31 12 1AZ . See FRONT AXLE - TIGHTENING TORQUES -- 650I
Turn swivel bearing a little and remove tension strut.
Fig. 28: Identifying Nuts And Screw

Installation:
Keep tension strut to swivel bearing connection clean and free from oil and grease.
31 12 138 REPLACING RUBBER MOUNTS ON BOTH TENSION STRUTS
 31 3 031
 31 3 032
IMPORTANT: The rubber mounts on both tension struts must be replaced! Note that the
2009 BMW 650i
 Check ball joints of tension struts while installed, replace tension struts if necessary
 Remove tension struts
IMPORTANT: If the tension struts already feature an identification mark with a centre punch,
it is necessary to replace both tension struts.
Mark tension struts with a punch mark in area (A).
Fig. 29: Identifying Punch Mark On Tension Struts

Using a press and special tools 31 3 031 and 31 3 032 , press rubber mount out of tension strut.
NOTE: Special tool 31 3 031 must be exactly flush with rubber mount bushing.
Fig. 30: Pressing Rubber Mount Out Of Tension Strut

Installation:
2009 BMW 650i
Align rubber mount by way of arrow to marking on tension strut and press in. The deviation must not exceed ±
5°.
Fig. 31: Identifying Rubber Mount Deviation

Installation:
Protrusion (A) equally large.
Fig. 32: Identifying Protrusion

21 WHEEL BEARINGS AND STUB AXLE

31 21 090 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT SWIVEL BEARING
 31 2 230
 Remove front brake disc . See FRONT BRAKES .

2009 BMW 650i
 Remove front pulse generator from swivel bearing . See 34 52 525 REPLACING ONE FRONT
PULSE GENERATOR .
 Remove control arm from swivel bearing . See control arm.
 Remove tie rod end from swivel bearing . See 32 21 151 REPLACING LEFT OR RIGHT TIE ROD .
 Remove bracket for stabilizer link from swivel bearing . See 31 35 007 Removing and
installing/replacing holder for left or right push rod/stabilizer.
 Remove tension strut from swivel bearing . See 31 12 080 Removing and installing/replacing both
tension struts.
E63, E64: Spread swivel bearing with special tool 31 2 230 .
Lower swivel bearing with workshop jack.
Installation:
Keep press fit of swivel gearing and spring strut in lower area clean and free from oil and grease.
Spread swivel bearing with special tool 31 2 230 , align by means of gap to web on back of spring strut and
raise as far as it will go.

Replacement:
Modify or if necessary replace wheel bearing . See 31 21 180 Replacing bearings (wheel hub) for front
wheel.
Modify brake carrier/brake guard plate . See DISC .
After installation:
2009 BMW 650i
31 21 180 REPLACING BEARINGS (WHEEL HUB) FOR FRONT WHEEL
 Remove swivel bearing 31 21 090 Removing and installing/replacing left or right swivel bearing.
IMPORTANT: When clamping swivel bearing unit, make sure it is only clamped at wheel
bearing.
Clamp swivel bearing as illustrated.
Fig. 34: Locating Swivel Bearing Clamping Position

Release screws and remove swivel bearing upwards.
Fig. 35: [Locating Bolts]

Keep tapped holes (1) clean and free from grease.

2009 BMW 650i
Installation:
If the wheel bearing is not replaced, all the tapped holes (1) in the wheel bearing must be reconditioned.
Replace screws.
Fig. 36: Identifying Tapped Holes And Contact Surface Of Wheel Bearing
31 SPRING STRUT
2009 BMW 650i

Facts:
2009 BMW 650i
Procedure:
31 31 000 REMOVING AND INSTALLING COMPLETE LEFT OR RIGHT SPRING STRUT SHOCK
ABSORBER
IMPORTANT: If the centering pin is missing from the support bearing, the position of the
studs to the wheel arch must be marked so that the original camber is
approximately maintained.
Only one nut may ever be released for marking.
 Remove swivel bearing .
M5:
Unclip connecting cable (1) from spring strut dome cover (3).
Detach connecting cable (1) from spring strut.
Fig. 38: Identifying Plug Connection, Connecting Cable And Spring Strut Dome Cover
2009 BMW 650i
If necessary, release expander rivet (1).
If necessary, unclip spring strut dome cover (2) from front cross-strut.
Fig. 39: Identifying Expander Rivet And Spring Strut Dome Cover
Centering pin missing: Make position of studs in relation to wheel arch.
Secure spring strut against falling out.
Unscrew nuts.
Remove spring strut downwards out of wheel arch.
Installation:
Align spring strut using centering pin to bore in wheel arch or studs to wheel arch and push upwards.

2009 BMW 650i
Fig. 40: Locating Nuts

After installation:
centering pin.
31 31 031 REPLACING FRONT LEFT OR RIGHT SPRING STRUT SHOCK ABSORBER
 31 2 210
 31 3 341
 31 3 354
 31 3 355
springs.
2009 BMW 650i
 Remove front spring strut
Removing:
Fit special tools 31 3 354 and 31 3 355 from above on special tool 31 3 341 until locking pins (1) can be felt and
heard to snap into place.
Check seating of special tools 31 3 354 and 31 3 355 , correct if necessary.

WARNING: During tensioning, spring plate must rest correctly in special tool 31 3
354 !
During tensioning, lower coil of coil spring must rest completely in recess
of special tool 31 3 355 !
Clean coil spring to remove coarse contamination and take up with special tools 31 3 354 and 31 3 355 .
Twist spring strut until end of coil spring (1) is flush with end of special tool 31 3 355 .

2009 BMW 650i
Fig. 42: Identifying Coil Spring And Special Tools

Take off cap.
Release nut with special tool 31 2 210 (grip piston rod in the process).
Remove support bearing, dust sleeve and shim.
Remove spring strut with auxiliary damper, gaiter and lower spring pad sideways from tensioned coil spring.

Remove auxiliary damper (1) with gaiter (2) and lower spring pad (3).
Assembly:
Check auxiliary damper (1), gaiter (2) and lower spring pad (3) for damage, replace if necessary.
Attach lower spring pad (3) to spring plate.

2009 BMW 650i
Attach auxiliary spring (1) and gaiter (2) to piston rod.
Fig. 44: Identifying Auxiliary Damper, Gaiter And Lower Spring Pad
Insert spring strut in tensioned coil spring. End of coil spring (1) must be aligned as illustrated to lower spring
pad (2).
NOTE: End of coil spring (1) must not touch against shoulder of spring pad.
The recess only serves to reinforce and correctly seat the lower spring pad and
does not serve as a stop for the spring end.
Fig. 45: Identifying Coil Spring And Lower Spring Pad

Attach shim to piston rod.
Attach dust sleeve and support bearing to piston rod.
2009 BMW 650i
spring plate.

Tighten down nut with special tool 31 2 210 (grip piston rod in the process).
Check installation position of gaiter, correct fold if necessary.
After installation:
centering pin.

DOME
IMPORTANT: Vehicles must not be driven without tension struts.

Driving without tension struts will result in bodywork damage.
 Remove lower microfilter housing section on left/right. See CABIN AIR FILTER .
If necessary, remove cover on spring strut dome on left/right:

2009 BMW 650i
 Remove cover (3),

 taking care not to damage retaining lug (2)
Fig. 47: Identifying Expander Rivets, Cover And Retaining Lug

 Release expander rivets on panel (2)

 Remove panel (2) in direction of arrow
Fig. 48: Removing Panel

IMPORTANT: modified screw connection!

Screws must be replaced and - because of the modified surface coating -
tightened to increased torque!
Release screws (1).

2009 BMW 650i
Installation:
Replace screws.
Tightening torque 51 61 1AZ . See BODY EQUIPMENT - TIGHTENING TORQUES .
Fig. 49: Identifying Tension Strut

33 SPRING WITH SUSPENSION

31 33 001 REPLACING FRONT LEFT OR RIGHT SPRING STRUT SUPPORT BEARING
 31 2 210
 31 3 341
 31 3 354
 31 3 355
springs.
2009 BMW 650i

Removing:

354 !

2009 BMW 650i

Take off cap.
Remove support bearing and dust sleeve.

If necessary, twist/drive out centering pin (1).
NOTE: If a support bearing (2) was fitted without centering pin (1), the centering pin (1)
of the new support bearing (2) must be twisted or driven out.
2009 BMW 650i
Fig. 53: Identifying Support Bearing And Centering Pin

Assembly:
pad (2).


2009 BMW 650i
spring plate.

After installation:
centering pin.
31 33 095 MEASURING RIDE-LEVEL HEIGHT OF VEHICLE
2009 BMW 650i

31 33 100 REMOVING AND INSTALLING/REPLACING COIL SPRING FOR LEFT OR RIGHT

FRONT SPRING STRUT
 31 2 210
 31 3 341
 31 3 354
 31 3 355
springs.
IMPORTANT: Both coil springs on the relevant axle must be replaced only in the event of
corrosion breakage!
2009 BMW 650i
entered.
 Remove front spring strut . See 31 31 000 Removing and installing complete left or right spring strut
shock absorber.
Removing:

354 !

2009 BMW 650i

Take off cap.

Remove coil spring with spring plate from special tools 31 3 354 and 31 3 355 .
2009 BMW 650i
Fig. 60: Identifying Special Tools 31 3 354 And 31 3 355

Remove spring plate (2) with upper spring pad (1).
Assembly:
Check upper spring pad (1) for damage, replace if necessary.
Fit spring plate (2) with upper spring pad (1) on new coil spring.
NOTE: End of coil spring must be positively aligned to spring pad (1).
Fig. 61: Identifying Upper Spring Pad And Spring Plate

354 !
2009 BMW 650i
Insert coil spring with spring plate in special tools 31 3 355 and 31 3 354 .
NOTE: Twist coil spring until lower end of coil spring (1) is flush with end (2) of special
tool 31 3 355 .

pad (2).
The recess only serves to reinforce and correctly seat the lower spring pad and does not serve as a stop for the
spring end.
2009 BMW 650i

spring plate.

2009 BMW 650i
After installation:
centering pin.
35 STABILIZER BAR
31 35 000 REMOVING AND INSTALLING/REPLACING FRONT STABILIZER

 If necessary, remove wheel suspension cover on both sides
 Remove stabilizer link on both sides from stabilizer 31 35 005 Removing and installing/replacing push
rod (stabilizer link) for left/right stabilizer
If necessary, remove holder for hydraulic lines from retaining bracket.
Release nut (1) and screw (2) at both ends.
Remove stabilizer from front axle carrier.
Installation:
Check both rubber mounts for damage, replace if necessary.

2009 BMW 650i
Fig. 66: Identifying Nut And Screw

Replacement:
Remove rubber mount on both sides from stabilizer . See 31 35 021 Replacing rubber mounts of stabilizer
retaining fixture on front axle carrier.
31 35 005 REMOVING AND INSTALLING/REPLACING PUSH ROD (STABILIZER LINK) FOR

LEFT/RIGHT STABILIZER
NOTE: Stabilizer links may only be replaced in pairs.
Release nuts (1, 2); if necessary, grip at Torx socket.
Installation:

2009 BMW 650i

31 35 007 REMOVING AND INSTALLING/REPLACING HOLDER FOR LEFT OR RIGHT PUSH

ROD/STABILIZER
Remove front wheel .
Remove stabilizer link from holder (1). See 31 35 005 Removing and installing/replacing push rod
(stabilizer link) for left/right stabilizer.
Release screw (2).
Fig. 68: Identifying Holder

Support swivel bearing with workshop jack and a suitable mounting.
Unscrew nut (1).

2009 BMW 650i
Remove holder (2) for brake hose, pulse generator and if necessary brake pad sensor.
Remove screw (4) with holder (3) towards front.
Installation:
Fig. 69: Identifying Holder Nut

31 35 021 REPLACING RUBBER MOUNTS OF STABILIZER RETAINING FIXTURE ON FRONT

AXLE CARRIER
 Remove stabilizer from front axle carrier . See 31 35 000 Removing and installing/replacing front
stabilizer.
Remove retaining bracket (1), if necessary retaining plate (3) and rubber mount (2) on both sides.
Installation:
Keep retaining bracket (1), rubber mount (2) and stabilizer clean and free from oil and grease.
oil and grease.
2009 BMW 650i
Fig. 70: Identifying Retaining Bracket, Retaining Plate And Rubber Mount
90 TROUBLESHOOTING
31 90 ... FRONT AXLE TROUBLESHOOTING
Follow troubleshooting for steering/shock absorbers .
FRONT AXLE TROUBLESHOOTING CHART

Fault Cause Remedy
Grinding noise (louder
Wheel bearings faulty Replace wheel bearings
when negotiating bends)
Wheel imbalance Balance wheels
Radial/lateral rim
Vibration Check rims , replace if necessary
runout
Radial/lateral rim
Check rims , replace if necessary
runout
Rubber mount of
control arm faulty
Ball joint in control arm
Steering-wheel shake Replace control arms
worn
Rubber mount of
Replace rubber mounts on both tension struts
tension strut faulty
Ball joint on tension
Replace both tension struts
strut worn
Refer to 90 TROUBLESHOOTING
Rubber mount of
control arm faulty
2009 BMW 650i
worn
Rubber mount of
Excessive steering wheel tension strut faulty Replace rubber mounts on both tension struts
play/steering wheel
inclination Ball joint on tension
strut worn
Tighten down bolts (refer to REMOVING AND
Bolts for reinforcement
INSTALLING/REPLACING REINFORCEMENT
plate loose
PLATE)
Bolts for front axle
carrier to engine carrier Replace bolts
loose
Bolt for spring strut to
Replace bolt & nut
swivel bearing loose
Rattling noise Ball joint in control arm
worn
strut worn
Rubber mounts for
stabilizer bar bracket Replace both rubber mounts of stabilizer bar bracket
faulty
Ball joints on stabilizer
Replace both stabilizer links
link(s) worn
Front or rear axle
Check suspension components for damage; if
Excessive tyre wear alignment incorrectly
necessary, carry out chassis/wheel alignment check
adjusted

Fault Cause Remedy
Visually inspect auxiliary spring for
Shock absorber knocking Rubber damper faulty
cracking, replace auxiliary spring
(bottoming)
Shock absorber mounting loose Tighten shock absorber
Rattling noise Support bearing faulty/hardened Replace support bearing
Worn down areas (flattened
areas) on tire profile
Long after-swinging of body Shock absorber leaking
Replace shock absorber
after driving over rough road (insufficient shock absorber effect)
2009 BMW 650i
successive uneven surfaces (insufficient shock absorber effect) Replace shock absorber
Wheels jumping even on normal Shock absorber leaking
road surfaces (insufficient shock absorber effect)
Separating skin in vent holes of
Whistling noises Remove separating skin
auxiliary spring
SPECIAL TOOLS
See FRONT AXLE - SPECIAL TOOLS .
2006 BMW 650i
SUSPENSION
00 GENERAL
 Headaches
 Dizziness
 Stomach aches
 Vomiting
 Diarrhoea
 Cramps/fits
 Unconsciousness

First aid measures:
Danger of injury!

2006 BMW 650i
 Impaired sight

First aid measures:

Recycling:

2006 BMW 650i

contact points.
necessary.

points!

2006 BMW 650i


2006 BMW 650i


2006 BMW 650i


2006 BMW 650i



2. Steering gear
4. Control arm
6. Swivel bearing
7. Tie rod end
8. Tie rod
2006 BMW 650i
Facts:
Consequence:
Procedure:

bristles!
procedure:
Troubleshooting
2006 BMW 650i

OK carrier
tie rod end is
deformed

bearing
and swivel bearing
Replace tie rods
2006 BMW 650i

Procedure:


2006 BMW 650i



2006 BMW 650i


SHOCK ABSORBER)

system.

2006 BMW 650i
support arm
TORQUES .

TORQUES -- 650I .


2006 BMW 650i


After installation:

2006 BMW 650i
centering pin.

Installation:

Replacement:
All except M5:

2006 BMW 650i
Installation:
Replacement:


2006 BMW 650i
Installation:
Replace screws (1).

M5 only:
Installation:
2006 BMW 650i

Release screws (1).
Installation:

2006 BMW 650i
11 FRONT SUB-FRAME

system.

front axle carrier.

2006 BMW 650i
Installation:

After installation:

 00 2 030
 00 2 040
 31 4 012
 33 3 274

system.
2006 BMW 650i


TORQUES -- 650I .

TORQUES -- 650I .
2006 BMW 650i

TORQUES -- 650I .



2006 BMW 650i

Installation:
2006 BMW 650i

Release screw.

TORQUES -- 650I .

After installation:

2006 BMW 650i



Unscrew nut (1).

2006 BMW 650i
Installation:

After installation:


2006 BMW 650i
Installation:

Installation:
 31 3 031
 31 3 032
2006 BMW 650i


Installation:
2006 BMW 650i
5°.

Installation:


 31 2 230

2006 BMW 650i
PULSE GENERATOR .
tension struts.
Installation:

Replacement:
wheel.
After installation:
2006 BMW 650i
bearing.



2006 BMW 650i
Installation:
Replace screws.
31 SPRING STRUT
2006 BMW 650i

Facts:
2006 BMW 650i
Procedure:
ABSORBER
M5:
2006 BMW 650i
Unscrew nuts.
Installation:

2006 BMW 650i

After installation:
centering pin.
 31 2 210
 31 3 341
 31 3 354
 31 3 355
springs.
2006 BMW 650i
Removing:

354 !

2006 BMW 650i

Take off cap.

Assembly:

2006 BMW 650i
pad (2).

2006 BMW 650i
spring plate.

After installation:
centering pin.

DOME


2006 BMW 650i





Release screws (1).

2006 BMW 650i
Installation:
Replace screws.


 31 2 210
 31 3 341
 31 3 354
 31 3 355
springs.
2006 BMW 650i

Removing:

354 !

2006 BMW 650i

Take off cap.

2006 BMW 650i

Assembly:
pad (2).


2006 BMW 650i
spring plate.

After installation:
centering pin.
2006 BMW 650i


FRONT SPRING STRUT
 31 2 210
 31 3 341
 31 3 354
 31 3 355
springs.
corrosion breakage!
2006 BMW 650i
entered.
shock absorber.
Removing:

354 !

2006 BMW 650i

Take off cap.

2006 BMW 650i

Assembly:

354 !
2006 BMW 650i
tool 31 3 355 .

pad (2).
spring end.
2006 BMW 650i

spring plate.

2006 BMW 650i
After installation:
centering pin.
35 STABILIZER BAR

Installation:

2006 BMW 650i

Replacement:

Installation:

2006 BMW 650i


ROD/STABILIZER
Release screw (2).

Unscrew nut (1).

2006 BMW 650i
Installation:


AXLE CARRIER
stabilizer.
Installation:
oil and grease.
2006 BMW 650i
90 TROUBLESHOOTING

Fault Cause Remedy
Radial/lateral rim
runout
Radial/lateral rim
runout
Rubber mount of
control arm faulty
worn
Rubber mount of
strut worn
Rubber mount of
control arm faulty
2006 BMW 650i
worn
Rubber mount of
play/steering wheel
strut worn
plate loose
PLATE)
loose
Replace bolt & nut
worn
strut worn
Rubber mounts for
faulty
link(s) worn
Front or rear axle
adjusted

Fault Cause Remedy
(bottoming)
2006 BMW 650i
auxiliary spring
SPECIAL TOOLS
2005 BMW 645Ci
2004-05 ENGINE Fuel System - Repair Instructions - E63
2004-05 ENGINE
Fuel System - Repair Instructions - E63
FUEL PICK-UP, CLEANING SYSTEM

16 00 FUEL SUPPLY SYSTEM E60/E63/E64
1. General
General function description of fuel system, refer to 16 00 GENERAL FUNCTION DESCRIPTION

FOR FUEL SUPPLY SYSTEMS .
2. Component designation
FUEL SUPPLY SYSTEM - COMPONENT DESIGNATION (E60/E63/E64)

1. Fuel filler neck 13. Service opening, right
2. Outlet protection valve 14. Filler vent connection (see
Fig. 1 )
14. Filler vent valve (see Fig.
2)
3. Electric fuel pump 15. Service vent valve
4. Fuel filter 16. Service vent valve
5. Feed line 17. Carbon canister
6. Fuel injectors 18. Tank vent valve
7. Pressure regulator 19. Purge air from carbon
canister to intake manifold
8. Suction jet pump, left 20. Air filter (insect strainer)
9. Suction jet pump, right 21. Digital Motor Electronics
10. Fuel level sensor, right 22. Lambda oxygen sensor
11. Fuel level sensor, left 23. Exhaust manifold
12. Service opening, left
3. Function description (see also drawing)
Fuel system
The saddle-shaped fuel tank contains the surge chamber with electric fuel pump on its right side.
The surge chamber ensures that the fuel pump is properly supplied in all vehicle operating states.
The suction jet pumps direct the fuel from the left and right halves of the tank into the surge chamber.
Suction jet pumps utilize the venturi effect to draw in further fuel via a jet and pump on both quantities of
2005 BMW 645Ci
Return line, pressure regulator and fuel filter are located in the tank.
Fuel supply to engine:
The electric fuel pump draws in fuel from the surge chamber and pumps it to the fuel filter/pressure
regulator via the delivery line to the fuel rail.
Pressure regulator and fuel filter are incorporated in a single unit in the tank. This removes the need for a
fuel return line.
The pressure regulator limits the pressure in the fuel feed line to 3.5 bar. If the pressure rises above 3.5
bar, the regulator opens a discharge hole. The excess fuel flows back through the discharge hole into the
right tank half (surge chamber) and drives the two suction jet pumps.
The fuel rail thus operates on a return-free basis.
Tank venting system (US version):
During refueling, the fuel tank is vented via the filler vent valve and the filler vent line. The
petrol/gasoline gases are directed during refueling via the filler vent valve and the vent line through the
carbon canister and thus discharged in filtered state to atmosphere. The carbon canister of the US version
therefore has a larger volume than that of the other national versions.
The filler vent valve in the tank is closed by the rising fuel in the event of overfilling. A pressure cushion
is created in the tank when the vent outlet is closed. This pressure cushion creates a backdraft of fuel in
the fuel filler pipe. The backdraft of fuel reaches the petrol/gasoline pump nozzle and cuts it out
automatically. A compensating volume of approx. 6 liters is thus maintained above the fuel level.
The compensating volume incorporates 2 service vent valves.
Both valves are designed as rollover valves. This prevents fuel from escaping from the fuel tank in
extreme vehicle positions (overturning, inclined position).
 Reduction of excess pressure:
The process of heating fuel creates excess pressure. The gases rising from the tank flow through the
service vent valves and the vent lines to the carbon canister.
 Equalization of vacuum pressure:
The process of pumping off fuel creates vacuum pressure. Air is routed in reverse sequence for pressure
equalization purposes. The fuel tank is supplied with fresh air via the air filter (insect strainer) on the
carbon canister and via the carbon canister itself.
The carbon canister removes hydrocarbons (HCs) from the gases created in the fuel tank and discharges
the cleaned air to atmosphere.
2005 BMW 645Ci
The condensed constituents of the fuel vapors remain in the tank because the tank has an integrated
compensating volume.
The carbon canister is regenerated by purging with fresh air.
The DME control unit opens the tank vent valve (depending on the load conditions and on lambda closed-
loop control). Thus the vacuum pressure of the engine intake manifold is applied at the purge air line. The
carbon canister is purged in this way. The fresh air needed for this purpose is supplied via the tank leak
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 line to the engine for combustion.
This operation is only possible while the engine is running.
Tank venting system (worldwide):
Refer to Tank venting system (US version) with following differences:
1. Carbon canister has a smaller capacity.

2. No tank leak diagnosis module or dust filter.
3. No pressure test line.
Leak diagnosis for tank venting system (US version):
The tank leak diagnosis module (see Fig. 2 ) serves to diagnose 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.
The tank leak diagnosis module 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.
Determining fill level in fuel tank:
The fuel fill level is measured by a lever-type sensor on either side of the fuel tank. The fuel level sensor
is supplied with 5 V by the instrument cluster and measures the voltage drop via the resistor on which the
lever sliding contact rests.
The combination of the determined values from the right and left lever-type sensors produces the actual
level in the fuel tank.
4. Service data, fuel system
Operating pressure: 3.5 bar
5. Schematic drawings of fuel supply systems

2005 BMW 645Ci
Fig. 1: Fuel Supply System Schematic Diagram (E60/63/64 ECE/Japan)

2005 BMW 645Ci
Fig. 2: Fuel Supply System Schematic Diagram (E60/E63/E64 US Version)

16 00 GENERAL FUNCTION DESCRIPTION FOR FUEL SUPPLY SYSTEMS
Fuel Supply Systems, Spark-Ignition Engines
Fuel system
The electric fuel pump in the fuel tank generates the pressure in the fuel system which is set by the pressure
regulator to a specific level.
Tank venting system
The tank venting system is an enclosed system which is vented via a carbon canister. The carbon is incorporated
in the carbon canister as granulate. The large surface of the carbon stores the fuel vapors which occur in the fuel
2005 BMW 645Ci
Regeneration is performed by way of purging with fresh air via the intake manifold. This process is controlled
by the engine control unit.
Fuel Supply Systems, Diesel Engines
Fuel system
The electric fuel pump in the fuel tank supplies the engine with fuel. Two types of high-pressure pump are used
for cylinder injection.
1. The distributor injection pump supplies each cylinder directly with fuel via the corresponding injection
nozzle.
2. The high-pressure pump for the common rail systems generates in the fuel rail the necessary pressure for
all the injection nozzles.
In common rail systems, a further pump (inline pump, M57/gear pump, M67) is connected between the high-
pressure pump and the electric fuel pump. This pump supports the fuel pump in the fuel tank in the event of a
high fuel demand.
Tank venting system
Diesel fuel is non-volatile and therefore a carbon canister is not required. The fuel tank is vented directly to
atmosphere.
16 00 005 DRAINING AND FILLING FUEL TANK
NOTE: For special tools, refer to FUEL SUPPLY SYSTEM - SPECIAL TOOLS - 645CI .
 13 5 460
IMPORTANT: Observe country-specific safety regulations. Ensure adequate ventilation in the

place of work! Connect the exhaust and extraction systems to the exhaust
tailpipe. The electric fuel pump must not operate without fuel! After completing
repairs but before starting the engine for the first time, fill the fuel tank with
min. 5 l fuel through the fuel filler pipe. Do not damage non-return flap when
pulling out extraction hose.
Drawing off fuel:
Start engine and allow to run.
The electric fuel pump runs.

2005 BMW 645Ci
right side of the fuel tank.
IMPORTANT: Once fuel has been drawn off through the fuel filler pipe, there are still residual
amounts in the fuel tank, in the fuel filter and in the fuel pump surge chamber.
NOTE: Fuel can be drawn out of the left and right sides of the tank through the filler
neck, leaving only a small residual amount.
This residual amount in the fuel tank is drawn off after removal of the sensors
for the fuel gauge (right/left).
Slide extraction hose of extractor unit into the fuel filler pipe, turning in the process if necessary.
Draw off fuel as much as possible with extractor unit.
Fig. 3: Draining Fuel With Extractor Unit

2005 BMW 645Ci
Follow drawing off of fuel on fuel gauge in instrument cluster.
Draining fuel filter and surge chamber:
Connect special tool 13 5 460 to connection of fuel filter (1).
Fig. 4: Connecting Special Tool To Fuel Filter

Connect special tool to extractor unit.
Draw off remaining fuel from filter and surge chamber.
A small amount of fuel still remains in the fuel tank.
Drawing off residual fuel amount from fuel tank:

2005 BMW 645Ci
container.
Remove fuel gauge sensor (right), refer to 16 12 000 REMOVING AND INSTALLING/REPLACING
FUEL GAUGE SENSOR (COMPLETE RIGHT SENSOR UNIT) .
Remove fuel gauge sensor (left), refer to 16 12 001 REMOVING AND INSTALLING/REPLACING FUEL
GAUGE SENSOR (COMPLETE LEFT SENSOR UNIT) .
Draw off residual fuel quantity through installation openings.
Fuel filling:
Slide extraction hose of extractor unit approx. 40 cm into fuel filler pipe.
Fig. 5: Filling Fuel From Suction Extractor Unit

2005 BMW 645Ci
Drawing off after fault in suction jet pump:
Draw off right half of tank completely through fuel filler pipe.
Drain surge chamber and fuel filter.
Remove sensor for fuel gauge (left), refer to 16 12 001 REMOVING AND INSTALLING/REPLACING
FUEL GAUGE SENSOR (COMPLETE LEFT SENSOR UNIT) .
Insert extraction hose through sensor opening in tank, fuel (also residual quantity) can be drawn off.
Fig. 6: Draining Fuel Tank

16 00 100 CHECKING FUEL TANK AND TANK VENTILATION SYSTEM FOR LEAKS

2005 BMW 645Ci
 13 3 010
 16 1 070
 16 1 171
 16 1 174
NOTE: The following procedure is only applicable to vehicles without the tank leak
diagnosis module. Check tank venting system if a leak is suspected.
Comply with the following conditions in order to obtain plausible test results:
 Content of fuel tank:

1. Maximum 90 %
2. Minimum 13 % (reserve telltale must not light up).
 Park the car in the workshop at least 2 hours before the test so that the fuel temperature is approximately
that of the workshop temperature (ideal fuel temperature approx. 10...20 °C).
 Never refuel the vehicle directly prior to the leak test due to the strong emission of gas by the fresh fuel.
Release screws and remove cover (1).
Fig. 7: Releasing Screws And Removing Cover

2005 BMW 645Ci
Disconnect line (1) from carbon canister and seal opening on canister with special tool 16 1 070.
Fig. 8: Disconnecting Line From Carbon Canister And Seal Opening

Remove fuel filler cap and connect special tool 16 1 174 to fuel filler neck.
Clamp special tool 16 1 174 on fuel filler neck with adjusting wheel (1).
2005 BMW 645Ci
Fig. 9: Clamping Special (16 1 174) Tool On Fuel Filler Neck With Adjusting Wheel
IMPORTANT: Set pressure regulator on special tool 16 1 171 fully in "-" direction.
Connect special tool 16 1 171 using compressed air line (1) to garage compressed air system (8...10 bar).
Connect pressure sensor (2) from Diagnosis and Information System with a measuring range of 0...3.5 bar.
IMPORTANT: Do not connect fast-release coupling (3) of special tool 16 1 171 yet.
2005 BMW 645Ci
Fig. 10: Connecting Special Tool (16 1 171) To Compressed Air System
Select "Measurement" function on Diagnosis and Information System (DIS).
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.
IMPORTANT: 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 delivery line from special tool 16 1 171 to fuel filler neck.
Allow a rest period of approx. 20 secs.

2005 BMW 645Ci
Read off and note down starting pressure value.
Wait approx. 60 secs.
Read off final pressure value and compare with starting pressure value.
Measurement evaluation:
FUEL PRESSURE MEASUREMENT EVALUATION

Pressure drop between
Measure again.
0.008 and 0.010 bar.
System leaking beyond permitted levels.
Pressure drop in 60 secs.
Carry out leak test, refer to 16 00 510 CONDUCTING LEAK TEST ON
greater than 0.010 bar.
FUEL TANK AND TANK VENTILATION SYSTEM .
16 00 102 CHECKING FUEL TANK AND TANK VENTING SYSTEM FOR LEAKS WITH TANK
LEAKAGE DIAGNOSIS MODULE (DM-TL)
NOTE: An OBD fault is indicated by the "Check Engine" indicator lamp in the
instrument cluster lighting up. This may indicate a leak in the tank venting
system. Information on this is provided by the fault memory of the DME control
unit.
 Read out fault memory of DME control unit and carry out a diagnosis in accordance with faults stored.
 A leak test with the DM-TL module is then carried out if:
 The components of the DM-TL module are O.K.
 An error is stored in the DME fault memory (tank leak detected).
Adhere to following conditions in order to carry out a correct leak test:
 Content of fuel tank < 90 %

 Reserve indicator lamp "off"
 Leave car in workshop for at least 2 hours so that fuel temperature comes into line with workshop
temperature (ideal fuel temperature approx. 10...20 °C).
 Do not under any circumstances fill up car with fresh fuel (strong exhalation of fresh fuel).
 Check that fuel tank cap is correctly seated.
WARNING: During the leak test, under no circumstances apply external

pressurization through the fuel filler neck as this may cause incorrect
readings.
Clear DME fault memory.

2005 BMW 645Ci
Work through tank leakage diagnosis module. Leakage test is carried out.
If fault is recorded again in DME fault memory (tank leak detected), carry out leak test, refer to 16 00 510
CONDUCTING LEAK TEST ON FUEL TANK AND TANK VENTILATION SYSTEM .
16 00 510 CONDUCTING LEAK TEST ON FUEL TANK AND TANK VENTILATION SYSTEM
NOTE: The following procedure is only applicable to vehicles with the tank leak
diagnosis module (DM-TL).
Select "Tank leak diagnosis module (DM-TL)" on Diagnosis and Information
System (DIS).
 The leak diagnosis pump pressurizes the fuel tank and tank venting system for 30 secs.
 If pressure is required for more than 30 secs., reactivate the "Activate" button after 30 secs. in each case.
For vehicles without tank leak diagnosis module:
Pressurize fuel tank and tank venting system.
When leak-testing with a leak detector: follow manufacturer's operating instructions.
IMPORTANT: On vehicles with tank leak diagnosis modules (DM-TL), do not work with
external pressurization as the tank venting system will leak under this
condition. On account of emerging fuel vapors, carry out all operations in well
ventilated rooms. Or use a suitable extractor system. Observe country-specific
accident prevention and occupational safety regulations.
The leak test can be carried out with a leak detector.
Possible causes may be:
 Fuel tank cap leaking (check fuel cap pressure relief valve)
 Tank venting lines leaking (fuel tank carbon canister - tank venting valve)
 Tank venting valve leaking (engine compartment)
 Fuel level sensor flange on tank leaking
2005 BMW 645Ci
Fig. 11: Identifying Leak Detector (Special Tool)

2005 BMW 645Ci
16 11 030 REMOVING AND INSTALLING FUEL TANK
IMPORTANT: After installation of fuel tank/prior to first engine start-up:
 Check ground connection at fuel filler neck to body for continuity. If

necessary, clean contact surface between body and fuel filler pipe screw
connection.
 Fill fuel tank with min. 5L fuel.
 Draw off fuel from fuel tank

 Remove rear right wheel.
 Remove rear right wheel arch trim
 Remove complete propeller shaft
 Remove handbrake Bowden cables from wheel carrier and unclip from fuel tank
 Remove right tension strut for rear axle
 Partially detach rear left and right underbody panelling.
Unscrew nut (1).
Tightening torque, refer to 16 12 11AZ in FUEL SUPPLY SYSTEM - TIGHTENING TORQUES .
Disconnect filler vent line (3) from fuel filler pipe.

2005 BMW 645Ci
Fig. 12: Disconnecting Filler Vent Line From Fuel Filler Pipe
Installation:
Replace hose clip.
Release screws and remove heat shield (1).

2005 BMW 645Ci

Unlock and disconnect vent line (1) from carbon canister.
Unclip line from mountings (2) and mountings in wheel arch and feed out vent line.
2005 BMW 645Ci
Fig. 14: Disconnecting Vent Line From Carbon Canister

Unlock and disconnect plug connections (1) of feed line.

2005 BMW 645Ci
Fig. 15: Disconnecting Feed Line Plug Connections

Release screw.

2005 BMW 645Ci

Heavily support the fuel tank.

2005 BMW 645Ci
Fig. 17: Supporting Fuel Tank

Release screws for tightening straps on left and right and remove tightening straps.

2005 BMW 645Ci
Fig. 18: Removing Tightening Straps Screws

Installation:
Note rubber mount with spacer bush.

2005 BMW 645Ci
Fig. 19: Identifying Rubber Mount With Spacer Bush

Wide collar on spacer bush points to screw head.
Lower tank until plug (1) on top side of right tank half is accessible.
Unlock plug (1) and detach from delivery unit.
NOTE: Get a second person to feed out vent lines to wheel arch while removing tank
towards bottom.
2005 BMW 645Ci
Fig. 20: Releasing Plug And Detaching From Delivery Unit

Installation:
Feed vent lines (1) and (2) through body.
Do not kink lines.

2005 BMW 645Ci
Fig. 21: Installing Vent Lines

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.

2005 BMW 645Ci
bar).
Fig. 22: Connecting Special Tool (16 1 171) To Compressed Air System
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
Install filler cap on selected special tool.

2005 BMW 645Ci
Fig. 23: Identifying Special Tools (16 1 172 And 16 1 173)

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!
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 fuel filler neck.
Wait 60 secs.
2005 BMW 645Ci
EQUIPMENT LEAK TESTING MEASUREMENT EVALUATION

Testing equipment leaking.
Pressure drop > 0.012 bar
Check connection points for leaks.
Check Filler Cap Pressure Relief!
Follow same test procedure as for "Checking testing equipment for leaks".
FILLER CAP PRESSURE RELIEF MEASUREMENT EVALUATION

Filler cap pressure relief valve faulty.
Pressure drop > 0.012 bar
Replace filler cap I.
FUEL TRANSFER SENSOR FOR GAUGE

16 12 000 REMOVING AND INSTALLING/REPLACING FUEL GAUGE SENSOR (COMPLETE
RIGHT SENSOR UNIT)
 16 1 020
IMPORTANT: Ensure adequate ventilation in the place of work! Ensure absolute cleanliness
when working on the open fuel tank. Contaminants in the fuel tank can impair
driving operation or may even result in vehicle breakdown!
 Draw off fuel completely from fuel tank

 Remove left sensor unit
Fold carpet (1) forwards.
Detach insulating mat (2) above left and right sensor units at perforation and fold back towards rear. Pop out
rubber plugs here.
2005 BMW 645Ci
Fig. 24: Folding Carpet And Back Rubber Mat

IMPORTANT: Do not damage gasket.
Release nuts (1) on left and right.
Fold metal cover of left and right sensor units upwards.

2005 BMW 645Ci
Fig. 25: Releasing Nuts

IMPORTANT: Fuel line is pressurized. Catch escaping fuel in a suitable container.
If necessary, unlock and disconnect plug connection (1) of right sensor unit.
If necessary, release and disconnect hose (2) for independent heating (E60 only).
2005 BMW 645Ci
Fig. 26: Disconnecting Right Sensor Unit Plug Connection

Release rotary catch of left and right sensor units with special tool 16 1 020.
2005 BMW 645Ci
Fig. 27: Releasing Left And Right Sensor Units Rotary Catch
Installation:
Replace rubber seal on left and right.
IMPORTANT: Risk of breakage! Carefully raise connecting cover. In so doing, do not pull
excessively on connecting piece of fuel feed.
Installation:
2005 BMW 645Ci
During torque tightening, notch (3) on screw cap can be clearly heard and felt to engage toothed segment (4) on
fuel tank.
Fig. 28: Connecting Cover Installing Sequence

Secure a cable to hose pack through left service opening in tank.
The cable facilitates reinstallation of the hose pack.
Carefully remove right sensor unit from fuel tank.
IMPORTANT: Surge chamber is filled with fuel. Drain surge chamber through upper opening
(1). Catch fuel in a suitable container.
2005 BMW 645Ci
Fig. 29: Draining Surge Chamber Through Upper Opening

Feed hose pack out of fuel tank.
Installation:
The new sensor unit is supplied with a plastic cover over the hose pack.
Secure the cable pulled through the tank during removal to the eyelet on the plastic cover.
Carefully feed hose pack through fuel tank using cable.
IMPORTANT: The lines on the connection are turned to the sensor unit as the hose pack is
fed in. Turn sensor unit in the same direction of rotation and align. It is
absolutely essential to avoid kinking the hoses.
2005 BMW 645Ci
Replacing fuel level sensor:
Unlock and disconnect plug (2).
Release catches (1) and pull fuel level sensor out of unit.
Fig. 30: Releasing Catches And Removing Fuel Level Sensor


LEFT SENSOR UNIT)
 16 1 020
2005 BMW 645Ci
IMPORTANT: Ensure adequate ventilation in the place of work! Ensure absolute cleanliness
when working on the open fuel tank. Contaminants in the fuel tank can impair
driving operation or may even result in vehicle breakdown!

 Remove rear seat bench
Detach insulating mat (2) at perforation and fold back towards rear, pop out rubber plugs here.
Fig. 31: Folding Carpet

Fold back rubber mat.
Release nuts (1) and fold back metal cover.

2005 BMW 645Ci
Fig. 32: Folding Back Metal Cover

IMPORTANT: Fuel line is pressurized. Catch escaping fuel in a suitable container.
Disconnect plug connection.
Release and disconnect feed line (1).
M57TU:
Release and disconnect feed and return lines.

2005 BMW 645Ci
Fig. 33: Releasing And Disconnecting Feed Line

IMPORTANT: Fuel gauge must roughly indicate zero before the left tank opening is opened. If
the suction jet pump is faulty, the fuel level in the left tank half may be above
the service opening! Large quantities of fuel may emerge on opening! In this
event, keep left tank half closed and feed extraction hose through right service
opening to left tank half.
Release screw cap with special tool 16 1 020.
Installation:
Replace rubber gasket.

2005 BMW 645Ci
Fig. 34: Releasing Screw Cap With Special Tool

IMPORTANT: Risk of breakage! Carefully raise fuel level sensor until sensor flange projects
out of tank opening. In so doing, do not pull excessively on connecting piece of
fuel return.
Installation:
When installing fuel level sensor, make sure that lug (1) engages opening (2) in fuel tank.
During torque tightening, notch (3) on screw cap can be clearly heard and felt to engage toothed segment
(4) on fuel tank.
2005 BMW 645Ci
Fig. 35: Fuel Level Sensor Installing Sequence

Carefully remove left sensor unit from tank.
Disconnect line (1) to fuel filter and seal off at fuel filter.
Disconnect suction jet pump from fuel filter.
To do so, press catch (2) downwards and detach suction jet pump.
IMPORTANT: Look out of escaping fuel. Catch fuel in a suitable container.

2005 BMW 645Ci
Fig. 36: Disconnecting Fuel Filter Line And Removing Fuel Filter Sealing
E60/M57TU only:
Unlock line (1).
Pull suction jet pump out of holder.
To do so, press catch (2) downwards and detach suction jet pump (2).
2005 BMW 645Ci
Fig. 37: Pressing Catch And Detaching Suction Jet Pump

Unlock and disconnect plug (1) of hose pack.
NOTE: Release plug by pressing lock and disconnect.

2005 BMW 645Ci
Fig. 38: Disconnecting Hose Pack Plug

Unlock plug (2) and press out in direction of arrow.
Disconnect cable from pressure regulator and feed out of cable gland.
2005 BMW 645Ci
Fig. 39: Releasing Catches And Removing Fuel Level Sensor

16 12 010 REMOVING AND INSTALLING/REPLACING CARBON CANISTER

2005 BMW 645Ci
Fig. 40: Releasing Screws And Removing Heat Shield

Disconnect lines (1) from carbon canister (3).
Release screws (2).
Remove carbon canister (3).

2005 BMW 645Ci
Fig. 41: Disconnecting Lines From Carbon Canister

16 12 010 REMOVING AND INSTALLING/REPLACING CARBON CANISTER WITH DM-TL
DM-TL = Tank Leak Diagnosis Module

2005 BMW 645Ci
Fig. 42: Releasing Screws And Removing Heat Shield (Canister With DM-TL)
Disconnect plug (1) and lines (2) from carbon canister.
Release screws (3).

2005 BMW 645Ci
Fig. 43: Disconnecting plug, Lines and Screws From Carbon Canister (Canister With DM-TL)
Carefully lower carbon canister (1), disconnect line (2) from tank leak diagnosis module and remove carbon
canister.
2005 BMW 645Ci
Fig. 44: Lowering Carbon Canister And Disconnecting Line From Tank Leak Diagnosis Module
(Canister With DM-TL)
FUEL VENTILATION
16 13 015 REMOVING AND INSTALLING/REPLACING TANK LEAK DIAGNOSIS MODULE
 Remove carbon canister with tank leak diagnosis module.
Release screws (1).
Tightening torque. refer to 16 13 3AZ in FUEL SUPPLY SYSTEM - TIGHTENING TORQUES .
Disconnect tank leak diagnosis module (2) from carbon canister in direction of arrow.
2005 BMW 645Ci
Fig. 45: Disconnecting Tank Leak Diagnosis Module From Carbon Canister
Installation:
FUEL PUMP
16 14 060 REMOVING AND INSTALLING/REPLACING DUST FILTER FOR TANK LEAKAGE
DIAGNOSIS MODULE (DM-TL)
 Remove rear left wheel arch trim.

 Remove carbon canister.
2005 BMW 645Ci
Disconnect line (2) from tank leak diagnosis module.
Fig. 46: Disconnecting Line From Tank Leak Diagnosis Module (DM-TL)
Unclip line from holder.
Release screws (1) and remove dust filter with line.

2005 BMW 645Ci
Fig. 47: Releasing Screws And Removing Dust Filter With Line
2006 BMW 650i
ENGINE Fuel Supply System - Repair Instructions - 5 & 6 Series
ENGINE
Fuel Supply System - Repair Instructions - 5 & 6 Series
00 DRAWING OFF OF FUEL, SYSTEM CLEANING

16 00 GENERAL FUNCTION DESCRIPTION FOR FUEL SUPPLY SYSTEMS
Fuel supply systems, spark-ignition engines
Fuel system
The electric fuel pump in the fuel tank generates the pressure in the fuel system which is set by the pressure
regulator to a specific level.
Tank venting system
The tank venting system is an enclosed system which is vented via a carbon canister. The carbon is incorporated
in the carbon canister as granulate. The large surface of the carbon stores the fuel vapors which occur in the fuel
tank. The carbon canister must be regenerated on a regular basis so as to be able to continue storing fuel vapors.
Regeneration is performed by way of purging with fresh air via the intake manifold. This process is controlled
by the engine control unit.
Fuel supply systems, diesel engines
Fuel system
The electric fuel pump in the fuel tank supplies the engine with fuel. Two types of high-pressure pump are used
for cylinder injection.
1. The distributor injection pump supplies each cylinder directly with fuel via the corresponding injection
nozzle.
2. The high-pressure pump for the common rail systems generates in the fuel rail the necessary pressure for
all the injection nozzles.
In common rail systems, a further pump (inline pump, M57/gear pump, M67) is connected between the high-
pressure pump and the electric fuel pump. This pump supports the fuel pump in the fuel tank in the event of a
high fuel demand.
Tank venting system
Diesel fuel is non-volatile and therefore a carbon canister is not required. The fuel tank is vented directly to
atmosphere.
16 00 005 DRAINING AND FILLING FUEL TANK

2006 BMW 650i
 13 5 460
 16 1 080. See FUEL SUPPLY SYSTEM - SPECIAL TOOLS .
IMPORTANT: Observe country-specific safety regulations.

Ensure adequate ventilation in the place of work!
Connect the exhaust and extraction systems to the exhaust tailpipe.
The electric fuel pump must not operate without fuel!
After completing repairs but before starting the engine for the first time, fill the
fuel tank with min. 5L fuel through the fuel filler pipe.
Do not damage non-return flap when pulling out extraction hose.
Diesel vehicles:
Before starting the engine for the first time, if the tank has been run dry or drawn off, fill with diesel fuel and
turn on ignition for approx. 1 minute. The fuel circuit is thus filled and vented, which results in the engine firing
more quickly.
Drawing off fuel:
Start engine and allow to run.
The electric fuel pump runs.
In this way, the fuel is repumped through the suction jet pump and the tank expansion line from the left to the
right side of the fuel tank.
IMPORTANT: Once fuel has been drawn off through the fuel filler pipe, there are still residual
amounts in the fuel tank, in the fuel filter and in the fuel pump surge chamber.
NOTE: Fuel can be drawn out of the left and right sides of the tank through the filler
neck, leaving only a small residual amount.
This residual amount in the fuel tank is drawn off after removal of the sensors
for the fuel gauge (right/left).
Insert special tool 16 1 080 into filler neck.
Special tool 16 1 080 has two different diameters for petrol/gasoline and diesel vehicles!
Slide extraction hose of extractor unit through special tool 16 1 080 into the fuel filler pipe, turning in the
process if necessary.
Draw off fuel as much as possible with extractor unit.
Follow drawing off of fuel on fuel gauge in instrument cluster.

2006 BMW 650i

Draining fuel filter and surge chamber:
Connect special tool 13 5 460 to connection of fuel filter (1). Connect special tool to extractor unit.
Draw off remaining fuel from filter and surge chamber.
A small amount of fuel still remains in the fuel tank.
Fig. 2: Identifying Special Tool And Fuel Filter

Drawing off residual fuel amount from fuel tank:
IMPORTANT: Ensure car interior is adequately ventilated.

Catch dripping fuel in a suitable container.
2006 BMW 650i
Remove fuel gauge sensor (left).
IMPORTANT: Fuel gauge must roughly indicate zero before the left tank opening is opened.
If the suction jet pump is faulty, the fuel level in the left tank half may be above
the service opening!
Large quantities of fuel may emerge on opening!
In this event, keep left tank half closed and feed extraction hose through right
service opening to left tank half.
Draw off residual fuel quantity through installation openings.
Fuel filling:
Insert special tool 16 1 080 into filler neck.
Special tool 16 1 080 has two different diameters for petrol/gasoline and diesel vehicles!
Slide extraction hose of extractor unit, approx. 40 cm into fuel filler pipe.
Fill fuel from suction extractor unit.

Drawing off after fault in suction jet pump:
Draw off right half of tank completely through fuel filler pipe.
Drain surge chamber and fuel filter.
Remove sensor for fuel gauge (left).

2006 BMW 650i
Fig. 4: Identifying Fuel Filler Pipe

11 FUEL TANK WITH MOUNTING

16 11 030 REMOVING AND INSTALLING FUEL TANK
IMPORTANT: After installation of fuel tank/prior to first engine start-up:

Check electrical resistance between earthing/grounding cable (fuel filler pipe)
and wheel hub.
Measured value approx. 0.6 ohms
Fill fuel tank with min. 5 l fuel.

 Remove rear right wheel arch trim. See 51 71 041 REMOVING AND INSTALLING/REPLACING
REAR LEFT OR RIGHT WHEEL ARCH COVER .
 Remove complete propeller shaft. See 26 11 000 REMOVING AND INSTALLING COMPLETE
PROPELLER SHAFT (CONSTANT-VELOCITY JOINT) .
 Remove handbrake Bowden cables from wheel carrier and unclip from fuel tank. See 34 41 120
REMOVING AND INSTALLING/REPLACING BOTH HANDBRAKE BOWDEN CABLES .
 Remove right tension strut for rear axle. See 33 33 001 REPLACING LEFT OR RIGHT REAR
AXLE CARRIER COMPRESSION STRUT .
Unfasten nut.
Tightening , see 16 12 11AZ in FUEL SUPPLY SYSTEM - TIGHTENING TORQUES .

2006 BMW 650i
Fig. 5: Locating Unfasten Nut

Disconnect filler vent line (4) from fuel filler pipe.
Vehicles with petrol/gasoline engines:
Disconnect service vent line (2) from carbon canister.
Unclip both lines and remove retaining clip (3).
Installation:
Replace hose clip (1).
Fig. 6: Locating Filler Vent Line And Hose Clip

2006 BMW 650i
Unlock and disconnect plug connections (1) of feed line.
If necessary, disconnect line (2) for independent heating.
Vehicles with diesel engines:
Unlock and disconnect feed and return lines.
If necessary, disconnect line for independent heating.
Fig. 7: Identifying Plug Connection And Line

Release screw.
Tightening torque, see 16 11 1AZ in FUEL SUPPLY SYSTEM - TIGHTENING TORQUES .

2006 BMW 650i
Heavily support the fuel tank.
Fig. 9: Identifying Fuel Tank Support

Release screws for tightening straps on left and right and remove tightening straps.
Fig. 10: Removing Tightening Straps

Installation:
Note rubber mount with spacer bush.
Wide collar on spacer bush points to screw head.

2006 BMW 650i
Fig. 11: Identifying Spacer Bush

Lower tank until plug (1) on top side of right tank half is accessible.
Unlock plug (1) and detach from delivery unit.
NOTE: Get a second person to feed out vent lines to wheel arch while removing tank
towards bottom.

Installation:
Feed vent lines (1) and (2) through body.
Do not kink lines.

2006 BMW 650i
Fig. 13: Identifying Feed Vent Lines

16 11 130 CHECKING TANK CAP PRESSURE RELIEF VALVE
 13 3 010
 16 1 171
 16 1 172
 Remove tank cap
Turn pressure regulator on special tool 16 1 171 counterclockwise up to stop.
Connect special tool 16 1 171 via compressed air line (1) to workshop/garage compressed air system (8...10
bar).
Connect pressure sensor (2) of Diagnosis and Information System with a measuring range of 0...25 bar.
2006 BMW 650i
Fig. 14: Identifying Compressed Air Line And Pressure Sensor And Special Tool
Select special tool 16 1 172 or 16 1 173 matching vehicle's filler cap and attach to quick release coupling of
Install tank cap on selected special tool.

Check testing equipment for leaks!
Using special tool 13 3 010, disconnect supply line (1) from special tool 16 1 171 to fuel filler neck.
2006 BMW 650i
Read off and note down starting pressure.
Wait approx. 120 secs.
Read off final pressure value and compare with starting pressure value.
Fig. 16: Identifying Special Tool And Supply Line

 Pressure drop up to 0.01 bar: System OK

 Pressure drop over 0.02 bar: System leaking beyond permitted levels
If system is leaking, check connection points for leaks.
Check tank cap pressure relief valve.
Follow same test procedure as for "Checking testing equipment for leaks".
 Pressure drop up to 0.01 bar: Tank cap pressure relief valve OK

 Pressure drop over 0.02 bar: Tank cap is leaking and must be replaced
12 FUEL DELIVERY, SENSOR FOR DISPLAY

16 12 ... CHECKING REPUMPING FUNCTION OF SUCTION-JET PUMP WITH BMW DIAGNOSIS
SYSTEM
2006 BMW 650i
IMPORTANT: Ensure adequate ventilation in the place of work!

Ensure absolute cleanliness when working on the open fuel tank.
Contaminants in the fuel tank can impair driving operation or may even result
in vehicle breakdown!
Catch escaping fuel in a suitable container.
 Fill level must be < or = 28 l

 If necessary, draw off fuel from fuel tank
 Pour two to three litres of fuel into the left tank chamber via the flange opening
 Path:
 Brief test KOMBI Instrument cluster
 Diagnosis control unit functions
 Diagnosis requests
 Tank sensor 1, tank sensor 2
NOTE: Tank sensor 1 = right tank sensor

Tank sensor 2 = left tank sensor
Start engine.
Compare display for left and right tank chambers.
Repumping function OK
If fill level of tank sensor 2 (left chamber) is falling (approx. one litre per minute).
Repumping function not OK
If fill level of tank sensor 2 (left chamber) is stable or rising.

RIGHT SENSOR UNIT)

2006 BMW 650i

 Remove rear seat. See SEATS - REPAIR .
 Remove left sensor unit
Detach insulating mat (2) above left and right sensor units at perforation and fold back towards rear. Pop out
rubber plugs here.
Fold back rubber mat (2).
Fig. 17: Detaching Insulating Mat


Release nuts (1) on left and right.
Fold metal cover of left and right sensor units upwards.
2006 BMW 650i

IMPORTANT: Fuel line is pressurized.

If necessary, unlock and disconnect plug connection (1) of right sensor unit.
If necessary, release and disconnect hose (2) for independent heating (E60 only).
Fig. 19: Identifying Plug And Hose

Release rotary catch of left and right sensor units with special tool 16 1 020. See FUEL SUPPLY SYSTEM -
SPECIAL TOOLS .
Installation:
Replace rubber seal on left and right.

2006 BMW 650i

IMPORTANT: Risk of breakage!

Carefully raise connecting cover. In so doing, do not pull excessively on
connecting piece of fuel feed.
Installation:
When installing connecting cover, make sure that lug (1) in opening (2) engages fuel tank.
fuel tank.
Fig. 21: Identifying Lug, Notch And Toothed Segment

Secure a cable to hose pack through left service opening in tank.
The cable facilitates reinstallation of the hose pack.

2006 BMW 650i
Carefully remove right sensor unit from fuel tank.
IMPORTANT: Surge chamber is filled with fuel.

Drain surge chamber through upper opening (1).
Catch fuel in a suitable container.
Feed hose pack out of fuel tank.
Fig. 22: Identifying Surge Chamber

Installation:
The new sensor unit is supplied with a plastic cover over the hose pack.
Secure the cable pulled through the tank during removal to the eyelet on the plastic cover.
Carefully feed hose pack through fuel tank using cable.
IMPORTANT: The lines on the connection are turned to the sensor unit as the hose pack is
fed in.
Turn sensor unit in the same direction of rotation and align.
It is absolutely essential to avoid kinking the hoses.
Remove the plastic cover after feeding in the hose pack.

2006 BMW 650i
Fig. 23: Disconnecting Plug


LEFT SENSOR UNIT) AND FUEL FILTER


 Remove rear seat bench
 Check repumping function of suction-jet pump

2006 BMW 650i




M57TU:
2006 BMW 650i
Fig. 26: Identifying Feed Line

If the suction jet pump is faulty, the fuel level in the left tank half may be above
the service opening!
In this event, keep left tank half closed and feed extraction hose through right
service opening to left tank half.
Release screw cap with special tool 16 1 020.
Installation:

2006 BMW 650i

Carefully raise fuel level sensor until sensor flange projects out of tank
opening. In so doing, do not pull excessively on connecting piece of fuel
return.
Installation:
fuel tank.
Fig. 28: Identifying Lug, Notch And Toothed Segment

IMPORTANT: Look out of escaping fuel.

2006 BMW 650i
Fig. 29: Disconnecting Line To Fuel Filter

E60/M57TU only:
Unlock line (1).
Fig. 30: Detaching Suction Jet Pump


2006 BMW 650i
Fig. 31: Releasing Plug

Fig. 32: Releasing Catches

16 12 010 REMOVING AND INSTALLING/REPLACING CARBON CANISTER (VERSION 1)
 Remove rear right wheel arch trim.

2006 BMW 650i
Unfasten screws.
Installation:
Remove carbon canister (3).
Fig. 33: Identifying Carbon Canister And Line

16 12 010 REMOVING AND INSTALLING/REPLACING CARBON CANISTER (VERSION 2)
Fig. 34: Release Screws And Remove Heat Shield (1)
Disconnect lines (1) from carbon canister (3). Unfasten screws (2). Tightening torque, see 16 13 2AZ in 16 13
TANK VENTILATION . Remove carbon canister (3).
2006 BMW 650i
Fig. 35: Disconnect Lines (1) From Carbon Canister (3)

(VERSION 1)
DM-TL = diagnosis module-tank leakage
 Remove rear right wheel.

 Remove right wheel arch trim.
Unlock and detach lines (1) to (3).
1. Scavenging air line

2. Vent line to fuel tank
3. Evaporation line
Fig. 36: Identifying Scavenging Air Line, Vent Line And Evaporation Line
2006 BMW 650i
Release screws and remove carbon canister with DM-TL towards bottom.
Fig. 37: Disconnecting Plug


(VERSION 2)
DM-TL = diagnosis module-tank leakage
Fig. 38: Release Screws And Remove Heat Shield (1)
Disconnect plug (1) and lines (2) from carbon canister. Release screws (3). Tightening torque, see 16 13 2AZ in
16 13 TANK VENTILATION .
2006 BMW 650i
Fig. 39: Disconnect Plug (1) And Lines (2) From Carbon Canister
Carefully lower carbon canister (1), disconnect line (2) from tank leak diagnosis module and remove carbon
canister.
Fig. 40: Removing Carbon Canister
FUEL DEAERATION
16 13 015 REMOVING AND INSTALLING/REPLACING TANK LEAK DIAGNOSIS MODULE
 Remove carbon canister with tank leak diagnosis module.
Release screws (1). Tightening torque, see 16 13 3AZ in 16 13 TANK VENTILATION . Disconnect tank leak
diagnosis module (2) from carbon canister in direction of arrow.
2006 BMW 650i
Fig. 41: Disconnect Tank Leak Diagnosis Module (2) From Carbon Canister In Direction Of Arrow
Installation: Replace sealing ring.
FUEL PUMP
16 14 017 REMOVING AND INSTALLING/REPLACING FUEL FILTER WITH FUEL LEVEL
SENSOR
 16 1 020 See FUEL SUPPLY SYSTEM - SPECIAL TOOLS .
Recycling
Fuel escapes when fuel lines are detached. Have a suitable collecting container ready.
Catch and dispose of escaping fuel.
IMPORTANT: Ensure adequate ventilation in the place of work! Avoid skin contact (wear
gloves)!
Before starting the engine for the first time:
 Fill fuel tank with at least 5 liters of fuel.

2006 BMW 650i

 Remove REAR SEAT BENCH
 Check repumping function of suction-jet pump
Detach insulating mat (2) at perforation and fold back towards rear, pop out rubber plugs here.


2006 BMW 650i
Fig. 43: Identifying Nuts And Fold Back Metal Cover


M57TU:
Fig. 44: Identifying Feed Line

If the suction jet pump is faulty, the fuel level in the left tank half may be above the service opening!
In this event, keep left tank half closed and feed extraction hose through right service opening to left tank half.
Release screw cap with special tool 16 1 020 .
Installation:
Tightening torque 16 14 2AZ . See FUEL PUMP .

2006 BMW 650i


Carefully raise fuel level sensor until sensor flange projects out of tank
opening. In so doing, do not pull excessively on connecting piece of fuel
return.
Installation:
Fit screw cap without using a tool and tighten hand-tight.
Then tighten screw cap with special tool 16 1 020 until notch (3) points to marking (4).
Fig. 46: Identifying Service Cap Lug And Notch

2006 BMW 650i
IMPORTANT: Look out of escaping fuel.

Disconnect line (1) to fuel filter.
Fig. 47: Identifying Line To Fuel Filter

Fig. 48: Identifying Catch

E60/M57TU only:
2006 BMW 650i
Unlock line (1).
Fig. 49: Identifying Line And Catch



2006 BMW 650i
Fig. 51: Pressing Plug

2005 BMW 645Ci
2004-2005 ENGINE PERFORMANCE Fuel System - Repair Instructions - E63
2004-2005 ENGINE PERFORMANCE
Fuel System - Repair Instructions - E63
FUEL PUMP WITH DRIVE AND LINE

13 31 ... NOTES ON FUEL PRESSURE CHECK (REFERENCE PRESSURE: ENVIRONMENT)
Feature Of This Version With Ambient Pressure
The connection for the vacuum hose of the fuel pressure regulator is located between the throttle and the air
cleaner or on the air cleaner.
Test Precondition
The correct fuel pressure regulator is fitted.
 Using the EPC, check whether the fuel pressure regulator suitable for the car is fitted:
Connect test adapter.
Description Of Operation
The control function of the fuel pressure regulator must be guaranteed under all operating conditions. The fuel
pump must always be able to generate a higher fuel pressure than the pressure regulated by the pressure
regulator.
The injection rate is adjusted by means of the injection time; the injection time is controlled by the DME.
Description Of Operation: Fuel Return Line
When the engine is at a standstill and the ignition key is in position 0, the fuel return line after the pressure
regulator is at zero pressure.
Description Of Operation: Pressure Retaining Function
The pressure regulator closes when the engine is at a standstill and the ignition key is in position 0. The fuel
pressure in the delivery line is retained over an extended period.
A non-return valve closes in the fuel pump. These measures help to retain the fuel pressure in the fuel system.
Extended starting times are thus avoided.
Complaint: Drive Characteristic Faults, Lack Of Power
 Run engine at idle speed and measure fuel pressure.

2005 BMW 645Ci
 Line cross-sections in fuel feed are constricted or fuel filter is clogged, or

 Fuel pump voltage supply is not O.K.: e.g. as a result of high contact resistance (corrosion) in plug
connection between wiring harness and fuel pump.
If the measured value is greater than the nominal value + 0.2 bar:
 Turn off engine stop and then observe measured value.

 If measured value drops to nominal value, then line cross-sections in fuel return are constricted or
clogged.
 Check the fuel lines for kinks.
If no kinks are visible:
 Replace return lines
If measured value remains too high, then pressure regulator is in all probability faulty.
IMPORTANT: With less likelihood, the return line may be completely blocked. When the
pressure regulator is removed, fuel could escape under pressure!
 Have a cleaning cloth ready and catch and dispose of escaping fuel.
 Replace the return line but not the pressure regulator.
Complaint: Starting Problems
 Run engine briefly at idle speed and switch off.

 Note down measured value while engine is stopped.
 Read off measured value again after approx. 20 to 30 minutes while engine is stopped.
Special tool 13 3 010 (hose clamp) is required for the following test.
If the measured value has dropped by more than 0.5 bar:
 Start engine and wait briefly for a stable pressure increase.

 Switch off the engine and immediately pinch off the delivery line just before the pressure gauge with the
 Note down measured value
 Read off measured value again after approx. 20 to 30 minutes while engine is stopped
If the measured value has now dropped by less than 0.5 bar, the following faults can be present:
 Fault in delivery lines

 Fault in in-tank delivery hose
2005 BMW 645Ci
 Faulty pressure-holding non-return valve in fuel pump
Check components. Replace faulty components.
If the measured value has dropped by more than 0.5 bar again:
 Replace pressure regulator
NOTE:  All the fuel hoses and hose clips which were detached within the
framework of the checks must be replaced.
 Interrogate fault memory of DME control unit. Check stored fault
messages. Rectify faults. Now clear the fault memory.
CHECKING FUEL PUMP DELIVERY PRESSURE (N62)
NOTE: For special tools, refer to FUEL SYSTEM - SPECIAL TOOLS - 645CI .
 13 3 010
 13 5 220
IMPORTANT: The fuel in the fuel lines is under pressure (approx. 3 bar)! Catch and dispose
of escaping fuel.
Remove dust cap from measuring valve on fuel rail. Unscrew check valve (1) on special tool kit 13 5 220. Fit
special tool kit 13 5 220 on measuring valve and tighten knurled nut until hand-tight. Start engine.
2005 BMW 645Ci
Fig. 1: Unscrew Check Valve (1) On Special Tool Kit 13 5 220

IMPORTANT: Do not under any circumstances screw in the check valve up to the mechanical
stop. This could damage the valve in the pressure regulator housing.
Screw in check valve (1) until a pressure reading is indicated on DIS Tester.
 Connect pressure sensor to DIS Tester

 Start engine
 Select Measurement
 Multimeter function appears
 Select Pressure test
 Read off fuel pressure
Compare actual value of test pressure with specified value. See FUEL SYSTEM - TECHNICAL DATA .
Switch off engine.
INJECTION NOZZLE AND LINES

13 53 240 REPLACING COMPLETE INJECTION PIPE (N62)
NOTE: For special tools, refer to FUEL SYSTEM - SPECIAL TOOLS - 645CI .
 13 5 281

2005 BMW 645Ci

 Remove ignition coil covers
Unlock plugs (1) on servomotors and disconnect.
Detach plug connections (2) of knock sensors from cable strips.
Unclip cable (3).
Fig. 2: Detaching Knock Sensors Plug Connections

Unlock and disconnect following plug connections.
 Fuel rail, left and right, on cable duct

 Throttle-valve assembly
 All solenoid valves
 Both temperature sensors
 Oil-pressure switch
 Tank venting valve
2005 BMW 645Ci
 Alternator
 Differential pressure sensor
 Servomotor on intake air manifold
 Pulse generator on left exhaust and inlet camshafts
 Left eccentric shaft sensor
Unfasten screws.
Remove brackets (4), place cable ducts to one side.
Fig. 3: Removing Brackets

Recycling
Fuel escapes when fuel line is detached. Catch and dispose of escaping fuel.
Remove protective cap from compressed air connection (1).
Blow fuel back into tank with a short blast of compressed air (max. 3 bar) at compressed air connection (1).
2005 BMW 645Ci
Remove both injection pipes (2) towards top.
Fig. 4: Removing Protective Cap From Compressed Air Connection

Unlock and disconnect fuel hose (1).

2005 BMW 645Ci
Fig. 5: Disconnecting Fuel Hose

Seal fuel hose with special tool 13 5 281.

2005 BMW 645Ci
Fig. 6: Sealing Fuel Hose With Special Tool

Unfasten screws.
2005 BMW 645Ci

Unlock connector and remove.
Lever out retainers (1).

2005 BMW 645Ci
Fig. 8: Removing Retainers

Pull fuel injectors out of injection pipe.
Installation:
Replace sealing rings on fuel injectors and coat with anti-friction rubber coating.
NOTE: Check stored fault messages. Now clear the fault memory.
THROTTLE AND OPERATION

13 54 030 REMOVING AND INSTALLING/SEALING THROTTLE ASSEMBLY (N62)

2005 BMW 645Ci

 Remove air intake hose
Unfasten screws.
Remove throttle assembly (2).
Fig. 9: Removing Throttle Assembly

Installation:
Replace sealing ring (1) of throttle assembly (2).

2005 BMW 645Ci
Fig. 10: Replacing Throttle Assembly Sealing Ring

Installation:
13 54 250 REPLACING AIR INTAKE HOSE (BETWEEN AIRMASS FLOW SENSOR AND
THROTTLE VALVE ASSEMBLY) (N62)

2005 BMW 645Ci
Detach air-mass flow sensor (2) from throttle valve assembly.
Detach air intake hose (2) from air-mass flow sensor.
Fig. 11: Detaching Air Intake Hose From Air-Mass Flow Sensor
Installation:
Check sealing rings for damage, replace if necessary.
SENSOR FOR CONTROL UNIT

13 62 010 REMOVING AND INSTALLING/REPLACING DIFFERENTIAL PRESSURE SENSOR
(N62)
DIFFERENTIAL PRESSURE SENSOR REMOVING AND INSTALLING WORKSTEP (N62)

2005 BMW 645Ci
Work step Note:

Installation location: On rear side of intake air
manifold.
Remove design cover. E65/E66 only
Remove both lower microfilter housing sections. E60/E61/E63/E64 only
Remove engine compartment bulkhead. E65/E66 only
Remove cover for ignition coils on left and right.
Unlock and disconnect following plug connections. Lines to oxygen sensors remain connected.
Lines to electronics box remain connected.
 Fuel rail, left and right, on cable duct
 Throttle-valve assembly
 Knock sensor, left and right
 All solenoid valves
 Both temperature sensors
 Oil-pressure switch
 Tank venting valve
 Alternator
 Valvetronic servomotor, left and right
 Pulse generator on exhaust and inlet
camshafts, left and right
 Eccentric shaft sensor, left and right
Unfasten screws.
Take off holder (4).

2005 BMW 645Ci
Fig. 12: Removing Holder

Lay cable ducts to one side.
Unfasten screws.
Pull differential pressure sensor (2) out of intake air manifold.

2005 BMW 645Ci
Fig. 13: Removing Differential Pressure Sensor From Intake Air Manifold
Installation:
13 62 531 REPLACING COOLANT TEMPERATURE SENSOR (N62)

Only perform these tasks on an engine that has cooled down.
2005 BMW 645Ci
E65 only. E66:
Recycling
Catch and dispose of escaping coolant.

Coolant temperature sensor is mounted on water pipe at front.
Release temperature sensor (2).
Fig. 14: Releasing Temperature Sensor

Installation:
Tightening torque, refer to 13 62 2AZ in FUEL SYSTEM - TIGHTENING TORQUES - 645CI .

2005 BMW 645Ci
If necessary, top up coolant.
13 62 560 REMOVING AND INSTALLING/REPLACING AIRMASS FLOW SENSOR (N62)
 Read out fault memory of DME control unit.

Open clips (1).
Unfasten clip.
Remove top section (3) of intake filter housing.

2005 BMW 645Ci
Fig. 15: Removing Intake Filter Housing Top Section

Installation:
Check sealing ring between air-mass flow sensor and air intake hose for damage, replacing if necessary.
Unfasten screws.
Pull air-mass flow sensor (1) out of upper section of intake filter housing.
2005 BMW 645Ci
Fig. 16: Removing Air-Mass Flow Sensor From Intake Filter Housing Top Section
NOTE: Check stored fault messages.
START VALVES
13 64 541 REPLACING ALL FUEL INJECTORS
This work step is described in the section "Removing complete injection pipe", refer to 13 53 240
REPLACING COMPLETE INJECTION PIPE (N62).
INTAKE SILENCER
2005 BMW 645Ci
Release clamp and detach air intake hose.
Installation:
Check seal, replacing if necessary.
Unfasten screws.
Remove intake filter housing (2) towards top.
Fig. 17: Removing Intake Filter Housing

AIR CLEANER
2005 BMW 645Ci
Open clips (1).
Lift top section (2) of intake filter housing.
Fig. 18: Removing Intake Filter Housing Top Section (N62)

Remove air cleaner element (1).
Installation:
Clean upper and lower sections of intake filter housing from inside.
Install new air cleaner element.
2005 BMW 645Ci
Fig. 19: Installing Air Cleaner Element

CARBON CANISTER VENTILATION

13 90 500 REPLACING TANK VENTING VALVE (N62)

Tank venting valve is fitted at front on left side of cylinder head cover.
2005 BMW 645Ci
Unlock vent hose on intake air manifold and disconnect.
Unlock vent hose on tank venting valve (2) and disconnect.
Remove tank venting valve (2) from holder.
Fig. 20: Removing Tank Venting Valve From Holder

NOTE: Rectify faults. Now clear the fault memory.

2005 BMW 645Ci
ELECTRICAL 2004-07 - 6-Series (E63/64)
ELECTRICAL
2004-07 - 6-Series (E63/64)
IDENTIFICATION
WARNING: Vehicles are equipped with air bag supplemental restraint system. Before
attempting any repairs involving steering column, instrument panel or
related components, see appropriate AIR BAG SAFETY PRECAUTIONS
and DISABLING & ACTIVATING AIR BAG SYSTEM in AIR BAG
RESTRAINT SYSTEMS article.
CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle. See appropriate COMPUTER
RELEARN PROCEDURES article in GENERAL INFORMATION before
disconnecting battery.
COMPONENT IDENTIFICATION
FUSES IN GLOVE BOX
For location, amperage and components covered, see Fig. 1.

2005 BMW 645Ci
Fig. 1: Locating Fuses In Glove Box

FUSES IN LUGGAGE COMPARTMENT
For location, amperage and components covered, see Fig. 2.

2005 BMW 645Ci
Fig. 2: Locating Fuses In Luggage Compartment

INTEGRATED SUPPLY MODULE
The integrated supply module is located in right rear of engine compartment. See Fig. 3. The integrated supply
module contains the following fuses:
 F001 - 30 Amp - Variable valve timing gear control module and fuel injectors 5-8.
 F002 - 20 Amp - Fuel tank vent valve, bank 2 camshaft sensors and bank 2 VANOS solenoid valves.
 F003 - 20 Amp - Ignition coils 1-4.
 F004 - 20 Amp - Ignition coils 5-8.
 F005 - 30 Amp - Crankshaft sensor, hot-film air mass meter, bank 1 camshaft sensors, characteristic map
thermostat, and bank 1 VANOS solenoid valves.
 F006 - 20 Amp - Fuel injectors 1-4.
 F007 - 20 Amp - Sequential Manual Transmission (SMG).
2005 BMW 645Ci
 F008 - 30 Amp - Oil quality sensor and oxygen sensors.

 F009 - 10 Amp - Fuel pump relay, exhaust flap, radiator shutter solenoid switch, E-box fan, fuel tank
leakage diagnostic module and secondary air pump relay.
 F010 - 40 Amp - Relay 1 variable valve timing gear control module.
 F011 - 40 Amp - Relay 2 variable valve timing gear control module.
Fig. 3: Locating Integrated Supply Module

REAR FUSE HOLDER
Rear fuse holder is located in luggage compartment. See Fig. 4. Rear fuse holder contains the following:
 F90 - 200 Amp - Front fuse holder.

 F91 - 100 Amp - Integrated supply module, valve timing.
 F92 - 100 Amp - Electric auxiliary heater.
2005 BMW 645Ci
Fig. 4: Locating Rear Fuse Holder

2005 BMW 645Ci
2004-05 MANUAL & AUTOMATIC TRANSMISSIONS Gear Shift Mechanisms - 6-Series (E63)
2004-05 MANUAL & AUTOMATIC TRANSMISSIONS
Gear Shift Mechanisms - 6-Series (E63)
ADJUSTMENTS
INTERLOCK CABLE
Move selector lever (1) to "P" position (front stop of shifting gate).
Loosen screw (4). It must be possible to move cable (2) slightly in holder (3).
Move ignition key to "0" position and remove.
Press interlock locking pawl (5) downwards as far as it will go.
Tighten screw (4). See Fig. 1 . See TORQUE SPECIFICATIONS .

2005 BMW 645Ci
Fig. 1: Adjusting Interlock Cable

To check adjustment of interlock, turn ignition key to "ignition" position and "0" position. Interlock locking
pawl (1) must rest (3) on shift tower (2). If necessary, adjust interlock cable again. See Fig. 2 .
2005 BMW 645Ci
Fig. 2: Checking Interlock Adjustment

SELECTOR LEVER
Check cable for ease of movement.
Adjust as follows:
 Move selector lever to "P" setting. See Fig. 3 .

 Grip clamp bushing (1). Loosen nut (2).
 Press selector lever (3) forwards (park position).
 Press cable (4) in direction of arrow and release again.
 Grip clamping piece (1). Tighten nut (2).
 During installation, move selector lever into "P" setting. Check whether parking lock is engaged by
2005 BMW 645Ci


SHIFT LEVER
Remove underbody protection. Detach exhaust system from catalytic converter. Remove exhaust bracket from
transmission and exhaust. Lower exhaust system at front.

2005 BMW 645Ci

Detach knob with a firm tug. See Fig. 5 . Do not turn knob when detaching as this will shear off the turning lock
in the knob.
NOTE: Upon Installation: Fit knob on selector lever, align and press on until it snaps
noticeably into place.
2005 BMW 645Ci
Fig. 5: Detaching Knob

Press installation frame of rubber gaiter (1) together a little and remove rubber gaiter (1) from center console.
See Fig. 6 .
2005 BMW 645Ci
Fig. 6: Removing Rubber Gaiter

Upon Installation: Feed rubber gaiter (1) downwards and fit on selector lever (2). Pull rubber gaiter (1) over
selector lever and insert in center console. See Fig. 7 .
2005 BMW 645Ci
Fig. 7: Installing Rubber Gaiter

Upon Installation: Push rubber gaiter (1) down until groove (2) is fully exposed. See Fig. 8 .
2005 BMW 645Ci
Fig. 8: Identifying Groove

Remove soundproofing (1). See Fig. 9 .

2005 BMW 645Ci
Fig. 9: Identifying Soundproofing

Lift off retainer (1). Remove shims (3). Remove selector rod (2). See Fig. 10 .
NOTE: Upon Installation: Grease selector rod pin. Make sure shims (3) are in correct
position.
2005 BMW 645Ci
Fig. 10: Installing Shims

Insert special tool 251110 in mounting and turn 90 degrees counterclockwise. Press mount upwards out of
selector arm. See Fig. 11 .
2005 BMW 645Ci
Fig. 11: Pressing Mount Upward Out Of Selector Arm

Remove rubber gaiter from body cutout and lift out with selector lever. See Fig. 12 .
2005 BMW 645Ci
Fig. 12: Removing Rubber Gaiter

Upon Installation: Insert rubber gaiter with arrow in direction of travel towards front. See Fig. 13 .
2005 BMW 645Ci
Fig. 13: Inserting Rubber Gaiter

Upon 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. See Fig. 14 .
2005 BMW 645Ci
Fig. 14: Installing Selector Lever In Selector Arm

Upon Installation: Press mount in area of retaining lugs into selector arm until it audibly snaps into place. See
Fig. 15 .
2005 BMW 645Ci
Fig. 15: Pressing Mount In Area Of Retaining Lugs

Upon Installation: Pull inner rubber gaiter over bowl on selector arm and press outer rubber gaiter into body
cutout. See Fig. 16 .
2005 BMW 645Ci
Fig. 16: Pulling Inner Rubber Gaiter Over Bowl

SELECTOR LEVER
Detach mount from selector lever. See Fig. 17 .
NOTE: Upon Installation: Grease ball joint.
Detach rubber gaiter from selector lever. See Fig. 18 .

2005 BMW 645Ci
Fig. 17: Detaching Mount From Selector Lever

2005 BMW 645Ci
Fig. 18: Detaching Rubber Gaiter From Selector Lever

Upon Installation: Degrease selector lever (1). Coat rubber bellows on inside of shaped section (2) with
Circolight lubricant. Pull rubber gaiter from above over selector lever and align. Arrow (3) on rubber gaiter
must point in direction of travel (A). See Fig. 19 .
2005 BMW 645Ci
Fig. 19: Pulling Rubber Gaiter From Above Over Selector Lever
BEARING SHELL FOR SHIFT LEVER
Remove shift lever. See SHIFT LEVER . Detach mount from selector lever. Grease ball joint. See Fig. 17 .
SHIFT LEVER GRIP/KNOB
Do not twist knob during removal as this would cause the turning lock in the knob to shear off. Tug firmly to
remove knob. See Fig. 20 . During installation, fit knob on selector lever, align and press on until it snaps
2005 BMW 645Ci
noticeably into place.
Fig. 20: Detaching Knob

During installation, ensure rubber gaiter (1) is pushed down until groove (2) is fully exposed. See Fig. 21 .
2005 BMW 645Ci
Fig. 21: Identifying Groove

SHIFT LEVER COVER (GAITER)
Remove SHIFT LEVER KNOB . The method for removing the gaiter is the same for manual and automatic
transmissions. Carefully pull gaiter (1) taut on leather. Press frame (2) inwards slightly until catch is released.
Lift out gaiter (3). See Fig. 22 . During installation, retaining lugs must not be damaged. See Fig. 23 .
2005 BMW 645Ci
Fig. 22: Removing Gaiter

2005 BMW 645Ci
Fig. 23: Identifying Retaining Lugs

SHIFT ROD JOINT
Release exhaust system at catalytic converter and lower. Remove heat shield at front. Support transmission with
a hoist. Remove transmission crossmember. See MANUAL TRANSMISSION . Remove transmission bearing
block. Lift off retainer (1). Disconnect shift rod (2). During installation, grease shift rod. Make sure shims (3)
are in correct position. See Fig. 24 .
2005 BMW 645Ci
Fig. 24: Identifying Retainer, Shift Rod & Shims

Lever spring washer (1) out of groove and push a little toward rear. Press dowel pin (2) upward/downward out
of shift rod joint and remove shift rod joint. During installation, grease ball of selector shaft. Replace spring
washer (1). See Fig. 25 .
2005 BMW 645Ci
Fig. 25: Replacing Spring Washer

During installation, check rubber ring (1) in shift rod joint (2) and replace if necessary. See Fig. 26 .
2005 BMW 645Ci
Fig. 26: Checking Rubber Ring In Shift Rod Joint

SHIFT ARM FOR SHIFT LEVER MOUNT
Remove shift lever. See SHIFT LEVER . Support transmission with a hoist. Remove transmission
crossmember. See MANUAL TRANSMISSION . Remove transmission support block. Lower support bearing
(1) out of fixture. See Fig. 27 .
2005 BMW 645Ci
Fig. 27: Levering Out Support Bearing

During installation, install support bearing (1) with arrow (2) facing upwards in holder. See Fig. 28 .
2005 BMW 645Ci
Fig. 28: Installing Support Bearing With Arrow Facing Upward

Unlock bearing pin (1) in direction of arrow and remove. Grease bearing pin. See Fig. 29 .
2005 BMW 645Ci
Fig. 29: Unlocking Bearing Pin

Remove shift arm. Detach support bearing (1) from shift arm. During installation, grease bearing journal.
Attach support bearing (1) with opening (3) toward rear on shift arm. See Fig. 30 .
2005 BMW 645Ci
Fig. 30: Attaching Support Bearing

Replace bearing bushing if damaged. Press out bearing bushing. Coat new bearing bushing with Circolight
lubricant and then press into shift arm until side flanges of bearing bushing protrude uniformly. See Fig. 31 .
2005 BMW 645Ci
Fig. 31: Identifying Bearing Bushing

BEARING BUSHINGS FOR SHIFT ARM
Press out bearing bushing (1). Coat new bearing bushing (1) with Circolight lubricant and then press into shift
arm until side edges of bushing protrude uniformly. See Fig. 31 .
SHIFT ARM SUPPORT

2005 BMW 645Ci
Remove transmission underbody protection if necessary. On V8, remove reinforcement carrier. Remove
exhaust system from exhaust manifold and lower. Remove left and right heat shield.
Lever out support bearing (1) from bracket. Pull support off shift arm. See Fig. 27 .
During installation, insert support bearing (1) with arrow (2) pointing up into retainer. See Fig. 28 .
Detach support bearing (1) from shift arm. During installation, grease bearing pin of shift arm. Attach support
bearing (1) with opening (3) facing rear to shift arm. See Fig. 30 .
SHIFT TOWER (STEPTRONIC)
Remove rear underbody protection. Remove center console. See CENTER CONSOLE. Move selector lever to
park position "P". Grip clamping sleeve (1) and slacken nut (2). See Fig. 32 . During installation, adjust selector
lever. See SELECTOR LEVER .
2005 BMW 645Ci
Fig. 32: Gripping Clamping Sleeve & Slackening Nut

Brace cable on hex head (1) and loosen nut (2). Pull cable (3) out of bracket. See Fig. 33 .
2005 BMW 645Ci
Fig. 33: Bracing Cable On Hex Head & Loosening Nut

Disconnect plugs (1 and 2). Release screw (3). Slide interlock cable (4) down using a screwdriver (5) from shaft
of interlock locking pawl towards left. After installation, adjust interlock function. See INTERLOCK
CABLE . See Fig. 34 .
2005 BMW 645Ci
Fig. 34: Sliding Interlock Cable Down

Release screws (1). Feed sleeve (2) out of body. See Fig. 35 . Lift shift tower out of center console. During
installation, ensure seal is not damaged. See Fig. 36 . See TORQUE SPECIFICATIONS .
2005 BMW 645Ci
Fig. 35: Feeding Sleeve Out Of Body

2005 BMW 645Ci
Fig. 36: Checking Seal For Damage

Cable On Shift Tower 11 (15)
Crossmember To Body 31 (42)
Transmission Mount To Crossmember 15 (21)
INCH Lbs. (N.m)
Interlock Cable On Shift Tower 62 (7)
Shift Console To Tunnel 62 (7)
2005 BMW 645Ci
2004-05 ACCESSORIES & BODY, CAB General Electrical System - Repair Information - E63
General Electrical System - Repair Information - E63
TROUBLE SHOOTING
12 00 ... INSTRUCTIONS ON STARTING AID
Do not start the engine with help of starting sprays.
Preparation:
Conform with the following when starting engine with starting cable.

both vehicles.
tension!
speed.
Carrying out:
Always conform with the procedures to avoid injury to persons or damage to parts.

ignited by sparks.
Danger of explosion!
2005 BMW 645Ci
After engine of vehicle to be started has started up, first disconnect the jump lead on the negative
terminal/ground connection. Then remove jump lead from positive terminals.
61 00 ... VERSION WITH AFS: SETTING STEERING ANGLE (AFTER RECONNECTING VEHICLE
BATTERY)
NOTE: Version with AFS: After reconnecting the vehicle battery, refer to 12 00 ...
INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY , carry out
the following procedure for setting the steering angle:
 Start engine.
 Turn steering wheel left to full lock.
 Turn steering wheel right to full lock.
 Turn steering wheel to central position.
 Turn off engine.
 Turn on ignition (terminal 15), AFS telltale and Check Control message go
out.
NOTE: Entry in the fault memory remains unaffected by this procedure, therefore if
necessary

 Clear fault memory
61 00 ... BATTERY
NOTE: Important notes and instructions for handling batteries in the dealership can be
found in:
 Battery master document

 Disconnecting battery, refer to 12 00 ... INSTRUCTIONS FOR
 Battery charging, refer to 61 00 ... BATTERY CHARGING.
 Welding work, refer to WELDING WORK (OVERLOAD PROTECTION OF
CONTROL UNITS) .
 External jump-starting aid, refer to EXTERNAL JUMP-STARTING AID .
Battery Care And Maintenance
In low-maintenance batteries, check the acid level at least once a year. If necessary, top up with distilled water
up to the top marking.
The increasing number of electronic control units in the car reduces the self-discharging time of the battery
2005 BMW 645Ci
(even in standby mode). To maintain the battery service life and to avoid exhaustive discharging, recharge laid-
up vehicles every 6 weeks at the latest. The time for self-discharging depends on vehicle type and equipment
specification.
Battery Test
The battery acid density can be used to measure the charge state. However this test produces uncertainty caused
by a design-related range of variation. The acid density e.g. for a charged battery is 1.28 kg/l (in the tropical
version the acid density is 1.23 kg/l).
Another interference factor is the acid lamination immediately after filling with distilled water.
Battery wear with partially sulfated and/or heavily contaminated plates will also lead to incorrect acid density
test results.
61 00 ... BATTERY CHARGING
If a normal or quick charger is used to charge the battery, the battery must be disconnected from the vehicle
electrical system and removed. This prevents damage to paintwork and upholstery.
Ideally, battery charging is performed with BMW-approved charging computers.
IMPORTANT: In order to prevent the intelligent battery sensor from malfunctioning, the
charging terminals in the engine compartment must be used without fail in
vehicles from E60 and should be used if possible in other vehicles.
IMPORTANT: Before charging the battery while it is installed, first carry out a closed-circuit
current test, refer to 61 20 ... BATTERY OPEN-CIRCUIT CURRENT TEST. If here
the voltage is 10 V or less, one or more of the cells may be faulty or the entire
battery may already be damaged. In this case, always remove the battery as
escaping gases during charging could damage the interior equipment and trim.
Attempt to regenerate faulty cells with low charging current.
If necessary, open existing plugs on the individual cells.
61 00 ... NOTES ON HANDLING OPTICAL FIBERS
CAUTION: To avoid damage when handling optical fibers, comply with the following
points:
 The minimum permitted bending radius is 25 mm

 Do not subject optical fibers to compressive and tensile load
 Protect optical fibers against the effects of heat equal to or greater than 85°C (e.g. during welding work,
drying work with infrared heater or hot air blower)
2005 BMW 645Ci
NOTE: The optical fibers are colored differently as follows:
 Green=MOST (Media Oriented Systems Transport) optical fibers

 Yellow=ISIS (Intelligent Safety and Integration System) optical fibers
 Orange=repair optical fibers
Follow instructions for processing cables and optical fibers.
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:
Safety regulations for handling components of airbag system.
Instructions for disconnecting and connecting battery, refer to 12 00 ... INSTRUCTIONS FOR
Procedure for cable repair
In event of non-visible damage to wiring harness:
Disconnect plug connection on airbag module or on adapter plug. It is absolutely vital to disconnect the contacts
in succession as there is a risk of them being mixed up! Cut through one cable after the other at an appropriate
position, do not under any circumstances cut through both cables at the same time. Insulate cables remaining in
wiring harness with insulating tape. Now disconnect plug connection on airbag control unit. Unpin contacts. Cut
through one cable after the other at an appropriate position and insulate with insulating tape, do not under any
circumstances cut through both cables at the same time. Pin contacts of repair cable for airbag control unit in
control unit plug, assignment of repair cables is relevant. Lay repair cable in car parallel to existing airbag lead.
Now pin in contacts for airbag control unit or contacts of adapter plug, assignment of repair cables is relevant.
Cut off excess length of repair cable in proximity (visible area) of airbag module or of adapter plug. Twist open
cables. With the connectors and shrink-fit hoses in the Electronic Parts Catalogue (EPC), reconnect the cables
with the same cable colours. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface
(shrink-fit hoses) with insulating tape to prevent cables from twisting open.
Instructions for cutting off, insulating, crimping cables, installing and removing contacts:
Cutting off and insulating cables.
Repairing a plug connection using connectors.

2005 BMW 645Ci
Installing and removing contacts, refer to 61 13 ... OPENING PLUG HOUSINGS AND REMOVING
CONTACTS OF DIFFERENT PLUG SYSTEMS.
In event of visible damage:
Expose cable at damaged areas. Cut through one cable after the other at an appropriate position and insulate
cables no longer required in wiring harness with insulating tape, do not under any circumstances cut through
both cables at the same time. Now, depending on the scope of work, unpin contacts either on airbag control
unit/airbag module or on adapter plug. Cut off unpinned cables. Insulate cables remaining in wiring harness
with insulating tape. Now pin in contacts of repair cable, assignment of repair cables is relevant. Lay repair lead
in car parallel to existing airbag lead up to cutting point. Cut off excess length of repair lead. Twist open cables.
Connect cables with connectors and shrink-fit hoses in Electronic Parts Catalogue (EPC), assignment of repair
cables is relevant. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface (shrink-fit
hoses) with insulating tape to prevent cables from twisting open.
61 00 ... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY
Battery acid is highly corrosive:
Do not allow any battery acid to come into contact with the eyes, the skin or clothing. Therefore wear protective
clothing, gloves and goggles.
Do not tilt the battery, acid may emerge from the vent opening.
In event of contact with acid:
If acid is splashed 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, neutralize it immediately with a soapy solution and rinse with lots
of water.
Seek medical attention immediately if battery acid is accidentally swallowed.
Explosion hazard:
Strictly no flames, sparks, naked light or smoking!
A highly explosive mixture of electrolytic gas is created when batteries are charged. The rooms where charging
is carried out must therefore always be well ventilated.
Avoid the formation of sparks when handling cables, wiring and electrical devices.
Turn the ignition lock to the 0 position before disconnecting or connecting the battery.
Do not place tools or any similar object on the battery (danger of short-circuiting and explosion!).
2005 BMW 645Ci
61 13 .. UNLOCKING AND DISCONNECTING DIFFERENT PLUG CONNECTIONS
NOTE: Examples of unlocking and disconnecting different plug connections.
Press lock and open clip in direction of arrow.
Fig. 1: Pressing Lock And Opening Clip


2005 BMW 645Ci

Open clip in direction of arrow and disconnect plug connection in direction of arrow.
2005 BMW 645Ci
Fig. 3: Opening Clip And Disconnecting Plug Connection

Press lock and disconnect plug connection in direction of arrow.

2005 BMW 645Ci
Fig. 4: Pressing Lock And Disconnecting Plug Connection


2005 BMW 645Ci


2005 BMW 645Ci


2005 BMW 645Ci


2005 BMW 645Ci


2005 BMW 645Ci

AUXILIARY CABLES
61 12 ... GENERAL INFORMATION ON INTELLIGENT BATTERY SENSOR (IBS)
NOTE: Do not connect continuous trickle charger to the cigarette lighter.
The cigarette lighter is powered by the rear distribution box via a relay. This relay drops out after terminal 15
OFF. This means that a continuous trickle charger connected to the cigarette lighter is disconnected from the
battery.
Charge the battery via the jump-start connection points. Only then can the power supply be registered by the
vehicle.
Warning! Danger of destruction in event of mechanical strain

2005 BMW 645Ci
 Do not introduce any additional connections at the battery negative terminal.

 Do not modify the grounding cable. The grounding cable also serves to dissipate heat.
 Do not establish any connection between the IBS and the sensor screw.
 Do not use force when disconnecting the pole shoe from the battery terminal:
 Do not pull on the grounding cable.
 Do not place any tools under the IBS to lever off the pole shoe.
 Do not use IBS connections as levers.

 Use a torque wrench and set tightening torque in accordance with repair instructions.
 Do not release or tighten down sensor screw (screw with Torx head).
 Avoid contact between IBS and ground.
Warning! Danger of destruction to IBS and cables when battery is replaced
 The IBS and the cables can be destroyed by mechanical strain when the battery is replaced. Therefore
avoid mechanical strain.
 The size (capacity) of the battery required for the car is coded in the Car Access System (CAS).
 Use the battery size (capacity) installed as standard when replacing the battery.
 Recode the Car Access System (CAS) when installing a battery with a different capacity.
 Delete fault entries in the Digital Motor Electronics (DME) associated with battery replacement.
 Always proceed in accordance with the repair instructions.
NOTE: Battery draining possible in spite of the intelligent battery sensor IBS
being fault-free.
 A battery can be drained (e.g. with lights or radio switched on) even when the IBS functions perfectly in
conjunction with power management.
 For this reason, only replace the IBS when a corresponding fault is entered in the DME or DDE.
61 12 002 REPLACING POSITIVE BATTERY CABLE (FROM BATTERY TO LUGGAGE

COMPARTMENT CONNECTOR)
WARNING: Observe safety instructions for handling vehicle battery, refer to 61 00 ...
SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY.
 Remove left luggage compartment wheel arch trim
Release plastic nuts (1).
Remove underlay for floor panel at rear left (2).

2005 BMW 645Ci
Remove underlay for luggage compartment floor panel (3).
Fig. 10: Removing Underlay For Luggage Compartment Floor Panel

Disconnect battery negative lead (1).
Disconnect plug connection (2) of one-pin IBS cable (3).
Release nut (5) of safety battery terminal (4), tightening torque, refer to 61 21 1AZ in GENERAL
ELECTRICAL SYSTEM - TIGHTENING TORQUES - 645CI .
IMPORTANT: Do not under any circumstances pull/lever safety battery terminal (4) off by
force.
Detach safety battery terminal (4) towards top, lay to one side and secure.
2005 BMW 645Ci
Fig. 11: Detaching Safety Battery Terminal Towards Top

Unlock cable lug mounting (1) and fold back.
Unscrew bolt (2).
Unclip cable lug mounting (1) from positive battery cable (3) and remove.
WARNING: Risk of short circuits! When installing, ensure:
 Correct seating of cable lug mounting (1) on positive battery cable

(3)
 Correct screw connection
2005 BMW 645Ci
Fig. 12: Unclipping Cable Lug Mounting From Positive Battery Cable
Unclip positive battery cable (1) from cable guides (2) and remove.
2005 BMW 645Ci
Fig. 13: Unclipping Positive Battery Cable From Cable Guides

61 12 013 REPLACING BATTERY NEGATIVE LEAD
INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY and
61 00 ... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY.
Notes and instructions on Intelligent Battery Sensor IBS, refer to 61 12 ...
GENERAL INFORMATION ON INTELLIGENT BATTERY SENSOR (IBS).
 Remove trim on tail panel, refer to 51 46 050 REMOVING AND INSTALLING/REPLACING TOP
TRIM ON REAR APRON .
2005 BMW 645Ci
 Remove right luggage compartment wheel arch trim, refer to 51 47 161 REMOVING AND
Remove underlay for floor panel (1).
Release nut (2) on battery negative terminal.
Tightening torque, refer to 61 21 1AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING

TORQUES - 645CI .
IMPORTANT: Do not under any circumstances use force to pull off pole shoe. Do not under
any circumstances release socket-head cap screw of IBS.
Detach battery negative lead (5) with intelligent battery sensor (IBS) in upward direction.
Release nut (6) and battery negative cable (5).

TORQUES - 645CI .
2005 BMW 645Ci
Fig. 14: Replacing Battery Negative Lead

Replacement:
Carry out programming/coding, refer to DIAGNOSIS PROGRAMMING/CODING.

61 12 065 REPLACING WIRING HARNESS FOR FRONT BUMPER

2005 BMW 645Ci
Disconnect plug connections (1) on ultrasonic transducer.
Unclip wiring harness (2) from bumper trim.
Fig. 15: Disconnecting Plug Connections (1) On Ultrasonic Transducer

Unlock plug (1) in direction of arrow from bumper trim.

2005 BMW 645Ci
Fig. 16: Unlock Plug (1) In Direction Of Arrow From Bumper Trim
Installation:
Make sure wiring harness (2) is correctly laid.
61 12 067 REPLACING WIRING HARNESS FOR REAR BUMPER
TRIM .
Unlock and disconnect plug connections (1) from ultrasonic converter.

2005 BMW 645Ci
connections (3) from rear lights.
Fig. 17: Replacing Wiring Harness For Rear Bumper

Installation:
Make sure wiring harness is correctly laid.
61 12 200 REPLACING WIRING HARNESS IN LEFT OR RIGHT FRONT DOOR
 Close front side window completely

 Remove luggage compartment floor trim panel
 Disconnect battery negative lead, refer to 61 20 900 DISCONNECTING AND CONNECTING
BATTERY NEGATIVE LEAD.
 Remove trim on armrest of front door, refer to 51 41 075 REMOVING AND
INSTALLING/REPLACING TRIM ON ARMREST ON LEFT OR RIGHT REAR DOOR .
 Remove rocker switch for side window operation, refer to 61 31 115 REPLACING ROCKER
SWITCH FOR SIDE-WINDOW OPERATION.
2005 BMW 645Ci
 Remove front acoustic insulation, refer to 51 48 060 REMOVING AND INSTALLING/REPLACING
SOUND INSULATION IN FRONT DOOR, LEFT OR RIGHT .
Unlock plug connection (3) for outside door mirror and disconnect.
Disconnect cable ties (1) and feed out wiring harness for outside door mirror.
Unlock and disconnect plug connection (2) for speaker.
Unlock and disconnect plug connection (4) for power window.
Disconnect plug connection (5) on door pressure sensor.
Fig. 18: Removing Wiring Harness In Left Or Right Front Door

2005 BMW 645Ci
Make sure door wiring harness is correctly laid.
Unclip wiring harness (2) at points (3).
Fig. 19: Unfastening Plug Connection (1) And Uncliping Wiring Harness (2) At Points (3)
Installation:
Make sure wiring harness is correctly laid.
Unclip door wiring harness (3) at points (1).
Release expansion rivets (2).

2005 BMW 645Ci
Fig. 20: Uncliping Door Wiring Harness (3) At Points (1) And Releasing Expansion Rivets (2)
Installation:
Make sure door wiring harness is correctly laid.
Release screw (1), fold door wiring harness plug on A-pillar (2) downwards slightly and remove.
Unlock plug connection behind and disconnect.
Pull rubber grommet (3) out of front door.
Feed out door wiring harness towards front to A-pillar and remove.
2005 BMW 645Ci
Fig. 21: Identifying Screw (1), Door Wiring Harness Plug On A-Pillar (2) And Rubber Grommet (3)
61 13 .. UNLOCKING AND DISCONNECTING DIFFERENT PLUG CONNECTIONS

2005 BMW 645Ci
Fig. 22: Pressing Lock And Open Clip


2005 BMW 645Ci

2005 BMW 645Ci


2005 BMW 645Ci


2005 BMW 645Ci


2005 BMW 645Ci


2005 BMW 645Ci


2005 BMW 645Ci


2005 BMW 645Ci

PLUG CONNECTION TERMINAL

61 00 ... NOTES ON HANDLING OPTICAL FIBERS
For notes on handling optical fibers, refer to 61 00 ... NOTES ON HANDLING OPTICAL FIBERS
For repairing airbag cables, refer to 61 00 ... REPAIRING AIRBAG CABLES.
61 13 SPECIAL TOOLS FOR WIRING HARNESS REPAIRS

2005 BMW 645Ci
NOTE: For special tools, refer to BODY ELECTRICAL - SPECIAL TOOLS - 645CI (E63) .
 61 1 150
 61 1 190
 61 4 320
 61 8 084
 61 9 020
 61 9 029
 61 9 041
 61 9 042
 61 9 043
 61 9 044
Repair ranges I, II, III for vehicle electrical system
I. Order No.: 81 24 9 408 080

II. Order No.: 81 24 9 408 300
III. Order No.: 81 24 9 408 400
NOTE: Operating instructions for the special tools contained in TIS article, refer to
"Tool for wiring harness repair, repair range I, II, III", special tool 61 8 084.
2005 BMW 645Ci
Fig. 31: Identifying Wiring Harness Repair Special Tools (1 Of 9)

Repair range IV for vehicle electrical system, special tool 61 9 020:
Contents:
 Special tool 61 9 041 (hand pliers)

2005 BMW 645Ci
 Special tool 61 9 043 (wire stripper)

 Special tool 61 9 044 (matrix)
NOTE: Operating instructions for the special tools contained in the this article, refer to
"repair range IV for vehicle electrical system (Vol. 1 / Vol. 2 / Vol. 3 / Vol. 4)",

Special tool 61 9 043 (wire stripper with wire cutter) for cutting and stripping wires.
Handling:
Cutting to length and stripping insulating from cables, refer to 61 13 CUTTING TO LENGTH AND
STRIPPING INSULATION FROM CABLES.
2005 BMW 645Ci

Special tool 61 9 041 (hand pliers) with special tool 61 9 042 (matrix) for crimping connectors and contact
tubes for fan connectors up to a wire cross-section of 2.5 mm2 and for pushing on contact tubes for fan
connectors.
Handling:
Crimping stop parts (contacts), refer to 61 13 CRIMPING ON STOP PARTS.
Fan connector for retrofitting/repairs, refer to 61 13 INSTALLING FAN CONNECTOR FOR

RETROFITTING/REPAIRS.
2005 BMW 645Ci

Special tool 61 9 041 (hand pliers) with special tool 61 9 044 (matrix) for crimping cable guide and strain relief
device on antenna elbow plug.
Handling:
Antenna elbow plug on radio receiver, refer to 61 13 ... ANTENNA ELBOW PLUG ON RADIO
RECEIVER.
2005 BMW 645Ci

Special tool 61 1 150 (release and pressing-out tool) for:
 releasing round plug housings

 releasing relay carriers
 pressing out contacts
 removing indicator lights
2005 BMW 645Ci

Handling:
Opening plug housings and removing contacts of different plug systems, refer to 61 13 ... OPENING PLUG
HOUSINGS AND REMOVING CONTACTS OF DIFFERENT PLUG SYSTEMS.
Repair kit for ignition cables and for crimping fan connector receptacles 4 mm2
Handling:
Crimping stop parts (contacts), refer to 61 13 CRIMPING ON STOP PARTS.
Service Information 1 03 89 (037)

2005 BMW 645Ci

Special tool 61 4 320 (crimping set with pliers) for:
 Cutting to length and stripping insulation from optical fibers, refer to 61 13 ... CUTTING OFF,
STRIPPING INSULATION AND CUTTING OPTICAL FIBRES TO LENGTH.
 Crimping optical fibers, refer to 61 13 ... CRIMPING OPTICAL FIBRES.
 Crimping MPQ contacts, refer to 61 13 ... CRIMPING MICRO POWER QUADLOCK CONTACTS
(MPQ).
2005 BMW 645Ci
 Crimping MQS contacts, refer to 61 13 ... CRIMPING MICRO QUADLOCK SYSTEM CONTACTS
(MQS).

Special tool 61 1 190 pliers for insulation displacement connector for repairing ribbon cables.
2005 BMW 645Ci

Handling:
Repairing ribbon cables, refer to 61 13 ... REPAIRING RIBBON CABLES.
61 13 ... UNLOCKING AND DISCONNECTING DIFFERENT PLUG CONNECTIONS

2005 BMW 645Ci


2005 BMW 645Ci

2005 BMW 645Ci


2005 BMW 645Ci


2005 BMW 645Ci


2005 BMW 645Ci


2005 BMW 645Ci


2005 BMW 645Ci


2005 BMW 645Ci

61 13 ... BASE OF TAB CONNECTOR HOUSINGS
Unlock hook (1) with special tool 61 1 360 and slide plug housing downwards out of base.
2005 BMW 645Ci
Fig. 49: Unlocking Hook (1) With Special Tool 61 1 360 And Sliding Plug Housing Downwards Out Of
Base
61 13 ... ANTENNA ELBOW PLUG ON RADIO RECEIVER
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).
2005 BMW 645Ci
Fig. 50: Identifying Lengths Strip Insulation From Antenna Cable

Create a loop on inner conductor.

2005 BMW 645Ci
Fig. 51: Creating 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.
2005 BMW 645Ci
Fig. 52: Matching Soldering Tip

Special tool 61 9 041 (hand pliers) in conjunction with special tool 61 9 044 (matrix) is used to crimp antenna
angle plug.
Special tools for wiring harness repairs

2005 BMW 645Ci
Fig. 53: Crimping Antenna Angle Plug

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.

2005 BMW 645Ci
Fig. 54: Squeezing Grips Lightly And Pushing Unlocking Lever

Place antenna angle plug with cable guide and strain relief in matrix (1).
2005 BMW 645Ci
Fig. 55: Placing Antenna Angle Plug With Cable Guide And Strain Relief In Matrix
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.
2005 BMW 645Ci
Fig. 56: Removing Antenna Angle Plug With Antenna Cable From Special Tool
61 13 ... CRIMPING MICRO POWER QUADLOCK CONTACTS (MPQ)
 61 4 320
To crimp MPQ contacts, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 325 (2) from crimping
set 61 4 320.
NOTE: Pliers (1) open automatically as far as they will go when handles are pressed
together.
2005 BMW 645Ci
Fig. 57: Crimping MPQ Contacts Using Pliers

Open pliers (1).
NOTE: Place contact (2) with utmost care in designated nest (observe cable cross-
section) in crimping head (3). Make sure it is exactly positioned.
Place MPQ contact (2) in crimping head (3).
Close pliers (1) one notch.

2005 BMW 645Ci
Fig. 58: Placing MPQ Contact In Crimping Head

NOTE: Follow procedure for cutting and stripping insulation from cables, refer to 61 13
CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES.
Insert stripped cable (2).
Close pliers (1) fully.
Open pliers (1) and remove cable (2).
NOTE: Check contact for correct crimping, refer to 61 13 CRIMPING ON STOP PARTS.
2005 BMW 645Ci
Fig. 59: Inserting Stripped Cable

61 13 ... CRIMPING MICRO QUADLOCK SYSTEM CONTACTS (MQS)
 61 4 320
To crimp MQS contacts, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 324 (2) from crimping
set 61 4 320.
together.
2005 BMW 645Ci
Fig. 60: Crimping MQS Contacts Using Pliers

Open pliers (1).
Fold up contact carrier (2).
Insert MQS contact (3) in contact carrier (2).
Fold back contact carrier (2).

2005 BMW 645Ci
Fig. 61: Inserting MQS Contact In Contact Carrier

Close pliers (1) one notch.
Insert stripped cable (2).

2005 BMW 645Ci
Fig. 62: Inserting Stripped Cable

Open pliers (1).
Open contact carrier (2) gently and carefully remove MQS contact.
2005 BMW 645Ci
Fig. 63: Opening Contact Carrier Gently

61 13 ... CRIMPING ANNULAR CONTACTS
CrimpacII crimping pliers from repair kit 1 are used to crimp annular contacts.
2005 BMW 645Ci
Fig. 64: Identifying CrimpacII Crimping Pliers

Open crimping pliers (1).
NOTE: Place contact (2) in designated nest (observe wire cross-section) with particular
care. Make sure it is exactly positioned.
Insert annular contact (2) in crimping pliers (1).
Close crimping pliers (1) gently and keep closed.

2005 BMW 645Ci
Fig. 65: Inserting Annular Contact In Crimping Pliers

Feed stripped cable (1) into annular contact (2) completely.
Close crimping pliers (3) fully.
Open crimping pliers (3) and remove cable (2).
2005 BMW 645Ci
Fig. 66: Opening Crimping Pliers And Removing Cable

61 13 ... CRIMPING OPTICAL FIBRES
 61 4 320
To crimp optical fibres, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 323 (2) from crimping
set 61 4 320.
together.
2005 BMW 645Ci
Fig. 67: Crimping Optical Fibres Using Pliers

Move contact guide by means of stop lever (1) into corresponding position (pin contact or jack).
2005 BMW 645Ci
Fig. 68: Moving Contact Guide By Means Of Stop Lever Into Corresponding Position
Open pliers (2).
Place pin contact or jack (1) in crimping head and secure with locking lever (3).
2005 BMW 645Ci
Fig. 69: Placing Pin Contact Or Jack In Crimping Head

NOTE: Follow procedure for cutting and stripping insulation from optical fibres, refer
to 61 13 ... CUTTING OFF, STRIPPING INSULATION AND CUTTING OPTICAL
FIBRES TO LENGTH.
Insert stripped optical fibre (1) as far as it will go into pin contact or jack (2).
Open pliers (3) and locking lever (4).
Remove optical fibre (1).

2005 BMW 645Ci
Fig. 70: Opening Pliers And Locking Lever

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).
2005 BMW 645Ci
Fig. 71: Identifying End Of Optical Fibre

61 13 ... CUTTING OFF, STRIPPING INSULATION AND CUTTING OPTICAL FIBRES TO

LENGTH
 61 4 320
To cut off, strip insulation and cut optical fibres to length, use pliers 61 4 321 (1) in conjunction with crimping
head 61 4 322 (2) from crimping set 61 4 320.
together.
2005 BMW 645Ci
Fig. 72: Cutting Off Strip Insulation And Cutting Optical Fibres To Length Use Pliers
Cutting optical fibre
Open pliers (1).
Place optical fibre (2) in cutting device (3).
Close pliers (1) and remove optical fibre (2).

2005 BMW 645Ci
Fig. 73: Placing Optical Fibre In Cutting Device

Stripping insulation from optical fibre
Open pliers (1).
Open lever (2) in direction of arrow.

2005 BMW 645Ci
Fig. 74: Opening Lever

Slide optical fibre (1) into stripping device (2) until flush at point (3).
Close clamping lever (5) in direction of arrow.
Open pliers (4) by one tooth notch.
Open clamping lever (5) against direction of arrow again and remove optical fibre (1).
NOTE: A stripping replacement blade set is available under number 61 4 327.

2005 BMW 645Ci
Fig. 75: Opening Pliers By One Tooth Notch

Cutting optical fibre to length
IMPORTANT: The cutting blade must be replaced prior to each cutting of the optical fibre.
Pull pin (1) in direction of arrow.
Fold up blade retaining link (2) in direction of arrow.

2005 BMW 645Ci
Fig. 76: Folding Up Blade Retaining Link

WARNING: Risk of injury when changing the blade.
Remove blade (1) and replace.

2005 BMW 645Ci
Fig. 77: Removing Blade And Replacing

Installation:
Make sure blade (1) is correctly seated on locating points (2).
Open pliers (3).
Slide optical fibre (1) into cutting device (2) until insulation of optical fibre (1) butts against clamping device.
Close pliers (3) fully and keep closed.
Remove optical fibre (1).

2005 BMW 645Ci
Fig. 78: Removing Optical Fibre

61 13 ... OPENING PLUG HOUSINGS AND REMOVING CONTACTS OF DIFFERENT PLUG

SYSTEMS
Abbreviations and what they mean:
ABBREVIATIONS MEANING
MDK
Miniature double flat spring contact
3plus
JPT ELA Junior Power Timer flat spring contacts with strand sealing
DFK ELA Double flat spring contacts with strand sealing
Elo Electronic contacts with and without strand sealing Manufacturer: Siemens
Elo Power Electronic contacts for heavy loads with and without strand sealing Manufacturer: Siemens
Micro Quadlock System electronic contacts with and without strand sealing Manufacturer:
MQS
2005 BMW 645Ci
Micro Power Quadlock electronic contacts for heavy loads with and without strand sealing
MPQ
Manufacturer: AMP
D 1.5 / 2.5 Round contacts of 1.5 mm or 2.5 mm diameter
Ultrasonic-welded connectors:
Ultrasonic-welded connectors (1) can be identified by the welds (2) on their longitudinal side.
The contacts of these connectors cannot be replaced. Replace plug completely.
Fig. 79: Identifying Ultrasonic-Welded Connectors

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
61 13 ... PLUG HOUSING, LCC CONTACT (LOAD CURRENT CONTACT)

2005 BMW 645Ci
 61 1 200
Socket housing:
Press lock (1) with suitable tool (2) in direction of arrow out of socket housing (3).
Fig. 80: Pressing Lock With Suitable Tool

Pull lock (1) out of socket housing (2).

2005 BMW 645Ci
Fig. 81: Pulling Lock Out Of Socket Housing

Insert special tool 61 1 200 into socket housing (1) and pull out lead with LCC contact (2) in direction of arrow.
2005 BMW 645Ci
Fig. 82: Inserting Special Tool 61 1 200 Into Socket Housing

Pin housing:
Unlock locking slide (1) of pin housing (2) with suitable tool (3) in direction of arrow.
2005 BMW 645Ci
Fig. 83: Unlocking Locking Slide Of Pin Housing With Suitable Tool
Insert special tool 61 1 200 into pin housing (1) and pull out lead with LCC contact (2) in direction of arrow.
2005 BMW 645Ci
Fig. 84: Inserting Special Tool Into Pin Housing

61 13 ... RELAY CARRIER
Place special tool 61 1 153 on relay carrier (1) and carefully pull in direction of arrow until retaining lugs (2) on
relay carrier are raised.
2005 BMW 645Ci
Fig. 85: Placing special tool on relay carrier

Pull relay carrier (2) in direction of arrow into first catch (3).
2005 BMW 645Ci
Fig. 86: Pulling Relay Carrier

Press down arrester hook (4) of appropriate contact and pull out cable with contact.
Press out double flat spring contact with special tool 61 1 136 or 61 1 137 (ejector).
2005 BMW 645Ci
Fig. 87: Pressing Down Arrester Hook Of Appropriate Contact

61 13 ... REPAIRING RIBBON CABLES
 61 1 190
Place ribbon cables (1) in connector housing (2) and close cover (3).
2005 BMW 645Ci
Fig. 88: Placing Ribbon Cables In Connector Housing

Place connector housing (1) in pliers (2) 61 1 190.
Close pliers (2).

2005 BMW 645Ci
Fig. 89: Placing Connector Housing In Pliers

61 13 ... RETAINING BRACKET
Pull relevant fuse out of fuse block (1).
NOTE: Mark positions when removing fuses.
Pull locking slide (2) out of fuse block (1) as far as it will go.
2005 BMW 645Ci
Fig. 90: Pulling Locking Slide Out Of Fuse Block

With special tool 61 1 136 or 61 1 137 (ejector), press back arrester hook (3) of appropriate contact and pull out
cable.
2005 BMW 645Ci
Fig. 91: Press Back Arrester Hook With Special Tool

61 13 ... SOCKET HOUSING (RADIO PLUG), HYBRID SYSTEM MQS/MPQ
Manufactured by AMP: The following contact types without strand sealing can be fitted in the plug housings:
 MQS (Micro Quadlock System)

 MPQ, width 2.8 mm (Micro Power Quadlock)
 MPQ, width 5.2 mm (Micro Power Quadlock)
Removing MPQ contacts from radio plug:
Press lock (1) in direction of arrow.
Detach secondary lock (2) from radio plug.

2005 BMW 645Ci
Fig. 92: Detaching Secondary Lock From Radio Plug

Feed special tool 61 1 135 past side of contact.
Press special tool 61 1 135 in direction of arrow.
Pull wire (1) with socket contact out of radio plug (2).
2005 BMW 645Ci
Fig. 93: Pulling Wire With Socket Contact Out Of Radio Plug
Removing MQS contacts from contact carrier:
Press lock (1) in direction of arrow and pull housing (2) out of radio plug.
2005 BMW 645Ci
Fig. 94: Pulling Housing Out Of Radio Plug

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.
2005 BMW 645Ci
Fig. 95: Pulling Contact Carrier Out Of Housing

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).
NOTE: The illustration shows an 8-pin socket housing where removal of the contacts is
identical.
2005 BMW 645Ci
Fig. 96: Holding Down Retaining Hook Of Socket Contact

Hold down arrester hook in secondary lock (1) again. Pull wire with socket contact (2) out of contact carrier (3).
2005 BMW 645Ci
Fig. 97: Holding Down Arrester Hook In Secondary Lock

Removing MPQ contacts from contact carrier:
Remove contact carrier (1) with MQS contacts from radio plug.
Raise lock (2) on radio plug.
Pull contact carrier (3) out of radio plug.

2005 BMW 645Ci
Fig. 98: Pulling Contact Carrier Out Of Radio Plug

Press lock (1) in direction of arrow.
Pull secondary lock (2) in direction of arrow completely out of contact carrier (3).
2005 BMW 645Ci
Fig. 99: Pulling Secondary Lock Completely Out Of Contact Carrier

Press special tool 61 1 135 on inside of contact into contact carrier (2).
Pull wire with socket contact (1) out of contact carrier (2).
2005 BMW 645Ci
Fig. 100: Pulling Wire With Socket Contact Out Of Contact Carrier
61 13 040 REPLACING DISTRIBUTION BOX (PASSENGER COMPARTMENT)
 Remove trim for instrument panel, bottom left, refer to 51 45 181 REMOVING AND
2005 BMW 645Ci
 Remove right glovebox with housing, refer to 51 16 366 REMOVING AND INSTALLING RIGHT
GLOVEBOX WITH HOUSING (WITHOUT ACTIVE KNEE PROTECTION) or 51 16 367
REMOVING AND INSTALLING RIGHT GLOVEBOX WITH HOUSING (WITH ACTIVE
KNEE PROTECTION) .
Release screws (1) and remove distribution box (2).
Fig. 101: Releasing Screws (1) And Removing Distribution Box (2)
Unlock and disconnect all plug connections (1).
Unlock relay base (3) and disconnect.
Fold up covers (2) from battery positive cable.

2005 BMW 645Ci
Fig. 102: Disconnecting Distribution Box

Release nut underneath.

TORQUES - 645CI .
Remove battery positive lead from fuse box.
Installation:
Make sure battery positive lead is correctly seated on fuse box.
Replacement:
Remove fuses.
61 13 042 REPLACING DISTRIBUTION BOX (LUGGAGE COMPARTMENT)

2005 BMW 645Ci
 Remove control unit cover
Fig. 103: Unlocking Plug Connections (1)

Detach plug connection (1) in direction of arrow and disconnect.

2005 BMW 645Ci
Fold up covers (4).
Unscrew nuts (3).

TORQUES - 645CI .
Pull distribution box upwards out of control unit receptacle.
Fig. 104: Removing Distribution Box (Luggage Compartment)

Replacement:
Remove fuses and relays.
61 13 CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES
Special tool 61 9 043 (cable stripper with wire cutter) for cutting and stripping insulation from cables.
2005 BMW 645Ci

Refer to repair instructions:
Special tools for wiring harness repairs, refer to 61 13 SPECIAL TOOLS FOR WIRING HARNESS
REPAIRS.
Cutting to length:
Slide upper handle of cable stripper (6) in direction of arrow until cutting tool (7) becomes visible. Open
stripper in final position and hold in this position.
2005 BMW 645Ci
Fig. 106: Sliding Upper Handle Of Cable Stripper (6) In Direction Of Arrow Until Cutting Tool (7)
Becomes Visible
Hold wire (8) between cutters and squeeze tool handles as far as they will go.
2005 BMW 645Ci
Fig. 107: Identifying Wire (8)

Stripping insulation
Guide wire (1) until behind knife. Wire length (2) behind knife blade represents the length from which
insulation will be stripped.
2005 BMW 645Ci
Fig. 108: Identifying Wire Length to Be Stripped

Stripped length:
WIRE 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
Squeeze tool handles until wire is held tight by jaws (3).

2005 BMW 645Ci
Fig. 109: Identifying Jaws (3)

Continue to squeeze tool handles. This strips insulation from wire (4).
Fig. 110: Stripping Insulation From Wire (4)

2005 BMW 645Ci
Open cable stripper and remove stripped wire (5).
Fig. 111: Identifying Stripped Wire (5)

61 13 CRIMPING ON STOP PARTS
Crimping Butt Connectors And Contact Sleeves For Fan Connectors Up To 2.5 MM2
The special tool 61 9 041 (crimping tool) in conjunction with 61 9 042 (matrix) are used for crimping stop parts
(contacts), refer to 61 13 CRIMPING ON STOP PARTS.
2005 BMW 645Ci
Fig. 112: Identifying Special Tool 61 9 041 (Crimping Tool)

Special tools for wiring harness repairs, refer to 61 13 SPECIAL TOOLS FOR WIRING HARNESS
REPAIRS.
OR:

2005 BMW 645Ci
Fig. 113: Unlocking Special Tool 61 9 041

NOTE: Designation on nests (3) of special tool 61 9 042 indicate which contacts can be
used in which crimping nests.
The following wire cross-section sizes and their corresponding stops can be used:
Wire cross-section size
1. 0.35 ... 0.5 mm2

2. 0.75 ... 1.0 mm2
3. 1.5 mm3
4. 2.5 mm2
2005 BMW 645Ci
Fig. 114: Identifying Cross-Section Sizes And Their Corresponding Stops

Example for choosing a nest:

2005 BMW 645Ci
Fig. 115: Choosing A Nest

For further operating instructions, refer to operating instructions for repair range IV for vehicle electrical system
61 9 020.
CAUTION: The contacts must be inserted in the matrix nest with utmost care. In so
doing, ensure wire crimp and insulation crimp are exactly positioned.
Insert contact section of contact sleeves (4) for comb connector or crimp connector (5) in predetermined nest.
Fig. 116: Identifying Contact Sleeves (4) And Connector (5)

Preload contact by squeezing matrix in crimping tool. Grip contact (6) firmly only, do not crimp.
2005 BMW 645Ci
Fig. 117: Preloading Contact By Squeezing Matrix In Crimping Tool

NOTE: Follow procedure for cutting and stripping insulation from cable, refer to 61 13
Cutting To Length And Stripping Insulation From Cables.
Insert stripped end of wire (7) in the contact. Ensure insulation and stripped wire end are correctly laid in
contact.
2005 BMW 645Ci
Fig. 118: Inserting Stripped End Of Wire (7) In The Contact

Compress crimping tool as far as it will go.
Crimping tool unlocks automatically.
Take contact out of crimping tool.
Crimping Contact Sleeves For Fan Connectors 4 MM2 And Ignition Cable Contacts
The special tool 12 1 081 (crimping tool) in conjunction with 12 1 083 (matrix) are used to attach the ignition
cable contacts and to crimp the contact sleeves 4 mm2 for fan connectors.
2005 BMW 645Ci
Fig. 119: Identifying 12 1 081 (Crimping Tool) And 12 1 083 (Matrix)

61 13 SPECIAL TOOLS FOR WIRING HARNESS REPAIRS.
Releasing special tool 12 1 081:
2005 BMW 645Ci
Fig. 120: Squeezing Grips (1) Lightly And Pushing Unlocking Lever (2) In Direction Of Arrow
OR:
Insert contact sleeve 4 mm2 in nest with lock (1) as far as it will go.
2005 BMW 645Ci
Fig. 121: Inserting Contact Sleeve 4 MM2 In Nest With Lock (1) As Far As It Will Go
Preload contact by squeezing matrix in crimping tool. Grip contact (1) firmly only, do not crimp.
2005 BMW 645Ci
Fig. 122: Preloading Contact By Squeezing Matrix In Crimping Tool

Insert stripped end of wire (1) in the contact. Ensure insulation and stripped wire end are correctly laid in
contact.
2005 BMW 645Ci
Fig. 123: Inserting Stripped End Of Wire (1) In The Contact

Compress crimping tool as far as it will go.
Crimping tool unlocks automatically.
Take contact out of crimping tool.
Checking Crimping
Check insulation crimp (8) and wire crimp (9) against following illustrations to ensure crimps are correctly
located.
NOTE: Illustration shows butt connectors and contact sleeves for fan connectors
knocked on one side. The crimping procedure is identical here.
2005 BMW 645Ci
Fig. 124: Checking Insulation Crimp (8) And Wire Crimp (9)
Correct crimping:
Visible conductor end (10).
Visible insulation end (11).

2005 BMW 645Ci
Fig. 125: Identifying Conductor End (10) And Insulation End (11)
Incorrect crimping:
Conductor end (10) inserted too far.
Insulation end (11) in wire crimp.

2005 BMW 645Ci
Fig. 126: Identifying Incorrect Crimping Method (1 Of 2)

If necessary, repeat crimping with a new contact.
Incorrect crimping:
Conductor end (10) not visible.
Insulation end (11) not visible.

2005 BMW 645Ci
Fig. 127: Identifying Incorrect Crimping Method (2 Of 2)

If necessary, repeat crimping with a new contact.
For further handling instructions, refer to operating instructions for repair range IV for vehicle electrical system
61 9 020.
61 13 INSTALLING FAN CONNECTOR FOR RETROFITTING/REPAIRS
NOTE: The repair range IV for vehicle electrical system 61 9 020 contains the required
special tools and individual parts for retrofitting and repair work with the aid of
fan connectors.
2005 BMW 645Ci

Choose contact sleeve (up to 4 mm2 ) in accordance with wire cross-section.

2005 BMW 645Ci
Fig. 129: Choosing Contact Sleeve (Up To 4 MM2 )

Alternatively:
Choose repair kit A for contact sleeves (up to 2.5 mm2 ) for fan connectors.
2005 BMW 645Ci
Fig. 130: Identifying Kit A

Cut through wire loop (1) in wiring harness at determined point (2) with special tool 61 9 043.
2005 BMW 645Ci
Fig. 131: Cutting Through Wire Loop (1) In Wiring Harness At Determined Point (2)
Strip insulation from both wire ends.
61 13 CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES.
Crimp contact sleeves on both wire ends.

2005 BMW 645Ci
Fig. 132: Crimping Contact Sleeves On Both Wire Ends

61 13 CRIMPING ON STOP PARTS
Crimp connecting cable for retrofitting likewise with contact sleeve.

2005 BMW 645Ci
Fig. 133: Crimping Connecting Cable For Retrofitting Likewise With Contact Sleeve
Take fan connectors from repair range IV for vehicle electrical system 61 9 020 and cut required number of
cores to length.
2005 BMW 645Ci
Fig. 134: Identifying Fan Connectors

The special tool 61 9 041 (crimping tool) in conjunction with 61 9 042 (matrix) are used for pushing contact
sleeves onto fan connectors.
2005 BMW 645Ci
Fig. 135: Identifying Special Tool 61 9 041 (Crimping Tool)

2005 BMW 645Ci
Fig. 136: Squeezing Grips (1) Lightly And Pushing Unlocking Lever (2) In Direction Of Arrow
OR:
Insert prepared fan connector (3) in special tool 61 9 041/61 9 042.

2005 BMW 645Ci
Fig. 137: Inserting Prepared Fan Connector (3) In Special Tool 61 9 041/61 9 042
Attach wire with contact sleeve to fan connector.

2005 BMW 645Ci
Fig. 138: Attaching Wire With Contact Sleeve To Fan Connector

Press crimping tool together and slide contact sleeve firmly home.
2005 BMW 645Ci
Fig. 139: Pressing Crimping Tool Together And Sliding Contact Sleeve Firmly Home
CAUTION: Once contact sleeves have been pushed on, they should not be detached
again from the fan connector or reused.
Push on further contact sleeves for potential branching.

2005 BMW 645Ci
Fig. 140: Pushing 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 shrink-fit hose and heat up with hot air blower (approx. 250°C) (2).
2005 BMW 645Ci
Fig. 141: Identifying Sealing Compound (1) And Shrink-Fit Hose (2)
NOTE: Ensure that fan connector has sufficient contact surface on mounting point.
Do not heat shrink-fit hose on edges of fan connector too strongly, risk of cracking.
Allow shrink-fit hose to cool down until hand-warm. Then press sealing material again into contacts and onto
edges of fan connector.
If necessary, carefully heat shrink-fit hose again.
Installation in dry area (interior, luggage compartment):
Slide assembled fan connector into insulation housing until it locks into place.
2005 BMW 645Ci
Fig. 142: Sliding Assembled Fan Connector Into Insulation Housing Until It Locks Into Place
BATTERY
Observe safety instructions for handling vehicle battery, refer to 61 00 ... SAFETY INSTRUCTIONS FOR
HANDLING VEHICLE BATTERY.
2005 BMW 645Ci
 Detach terminal of battery negative lead from car battery and second battery if fitted, refer to 61 20 900
DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD. Cover battery negative
terminal(s) and secure.
 When fitting terminal for battery negative lead: Tightening torque, refer to 61 21 1 AZ in , refer to 61 21
1AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - 645CI .
reactivated.
Example:
 Activate sliding sunroof, refer to 54 0 ... NOTES ON PANORAMA GLASS

ROOF (INITIALIZATION/NORMALIZATION/LEARNING OF
CHARACTERISTIC CURVE) .
 Vehicles with AFS only: Activate steering angle, refer to 61 00 ... VERSION
WITH AFS: SETTING STEERING ANGLE (AFTER RECONNECTING
VEHICLE BATTERY).
 If necessary, activate power windows.
Vehicles With A Two-Battery System

2005 BMW 645Ci
Two AGM batteries are used as a storage battery.
is open.
voltage at the starter battery of greater than or equal to ace;13.5 V. The isolating relay is closed and thus the
equipment battery is connected in parallel. Both batteries are now charged.
Prerequisite:
operation when the engine is running. A special mode can be set by means of
diagnosis for workshop/garage operation. The isolating relay is closed from
terminal R in this operating mode. This mode is automatically reset once a
distance of 5 km has been driven.
Trickle charging
Increased closed-circuit current consumption can be compensated with the aid of the battery trickle charger
2005 BMW 645Ci
via the jump start terminal.
charging function).
12 00 ... INSTRUCTIONS ON STARTING AID
Do not start the engine with help of starting sprays.
Preparation:
Conform with the following when starting engine with starting cable.

both vehicles.
tension!
speed.
Carrying out:
Always conform with the procedures to avoid injury to persons or damage to parts.

2005 BMW 645Ci
ignited by sparks.
Danger of explosion!
After engine of vehicle to be started has started up, first disconnect the jump lead on the negative
terminal/ground connection. Then remove jump lead from positive terminals.
61 00 ... VERSION WITH AFS: SETTING STEERING ANGLE (AFTER RECONNECTING VEHICLE
BATTERY)
NOTE: Version with AFS: After reconnecting the vehicle battery, refer to 12 00 ...
INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY , carry out
the following procedure for setting the steering angle:
 Start engine.
 Turn steering wheel left to full lock.
 Turn steering wheel right to full lock.
 Turn steering wheel to central position.
 Turn off engine.
 Turn on ignition (terminal 15), AFS telltale and Check Control message go
out.
NOTE: Entry in the fault memory remains unaffected by this procedure, therefore if
necessary

61 00 ... BATTERY
For Battery, refer to 61 00 ... BATTERY.
61 00 ... BATTERY CHARGING
For battery charging, refer to 61 00 ... BATTERY CHARGING.
61 00 ... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY
For safety instructions for handling vehicle battery, refer to 61 00 ... SAFETY INSTRUCTIONS FOR
61 20 ... THRESHOLD VALUES FOR BATTERY INSPECTION OF ALL BATTERY (TELEPHONE

EXCEPT FOR TELEPHONE BATTERY)
2005 BMW 645Ci
Safety instructions for handling vehicle battery, refer to 61 00 ... SAFETY INSTRUCTIONS FOR
Test step 1 - before charging the battery
BATTERY REFERENCE (BEFORE CHARGING)

Charge state 1) Starting capability 2) Test result
Not testable Charge
less than 50 % 2) Charge
more than 50 % less than 75 % Charge
more than 50 % more than 75 % 3) Charge
more than 80 % more than 75 % O.K.
Test step 2 - after charging the battery
BATTERY REFERENCE (AFTER CHARGING)

Charge condition 1) Starting capability 2) Test result
Not testable Defective
less than 50 % less than 75 % Charge
more than 50 % more than 75 % Charge
1) Charge condition and starting power must always be evaluated together
2) When test charging for more than 5 hours, use charger Gossen CG 32 or Siemens / Gossen VB 801
3) Fully charge until charge state is more than 80 %.
NOTE: If battery was checked on the positive terminal in the engine compartment,
repeat check directly on battery for sake of safety.
61 20 ... BATTERY OPEN-CIRCUIT CURRENT TEST
NOTE: Observe safety instructions for handling vehicle battery, refer to 61 00 ...
SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY. Observe Service
Information Adapter for open-circuit current measurement.
2005 BMW 645Ci

The open-circuit current test is performed using the Diagnosis and Information System (DIS).
2005 BMW 645Ci
61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD
SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY. Follow
instructions for disconnecting and connecting battery, refer to 12 00 ...
INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY
 Remove luggage compartment floor trim panel with fitted mat, refer to 51 47 101 REMOVING AND
Version with intelligent battery sensor (IBS):
Slacken nut (1).

TORQUES - 645CI .
IMPORTANT: Do not under any circumstances use force to pull off pole shoe. Do not under
any circumstances release socket head cap screw of IBS (2).
Detach battery negative lead (3) with IBS (2) in upward direction, lay to one side and secure.
2005 BMW 645Ci
Fig. 144: Disconnecting Battery Negative Lead (with Intelligent Battery Sensor)
Version without intelligent battery sensor (IBS):
Disconnect battery negative lead (1).
IMPORTANT: Cover battery negative terminal post and secure negative lead (1) at side.

TORQUES - 645CI .
2005 BMW 645Ci
Fig. 145: Disconnecting Battery Negative Lead (without Intelligent Battery Sensor)
BATTERY/VAPOUR SEPARATOR
61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD
For disconnecting and connecting battery negative lead, refer to 61 20 900 DISCONNECTING AND
CONNECTING BATTERY NEGATIVE LEAD.
61 21 010 REMOVING AND INSTALLING BATTERY

2005 BMW 645Ci
 Remove luggage compartment floor trim panel with fitted mat, refer to 51 47 101 REMOVING AND
Disconnect battery negative lead (1), refer to 61 20 900 DISCONNECTING AND CONNECTING
Disconnect plug connection (2) of one-pin IBS cable (3).
Release nut (5) of safety battery terminal (4), tightening torque, refer to 61 21 1AZ inGENERAL
IMPORTANT: Do not under any circumstances pull/lever safety battery terminal (4) off by
force.
Detach safety battery terminal (4) towards top, lay to one side and secure.
Fig. 146: Disconnecting Plug Connection Of One-Pin IBS Cable And Releasing Nut Of Safety Battery
2005 BMW 645Ci
Terminal
Release both threaded pins (1) and remove both holders (2).
Detach vent (3) in direction of arrow.
Fold both clips (4) open.
Pull back battery (5) towards rear right out of associated mounts.
Lift out battery (5).
Installation:
Make sure battery (5) is correctly seated in associated mounts.

2005 BMW 645Ci
SWITCH HORN SMALL

61 30 010 REMOVING AND INSTALLING/REPLACING ACTUATING UNIT FOR LEFT OR RIGHT
FRONT SEAT
"Removing and installing/replacing outer cover on front seat (sport/electric)", refer to 52 16 040 REMOVING
AND INSTALLING/REPLACING OUTER COVER ON FRONT LEFT OR RIGHT SEAT
(SPORTS/ELECTRIC) .
SWITCH
61 31 ... OVERVIEW OF SWITCHES IN STEERING WHEEL AREA
2005 BMW 645Ci
Fig. 148: Overview Of Switches In Steering Wheel Area

61 31 006 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.
DISCHARGE).

2005 BMW 645Ci
 Remove top section of steering column casing, refer to 32 31 004 REMOVING AND INSTALLING /
REPLACING UPPER SECTION OF STEERING COLUMN TRIM .
 If necessary, remove deformation element for steering column trim.
NOTE: Comply with notes and instructions on handling optical wave guides, refer to 61
00 ... NOTES ON HANDLING OPTICAL FIBERS.
Release screws (1).
Pull back fixture for steering column switch (2) in direction of arrow.
Disconnect plug connections behind and remove fixture for steering column stalk (2).
Fig. 149: Releasing Screw And Removing Fixture For Steering Column Stalk
2005 BMW 645Ci
 Remove turn indicator/headlight dipping switch, refer to 61 31 016 REMOVING AND

INSTALLING/REPLACING TURN INDICATOR/HEADLIGHT DIPPING SWITCH.
 Remove windshield wiper switch, refer to 61 31 040 REMOVING AND INSTALLING/REPLACING
SWITCH FOR WINDSHIELD WIPERS.
 If necessary, remove cruise control switch, refer to 61 31 018 REMOVING AND
INSTALLING/REPLACING CRUISE CONTROL SWITCH.
Replacement:
 Carry out programming/coding, refer to DIAGNOSIS PROGRAMMING/CODING.

 Vehicles without active front steering:
 Carry out adjustment of steering angle sensor.
 Vehicles with active front steering:

 Carry out active front steering start-up/adjustment, refer to 32 10 005 ADJUSTMENT FOR
ACTIVE FRONT STEERING .
61 31 006 REMOVING AND INSTALLING/REPLACING FIXTURE FOR STEERING COLUMN

STALK (FROM 09/2005)
WARNING: Move wheels into straight-ahead position and do not alter this position
during the repair work.
DISCHARGE).
Comply with notes and instructions on handling optical fibres .
 Remove steering wheel.

 Remove front section of steering column trim.
 Remove lower section of steering column trim.
 Remove top section of steering column casing.
 If necessary, remove deformation element for steering column trim.
Disconnect plug connections from rear on fixture for steering column stalk (2). Release screws (1). Remove
fixture for steering column switch (2) in direction of arrow.
Installation: Carry out steering angle sensor adjustment . On vehicles with active front steering, steering angle
sensor adjustment is performed by means of initial operation / adjustment of active front steering.
2005 BMW 645Ci
 Remove turn indicator/headlight dipping switch.

 Remove windshield wiper switch.
 If necessary, remove cruise control switch.
 Remove volute spring cassette.
 Carry out vehicle programming/coding.
 Carry out steering angle sensor adjustment.
61 31 011 REMOVING AND INSTALLING/REPLACING VOLUTE SPRING CASSETTE
 Remove fixture for steering column stalk
Unlock catches (1) and remove volute spring cassette (2) in direction of arrow from fixture for steering column
switch (3).
2005 BMW 645Ci
Fig. 150: Unlocking Catches And Removing Volute Spring Cassette From Fixture For Steering Column
Switch
Installation:
Seat volute spring cassette exactly on plug connections (1), guide (2) and mounts (3).
Fig. 151: Seating Volute Spring Cassette Exactly On Plug Connections, Guide And Mounts
61 31 016 REMOVING AND INSTALLING/REPLACING TURN INDICATOR/HEADLIGHT

DIPPING SWITCH
 Remove front section of steering column trim, refer to 32 31 010 REMOVING AND
2005 BMW 645Ci
Release screws (1) and remove turn indicator/headlight dipping switch (2) towards rear.
Fig. 152: Releasing Screws And Removing Turn Indicator/Headlight Dipping Switch Towards Rear
61 31 018 REMOVING AND INSTALLING/REPLACING CRUISE CONTROL SWITCH
INSTALLING/REPLACING FRONT SECTION OF STEERING COLUMN TRIM .
Release screws (1) and remove cruise control switch (2) towards rear.
2005 BMW 645Ci
Fig. 153: Releasing Screws And Removing Cruise Control Switch Towards Rear
61 31 020 REMOVING AND INSTALLING/REPLACING IGNITION STARTER SWITCH
 Move ignition lock to key position 0 (stop)

 Remove lower section of steering column trim, refer to 32 31 020 REMOVING AND INSTALLING /
REPLACING LOWER SECTION OF STEERING COLUMN TRIM .
IMPORTANT: Before removing ignition starter switch (1), secure inner shaft against turning:
Insert a M2.5*8 screw in bore (2).
2005 BMW 645Ci
Fig. 154: Identifying Ignition Starter Switch

Installation:
Remove screw in bore (2).
Release screws (1), tightening torque, refer to 61 31 1AZ in GENERAL ELECTRICAL SYSTEM -
TIGHTENING TORQUES - 645CI .
Installation:
Secure screws (1) with sealing paint.
IMPORTANT: Carefully unlock and disconnect associated plug connection for ribbon cable.
Replace the ribbon cable if damaged. The ribbon cable leads to the control unit
for the Car Access System, refer to 61 35 015 REMOVING AND INSTALLING
2005 BMW 645Ci
Remove ignition starter switch (2).
Fig. 155: Securing Screws With Sealing Paint

61 31 023 REMOVING AND INSTALLING/REPLACING START/STOP SWITCH
 00 9 340
Attach special tool 00 9 340 as illustrated.
Unclip Start/Stop switch (1) with associated ribbon cable.

2005 BMW 645Ci
Fig. 156: Identifying Start/Stop Switch (1)

IMPORTANT: Carefully unlock and disconnect associated plug connection for ribbon cable.
Replace the ribbon cable if damaged.
Remove Start/Stop switch (1).
61 31 035 REMOVING AND INSTALLING/REPLACING SWITCH FOR STEERING COLUMN

ADJUSTMENT
Disconnect associated plug connections of steering column adjustment switch (1).

2005 BMW 645Ci
Remove steering column adjustment switch (1) towards front from fixture for steering column stalk (2).
Fig. 157: Removing Steering Column Adjustment Switch Towards Front From Fixture For Steering
Column Stalk
61 31 037 REMOVING AND INSTALLING/REPLACING LIGHTING CONTROL UNIT
 Remove left fresh-air grill, refer to 64 22 137 REMOVING AND INSTALLING/REPLACING LEFT
FRESH-AIR GRILL .
Replacement:
Release screws (1).

2005 BMW 645Ci
Fig. 158: Removing Lighting Control Unit From Left Fresh-Air Grill
61 31 040 REMOVING AND INSTALLING/REPLACING SWITCH FOR WINDSHIELD WIPERS
INSTALLING/REPLACING FRONT SECTION OF STEERING COLUMN TRIM .
Release screws (1) and remove windshield wiper switch (2) towards rear.
2005 BMW 645Ci
Fig. 159: Releasing Screws And Removing Windshield Wiper Switch Towards Rear
61 31 052 REMOVING AND INSTALLING/REPLACING CENTER CONSOLE SWITCH CLUSTER
DISCHARGE).
 Remove trim for storage tray, refer to 51 16 212 REMOVING AND INSTALLING TRIM FOR
CENTER CONSOLE .
Release screws (1).
Unclip center console switch cluster (2) in direction of arrow from trim for storage tray (3) and remove.
2005 BMW 645Ci
Installation:
Make sure center console switch cluster (2) engages correctly in trim for storage tray (3).
Fig. 160: Removing Center Console Switch Cluster From Trim For Storage Tray
Replacement:
61 31 062 REMOVING AND INSTALLING/REPLACING BUTTON FOR STEERING WHEEL

HEATING
This operation is described in: 61 31 035 REMOVING AND INSTALLING/REPLACING SWITCH FOR
STEERING COLUMN ADJUSTMENT
2005 BMW 645Ci
AIRBAG DEACTIVATION
 E60, E63: Remove front roofliner trim, refer to 51 44 ... REMOVING AND INSTALLING FRONT
ROOFLINER TRIM .
 E64: Remove front roofliner trim insert
Press locks (1) and unclip indicator for front passenger airbag deactivation (2) in direction of arrow from front
roofliner trim (3).
Fig. 161: Pressing Locks And Unclipping Indicator For Front Passenger Airbag Deactivation From Front
Roofliner Trim
61 31 079 REMOVING AND INSTALLING/REPLACING SWITCH FOR HAZARD WARNING

SYSTEM/CENTRAL LOCKING
2005 BMW 645Ci
 64 1 020
Lever out switch for hazard warning system/central locking (1) with special tool 64 1 020 and pull back.
Disconnect associated plug connection and remove switch for hazard warning system/central locking (1).
Fig. 162: Levering Out Switch For Hazard Warning System/Central Locking (1) With Special Tool 64 1
020
61 31 083 REMOVING AND INSTALLING/REPLACING SWITCH FOR UNLOCKING REAR LID
NOTE: To unclip switch for unlocking rear lid (4), partially detach mucket (1). Grip from
2005 BMW 645Ci
outside behind footwell side trim panel on A-pillar on left (2).
Press retaining lugs (3) together and feed switch for unlocking rear lid (4) out of footwell side trim panel on A-
pillar on left (2).
Disconnect associated plug connection and remove switch for unlocking rear lid (4).
Fig. 163: Removing/Installing Switch For Unlocking Rear Lid

61 31 104 REMOVING AND INSTALLING/REPLACING SHIFTERS FOR SMG TRANSMISSION

(BOTH)
 Remove steering wheel retaining plate (sports steering wheel), refer to 61 31 220 REMOVING AND
INSTALLING/REPLACING MULTIFUNCTION STEERING WHEEL SWITCH (SPORTS
2005 BMW 645Ci
NOTE: Illustrations show sports steering wheel (4) removed.
Disconnect plug connections (1).
Loosen screws (2).
Remove both shifters for SMG transmission (3) in direction of arrow from sports steering wheel (4).
Installation:
Make sure electrical leads are correctly routed.
Fig. 164: Removing/Installing Shifters For SMG Transmission

61 31 115 REPLACING ROCKER SWITCH FOR SIDE-WINDOW OPERATION

2005 BMW 645Ci
 00 9 341
Carefully lever out rocker switch for side window operation (1) with special tool 00 9 341 at specified points
(2).
Remove rocker switch for side window operation (1) from door trim panel (3) slightly.
Fig. 165: Removing Rocker Switch For Side Window Operation From Door Trim Panel
Disconnect associated plug connection and remove rocker switch for side window operation (1).
Installation:
Retaining clips (1) of rocker switch for side window operation (2) must not be damaged.
2005 BMW 645Ci
Make sure rocker switch for side window operation (2) is correctly seated.
Fig. 166: Retaining Clips Of Rocker Switch For Side Window Operation
61 31 176 REMOVING AND INSTALLING/REPLACING EMERGENCY CALL BUTTON
ROOFLINER TRIM .
Press catches (1) and unclip emergency call button (2) downwards from front roofliner trim (3).
2005 BMW 645Ci
Fig. 167: Pressing Catches And Unclipping Emergency Call Button Downwards From Front Roofliner
Trim
61 31 177 REMOVING AND INSTALLING/REPLACING SWITCH FOR SLIDE/TILT SUNROOF
ROOFLINER TRIM .
Press catches (1) and unclip switch for slide/tilt sunroof (2) in direction of arrow from front roofliner trim (3).
2005 BMW 645Ci
Fig. 168: Pressing Catches And Unclipping Switch For Slide/Tilt Sunroof From Front Roofliner Trim
Installation:

61 31 192 REPLACING KNOB FOR CONTROLLER
Detach knob for controller (1) in direction of arrow.

2005 BMW 645Ci
Fig. 169: Detaching Knob For Controller

Installation:
Fit knob for controller (1) so that guides (2) are seated in mountings (3).
Press knob for controller (1) in middle until it engages.

2005 BMW 645Ci
Fig. 170: Fitting Knob For Controller So That Guides Are Seated In Mountings
61 31 193 REMOVING AND INSTALLING/REPLACING BUTTON UNIT (FOR ON-BOARD

MONITOR)
 00 9 341
Unclip button unit (1) and lever out in direction of arrow.
Unlock and disconnect associated plug connection, remove button unit (1).
2005 BMW 645Ci
Fig. 171: Removing Button Unit

61 31 195 REMOVING AND INSTALLING (REPLACING) FRONT CONTROLLER
DISCHARGE).
 Remove knob for controller, refer to 61 31 192 REPLACING KNOB FOR CONTROLLER.
COMPARTMENT .
Release screws (1).

2005 BMW 645Ci
Remove controller (2) in direction of arrow from storage compartment (3).
Fig. 172: Removing Controller From Storage Compartment

Replacement:
61 31 208 REMOVING AND INSTALLING/REPLACING SWITCH FOR FRONT LUMBAR

SUPPORT
This operation is described in: 52 16 040 REMOVING AND INSTALLING/REPLACING OUTER

COVER ON FRONT LEFT OR RIGHT SEAT (SPORTS/ELECTRIC)
61 31 220 REMOVING AND INSTALLING/REPLACING MULTIFUNCTION STEERING WHEEL

SWITCH (SPORTS STEERING WHEEL)
2005 BMW 645Ci
 Remove airbag unit
NOTE: Illustration shows steering wheel removed.
Release screws (1).
IMPORTANT: Risk of breakage! Lever out complete steering wheel retaining plate (4) with
decorative trim (3) all round, do not tilt!
Release complete steering wheel retaining plate (4) with decorative trim (3) in direction of arrow from fixtures
(2).
Disconnect associated plug connections and remove complete steering wheel retaining plate (4) with decorative
trim (3).
2005 BMW 645Ci
Fig. 173: Releasing Screws From Steering Wheel

Installation:
NOTE: Illustrations depict removal of the left multifunction steering wheel switch. The
right multifunction steering wheel switch is removed in the same way.
Release screws (1) and remove left multifunction steering wheel switch (2) from decorative trim (3).
Installation:
Make sure there is a uniform gap between both multifunction steering wheel switches and decorative trim (3).
Fig. 174: Removing Left Multifunction Steering Wheel Switch From Decorative Trim
2005 BMW 645Ci
61 31 231 REMOVING AND INSTALLING/REPLACING STEERING WHEEL ELECTRONICS

CONTROL UNIT
 Remove airbag unit
E60, E61: Version with standard steering wheel, illustrations show steering wheel removed:
Release screws (1).
Remove steering wheel retaining plate (2) upwards out of multifunction steering wheel (3).
Fig. 175: Removing Steering Wheel Retaining Plate Upwards Out Of Multifunction Steering Wheel
E60, E61: Version with sports steering wheel; E63, E64, illustrations show steering wheel removed:
2005 BMW 645Ci
Release screws (1).
IMPORTANT: Risk of breakage! Lever out complete steering wheel retaining plate (4) with
decorative trim (3) all round, do not tilt!
Release complete steering wheel retaining plate (4) with decorative trim (3) in direction of arrow from fixtures
(2).
Disconnect associated plug connections and remove complete steering wheel retaining plate (4) with decorative
trim (3).
Fig. 176: Releasing Steering Wheel Retaining Plate With Decorative Trim From Fixtures
Installation:

2005 BMW 645Ci
All:
Pull steering wheel electronics control unit (1) in direction of arrow out of steering wheel (2).
Fig. 177: Pulling Steering Wheel Electronics Control Unit Out Of Steering Wheel
Remove steering wheel electronics control unit (2).
Installation:
Guide pins (3) of steering wheel electronics control unit (2) must be exactly seated in associated mountings.
Make sure electrical leads (4) are correctly routed.

2005 BMW 645Ci
Fig. 178: Disconnecting Plug Connections And Removing Steering Wheel Electronics Control Unit
61 31 241 REMOVING AND INSTALLING/REPLACING ENGINE HOOD CONTACT SWITCH
Pull engine hood contact switch (2) in direction of arrow and feed out of microfilter air duct (3).
2005 BMW 645Ci
Fig. 179: Pulling Engine Hood Contact Switch And Feeding Out Of Microfilter Air Duct
61 31 255 REPLACING SWITCH FOR OUTSIDE MIRROR
This operation is described in: 61 31 115 REPLACING ROCKER SWITCH FOR SIDE-WINDOW
OPERATION.
61 31 270 REMOVING AND INSTALLING/REPLACING SWITCH FOR REVERSING LIGHT (DME)
 If necessary, remove rear underbody protection, refer to 51 47 491 REMOVING AND

INSTALLING/REPLACING REAR UNDERBODY PROTECTION .

2005 BMW 645Ci
Fig. 180: Identifying Plug Connection (1) And Reversing Light (2)
61 31 287 REMOVING AND INSTALLING/REPLACING DRIVING DYNAMICS SWITCH
 64 1 020
 Remove finisher for preselector lever, refer to 51 16 210 REMOVING AND

INSTALLING/REPLACING TRIM FOR PRESELECTOR LEVER (GEARSHIFT LEVER) .
NOTE: The illustrations show the removal of the driving dynamics switch in versions
with automatic transmissions.
2005 BMW 645Ci
Release screws (1).
If necessary, lever out actuation trim (4) with special tool 64 1 020 and remove.
Remove driving dynamics switch (2) in direction of arrow from finisher for preselector lever (3).
Fig. 181: Removing Actuation Trim With Special Tool 64 1 020

61 31 299 REMOVING AND INSTALLING/REPLACING CLUTCH SWITCH MODULE
 Remove trim panel for pedal assembly, refer to 51 45 185 REMOVING AND
NOTE: Clutch master cylinder (2) is removed for purposes of clarity.

2005 BMW 645Ci
Lever out clutch switch module (1) from clutch master cylinder (2) with screwdriver.
Unlock plug (4) and disconnect from housing (3).
Fig. 182: Disconnecting Plug From Housing

Installation:
Clutch switch module is protected against incorrect installation.
Clutch switch module must snap audibly into place.

2005 BMW 645Ci
Fig. 183: Identifying Clutch Switch Module

61 31 310 REPLACING BRAKE LIGHT SWITCH
Pull brake light switch (2) in direction of arrow out of brake light switch holder (3).
Installation:
 Press brake pedal (4) to floor.

2005 BMW 645Ci
 Grip brake light switch holder (3), slowly return brake pedal (4) to starting position and pull back to stop.
Fig. 184: Pulling Brake Light Switch Out Of Brake Light Switch Holder
NOTE: Removing brake light switch holder (2):
Press brake pedal.
Press catches (1) together and unclip brake light switch holder (2) from bearing block (3).
2005 BMW 645Ci
Fig. 185: Pressing Catches Together And Unclipping Brake Light Switch Holder From Bearing Block
61 31 330 REMOVING SWITCH FOR GLOVEBOX LIGHT
 64 1 020
Lever switch for glovebox light (1) with special tool 64 1 020 as pictured out of glovebox housing (2).
Unlock and disconnect associated plug connection, remove switch for glovebox light (1).
2005 BMW 645Ci
Fig. 186: Disconnecting Associated Plug Connection And Removing Switch For Glovebox Light
61 31 382 REPLACING LEVEL SWITCH FOR COOLANT
WARNING: Danger of scalding! Only perform this work after engine has cooled down.
Release screws (1).
Unlock plug connection for coolant level switch (4) and disconnect.
Pull coolant expansion tank (2) in direction of arrow out of grommet (3) underneath.
Installation:
2005 BMW 645Ci
If necessary, replace grommet (3).
IMPORTANT: Do not damage connected water hoses. Reposition coolant expansion tank (2)
as far as possible until coolant level switch (4) forms the highest point. This
will prevent coolant from escaping on opening. If necessary, catch escaping
coolant and feed back in later.
Fig. 187: Pulling Coolant Expansion Tank Out Of Grommet Underneath

NOTE: For purposes of clarity, illustration shows coolant expansion tank (2) removed.
Turn coolant level switch (1) in direction of arrow, pull upwards out of coolant expansion tank (2) and remove.
2005 BMW 645Ci
Fig. 188: Removing Coolant Level Switch Out Of Coolant Expansion Tank
61 31 470 REMOVING AND INSTALLING/REPLACING RELAY/MODULE
GLOVEBOX WITH HOUSING (WITHOUT ACTIVE KNEE PROTECTION) or 51 16 367
REMOVING AND INSTALLING RIGHT GLOVEBOX WITH HOUSING (WITH ACTIVE
KNEE PROTECTION) .
2005 BMW 645Ci
Detach relay (1).
Fig. 189: Detaching Relay (1)

61 31 492 REPLACING LEVEL SWITCH FOR WINDSCREEN WASHER SYSTEM
Release screws (1).
Detach cover (2) from front underride protection (3) and feed out in direction of arrow.
Remove cover (2).

2005 BMW 645Ci
Fig. 190: Detaching Cover From Front Underride Protection

E60, E61 with M aerodynamic kit only:
Catch any escaping washer fluid if necessary.
Turn level switch for windscreen washer system (2) in direction of arrow, pull down out of fluid reservoir (3)
and remove.
2005 BMW 645Ci
Fig. 191: Removing Turning Level Switch For Windscreen Washer System
All others:
Catch any escaping washer fluid if necessary.
Turn level switch for windscreen washer system (2) in direction of arrow, pull down out of fluid reservoir (3)
and remove.
2005 BMW 645Ci
Fig. 192: Removing Turn Level Switch For Windscreen Washer System
Installation:
Fill fluid tank for windscreen washer system.
61 31 996 CARRY OUT STEERING ANGLE SENSOR ADJUSTMENT
IMPORTANT: In vehicles with active front steering, steering angle sensor adjustment is
integrated in the service function "Initial operation/adjustment for active front
steering" and must not be carried out separately! Refer to 32 10 005
ADJUSTMENT FOR ACTIVE FRONT STEERING .
NOTE: Steering angle sensor adjustment must be carried out:
 after adjustment work on the front axle/steering

2005 BMW 645Ci
 after all mechanical work on the steering system

 after the following components have been replaced/coded:
 Steering column switch cluster
 DSC control unit
 ARS control unit
Connect vehicle to BMW diagnosis system. Select and carry out steering angle sensor adjustment under Service
functions.
HORN
61 33 060 REMOVING AND INSTALLING/REPLACING BOTH FANFARE HORNS
 Remove front right wheel arch trim, refer to 51 71 040 REMOVING AND
Release nut (2) and remove low-pitch fanfare horn (3).
Release nut (4) and remove high-pitch fanfare horn (5) with retaining plate.
2005 BMW 645Ci
Fig. 193: Releasing Nut And Removing High-Pitch Fanfare Horn With Retaining Plate
ECUS MODULES
32 43 010 REMOVING AND INSTALLING / REPLACING CONTROL UNIT FOR ACTIVE FRONT
STEERING
DISCHARGE).
IMPORTANT: Do not kink floor panelling under any circumstances!
After installation:
2005 BMW 645Ci
 Replacement/coding only: Carry out adjustment for active front steering, refer to 32 10 005
ADJUSTMENT FOR ACTIVE FRONT STEERING .
 Remove right entrance strip, refer to 51 47 000 REMOVING AND INSTALLING/REPLACING

FRONT (INSIDE) LEFT OR RIGHT ENTRANCE COVER STRIP .
 Remove right front seat, refer to 52 14 000 REMOVING AND INSTALLING LEFT OR RIGHT
FRONT SEAT (NORMAL/ELECTRIC) or 52 16 000 REMOVING AND INSTALLING FRONT
SEAT (SPORTS/ELECTRIC), LEFT OR RIGHT .
 If necessary, remove front right floor mat
 Remove side trim in front right footwell, refer to 51 43 075 REMOVING AND
INSTALLING/REPLACING SIDE TRIM PANEL, FOOTWELL, ON A-PILLAR, RIGHT .
 Fold back front right floor trim
 Remove kickplate in footwell in front of and next to control unit; if necessary, cut along specified lines
with knife and secure later with adhesive tape
Release screws (1).

TORQUES - 645CI .
Lay grounding cable to one side.
Installation:
Secure grounding cable as illustrated to retaining plate.

2005 BMW 645Ci
Fig. 194: Securing Grounding Cable To Retaining Plate

Raise active front steering control unit and turn over.
Remove active front steering control unit.

2005 BMW 645Ci
Fig. 195: Unlocking And Removing Connector

61 35 .. OVERVIEW OF CONTROL UNITS

2005 BMW 645Ci
Fig. 196: Identifying Control Unit Locations

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:
2005 BMW 645Ci
 E - Electro
 S - Static
 D - Discharge
Statically charged persons can discharge by touching electrical components.
NOTE: Humans can only detect a discharge starting from a level of approx. 3000 V.
The danger threshold for electrical components already starts from a level of approx. 100 V.
Fig. 197: Identifying Discharge By Touching Electrical Components

IMPORTANT: Do not touch pins or multi-pin connectors directly! Touch electrical

components by their housings only.
2005 BMW 645Ci
Fig. 198: Do Not Touch Pins Or Multi-Pin Connectors Directly

IMPORTANT: To prevent electrical components from being damaged or destroyed by

electrostatic discharge, it is absolutely essential to comply with the following
instructions:
 When replacing electrical components, leave the replacement

components in their original packaging until immediately before they are
to be installed
 If necessary, always return a removed component in its original
packaging (always pack the component away immediately)
 Read and comply with user information on using the associated ESD
special tool 12 7 060
61 35 015 REMOVING AND INSTALLING (REPLACING) CONTROL UNIT FOR CAR ACCESS
SYSTEM
DISCHARGE).
2005 BMW 645Ci
IMPORTANT: Carefully unlock and disconnect associated plug connection for ribbon cable
(1). Replace ribbon cable (1) if:
 plug connection for ribbon cable (1) is damaged

 control unit for Car Access System (3) is replaced
The ribbon cable leads to the ignition starter switch, refer to 61 31 020 REMOVING AND
INSTALLING/REPLACING IGNITION STARTER SWITCH.
Release screw (4) and remove control unit for Car Access System (3) in direction of arrow.

Installation:
Feed guide (1) of control unit for Car Access System (2) correctly into associated mounting.
2005 BMW 645Ci
Fig. 200: Feeding Guide Of Control Unit For Car Access System Correctly Into Associated Mounting
Replacement:
Version with independent heating:
Initialize all independent heating remote controls, refer to 64 12 ... INITIALIZING INDEPENDENT
HEATING REMOTE CONTROL .
61 35 030 REMOVING AND INSTALLING (REPLACING) POWER MODULE
DISCHARGE).
2005 BMW 645Ci

Unclip electric lead (1) at point (2).
Pull power module (3) slightly out of mounting for control units (4).
Remove power module (3).
Fig. 201: Unclipping Electric Lead And Pulling Power Module Out Of Mounting For Control Units
Replacement:
2005 BMW 645Ci
61 35 125 REMOVING AND INSTALLING/REPLACING BODY MODULE
DISCHARGE).

 Detach airbag control unit with gateway module
Unlock catches (3) in direction of arrow and remove body module (2) from equipment carrier (4).
2005 BMW 645Ci
Fig. 202: Removing Body Module

Replacement:
61 35 177 REMOVING AND INSTALLING (REPLACING) RAIN/LIGHT SENSOR
DISCHARGE).
Expand two-part mirror base cover (1) by pressing from below and detach.
Feed out two-part mirror base cover (1) and remove.

2005 BMW 645Ci
NOTE: Catches of two-part mirror base cover (1) must not be damaged.
Fig. 203: Removing Two-Part Mirror Base Cover

Press locks (1) in direction of arrow and remove rain/light sensor (2) towards bottom.
Installation:
Do not damage optical element covered by rain/light sensor (2).
If necessary, initialize rain/light sensor, refer to 61 35 679 INITIALIZING RAIN/LIGHT SENSOR.

2005 BMW 645Ci
Fig. 204: Pressing Locks And Removing Rain/Light Sensor Towards Bottom
Replacement:
61 35 220 REMOVING AND INSTALLING (REPLACING) CONTROL UNIT FOR LEFT OR RIGHT
FRONT DOOR
DISCHARGE).
2005 BMW 645Ci
Release screws (2).
If necessary, unclip electric leads at point (3).
Remove control unit in front door (4).
Fig. 205: Removing Control Unit For Left Or Right Front Door
Replacement:
61 35 285 REMOVING AND INSTALLING (REPLACING) LIGHT MODULE

2005 BMW 645Ci

DISCHARGE).
Unlock catch (1) and feed out/remove light module (2) in direction of arrow.
Installation:
Make sure light module (2) is correctly seated in mounting (3) and catch (1).
Fig. 206: Removing Light Module

2005 BMW 645Ci
Replacement:
61 35 679 INITIALIZING RAIN/LIGHT SENSOR
NOTE: Initialization is necessary:
 After replacing windshield

 When installing a used rain/light sensor
NOTE:  Connect BMW diagnosis system

 Initialize rain/light sensor.
61 35 714 REMOVING AND INSTALLING/REPLACING ELECTRONIC CONTROL UNIT FOR

SLIDE/TILT SUNROOF (PANORAMIC GLASS SUNROOF)
DISCHARGE).
 Remove trim for instrument panel at bottom right, refer to 51 45 181 REMOVING AND
Open lock (1) and pull back control unit for slide/tilt sunroof (2).
Unlock and disconnect plug connections (3) and remove control unit for slide/tilt sunroof (2).
2005 BMW 645Ci
Fig. 207: Removing Electronic Control Unit For Slide/Tilt Sunroof

Installation:

Replacement:
IMPORTANT: There is a risk of permanent battery discharge if programming/coding is not

carried out!
61 35 795 REMOVING AND INSTALLING (REPLACING) CONTROL UNIT FOR ADAPTIVE

HEADLIGHT
2005 BMW 645Ci
DISCHARGE).
Unlock catch (1) in direction of arrow.
Pull control unit for adaptive headlight (2) out of equipment carrier (3) slightly.
Remove control unit for adaptive headlight (2).

2005 BMW 645Ci
Replacement:
61 35 900 REMOVING AND INSTALLING/REPLACING RING ANTENNA OF ELECTRONIC

IMMOBILIZER
 61 3 300
Position special tool 61 3 300 as illustrated with flattened side (A) to ring antenna of electronic immobilizer (2).
Lever out ring antenna of electronic immobilizer (2) in direction of arrow and remove.
2005 BMW 645Ci
Fig. 209: Removing Ring Antenna Of Electronic Immobilizer

61 35 950 REMOVING AND INSTALLING (REPLACING) CONTROL UNIT FOR COMFORT

ACCESS SYSTEM
DISCHARGE).
NOTE: The comfort access system is a radio-based system and can be interfered with
by radio waves from other systems (e.g. mobile phone).
2005 BMW 645Ci

Unlock catch (2) in direction of arrow and remove control unit for comfort access system (3) from device
carrier (4).
Fig. 210: Removing And Installing Control Unit For Comfort Access System
Installation:
Make sure control unit (3) is correctly seated in device carrier (4).
Replacement:
2005 BMW 645Ci
61 35 953 REMOVING AND INSTALLING/REPLACING INTERIOR ANTENNA FOR COMFORT

ACCESS SYSTEM (FRONT)
 Remove switch for hazard warning system/central locking, refer to 61 31 079 REMOVING AND
INSTALLING/REPLACING SWITCH FOR HAZARD WARNING SYSTEM/CENTRAL
LOCKING.
 Remove center fresh air grill, refer to 64 22 165 REMOVING AND INSTALLING/REPLACING
CENTER FRESH-AIR GRILL .
 Remove driving dynamics switch, refer to 61 31 287 REMOVING AND INSTALLING/REPLACING
DRIVING DYNAMICS SWITCH.
CENTER CONSOLE .
 Remove rear seat, refer to 52 24 005 REMOVING AND INSTALLING OR REPLACING REAR
SEAT .
 Remove rear cup holder, refer to 51 16 204 REMOVING AND INSTALLING/REPLACING REAR
CUP HOLDER .
 Remove storage compartment, refer to 51 16 200 REMOVING AND INSTALLING STORAGE
COMPARTMENT .
Version with telephone:
 Disconnect plug for eject box, refer to 84 11 610 REMOVING AND INSTALLING/REPLACING
EJECT BOX (CORDLESS KEYPAD HANDSET) .
Release screws (1).
Remove interior antenna for comfort access system (3).

2005 BMW 645Ci
Fig. 211: Removing And Installing Interior Antenna For Comfort Access System (Front)
61 35 954 REMOVING AND INSTALLING/REPLACING INTERIOR ANTENNA FOR COMFORT

ACCESS SYSTEM (REAR)
LOCKING.
 Remove center fresh air grill, refer to 64 22 165 REMOVING AND INSTALLING/REPLACING
CENTER FRESH-AIR GRILL .
 Remove driving dynamics switch, refer to 61 31 287 REMOVING AND INSTALLING/REPLACING
2005 BMW 645Ci
DRIVING DYNAMICS SWITCH.

CENTER CONSOLE .
SEAT .
 Remove rear cup holder, refer to 51 16 204 REMOVING AND INSTALLING/REPLACING REAR
CUP HOLDER .
COMPARTMENT .
Version with telephone:
 Disconnect plug for eject box, refer to 84 11 610 REMOVING AND INSTALLING/REPLACING
EJECT BOX (CORDLESS KEYPAD HANDSET) .
Release screws (1).

2005 BMW 645Ci
Fig. 212: Removing And Installing Interior Antenna For Comfort Access System (Rear)
61 35 965 REMOVING AND INSTALLING/REPLACING REAR PARCEL ANTENNA FOR

COMFORT ACCESS SYSTEM
 Remove both trims for roof pillar at rear, refer to 51 43 251 REMOVING AND
(CPILLAR) .
SEAT .
 Remove both rear head restraints, refer to 52 24 390 REMOVING AND INSTALLING /
 Remove armrest for rear seat backrest, refer to 52 24 030 REMOVING AND INSTALLING
COMPLETE ARMREST FOR REAR SEAT BACKREST .
 Remove backrest, refer to 52 24 010 REMOVING AND INSTALLING / REPLACING
2005 BMW 645Ci
 Remove both trims for door pillar at top, refer to 51 43 148 REMOVING AND INSTALLING OR
REPLACING TRIM ON LEFT OR RIGHT DOOR PILLAR (TOP) .
 Remove both trims on armrest of side trim, refer to 51 43 ... REMOVING AND
INSTALLING/REPLACING TRIM ON ARMREST OF LEFT OR RIGHT SIDE TRIM PANEL .
 Remove both side trim panels at rear, refer to 51 43 002 REMOVING AND INSTALLING REAR
LEFT OR RIGHT SIDE TRIM PANEL .
 Remove panel for rear window shelf, refer to 51 46 006 REMOVING AND
INSTALLING/REPLACING TRIM FOR REAR PARCEL SHELF .
Release screws (1).
Fig. 213: Removing And Installing Rear Parcel Antenna For Comfort Access System
2005 BMW 645Ci
61 35 970 REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT ANTENNA

FOR COMFORT ACCESS SYSTEM
 Remove control unit cover
Pull luggage compartment antenna (2) for comfort access system from control unit receptacle (3).
Fig. 214: Removing And Installing Luggage Compartment Antenna For Comfort Access System
61 35 975 REMOVING AND INSTALLING/REPLACING BUMPER ANTENNA FOR COMFORT

ACCESS SYSTEM
2005 BMW 645Ci
TRIM .
Press catches (1), feed out bumper antenna for comfort access system (3) in direction of arrow and remove.
Fig. 215: Removing And Installing Bumper Antenna For Comfort Access System
64 11 970 REPLACING FOGGING SENSOR

2005 BMW 645Ci
 00 9 317
 Remove two-part mirror base cover, refer to 61 35 177 REMOVING AND INSTALLING
(REPLACING) RAIN/LIGHT SENSOR.
WARNING: Make sure rooms are well ventilated when working with adhesive remover
indoors.
IMPORTANT: Do not under any circumstances use paint thinner to clean the bonding
surface.
NOTE: If necessary, carefully heat fogging sensor (2) with a hot air blower to approx.
40-60°C.
Lift off fogging sensor (2) with special tool 00 9 317 and slowly pull off from windshield.
2005 BMW 645Ci
Fig. 216: Disconnecting Plug Connection And Lifting Off Fogging Sensor (2) With Special Tool 00 9 317
Installation:
Bonding surface must be dry and free of dust and grease.
Clean bonding surface with adhesive remover.
After cleaning, do not touch bonding surface with bare hands.
Pull off protective film completely from fogging sensor (3).
Place mounting template (1) as pictured on rain sensor (2).
Press fogging sensor (3) in direction of arrow with a contact pressure of less than or equal to 15 N/cm2 onto
inside of windshield.
2005 BMW 645Ci
NOTE: Firm thumb pressure attains approx. 30 N/cm2 .
Remove mounting template (1) carefully from fogging sensor (3).
Fig. 217: Removing Mounting Template From Fogging Sensor

RA DIAGNOSIS PROGRAMMING/CODING

RELAYS
2005 BMW 645Ci
61 13 ... RELAY CARRIER
Place special tool 61 1 153 on relay carrier (1) and carefully pull in direction of arrow until retaining lugs (2) on
relay carrier are raised.
Fig. 218: Identifying Relay Carrier And Retaining Lugs

2005 BMW 645Ci
Pull relay carrier (2) in direction of arrow into first catch (3).
Fig. 219: Pulling Relay Carrier Into First Catch

Press down arrester hook (4) of appropriate contact and pull out cable with contact.
Press out double flat spring contact with special tool 61 1 136 or 61 1 137 (ejector).
2005 BMW 645Ci
Fig. 220: Pressing Down Arrester Hook Of Appropriate Contact And Pulling Out Cable With Contact
61 31 470 REMOVING AND INSTALLING/REPLACING RELAY/MODULE
For Removing and installing/replacing relay/module, refer to 61 31 470 REMOVING AND

INSTALLING/REPLACING RELAY/MODULE.
WINDSCREEN WIPERS
61 61 ... OVERVIEW OF WINDOW WIPER SYSTEMS
2005 BMW 645Ci
Fig. 221: Identifying Window Wiper System Components

61 61 041 REPLACING BOTH WINDSHIELD WIPER BLADES
IMPORTANT: The windshield wiper arms can only be folded away approx. 45° from the
windshield. Make sure the wiper arm does not contact the windshield without
its wiper blade.
Fold wiper arm (1) away from windshield.
Press lock (2) and remove wiper blade (3) in direction of arrow.
Installation:
Make sure wiper blade (3) is correctly seated.

2005 BMW 645Ci
Fig. 222: Pressing Lock And Removing Wiper Blade

Fold wiper arm back onto windshield.
61 61 101 REMOVING AND INSTALLING BOTH WINDSHIELD WIPER ARMS
 61 6 060
IMPORTANT: Do not damage wiper arms when removing (risk of breakage).
Installation:
2005 BMW 645Ci
Adjust the position of the relevant wiper arm in the wiper rest position.
Measure distance between wiper lip (1) and top edge of cowl panel cover (3) at mounting point (2) of wiper
blade.
Adjustment measurements:
 A: 87 +/- 3 mm
 B: 69 +/- 3 mm
Fig. 223: Measuring Distance Between Wiper Lip And Top Edge Of Cowl Panel Cover
Removing left wiper arm:
Unclip wiper arm cap (1) and remove in direction of arrow.

2005 BMW 645Ci
Fig. 224: Removing Unclipping Wiper Arm Cap

Installation:
Catches (1) of wiper arm cap (2) must not be damaged.
Make sure wiper arm cap (2) is correctly seated.

2005 BMW 645Ci
Fig. 225: Identifying Catches Of Wiper Arm Cap

Unscrew nut (1).
Installation:

TORQUES - 645CI .
IMPORTANT: Observe tightening specification (settling time) without fail (risk of detaching).
Remove wiper arm (2) in direction of arrow.

2005 BMW 645Ci
Fig. 226: Removing Wiper Arm

Pull off adjusting disk (1) with special tool 61 6 060.
Installation:
Replace adjusting disk (1).
Mount adjusting disk (1) together with wiper arm on shaft.
Check/adjust contact angle of wiper arms to windshield.

2005 BMW 645Ci
Fig. 227: Pulling Off Adjusting Disk With Special Tool 61 6 060
Removing right wiper arm:
Remove caps (1).

2005 BMW 645Ci
Fig. 228: Removing Caps

Unscrew nuts (1).

2005 BMW 645Ci
Fig. 229: Unscrewing Nuts

Installation:

TORQUES - 645CI .
IMPORTANT: Observe tightening specification (settling time) without fail (risk of detaching).
Detach wiper arm (1) as illustrated with special tool 61 6 060.

2005 BMW 645Ci
Fig. 230: Detaching Wiper Arm

Installation:
Check/adjust contact angle of wiper arms to windshield.
61 61 102 REPLACING BOTH WINDSHIELD WIPER ARMS
Remove both windshield wiper arms, refer to 61 61 101 REMOVING AND INSTALLING BOTH
WINDSHIELD WIPER ARMS.
NOTE: If necessary, fit wiper blades on new wiper arms, refer to 61 61 041 REPLACING
BOTH WINDSHIELD WIPER BLADES.
2005 BMW 645Ci
COMPLETELY WITH MOTOR
 Remove cowl panel cover.

 Remove tension strut on spring strut dome, refer to 51 71 373 REMOVING AND
 Remove fresh air duct, refer to 64 31 053 REMOVING AND INSTALLING OR REPLACING
FRESH AIR DUCT .
IMPORTANT: Before fitting windshield wiper arms, allow wiper motor to run into rest
position.
Release screws (1).
Installation:

TORQUES - 645CI .
Remove cross-strut bearing block (2) in direction of arrow.

2005 BMW 645Ci
Fig. 231: Removing Cross-Strut Bearing Block

Release screws (A5...A1).
Installation:
Insert screws (A1...A5) in specified sequence until hand-tight.
To tighten down screw (A2), if necessary move complete wiper console linkage (2) into reversal position.
Tighten down screws (A1...A5) in specified sequence to tightening torque, refer to 61 61 6AZ in GENERAL
2005 BMW 645Ci
Fig. 232: Disconnecting Plug Connection And Releasing Screws

Lever out complete wiper console (2) in direction of arrow.
HEADLIGHT WASHER SYSTEM

61 61 ... OVERVIEW OF WINDOW WIPER SYSTEMS
2005 BMW 645Ci
Fig. 233: Identifying Headlight Washer System Components

61 67 010 REMOVING AND INSTALLING/REPLACING WASHER PUMP OF HEADLIGHT

CLEANING SYSTEM
Release screws (1).
Remove cover (2).

2005 BMW 645Ci

NOTE: For purposes of clarity, illustration shows front wheel removed.
Unfasten screws.
Fold back wheel arch trim (1) slightly in direction of arrow.

2005 BMW 645Ci
Fig. 235: Folding Back Wheel Arch Trim

NOTE: Catch any escaping washer fluid if necessary.
Unlock hose (2) and detach from washer pump of headlight cleaning system (3).
Turn washer pump of headlight cleaning system (3) in direction of arrow and pull upwards out of fluid tank for
windshield washer system (4).
2005 BMW 645Ci
Fig. 236: Detaching Hose From Washer Pump Of Headlight Cleaning System
Installation:
 Replace strainer for washer pump of headlight cleaning system.

 If necessary, coat sealing ring of washer pump for headlight cleaning system with antiseize agent.
 Ensure hose is laid without kinks.
 Fill fluid tank for windscreen washer system.
61 67 040 ADJUSTING SPRAY NOZZLES FOR HEADLIGHT CLEANING SYSTEM
NOTE: The spray nozzles of the headlight cleaning system have been adjusted at the
factory and normally this setting is not altered (except by an accident). The
nozzles therefore do not have to be adjusted. The spray nozzles do not have to
be adjusted even in the event of replacement as the nozzles themselves and the
2005 BMW 645Ci
preset.
61 67 045 REMOVING AND INSTALLING/REPLACING SPRAY NOZZLES FOR LEFT OR RIGHT

HEADLIGHT CLEANING SYSTEM
TRIM .
Press lock (2) and detach hose connection (1).
Press catch together in direction of arrow and remove spray nozzle for headlight cleaning system (3) towards
bottom.
Fig. 237: Pressing Lock And Detaching Hose Connection

2005 BMW 645Ci
Unlock catches (1) of trim (3) through punched holes (2).
Remove trim (3) from above.
Fig. 238: Unlocking Catches Of Trim Through Punched Holes

Installation:
Following parts of spray nozzle (1) must not be damaged or missing:
2 Sealing ring
3 Catch
Catches (3) of trim (4) must not be damaged or missing.

2005 BMW 645Ci
Fig. 239: Identifying Sealing ring And Catch

WINDOW WASHER SYSTEM

61 71 015 REMOVING AND INSTALLING/REPLACING A JET NOZZLE IN WINDSHIELD
WASHER SYSTEM
NOTE: The jet nozzles of the windshield washer system are preset at the factory and
cannot be readjusted.
Unlock plug housing (2) and disconnect.
Detach connector (3) in direction of arrow from nozzle of windshield washer system (4).
2005 BMW 645Ci
Unlock nozzle of windshield washer system (4), press out through opening and remove.
Installation:
Make sure nozzle of windshield washer system (4) is correctly seated.
Ensure hose is laid without kinks.
Fig. 240: Removing Jet Nozzle In Windshield Washer System

61 71 061 REPLACING FLUID TANK FOR WINDSCREEN WASHER SYSTEM
 If necessary, remove front left wheel, refer to 36 10 300 REMOVING OR INSTALLING FRONT OR
REAR WHEEL .
2005 BMW 645Ci
INSTALLING/REPLACING WINDSCREEN WASHER PUMP.

 If necessary, remove washer pump for headlight cleaning system, refer to 61 67 010 REMOVING AND
INSTALLING/REPLACING WASHER PUMP OF HEADLIGHT CLEANING SYSTEM.
 Remove level switch, refer to 61 31 492 REPLACING LEVEL SWITCH FOR WINDSCREEN
WASHER SYSTEM.
Release screws (1).
Feed out air duct (2).
Fig. 241: Feeding Out Air Duct

Release screws (1).
Feed out fluid tank for windscreen washer system (2) slightly in direction of arrow.
2005 BMW 645Ci
Fig. 242: Feeding Out Fluid Tank For Windscreen Washer System
Detach associated filler hose from fitting on fluid tank.
Installation:
 Replace sealing rings and strainers of washer pumps.

 Coat sealing rings of washer pumps with antiseize agent.
 Lay lines of washer pumps without kinks and clip into holders on fluid tank.
61 71 100 REMOVING AND INSTALLING/REPLACING WINDSCREEN WASHER PUMP
Release screws (1).
2005 BMW 645Ci

Remove cover (2).
NOTE: For purposes of clarity, illustration shows front wheel removed.
Unfasten screws.
Fold back wheel arch trim (1) slightly in direction of arrow.

2005 BMW 645Ci
Fig. 244: Folding Back Wheel Arch Trim

NOTE: Catch any escaping washer fluid if necessary.
Detach hose (2) from windscreen washer pump (3).
Pull windscreen washer pump (3) up and out of fluid reservoir for windscreen washer system (4).
2005 BMW 645Ci
Fig. 245: Disconnecting Plug Connection And Detaching Hose From Windscreen Washer Pump
Installation:
 Replace strainer for windscreen washer pump.

 If necessary, coat sealing ring of windscreen washer pumps with antiseize agent.
 Ensure hose is laid without kinks.
 Fill fluid tank for windscreen washer system.
2006 BMW 650i
HVAC Air Conditioning & Heating Systems - Repair Instructions - E63
HVAC
Air Conditioning & Heating Systems - Repair Instructions - E63
HEATER WITH OPERATION

64 11 ... INSTALLING SERVODRIVE
Installation:
If necessary, align shaft of flap(s) to be actuated to position of servodrive to be installed.
Fig. 1: Identifying Servodrive

64 11 206 REMOVING AND INSTALLING OR REPLACING HEATER

2006 BMW 650i
 Draw off refrigerant from A/C system, refer to 64 50 009 DRAWING OFF, EVACUATING AND
FILLING A/C SYSTEM (R 134A).
 Remove instrument panel trim, refer to 51 45 030 REMOVING AND INSTALLING INSTRUMENT
PANEL TRIM .
 Remove temperature sensor for cold-air distributor, refer to 64 11 916 REPLACING TEMPERATURE
SENSOR FOR COLD-AIR DISTRIBUTOR.
 Remove control unit for Car Access System, refer to 61 35 015 REMOVING AND INSTALLING
(REPLACING) CONTROL UNIT FOR CAR ACCESS SYSTEM .
 In appropriate version:
 Remove head-up display, refer to 62 30 010 REMOVING AND INSTALLING/REPLACING
HEAD-UP DISPLAY .
WARNING: Cover protruding threaded pins, corner points and edges on support tube
to prevent injuries.
WARNING: Follow instructions for working on cooling system, refer to 17 00 ...

INSTRUCTIONS FOR WORKING ON COOLING SYSTEM. .
Unscrew nuts (1).
Installation:
Tightening torque, refer to 64 53 8AZ in HEATING AND AIR CONDITIONING - TIGHTENING

TORQUES - 645CI .
Detach refrigerant line (2) in direction of arrow.
Unclip refrigerant line (3).

2006 BMW 650i
Fig. 2: Detaching Refrigerant Line In Direction Of Arrow

WARNING:  When installing heater, make sure left and right air ducts are
correctly seated.
 Check left and right air ducts for leaks.
 If necessary, reseal left and right air ducts with butylene tape.
 If left and right air ducts are resealed, make sure air flaps can move
freely.
Feed out rubber grommet (1).
Installation:
Make sure rubber grommet (1) is correctly seated.

2006 BMW 650i
Fig. 3: Releasing Nut And Detach Refrigerant Lines And In Direction Of Arrow
Installation:
Tightening torque refer to 64 53 7AZ in HEATING AND AIR CONDITIONING - TIGHTENING

TORQUES - 645CI .
Replace sealing rings.
Release nuts (5) on right air duct.
Installation:

TORQUES - 645CI .
2006 BMW 650i
Installation:
Release spring clamps (2) and detach coolant hoses (3).
IMPORTANT: Carefully blow through aluminum triple pipe to remove remaining coolant from
heat exchanger for heating system.
Installation:
Vent cooling system and check for leaks, refer to 17 00 039 VENTING COOLING SYSTEM AND
CHECKING FOR LEAKS (N62) .
Release nuts (4) on left air duct.
Fig. 4: Releasing Nuts On Left Air Duct

2006 BMW 650i
Installation:

TORQUES - 645CI .
Remove soundproofing from left A-pillar (1) in direction of arrow.
Release screws (2).
Remove left air duct (4) in direction of cold-air distributor (3).
Fig. 5: Removing Left Air Duct In Direction Of Cold-Air Distributor

Remove soundproofing from right A-pillar (1) in direction of arrow.
Release screws (2).

2006 BMW 650i
Remove right air duct (4) in direction of cold-air distributor (3).
Fig. 6: Removing Soundproofing From Right A-Pillar

Carefully lever out locks (1) and (2).
Detach cold-air distributor (3) in direction of arrow.
Installation:
Make sure cold-air distributor (3) is correctly seated.

2006 BMW 650i
Fig. 7: Detaching Cold-Air Distributor

IMPORTANT: Follow instructions for handling optical fibers, refer to 61 00 ... NOTES ON
 Disconnect all necessary cable ties on support tube.

 Release wiring harnesses/cable ducts and lay to one side.
 If necessary, remove control units/disconnect plug connections.
Installation:
Make sure wiring harnesses/cable ducts are correctly routed and secured.
2006 BMW 650i
CD CHANGER .
Release screws (2).
Set fuse-carrier (3) down in footwell.
Fig. 8: Releasing Screws From CD Changer

2006 BMW 650i
Fig. 9: Removing Footwell Heater Ducts

Feed out footwell heater ducts (1) and remove.
Release screws (2), tightening torque, refer to 51 71 15AZ in BODY EQUIPMENT - TIGHTENING
TORQUES - 645CI .
Release screws (3), tightening torque, 21.4 N.m.
Release nuts (4), tightening torque, refer to 51 71 15AZ in BODY EQUIPMENT - TIGHTENING
TORQUES - 645CI .
Pull back support tube (5) and remove from vehicle with assistance of a second person.
If necessary, unlock and disconnect plug connections on heater (1).
Remove heater (1) in direction of arrow.

2006 BMW 650i
Fig. 10: Removing Heater In Direction Of Arrow

Installation:
Make sure heater (1) is correctly seated.
Installation:
Make sure condensate drain (1) is correctly seated in grommet (2) on both sides.
2006 BMW 650i
Fig. 11: Installing Condensate Drain Is Correctly Seated In Grommet On Both Sides
64 11 208 REPLACING HEATER CORE
 Remove heater.
Release screws (1).
Press lock (2) and remove cover (3) in direction of arrow.
Installation:
Ensure cover (3) is correctly seated.

2006 BMW 650i
Fig. 12: Ensuring Cover Is Correctly Seated

Pull out clips (1) in direction of arrow.
Installation:
Make sure clips (1) are correctly and firmly seated.
Pull pipes (2) out of heater core (3).
Installation:
Coat sealing rings with antiseize agent.

2006 BMW 650i
Pull out heater core (3) in direction of arrow.

Installation:
Make sure heater core (3) is correctly seated.
64 11 213 REMOVING AND INSTALLING/REPLACING HEATER - A/C UNIT FAN
GLOVEBOX WITH HOUSING (WITHOUT ACTIVE KNEE PROTECTION) .
2006 BMW 650i
 Remove bottom right instrument panel trim, refer to 51 45 181 REMOVING AND
COMPARTMENT .
 Remove audio system controller, refer to 65 12 200 REMOVING AND INSTALLING (REPLACING)
AUDIO SYSTEM CONTROLLER , remove Car Communication Computer, refer to 65 83 010
REMOVING AND INSTALLING/REPLACING CAR COMMUNICATION COMPUTER .
Remove middle function carrier (5) in direction of arrow.
Fig. 14: Removing Middle Function Carrier In Direction Of Arrow

Installation:
2006 BMW 650i
Make sure middle function carrier (5) is correctly seated.
Disconnect left air duct (1) in direction of arrow (2) and (3).
Fig. 15: Disconnecting Left Air Duct In Direction Of Arrow

Installation:
Make sure right air duct (1) is correctly seated.
Disconnect right air duct (1) in direction of arrow (2) and (3).
2006 BMW 650i
Fig. 16: Disconnecting Right Air Duct In Direction Of Arrow

Installation:
Make sure right air duct (1) is correctly seated.
Release screws (2).
Remove cover (3) in direction of arrow.
Installation:

2006 BMW 650i
Fig. 17: Ensuring Correct Cable Routing

Release screws (1).
Remove fan for heater - A/C unit (2) in direction of arrow.

2006 BMW 650i
Fig. 18: Removing Fan For Heater - A/C In Direction Of Arrow

Installation:
Make sure fan for heater - A/C unit (2) is correctly seated.
Replacement:
Unlock controller for heater - A/C unit fan (1) with a suitable screwdriver (2) and remove.

2006 BMW 650i
Fig. 19: Unlocking Controller For Heater - A/C Unit Fan With A Suitable Screwdriver
Installation:
Make sure controller for heater - A/C unit fan (1) is correctly seated.
64 11 225 REPLACING CONTROLLER FOR HEATER/AIR CONDITIONER FAN
 Removing and installing/replacing blower for heater/air conditioner, refer to 64 11 213 REMOVING
AND INSTALLING/REPLACING HEATER - A/C UNIT FAN.
64 11 262 REMOVING AND INSTALLING/REPLACING AUXILIARY WATER PUMP
WARNING: Danger of scalding! Only perform this work after engine has cooled down.
2006 BMW 650i

 Disconnect coolant hoses from auxiliary water pump.
Unlock fast-release couplings (1) and detach coolant hoses from auxiliary water pump (4).
Installation:
COOLING SYSTEM. .
Fill and vent cooling system, refer to 17 00 005 DRAINING AND ADDING COOLANT (N62) .
2006 BMW 650i
Installation:
Remove auxiliary water pump (4) in direction of arrow.
Replacement:
Detach auxiliary water pump fixture (1) in direction of arrow from auxiliary water pump (2).
Fig. 21: Detaching Auxiliary Water Pump Fixture

2006 BMW 650i
Installation:
Make sure auxiliary water pump (2) is correctly seated in auxiliary water pump fixture (1).
64 11 274 REPLACING WATER VALVE FOR HEATER

 Disconnect coolant hoses from water hose for heater.
Release spring clamps (2) and detach coolant hoses.
Pull out water valve for heater (3) towards top.

2006 BMW 650i
Installation:
Fill and vent cooling system, refer to 17 00 005 DRAINING AND ADDING COOLANT (N62) .
Installation:
Make sure water valve (1) is correctly seated in grommets (2) and rubber mount (3).
If necessary, replace grommets (2) and rubber mount (3).
Fig. 23: Replacing Grommets And Rubber Mount

64 11 324 REPLACE THE BUTTON CAPS FOR THE HEATER CONTROLS (E60/E61 FROM
03/2007, E63/E64 FROM 09/2007)
2006 BMW 650i
 Remove control panel for heating - air conditioning.
Turn temperature selector wheel (1) to stop (arrow).
Fig. 24: Turn Temperature Selector Wheel (1) To Stop (Arrow)

NOTE: Air flow control (2) has no end stop.
Unclip the protective cap (1) of the temperature selector wheels and air flow controller with button cap (2) in
direction of arrow.
Fig. 25: Unclip The Protective Cap (1) Of The Temperature Selector Wheels
Installation note: Clip protective cap (1) of the left temperature selector wheel in with mark pointing to the left
(arrow). Clip the protective cap of the right temperature selector wheel in with mark pointing to the right.
2006 BMW 650i
Fig. 26: Clip Protective Cap (1) Of The Left Temperature Selector Wheel In With Mark Pointing To The
Left (Arrow)
Installation note: Mark (1) must be aligned with mark (2) of the protective cap of the air flow controller (3).
Protective cap must audibly snap into place.
Fig. 27: Mark (1) Must Be Aligned With Mark (2) Of The Protective Cap Of The Air Flow Controller (3)
Set included special tool (2) onto the switch block (1) as shown. Press the special tool to the stop onto the
switch block. Carefully pull both switch blocks (1) out with special tool (2).
NOTE: If applicable, the switch springs located behind the switch block will fall out
when pulling out the switch block.
2006 BMW 650i
Fig. 28: Carefully Pull Both Switch Blocks (1) Out With Special Tool (2)
Carefully insert the switch springs (1) into the inlet (2) of the switch block (3) as shown. Carefully clip switch
blocks (3) into the operating unit of the air conditioning.
Installation note: The repair kit includes 7 switch springs. However, only 5 switch springs will be installed.
The switch spring positions may not be changed during installation. Check buttons and switch springs for
function.
Fig. 29: Carefully Insert The Switch Springs (1) Into The Inlet (2) Of The Switch Block (3)
Installation note: The springs must be inserted in the left switch block as shown.
2006 BMW 650i
Fig. 30: Springs Must Be Inserted In The Left Switch Block As Shown
Installation note: The springs must be inserted in the right switch block as shown.
Fig. 31: Springs Must Be Inserted In The Right Switch Block As Shown
Check function of the heating and air conditioning system.
64 11 377 REMOVING AND INSTALLING (REPLACING) CONTROL PANEL FOR HEATER - A/C
SYSTEM
DISCHARGE) .

2006 BMW 650i
Release screws (1).
Unclip control panel for heater - A/C system (2) all round and remove from middle trim for instrument panel
(3).
Fig. 32: Unclipping Control Panel For Heater - A/C System

64 11 803 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR LEFT FRESH-

AIR/REIRCULATED-AIR FLAP
2006 BMW 650i
REPLACING EVAPORATOR TEMPERATURE SENSOR.
Press lock (2) and pull out servodrive for left fresh-air/ recirculated-air flap (3) in direction of arrow.
Fig. 33: Removing Servo Drive

Installation:
Follow repair instruction "Installing servodrive", refer to 64 11 ... INSTALLING SERVODRIVE.
Servodrive for left fresh-air/recirculated-air flap (3) must snap audibly into place.
64 11 808 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR RIGHT FRESH-

AIR/RECIRCULATED AIR FLAP
2006 BMW 650i
 Remove bottom right trim panel from instrument panel, refer to 51 45 181 REMOVING AND
Press lock (2) and pull out servodrive for right fresh-air/ recirculated-air flap (3) in direction of arrow.
Fig. 34: Pulling Out Servodrive For Right Fresh-Air/ Recirculated-Air Flap
Installation:
Servodrive for right fresh-air/recirculated-air flap (3) must snap audibly into place.
2006 BMW 650i
64 11 830 REPLACING SERVODRIVE FOR LEFT VENTILATION FLAP
 Remove air distributor in footwell and heating duct in rear compartment on left, refer to 64 11 943
Press lock (2) and pull out servodrive for left ventilation flap (3) in direction of arrow.
Fig. 35: Pulling Out Servodrive For Left Ventilation Flap In Direction
Installation:
2006 BMW 650i
Servodrive for left ventilation flap (3) must snap audibly into place.
64 11 832 REPLACING SERVODRIVE FOR RIGHT VENTILATION FLAP
PANEL TRIM .
Fig. 36: Removing Instrument Panel Trim

Press lock (2) and pull out servodrive for right ventilation flap (3) in direction of arrow.
2006 BMW 650i
Installation:
Servodrive for right ventilation flap (3) must snap audibly into place.
64 11 840 REPLACING SERVODRIVE FOR LEFT FOOTWELL FLAP
 Remove trim for instrument panel, refer to 51 45 030 REMOVING AND INSTALLING
INSTRUMENT PANEL TRIM .
Press lock (1) and unclip servodrive for left footwell flap (2) in direction of arrow.

2006 BMW 650i
Installation:
64 11 842 REPLACING SERVODRIVE FOR RIGHT FOOTWELL FLAP
 Remove trim for instrument panel, refer to 51 45 030 REMOVING AND INSTALLING
INSTRUMENT PANEL TRIM .
Press lock (1) and unclip servodrive for right footwell flap (2) in direction of arrow.

2006 BMW 650i
Installation:
64 11 869 REPLACING SERVODRIVE OF STRATIFICATION FLAP
 Remove air distributor in footwell and air duct at side, refer to 64 11 943 REPLACING
EVAPORATOR TEMPERATURE SENSOR.
Press lock (2) and pull out servodrive for stratification flap (3) in direction of arrow.
Fig. 39: Removing Right Glovebox With Housing

Installation:
2006 BMW 650i
Servodrive for stratification flap (3) must snap audibly into place.
64 11 875 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR DEFROSTING FLAP
 Remove air distributor in footwell and heating duct in rear compartment on left, refer to 64 11 943
Press lock (1) and pull out servodrive for defrosting flap (2) in direction of arrow.
Fig. 40: Removing Trim Panel For Pedal Assembly

2006 BMW 650i
Installation:
Servodrive for defrosting flap (2) must snap audibly into place.
64 11 902 REPLACING SENSOR FAN FOR INTERIOR TEMPERATURE
 Remove control panel for heater - A/C system.
Release screws (1).
Pull out sensor blower for interior temperature (2) in direction of arrow.
Installation:
Make sure pins (3) are correctly seated in base (4).

2006 BMW 650i
Fig. 41: Removing Control Panel For Heater - A/C System

64 11 912 REMOVING AND INSTALLING/REPLACING TEMPERATURE SENSOR FOR HEATING

UNIT
 Remove on-board monitor, refer to 65 82 050 REMOVING AND INSTALLING (REPLACING)

ONBOARD MONITOR .
Unlock plug connection (1) on left/right and disconnect.
Pull out temperature sensor for heating unit in direction of arrow out of heating unit (2).
2006 BMW 650i
Fig. 42: Removing On-Board Monitor

Installation:
Make sure temperature sensor for heating unit is correctly seated.
64 11 916 REPLACING TEMPERATURE SENSOR FOR COLD-AIR DISTRIBUTOR
 Remove audio system controller, refer to 65 12 200 REMOVING AND INSTALLING (REPLACING)
AUDIO SYSTEM CONTROLLER , remove Car Communication Computer, refer to 65 83 010
REMOVING AND INSTALLING/REPLACING CAR COMMUNICATION COMPUTER .

2006 BMW 650i
Turn temperature sensor for cold-air distributor (1) counterclockwise, feed out towards bottom and remove.
If necessary, release screws (3) and (4).
Pull back center function carrier (5) at top slightly.
Fig. 43: Removing Audio System Controller

Installation:
Make sure temperature sensor for cold-air distributor (1) is correctly seated.
64 11 943 REPLACING EVAPORATOR TEMPERATURE SENSOR

2006 BMW 650i
Release screw (1).
Detach heating duct in rear compartment on left (2) in direction of arrow from air distributor in footwell (3).
Fig. 44: Detaching Heating Duct In Rear Compartment On Left

Pull out air distributor in footwell (3) in direction of arrow.
Installation:
Make sure heating duct in rear compartment on left (2) and air distributor in footwell (3) are correctly seated.
Unscrew bolt (1).

2006 BMW 650i
Fig. 45: Pulling Out Heating Duct In Rear Compartment On Left

Installation:
Make sure heating duct in rear compartment on left (2) is correctly seated.
Pull out evaporator temperature sensor (2) in direction of arrow and feed out.
2006 BMW 650i
Fig. 46: Pulling Out Evaporator Temperature Sensor

Installation:
Ensure evaporator temperature sensor (2) is correctly seated.
64 11 970 REPLACING FOGGING SENSOR
NOTE: For special tools, refer to HEATING & AIR CONDITIONING - SPECIAL TOOLS -
645CI (E63) .
 00 9 317

2006 BMW 650i
 Remove two-part mirror base cover, refer to 61 35 177 REMOVING AND INSTALLING
(REPLACING) RAIN/LIGHT SENSOR .
WARNING: Make sure rooms are well ventilated when working with adhesive remover
indoors.
IMPORTANT: Do not under any circumstances use paint thinner to clean the bonding
surface.
NOTE: If necessary, carefully heat fogging sensor (2) with a hot air blower to approx.
40-60°C.
Lift off fogging sensor (2) with special tool 00 9 317 and slowly pull off from windshield.
2006 BMW 650i
Fig. 47: Lifting Off Fogging Sensor (2) With Special Tool 00 9 317 And Slowly Pulling Off From
Windshield
Installation:
Bonding surface must be dry and free of dust and grease.
After cleaning, do not touch bonding surface with bare hands.
Pull off protective film completely from fogging sensor (3).
Place mounting template (1) as pictured on rain sensor (2).
Press fogging sensor (3) in direction of arrow with a contact pressure of °15 N/cm2 onto inside of windshield.
NOTE: Firm thumb pressure attains approx. 30 N/cm2 .
Remove mounting template (1) carefully from fogging sensor (3).

2006 BMW 650i
Fig. 48: Installing Fogging Sensor

64 11 991 REMOVING AND INSTALLING/REPLACING SENSOR FOR AUTOMATIC

RECIRCULATED AIR CONTROL
Feed out sensor for automatic recirculated air control (2) in direction of arrow and remove.
2006 BMW 650i
Fig. 49: Removing Automatic Recirculated Air Control

Installation:
Make sure sensor for automatic recirculated air control (2) is correctly seated.
64 11 992 REMOVING AND INSTALLING/REPLACING SOLAR SENSOR
 Remove speaker frame from trim for instrument panel at top, refer to 51 45 115 REMOVING AND
INSTALLING SPEAKER FRAME ON PANEL FOR INSTRUMENT PANEL AT TOP .
Unlock catches (1) in direction of arrow and remove solar sensor (2) from speaker frame (3).
2006 BMW 650i
Fig. 50: Unlocking Catches (1) In Direction Of Arrow And Removing Solar Sensor (2) From Speaker
Frame (3)
Installation:
Catches (1) on speaker frame (3) must not be damaged.
Make sure solar sensor (2) is correctly seated in speaker frame (3).
AUXILIARY HEATER WITH CONTROL ELEMENTS

64 12 ... INITIALIZING INDEPENDENT HEATING REMOTE CONTROL
The following steps are required for initializing a new independent heating remote control or after replacing the
Car Access System control unit:
2006 BMW 650i
b. Within 5 seconds: Switch ignition lock from terminal "0" to terminal "R" and then back to terminal "0".
c. Press and hold down "OFF" button on independent heating remote control.
d. Press "ON" button on independent heating remote control 3 times in succession
The vehicle's central locking closes and opens automatically on successful initialization.
NOTE: Both independent heating remote controls must be reinitialized after the Car
Access System control unit has been replaced.
64 12 ... REPLACING BURNER INSERT FOR INDEPENDENT HEATER
Carry out following tasks after engine and independent heater have
cooled down.
IMPORTANT: The burner insert may only be replaced after the 24-month warranty period has
elapsed.
The entire independent heater must be replaced during the warranty period
 Remove complete independent/auxiliary heater.
Release screws (1) and remove bracket (2) from heater. Tightening torque, see 64 12 2AZ in 12 AUXIL.
HEATER WITH CONTROL ELEMENTS .
Fig. 51: Release Screws (1) And Remove Bracket (2) From Heater
2006 BMW 650i
Release hose clamp (1) on hose for circulating pump and disconnect hose. Release hose clamp (2) on intake
filter hose and disconnect hose.
Installation: Check all water hoses for damage, replace if necessary.
Fig. 52: Release Hose Clamp (1) On Hose For Circulating Pump
Carefully lift cover (1) off heater.
Fig. 53: Carefully Lift Cover (1) Off Heater


2006 BMW 650i


Release screws (1). Tightening torque, see 64 12 3AZ in 12 AUXIL. HEATER WITH CONTROL
ELEMENTS . Replace all screws. Carefully lift out combustion air blower unit (2).
2006 BMW 650i
Fig. 56: Carefully Lift Out Combustion Air Blower Unit (2)
Release screws (1) and pull out burner insert (3) with grommet (2). Replace all screws. Tightening torque, see
64 12 4AZ in 12 AUXIL. HEATER WITH CONTROL ELEMENTS .
Installation: Make sure grommet (2) is in correct installation position.
Fig. 57: Ensure Grommet (2) Is In Correct Installation Position

Installation:
 Replace seals (1, 2) and clean sealing surfaces thoroughly.

 If necessary, remove soot deposits.
 To prevent the fuel pipe on the burner element being damaged, coat seal (2) with spirit when fitting
housing.
2006 BMW 650i
Fig. 58: Replace Seals (1, 2) And Clean Sealing Surfaces

After installation: Fill and vent cooling system and check for leaks
64 12 120 REMOVING AND INSTALLING/REPLACING INTAKE MUFFLER FOR

INDEPENDENT/AUXILIARY HEATER
 Remove left front wheel, refer to 36 10 300 REMOVING OR INSTALLING FRONT OR REAR
WHEEL .
 Remove front left wheel arch lining, refer to 51 71 040 REMOVING AND
 Remove left underbody paneling.
Disconnect plug connections (1) and (2).
IMPORTANT: To avoid damaging the independent heater, it is absolutely essential to adhere

to the following connecting sequence for the plug connections during
installation:
1. Plug connection (1)

2. Plug connection (2)
Release screws (3).
Fold independent heater (4) in direction of arrow to one side.

2006 BMW 650i
Fig. 59: Removing Left Underbody Paneling

Installation:
Make sure exhaust pipe of independent heater (4) is correctly seated in muffler (5).
Detach cable strap (1).
Release spring clip (2) and detach corrugated tube from independent/auxiliary heater.
Remove intake muffler for independent/auxiliary heater (3).

2006 BMW 650i
Fig. 60: Releasing Spring Clip And Detach Corrugated Tube From Independent/Auxiliary Heater
NOZZLE AND OUTLETS

64 22 137 REMOVING AND INSTALLING/REPLACING LEFT FRESH-AIR GRILL
645CI (E63) .
 64 1 020
Lever out nozzle (1) at retaining points (2) and remove.

2006 BMW 650i
Fig. 61: Levering Out Nozzle (1) At Retaining Points (2)

Unscrew bolt (1).
Hook special tool 64 1 020 into left fresh-air grill (2).
Unclip left fresh-air grill (2) towards rear and pull back.
Unlock and disconnect associated plug connection, remove left fresh-air grill (2).
2006 BMW 650i
Fig. 62: Hooking Special Tool 64 1 020 Into Left Fresh-Air Grill (2)
Replacement:
Remove lighting control unit, refer to 61 31 037 REMOVING AND INSTALLING/REPLACING

LIGHTING CONTROL UNIT .
64 22 138 REMOVING AND INSTALLING/REPLACING RIGHT FRESH-AIR GRILL
 Remove decorative strip on instrument panel on right, refer to 51 45 380 REMOVING AND
INSTALLING (REPLACING) RIGHT DECORATIVE STRIP ON INSTRUMENT PANEL .
Release screws (1).

2006 BMW 650i
Fig. 63: Releasing Screws (1) And Pulling Back Right Fresh-Air Grill (2)
64 22 165 REMOVING AND INSTALLING/REPLACING CENTER FRESH-AIR GRILL
645CI (E63) .
 00 9 341
LOCKING .
2006 BMW 650i
Release screw (1).
Lever out trim for center instrument panel (2) completely with center fresh-air grill (3) all round and remove.
Fig. 64: Levering Out Trim For Center Instrument Panel (2)
Replacement:
Remove trim for center instrument panel (4) in direction of arrow from center fresh-air grill (3).
2006 BMW 650i
Fig. 65: Removing Trim For Center Instrument Panel

Installation:
Make sure trim for center instrument panel (4) is correctly seated in associated mounts of center fresh-air grill
(3).
MICROFILTER
64 31 010 REPLACING MICROFILTER FOR INTERIOR VENTILATION
If necessary, disconnect plug connection for engine hood contact switch.
Turn quick-release fastener (1) approx. 90° counterclockwise.
Open holder (2) in direction of arrow.

2006 BMW 650i
Remove microfilter air duct (3) in direction of arrow.
Fig. 66: Removing Microfilter Air Duct

Installation:
Make sure microfilter air duct (3) is correctly seated.
Lever microfilter for interior ventilation (1) in direction of arrow out of microfilter air duct (2) and remove.
2006 BMW 650i
Fig. 67: Identifying Microfilter

Installation:
Make sure microfilter for interior ventilation (1) is correctly seated in microfilter air duct (2).
64 31 053 REMOVING AND INSTALLING OR REPLACING FRESH AIR DUCT
All models:
 Remove microfilter housing lower sections on left and right, refer to 64 31 061 REMOVING AND
INSTALLING/REPLACING LEFT OR RIGHT MICROFILTER HOUSING LOWER SECTION.
 Remove tension strut on spring strut dome, refer to 51 71 373 REMOVING AND
2006 BMW 650i
M57 only:
 Remove air cleaner element.
Unscrew bolt (1).
Installation:

TORQUES - 645CI .
Loosen screws (2).
Installation:

TORQUES - 645CI .
2006 BMW 650i
Fig. 68: Removing Tension Strut On Spring Strut Dome

Turn quick-release fastener (3) approx. 90° counterclockwise.
If necessary, release screw on pipe clamp.
Installation:

TORQUES - 645CI .
Feed out fresh air duct (4) in direction of arrow and remove.
Installation:
If necessary, replace damaged seals.
Make sure fresh air duct (4) is correctly seated.
64 31 061 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT MICROFILTER

HOUSING LOWER SECTION
 Remove microfilter air duct, refer to 64 31 010 REPLACING MICROFILTER FOR INTERIOR
VENTILATION.
Left microfilter housing lower section:
Unclip hose.
Installation:
Make sure hose is correctly seated.
Right microfilter housing lower section:
Installation:
Left or right microfilter housing lower section:
Partially detach engine compartment gasket (1).

2006 BMW 650i
Feed out microfilter housing lower section (4) in direction of arrow and remove.
Installation:
Make sure microfilter housing lower section (4) is correctly seated.
Fig. 69: Detaching Engine Compartment Gasket

AIR CONDITIONING SYSTEM

64 50 ... INSTRUCTIONS FOR HANDLING REFRIGERANT R 134A
WARNING: Although R 134a at normal temperature is non-toxic, non-flammable and

not explosive in air in any mixture ratio, it is still essential to follow
2006 BMW 650i
various safety precautions.
The filled refrigerant circuit of the A/C system is subject to gauge pressure. When carrying out repairs on the
A/C system, it is absolutely essential to draw off the refrigerant.
Do not weld or solder on filled A/C systems or in rooms into which R 134a may have leaked. Exposure to
flames or high temperatures (< or = 50 °C) may give rise to toxic decomposition products (fluorine gas). For
this reason, do not smoke either.
R 134a must be drawn off, cleaned and returned to the A/C system with a service station following the relevant
Avoid all contact with liquid or gaseous R 134a. Wear protective goggles and gloves when working on the
refrigerant circuit. R 134a acting on the skin can cause frostbite. Rinse affected body parts thoroughly with cold
water. If R 134a gets into your eyes, likewise rinse with plenty of water and, if necessary, remove contact lenses
if worn. Then seek immediate medical attention. Likewise seek immediate medical attention if you experience
problems after inhaling R 134a fumes.
As a gas, R 134a is colorless, odorless and heavier than air. If it gets into the atmosphere, this may result
especially in workshop pits in an imperceptible danger of asphyxiation or in cardiac palpitations. Ventilate
rooms adequately; if necessary, turn on installed extractor systems.
For a properly functioning A/C system, it is essential to have the greatest possible levels of cleanliness when
working on the A/C system and the best possible evacuation (at least 30 minutes dehumidification from
refrigerant circuit) before each filling of the A/C system.
R 134a absorbs moisture very easily. Therefore seal off opened pipes, condenser, evaporator, compressor and
drier bottle immediately with plugs.
With replacement parts, the plugs may only be removed immediately before the lines are connected.
In the event of warranty claims, the old parts must be provided with plugs to be able to determine the cause of
the damage.
If an A/C system has been completely drained by leakage, accident or repair, the drier element must be replaced
as excessive moisture may have entered the system. See .
Store filled pressurized refrigerant bottles in such a way that they are not exposed to direct sunlight or other heat
sources (max. 45 °C). Also avoid exposing them to mechanical stress (e.g. by dropping).
In the event of fire, carbon dioxide (CO2), extinguishant powder and a sprayed water jet are deemed to be
suitable extinguishants. Cool reservoirs at risk with a sprayed water jet (risk of bursting!).
IMPORTANT: After each refill of an A/C system, check that protective caps of filling valves
are hand-tight. They serve as additional seals.
2006 BMW 650i
64 50 ... LEAK TESTING WITH ULTRAVIOLET ADDITIVES (UV ADDITIVES) (BMW LEAK-
TESTING CASE)
IMPORTANT: It is absolutely essential to read and comply with the equipment manufacturer's
instructions for use provided in the equipment case!
Read and comply with the instructions for use provided with the special tool
particularly with regard to accident prevention, health protection and
environmental protection.
Use only BMW-approved UV-additives (e.g. TRACER).
Only the basic procedure is described in the following!
WARNING: Avoid contact with refrigerant.

Follow safety precautions when handling refrigerant .
IMPORTANT: UV lamp gets very hot in the radiation area!

Do not use the UV lamp without the filter glass.
Eyes and skin will suffer damage if the UV lamp is used without the filter glass.
When using the UV lamp, wear the protective goggles provided in the case.
NOTE:  Fill the hose system of the hand pump completely with UV additive PRIOR
to use
 Use the UV additive exclusively for BMW-approved refrigerant oils
 Do not operate the A/C system while the hand pump is connected or in use
 The A/C system must always be filled with an adequate amount of
refrigerant to enable the leak-detecting agent to be properly distributed
Before actually testing for leaks, check the entire refrigerant circuit using the UV leak-detecting lamp to ensure
that no AV additive is already in the area of the refrigerant circuit.
If already illuminated areas are found, carefully clean the area in question with the cleaning agent contained in
the case.
On initial use :
Connect hand pump (1) to additive cartridge (2) and hose piece (3).
2006 BMW 650i
Fig. 70: Identifying Hand Pump And Additive Cartridge With Hose Piece
On initial use :
Attach vent valve (1) to quick-connect coupling (2).
Turn handle (3) on hand pump to advance the plunger until a small amount of UV additive emerges. This vents
the hose system.
IMPORTANT: The entire hand pump with hose system must not be disassembled again once
the filling work has been completed.
Fig. 71: Attaching Vent Valve To Quick-Connect Coupling

Attach quick-connect coupling (1) to low-pressure connection (2) of A/C system.
Turn handle on hand pump (3) until the required amount of UV additive is added.
2006 BMW 650i
The quantity of UV additive to be added is dependent on the amount of refrigerant in the refrigerant circuit :
 A/C systems with refrigerant filling up to 900 g: one graduation mark (4) on additive cartridge
 A/C systems with refrigerant filling in excess of 900 g: two graduation marks (4) on additive cartridge
Fig. 72: Identifying Handle On Hand Pump

NOTE: After filling, remove quick-connect coupling (1) and if necessary use the
cleaning agent contained in the special tool case to clean up the UV additive.
Further tasks :
 Start engine.
 Run A/C system at highest setting for 5-10 minutes in order to ensure adequate distribution of dye in the
system
 Switch off engine
 Check all A/C system components for possible leaks
 Possible leaks show up in luminous green
Complete accompanying information label (1) with the relevant data and attach in an easily visible position next
to the filling capacity information label (2).
2006 BMW 650i
Fig. 73: Identifying Information Label

64 52 ... INSTRUCTIONS FOR OPENING AND REPLACING PARTS IN REFRIGERANT CIRCUIT
WARNING:  Avoid contact with refrigerant and refrigerant oil

 Follow safety instructions for handling R 134a refrigerant .
 Follow safety instructions for handling refrigerant oil .
CAUTION:  Always use new O-rings each time A/C connections are opened.
 Moisten O-rings with refrigerant oil prior to fitting.
 Seal all parts to be returned at openings to prevent ingress of
moisture or foreign bodies.
I. Opening refrigerant circuit without part replacement, as preliminary work to further work
(e.g. engine removal):
Work sequence:
 Draw off A/C system, then determine drawn-off refrigerant oil quantity.
 Carry out main work
 Replace removed refrigerant oil with new refrigerant oil
 Evacuate and fill A/C system .
II. Part replacement and part replacement on account of insidious leak
(minor leak, e.g. hairline crack)
Work sequence:
2006 BMW 650i
 Draw off A/C system, then determine drawn-off refrigerant oil quantity.
 Carry out part replacement
 Additionally replenish new refrigerant oil in accordance with replaced parts:
 Compressor: refer to NOTES ON REPLACING COMPRESSOR
 Evaporator: 10 ml
 Condenser: 10 ml
 Desiccant insert / desiccant bottle: 30 ml
 Each replaced refrigerant line: 10 ml
 Condenser with integrated dryer: 30 ml
 Safety pressure switch and seals: no additional refrigerant oil
 Evacuate and fill A/C system . See 64 50 009 DRAWING OFF, EVACUATING AND FILLING
A/C SYSTEM (R 134A).
III. Part replacement on account of sudden leak
(major leak, e.g. pipe break due to accident)
Work sequence:
 Draw off A/C system, then determine drawn-off refrigerant oil quantity. See 64 50 009
DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A).
 Carry out part replacement
 Additionally replenish 25 ml new refrigerant oil and new refrigerant oil in accordance with
replaced parts:
 Compressor: refer to NOTES ON REPLACING COMPRESSOR
 Evaporator: 10 ml
 Condenser: 10 ml
 Desiccant insert / desiccant bottle: 30 ml
 Each replaced refrigerant line: 10 ml
 Condenser with integrated dryer: 30 ml
 Safety pressure switch and seals: no additional refrigerant oil
 Evacuate and fill A/C system . See 64 50 009 DRAWING OFF, EVACUATING AND FILLING
A/C SYSTEM (R 134A).
64 50 ... AIR CONDITIONER TEST (R 134A)
Before A/C efficiency test, satisfy following conditions:
1. Provide a MoDiC or DIS.

2006 BMW 650i
2. Provide a thermometer with separate gauge.

3. Compressor load (intake air temperature of approx. 50°C)
Re 1:
Connect MoDiC or DIS to car and display evaporator temperature.
Re 2:
Position a thermometer with a separate gauge approx. 5 cm below the roofliner at the height of the B-pillar. Lay
gauge outwards out of vehicle interior.
Re 3:
Heating up vehicle interior:
 A/C button is not activated during heating up.

 Close all windows and doors.
 Set recirculated air mode.
 Select air distribution mode for footwell and defrosting.
 Maximum temperature setting.
 Maximum fan stage.
 Run engine at approx. 2000 RPM.
A/C efficiency test:
Turn on A/C compressor at a vehicle interior temperature of 50° Celsius.
After 2-3 minutes, evaporator sensor temperature must be 10° Celsius.
Draw off A/C system if this temperature is not reached, refer to 64 50 009 DRAWING OFF, EVACUATING
AND FILLING A/C SYSTEM (R 134A). Measure amount of refrigerant drawn off.
If drawn-off quantity does not correspond to specified fill quantity: replenish refrigerant.
If refrigerant quantity is correct fill A/C system.
NOTE: A/C systems with uncontrolled compressors only:
If necessary, then continue troubleshooting by pressure measurement.
64 50 ... LEAK-TESTING WITH LEAK TESTER DEVICE

2006 BMW 650i
refrigerant, refer to 64 50 ... SAFETY INSTRUCTIONS FOR HANDLING

REFRIGERANT R 134A.
Carry out leak-testing with a leak tester device from the workshop equipment catalog following the device
manufacturer's operating instructions.
If leaks not to be localized are already identified during evacuation, the A/C system must nevertheless be filled,
refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A). Then test for
leaks with leak tester device.
NOTE: Refrigerant is heavier than air.
Therefore always conduct the leak test below the lines and components to be tested.
Shield lines and components against strong blasts of air (wind, drawing off).
Tighten down loose lines, mark leaks.
Then draw off draw off A/C system, refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING
A/C SYSTEM (R 134A), and seal off or repair leakage points.
Then refill A/C system and test for leaks, refer to 64 50 009 DRAWING OFF, EVACUATING AND
64 50 ... SAFETY INSTRUCTIONS FOR HANDLING REFRIGERANT R 134A
WARNING: Although R 134a at normal temperature is non-toxic, non-flammable and

not explosive in air in any mixture ratio, it is still essential to follow
various safety precautions.
The filled refrigerant circuit of the A/C system is subject to gauge pressure. When carrying out repairs on the
A/C system, it is absolutely essential to draw off the refrigerant.
Do not weld or solder on filled A/C systems or in rooms into which R 134a may have leaked. Exposure to
flames or high temperatures (equal 50°C) may give rise to toxic decomposition products (fluorine gas). For this
reason, do not smoke either.
R 134a must be drawn off, cleaned and returned to the A/C system with a service station following the relevant
Avoid all contact with liquid or gaseous R 134a. Wear protective goggles and gloves when working on the
refrigerant circuit. R 134a acting on the skin can cause frostbite.
Wash off 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
2006 BMW 650i
As a gas, R 134a is colorless, odorless and heavier than air. If it gets into the atmosphere, this may result
especially in workshop pits in an imperceptible danger of asphyxiation or in cardiac palpitations. Ventilate
rooms adequately; if necessary, turn on installed extractor systems.
For a properly functioning A/C system, it is essential to have the greatest possible levels of cleanliness when
working on the A/C system and the best possible evacuation (at least 30 minutes dehumidification from
refrigerant circuit) before each filling of the A/C system.
R 134a absorbs moisture very easily. Therefore seal off opened pipes, condenser, evaporator, compressor and
drier bottle immediately with plugs.
With replacement parts, the plugs may only be removed immediately before the lines are connected.
In the event of warranty claims, the old parts must be provided with plugs to be able to determine the cause of
the damage.
If an A/C system has been completely drained by leakage, accident or repair, the drier element must be replace
as excessive moisture may have entered the system.
Store filled pressurized refrigerant bottles in such a way that they are not exposed to direct sunlight or other heat
sources (max. 45°C). Also avoid exposing them to mechanical stress (e.g. by dropping).
In the event of fire, carbon dioxide (CO2), extinguishant powder and a sprayed water jet are deemed to be
suitable extinguishants. Cool reservoirs at risk with a sprayed water jet (risk of bursting!).
CAUTION: After each refill of an A/C system, check that protective caps of filling
valves are hand-tight. They serve as additional seals.
64 50 ... SAFETY PRECAUTIONS WHEN HANDLING REFRIGERANT OIL (FOR REFRIGERANT

R 134A)
WARNING: Observe the following points when handling refrigerant oil:
 Wear protective goggles.

 Wear gloves made from impermeable plastic.
 Do not swallow.
 Do not inhale.
Action to be taken after contact with refrigerant oil:
 After contact with eyes, rinse thoroughly with plenty of water and
take out contact lenses (if worn). Then seek immediate medical
attention.
2006 BMW 650i
soap and water.

 Do not induce vomiting if oil is swallowed, seek immediate medical
attention.
 If inhaled, introduce the person affected to fresh air. Seek medical
attention if problems persist.
WARNING: Refrigerant oil is non-combustible and non-explosive at normal

temperatures. In spite of this, the following precautions must be
observed:
 Do not store in the vicinity of flames, heat sources or strongly

oxidizing materials.
 Suitable extinguishants: carbon dioxide (CO2 ), dry extinguishant,
foam.
Recycling:
Dispose of drawn-off refrigerant oil as hazardous waste.
Absorb escaping refrigerant oil with fluid-binding material.
Notify the relevant authorities if larger amounts of refrigerant oil are discharged into above-ground water
supplies, drainage systems or subsoil.
64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A)
WARNING: Avoid contact with refrigerant and refrigerant oil.
Follow safety instructions for handling refrigerant R 134a, refer to 64 50 ... SAFETY INSTRUCTIONS FOR
HANDLING REFRIGERANT R 134A.
Follow safety instructions for handling refrigerant oil, refer to 64 50 ... SAFETY PRECAUTIONS WHEN
HANDLING REFRIGERANT OIL (FOR REFRIGERANT R 134A).
IMPORTANT: Risk of damage! Restart engine only when A/C system has been correctly filled.
NOTE: Draw off, evacuate and fill the A/C system in accordance with the operating
instructions of the relevant service station.
E60 only:
2006 BMW 650i
If necessary, to connect service station, use manufacturer's adapter for high-pressure connection (red).
Instructions for drawing off A/C system:
To help separation of refrigerant and refrigerant oil, run engine at low speed (800-1200 RPM) and with A/C
system turned on for a few minutes.
The limits the entrainment of refrigerant oil while it is drawn off.
Drawn-off refrigerant oil must be changed and reintroduced via the service station.
If at the end of the drawing-off procedure the service station moisture indicator shows that the drawn-off
refrigerant is excessively moist, clean the refrigerant in accordance with the service station operating
instructions.
Recycling:
Dispose of drawn-off refrigerant oil as hazardous waste.
Instructions for evacuating off A/C system:
The evacuation procedure removes all traces of ambient air, water vapor and any other gases present from the
A/C system.
This enables subsequent system filling with refrigerant.
A decrease in the vacuum level indicates a leak in the refrigerant circuit, refer to 64 50 ... LEAK-TESTING
WITH LEAK TESTER DEVICE.
Instructions for filling A/C system:
Before filling with refrigerant, top up the refrigerant oil entrained during drawing off.
Depending on the type of component replaced on the A/C system, it may be necessary to top up the refrigerant
oil, even if no measurable losses have occurred during drawing off. Read and comply with the A/C system
manufacturer's notes in this regard and the operating instructions of the relevant service station.
Information on the required refrigerant fill quantity for the entire A/C system is contained on the rating plate (1)
in the engine compartment.
If necessary, refer to HEATING AND AIR CONDITIONING - TECHNICAL DATA for fill quantities.
2006 BMW 650i
Fig. 74: Indicating Display For Filling A/C System

Installation:
Reseal refrigerant filler necks on vehicle with sealing caps.
AC HOUSING/EVAPORATOR
64 51 LEAK-TESTING EVAPORATOR
WARNING: It is essential, when handling nitrogen, to observe the standard national

safety regulations.
Ensure that employees are advised of how to handle pressurized vessels

and nitrogen correctly (danger of asphyxiation). For this purpose, follow
the notes and instructions in the technical safety specifications available
2006 BMW 650i
from the gas supplier.
 Remove expansion valve
Replace sealing rings. Use special tool 00 9 030 to mount sealing rings without damaging them.
Fig. 75: Replace Sealing Rings

Connect special tool 64 5 126 to retaining clip and screws of expansion valve. Tightening torque 64 53 9AZ .
Connect special tool 64 5 121 to special tool 64 5 126 .
Fig. 76: Connecting Special Tools To Retaining Clip And Screws Of Expansion Valve
IMPORTANT: Risk of damage: Use only nitrogen pressure bottles with pressure reducers for
leak-testing.
2006 BMW 650i
and pressures in excess of 20 bar may cause damage to the evaporator.
Connect nitrogen pressure bottle with pressure reducer to pressure gauge and then connect to special tool 64 5
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 evaporator unit.
WARNING: After leak-testing, unscrew special tool 64 5 121 slowly from special tool
64 5 126 to reduce pressure.
After leak-testing:
 Replace sealing rings. Use special tool 00 9 030 to mount sealing rings without damaging them.
64 51 ... LEAK-TESTING CONDENSER
Special tools Required
 00 9 030 (Wedge)
 64 5 121 (Connection hose with clamp)
 64 5 122 (Climate condenser test adapter)
 64 5 123 (Climate condenser seal plug)
Refrigerant circuit is under high pressure!
Follow safety instructions for handling refrigerant
Comply with the standard national safety instructions and precautions on

handling nitrogen.
2006 BMW 650i
Ensure that employees are advised of how to handle pressurized vessels

and nitrogen correctly (danger of asphyxiation). For this purpose, follow
the notes and instructions in the technical safety specifications available
from the gas supplier.
 Drain off air conditioner

 Detach refrigerant lines from condenser
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.
Fig. 77: Identifying Special Tool 64 5 122, 64 5 123 & Sealing Rings
Fit and secure sealing adapter 64 5 123 to connection of low-pressure line.
Fit and secure test adapter 64 5 122 to connection of low-pressure line.
Tightening torque, see 64 53 6AZ in 53 CONDENSER AND DRYER .

2006 BMW 650i
Fig. 78: Identifying Special Tool 64 5 122 & 64 5 123

Connect special tool 64 5 122 to special tool 64 5 121 .
Fig. 79: Identifying Special Tool 64 5 122 & 64 5 121

IMPORTANT: Risk of damage: Use only nitrogen pressure bottles with pressure reducers for
leak-testing.
Pressurize condenser to 10 bar slowly only. Excessively fast pressurization

and pressures in excess of 20 bar may cause damage to the condenser.
Connect nitrogen pressure bottle with pressure reducer to pressure gauge and then connect to special tool 64 5
121 (connecting hose).
NOTE:  Testing apparatus must be leakproof.

 Ambient temperature and temperature of vehicle must not change during
the test procedure.
 Do not move the vehicle during this period
2006 BMW 650i
Apply test pressure of 10 bar slowly and close nitrogen pressure bottle.
Check leak-tightness of testing apparatus and of connection to refrigerant line.
Set test pressure of 10 bar is only permitted to drop by 2 bar to 8.5 bar over a test period of 1.5 hours.
If the pressure loss is greater than 1.5 bar, this indicates that there is a leak in the condenser unit.
WARNING: After leak-testing, unscrew special tool 64 5 121 slowly from special tool
64 5 122 to reduce pressure.
After leak-testing:
 Replace all sealing rings. Use special tool 00 9 030 to mount sealing rings without damaging them.
 Assemble A/C system
 Evacuate and fill A/C system
64 51 001 CLEANING EVAPORATOR
645CI (E63) .
 64 1 480
WARNING: When handling cleaning agent, observe following protection measures:

Wear protective rubber gloves and protective goggles. If cleaning agent
comes into contact with eyes or skin, wash immediately with lots of water.
IMPORTANT: To avoid dirtying vehicle interior:
 Close all air vents.

 Switch heating - A/C system to recirculated-air mode.
Recycling:
Carry out the cleaning operation in a suitable washing bay as the emerging cleaning agent escapes through the
drain openings in the transmission tunnel.
After completing cleaning, allow car to drip-dry for approx. 5 minutes.

2006 BMW 650i
FRESH AIR DUCT.
Partially detach transmission underbody protection (6) for draining cleaning fluid:
Release screws (2 ... 4) in rear area and press heat shield (5) away.
Fig. 80: Releasing Screws (2 ... 4) In Rear Area And Press Heat Shield (5) Away
Connect special tool 64 1 480 (spray lance) to spraying equipment.
Insert spray lance (1) through opening (2) to fresh air duct.
2006 BMW 650i
Fig. 81: Inserting Spray Lance Through Opening To Fresh Air Duct
By moving spray lance (1) back and forth, spray a uniform amount of cleaning agent onto evaporator.
NOTE: After rinsing with water, blow out evaporator with spray lance and air only for
approx. 5 minutes. Do this predominantly in the center of the evaporator to dry
the fan motor behind. Set heating - A/C system to footwell ventilation and fresh-
air mode. Open windows/doors. Start car and run heating - A/C system at
maximum fan power for approx. 5 minutes in order to dry heating - A/C system.
In order to eliminate the last remnants of cleaning agent, repeat this procedure
shortly before handover to the customer.
64 51 525 REMOVING AND INSTALLING OR REPLACING EXPANSION VALVE
 Draw off refrigerant from A/C system, refer to 64 50 009 DRAWING OFF, EVACUATING AND
FRESH AIR DUCT.
Feed out rubber grommet (1).

2006 BMW 650i
Installation:
Unscrew nut (2).
Fig. 82: Removing Expansion Valve

Installation:

TORQUES - 645CI .
Detach refrigerant lines (3) and (4) in direction of arrow.
Installation

2006 BMW 650i
Release screws (1).

Installation:

TORQUES - 645CI .
Detach expansion valve (2) in direction of arrow.
Installation:
Make sure soundproofing (3) is correctly seated.
64 51 591 REMOVING AND INSTALLING/REPLACING EVAPORATOR

2006 BMW 650i
 Remove heater.
 Remove heater core, refer to 64 11 208 REPLACING HEATER CORE.
 Remove expansion valve refer to 64 51 525 REMOVING AND INSTALLING OR REPLACING
EXPANSION VALVE.
 Remove rear compartment air duct.
 Remove fan for heater/air conditioner.
 Remove servodrive of left fresh-air/recirculated-air flap, refer to 64 11 803 REMOVING AND
INSTALLING/REPLACING SERVODRIVE FOR LEFT FRESH-AIR/REIRCULATED-AIR
FLAP.
Carefully pull off bulkhead seals (1) from heater/air conditioner (2) so that there are no remaining parts left
behind.
Fig. 84: Pulling Off Bulkhead Seals (1) From Heater/Air Conditioner (2)
2006 BMW 650i
Installation:
Replace bulkhead seals (1).
Release screws (1).
Press lock (2).
Remove pipe holder (3) complete with pipes (4).
Fig. 85: Removing Pipe Holder Complete With Pipes

Release screws (1).

2006 BMW 650i

Release screws (1).
Installation:
Make sure flaps (2) are correctly seated in mountings (3).

2006 BMW 650i
Fig. 87: Installing Flaps (2)

Release screws (1).
Remove upper housing section (2) in direction of arrow.
Installation:
Make sure upper housing section (2) is correctly seated on lower housing section.
Make sure flaps (3) are correctly seated in mountings (4).

2006 BMW 650i
Fig. 88: Removing Upper Housing Section In Direction

Release screws (1).
Release clip (2).
Remove cover (3) in direction of arrow.

2006 BMW 650i
Fig. 89: Removing Cover In Direction Of Arrow

Installation:
Make sure cover (3) is correctly seated.
IMPORTANT: Do not bend radiator fins. If necessary, clean or straighten radiator fins with
slat comb.
Pull evaporator (1) in direction of arrow out of lower housing section (2).
Installation:
If necessary, replace seal (3).
Make sure seal (3) is correctly seated in lower housing section (2).
2006 BMW 650i
Fig. 90: Pulling Evaporator In Direction Of Arrow Out Of Lower Housing

Replacement:
Remove plate (2) and seal (3) from evaporator (3).

2006 BMW 650i
Fig. 91: Removing Plate And Seal From Evaporator

COMPRESSOR
64 52 ... INSTRUCTIONS FOR COMPRESSOR REPLACEMENT
IMPORTANT: Compressors with plastic belt pulleys:
 Avoid impacts/knocks to plastic belt pulley (caused by tools, contact with

base).
 Return faulty compressors in their original packaging only.
IMPORTANT: When starting up a new compressor for the first time, it is absolutely essential
to carry out the following breaking-in procedure:
2006 BMW 650i
 Set all air vents in instrument cluster to "OPEN"

 Start engine and let it stabilize at idle speed
 Set blower output to min. 75% of max. blower output
 Switch on A/C system and run for at least 2 minutes at idle speed (risk of
damage at higher speed!)
When evacuating the air-conditioning system, refrigerant oil is also extracted and collected in the oil separator
of the service station.
Fig. 92: Identifying Oil Separator

After evacuation, the refrigerant must be filtered in the service station as the oil separator could still contain a
liquid refrigerant/oil mixture. The filtering process gasifies the refrigerant completely and only the previously
bound refrigerant oil remains in the oil separator. Measure and note down this quantity of refrigerant oil,
refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A).
2006 BMW 650i
container.
Fig. 93: Transferring Refrigerant Oil Into A Measuring Container

Measure the amount of refrigerant oil collected from the previous compressor.
2006 BMW 650i
Fig. 94: Measuring Amount Of Refrigerant Oil Collected From Previous Compressor
Depending on its design, the new compressor is filled at the factory with 120 to 200 g refrigerant oil. Open filler
plug and pour entire contents of compressor into a clean container.
2006 BMW 650i
Fig. 95: Opening Filler Plug And Pour Entire Contents Of Compressor Into A Clean Container
Installation:
If necessary, replace gasket.
Observe tightening torque, refer to 64 52 2AZ in HEATING AND AIR CONDITIONING - TIGHTENING
TORQUES - 645CI .
From this refrigerant oil, pour the same amount (as drained from the previous compressor) + 10 g extra into a
clean measuring container and pour again into the new compressor.
2006 BMW 650i
Fig. 96: Measuring Refrigerant Oil For New Compressor

Remaining refrigerant oil can be poured into service station tank, refer to 64 50 009 DRAWING OFF,
EVACUATING AND FILLING A/C SYSTEM (R 134A).
Otherwise the excess refrigerant oil must be disposed of correctly.
On account of its hygroscopic properties, refrigerant oil must not be stored in open containers.
The refrigerant oil drawn off from the oil separator of the service station and from the previous compressor
must not be reused and must be correctly disposed of.
2006 BMW 650i
Fig. 97: Disposing Old Refrigerant Oil

After installing the new compressor, it is essential before filling the A/C system to pour the same amount of the
previously drawn off refrigerant oil into the system again,
refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A).
2006 BMW 650i
Fig. 98: Recharging A/C System

Installation:
If A/C system is opened for more than 24 hours: Replace drier bottle/drier insert.
64 52 ... NOTES/INSTRUCTIONS ON WORKING ON AIR-CONDITIONING SYSTEMS
WARNING: Avoid contact with refrigerant and refrigerant oil. Follow safety
instructions for handling refrigerant R 134a, refer to 64 50 ... SAFETY
INSTRUCTIONS FOR HANDLING REFRIGERANT R 134A. Follow safety
instructions for handling refrigerant oil refer to 64 50 ... SAFETY
PRECAUTIONS WHEN HANDLING REFRIGERANT OIL (FOR
REFRIGERANT R 134A). Scalding hazard! Work on the cooling system
may only be carried out when it has cooled down.
2006 BMW 650i
INSTRUCTIONS FOR COMPRESSOR REPLACEMENT.
NOTE: If A/C system is opened for more than 24 hours: Replace desiccant insert for
A/C system, refer to 64 53 517 REPLACING DESICCANT INSERT FOR A / C
SYSTEM (CONDENSER REMOVED).
64 52 523 REPLACING A/C SYSTEM COMPRESSOR (S85)
WARNING: Read and comply with warnings relating to working on A/C systems, refer
to 64 52 ... NOTES/INSTRUCTIONS ON WORKING ON AIR-CONDITIONING
SYSTEMS.
 Drawing off, evacuating and filling the A/C system are not included in the time value given for this
work operation.
 Remove right intake filter housing. See 13 71 020 REMOVING AND INSTALLING RIGHT
INTAKE FILTER HOUSING (S85)
 Remove A/C compressor drive belt. See 28 V-RIBBED BELT W-TENSIONER
 Remove front underbody protection. See 47 FLOOR-LUGGAGE COMPARTMENT-ENGINE
 Remove stabilizer from front axle carrier. See 31 35 000 REMOVING AND
INSTALLING/REPLACING FRONT STABILIZER
 Remove right tension strut from front axle carrier. See 31 12 080 REMOVING AND
INSTALLING/REPLACING BOTH TENSION STRUTS
Release screws (1). Tightening torque, see 64 52 1AZ in 52 COMPRESSOR . Disconnect pressure and suction
lines. Installation: Replace sealing rings. Use special tool 00 9 030 to mount sealing rings without damaging
them. Disconnect plug connection (2).
Fig. 99: Release Screws And Disconnect Plug Connection (2)

2006 BMW 650i
Release screw (1). Tightening torque, see 64 52 3AZ in 52 COMPRESSOR .
Fig. 100: Release Screw (1)

IMPORTANT: Close openings or line to compressor with special tool 32 1 270, to avoid media
leak and dirt contamination.
NOTE: Secure compressor (1) against falling out.
Release screws (2, 3). Tightening torque, see 64 52 3AZ in 52 COMPRESSOR . Feed out compressor (1).
Fig. 101: Release Screws (2, 3)

After installation: Evacuate and fill A/C system
64 52 524 REPLACING A/C SYSTEM COMPRESSOR (N62)

2006 BMW 650i
SYSTEMS.
 Remove front assembly underside protection, refer to 51 47 490 REMOVING AND INSTALLING /
 Remove A/C compressor drive belt
 Release stabilizer on front axle, refer to 37 11 010 REMOVING AND INSTALLING/REPLACING
FRONT ACTIVE STABILIZER .
NOTE: The time value given for this work operation does not include drawing off,
evacuating and filling the A/C system!
 Drain off air conditioner, refer to 64 50 009 DRAWING OFF, EVACUATING

AND FILLING A/C SYSTEM (R 134A).
IMPORTANT: Do not place front panel center section (2) on jump start terminals. Do not kink
Bowden cables for engine hood locking.
Release screws (1).
Remove front panel center section (2) in direction of arrow and place to one side.
2006 BMW 650i
Fig. 102: Releasing Screws (1) And Removing Front Panel Center Section (2) In Direction Of Arrow
Release screws (1) and feed out refrigerant lines (2).

TORQUES - 645CI .
2006 BMW 650i
Fig. 103: Releasing Screws (1) And Feeding Out Refrigerant Lines (2)
Release screw (1) and disconnect coolant line connection.

2006 BMW 650i
Fig. 104: Releasing Screw (1) And Disconnecting Coolant Line Connection
Installation:
Replace all sealing rings.

TORQUES - 645CI .
Release bolt (1) and remove bracket for oil lines (2).
2006 BMW 650i
Fig. 105: Releasing Bolt (1) And Removing Bracket For Oil Lines (2)

TORQUES - 645CI .
IMPORTANT: Secure compressor (1) against falling out.
Release screw and nut (3).
Release bolts (4) and feed out compressor (1) downwards with refrigerant lines.
2006 BMW 650i
Fig. 106: Removing A/C Compressor


TORQUES - 645CI .
Adapter sleeves (1) must not be damaged.

2006 BMW 650i
Fig. 107: Identifying Adapter Sleeves

Replace damaged adapter sleeves.
Replacement:
Release screws (1) and remove refrigerant lines.

2006 BMW 650i

Installation:

TORQUES - 645CI .
64 52 524 REPLACING A/C SYSTEM COMPRESSOR (N62, WITH DYNAMIC DRIVE)
SYSTEMS.

2006 BMW 650i

 Remove alternator drive belt, refer to 11 28 010 REPLACING ALTERNATOR DRIVE BELT (N62) .
 Release stabilizer on front axle, refer to 37 11 010 REMOVING AND INSTALLING/REPLACING
FRONT ACTIVE STABILIZER .
 Release coolant tank and place to one side

IMPORTANT: Do not place front panel center section (2) on jump start terminals. Do not kink
Bowden cables for engine hood/bonnet locking.
Release screws (1).
Remove front panel center section (2) in direction of arrow and place to one side.
2006 BMW 650i
Release screws (1) and feed out refrigerant lines (2).
Fig. 110: Releasing Screws (1) And Feeding Out Refrigerant Lines (2)

TORQUES - 645CI .
Release screw (1) and disconnect connection.

2006 BMW 650i
Fig. 111: Releasing Screw (1) And Disconnecting Connection


TORQUES - 645CI .
IMPORTANT: Secure compressor (2) against falling out.
Disconnect plug connection (1). Release bolt and nut (3).
Release bolts (4), remove bracket for oil lines (5) and feed out compressor (2) downwards with refrigerant lines.
2006 BMW 650i
Fig. 112: Removing A/C Compressor With Dynamic Drive


TORQUES - 645CI .
Adapter sleeves (1) must not be damaged.

2006 BMW 650i
Fig. 113: Identifying Adapter Sleeves (1)

Replace damaged adapter sleeves.
Installation:
Before feeding in compressor, insert rear bolt (1) with shim (2).
2006 BMW 650i
Fig. 114: Inserting Rear Bolt (1) With Shim (2)

Replacement:
Release screws (1) and remove refrigerant lines.

2006 BMW 650i
Fig. 115: Releasing Screws (1) And Removing Refrigerant Lines

Installation:

TORQUES - 645CI .
CONDENSER AND DRYER WITH LINES

64 53 ... NOTES ON REPLACING DRIER BOTTLE OR DRIER INSERT
The drier bottle or drier insert does not have to be replaced at regular service intervals in a functioning,
leakproof A/C system.
However, the drier bottle or drier insert must be replaced without fail in the event of:
 fouling of the refrigerant by filings/shavings (e.g. when the compressor is clamped)

2006 BMW 650i
 a leaking A/C system or loss of refrigerant

 the refrigerant circuit being opened for a period exceeding 24 hours, e.g. during repair work.
64 53 517 REPLACING DESICCANT INSERT FOR A/C SYSTEM (CONDENSER REMOVED)
Remove cover cap (1) from condenser (2).
Fig. 116: Removing Cover Cap From Condenser

Press sealing cap (1) inwards and remove Seeger circlip ring (2).
2006 BMW 650i
Fig. 117: Pressing Sealing Cap Inwards Remove Seeger Circlip Ring
With assistance of a screwed-in screw (1), remove sealing cap (2) from condenser (3).
2006 BMW 650i
Fig. 118: Removing Sealing Cap From Condenser

Installation:
Replace sealing rings (1) of sealing cap (2) and coat with suitable refrigerant oil (cf. EPC).
2006 BMW 650i
Fig. 119: Installing Sealing Rings Of Sealing Cap

Withdraw desiccant insert in direction of arrow from capacitor (2).

2006 BMW 650i
Fig. 120: Inserting In Direction Of Arrow From Capacitor

64 53 518 REPLACING DESICCANT INSERT FOR A/C SYSTEM (CONDENSER REMOVED)
SYSTEMS.
Remove protective cap (1) from condenser for A/C system (2).
2006 BMW 650i
Fig. 121: Removing Protective Cap From Condenser For A/C System
Press sealing cap (1) inwards and remove circlip (2).

2006 BMW 650i
Fig. 122: Removing Circlip

Remove protective cap (2) from condenser for A/C system (3) with aid of an inserted screw (1).
2006 BMW 650i
Fig. 123: Removing Protective Cap From Condenser For A/C System
Installation:
Replace sealing rings (1) of sealing cap (2) and coat with suitable refrigerant oil.
2006 BMW 650i
Fig. 124: Installing Sealing Rings Of Sealing Cap And Coat With Suitable Refrigerant Oil
Remove desiccant insert for A/C system (1) in direction of arrow from condenser for A/C system (2).
2006 BMW 650i
Fig. 125: Removing Desiccant Insert For A/C System

64 53 520 REPLACING SAFETY PRESSURE SWITCH
instructions for handling refrigerant oil, refer to 64 50 ... SAFETY
REFRIGERANT R 134A).

2006 BMW 650i
A/C system, refer to 64 53 518 REPLACING DESICCANT INSERT FOR A/C
If necessary, release holder for lines (not illustrated).
Release safety pressure switch (2), tightening torque, see 64 53 13AZ in 64 53 REFRIGERANT LINES AND
EXPANSION VALVE .
Fig. 126: Identifying Plug Connection (1) And Safety Pressure Switch (2) (Except M6)
2006 BMW 650i
Fig. 127: Identifying Plug Connection (1) And Safety Pressure Switch (2) (M6)
64 53 551 REMOVING AND INSTALLING / REPLACING CONDENSER FOR A/C SYSTEM
 Drain off air conditioner, refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C
SYSTEM (R 134A).
A/C system, refer to 64 53 517 REPLACING DESICCANT INSERT FOR A / C
Release screws (1) and remove lines (2) in direction of arrow.

2006 BMW 650i
Fig. 128: Releasing Screws (1) And Removing Lines (2)

Installation:

TORQUES - 645CI .
Pull out condenser.
Installation:
Replace sealing rings (1, 2) and coat with refrigerant oil.

2006 BMW 650i
Fig. 129: Installing Sealing Rings And Coat With Refrigerant Oil
64 53 551 REMOVING AND INSTALLING / REPLACING CONDENSER FOR A/C SYSTEM (N62)
 Drain off air conditioner, refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C
SYSTEM (R 134A).
2006 BMW 650i
NOTE: If A/C system is opened for more than 24 hours: Replacing drier insert for A/C
system, refer to 64 53 518 REPLACING DESICCANT INSERT FOR A/C SYSTEM
(CONDENSER REMOVED).
Release screws (1).

TORQUES .
Disconnect suction and pressure lines (2) and lay to one side.
Fig. 130: Disconnecting Suction And Pressure Lines

Lift out condenser.
Installation:
2006 BMW 650i
Replace sealing rings and coat with suitable refrigerant oil.

2005 BMW 645Ci
HVAC Automatic Heating/Air-Conditioning System - SI Techniques - E60, E61, E63, E64
HVAC
Automatic Heating/Air-Conditioning System - SI Techniques - E60, E61, E63, E64

E64, E65, E66, E87, E90, E91

E63, E64, E65, E66, E87, E90, E91 .

E64

E63, E64 .
INTEGRATED AUTOMATIC HEATING/AIR-CONDITIONING SYSTEM (IHKA),

BASIC AND HIGH E60, E61, E63, E64
2005 BMW 645Ci
Fig. 1: Identifying Integrated Automatic Heating/Air-Conditioning System Basic And High

INTRODUCTION
The integrated automatic heating/air conditioning system (IHKA) is available in the versions Basic and High
(special equipment option 534).
 E60 and E61
Standard equipment: IHKA Basic (IHKA High on 545i)
 E63 and E64
Standard equipment: IHKA High
The automatic air-conditioning system High generates a very high level of climatic comfort with separate
adjustment for the driver's side and for the front-passenger side.
New Features Of The IHKA:

2005 BMW 645Ci
 An Electric Auxiliary Heater working on the PTC principle (positive temperature coefficient) is
installed on vehicles with diesel engines
The electric auxiliary heater is a component of the heat exchanger for the heating system. Electric heating
elements made of aluminium have been added to the plates in the coolant flow of the heating system heat
exchanger. The air drawn in is directly heated by these heating elements and fed into the vehicle interior
through the air vents. In principle, the electric auxiliary heater works like an electric fan heater.
 Condensation Sensor
The condensation sensor detects an imminent misting up of the windscreen, before condensation actually
forms. To prevent the windows from misting over, the IHKA control unit starts to work through a table of
measures as soon as a certain level of humidity is detected at the windscreen.
 LIN Bus (Local Interconnect Network Bus)
The LIN bus serves to actuate flap motors, the electric auxiliary heater and the blower motor in the
heating/air-conditioning system.
 Convertible Program (E64 Only)
The convertible program adapts the air-conditioner settings (blower, airflow, temperature) to the
conditions created by the open top. The settings do not have to be changed when the top is opened or
closed.
When the convertible top is opened and the air-conditioning system is in automatic mode, the convertible
program is automatically activated.
The convertible program is stored in the IHKA control unit.
DIFFERENCES BETWEEN IHKA BASIC AND IHKA HIGH

Component Basic High
Solar sensor - 1
Condensation sensor - 1
AUC sensor - 1
Sensor for heating system heat exchanger 1 2
Ventilation temperature sensor - 1
Rear compartment flap motor (air stratification) - 1
Ventilation flap motor 1 2
Footwell flap motor 1 2
Differences/modifications from E39:
 New IHKA controls with additional functions: OFF button, temperature and airflow are set with rotary
2005 BMW 645Ci
High, the manual air distribution is set with the controller on the CID (Central Information Display).
 Revised display concept
The scale on the rotary switch for the blower setting has a 9-element LED display. The manual blower
speed setting is shown by the corresponding LEDs lighting up. In automatic mode, the display remains
off (IHKA High only).
The LCD display from earlier versions has been discontinued. Additional air-conditioning functions such
as air stratification or independent heater (option 536) are selected and activated in the Central
Information Display (CID) using the controller.
 The flap drives are only operated by flap motors.

 Separate left/right-hand footwell flaps, (IHKA High only)
 Separate ventilation flaps, (IHKA High only)
 Intake fan arrangement in the heating/air-conditioning system
The fan is located after the evaporator.
 On vehicles with diesel engine, a heating system heat exchanger is installed with integrated electric
auxiliary heater. The same heating system heat exchanger is used for both Basic and High versions.
 Clutchless, externally actuated a/c compressor with regulated performance
 Sensor for automatic air-recirculation control (AUC sensor, IHKA High only)
 Solar sensor for taking external light/heat sources into account, which could affect the air conditioning in
the vehicle interior (IHKA High only).
Benefits of system:
 The efficiency and functionality of the IHKA has been improved compared to the predecessor model.
Despite this, the size is some 1/3 smaller than on the E39.
 The electric auxiliary heater accelerates the heating of the vehicle interior, especially at low ambient
temperatures and during the cold-start phase. This clears the windows of condensation more quickly.
 The condensation sensor automatically prevents/eliminates condensation on the inside of the windscreen,
before it becomes visible.
 The variable evaporator control extracts less humidity from the air. This reduces the risk of mucous
membranes drying out.
IHKA System Overview: E60, E61, E63, E64
For technical reasons, the system overview is divided up as follows:
 Inputs/outputs, IHKA Basic

 System circuit diagram, IHKA Basic
 Inputs/outputs, IHKA High
2005 BMW 645Ci
 Inputs/outputs, electric auxiliary heater (diesel engine only)

 System circuit diagram, electric auxiliary heater (diesel engine only)
 Inputs/outputs, independent heater
 System circuit diagram, independent heater
 Heater circuit, engine M54B22/B30 (IHKA Basic)
 Heater circuit, engine M54B22/B30 with independent heater (IHKA Basic)
 Heater circuit, engine M54B22/B30 (IHKA High)
 Heater circuit, engine M54B22/B30 with independent heater (IHKA High)
 Heater circuit, engine M57D30TU (IHKA Basic)
 Heater circuit, engine M57D30TU with independent heater (IHKA Basic)
 Heater circuit, engine M57D30TU (IHKA High)
 Heater circuit, engine M57D30TU with independent heater (IHKA High)
 Overview of heating/air-conditioning system components
Inputs/Outputs, IHKA Basic

2005 BMW 645Ci
Fig. 2: Inputs/Outputs Block Diagram (IHKA Basic)

2005 BMW 645Ci
Fig. 3: Legend For Inputs/Outputs Block Diagram (IHKA Basic)

System Circuit Diagram, IHKA Basic

2005 BMW 645Ci
Fig. 4: System Circuit Diagram (IHKA Basic)

2005 BMW 645Ci
Fig. 5: Legend For System Circuit Diagram (IHKA Basic)

Inputs/Outputs, IHKA High

2005 BMW 645Ci
Fig. 6: Inputs/Outputs Block Diagram (IHKA High)

2005 BMW 645Ci
Fig. 7: Legend for Inputs/outputs (IHKA High)

System Circuit Diagram, IHKA High

2005 BMW 645Ci
Fig. 8: System Circuit Diagram (IHKA High)

2005 BMW 645Ci
Fig. 9: Legend For System Circuit Diagram (IHKA High - Nos. 1-24)
2005 BMW 645Ci
Fig. 10: Legend For System Circuit Diagram (IHKA High - Nos. 25-End)
Inputs/Outputs, Electric Auxiliary Heater (Diesel Engine Only)

2005 BMW 645Ci
Fig. 11: Inputs/Outputs Block Diagram Electric Auxiliary Heater (Diesel Engine Only)
System Circuit Diagram, Electric Auxiliary Heater (Diesel Engine Only)

2005 BMW 645Ci
Fig. 12: System Circuit Diagram, Electric Auxiliary Heater (Diesel Engine Only)
2005 BMW 645Ci
Inputs/Outputs, Independent Heater
Fig. 13: Inputs/Outputs Block Diagram Independent Heat

2005 BMW 645Ci
Fig. 14: Legend For Inputs/Outputs Block Diagram Independent Heater

System Circuit Diagram, Independent Heater

2005 BMW 645Ci
Fig. 15: System Circuit Diagram, Independent Heater

2005 BMW 645Ci
Fig. 16: Legend For System Circuit Diagram, Independent Heater

Heater Circuit, Engine M54B22/B30 (IHKA Basic)

2005 BMW 645Ci
Fig. 17: Heater Circuit, Engine M54B22/B30 (IHKA Basic)

Heater Circuit, Engine M54B22/B30 With Independent Heater (IHKA Basic)

2005 BMW 645Ci
Fig. 18: Heater Circuit, Engine M54B22/B30 With Independent Heater (IHKA Basic)
Heater Circuit, Engine M54B22/B30 (IHKA High)

2005 BMW 645Ci
Fig. 19: Heater Circuit, Engine M54B22/B30 (IHKA High)

Heater Circuit, Engine M54B22/B30 With Independent Heater (IHKA High)

2005 BMW 645Ci
Fig. 20: Heater Circuit, Engine M54B22/B30 With Independent Heater (IHKA High)
Heater Circuit, Engine M57D30TU (IHKA Basic)

2005 BMW 645Ci
Fig. 21: Heater Circuit, Engine M57D30TU (IHKA Basic)

Heater Circuit, Engine M57D30TU With Independent Heater (IHKA Basic)

2005 BMW 645Ci
Fig. 22: Heater Circuit, Engine M57D30TU With Independent Heater (IHKA Basic)
Heater Circuit, Engine M57D30TU (IHKA High)

2005 BMW 645Ci
Fig. 23: Heater Circuit, Engine M57D30TU (IHKA High)

Heater Circuit, Engine M57D30TU With Independent Heater (IHKA High)

2005 BMW 645Ci
Fig. 24: Heater Circuit, Engine M57D30TU With Independent Heater (IHKA High)
Overview Of Heating/Air-Conditioning System Components

2005 BMW 645Ci
Fig. 25: Overview Of Heating/Air-Conditioning System Components


2005 BMW 645Ci
Sensors:
Interior Temperature Sensor
The force-ventilated sensor with interior temperature sensor fan is fitted in the IHKA controls. The sensor
measures the temperature of the air drawn in from the vehicle interior by the integrated interior temperature
sensor blower.
Solar Sensor (IHKA High Only)
The solar sensor is located in the middle of the dashboard. (The installation position of the solar sensor in the
E63/E64 has been turned through 180°.) This sensor is only active in automatic mode. The solar sensor takes
external sources of light or heat (e.g. direct sunlight) into account, which could affect the air conditioning of the
vehicle interior.
The sensor consists of 2 photoresistors. The sensor supplies the IHKA control unit with analogue signals for the
driver's and front-passenger sides. The signal depends on the intensity of sunlight.
Sensor For Automatic Air-Recirculation Control (IHKA High Only)
The AUC sensor is installed at the top of the fan cowl. The sensor is exposed to the sideways downwind from
the auxiliary fan. The AUC sensor detects the following pollutant emissions from spark-ignition and diesel
engines:
 Hydrocarbons (HC)
 Carbon monoxide (CO)
 Nitric oxides (nitrogen monoxide NO, nitrogen dioxide NO2)
Condensation Sensor (IHKA High Only)
The sensor is located under the rain/light sensor. In IHKA automatic mode, the sensor measures the humidity in
the vehicle interior and on the inside of the windscreen. The sensor detects an imminent misting up of the
windscreen, before condensation actually forms. The condensation sensor is not active in the convertible
program.
The condensation sensor is located on the inside of the windscreen, under the mirror base cover, beneath the
rain-light sensor. The condensation sensor must be positioned within the sweep range of the windscreen wiper.
This ensures that changes in temperature caused by snow or ice on the outside of the windscreen have no effect.
Construction
2005 BMW 645Ci
Fig. 26: Identifying Condensation Sensor E60, E61, E63, E64

How It Works
The condensation sensor is only active when the IHKA is in automatic mode. The condensation sensor
indirectly exposes condensation on the window surfaces. In other words, the condensation sensor monitors the
environment in which condensation forms on the window surfaces. Humidity on the windscreen and the
temperature of the windscreen inside the vehicle are measured and a frequency-dependent signal is generated.
To measure the atmospheric humidity, the condensation sensor contains a capacitive sensor element. The sensor
element is a component of an electrical oscillation circuit. The oscillation circuit is detuned in proportion to the
change in humidity at the windscreen. The resonant frequency of the oscillation circuit is then used as a
2005 BMW 645Ci
Moreover, the interior and exterior temperatures and the temperatures of the windscreen inside the vehicle are
evaluated. If an air humidity of more than 65 % is detected at the windscreen, the IHKA control unit will initiate
measures to prevent condensation on the windows.
Heating System Heat Exchanger Sensor
The sensor is integrated in the heating/air-conditioning system. On the IHKA Basic, the sensor measures the
delivery temperature on the driver's side, directly on the delivery side of the heating system heat exchanger. On
the IHKA High, 2 sensors are installed as the delivery temperatures are measured separately at the heating
system heat exchanger for the driver's side and for the front-passenger side.
Evaporator Temperature Sensor
The sensor measures the outlet temperature of the refrigerant at the evaporator to prevent icing from occurring.
Ventilation Temperature Sensor (IHKA High Only)
A sensor is integrated in the air duct to measure the ventilation temperatures. This sensor measures the delivery
temperature directly in the middle of the ventilation grille.
Refrigerant Pressure Sensor
This sensor is located in the pressure line between the condenser and the evaporator. Depending on the sensor
signal, the A/C compressor is switched off by the IHKA control unit in the event of excessively high system
pressure.
Control Unit:
IHKA Controls/Control Unit
The IHKA controls and the IHKA control unit are united in a single component. The Basic and High versions
have different IHKA controls.
The IHKA controls/control unit is located in the middle of the dashboard, beneath the centre ventilation grille.
Construction
The air conditioner is available in the versions Basic and High. These each have their own IHKA controls.
Integrated in the IHKA controls is a force-ventilated sensor for measuring the interior temperature. For reasons
relating to production, the display for independent heater operation is always integrated.
The following overviews show the layout and pin assignments for the:
 IHKA Basic
2005 BMW 645Ci
Layout And Pin Assignment For IHKA Basic
Fig. 27: Identifying Control Panel IHKA Basic

Pin Assignment For Connector X18793, 18-Pin Black
PIN ASSIGNMENT FOR IHKA BASIC CONNECTOR X18793, 18-PIN BLACK

1 E/A LIN bus, data
2 - -
3 E Signal from refrigerant pressure sensor
4 V Terminal 15, power supply for refrigerant pressure sensor
5 - -
6 E/A CAN-bus high
7 E/A CAN-bus low
8 M Earth for refrigerant pressure sensor
2005 BMW 645Ci
9 - -
10 V Terminal 30, power supply
11 A Control valve in A/C compressor
12 A Water valve
13 A Auxiliary water pump
14 A Relay for heated rear window
15 A Heated washer jets
16 E PWM signal from DDE for electric auxiliary heater
17 - -
18 M Earth point, terminal 31
A = Output
E = Input
M = Earth
V = Supply
PIN ASSIGNMENT FOR IHKA BASIC CONNECTOR X01130, 12-PIN BLACK

1 E Signal from heating system heat exchanger sensor
2 - -
3 E Signal from evaporator temperature sensor
4 - -
5 - -
6 M Earth point for sensors
7 A PWM signal to electric auxiliary heater
8 - -
9 - -
10 V LIN bus, supply
11 E/A N bus, data
12 M LIN bus, earth
A = Output
E = Input
M = Earth
V = Supply
Layout And Pin Assignment For IHKA High

2005 BMW 645Ci
Fig. 28: Identifying Control Panel IHKA High

PIN ASSIGNMENT FOR IHKA HIGH CONNECTOR X13765, 2-PIN BLACK

1 V Terminal 30, power supply
2 M Terminal 31, earth
M = Earth
V = Supply
2005 BMW 645Ci

1 E Signal from left-hand heating system heat exchanger sensor
2 E Signal from right-hand heating system heat exchanger sensor
3 E Signal from evaporator temperature sensor
4 - -
5 - -
6 E/A Earth point for sensors
7 A PWM signal to electric auxiliary heater
8 - -
9 - -
10 V LIN bus, supply
11 E/A LIN bus, data
12 M LIN bus, earth
A = Output
E = Input
M = Earth
V = Supply
PIN ASSIGNMENT FOR IHKA HIGH CONNECTOR X1527, 26-PIN BLUE

1 E/A LIN bus, data
2 V AUC sensor, supply
3 E Signal from AUC sensor
4 V Condensation sensor, power supply
5 E Signal from condensation sensor
6 E/A CAN-bus high
7 E/A CAN-bus low
8 V Refrigerant pressure sensor, supply
9 E Signal from refrigerant pressure sensor
10 V Solar sensor, power supply
11 E Solar sensor, left signal (E63/E64 right signal)
12 E Solar sensor, right signal (E63/E64 left signal)
13 M Solar sensor, earth
14 E PWM signal from DDE for electric auxiliary heater
15 A Control valve in A/C compressor
16 E Dual water valve, left
17 E Dual water valve, right
18 A Auxiliary water pump
19 A Relay for heated rear window
2005 BMW 645Ci
20 A Heated washer jets

21 M Refrigerant pressure sensor, earth
22 V Rear stratification flap, power supply (not E63)
23 E Signal from rear stratification flap (not E63)
24 E Signal from ventilation temperature sensor
25 M Earth point for AUC, ventilation temperature and condensation sensor
26 M Rear stratification control
A = Output
E = Input
M = Earth
V = Supply
Actuators:
Electric Auxiliary Heater
The heating elements of the electric auxiliary heater are integrated into the heating system heat exchanger and
directly heat the air drawn in to control the temperature of the air inside the vehicle.
The electric auxiliary heater is part of the heating system heat exchanger in the heating/air-conditioning system
on vehicles with diesel engine. The heating system heat exchanger integrated into the heating/air-conditioning
system, located above the blower and perpendicular to the evaporator.
2005 BMW 645Ci
Fig. 29: Identifying Electric Auxiliary Heater

Construction
The electric auxiliary heater consists of 4 heating cells. Each heating cell contains 4 heating elements. The
heating elements are grouped into pairs to form heating chains. A total of 8 heating chains can be selected in 8
heating levels. The regulator for the electric auxiliary heater is secured directly on the heating system heat
exchanger with clamps). Regulator and heating system heat exchanger form a single unit.
The following illustrations show:
 The construction of the electric auxiliary heater

2005 BMW 645Ci
Fig. 30: Construction Of The Electric Auxiliary Heater

 The construction of a heating cell

2005 BMW 645Ci
Fig. 31: Construction Of A Heating Cell

The heating elements are held in place by a plastic frame and a tensioning spring.
How It Works
The following functions are explained:
 Heating element
 How the electric auxiliary heater is activated
Heating Element
2005 BMW 645Ci
The heating element in the electric auxiliary heater are PTC resistors. The heating elements are made up of
individual ceramic semiconductor resistors.
The following illustration shows the characteristic curve of a heating element.
Fig. 32: Characteristic Curve Of Heating Element (Electric Auxiliary Heater)

From a certain temperature TRmin, the resistance of a heating element has a positive temperature coefficient. In
other words, as the temperature rises, the electrical resistance of the heating element also increases. The
2005 BMW 645Ci
curve.
This electrical characteristic of the heating element resistance allows a maximum temperature of approx. 120 °C
in the heating cell, which does not constitute a problem for the heating/air-conditioning system.
This "physical" over-temperature protection is maintained even if the blower were to fail.
The temperature of the heating element rises quickly when current is applied (maximum operating temperature
approx. 120 °C). From about 80 °C, the heating element begins to reduce its current consumption. The heat
from the heating element is fed into the heating cell. The airflow generated by the blower flows across the
heating cell. This warms up the air-mass flow. The warm air is then fed into the vehicle interior.
How The Electric Auxiliary Heater Is Activated
The electric auxiliary heater is activated by the IHKA control unit via the LIN bus. The DDE (digital diesel
electronics) actuates the electric auxiliary heater with a pulse-modulated signal (PWM signal). The PWM signal
from the DDE tells the electric auxiliary heater regulator the maximum available electrical power (depends on
resources in the vehicles electrical system).
The regulator in the electric auxiliary heater automatically controls how the heating chains are switched on and
off. The individual heating levels/heating chains are switched on/off with delayed switching times. This
prevents larger current fluctuations in the vehicle electrical system.
The heating chains are switched on and off by the electric auxiliary heater regulator according to set parameters:
 Heat Output Setting

 Permissible Number Of Heating Chains
 Electrical System
 Priority For Driver's Side
 Limited Maximum Number Of Heating Chains
 General Conditions
 Self-Check (Safety Functions)
Heat Output Setting
The heat output setting is made with the rotary switch and is converted into a specified value. On the IHKA
Basic (without left/right separation), the specified value for the driver's side applies.
Permissible number of heating chains
This parameter enables the heating chains to be activated and priorities to be assigned (depending on heating
requirements for the driver's side and the front-passenger side). The input parameter corresponds to the
maximum number of heating chains permitted.
Electrical System
2005 BMW 645Ci
This parameter provides information about the resources in the vehicle electrical system. With this information,
the auxiliary heater regulator decides how many heating chains can be activated.
Priority For Driver's Side
This parameter ensures the driver's side is given preference. If an odd number of heating chains is activated,
there will always be one heating chain more activated for the driver's side.
Limited Maximum Number Of Heating Chains
This parameter provides information about the maximum number of heating chains that is permissible. The
parameter depends on the resources available in the vehicle electrical system, the general conditions and the
self-check functions.
General Conditions
Depending on the ambient temperature, the maximum permissible number of heating chains may be limited.
If the defrost function is selected at the IHKA controls, the maximum number of heating levels is activated,
depending on the resources available in the vehicle electrical system.
Self-Check (Safety Functions)
The self-check of the electric auxiliary heater regulator includes the following protective functions:
 Overvoltage
 Undervoltage
 LIN bus signal failure
 Incorrect command
 Temperature monitoring as protection against thermal overload (heating chains OFF if temperature
greater than 115 °C, heating chains ON again when temperature drops below 110 °C)
 Short-circuit detection
 Open circuit
 Reset (software reset)
 Monitoring of correct order in function sequence
If one of these protective functions is activated, all active heating chains will be switched off.
If one of the heating chains is recognised as being defective, the next heating chain will be used as a substitute.
Flap Motors
On the IHKA Basic, 6 flap motors control the ventilation flaps. The IHKA High has 9 flap motors due to the
left/right separation for the driver's side and the front-passenger side and because of the additional rear
2005 BMW 645Ci
Fig. 33: Identifying Flap Motor Locations

Construction
All flap motors are of basically the same design. External distinguishing features are merely the different output
members (e.g. levers and jaws) and the location/orientation of the connector.
2005 BMW 645Ci
Fig. 34: Identifying Flap Motor

How It Works
The flap motors are actuated by the IHKA control unit via the LIN bus and are supplied with power and with an
earth connection. At rest, the IHKA control unit switches the power supply off.
The flap motors have an integrated circuit in the connector housing. This circuit controls the coil of the flap
motor. The circuit is compatible with bus technology and is capable of diagnosis (LIN bus).
The flap motors for the fresh-air/air-recirculation flaps are high-speed motors. The adjusting time
CLOSED/OPEN is approx. 2 seconds. The other flap motors are normal-speed motors. The adjusting time
CLOSED/OPEN is approx. 7 seconds.
The number of steps of the flap motors depends on the adjustment range of the flaps to be actuated. Example:
Step motor Setting angle Number of steps Adjusting time

CLOSED/OPEN
Fresh-air/air-recirculation flap, left 115° 640 steps approx. 2 seconds
2005 BMW 645Ci
Fresh-air/air-recirculation flap, right 95° 530 steps approx. 1.7 seconds

Defroster flap 72° 1440 steps approx. 7.2 seconds
Cold-air flap 69° 1370 steps approx. 6.9 seconds
All flap motors are actuated by the IHKA control unit via the LIN bus. Each flap motor has an address
permanently stored by the manufacturer, which allows unambiguous identification during bus communications.
For this reason, all flap motors are different and cannot be interchanged.
Cutoff On Blocking
The integrated circuits in the flap motors recognise a blocking of the flap motor from the increased current
consumption. The integrated circuits report the fault to the IHKA control unit via the LIN bus. Defective flap
motors are then no longer actuated.
Reference Run Of All Flaps
The step motors are unable to recognise the current (actual) position. They always move relative to an end
position of the flaps (reference point). One of the end positions of the flaps (closed/fully open) serves as
reference point.
The flaps are moved to one of the end positions
 If the IHKA control unit is exchanged,
or
 If the power supply is interrupted.
The end position is selected in such a ways that the subsequent nominal position can be reached by the shortest
route. The reference run can also be initiated by the BMW diagnosis system.
Positioning Of Fresh-Air/Air-Recirculation Flaps
When the vehicle is shut down (ignition OFF), the fresh-air/air-recirculation flap is moved to the "fresh air"
position. This ensures that the interior will be supplied with outside (fresh) air in the event of the IHKA failing,
regardless of the circumstances.
Blower With Blower Regulator
The blower generates the necessary airflow. The blower is installed after the evaporator in the heating/air-
conditioning system (suction fan) and is equipped with 2 blower wheels.
The blower regulator is fitted directly on the blower motor housing. The blower regulator is capable of self-
diagnosis. The blower regulator is actuated by the IHKA control unit (via the LIN bus). The blower regulator
controls the blower motor with a pulse-modulated signal (PWM signal).
2005 BMW 645Ci
The A/C compressor compresses the refrigerant drawn in from the evaporator and presses it to the condenser.
The A/C compressor used is clutch-free. That means that the A/C compressor always runs with the engine. A
swash plate in the A/C compressor allows the output to be smoothly regulated. To reduce load, only the cooling
output actually needed is generated.
Construction
Fig. 35: Cut-Away View Of A/C Compressor

2005 BMW 645Ci
Fig. 36: Cut-Away View Of A/C Compressor Belt Drive

How It Works
2005 BMW 645Ci
Fig. 37: Sectional View Of A/C Compressor Components

Within the A/C compressor, the delivery volume and thus the pressure in the refrigerant circuit is generated by
7 pistons. The piston stroke is controlled by a swash plate.
With the help of this movement, the swash plate regulates:
 The Zero Position

 The Maximum Displacement (100 %)
 The Range Of Adjustment (2-100 %)
The electric control valve influences the balance of forces on the swash plate and thus the adjustment of the
2005 BMW 645Ci
displacement.
An increase in pressure in the crank chamber increases the forces acting of the reverse side of pistons (towards
minimum stroke). The displacement from the swash plate is decreased.
When the pressure in the crank chamber approaches the suction pressure due to equalisation through the
compensation bore, the resulting forces on the surface of the pistons (towards maximum stroke) are in total
greater than the forces acting on the reverse side of the pistons. The displacement from the swash plate is
increased.
Zero Position
Fig. 38: Identifying A/C Compressor "Zero Position"

2005 BMW 645Ci
The electric control valve is open when no current is applied. The force from spring 1 is greater than that of
spring 2. In this situation, the suction pressure does not work on the bellows from spring 1.
Refrigerant flows into the crank chamber from the high-pressure side. The balance of forces shifts towards the
swash plate. This moves the swash plate to a position that is almost vertical, not deflected. In this position, a
compression coefficient of between 0 and 2 % is achieved, which serves to maintain internal lubrication.
Maximum Displacement (100 %)
Fig. 39: Identifying A/C Compressor "Maximum Displacement 100%" Position

The electric control valve is placed under current (by the IHKA control unit) and thus closed. The force from
spring 1 is less than the sum of the forces of the coil plus spring 2 plus bellows (spring 1). In this situation, the
suction pressure acts on the bellows with spring 1 and thus generates an additional force that tries to close the
2005 BMW 645Ci
No refrigerant is able to flow into the crank chamber from the high-pressure side. The pressure in the crank
chamber is reduced via the compensation bore until the pressure in the crank camber corresponds to the suction
pressure. The balance of forces shifts. The forces that act on the surface of the piston are greater than those that
act on the swash plate. The result is maximum deflection of the swash plate (maximum displacement).
Range Of Adjustment 2-100 %
In regulated operation, the electric control valve is actuated by the IHKA control unit with a pulse-modulated
signal (PWM signal), depending on the suction pressure. The electric control valve enables the springs and the
bellows to change the characteristic curve. The result is a smoothly variable output adjustment between 2 and
100 % and the realisation of "variable evaporator control" between 2 °C and 7 °C.
To reduce load, only the cooling output actually needed is generated. The criteria for control and switching
on/off are:
 A/C compressor speed (engine speed)

 A/C compressor load torque (CAN message from IHKA control unit to DME/DDE unit)
 Torque limitation (CAN message from DME/DDE control unit to IHKA control unit) Possible restriction
of A/C compressor load torque at kick-down position or if coolant temperature is too high
 Limitation of refrigerant pressure
Protective Function If A/C Compressor Is Blocked
The rubber element transfers the torque from the pulley to the A/C compressor driver. Besides its function as a
vibration damper, this rubber element also fulfils a protective function in the event of the A/C compressor
blocking. If the A/C compressor is blocked, the rubber element allows slip. Transmission of torque from the
pulley to the driver, which is linked to the shaft of the A/C compressor, is interrupted.
2005 BMW 645Ci
Fig. 40: Protective Function - A/C Compressor Is Blocked

Evaporator
The evaporator plates are cooled by the refrigerant that has been evaporated inside the evaporator. The airflow
generated by the blower is fed over the cooled evaporator plates. The air is cooled and dried and fed into the
vehicle.
Auxiliary Water Pump
The auxiliary water pump serves to make sure that the coolant flow rate needed in the heater circuit is
maintained, even at low engine speeds. On vehicles with diesel engine and independent heating (option 536),
there is no auxiliary water pump in the engine compartment. Its job is assumed by the independent heater's
auxiliary water pump and is controlled by the independent heating control unit.
Water Valve
The water valve works electromagnetically and meters the coolant flow rate to the heating system heat
exchanger as it is needed. This determines the temperature of the air used for heating the vehicle interior.
On the IHKA High, a dual water valve is used for the left/right separation of the heating system heat exchanger.
2005 BMW 645Ci
Switchover Valve
The switchover valve is only installed if the vehicle is equipped with independent heating (option 536).
The switchover valve regulates the inlet to the independent heating as follows:
 From the radiator and the auxiliary water pump
or
 From the return flow from the heating system heat exchanger
The switchover valve is actuated by the independent heating control unit.
Auxiliary Fan
The auxiliary fan is standard on all vehicles with IHKA. Besides the engine cooling, the auxiliary fan is also
needed for cooling the condensers.
Condenser With Integrated Drier Flask
Refrigerant is converted from gas into liquid in the condenser. Any water that may be present in the refrigerant
circuit is collected in the integrated drier flask, which is installed downstream of the condenser. The drier
element can be exchanged.
Expansion Valve
The expansion valve is directly on the evaporator in the heating/air-conditioning system. The valve regulates the
injection rate in the evaporator. Only as much liquid refrigerant is permitted to enter the evaporator as the
evaporator is able to completely evaporate. Drops of liquid that have not been evaporated could cause damage
in the A/C compressor.
Additional Components:
Microfilter
On the IHKA Basic, fresh air for interior ventilation is fed through a system of microfilters. On the IHKA High,
a microfilter with activated carbon is fitted. The activated charcoal filter helps to provide additional purification
of the incoming air from gaseous pollutant emissions. When a filter replacement is needed, this will be
indicated by the Condition Based Service (CBS) display.
Rear Air-Stratification Flap Potentiometer (IHKA High Only)
The selected potentiometer setting is transposed into the rear compartment flap motor position.
LIN Bus
2005 BMW 645Ci
 Electric auxiliary heater

 Flap motors
 Blower with blower regulator
Control And Display Functions Via Controller And Central Information Display
The following control and display functions are selected and activated on the CID (Central Information
Display) with the controller (move controller to left in start menu):
 Temperature control (IHKA Basic)
The temperature for the driver's and front-passenger sides are centrally set on the IHKA controls. The
temperature can be increased or decreased from this central setting using 3 selectable settings (warmer,
neutral, colder).
 Temperature control (IHKA High)
The temperature can be increased or decreased separately on the driver's side and front-passenger side in
4 increments.
 Independent heater (optional)
Select between direct operation and programming with timer.
 Independent ventilation (IHKA High only)
Select between direct operation and programming with timer.
 Air distribution (IHKA High only)
The airflow for the driver's and front-passenger sides are centrally set on the IHKA controls. Deviating
from these central setting, the airflow can be adjusted separately for the footwell and upper body (driver's
and front-passenger sides).
The driver-side setting applies for both sides in the area of the windscreen.
>E64 When the convertible program is active, air distribution is switched to the upper body and head. Airflow
to the footwell is throttled.
 A/C program
The A/C program is called up as follows:

1. Press the controller in the start menu (5. menu)
2. Select "Vehicle settings" and press controller.
3. Select "A/C settings" and press controller.
2005 BMW 645Ci
4. The following settings are available in the menu level "automatic program":
 gentle
 medium
 intensive
 convertible program (selection only possible when convertible top is open)
The selection of gentle, medium and intensive is not possible when the convertible program is
active. When the convertible program is deactivated, the air-conditioning system acts as if the
convertible top were closed (selection of gentle, medium and intensive is again possible).
Convertible Top Module (E64 Only)
NOTE: The following control unit is also active in the IHKA:
The convertible top module (CVM) provides the IHKA control unit with the signal whether the convertible top
is open or closed. The convertible top module is connected to the K-CAN.
The convertible top module is installed under the rear left side trim.
SYSTEM FUNCTIONS
The IHKA comprises the flowing functions:
 Temperature control
 Evaporator control
 Air distribution setting
 Airflow control
 Sunlight adaptation (solar sensor, IHKA High only)
 MAX cooling (IHKA High only)
 Maximum heating
 Residual heat (IHKA High only)
 Defrost function (IHKA High only)
 Heated rear window
 Heated washer jets
 OFF
 Air recirculation mode
 Automatic air recirculation
 Automatic air-recirculation control (IHKA High)
 Program for avoiding condensation on the window surfaces (IHKA High only)
 Convertible program (E64 only)
2005 BMW 645Ci
 Independent heater (option 536)
Temperature Control
In the heating/air-conditioning system, the air-mass flow is first cooled and dried at the evaporator (provided the
air conditioner is switched on). Then the airflow is heated to the required temperature at the heating system heat
exchanger.
 IHKA Basic
The temperature in the heating system heat exchanger is controlled with the help of the heating system
heat exchanger sensor and a pulsed water valve in the heater circuit. The water valve is actuated with a
pulse-modulated signal (PWM signal) by the IHKA control unit. A map for the heating system heat
exchanger determines the opening times for the water valve, depending on the engine speed.
A master controller regulates the temperature inside the vehicle. Regulation is based on the specification
set at the rotary switch (adjustment range: 17-27 °C) and the actual value (= interior temperature). The
lead parameter is derived from the comparison of the actual interior temperature and the corrected
specification (customer setting + ambient temperature).
Compared to the set specification, the interior temperature is raised in the cold so that a comfortable level
is achieved even at negative temperatures, despite the temperature setting being unchanged. The ambient
temperature is transmitted through the body CAN (controller area network) to the IHKA control unit.
An auxiliary regulating circuit relieves the master controller by eliminating any fault quantities that could
be detected in the heating/air-conditioning system in the form of a temperature change. Disturbances are
caused by:
 Fluctuations in air volume
 Fluctuations in coolant flow in engine heater circuit
 Temperature changes in fresh air
 IHKA High
The separate temperature setting for the driver's side and the front-passenger side affects:
 Heating system heat exchanger with left/right separation
 2 heating system heat exchanger sensors
 Dual water valve
The temperature is regulated by 2 master controllers. Regulation is based on the specification set at the
rotary switch and the actual value (= interior temperature). Through the left/right separation, 2 auxiliary
regulating circuits relieve the two master controllers.
The solar sensor compensates for additional fault quantities caused by external sources of light or heat
(e.g. direct sunlight).
2005 BMW 645Ci
NOTE: Reaching maximum outlet temperature in ventilation area. The maximum outlet
temperature in the ventilation area is reached as follows:
 Set the rotary switch for temperature selection to maximum temperature

(28 °C)
 Set temperature layering as follows with the CID:
 IHKA Basic:
Air stratification to "red" (warmer)
 IHKA High:
All 4 red bars must be displayed.
Evaporator Control
The evaporator temperature is regulated with the help of the evaporator temperature sensor and a controllable
expansion valve. The evaporator temperature is set to the predefined specification of 2 °C. Lower temperatures
are not possible due to the risk of icing.
If the "variable evaporator control" function has been encoded, the specified evaporator temperature is
calculated in the range between 2 and 7 °C. The specification depends on the ambient temperature, the
ventilation temperature and the refrigerant pressure. A variable evaporator control reduces dehumidification.
This reduces the risk of mucous membranes drying out.
Air Distribution Setting
Occupants have the possibility of allowing the air distribution to be decided by the automatic program (AUTO
button). Alternatively, manual selection (defrost, ventilation, footwell) allows an individual, personal air
distribution.
Important for the optimal function of the air distribution is that the manually adjustable air vents are open.
Airflow Control
The airflow control is dependent on the following settings and control actions:
 Manual blower setting
The blower setting is made with the rotary switch in the IHKA controls.
 Automatic blower and flap setting
The automatic blower and flap functions are activated when the AUTO button is pressed.
Automatic blower speed increase

2005 BMW 645Ci
The automatic blower speed increase function is available with both manual and automatic flap settings.
To make a rapid heating or cooling possible from extreme interior temperatures, the standard range of
adjustment is extended.
 Dynamic pressure compensation
Without dynamic pressure compensation, the airflow through the fresh air grille would be increased
disproportionately with increasing road speed. This effect is compensated for by the opening angle of the
fresh-air flap being reduced as speed increases. (The road speed comes from the instrument cluster,
through the body CAN to the IHKA control unit. The opening angle is regulated according to an
empirically defined map.)
 Blower control
If needed, priority levels are transmitted (through the body CAN) from the power module consumer
cutoff to reduce the blower output.
 Effect of terminal 50
During the starting process (terminal 50 ON), the blower is set to OFF to relieve the vehicle battery.
Sunlight Adaptation (Solar Sensor, IHKA High Only)
The influence on IHKA regulation by the solar sensor is assigned separately to the driver's side and to the front-
passenger side.
The following functions are modified when automatic mode is activated:
 Blower (individual blower proportions of the overall blower output are increased or decreased)
 Air stratification (stratification temperature adjusted)
 Flaps (position of ventilating flaps adjusted)
MAX Cooling (IHKA High)
The MAX button makes it possible for the user to select maximum cooling with just one press of a button at the
IHKA controls.
When the MAX button is pressed, all functions, including the defrost function, are deactivated. The air-
conditioning function is activated (if it was not already activated) and defined settings are selected (e.g.
temperature control is deactivated, the dual water valve is closed).
Maximum Heating
If the rotary switch for temperature selection is turned to the end stop, maximum heating is activated.
Regulation of the vehicle's interior temperature is suspended. Predefined settings are selected (e.g. temperature
2005 BMW 645Ci
Residual Heat (IHKA High Only)
The residual-heat function makes it possible to utilise the waste heat from the engine to heat the vehicle interior
when the engine is not running. The auxiliary water pump is activated to circulate the water.
Switch-on conditions:
 REST button in IHKA controls ON
and
 Ambient temperature below 25 °C
and
 Engine temperature above 60 °C
and
 Ignition lock position R or ignition OFF
and
 15 minutes after terminal 15 OFF not yet expired
Defrost Function (IHKA High Only)
The defrost function is activated with the defrost button in the IHKA controls. This opens the defroster flap (on
the inside in front of the windscreen) fully. The fresh-air/airrecirculation flaps move to the "fresh air" position.
All other flaps are closed. The blower can be set manually.
Heated Rear Window
The heated rear window is switched on by pressing the heated rear window button in the IHKA controls. The
function indicator lamp in the button lights up.
The heated rear window is switched off when the button is pressed again, or automatically when the heating
period of 10 or 17 minutes has expired. If the button is pressed again during the heating phase, the afterheating
phase (approx. 5 minutes) starts.
 Defrosting phase
When terminal 15 is switched ON, the first time the system is switched on, the time span for the heated
rear window is defined as follows:
Ambient temperature down to -15 °C: Heating period: 10 minutes

2005 BMW 645Ci
Ambient temperature below 15 °C: Heating period: 17 minutes
 Pulsing
After the defrosting phase, the heating phase (60 minutes at 1/3 heat output pulsing) begins (on-off cycle:
3 seconds ON, 9 seconds OFF).
The function indicator lamp in the button is off during pulsing.
Heated Washer Jets
The washer jets are heated, depending on the ambient temperature (under 3 °C). The IHKA control unit actuates
the nozzle heating.
OFF
Press the OFF button to completely switch the IHKA controls off.
Air-Recirculation Mode
In air-recirculation mode, the flow of outside air can be stopped to prevent pollution from entering the vehicle,
e.g. in traffic congestion. Air from the vehicle interior is continuously circulated.
To prevent the windows from misting over, air recirculation is only available for a limited period of time.
Automatic Air Recirculation
In automatic mode, the system will automatically switch to air-recirculation mode if an extreme cooling output
is called for. This allows the vehicle interior to be cooled more quickly. Air from the vehicle interior that has
already been cooled is fed through the evaporator again. This reduces the temperature level much faster than it
would in normal operation.
Automatic air-recirculation mode initially runs for 12 minutes in full air-recirculation mode and then
continuously in partially fresh-air mode (fresh-air flap opening angle: approx. 10 %).
Automatic Air-Recirculation Control (IHKA High)
If the AUC sensor detects an excessively high pollutant level in the environment, the IHKA control unit will
automatically switch to air-recirculation mode.
Because of the lack of a fresh-air supply, air-recirculation mode is only available for a limited period of time:
 In heating mode at ambient temperatures above 6 °C, air recirculation is limited to 4 minutes. This is
followed by fresh air for 1 minute.
 In air-conditioning mode at ambient temperatures above 6 °C, air recirculation is limited to 12 minutes.
2005 BMW 645Ci
 At ambient temperatures between 6 °C and 0 °C, air recirculation is limited to 3 minutes.
At ambient temperatures below 0 °C, air recirculation is limited to 2 minutes.
This is followed by fresh air for 1 minute.
When the engine is started and the AUC function activated, fresh air is always selected for approx. 40 seconds
due to the warming phase of the AUC sensor.
Program for avoiding condensation on the window surfaces (IHKA High only)
Measures to prevent condensation on the windscreen depend on a number of conditions:
 The engine must be running

 The IHKA must be in automatic mode
The IHKA control unit evaluates condensation sensor signal (humidity). If condensation on the windscreen is
imminent, the following measures are initiated in turn until the condensation has been eliminated. If one
measure proves to be ineffective, the next measure is initiated. Once successful, the measures previously
performed are reversed step-by-step in reverse order.
Measures against condensation on windscreen:
 Open the defrost flaps further (max. 17.5 %)

 Switch to partially fresh air from air-recirculation/AUC/automatic air-recirculation mode
 Switch from partially fresh air in air-recirculation/AUC/automatic air-recirculation mode to fresh air
 Switch off variable evaporator control
 Raise blower speed (max. 28 %)
 Reduce airflow to footwell (by about 60 %)
 Increase temperature setting (by max. 2.5 °C)
Convertible Program (E64 Only)
The convertible program is activated in the factory, (this factory setting can be deactivated win the Car and Key
Memory). Switch-on conditions:
 Terminal 15 ON
 Convertible top open
The convertible program comprises the following functions:
 The condensation sensor is switched off

 The blower speed increases with increasing road speed
2005 BMW 645Ci
 Dynamic pressure compensation is changed, i.e. as road speed increases, the volume of air fed into the
vehicle through the fresh air grille increases.
 Solar sensor control variables are changed
When the convertible top is open, the solar sensor evaluates the surrounding brightness (darkness to
intense sunshine) more strongly. For this reason, the solar sensor has a stronger effect on the IHKA
controls when the convertible top is open.
In the convertible program, the blower speed can be changed manually at the IHKA controls. The automatic
flap control remains active (no change to flap position). If the convertible program is active and the flap
positions are changed with the CID and controller, the convertible program will be deactivated. This means that
manual settings will be assumed, unchanged settings will revert to those that the air-conditioning system had
before the convertible top was closed.
The convertible program can be completely reactivated by pressing the AUTO button.
Independent Ventilation Function
The independent ventilation function is activated either via the Central Information Display (CID) or via
Telestart (through the Car Access System (CAS)). There are 2 ways of activating the system via the CID:
Direct operation or programming using the timer.
If the independent ventilation function is programmed via the timer, the independent ventilation function will
only be available at exterior temperatures above 15 °C. The battery's charge level is constantly monitored by the
intelligent battery sensor throughout the independent ventilation function. If the necessary charge level is not
maintained, the IHKA control unit will deactivate the independent ventilation function.
Independent Heater (Option 536)
The independent heating function is activated either via the Central Information Display (CID) or via Telestart
(through the Car Access System (CAS)). There are 2 ways of switching the system on via the CID:
Direct operation or programming using the timer.
Conditions required for switching the independent heater on:
 Exterior temperature below 15 °C (only applicable after programming with the timer)
 Sufficient fuel in the vehicles tank for a range of at least 50 km
 On-board supply voltage OK
The independent heater has the following functions:
 Auxiliary heating with running engine (pseudo auxiliary heating)

 Telestart (via CAS)
2005 BMW 645Ci
Auxiliary Heating With Running Engine (Pseudo Auxiliary Heating)
When the independent heater is running, pseudo auxiliary heating mode is started when the engine is started.
When pseudo auxiliary heating mode is activated, the independent heater indicator lamp goes out.
If the engine temperature is greater than or equal to the temperature of the independent heating circuit, the
system will change from pseudo auxiliary heating mode to auxiliary heating. These two modes differ in that
only the independent heater circuit is used in pseudo auxiliary heating mode, while in auxiliary heating mode
the larger heater circuit is used.
Telestart (via CAS)
The average range of the Telestart transmitter is approx. 150 meters. The CAS forwards the signal from the
Telestart transmitter through the body CAN to the following control units:
 IHKA control unit

 Independent heater control unit
Low-Voltage Cutout (via DME/DDE)
The battery's charge level is constantly monitored by the intelligent battery sensor throughout the independent
heating operation. If the necessary charge level is not maintained, the IHKA control unit will deactivate the
independent heating operation.
 General information: refer to GENERAL INFORMATION FOR SERVICE STAFF ON THE

IHKA:E60, E61, E63, E64.
 Diagnostics: N/A
 Encoding/programming: refer to ENCODING/PROGRAMMING IHKA: E60, E61, E63, E64.
 Car and Key Memory: refer to IHKA CAR & KEY MEMORY: E60, E61, E63, E64.
General Information For Service Staff On The IHKA:E60, E61, E63, E64
Replacement Of Electric Auxiliary Heater
IMPORTANT: Only replace the electric auxiliary heater and heating system heat exchanger
complete. The electric auxiliary heater and the heating system heat exchanger
form a single unit. This unit must not be separated during service work. In the
event of a defect, the entire unit must be replaced.
Microfilter Wear Level

2005 BMW 645Ci
a calculation model (algorithm) to simulate the condition of the microfilter from the following factors:
 Ambient temperature
 Signal from rain-light sensor (IHKA High only, otherwise substitute value)
 Signal from solar sensor (IHKA High only)
 Blower voltage
 Air conditions (recognised from frequent or infrequent use of air recirculation)
 Vehicle road speed
 Service interval display (SIA) timer
 Odometer reading
The IHKA control unit forwards the following data to the instrument cluster (via the body CAN):
 Microfilter availability in percent

 Time remaining until next service
Replacement Of Instrument Cluster And IHKA Control Unit
IMPORTANT: Do not replace the instrument cluster and the IHKA control unit at the same
time. The instrument cluster and the IHKA control unit must not be replaced at
the same time as the last valid data (redundant memory) for service operations
would then be lost.
Running In A/C Compressor
IMPORTANT: Run the A/C compressor in after replacement. If the A/C compressor has been
replaced or if the refrigerant circuit has been recharged, the A/C compressor
must be run in. Running in is needed to make sure that adequate lubrication
(oil distribution) is available. Only perform running in with the BMW diagnosis
system.
The A/C compressor must be run in the specified engine speed range during running in. The oil added by the
manufacturer is then mixed with the liquid refrigerant.
IMPORTANT: Do not exceed the specified engine speed. Running in will automatically be
aborted if the engine speed exceeds the specified engine speed range.
Running in must then be repeated in full.
Installation Of Condensation Sensor
IMPORTANT: Use the positioning aid when installing the condensation sensor. To prevent
the rain-light sensor interfering with the condensation sensor, a minimum
distance must be maintained between the two sensors. For this reason, the
2005 BMW 645Ci
installation.
Fig. 41: Using Positioning Aid For Condensation Sensor Installation

Encoding/Programming IHKA: E60, E61, E63, E64
Encoding
When encoding vehicle-specific data, the following details (among others) must be taken into account:
 Engine type (diesel or spark-ignition)

2005 BMW 645Ci
 Optional equipment (e.g. independent heater, IHKA High)

 Control unit version (IHKA High or IHKA Basic) Programming The IHKA control unit can be flash
programmed via the body CAN (body controller area network).
Programming
The IHKA control unit can be flash programmed via the body CAN (body controller area network).
IHKA Car & Key Memory: E60, E61, E63, E64
Car & Key Memory
The following functions can be programmed either at the end of assembly or at the dealership:
IHKA CAR & KEY MEMORY

Function Description Possible setting
Key-specific setting of The Key Memory settings for the IHKA can - active
heating, air conditioning, be activated or deactivated. If "active" is or
ventilation selected, the settings of the blower and air - not active
conditioning functions (AUC, air
recirculation, air flaps, defroster) are stored
for each key individually.
OFF memory The setting "air conditioner OFF" (IHKA - active
controls off, flaps closed) is retained when the or
ignition is switched ON. - not active
Air-recirculation memory Air recirculation is retained after restarting - active
the engine. This function operates regardless or
of the key used. - not active
Blower correction In automatic mode, the blower speed can be - raise
raised or lowered by 10 %. - not active
- lower
Correction of nominal The temperature setting in the display can be - + 3 degrees
values for flaps corrected by the said amount. - + 2 degree
- + 1 degree
- not active
- -1 degree
- -2 degrees
- -3 degrees
Convertible program The A/C settings are adapted to take account (1) - active
of the open convertible top. The settings do or
not have to be changed when the convertible - not active
top is opened or closed.
(1) Note: Only change this setting when the convertible top is open. This setting can only be changed in
the CID when the convertible top is open.
2005 BMW 645Ci
When terminal 15 is switched off, the control settings for 4 different users can be stored in the EEPROM
(electronically erasable programmable read-only memory) of the IHKA control unit. These key-dependent
control setting are reactivated when terminal 15 is switched on again with the respective remote control. The
IHKA control unit receives the number of the current remote control as a CAN message from the Car Access
System (CAS) (via the body CAN). There are 4 remote controls for each vehicle.
In addition to the data records for the 4 remote controls, the IHKA also receives a fifth data record that can be
assigned to a mechanical key. This data record serves as a standard setting, e.g. in the event of no valid remote
control being recognised.
The following data are stored in the EEPROM of the IHKA control unit for each remote control and as a
standard setting for the mechanical key:
 Air-Stratification Flap Setting

 Blower Speed Setting In Manual Mode
 Defroster-Flap Setting In Manual Mode
 Ventilation-Flap Setting, Top Right, In Manual Mode
 Footwell-Flap Setting, Left, In Manual Mode
 Footwell-Flap Setting, Right, In Manual Mode
 Ventilation-Flap Setting, Left, In Manual Mode
 Ventilation-Flap Setting, Right, In Manual Mode
NATIONAL VERSIONS
The hardware of the IHKA controls are available temperature displays in °C (Celsius) or in °F (Fahrenheit).
Subject to change.
2009 BMW 650i
ACCESSORIES & EQUIPMENT Instruments - SI Techniques - 650i, M6, X5
ACCESSORIES & EQUIPMENT
Instruments - SI Techniques - 650i, M6, X5
MODIFICATIONS TO "CONDITION BASED SERVICE" MAINTENANCE

SYSTEM BMW
Fig. 1: Condition Based Service Maintenance System

Background:
 Passenger compartment microfilter: Coupled to a multiple of the oil service.

 Spark plug: Coupled to a multiple of the oil service.
 Diesel particulate filter: Critical range covered by Check Control.
 Exhaust emissions test: Cancellation in all regions except V6 China (can also be controlled manually via
DIS Tester).
HEAD-UP DISPLAY E60, E61, E63, E64, E70 (FUTURE X5)

2009 BMW 650i
Fig. 2: Identifying Head-Up Display

INTRODUCTION
The head-up display is used to display information relevant to driving the vehicle (e.g. navigation instructions,
driving speed) in an ergonomically favorable position on the windscreen. Information appears as a virtual image
approximately at the front of the bonnet.
NOTE: Displays in the instrument cluster and in the central information display
Information relevant to driving the vehicle still appears in the customary
manner in the instrument cluster and in the central information display.
The information displayed on the head-up display is independent of the equipment level. You can select the
information using the controller on the Central Information Display (CID).
The following information can be shown on the head-up display:
 Check - Control messages

 Active Cruise Control (ACC) or cruise-control system (FGR)
 Navigation instructions
 Vehicle road speed
2009 BMW 650i
Benefits of the head-up display:
 Important information relevant to driving the vehicle can be received without the driver having to take his
eyes off the road.
 This makes driving more relaxing. The eyes do not have to refocus as much or as frequently (i.e. when
the eyes move from a wide view of the road to a small display in the instrument cluster).
The head-up display is employed for the first time as special equipment (option 610) on the E60.
Launch date is 11/2003.
The HUD of the E60 is identical to that of the E61.
The windscreens on the E63 and E64 are tilted more. The following modifications related to the HUD are
therefore required for the E63/E64:
 Modified mirror set

 Modified integration into the instrument panel
The HUD in the E70 (future X5) differs from the HUD in E60, E61, E63, E64 in the following respects:
 2 mirrors instead of 4 mirrors

 Image orientation of the virtual image can be height -adjusted
 Head-up display can be adjusted without an adjustment tool (with BMW diagnosis system).
The SMG system comprises the following key components:
 HUD: Head-up display
The head-up display can be compared to a projector. The image is formed by the projection display and is
illuminated by the light source.
 Display range of the head-up display
The display range of the head -up display is optically divided into 2 sections. The upper section is used to
display navigation instructions. the lower section is used to display speed -related information.
 Windscreen
A special windscreen is needed for the head-up display to appear optimally.
 Button for switching head-up display on and off

2009 BMW 650i
The following components are networked for the function of the head -up display (in alphabetical order):
 Active cruise control or cruise control
The following signals are sent by optional extra 541 "Active Cruise Control" (ACC) or optional extra 540
"Cruise Control" or optional extra 544 "Cruise Control with Brake Function":
 Set speed (= selected driving speed)

 Distance (ACC only)
 Object detection (ACC only)
 Regulation display (ACC only)
 Transfer prompt (ACC only)
 CAS: Car access system
The CAS provides input signals relating to terminal status (e.g. terminal 15 ON).
The head-up display is operational when terminal 15 is switched ON.
 CHAMP or CCC or M -ASK: Multimedia platform or Car Communication Computer or multi -

audio system controller
To display the navigation directions in the head-up display, the following signals are sent by the CHAMP
(multimedia platform: CHAMP; Central Head Unit and Multimedia Platform) or CCC or M -ASK:
 Next road
 Driving direction arrow
 Distance to road intersection/junction
 Bar gauge
The signals are sent via the MOST (Media Oriented System Transport) data bus.
 CID and CON: Central Information Display and controller
The preset brightness of the head -up display can be individually set using the CID. The brightness
adjustment (= difference between set value and basic setting) is stored in the head -up display through the
Car and Key Memory.
The CID can be used to select which information is displayed in the head -up display (e.g. Check -Control
messages, navigation instructions).
The controller is the control element for selecting setting in the CID.
E70 (future X5)

2009 BMW 650i
 DME or DDE: Digital engine electronics or digital diesel electronics
The head-up display receives signals from the DME or DDE regarding the cruise -control system or
active cruise control. The signals are transmitted via the PT -CAN and K-CAN.
 FRM: Footwell module

E70 (future X5)
The footwell module controls and monitors the vehicle lights. Information is received and transmitted via
the K -CAN data bus (body controller -area network).
The footwell module provides the terminal 58g signal via the K -CAN. The footwell module also
transmits the dimmer signal to the head-up display.
 JBE: Junction box electronics

E70 (future X5)
The junction box electronics is the data interface between the bus systems that are important for the head
- up display:
 Body CAN (K -CAN)

 Powertrain CAN (PT-CAN)
The diagnosis lead is connected to the JBE.
 KGM: Body gateway module from 09/2005

E60, E61, E63, E64
The KGM supersedes the SGM. The KGM is the data interface between the bus systems that are of
importance for the head -up display:

The diagnosis wire is connected to the KGM.
 KOMBI: Instrument cluster
The instrument cluster transmits the following signals to the head-up display through the K-CAN:
Vehicle road speed

 Check -Control messages
 LM: Light module

E60, E61, E63, E64
2009 BMW 650i
The light module controls and monitors all vehicle lights. Information is received and transmitted via the
K -CAN data bus (body controller -area network).
The light module provides the terminal 58g signal via the K-CAN. The light module also transmits the
dimmer signal to the head-up display.
 RLS: Rain -light sensor
Vehicles with the "head-up display" optional extra (option 610) require a special rain/light sensor.
Modifications compared to the previous rain/light sensor:
 Viewing angle
On the previous rain/light sensor, the viewing angle has been directed more upwards (towards the
sky). With the rain/light sensor for the head -up display, the viewing angle is directed more towards
the virtual image (from the perspective of the rain/light sensor, downwards).
The rain/light sensor measures the ambient light conditions in the background of the virtual image.
Thus the display brightness is optimally adjusted to the ambient brightness of the virtual image.
 Optical element
The optical element is adjusted to the new viewing angle.
 Evaluation electronics
The evaluation electronics have also been modified (signal evaluation and software).
As before, the signal is available via the K-CAN.
 SGM: Safety and gateway module up to 09/2005

E60, E61, E63, E64
The SGM is replaced by the KGM as from 09/2006.
The SGM is the data interface (gateway) between the bus systems that are important for the head -up
display:

 Byteflight
The diagnosis wire is connected to the SGM.

2009 BMW 650i
The steering column switch cluster (SZL) sends the signals from the Active Cruise Control (ACC) or the
Cruise Control (FGR) to the head -up display.
The settings of the ACC or FGR are selected using the steering column switch.
SYSTEM FUNCTIONS
The head-up display comprises the following functions:
 Switch-on response
 Projection of virtual image in front of the vehicle
 Automatic adaptation of display brightness
 Prioritisation of displays
Switch-on response
The head-up display is partially operational when terminal R is switched ON. This means:
 The projection display is initialized but information is not yet displayed.

 The head-up display is able to communicate with other bus -elements via the MOST and K -CAN data
buses.
The head-up display is operational when terminal 15 is switched ON. This means:
 The light source is switched on when the button for switching the head -up display on and off is pressed.
 The projection display cover panel is folded out of the beam by the stepper motor.
E70 (future X5)
The E70 (future X5) has no cover panel for the projection display. One mirror is swivelled away to
protect the display against direct sunlight when parked. As from terminal 15 ON the mirror is swivelled
from the park position into the position stored by the Car and Key Memory.
 The automatic adaptation of the display brightness is activated.


E70 (future X5)
The image orientation of the virtual image can be height -adjusted.
Projection of virtual image in front of the vehicle
The head-up display projects a virtual image, i.e. an image that appears to hang in mid -air without a fixed
image carrier (e.g. projection screen or similar).
The image is generated on a projection display in the head -up display and deflected by the windscreen in such a
2009 BMW 650i
as when looking in a mirror: the observer looks not at the mirror but behind the mirror.)
The size of the virtual image is approx. 20 x 10 cm (width x height). The virtual image can only be seen from a
defined area from the driver's side.
Automatic adaptation of display brightness
The automatic adaptation of display brightness prevents major sudden changes in the brightness of the head - up
display when the vehicle moves between different ambient lighting conditions (e.g. from light to dark and from
dark to light when driving through a tunnel).
The automatic adjustment of the display brightness depends on
 the ambient lighting conditions,

 the brightness adjustment setting,
 the dimmer setting for instrument lighting (only when the lights are on).
The surrounding brightness (day, night, twilight, sunshine, etc.) is recorded by the rain/light sensor. The value
of the brightness adjustment (difference between base setting and individually set display brightness) is stored
in the head -up display. When the lighting is switched on (terminal 58g, lights ON) the brightness of the head -
up display is also influenced by the dimmer setting of the instrument lighting.
Prioritisation of displays
The information in the head-up display is classified according to priority (= importance for the driver). Displays
with low priority are overwritten by displays with higher priority.
PRIORITISATION OF DISPLAYS CHART

Priority Function
1 Warnings from Active Cruise Control (ACC)
2 Check-Control messages
3 Test functions (= aids when troubleshooting without BMW diagnosis system)
4 Navigation instructions
OPERATION
The head-up display is controlled using the following control elements:
 Button for switching head -up display on and off

 Dimmer for instrument lighting
 Controller for selecting brightness of head -up display in Central Information Display (CID)
E70 (future X5)
Controller and CID for adjusting the image orientation of the virtual image
2009 BMW 650i
PRECONDITIONS FOR ACTIVATION
The conditions required to switch the head-up display on are:
 Terminal 15 switched on
 Button for switching head -up display on and off switched on
National versions
Left-hand drive and right -hand drive vehicles each have different head-up displays. The constructions mirror
each other nearly identically.
Subject to change.
IDRIVE, CENTRAL INFORMATION DISPLAY AND CONTROLLER E60, E61,

E63, E64, E87, E90, E91, E92
Fig. 3: Identifying Idrive, Central Information Display And Controller

INTRODUCTION
2009 BMW 650i
iDrive was introduced with the E65.
Due to the position of the screen and the controller as well as the operations logic, iDrive is the leading control
system in vehicles.
iDrive was consistently developed for the E60 and the ranges which follow:
Due to the increased number of functions in the vehicle, improvements were also made to the ergonomics. The
menu structure contains 5 menus in contrast to the E65 which contains 8 menus.
iDrive is characterized by:
 clear differentiation and optimum layout of the driving area for driving and convenience
 Calmer atmosphere inside the vehicle due to a reduced number of switches
 straightforward, logical controls
 ergonomic positioning and design of display and control elements
 integrational approach: the front passenger has access to all convenience functions
iDrive is also employed on the new BMW 1-Series and 3-Series.
In conjunction with the Multi -audio system controller (M -ASK) or Car Communication Computer (CCC),
there is a display for the iDrive.
On the BMW 1-Series the folding Central Information Display (CID) is located in the middle of the dashboard.
On the BMW 3-Series, the Central Information Display is fixed and integrated into the dashboard.
iDrive consists primarily of the following components:
 Central Information Display (CID)
The CID is the central graphic display unit. A number of displays are available depending on the
equipment fitted:
CENTRAL INFORMATION DISPLAY CHART

E60, E61, E63, E64, E90, CID colour 6.5 inch, fully CID colour 8.8 inch, fully
E91, E92 integra (combined with integrated (combined
option 606 "Business with option 609
navigation system" with "Professional navigation
arrow display) in system" with map view)
conjunction with M -ASK in conjunction with CCC
E87 CID colour 6.5 inch, folding
(with option 606 "Business navigation system" with
2009 BMW 650i
arrow display in conjunction with M -ASK) (with

option 609 "Professional navigation system" with
map view in conjunction with CCC) no Assistance
window and therefore no split-screen display
The Central Information Display is connected via a LVDS data line (Low Voltage Differential Signalling)
to the M - ASK or CCC.
 Controller with menu button
The controller is the central control element for the Central Information Display or iDrive. The
controller is located in the centre console behind the gear lever or, in the case of automatic transmission,
the selector lever.
The menu button is located behind the Controller (with CCC, two -part option: menu button and Push -to-
talk button for voice recognition system).
The controller is connected via the K-CAN to the M-ASK/CCC.
The controller is operated in the same way as on the 7 Series by slide or turn and then press.
The Controller always returns to its home position when released. The basic variant of the Controller,
however, only has 4 sliding directions: forward, back, to the right and to the left.
In the High version, the controller has 8 directions of movement for the following function: destination
input using crosshairs.
 Loudspeakers
The loudspeakers output the audio signals from the M-ASK or the CCC, as applicable.
The control unit that manages the functions of iDrive depends on the vehicle equipment:
 M-ASK: Multi-audio system controller
The M-ASK combines a number of functions in a single control unit, as follows:
Audio system controller (ASK)

 Control unit for the Central Information Display
 Navigation system with DVD drive
 Aerial tuner
 CCC: Car Communication Computer
The CCC incorporates further functions at the top end of the range in the form of a control unit (e.g. voice
recognition system).
2009 BMW 650i
The M-ASK or the CCC generates the LVDS data (Low Voltage Differential Signaling) for graphical
presentation on the Central Information Display.
SYSTEM FUNCTIONS
The further development of the iDrive for the 5 Series, 6 Series and 1 Series comprises:
 revised menus
 hierarchical structure of the menus
 Additional orientation guides
Revised menus
The start menu consists of 4 menus.
The 4 menus on the Central Information Display are situated on intersecting axes in the same way as the 4
points of the compass (as viewed in the clockwise direction) as follows:
 Communication
Slide the Controller forward (= "north"): e.g. functions such as telephone, short text message or BMW
Assist
 Navigation
Slide the Controller to the right (= "east"): e.g. functions such as route, on -board information or address
book
 Entertainment
Slide the Controller back (= "south"): e.g. functions such as radio, CD or TV
 Climate
Slide the Controller to the left (= "west"): e.g. functions such as air distribution or heat distribution for
seats
There is also an additional fifth menu for selecting the individual user presets.
 Settings (i= Information)
Press Controller in the start menu: e.g. functions such as "Settings for entertainment", "Settings for
display" and "Settings for vehicle"
The start menu will always appear when the menu button behind the controller is pressed.
2009 BMW 650i
Exceptions to this are the submenus in menu 5: When the Controller is pressed, menu 5 "Settings" is initially
called up. If the controller is pressed once more, the start menu is called up.
Hierarchical structure of the menus (operating logic)
The operating logic has a strictly hierarchical menu structure.
 Displaying the menu path
The current position in the menu structure can be seen by displaying the menu path (list of menu items
selected to date in the individual menu lines, reading from top to bottom).
 Navigating through the menus
Slide the Controller to switch from one menu to another.
Sliding the Controller forward means: Go one level higher in the menu hierarchy. Sliding the Controller
to the rear means: Go one level lower in he menu hierarchy.
In split-screen mode, sliding the Controller to the right selects the assistance window. Slide the Controller
to the left to exit the assistance window (assistance window displays additional information).
 Changing the settings
If you want to change settings or view them in the submenus, turn the controller and press it down.
Additional orientation guides
The following features provide visual orientation in the menus:
 Orientation by special background colours
Each menu has a background colour of its own.
Communication = blue
Navigation = green
Entertainment = orange
Climate = red
Settings = grey
The associated submenus also have the same background colour. This makes assignment of the submenus
straightforward.
2009 BMW 650i
 Orientation by position indicator
A small, coloured symbol for each of the 4 menus appears in the top menu line: A diamond. The 4
corners of the diamond correspond to the 4 directions of the menus. A small square indicates the corner
corresponding to the currently selected menu.
 Status line for information at a glance
The status line contains the most important information on the various functions, such as settings of the
air conditioning system or the radio station currently selected.
The start menu always appears when the menu button behind the controller is pressed.
National versions
The language package for the possible display languages is encoded at the end -of-line.
Subject to change.
INSTRUMENT CLUSTER E60, E61, E63, E64
Fig. 4: Identifying Instrument Cluster

2009 BMW 650i
INTRODUCTION
The instrument cluster in the BMW 5 -Series and in the BMW 6-Series is distinguished by: compact design and
conspicuous optics. Two large pointer instruments show speed and engine revolutions. On the E63/E64, the
speedometer has a finer scale.
2 small pointer instruments (hanging needles) display the following:
 E61/E61: Fuel reserve and current fuel consumption

 E63/E64: Fuel reserve and engine oil temperature
The single-colour indicator and warning lights are arrayed between the two pointer instruments.
There is no warning light to indicate that the fuel level is low. Then the fuel reserve level has been reached, a
Check - Control message will be displayed.
Between the two pointer instruments there is an LCD display.
For the first time, 2 moving -disc instruments are used in the instrument cluster. The moving-disc instruments
show the speed setting for the cruise control system and the variable engine speed warning zone.
The scales of the instrument cluster are country -specific, vehicle-specific and engine-specific. Navigation-
system messages are not shown in the instrument cluster.
The instrument cluster receives input signals from the following components:
 Ambient temperature sensor
The ambient temperature sensor supplies the value for the temperature outside the vehicle to the
instrument cluster. The ambient temperature is shown on the LCD display. Instrument resolution is 0.5 °C
(1 °F). The value for ambient temperature is also made available to other control units via the K -CAN.
 Fuel-level sensors, left and right
The fuel tank contains two fuel -level sensors. Each fuel-level sensor sends a signal indicating the amount
of fuel in the tank. A value is obtained by adding the two signals.
 Coolant-level switch
The coolant-level switch sends a signal if the coolant level is too low (Reed contact). The information is
output on the LCD display in the form of a Check -Control message.
 Windscreen washer fluid level switch

2009 BMW 650i
The windscreen washer fluid level switch sends a signal if the fluid level is too low. The information is
output on the LCD display in the form of a Check -Control message.
 Parking brake warning switch
The parking brake warning switch indicates that the handbrake is applied. The general brake warning
lamp lights up red when the handbrake is applied.
 Reset button
The reset button is used for the following functions:
 Reset trip meter

 Call up Condition Based Service (CBS)
 Call up Test functions (only for service staff)
 Axial buttons in turn-signal/main-beam switch
The axial buttons (Check-Control button at top, on -board computer button at bottom) are for the
following functions:
 Menu of the Check -Control system in the LCD display and clock/date selection
 Menu of the on-board computer in the LCD display
The signal generated when one of the axial buttons is pressed is transmitted through the bus system.
The following control units communicate via the PT-CAN or the K-CAN with the control unit of the instrument
cluster:
 Dynamic Stability Control
An active regulation sequence or a fault in the DSC will be indicated by the corresponding indicator and
warning light (ABS, DSC or DTC).
The brake pad wear sensors are also connected to the DSC control unit. The general brake warning light
is actuated if the brake pads wear to the permissible limit. Front and rear brake pad wear is a CBS service
operation (sensor-based).
 Active Cruise Control
There are now a permanent indicator and warning lights in the instrument cluster for Active Cruise
Control (ACC). They indicate: Object detected or driver override, distance levels 1 to 4.
 Active front steering
A fault in the active front steering system is indicated by the corresponding indicator and warning light
2009 BMW 650i
 Digital engine electronics or digital diesel electronics
The appropriate indicator and warning light is activated to indicate a fault in the DME or DDE.
Engine oil is a CBS service operation (sensor -based).
 Electronic transmission control
The EGS control unit supplies the signal for the gear engaged to the instrument cluster. The selected gear
is shown in the selector -lever and shift indicator in the LCD display.
 Safety and gateway module
The appropriate indicator and warning light is activated to indicate a fault in the passive safety system
(airbag).
The SGM is the gateway between the byteflight , PT-CAN and K-CAN data buses . The diagnosis lead
is also connected at the SGM.
 Light module
A fault in the lighting system is indicated by the light module (LM) actuating the corresponding indicator
and warning light.
 Integrated automatic heating and air -conditioning system
The IHKA calculates the condition of the microfilter. The condition of the microfilter is CBS service
operation.
 Car Access System
The CAS control unit serves for redundant data storage. The following are stored in the CAS control unit
(redundantly to the instrument cluster):
 Vehicle identification number

 Odometer reading
 CBS data
 Multi-audio system controller / Car Communication Computer and Central Information Display
For the instrument cluster, the M -ASK and CCC serve as an interface to the Central Information Display
(CID). The CID displays detailed texts concerning Check -Control messages and information about CBS
and other on-board computer functions. The CID also enables the driver to change the units of
measurement (e.g. Celsius to Fahrenheit, and vice versa) for the instrument cluster.
Moreover, the M -ASK and CCC establish a telephone connection when a CBS serve operation is due (=
2009 BMW 650i
Other control units communicate via the bus to send messages (Check-Control messages) to the instrument
cluster. The instrument cluster emits these Check -Control messages via symbols in the LCD display.
The instrument cluster internally controls the following instruments and indicators:
 Pointer instruments and moving-disc indicators
The instrument cluster incorporates a number of instruments that operate with step motors, namely:
 Speedometer
 Revolution counter
 Fuel gauge
 Fuel consumption indicator (E60/E61)
 Engine oil temperature (E63/E64)
 Moving-disc instrument for the speed setting of the cruise control system
 Moving-disc instrument for the variable engine-revolutions advance-warning field
 Indicator and warning lights:
The single-colour indicator and warning lights that are required by law are at the top, centered between
the two large analogue instruments (exception: turn signal indicator lights at sides).
The most important indicator and warning lights briefly light up during the pre -drive-check when
terminal 15 is switched ON. The indicator warning lights and symbols are illuminated by LEDs which are
soldered into place.
 LCD display
The LCD display is centered at the bottom between the two large pointer instruments. The LCD display is
divided into two zones. The top zone shows information such as the time and date and the ambient
temperature. In addition, Check-Control messages appear by means of a symbol in the top area. The
bottom zone displays information concerning the on-board computer functions, for example, and the
drive range currently selected for the automatic transmission. The LCD display is activated when terminal
R is switched ON.
 Acoustic generator
Acoustic warnings are issued in support of the Check-Control messages. The instrument cluster controls
these warnings by means of the K -CAN. The M-ASK and CCC emit acoustic warnings through the
loudspeakers.
An additional loudspeaker in the instrument cluster issues the following acoustic warnings:
 Flash
 Hazard warning lights
2009 BMW 650i
SYSTEM FUNCTIONS
The control unit of the instrument cluster incorporates certain functions over and above the display and
indication functions, namely:
 Lighting of the instrument cluster

 Dimming of the instrument cluster
 High and low-voltage detection for the instrument cluster
 Heating and contrast for the LCD display
 On-board computer functions
 Check -Control messages
 Pre-drive check
 Condition Based Service (CBS)
 Vehicle identification check
Lighting of the instrument cluster
The instrument cluster has an integral power supply unit. The power supply is connected to terminal 30. The
power supply provides the supply voltage for the instrument cluster.
This arrangement means that the lighting of the instrument cluster is independent of the onboard power supply.
If the onboard power supply is disrupted (voltage dips), the brightness cannot fluctuate.
LEDs in BMW orange provide backlighting for the LCD display, the pointers of the analog instruments and the
scale rings.
The pointers and the scale rings are illuminated when the lights are switched ON (= function display).
The display itself is not backlit unless it contains a reading.
Dimming of the instrument cluster
The brightness of the LCD display and all indicator and warning lights is adapted to suit ambient lighting
conditions. This function is implemented by a phototransistor in the instrument cluster.
The brightness signal is calculated in the instrument cluster on the basis of the following values:
 Signal from the phototransistor (ambient luminosity)

 Dimmer signal (on the control panel for the lights)
The brightness signal calculated in this way is made available to the other control units via the K -CAN.
High and low-voltage detection for the instrument cluster

2009 BMW 650i
memory are permitted. The instrument cluster initiates data backup in advance of a pending reset triggered by
undervoltage.
Overvoltage in the onboard power supply is also detected.
If the on-board voltage is greater than 16 volts:
 Certain inputs and outputs are disabled in order to protect the hardware.
 Indicator and warning lights are dimmed for the duration of the overvoltage or are deactivated in order to
prevent overload.
Heating and contrast for the LCD display
A heater built into the display ensures good legibility even at low ambient temperatures. The heater is switched
on if the temperature of the LCD display is below 10 °Celsius. The switch-on signal is transmitted (by the CAS
control unit to the instrument cluster via the K -CAN) when the driver's door is opened.
The contrast of the LCD display is automatically set as a function of the temperature of the LCD display and the
operating time. A counter registers the standby times and operating times logged by the instrument cluster, so
that due allowance can be made for ageing. Contrast voltage is automatically adjusted depending on increasing
time in operation (ageing).
On-board computer functions
There are two ways in which on-board computer functions can be displayed:
 in the instrument cluster

 in the Central Information Display (extended on -board computer functions)
The on-board computer functions for the instrument cluster are as follows:
 Ambient temperature
 Time
 Date
 Average consumption (resettable)
 Range
 Average speed (resettable)
The on-board computer function required can be displayed: When terminal R is ON by pressing the on -board
computer button on the turn -signal/main-beam switch in a specific sequence. The last line is followed by an
empty line, before the first line reappears on the screen (rolling list). When terminal R switches ON, the on -
board computer function most recently selected by means of the on -board computer button reappears. If the on-
board computer button is pressed and held down for longer than 2 seconds, the values of the resettable on -
board computer functions are recalculated.
2009 BMW 650i
Check-Control messages
The Check-Control system informs the driver if important functions, information or warnings are no longer
available. Check-Control messages are displayed in the form of a symbol on the LCD display (red, yellow,
orange). The instrument cluster discharges the functions of priority control for the Check -Control messages.
The readings for time and date and ambient temperature are overwritten. If a Check -Control message is present
but not displayed, this will be indicated by warning triangle in the LCD display.
Supplementary notes and instructions are available for most Check-Control messages and are displayed in the
Central Information Display (CID) (short form can be found in the status bar).
In addition to the visual display, the Check-Control system also alerts the driver with acoustic signals.
Depending on the importance of the associated message, a single or double gong with varying volume and tone
will sound.
Current Check-Control messages can be called up with the Check-Control button (press and hold for longer
than 2 seconds) on the turn-signal/main-beam switch. The Check-Control messages can then be viewed in
sequence (press for less than 2 seconds). When the Check-Control button is pressed, this is registered via the K
-CAN.
If 8 seconds pass without a button being pressed, either the time and ambient temperature or a current Check -
Control message with priority 1 will appear.
Pre-drive check
The pre-drive check serves as:
 A check of internal functions in the instrument cluster

 Monitoring of the live signals from all control units that may emit Check -Control messages
During the pre-drive check, the most important indicator and warning lights are activated for 4 seconds when
terminal 15 is switched ON. Exception: Indicator and warning lights for airbags actuated when terminal R is
switched ON.
The following indicator and warning lights are activated in the pre-drive check:
 Seat-belt warning
 Airbag (initially yellow, then red)
 Anti -lock brake system (ABS)
 General brake warning light (initially yellow, then red)
 Emission warning lamp
 Dynamic Stability Control (DSC)
 Active Front Steering
 ACC control by driver or object detected (initially yellow, then red)
2009 BMW 650i
Once a pre-drive check completes successfully, all indicator and warning lights are switched off. If a fault
occurs during the pre-drive check, the check is interrupted for the system in question. The indicator and warning
lights for this system remain on. The Check-Control system issues the appropriate message.
Condition Based Service
Condition Based Service (CBS), as the name suggests, is a means of ensuring that the car is serviced as and
when necessary. CBS has been in use in the field of service since the launch of the E65. CBS is a landmark in
the increasingly close communication and networking between vehicles and Service. The vehicle -specific
scope of service required is registered automatically. In conjunction with TeleService1, an automatic Service
call can be placed, notifying the home dealership that Service is due.
The instrument cluster calculates when a service interval is due. When terminal 15 is switched ON, the "Next
Service" indicator appears in the LCD display (remaining visible for 6 seconds). The countdown distance or the
countdown time is also shown.
More information on CBS can be called up at the same time on the central information display (CID).
At this time, nine CBS scopes have been defined for the E60:
 Engine oil
 Micro filter
 Front brake pads
 Rear brake pads
 Brake fluid
 Vehicle check
 Spark plugs (DME only)
 Statutory vehicle inspection
 Statutory emissions test
The service interval can be reset by means of the reset button in the instrument cluster (press and hold down for
longer than 5 seconds). The target date for the vehicle inspection and emissions test can only be entered in the
CID via the controller.
Vehicle identification check
The information stored redundantly in the instrument cluster and the CAS control unit (Car Access System) is:
 Vehicle identification number

 Odometer reading
 CBS data
The vehicle identification number and odometer are used to prevent manipulation. CBS data are important in
the service organization (KeyReader and service acceptance module (SAM)) and must not be lost
2009 BMW 650i
US national version
The speed scale is shown in both mph (miles per hour) and in km/h (kilometres per hour). Fuel consumption is
shown in mpg (miles per gallon).
The general brake warning lamp is replaced by: the word "BRAKE".
The indicator lamp for rear foglight is not activated.
The indicator and warning light for the engine is replaced by: the words "SERVICE ENGINE SOON".
The warning "CHECK GAS CAP" is displayed by a Check-Control message (symbol).

2005 BMW 645Ci
2004-05 ACCESSORIES & BODY, CAB Instruments - Repair Instructions - E63
Instruments - Repair Instructions - E63
INSTRUMENT CLUSTER
62 11 280 REMOVING AND INSTALLING (REPLACING) INSTRUMENT CLUSTER
IMPORTANT: Read and comply with notes on protection against electrostatic discharge (ESD
DISCHARGE) .
NOTE:  Comply with notes and instructions on handling fibre-optic cables, refer to
61 00 ... NOTES ON HANDLING OPTICAL FIBERS .
 Extend steering wheel completely and lower

IMPORTANT: Risk of damage! Cover instrument panel (2) on both sides of instrument cluster
(3) with suitable protective film (1) to prevent damage.
2005 BMW 645Ci
Fig. 1: Identifying Instrument Cluster Components

Release screws (1).
Pull back instrument cluster (2) slightly.
Unlock associated plug connection and disconnect.
Feed out/unclip associated wiring harness.
Remove instrument cluster (2).

2005 BMW 645Ci
Fig. 2: Removing Instrument Cluster

Replacement:

HEAD-UP-DISPLAY
2005 BMW 645Ci
62 30 ... ADJUSTING HEAD-UP DISPLAY (DISPLAY ADJUSTMENT)
NOTE: Display adjustment (correction of lopsided display) is possible from 12/2003.

The following text only describes display adjustment. How to adjust the height
of the head-up display is described separately, refer to 62 30 517 ADJUSTING
HEAD-UP DISPLAY (HEIGHT ADJUSTMENT).
NOTE: Vehicles with head-up displays are fitted with special windscreens. These
windscreens are marked with the letters "HUD" on the outside at bottom right
below the seal (1). Prior to adjustment, fold seal (1) back and make sure that a
correct windscreen is fitted.


2005 BMW 645Ci
 Check that windscreen bears the "HUD" label

ONBOARD MONITOR .
 If necessary, cover windscreen (to darken the adjustment image)
 Switch on head-up display.
 Call up test image 6 via diagnosis
Unclip flexible shaft (1) in direction of arrow from holder (2).
IMPORTANT: Turn flexible shaft (1) in clockwise direction only, otherwise risk of breakage!
Fig. 4: Unclipping Flexible Shaft From Holder

Turn flexible shaft (1) by hand for display adjustment.

2005 BMW 645Ci
62 30 005 REMOVING AND INSTALLING/REPLACING TRIM FOR HEAD-UP DISPLAY
NOTE: For special tools, refer to INSTRUMENTS - SPECIAL TOOLS - 645CI (E63) .
 00 9 317
Lever out trim for head-up display (1) with special tool 00 9 317 from mounting points (2).
Fig. 5: Levering Out Trim For Head-Up Display With Special Tool 00 9 317
Feed trim for head-up display (1) in direction of arrow out of instrument panel trim (2) and remove.
Installation:
2005 BMW 645Ci
Fig. 6: Ensure Retaining Lugs Of Trim For Head-Up Display Are Correctly Seated
62 30 010 REMOVING AND INSTALLING/REPLACING HEAD-UP DISPLAY
DISCHARGE) .
IMPORTANT: Do not scratch head-up display lens!
PANEL TRIM .
2005 BMW 645Ci
Release screws (1).
Remove air duct (2) from air distributor (3).
If necessary, remove fitted foam seal (4) from head-up display (5).
Fig. 7: Removing Fitted Foam Seal From Head-Up Display

If necessary, unclip fitted flexible shaft (display adjustment), refer to 62 30 ... ADJUSTING HEAD-UP
DISPLAY (DISPLAY ADJUSTMENT).
Installation:
 Clean head-up display lens.

2005 BMW 645Ci
 Adjust head-up display (5), refer to 62 30 ... ADJUSTING HEAD-UP DISPLAY (DISPLAY
ADJUSTMENT) or 62 30 517 ADJUSTING HEAD-UP DISPLAY (HEIGHT ADJUSTMENT).
 Make sure eccentric (2) is in correct installation position.
 If fitted, make sure flexible shaft is in correct installation position.
Release lock nut (1) and remove.
Remove eccentric (2) in direction of arrow.
Release screws (3).
Pull head-up display (5) back slightly and fold upwards.
Unlock and disconnect plug connection (4) and remove head-up display (5).
Fig. 8: Removing Head-Up Display

2005 BMW 645Ci
Installation:
Make sure centering caps (1) are correctly seated on lugs (2) of head-up display (3).
Fig. 9: Centering Caps Are Correctly Seated On Lugs Of Head-Up Display

Replacement:
Carry out programming/coding.

2005 BMW 645Ci
62 30 517 ADJUSTING HEAD-UP DISPLAY (HEIGHT ADJUSTMENT)
NOTE: For special tools, refer to INSTRUMENTS - SPECIAL TOOLS - 645CI (E63) .
 62 1 121
 62 1 122
NOTE: The following text only describes how to adjust the height of the head-up
display. How to correct a lopsided display (display adjustment) is described
separately, refer to 62 30 ... ADJUSTING HEAD-UP DISPLAY (DISPLAY
ADJUSTMENT).
NOTE: Vehicles with head-up displays are fitted with special windscreens. These
windscreens are marked with the letters "HUD" on the outside at bottom right
below the seal (1). Prior to adjustment, fold seal (1) back and make sure that a
correct windscreen is fitted.
2005 BMW 645Ci
Fig. 10: Identifying Correct Windscreen Fitted

 Check that windscreen bears the "HUD" label

 Move steering wheel into maximum "lower" and "retracted" position
 Unclip both sun visors from counter-supports and fold to one side
 If necessary, cover windscreen (to darken the adjustment image)
 Switch on head-up display.
 Call up test image via diagnosis for height adjustment Switch on test image for max. 1/2 hour.
If test image is operated for a longer period, switch fan to speed 3 to avoid overheating.
IMPORTANT: Do not scratch windscreen when installing and removing special tool 62 1 121.
2005 BMW 645Ci
Carefully engage special tool 62 1 121 in both counter-supports (1) of sun visors.
NOTE: If special tool 62 1 121 is difficult to engaged, if necessary release its adjusting
screws and turn/switch the associated locators.
Center special tool 62 1 121 and secure with adjusting screws (2).
Fig. 11: Centering Special Tool 62 1 121 And Securing With Adjusting Screws
Check height adjustment using scale on special tool 62 1 121.

2005 BMW 645Ci
Fig. 12: Checking Height Adjustment Using Scale On Special Tool 62 1 121
If height adjustment is not correct:

ONBOARD MONITOR .
 To avoid damage: apply fabric adhesive tape (1) in area of on-board monitor to decorative strip on
instrument panel on right side (2).
 Fit special tool 62 1 122 as illustrated on lock nut (3).
 Release lock nut (3).
 Correct height adjustment by turning eccentric.
 Secure lock nut (3), tightening torque 18.5 N.m

2009 BMW 650i
SUSPENSION Integrated Suspension Systems - 650i, M6
SUSPENSION
Integrated Suspension Systems - 650i, M6
00 GENERAL
 Headaches
 Dizziness
 Stomach aches
 Vomiting
 Diarrhoea
 Cramps/fits
 Unconsciousness

First aid measures:
Danger of injury!

2009 BMW 650i
 Impaired sight

First aid measures:

Recycling:

2009 BMW 650i
1. Use only BMW-distributed/approved trolley jacks which have rubber plate contact points.
2. Trolley jacks must be regularly serviced and always checked for functional reliability before they are
used!
3. Check the rubber plate on the trolley jack prior to each use, replacing if necessary.
Fig. 1: Identifying Trolley Jacks

points!

2009 BMW 650i
Fig. 2: Identifying Vehicle Jacking Points

37 ... . OVERVIEW OF INTEGRATED SUSPENSION SYSTEMS (FRONT AXLE)
Fig. 3: Identifying Vent Hose, Dynamic Drive Control Unit And Transversal Acceleration Sensor
37 .. ... OVERVIEW OF INTEGRATED SUSPENSION SYSTEMS (REAR AXLE)

2009 BMW 650i
Fig. 4: Identifying Pressure Line For Oscillating Motor And Active Stabilizer
37 10 001 INITIAL OPERATION WITH TEST RUN OF DYNAMIC DRIVE
NOTE: The Service function Initial operation of Dynamic Drive must be carried out
after:
 Work on the Dynamic Drive system which involved opening hydraulic lines
 Replacement / Programming / Coding Dynamic Drive control unit
 Replacement lateral acceleration sensor
 Parameters and zero point of new sensors have been learned
Bleeding power steering:
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!
Use only Pentosin CHF11S from original containers!
The fill level may only be checked or adjusted when the engine is stopped! The
2009 BMW 650i
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.
CHF Pentosin CHF11S
Fig. 5: Identifying Fluid Reservoirs Caps With Identification Marks

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 15 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 . See INTEGRATED SUSPENSION SYSTEMS --
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
2009 BMW 650i
Performing initial operation with test run:

Vehicle executes heavy rolling motions during initial operation! Therefore
observe the following instructions without fail:
 Do not allow any persons to remain in the vehicle or directly on the

vehicle
 Keep the vehicle doors closed.
 Maintain a safety distance around the vehicle of 1 m to persons,
objects, walls etc.
 Vehicle must be standing horizontally with all wheels on a firm
surface
 Do not under any circumstances carry out initial operation on a
lifting platform, wheel alignment analyzer or similar!
 Avoid heavy loads
1. Check load; if necessary, remove load from the vehicle

2. Bring engine up to operating temperature
NOTE: Hydraulic fluid temperature must be between 50 °C and 70 °C (vehicle at

normal operating temperature)
3. Connect vehicle to DIS or MoDiC BMW scan tool.

4. Start initial operation in SERVICE FUNCTIONS. Follow instructions in DIS.
11 FRONT CONTROL AND SUSPENSION ELEMENTS

37 10 ... REMOVING AND INSTALLING/REPLACING PRESSURE RELIEF VALVES
IMPORTANT: Before releasing, it is essential to remove corrosion and dirt from the area
around the pressure relief valves!
Pull vent hose (3) out of Y-piece at marked position (see arrow). Vent line can be removed by sliding back the
protruding collar on the Y-piece.
IMPORTANT: Do not open banjo bolts (2).

2009 BMW 650i
Release pressure relief valve (1) directly from oscillating motor.
Fig. 6: Release Pressure Relief Valve (1) Directly From Oscillating Motor
Installation: Replace distributor lines (2). Screw pressure relief valve fully into oscillating motor and remove
plug. Tightening torque, see 37 11 1AZ in 37 11 CONTROL AND SUSPENSION ELEMENTS, FRONT .
IMPORTANT: Slide in yellow distributor line in forward direction of travel and black
distributor line in rearward direction of travel. Slide distributor lines (2) into
pressure relief valve (1) up to second marking (M).
Fig. 7: Slide Distributor Lines (2) Into Pressure Relief Valve (1) Up To Second Marking (M)
37 10 005 REMOVING AND INSTALLING/REPLACING VENT HOSE FOR ACTIVE STABILIZER

(FRONT)

2009 BMW 650i
 Remove front assembly underside protection . See 51 47 490 REMOVING AND INSTALLING /
Distribution hose:
Release nuts (1).
Tightening torque 37 11 2AZ. See INTEGRATED SUSPENSION SYSTEMS - TIGHTENING TORQUES

-- 650I .
Withdraw vent line (3) from distribution hose (2).
Remove distribution hose (2).
Fig. 8: Identifying Vent Line From Distribution Hose

Vent hose:
Withdraw seal plug (1) from front axle carrier.
Remove vent line with filter from front axle carrier.

2009 BMW 650i
Fig. 9: Identifying Seal Plug From Front Axle Carrier

Observe the following when replacing vent valves:
Release vent valves (1).
Installation:
Push distribution hose (2) into vent valves (1) up to middle between markings (M).

-- 650I .
Screw vent valves (1) completely into oscillating motor.
Remove assembly plugs from both vent valves (1).
Fig. 10: Pushing Distribution Hose Into Vent Valves

2009 BMW 650i
system.
NOTE: A light film of grease on the anti-friction bearing in no way impairs the
operational capability of the stabilizer.
In a warranty case you must always provide a fault memory printout, even
where there is no fault memory entry, with the defective part.
 Remove stabilizer link on both sides from stabilizer . See 31 35 005 REMOVING AND
INSTALLING/REPLACING PUSH ROD (STABILIZER LINK) FOR LEFT/RIGHT
STABILIZER .
IMPORTANT: Risk of damage! Pressure lines must not have any contact with the stabilizer
(minimum distance 5 mm)!
Mark installation position of pressure lines to oscillating motor.
Remove pressure and vent lines from oscillating motor.
Installation:
Carry over identification to new component.
Pressure lines are protected against being mixed up by different thread diameters on the oscillating motor
connection.

TORQUES -- 650I .
2009 BMW 650i
Fig. 11: Identifying Pressure Lines To Oscillating Motor Nut

IMPORTANT: To prevent the stabilizer from being distorted, secure first the left retaining
bracket (without elongated holes) and then the right retaining bracket (with
elongated holes) to the front axle carrier.
If necessary, remove holder with hydraulic line(s) from retaining bracket.
Release screw (1) and nut (2) on both sides.
Check anti-friction bearing on both sides for damage; if necessary, replace stabilizer (observe note at start of
repair instruction).
Installation:
Check rubber mount on both sides , replace if necessary. See 31 35 021 REPLACING RUBBER MOUNTS
OF STABILIZER RETAINING FIXTURE ON FRONT AXLE CARRIER .
Tightening torque 31 35 1AZ. See FRONT AXLE - TIGHTENING TORQUES -- 650I .

2009 BMW 650i
Fig. 12: Identifying Hydraulic Line From Retaining Bracket Nut And Screw
Replacement:
Remove rubber mount on both sides from stabilizer. See 31 35 021 REPLACING RUBBER MOUNTS OF
STABILIZER RETAINING FIXTURE ON FRONT AXLE CARRIER .
After installation:
 Fill and bleed hydraulic system . See 32 13 006 BLEEDING POWER STEERING UNIT .
 Carry out initial DYNAMIC DRIVE operation. See 37 10 001 Initial operation with test run of
Dynamic Drive.
12 REAR CONTROL AND SUSPENSION ELEMENTS

37 12 220 REMOVING AND INSTALLING/REPLACING REAR ACTIVE STABILIZER
 33 0 170 . See REAR AXLE - SPECIAL TOOLS -- 650I .
system.
operational capability of the stabilizer.
2009 BMW 650i

 E64: Remove rear cross strut by first removing exhaust system. See EXHAUST SYSTEM - REPAIR
INSTRUCTIONS . Remove rear left and right heat shields. Release nuts and screws. Tightening torque
51 61 6AZ. See BODY EQUIPMENT - TIGHTENING TORQUES . Remove cross strut toward
bottom.
Release screws (1).
Installation:
Insert screws (1).
Align pressure lines to rear axle carrier.

TORQUES -- 650I .
Fig. 13: Identifying Rear Axle Carrier Screw

Remove stabilizer from rear axle carrier.
2009 BMW 650i
Installation:
Check rubber mount on both sides , replace if necessary. See STABILIZER BAR RUBBER MOUNTS .
Tightening torque 33 55 3AZ. See REAR AXLE - TIGHTENING TORQUES .
Fig. 14: Identifying Rear Axle Carrier Nut


TORQUES -- 650I .
Disconnect pressure lines and seal off with seal plugs.
Remove stabilizer links on both sides from stabilizer. See 33 55 040 REPLACING STABILIZER LINKS
FOR STABILIZER .
Installation:
connection.
2009 BMW 650i
Fig. 15: Identifying Stabilizer Nuts

Assembly: Pressure lines to oscillating motor
NOTE: Before the stabilizer is installed, the pressure lines must be aligned to the
oscillating motor and secured using banjo bolts.
Installation:
1. Screw nuts into stabilizer, do not tighten down

2. Attach special tool 33 0 170 to pressure lines (the side of the special tool illustrated must point in the
direction of the oscillating motor)
3. Tighten down nuts

TORQUES -- 650I .
4. Remove special tool

2009 BMW 650i
Replacement:
Remove rubber mount on both sides from stabilizer. See STABILIZER BAR RUBBER MOUNTS .
After installation:
 Fill and bleed hydraulic system See 37 10 001 Initial operation with test run of Dynamic Drive.
 If necessary, carry out initial Dynamic Drive operation . See 37 10 001 Initial operation with test run of
Dynamic Drive.
13 CONNECTING LINES
37 13 100 REMOVING AND INSTALLING/REPLACING PRESSURE LINES FOR OSCILLATING
MOTOR/FRONT AXLE
Remove front pressure lines (1) (from oscillating motor to junction I at side in wheel arch)
Remove rear pressure lines (2) (from junction I to valve block)
Fig. 17: Identifying Front Pressure Lines And Rear Pressure Lines
37 13 110 REMOVING AND INSTALLING/REPLACING PRESSURE LINE FOR OSCILLATING

MOTOR/REAR AXLE
Remove front pressure lines (1) (from valve block to junction I on vehicle underbody)
Remove middle pressure lines (2) (from junction I to junction III on vehicle underbody)
Remove rear pressure lines (3) (from junction III on vehicle underbody to oscillating motor)
2009 BMW 650i
Fig. 18: Identifying Front Pressure Lines, Rear Pressure Lines And Middle Pressure Lines
14 ELECTRICAL COMPONENTS
NOTE: The Service function Initial operation of Dynamic Drive must be carried out
after:
 Work on the Dynamic Drive system which involved opening hydraulic lines
 Replacement / Programming / Coding Dynamic Drive control unit
 Replacement lateral acceleration sensor
 Parameters and zero point of new sensors have been learned
Bleeding power steering:
system.
CHF Pentosin CHF11S

2009 BMW 650i


temperature) adjust a fill height 15 mm above the "MAX"mark. Do not
Hydraulic fluid: see OPERATING FLUIDS - INTEGRATED SUSPENSION SYSTEMS .
3. Start engine
Performing initial operation with test run:

Vehicle executes heavy rolling motions during initial operation! Therefore
observe the following instructions without fail:
 Do not allow any persons to remain in the vehicle or directly on the

vehicle
 Keep the vehicle doors closed.
2009 BMW 650i
 Maintain a safety distance around the vehicle of 1 m to persons,

objects, walls etc.
 Vehicle must be standing horizontally with all wheels on a firm
surface
 Do not under any circumstances carry out initial operation on a
lifting platform, wheel alignment analyzer or similar!
 Avoid heavy loads
1. Check load; if necessary, remove load from the vehicle

2. Bring engine up to operating temperature
NOTE: Hydraulic fluid temperature must be between 50 °C and 70 °C (vehicle at

normal operating temperature)
3. Connect vehicle to DIS or MoDiC

4. Using DIS or MoDiC, Start initial operation in SERVICE FUNCTIONS. Follow instructions in DIS.
37 14 017 REMOVING AND INSTALLING/REPLACING FRONT MOUNTED ACCELERATION

SENSOR (M MODEL)
DISCHARGE) .

 Partially detach front wheel arch cover (in rear area). See 51 71 040 REMOVING AND
Release screws (1). Disconnect plug connection (2). Remove front mounted acceleration sensor (3).
2009 BMW 650i
Fig. 20: Removing Front Mounted Acceleration Sensor

37 14 027 REMOVING AND INSTALLING/REPLACING REAR MOUNTED ACCELERATION

SENSOR (M MODEL)
DISCHARGE) .
 Remove luggage compartment trim on side panel on right. See 51 47 161 REMOVING AND
Unscrew nuts (1). Disconnect connector (2). Remove rear mounted acceleration sensor (3).
Fig. 21: Removing Rear Mounted Acceleration Sensor (3)

2009 BMW 650i
37 14 055 REMOVING AND INSTALLING/REPLACING DYNAMIC DRIVE CONTROL UNIT
DISCHARGE) .
 Disconnect battery negative lead . See 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND
 Remove trim for instrument panel, bottom left . See 51 45 181 REMOVING AND
 Remove side trim in front right footwell . See 51 43 075 REMOVING AND
Release nut (2) and nut (concealed) above control unit.

TORQUES -- 650I .
Pull out Dynamic Drive control unit towards bottom.
Fig. 22: Releasing Nut Control Unit

After installation:
 Replacement only: Using scan tool, carry out programming/coding

 Only when replacing / programming / coding: Carry out steering angle sensor adjustment/adjustment for
active front steering . See 32 10 005 ADJUSTMENT FOR ACTIVE FRONT STEERING .
2009 BMW 650i
001 Initial Operation With Test Run Of Dynamic Drive.

 Version with active front steering: Teach in mid-position for power steering . See 32 00 ... TEACHING
IN CENTER POSITION FOR POWER STEERING (ACTIVE FRONT STEERING) (FROM
03/2007) .
37 14 511 REPLACING FRONT RIDE-HEIGHT SENSOR
DISCHARGE) .
NOTE:  Build date up to 03/04: Variant (A) - connection (1) points downwards
 Build date from 03/04: Variant (B) - connection (2) points upwards
Build date up to 03/2004:
IMPORTANT: If the front ride-height sensor has been installed twisted in relation to variant
(A), e.g. due to wiring harness replacement, the following control units must be
recoded.
 Light module with headlight vertical aim control

 Adaptive headlight
Fig. 23: Identifying Front Ride-Height Sensor Relation To Variant

 If necessary, remove right steering gear cover
Shown on build date up to 03/2004:

2009 BMW 650i
Release nut (1) and disconnect jointed rod.

-- 650I .
Release screws (2), remove ride-height sensor from bracket and disconnect plug connection (3).
Installation:
Sensor lever must point from ride-height sensor to right front wheel.
Build date up to 03/04: If necessary, tie back connecting cable for ride-height sensor.

-- 650I .
Fig. 24: Locating Plug Connection, Nut And Screw

After installation:
 Check headlight adjustment, correct if necessary.
37 14 511 REPLACING FRONT RIDE-HEIGHT SENSOR (M5, M6)
DISCHARGE) .
 Remove right steering gear cover.

2009 BMW 650i
COMPONENTS . Release screws (2), remove ride-height sensor from bracket and disconnect plug connection
(3).
Installation: Sensor lever must point from ride-height sensor to right front wheel. Tightening torque, see 37 14
6AZ in 14 ELECTRICAL COMPONENTS ..
After installation: Check headlight adjustment, correct if necessary. See 63 10 004 ADJUSTING
HEADLIGHTS .
37 14 512 REPLACING REAR RIDE-HEIGHT SENSOR
DISCHARGE) .
Release nut and disconnect jointed rod (3).
Installation:

TORQUES .
Release screws (1).

TORQUES .
Disconnect plug connection (4) and remove ride-height sensor.
Installation:
Sensor lever (2) must point outwards from ride-height sensor.

2009 BMW 650i
Fig. 25: Identifying Sensor Lever, Plug Connection And Jointed Rod
After installation:
 Check headlight adjustment, correct if necessary. See 63 10 004 ADJUSTING HEADLIGHTS .
37 14 610 REMOVING AND INSTALLING / REPLACING TRANSVERSAL-ACCELERATION

SENSOR
DISCHARGE) .
 Remove right front seat . See SEATS - REPAIR .

 Lift floor panelling and fold back to one side
Release screws (1).

TORQUES -- 650I .

2009 BMW 650i
Fig. 26: Identifying Right Front Seat Screw

After installation:
 If necessary, carry out initial Dynamic Drive operation . See 37 10 001 Initial Operation With Test Run
Of Dynamic Drive.
37 15 055 REMOVING AND INSTALLING/REPLACING EDC CONTROL UNIT

(M MODEL)
DISCHARGE) .
 Remove trim for instrument panel, bottom left.

 Remove footwell side trim panel on A-pillar, right.
Press floor trim at front right to one side. Open cutout in insulating mat (shown with dotted line) and release nut
(1). Disconnect plug connections (2). Unscrew nut (3). Slide control unit (4) with bracket upwards and remove
sideways.
Replacement only: Remove control unit (4) from bracket.

2009 BMW 650i
Fig. 27: Removing Control Unit From Bracket

22 PUMP ASSEMBLY WITH CONTAINER

37 20 001 REMOVING AND INSTALLING/REPLACING DYNAMIC DRIVE VALVE BLOCK
system.
NOTE: In a warranty case you must always provide a fault memory printout, even
 Remove bottom right wheel arch trim . See 51 71 ... REMOVING AND INSTALLING/REPLACING
FRONT (BOTTOM) RIGHT WHEEL ARCH TRIM .
 Partially remove right underbody paneling . See 51 47 ... REMOVING AND
INSTALLING/REPLACING LEFT OR RIGHT UNDERBODY PANELING .
Release nuts (1, 2) (pressure lines to rear axle oscillating motor).

TORQUES -- 650I .
Release nut (3) (return line)

TORQUES -- 650I .
2009 BMW 650i
Release nut (4) (pressure line)

TORQUES -- 650I .
Release nuts (5, 6) (pressure lines to front axle oscillating motor).

TORQUES -- 650I .
Installation:
Fig. 28: Identifying Pressure Lines To Front Axle Oscillating Motor Components
Make sure hydraulic lines are laid without tension and with sufficient spacing to adjoining components.
Partially detach front right wheel arch trim. . See 51 71 040 REMOVING AND INSTALLING/REPLACING
Remove grounding strap from valve block.
Release screws (3).

TORQUES -- 650I .
Raise valve block and remove towards front.

2009 BMW 650i
Fig. 29: Identifying Plug Connections

Disconnect all plug connections (1) on valve block.
Unclip wiring set from valve block.
Fig. 30: Identifying Plug Connections On Valve Block

After installation:
 Fill and bleed hydraulic system . See 37 10 001 Initial Operation With Test Run Of Dynamic Drive.
 If necessary, carry out initial Dynamic Drive operation . See 37 10 001 Initial Operation With Test Run
Of Dynamic Drive.
37 20 505 REMOVING AND INSTALLING/REPLACING DYNAMIC DRIVE HOLDER/VALVE

BLOCK
2009 BMW 650i
system.
After installation:
 Fill and bleed hydraulic system . See 37 10 001 Initial Operation With Test Run Of Dynamic Drive.
 If necessary, carry out initial operation for Dynamic Drive . See 37 10 001 Initial Operation With Test
Run Of Dynamic Drive.
 Remove Valve Block.
Release screws (1).

TORQUES -- 650I .
Take off holder (2).
Fig. 31: Identifying Valve Block Screw

90 TROUBLESHOOTING
37 90 ... TROUBLESHOOTING ON DYNAMIC DRIVE (ARS)
TROUBLESHOOTING ON DYNAMIC DRIVE (ARS) CHART

Fault Cause Remedy
Screw connections on Refer to 31 90 ... FRONT AXLE
front axle/rear axle TROUBLESHOOTING and 33 90 ...
2009 BMW 650i
1. Check stabilizer link joints for

damage/play; if necessary, replace
Stabilizer link loose or stabilizer link . See 35
defective STABILIZER BAR .
2. Tighten down screw connections to
torque.
Stabilizer screw
connection loose.
Tighten down screw
connections.
1. Check whether hydraulic lines are
installed in holders twisted (when
system is depressurized, hydraulic
lines must be guided in holders
Hydraulic lines
virtually without elastic distortion of
installed distorted
decoupling elements).
2. Align all hydraulic lines for
Dynamic Drive as specified in
repair instruction
Hydraulic lines fitted
fitted too closely or have
Noises (banging, rattling) during too closely or have
insufficient clearance (for minimum
straight-ahead driving and gentle insufficient clearance
clearance, see repair instruction)
steering through centre (elastic movement of
line during pressure 2. Align all hydraulic lines for
build-up) Dynamic Drive as specified in
repair instruction
1. Check whether line holders are
correctly screwed and holder halves
Line holders loose are correctly engaged
2. Fit all line holders as specified in
repair instruction .
1. Check whether decoupling elements
Decoupling elements of
(rubber) are present and correctly
hydraulic lines must not
fitted or damaged
be damaged or missing
2. Replace/fit decoupling elements
valve block holder
fitted or damaged
damaged or missing
2. Replace valve block holder
Line holders on
hydraulic lines missing 1. Check whether line holders are
or fitted in incorrect present and fitted in correct position
2009 BMW 650i
repair instruction
1. Carry out initial Dynamic Drive
Valve block does not operation
conform to 2. If other causes are ruled out or if
specifications diagnosis faults are detected,
replace valve block
Screw connections on Refer to 31 90 ... FRONT AXLE
front axle/rear axle TROUBLESHOOTING and 33 90 ...
loose REAR AXLE TROUBLESHOOTING .
1. Check stabilizer link joints for
damage; if necessary, replace
Stabilizer link stabilizer link . See 35
loose/defective STABILIZER BAR .
2. Tighten down screw connections to
torque
Stabilizer screw
Tighten down screw connections
connection loose
installed in holders twisted (when
system is depressurized, hydraulic
lines must be guided in holders
Hydraulic lines
virtually without elastic distortion of
Rattling noises during excitation installed distorted
decoupling elements)
provided by road surface and
straight-ahead driving (without 2. Align all hydraulic lines for
altering steering wheel position) and Dynamic Drive as specified in
Noises occur to a large extent repair instruction.
independently of temperature 1. Check whether hydraulic lines are
influences Hydraulic lines fitted
fitted too closely or have
too closely or have
insufficient clearance (for minimum
insufficient clearance
clearance, see repair instruction)
(elastic movement of
line during pressure 2. Align all hydraulic lines for
build-up) Dynamic Drive as specified in
repair instruction
1. Check whether line holders are
correctly screwed and holder halves
Line holders loose are correctly engaged
2. Fit all line holders as specified in
repair instruction
hydraulic lines must not
fitted or damaged
be damaged or missing
2. Replace or fit decoupling elements
2009 BMW 650i

valve block holder
fitted or damaged
damaged or missing
2. Replace valve block holder
Line holders on 1. Check whether line holders are
hydraulic lines missing present and fitted in correct position
or fitted in incorrect 2. Fit all line holders as specified in
position repair instruction
Protective rubber cap 1. Check whether protective rubber
(black) not removed cap (black) is fitted on Y -
from Y-connecting connecting piece
piece of front axle 2. Pull protective rubber cap (black)
active stabilizer off Y-piece and fit pneumatic line as
pneumatic lines specified in repair instruction
1. Check whether air filter element
(black plastic) is filled to
overflowing at end of vent line with
Pentosin
Vent valve leaking
2. If other causes are ruled out and
noise is reproducible during test
drive, replace vent valves and air
filter element in pairs
Valve block does not operation
conform to 2. If other causes are ruled out or if
specifications diagnosis faults are detected,
replace valve block
Rattling noises during excitation 1. Check during test drive whether
provided by road surface and noises occur during straight-ahead
straight-ahead driving (without driving and one-side excitation
altering steering wheel position) and provided by road surface on front
Vent valve defective
Noises only at higher temperatures axle
(i.e. from outside temperatures from 2. If other causes are ruled out and
25 °C or in event of greatly heated-up noise is reproducible during test
vehicle at operating temperature) drive, replace vent valves in pairs
Flow noise of hydraulic
crushed or bent
fluid in damaged
hydraulic lines 2. Rectify identified defects on
Noises (hissing) hydraulic lines
Flow noise of hydraulic operation
2009 BMW 650i
conforming to diagnosed during initial operation,

specifications replace valve block
1. Check whether whining noises
come from power steering pump or
Whining noises during cornering at Whining noises from
pump drive
an engine speed pump drive
2. If not yet done, install noise-
optimized belt pulley
1. Check whether Dynamic Drive
Dynamic Drive pressure line between power
pressure line has steering pump and valve block is
impaired function or is crushed or bent
Pump noise from engine damaged 2. Replace Dynamic Drive pressure
compartment depending on engine line
speed or only during cornering
1. Check whether power steering
Power steering pump pump and pump drive are damaged
defective 2. If other causes are ruled out, replace
power steering pump
2005 BMW 645Ci
2004-05 SUSPENSION Integrated Suspension Systems - Repair Instructions - E63
2004-05 SUSPENSION
Integrated Suspension Systems - Repair Instructions - E63
GENERAL
37 ... OVERVIEW OF INTEGRATED SUSPENSION SYSTEMS (FRONT AXLE)
Fig. 1: Locating Integrated Suspension Systems Components (Front Axle)

2005 BMW 645Ci
Fig. 2: Locating Integrated Suspension Systems Components (Rear Axle)

The vehicle will perform strong rolling motions during the initial operation run.
Keep wheel arches clear, vehicle must stand on level ground. No persons are permitted inside the vehicle or
directly around the vehicle during initial operation.
Maintain a safety distance around the vehicle of 1 m to persons, objects, walls etc.
Avoid heavy loads.

2005 BMW 645Ci
Failure to comply with the specified instructions may result in personal injury and damage to the vehicle!
After completing all forms of work on the dynamic drive and steering systems which involved opening up
hydraulic lines, it will be necessary to bleed the steering system and start the dynamic drive by means of DIS.
For performance of initial operation, the systems must be in the normal temperature range, i.e. initial operation
must not be performed with an extremely hot or cold dynamic drive system. Procedure:
1. Check fluid level in hydraulic tank and top up to "MAX" while engine is stopped.
2. Start engine and run at idle for at least 1 minute.
3. Turn steering wheel left and right to full lock twice, then move steering wheel to straight-ahead position.
4. Check fluid level with engine stopped: Top up to "MAX".
5. Connect vehicle to DIS or MoDiC.
6. Start initial operation in SERVICE FUNCTIONS. Observe above-mentioned safety precautions. Follow
instructions in DIS.
7. Check fluid level in tank (engine off), top up to "MAX".
FRONT CONTROL AND SUSPENSION

2005 BMW 645Ci

37 10 005 REMOVING AND INSTALLING/REPLACING VENT HOSE FOR ACTIVE STABILIZER

(FRONT)
2005 BMW 645Ci
Release nuts (1).
Withdraw vent line (3) from distribution hose (2).
Remove distribution hose (2).
Fig. 4: Removing Distribution Hose

Vent hose:
Withdraw seal plug (1) from front axle carrier.

2005 BMW 645Ci
Fig. 5: Removing Seal Plug From Front Axle Carrier

Remove vent line with filter from front axle carrier.
Observe the following when replacing vent valves:
Release vent valves (1).
Installation:
Push distribution hose (2) into vent valves (1) up to middle between markings (M).
Tightening torque 14 N.m.
Screw vent valves (1) completely into oscillating motor.

2005 BMW 645Ci
Fig. 6: Removing Vent Valves

37 11 010 REMOVING AND INSTALLING/REPLACING FRONT ACTIVE STABILIZER
system.
operational capability of the stabilizer. In a warranty case you must always
provide a fault memory printout, even where there is no fault memory entry,
with the defective part.

2005 BMW 645Ci
 Remove stabilizer link on both sides from stabilizer, refer to FRONT STABILIZER BAR .
Mark installation position of pressure lines to oscillating motor. Release nuts (1, 2).

Remove pressure and vent lines from oscillating motor.
Installation:
2005 BMW 645Ci
connection.
If necessary, remove holder with hydraulic line(s) from retaining bracket.
Release screw (1) and nut (2) on both sides.
Fig. 8: Releasing Screws And Nuts


2005 BMW 645Ci
Installation:
Tightening torque 30.5 N.m.
Replacement:
Remove rubber mount on both sides from stabilizer.
After installation:
 Fill and bleed hydraulic system, refer to 32 13 006 BLEEDING POWER STEERING UNIT .
 Carry out initial DYNAMIC DRIVE operation, refer to 37 10 001 INITIAL OPERATION WITH
REAR CONTROL AND SUSPENSION

2005 BMW 645Ci

37 12 220 REMOVING AND INSTALLING / REPLACING REAR ACTIVE STABILIZER
 33 0 170
system.
2005 BMW 645Ci
E64:
 Remove rear cross strut
Release screws (1).
Installation:
Insert screws (1).
Align pressure lines to rear axle carrier.

2005 BMW 645Ci

Remove stabilizer from rear axle carrier.
Installation:

2005 BMW 645Ci

Disconnect pressure lines and seal off with seal plugs.
Remove stabiliser links on both sides from stabilizer.

2005 BMW 645Ci
Installation:
connection.
Fig. 12: Disconnecting Pressure Lines

Assembly: Pressure lines to oscillating motor
NOTE: Before the stabilizer is installed, the pressure lines must be aligned to the
oscillating motor and secured using banjo bolts.
Installation:
2005 BMW 645Ci
2. Attach special tool 33 0 170 to pressure lines (the side of the special tool illustrated must point in the
direction of the oscillating motor)
Fig. 13: Attaching Special Tool 33 0 170 To Pressure Lines

3. Tighten down nuts
4. Remove special tool
Replacement:
Remove rubber mount on both sides from stabilizer.
After installation:
2005 BMW 645Ci
 If necessary, carry out initial Dynamic Drive operation, refer to 37 10 001 INITIAL OPERATION
CONNECTING LINES
Fig. 14: Locating Integrated Suspension System Components (Front Axle)

2005 BMW 645Ci

37 13 100 REMOVING AND INSTALLING/REPLACING PRESSURE LINES FOR OSCILLATING

MOTOR/FRONT AXLE
Remove front pressure lines (1) (from oscillating motor to junction I at side in wheel arch)
Remove rear pressure lines (1) (from junction I to valve block)

2005 BMW 645Ci
Fig. 16: Removing Front And Rear Pressure Lines (Front Axle)
37 13 110 REMOVING AND INSTALLING/REPLACING PRESSURE LINE FOR OSCILLATING

MOTOR/REAR AXLE
Remove front pressure lines (1) (from valve block to junction I on vehicle underbody)
Remove middle pressure lines (2) (from junction I to junction III on vehicle underbody)
Remove rear pressure lines (3) (from junction III on vehicle underbody to oscillating motor)
2005 BMW 645Ci
Fig. 17: Removing Front And Rear Pressure Lines (Rear Axle)
2005 BMW 645Ci

37 .. .. OVERVIEW OF INTEGRATED SUSPENSION SYSTEMS (REAR AXLE)

2005 BMW 645Ci

37 14 055 REMOVING AND INSTALLING / REPLACING DYNAMIC DRIVE CONTROL UNIT
protection).
After installation:
 Replacement only: Carry out coding

 Replacement/coding only: Carry out steering angle sensor adjustment/adjustment for active front steering
 Carry out initial DYNAMIC DRIVE operation, refer to 37 10 001 INITIAL OPERATION WITH
2005 BMW 645Ci

 Remove trim for instrument panel, bottom left
 Remove side trim in front right footwell

Release nut (2) and nut (concealed) above control unit.
Tightening torque 2.5 N.m.
Pull out Dynamic Drive control unit towards bottom.

2005 BMW 645Ci
37 14 511 REPLACING FRONT RIDE-HEIGHT SENSOR
protection).
After installation:
NOTE:  Build date up to 03/04: Variant (A) - connection (1) points downwards
 Build date from 03/04: Variant (B) - connection (2) points upwards
Fig. 21: Identifying Front Ride-Height Sensor (Before And After 03/04 Manufactured)
Build date up to 03/04:

2005 BMW 645Ci
IMPORTANT: If the front ride-height sensor has been installed twisted in relation to variant
(A), e.g. due to wiring harness replacement, the following control units must be
recoded.
 Light module with headlight vertical aim control

 Adaptive headlight
 Remove underbody protection

 If necessary, remove right steering gear cover
Shown on build date up to 03/04:
Release nut (1) and disconnect control rack.
Installation:
Release screws (2) and remove ride-height sensor from bracket.

2005 BMW 645Ci
Fig. 22: Removing Ride-Height Sensor From Bracket

Installation:
Build date up to 03/04: If necessary, tie back connecting cable for ride-height sensor.
37 14 512 REPLACING REAR RIDE-HEIGHT SENSOR
protection).
After installation:
 E61: Carry out ride-height calibration

2005 BMW 645Ci
Fig. 23: Removing Control Rod From Jointed Rod

Release nut and remove control rod (3) from jointed rod (2).
Installation:
Release screws (1).
Disconnect plug connection (4) and remove ride-height sensor.

2005 BMW 645Ci
Jointed rod (2) must point from ride-height sensor to rear wheel.
37 14 610 REMOVING AND INSTALLING/REPLACING TRANSVERSAL-ACCELERATION

SENSOR
protection).
After installation:
 Carry out following steps with BMW diagnosis system.

 Learn sensor parameters
 Learn sensor zero point
 Remove right front seat

 Lift floor panelling and fold back to one side
Release screws (1).

2005 BMW 645Ci

PUMP ASSEMBLY WITH CONNECTIONS

37 20 001 REMOVING AND INSTALLING/REPLACING DYNAMIC DRIVE VALVE BLOCK
system.
NOTE: In a warranty case you must always provide a fault memory printout, even
2005 BMW 645Ci
 Remove bottom right wheel arch trim
 Partially remove right underbody paneling

Release nuts (1, 2) (pressure lines to rear axle oscillating motor).
Release nut (3) (return line)
Release nut (4) (pressure line)
Release nuts (5, 6) (pressure lines to front axle oscillating motor).

2005 BMW 645Ci
Installation:
Partially detach front right wheel arch trim.
Remove grounding strap from valve block. Release screws (3).


2005 BMW 645Ci
Disconnect all plug connections (1) on valve block.
Fig. 27: Disconnecting Valve Block Plug Connections

Unclip wiring set from valve block.
After installation:
 If necessary, carry out initial Dynamic Drive operation, refer to 37 10 001 INITIAL OPERATION
2005 BMW 645Ci
2004-05 ACCESSORIES & BODY, CAB Exterior Lighting & Interior Illumination - Repair Instructions - E63
Exterior Lighting & Interior Illumination - Repair Instructions - E63
LAMP SETTINGS
63 10 ... TEST REQUIREMENTS FOR HEADLIGHT VERTICAL AIM ADJUSTMENT
 Car parked on level ground.

 Replace faulty glass and mirrors and blackened light bulbs.
 Check tyre pressure and correct if necessary.
 Apply load equivalent to one person on driver's seat (approx. 75 kg).
 Vehicle with full fuel tank or appropriate additional weight in luggage compartment.
 Correct adjustment of headlights in relation to engine hood (gap dimensions).
 Manual headlight vertical aim control: Turn handwheel to 0 position.
 Automatic headlight vertical aim control: Wait approx. 30 seconds after switching on lights.
 Version with xenon headlights: Wait 80 seconds after switching on lights. During this time, do not move
the vehicle and avoid vibrations.
 Align headlight aimer with vehicle longitudinal axis and parallel to parking surface. Set marking line (M)
on aimer to distance (e). Scale graduations on aimer are equal to a gradient in cm at a distance of 10
meters.
Fig. 1: Adjusting Headlight Vertical Aim

Light/Dark Limit Of Headlights In Headlight Aimer
e Adjustment dimension, headlights:
 as per type plate on headlight housing in % (e.g.: 1.0 % = 10 cm / 10 m = 10 on headlight aimer).
Adjustment dimension, fog lights:

2005 BMW 645Ci
 all vehicles 2.0 % = 20 cm / 10 m = 20 on headlight aimer.
H Height of center of headlight above parking surface.
h H - e = height of marking line above parking surface
+ Central mark = center point of high-beam headlight.
M Marking line of headlamp aimer
S Parking surface of vehicle and headlight aimer
Adjustment dimension (e) is only valid for EUR. Observe differing national regulations.
63 10 004 ADJUSTING HEADLIGHTS
NOTE: Comply with test preconditions for headlight adjustment, refer to 63 10 ... TEST
REQUIREMENTS FOR HEADLIGHT VERTICAL AIM ADJUSTMENT .
Adjust headlights at adjusting screws (1) and (2).
A definite allocation of adjusting screws is not possible.
1. Adjustment screw primarily for vertical adjustment

2. Adjustment screw primarily for lateral adjustment
2005 BMW 645Ci
Fig. 2: Adjusting Headlights At Adjusting Screws

63 10 014 ADJUSTING FOG LAMPS
Comply with test preconditions for headlight adjustment, refer to 63 10 ... TEST REQUIREMENTS FOR
HEADLIGHT VERTICAL AIM ADJUSTMENT .
Adjust fog lamp (1) at adjusting screw (2).

2005 BMW 645Ci
Fig. 3: Adjusting Fog Lamp At Adjusting Screw

HEADLIGHTS
63 12 010 REMOVING AND INSTALLING/REPLACING LEFT HEADLIGHT (XENON
HEADLIGHT)
TRIM .
WARNING: Follow instructions for handling light bulbs (exterior lights), refer to 63
99 ... INSTRUCTIONS FOR HANDLING LIGHT BULBS (EXTERIOR
LIGHTS) .
2005 BMW 645Ci
Release screws (1) and screw (2).
Installation:
Adjust headlight to fit by way of 4 screw fastening points.
Pull headlight (3) forwards slightly.
NOTE: Direction indicator (4) remains fitted.
Fig. 4: Pulling Headlight Forwards Slightly

Remove headlamp (3).

2005 BMW 645Ci
 Adjust headlight (1) to fit by means of adjusting screw (2).

 Tighten retaining screw (3) while simultaneously gripping nut (4).
Fig. 5: Adjusting Headlight To Fit By Means Of Adjusting Screw

Installation:
 Observe gap dimensions.

 Adjust headlights, refer to 63 10 004 ADJUSTING HEADLIGHTS .
Replacement:
 Remove ignition unit and lamp for xenon headlight, refer to 63 99 076 REPLACING LAMP FOR
LEFT XENON HEADLIGHT .
 Remove control unit for xenon headlight, refer to 63 12 860 REPLACING CONTROL UNIT FOR
2005 BMW 645Ci
 If necessary, remove drive unit for adaptive headlight, refer to 63 12 895 REPLACING DRIVE FOR
LEFT ADAPTIVE HEADLIGHT .
63 12 015 REMOVING AND INSTALLING LEFT HEADLIGHT (ADAPTIVE HEADLIGHT)
"Removing and installing left headlight (xenon headlight)", refer to 63 12 010 REMOVING AND
INSTALLING/REPLACING LEFT HEADLIGHT (XENON HEADLIGHT) .
63 12 016 REPLACING LEFT HEADLIGHT (ADAPTIVE HEADLIGHT)
IMPORTANT: Read and comply with notes on protection against electrostatic discharge (ESD
DISCHARGE) .
LIGHTS) .
 Remove left headlight, refer to 63 12 010 REMOVING AND INSTALLING/REPLACING LEFT

HEADLIGHT (XENON HEADLIGHT) .
 Remove drive unit for adaptive headlight, refer to 63 12 895 REPLACING DRIVE FOR LEFT
ADAPTIVE HEADLIGHT .
 Remove control unit for left xenon headlight, refer to 63 12 860 REPLACING CONTROL UNIT FOR
 Remove bulb for left xenon headlight (ignition unit), refer to 63 99 076 REPLACING LAMP FOR
After installation:
 Carry out programming/coding, refer to Diagnosis Programming/Coding .

 Adjust headlight, refer to 63 10 004 ADJUSTING HEADLIGHTS .

2005 BMW 645Ci
63 12 860 REPLACING CONTROL UNIT FOR LEFT XENON HEADLIGHT
WARNING: Version with xenon headlights: Danger to life due to high voltage!
Therefore disconnect all components from voltage supply before removal.
Work on the entire xenon lighting system (ignition unit, control unit and
lamp) may only be carried out by specialist personnel.
 Remove left headlight, refer to 63 12 010 REMOVING AND INSTALLING/REPLACING LEFT

HEADLIGHT (XENON HEADLIGHT) .
Release screws (1).
Remove control unit for xenon headlight (2) from headlight (3).
Fig. 6: Removing Control Unit For Xenon Headlight From Headlight

2005 BMW 645Ci
Installation:
Fit control unit for xenon headlight (3) exactly on headlight.
Make sure plug housing (1) is correctly seated on pin housing (2).
Fig. 7: Fitting Control Unit For Xenon Headlight Exactly On Headlight

63 12 861 REPLACING CONTROL UNIT FOR RIGHT XENON HEADLAMP
Operation is described in: Replacing control unit for left xenon headlamp, refer to 63 12 860 REPLACING
CONTROL UNIT FOR LEFT XENON HEADLIGHT .
63 12 870 REPLACING IGNITION UNIT FOR LEFT XENON HEADLIGHT
2005 BMW 645Ci
Release screws (1).
Fold down cover (2) and remove front wheel arch trim (3).
Fig. 8: Removing Front Wheel Arch Trim

Unlock catch (1) in direction of arrow and fold down cover (2).
Remove cover (2) from headlight (3) and feed out through opening in front wheel arch trim (4).
2005 BMW 645Ci
Fig. 9: Removing Cover From Headlight And Feed Out Through Opening In Front Wheel Arch Trim
Turn ignition unit for xenon headlight (1) approx. 30° counterclockwise and detach from headlight (3).
NOTE: Plug connection (2) is automatically released by turning ignition unit for xenon
headlight (1).
Feed out ignition unit for xenon headlight (1) through opening in headlight (4) and remove.
2005 BMW 645Ci
Fig. 10: Feeding Out Ignition Unit For Xenon Headlight Through Opening In Headlight
Installation:
63 12 895 REPLACING DRIVE FOR LEFT ADAPTIVE HEADLIGHT
DISCHARGE) .
Therefore disconnect all components from voltage supply before removal.
 Remove front left wheel arch cover, refer to 51 71 040 REMOVING AND
2005 BMW 645Ci
Remove drive for adaptive headlight (2) in direction of arrow from headlight (3).
Fig. 11: Removing Drive For Adaptive Headlight

Installation:
Fit drive for adaptive headlight (1) exactly on headlight.
Make sure pin housing (2) is correctly seated in plug housing (3).
2005 BMW 645Ci
Fig. 12: Fitting Drive For Adaptive Headlight

Carry out coding/programming, refer to DIAGNOSIS PROGRAMMING/CODING .
63 12 896 REPLACING DRIVE FOR RIGHT ADAPTIVE HEADLIGHT
Operation is described in: Replacing drive for left adaptive headlight, refer to 63 12 895 REPLACING DRIVE
FOR LEFT ADAPTIVE HEADLIGHT .
TURN SIGNAL INDICATOR

63 13 150 REMOVING AND INSTALLING/REPLACING COMPLETE FRONT LEFT TURN SIGNAL
LAMP

2005 BMW 645Ci
Release screw (1) on turn signal lamp (2).
Fig. 13: Releasing Screw On Turn Signal Lamp

Release screws (1).
Release screws (2) on front side panel (3).
Installation:
Make sure front side panel reinforcement plate is correctly seated.
Observe gap dimensions.

2005 BMW 645Ci
Raise front side panel (3) slightly and remove front turn signal lamp (4) in direction of travel.
Fig. 14: Releasing Screws On Front Side Panel

Installation:
Make sure metal nuts (1) are correctly seated.
Replacement:
If necessary, release screw (2) and remove holder (3) from front turn signal lamp (4).
2005 BMW 645Ci
Fig. 15: Removing Holder From Front Turn Signal Lamp

63 13 200 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT AUXILIARY

TURN SIGNAL LAMP
Slide front auxiliary turn signal lamp (1) with trim strip (2) towards rear and fold out in direction of arrow from
front side panel (3).
2005 BMW 645Ci
Fig. 16: Sliding Front Auxiliary Turn Signal Lamp

Remove trim strip (1) from front auxiliary turn signal lamp (2).
Remove front auxiliary turn signal lamp (2).

2005 BMW 645Ci
Fig. 17: Removing Trim Strip From Front Auxiliary Turn Signal Lamp
Installation:
Make sure trim strip (1) is correctly seated on front auxiliary turn signal lamp (2).
Fixtures (3), guide (4) and tab (5) must not be damaged.
2005 BMW 645Ci
Fig. 18: Making Sure Trim Strip Is Correctly Seated On Front Auxiliary Turn Signal Lamp
LIGHTS) .
Replacement:
If necessary, convert bulb, refer to 63 99 295 REPLACING BULB FOR AUXILIARY TURN SIGNAL
LIGHT, FRONT LEFT OR RIGHT .
FOG LIGHTS, AUXILIARY LIGHTS

63 17 060 REMOVING AND INSTALLING (REPLACING) LEFT OR RIGHT FRONT FOG LAMP
E60/E61 only:
2005 BMW 645Ci
Release screws (1).
Detach cover (2) from front under ride protection (3) and feed out in direction of arrow.
Fig. 19: Detaching Cover From Front Under Ride Protection

Remove cover (2).
E63/E64 only:
Release screws (1) and screw (2).
Detach cover (3) from front under ride protection (4) and feed out in direction of arrow.
Remove cover (3).

2005 BMW 645Ci
Fig. 20: Detaching Cover From Front Under Ride Protection

All:
Release screws (2).
Feed front fog lamp (3) in direction of arrow out of mounting (4) and remove.
2005 BMW 645Ci
Fig. 21: Removing Front Fog Lamp

Replacement:
If necessary, convert bulb, refer to 63 99 295 REPLACING BULB FOR AUXILIARY TURN SIGNAL
LIGHT, FRONT LEFT OR RIGHT .
LIGHTS) .
Installation:
Note type of bulb.
Replacement:
2005 BMW 645Ci
Adjust front fog lamps, refer to 63 10 014 ADJUSTING FOG LAMPS .
REAR LIGHT CLUSTER

63 21 055 REPLACING A SOCKET HOUSING FOR LEFT OR RIGHT REAR LIGHT (ON SIDE
PANEL)
LIGHTS) .
Fold back covers (1) in direction of arrow and remove.
Fig. 22: Folding Back Cover And Removing

Turn socket housing for rear light (1) in direction of arrow and remove from rear light (2).
2005 BMW 645Ci
Cut associated two-core lead with sufficient residual length remaining in vehicle and remove socket housing for
rear light (1), refer to 63 21 055 REPLACING A SOCKET HOUSING FOR LEFT OR RIGHT REAR
LIGHT (ON SIDE PANEL) .
Installation:
Wiring is carried out with connectors.
If necessary, secure two-core lead against rattling.
Fig. 23: Turning Socket Housing For Rear Light

63 21 057 REPLACING A SOCKET HOUSING FOR LEFT OR RIGHT REAR LIGHT (ON BUMPER
TRIM)
2005 BMW 645Ci
LIGHTS) .
 Remove rear bumper trim, refer to 51 12 156 REMOVING AND INSTALLING REAR BUMPER .
Turn associated socket housing and remove from rear light (3).
1. Socket housing of bulb for rear fog light

2. Socket housing of bulb for reversing light
Fig. 24: Turning Associated Socket Housing And Removing From Rear Light
Cut associated two-core lead with sufficient residual length remaining in vehicle and remove socket housing.
Installation:
2005 BMW 645Ci
Wiring is carried out with connectors.
63 21 101 REPLACING SEALING FRAME FOR LEFT OR RIGHT REAR LIGHT (ON SIDE PANEL)
 Remove rear light, refer to 63 21 180 REMOVING AND INSTALLING/REPLACING LEFT OR

RIGHT REAR LIGHT (IN SIDE PANEL) .
Detach sealing frame for rear light (1) from rear light (2).
Fig. 25: Detaching Sealing Frame For Rear Light From Rear Light
Installation:
Sealing frame for rear light (1) is centered via guides (3).
2005 BMW 645Ci
Make sure sealing frame for rear light (1) is correctly bonded all round on rear light (2).
63 21 180 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT REAR LIGHT (IN SIDE
PANEL)
 Partially remove luggage compartment wheel arch trim, refer to 51 47 151 REMOVING AND
INSTALLING/REPLACING LEFT LUGGAGE COMPARTMENT WHEEL ARCH TRIM or 51
47 161 REMOVING AND INSTALLING/REPLACING RIGHT LUGGAGE COMPARTMENT
WHEEL ARCH TRIM .
Release nut (2), tightening torque 2.5 N.m.
Remove rear light (4) in outwards direction from side panel (5).
Installation:
If necessary, adjust rear light (4) to fit by way of adjusting elements (6).
Observe gap dimensions.

2005 BMW 645Ci
Fig. 26: Removing Rear Light In Outwards Direction From Side Panel
Installation:
Make sure rear light seal (1) is correctly seated, replace if necessary.
Guides (3) of rear light (2) must be visible.

2005 BMW 645Ci
Fig. 27: Making Sure Rear Light Seal Is Correctly Seated

63 21 183 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT REAR LIGHT
Release screws (2).
Feed rear light (3) in direction of arrow out of bumper trim (4) and remove.
2005 BMW 645Ci
Fig. 28: Unfastening Plug Connection And Disconnecting

Installation:
Plastic lugs (1) must not be damaged.

2005 BMW 645Ci
Fig. 29: Making Sure Electrical Leads Are Correctly Routed

BRAKE LIGHTS
63 25 000 REMOVING AND INSTALLING/REPLACING AUXILIARY BRAKE LIGHT
Detach cover for auxiliary brake light (1) on both sides in direction of arrow and unclip at points (2).
2005 BMW 645Ci
Fig. 30: Detaching Cover For Auxiliary Brake Light On Both Sides
Feed cover for auxiliary brake light (1) in direction of arrow out of molded roofliner (3) and remove.
Installation:
Retaining bar (1), clips (2) and guides (3) must not be damaged.
Make sure cover for auxiliary brake light (4) is correctly seated.
2005 BMW 645Ci
Fig. 31: Seating Auxiliary Brake Light

Unlock slide (2) on both sides and remove auxiliary brake lights (3) in direction of arrow from rear window (4).
2005 BMW 645Ci
Fig. 32: Removing Auxiliary Brake Light

Installation:
Make sure auxiliary brake light (3) is correctly positioned in rear window (4).
LICENSE PLATE LIGHTS

63 26 000 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT LICENSE PLATE
LIGHT
 64 1 020
Lever license plate light (1) with special tool 64 1 020 out of rear bumper trim (2).
2005 BMW 645Ci
Unlock plug connection underneath and disconnect.
Remove license plate light (1), refer to 63 26 000 REMOVING AND INSTALLING/REPLACING LEFT
OR RIGHT LICENSE PLATE LIGHT .
Fig. 33: Removing License Plate Light

LIGHTS) .
Replacement:
If necessary, remove bulb.
INFERIOR LIGHTS
2005 BMW 645Ci
63 31 000 REMOVING AND INSTALLING/REPLACING COMPLETE CEILING LIGHT (FRONT)
 00 9 341
IMPORTANT: Follow instructions for handling light bulbs (interior lights), refer to 63 99 ...
INSTRUCTIONS FOR REPLACING LIGHT BULBS (INTERIOR LIGHTS) .
Unclip ceiling light (1) with special tool 00 9 341 at points (2).
Feed ceiling light (1) in direction of arrow out of front roofliner trim (3).
Unlock associated plug connection and disconnect.
Remove ceiling light (1).

2005 BMW 645Ci
Installation:
Retaining clips (1) and guides (2) must not be damaged.
Make sure ceiling light (3) is correctly seated.
Fig. 35: Checking Ceiling Light Is Correctly Seated

Replacement:
 If necessary, convert bulbs, refer to 63 99 295 REPLACING BULB FOR AUXILIARY TURN
SIGNAL LIGHT, FRONT LEFT OR RIGHT .
 Note type of bulb.
2005 BMW 645Ci
 64 1 020
Replacement: If necessary, remove bulb.
In footwell:
Lever out footwell light (1) with special tool 64 1 020 as illustrated.
Disconnect associated plug connection and remove footwell light (1).
Fig. 36: Removing Footwell Light

2005 BMW 645Ci
Note type of bulb.
On underside of door:
Lever out footwell light (1) with special tool 64 1 020 as illustrated.
Disconnect associated plug connection and remove footwell light (1).
Replacement:
Note type of bulb.
Fig. 37: Removing Footwell Light

63 31 050 REMOVING AND INSTALLING/REPLACING MIRROR LIGHT

2005 BMW 645Ci

Replacement: If necessary, convert bulb, refer to 63 99 295 REPLACING BULB
FOR AUXILIARY TURN SIGNAL LIGHT, FRONT LEFT OR RIGHT .
Fold down sun visor (2).
Lever front mirror light (1) in direction of arrow.
Disconnect plug connection underneath and remove mirror plate light (1).
Fig. 38: Removing Mirror Plate Light

Replacement:
Note type of bulb.

2005 BMW 645Ci
 64 1 020
Lever out luggage compartment light (1) with special tool 64 1 020 as illustrated.
Disconnect associated plug connection and remove luggage compartment light (1).
Fig. 39: Removing Luggage Compartment Light

Replacement:
2005 BMW 645Ci
63 31 150 REMOVING AND INSTALLING/REPLACING GLOVEBOX LIGHT
 64 1 020
Lever glovebox light (1) with special tool 64 1 020 as illustrated out of glovebox housing (2).
Disconnect associated plug connection and remove glovebox light (1).
Fig. 40: Levering Glovebox Light With Special Tool 64 1 020

2005 BMW 645Ci
Note type of bulb.
63 31 160 REMOVING AND INSTALLING/REPLACING DOOR MIRROR LIGHT
 Remove retaining ring on door mirror, refer to 51 16 045 REMOVING AND

INSTALLING/REPLACING RETAINING RING ON LEFT OR RIGHT DOOR MIRROR .
Unclip door mirror light (1) in direction of arrow from retaining ring on door mirror (2) and remove.
Fig. 41: Unclipping Door Mirror Light

LIGHT BULBS
63 99 ... INSTRUCTIONS FOR HANDLING LIGHT BULBS (EXTERIOR LIGHTS)
2005 BMW 645Ci
WARNING: Xenon headlights: Danger to life due to high voltage! Work on the entire
xenon lighting system (ignition unit, control unit and lamp) may only be
carried out by specialist personnel.
WARNING: Halogen lamps are under pressure: To avoid injury, wear protective
goggles and gloves.
IMPORTANT: To prevent short-circuiting, disconnect light bulbs from voltage supply prior to
replacement.
Do not touch the glass bulbs in new lights bulbs as even the slightest contamination will burn in and reduce bulb
service life.
Only touch light bulbs with clean gloves or a clean cloth.
Do not expose light bulbs to mechanical vibrations.
Use only recommended light bulbs.
Follow the light bulb manufacturer's instructions without fail.
63 99 ... INSTRUCTIONS FOR REPLACING LIGHT BULBS (INTERIOR LIGHTS)
CAUTION: To prevent short-circuiting, disconnect light bulbs from voltage supply

prior to replacement.
Do not touch the glass bulbs in new lights bulbs as even the slightest contamination will burn in and reduce bulb
service life.
Only touch light bulbs with clean gloves or a clean cloth.
Do not expose light bulbs to mechanical vibrations.
Use only recommended light bulbs.
Follow the light bulb manufacturer's instructions without fail.
63 99 002 REPLACING HALOGEN BULB FOR HIGH-BEAM HEADLIGHT ON LEFT
LIGHTS) .
Unclip housing (1) at points (2).

2005 BMW 645Ci
Remove cover (3) from housing (1).
Fig. 42: Removing Cover From Housing

Unclip engine hood lock pull (1) in area (2) and disengage at point (3).
Place housing (4) with associated pulls in working area to one side.
2005 BMW 645Ci
Fig. 43: Removing Housing

Installation:
Make sure engine hood lock pulls are correctly laid.
Unlock catch (1) and remove cap (2) in direction of arrow.

2005 BMW 645Ci
Fig. 44: Unlocking Catch And Removing Cap

Unclip bulb (1) by pressing on plug (2).
Remove bulb (1) from headlight (3) slightly, disconnect plug connection and remove bulb.
Installation:
Insert bulb (1) in headlight (3) at bottom at first and then tilt upwards until bulb snaps audibly into place.
2005 BMW 645Ci
Fig. 45: Inserting Bulb In Headlight

Make sure bulb (1) is correctly seated in catches (4).
Note type of bulb.
63 99 076 REPLACING LAMP FOR LEFT XENON HEADLIGHT
LIGHTS) .
 Remove ignition unit for left xenon headlight, refer to 63 12 870 REPLACING IGNITION UNIT FOR
Unlock retaining ring (1) in counterclockwise direction and remove.
Remove bulb for xenon headlight (2) in direction of arrow from headlight (3).
2005 BMW 645Ci
Fig. 46: Removing Bulb For Xenon Headlight

Installation:
Insert bulb for xenon headlight (2) exactly in headlight (3).
Note type of bulb.
Installation:
Observe "Top marking" (1).
Fit retaining ring (2) on headlight is such a way that apertures (3) slide over fixtures for ignition unit (4).
2005 BMW 645Ci
Fig. 47: Fitting Retaining Ring On Headlight

63 99 140 REPLACING BULB FOR SIDE MARKER LAMP, FRONT LEFT
LIGHTS) .
Unclip housing (1) at points (2).
Remove cover (3) from housing (1).

2005 BMW 645Ci
Fig. 48: Removing Cover From Housing

Unclip engine hood lock pull (1) in area (2) and disengage at point (3).
Place housing (4) with associated pulls in working area to one side.
2005 BMW 645Ci
Fig. 49: Removing Housing

Installation:
Make sure engine hood lock pulls are correctly laid.
Unlock catch (1) and remove cap (2) in direction of arrow.

2005 BMW 645Ci
Fig. 50: Unlocking Catch And Removing Cap

NOTE: Illustration shows headlight removed. Plug connection already unlocked and
disconnected.
Turn holder with bulb for side marker lamp (1) counterclockwise with aid of lug (2) and remove from headlight
(3).
2005 BMW 645Ci
Fig. 51: Removing Side Marker Lamp

Installation:
Holder with bulb for side marker lamp (1) must be correctly seated in mounting.
Note type of bulb.
63 99 201 REPLACING HALOGEN BULB FOR LEFT OR RIGHT FRONT FOG LAMP
LIGHTS) .

2005 BMW 645Ci
Fig. 52: Turning Bulb With Bulb Holder

Installation:
Note type of bulb.
63 99 273 REPLACING BULB FOR FRONT LEFT TURN SIGNAL LIGHT
LIGHTS) .
Bulb, interior:
Turn lever (1) counterclockwise and pull bulb holder (2) towards rear out of turn signal housing (3).
2005 BMW 645Ci
Installation:
Note type of bulb.
Make sure bulb holder (2) is correctly seated in turn signal housing (3).
Fig. 53: Checking Bulb Holder Is Correctly Seated In Turn Signal Housing
Bulb, exterior:
NOTE: Front wheel removed for purposes of clarity.
Release screws (1).
Fold down cover (2) and remove front wheel arch trim (3).
2005 BMW 645Ci
Fig. 54: Removing Front Wheel Arch Trim

Turn bulb holder (2) counterclockwise and pull towards rear out of turn signal housing (3).
2005 BMW 645Ci
Fig. 55: Turning Bulb Holder Counterclockwise And Pull Towards Rear Out Of Turn Signal Housing
Remove bulb from bulb holder (1).
Installation:
Note type of bulb.
63 99 295 REPLACING BULB FOR AUXILIARY TURN SIGNAL LIGHT, FRONT LEFT OR RIGHT
LIGHTS) .

2005 BMW 645Ci
INSTALLING/REPLACING FRONT LEFT OR RIGHT AUXILIARY TURN SIGNAL LAMP .
Turn bulb holder (1) approx. 45° counterclockwise and remove from front auxiliary turn signal light (2).
Fig. 56: Removing Front Auxiliary Turn Signal Light

Pull bulb out of holder (1).
Installation:
Note type of bulb.
63 99 312 REPLACING BULB(S) FOR LEFT OR RIGHT REAR LIGHT (ON BUMPER TRIM, REAR
FOG LIGHT, REVERSING LIGHT)
2005 BMW 645Ci
LIGHTS) .
Turn associated bulb holder and remove from rear light (3).
1. Bulb holder of bulb for rear fog light

2. Bulb holder of bulb for reversing light
Fig. 57: Turning Associated Bulb Holder And Removing From Rear Light
Remove bulb for rear light (1) in direction of arrow from bulb holder (2).
2005 BMW 645Ci
Fig. 58: Removing Bulb For Rear Light From Bulb Holder
Installation:
Note type of bulb.
63 99 315 REPLACING BULB(S) FOR LEFT OR RIGHT REAR LIGHT (REAR TURN INDICATOR
LIGHT)
LIGHTS) .
 Remove socket housing for rear light, refer to 63 21 055 REPLACING A SOCKET HOUSING FOR
2005 BMW 645Ci
Remove bulb for rear light (1) in direction of arrow from bulb holder (2).
Fig. 59: Removing Bulb For Rear Light From Bulb Holder
Installation:
Note type of bulb.
63 99 401 REPLACING BULB FOR LEFT OR RIGHT LICENSE PLATE LIGHT
LIGHTS) .

2005 BMW 645Ci
OR RIGHT LICENSE PLATE LIGHT .
Turn bulb holder (1) in direction of arrow and withdraw from license plate light (2).
Fig. 60: Turning Bulb Holder And Withdraw From License Plate Light
Detach bulb (1) in direction of arrow.

2005 BMW 645Ci
Fig. 61: Detaching Bulb

Installation:
Note type of bulb.

2005 BMW 645Ci
2004-05 MANUAL TRANSMISSION Removal & Installation - 545i & 645Ci (GS6S53BZ SMG)
2004-05 MANUAL TRANSMISSION
Removal & Installation - 545i & 645Ci (GS6S53BZ SMG)
IDENTIFICATION
545i (E60) 4.4 L (N62)
645Ci (E63) 4.4 L (N62)

MANUAL TRANSMISSION
CAUTION: Use only the approved gear oil. Failure to comply with this requirement
will result in serious damage to the transmission. See SERVICING - M/T .
Removal

2. Remove front underbody protection. Release screws (1). See Fig. 1 . Remove reinforcement plate.
2005 BMW 645Ci
Fig. 1: Removing Reinforcement Plate

3. Remove complete exhaust system. See REMOVING AND INSTALLING COMPLETE EXHAUST
SYSTEM (N62).
4. Remove oxygen sensors.
2005 BMW 645Ci

6. Pull plug (1) off pulse generator. See Fig. 3 . Release screw (2) and remove pulse generator.
2005 BMW 645Ci

2005 BMW 645Ci
Fig. 4: Detaching Plug From Oil Level Sensor

8. Detach plug (1) from cable duct. See Fig. 5 .

2005 BMW 645Ci
Fig. 5: Detaching Plug From Cable Duct

9. Press in retaining lugs (1) with screwdriver (2) and remove cable duct (3). See Fig. 6 . Tie wiring harness
to one side.
2005 BMW 645Ci
Fig. 6: Removing Cable Duct

10. Release screws (1) to support transmission. See Fig. 7 .

2005 BMW 645Ci
Fig. 7: Releasing Transmission To Engine Screws

11. Support transmission with Special Tools (00 2 030, 23 0 132, 23 0 131, 23 0 136) and (21 0 135). See
Fig. 8 .
2005 BMW 645Ci

12. Unfasten screws (1) and nuts (2). See Fig. 9 . Remove transmission cross-member.
2005 BMW 645Ci

13. Remove propeller shaft from transmission. Release center bearing. See REMOVING AND
INSTALLING COMPLETE PROPELLER SHAFT. Tie propeller shaft to one side.
14. Disconnect plug connections (1) and (2). See Fig. 10 . Release cable strap (3).
2005 BMW 645Ci

15. Disconnect plug connections (1) and (2) and unclip cable from holder. See Fig. 11 .
2005 BMW 645Ci
Fig. 11: Locating Plug Connections

16. Detach plugs (4) from clutch travel sensor. See Fig. 12 .
2005 BMW 645Ci
Fig. 12: Detaching Plugs From Clutch Travel Sensor

17. Detach plug (1) from sensor. See Fig. 13 .

2005 BMW 645Ci
Fig. 13: Detaching Plug From Sensor

CAUTION: Do not allow the transmission to hang off from the transmission
input shaft as this will deform the clutch plate.
18. Unfasten screws. See Fig. 14 .

2005 BMW 645Ci
Fig. 14: Locating Transmission Mounting Screws

Installation
1. Check that dowel sleeves are correctly seated. See Fig. 15 . Replace damaged dowel sleeves. Ensure
correct position of cover plate.
2005 BMW 645Ci

2. Check lubrication of transmission input shaft for sticky consistency. See Fig. 16 . If grease is sticky,
replace clutch plate. Check clutch plate for friction rust in taper splines and replace if necessary. Remove
any grease and lining abrasion from taper splines of clutch plate by mechanical means (with a cloth).
2005 BMW 645Ci
Fig. 16: Checking Lubrication Of Transmission Input Shaft

3. Remove and clean release bearing and release lever. Push on grease Scraper Ring (21 2 240) as far as it
will go. See Fig. 17 . Grease splines (1) of input shaft with a brush. Detach grease scraper ring.
2005 BMW 645Ci
Fig. 17: Locating Grease Scraper Ring

4. To complete installation, reverse removal procedure. Tighten fasteners to specification. See TORQUE
SPECIFICATIONS . After completing work:
 Perform adaptation using DIS Tester, refer to Service Functions in DIS Tester (Teach in
transmission).
 Check gear oil level. Use only the approved transmission fluid.
 Check fluid level in hydraulic system.
 Read out fault memory and clear entered faults.
Failure to comply with this requirement will result in serious damage to the manual transmission.
2005 BMW 645Ci
Stage 1 41 (56)
Stage 2 Additional 90°
Transmission Cross Member-To-Body 14 (19)
Transmission Mount-To-Transmission/Transmission Cross/Member 14 (19)
Hex Screws
M8 Thread 18 (25)
M10 Thread 36 (49)
M12 Thread 55 (74)
Screw With Torx Head
M8 Thread 16 (22)
M10 Thread 32 (43)
M12 Thread 53 (72)
INCH Lbs. (N.m)
Transmission-To-Engine M6 Thread 80 (9)
2005 BMW 645Ci
2004-05 MANUAL TRANSMISSION Removal & Installation - 545i & 645Ci (GS6-53BZ)
2004-05 MANUAL TRANSMISSION
Removal & Installation - 545i & 645Ci (GS6-53BZ)
IDENTIFICATION
545i (E60) 4.4 L (N62)
645Ci (E63) 4.4 L (N62)

MANUAL TRANSMISSION
CAUTION: Use only the approved gear oil. Failure to comply with this requirement
will result in serious damage to the transmission. See SERVICING - M/T .
Removal

2. Remove underbody protection at front and rear. Release screws (1). See Fig. 1 . Remove reinforcement
plate.
3. Remove exhaust system after catalytic converter. See REMOVING AND INSTALLING COMPLETE
4. Remove oxygen sensors.
6. Detach plug (1) from reversing light switch. See Fig. 3 . Release cable from retainers.
7. Pull plug (1) off pulse generator. See Fig. 4 . Release screw (2) and remove pulse generator.
9. Detach plug (1) from cable duct. See Fig. 6 .
10. Press in retaining lugs (1) with screwdriver (2) and remove cable duct (3). See Fig. 7 . Tie wiring harness
to one side.
11. Release screws (1). See Fig. 8 .
12. Supporting transmission: support with Special Tools (23 0 136, 23 0 131, 23 0 132) and (00 2 030). See
Fig. 9 .
13. Release screws (1) and nuts (2) and remove transmission cross-member. See Fig. 10 .
14. Remove propeller shaft from transmission. Release center bearing. See REMOVING AND
INSTALLING COMPLETE PROPELLER SHAFT. Tie propeller shaft to one side.
NOTE: Pressure line of clutch slave cylinder remains connected.

2005 BMW 645Ci
15. Slowly relieve tension on clutch slave cylinder otherwise air is drawn in through sealing sleeve. Release
nuts and remove clutch slave cylinder. See Fig. 11 .
16. Lever out retainer (1). See Fig. 12 . Disengage shift rod (2).
17. Release and remove bearing pins (1) in direction of arrow. See Fig. 13 .
18. Lift out shift arm (1). See Fig. 14 .
CAUTION: Do not allow the transmission to hang off from the transmission
input shaft as this will deform the clutch plate.
19. Unfasten screws. See Fig. 15 . Pull out transmission towards rear and remove.

2005 BMW 645Ci

2005 BMW 645Ci
Fig. 3: Disconnecting Plug From Reversing Light Switch

2005 BMW 645Ci

2005 BMW 645Ci
Fig. 5: Detaching Plug From Oil Level Sensor

2005 BMW 645Ci
Fig. 6: Detaching Plug From Cable Duct

2005 BMW 645Ci
Fig. 7: Removing Cable Duct

2005 BMW 645Ci
Fig. 8: Releasing Transmission To Engine Screws

2005 BMW 645Ci

2005 BMW 645Ci

2005 BMW 645Ci
Fig. 11: Removing Clutch Slave Cylinder

2005 BMW 645Ci
Fig. 12: Disconnecting Shift Rod

2005 BMW 645Ci
Fig. 13: Removing Bearing Pins

2005 BMW 645Ci
Fig. 14: Lifting Out Shim Arm

2005 BMW 645Ci
Fig. 15: Locating Transmission-To-Engine Screws

Installation
1. Check that dowel sleeves are correctly seated. See Fig. 16 . Replace damaged dowel sleeves.
2. Check lubrication of transmission input shaft for sticky consistency. See Fig. 17 . If grease is sticky, clean
input shaft and replace clutch plate. Check clutch plate for friction rust in splines and replace if necessary.
Mechanically remove existing grease and lining abrasion from splines of clutch plate (with a cloth).
3. Remove and clean release bearing and release lever. Push on grease Scraper Ring (21 2 221) as far as it
will go. See Fig. 18 . Grease splines (1) of input shaft with a brush. Detach grease scraper ring.
2005 BMW 645Ci
SPECIFICATIONS . Grease bearing pins (1). See Fig. 14 . Grease shift rod. Make sure shims (3) are in
correct position. See Fig. 12 . After completion of work, check gear oil level.

2005 BMW 645Ci
Fig. 17: Checking Lubrication Of Transmission Input Shaft

2005 BMW 645Ci
Fig. 18: Locating Grease Scraper Ring

Clutch Slave Cylinder-To-Clutch Housing/Transmission Case 16 (22)
Stage 1 41 (56)
Transmission Cross Member-To-Body 14 (19)
Transmission Mount-To-Transmission Support Bracket/Transmission 14 (19)
Cross/Member
Hex Screws
2005 BMW 645Ci
M8 18 (25)
M10 36 (49)
M12 55 (74)
Screw With Torx Head
M8 16 (22)
M10 32 (43)
M12 53 (72)
INCH Lbs. (N.m)
Transmission-To-Engine M6 Thread 80 (9)
2005 BMW 645Ci
2004-05 MANUAL TRANSMISSIONS Servicing - GS6-53BZ/DZ & GS6S53BZ (SMG)
2004-05 MANUAL TRANSMISSIONS
Servicing - GS6-53BZ/DZ & GS6S53BZ (SMG)
APPLICATION
MANUAL TRANSMISSION APPLICATION
5-Series (E60)
545i (8/03 To 2005) ZF Type H & ZF Type G
6-Series (E63)
645Ci (2004-05) ZF Type G
LUBRICATION
SERVICE INTERVALS
Inspect fluid level when vehicle is serviced. DO NOT drain fluid, transmission has lifetime fluid.
CHECKING FLUID LEVEL
NOTE: Numbers in text refer to numbers in figure.
Check lubricant at fill hole (2). See Fig. 1 . Lubricant should be at bottom of filler plug hole.
2005 BMW 645Ci
Fig. 1: Locating Transmission Oil Drain & Filler Plugs

RECOMMENDED FLUID
From model year 2004, some manual transmissions are filled with Castrol MTF-LT-2 lifetime fluid. This fluid
has the same properties as the MTF-LT-1 fluid. The MTF-LT-1 fluid may be mixed or substituted for the MTF-
LT-2 manual transmission fluid.
FLUID CAPACITIES
Fluid capacity is approximately 1.4 qts. (1.3L). Transmission should be filled to bottom of filler plug hole. See
Fig. 1 .
ADJUSTMENTS
DRAINING/TOPPING UP GEAR OIL IN MANUAL TRANSMISSION
2005 BMW 645Ci
NOTE: Gearbox must be at normal operating temperature. For correct gear oil, see
RECOMMENDED FLUID . For filling capacities, see FLUID CAPACITIES .
Draining Gear Oil
 Release oil drain plug (1) and filler plug (2). See Fig. 1 .
 Clean oil drain plug (1) and screw in. Tighten to specification. See TORQUE SPECIFICATIONS .
Filling Transmission With Gear Oil
 Pour in gear oil until overflowing.

 Tighten in filler screw (2). See Fig. 1 . Tighten to specification. See TORQUE SPECIFICATIONS .
GEARSHIFT LINKAGE
No external adjustment is necessary.

REPLACING RADIAL SHAFT SEAL FOR OUTPUT FLANGE (GS6-53BZ/DZ G-TRANSMISSION)
CAUTION: After completion of work, check transmission fluid level. See CHECKING
FLUID LEVEL . Use only approved transmission fluid. See
RECOMMENDED FLUID . Failure to comply with this instruction will result
in serious damage to the transmission.
Unflange propeller shaft from transmission and tie up to one side. Tasks are described in Removing propeller
shaft. See REMOVING AND INSTALLING COMPLETE PROPELLER SHAFT .
WARNING: Scalding hazard. Fit flange wearing suitable protective gloves only.
Brace output flange with Special Tool (23 0 020). See Fig. 2 . Release collar nut with Special Tool (23 2 320).
Upon installation, mark flange with thermo pin and heat to min. 80°- 100°. DO NOT drive on flange. Secure
collar nut with Loctite 243. Tighten to specification. See TORQUE SPECIFICATIONS .
2005 BMW 645Ci
Fig. 2: Releasing Collar Nut

Detach output flange (1) with Special Tool (33 1 150) and adapter plate (33 1 154) from output shaft. See Fig.
3.
2005 BMW 645Ci
Fig. 3: Detaching Output Flange

Release screw on Special Tool (23 3 210). See Fig. 4 . Slide Special Tool (23 3 210) over output shaft and
screw into sealing ring firmly.
2005 BMW 645Ci
Fig. 4: Screwing Special Tool Into Sealing Ring

Insert screw into Special Tool (23 3 210) again and continue turning until sealing ring is pulled out of
transmission housing. See Fig. 5 . If necessary, remove ring spring of sealing ring.
2005 BMW 645Ci
Fig. 5: Pulling Sealing Ring Out Of Transmission Housing

Installation: coat sealing lips of new radial seal with gear oil. Drive in radial seal as far as it will go with Special
Tool (23 3 230) and plastic hammer. See Fig. 6 .
2005 BMW 645Ci

REPLACING RADIAL SHAFT SEAL FOR SELECTOR SHAFT (GS6-53BZ/DZ)
CAUTION: After completion of work, check transmission fluid level. See CHECKING
FLUID LEVEL . Use only approved transmission fluid. See
RECOMMENDED FLUID . Failure to comply with this instruction will result
in serious damage to the transmission.
Shift transmission into 2nd gear. Unflange propeller shaft from transmission and tie up to one side. Tasks are
described in Removing propeller shaft. See REMOVING AND INSTALLING COMPLETE PROPELLER
SHAFT .
2005 BMW 645Ci
cylinder pin (2). See Fig. 7 .
Fig. 7: Removing Retaining Ring

Screw in Special Tool (23 0 210) until it is firmly connected with radial seal (1). See Fig. 8 . Pull out radial seal
with Special Tool (23 0 210).
2005 BMW 645Ci
Fig. 8: Pulling Out Radial Seal For Selector Shaft

Coat sealing lips of radial seal and selector shaft with gear oil. Drive in radial seal with Special Tool (23 0 220).
See Fig. 9 .
2005 BMW 645Ci
Fig. 9: Driving In Radial Seal For Selector Shaft

REMOVING HYDRAULIC PUMP RELAY (SMG)
Remove microfilter housing lower sections on left and right. See CABIN AIR FILTERS . Remove tension
strut on spring strut dome. See TENSION STRUTS .
Unscrew bolt (1) of fresh air duct. See Fig. 10 . Loosen screws (2). Turn quick-release fastener (3) approx. 90°
counterclockwise. If necessary, release screw on pipe clamp. Feed out fresh air duct (4) in direction of arrow
and remove. Upon installation, if necessary, replace damaged seals. Make sure fresh air duct (4) is correctly
seated. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .
2005 BMW 645Ci
Fig. 10: Removing Fresh Air Duct

Unlock stopper (1) in direction of arrow. See Fig. 11 . Unfasten screws. Lift out cover (2).
2005 BMW 645Ci
Fig. 11: Removing Hydraulic Relay Cover

Unlock and disconnect relay (1). See Fig. 12 .

2005 BMW 645Ci
Fig. 12: Removing Hydraulic Pump Relay

REPLACING EXPANSION TANK GS6S53BZ (SMG)
NOTE: After completing work, check fluid level in hydraulic system by means of DIS
Tester "Service Function". Perform "Teach in transmission" service function by
means of DIS Tester.
Disconnect battery. See INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .
Remove underbody protection. Release exhaust system at front and lower. See REMOVING AND
INSTALLING COMPLETE EXHAUST SYSTEM (N62) .
Remove heat shields (1) on left and right. See Fig. 13 .

2005 BMW 645Ci

Support transmission, release screws (1) and nuts (2) and remove transmission cross-member. See Fig. 14 .
Upon installation, tighten fasteners to specification. See TORQUE SPECIFICATIONS . Lower transmission.
2005 BMW 645Ci

Release screws (1). See Fig. 15 . Remove expansion tank (2) in direction of arrow. Upon installation, replace
both sealing rings. Grease sealing rings. Tighten screws to specification. See TORQUE SPECIFICATIONS .
2005 BMW 645Ci
Fig. 15: Removing Expansion Tank

REPLACING PRESSURE SENSOR GS6S53BZ (SMG)
CAUTION: Before working on hydraulic system: reduce pressure in hydraulic system

by means of service function in DIS Tester. Disconnect hydraulic pump
relay in electronics box. DO NOT reconnect relay for entire duration of
repair work.
NOTE: After completing work: check fluid level in hydraulic system by means of DIS
Remove assembly underside protection.

2005 BMW 645Ci
See TORQUE SPECIFICATIONS .
Fig. 16: Removing Protective Plate

Disconnect plug and release pressure sensor (2). See Fig. 17 . Upon installation, replace sealing ring. Tighten
fasteners to specification. See TORQUE SPECIFICATIONS .
2005 BMW 645Ci
Fig. 17: Releasing Pressure Sensor

REPLACING SOLENOID VALVE EV3 FOR SELECTION ANGLE BRAKE GS6S53BZ (SMG)

repair work.
2005 BMW 645Ci
Loosen screws (1). See Fig. 18 . Release pressure accumulator (2) at hexagon head (3). Upon installation,
tighten fasteners to specification. See TORQUE SPECIFICATIONS .
Fig. 18: Releasing Pressure Accumulator At Hexagon Head

Installation: replace sealing ring (1). See Fig. 19 . Pay attention to installation position of sealing ring.
2005 BMW 645Ci
Fig. 19: Locating Sealing Ring

Detach plug from solenoid valve EV3 (1). See Fig. 17 .
Release screws (1) and pull solenoid valve out. See Fig. 20 . Upon installation, replace sealing ring. Tighten
screws to specification. See TORQUE SPECIFICATIONS .
2005 BMW 645Ci
Fig. 20: Removing Solenoid Valve

REPLACING PRESSURE ACCUMULATOR GS6S53BZ (SMG)
For procedure, see REPLACING SOLENOID VALVE EV3 FOR SELECTION ANGLE BRAKE
GS6S53BZ (SMG) .
REPLACING A SOLENOID VALVE (CLUTCH OR GEARSHIFT) GS6S53BZ (SMG)

repair work.
2005 BMW 645Ci
Procedure is identical for all solenoid valves: (1) Solenoid valve EV3, (2) Pressure sensor, (3) Solenoid valve
EV2, (4) Solenoid valve EV1 and (5) Solenoid valve EV0. See Fig. 17 .
Remove assembly underside protection. Remove heat shield.
Release screws (1) and remove protective plate. See Fig. 16 . Upon installation, tighten screws to specification.
Release screws (2). See Fig. 21 . Upon installation, tighten screws to specification. See TORQUE
SPECIFICATIONS .

Remove screws (1) and (2). See Fig. 22 . Lower valve block until screws of solenoid valve are accessible. Upon
installation, tighten screws to specification. See TORQUE SPECIFICATIONS .
2005 BMW 645Ci
Fig. 22: Lowering Valve Block

Detach plug from solenoid valve. Release screws (1) and pull solenoid valve out. See Fig. 23 . Upon
installation: replace sealing ring. Tighten screws to specification. See TORQUE SPECIFICATIONS .
2005 BMW 645Ci
Fig. 23: Removing Solenoid Valve

REPLACING VALVE BLOCK GS6S53BZ (SMG)

repair work.
2005 BMW 645Ci
Release screws (1) and remove protective plate. See Fig. 16 . Upon installation, tighten screws to specification.
Loosen screws (1). See Fig. 18 . Release pressure accumulator (2) at hexagon head (3). Upon installation,
tighten fasteners to specification. See TORQUE SPECIFICATIONS .
Installation: replace sealing ring (1). See Fig. 19 . Pay attention to installation position of sealing ring.
Release stud bolt (1). See Fig. 24 . Lift out expansion tank in direction of arrow from valve block. Upon
installation, tighten bolt to specification. See TORQUE SPECIFICATIONS .
Fig. 24: Removing Expansion Tank From Valve Block

NOTE: Plugs of solenoid valves must not be mixed up.
Pull off plug (1). See Fig. 25 .

2005 BMW 645Ci
Fig. 25: Pulling Off Plug

Unlock and disconnect lines (1) and (2). See Fig. 26 and Fig. 27 . Upon installation, replace sealing rings.
2005 BMW 645Ci
Fig. 26: Disconnecting Lines

2005 BMW 645Ci
Fig. 27: Locating Lines

Remove screws (1) and (2). See Fig. 22 . Remove valve block. Upon installation, tighten screws to
specification. See TORQUE SPECIFICATIONS .
REPLACING HYDRAULIC PUMP GS6S53BZ (SMG)

repair work.
2005 BMW 645Ci
Remove underbody protection. Remove right heat shield.
Release screw (1) and remove grounding strap. See Fig. 28 .
Fig. 28: Removing Grounding Strap

Release line (1) and screws (2). See Fig. 29 . Unlock connector and remove. Remove hydraulic pump. Upon
installation, tighten fasteners to specification. See TORQUE SPECIFICATIONS .
2005 BMW 645Ci
Fig. 29: Removing Hydraulic Pump

REPLACING CLUTCH ACTUATOR GS6S53BZ (SMG)

repair work.
2005 BMW 645Ci
Unlock connector and remove. Unlock and disconnect line (1). See Fig. 30 . Release nuts (2) and remove clutch
actuator (3). Upon installation, replace sealing ring. Tighten nuts to specification. See TORQUE
SPECIFICATIONS .
Fig. 30: Removing Clutch Actuator

Clutch Slave Cylinder-To-Clutch Housing/Transmission Housing 16 (22)
Drain & Fill Plug
M18x1.5 Hexagon Socket Thread 26 (35)
M12x1.5 18 (25)
Output Flange
2005 BMW 645Ci
Step 1 148 (200)

Step 2 Release
Step 3 103 (140)
Pressure Accumulator-To-Valve Block 22 (30)
Protecting Plate/Valve Block-To-Transmission 15 (20)
Retaining Screw For Hydraulic Line 13 (18)
Transmission Cross Member-To-Body
M8 Thread 15 (21)
M10 Thread 31 (42)
Transmission Mount-To-Transmission Support Bracket/Transmission Cross 15 (21)
Member
INCH Lbs. (N.m)
Fresh Air Duct-To-Mounting Bracket, Left/Right 40 (4.5)
Fresh Air Duct-To-Bearing Block 31 (3.5)
Pipe Clamp-To-Fresh Air Duct 18 (2.0)
Protective Plate/Expansion Tank/Shift Actuator/Bracket Pressure 89 (10)
Accumulator/Hydraulic Pump/Valve Block-To-Transmission Housing
Valves-To-Valve Block 31 (3.5)
2005 BMW 645Ci
2001-05 MANUAL TRANSMISSIONS Servicing
2001-05 MANUAL TRANSMISSIONS
Servicing
APPLICATION
MANUAL TRANSMISSION APPLICATION
M Coupe & M Roadster (E36/7)
2001-02 ZF Type C
M3 (E46)
2001-05 Getrag Type D Or Getrag
Type D With SMG
M5 (E39)
2001-03 S6S-420G
X3 (E83)
2004-05 ZF G56X337BZ
X5 (E53)
3.0L (2001-05) ZF Type H
Z3 (E36/7)
2001-02 ZF G56X37BZ
Z4 (E85)
2003-05 (2.5) Getrag Type B+
2003-05 (3.0L) ZF Type H & ZF Type H
With SMG
Z8 (E52)
2001-03 Getrag
3-Series (E46)
325i (4/01 To 2005), 330 & 330Ci (6/00 To 2005) & 325i & 325Ci S5D-280Z Or ZF Type H
(9/00 To 2005)
330xi (6/00 To 2005) S5D-280Z Or ZF Type H
5-Series (E39)
525i & 530i (3/01 To 2003) S5D-280Z
540i (1/97 To 2003) S6S-420G
5-Series (E60)
525i, 530i & 545i (8/03 To 2005) ZF Type H & ZF Type G
6-Series (E63)
645Ci (2004-05) ZF Type G
LUBRICATION
2005 BMW 645Ci
Inspect fluid level when vehicle is serviced. DO NOT drain fluid, transmission has lifetime fluid except for the
following exceptions:
 M3 - Change oil at 1200 mile service and each Inspection II.

 M5 - Change oil at 1200 mile service, then fill with lifetime oil.
CHECKING FLUID LEVEL
Check lubricant at fill hole. Lubricant should be at bottom of filler plug hole.
RECOMMENDED FLUID
For model years 1998-2003, all manual transmissions are filled with Esso/Exxon MTF-LT-1 lifetime fluid. A
Yellow label with the letters MTF-LT-1 is located next to the oil filler plug. Except for models specified under
SERVICE INTERVALS, no oil change is required for the service life of the transmission.
From model year 2004, some manual transmissions are filled with Castrol MTF-LT-2 lifetime fluid. This fluid
has the same properties as the MTF-LT-1 fluid. The MTF-LT-1 fluid may be mixed or substituted for the MTF-
LT-2 manual transmission fluid.
NOTE: The following does not apply to transmissions filled with lifetime fluid.
Cold Shift Effort
Transmission cold shift effort is reduced by replacing the original oil (SAE 80 or Mobil SHC 630) with a
reputable brand single-grade HD engine mineral oil of API-SE standards (SAE 20, SAE 30, or SAE 40).
Thinner oils run the risk of increased gear noise. A further reduction in shift effort can be obtained by using
ATF , but gear noise will be more noticeable compared to single-grade engine mineral oils. For summer
operation it is recommended that ATF or engjne oil be drained and replaced by the original lubricant, either
SAE 80 or Mobil SHC 630 transmission fluid.
FLUID CAPACITIES
Fluid capacity is approximately 1.4 qts. (1.3L). Transmission should be filled to bottom of filler plug hole.
ADJUSTMENTS
GEARSHIFT LINKAGE
No external adjustment is necessary.
2005 BMW 645Ci
Drain & Fill Plug (All Models) 37 (50)

2006 BMW 650i
BRAKES Pedal Assembly - Repair - 650i
BRAKES
Pedal Assembly - Repair - 650i
11 PEDAL MOUNTING BLOCK

35 11 000 REMOVING AND INSTALLING COMPLETE BEARING BLOCK FOR FOOT PEDAL
 Remove pedal trim . See 51 45 185 REMOVING AND INSTALLING/REPLACING PANEL FOR
PEDALS .
 Vehicles with electric steering column:
 Remove electric steering column drive . See 67 64 010 REMOVING AND
ADJUSTMENT .
IMPORTANT: After completion of work, carry out function check.
Release nuts (3) and remove bearing block.
Installation:
Tightening torque 35 11 1AZ . See PEDALS - TIGHTENING TORQUES -- 650I .
Fig. 1: Identifying Plug Connection, Locking Clip And Nut

2006 BMW 650i
31 CLUTCH PEDAL WITH LINK

35 31 000 REMOVING AND INSTALLING / REPLACING CLUTCH PEDAL
 Remove pedal trim. See 51 45 185 REMOVING AND INSTALLING/REPLACING PANEL FOR
PEDALS .
 Remove CAS control unit.
Check function after completing tasks.
Disconnect return spring (1).
Unclip fastener (2).
Pull out pin (3).
If necessary, disconnect over-center helper spring.
Fig. 2: Identifying Return Spring, Fastener And Pin

Press hook (1) together and pull out pin.
Installation:
Replace pin.
Remove clutch pedal.

2006 BMW 650i
Fig. 3: Identifying Hook And Pin

40 ACCELERATOR PEDAL ACTUATION

35 40 001 REMOVING AND INSTALLING/REPLACING ACCELERATOR PEDAL MODULE
Unscrew screw.
Pull accelerator pedal module upwards out of fixture.
Installation:
Tightening torque, 35 40 1AZ. See PEDALS - TIGHTENING TORQUES -- 650I .
Fig. 4: Pulling Accelerator Pedal Module Upwards Out Of Fixture

Pull off plug (1).

2006 BMW 650i
Fig. 5: Identifying Accelerator Pedal Module Plug

IMPORTANT: Accelerator pedal module can only be replaced completely with adapter plate.
2005 BMW 645Ci
2004-07 BRAKES Pedal Assembly - Repair Instructions - 6-Series (E63/64)
2004-07 BRAKES
Pedal Assembly - Repair Instructions - 6-Series (E63/64)
PEDAL MOUNTING BLOCK

35 11 000 REMOVING AND INSTALLING COMPLETE BEARING BLOCK FOR FOOT PEDAL
 Remove pedal trim, refer to 51 45 185 REMOVING AND INSTALLING/REPLACING TRIM FOR
PEDAL ASSEMBLY .
 Vehicles with electric steering column:
 Remove electric steering column drive, refer to 67 64 010 REMOVING AND
ADJUSTMENT .
 Vehicles with manual transmission:
 Remove clutch pedal, refer to 35 31 000 REMOVING AND INSTALLING / REPLACING
CLUTCH PEDAL.
 Remove clutch master cylinder.
IMPORTANT: After completion of work, carry out function check.
Release nuts (3) and remove bearing block.

2005 BMW 645Ci
Fig. 1: Removing Bearing Block

Installation:
Tightening torque, refer to 35 11 1AZ in PEDAL ASSEMBLY - TIGHTENING TORQUES - 645CI .
CLUTCH PEDAL WITH LINKAGE

35 31 000 REMOVING AND INSTALLING / REPLACING CLUTCH PEDAL
 Remove pedal trim, refer to 51 45 185 REMOVING AND INSTALLING/REPLACING TRIM FOR
PEDAL ASSEMBLY .
2005 BMW 645Ci
 Remove CAS control unit, refer to 61 35 015 REMOVING AND INSTALLING (REPLACING)
CONTROL UNIT FOR CAR ACCESS SYSTEM .
Check function after completing tasks.
Disconnect return spring (1).
Unclip fastener (2).
Pull out pin (3).
Fig. 2: Disconnecting Return Spring

If necessary, disconnect over-center helper spring.
Press hook (1) together and pull out pin.

2005 BMW 645Ci
Fig. 3: Pressing Hook And Removing Pin

Installation:
Replace pin.
Remove clutch pedal.
ACCELERATOR PEDAL
35 40 001 REMOVING AND INSTALLING/REPLACING ACCELERATOR PEDAL MODULE
Unscrew screw.
Pull accelerator pedal module upwards out of fixture.

2005 BMW 645Ci
Fig. 4: Removing Accelerator From Fixture

Installation:
Tightening torque, refer to 35 40 1AZ in , refer to 35 11 1AZ in PEDAL ASSEMBLY - TIGHTENING

TORQUES - 645CI .
Pull off plug (1).

2005 BMW 645Ci

Remove accelerator pedal module.
IMPORTANT: Accelerator pedal module can only be replaced completely with adapter plate.
2006 BMW 650i
DRIVELINE/AXLES Propeller Shaft - 650i, M6
DRIVELINE/AXLES
Propeller Shaft - 650i, M6
00 PROPELLER SHAFT GENERAL

26 00 ... PROPELLER SHAFT DEFLECTION ANGLES
IMPORTANT: Propeller shaft deflection angles are not available.
11 PROPELLER SHAFT ASSEMBLY

26 11 000 REMOVING AND INSTALLING COMPLETE PROPELLER SHAFT (CONSTANT-
VELOCITY JOINT)
 Remove rear underbody protection.

 Remove complete exhaust system.
 Remove heat shield.
NOTE: M57 only.
 Support transmission from underneath.

 Remove transmission cross-member.
Release screws.
Installation:
ZNS bolts and nuts must be replaced.
IMPORTANT: Only M57:

The bolt without washer may only be tightened by means of the nut.
The bolt with rolled-on washer which has ribbed teeth facing the support side
must be tightened by means of the bolt.
Observe different tightening torques.
Tightening torque, 26 11 1AZ. See PROPELLER SHAFT - TIGHTENING
TORQUES .
2006 BMW 650i
Fig. 1: Locating ZNS Bolts And Nuts

Release bolts and replace.
Fig. 2: Locating Support Side Bolt

Using a screwdriver, press constant velocity joint off drive flange at disassembly grooves.
2006 BMW 650i
Fig. 3: Pressing Constant Velocity Joint Off Drive Flange

IMPORTANT: Do not let propeller shaft fall into joints.

Joints and rubber sleeve can be damaged on constant-velocity joint.
Fig. 4: Do Not Allow Propeller Shaft To Fall Into Joints

Grip propeller shaft at centre bearing and release screws.
Tightening torque, 26 11 6AZ. See PROPELLER SHAFT - TIGHTENING TORQUES .
Fig. 5: Locating Propeller Shaft Centre Bearing

Bend propeller shaft downwards at centre bearing.
Remove propeller shaft from transmission output flange and detach constant-velocity joint from rear axle
differential.
2006 BMW 650i
Fig. 6: Removing Propeller Shaft From Transmission Output Flange

Installation:
Withdraw constant-velocity joint (1) up to stop.
Fit shims.
Attach propeller shaft with pulled-apart constant-velocity joint to drive flange of rear differential.
Alternately tighten 2 opposing screws to draw constant-velocity joint evenly into the input flange.
Replace ZNS bolts.
Tightening torque, 26 11 4AZ. See PROPELLER SHAFT - TIGHTENING TORQUES .
Fig. 7: Withdraw Constant-Velocity Joint To Stop

Installation:
Check centering mount (4).

2006 BMW 650i
Replace damaged centering mount.
Grease centering mount.
Fig. 8: Check Centering Mount

Installation:
The aluminum propeller shaft contains a crash element.
Check the crash element before installing the propeller shaft.
Replace the propeller shaft if the crash element has been pushed together.
1. Deformation travel approx. 100 mm

2. Aluminum tubing
3. Bearing journal
Fig. 9: Identifying Propeller Shaft Deformation Travel (1), Aluminum Tubing (2), and Bearing Journal
(3)
2006 BMW 650i
26 11 051 REPLACING FLEXIBLE DISK FOR PROPELLER SHAFT

 Remove heat shields.
 Remove propeller shaft at transmission and centre bearing.
NOTE: To protect constant-velocity joint, tie back propeller shaft in area of centre
bearing.
Release screws and remove flexible disk (1) from propeller shaft.
Tightening torque: 26 11 1AZ. See PROPELLER SHAFT - TIGHTENING TORQUES .
Installation:
Arrows (3) on circumference of flexible disk must point to flange arms (2).
Tighten down screw connection via nut only.
Fig. 10: Removing Flexible Disk (1) From Propeller Shaft

Installation:
Check centering element, replace centering element if damaged.

2006 BMW 650i
Fig. 11: Checking Centering Element

26 11 090 REMOVING AND INSTALLING /REPLACING CENTERING MOUNT FOR PROPELLER

SHAFT
 00 5 500
 11 1 310
 11 2 030
 Remove propeller shaft.
Fill centering bore (1) completely with viscous grease.
Drive special tool 11 1 310 with a plastic hammer into centering bore.
The centering mount (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 mount, you can also fill the centering bore with water instead of
grease.
2006 BMW 650i
Fig. 12: Identifying Centering Bore With Special Tool (11 1 310)
Installation:
Remove grease/water from mount bore.
Drive in centering (1) with special tools 11 2 030 and 00 5 500 into propeller shaft (observe protrusion).
Installation:
Observe protrusion A = 4+2 mm of centering (1).

2006 BMW 650i
Fig. 14: Identifying Propeller Shaft Centering

26 11 160 REPLACING CONSTANT-VELOCITY JOINT FOR PROPELLER SHAFT
 23 1 160
 26 1 110
 26 1 121
 26 1 122
 31 2 102
 31 2 104
Lever sealing cap (1) with screwdriver (2) out of constant-velocity joint (3).
NOTE: Replace sealing cap (1) with seal.

2006 BMW 650i
Fig. 15: Identifying Sealing Cap With Seal

NOTE: Installation sequence:
1. Constant-velocity joint
2. Seal
3. Sealing cap
Fig. 16: Identifying Constant-Velocity Joint, Seal And Sealing Cap

Lift off retainer
Installation:
Replace circlip.
2006 BMW 650i
Fig. 17: Locating Circlip

Force cap off constant velocity joint.
Installation:
Insert sealing washer (1) into constant-velocity joint.
Fig. 18: Inserting Sealing Washer Into Constant-Velocity Joint

Detach constant-velocity joint (1) with special tool 26 1 110 and commercially available special tool (2).
2006 BMW 650i
Fig. 19: Detaching Constant-Velocity Joint With Special Tool (26 1 110)
Release clamp (1) and detach cap with gaiter.
Push on new cap with gaiter.
NOTE: Do not tighten down clamp (1) yet.
Fig. 20: Pushing On Cap With Gaiter

Mount constant-velocity joint with special tool 23 1 160 up to stop.
Align bores of constant velocity joint and cap to each other.
Tighten down clamp on gaiter.
NOTE: Keep toothing free of grease.

Inject new grease into constant velocity joint from rubber gaiter and flange
sides.
2006 BMW 650i

NOTE: Prepare special tools 31 2 102 and 31 2 104.
Press sealing cap with special tools 26 1 121, 26 1 122, 31 2 102 and 31 2 104 into constant-velocity joint (1).
NOTE: Align sealing cap and seal to bores of constant-velocity joint with screw.
2006 BMW 650i
Fig. 23: Identifying Constant-Velocity Joint And Special Tool (26 1 22), (26 1 121), (31 2 104)
Push cap (1) onto constant-velocity joint (2).
Fig. 24: Pushing Cap Onto Constant-Velocity Joint

12 CENTRE CONSOLE ASSEMBLY

26 12 001 REPLACING COMPLETE PROPELLER SHAFT CENTRE BEARING (CONSTANT-
VELOCITY JOINT)
 00 7 500
 24 0 090
 24 1 050
 33 1 307
2006 BMW 650i
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.
Fig. 25: Mark Front Propeller Shaft Relative To Rear Propeller Shaft With Paint Stick
Release screw (1).
Pull propeller shaft apart.
Installation:
Thread free from grease.
When pushing shaft together, make sure that markings match up.
Insert bolt (1) with thread-locking liquid.
Tightening torque 26 11 5AZ. See PROPELLER SHAFT - TIGHTENING TORQUES .
Fig. 26: Identifying Thread-Locking Bolt

2006 BMW 650i
Remove shim and dust gaiter.
Fig. 27: Removing Shim And Dust Gaiter

Pull off centre bearing with special tool 00 7 500 / 33 1 307 and commercially available puller.
Fig. 28: Pulling Centre Bearing With Special Tool (00 7 500) And (33 1 307)
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.
2006 BMW 650i
2005 BMW 645Ci
2004-05 DRIVELINE/AXLE Propeller Shaft - Repair Instructions - 6-Series
2004-05 DRIVELINE/AXLE
Propeller Shaft - Repair Instructions - 6-Series
PROPELLER SHAFT GENERAL

26 00 ... PROPELLER SHAFT DEFLECTION ANGLES
IMPORTANT: Specifications on propeller shaft deflection angles For E53,E6x,E8x,E9x

Only possible on request with the vehicle identification number of the problem
vehicle.
PROPELLER SHAFT ASSEMBLY

26 11 000 REMOVING AND INSTALLING COMPLETE PROPELLER SHAFT
Remove rear underbody protection.

Remove complete exhaust system.
Remove heat shield.
NOTE: M57 only.
 Support transmission from underneath

Unfasten screws.
2005 BMW 645Ci

Installation:
ZNS bolts and nuts must be replaced.
IMPORTANT: Only M57: The bolt without washer may only be tightened by means of the nut.
The bolt with rolled-on washer which has ribbed teeth facing the support side
must be tightened by means of the bolt. Observe different tightening torques.
Tightening torque, refer to 26 11 1AZ in PROPELLER SHAFT - TIGHTENING
TORQUES - 6-SERIES .
Release bolts and replace.

2005 BMW 645Ci
Fig. 2: Releasing Bolts

Using a screwdriver, press constant velocity joint off drive flange at disassembly grooves.
2005 BMW 645Ci
Fig. 3: Pressing Constant Velocity Joint Off Drive Flange

IMPORTANT: Do not let propeller shaft fall into joints. Joints and rubber sleeve can be
damaged on constant velocity joint.
2005 BMW 645Ci
Fig. 4: Do Not Let Propeller Shaft Fall Into Joints

Grip propeller shaft at centre bearing and release screws.

2005 BMW 645Ci
Fig. 5: Griping Propeller Shaft At Centre Bearing

Tightening torque, refer to 26 11 6AZ in PROPELLER SHAFT - TIGHTENING TORQUES - 6-SERIES .
Bend propeller shaft downwards at centre bearing.
Remove propeller shaft from transmission output flange and detach constant-velocity joint from rear axle
differential.
2005 BMW 645Ci
Fig. 6: Removing Propeller Shaft From Transmission Output Flange

Installation:
Withdraw constant-velocity joint (1) up to stop.
Fit shims.
Attach propeller shaft with pulled-apart constant-velocity joint to drive flange of final drive.
2005 BMW 645Ci
Fig. 7: Attaching Propeller Shaft With Pulled-Apart Constant-Velocity Joint To Drive Flange Of Final
Drive
Alternately tighten 2 opposing screws to draw constant-velocity joint evenly into the input flange.
Replace ZNS bolts.
Installation:
2005 BMW 645Ci
Check centering mount (4).
Fig. 8: Checking Centering Mount

Replace damaged centering mount.
Grease, Refer to BMW Service OPERATING FLUIDS - DRIVE SHAFT .
Installation:
The aluminum propeller shaft contains a crash element.
Check the crash element before installing the propeller shaft.
Replace the propeller shaft if the crash element has been pushed together.
2005 BMW 645Ci
1 Deformation travel approx. 100 mm
2 Aluminum tubing
3 Bearing journal
Fig. 9: Identifying Bearing Journal

Propeller shafts: refer to Technical DataPROPELLER SHAFT - TECHNICAL DATA - 6-SERIES .

2005 BMW 645Ci
26 11 051 REPLACING FLEXIBLE DISK FOR PROPELLER SHAFT

 Remove heat shields.
 Remove propeller shaft at transmission and centre bearing.
NOTE: To protect constant-velocity joint, tie back propeller shaft in area of center
bearing.
Release screws and remove flexible disk (1) from propeller shaft.
Installation:
Arrows (3) on circumference of flexible disk must point to flange arms (2).

2005 BMW 645Ci
Fig. 10: Replacing Self-Locking Nuts

Tighten down screw connection via nut only.
Installation:
Check centering element, replace centering element if damaged.

2005 BMW 645Ci
Fig. 11: Identifying Centering Element

26 11 090 REMOVING AND INSTALLING/REPLACING CENTERING MOUNT FOR PROPELLER

SHAFT
NOTE: For special tools, refer to PROPELLER SHAFT - SPECIAL TOOLS - 6-SERIES .
 00 5 500
 11 1 310
 11 2 030
2005 BMW 645Ci
Remove propeller shaft.
Fill centering bore (1) completely with viscous grease.
Drive special tool 11 1 310 with a plastic hammer into centering bore.
Fig. 12: Driving Special Tool 11 1 310 With A Plastic Hammer Into Centering Bore
The centering mount (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 mount, you can also fill the centering bore with water instead of
grease.
Installation:
2005 BMW 645Ci
Remove grease/water from mount bore.
Drive in centering (1) with special tools 11 2 030 and 00 5 500 into propeller shaft (observe protrusion).
Fig. 13: Driving In Centering (1) With Special Tools 11 2 030 And 00 5 500
Installation:
Observe protrusion A = 4+2 mm of centering (1).

2005 BMW 645Ci
Fig. 14: Observe Protrusion A Of Centering Mount (1)

26 11 160 REPLACING CONSTANT-VELOCITY JOINT FOR PROPELLER SHAFT
 23 1 160
 26 1 110
 26 1 121
 26 1 122
 31 2 102
 31 2 104
2005 BMW 645Ci
Lever sealing cap (1) with screwdriver (2) out of constant velocity joint (3).
NOTE: Replace sealing cap (1) with seal.
Fig. 15: Replacing Sealing Cap With Seal

NOTE: Installation sequence:
1. Constant-velocity joint
2. Seal
3. Sealing cap
2005 BMW 645Ci
Fig. 16: Installing Velocity Joint From Propeller Shaft

Lift off retainer
Installation:
Replace circlip.
2005 BMW 645Ci
Fig. 17: Installing Circlip

Force cap off constant velocity joint.
Installation:
Insert sealing washer (1) into constant-velocity joint.

2005 BMW 645Ci
Fig. 18: Inserting Sealing Washer Into Constant-Velocity Joint

Detach constant-velocity joint (1) with special tool 26 1 110 and commercially available special tool (2).
2005 BMW 645Ci
Fig. 19: Detaching Constant-Velocity Joint With Special Tool 26 1 110

Release clamp (1) and detach cap with gaiter.
Push on new cap with gaiter.
NOTE: Do not tighten down clamp (1) yet.

2005 BMW 645Ci
Fig. 20: Pushing On New Cap With Gaiter

Mount constant-velocity joint with special tool 23 1 160 up to stop.

2005 BMW 645Ci
Fig. 21: Mounting Constant-Velocity Joint With Special Tool 23 1 160

Align bores of constant velocity joint and cap to each other.
Tighten down clamp on gaiter.
NOTE: Keep toothing free of grease. Inject new grease into constant velocity joint from
rubber gaiter and flange sides.
NOTE: Prepare special tools 31 2 102 and 31 2 104.

2005 BMW 645Ci

Press sealing cap with special tools 26 1 121, 26 1 122, 31 2 102 and 31 2 104 into constant- velocity joint (1).
2005 BMW 645Ci
Fig. 23: Pressing Sealing Cap With Special Tools 26 1 121, 26 1 122, 31 2 102 And 31 2 104
NOTE: Align sealing cap and seal to bores of constant-velocity joint with screw.
Push cap (1) onto constant-velocity joint (2).

2005 BMW 645Ci
Fig. 24: Pushing Cap Onto Constant-Velocity Joint

CENTRE CONSOLE ASSEMBLY

26 12 001 REPLACING COMPLETE PROPELLER SHAFT CENTRE BEARING (CONSTANT-
VELOCITY JOINT)
 00 7 500
 24 0 090
 24 1 050
 33 1 307
2005 BMW 645Ci
Remove propeller shaft.
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.
Fig. 25: Marking Propeller Shaft

Release screw (1).

2005 BMW 645Ci
Fig. 26: Release Screw Propeller Shaft Apart

Pull propeller shaft apart.
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.

2005 BMW 645Ci
Fig. 27: Removing Shim And Dust Gaiter

Pull off centre bearing with special tool 00 7 500 / 33 1 307 and commercially available puller.
2005 BMW 645Ci
Fig. 28: Pulling Off Centre Bearing With Special Tools 00 7 500/33 1 307
Drive new centre bearing firmly home with special tool 24 0 090 or 24 1 050.
2005 BMW 645Ci
Fig. 29: Driving New Centre Bearing Firmly Home With Special Tools 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.
2009 BMW 650i
SUSPENSION
Rear - 650i, M6
00 GENERAL
 Headaches
 Dizziness
 Stomach aches
 Vomiting
 Diarrhoea
 Cramps/fits
 Unconsciousness

First aid measures:
Danger of injury!

2009 BMW 650i
 Impaired sight

First aid measures:

Recycling:

2009 BMW 650i

contact points.
necessary.

points!


differential cover!
2009 BMW 650i


2009 BMW 650i

Facts:
Consequence:
2009 BMW 650i
Procedure:

bristles!
2009 BMW 650i

THE FOLLOWING WORK



2. Swinging arm
2009 BMW 650i
3. Integral link
5. Control arm
6. Guide arm


2009 BMW 650i


2009 BMW 650i

10 FINAL DRIVE

Check oil level.
2009 BMW 650i

Installation:

2009 BMW 650i

Time-Oil" sticker.
Recycling:
DATA .
Installation:
2009 BMW 650i

No oil drain plug:
2009 BMW 650i

Installation:

2009 BMW 650i

E63 N52 188L / 188LW
N62, N62TU 215K
S85 215 with lock
E64 N52 188L / 188LW
N62, N62TU 215K
K Compact
L Light-running



bent).
2009 BMW 650i

Unfasten screws.

2009 BMW 650i


about noise.
TOOLS .

2009 BMW 650i

After installation:

Release screws (1).
Unscrew screws (2).
Remove cover.
Installation:
2009 BMW 650i

Release screw (1).
Unscrew screws (2).
Remove cover.
Installation:

2009 BMW 650i



2009 BMW 650i
rear differential.

 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
2009 BMW 650i
TOOLS .
 33 1 150
 33 1 341
 33 3 440
 33 3 470
 33 3 480

differential!

2009 BMW 650i

215K / with lock:

188K/L:

2009 BMW 650i



2009 BMW 650i

Fit drive flange.
can be screwed on.

2009 BMW 650i



After installation:

2009 BMW 650i
Installation:

Installation:
REAR AXLE .
2009 BMW 650i

Replacement:
After installation:
 00 5 010
 00 5 500
 32 1 060
 33 1 308
 33 3 400
 33 4 240
 33 4 250
TOOLS .

2009 BMW 650i

diameter).
00 5 500 + 33 3 400 : 168K/L - 78x44x10
00 5 500 + 33 4 240 : 188K/L/LW - 90x44x10
00 5 500 + 33 4 250 : 215K/L/LW, 220K to 230K - 100x50x10
33 5 030 : 210, 215 with lock - 76x50x10

2009 BMW 650i
After installation:
damage.

Series .
 188L / 188LW
 215K
 215 with lock
After installation:

 33 3 312
 33 4 161
 33 4 162
 33 4 166
 33 4 311
 33 4 312
 33 4 465
2009 BMW 650i


2009 BMW 650i

go.


FRONT (M6)
 33 3 312
 33 4 161
 33 4 162
 33 4 466
2009 BMW 650i

2009 BMW 650i

 33 4 281
 33 4 282
 33 4 283
 33 4 284
 33 4 465
2009 BMW 650i

as it will go.
2009 BMW 650i


(M6)
 33 4 281
 33 4 282
 33 4 283
 33 4 284
 33 4 465
2009 BMW 650i

Circolight

will go.
2009 BMW 650i
21 OUTPUT SHAFTS
 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

the output shaft.
2009 BMW 650i


070 .
2009 BMW 650i


tools 33 2 202 and 33 5 070 .
2009 BMW 650i

070 .


2009 BMW 650i

tools 33 2 202 and 33 5 070 .

2009 BMW 650i


Apply handbrake.
Remove rear wheel .
Unscrew collar nut.
Installation:

2009 BMW 650i

Installation:

2009 BMW 650i

After installation:
Remove rear wheel.

2009 BMW 650i

2009 BMW 650i
 21 2 120
 26 1 110
Clean output shaft.
Installation:

2009 BMW 650i
Remove circlip (4).
Installation:
joint.


2009 BMW 650i

Installation:

2009 BMW 650i
Installation:
Pull new gaiter on.

electric inscriber.
2009 BMW 650i
31 REAR SUB-FRAME
 00 2 030
 00 2 040
 33 4 232
system.



2009 BMW 650i
Installation:

2009 BMW 650i

After installation:

system.

2009 BMW 650i

After installation:


 00 2 030
 00 2 040
 33 3 274
 33 4 232
2009 BMW 650i




2009 BMW 650i
Installation:

2009 BMW 650i


LINK

Installation:

2009 BMW 650i

After installation:

check.


2009 BMW 650i

Installation:

2009 BMW 650i

Installation:

Unfasten nut.
Installation:

2009 BMW 650i

After installation:

2009 BMW 650i
Installation:

Unscrew nut (1).

2009 BMW 650i
Installation:

Replacement:
After installation:
Variants:
2009 BMW 650i

Unscrew nut (1).
Installation:

2009 BMW 650i

Installation:

2009 BMW 650i

After installation:
 33 3 333
 33 4 191
 33 4 192
 33 4 193

2009 BMW 650i

Remove circlip (1).
Installation:

2009 BMW 650i

After installation:

CARRIER
Remove rear wheel .
collar nut.
Unscrew collar nut.
Release handbrake.
Installation:

2009 BMW 650i

REAR BRAKE DISCS .
Replacement:
2009 BMW 650i

33 AXLE MOUNTING

Risk of damage!

Release screws (2).
Installation:

2009 BMW 650i

 33 4 153
 33 4 154
 33 4 155
 33 4 271
 33 4 272
 33 4 274

necessary.
2009 BMW 650i

observed.
2009 BMW 650i

41 WHEEL BEARINGS
 33 2 116
 33 2 160
 33 2 201
Apply handbrake.
Remove rear wheel .
Unscrew collar nut.

2009 BMW 650i
Installation:

bearing.
2009 BMW 650i
be reused!
Installation:
After installation:
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
inner race.
2009 BMW 650i
Inner Race


2009 BMW 650i

Installation:

2009 BMW 650i
52 SHOCK ABSORBER
Facts:
Consequence:
Procedure:
ABSORBER

Release screw.
2009 BMW 650i
Installation:
Replace screw.

Unscrew nuts (1).
Installation:

2009 BMW 650i


 31 3 341
springs.
2009 BMW 650i

Version with EDC:
Removing:
snap into place.

2009 BMW 650i




2009 BMW 650i

Assembly:
2009 BMW 650i
2009 BMW 650i


2009 BMW 650i

After installation:
Control (EDC).
 31 3 341
springs.
2009 BMW 650i
Version with EDC:
Removing:
snap into place.


2009 BMW 650i

(Arrow)
2009 BMW 650i

Assembly:
2009 BMW 650i
2009 BMW 650i


2009 BMW 650i

SHOCK ABSORBER

2009 BMW 650i

 31 3 341
springs.

2009 BMW 650i
Removing:
into place.


2009 BMW 650i

(Arrow)

2009 BMW 650i

Assembly:


2009 BMW 650i

2009 BMW 650i
2009 BMW 650i
Absorber

2009 BMW 650i

MODEL)
absorber.
55 STABILIZER BAR
Installation:

2009 BMW 650i

Replacement:
Installation:
oil and grease.
2009 BMW 650i

Installation:
Installation:

2009 BMW 650i

90 TROUBLESHOOTING

2009 BMW 650i
Fault Cause Remedy

suspension faulty
faulty
or guide arm faulty
faulty
suspension faulty

Fault Cause Remedy
spring
2009 BMW 650i

tube
defective
on tyre profile
effect)
effect)
effect)
2006 BMW 650i
2007-08 ACCESSORIES AND EQUIPMENT Restraint Systems - 650i, M6
2007-08 ACCESSORIES AND EQUIPMENT
Restraint Systems - 650i, M6
00 GENERAL
72 SAFETY PRECAUTIONS AND GENERAL INFORMATION
Safety instructions
-> 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 and electronic equipment
-> Unlocking/locking airbag plug connections
-> Repairing airbag leads. See 61 00 ... REPAIRING AIRBAG CABLES .
-> Handling optical fibres . See 61 00 ... NOTES ON HANDLING OPTICAL FIBERS .
Check
-> Check seat belt.
-> Checklist for seat belt.
Airbag system
-> Deactivating airbags.
-> Procedure after airbag triggering.
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:
2006 BMW 650i
generator components can cause accidental deployment and result in injury

and vehicle damage!
This applies in particular to the following components:
 Airbag modules (driver's/front passenger airbags, side airbags)

 Buckle/belt tensioner
 Head airbag (ITS, AHPS)
 Active knee protection
 Active head restraint
 Safety battery terminal (SBK)
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. Disassembly and assembly

 Inspection, testing and installation work may only be carried out by expert trained personnel in
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, the following prescribed waiting
period must be observed without fail:
 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
2006 BMW 650i
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.
 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.
 Before installing, subject airbag system components (including electronic diagnostic components)
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 diagnostic system / DIS.
 Danger of injury: The airbag module may only be set down with the airbag itself facing upwards .
Otherwise the generator will be thrown upwards if it is fired.
 Do not point the firing pellet of a gas generator at other persons.
 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.
 When carrying out straightening and welding work with an electric welder:
 Cover negative terminal (post)
 Avoid all contact with the skin when removing a fired airbag module - wear gloves. Wash with
water after contact with the skin.
3. Transport
 Components with gas generators must be sent off in the packaging of the new components.
4. Storage
 Observe the regulations of the relevant trade supervisory authority and the applicable national
regulations.
2006 BMW 650i
Fig. 1: Overview Of Airbag Modules, Seat Belts And Airbag Control Units
11 SEAT BELTS
Safety instructions

2006 BMW 650i
-> Repairing airbag leads. See 61 00 ... REPAIRING AIRBAG CABLES
-> Handling optical fibres . See 61 00 ... NOTES ON HANDLING OPTICAL FIBERS
Check
-> Check seat belt
-> Checklist for seat belt
Airbag system
-> Deactivating airbags
-> Procedure after airbag triggering
72 11 ... CHECKING AUTOMATIC SAFETY 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 car involved in the accident
were occupied. If this is not possible, check all the seat belts in the car and replace them if necessary.
In the event of deformations on the car, you must subject the components of the restraint system affected in this
area such as e.g.
 Seat belt
 Seatbelt height adjustment
 Triggering sensors
 etc.
to a function check and a visual inspection.
If you are in any doubt as to the unimpaired functional capability 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 side impact with
permanently deformed impact dampers/deformation elements or cross-members), the complete seat belt must be
replaced! The complete seat belt comprises:
2006 BMW 650i
 Lower strap
 Seat belt buckle (buckle tensioner)
 Retaining screws of all components
The following must also be checked and if necessary replaced:
 Seatbelt mountings on the car body

 Seatbelt mountings on the seat
 seat runners.
 Seat structure (frame, etc.)
Alignment tests on the seat and the seat runners are not permitted!
The following explanations and the checklist for the automatic safety 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 cannot be used again.
Checking automatic reel and seatbelt 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 impact.
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 applied fully while driving on a dry surface and at a road speed
equal to twice that of 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 strap is pulled out suddenly, this system is also OK.
Automatic reel does not require servicing and must not be opened.
Precondition for complete, problem-free retraction of straps:
 the straps must not be twisted!

 the straps must not be damaged!
When placed to one side, the straps of the front seats must retract fully.
2006 BMW 650i
With the 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 strap is reguided.
Belt straps should only be cleaned with a luke-warm soap solution or a commercial laundry detergent.
Belt straps must never be cleaned chemically or dyed.
The automatic reel and strap must be replaced in the event of:
1. creases
2. unraveling
3. pinches
4. cracks and tears
5. traces of melting
6. traces of wear on casing of seat belt tongue or on reversing clip.
Checking lower strap (belt buckle tensioner):
To fasten a seat belt, the tongue should insert easily and with a loud click in the lock.
When the "Red button" is pressed, the tongue must be ejected from the lock under spring pressure.
If the lock cover is missing or damaged, the lower strap must be replaced.
Replace the triggered belt buckle tensioner including the complete seat belt with seatbelt height adjustment and
retaining screws and check the

 seat runners.
 Seat structure.
Criteria for a triggered mechanical belt buckle tensioner:
 very low position of seatbelt buckle (comparisons with new part).
Criteria for a triggered pyrotechnical belt buckle tensioner:

 Airbag warning lamp 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
2006 BMW 650i
is definite that the belt system was not used (seat was not occupied), there is no need to replace the
 upper strap
 attachment parts (belt height adjustment, screws)
 seatbelt mountings on the car body
 seat runners.
after a check.
72 11 ... INSPECTION LIST FOR AUTOMATIC SEAT BELT
AUTOMATIC SEAT BELT INSPECTION REFERENCE LIST

Replace complete automatic seat belt
Was the automatic seat belt with lower strap replaced after The following must also be checked and
an accident, e.g. frontal and/or oblique impact in which replaced, if necessary:
No
the impact absorbers/deformation elements were seatbelt mountings on the car body
permanently deformed? seatbelt mountings on the seat
seat runners.
Yes
Does seat belt lock when pulled out suddenly? No Replace automatic seat belt (upper strap).
Yes
Automatic reel is loose - tighten reel.
If fault persists:
Can the strap be pulled out without jamming? No
Return spring broken - replace automatic
seat belt (upper strap).
Yes
Does the strap on the front seat belts retract automatically? Automatic reel is loose - tighten reel.
Does the strap on the rear seat belts retract automatically, Excessive friction in belt guides - replace
a small remaining loop is acceptable No automatic seat belt (upper strap).
if this remaining loop is fully retracted when the strap is Return spring broken - replace automatic
readjusted. seat belt (upper strap).
Yes
Excessive friction in belt guides - replace
automatic seat belt (upper strap).
Does automatic reel make a squeaking noise when belt is
Yes Reel is loose - tighten reel.
fastened or unfastened?
No
Is the plastic casing on the latch free from damage in the
No Replace complete automatic seat belt
area of the belt opening?
Yes
Is the fully extended strap free from pinches, burn marks,
tears and cuts, folding and unravelling?
2006 BMW 650i
Yes
When the seat belt is fitted, is the latch ejected with spring
pressure from the buckle when the "Red button" is No Replace complete automatic seat belt
pressed?
Yes
Does fastened seat belt lock when stopping vehicle
quickly on a dry road at a road speed twice as fast as No Replace complete automatic seat belt
walking speed?
Yes
If dirt and marks cannot be removed with
Is fully pulled-out belt free of serious dirt and other commercially available mild-action
No
marks? detergent, the automatic seat belt (upper
strap) must be replaced.
Yes
Replace both damaged parts and
complete automatic-reel seat belt.
The following must also be checked and
In the case of seat-integrated seat belts, is front tongue of
No replaced, if necessary:
reclining mechanism or seat rail free of deformation?
seatbelt mountings on the car body
seatbelt mountings on the seat
seat runners.
Yes
The automatic seat belt is O.K.!
72 11 030 REMOVING AND INSTALLING/REPLACING FRONT SEAT BELT (COMPLETE)
WARNING: Read and comply with Safety regulations for handling airbag modules and
pyrotechnical belt tensioners.
Inexpert handling can trigger off the airbag or the belt tensioner and thus
cause injuries.
 Disconnect battery negative lead . See 61 00 ... BATTERY .

 Follow instructions for unlocking and locking airbag plug connections. See 72 12 ... Unlocking/locking
airbag plug connections.
 Removing and installing rear left or right side trim panel . See 51 43 002 REMOVING AND
INSTALLING REAR LEFT OR RIGHT SIDE TRIM PANEL .
 Removing and installing or replacing trim on left or right door pillar (top). See 51 43 ... REMOVING
AND INSTALLING/REPLACING TRIM ON ARMREST OF LEFT OR RIGHT SIDE TRIM
PANEL .
NOTE: If a seat belt which is damaged due to an accident is exchanged, always check
2006 BMW 650i
1 = Protective cap
2 = Screw securing slide bar to body
Tightening torque 72 11 04AZ.
3 = Rosette
4 = Space bush
5 = Strap
6 = Slide bar
Fig. 2: Identifying Protective Cap, Space Bush, Strap And Slide Bar
Unfasten screws.
Unscrew bracket.
2006 BMW 650i
Fig. 3: Locating Bracket Screw

Release screw.
Remove reversing clip.

Release screw.
Remove inertia reel unit.

2006 BMW 650i
Fig. 5: Locating Inertia Reel Unit Screw

Installation:
Coding (1) of automatic reel must be seated in opening (2) of body.
Retaining screw (3) locates automatic reel in position.
Fig. 6: Identifying Coding And Retaining Screw

NOTE: The following work step ends here:

Removing and installing/replacing front seat belt (automatic reel)
Removing and installing/replacing front left or right lower strap (seat belt tensioner)
 Remove front seat . See SEATS - REPAIR .

2006 BMW 650i
the belt tensioner retaining bracket on the seat rail 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!
Unlock plug connection (1) for belt tensioner and disconnect.
Release screw (3) and remove belt tensioner.
Installation:
Replace microencapsulated screw.
Replace cable strap.
Plug connection (1) on belt tensioner must not be under strain.
Fig. 7: Identifying Plug Connection, Cable Strap And Screw

Installation:
Check that cable holder is in correct position on belt tensioner.

2006 BMW 650i
Fig. 8: Locating Belt Tensioner Retaining Screw

Check retaining bracket (1) of belt tensioner on seat rail for damage (bending), replace if necessary.
To replace retaining bracket, release screw (2) and remove retaining bracket (1).
Fig. 9: Identifying Retaining Bracket And Screw

72 11 033 REMOVING AND INSTALLING/REPLACING FRONT SEAT BELT (REEL)
cause injuries.
 Removing and installing rear left or right See 51 43 002 REMOVING AND INSTALLING REAR
2006 BMW 650i
PANEL .
the slide bar (6) for damage (bending) and replace if necessary.
1 = Protective cap
3 = Rosette
4 = Space bush
5 = Strap
6 = Slide bar
Fig. 10: Identifying Protective Cap, Screw, Space Bush And Strap
Unfasten screws.
Unscrew bracket.
2006 BMW 650i

Release screw.

Release screw.

2006 BMW 650i

Installation:

72 11 041 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT LOWER STRAP

(BELT TENSIONER)
Incorrect handling can trigger off the bet tensioner and cause injury.

2006 BMW 650i

 Follow instructions for unlocking and locking airbag plug connections. . See 72 12 ... Unlocking/locking
seat!
Installation:

Installation:
2006 BMW 650i


72 11 092 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT SEAT BELT

(ROLLER)
 Remove backrest for rear seat . See SEATS - REPAIR .
NOTE: Illustration shows removal of left side.

The right side is removed in the same way as the left side.
2006 BMW 650i
NOTE: Before removing reversing clip, mark position to ensure correct alignment when
installing.
Release screw (1).
Remove reversing clip (2).
Fig. 18: Identifying Automatic Reel And Screw

Release screw (1) on automatic reel (2).
Remove automatic reel (2) in direction of arrow.
Installation:

2006 BMW 650i
Fig. 19: Removing Automatic Reel

Release screw (2).
Remove seat belt (1).
Fig. 20: Identifying Seat Belt And Screw

Installation:
Secure fitting of seat belt (1) by means of stop (3) in guide.
72 11 096 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT LOWER STRAP

(BELT BUCKLE)
 Remove rear seat See SEATS - REPAIR .
(2) Seat belt buckle, left

(3) Seat belt buckle, right
Release screw (1) on left and right.
Remove relevant seat belt buckle.

2006 BMW 650i
Fig. 21: Identifying Seat Belt Buckle And Screw


(COMPLETE)

installing.
Release screw (1).

2006 BMW 650i

Installation:
Fig. 23: Remove Automatic Reel

Release screw (2).

2006 BMW 650i
Installation:
NOTE: The work step for "Removing and installing/replacing left or right seat belt"
ends here.

Removing and installing/replacing rear left or right lower strap (belt buckle).
 Remove rear seat . See SEATS - REPAIR .


2006 BMW 650i

2006 BMW 650i
12 AIRBAG GENERATOR
Safety regulations:
2006 BMW 650i
Instructions for disconnecting and connecting battery. See 61 00 ... BATTERY .
Installing and removing contacts. See PLUG CONNECTION TERMINAL .

2006 BMW 650i
Safety instructions
-> Repairing airbag leads . See PLUG CONNECTION TERMINAL .
-> Handling optical fibres . See PLUG CONNECTION TERMINAL .
Check
-> Check seat belt
Airbag system
IMPORTANT: Failure to comply with the warning notices and repair instructions for gas
and vehicle damage!

2006 BMW 650i
1. Regulations


BMW Service.
secured against access by other persons.
 Individual components must never be repaired. Instead, always replace them.
2006 BMW 650i
Before installing, subject airbag system components (including electronic diagnostic components)

 Danger of injury: The airbag module may only be set down with the airbag itself facing upwards.
 Disconnect battery. See 61 00 ... BATTERY .
3. Transport
4. Storage
regulations.
72 12 ... DEACTIVATING FRONT PASSENGER AIRBAGS WITH KEY-OPERATED SWITCH
WARNING: The responsibility for deactivation/activation rests with the customer.

Depending on the occupation of the front passenger seat, the front
passenger and side airbags must be (de - )activated in accordance with
the Owner's Handbook.
The passenger airbag can only be deactivated in accordance with the following instructions if the vehicle is
equipped with a suitable key-operated switch!
The key-operated switch can be retrofitted if it is missing and has been ordered as an optional extra.
Key-operated switch:
 Optional extra SA 5DA for MINI

 Optional extra SA 470 for BMW
E83 up to 09/2004 only:
see DEACTIVATION OF AIRBAGS
E83 from 09/2004 only:

2006 BMW 650i
Deactivation via key-operated switch, see following work steps
R50/R53 up to 04/2004 only:
R50/R53 from 04/2004 only:
The following airbags are deactivated simultaneously with the key-operated switch (1):
 Passenger airbag
 Side airbag (passenger side)
 If necessary, knee airbag in US models (passenger side)
The airbags can only be deactivated/reactivated while the vehicle is stationary and with the door open.
Fig. 27: Identifying Key-Operated Switch

IMPORTANT: The head airbag remains active.
Deactivation
1. Turn key-operated switch with ignition key to "OFF" position.
Deactivatable airbags on passenger side out of operation.
Head airbag on passenger side remains active.
All airbags on driver side remain active.

2006 BMW 650i
Activation
Fig. 28: Turning Key-Operated Switch

2. Turn key-operated switch with ignition key to "ON" position.
All the airbags in the vehicle are activated and are triggered in appropriate situations.
Warning lamp
When the ignition key is turned in the ignition lock, the function of the airbag system is checked and the
warning lamp in the center console lights up for several seconds.
1. The warning lamp is permanently lit when the passenger airbags are deactivated
2. The warning lamp goes out after a few seconds when the passenger airbags are activated
Fig. 29: Identifying Airbags Warning Lamp

2006 BMW 650i
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 up to 04/2004 and E83 up to 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

 Disconnect battery . See 61 00 ... BATTERY .
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)
2006 BMW 650i
 Replacement of passenger belt with belt force limitation by version without belt force limitation
Fig. 30: Locating Stick On Warning Signs (Passenger Airbag)

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
Fig. 31: Locating Stick On Warning Signs (Side Airbag, Front)

Side airbag, rear

2006 BMW 650i

 Code airbag control unit (via CIP)
Fig. 32: Locating Stick On Warning Signs (Side Airbag, Rear)

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.

2006 BMW 650i
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.
Fig. 34: Locating Stick On Warning Signs (Side Airbag)

Passenger Airbag Off light (US version 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 (except US version)
The function of the airbag system is checked when the ignition key is turned in the ignition switch.
CODING OF AIRBAG CONTROL UNIT

Coding
Warning lamp lights up:
before after
1. Warning lamp lights up continuously if an airbag is deactivated X
2. Warning lamp goes out after several seconds when airbags are deactivated X
3. Warning lamp goes out after several seconds when airbags are activated X X
2006 BMW 650i
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 (e.g. AHPS2)
 Knee airbag
 Belt 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 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 be removed and disposed of by special waste
disposal companies!
Comply with Safety regulations for handling airbag system components.

 Only approach the vehicle after a few minutes have elapsed
used parts.
2006 BMW 650i
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).
handling a fired gas generator! The burning of solid fuel will heat up the
2006 BMW 650i
72 12 ... PROCEDURE AFTER AIRBAG TRIGGERING AS RESULT OF AN ACCIDENT
Check and/or replace following components after airbag triggering:
Satellites (control unit + sensor)
 Components
 Satellite, A-/B-pillar, left/right
 Satellite, front door
 Satellite, rear seat
 Satellite, driver's/front passenger seat

2006 BMW 650i
 Procedure
 Read out fault memory
 Disconnect battery and observe waiting period
 Rectify faults
 Reconnect battery and observe waiting period
 Turn off ignition and wait at least 2 minutes (no consumers may be switched on during this period
such as e.g. inside lights, radio, etc.)
 Switch ignition on.
 Clear fault memory and if necessary rectify faults
Cables and plugs
 Components and procedure

 Check cables and plugs for damage, replace if necessary.
Belt system
 Components
 Automatic safety belt tensioner
 Belt buckle tensioner
 Seat belt height adjustment
 Procedure
 Check components, replace if necessary
Seats
 Components
 Seat
 Airbag module
 Active head restraint
 Procedure
 Check seats (function check of seat mechanism), replace if necessary
 Check seat screw/bolt connections
 Replace gas generator of active head restraint system
If the severity of the impact 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.
2006 BMW 650i
The repair work can be carried out in the car 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 seat cover with padding
Driver's airbag
 Components
 Airbag module
 Steering wheel
 Steering column (if damaged)
 Procedure
 Replace steering wheel
Passenger airbag
 Components
 Airbag module
 Instrument panel trim
 Supporting tube (if damaged)
 Procedure
Side airbag, front/rear
 Components
 Airbag module
 Door trim panel
 Door in white
 Seat
 Procedure
Head airbag (AHPS)
 Components
 Airbag module
 Trim, A-pillar
2006 BMW 650i
 Trim, B-pillar (if damaged)

 Trim, C-pillar (if damaged)
 Bodyshell
 Procedure
Knee airbag
 Components
 Panel (driver's side)
 Lower section of glovebox
 Active knee protector (driver's and passenger sides)
 Procedure
Passive knee protector
 Components
 Glovebox incl. knee protector (passenger side)
 Procedure
 Check components for damage, replace if necessary
 Check fastening elements
72 12 ... UNLOCKING/LOCKING AIRBAG PLUG CONNECTIONS
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:
2006 BMW 650i
Method 1:
Simultaneously pull cover (1) upwards at lugs on left and right (2).
Fig. 36: Unlocking Airbag Plug Connection (Method 1)

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.
2006 BMW 650i
Fig. 38: Unlocking Airbag Plug Connection

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.
Fig. 39: Pressing Cover Downwards

Airbag plug connection on gas generator/airbag module is straight (2 versions)
Version 1:
Press locking/unlocking plate (1) at edge (4).

2006 BMW 650i
Fig. 40: Pressing Locking/Unlocking Plate

Fig. 41: Identifying Airbag Plug Connection

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.
2006 BMW 650i
Fig. 42: Identifying Detent Lug And Locking/Unlocking Plate

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.
2006 BMW 650i
Installation:
Insert plug connection in initial engagement position in gas generator/airbag module and engage in final
engagement position.
Fig. 44: Identifying Lock Button And Plug

Illustration of version 3 with gas generator:
A. Initial engagement position

B. Final engagement position
1. Lock button
2. Gas generator
Fig. 45: Identifying Lock Button And Gas Generator

2006 BMW 650i
Press locking clip at edge and disconnect plug (1).
Installation:
Check for correct engagement.
Fig. 46: Pressing Locking Clip

72 12 000 REMOVING AND INSTALLING/REPLACING AIRBAG MODULE ON PASSENGER SIDE
Incorrect handling can activate airbag and cause injury.

 Follow instructions for unlocking and locking airbag plug connections. See Unlocking/locking airbag
plug connections.
 Remove glovebox with housing. See 51 16 366 REMOVING AND INSTALLING RIGHT
Version (E60/E61) with front drinks holder:
 Remove front outer cup holder carrier

 Release front inner cup holder carrier
Inner carrier can only be removed together with airbag module.
Unfasten plug connection (1) and disconnect. Remove plug connection from holder (by turning).
2006 BMW 650i
E63/ E64:
Release screws (3) and carefully feed out airbag module (2) towards bottom.
E60:
Release screws (3); if necessary, slide front inner cup holder carrier slightly to one side.
Carefully remove airbag module (2), if necessary with front inner cup holder carrier, towards bottom rear.
Fig. 47: Identifying Airbag Module, Plug Connection And Screw

Installation:
When inserting airbag module (1) in channel (2), make sure channel rests all round airbag module. If necessary,
pull channel apart at sides.
Replace screws.

2006 BMW 650i
Fig. 48: Identifying Airbag Module

72 12 010 REMOVING AND INSTALLING/REPLACING AIRBAG MODULE ON LEFT OR RIGHT

FRONT DOOR
Front and rear airbag modules must not be mixed up.

 Remove front door trim . See 41 FRONT DOOR TRIM PANEL .
Unfasten screws.
Carefully remove airbag module.
Installation:
Before installing airbag module, remove all foreign bodies (screws, etc.) from installation recess.
Replace screws.
Fig. 49: Locating Airbag Module Screws

72 12 040 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT AFPS1 HEAD AIRBAG

(VERSION WITHOUT GLASS TILT SUNROOF)
2006 BMW 650i
Incorrect handling can activate head airbag and cause injury.
The AHPS head airbag must be replaced if it is damaged during removal
or installation.
A damaged AHPS head airbag exhibits an impaired protective function
and in extreme cases loses its protective function altogether.

plug connections.
 Remove roofliner . See 44 ROOF TRIM PANEL .
Fig. 50: Identifying Screws And Holder

Release all screws (1) on holder (2).

2006 BMW 650i
Release rear screw.
Remove rear AHPS1.

Release front screws (1 and 2).
Tightening torques:
 Screw 1 72 12 04AZ
 Screw 2 72 12 06AZ
Carefully feed gas generator out of guides towards rear, unlocking and disconnecting plug (3) in the process.
Remove gas generator completely.
Fig. 52: Identifying Plug And Screw

2006 BMW 650i
NOTE: View of retaining screw with anchor fitting of AHPS1 head airbag:
1. Anchor fitting, AHPS1 head airbag

2. Lock washer
3. Retaining screw
Fig. 53: Identifying Retaining Screw And Lock Washer


(VERSION WITH GLASS TILT SUNROOF)
or installation.
NOTE: Except for the operations for Removing headliner, this task is identical to:
 Removing and installing/replacing left or right AHPS head airbag (version

without glass tilt sunroof). See 72 12 040 Removing and
installing/replacing left or right AFPS1 head airbag (version without glass
tilt sunroof).
14 CHILD SEAT QUICK FASTER

72 14 ... REMOVING AND INSTALLING/REPLACING TOP TETHER EYELETS FOR CHILD SEAT
NOTE: Two or three Top Tether eyelets are installed, depending on the model.
2006 BMW 650i
Lever out covers (1) and release screws underneath.
Remove Top Tether eyelets (2).
Fig. 54: Identifying Covers And Eyelets

IMPORTANT: Ensure Top Tether eyelets (1) are in correct installation position.
It must be possible for Top Tether eyelets (1) to be tilted in the direction of
head restraints (2).
Fig. 55: Identifying Eyelets And Head Restraints

2009 BMW 650i
Restraint Systems - 650i, M6
00 GENERAL
Safety instructions
-> Repairing airbag leads. See 61 00 ... REPAIRING AIRBAG CABLES .
-> Handling optical fibres . See 61 00 ... NOTES ON HANDLING OPTICAL FIBERS .
Check
-> Check seat belt.
-> Checklist for seat belt.
Airbag system
-> Deactivating airbags.
2009 BMW 650i

and vehicle damage!

1. Regulations


BMW Service.
2009 BMW 650i
Individual components must never be repaired. Instead, always replace them.

 Danger of injury: The airbag module may only be set down with the airbag itself facing upwards .
3. Transport
4. Storage
regulations.
2009 BMW 650i
11 SEAT BELTS
Safety instructions

2009 BMW 650i
-> Repairing airbag leads. See 61 00 ... REPAIRING AIRBAG CABLES
-> Handling optical fibres . See 61 00 ... NOTES ON HANDLING OPTICAL FIBERS
Check
-> Check seat belt
Airbag system
-> Procedure after airbag triggering
72 11 ... CHECKING AUTOMATIC SAFETY 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 car involved in the accident
were occupied. If this is not possible, check all the seat belts in the car and replace them if necessary.
In the event of deformations on the car, 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 functional capability 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 side impact with
permanently deformed impact dampers/deformation elements or cross-members), the complete seat belt must be
replaced! The complete seat belt comprises:
2009 BMW 650i
 Lower strap
 Seat belt buckle (buckle tensioner)
 Retaining screws of all components
The following must also be checked and if necessary replaced:

 seat runners.
 Seat structure (frame, etc.)
Alignment tests on the seat and the seat runners are not permitted!
The following explanations and the checklist for the automatic safety 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 cannot be used again.
Checking automatic reel and seatbelt 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 impact.
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 applied fully while driving on a dry surface and at a road speed
equal to twice that of 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 strap is pulled out suddenly, this system is also OK.
Automatic reel does not require servicing and must not be opened.
Precondition for complete, problem-free retraction of straps:
 the straps must not be twisted!

 the straps must not be damaged!
When placed to one side, the straps of the front seats must retract fully.
2009 BMW 650i
With the 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 strap is reguided.
Belt straps should only be cleaned with a luke-warm soap solution or a commercial laundry detergent.
Belt straps must never be cleaned chemically or dyed.
The automatic reel and strap must be replaced in the event of:
1. creases
2. unraveling
3. pinches
4. cracks and tears
5. traces of melting
6. traces of wear on casing of seat belt tongue or on reversing clip.
Checking lower strap (belt buckle tensioner):
To fasten a seat belt, the tongue should insert easily and with a loud click in the lock.
When the "Red button" is pressed, the tongue must be ejected from the lock under spring pressure.
If the lock cover is missing or damaged, the lower strap must be replaced.
Replace the triggered belt buckle tensioner including the complete seat belt with seatbelt height adjustment and
retaining screws and check the

 seat runners.
 Seat structure.
Criteria for a triggered mechanical belt buckle tensioner:
Criteria for a triggered pyrotechnical belt buckle tensioner:

 Airbag warning lamp 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
2009 BMW 650i
is definite that the belt system was not used (seat was not occupied), there is no need to replace the
 upper strap
 attachment parts (belt height adjustment, screws)
 seatbelt mountings on the car body
 seat runners.
after a check.
72 11 ... INSPECTION LIST FOR AUTOMATIC SEAT BELT
AUTOMATIC SEAT BELT INSPECTION REFERENCE LIST

Replace complete automatic seat belt
Was the automatic seat belt with lower strap replaced after The following must also be checked and
an accident, e.g. frontal and/or oblique impact in which replaced, if necessary:
No
the impact absorbers/deformation elements were seatbelt mountings on the car body
permanently deformed? seatbelt mountings on the seat
seat runners.
Yes
Does seat belt lock when pulled out suddenly? No Replace automatic seat belt (upper strap).
Yes
Automatic reel is loose - tighten reel.
If fault persists:
Can the strap be pulled out without jamming? No
Yes
Does the strap on the front seat belts retract automatically? Automatic reel is loose - tighten reel.
Does the strap on the rear seat belts retract automatically, Excessive friction in belt guides - replace
a small remaining loop is acceptable No automatic seat belt (upper strap).
if this remaining loop is fully retracted when the strap is Return spring broken - replace automatic
readjusted. seat belt (upper strap).
Yes
Excessive friction in belt guides - replace
automatic seat belt (upper strap).
Does automatic reel make a squeaking noise when belt is
Yes Reel is loose - tighten reel.
fastened or unfastened?
No
Is the plastic casing on the latch free from damage in the
area of the belt opening?
Yes
Is the fully extended strap free from pinches, burn marks,
tears and cuts, folding and unravelling?
2009 BMW 650i
Yes
When the seat belt is fitted, is the latch ejected with spring
pressure from the buckle when the "Red button" is No Replace complete automatic seat belt
pressed?
Yes
Does fastened seat belt lock when stopping vehicle
quickly on a dry road at a road speed twice as fast as No Replace complete automatic seat belt
walking speed?
Yes
If dirt and marks cannot be removed with
Is fully pulled-out belt free of serious dirt and other commercially available mild-action
No
marks? detergent, the automatic seat belt (upper
strap) must be replaced.
Yes
Replace both damaged parts and
complete automatic-reel seat belt.
The following must also be checked and
In the case of seat-integrated seat belts, is front tongue of
No replaced, if necessary:
reclining mechanism or seat rail free of deformation?
seatbelt mountings on the car body
seatbelt mountings on the seat
seat runners.
Yes
The automatic seat belt is O.K.!
72 11 030 REMOVING AND INSTALLING/REPLACING FRONT SEAT BELT (COMPLETE)
cause injuries.

 Follow instructions for unlocking and locking airbag plug connections. See 72 12 ... Unlocking/locking
 Removing and installing rear left or right side trim panel . See 51 43 002 REMOVING AND
INSTALLING REAR LEFT OR RIGHT SIDE TRIM PANEL .
PANEL .
2009 BMW 650i
1 = Protective cap
3 = Rosette
4 = Space bush
5 = Strap
6 = Slide bar
Fig. 2: Identifying Protective Cap, Space Bush, Strap And Slide Bar
Unfasten screws.
Unscrew bracket.
2009 BMW 650i

Release screw.

Release screw.

2009 BMW 650i

Installation:

NOTE: The following work step ends here:

Removing and installing/replacing front seat belt (automatic reel)
Removing and installing/replacing front left or right lower strap (seat belt tensioner)

2009 BMW 650i
seat!
Installation:

Installation:

2009 BMW 650i


72 11 033 REMOVING AND INSTALLING/REPLACING FRONT SEAT BELT (REEL)
cause injuries.
 Removing and installing rear left or right See 51 43 002 REMOVING AND INSTALLING REAR
2009 BMW 650i
PANEL .
the slide bar (6) for damage (bending) and replace if necessary.
1 = Protective cap
3 = Rosette
4 = Space bush
5 = Strap
6 = Slide bar
Fig. 10: Identifying Protective Cap, Screw, Space Bush And Strap
Unfasten screws.
Unscrew bracket.
2009 BMW 650i

Release screw.

Release screw.

2009 BMW 650i

Installation:

72 11 041 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT LOWER STRAP

(BELT TENSIONER)
Incorrect handling can trigger off the bet tensioner and cause injury.

2009 BMW 650i

 Follow instructions for unlocking and locking airbag plug connections. . See 72 12 ... Unlocking/locking
seat!
Installation:

Installation:
2009 BMW 650i



(ROLLER)

2009 BMW 650i
installing.
Release screw (1).

Installation:

2009 BMW 650i
Fig. 19: Removing Automatic Reel

Release screw (2).

Installation:
72 11 096 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT LOWER STRAP

(BELT BUCKLE)
 Remove rear seat See SEATS - REPAIR .


2009 BMW 650i


(COMPLETE)

installing.
Release screw (1).

2009 BMW 650i

Installation:
Fig. 23: Remove Automatic Reel

Release screw (2).

2009 BMW 650i
Installation:
NOTE: The work step for "Removing and installing/replacing left or right seat belt"
ends here.

Removing and installing/replacing rear left or right lower strap (belt buckle).
 Remove rear seat . See SEATS - REPAIR .


2009 BMW 650i

2009 BMW 650i
12 AIRBAG GENERATOR
Safety regulations:
2009 BMW 650i
Instructions for disconnecting and connecting battery. See 61 00 ... BATTERY .

2009 BMW 650i
Safety instructions
-> Repairing airbag leads . See PLUG CONNECTION TERMINAL .
-> Handling optical fibres . See PLUG CONNECTION TERMINAL .
Check
-> Check seat belt
Airbag system
and vehicle damage!

2009 BMW 650i
1. Regulations


BMW Service.
2009 BMW 650i
Before installing, subject airbag system components (including electronic diagnostic components)

 Disconnect battery. See 61 00 ... BATTERY .
3. Transport
4. Storage
regulations.
72 12 ... DEACTIVATING FRONT PASSENGER AIRBAGS WITH KEY-OPERATED SWITCH
WARNING: The responsibility for deactivation/activation rests with the customer.

Depending on the occupation of the front passenger seat, the front
passenger and side airbags must be (de - )activated in accordance with
the Owner's Handbook.
The passenger airbag can only be deactivated in accordance with the following instructions if the vehicle is
equipped with a suitable key-operated switch!
The key-operated switch can be retrofitted if it is missing and has been ordered as an optional extra.
Key-operated switch:
 Optional extra SA 5DA for MINI

 Optional extra SA 470 for BMW
E83 up to 09/2004 only:
E83 from 09/2004 only:

2009 BMW 650i
R50/R53 up to 04/2004 only:
R50/R53 from 04/2004 only:
The following airbags are deactivated simultaneously with the key-operated switch (1):
 Passenger airbag
 Side airbag (passenger side)
 If necessary, knee airbag in US models (passenger side)
The airbags can only be deactivated/reactivated while the vehicle is stationary and with the door open.
Fig. 27: Identifying Key-Operated Switch

IMPORTANT: The head airbag remains active.
Deactivation
1. Turn key-operated switch with ignition key to "OFF" position.
Deactivatable airbags on passenger side out of operation.
Head airbag on passenger side remains active.
All airbags on driver side remain active.

2009 BMW 650i
Activation
Fig. 28: Turning Key-Operated Switch

2. Turn key-operated switch with ignition key to "ON" position.
All the airbags in the vehicle are activated and are triggered in appropriate situations.
Warning lamp
When the ignition key is turned in the ignition lock, the function of the airbag system is checked and the
warning lamp in the center console lights up for several seconds.
1. The warning lamp is permanently lit when the passenger airbags are deactivated
2. The warning lamp goes out after a few seconds when the passenger airbags are activated
Fig. 29: Identifying Airbags Warning Lamp

2009 BMW 650i
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 up to 04/2004 and E83 up to 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

 Disconnect battery . See 61 00 ... BATTERY .
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)
 Code airbag control unit (see DIS).
 Documentation of customer consent and storage in car's file
2009 BMW 650i
 Replacement of passenger belt with belt force limitation by version without belt force limitation

Side airbag, front

 Code airbag control unit (see DIS)
Fig. 31: Locating Stick On Warning Signs (Side Airbag, Front)

Side airbag, rear

2009 BMW 650i

 Code airbag control unit (via CIP)
Fig. 32: Locating Stick On Warning Signs (Side Airbag, Rear)

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.

2009 BMW 650i
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.
Fig. 34: Locating Stick On Warning Signs (Side Airbag)

Passenger Airbag Off light (US version 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 (except US version)
The function of the airbag system is checked when the ignition key is turned in the ignition switch.
CODING OF AIRBAG CONTROL UNIT

Coding
Warning lamp lights up:
before after
1. Warning lamp lights up continuously if an airbag is deactivated X
2. Warning lamp goes out after several seconds when airbags are deactivated X
3. Warning lamp goes out after several seconds when airbags are activated X X
2009 BMW 650i
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 (e.g. AHPS2)
 Knee airbag
 Belt 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 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 be removed and disposed of by special waste
disposal companies!
Comply with Safety regulations for handling airbag system components.

 Only approach the vehicle after a few minutes have elapsed
used parts.
2009 BMW 650i
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).
handling a fired gas generator! The burning of solid fuel will heat up the
2009 BMW 650i
 Components

2009 BMW 650i
 Procedure
 Rectify faults
Cables and plugs

Belt system
 Components
 Seat belt height adjustment
 Procedure
Seats
 Components
 Seat
 Airbag module
 Procedure
2009 BMW 650i
Driver's airbag
 Components
 Airbag module
 Steering wheel
 Procedure
Passenger airbag
 Components
 Airbag module
 Procedure
 Components
 Airbag module
 Door trim panel
 Door in white
 Seat
 Procedure
Head airbag (AHPS)
 Components
 Airbag module
 Trim, A-pillar
2009 BMW 650i

 Bodyshell
 Procedure
Knee airbag
 Components
 Procedure
 Components
 Procedure
72 12 ... UNLOCKING/LOCKING AIRBAG PLUG CONNECTIONS
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:
2009 BMW 650i
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).
2009 BMW 650i
Fig. 38: Unlocking Airbag Plug Connection

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.
Fig. 39: Pressing Cover Downwards

Airbag plug connection on gas generator/airbag module is straight (2 versions)
Version 1:
Press locking/unlocking plate (1) at edge (4).

2009 BMW 650i

Fig. 41: Identifying Airbag Plug Connection

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.
2009 BMW 650i
Fig. 42: Identifying Detent Lug And Locking/Unlocking Plate

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.
2009 BMW 650i
Installation:
Insert plug connection in initial engagement position in gas generator/airbag module and engage in final
engagement position.
Fig. 44: Identifying Lock Button And Plug

Illustration of version 3 with gas generator:
A. Initial engagement position

B. Final engagement position
1. Lock button
2. Gas generator
Fig. 45: Identifying Lock Button And Gas Generator

2009 BMW 650i
Press locking clip at edge and disconnect plug (1).
Installation:
Check for correct engagement.
Fig. 46: Pressing Locking Clip

72 12 000 REMOVING AND INSTALLING/REPLACING AIRBAG MODULE ON PASSENGER SIDE

plug connections.
 Remove glovebox with housing. See 51 16 366 REMOVING AND INSTALLING RIGHT
Version (E60/E61) with front drinks holder:
 Remove front outer cup holder carrier

 Release front inner cup holder carrier
Inner carrier can only be removed together with airbag module.
Unfasten plug connection (1) and disconnect. Remove plug connection from holder (by turning).
2009 BMW 650i
E63/ E64:
Release screws (3) and carefully feed out airbag module (2) towards bottom.
E60:
Release screws (3); if necessary, slide front inner cup holder carrier slightly to one side.
Carefully remove airbag module (2), if necessary with front inner cup holder carrier, towards bottom rear.
Fig. 47: Identifying Airbag Module, Plug Connection And Screw

Installation:
When inserting airbag module (1) in channel (2), make sure channel rests all round airbag module. If necessary,
pull channel apart at sides.
Replace screws.

2009 BMW 650i
Fig. 48: Identifying Airbag Module

72 12 010 REMOVING AND INSTALLING/REPLACING AIRBAG MODULE ON LEFT OR RIGHT

FRONT DOOR
Front and rear airbag modules must not be mixed up.

 Remove front door trim . See 41 FRONT DOOR TRIM PANEL .
Unfasten screws.
Carefully remove airbag module.
Installation:
Before installing airbag module, remove all foreign bodies (screws, etc.) from installation recess.
Replace screws.
Fig. 49: Locating Airbag Module Screws


(VERSION WITHOUT GLASS TILT SUNROOF)
2009 BMW 650i
or installation.

plug connections.
 Remove roofliner . See 44 ROOF TRIM PANEL .
Fig. 50: Identifying Screws And Holder

Release all screws (1) on holder (2).

2009 BMW 650i
Release rear screw.
Remove rear AHPS1.

Release front screws (1 and 2).
Tightening torques:
 Screw 1 72 12 04AZ
 Screw 2 72 12 06AZ
Carefully feed gas generator out of guides towards rear, unlocking and disconnecting plug (3) in the process.
Remove gas generator completely.
Fig. 52: Identifying Plug And Screw

2009 BMW 650i
NOTE: View of retaining screw with anchor fitting of AHPS1 head airbag:
1. Anchor fitting, AHPS1 head airbag

2. Lock washer
3. Retaining screw
Fig. 53: Identifying Retaining Screw And Lock Washer


(VERSION WITH GLASS TILT SUNROOF)
or installation.
NOTE: Except for the operations for Removing headliner, this task is identical to:
 Removing and installing/replacing left or right AHPS head airbag (version

without glass tilt sunroof). See 72 12 040 Removing and
installing/replacing left or right AFPS1 head airbag (version without glass
tilt sunroof).
14 CHILD SEAT QUICK FASTER

72 14 ... REMOVING AND INSTALLING/REPLACING TOP TETHER EYELETS FOR CHILD SEAT
NOTE: Two or three Top Tether eyelets are installed, depending on the model.
2009 BMW 650i
Lever out covers (1) and release screws underneath.
Remove Top Tether eyelets (2).
Fig. 54: Identifying Covers And Eyelets

IMPORTANT: Ensure Top Tether eyelets (1) are in correct installation position.
It must be possible for Top Tether eyelets (1) to be tilted in the direction of
head restraints (2).
Fig. 55: Identifying Eyelets And Head Restraints

2006 BMW 650i
2006-07 ACCESSORIES AND EQUIPMENT Seats - Repair - 650i, M6
Seats - Repair - 650i, M6
13 FRONT SEAT, NORMAL, MANUAL

52 13 ... REMOVING AND INSTALLING/REPLACING TRIM FOR RELEASE HANDLE ON LEFT
OR RIGHT FRONT SEAT (NORMAL/MANUAL)
Remove release handle on left or right front seat, refer to 52 14 033 Removing and installing/replacing
release handle on left or right front seat (normal/electric).
Unlock catches from outside by applying light pressure through trim slot and remove trim from side.
NOTE: On both sides on passenger seat.
Fig. 1: Identifying Trim

Installation:
Catches (1) on trim must not be damaged.

2006 BMW 650i
Fig. 2: Identifying Catches

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).
Fig. 3: Identifying Headrest And Lock

52 14 060 REMOVING AND INSTALLING / REPLACING VALVE HOUSING FOR FRONT LEFT
OR RIGHT LUMBAR SUPPORT (NORMAL / MANUAL)
 52 0 050 . See SEATS - SPECIAL TOOLS .

2006 BMW 650i
 Remove rear panel on front seat
E83:
If necessary, detach tensioning cables from backrest frame (2).
Fig. 4: Identifying Backrest Cover

E63:
Detach tensioning cables (1) from backrest frame (2).
Disconnect all retainers.
Detach partial cover (2) from backrest frame.
Installation:
Lock new retainers by bending with special tool 52 0 050 . See SEATS - SPECIAL TOOLS .
2006 BMW 650i
Fig. 5: Identifying Tensioning Cables And Partial Cover

NOTE: If necessary, gently heat air hose when firmly seated.
Disconnect air hoses (2...4) from valve housing (1).
2 Hose (blue) top cushion

3 Hose (clear) lumbar drive
4 Hose (red) bottom cushion
Fig. 6: Identifying Plug Connection And Air Hoses

Release screw (1) from inside.
Remove valve housing (3) with metal nut (2).

2006 BMW 650i
Fig. 7: Removing Valve Housing

Installation:
Pay attention to seat heating cable guide (1).
Lay air hoses (2) without kinks through hole (3).
Check function.
Fig. 8: Identifying Seat Heating Cable Guide

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 Replacing seat cover for left or right front seat
(sports/electric).
Release left screw (1) and slacken right screw only.

2006 BMW 650i
Release left/right screws (3).
Slacken left/right screws (4) only.
Lever out retaining plate (2) on left.
Installation:
Tightening Torque, refer to SEATS - TIGHTENING TORQUES .
Fig. 9: Identifying Retaining Plate And Screws

Press seat pan (4) upwards, thereby relieving tension on flex mat.
Release screw (1) and remove support (2) from gear (3).
Installation:
Tightening Torque, refer to SEATS - TIGHTENING TORQUES . .

2006 BMW 650i
Installation:
Using split-pin drift (1), lift support (2) onto guide (3).
Fig. 11: Installing Split-Pin Drift And Lift Support Onto Guide
Version with seat occupancy detector:
If necessary, unhook control unit (1) and cable (3) from holders (2).
Fig. 12: Identifying Control Unit And Cable

Turn seat pan (1) upwards.
Detach flexmat (2) at rear from mounts (3).

2006 BMW 650i
Fig. 13: Identifying Flexmat

Detach seat pan (1) on left/right backwards/top from mount (2) and remove.
Fig. 14: Detaching Seat Pan

Detach flexmat (1) from mounts (2) on seat pan (3).

2006 BMW 650i
Fig. 15: Detaching Flexmat From Mounts

Removing thigh support from seat pan:
Unhook spring (1) from thigh support (2).
Fig. 16: Locating Spring

Release screws (1) and remove thigh support (2).
Fig. 17: Identifying Thigh Support And Screws

If necessary, release screws (1) and remove guide rails (2) from seat pan (3).
2006 BMW 650i
Fig. 18: Identifying Guide Rails

14 FRONT SEAT, NORMAL, ELECTRICAL

release handle on left or right front seat (normal/electric).

Installation:

2006 BMW 650i

52 14 ... REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT CRASH-ACTIVE

HEAD
pyrotechnical belt pretensioners. Incorrect handling may result in
triggering of the crash-active head and thereby cause injury.
Switch off ignition!

 Remove rear panel
Unfasten plug connection (1) and disconnect. Feed wiring harness out of backrest frame Lift out head restraint.
Fig. 21: Unfasten Plug Connection

2006 BMW 650i
Fig. 22: Lift Out Head Restraint

52 14 ... REMOVING AND INSTALLING/REPLACING GUIDE FOR FRONT LEFT OR RIGHT

HEAD RESTRAINT (NORMAL/ELECTRIC)
 Removing And Installing Guide For Front Head Restraint .
52 14 ... REMOVING AND INSTALLING/REPLACING SEAT PAN AND FLEX MAT ON LEFT OR
RIGHT FRONT SEAR (NORMAL/ELECTRIC)
 Remove seat cover for front seat.
Release screw (3) on left/right.
Remove left retaining plate (2) downwards.
Installation:
Tightening torque, see 52 10 9AZ in SEATS - TIGHTENING TORQUES .

2006 BMW 650i

Fig. 24: Identifying Seat Pan

Release screws (1) and remove retaining plates (2).
Installation:

2006 BMW 650i
Fig. 25: Identifying Retaining Plates And Screws

Unhook cable (1) from holder (2).
Fig. 26: Identifying Holder And Holder

Detach flex mat (2) at rear from mounts (3).

2006 BMW 650i
Fig. 27: Detaching Flex Mat

Detach seat pan (1) on left and right towards rear/top from mount (2) and remove.

Detach flex mat (1) from mounts (2) for seat pan (3).
2006 BMW 650i
Fig. 29: Detaching Flex Mat From Mounts

52 14 000 REMOVING AND INSTALLING LEFT OR RIGHT FRONT SEAT (NORMAL/ELECTRIC)
 Remove head restraint .
pyrotechnical belt tensioners. See AIR BAG DEACTIVATION
PROCEDURES . Incorrect or improper handling may trigger the
pyrotechnical belt pretensioner or side airbag and thereby cause injury.
Adjust front seat as far forward and upward as possible.
Release seatbelt screw (1) and feed out seatbelt strap (2).
Tightening torque, see 72 11 1AZ in RESTRAINT SYSTEM - TIGHTENING TORQUES .
Fig. 30: Identifying Seatbelt Screw And Feed Out Seatbelt Strap
Move front seat forwards/upwards as far as possible.
Release bolts (1).
Installation:
Replace microencapsulated screws.

2006 BMW 650i
Move front seat backwards/downwards as far as possible.

If necessary, unclip protective caps upwards.
Release screws (3).
Installation:
Replace microencapsulated screws.
Move 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).

2006 BMW 650i
Lift out front seat.
Installation:
Carpet must not get between seat rails and floor pan in area of fastening points (grating noises).
52 14 025 REMOVING AND INSTALLING/REPLACING SEAT MECHANISM ON LEFT OR RIGHT

 61 2 071
 61 2 074 . See GENERAL ELECTRICAL SYSTEM - SPECIAL TOOLS
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).
Fig. 33: Identifying Retaining Bracket And Cable Holder

Attach cable 61 2 074 to cable 61 2 071 and connect plug connection (1) to front seat.
2006 BMW 650i
Connect cable 61 2 071 to battery.
Check function.

52 14 030 REMOVING AND INSTALLING/REPLACING BACKREST FRAME ON FRONT LEFT OR

RIGHT SEAT (NORMAL/ELECTRIC)
Replacement only:
 Remove backrest cover

 Remove lumbar cushion
 Remove valve housing for lumbar support
 Remove drive unit. See DRIVE, SEAT ADJUSTMENT .
 Remove release mechanism on front seat
Removing backrest frame only:
Unhook backrest cover (1) on left and right.
IMPORTANT: Do not under any circumstances turn screw underneath screw (2), this would
destroy the seat frame.
Release screws (2) on left and right.
Installation:
2006 BMW 650i
Replace screws (microencapsulated).
Remove backrest frame (3) with backrest cover towards top.

Replacing backrest frame only:
Detach mount (1) for rear panel towards top/rear from backrest frame (2).
Fig. 36: Identifying Backrest Frame

Installation:
Catch (1) and guide (2) on mount (3) for rear panel must not be damaged.
Guide taper (4) must point downwards.

2006 BMW 650i
Fig. 37: Identifying Catch And Guide On Mount

If necessary, remove mat (1) from spring wire (2) of backrest frame (3).
Fig. 38: Identifying Spring Wire Of Backrest Frame

Installation:
If necessary, suspend mat (1) on uppermost spring wire (2) on backrest frame (3).
2006 BMW 650i
Fig. 39: Identifying Uppermost Spring Wire On Backrest Frame

52 14 033 REMOVING AND INSTALLING/REPLACING RELEASE HANDLE ON LEFT OR RIGHT

Lever off release lever with screwdriver.
NOTE: To protect trim, use a suitable base (1).
Installation:
Retaining lugs on release unit must not be damaged.
Fig. 40: Releasing Lever With Screwdriver

52 14 034 REMOVING AND INSTALLING/REPLACING RELEASE MECHANISM ON FRONT

LEFT OR RIGHT SEAT
Remove release lever on front seat.

2006 BMW 650i
Remove rear panel on front seat.
Remove cover on left and right:
 Unclip catch (1) towards rear

 Unclip catch (2) towards front
 Lift out cover of guide (3) towards bottom and side
Installation:
Catches (1, 2) and guide (3) of cover must not be damaged.
Fig. 41: Identifying Cover Catch

Unclip cable on left and right:
 Press together catches (1) and detach lug towards outside

 Unclip catch (2) of cable mount towards top and remove towards outside
Installation:
Catches (1) must not be damaged.
After installation, they must always point outwards (away from seat).
2006 BMW 650i

Installation:
Catch (1) and guide bearing (2) must not be damaged.
Fig. 43: Identifying Catch And Guide Bearing

Unclip release mechanism towards top.
Installation:
Cable covering must point out a little over covering mount.

2006 BMW 650i
Fig. 44: Uncliping Release Mechanism

Installation:
 Release screw (1) and remove seat back towards top.

 Insert adjusting tool (2) in seat back and secure with screw (1).
 Clip cable on both sides onto mounting lug (3).
 Slide catch lug (4) into cable end clip until there is no cable play.
 Lock catch by pushing up retaining ring (5).
 Unclip cable, remove adjusting element (2), install seat backrest.
Fig. 45: Identifying Seat Back Screw And Mounting Lug

NOTE: Catch can no longer be released when retaining ring has snapped into place.
52 14 040 REMOVING AND INSTALLING/REPLACING OUTER COVER ON FRONT LEFT OR

2006 BMW 650i
Remove and install/replace outer cover on front left or right seat (sports/electric),
refer to 52 16 040 Removing and installing/replacing outer cover on front left or right seat
(sports/electric).
52 14 041 REMOVING AND INSTALLING/REPLACING INNER COVER ON FRONT LEFT OR

No information available.
52 14 050 REPLACING LUMBAR CUSHION ON FRONT LEFT OR RIGHT SEAT

 64 1 020 . See HEATING AND AIR CONDITIONING - SPECIAL TOOLS .
Detach tensioning cables (1) from backrest frame.
Installation:
2006 BMW 650i
Detach drive unit (1) for lumbar cushion from backrest frame.
Installation:
If necessary, use new adhesive tape (double-sided).
Detach backrest cover (2) from backrest frame by lifting out piping.
NOTE: If necessary, use special tool 64 1 020 . See HEATING AND AIR CONDITIONING -
SPECIAL TOOLS .

Disconnect hoses (2) and (3) from valve housing (1).

Installation:
Air hoses (2) and (3) must be laid without kinks.

2006 BMW 650i
Fig. 48: Identifying Valve Housing And Hoses

Detach lumbar cushion (1) from spring wire (2).
Version with seat heating:
Slide cable (3) for seat heating to one side.
Fig. 49: Identifying Lumbar Cushion And Spring Wire

Press back support (1) a little.
Turn lumbar cushion (2) and pull out downwards.

2006 BMW 650i
Fig. 50: Turning Lumbar Cushion

Installation:
Check lumbar cushion at top (1) and bottom (2) for damage.
Air hoses (3) must not be kinked.
Fig. 51: Identifying Air Hoses

Installation:
Attach lumbar cushion (1) to third wire (2) above spring (3).
2006 BMW 650i
Fig. 52: Identifying Lumbar Cushion

NOTE: For purposes of clarity, shown here without valve housing.
Installation:
Fig. 53: Identifying Seat Heating Cable Guide And Air Hoses
Installation:
Check function.
2006 BMW 650i
E83:

E63:
Installation:
2006 BMW 650i


Fig. 56: Identifying Plug Connection And Air Hoses


2006 BMW 650i
Fig. 57: Identifying Valve Housing

Installation:
Check function.
52 14 070 REMOVING AND INSTALLING/REPLACING SEAT ANGLE ADJUSTER ON LEFT OR

RIGHT FRONT SEAT (NORMAL/ELECTRIC)
 Remove front seat.

 Remove outer cover
2006 BMW 650i
Release screws (1).
Release screw (2).
Unclip carrier (3) from seat mechanism at rear.
Fig. 59: Identifying Seat Mechanism Carrier And Screw

Unlock plug connection (1) on drive unit (2) and disconnect.
Fig. 60: Identifying Plug Connection On Drive Unit

Release screws (1).
Installation:
Replace Taptite screws (1).

2006 BMW 650i
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.
Fig. 61: Identifying Seat Angle Adjuster And Screws

52 14 198 REMOVING AND INSTALLING/REPLACING REAR PANEL ON LEFT OR RIGHT

FRONT SEAT BACKREST (NORMAL/ELECTRIC)
No information available
52 14 390 REMOVING AND INSTALLING OR REPLACING FRONT LEFT OR RIGHT HEAD

RESTRAINTS (NORMAL/ELECTRIC)
52 14 400 REPLACING SEAT COVER FOR LEFT OR RIGHT FRONT SEAT

(NORMAL/ELECTRIC)
If replacing seat cover with thigh support for left or right front seat, see 52 16 400 Replacing seat cover for left
or right front seat (sports/electric).
52 14 405 REPLACING BACKREST COVER FOR FRONT LEFT OR RIGHT SEAT

(NORMAL/ELECTRIC)
2006 BMW 650i


 Remove guide for head restraint .
 Remove trim for release handle . See 52 13 ... Removing and installing/replacing trim for release
handle on left or right front seat (normal/manual).

Installation:
NOTE: If necessary, use special tool 64 1 020 .

2006 BMW 650i

Expose cable for seat heating.
Feed cable (2) out of holder (3).
Fig. 64: Identifying Plug Connection And Feed Cable

Detach backrest cover (1) at sides towards front and remove with support upwards from backrest frame (2).
2006 BMW 650i

Release retainers (1) on left and right of backrest cover (2).
Fig. 66: Identifying Retainers Of Backrest Cover

Release all retainers.
Remove backrest cover (1) from support.
NOTE: Remove all remnants of clips from backrest cover (1) and padding.
2006 BMW 650i
Fig. 67: Identifying Backrest Cover Clips

Installation:
Bend new retainer (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

Replacement of backrest cover:
Pull trim threads (1) out of backrest cover.

2006 BMW 650i
Cut new backrest cover to size and insert trim wires (1).
2 Seat heater cable
Fig. 69: Identifying Trim Threads

52 14 415 REPLACING SUPPORT FOR LEFT OR RIGHT FRONT SEAT (NORMAL/ELECTRIC)
WARNING: US/CND front passenger seat (with OC3 mat) only:

The support can only be removed in conjunction with the OC3 mat.
If support is defective, both parts may only be replaced together.
After fitting new support, enable OC3 mat with BMW diagnosis system.
The operation for removing the support with/without OC3 mat is described in:
 Replacing seat cover for front seat
Enabling seat occupancy detector (OC3 mat):
 Connect BMW diagnosis system

 Release seat occupancy detector
 Clear fault memory if necessary
52 14 420 REPLACING PADDING FOR LEFT OR RIGHT FRONT SEAT BACKREST

(NORMAL/ELECTRIC)
Replace backrest cover for left or right front seat . See 52 14 405 Replacing backrest cover for front left or
right seat (normal/electric).
52 14 899 ADDITIONAL WORK (NORMAL/ ELECTRIC) WITH DEFECTIVE DRIVE FOR

LONGITUDINAL ADJUSTMENT
2006 BMW 650i
Set seat tilt adjustment to max. up setting.
Release screw (1) on actuator drive (2) of longitudinal seat adjustment.
Fig. 70: Identifying Screw On Actuator Drive

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

2006 BMW 650i
 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
Fig. 72: Identifying Input Shaft And Internal Gear

Using a pneumatic saw (1), cut through drive shaft (2) from rear.
Fig. 73: Identifying Pneumatic Saw

2006 BMW 650i
Fig. 74: Removing Drive Shaft From Gear

Release screw (1) and remove gear (2).
Fig. 75: Removing Screw And Gear

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)
2006 BMW 650i
Fig. 76: Identifying Drive Shaft

Replace seat mechanism on front seat.
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.
Fig. 77: Locating Outer Front Cover Screws

16 FRONT SEAT, SPORTS, ELECTRICAL

2006 BMW 650i

Installation:



2006 BMW 650i
Replacement only:
 Remove backrest cover

 Remove drive unit for lumbar support
 Remove release mechanism on front seat
Installation:

2006 BMW 650i
Fig. 81: Identifying Backrest Frame

Installation:

2006 BMW 650i
Fig. 83: Identifying Spring Wire Of Backrest Frame

Installation:
Fig. 84: Identifying Uppermost Spring Wire On Backrest Frame


LEFT OR RIGHT SEAT
Remove release lever on front seat.
Remove rear panel on front seat.

2006 BMW 650i
Installation:
Fig. 85: Identifying Cover Catch


Installation:

2006 BMW 650i
Installation:

Installation:
Fig. 88: Uncliping Release Mechanism

Installation:
2006 BMW 650i

Fig. 89: Identifying Seat Back Screw And Mounting Lug


Installation:
2006 BMW 650i

Installation:

NOTE: If necessary, use special tool 64 1 020 .

2006 BMW 650i
Installation:
Fig. 92: Identifying Valve Housing And Hoses

Fig. 93: Identifying Lumbar Cushion And Spring Wire


2006 BMW 650i
Fig. 94: Turning Lumbar Cushion

Installation:
Fig. 95: Identifying Air Hoses

Installation:
2006 BMW 650i
Fig. 96: Identifying Lumbar Cushion

Installation:
Installation:
Check function.
52 14 385 REPLACING GAS CARTRIDGE (PYROACTIVATOR) FOR CRASH-ACTIVE HEAD

RESTRAINT ON FRONT SEAT
2006 BMW 650i
pyrotechnical belt pretensioners. Incorrect handling may result in
triggering of the crash-active head restraint and thereby cause injury.
IMPORTANT: The pyrotechnical device may be replaced up to 5 times. Triggering frequency

is denoted on the sticker on the head restraint carrier. Stickers are available as
spare parts.
Starting situation: Head restraint is in the crash position after being triggered. Note that pyroactivator can only
be removed in the triggered state. The complete crash-active head restraint must be replaced if the event of a
head restraint fault signal and an untriggered pyroactivator.
Fig. 98: Head Restraint In Crash Position After Being Triggered

Removing cover: Raise cover (1) and pull towards rear.
Fig. 99: Raise Cover And Pull Toward Rear

2006 BMW 650i
Removing pyrotechnical device: Press together retainer (1) for pyrotechnical device at lugs. Feed out
pyrotechnical device.
Fig. 100: Removing Pyrotechnical Device

Removing pyroactivator: Pull pyroactivator (2) out of mounting (1) for pyrotechnical device. Unlock plug
connection (3) and disconnect. Important! Dispose of plastic element and pyroactivator.
Fig. 101: Removing Pyroactivator

Procedure for installing pyrotechnical device: Bringing head restraint together - version without button (MFS):
Pull spring catches apart and push head restraint together. Maintain position. Bringing head restraint together -
version with button (Basic): Press button (1) and push head restraint together. Maintain position.
2006 BMW 650i
Fig. 102: Pulling Spring Catches Apart And Pushing Head Restraint Together
Fig. 103: Pressing Button (1) And Pushing Head

d restraint in position and push release plate (1) upwards up to stop. Release plate (1) must audibly snap into
place.
2006 BMW 650i
Fig. 104: Holding Pushed-Together Head Restraint In Position And Pushing Release Plate (1) Upward
Up To Stop
Checking head restraint lock: Check end position of release plate (1). All four springs must be engaged
(snapped into place).
Fig. 105: Checking End Position Of Release Plate (1)

Replacing pyrotechnical device: Connect plug (1) to new pyroactivator (2) and lock. Clip pyroactivator (2) into
new mounting (3).
2006 BMW 650i
Fig. 106: Connecting Plug (1) To New Pyroactivator (2)

Installing pyrotechnical device: Press together retainer for pyrotechnical device at lugs. Insert retainer for
pyrotechnical device into release plate and tilt in upward direction. Retainer for pyrotechnical device must
audibly snap into place. Note: Check seating of retaining lugs in retainer.
Fig. 107: Press Together Retainer For Pyrotechnical Device At Lugs

Laying wiring harness: Secure wiring harness in carrier section with strain relief.
2006 BMW 650i
Fig. 108: Secure Wiring Harness In Carrier Section

Mounting cover: Clip cover onto carrier section. Cover must audibly snap into place.
Fig. 109: Clip Cover In Position



2006 BMW 650i
Fig. 110: Identifying Screw On Actuator Drive

A. No function:

B. Actuator drive running:

 Continue with
2006 BMW 650i
(2) Input shaft

(3) Internal gear
Fig. 112: Identifying Input Shaft And Internal Gear

Using a pneumatic saw (1),
cut through drive shaft (2) from rear.
Fig. 113: Identifying Pneumatic Saw

Remove drive shaft (1) from gear (2).

2006 BMW 650i

Fig. 115: Removing Screw And Gear

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).
2006 BMW 650i
Fig. 116: Identifying Drive Shaft


Remove outer front cover .
Fig. 117: Locating Outer Front Cover Screws

Remove seat cover with padding,
refer to 52 16 400 Replacing seat cover for left or right front seat (sports/electric).
2006 BMW 650i
Installation:
Tightening Torque, refer to 52 10 9AZ in SEATS - TIGHTENING TORQUES .

Installation:
Tightening Torque, see 52 10 9AZ in SEATS - TIGHTENING TORQUES .
.
2006 BMW 650i
Fig. 119: Identifying Seat Pan

Installation:
Fig. 120: Installing Split-Pin Drift And Lift Support Onto Guide
2006 BMW 650i
Fig. 121: Identifying Control Unit And Cable

Fig. 122: Identifying Flexmat

2006 BMW 650i

Fig. 124: Detaching Flexmat From Mounts


2006 BMW 650i
Fig. 125: Locating Spring

Fig. 126: Identifying Thigh Support And Screws

2006 BMW 650i

52 16 011 REMOVING AND INSTALLING/REPLACING BOWDEN CABLE FOR REAR

COMPARTMENT ENTRANCE AID
 Remove seat
 Remove rear panel
 Remove inner cover
Lay seat on seat surface/backrest or left seat side.
Unhook and remove springs (1).
Remove retainers (2).
Fig. 128: Identifying Springs And Retainers

Release screw (1) of cable mount (2).
Detach cable mount (2) and cable eye (3) from shaft.
Feed cable out of holder (4).

2006 BMW 650i
Fig. 129: Identifying Cable Mount And Cable Eye

Disconnect spring (1).
Unclip sleeve (2) of Bowden cable from guide.
Feed out cable (3).
Fig. 130: Uncliping Sleeve

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 ... Removing and installing/replacing seat pan and flex mat on front left or right seat
(sports/electric).
Remove backrest frame on front seat,

2006 BMW 650i
refer to 52 14 030 Removing and installing/replacing backrest frame on front left or right seat
(normal/electric).
Remove seatbelt tensioner,
For tightening torque, see 72 11 030 in RESTRAINT SYSTEM - TIGHTENING TORQUES .
Disconnect all plug connections (1) from actuator drives.
Remove seat wiring harness from seat mechanism (2).
Fig. 131: Identifying Seat Wiring Harness

Installation:
Perform function check:
Connect cable 61 2 071 to battery,
connect cable 61 2 074 to cable 61 2 071 and plug connection (1) to front seat.
2006 BMW 650i


FRONT SEAT (SPORTS/ELECTRIC)
Removing and installing/replacing release handle on left or right front seat (normal/electric)

RIGHT SEAT (SPORTS/ELECTRIC)
Unscrew bolt (1).
Fig. 133: Locating Bolt

Removing top cover:

2006 BMW 650i
Fig. 134: Identifying Top Cover Components

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).
Fig. 135: Identifying Lever Lugs On Cover

2006 BMW 650i
Lever out cover (1) at rear, detach at front from guide and remove.
Fig. 136: Identifying Cover Lever

Installation:
Do not crush cables (1) during installation.
Insert lugs (2) into mounts (3) and snap into place.
Fig. 137: Identifying Cables And Lugs

Lever out lugs (2) and detach switch combination (3).

2006 BMW 650i
Fig. 138: Identifying Plug Connection And Switch Combination

Installation:
Guides (1) and catches (2) on switch combination (3) must not be damaged.
Fig. 139: Identifying Guides And Catches

Model with lumbar supports:
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.
2006 BMW 650i
Fig. 140: Identifying Plug Connection And Catches

Installation:
Following parts must not be damaged,
replace cover (4) if necessary:
1. Mounts for switch combination

2. Guide, front
3. Tabs
Fig. 141: Identifying Switch Combination Mounts, Guide And Tabs

Replacement of switch combination only or in event of further work on front seat:
Disconnect plug connection (1) and remove switch combination (2).

2006 BMW 650i
Fig. 142: Identifying Switch Combination


Replacing inner cover on left or right front seat (normal/electric).

RIGHT FRONT SEAT (SPORT/ELECTRIC)

Release screws (1).
Release screw (2).

2006 BMW 650i
Fig. 143: Identifying Seat Mechanism Carrier And Screw

Fig. 144: Identifying Plug Connection On Drive Unit

Release screws (1).
Installation:
Release screw (2).

2006 BMW 650i
Installation:
seat pan.
Fig. 145: Identifying Seat Angle Adjuster And Screws

52 16 095 REMOVING AND INSTALLING/REPLACING THIGH SUPPORT HOLDER ON FRONT

Unfasten thigh support and pull completely towards front.
Detaching cushion for thigh support:
Bend open retaining plates (1) and remove cover piping (2).
Fig. 146: Removing Retaining Plates And Cover Piping

NOTE: Cushion (1) is attached at front with double-sided adhesive tape (3) to holder
2006 BMW 650i
Pull cushion (1) towards top off holder (2).
Fig. 147: Pushing Cushion

Lever trim wire (1) out of mounts (2).
Installation:
Stick new double-sided adhesive tape (4) to holder (3) or attach mount with spray adhesive.
Fig. 148: Identifying Double-Sided Adhesive Tape

NOTE: The operation "Removing cushion for thigh support" ends here.
Removal of "Thigh support holder" only:
Unhook spring (1) at bottom from holder (2) and seat frame (3).
2006 BMW 650i
Fig. 149: Identifying Thigh Support Holder And Seat Frame

Release screws (1).
Press operating lever (2) fully and detach holder (3) for thigh support towards front from seat frame (4).
Fig. 150: Identifying Holder And Seat Frame

Installation:
Following parts on holder (5) must not be damaged:
1. Mounts for trim wire

2. Holding-down elements for trim wire
3. Guide sleeves
4. Double-sided adhesive tape (replace or coat with spray adhesive for assembly)
2006 BMW 650i
Fig. 151: Identifying Guide Sleeves And Double-Sided Adhesive Tape

Installation:
If necessary, release screws (1) and remove guide rails (2) from seat frame (3).


 Move thigh support forwards fully
Release screws (2).

2006 BMW 650i
Insert screws (2) with Loctite.
Fig. 153: Identifying Plug Connection And Screws

Detach seat cover (1) in marked area from carrier (2) for thigh support.
Feed plug out of carrier (2) for thigh support.
Remove carrier (2) for thigh support.
Fig. 154: Identifying Seat Cover And Carrier



2006 BMW 650i
Release screws (2).
Installation:
Fig. 155: Identifying Plug Connection And Screws

Fig. 156: Identifying Seat Cover And Carrier

52 16 198 REMOVING AND INSTALLING/REPLACING REAR PANEL ON FRONT LEFT OR

RIGHT SEAT BACKREST (SPORTS/ELECTRIC)
2006 BMW 650i
Remove and install/replace rear panel on front left or right seat backrest (sports/manual)
52 16 390 REMOVING AND INSTALLING/REPLACING FRONT HEAD RESTRAINT

(SPORTS/ELECTRIC) ON LEFT OR RIGHT
Replacing front left or right head restraint (normal/manual).
52 16 400 REPLACING SEAT COVER FOR LEFT OR RIGHT FRONT SEAT (SPORTS/ELECTRIC)

 Remove outer cover with actuating unit
WARNING: US/CDN front passenger seat (with OC3 mat) only:

To avoid damaging the OC3 mat, it is essential to carry out the following
operations with extra care.
When replacing seat cover:
If seat cover is defective, seat cover and padding with OC3 mat must be replaced together.
New seat cover is supplied with padding, OC3 mat and if necessary seat heating.
When replacing padding with OC3 mat:
If OC3 mat or padding is defective, both parts may only be replaced together.
These must be fitted with the seat cover from the car.


2006 BMW 650i
If necessary, disconnect plug connection (1).
Release cable strap (2).
Detach cable (3) from holder (4).
Fig. 157: Identifying Plug Connection And Cable Strap

Fig. 158: Identifying Cable And Holder

Release screw (1) on inside/outside.
Unclip clips (3) towards bottom and pull trim (2) out a little.
2006 BMW 650i
Fig. 159: Identifying Screw And Clips

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).
Fig. 160: Identifying Trim And Carrier

Installation:
Cable holders (1) on carrier (2) must not be damaged.

2006 BMW 650i
Fig. 161: Identifying Cable Holders On Carrier

Installation:
Clips (1) on sports seat trim (2) must not be damaged.
Fig. 162: Identifying Clips Sports Seat Trim

NOTE: The operation "Removing holder for actuation" ends here.
If necessary, disconnect plug connection (1) from control unit (2).

2006 BMW 650i
Fig. 163: Identifying Plug Connection And Control Unit

If necessary, release locks (1) and detach plug housing (2).
Fig. 164: Identifying Locks And Plug Housing

If necessary, press lock (1) downwards and detach cover (2).

2006 BMW 650i
Fig. 165: Identifying Cover

Disconnect plug connection (1) for seat heating from plug housing (2).
Fig. 166: Identifying Plug Connection And Housing

Pull cable (1) out of holders (2).

2006 BMW 650i
Fig. 167: Identifying Cable And Holders

E46 only:
Pull out tongue (1) on seat cover (2) on left/right.
Fig. 168: Pulling Out Tongue On Seat Cover

Detach seat cover (1) from seat frame (2).
Fig. 169: Detaching Seat Cover From Seat Frame

Pull out cover welt (1) completely from seat frame (2).
2006 BMW 650i
Fig. 170: Pulling Out Cover Welt

Fold in ends (1) on seat cover and push through under backrest (2) towards front.
Fig. 171: Identifying Backrest

2006 BMW 650i

NOTE: Cushion (1) is secured at front with double-sided adhesive tape (3) to carrier (2).
Pull cushion (1) towards top off carrier (2).

Installation:
Stick new double-sided adhesive tape (4) to carrier (3) or attach mount with spray adhesive.
2006 BMW 650i

Model without seat heating and without seat occupancy detector:
Remove seat cover (1) with thigh support (2) towards front/top.
Fig. 175: Removing Seat Cover With Thigh Support

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.

2006 BMW 650i
Fig. 176: Identifying Seat Cover And Feed Cable

Replacing padding or sensor mat:
Release clips (1) and (2) at rear left/right from support (3).
Fig. 177: Locating Clips

Release all clips (1) on left/right and centre (2) from support (3).
2006 BMW 650i
Fig. 178: Identifying Support Clips

Installation:
Note routing of seat heater cable (1).
Do not damage with clips.
Fig. 179: Identifying Seat Heater Cable

Version with OC3 mat:
 OC3 mat must not be kinked under any circumstances.
Detach all retainers in side area from longitudinal wires (1).
Pull trim wires (1) forward out of seat cover.

2006 BMW 650i
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.
Fig. 180: Identifying Trim Wires And Cross-Wires

Remove padding (1) from seat cover (2).
Fig. 181: Removing Padding

Installation:
If necessary, detach heating mat (1) from adhesive tape (2) of thigh support.
3 Seat heater cable

2006 BMW 650i
Fig. 182: Identifying Heating Mat And 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).

2006 BMW 650i
Fig. 184: Identifying Feed Seat Heater Cable Through Bore Hole
Padding (1) with OC3 mat (2).
IMPORTANT: No retainer remainders may be fitted as well.

Handle OC3 mat with extreme care.
Do not kink OC3 mat.
Do not clamp OC3 mat.
OC3 mat must lie without folds under seat cover.
Fig. 185: Identifying Padding With OC3 Mat

Installation:
Bend new clips (2) with special tool 52 0 050 .
1. Padding
2. Retainer
3. Trim thread in padding
2006 BMW 650i
4. Trim thread in cover

5. Seat cover

Installation:
Support (2) must be coated with wax (1) to prevent grinding noises.
Do not remove wax (1) on support (2).
Fig. 187: Identifying Wax On Support

Passenger seat only (replacing sensor mat):
Installation:
In order to guarantee the function and fastening (adhesive strength) at the sticking surfaces of sensor mat (1),
the foam most not show any traces of damage at all!
2006 BMW 650i
Replace the foam if it is hardened or damaged particularly in the area of the sticking surfaces.
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).
Fig. 188: Identifying Sensor Mat

Installation:
Detach liner (1) at individual points and stick sensor mat (2) onto foam (3).
Fig. 189: Identifying Liner And Sensor Mat

NOTE: The operation "Replacing support or sensor mat" ends here.

2006 BMW 650i
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
Fig. 190: Identifying Trim Threads And Seat Cover


 Remove outer cover with actuating unit
WARNING: US/CDN front passenger seat (with OC3 mat) only:

To avoid damaging the OC3 mat, it is essential to carry out the following
operations with extra care.
When replacing seat cover:
If seat cover is defective, seat cover and padding with OC3 mat must be replaced together.
New seat cover is supplied with padding, OC3 mat and if necessary seat heating.
2006 BMW 650i
When replacing padding with OC3 mat:
If OC3 mat or padding is defective, both parts may only be replaced together.
These must be fitted with the seat cover from the car.

Fig. 191: Identifying Plug Connection And Cable Strap


2006 BMW 650i
Fig. 192: Identifying Cable And Holder

Fig. 193: Identifying Screw And Clips

Release screws (1).

2006 BMW 650i
Fig. 194: Identifying Trim And Carrier

Installation:

Installation:

2006 BMW 650i
Fig. 196: Identifying Clips Sports Seat Trim

Fig. 197: Identifying Plug Connection And Control Unit


2006 BMW 650i
Fig. 198: Identifying Locks And Plug Housing


2006 BMW 650i
Fig. 200: Identifying Plug Connection And Housing

Fig. 201: Identifying Cable And Holders

E46 only:
Fig. 202: Pulling Out Tongue On Seat Cover


2006 BMW 650i

Fig. 204: Pulling Out Cover Welt

2006 BMW 650i
Fig. 205: Identifying Backrest



Installation:
2006 BMW 650i



2006 BMW 650i
Fig. 210: Identifying Seat Cover And Feed Cable

Replacing padding or sensor mat:
Fig. 211: Locating Clips

2006 BMW 650i
Fig. 212: Identifying Support Clips

Installation:
Fig. 213: Identifying Seat Heater Cable

Version with OC3 mat:
 OC3 mat must not be kinked under any circumstances.
Detach all retainers in side area from longitudinal wires (1).
Pull trim wires (1) forward out of seat cover.

2006 BMW 650i
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.
Fig. 214: Identifying Trim Wires And Cross-Wires

Remove padding (1) from seat cover (2).
Fig. 215: Removing Padding

Installation:
3 Seat heater cable

2006 BMW 650i
Fig. 216: Identifying Heating Mat And Seat Heater Cable


Installation:

2006 BMW 650i
Fig. 218: Identifying Feed Seat Heater Cable Through Bore Hole
Padding (1) with OC3 mat (2).
IMPORTANT: No retainer remainders may be fitted as well.

Handle OC3 mat with extreme care.
Do not kink OC3 mat.
Do not clamp OC3 mat.
OC3 mat must lie without folds under seat cover.
Fig. 219: Identifying Padding With OC3 Mat

Installation:
Bend new clips (2) with special tool 52 0 050 .
1. Padding
2. Retainer
3. Trim thread in padding
2006 BMW 650i
4. Trim thread in cover

5. Seat cover

Installation:

Installation:
In order to guarantee the function and fastening (adhesive strength) at the sticking surfaces of sensor mat (1),
the foam most not show any traces of damage at all!
2006 BMW 650i
Replace the foam if it is hardened or damaged particularly in the area of the sticking surfaces.
Fig. 222: Identifying Sensor Mat

Installation:
Fig. 223: Identifying Liner And Sensor Mat


2006 BMW 650i
3 Seat heater cable
Fig. 224: Identifying Trim Threads And Seat Cover

52 16 415 REPLACING SUPPORT FOR LEFT OR RIGHT FRONT SEAT (SPORT/ELECTRIC)

The support can only be removed in conjunction with the OC3 mat.
 Replacing seat cover on front seat


(SPORT/ELECTRIC)
This operation is described in section on:
Replace backrest cover for left or right front seat .

2006 BMW 650i
24 REAR SEAT, NORMAL

52 24 ... REMOVING AND INSTALLING / REPLACING SKI BAG WITH CASING
 Remove ski bag cover

 Remove backrest
Release screws (1).
Release screw (2).
Remove casing towards front.
Fig. 225: Identifying Casing Screws

52 24 005 REMOVING AND INSTALLING OR REPLACING REAR SEAT
Unclip rear seat on left/right towards top.
Lift rear seat out of vehicle.
Installation:
Feed in seat belt buckles (1) through designated openings in rear seat.
2006 BMW 650i
Fig. 226: Identifying Seat Belt Buckles

52 24 010 REMOVING AND INSTALLING / REPLACING BACKREST

 Remove head restraint
 Remove armrest
Release screws (1) on backrest.
Release screws (2) on seatbelt anchor fitting.
Tightening torque, see 72 11 22AZ .in RESTRAINT SYSTEM - TIGHTENING TORQUES .
NOTE: End of work when removing side trim panel and/or rear parcel shelf.
Fig. 227: Identifying Screws On Seatbelt Anchor Fitting

2006 BMW 650i
Unlock detent lugs (1) on back and remove seatbelt outlet trim (2).
Installation:
Replace seatbelt outlet trims in event of faulty detent lugs.
Fig. 228: Identifying Detent Lugs And Seatbelt Outlet Trim

Feed seat belt (1) out of
(2) Seatbelt outlet trim

(3) Backrest
Fig. 229: Identifying Seatbelt Outlet Trim And Backrest

52 24 030 REMOVING AND INSTALLING COMPLETE ARMREST FOR REAR SEAT BACKREST
Press lock (1) and remove filler element (2).

2006 BMW 650i
Make sure filler element is correctly inserted in backrest.
Fig. 230: Removing Filler Element

52 24 390 REMOVING AND INSTALLING / REPLACING REAR HEAD RESTRAINTS
Pull out head (1) firmly.
Installation:
Press head restraint (1) downwards until it engages audibly in notches.
Fig. 231: Pulling Out Head Restraint

52 24 400 REPLACING SEAT COVER FOR REAR SEAT

2006 BMW 650i
Fig. 232: Identifying Rear Seat Retainers And Piping Area

Detach retainers in areas (1).
Lever out piping in areas (2) with special tool 64 1 020.
Detaching cover and padding:
 Release all retainers in marked area.

 Remove seat cover from padding.
 Remove remaining retainers from cover and padding
Installation:
 Insert new retainers with special tool 52 0 050 .

2006 BMW 650i
Fig. 233: Identifying Retainers Area

Replacing cover:
 Pull all trim wires out of seat cover

 If necessary, cut in take-up for trim wires of new cover
 Push trim wires into new seat cover
Fig. 234: Identifying Trim Wires

If necessary, replace head restraint guide (1).
Lever out detent ring (2) with plastic wedge.

2006 BMW 650i
Fig. 235: Identifying Head Restraint Guide And Detent Ring

52 24 408 REPLACING BACKREST COVER FOR LEFT OR RIGHT REAR SEAT

 Remove backrest for rear seat

2006 BMW 650i
Fig. 236: Identifying Rear Seat Retainers And Piping Area

Lever out piping in areas (2) with special tool 64 1 020 .
Detaching cover from padding:

 Remove cover from padding.
Installation:
Insert new retainers with special tool 52 0 050 .

2006 BMW 650i
Fig. 237: Identifying Retainers Area

Replacing cover:

 If necessary, cut pockets in new cover for trim wires
 Push trim wires into pockets
Fig. 238: Identifying Trim Wires


2006 BMW 650i
Fig. 239: Identifying Restraint Guide And Detent Ring

2009 BMW 650i
ACCESSORIES & EQUIPMENT Seats - SI Techniques - 650i
ACCESSORIES & EQUIPMENT
Seats - SI Techniques - 650i
ELECTRICALLY ADJUSTABLE SEATS E63, E64
Fig. 1: Identifying Electrically Adjustable Seats

INTRODUCTION
The E63 and E64 will feature electrically adjustable driver's and passenger's seats as standard.
Electrically adjustable sports seats will be optionally available. The sports seats additionally feature a manual
seat depth adjustment facility, more pronounced formed seat upholstery and a lumbar support.
The electrical control is identical for both the basic seat and sport seat.
In both seat versions, the driver's seats are additionally equipped with a seat memory.
The body bus (K -bus) connects the driver's seat module (SMFA) to the centre console switch cluster (SZM). In
the E64, the passenger's seat module (SMBF) is also connected to this K -bus.
the centre console switch cluster represents the interface between the K -bus of the seats and the body controller
2009 BMW 650i
The system features the following switches and sensors:
 Seat adjustment buttons
The seat adjustment buttons are located on the outer sides of the seat cushions. They vary in terms of
number and function. The E64 seat is additionally equipped with an option for electrically adjusting the
head restraints (headrests).
 Lumbar support button
A rocker switch is provided on the seat to adjust the lumbar support.
 Seat memory button
Only the driver's seat features additional buttons for the seat memory.
 Seat heating switch
The buttons for controlling the seat heating are included in the centre console switch cluster.
 Hall sensors
Hall sensors are installed for the purpose of detecting the position of the seats. The sensors are integrated
in the seat drive units.
 Temperature sensor for seat heating
A temperature sensor is installed in each of the seat cushions for the seat heating.
The seats are controlled by the following control units:
 Centre console switch cluster
In addition to the switches, the electronic circuits for the heating control and monitoring functions are
integrated in he centre console switch cluster (SZM). The SZM is also responsible for the electronic
control of the steering column adjustment function.
 E63/E64 Driver's seat module
The control unit of the driver's seat module (SMFA) communicates via the K -bus with the centre console
switch cluster (SZM).
 Passenger's seat module, E64 only

2009 BMW 650i
console switch cluster (SZM).
In the E63 the drive units are controlled directly by a load circuit.
The following actuators are driven to perform the seat functions:
 Seat heating
The seat cushion heating and backrest heating are installed such that they cover the entire area. Even the
side sections and thigh supports are heated.
 Seat adjustment drive units
The following drive units are installed in the E63 and E64 seat:
 Drive unit for seat forward/backward adjustment with 2 adjustment speeds

 Drive unit for seat height adjustment
 Drive unit for seat cushion tilt adjustment
 Drive unit for backrest angle adjustment
Additionally installed in the E64:
 Drive unit for head restraint height adjustment

 Head restraint angle adjustment
The head restraint angle adjustment as well as the seat depth adjustment on the sports seat are always
manual.
 Lumbar support
The lumbar support in the seat backrest consists of 2 lumbar cushions as well as an electric air pump with
electrically operated valves.
The following displays provide seat status information:
 Central Information Display
A corresponding check control message is shown on the central information display (CID) when, for
example, a backrest is not locked in correctly (E64 only).
 Head-up display
A corresponding check control message and an information text are shown in the head -up display (HUD)
when the backrest is not locked in correctly (E64 only).
2009 BMW 650i
3 light emitting diodes (LEDs) in the centre console switch cluster indicate the switched status of the seat
heating system.
Seat communication features the following bus systems:
 Body controller area network
The body controller area network (K -CAN) is a two-wire bus for communication between all control
units connected to the K-CAN.
 Body bus
The body bus (K -bus) is a single-wire connection. The centre console switch cluster and the seat modules
communicate with each other via the K-bus.
SYSTEM FUNCTIONS
The system functions of the electrically operated seats include:
 Seat adjustment
 Rear easy-entry facility
 Seat heating
Seat adjustment
The installed seats feature the following seat adjustment options:
 Seat forward/backward adjustment (with electric drive unit, 2 speed stages)

 Seat height adjustment (with electric drive unit)
 Seat depth adjustment (manual only, sports seat only)
 Backrest angle adjustment (with electric drive unit)
 Head restraint height adjustment (E63: manual; E64: with electric drive unit)
 Head restraint angle adjustment (manual only)
 Lumbar support height adjustment (electropneumatic)
 Lumbar support depth adjustment (electropneumatic)
The standard seat forward/backward adjustment, seat height adjustment, seat cushion tilt adjustment and
backrest angle adjustment facilities are each operated with separate electric drive units in all seats. The head
restraint height adjustment is driven by an electric drive unit only on the E64.
All these functions are controlled via the control panel on the outer sides of the seat cushions. Signals from the
respective button trigger seat adjustment in the required directions.
A separate rocker switch is used to operate the lumbar support. An electric pump supplies the lumbar support
2009 BMW 650i
height and thickness of the lumbar support.
The limit stop is calculated for each drive unit in order to reduce the load of the electric drive units to a
minimum. Automatic recognition of the limit stops is integrated in each of the electric drive units. Hall sensors
integrated in the drive units register the adjustment distances which are processed in the seat module. In the
event of the drive unit blocking, the detected position value is interpreted as the limit stop. All subsequent
adjustments are interrupted just before this point.
Once the obstruction has been removed, adjustment can again extend beyond the newly detected limit stop
when the seat adjustment button is pressed again.
Rear easy-entry facility
The rear easy-entry facility is controlled by a push -button on the seat backrest. The rear easy -entry facility can
be activated only under the following conditions:
 The vehicle must be stationary with no wheels turning

 The door must be opened
Rapid adjustment is achieved with the second speed stage of the drive unit for seat forward/backward
adjustment.
The seat moves for as long as the button is pressed. At the same time, the backrest can be released manually and
folded forward.
The seat moves back to its initial position when the seat adjustment button is pressed back.
Seat heating
The seat heating system heats the seat cushion and backrest including the side sections. Separate seat heating
switches (push-buttons) in the centre console switch cluster (SZM) control the driver's seat and passenger's seat.
The centre console switch cluster controls the seat heating electronically. The system is monitored by a
temperature sensor. The seat heating is operational as from terminal 15 "ON".
3 LEDs located above the seat heating switches indicate the heating stage currently active in the seat heating
system.
NOTE: The seat heating is not actuated while the steering column is adjusted.
The current at the centre console switch cluster would be too high if the seat
heating and steering column adjustment were operated simultaneously. The
seat heating is interrupted in order to protect the centre console switch cluster
(SZM).
2005 BMW 645Ci
2004-05 ACCESSORIES & BODY, CAB Seats - Repair Instructions - E63
Seats - Repair Instructions - E63
FRONT SEAT, NORMAL, MANUAL

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.
Fig. 1: Releasing Catches And Sliding Guide Upwards

2005 BMW 645Ci
Pull guide (1) out of backrest (2).
Fig. 2: Removing Guide Out Of Backrest

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.
2005 BMW 645Ci
Fig. 3: Installing Front Left Or Right Head Restraint Guide

Guide for head restraint without pushbutton:
Release catches (1) and slide guide (2) upwards.

2005 BMW 645Ci
Fig. 4: Releasing Catches And Sliding Guide Upwards

Pull guide (1) out of backrest (2).

2005 BMW 645Ci
Fig. 5: Removing Guide Out Of Backrest

Installation:
Catch (1) on guide (2) must not be damaged.

After installing guide (2), make sure it is properly seated.
2005 BMW 645Ci
Fig. 6: Identifying Catch (1) On Guide (2)

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 REPLACING SEAT COVER ON LEFT OR RIGHT
FRONT SEAT (NORMAL/MANUAL) .

2005 BMW 645Ci
Fig. 7: Removing Left Retaining Plate

Installation:
Tightening torque, refer to 52 10 9AZ in SEATS - TIGHTENING TORQUES - 645CI .
Press seat pan (1) upwards, thereby relieving tension on flexmat.

2005 BMW 645Ci
Fig. 8: Pressing Seat Pan Upwards


2005 BMW 645Ci
Fig. 9: Removing Retaining Plates

Installation:

2005 BMW 645Ci
Fig. 10: Unhooking Cable From Holder


2005 BMW 645Ci
Fig. 11: Turning Seat Pan Upwards And Detaching Flexmat (2) At Rear From Mounts (3)
2005 BMW 645Ci
Fig. 12: Removing Seat Pan On Left/Right Backwards/Top From Mount


2005 BMW 645Ci
Fig. 13: Detaching Flexmat From Mounts On Seat Pan


Remove release handle on left or right front seat,
refer to 52 14 033 REMOVING AND INSTALLING/REPLACING RELEASE HANDLE ON LEFT OR

RIGHT FRONT SEAT (NORMAL/ELECTRIC) .

2005 BMW 645Ci
Fig. 14: Unlocking Catches From Outside By Applying Light Pressure Through Trim Slot
Installation:

2005 BMW 645Ci

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).

2005 BMW 645Ci
Fig. 16: Removing Trim

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).

2005 BMW 645Ci
Fig. 17: Removing And Installing / Replacing Front Headrest (Normal/ Manual)
52 13 400 REPLACING SEAT COVER ON LEFT OR RIGHT FRONT SEAT (NORMAL/MANUAL)
NOTE: For special tools, refer to SEATS - SPECIAL TOOLS - 645CI (E63) .
 52 0 050
Seat cover must not be separated from padding.

2005 BMW 645Ci
 Remove inner cover, refer to 52 13 041 REMOVING AND INSTALLING / REPLACING INNER
COVER ON LEFT OR RIGHT FRONT SEAT BACKREST (NORMAL/ MANUAL) .
 Remove cover (normal/electric), refer to 52 16 040 REMOVING AND INSTALLING/REPLACING
OUTER COVER ON FRONT LEFT OR RIGHT SEAT (SPORTS/ELECTRIC) , or outer actuating
unit.
Seat with electric actuating unit only:
Release screws (1).

2005 BMW 645Ci
Fig. 18: Removing Trim And Carrier

Installation:

2005 BMW 645Ci

E46 only:

2005 BMW 645Ci
Fig. 20: Pulling Out Tongue On Seat Cover On Left/Right (E46 Only)

2005 BMW 645Ci


2005 BMW 645Ci
Fig. 22: Identifying Control Unit And Plug Connection (Version With Seat Occupancy Detector)
If necessary, lever catch (1) towards top and detach cover (2).
2005 BMW 645Ci
Fig. 23: Detaching Cover (Version With Seat Heating)

Disconnect plug connection (1) from seat heating.

2005 BMW 645Ci
Fig. 24: Disconnecting Plug Connection From Seat Heating

Disconnect plug connection (1) from seat heating.
Expose cable (2).

2005 BMW 645Ci
Fig. 25: Identifying Cable

Release retainers (1) on left/right.
Pull out cover tabs (2) on left/right.

2005 BMW 645Ci
Fig. 26: Pulling Out Cover Tabs

2005 BMW 645Ci
Fig. 27: Pulling Out Cover Welt Completely From Seat Frame
Installation:
Begin assembly in middle.
Cover piping (1) and seat frame (2) have markings for middle position.
2005 BMW 645Ci
Fig. 28: Identifying Middle Position Marking Of Piping And Seat Frame
Fold in tongues (1) on seat cover and push through under backrest (2) towards front.
2005 BMW 645Ci
Fig. 29: Folding In Tongues (1) On Seat Cover And Pushing Through Under Backrest (2)
Remove seat cover (1) towards front/top.

2005 BMW 645Ci
Fig. 30: Removing Seat Cover Towards Front/Top (Model Without Seat Heating And Without Seat
Occupancy Detector)
Remove seat cover (1) towards front/top.

2005 BMW 645Ci
Fig. 31: Removing Seat Cover Towards Front/Top (Version With Seat Heater And/Or With Seat
Occupancy Detector)
Installation:
The support is coated with wax to prevent grinding noises.
Do not remove wax (1) on seat pan (2).

2005 BMW 645Ci
Fig. 32: Identifying Wax On Seat Pan

US/CND front passenger seat (with OC3 mat) only:
New seat cover must be completely installed with padding, seat heating and OC3 mat.
Release seat occupancy detector:

The operation "Replacing seat cover for front seat" ends here for the above-mentioned vehicles.
Replacing support:
2005 BMW 645Ci
Detach retainers (1) at rear left/right from support (2).
Fig. 33: Detaching Retainers At Rear Left/Right From Support

Remove seat cover from support (foam rubber section).
Remove all remnants of clips from seat cover and support.

2005 BMW 645Ci
Fig. 34: Removing All Remnants Of Clips From Seat Cover And Support
Installation:
Bend new clips (2) with special tool 52 0 050.

2005 BMW 645Ci
Fig. 35: Bending New Clips With Special Tool 52 0 050

Installation:
The support is coated with wax to prevent grinding noises.

2005 BMW 645Ci

Passenger seat only (replacing support):
Installation:
Make sure foam is not extensively damaged (malfunction of passenger seat occupancy detector).

2005 BMW 645Ci
Fig. 37: Aligning Sensor Mat On Foam

Installation:
2005 BMW 645Ci
Fig. 38: Detaching Liner (1) At Individual Points And Sticking Sensor Mat (2) Onto Foam (3)
NOTE: The work for "Replacing support" ends here.
Pull plug (1) out of bore hole (2).
Carefully remove sensor mat (3) from support (4).

2005 BMW 645Ci
Fig. 39: Removing Sensor Mat From Support

NOTE: The operation "Replacing sensor mat" ends here.
Cable (3) for seat heating.

2005 BMW 645Ci
Fig. 40: Removing Seat Cover

 52 0 050
 Remove rear panel on front seat, refer to 52 14 198 REMOVING AND INSTALLING/REPLACING
REAR PANEL ON LEFT OR RIGHT FRONT SEAT BACKREST (NORMAL/ELECTRIC) or 52
16 198 REMOVING AND INSTALLING/REPLACING REAR PANEL ON FRONT LEFT OR
2005 BMW 645Ci
E83:
Fig. 41: Detaching Backrest Cover From Backrest Frame (E83)

E63:

2005 BMW 645Ci
Fig. 42: Detaching Tensioning Cables From Backrest Frame (E63)

Installation:
Lock new retainers by bending with special tool 52 0 050.

2005 BMW 645Ci
Fig. 43: Disconnecting Air Hoses From Valve Housing


2005 BMW 645Ci
Fig. 44: Removing Valve Housing With Metal Nut

Installation:
Check function.
2005 BMW 645Ci
Fig. 45: Identifying Seat Heating Cable Guide And Air Hose

 Remove front seat, refer to 52 14 000 REMOVING AND INSTALLING LEFT OR RIGHT FRONT
SEAT (NORMAL/ELECTRIC) .
 Remove outer cover, refer to 52 16 040 REMOVING AND INSTALLING/REPLACING OUTER
COVER ON FRONT LEFT OR RIGHT SEAT (SPORTS/ELECTRIC) .
Release screws (1).
Release screw (2).

2005 BMW 645Ci
Fig. 46: Unclipping Carrier From Seat Mechanism At Rear


2005 BMW 645Ci
Fig. 47: Disconnecting Plug Connection On Drive Unit

Release screws (1).
Installation:
Release screw (2).

2005 BMW 645Ci
Fig. 48: Removing Seat Angle Adjuster

Installation:
seat pan.
refer to 52 16 400 REPLACING SEAT COVER FOR LEFT OR RIGHT FRONT SEAT
(SPORTS/ELECTRIC) .

2005 BMW 645Ci
Fig. 49: Removing Retaining Plate

Installation:
Tightening Torque, refer to 52 10 9AZ in SEATS - TIGHTENING TORQUES - 645CI .
2005 BMW 645Ci

Installation:
Installation:
2005 BMW 645Ci
Fig. 51: Lifting Support Onto Guide

2005 BMW 645Ci
Fig. 52: Unhooking Control Unit And Cable From Holders


2005 BMW 645Ci
Fig. 53: Detaching Flexmat

2005 BMW 645Ci


2005 BMW 645Ci


2005 BMW 645Ci
Fig. 56: Unhooking Spring From Thigh Support


2005 BMW 645Ci
Fig. 57: Removing Thigh Support

2005 BMW 645Ci
Fig. 58: Removing Guide Rails From Seat Pan

FRONT SEAT NORMAL, ELECTRIC

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 REPLACING SEAT COVER ON LEFT OR RIGHT FRONT SEAT

(NORMAL/MANUAL) .

2005 BMW 645Ci
Fig. 59: Removing Left Retaining Plate

Installation:
Press seat pan (1) upwards, thereby relieving tension on flexmat.

2005 BMW 645Ci


2005 BMW 645Ci
Fig. 61: Removing Retaining Plates

Installation:

2005 BMW 645Ci
Fig. 62: Unhooking Cable From Holder


2005 BMW 645Ci
Fig. 63: Detaching Flexmat At Rear From Mounts

2005 BMW 645Ci
Fig. 64: Detaching Seat Pan On Left/Right Backwards/Top From Mount


2005 BMW 645Ci


Remove release handle on left or right front seat,
refer to 52 14 033 REMOVING AND INSTALLING/REPLACING RELEASE HANDLE ON LEFT OR


2005 BMW 645Ci
Installation:

2005 BMW 645Ci


HEAD RESTRAINT (NORMAL/ELECTRIC)
 Removing and installing guide for front head restraint (normal/manual), refer to 52 13 ... REMOVING
AND INSTALLING/REPLACING GUIDE FOR FRONT LEFT OR RIGHT HEAD
RESTRAINT .
52 14 000 REMOVING AND INSTALLING LEFT OR RIGHT FRONT SEAT (NORMAL/ELECTRIC)
 Remove head restraint, refer to 52 13 390 REMOVING AND INSTALLING / REPLACING FRONT
2005 BMW 645Ci
pyrotechnical belt tensioners. Incorrect or improper handling may trigger
the pyrotechnical belt tensioner or side airbag and thereby cause injury.
Adjust front seat as far forward and upward as possible.
Release seatbelt screw (1) and feed out seatbelt strap (2).
Fig. 68: Identifying Seatbelt Screw And Seatbelt Strap

Move front seat forwards/upwards as far as possible.

2005 BMW 645Ci
Fig. 69: Identifying Seat Screws

Move front seat backwards/downwards as far as possible.
If necessary, unclip protective caps upwards.
Move 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).

2005 BMW 645Ci
Fig. 70: Disconnecting Plug Connection By Unlocking Lock

Lift out front seat.
Installation:
Floor carpet must not enter area between seat rails and floor panel beside screw points (grating noises).
52 14 025 REMOVING AND INSTALLING/REPLACING SEAT MECHANISM ON LEFT OR RIGHT

2005 BMW 645Ci
 61 2 071
 61 2 074
Carry out following tasks beforehand:
 Remove seat pan and flexmat on front seat, refer to 52 13 ... REMOVING AND
INSTALLING/REPLACING SEAT PAN AND FLEXMAT (NORMAL/MANUAL), LEFT OR
RIGHT .
 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).
Fig. 71: Removing Retaining Bracket With Seat Wiring Harness From Seat Mechanism
2005 BMW 645Ci
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.
Fig. 72: Attaching Cable 61 2 074 To Cable 61 2 071 And Connecting Plug Connection To Front Seat

2005 BMW 645Ci
Replacement only:
 Remove backrest cover, refer to 52 14 405 REPLACING BACKREST COVER FOR FRONT LEFT
OR RIGHT SEAT (NORMAL/ELECTRIC) .
 Remove drive unit for lumbar support, refer to 67 66 010 REMOVING AND
INSTALLING/REPLACING LUMBAR SUPPORT DRIVE MECHANISM ON FRONT SEAT,
LEFT OR RIGHT .
 Remove release mechanism on front seat, refer to 52 14 03452 14 034 REMOVING AND
INSTALLING/REPLACING RELEASE MECHANISM ON FRONT LEFT OR RIGHT SEAT .

2005 BMW 645Ci
Installation:
2005 BMW 645Ci
Fig. 74: Detaching Mount For Rear Panel Towards Top/Rear From Backrest Frame
Installation:

2005 BMW 645Ci

2005 BMW 645Ci
Fig. 76: Removing Mat From Spring Wire Of Backrest Frame

Installation:
2005 BMW 645Ci
Fig. 77: Installing Mat On Uppermost Spring Wire On Backrest Frame


Lever off release lever with screwdriver.
NOTE: To protect trim, use a suitable base (1).
Installation:
Retaining lugs on release unit must not be damaged.

2005 BMW 645Ci
Fig. 78: Removing And Installing/Replacing Release Handle On Left Or Right Front Seat
(Normal/Electric)

LEFT OR RIGHT SEAT
Remove release lever on front seat, refer to 52 14 033 REMOVING AND INSTALLING/REPLACING
RELEASE HANDLE ON LEFT OR RIGHT FRONT SEAT (NORMAL/ELECTRIC) .
Remove rear panel on front seat, refer to 52 14 198 REMOVING AND INSTALLING/REPLACING REAR
PANEL ON LEFT OR RIGHT FRONT SEAT BACKREST (NORMAL/ELECTRIC) or 52 16 198
REMOVING AND INSTALLING/REPLACING REAR PANEL ON FRONT LEFT OR RIGHT SEAT
BACKREST (SPORTS/ELECTRIC) .

2005 BMW 645Ci

Fig. 79: Lifting Out Cover Of Guide Towards Bottom And Side
Installation:

2005 BMW 645Ci
Fig. 80: Removing Catch Of Cable

Installation:

Installation:

2005 BMW 645Ci


2005 BMW 645Ci
Fig. 82: Unclipping Release Mechanism Towards Top

Installation:
Installation:

2005 BMW 645Ci
Fig. 83: Installing Release Mechanism On Front Left Or Right Seat


Remove and install/replace outer cover on front left or right seat (sports/electric), refer to 52 16 040
REMOVING AND INSTALLING/REPLACING OUTER COVER ON FRONT LEFT OR RIGHT
SEAT (SPORTS/ELECTRIC) .

2005 BMW 645Ci
Replacing inner cover on left or right front seat (normal/electric), refer to 52 13 041 REMOVING AND
INSTALLING / REPLACING INNER COVER ON LEFT OR RIGHT FRONT SEAT BACKREST
(NORMAL/ MANUAL) .
 52 0 050
 64 1 020
RIGHT SEAT BACKREST (SPORTS/ELECTRIC) .

2005 BMW 645Ci
Fig. 84: Detaching Partial Cover From Backrest Frame

Installation:
Installation:
NOTE: If necessary, use special tool 64 1 020.

2005 BMW 645Ci
Fig. 85: Detaching Drive Unit For Lumbar Cushion From Backrest Frame

2005 BMW 645Ci
Fig. 86: Disconnecting Hoses And From Valve Housing

Installation:

2005 BMW 645Ci
Fig. 87: Detaching Lumbar Cushion From Spring Wire


2005 BMW 645Ci
Fig. 88: Removing Lumbar Cushion

Installation:

2005 BMW 645Ci
Fig. 89: Identifying Lumber Cushion And Air Hoses

Installation:
2005 BMW 645Ci
Fig. 90: Attaching Lumbar Cushion To Third Wire Above Spring

Installation:

2005 BMW 645Ci
Fig. 91: Identifying Seat Heating Cable Guide And Air Hoses Without Kinks
Installation:
Check function.
 52 0 050

2005 BMW 645Ci
E83:
Fig. 92: Detaching Backrest Cover From Backrest Frame (E83)

E63:

2005 BMW 645Ci
Fig. 93: Detaching Tensioning Cables From Backrest Frame (E63)

Installation:

2005 BMW 645Ci
Fig. 94: Disconnecting Air Hoses From Valve Housing


2005 BMW 645Ci
Fig. 95: Removing Valve Housing With Metal Nut

Installation:

2005 BMW 645Ci
Fig. 96: Identifying Seat Heating Cable Guide And Air Hoses Without Kinks
Check function.

Release screws (1).

2005 BMW 645Ci


2005 BMW 645Ci

Release screws (1).
Installation:
Release screw (2).

2005 BMW 645Ci
Fig. 99: Removing Seat Angle Adjuster On Left Or Right Front Seat (Normal/Electric)
Installation:
seat pan.
52 14 198 REMOVING AND INSTALLING/REPLACING REAR PANEL ON LEFT OR RIGHT

FRONT SEAT BACKREST (NORMAL/ELECTRIC)
Replacing rear panel on left or right front seat backrest (normal/manual).
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), refer to 52 13 390 REMOVING AND
INSTALLING / REPLACING FRONT HEADREST (NORMAL/ MANUAL) .
52 14 400 REPLACING SEAT COVER FOR LEFT OR RIGHT FRONT SEAT

2005 BMW 645Ci
Operation differs as follows and is described in:
Replacing seat cover without thigh support for left or right front seat, refer to 52 13 400 REPLACING SEAT
COVER ON LEFT OR RIGHT FRONT SEAT (NORMAL/MANUAL) .
Replacing seat cover with thigh support for left or right front seat, refer to 52 16 400 REPLACING SEAT
COVER FOR LEFT OR RIGHT FRONT SEAT (SPORTS/ELECTRIC) .
52 14 405 REPLACING BACKREST COVER FOR FRONT LEFT OR RIGHT SEAT

(NORMAL/ELECTRIC)
 52 0 050
 64 1 020
 Remove guide for head restraint, refer to 52 14 ... REMOVING AND INSTALLING/REPLACING
GUIDE FOR FRONT LEFT OR RIGHT HEAD RESTRAINT (NORMAL/ELECTRIC) .
 Remove trim for release handle, refer to 52 13 ... REMOVING AND INSTALLING/REPLACING
TRIM FOR RELEASE HANDLE ON LEFT OR RIGHT FRONT SEAT (NORMAL/MANUAL) .

2005 BMW 645Ci
Fig. 100: Detaching Tensioning Cables From Backrest Frame

Installation:

2005 BMW 645Ci
Fig. 101: Detaching Backrest Cover From Backrest Frame By Lifting Out Piping
Expose cable for seat heating.
Feed cable (2) out of holder (3).

2005 BMW 645Ci
Fig. 102: Disconnecting Plug Connection And Cable Out Of Holder

Detach backrest cover (1) at sides towards front and remove with support upwards from backrest frame (2).
2005 BMW 645Ci
Fig. 103: Removing Backrest Cover From Backrest Frame

Release retainers (1) on left and right of backrest cover (2).

2005 BMW 645Ci
Fig. 104: Releasing Retainers On Left And Right Of Backrest Cover

NOTE: Remove all remnants of clips from backrest cover (1) and padding.
2005 BMW 645Ci
Fig. 105: Removing All Remnants Of Clips From Backrest Cover And Padding
Installation:
Bend new retainer (2) with special tool 52 0 050.

2005 BMW 645Ci
Fig. 106: Installing Retainer With Special Tool 52 0 050

Replacement of backrest cover:
Pull trim threads (1) out of backrest cover.
Installation:
Cut new backrest cover to size and insert trim wires (1).
(2) Seat heater cable

2005 BMW 645Ci
Fig. 107: Identifying Seat Heater Cable And Trim Wires

52 14 415 REPLACING PADDING FOR LEFT OR RIGHT FRONT SEAT (NORMAL/ELECTRIC)
WARNING: US/CND front passenger seat (with OC3 mat) only: The support can only
be removed in conjunction with the OC3 mat. If support is defective, both
parts may only be replaced together. After fitting new support, enable
OC3 mat with BMW diagnosis system.
 Replacing seat cover on front seat, refer to 52 14 400 REPLACING SEAT COVER FOR LEFT OR

2005 BMW 645Ci


(NORMAL/ELECTRIC)
Replace backrest cover for left or right front seat, refer to 52 14 405 REPLACING BACKREST COVER
FOR FRONT LEFT OR RIGHT SEAT (NORMAL/ELECTRIC) .

Fig. 108: Releasing Screw On Actuator Drive Of Longitudinal Seat Adjustment

2005 BMW 645Ci
Fig. 109: Removing Servodrive

A. No function:

 Continue with

2005 BMW 645Ci
Fig. 110: Identifying Faulty Gear, Input Shaft And Internal Gear
(2) Input shaft
(3) Internal gear

2005 BMW 645Ci
Fig. 111: Cutting Drive Shaft From Rear


2005 BMW 645Ci


2005 BMW 645Ci
Fig. 113: Removing Gear

Over rest of drive shaft (1), adjust front seat, release screws on floor panel and remove front seat, refer to 52 14
000 REMOVING AND INSTALLING LEFT OR RIGHT FRONT SEAT (NORMAL/ELECTRIC) .
NOTE: If gear (4) is faulty, detach cover (2), release screws (3), and remove gear (4).
2005 BMW 645Ci
Fig. 114: Removing Faulty Gear


Remove outer front cover.

2005 BMW 645Ci
Fig. 115: Removing And Installing/Replacing Carrier For Outer Cover On Left Or Right Front Seat
(Sports/Electric)
FRONT SEAT, SPORTS, ELECTRIC

Remove release handle on left or right front seat, refer to 52 14 033 REMOVING AND
INSTALLING/REPLACING RELEASE HANDLE ON LEFT OR RIGHT FRONT SEAT
(NORMAL/ELECTRIC) .

2005 BMW 645Ci
Installation:

2005 BMW 645Ci


Replacement only:
 Remove backrest cover, refer to 52 14 405 REPLACING BACKREST COVER FOR FRONT LEFT
OR RIGHT SEAT (NORMAL/ELECTRIC) .
2005 BMW 645Ci

 Remove drive unit for lumbar support, refer to 67 66 010 REMOVING AND
INSTALLING/REPLACING LUMBAR SUPPORT DRIVE MECHANISM ON FRONT SEAT,
LEFT OR RIGHT .
 Remove release mechanism on front seat, refer to 52 14 034 REMOVING AND
INSTALLING/REPLACING RELEASE MECHANISM ON FRONT LEFT OR RIGHT SEAT .
Installation:

2005 BMW 645Ci
Fig. 118: Unhooking Backrest Cover On Left And Right

2005 BMW 645Ci
Fig. 119: Detaching Mount For Rear Panel Towards Top/Rear From Backrest Frame
Installation:

2005 BMW 645Ci
Fig. 120: Identifying Catch And Guide On Mount Of Rear Panel

2005 BMW 645Ci
Fig. 121: Removing Mat From Spring Wire Of Backrest Frame (3)
Installation:
2005 BMW 645Ci
Fig. 122: Installing Mat On Uppermost Spring Wire On Backrest Frame


LEFT OR RIGHT SEAT
Remove release lever on front seat, refer to 52 14 033 REMOVING AND INSTALLING/REPLACING
RELEASE HANDLE ON LEFT OR RIGHT FRONT SEAT (NORMAL/ELECTRIC) .
Remove rear panel on front seat, refer to 52 14 198 REMOVING AND INSTALLING/REPLACING REAR
PANEL ON LEFT OR RIGHT FRONT SEAT BACKREST (NORMAL/ELECTRIC) or 52 16 198
REMOVING AND INSTALLING/REPLACING REAR PANEL ON FRONT LEFT OR RIGHT SEAT
BACKREST (SPORTS/ELECTRIC) .

2005 BMW 645Ci
Fig. 123: Unclipping Catch

Installation:

2005 BMW 645Ci
Fig. 124: Removing Catch Of Cable Mount

Installation:

Installation:

2005 BMW 645Ci


2005 BMW 645Ci
Fig. 126: Unclipping Release Mechanism Towards Top

Installation:
Installation:

2005 BMW 645Ci
Fig. 127: Installing Release Mechanism On Front Left Or Right Seat

 52 0 050
 64 1 020
2005 BMW 645Ci
Fig. 128: Detaching Tensioning Cables From Backrest Frame

Installation:

2005 BMW 645Ci
Installation:
Fig. 129: Detach Backrest Cover From Backrest Frame By Lifting Out Piping

2005 BMW 645Ci
Fig. 130: Disconnecting Hoses From Valve Housing

Installation:

2005 BMW 645Ci
Fig. 131: Detaching Lumbar Cushion From Spring Wire


2005 BMW 645Ci
Fig. 132: Removing Lumber Cushion

Installation:

2005 BMW 645Ci
Fig. 133: Identifying Lumber Cushion And Air Hoses

Installation:
2005 BMW 645Ci
Fig. 134: Attaching Lumbar Cushion To Third Wire Above Spring

Installation:

2005 BMW 645Ci
Fig. 135: Identifying Seat Heating Cable Guide, Air Hoses Without Kinks
Installation:
Check function.


2005 BMW 645Ci
Fig. 136: Releasing Screw On Actuator Drive Of Longitudinal Seat Adjustment

2005 BMW 645Ci
Fig. 137: Removing Servodrive

A. No function:

 Continue with

2005 BMW 645Ci
(2) Input shaft
(3) Internal gear
Fig. 138: Identifying Gear, Input Shaft And Internal Gear


2005 BMW 645Ci
Fig. 139: Cutting Drive Shaft From Rear


2005 BMW 645Ci


2005 BMW 645Ci
Fig. 141: Releasing Screw And Removing Gear

Over rest of drive shaft (1), adjust front seat, release screws on floor panel and remove front seat, refer to 52 14
000 REMOVING AND INSTALLING LEFT OR RIGHT FRONT SEAT (NORMAL/ELECTRIC) .
NOTE: If gear (4) is faulty, detach cover (2), release screws (3), and remove gear (4).
2005 BMW 645Ci
Fig. 142: Removing Gear


Remove outer front cover.

2005 BMW 645Ci
Fig. 143: Removing And Installing/Replacing Carrier For Outer Cover On Left Or Right Front Seat
(Sports/Electric)

HEAD RESTRAINT (SPORTS/ELECTRIC)
 Removing and installing guide for front head restraint (normal/manual), refer to 52 13 ... REMOVING
AND INSTALLING/REPLACING GUIDE FOR FRONT LEFT OR RIGHT HEAD
RESTRAINT .

2005 BMW 645Ci
refer to 52 16 400 REPLACING SEAT COVER FOR LEFT OR RIGHT FRONT SEAT
(SPORTS/ELECTRIC) .
Fig. 144: Levering Out Retaining Plate On Left

Installation:

2005 BMW 645Ci

Installation:
Installation:
2005 BMW 645Ci
Fig. 146: Installing Lift Support Onto Guide

2005 BMW 645Ci
Fig. 147: Unhooking Control Unit And Cable From Holders


2005 BMW 645Ci
Fig. 148: Detaching Flexmat At Rear From Mounts

2005 BMW 645Ci
Fig. 149: Removing Seat Pan


2005 BMW 645Ci


2005 BMW 645Ci
Fig. 151: Unhooking Spring From Thigh Support


2005 BMW 645Ci
Fig. 152: Removing Thigh Support

2005 BMW 645Ci
Fig. 153: Removing Guide Rails From Seat Pan

52 16 000 REMOVING AND INSTALLING FRONT SEAT (SPORTS/ELECTRIC), LEFT OR RIGHT
Removing and installing front seat (normal/manual), left or right, refer to 52 14 00052 14 000 REMOVING
AND INSTALLING LEFT OR RIGHT FRONT SEAT (NORMAL/ELECTRIC) .
52 16 011 REMOVING AND INSTALLING/REPLACING BOWDEN CABLE FOR REAR

COMPARTMENT ENTRANCE AID
 Remove seat, refer to 52 16 000 REMOVING AND INSTALLING FRONT SEAT

(SPORTS/ELECTRIC), LEFT OR RIGHT .
2005 BMW 645Ci
PANEL ON FRONT LEFT OR RIGHT SEAT BACKREST (SPORTS/ELECTRIC) .

Lay seat on seat surface/backrest or left seat side.
Unhook and remove springs (1).
Remove retainers (2).
Fig. 154: Removing Springs And Retainers

Release screw (1) of cable mount (2).

2005 BMW 645Ci
Detach cable mount (2) and cable eye (3) from shaft.
Feed cable out of holder (4).

Disconnect spring (1).
Unclip sleeve (2) of Bowden cable from guide.
Feed out cable (3).

2005 BMW 645Ci
Fig. 156: Removing Bowden Cable For Rear Compartment Entrance Aid
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 ... REMOVING AND
INSTALLING/REPLACING SEAT PAN AND FLEX MAT ON FRONT LEFT OR RIGHT SEAT
(SPORTS/ELECTRIC) .
Remove backrest frame on front seat.
Remove seatbelt tensioner.
Disconnect all plug connections (1) from actuator drives.
Remove seat wiring harness from seat mechanism (2).

2005 BMW 645Ci
Fig. 157: Identifying Plug Connections (1) And Seat Mechanism (2)
Installation:
Perform function check:
Connect cable 61 2 071 to battery, connect cable 61 2 074 to cable 61 2 071 and plug connection (1) to front
seat.
2005 BMW 645Ci
Fig. 158: Connecting Cable 61 2 074 To Cable 61 2 071 And Plugging Connection (1) To Front Seat

FRONT SEAT (SPORTS/ELECTRIC)
Removing and installing/replacing release handle on left or right front seat (normal/electric), refer to 52 14 033
REMOVING AND INSTALLING/REPLACING RELEASE HANDLE ON LEFT OR RIGHT FRONT

Unscrew bolt (1).

2005 BMW 645Ci
Fig. 159: Unscrewing Bolt

Removing top cover:

2005 BMW 645Ci
Fig. 160: Removing Top Cover

Lever lugs (1) on cover (3) out of brackets (2).

2005 BMW 645Ci
Fig. 161: Levering Lugs On Cover Out Of Brackets

Lever out cover (1) at rear, detach at front from guide and remove.
2005 BMW 645Ci
Fig. 162: Levering Out Cover At Rear

Installation:
Do not crush cables (1) during installation.

Insert lugs (2) into mounts (3) and snap into place.
2005 BMW 645Ci
Fig. 163: Inserting Lugs Into Mounts

Lever out lugs (2) and detach switch combination (3).

2005 BMW 645Ci
Fig. 164: Detaching Switch Combination

Installation:
Guides (1) and catches (2) on switch combination (3) must not be damaged.
2005 BMW 645Ci
Fig. 165: Identifying Guides And Catches On Switch Combination

Model with lumbar supports:
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.
2005 BMW 645Ci
Fig. 166: Removing Switch From Cover

Installation:
Following parts must not be damaged, replace cover (4) if necessary:

2005 BMW 645Ci
Fig. 167: Identifying Mounts For Switch Combination, Guide, Front And Tabs
Replacement of switch combination only or in event of further work on front seat:
Disconnect plug connection (1) and remove switch combination (2).

2005 BMW 645Ci
Fig. 168: Removing Switch Combination


Replacing inner cover on left or right front seat (normal/electric), refer to 52 13 041 REMOVING AND
INSTALLING / REPLACING INNER COVER ON LEFT OR RIGHT FRONT SEAT BACKREST
(NORMAL/ MANUAL) .

RIGHT FRONT SEAT (SPORT/ELECTRIC)

2005 BMW 645Ci
Release screws (1).
Release screw (2).


2005 BMW 645Ci

Release screws (1).
Installation:
Release screw (2).

2005 BMW 645Ci
Fig. 171: Removing Seat Angle Adjuster On Left Or Right Front Seat (Sport/Electric)
Installation:
seat pan.

Detaching cushion for thigh support:
2005 BMW 645Ci
Fig. 172: Removing Cover Pipings

NOTE: Cushion (1) is attached at front with double-sided adhesive tape (3) to holder
(2).
Pull cushion (1) towards top off holder (2).

2005 BMW 645Ci
Fig. 173: Pulling Cushion Towards Top


2005 BMW 645Ci
Fig. 174: Levering Trim Wire Out Of Mounts

Installation:
Stick new double-sided adhesive tape (4) to holder (3) or attach mount with spray adhesive.
NOTE: The operation "Removing cushion for thigh support" ends here.
Removal of "Thigh support holder" only:
Unhook spring (1) at bottom from holder (2) and seat frame (3).
2005 BMW 645Ci
Fig. 175: Unhooking Spring At Bottom From Holder And Seat Frame
Release screws (1).
Press operating lever (2) fully and detach holder (3) for thigh support towards front from seat frame (4).
2005 BMW 645Ci
Fig. 176: Detaching Thigh Support Holder

Installation:
Following parts on holder (5) must not be damaged:

1. Mounts for trim wire
2. Holding-down elements for trim wire
3. Guide sleeves
4. Double-sided adhesive tape (replace or coat with spray adhesive for assembly)
2005 BMW 645Ci
Fig. 177: Identifying Parts Of Holder

Installation:
If necessary, release screws (1) and remove guide rails (2) from seat frame (3).
2005 BMW 645Ci
Fig. 178: Removing Guide Rails From Seat Frame


Release screws (2).

2005 BMW 645Ci

Installation:

2005 BMW 645Ci
Fig. 180: Removing Carrier For Thigh Support

52 16 198 REMOVING AND INSTALLING/REPLACING REAR PANEL ON FRONT LEFT OR

RIGHT SEAT BACKREST (SPORTS/ELECTRIC)
Remove and install/replace rear panel on front left or right seat backrest (sports/manual).
52 16 390 REMOVING AND INSTALLING/REPLACING FRONT HEAD RESTRAINT

(SPORTS/ELECTRIC) ON LEFT OR RIGHT
Replacing front left or right head restraint (normal/manual), refer to 52 13 390 REMOVING AND
INSTALLING / REPLACING FRONT HEADREST (NORMAL/ MANUAL) .
2005 BMW 645Ci
 52 0 050
Seat cover must not be separated from padding.
All parts must be replaced completely and released with the diagnosis system in event of defective seat cover,
 Remove outer cover with actuating unit, refer to 52 16 040 REMOVING AND
INSTALLING/REPLACING OUTER COVER ON FRONT LEFT OR RIGHT SEAT
(SPORTS/ELECTRIC) .

2005 BMW 645Ci
Fig. 181: Disconnecting Plug Connection And Releasing Cable Strap


2005 BMW 645Ci
Fig. 182: Detaching Cable From Holder

2005 BMW 645Ci
Fig. 183: Removing Trim

Release screws (1).

2005 BMW 645Ci
Fig. 184: Removing Trim And Carrier

Installation:

2005 BMW 645Ci

Installation:

2005 BMW 645Ci
Fig. 186: Identifying Clips On Sports Seat Trim


2005 BMW 645Ci
Fig. 187: Disconnecting Plug Connection From Control Unit (Version With Seat Occupancy Detector)

2005 BMW 645Ci
Fig. 188: Releasing Locks And Detaching Plug Housing


2005 BMW 645Ci
Fig. 189: Detaching Cover

2005 BMW 645Ci
Fig. 190: Disconnecting Plug Connection For Seat Heating From Plug Housing

2005 BMW 645Ci
Fig. 191: Pulling Cable Out Of Holders

E46 only:

2005 BMW 645Ci
Fig. 192: Pulling Out Tongue On Seat Cover On Left/Right (E46)


2005 BMW 645Ci

2005 BMW 645Ci
Fig. 194: Pulling Out Cover Welt Completely From Seat Frame
2005 BMW 645Ci
Fig. 195: Folding Seat Cover Ends

2005 BMW 645Ci
Fig. 196: Removing Cover Piping


2005 BMW 645Ci
Fig. 197: Pulling Cushion Towards Top Off Carrier


2005 BMW 645Ci
Fig. 198: Levering Trim Wire Out Of Mounts

Installation:
Stick new double-sided adhesive tape (4) to carrier (3) or attach mount with spray adhesive.
2005 BMW 645Ci


2005 BMW 645Ci

US/CND front passenger seat (with OC3 mat) only:
New seat cover must be completely installed with padding, seat heating and OC3 mat.
Release seat occupancy detector:

The operation "Replacing seat cover for front seat" ends here for the above-mentioned vehicles.
Replacing support or sensor mat:

2005 BMW 645Ci
Fig. 201: Releasing Clips At Rear Left/Right From Support

2005 BMW 645Ci
Fig. 202: Releasing All Clips On Left/Right And Centre From Support
Installation:

2005 BMW 645Ci
Fig. 203: Identifying Routing Of Seat Heater Cable

Remove seat cover from support (foam rubber section).
Remove all remnants of clips from seat cover and support.

2005 BMW 645Ci
Fig. 204: Removing All Remnants Of Clips From Seat Cover And Support
Remove support (1) from seat cover (2).

2005 BMW 645Ci
Fig. 205: Removing Support From Seat Cover

Installation:
3 Seat heater cable

2005 BMW 645Ci
Fig. 206: Detaching Heating Mat From Adhesive Tape Of Thigh Support
2005 BMW 645Ci
Fig. 207: Sticking Double-Sided Adhesive Tape To Support

Installation:

2005 BMW 645Ci
Fig. 208: Identifying Feed Seat Heater Cable

Installation:
Bend new clips (2) with special tool 52 0 050.

2005 BMW 645Ci
Fig. 209: Bending Clips With Special Tool 52 0 050

Installation:

2005 BMW 645Ci

Installation:

2005 BMW 645Ci
Fig. 211: Feeding Plug Through Bore Hole

Installation:
2005 BMW 645Ci
Fig. 212: Installing Sensor Mat Onto Foam

(3) Seat heater cable

2005 BMW 645Ci
Fig. 213: Removing Seat Cover

52 16 405 REPLACING BACKREST COVER ON FRONT LEFT OR RIGHT SEAT

(SPORTS/ELECTRIC)
 52 0 050
Except for steps detailed below, operation is identical to:
 Replacing backrest cover for left or right front seat (normal/electric).
Additional retainers in side sections:

2005 BMW 645Ci
Release clips (1).
Fold back piping (2) with backrest cover (3).
Fig. 214: Folding Back Piping With Backrest Cover

Detach all remaining clips.
NOTE: Remove all remnants of clips from backrest cover (1) and support.
2005 BMW 645Ci
Fig. 215: Removing All Remnants Of Clips From Backrest Cover And Support
Installation:
Bend new retainer (2) with special tool 52 0 050.

2005 BMW 645Ci
Fig. 216: Bending Retainer With Special Tool 52 0 050

52 16 415 REPLACING PADDING FOR LEFT OR RIGHT FRONT SEAT (SPORT/ELECTRIC)
Replacing seat cover on left or right front seat, refer to 52 16 400 REPLACING SEAT COVER FOR LEFT
OR RIGHT FRONT SEAT (SPORTS/ELECTRIC) .

(SPORT/ELECTRIC)
Replace backrest cover for left or right front seat, refer to 52 16 405 REPLACING BACKREST COVER ON
FRONT LEFT OR RIGHT SEAT (SPORTS/ELECTRIC) .
2005 BMW 645Ci
REAR SEAT, NORMAL

52 24 ... REMOVING AND INSTALLING / REPLACING SKI BAG WITH CASING
 Remove ski bag cover, refer to 51 47 140 REMOVING AND INSTALLING/REPLACING PANEL
FOR LUGGAGE COMPARTMENT PARTITION .
 Remove backrest, refer to 52 24 010 REMOVING AND INSTALLING / REPLACING
BACKREST .
Release screws (1).
Release screw (2).
Remove casing towards front.
Fig. 217: Removing And Installing / Replacing Ski Bag With Casing
2005 BMW 645Ci
52 24 005 REMOVING AND INSTALLING OR REPLACING REAR SEAT
Unclip rear seat on left/right towards top.
Lift rear seat out of vehicle.
Installation:
Feed in seat belt buckles (1) through designated openings in rear seat.
Fig. 218: Removing And Installing Or Replacing Rear Seat

52 24 010 REMOVING AND INSTALLING / REPLACING BACKREST

2005 BMW 645Ci
SEAT .
 Remove head restraint, refer to 52 13 390 REMOVING AND INSTALLING / REPLACING FRONT
HEADREST (NORMAL/ MANUAL) .
 Remove armrest, refer to 52 24 030 REMOVING AND INSTALLING COMPLETE ARMREST
FOR REAR SEAT BACKREST .
Release screws (1) on backrest.
Release screws (2) on seatbelt anchor fitting.
Unclip backrest forcefully forwards out of partition wall.
Fig. 219: Unclipping Backrest

2005 BMW 645Ci
Installation:
Make sure retainers are correctly seated in backrest.
NOTE: End of work when removing side trim panel and/or rear parcel shelf.
Unlock detent lugs (1) on back and remove seatbelt outlet trim (2).
Fig. 220: Removing Seatbelt Outlet Trim

Installation:
Replace seatbelt outlet trims in event of faulty detent lugs.
Feed seat belt (1) out of

2005 BMW 645Ci
(3) Backrest
Fig. 221: Identifying Seat Belt, Seat Belt Outer Trim And Backrest
52 24 030 REMOVING AND INSTALLING COMPLETE ARMREST FOR REAR SEAT BACKREST
Press lock (1) and remove filler element (2).
Installation:
Make sure filler element is correctly inserted in backrest.

2005 BMW 645Ci
Fig. 222: Removing And Installing Complete Armrest For Rear Seat Backrest
52 24 390 REMOVING AND INSTALLING / REPLACING REAR HEAD RESTRAINTS
Pull out head restraint (1) firmly.
Installation:
Press head restraint (1) downwards until it engages audibly in notches.

2005 BMW 645Ci
Fig. 223: Removing And Installing / Replacing Rear Head Restraints

52 24 400 REPLACING SEAT COVER FOR REAR SEAT
 52 0 050
SEAT .

2005 BMW 645Ci
Fig. 224: Detaching Retainers And Piping From Rear Seat

Detaching cover and padding:

 Remove seat cover from padding.
2005 BMW 645Ci
Fig. 225: Detaching Cover And Padding

Installation:
 Insert new retainers with special tool 52 0 050.
Replacing cover:

 If necessary, cut in take-up for trim wires of new cover
 Push trim wires into new seat cover
2005 BMW 645Ci
Fig. 226: Replacing Cover


2005 BMW 645Ci

52 24 408 REPLACING BACKREST COVER FOR LEFT OR RIGHT REAR SEAT
 52 0 050
 64 1 020
 Remove backrest for rear seat, refer to 52 24 010 REMOVING AND INSTALLING / REPLACING
BACKREST .
2005 BMW 645Ci
Fig. 228: Identifying Retainers And Piping On Right Rear Seat Backrest Cover
Detaching cover from padding:

 Remove cover from padding.
2005 BMW 645Ci
Fig. 229: Detaching Cover From Padding

Installation:
Insert new retainers with special tool 52 0 050.
Replacing cover:

 If necessary, cut pockets in new cover for trim wires
 Push trim wires into pockets
2005 BMW 645Ci
Fig. 230: Replacing Cover


2005 BMW 645Ci

2006 BMW 650i
2006-07 ACCESSORIES AND EQUIPMENT Convertible Top - 6-Series
Convertible Top - 6-Series
10 SUNROOF
54 0 ... REPAIR INSTRUCTIONS FOR BONDED SEALS
1. General information on handling rubber seal profiles:

 If seals reveal partly detached protective film on delivery, they must not be bonded.
 Store seals at 15 °C to 25 °C.
 If, during the handling, the protective film has come off before bonding, it can still be bonded.
 Bonding at room and object temperature >20 °C. Temperatures between 40 and 50 °C significantly
increase initial adhesion.
 Seals, which are subjected to temperatures above 80 °C after gluing, will be very difficult to
remove.
2. Damage pattern and repair
1. Partially detached bond (rubber-adhesive tape or adhesive tape-paint)
 Up to 120 mm for retouching without auxiliary resources
 Up to 200 mm repaired with pressing-on tools on straight surfaces
a. Cleaning damaged areas:

 Degrease bonded area with adhesive cleaner and remove other residues.
NOTE: Use necessary cotton - or fluff-free paper towel once only.

When using solvent:
expose repair area to air for at least 2 minutes.
b. Applying adhesive:
 With a fine nozzle, apply a wafer-thin bead to adhesive tape.
NOTE: Use contact adhesive (e.g. Terokal 2444)
CAUTION: Avoid contact to skin!

Do not apply adhesive to visible painted surfaces.
c. Pressing on rubber seal:

 Press down seal using contact pressure (forced pressure not necessary) for at least 1
minute.
CAUTION: Load can only be applied to the bond after a period of 2

minutes. This waiting time is absolutely essential.
2006 BMW 650i
2. Larger defects (mechanical damage and larger separations of seal)

 A complete replacement of the rubber seal is necessary.
a. Peeling off damaged rubber seal:

 Pull off rubber seal slowly at an angle up to 20° under uniformly strong tension.
NOTE: Make sure the connection between adhesive tape and seal is
retained.
If the connection between adhesive tape and seal is detached:
Carefully and slowly detach adhesive tape at an angle of 20°
from roof opening or lid.
If, in the case of older seals, you are peeling off using a hot air
blower: Do not damage paintwork.
Do not detach rubber-adhesive tape connection if at all
possible.
b. Cleaning bonded area:

 Degrease bonded area with adhesive cleaner and remove other residues.
NOTE: Use necessary cotton - or fluff-free paper towel once only.

When using solvent:
expose repair area to air for at least 2 minutes.
c. Detaching protective film from bonded area:

 Detach protective film from rubber seal in sections.
CAUTION: Once the protective film has been removed, do not under
any circumstances touch the exposed bonded area.
d. Applying rubber seal:

 Apply rubber seal on roof opening edge beginning at rear center. Use upper lip as
application edge. Press on seal continuously by hand. Carefully unwrap seal at radii
without tension and press down (critical area).
NOTE: If positioned incorrectly, the seal can still be pulled off,

repositioned and pressed on again.
e. Establishing seal joint:

 Mark contact point at joint by pressing down loose end on seal of already bonded end.
Then cut and press down loose end at same height.
NOTE: Small areas of seal can remain stuck to adhesive tape of loose
end.
2006 BMW 650i
f. Pressing on seal:
 Press on seal using a roller
 Adhesive tape width up to 5 mm Application pressure approx. 5 N
 Adhesive tape width up to 10 mm Application pressure approx. 10 N
Sliding sunroof seal only:
 Press against seal strongly with a roller. Application pressure approx. 70 N.
E36 sliding sunroof seal only:
 Application pressure approx. 30 N.

 Tear off tear - off lip at rear and side in area of narrower flange.
3. Checking rubber seal

 Check the bonded seals for correct positioning and perfect adhesion. The bonding can be checked
by pressing back the sealing lip.
 The force required to peel off the seal immediately after gluing must be greater than 10 N/cm.
25 SOFT-TOP FLAP
51 00 ... SERVICE POSITION OF CONVERTIBLE TOP COMPARTMENT LID
 54 3 120 . See SLIDE/TILT SUNROOF AND CONVERTIBLE TOP - SPECIAL TOOLS .
WARNING: Danger of locking in position!
Open convertible top compartment lid until all hydraulic cylinders are completely extended.
2006 BMW 650i
Fig. 1: Identifying Convertible Top Compartment Lid

Open convertible top compartment.
Removing hydraulic cylinder at top right or left:
1. Raise retaining spring and push to end of hydraulic cylinder.

2. Remove hydraulic cylinder (2) from ball end.
Fig. 2: Removing Hydraulic Cylinder From Ball End

1. Place special tool 54 3 120 in convertible top frame. See SLIDE/TILT SUNROOF AND
CONVERTIBLE TOP - SPECIAL TOOLS .
2. Clip ball socket of special tool on ball stud.
NOTE: If necessary, remove second hydraulic cylinder at top right or left.

2006 BMW 650i
31 CONVERTIBLE TOP LINKAGE

54 31 ... NOTES ON CONVERTIBLE TOP
 00 2 030 .
 54 3 140 .
WARNING: You are exposed to the risk of trapping body parts when working on the
installed or removed convertible top.
Necessary tasks:
 Convertible top actuation in event of a technical fault. See 54 34 ... Opening/Closing Convertible Top
In Event Of A Technical Fault.
 Repair instructions for hydraulic system. See 54 34 ... Repair Instructions For Hydraulic System Of
Convertible Top And Convertible Top Compartment Lid.
 Troubleshooting automatic convertible top. See 54 90 ... Troubleshooting, Automatic Convertible Top.
Function description (open/close):
Opening and closing of convertible top is only possible:
 when the side windows are slightly lowered

 when the rear window is completely lowered
 when the convertible top compartment base is lowered
 speed must be under 30 km/h
 rear lid must be closed
 outside temperature is between -10 °C and +80 °C
 Hydraulic pump motor < or =90 °C
 from ignition lock position "R" (radio setting)
2006 BMW 650i
Fig. 4: Opening Convertible Top

 while control switch in instrument panel is pressed
Positioning removed convertible top:
Mount convertible top holders 54 3 140 on support tube 54 3 201 and fit on universal lifter 00 2 030 .
IMPORTANT: Use special tools only in conjunction with universal lifter 00 2 030 .
There is a risk of tilting over if other lifting equipment is used.
IMPORTANT: Pay attention to cables and hydraulic lines when fitting convertible top.
Cables/lines must not be trapped.
Place convertible top over threaded bolts.
Secure convertible top with original nuts.

2006 BMW 650i
Suspend kinematics box at side from special tool 54 3 140 .
Fig. 6: Identifying Convertible Top Threaded Bolts

IMPORTANT: Always move the convertible with a 2nd person helping (risk of damage).
Make sure force is always exerted uniformly to the convertible top sides
otherwise the frame will be bent.
Raise convertible top at main pillars and close.
Fig. 7: Identifying Convertible Top At Main Pillars

34 MOTOR-OPERATED CONVERTIBLE TOP

54 34 ... ADJUSTING BOTH BOWDEN CABLES FOR CONVERTIBLE TOP COMPARTMENT LID
LOCK
NOTE: This operation is described in:

2006 BMW 650i
 Adjusting convertible top compartment lid lock.
54 34 ... BLEEDING HYDRAULIC SYSTEM
Bleeding hydraulic system in event of excessive noise build-up:
 Convertible top must be opened and closed several times

 The hydraulic system is automatically bled in the fluid reservoir in the process
54 34 ... MOUNTING OF HYDRAULIC COMPONENTS
If line connections on the hydraulic unit or the hydraulic lines remain open for an extended period of time (e.g.
storage, maintenance time), they must be protected against the penetration of moisture and dirt particles.
Proceed as described below in this respect.
The new method can even be used on older systems.
Screw plugs and cap nuts are included in the "Banjo bolts for hydraulic unit" kit.
Sealing caps, sealing plugs and screw plugs are included in the "Hydraulic repair kit" (all sourcing reference:
BMW Parts Service).
Connections on hydraulic unit:
Use screw plugs (1) for this purpose.
In case of screw plugs from "Banjo bolts ..." kit, use the old seals.
Fig. 8: Identifying Screw Plugs

Connections on cylinder:
2006 BMW 650i
In case of connections with cap nuts, use seal plugs (as on hydraulic unit).
Fig. 9: Identifying Seal Plugs

Line connections (old):
Use screw plugs (1), cap nuts (2) and old seals for this purpose.
Fig. 10: Identifying Screw Plugs And Cap Nuts

Line connections (new):
Attach seal plug or cap (1) in or to line connection (2).

2006 BMW 650i
Fig. 11: Identifying Seal Plug Or Cap

54 34 ... OPENING/CLOSING CONVERTIBLE TOP IN EVENT OF A TECHNICAL FAULT
IMPORTANT: Always conduct convertible top movements with the assistance of a second
person (risk of damage).
Make sure force is always exerted uniformly to the convertible top sides
otherwise the frame will be bent.
Front doors must be permanently opened.
Unlocking convertible top lock:
 Lever out cover (1) towards bottom

 Insert double L-shaped Allen key (car's tool kit) into screw
 Unlock lock on cowl panel by turning

Unlocking convertible top compartment lid:

2006 BMW 650i
 Open rear lid.

 Pop actuator button (1) on left and right out of luggage compartment trim panel.
 Pull actuator button (1) on left and right and unlock convertible top compartment lid.
Fig. 13: Pulling Actuator Button

Opening convertible top by hand:
 Lower rear window

 Unlock and raise front bow
 Unlock convertible top compartment lid
 Raise fins and front bow with counterpressure
 Open and support convertible top compartment lid
 Fold convertible top under supports of fins and stow in convertible top compartment
 Close convertible top compartment lid
Fig. 14: Unlocking Convertible Top Compartment Lid

2006 BMW 650i
IMPORTANT: Convertible top compartment lid cannot be locked manually. Move vehicle at
low speed only.
Closing convertible top by hand:
 Unlock and open convertible top compartment lid

 Lift convertible top at main pillars out of convertible top compartment
 Bend fins and close convertible top compartment lid
 Lower front bow and fins (tension)
 Lock convertible top lock
Fig. 15: Unlocking Convertible Top Compartment Lid

54 34 ... REPAIR INSTRUCTIONS FOR HYDRAULIC SYSTEM OF CONVERTIBLE TOP AND

CONVERTIBLE TOP COMPARTMENT LID
1. Definitions of terms
HYDRAULIC SYSTEM OF CONVERTIBLE TOP CONVERTIBLE REFERENCE CHART

 Turn ignition lock to "0" position.
 E46c: Wait 15 seconds
Hydraulic system at
zero pressure E52: Wait 2 minutes Hydraulic system has no or only very
or low pressure
Untensioned state: E85: Emergency actuation or wait 2
minutes
E64: Wait 5 seconds.

Mechanical
actuation:  Convertible top is opened or closed Observe Point 3
2006 BMW 650i
actuation:  Always move convertible top with

aid of a second person
Even short-circuiting of lines is
Closed system:  All lines are connected possible""
 Open and close convertible top
several times (min. 3 times)
Function Test: refer to Operating Instructions
 Check fluid level in hydraulic unit;
if necessary, top up fluid
 Unfastening of quick-release
Hydraulic system cannot build up
Short circuit (E46c couplings
pressure
only):  Connection of supply and return Convertible top can be moved
lines
 Checking of convertible top Convertible top must be secured! Move
Function Test: function if possible on removed 2-3 times
convertible top
When the convertible top is installed, it
Convertible top  Convertible top fully open (folded is in the closed convertible top
stowed: together) compartment
2. When working on hydraulic system, observe the following

 Once it has been removed, the convertible top must be safely stowed or tensioned (e.g. with screw
clamps to work bench).
On some models, the special tool must be used.
The universal lever is required here.
 When the hydraulic system is open (unscrewing of lines, topping up of fluid, etc.), always provide
sufficient cloths to catch leak-off fluid.
Also provide an adherent protective cover to cover/protect fittings.
 Hydraulic system must be at zero pressure.

 E46c only: The disconnected supply and return lines to the convertible top can be connected to
each other (establish "short circuit"). The system is thereby closed again. The clutches are protected
against damage. The hydraulic system cannot build up a high pressure. The convertible top can be
moved.
 Disconnect or unscrew feed and return lines if possible at a later stage, when the convertible top is
stowed and untensioned (check fluid).
 Once the hydraulic system has been opened, first check the fluid level after completing the tasks
before carrying out a function test.
 After disconnecting the hydraulic lines from hydraulic components, do not move the convertible
2006 BMW 650i
 Piston rods must not be damaged (e.g. scratches). Even paint mist and welding spots are harmful.
When working in the vicinity of hydraulic cylinders, cover the cylinders with suitable materials.
If the hydraulic unit or the lines stay removed for an extended period of time, the bores on the

hydraulic unit and the hose connections must be sealed off (observe fitting instructions).
3. Mechanical operation of convertible top
 E46c: only with ignition switched off.
If lines are disconnected, connect them to each other if at all possible.
E52/E85: Emergency actuation

 In the event of repeated actuation, the system fluid is pumped into the supply tank of the hydraulic
unit. If hydraulic components are now replaced, there will be too much fluid in the system. This
may cause damage to the system in event of actuation. (Checking fluid level, see Points 4 and 5).
4. Check fluid level
 E46c: only when convertible top is stowed and convertible top compartment lid is closed.
E52, E85: only with convertible top closed.
See 54 34 ... Topping up/extracting fluid, checking fluid level

 Fluid level must be within the markings (circle/cross).
 Fluid is supplied with the repair kits (e.g. banjo bolts/seals, hoses, cylinders) and is available
separately).
5. Top up/extract fluid
 E46c: only when convertible top is stowed and convertible top compartment lid is closed.
E52, E85: only with convertible top closed.
E64: the hydraulic fluid does not have to be changed because the system is filled with life - time
fluid. Only the approved hydraulic fluid may be used in the event of leaks.
 See 54 34 ... Topping up/extracting fluid, checking fluid level
 Remove hydraulic unit without detaching lines.
 Fluid is supplied with the repair kits (e.g. banjo bolts/seals, hoses, cylinders) and is available
separately).
 Pour in fluid with bottle through filling orifice.
 Hydraulic unit must be removed if overfilled. Allow fluid to escape through filling orifice and
collect.
6. Bleeding hydraulic system
 E64: if there is a significant build - up of noise while the convertible top is moving, the convertible
top must be opened and closed several times. The hydraulic system is automatically bled in the
fluid reservoir in the process.
2006 BMW 650i
54 34 ... TOPPING UP/EXTRACTING FLUID, CHECKING FLUID LEVEL
NOTE: No changing of the hydraulic fluid necessary.
 The hydraulic fluid does not have to be changed because the system is filled with life-time fluid.
 Only the approved hydraulic fluid may be used in the event of leaks.
NOTE: All hydraulic cylinders must be completely extended.

Support convertible top compartment lid in service position . See 51 00 ...
Service position of convertible top compartment lid.

Checking fluid level:
Unfasten screws.
Installation:
Replace Torx screws and insert with Loctite.
Unclip front cover (1) for hydraulic unit.

2006 BMW 650i
Fig. 17: Uncliping Front Cover

Fluid level must be within the markings (arrow) when the unit is horizontal.
Fig. 18: Identifying Fluid Level Markings

Topping up fluid:
Align hydraulic unit horizontally.
Open fluid filler plug.
Pour in required amount of fluid from fluid bottle.
Installation:
Check fluid level in the meantime.
Pour in hydraulic fluid only up to marking on fluid reservoir.

2006 BMW 650i

IMPORTANT: Protect components and work area with suitable materials (e.g. cloths).
Extracting fluid:
Open fluid filler plug.
Tilt hydraulic unit and let fluid flow out or draw off with a suitable auxiliary apparatus.

54 34 001 CHECKING FUNCTION OF EH CONVERTIBLE TOP
Carefully close convertible top until rotary latch (1) has retracted by approx. 1/3 into striker.
Rotary latch (1) and journal (2) must close silently.
If necessary, adjust convertible top.
The convertible top is centered by the journal (2) as it retracts into the guide.
Close convertible top, open and then close again.
Check all line connections for fluid leaks.
If necessary, check fluid level.

2006 BMW 650i
Fig. 21: Identifying Rotary Latch And Journal

Function description (open/close):
Opening and closing of convertible top is only possible:
 when the side windows are slightly lowered

 when the rear window is completely lowered
 when the convertible top compartment base is lowered
 speed must be under 30 km/h
 rear lid must be closed
 outside temperature is between -10 °C and +80 °C
 hydraulic pump motor < or =90 °C
 from ignition lock position "R" (radio setting)
 while control switch in instrument panel is pressed
Fig. 22: Opening And Closing Of Convertible Top

2006 BMW 650i
In event of function problems:
 Check ambient conditions (e.g. convertible top compartment base, rear lid, rear window etc.)
 Perform diagnosis on convertible top (mechanical components, hydraulic components, sensors etc.)
 Perform emergency actuation
54 34 005 REMOVING AND INSTALLING/REPLACING HYDRAULIC UNIT FOR CONVERTIBLE

TOP DRIVE
 Support convertible top compartment lid in service position. See 51 00 ... Service position of convertible
top compartment lid.
 Remove side trim panel upper section . See 51 43 002 REMOVING AND INSTALLING REAR LEFT
OR RIGHT SIDE TRIM PANEL .
CAUTION: Hydraulic fluid may emerge from the disconnected lines and the open
connections on the hydraulic unit.
Protect components and work area with suitable materials (e.g. cloths).
Follow repair instructions for hydraulic system.
Do not fit hydraulic lines in kinked, crushed or transposed condition.
Unfasten screws.
Installation:
Clip hydraulic unit open.
Remove moulded part.

2006 BMW 650i
Fig. 23: Removing Moulded Part

Disconnect cable straps on left and right.
Installation:
Replace faulty cable straps.
Detach moulded part (1) from hydraulic lines and electrical cables.
Fig. 24: Removing Moulded Part

Left side of car:
Disconnect all cable straps.
Installation:
2006 BMW 650i
Feed out electrical cable.

Right side of car:
Unlock and disconnect upper plug connections (1).
Disconnect cable straps.
Installation:
Feed out electrical cable.
Fig. 26: Disconnecting Upper Plug Connections

2006 BMW 650i
Disconnecting hydraulic lines from drive hydraulics:
 Release screws and push lockplates (1) in direction of arrow.

 Detach hydraulic lines.
 Remove hydraulic unit.
Installation:
Hydraulic lines and connections are marked with numbers to prevent mix-ups.
Check fluid level or top up if necessary.
Fig. 27: Releasing Screws And Push Lockplates

54 34 006 REMOVING AND INSTALLING/REPLACING LEFT HYDRAULIC CYLINDER FOR

 Follow repair instructions for hydraulic system

 Support convertible top compartment lid in service position . See 51 00 ... Service position of
convertible top compartment lid.
connections on the hydraulic cylinder.
Release screw (1) and remove holder (2) for hydraulic lines.
2006 BMW 650i
Fig. 28: Identifying Screw And Holder

Raise locking clip (1) and detach cylinder from ball end.
Installation:
Hall sensor line must be tied with cable straps.
Fig. 29: Identifying Locking Clip

Disconnecting hydraulic lines from cylinder:
Open retainer (1) at bottom/top on cylinder with screwdriver.
Detach hydraulic lines (2).

2006 BMW 650i
IMPORTANT: Protect joints (lines and cylinder) against dripping fluid, e.g. with a cleaning
cloth.
Observe hose markings.
Left hydraulic cylinder only:
Release screw (3) and remove Hall sensor.
Installation:
Make sure metal angle is correctly installed under Hall sensor.
Fig. 30: Identifying Hall Sensor Screw

54 34 007 REMOVING AND INSTALLING/REPLACING RIGHT HYDRAULIC CYLINDER FOR

Removal is described in:
Removing left hydraulic cylinder for convertible top compartment lid.
54 34 008 REMOVING AND INSTALLING/REPLACING HYDRAULIC CYLINDER FOR LEFT

CLAMPING BAR

 Partially remove convertible top fabric until working area is accessible
2006 BMW 650i
Support convertible top compartment lid in service position. See 51 00 ... Service position of convertible top
compartment lid.

Removing hydraulic cylinder:
 Remove retaining ring (1).

 Slide locking clip (2) upwards.
 Detach ball sockets at sides.
 Feed out hydraulic cylinder.
Installation:
 Carry out operational check. See 54 34 001 Checking function of EH convertible top.
 Check convertible top settings. See 54 34 100 Adjusting convertible top .
 Check fluid level. See 54 34 ... Topping up/extracting fluid, checking fluid level .
Fig. 32: Identifying Retaining Ring And Locking Clip

2006 BMW 650i
Release screw and remove lockplate (1).
Tightening torque 54 34 12AZ. See SLIDE/TILT SUNROOF AND CONVERTIBLE TOP -

Detach locking clip (3).
Detach cable straps (2).
Installation:
Fig. 33: Identifying Locking Clip And Cable Straps

Detach hydraulic lines.
IMPORTANT: Protect joints (lines and cylinder) against dripping fluid, e.g. with a cleaning
cloth.
306.5 ± 2 mm hydraulic cylinder protected with net hose on delivery.

2006 BMW 650i
Fig. 34: Detaching Hydraulic Lines

54 34 009 REMOVING AND INSTALLING/REPLACING HYDRAULIC CYLINDER FOR RIGHT

CLAMPING BAR
Removing hydraulic cylinder for left clamping bar.
54 34 016 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT HYDRAULIC

CYLINDER FOR CONVERTIBLE TOP
 Remove EH convertible top

 Position EH convertible top on special tool and close
NOTE: The hydraulic cylinder is only accessible when the convertible top is removed
and closed.
If necessary, cut cable straps.
Installation:
Replace cable straps.

2006 BMW 650i
Fig. 35: Locating Cable Straps

Remove circlip.
Drive bearing pin through.
Fig. 36: Identifying Bearing Pin And Circlip

Slide hydraulic cylinder (1) forwards in direction (2) and feed out in direction (3).
2006 BMW 650i
Fig. 37: Sliding Hydraulic Cylinder

Replacing hydraulic cylinder:
IMPORTANT: Hydraulic fluid may emerge from the disconnected lines and the open
Remove retaining bracket (1).
Disconnect hydraulic line (2).
Fig. 38: Removing Retaining Bracket

Release screw (1).
Push retaining plate (2) up.
Disconnect hydraulic line (3).

2006 BMW 650i
Fig. 39: Identifying Retaining Plate And Screw

54 34 018 REMOVING AND INSTALLING/REPLACING CONVERTIBLE TOP COMPARTMENT
Support convertible top compartment lid in service position. . See 51 00 ... Service position of convertible top
compartment lid.

Unfasten screws.
Remove complete hydraulic unit (1) until screws of convertible soft top compartment are exposed.
2006 BMW 650i

Release screws all round.
Tightening torque 54 34 18AZ . See SLIDE/TILT SUNROOF AND CONVERTIBLE TOP -

Raise convertible top compartment slightly and move a little to left.
Unfasten plug connection and disconnect.
Lift out convertible top compartment toward top and front.
Fig. 42: Locating Convertible Compartment Screws

54 34 034 REMOVING AND INSTALLING/REPLACING COMPLETE HYDRAULIC SYSTEM FOR

CONVERTIBLE TOP

2006 BMW 650i
 Remove hydraulic cylinder for convertible top

 Remove hydraulic cylinder for convertible top compartment lid
 Remove hydraulic cylinder for clamping bar
NOTE: Hydraulic circuit remains closed during this operation.
Release Torx screws.
Installation:
If necessary, disconnect cable straps from hydraulic lines.
Remove hydraulic unit (1) with hydraulic system.

54 34 060 REMOVING AND INSTALLING/REPLACING BOWDEN CABLES FOR CONVERTIBLE

TOP COMPARTMENT LID LOCK
 Remove top side trim panel. See 51 43 002 REMOVING AND INSTALLING REAR LEFT OR
NOTE: Shown removed here for purposes of clarity.
Disconnect all cable straps on Bowden cable.
Installation:
2006 BMW 650i
Unscrew bolt (1).
Unclip Bowden cable from holder (2).
Disconnect cable.
Fig. 44: Uncliping Bowden Cable From Holder

Slacken nuts.
Disconnect cable.
Remove Bowden cable.
Installation:
Adjust convertible top compartment lid lock.

2006 BMW 650i
54 34 070 ADJUSTING LEFT OR RIGHT CONVERTIBLE TOP COMPARTMENT LID LOCK
NOTE: Prerequisite:
Following components are properly installed and adjusted:
 Convertible top compartment cover

 Seals
Striker (1) must immerse at distance (A) into rotary latch (2).
A = approx. 3 mm
Striker (2) is centered by the wedge shape of the convertible top compartment lid lock (1).
Fig. 46: Identifying Striker Distance

Distance (A) is adjusted via the Bowden cable on the kinematics box.
NOTE: If necessary, mark the position to ensure correct alignment during removal and
installation.
2006 BMW 650i
Fig. 47: Identifying Slacken Nuts

54 34 080 REMOVING AND INSTALLING LEFT OR RIGHT CONTROL ELEMENT
 Remove convertible top fastener. See 54 34 127 Removing and installing/replacing cowl panel trim
(convertible top fastener).
Lever out retaining bar (1) and detach ball socket (2).
Fig. 48: Removing Retaining Bar

Release retaining ring (1).
Detach control element (2) from pin.
Installation:
2006 BMW 650i
Fig. 49: Releasing Retaining Ring

54 34 085 ADJUSTING (TENSIONING) CONTROL ELEMENT
 Relieve tension on control element

 Close convertible top completely
Move a piece of paper between pin and guide in marked area (3).
Tension control element (1) by turning.
Tension control element (1) until contact can be felt between pin, paper and guide.
Remove paper and tension control element (1) by another 1/2 turn.
Tighten lock nut (2).
Fig. 50: Removing Paper And Tension Control Element

2006 BMW 650i
54 34 100 ADJUSTING CONVERTIBLE TOP
NOTE: Observe body gap dimensions for ideal adjustment of convertible top in relation
to body.
Convertible top fins must be vertical during the adjustment operation.
Convertible top is not screwed down during the adjustment operation.
2006 BMW 650i
Fig. 51: BMW Body Gap Dimensions (1 Of 3)


2006 BMW 650i

Height adjustment:
Turn adjusting sleeves (1) for height adjustment with special tool 54 3 000 . See SLIDE/TILT SUNROOF
AND CONVERTIBLE TOP - SPECIAL TOOLS .
1. Adjusting sleeves and retaining pins for height adjustment

2. Special tool
2006 BMW 650i
 Turn counterclockwise = lower convertible top

 Turn clockwise = raise convertible top
Longitudinal and lateral adjustment:
The elongated holes on the main bearing allow the convertible top to be adjusted in the longitudinal and lateral
directions.
Fig. 54: Turning Adjusting Sleeves

NOTE: After settling procedure, make sure there is a uniform gap between convertible
top (1) and convertible top compartment lid trim (2).
Gap 3 ± 2 mm
dimension
Fig. 55: Identifying Convertible Top Compartment Lid Trim

2006 BMW 650i
Fixing convertible top adjustment made:
Lock inner bolt and tighten down adjustment nut (1).
IMPORTANT: Before carrying out function checks, screw down convertible top.
Fig. 56: Locating Adjustment Nut

54 34 101 REMOVING AND INSTALLING COMPLETE EH CONVERTIBLE TOP
 Remove REMOVING AND INSTALLING REAR LEFT OR RIGHT SIDE TRIM PANEL .
 Remove outer REMOVING AND INSTALLING/REPLACING OUTER WINDOW CAVITY
COVER STRIP FOR DOOR WINDOW, REAR LEFT OR RIGHT .
 Remove convertible top compartment lid . Loosen screw (1). Unscrew bolt (2). Tightening torque, see 51
17 4AZ in SLIDE/TILT SUNROOF AND CONVERTIBLE TOP - TIGHTENING TORQUES .
Remove convertible top compartment lid with assistance of a second person upwards from hinge. Set
convertible top compartment lid down on a clean surface.
2006 BMW 650i
Fig. 57: Removing Convertible Top Compartment Lid

 Remove kinematics box
Before removing convertible top, mark position of main bearing in relation to body.
When installing convertible top, align main bearing to markings.
Fig. 58: Identifying Main Bearing Markings

Measure distance between retaining plate and main bearing for convertible top on left and right and if necessary
carry over measurement to new convertible top.
This roughly determines the longitudinal adjustment.
Installation:
If necessary, adjust distance for longitudinal alignment of convertible top.

2006 BMW 650i
Check gap dimensions. See Fig. 51Fig. 53.
Fig. 59: Identifying Distance Between Retaining Plate And Main Bearing
Lock threaded pin with internal Torx and release nuts.

Fig. 60: Locating Internal Torx Nut

NOTE: The right side is removed in the same way as the left side.
Disconnect cable straps (1) on left and right.
Installation:

2006 BMW 650i

Stow convertible top with assistance of a second person uniformly in convertible soft top compartment.
Fig. 61: Identifying Cable Straps And Screw

Release left and right screws (1).


Left side:
Unclip cable from retainers.

2006 BMW 650i
Detach cable straps (2).
Installation:
Replace faulty cable straps (2).
Unfasten plug connections (3) and disconnect.
Fig. 63: Locating Plug Connection And Cable Straps

Right side:
Unlock and disconnect upper and lower plug connections (1).
Installation:

2006 BMW 650i
Release screws (1) from retaining bracket on rear window module.

NOTE: Do not release retaining bracket on rollover protection - so as to ensure correct

installation of the rear window module.
Fig. 65: Identifying Retaining Bracket Screw

2006 BMW 650i
Fig. 66: Attaching Hook To Convertible Top Frame

NOTE: Carry out this part of the work with the assistance of two other persons.
Fit special tool 54 3 110 with supports (1).
Attach hook (2) to convertible top frame.
To lift out the convertible top uniformly, make sure the special tool is aligned parallel to the convertible top.
If necessary, adjust the height via the left and right threaded rods.
Check that supports and hook are securely seated.
Carefully lift out convertible top with lifting apparatus.
Measure and note down adjustment depth of all castle nuts.
Replacement:
Carry over adjustment depth of all castle nuts to new convertible top.
2006 BMW 650i
On reinstallation:
Check adjustment depth prior to installation.
After body repair work:
Adjust convertible top.
Fig. 67: Locating Castle Nuts

Installation:
Observe installation of kinematics box.
Carry out function check
Check gap dimensions. See 54 34 100 Adjusting convertible top.
54 34 120 REPLACING CONVERTIBLE TOP FABRIC
 Remove roofliner
Unfasten screws.
Feed rail (1) out of cowl panel seal.

2006 BMW 650i
Fig. 68: Locating Cowl Panel Seal Screws

Lift front convertible top fabric out of convertible top frame.
Fig. 69: Lifting Front Convertible Top Fabric Out Of Convertible Top Frame
Detach convertible top adhesive tab (1) from convertible top frame.
Installation:
Replace double-sided adhesive tape.
Unclip retainers and feed out tension cable (2).

2006 BMW 650i
Fig. 70: Identifying Convertible Top Adhesive Tab

Detach protective cover (1) from tensioning spring (2).
Disengage tensioning spring (2) and feed with tension cable (3) out of convertible top frame.
Installation:
Make sure protective cover is correctly positioned.
Risk of damage due to friction between convertible top fabric and tensioning spring.
Fig. 71: Identifying Tensioning Spring

Release Torx screws (1).
Installation:

2006 BMW 650i
Observe course of tightening straps. Turning not permitted.
Fig. 72: Identifying Torx Screws

Drill out rivets between seal (window guide).
Remove seal with rail and remove remnants of rivets.
Installation:
Because of larger rail depth, attach a nut as adapter between rivet and riveting pliers for riveting purposes.
IMPORTANT: Risk of damage to door window glass or to seal (window guide): Make sure
there are no parts protruding from rivet.
Rivet shank must be correctly torn off.
Fig. 73: Identifying Seal With Rail

Detach convertible top fabric from convertible top frame towards top.
2006 BMW 650i
1. Double-sided adhesive tape

2. Bow with convertible top cover
Installation:
Fig. 74: Detaching Convertible Top Fabric

Release screws (1) and detach convertible top fabric from convertible top frame.
Installation:
Fig. 75: Identifying Convertible Top Fabric Screw

Release Torx screw on left and right.
Installation:
2006 BMW 650i
Observe course of tightening straps. Turning not permitted.
Fig. 76: Identifying Torx Screw

NOTE: Marking tension cable fixture before releasing.
Release Torx screw.
Installation:
Turn tension cable fixture during installation into position (1) shown marked.
Replace Torx screw and insert with Loctite.

Fig. 77: Identifying Tension Cable Fixture

2006 BMW 650i
Drill out rivets between seal convertible top fabric.
Feed convertible top fabric with welt out of convertible top frame.
IMPORTANT: Risk of damage to body or to seal: Make sure there are no parts protruding
from rivet. Rivet shank must be correctly torn off.
Fig. 78: Identifying Seal Convertible Top Fabric Rivets

Release Torx screw (1).
Installation:
Replace Torx screws (1) and insert with Loctite.
Feed out front strap (2).
Fig. 79: Identifying Torx Screw

2006 BMW 650i
Remove convertible top fabric with threaded rods upwards out of convertible top frame.
Fig. 80: Removing Convertible Top Fabric

Feed convertible top fabric (1) with welt out of convertible top frame (2).
Fig. 81: Removing Convertible Top Fabric With Welt

Remove convertible top fabric.
Add final details to vehicle.
Installation:
Carry out function check.
Replacement only:
Position aluminum insert (2).

2006 BMW 650i
IMPORTANT: Adhesive area must be dry and free from dust and grease.
Once it has been cleaned, do not touch the adhesive area with bare hands.
Secure fabric tabs with double-sided adhesive tape on aluminum insert.
NOTE: User suitable backing as protection and to increase the contact pressure
surface.
Press fabric tabs onto aluminum rail with locking pliers (1).
Stick welt (3) onto convertible top fabric with double - sided adhesive tape.
Fig. 82: Identifying Locking Pliers And Stick Welt

54 34 127 REMOVING AND INSTALLING/REPLACING COWL PANEL TRIM (CONVERTIBLE

TOP FASTENER)
 Open convertible top partially until work area is accessible
Carefully raise seal (1) and expose screw (2).
Release screws (2).

2006 BMW 650i
Fig. 83: Identifying Seal And Screw

Unclip trip towards front (1) and remove towards bottom (2).
Installation:
If necessary, replace faulty clips.
Fig. 84: Uncliping Trip Front

54 34 130 REMOVING AND INSTALLING OR REPLACING HEADLINING IN CONVERTIBLE

TOP
 Remove cowl panel trim (convertible top fastener)

2006 BMW 650i

Release Torx screw (1) from front strap on left and right.
Installation:
Fig. 86: Locating Torx Screw

Convertible top rod (bow), front:
Unfasten screws.
2006 BMW 650i

Convertible top rod (bow), middle:
Unfasten screws.

Convertible top rod (bow), rear:
Unfasten screws.
2006 BMW 650i

Overview of front straps:

2006 BMW 650i
Course of front straps:
S1 through U1
S2 through U3, U4
SF through U3, U2
Release Torx screw from tension cable mounting (S2) on convertible top frame.
Release Torx screw from changeover lug (U1).
Installation:
Observe course of front straps.
Fig. 91: Identifying Torx Screws And Changeover Lug

Release Torx screws of changeover lugs (U2, U3, U4) for tension cable.
Release Torx screw from tension cable mounting (S1) on convertible top frame.
Installation:

2006 BMW 650i
Fig. 92: Identifying Torx Screws Of Changeover Lugs

Release Torx screw from tensioning spring (SF).
Feed out tension cables.
Installation:
Fig. 93: Identifying Torx Screw From Tensioning Spring (SF)

Installation:
Front strap (1) must be fitted in twisted condition.
Tension cable (2) must be above front strap (1), see Fig. 94.
2006 BMW 650i
Fig. 94: Identifying Front Strap And Tension Cable

Pull welt of roofliner (1) out of convertible top frame.
Release Torx screw (2).
Installation:

Pull welt of roofliner (1) out of convertible top frame.
Installation:
Make sure retainers are correctly seated on welt.
Remove roofliner from car.

2006 BMW 650i
Fig. 96: Pulling Welt Of Roofliner

54 34 138 REPLACING ALL RUBBER WINDOW SEALS ON CONVERTIBLE TOP FRAME
NOTE: Follow repair instructions for bonded seals.
Cowl panel seal:
Installation:
Replace Torx screws (1) and insert with Loctite.
Fig. 97: Pulling Welt Of Roofliner

Detach seal.
2006 BMW 650i
Fig. 98: Detaching Seal

Roof frame seal:
Release screws (1).
Installation:
Replace Torx screws.
Remove seal (2) with rail from outer side of roof frame.
Fig. 99: Identifying Seal With Rail

Rear seal:
Drill out rivets between seal (window guide).
Remove seal with rail and remove remnants of rivets.

2006 BMW 650i
Installation:
Because of larger rail depth, attach a nut as adapter between rivet and riveting pliers for riveting purposes.
IMPORTANT: Risk of damage to door window glass or to seal (window guide): Make sure
there are no parts protruding from rivet. Rivet shank must be correctly torn off.
Fig. 100: Locating Rivets Between Seal

NOTE: Marking tension cable fixture before releasing.
Release Torx screw.
Installation:
Turn tension cable fixture during installation into position (1) shown marked.
Replace Torx screw and insert with Loctite.

2006 BMW 650i
Fig. 101: Identifying Tension Cable Fixture

Release screws (1).
Pull welt (3) out of convertible top cover.
Remove seal (2).
Installation:
Stick welt (3) of seal in convertible top cover with cyanacrylate adhesive (fast-action adhesive).
Follow repair instructions for bonded seals.

Dust seal:
Detach seal (1) from fin.

2006 BMW 650i
Installation:
Follow repair instructions for bonded seals.

IMPORTANT: Incorrect bonding of the seals will result in leakage.
Replacement only:
Feed seal (2) out of rail (1) and replace seal.
Fig. 104: Identifying Seal And Rail

54 34 140 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT BASE PLATE
 Remove front roofliner trim.
Release screws (1).

2006 BMW 650i

Remove base plate.
Fig. 105: Identifying Base Plate Screw

54 34 159 REMOVING AND INSTALLING LEFT CONVERTIBLE TOP FASTENER
 Remove cowl trim panel. See 54 34 127 Removing and installing/replacing cowl panel trim
(convertible top fastener) .
Lever out retaining ring and detach ball socket (3).
NOTE: Do not misadjust control element.

If necessary, adjust (tension) control element.
Left convertible top fastener only:

2006 BMW 650i

Unfasten screws.
Installation:
Pull flex shaft (1) off drive.
Remove convertible top fastener.
Fig. 107: Identifying Flex Shaft

Ideal adjustment:
Convertible top must close flush with cowl panel.
Observe gap dimensions

2006 BMW 650i
Fig. 108: Identifying Convertible Top Flush With Cowl Panel

54 34 160 REMOVING AND INSTALLING RIGHT CONVERTIBLE TOP FASTENER
Removing left convertible top fastener.
54 34 205 REMOVING AND INSTALLING/REPLACING ALL HYDRAULIC LINES ON

CONVERTIBLE TOP
NOTE: The right side is removed in the same way as the left side.
Disconnect required cable straps.
Installation:
Replace cable straps.
Transposed lines are not permitted.
If necessary, feed out moulded part (1).

2006 BMW 650i
Fig. 109: Identifying Moulded Part

Convertible top hydraulics:
Fig. 110: Identifying Convertible Top Hydraulics Components

Disconnect corresponding hydraulic lines (1) from:
(2) Hydraulic cylinder for clamping bar

2006 BMW 650i
(3) Hydraulic cylinder for convertible top compartment lid
(4) Hydraulic cylinder for convertible top
(5) Hydraulic unit
IMPORTANT: Transposed lines are not permitted.
NOTE: Rod heads, hose outlet and connection fasteners can be turned as desired on
the cylinder and hydraulic unit!
54 34 250 REMOVING AND INSTALLING LEFT OR RIGHT TENSIONING BELT
 Partially remove convertible top fabric.
Fig. 111: Identifying Locking Pin And Screws

Release screws (1).

2006 BMW 650i
Open Velcro-type fastener in marked area.
Disengage locking pin (2) and remove tensioning belt.
Installation:
Make sure wiring harness is laid without kinks.
Make sure locking pin is correctly positioned in convertible top frame.
54 34 280 REMOVING AND INSTALLING/REPLACING REAR WINDOW MODULE
 Remove air outlet trim grill . See Fig. 128.

 Remove rear side trim panel
 Convertible top must be correctly adjusted
Open convertible top compartment lid until all hydraulic cylinders are extended.
compartment lid.
Fig. 112: Identifying Open Convertible Top Compartment Lid

Unlock and disconnect lower plug connection (1) on right side of vehicle.

2006 BMW 650i
Fig. 113: Identifying Lower Plug Connection

Release screws and set down hydraulic unit to one side.
Installation:
Fig. 114: Removing Torx Screws

NOTE: Leave retaining bracket screwed down on rollover protection.

Stop for adjusting rear window module.
Release screws (1).
Tightening torque 51 17 19AZ. See BODY EQUIPMENT - REPAIR INSTRUCTIONS - E63 .
Installation:
2006 BMW 650i
Fig. 115: Identifying Retaining Bracket Screws

Remove cover (2) on left and right.
Fig. 116: Identifying Cover And Screws

NOTE: Before releasing screws (2), mark position to ensure correct alignment during
installation.
Loosen screws (2).
Tightening torque 54 34 9AZ. See SLIDE/TILT SUNROOF AND CONVERTIBLE TOP - TIGHTENING
TORQUES .
Installation:
2006 BMW 650i
Replace all Torx screws and insert with Loctite.

Remove rear window module (1) from convertible top main bearing.
Installation:
Align rear window module to marking and adjust if necessary.
If necessary, adjust seal on convertible top compartment lid.
Fig. 118: Removing Rear Window Module

Adjusting rear window module:
IMPORTANT: Rear window will damage the seal during retraction if the pretension is too
high.
2006 BMW 650i
Allow rear window (1) to settle in seal (2) and tighten down screws of rear window module.
Fig. 119: Adjusting Rear Window Module

54 34 300 REMOVING AND INSTALLING/REPLACING REAR WINDOW
 Remove rear window module

 Remove seal for rear window
Unfasten screws.

Fig. 120: Locating screws

Slacken screws on left and right.

2006 BMW 650i

Disconnect left and right plug connections (2).
Fig. 121: Slacken Screws On Left And Right

Installation:
Adjust right grub screw to dimension A in relation to Hall sensor.
A = 1 mm
Calibrating rear window:
Rear window must be moved downwards (signal from Hall sensor - rear window at bottom).
This enables the convertible top module to determine the starting travel of the rear window travel sensor.
Fig. 122: Identifying Grub Screw Dimension

2006 BMW 650i
Check function.
WARNING: Power window unit has no anti-trapping mechanism.
54 34 305 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT

WINDOW GUIDE FOR REAR WINDOW
Seal (window guide) on convertible top fins:
Release screw (1).
Unscrew nuts (2).
Feed out convertible top fabric with threaded pins.
Replacement only:
Release screws (3).
Feed seal out of rail.

54 34 310 REMOVING AND INSTALLING/REPLACING SEAL FOR REAR

WINDOW
 Remove air outlet trim grill.

2006 BMW 650i
SUNROOF AND CONVERTIBLE TOP - TIGHTENING TORQUES . Remove panel at rear/front

for roll bar. Lever out trim (1) all round with special tool 00 9 317 and remove. Ribs (1) and guides (2) on
trim (3) must not be damaged.
Fig. 124: Removing Panel At Rear/Front For Roll Bar

Fig. 125: Lever Out Trim

2006 BMW 650i
Fig. 126: Ribs And Guides On Trim Must Not Be Damaged

Fig. 127: Levering Out Expander Rivets

Lever out expander rivets (1). Installation: If necessary, replace faulty expander rivets. Release screws
(1). Remove trim grill towards top.
2006 BMW 650i
Fig. 128: Removing Air Outlet Grill Trim Toward Top

Open convertible top compartment until all hydraulic cylinders are extended.
compartment lid.
Fig. 129: Identifying Convertible Top Compartment

Seal on rear window module:
Remove cover (2) on left and right.

2006 BMW 650i

Installation:
Detach seal towards top from rear window module.

54 34 315 REMOVING AND INSTALLING/REPLACING POWER WINDOW

UNIT (REAR WINDOW)
 Remove rear window

2006 BMW 650i
Disconnect cable straps and unclip guide tube for cable.
Release screws (1) and remove upper section for cable guide.
Remove complete power window unit with flex shafts.
Fig. 132: Identifying Cable Guide Screw

54 34 820 REMOVING AND INSTALLING KINEMATICS BOX

 Remove luggage compartment trim panels at left and right. See FLOOR/LUGGAGE/ENG COMP TR.
PANELS .
compartment lid.
Fig. 133: Identifying Open Convertible Top Compartment Lid

2006 BMW 650i
Release nut (1) through rear lid opening.
Fig. 134: Identifying Rear Lid Opening Nut

Release screws (1).
Remove kinematics box (2).
Fig. 135: Identifying Kinematics Box Screws

Replacement only:
 Disengage Bowden cable for unlocking convertible top

 Remove hydraulic cylinder for convertible top compartment lid
Adjusting kinematics box

2006 BMW 650i
NOTE: Kinematics box must not be at top dead center.
Insert screws (1).
It must still be possible to slide the kinematics box (2).
NOTE: This prevents the kinematics box from jamming.
Fig. 136: Identifying Kinematics Box Screws

Check Bowden cables for emergency release mechanism for ease of movement.
Pull kinematics box to bulkhead.
Tighten nut (1) to 0.5 Nm.
Close convertible top compartment lid via convertible top actuation.
NOTE: The kinematics box engages when the convertible top compartment lid is
closed.
Check Bowden cable for emergency release mechanism for tight seating.
Screw on nut (1) from luggage compartment.
Tightening torque 51 17 6AZ. See BODY EQUIPMENT - REPAIR INSTRUCTIONS .

2006 BMW 650i
Fig. 137: Identifying Luggage Compartment Nut

Fig. 138: Identifying Luggage Compartment Nut

Open convertible top compartment cover.
Tightening torque 51 17 06AZ. See BODY EQUIPMENT - REPAIR INSTRUCTIONS .

2006 BMW 650i
Fig. 139: Identifying Convertible Top Compartment Cover Screw

62 ROLL BAR, FOLDING

54 62 005 REMOVING AND INSTALLING/REPLACING ROLLOVER PROTECTION

When the actuators are electrically activated, there must be no persons
present in the vicinity of the rollover protection bars.
When a rollover protection bar is mechanically triggered, only one person
may be present underneath the protection bar.
IMPORTANT: When the actuators are activated, both rollover protection bars are
simultaneously triggered.
Trigger rollover protection bar.
 Stow convertible top in convertible top compartment (open) and support convertible top compartment lid
in service position . See 51 00 ... Service position of convertible top compartment lid.
 Disconnect plug connection for back-up antenna . See 65 20 150 REMOVING AND
INSTALLING/REPLACING BACK-UP ANTENNA .
 Remove air outlet trim grill. See Fig. 128.
 Remove ski bag
Unlock plug connection (1) on left and right and disconnect.

2006 BMW 650i

Unfasten screws and remove rollover bar from top.
Tightening torque 54 62 1AZ. See SLIDE/TILT SUNROOF AND CONVERTIBLE TOP - TIGHTENING
TORQUES .
NOTE: Carry out function check.
Fig. 141: Removing Rollover Bar Screw

54 62 500 TRIGGERING/RETRACTING ROLLOVER PROTECTION BARS (BMW DIAGNOSIS

SYSTEM)

When the actuators are electrically activated, there must be no persons
present in the vicinity of the rollover protection bars.
When a rollover protection bar is mechanically triggered, only one person
may be present underneath the protection bar.
2006 BMW 650i
IMPORTANT: Stow convertible top in convertible top compartment (open) and support rear
lid in service position. . See 51 00 ... Service position of convertible top
compartment lid.
When the actuators are activated, both rollover protection bars are
simultaneously triggered.
Triggering rollover protection bar:
NOTE: The rollover protection bar can be triggered mechanically if it fails to extend of
its own accord.
Triggering rollover protection bar mechanically:
Mechanical emergency release is performed through the luggage compartment.
 Remove panel for luggage compartment partition . See 51 47 140 REMOVING AND
INSTALLING/REPLACING PANEL FOR LUGGAGE COMPARTMENT PARTITION .
Insert L-shaped Allen key into opening on actuator.
Effect emergency release of rollover protection system by pressing.
Fig. 142: Inserting L-Shaped Allen Key Into Actuator

IMPORTANT: When retracting, make sure rollover protection bar snaps into place on lower
stop.
Slowly relieve load on rollover protection bar.
 Remove front air outlet grill . See Fig. 128.

2006 BMW 650i
Hold locking pawl (1) and press rollover protection bar (2) down as far as it will go until actuator is locked.
NOTE: Rollover protection bar must snap audibly into place!
Fig. 143: Pressing Rollover Protection Bar

90 TROUBLESHOOTING
54 90 ... TROUBLESHOOTING, AUTOMATIC CONVERTIBLE TOP
Fault Cause Movement Remedy
Convertible top does not Battery voltage is < 10.5 opening and closing Charge battery or run
open or close V engine
Outside temperature too opening and closing Set outside temperature
low or too high between -10 °C and +80 °
C
Hydraulic pump motor opening and closing hydraulic pump motor <
temperature too high or =90 °C
Terminal R"" not opening and closing Switch on terminal R"",
switched on check fuse terminal R""
Convertible top not opening and closing Emergency actuation
unlocked
Rear lid not closed opening and closing Close rear lid
Speed > 30 km/h opening and closing Slow vehicle down to
complete standstill
Convertible top opening and closing Lower convertible top
compartment not compartment
completely lowered
Rear window not lowered opening and closing Lower rear window
completely
2006 BMW 650i
Door windows not opening Lower door windows

lowered slightly
Fuses defective opening and closing Check fuses
Leads interrupted opening and closing Refer to diagnosis
Plug connections opening and closing Check plug connections,
interrupted repair if necessary
Control unit defective opening and closing Refer to diagnosis
Hall sensor fault opening and closing Refer to diagnosis
2005 BMW 645Ci
2004-05 STARTING & CHARGING SYSTEMS Starters - 645Ci
2004-05 STARTING & CHARGING SYSTEMS
Starters - 645Ci
DESCRIPTION
Bosch starter is a brush-type, series-wound electric motor with an overrunning clutch. Field frame carries pole
shoes and field coils, and is enclosed by commutator end frame and drive bushing. Armature shaft drive end
drives a reduction gear.
TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTING article in GENERAL INFORMATION.
CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle. See appropriate COMPUTER
RELEARN PROCEDURES article in GENERAL INFORMATION before
disconnecting battery. Obtain radio code card from customer. Note stored
stations and restore them after connecting battery. Stored settings of on-
board computer and clock will also be lost. All available cental keys must
be recoded for cars with first generation infrared transmitter locking
systems.
SOLENOID SWITCH
CAUTION: DO NOT turn cable lug while tightening down. There is a risk of a short
circuit to starter motor housing.
NOTE: Numbers in text apply to numbers in figures.
1. Turn off ignition. Remove starter. See STARTER .

2. Remove nut (1). See Fig. 1 . Remove cable lug (2).
3. Remove screws (1). See Fig. 2 .
4. Remove solenoid switch (1) and spring (2). See Fig. 3 . Unhook pin (3).
5. To install, reverse removal procedure. Check pin (3) for wear and apply grease. Tighten nut for cable lug
to specification. See TORQUE SPECIFICATIONS . Do NOT turn cable lug while tightening down.
2005 BMW 645Ci
Fig. 1: Removing Cable Lug

2005 BMW 645Ci
Fig. 2: Removing Solenoid Switch Screws

2005 BMW 645Ci
Fig. 3: Removing Solenoid Switch

STARTER
NOTE: Numbers in text apply to numbers in figures. For clarity, some figures are
shown on a removed engine.
1. Switch off ignition. Disconnect and cover battery negative terminal.

2. Remove reinforcement plate.
3. Release screw and nut. See Fig. 4 . Remove heat shield (1).
4. Remove nut (2). See Fig. 5 . Unlock plug (1) and remove.
5. Remove screws and pull release out of transmission mounting and remove. See Fig. 6 .
6. To install, reverse removal procedure. Check starter motor pinion and ring gear for damage. Tighten
fasteners to specification. See TORQUE SPECIFICATIONS .
2005 BMW 645Ci

2005 BMW 645Ci
Fig. 5: Removing Start Plug Connection

2005 BMW 645Ci
Fig. 6: Removing Starter Motor

STARTER SPECIFICATIONS
Torque Specifications
Reinforcement Plate-To-Front Axle Support/Engine Carrier (1) 41 (56)
INCH Lbs. (N.m)

Electrical Leads-To-Starter
5 mm 44 (5)
6 mm 62 (7)
8 mm 115 (13)
2005 BMW 645Ci
(1) Torque angle is 90 degrees plus 15 degrees.
WIRING DIAGRAMS
Fig. 7: Starter System Wiring Diagram (1 Of 2)

2005 BMW 645Ci
Fig. 8: Starter System Wiring Diagram (2 Of 2)

2006 BMW 650i
SUSPENSION Front - 650i, M6
SUSPENSION
Front - 650i, M6
00 ELECTRONIC CHASSIS ALIGNMENT

 Headaches
 Dizziness
 Stomach aches
 Vomiting
 Diarrhoea
 Cramps/fits
 Unconsciousness

First aid measures:
Danger of injury!

2006 BMW 650i
 Impaired sight

First aid measures:

Recycling:

2006 BMW 650i

contact points.
necessary.

points!

2006 BMW 650i



2006 BMW 650i


2. Steering gear
4. Control arm
6. Swivel bearing
7. Tie rod end
8. Tie rod
procedure:
Troubleshooting
1 Camber inside/toe-in outside the a. Screw connection not OK a. Check screw connections:
nominal value, adjustment of track Tie rod end to swivel
alignment possible b. Tie rod or journal of tie rod
end is deformed bearing Tie rod to power
steering gear Power steering
c. One or both tension struts gear to front axle carrier
is/are deformed
b. Replace tie rod, tension strut
d. Control arm deformed and swivel bearing
IMPORTANT:
If the journal of the tie rod
end is deformed, the
power steering gear must
2006 BMW 650i
also be replaced
c. Replace tension strut and

swivel bearing
d. Replace control arm, tension
strut and swivel bearing
2 Camber inside/toe-in outside the Powerful forces acting on Replace tie rods
nominal value, adjustment of track steering/front axle components Replace swivel bearing
alignment possible Replace power steering gear
Replace tension strut
3 Camber/toe-in outside the Powerful forces acting on front
nominal value, adjustment of track axle with distortion of:
alignment not possible
a) Screw connections a. Check screw connections,
b) Front axle support replace the relevant part if
c) See Pt. 1b) to d) necessary
f) Spring strut/piston rod
32 ... . OVERVIEW OF STEERING

2006 BMW 650i
Fig. 4: Identifying Steering Components (Except M Series)

2006 BMW 650i
Fig. 5: Identifying Steering Components (M Series)

1. Tie rod end / tie rod / gaiter

2. Power steering gear
3. Vane pump
4. Oil container
5. Steering spindle lower section
6. Sleeve
7. Steering column / electronic steering column lock
8. Overview of steering wheel/casing components
32 .. .. OVERVIEW OF STEERING WHEEL / CASING COMPONENTS / LOCK CYLINDER

2006 BMW 650i
Fig. 6: Identifying Steering Wheel/Casing Components

32 00 ... CHASSIS/WHEEL ALIGNMENT CHECK PROCEDURE
CHASSIS/WHEEL ALIGNMENT CHECK PROCEDURE

Check adherence
to test conditions
I
V
Position vehicle
on measuring
stand
I
V
Measure vehicle OK -> Carry out
ride height chassis/wheel
alignment check
2006 BMW 650i
measurement
without load
Read off setpoint
value in KDS
Tolerance -20 /
+40 mm per
wheel
permissible
Difference
between left /
right max. 10
mm permissible
Not OK / no data
I
V
Move vehicle
into normal
position
Introduce load
and measure ride
heights
Read off setpoint Not OK - >
value in KDS
Tolerance ± 10
mm per wheel
permissible
Difference
between left /
right max. 10
mm permissible
OK Check
I suspension for
V damage, repair
if necessary
Move vehicle <- Not OK
into design
position
Add/distribute
weights and
measure ride
heights
Read off setpoint
value in KDS
Tolerance ± 2
mm per wheel
2006 BMW 650i
Difference
between left /
right max. 2 mm
permissible
I
V
Carry out KDS
chassis/wheel
alignment check
with load up to
design position
32 00 ... GENERAL CHASSIS AND SUSPENSION DEFINITIONS
Fig. 7: Identifying Chassis And Suspension Definitions

32 00 ... GENERAL INFORMATION AND DEFINITIONS
Toe angle difference
a. Toe angle difference
D Center point of operating circle
The toe angle difference is the angle adjustment of the inner cornering wheel relative to the outer cornering
wheel when negotiating a curve. Steering is designed in such a way that angular position of wheels changes as
steering lock progresses.
A correctly adjusted toe angle difference produces equal values for left and right lock with consideration of
factory tolerances.
Toe angle difference provides information on corresponding operation of steering trapezoid for left or right
steering lock from center position.
2006 BMW 650i
Fig. 8: Identifying Toe Angle Difference

Camber
Inclination of the wheel from the perpendicular.
Fig. 9: Identifying Inclination Of Wheel From 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
2006 BMW 650i
Fig. 10: Identifying Toe

Caster
Is the inclination of the kingpin in the direction of travel viewed from the side. The line through the center point
of the spring strut support bearing and the control arm ball joint corresponds to the "kingpin".
Thanks to caster, wheels are pulled and not pushed. In a similar manner to king pin inclination, when driving in
curves or around corners, returning forces are reproduced to help return wheels to straight-ahead position.
Fig. 11: Identifying Caster Angle

Geometrical axis 1
Is the angle bisector from the total rear-wheel toe.
Front-wheel measurements are taken in reference to this axis.
Symmetrical axis 2
2006 BMW 650i
Fig. 12: Identifying Geometrical Axis 1 And Symmetrical Axis 2

Wheel offset
Angle by which one front wheel is displaced more towards front or rear than the other front wheel. The wheel
offset angle is positive when the right wheel is displaced towards the front and negative when it is displaced
towards the rear.
Fig. 13: Identifying Wheel Offset

Kingpin offset/scrub radius
Is the distance from the center of the wheel contact face to the intersection point of the kingpin extension. The
line through the center point of the spring strut support bearing and the control arm ball joint corresponds to the
"kingpin".
The scrub radius is influenced by camber, kingpin angle and wheel offset of the wheel rim.
2006 BMW 650i
Fig. 14: Identifying Kingpin Offset/Scrub Radius

32 00 ... IDENTIFICATION OF SUSPENSION WITHOUT LABEL
NOTE: If the front spring strut does not have a label for suspension identification, the
type of suspension can be identified from the part number in the Electronic
Parts Catalogue.
32 00 ... IDENTIFYING SUSPENSION FROM LABEL ON FRONT AXLE
NOTE: The type of suspension can be identified from the label on the spring
strut/shock absorber.
Label:
1. BMW part number

2. Type of suspension
 BA = Standard suspension (basic)
 SP = Sport suspension or rough road package

2006 BMW 650i
Fig. 15: Identifying Front Axle Label

 60BAX =E60, E61 AWD

 MSP = M Sport suspension
 CHL = China Long
 Option SA 815 = rough road package
In the case of "SP" identification, there is a further distinction between:
 Sport suspension without spacer ring (A)

 Rough road package with spacer ring (A) above the support bearing
Fig. 16: Identifying Spacer Ring

32 00 ... INFORMATION ON REPLACING STEERING GEAR AFTER ACCIDENT DAMAGE
Facts:
2006 BMW 650i
In the event of accidents or driving conditions similar to accidents, shocklike loads can cause different types of
damage to steering gears. When a steering gear is externally undamaged, it is sometimes only possible to
identify damage with great difficulty and with great effort. However, damage of this nature poses an
unacceptable risk to the vehicle because it can result in failure of the steering system.
Because of the disproportionate amount of effort involved, it is generally not sensible to check thoroughly all
the individual components of the steering gear and as an alternative it is necessary to take into account other
components which can be checked more easily.
Procedure:
The steering gear must be replaced if one or more of the following points apply:
A. Visible or noticeable damage to the steering gear

B. Unacceptable torque increase and jamming when the steering gear is turned from lock to lock (without
hydraulic assistance)
C. Permissible tolerances exceeded during axle/wheel alignment check (if necessary, include alignment
record with invoice / report)
D. Fire damage
E. Damage, permanent deformation or fractures to:
 Wheel rims in the event of a negative result from the wheel/axle alignment check
 Spring struts, steering knuckles, wheel carriers
 Control arms
 Compression or tension struts or stabilizer bars with this function
 Body-side screwing/bolting points for wheel guide/control components
 Front axle carrier
 Pitman arms
 Tie rods
 Steering gear fixtures
 Steering column
This guideline is binding for all accident repairs to BMW and MINI vehicles.
NOTE: If the steering gear replacement work which is required for safety reasons is
refused by the customer or an insurance company for cost reasons, a
memorandum to that effect must be drawn up and countersigned by the party
bearing the costs of the accident repair.
IMPORTANT: The vehicle's type approval will be invalidated whenever the function of any of
its safety components is compromised!
32 00 ... MOVING VEHICLE INTO DESIGN POSITION

2006 BMW 650i

 Version with air spring system:
 Remove ignition key
 Pull fuse for air supply unit control unit
 Add/distribute weights in area of spring struts until the vehicle ride height is within the tolerance (refer to
FRONT AXLE - RIDE HEIGHT - Technical Data).
Measure ride-level height of vehicle .
32 00 ... MOVING VEHICLE INTO NORMAL POSITION
 Check compliance with test conditions, bring vehicle to a stop if necessary.

 Version with air spring system: Carry out ride-height-calibration
 Check vehicle interior and luggage compartment (incl. luggage compartment recess) for load, unload
vehicle if necessary
 Introduce DIN load into vehicle. See FRONT AXLE - RIDE HEIGHT .
 Determine vehicle ride height
NOTE: If the vehicle ride height is not inside the tolerance (refer to Technical Data
article), the vehicle must be repaired (coil spring/leakage). See FRONT
AXLE - RIDE HEIGHT .
32 00 ... PERFORMING RIM RUNOUT COMPENSATION
NOTE: Rim runout compensation involves electronically recording the lateral runout of
the rim and the possible clamping error of the quick-clamping unit for one
wheel rotation and compensating the toe and camber for
measurement/alignment.
Raise body.
Perform rim runout compensation in accordance with equipment manufacturer's instructions.
Compress/deflect car.
32 00 ... TEST CONDITIONS FOR CHASSIS/WHEEL ALIGNMENT CHECK
Observe the following test conditions prior to the chassis/wheel alignment check:
2006 BMW 650i
2. Correct tread depth. The tread depth for each axle may differ from left to right by max. 3-4 mm.
3. Correct tire inflation pressure (see instruction plate on car).
4. Wheel bearing clearance OK
5. Steering backlash OK
6. Condition of suspension and shock absorbers OK
7. Cars with ride level control: Pull fuse of air supply unit so that there is no controlling down or up.
32 00 ... TROUBLESHOOTING AFTER WHEEL/CHASSIS ALIGNMENT CHECK ON FRONT

AXLE
Substandard roadholding, atypical noises, tires worn on one side and toe-in/camber values which deviate from
the nominal value are all indicators of damage to the suspension caused by road traffic accidents or similar
impacts.
To carry out proper repairs, you must follow the procedure set out in the troubleshooting table below depending
on the condition of the vehicle in question.
NOTE: If after chassis/suspension components have been replaced adjustment of

camber/track alignment is not possible, the vehicle must be placed on the
straightening bench.
Fault Cause Remedy
Toe deviation Tie rod end worn Replace tie rod end
Tie rod bent Replace tie rod
Rubber mount or ball joint of Replace control arms
control arm faulty
Rubber mount or ball joint/guide Replace rubber mount or guide
joint of tension strut faulty joint/both tension struts
Camber deviation Rubber mount or ball joint of Replace control arms
control arm faulty
Control arm deformed Replace control arms
Tension strut deformed Replace both tension struts
Spring strut/piston rod of shock Replace front spring strut
absorber deformed
Ride height between driver's and Check load, correct if necessary
passenger sides different Replace coil spring
Front axle carrier deformed Replace front axle carrier
2006 BMW 650i
NOTE: control arm faulty

Caster is defined by design and Control arm deformed Replace control arms
cannot be adjusted Rubber mount or ball joint/guide Replace rubber mount or guide
absorber deformed
passenger sides different Air spring strut: Carry out
rideheight-calibration
Check coil springs , replace if
necessary
Toe-difference angle deviation Tie rods not adjusted uniformly Adjust toe on left and right sides
Prerequisite: camber and caster are to same value
correct
Wheel-offset deviation Front axle carrier deformed Replace front axle carrier
Prerequisite: front wheels have Control arm deformed Replace control arms
equal single toe to geometrical
axis Tension strut deformed Replace both tension struts
32 00 ... TROUBLESHOOTING AFTER WHEEL/CHASSIS ALIGNMENT CHECK ON REAR AXLE
Substandard roadholding, atypical noises, tires worn on one side and toe/camber values which deviate from the
nominal value are all indicators of damage to the suspension caused by road traffic accidents or similar impacts.

straightening bench
Fault Cause Remedy
Camber/toe deviation Rubber mount/ball joint of control Replace control or guide arm
or guide arm faulty
Control or guide arm deformed Replace control or guide arm
Integral link deformed Replace integral link
faulty
Swinging arm deformed Replace swinging arm
2006 BMW 650i
faulty
Rear axle carrier deformed Replace rear axle carrier
Rear-wheel position incorrect Rear axle carrier laterally Replace rubber mount
displaced/skewed
32 00 150 KDS CHASSIS/WHEEL ALIGNMENT CHECK WITH LOAD UP TO DESIGN POSITION
Except M models:
IMPORTANT: Carry out chassis/wheel alignment with DIN load only:
A. If the technical preconditions for alignment with ride height input are not
in place
B. If, in spite of repairs having been carried out, the car's ride height between
the left and right sides is still outside the tolerance
C. If the vehicles in question have been involved in an accident
NOTE:  Read and comply with General information and definitions.

 Read and comply with General chassis definition.
 If necessary, prepare lifting platform.

 Drive vehicle onto lifting platform.
NOTE: The front and rear wheels must be positioned centrally on the rotary and
sliding plates.
 Remove locking pins from both rotary and sliding plates, align pickup using bubble level and activate
Fig. 17: Identifying Rotary And Sliding Plates

2006 BMW 650i
 Attach quick-clamping holder/quick-clamping unit to vehicle and remove clamping levers in area of front
wheels
 Attach pickup to quick-clamping holder/quick-clamping unit, align using bubble level and connect to
rotary plates
NOTE: When using quick-clamping units, perform RIM RUNOUT COMPENSATION

after installing the pickups.
Fig. 18: Identifying Quick-Clamping Holder/Quick-Clamping Unit

 If necessary, attach spoiler adapter.
Fig. 19: Identifying Spoiler Adapter

 If necessary, switch on chassis alignment system

 Enter customer and vehicle data
 Identify chassis version and select vehicle
2006 BMW 650i
 Enter tire pressure and tread depth

 Move vehicle into design position.
 Install brake tensioner.
Fig. 20: Identifying Brake Tensioner

E87, E90, E91, E92:

In order to avoid damaging the front side panel during the "Max. steering lock"
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.
 Perform input measurement in accordance with equipment manufacturer's instructions.

 Compare specified values with actual values.
Only in event of customer complaint (e.g. poor driving performance):
IMPORTANT: Do not remove screws/bolts (front axle carrier to engine carrier / body).
Slacken all screws/bolts (front axle carrier to engine carrier / body) and then retighten to specified torque.
Lowering front axle carrier. See 31 11 001 REPLACING FRONT AXLE CARRIER .
 If necessary, adjust front axle and rear axle

2006 BMW 650i
 Save and print out test record.

 Carry out steering angle sensor adjustment/adjustment for active front steering . See 61 31 996 Carry out
steering angle sensor adjustment.
 Insert locking pins into both rotary and sliding plates
 Remove chassis/wheel alignment system
32 00 155 KDS CHASSIS/WHEEL ALIGNMENT CHECK WITH RIDE-HEIGHT MEASUREMENT

WITHOUT LOAD
IMPORTANT: Do not carry out chassis/wheel alignment without load:
A. if the technical requirements for alignment with ride height input are not
in place
B. if, in spite of repairs having been carried out, the car's ride height between
C. if the vehicles in question have been involved in an accident


sliding plates.
2006 BMW 650i

 Enter customer and vehicle data.
 Measure and enter vehicle ride height . See FRONT AXLE - RIDE HEIGHT .
wheels
rotary plates



2006 BMW 650i

Fig. 24: Locating Brake Tensioner

E87, E90, E91, E92:


2006 BMW 650i
 Compare specified values with actual values

 Perform output measurement in accordance with equipment manufacturer's instructions.
 Carry out steering angle sensor adjustment/adjustment for active front steering . See 61 31 996 steering
angle sensor adjustment.
 Drive vehicle off lifting platform.
32 00 610 ADJUSTING TOE-IN AND CAMBER ON FRONT AXLE
 32 3 190
 32 4 150 . See STEERING & WHEEL ALIGNMENT - SPECIAL TOOLS .
IMPORTANT: Changes in axle geometry caused by accidents must under no circumstances

be rectified by camber adjustment!
NOTE: Camber and toe-in influence each other. Adjust the toe-in first in order to
simplify the adjustment procedure.
The centering pin may only be driven or twisted out if the camber is outside the
specified tolerance after toe adjustment.
Version with active front steering:
 Align steering wheel

 Set cumulative steering angle by means of the service function. Carry out initial operation/adjustment for
active front steering to "zero". See 32 10 005 Adjustment for active front steering.
 Install special tool 32 4 150 to secure active front steering power steering gear.
NOTE: If special tool 32 4 150 cannot be installed, the steering wheel must be
secured with the steering wheel arrester. The cumulative steering angle
must remain at "zero" during the adjustment operation.
2006 BMW 650i
IMPORTANT: Once the special tool 32 4 150 has been fitted, the cumulative steering angle
must still be set to "zero"!
 Check cumulative steering angle, reposition special tool 32 4 150 if necessary.
Version without active front steering:
If necessary, remove steering gear cover at side 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.
Fig. 25: Locating Markings On Cap And Steering Gear

Adjust toe-in:
Clean thread on tie rod.
Slacken clamping nut (2), gripping tie rod end (1) in the process.
Remove clamp (4).
Adjusting procedures:
1. Turn tie rod (3) to adjust toe-in to specified value.

2. Check cumulative steering angle; if necessary, set to "zero"
3. Check toe values; if necessary, repeat adjustment procedure
Tighten down clamping nut (2).

2006 BMW 650i
Fit clamp (4).
Fig. 26: Identifying Clamping Nut, Tie Rod End And Clamp
Adjusting camber:
M5:
Detach connecting cable (1) from front spring strut.
Fig. 27: Identifying Connector, Connecting Cable And Spring Strut Dome Cover

2006 BMW 650i
If necessary, remove protective cap.
Knock out centering pin (1) in downwards direction.
Clean wheel arch from below in area of support bearing with compressed air.
Slacken nut (2) approx. 1 to 1.5 turns.
Fig. 29: Identifying Centering Pin

Insert special tool 32 3 190 into wheel arch opening and over nut.
Replace nuts (3) and screw on but do not tighten down fully. Adjusting procedures:
1. Turn nut (4) in special tool 32 3 190 to adjust camber to specified value.
2006 BMW 650i
Tighten down nuts (3)

Replace nut (2) and tighten down.

After installation:
 Check directional stability of car; if necessary, repeat toe-in adjustment

 Version with active front steering: Remove special tool 32 4 150.
2006 BMW 650i
32 00 620 ADJUSTING REAR AXLE
NOTE: A camber change always means a toe change as well. The camber must
therefore be adjusted first.
Adjusting camber:
Replace nut (2) and tighten to 5 Nm.
Turn eccentric bolt (1) to adjust camber to setpoint value.
Tighten nut (2).
Fig. 32: Adjusting Camber

Adjusting toe:
Turn eccentric bolt (1) to adjust toe to specified value.
Tighten nut (2).

2006 BMW 650i
Fig. 33: Adjusting Toe

32 10 005 ADJUSTMENT FOR ACTIVE FRONT STEERING
NOTE: Adjustment of the active front steering must be carried out:

 Build date up to 03/2007: after the battery has been disconnected or
electrical plug connections on the steering column switch cluster have
been disconnected
 after replacement/programming or coding of the following components:
 Active front steering control unit
Connect vehicle to BMW diagnosis system.
Select and carry out initial operation/adjustment for active front steering under Service functions.
THE FOLLOWING WORK
2006 BMW 650i

 Release following screw/bolt connections:


2. Swinging arm
3. Integral link
5. Control arm
6. Guide arm
2006 BMW 650i
steering" and must not be carried out separately!

 after replacement / coding / programming of the following components:
 Fixture for switches of steering column / switch cluster / steering
angle sensor
 Dynamic Stability Control (DSC) control unit
 Control unit active anti-roll stabilization (ARS)
Connect vehicle to BMW diagnosis system or Software Service Station.
Select and carry out steering angle sensor adjustment under Service functions.
11 MECHANICAL STEERING
Facts:
Procedure:

D. Fire damage
2006 BMW 650i
 Control arms
 Pitman arms
 Tie rods
 Steering column
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
2006 BMW 650i
Fig. 35: Forces Created Cause Thrust Member (1) To Be Unloaded Against Spring (2)
IMPORTANT: Target status: steering must be free from play in all the mechanical
components (except for steering gear and tie rod)!
NOTE: For checking purposes, the steering gear must be pressurized by means of
electric or hydraulic assistance.
 Hydraulic steering assistance: Start engine.

 Electro-hydraulic steering assistance: Switch ignition on.
 Electric steering assistance: Turn on ignition and start engine.
32 11 100 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)!
 Remove tie rod end

 Remove underbody protective plate. See 51 47 490 REMOVING AND INSTALLING / REPLACING
FRONT UNDERBODY PROTECTION .
 If necessary, remove steering gear cover at side.
Clean tie rod.
Release band clamp (1) and ear clip (3).
Detach gaiter (2) from tie rod.
Installation:
Clean rack and check surface for damage (e.g. by corrosion).
Grease rack.
Clean tie rod and apply grease to taper.

2006 BMW 650i
Fig. 36: Identifying Gaiter, Clamp And Ear Clip

NOTE: This ensures that the gaiter is not rotated when the tie rod is rotated.
Replace and grease O-ring (1).
Fig. 37: Identifying O-Ring

After installation:

13 STEERING GEAR WITH SERVO UNIT

2006 BMW 650i
Procedure:

D. Fire damage
 Control arms
 Pitman arms
 Tie rods
 Steering column
32 13 006 BLEEDING POWER STEERING (VERSION WITH DYNAMIC DRIVE)

2006 BMW 650i

system.
ATF Automatic transmission fluid
CHF Pentosin CHF11S


2006 BMW 650i
Hydraulic fluid: BMW Service Operating Fluids . See STEERING - OPERATING FLUIDS .
3. Start engine
After filling:
 If necessary, carry out initial Dynamic Drive operation . See 37 10 001 INITIAL OPERATION
32 13 006 BLEEDING POWER STEERING UNIT

system.
CHF Pentosin CHF11S

2006 BMW 650i


3. Start engine
32 13 060 REMOVING AND INSTALLING/REPLACING POWER STEERING GEAR

system.
2006 BMW 650i
 Disconnect battery negative lead . See THE BATTERY .

 Remove tie rod end on both sides from swivel bearing . See 32 21 151 Replacing left or right tie rod.
 Replacement only: Remove tie rod end at both ends of tie rod . See 32 21 151 Replacing left or right tie
rod.
 Lower front axle support . See 31 11 001 REPLACING FRONT AXLE CARRIER .
 Remove left mounting bracket or engine mount from front axle carrier . See 11 FRONT SUB-FRAME .
 Engine mount with vacuum connection: Remove right engine mount from front axle carrier . See 11
FRONT SUB-FRAME .
IMPORTANT: Replacement only:

Banjo bolt (A) for pressure line (expansion hose) must be replaced by banjo
bolt with non-return valve (B).
Fig. 40: Identifying Banjo Bolt

If necessary, remove heat shield from power steering gear.
Release banjo bolts (1).
Disconnect pressure line and return line from power steering gear.
Installation:
2006 BMW 650i

TORQUES .

Release bolt (1).
Release nuts (2) and remove screws towards bottom.
Installation:
Replace screws and self-locking nuts.

TORQUES .
Fig. 42: Identifying Bolt And Nut

2006 BMW 650i
Disconnect plug connections (1-4).
Raise power steering gear and unclip wiring harness.

Move power steering gear to right and remove towards rear.
After installation:
 Fill And Bleed Hydraulic System . See 32 13 006 Bleeding power steering (version with Dynamic
Drive) or 32 13 006 Bleeding power steering unit.
 Perform chassis alignment check .
32 13 065 REMOVING AND INSTALLING/REPLACING ACTIVE FRONT STEERING POWER

STEERING GEAR
NOTE: Procedure is described in Removing and installing/replacing power steering

gear. See 32 13 060 Removing and installing/replacing power steering gear.
32 13 650 REMOVING AND INSTALLING/REPLACING EH CONVERTER FOR SERVOTRONIC
system.
2006 BMW 650i
 Remove reinforcement plate . See 11 FRONT SUB-FRAME .

 If necessary, remove heat shield.
Remove EH converter (3).
Installation:
Clean side return orifice with compressed air.
Align EH converter (3) to opening in power steering gear, press by hand into power steering gear up to stop,
insert screws (2) and tighten down.
Fig. 44: Identifying Plug Connection And EH Converter

After installation:
 Fill and bleed hydraulic system . See 32 13 006 Bleeding power steering (version with Dynamic Drive)
or 32 13 006 Bleeding power steering unit.
21 STEERING ARMS, TIE ROD, STEERING DAMPER

32 21 151 REPLACING LEFT OR RIGHT TIE ROD
2006 BMW 650i
After installation:

 Carry out steering angle sensor adjustment/adjustment for active front steering See 61 31 996 Carry out
Release nut; if necessary, grip brace at Torx socket.
Remove tie rod end from swivel bearing.
Installation:
Keep journal on tie rod end and bore hole in swivel bearing clean and free from grease.

TORQUES .

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:
2006 BMW 650i
Mount clamping ring (1).
Screw in tie rod end to measurement (A).
Fig. 46: Identifying Measurement "A"


TORQUES .
 Remove tie rod end from swivel bearing

 Remove gaiter from power steering gear and slide back
IMPORTANT: To avoid damage to rack and to suspension mounting, move rack in as far as
possible.
Unscrew tie rod with special tool 32 3 160 from rack of power steering gear and remove

2006 BMW 650i

Replace O-ring (1).
Grease rack and O-ring (1) (Refer to STEERING - OPERATING FLUIDS ).

Assembling new component with gaiter:
Release clamping nut (2).
Screw off tie rod end; if necessary, grip tie rod with open-end wrench.tie rod end
Remove clamping ring (1) and screw off clamping nut (2).
2006 BMW 650i
Screw clamping nut (2) onto tie rod.
Slide clamping ring (1) onto tie rod.
Determine measurement (A) on old part to simplify following adjustment of front axle.
Screw tie rod end onto tie rod to measurement (A).

TORQUES .
Fig. 49: Identifying Gaiter, Clamp And Clamping Ring

After installation:

32 41 ... INSTRUCTIONS FOR REMOVING AND INSTALLING EAR CLIPS
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.
2006 BMW 650i

The ear clip can be fitted not only axially but also radially after the hook fastener has been opened.
Fig. 51: Identifying Ear Clip

Attach hook fastener and press ear together with special tool 32 1 260.
2006 BMW 650i

Side cutter of special tool 32 1 260 can be used in areas which are difficult to access.

IMPORTANT: Gap (A) max. 1 mm!

2006 BMW 650i
Fig. 54: Identifying Gap

31 STEERING COLUMN
32 31 004 REMOVING AND INSTALLING / REPLACING UPPER SECTION OF STEERING
COLUMN TRIM
 Remove lower section of trim

Unclip steering column cover (1) from upper section of trim.
Fig. 55: Identifying Steering Column Cover

Unfasten screws.
2006 BMW 650i
Installation:
Replace expansion rivets.
Fig. 56: Locating Expansion Rivets

Bend upper section of trim on both sides outwards and remove towards top.
Fig. 57: Bending Upper Section Of Trim On Both Sides Outwards

Installation:
Locks (2) must engage in hooks (1) on both sides.

2006 BMW 650i
Fig. 58: Identifying Locks And Hooks

32 31 010 REMOVING AND INSTALLING/REPLACING FRONT SECTION OF STEERING

COLUMN COVER

 Remove steering wheel
Pull of front section.
Fig. 59: Pulling Front Section Of Steering Column Cover

Installation:
Locks (2) must engage in hooks (1).

2006 BMW 650i
Fig. 60: Identifying Lock And Hook

32 31 020 REMOVING AND INSTALLING / REPLACING LOWER SECTION OF STEERING

COLUMN TRIM
 Remove front section of trim

 Move steering column in "top" and "extended" position.
Release screw.
Unclip lower trim section (1).
If necessary, unclip wiring harness from lower trim section (1).
Installation:
Replace expansion rivet.

2006 BMW 650i
Fig. 61: Uncliping Lower Trim Section

Installation:

Unclip steering column cover (1) from lower section of trim (2).
Remove lower section of trim (2).
Fig. 63: Identifying Steering Column Cover And Lower Section Of Trim
32 31 070 REMOVING AND INSTALLING/REPLACING LOWER SECTION OF STEERING

SPINDLE
2006 BMW 650i
IMPORTANT: If the lower section of the steering spindle is separated from the power steering
gear/steering column, this can result in damage to the steering column switch
cluster when the steering wheel is turned!
If necessary, remove steering gear cover at side.
Release clamping screw.
Remove lower section of steering spindle from power steering gear.
Installation:
Recut thread.
Lower section of steering spindle can only be attached in one position to the power steering gear.
Replace clamping screw.
Clamping screw must rest in groove of power steering gear.

TORQUES .
Fig. 64: Removing Lower Section Of Steering Spindle From Power Steering Gear
IMPORTANT: Make sure universal joint is correctly seated.
Remove trim panel for pedal assembly. . See 51 45 185 REMOVING AND INSTALLING/REPLACING
TRIM FOR PEDAL ASSEMBLY .
When reinstalling lower section of steering spindle: mark installation position of universal joint in relation to
2006 BMW 650i
Switch on ignition.
Turn steering wheel approx. 45 °, hold securely and release clamping screw (1).
Turn steering wheel back and remove ignition key.
Remove lower section of steering spindle from steering column.
Installation:
Fig. 65: Identifying Clamping Screw

Recut thread.
Replace clamping screw (1).
Clamping screw (1) must rest in groove of steering column.

TORQUES .
After installation:
 Carry out steering angle sensor adjustment/adjustment for active front steering . See 61 31 996 Steering
 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

2006 BMW 650i
NOTE: Steering angle sensor is integrated in the steering column stalk fixture.
After installation:
 Replacement only: Carry out programming/coding

active front steering See 61 31 996 Carry out steering angle sensor adjustment.
 Version with active front steering: Teach in center position for power steering gear
32 31 087 REMOVING AND INSTALLING/REPLACING STEERING COLUMN LOCK
NOTE: Steering column lock can only replaced in vehicles from 09/2005 with electric
steering column adjustment.
 Remove trim panel for pedal assembly. See 51 45 185 REMOVING AND
NOTE: There is the risk of mixing up the 3-pin plug connection for the footwell light.
Release shear screws (2).
Remove steering column lock (3).
Installation:
Spherical side of shim must point to steering column lock (3).
Fig. 66: Identifying Plug Connection And Steering Column Lock

2006 BMW 650i
After installation:
 Carry out operational check.
32 31 090 REMOVING AND INSTALLING/REPLACING STEERING COLUMN
 Return steering to straight-ahead drive setting and remove ignition key

 Remove steering spindle lower section from steering column . See 32 31 070 Removing and
installing/replacing lower section of steering spindle.
 Remove upper section of trim.
Replacement only:
 Remove fixture for steering column stalk . See 61 31 006 REMOVING AND INSTALLING
(REPLACING) FIXTURE FOR STEERING COLUMN STALK .
Vehicles (up to 09/2005) with automatic transmissions:
Remove interlock cable (1) from steering lock positioning unit.
Fig. 67: Identifying Interlock Cable And Plug Connections

Version with electric steering column adjustment (build date up to 09/2004):

2006 BMW 650i
NOTE: As from 09/2004 the new steering column with a 6 -pin plug connection and
matching adapter lead will be supplied.
Installation:
Fit adapter lead between wiring harness and steering column.
Secure adapter lead to wiring harness.
Version with electric steering column adjustment:
Disconnect plug connection (3) from drive for electric steering column adjustment.
From 09/2005: Disconnect plug connection from electric steering column lock.
Remove interlock cable (1) from steering column.
Remove wiring harness (2) from steering column and place to one side.
Installation:
Replace ribbon cable from ignition starter switch to CAS control unit and secure with adhesive tape.
Fig. 68: Identifying Interlock Cable, Wiring Harness And Plug Connections
Mark installation position of steering column.
Unfasten screws.

2006 BMW 650i

Mark installation position of steering column (2).
Release screws (1).
Remove steering column (2) towards rear.
Installation:
Insert steering column (2) through instrument panel and insert screws (1).
Align steering column (2) by way of markings and tighten down screws (1).

TORQUES .
Fig. 70: Identifying Steering Column

2006 BMW 650i
Replacement:
 Remove ignition starter switch

 Remove ring antenna . See 61 31 020 REMOVING AND INSTALLING/REPLACING IGNITION
STARTER SWITCH .
 Remove lock cylinder . See 32 steering lock.
After installation:
 Perform function check:
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 lower section of steering spindle See 32 31 070 Removing and installing/replacing lower
section of steering spindle.
 Remove accelerator pedal module . See PEDAL ASSEMBLY - REPAIR .
Remove sleeve (1) from bulkhead.
Installation:
Coat sleeve from outside with silicone grease and insert from passenger compartment. Arrow (1) on sleeve must
point horizontally to left.
Check seating of sleeve in bulkhead, correct if necessary.

2006 BMW 650i
Fig. 71: Identifying Sleeve

After installation:
32 STEERING LOCK
32 32 050 REMOVING AND INSTALLING/REPLACING LOCK CYLINDER FOR STEERING LOCK
(UP TO 09/2005)

 Remove steering column trims.
STARTER SWITCH .
Insert ignition key into lock cylinder in such a way that release opening (arrow) remains accessible.
Turn ignition key to "R" position.
Insert special tool 32 3 110 into release opening (arrow) until end cap (1) is released.
Slide end cap (1) to ignition key and remove with special tool 32 3 110.
2006 BMW 650i
Fig. 72: Identifying End Cap And Special Tool 32 3 110

Installation:
Insert lock cylinder with end cap (1) and ignition key into steering column.
Align end cap (1) by way of opening to steering column and press into place.
Turn ignition key to "zero" position and remove.
32 32 170 REMOVING AND INSTALLING / REPLACING INTERLOCK CABLE (VEHICLES UP TO

09/2005)
 Remove trim for storage tray

 Remove front insert for ashtray
After installation:
 Adjusting interlock cable
Release screw (1) and remove bracket (2).
Move interlock cable (3) to left and then remove towards front.
If necessary, secure cord/cable to interlock cable (3).

2006 BMW 650i
Fig. 73: Identifying Interlock Cable And Bracket

IMPORTANT: Do not kink interlock cable.
Turn guide sleeve (1) through approx. 45°.
Remove interlock cable (2) from steering column and pull out.
If necessary, remove cord/wire from interlock cable (2).
Fig. 74: Turning Guide Sleeve

Replacement only:
Tie cord/wire to end of new interlock cable.
33 STEERING WHEEL
32 33 ... REPLACING DECORATIVE STRIP FOR SPORT STEERING WHEEL
2006 BMW 650i
The procedure is described in 61 31 220 REMOVING AND INSTALLING/REPLACING

MULTIFUNCTION STEERING WHEEL SWITCH (SPORTS STEERING WHEEL) .
32 33 001 REMOVING AND INSTALLING / REPLACING STEERING WHEEL
IMPORTANT: Do not twist volute spring cassette.

When installing, make sure that the driver on the rear side of the steering wheel
engages in the corresponding opening of the volute spring cassette.
 Remove airbag unit . See 32 34 020 Removing and installing / replacing airbag unit.
Move sport steering wheel to straight-ahead position.
Release screw (2) and remove steering wheel.
Secure volute spring cassette with adhesive tape against twisting.
Installation:
Make sure connecting lead(s) is/are correctly laid.

TORQUES .

Installation:
2006 BMW 650i
If necessary, move wheels to straight-ahead position.
Align steering wheel using grooved toothing (1) to steering column and attach.
Fig. 76: Identifying Grooved Toothing

Replacement:
Release screws (1).

Carefully remove multifunction steering wheel switches (2) with decorative
strip (3) and retaining plate (4) from steering wheel.
Disconnect plug connections on rear side.
Remove connecting lead from steering wheel.
Fig. 77: Identifying Multifunction Steering Wheel Switches, Decorative Strip And Retaining Plate
2006 BMW 650i
Installation:
Make sure connecting lead is correctly laid.
Make sure that decorative strip (3) and multifunction steering wheel switches (2) are correctly positioned on
steering wheel (guide pins must not be damaged).

TORQUES .
Version with Sequential Manual Gearbox/Transmission: remove shift paddles. See 61 31 104 REMOVING
AND INSTALLING/REPLACING SHIFTERS FOR SMG TRANSMISSION (BOTH) .
34 STEERING WHEEL FOR AIRBAG

32 34 020 REMOVING AND INSTALLING / REPLACING AIRBAG UNIT
WARNING: Observe the following instructions to avoid any risk of injury by the
airbag unit.
 Comply with safety regulations for handling components with gas generators.
 Do not exert any force on the airbag unit.
 Use only specified tools for releasing the airbag unit.
NOTE: Incorrect handling may result in triggering of the airbag unit and thereby cause
serious injury.
IMPORTANT: Steering wheel must be replaced if airbag unit has been triggered!
Follow procedure after airbag triggering.
Insert Torx screwdriver (T25) from below into opening on rear side of steering wheel until a spring resistance is
felt (approx. 3 cm).
Increase pressure on annular spring using Torx screwdriver (T25) until airbag unit is unlocked on both sides.
Installation:
Make sure connecting cables are correctly routed.

2006 BMW 650i
Snap airbag unit with uniform pressing force plane-parallel in direction of steering column shaft into steering
wheel.
Fig. 78: Identifying Torx Screwdriver (T25)


Airbag unit may only be set down with the airbag itself facing upwards.
Tilt airbag unit (1) towards front.
Disconnect plug connection (2) and remove airbag unit (1).
Fig. 79: Identifying Airbag Unit And Plug Connection


2006 BMW 650i
 Airbag module
 Side airbags
 Head airbag
 Knee airbag
 Belt pretensioner
1 Series: E81, E87

3 Series: E46, E90, E91, E92, E93
5 Series: E60, E61 from build date 09/2005
X3: E83
X5: E53, E70
Z4: E85, E86
further stripping work to ensure that all the gas generators in the vehicle are fired. The fired gas generators can
then be scrapped together with the vehicle.
Triggering failure
If correct triggering is not possible, the relevant components must (while observing the safety regulations for
If a triggering operation has failed:
 Disconnect the triggering device from the battery and

used parts.
2006 BMW 650i
Triggering of the gas generators may only be carried out by expert personnel and under the supervision of a
be observed.
triggering device with the corresponding cables.
inside the vehicle.
Wear protective goggles and protective gloves when handling a fired gas
generator!
The burning of solid fuel will heat up airbag unit - danger of burning
hands!
Wash skin with water after contact with fired gas generators!
1. Vehicles with central airbag control unit (all airbags, seat belt pretensioners, safety battery
terminal)
1. Expose airbag control unit.
2. Connect "Airbagmaster". For subsequent procedure, refer to operating instructions.
 Airbag module
 Side airbags
 Head airbag
 Knee airbag
 Belt tensioner
5 Series: E60, E61

6 Series: E63, E64
2006 BMW 650i
Firing failure

used parts.
Firing
be observed.
inside the vehicle.
generator!
hands!
1. Expose airbag plug connections.
2006 BMW 650i
and vehicle damage!

1. Regulations
The regulations quoted in the following refer to 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.


BMW Service.
2006 BMW 650i
1 minute for vehicles from 9/93


3. Transport
4. Storage
regulations.
 Components
 Satellite, vehicle center

2006 BMW 650i
 Procedure
 Rectify faults
Cables and plugs

Belt system
 Components
 Seatbelt height adjustment
 Procedure
Seats
 Components
 Seat
 Airbag module
 Procedure
2006 BMW 650i
Driver's airbag
 Components
 Airbag module
 Steering wheel
 Procedure
Passenger airbag
 Components
 Airbag module
 Procedure
 Components
 Airbag module
 Door trim panel
 Door in white
 Seat
 Procedure
Head airbag (AHPS)
 Components
 Airbag module
 Trim, A-pillar
2006 BMW 650i

 Bodyshell
 Procedure
Knee airbag
 Components
 Procedure
 Components
 Procedure
41 PUMP AND OIL SUPPLY


system.
2006 BMW 650i
CHF Pentosin CHF11S


3. Start engine
After filling:
2006 BMW 650i

system.
CHF Pentosin CHF11S


2006 BMW 650i

3. Start engine


2006 BMW 650i


2006 BMW 650i


32 41 ... INSTRUCTIONS FOR USING SPECIAL TOOL 32 4 000

 32 4 004
 32 4 005
 32 4 006
 32 4 011
 32 4 012
2006 BMW 650i
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:
Screw special tool 32 4 004 with M14 x 1.5 banjo bolt (1) and 2 sealing rings to special tool 32 4 000.
Screw special tool 32 4 011 onto pump and connect special tool 32 4 004.
Screw special tools 32 4 006 / 32 4 012 onto special tool 32 4 000 and connect pressure hose with M14 x 1.5
banjo bolts and 2 sealing rings.

2006 BMW 650i
Screw special tool 32 4 006 onto special tool 32 4 000 and connect pressure hose with M16 x 1.5 banjo bolt and
2 sealing rings.

Pressure hose connection to pump with M16 x 1.5 union screw:
Connect special tool 32 4 004 to pump.
Screw special tools 32 4 006 / 32 4 005 onto special tool 32 4 000 and connect pressure hose.

2006 BMW 650i
32 41 ... NOTES ON HYDRAULIC LINE WITH QUICK-CONNECT COUPLING
1. Quick-connect coupling with ID marking
Fig. 91: Identifying 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

2006 BMW 650i
Fig. 92: Identifying Quick-Connect Coupling With Indication Pins

Removing:
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 ... REPLACING LEVEL SWITCH FOR DYNAMIC DRIVE FLUID RESERVOIR

2006 BMW 650i
 Detach fluid reservoir from holder, raise and if necessary remove sideways
Turn level switch (2) through approx. 45° and remove towards bottom.
Fig. 93: Identifying Plug Connection And Level Switch

32 41 009 CHECKING FUNCTION OF POWER STEERING VANE PUMP
IMPORTANT: Prior to this check, first check all hose connections, the vane pump and the
power steering gear for leaks.
Adhere to the utmost cleanliness. Do not allow any dirt to enter the hydraulic
system.
After installation:
 Version with Dynamic Drive: If necessary, carry out initial operation for Dynamic Drive . See 37 10 001
INITIAL OPERATION WITH TEST RUN OF DYNAMIC DRIVE .

2006 BMW 650i
 Disconnect pressure line from vane pump
Version with Dynamic Drive only: . See 37 10 001 INITIAL OPERATION WITH TEST RUN OF
DYNAMIC DRIVE .
NOTE: 1. Pressure line to valve block (Dynamic Drive)

2. Pressure line to power steering gear
3. Suction line from fluid reservoir
Fig. 94: Identifying Pressure Lines And Suction Line

Connecting special tool:
Connect special tool 32 4 000 .
1. Connection, vane pump

2. Connection, power steering gear
2006 BMW 650i

Checking pump pressure:
1. Close valve (A).

2. Open valve (B).
3. Fill and bleed hydraulic system . See 32 13 006 Bleeding power steering (version with Dynamic Drive)
4. Start engine.
5. Heat hydraulic fluid to approx. 50 °C by moving steering wheel at increased engine speed.
6. Close valve (B) for max. 10 secs. and read off pressure.
7. Compare measured pressure with specified nominal pressure.
Fig. 96: Checking Pump Pressure

Replace vane pump if the nominal pressure is exceeded by more than 10 %.

2006 BMW 650i
Check belt tension if the nominal pressure is undershot by more than 10 %. Replace vane pump if belt
tension is OK.
32 41 033 REMOVING AND INSTALLING/REPLACING POWER STEERING PUMP FOR POWER

STEERING GEAR WITH ACTIVE FRONT STEERING (N62, N62TU)
system.
 Remove belt pulley
Release banjo bolt (1) and detach pressure line from power steering pump.
Release hose clamp (2) and detach suction line from power steering pump.
Installation:

TORQUES .
Fig. 97: Identifying Banjo Bolt And Hose Clamp

2006 BMW 650i

Variant (A) - build date up to 05/2004:

TORQUES .
Remove power steering pump (3) downwards.
Variant (B) - build date from 05/2004:
Release bolt (1) and nut (2).

TORQUES .

2006 BMW 650i
Fig. 99: Identifying Power Steering Pump

After installation:

STEERING GEAR WITH DYNAMIC DRIVE (N62, N62TU)

system.
NOTE: When replacing power steering pump:

Fluid reservoir must be replaced in event of metal abrasion, sluggish pump
shaft or increased wear!
The filter integrated in the fluid reservoir can only absorb a limited amount of
foreign particles. If the filter clogs, the hydraulic system can no longer be
sufficiently protected.
Metal abrasion is perceived in the fluid reservoir as metallically glittering
hydraulic fluid.
It is only necessary to replace the fluid reservoir because of leaks (e.g. at hose
connections) only in the event of the unavoidably high ingress of dirt.

2006 BMW 650i
 Relieve tension on drive belt and remove from power steering pump belt pulley
 Lower front axle carrier . See 31 11 506 LOWERING/RAISING FRONT AXLE CARRIER .
Unscrew nut (3).
Tightening torque, 32 41 6AZ. See STEERING AND WHEEL ALIGNMENT - TIGHTENING

TORQUES .
Release banjo bolt (2) and detach pressure line for Dynamic Drive from power steering pump.
Release banjo bolt (4) and disconnect pressure line for power steering from power steering pump.
Installation:

TORQUES .
Fig. 100: Identifying Banjo Bolts And Hose Clamp

Version with active front steering: Disconnect plug connection (1).
Release screw (2).

TORQUES .
2006 BMW 650i


TORQUES .

TORQUES .

2006 BMW 650i
After installation:
32 41 060 REMOVING AND INSTALLING/REPLACING VANE PUMP FOR POWER STEERING

(N62, N62TU)
NOTE: See 32 41 033 Removing and installing/replacing power steering pump for
power steering gear with active front steering (N62, N62TU).

(S85)
WARNING: Danger of poisoning if oil is ingested/absorbed through the skin! Risk of

injury if oil comes into contact with eyes and skin!
system. Close off pipe connections with plugs.
 Draw off and dispose of hydraulic fluid from fluid reservoir.

 Remove belt pulley.
 Remove drive belt tensioner. See 11 28 020 REPLACING TENSIONING DEVICE FOR
ALTERNATOR DRIVE BELT (S85)
 Remove front underbody protection. See 51 47 490 REMOVING AND INSTALLING / REPLACING
Unclip cover, release screw (1) and remove deflection pulley (2). Release screws (3, 4).
2006 BMW 650i
Fig. 103: Release Screw (1) And Remove Deflection Pulley (2)
Release banjo bolt (1) and detach pressure line (2) from vane pump. Installation: Replace all sealing rings.
Make sure pressure line is laid without tension and with sufficient spacing to adjoining components. Tightening
torque, see 32 41 3AZ in 32 41 PUMP AND OIL SUPPLY .
Fig. 104: Release Banjo Bolt (1) And Detach Pressure Line (2) From Vane Pump
Release hose clamp (3) and detach suction line (4) from vane pump. Release screws (5) and remove vane pump
towards front. Tightening torque, see 32 41 1AZ in 32 41 PUMP AND OIL SUPPLY .
After installation:
 Fill and bleed hydraulic system.

 Check pipe connections for leaks.
32 41 061 REPLACING POWER STEERING VANE PUMP

2006 BMW 650i
system.
After installation:
 Check function of vane pump

 Remove vane pump
Release screws (1).

TORQUES .
Remove belt pulley (2).
Installation:
Lettering on belt pulley (2) points forwards.
Fig. 105: Identifying Belt Pulley

2006 BMW 650i
POWER STEERING
NOTE: Carry out preliminary work as described in the document "Replacing drive belt".
Slacken screws (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.

TORQUES .

32 41 250 REMOVING AND INSTALLING/REPLACING FLUID RESERVOIR FOR POWER

STEERING
system.

2006 BMW 650i
 Draw off and dispose of hydraulic fluid from fluid reservoir

 M54, N52, N53, N54: Remove intake filter housing
Release screw (1).

TORQUES .
NOTE: If necessary, raise and/or turn fluid reservoir in order to gain better access to
hose clamps.
Remove hose clamps if necessary with special tool 32 1 260.
Disconnect suction and cooler return lines from fluid reservoir, check and if necessary replace.
Lift out fluid reservoir.
Fig. 107: Lifting Out Fluid Reservoir

After installation:
32 41 253 REMOVING AND INSTALLING / REPLACING FLUID RESERVOIR FOR POWER

STEERING WITH DYNAMIC DRIVE / ACTIVE FRONT STEERING

2006 BMW 650i
system.

Unscrew nuts.
Remove shims.
If necessary, remove bracket (not shown in illustration).
Installation:

TORQUES .
Fig. 108: Locating Self-Locking Nuts

plug connection and hose clamps.
If necessary, disconnect plug connection at level switch.
2006 BMW 650i
Fig. 109: Identifying Fluid Reservoir

Replacement:
If necessary, remove level switch.
After installation:
32 41 312 REPLACING SUCTION LINE WITH COOLER RETURN LINE FOR POWER STEERING
(S85)
system.

Remove right intake filter housing. See 13 71 020 REMOVING AND INSTALLING RIGHT
2006 BMW 650i
INTAKE FILTER HOUSING (S85) .
Loosen hose clamps (1). Disconnect suction line with cooler return line (2) from fluid reservoir. Installation:
Fig. 110: Loosen Hose Clamps And Disconnect Suction Line With Cooler Return Line
Expose suction line with cooler return line up to cutting line on engine carrier.
Release quick-connect coupling (1) and seal hydraulic lines with a suitable plug. Release ear clamp (2) and
remove suction line (3) with cooler return line in upward direction.
Installation: Make sure hydraulic line is laid without tension and with sufficient spacing to adjoining
components.
Fig. 111: Release Ear Clamp (2) And Remove Suction Line (3)
Remove alternator drive belt tensioner. See 11 28 020 REPLACING TENSIONING DEVICE FOR
2006 BMW 650i
ALTERNATOR DRIVE BELT (S85) . Expose suction line up to vane pump.
Release hose clamp (1) and detach suction line (2) from vane pump.
Fig. 112: Release Hose Clamp (1) And Detach Suction Line (2) From Vane Pump
After installation:

32 41 332 REPLACING PRESSURE LINE FOR POWER STEERING (S85)
WARNING: Danger to life! Secure engine in installation position to prevent it from

falling down. See 11 00 670 SECURING ENGINE IN INSTALLATION
POSITION (S85) .
system.

 Remove alternator drive belt. See 11 28 010 REPLACING ALTERNATOR DRIVE BELT (S85) .
 Remove pressure accumulator.
 Lower front axle support. See 31 11 506 LOWERING/RAISING FRONT AXLE CARRIER .
Release banjo bolt (1) and screw (3). Disconnect pressure line (2) from vane pump.
2006 BMW 650i
Installation: Replace all sealing rings. Screw in banjo bolt (3) and screw (1) (do not tighten down). Tighten
down first banjo bolt (1) and then screw (3).
Tightening torque, see 32 41 3AZ (banjo bolt) in 32 41 PUMP AND OIL SUPPLY . Tightening torque, see 32
41 5AZ (bolt) in 32 41 PUMP AND OIL SUPPLY .
Expose pressure line up to connection on power steering gear.
Fig. 113: Release Banjo Bolt (1) And Screw (3); Disconnect Pressure Line (2) From Vane Pump
Release banjo bolt (1) and remove pressure line (2). Installation: Replace all sealing rings. Make sure hydraulic
line is laid without tension and with sufficient spacing to adjoining components. Tightening torque, see 32 41
3AZ in 32 41 PUMP AND OIL SUPPLY .
Fig. 114: Release Banjo Bolt (1) And Remove Pressure Line (2)
2006 BMW 650i
After installation:

 Check engine oil level, correct if necessary.
32 41 351 REPLACING RETURN LINE FOR POWER STEERING (S85)

POSITION (S85) .
system.

Release quick-connect coupling and seal power steering cooler connection with a suitable plug. Installation:
Make sure hydraulic line is laid without tension and with sufficient spacing to adjoining components.
Fig. 115: Identifying Quick-Connect Coupling

Expose return line up to connection on power steering gear.
Release banjo bolt (1) and remove return line (2). Installation: Replace all sealing rings. Make sure hydraulic
2006 BMW 650i
Fig. 116: Release Banjo Bolt (1) And Remove Return Line (2)

43 ELECTRONIC POWER STEERING

32 00 ... TEACHING IN CENTER POSITION FOR POWER STEERING (ACTIVE FRONT
STEERING) (FROM 03/2007)
NOTE: Carry out the following procedure after disconnecting the battery or
disconnecting electrical plug connections on the steering column switch
cluster.
Turn on ignition, start engine if necessary.
Turn steering wheel twice in both directions to full lock.
IMPORTANT: If the indicator lamp does not go out after the ignition is turned on again, an
adjustment of the active front steering must be carried out.

2006 BMW 650i

been disconnected
32 43 010 REMOVING AND INSTALLING/REPLACING CONTROL UNIT FOR ACTIVE FRONT

STEERING
IMPORTANT: Use care to ensure protection against electrostatic damage.
 Remove right entrance strip . See 51 47 000 REMOVING AND INSTALLING/REPLACING

Fold back front right floor trim.
Remove kickplate in footwell in front of and next to control unit; if necessary, cut along specified lines with
knife and secure later with adhesive tape.
Release screws (1) and lay grounding cable to one side.
Installation:

TORQUES .
2006 BMW 650i

Disconnect plug connections and remove active front steering control unit.
Fig. 118: Removing Active Front Steering Control Unit

After installation:

 Only when replacing / programming / coding: adjustment for active steering
 Teach in mid-position for power steering
32 43 515 REMOVING AND INSTALLING/REPLACING YAW SENSOR FOR ACTIVE FRONT

STEERING
protection).
2006 BMW 650i
 Remove left front seat . See SEATS - REPAIR .

 Raise rear left floor trim in area of center console
Release screws (1).

TORQUES .

90 TROUBLESHOOTING
32 90 ... TROUBLESHOOTING ON STEERING
Observe troubleshooting on front axle and diagnosis help for steering (SI).
Fault Cause Remedy
Excessive steering wheel Screws at lower section of Replace screws and tighten down
play/steering wheel shake steering spindle to steering (refer to REMOVING AND
gear/steering column loose INSTALLING/REPLACING
LOWER SECTION OF STEERING
SPINDLE)
Bolt connection, universal Replace and tighten down bolts
joint/double joint, to lower
2006 BMW 650i
spindle/steering gear/steering
column loose
Journal of tie rod end deformed Replace steering gear and tie rod ends
Tie rod end worn Check steering gear rack; if necessary,
replace steering gear
Check tie rods, replace if necessary
Replace tie rod end
Steering gear rack damaged Replace steering gear
Refer to 90 TROUBLESHOOTING .
Steering wheel inclination Tie rod end worn Replace tie rod end
Front axle alignment incorrectly Carry out chassis/wheel alignment
adjusted check, adjust toe/track if necessary
2009 BMW 650i
SUSPENSION
Front - 650i, M6

 Headaches
 Dizziness
 Stomach aches
 Vomiting
 Diarrhoea
 Cramps/fits
 Unconsciousness

First aid measures:
Danger of injury!

2009 BMW 650i
 Impaired sight

First aid measures:

Recycling:

2009 BMW 650i

contact points.
necessary.

points!

2009 BMW 650i



2009 BMW 650i


2. Steering gear
4. Control arm
6. Swivel bearing
7. Tie rod end
8. Tie rod
procedure:
Troubleshooting
is/are deformed
IMPORTANT:
2009 BMW 650i
also be replaced

swivel bearing

2009 BMW 650i

2009 BMW 650i


3. Vane pump
4. Oil container
6. Sleeve

2009 BMW 650i


Check adherence
to test conditions
I
V
Position vehicle
on measuring
stand
I
V
alignment check
2009 BMW 650i
measurement
without load
Read off setpoint
value in KDS
Tolerance -20 /
+40 mm per
wheel
permissible
Difference
between left /
right max. 10
mm permissible
Not OK / no data
I
V
Move vehicle
into normal
position
Introduce load
and measure ride
heights
value in KDS
Tolerance ± 10
mm per wheel
permissible
Difference
between left /
right max. 10
mm permissible
OK Check
I suspension for
V damage, repair
if necessary
into design
position
Add/distribute
weights and
measure ride
heights
Read off setpoint
value in KDS
Tolerance ± 2
mm per wheel
2009 BMW 650i
Difference
between left /
right max. 2 mm
permissible
I
V
Carry out KDS
chassis/wheel
alignment check
with load up to
design position

factory tolerances.
2009 BMW 650i

Camber

Toe

2009 BMW 650i

Caster

Geometrical axis 1
Symmetrical axis 2
2009 BMW 650i

Wheel offset
towards the rear.

"kingpin".
2009 BMW 650i

Parts Catalogue.
Label:
1. BMW part number


2009 BMW 650i

 60BAX =E60, E61 AWD



Facts:
2009 BMW 650i
Procedure:

D. Fire damage
 Control arms
 Pitman arms
 Tie rods
 Steering column

2009 BMW 650i


Raise body.
2009 BMW 650i

AXLE
impacts.

Fault Cause Remedy
control arm faulty
control arm faulty
absorber deformed
2009 BMW 650i

absorber deformed
necessary
correct

straightening bench
Fault Cause Remedy
or guide arm faulty
faulty
2009 BMW 650i
faulty
displaced/skewed
Except M models:
in place


sliding plates.

2009 BMW 650i
wheels
rotary plates




2009 BMW 650i


E87, E90, E91, E92:



2009 BMW 650i


WITHOUT LOAD
in place


sliding plates.
2009 BMW 650i

wheels
rotary plates



2009 BMW 650i


E87, E90, E91, E92:


2009 BMW 650i

 32 3 190


2009 BMW 650i

Adjust toe-in:
Remove clamp (4).


2009 BMW 650i
Fit clamp (4).
Adjusting camber:
M5:

2009 BMW 650i

2009 BMW 650i


After installation:

2009 BMW 650i
Adjusting camber:
Tighten nut (2).

Adjusting toe:
Tighten nut (2).

2009 BMW 650i


been disconnected
THE FOLLOWING WORK
2009 BMW 650i



2. Swinging arm
3. Integral link
5. Control arm
6. Guide arm
2009 BMW 650i

angle sensor
Facts:
Procedure:

D. Fire damage
2009 BMW 650i
 Control arms
 Pitman arms
 Tie rods
 Steering column

backlash. 3 = Rack
2009 BMW 650i


Clean tie rod.
Installation:
Grease rack.

2009 BMW 650i


After installation:


2009 BMW 650i
Procedure:

D. Fire damage
 Control arms
 Pitman arms
 Tie rods
 Steering column

2009 BMW 650i

system.
CHF Pentosin CHF11S


2009 BMW 650i
3. Start engine
After filling:

system.
CHF Pentosin CHF11S

2009 BMW 650i


3. Start engine

system.
2009 BMW 650i

rod.
FRONT SUB-FRAME .


Installation:
2009 BMW 650i

TORQUES .

Release bolt (1).
Installation:

TORQUES .

2009 BMW 650i

After installation:

STEERING GEAR

system.
2009 BMW 650i

Installation:

After installation:

2009 BMW 650i
After installation:

Installation:

TORQUES .

Installation:
2009 BMW 650i


TORQUES .

possible.

2009 BMW 650i

Replace O-ring (1).

2009 BMW 650i

TORQUES .

After installation:


2009 BMW 650i


2009 BMW 650i



2009 BMW 650i

31 STEERING COLUMN
COLUMN TRIM


Unfasten screws.
2009 BMW 650i
Installation:


Installation:

2009 BMW 650i


COLUMN COVER


Installation:

2009 BMW 650i


COLUMN TRIM

Release screw.
Installation:

2009 BMW 650i

Installation:


SPINDLE
2009 BMW 650i
Installation:
Recut thread.

TORQUES .
2009 BMW 650i
Switch on ignition.
Installation:

Recut thread.

TORQUES .
After installation:

2009 BMW 650i
After installation:

Installation:

2009 BMW 650i
After installation:

Replacement only:


2009 BMW 650i
Installation:
Installation:
Unfasten screws.

2009 BMW 650i

Release screws (1).
Installation:

TORQUES .

2009 BMW 650i
Replacement:

STARTER SWITCH .
After installation:
components/wires
the process.
Installation:

2009 BMW 650i

After installation:
32 STEERING LOCK
(UP TO 09/2005)

STARTER SWITCH .
2009 BMW 650i

Installation:

09/2005)

After installation:

2009 BMW 650i


Replacement only:
33 STEERING WHEEL
2009 BMW 650i


Installation:

TORQUES .

Installation:
2009 BMW 650i

Replacement:
Release screws (1).

2009 BMW 650i
Installation:

TORQUES .

airbag unit.
serious injury.
Installation:

2009 BMW 650i
wheel.




2009 BMW 650i
 Airbag module
 Side airbags
 Head airbag
 Knee airbag
1 Series: E81, E87

3 Series: E46, E90, E91, E92, E93
X3: E83
X5: E53, E70
Z4: E85, E86
Triggering failure

used parts.
2009 BMW 650i
be observed.
inside the vehicle.
generator!
hands!
terminal)
 Airbag module
 Side airbags
 Head airbag
 Knee airbag
 Belt tensioner
5 Series: E60, E61

6 Series: E63, E64
2009 BMW 650i
Firing failure

used parts.
Firing
be observed.
inside the vehicle.
generator!
hands!
2009 BMW 650i
and vehicle damage!

1. Regulations
these regulations.


BMW Service.
2009 BMW 650i


3. Transport
4. Storage
regulations.
 Components

2009 BMW 650i
 Procedure
 Rectify faults
Cables and plugs

Belt system
 Components
 Procedure
Seats
 Components
 Seat
 Airbag module
 Procedure
2009 BMW 650i
Driver's airbag
 Components
 Airbag module
 Steering wheel
 Procedure
Passenger airbag
 Components
 Airbag module
 Procedure
 Components
 Airbag module
 Door trim panel
 Door in white
 Seat
 Procedure
Head airbag (AHPS)
 Components
 Airbag module
 Trim, A-pillar
2009 BMW 650i

 Bodyshell
 Procedure
Knee airbag
 Components
 Procedure
 Components
 Procedure


system.
2009 BMW 650i
CHF Pentosin CHF11S


3. Start engine
After filling:
2009 BMW 650i

system.
CHF Pentosin CHF11S


2009 BMW 650i

3. Start engine


2009 BMW 650i


2009 BMW 650i



 32 4 004
 32 4 005
 32 4 006
 32 4 011
 32 4 012
2009 BMW 650i


2009 BMW 650i
2 sealing rings.


2009 BMW 650i

Removing:
Assembly:

2009 BMW 650i

Removing:
Assembly:

2009 BMW 650i

system.
After installation:

2009 BMW 650i
DYNAMIC DRIVE .



2009 BMW 650i

1. Close valve (A).

2. Open valve (B).
4. Start engine.


2009 BMW 650i
tension is OK.

system.
Installation:

TORQUES .

2009 BMW 650i


TORQUES .

TORQUES .

2009 BMW 650i

After installation:


system.

hydraulic fluid.

2009 BMW 650i
Unscrew nut (3).

TORQUES .
Installation:

TORQUES .

Release screw (2).

TORQUES .
2009 BMW 650i


TORQUES .

TORQUES .

2009 BMW 650i
After installation:

(N62, N62TU)

(S85)


2009 BMW 650i
After installation:


2009 BMW 650i
system.
After installation:

Release screws (1).

TORQUES .
Installation:

2009 BMW 650i
POWER STEERING
Slacken screws (1)
Installation:

TORQUES .


STEERING
system.

2009 BMW 650i

Release screw (1).

TORQUES .
hose clamps.

After installation:


2009 BMW 650i
system.

Unscrew nuts.
Remove shims.
Installation:

TORQUES .

2009 BMW 650i

Replacement:
After installation:
(S85)
system.

2009 BMW 650i
components.
2009 BMW 650i
After installation:


POSITION (S85) .
system.

2009 BMW 650i
2009 BMW 650i
After installation:


POSITION (S85) .
system.


2009 BMW 650i


cluster.

2009 BMW 650i

been disconnected

STEERING

Installation:

TORQUES .
2009 BMW 650i


After installation:


STEERING
protection).
2009 BMW 650i

Release screws (1).

TORQUES .

90 TROUBLESHOOTING
Fault Cause Remedy
SPINDLE)
2009 BMW 650i
column loose
Replace tie rod end
2006 BMW 650i
SUSPENSION
Front - 650i, M6

 Headaches
 Dizziness
 Stomach aches
 Vomiting
 Diarrhoea
 Cramps/fits
 Unconsciousness

First aid measures:
Danger of injury!

2006 BMW 650i
 Impaired sight

First aid measures:

Recycling:

2006 BMW 650i

contact points.
necessary.

points!

2006 BMW 650i



2006 BMW 650i


2. Steering gear
4. Control arm
6. Swivel bearing
7. Tie rod end
8. Tie rod
procedure:
Troubleshooting
is/are deformed
IMPORTANT:
2006 BMW 650i
also be replaced

swivel bearing

2006 BMW 650i

2006 BMW 650i


3. Vane pump
4. Oil container
6. Sleeve

2006 BMW 650i


Check adherence
to test conditions
I
V
Position vehicle
on measuring
stand
I
V
alignment check
2006 BMW 650i
measurement
without load
Read off setpoint
value in KDS
Tolerance -20 /
+40 mm per
wheel
permissible
Difference
between left /
right max. 10
mm permissible
Not OK / no data
I
V
Move vehicle
into normal
position
Introduce load
and measure ride
heights
value in KDS
Tolerance ± 10
mm per wheel
permissible
Difference
between left /
right max. 10
mm permissible
OK Check
I suspension for
V damage, repair
if necessary
into design
position
Add/distribute
weights and
measure ride
heights
Read off setpoint
value in KDS
Tolerance ± 2
mm per wheel
2006 BMW 650i
Difference
between left /
right max. 2 mm
permissible
I
V
Carry out KDS
chassis/wheel
alignment check
with load up to
design position

factory tolerances.
2006 BMW 650i

Camber

Toe

2006 BMW 650i

Caster

Geometrical axis 1
Symmetrical axis 2
2006 BMW 650i

Wheel offset
towards the rear.

"kingpin".
2006 BMW 650i

Parts Catalogue.
Label:
1. BMW part number


2006 BMW 650i

 60BAX =E60, E61 AWD



Facts:
2006 BMW 650i
Procedure:

D. Fire damage
 Control arms
 Pitman arms
 Tie rods
 Steering column

2006 BMW 650i


Raise body.
2006 BMW 650i

AXLE
impacts.

Fault Cause Remedy
control arm faulty
control arm faulty
absorber deformed
2006 BMW 650i

absorber deformed
necessary
correct

straightening bench
Fault Cause Remedy
or guide arm faulty
faulty
2006 BMW 650i
faulty
displaced/skewed
Except M models:
in place


sliding plates.

2006 BMW 650i
wheels
rotary plates




2006 BMW 650i


E87, E90, E91, E92:



2006 BMW 650i


WITHOUT LOAD
in place


sliding plates.
2006 BMW 650i

wheels
rotary plates



2006 BMW 650i


E87, E90, E91, E92:


2006 BMW 650i

 32 3 190


2006 BMW 650i

Adjust toe-in:
Remove clamp (4).


2006 BMW 650i
Fit clamp (4).
Adjusting camber:
M5:

2006 BMW 650i

2006 BMW 650i


After installation:

2006 BMW 650i
Adjusting camber:
Tighten nut (2).

Adjusting toe:
Tighten nut (2).

2006 BMW 650i


been disconnected
THE FOLLOWING WORK
2006 BMW 650i



2. Swinging arm
3. Integral link
5. Control arm
6. Guide arm
2006 BMW 650i

angle sensor
Facts:
Procedure:

D. Fire damage
2006 BMW 650i
 Control arms
 Pitman arms
 Tie rods
 Steering column

backlash. 3 = Rack
2006 BMW 650i


Clean tie rod.
Installation:
Grease rack.

2006 BMW 650i


After installation:


2006 BMW 650i
Procedure:

D. Fire damage
 Control arms
 Pitman arms
 Tie rods
 Steering column

2006 BMW 650i

system.
CHF Pentosin CHF11S


2006 BMW 650i
3. Start engine
After filling:

system.
CHF Pentosin CHF11S

2006 BMW 650i


3. Start engine

system.
2006 BMW 650i

rod.
FRONT SUB-FRAME .


Installation:
2006 BMW 650i

TORQUES .

Release bolt (1).
Installation:

TORQUES .

2006 BMW 650i

After installation:

STEERING GEAR

system.
2006 BMW 650i

Installation:

After installation:

2006 BMW 650i
After installation:

Installation:

TORQUES .

Installation:
2006 BMW 650i


TORQUES .

possible.

2006 BMW 650i

Replace O-ring (1).

2006 BMW 650i

TORQUES .

After installation:


2006 BMW 650i


2006 BMW 650i



2006 BMW 650i

31 STEERING COLUMN
COLUMN TRIM


Unfasten screws.
2006 BMW 650i
Installation:


Installation:

2006 BMW 650i


COLUMN COVER


Installation:

2006 BMW 650i


COLUMN TRIM

Release screw.
Installation:

2006 BMW 650i

Installation:


SPINDLE
2006 BMW 650i
Installation:
Recut thread.

TORQUES .
2006 BMW 650i
Switch on ignition.
Installation:

Recut thread.

TORQUES .
After installation:

2006 BMW 650i
After installation:

Installation:

2006 BMW 650i
After installation:

Replacement only:


2006 BMW 650i
Installation:
Installation:
Unfasten screws.

2006 BMW 650i

Release screws (1).
Installation:

TORQUES .

2006 BMW 650i
Replacement:

STARTER SWITCH .
After installation:
components/wires
the process.
Installation:

2006 BMW 650i

After installation:
32 STEERING LOCK
(UP TO 09/2005)

STARTER SWITCH .
2006 BMW 650i

Installation:

09/2005)

After installation:

2006 BMW 650i


Replacement only:
33 STEERING WHEEL
2006 BMW 650i


Installation:

TORQUES .

Installation:
2006 BMW 650i

Replacement:
Release screws (1).

2006 BMW 650i
Installation:

TORQUES .

airbag unit.
serious injury.
Installation:

2006 BMW 650i
wheel.




2006 BMW 650i
 Airbag module
 Side airbags
 Head airbag
 Knee airbag
1 Series: E81, E87

3 Series: E46, E90, E91, E92, E93
X3: E83
X5: E53, E70
Z4: E85, E86
Triggering failure

used parts.
2006 BMW 650i
be observed.
inside the vehicle.
generator!
hands!
terminal)
 Airbag module
 Side airbags
 Head airbag
 Knee airbag
 Belt tensioner
5 Series: E60, E61

6 Series: E63, E64
2006 BMW 650i
Firing failure

used parts.
Firing
be observed.
inside the vehicle.
generator!
hands!
2006 BMW 650i
and vehicle damage!

1. Regulations
these regulations.


BMW Service.
2006 BMW 650i


3. Transport
4. Storage
regulations.
 Components

2006 BMW 650i
 Procedure
 Rectify faults
Cables and plugs

Belt system
 Components
 Procedure
Seats
 Components
 Seat
 Airbag module
 Procedure
2006 BMW 650i
Driver's airbag
 Components
 Airbag module
 Steering wheel
 Procedure
Passenger airbag
 Components
 Airbag module
 Procedure
 Components
 Airbag module
 Door trim panel
 Door in white
 Seat
 Procedure
Head airbag (AHPS)
 Components
 Airbag module
 Trim, A-pillar
2006 BMW 650i

 Bodyshell
 Procedure
Knee airbag
 Components
 Procedure
 Components
 Procedure


system.
2006 BMW 650i
CHF Pentosin CHF11S


3. Start engine
After filling:
2006 BMW 650i

system.
CHF Pentosin CHF11S


2006 BMW 650i

3. Start engine


2006 BMW 650i


2006 BMW 650i



 32 4 004
 32 4 005
 32 4 006
 32 4 011
 32 4 012
2006 BMW 650i


2006 BMW 650i
2 sealing rings.


2006 BMW 650i

Removing:
Assembly:

2006 BMW 650i

Removing:
Assembly:

2006 BMW 650i

system.
After installation:

2006 BMW 650i
DYNAMIC DRIVE .



2006 BMW 650i

1. Close valve (A).

2. Open valve (B).
4. Start engine.


2006 BMW 650i
tension is OK.

system.
Installation:

TORQUES .

2006 BMW 650i


TORQUES .

TORQUES .

2006 BMW 650i

After installation:


system.

hydraulic fluid.

2006 BMW 650i
Unscrew nut (3).

TORQUES .
Installation:

TORQUES .

Release screw (2).

TORQUES .
2006 BMW 650i


TORQUES .

TORQUES .

2006 BMW 650i
After installation:

(N62, N62TU)

(S85)


2006 BMW 650i
After installation:


2006 BMW 650i
system.
After installation:

Release screws (1).

TORQUES .
Installation:

2006 BMW 650i
POWER STEERING
Slacken screws (1)
Installation:

TORQUES .


STEERING
system.

2006 BMW 650i

Release screw (1).

TORQUES .
hose clamps.

After installation:


2006 BMW 650i
system.

Unscrew nuts.
Remove shims.
Installation:

TORQUES .

2006 BMW 650i

Replacement:
After installation:
(S85)
system.

2006 BMW 650i
components.
2006 BMW 650i
After installation:


POSITION (S85) .
system.

2006 BMW 650i
2006 BMW 650i
After installation:


POSITION (S85) .
system.


2006 BMW 650i


cluster.

2006 BMW 650i

been disconnected

STEERING

Installation:

TORQUES .
2006 BMW 650i


After installation:


STEERING
protection).
2006 BMW 650i

Release screws (1).

TORQUES .

90 TROUBLESHOOTING
Fault Cause Remedy
SPINDLE)
2006 BMW 650i
column loose
Replace tie rod end
2005 BMW 645Ci
2004-05 SUSPENSION Steering & Wheel Alignment - Repair Instructions - E63
2004-05 SUSPENSION
Steering & Wheel Alignment - Repair Instructions - E63
ELECTRONIC CHASSIS
32 .... OVERVIEW OF STEERING
Fig. 1: Identifying Steering Components

2005 BMW 645Ci

NOTE: Adjustment of the active front steering must be carried out

 after the battery has been disconnected or electrical plug connections on the steering column switch
cluster have been disconnected
 AL control unit
Select and carry out adjustment for active front steering under Service functions.

2005 BMW 645Ci
Fig. 2: Identifying Front Axle + Steering: Wheel/Chassis Component



2. Steering gear
4. Control arm
6. Swivel bearing
7. Tie rod end
8. Tie rod

2005 BMW 645Ci
Fig. 3: View Of Toe Specification

a Toe angle difference

2005 BMW 645Ci
factory tolerances.
2005 BMW 645Ci
Camber

2005 BMW 645Ci
2005 BMW 645Ci
Fig. 5: Identifying Inclination Of The Wheel From The Perpendicular

Toe

Measurement is performed in "straight-ahead mode".

Caster
2005 BMW 645Ci
Fig. 7: Identifying Caster

Geometrical axis 1
Symmetrical axis 2
2005 BMW 645Ci
Center line running through front and rear axles.
Fig. 8: View Of Geometrical Axis

Wheel offset
Angle by which one front wheel is displaced more towards front or rear than the other front wheel.
2005 BMW 645Ci
Fig. 9: View Of Wheel Offset

"kingpin".
2005 BMW 645Ci
Fig. 10: View Of Kingpin Offset/Scrub Radius

Parts Catalogue.
32 00 ... MOVE VEHICLE INTO NORMAL POSITION

2005 BMW 645Ci

 Introduce DIN load into vehicle
 Determine vehicle ride height, refer to RIDING HEIGHT ADJUSTMENT
NOTE: If the vehicle ride height is not inside the tolerance, the vehicle must be repaired
(coil spring/leakage).

 Add/distribute weights until the vehicle ride height is within the tolerance, refer to RIDING HEIGHT
ADJUSTMENT .
Measure ride-level height of vehicle
THE FOLLOWING WORK
2005 BMW 645Ci
Fig. 11: View Of Rear Axle Wheel/Chassis Alignment



2. Swinging arm
3. Integral link
5. Control arm
6. Traction strut
2005 BMW 645Ci
SUSPENSION ASSIGNMENT VIA OPTIONAL EXTRAS

Standard Low-slung sport Rough road
Optional extra suspension suspension package
OE225 Lack of sport x
suspension
OE226 Sport suspension x
OE330 Sport package x
OE337 M sport package x
OE338 M sport package x
II
OE768 Club sport x
OE815 Rough road x
package
32 00 ... TROUBLESHOOTING ON FRONT AXLE (WHEEL / CHASSIS ALIGNMENT CHECK)
Substandard roadholding, atypical noises, tyres worn on one side and toe-in/camber values which deviate from
impacts.
Also comply with the guidelines for repairs to the power steering gear necessitated by an accident.

straightening bench
REPLACED ADJUSTMENT OF CAMBER/TRACK

Fault Cause Remedy
Tie rod end worn Replace tie rod end
Rubber mount or ball joint of
Toe deviation Replace control arms
control arm faulty
Rubber mount or ball Replace rubber mount or
joint/guide joint of tension guide joint/both tension
strut faulty struts
control arm faulty
strut faulty struts
2005 BMW 645Ci

Spring strut/piston rod of
Replace front spring strut
shock absorber deformed
Camber deviation Check load, correct if
Ride height between driver's necessary
and passenger sides different
Replace coil spring
control arm faulty
strut faulty struts
Caster deviation
Spring strut/piston rod of
NOTE: Replace front spring strut
shock absorber deformed
Caster is defined by design and cannot
be adjusted Front axle carrier deformed Replace front axle carrier
Check load, correct if
necessary
Ride height between driver's Air spring strut: Carry out
and passenger sides different rideheight calibration
Check coil springs, replace
if necessary
Toe-difference angle deviation Prerequisite: Tie rods not adjusted Adjust toe on left and right
camber and caster are correct uniformly sides to same value
Wheel-offset deviation Prerequisite: front Front axle carrier deformed Replace front axle carrier
wheels have equal single toe to geometrical Control arm deformed Replace control arms
32 00 ... TROUBLESHOOTING ON REAR AXLE (WHEEL/CHASSIS ALIGNMENT CHECK)
Substandard roadholding, atypical noises, tyres worn on one side and toe/camber values which deviate from the

straightening bench
TROUBLESHOOTING ON REAR AXLE (WHEEL/CHASSIS ALIGNMENT CHECK)

Fault Cause Remedy
2005 BMW 645Ci
Rubber mount/ball joint of control or guide arm Replace control or guide

faulty arm
Replace control or guide
Control or guide arm deformed
arm
Camber/toe deviation Integral link deformed Replace integral link
Rubber mount of swinging arm faulty Replace swinging arm
Rubber mount of rear axle carrier faulty Replace rubber mount
Rear-wheel position
Rear axle carrier laterally displaced/skewed Replace rubber mount
incorrect
32 00 150 STANDARD CHASSIS / WHEEL ALIGNMENT WITH DIN LOAD
NOTE:  Read and comply with General information and definitions, refer to 32 00 ...
GENERAL INFORMATION AND DEFINITIONS.
 Read and comply with General chassis definition, refer to 32 00 ...
GENERAL CHASSIS AND SUSPENSION DEFINITIONS.
 Read and comply with notes on Chassis allocation via optional extra, refer
to 32 00 ... SUSPENSION ASSIGNMENT VIA OPTIONAL EXTRAS.
 Read and comply with More detailed information on chassis alignment
system (Beissbarth).
 If necessary, switch on chassis alignment system.
 Move vehicle into design position
 Enter tyre pressure and tread depth
 Attach quick clamping holder/quick clamping unit to vehicle and remove
clamping levers in area of front wheels
 Attach pickup to quick clamping holder/quick clamping unit, align using
bubble level and connect to rotary plates
 Remove locking pins from both rotary plate, align pickup using bubble
level and activate
IMPORTANT: E87, 90: In order to avoid damaging the front side panel during the "Max.
2005 BMW 645Ci
steering lock" 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.

 Compare specified values with actual values, refer to WHEEL ALIGNMENT SPECIFICATIONS .
IMPORTANT: Do not remove bolts (front axle carrier to engine carrier / body)!
Slacken all bolts (front axle carrier to engine carrier / body) and then retighten to specified torque

 Carry out steering angle sensor adjustment/adjustment for active front steering, refer to 32 10 005
ADJUSTMENT FOR ACTIVE FRONT STEERING.
 Version with Active Cruise Control: carry out fine adjustment
32 00 155 CHASSIS / WHEEL ALIGNMENT WITHOUT LOAD
NOTE:  Read and comply with General information and definitions, refer to 32 00 ...
GENERAL INFORMATION AND DEFINITIONS.
 Read and comply with General chassis definition, refer to 32 00 ...
GENERAL CHASSIS AND SUSPENSION DEFINITIONS.
 Read and comply with notes on Chassis allocation via optional extra, refer
to 32 00 ... SUSPENSION ASSIGNMENT VIA OPTIONAL EXTRAS.
 Read and comply with More detailed information on chassis alignment
system (Beissbarth).
 Check compliance with test conditions, bring vehicle to a stop if
necessary.
2005 BMW 645Ci
 If necessary, switch on chassis alignment system.

 Enter tyre pressure and tread depth
 Measure and enter vehicle ride height
 Attach quick clamping holder/quick clamping unit to vehicle and remove
clamping levers in area of front wheels
 Attach pickup to quick clamping holder/quick clamping unit, align using
bubble level and connect to rotary plates
 Remove locking pins from both rotary plate, align pickup using bubble
level and activate
IMPORTANT: E87, 90: In order to avoid damaging the front side panel during the "Max.
steering lock" 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.

 Compare specified values with actual values, refer to WHEEL ALIGNMENT SPECIFICATIONS .
IMPORTANT: Do not remove bolts (front axle carrier to engine carrier / body)!
Slacken all bolts (front axle carrier to engine carrier / body) and then retighten to specified torque

 Version with Active Cruise Control: carry out fine adjustment
2005 BMW 645Ci
 32 3 190
 32 4 150

After installation:
 Set cumulative steering angle by means of the service function "Carry out initial operation/adjustment for
active front steering" to "zero".
NOTE: If the special tool 32 4 150 cannot be installed, make sure during camber
or toe adjustment that the cumulative steering angle remains at "zero".
 Align steering wheel and secure with steering wheel arrester.
Adjusting toe-in/toe angle difference:
Remove clamp (4).
2005 BMW 645Ci

Fit clamp (4).
Fig. 12: Adjusting Tie Rod End

Adjusting camber:
M5:

2005 BMW 645Ci
Fig. 13: Unclipping Connecting Cable From Spring Strut Dome Cover
If necessary, unclip spring strut dome cover (2) from front cross strut.
2005 BMW 645Ci
Fig. 14: Unclipping Spring Strut Dome Cover From Front Cross Strut

2005 BMW 645Ci
Fig. 15: Knocking Out Centering Pin

Replace nuts (3) and screw on but do not tighten down fully.
2005 BMW 645Ci
Fig. 16: Turning Nut (4) In Special Tool 32 3 190 To Adjust Camber

3. Check camber values; if necessary, repeat adjustment procedure

2005 BMW 645Ci
Fig. 17: Identifying Nut (2)

Adjusting camber:
Tighten nut (2).

2005 BMW 645Ci
Tightening torque 165 Nm.
Fig. 18: Turning Eccentric Bolt Adjust Camber Setpoint Value

Adjusting toe:
Tighten nut (2).
Tightening torque 65 Nm.

2005 BMW 645Ci
Fig. 19: Turning Eccentric Bolt To Adjust Toe To Specified Value

MECHANICAL STEERING GEAR

 Remove tie rod end, refer to 32 21 151 REPLACING LEFT OR RIGHT TIE ROD.
 Remove underbody protective plate refer to 51 47 490 REMOVING AND INSTALLING /
REPLACING FRONT UNDERBODY PROTECTION and 51 47 491 REMOVING AND
2005 BMW 645Ci
Clean tie rod.
Fig. 20: Releasing Band Clamp And Ear Clip

Installation:
Grease rack.

2005 BMW 645Ci
Fig. 21: Replacing And Grease O-Ring

After installation:

32 13 060 REMOVING AND INSTALLING / REPLACING POWER STEERING GEAR
system.
After installation:
2005 BMW 645Ci
 Fill and bleed hydraulic system, refer to 32 13 006 BLEEDING POWER STEERING UNIT.
 Version with Dynamic Drive: If necessary, carry out initial Dynamic Drive operation
 Move engine into installation position

 Draw off and dispose off hydraulic fluid from fluid reservoir Observe country-specific waste-disposal
regulations
 Replacement only: Remove tie rod end at both ends of tie rod
Release banjo bolts (1, 4).
Version with Servotronic: Disconnect plug connection on Servotronic converter.
Disconnect pressure line (2) and return line (3) from power steering gear.
If necessary, remove hydraulic lines with bracket from power steering gear/front axle carrier.
2005 BMW 645Ci
Fig. 22: Disconnecting Pressure Line And Return Line From Power Steering Gear
Installation:
Replacement only: Replace banjo bolt (A) for pressure line with banjo bolt with non-return valve (B).
2005 BMW 645Ci
Fig. 23: Identifying Banjo Bolt (A) For Pressure Line With Banjo Bolt With Non-Return Valve (B)
Lower front axle support.
Remove left engine mount/mounting bracket from front axle carrier.
Release screw (1).

2005 BMW 645Ci
Fig. 24: Removing Left Engine Mount/Mounting Bracket From Front Axle Carrier
Installation:
Unlock and disconnect plugs (1...4).

2005 BMW 645Ci
Fig. 25: Raising Power Steering Gear And Wiring Harness


STEERING GEAR
NOTE: Procedure is described in 32 13 060 REMOVING AND INSTALLING / REPLACING

POWER STEERING GEAR.
STEERING GEAR WITH SERVO UNIT

2005 BMW 645Ci
After installation:

 Remove tie rod end, refer to 32 21 151 REPLACING LEFT OR RIGHT TIE ROD.
 Remove underbody protective plate, refer to 51 47 490 REMOVING AND INSTALLING /
REPLACING FRONT UNDERBODY PROTECTION and 51 47 491 REMOVING AND
Clean tie rod.
Fig. 26: Identifying Band Clamp

2005 BMW 645Ci
Grease rack.
Fig. 27: Replacing And Grease O-Ring

system.
After filling:
 Version with Dynamic Drive: Carry out initial Dynamic Drive operation, refer to 37 10 001 INITIAL
2005 BMW 645Ci
 Thoroughly clean fluid reservoir and its immediate surroundings

 Open and remove fluid reservoir cap
CHF Pentosin CHF11S
Fig. 28: Identifying Power Steering Unit

1. Topping up when engine stationary:

2005 BMW 645Ci
2. Bleeding:
 Start engine.
 Turn steering wheel twice each as far as left and right lock.
3. Oil level check with engine off:

 Check fluid level
 If necessary, top up hydraulic fluid to "MAX" level
4. Check:
32 13 060 REMOVING AND INSTALLING / REPLACING POWER STEERING GEAR
system.
 Move engine into installation position

 Draw off and dispose off hydraulic fluid from fluid reservoir Observe country-specific waste-disposal
regulations
 Replacement only: Remove tie rod end at both ends of tie rod
Release banjo bolts (1, 4).
Version with Servotronic: Disconnect plug connection on Servotronic converter.
Disconnect pressure line (2) and return line (3) from power steering gear.
If necessary, remove hydraulic lines with bracket from power steering gear/front axle carrier.
2005 BMW 645Ci
Fig. 29: Disconnecting Pressure Line And Return Line From Power Steering Gear
Installation:
Replacement only: Replace banjo bolt (A) for pressure line with banjo bolt with non-return valve (B).
2005 BMW 645Ci

Lower front axle support.
Remove left engine mount/mounting bracket from front axle carrier.
Release screw (1).

2005 BMW 645Ci
Fig. 31: Removing Lower Front Axle Support

Installation:
Unlock and disconnect plugs (1...4).

2005 BMW 645Ci
Fig. 32: Raising Power Steering Gear And Unclip Wiring Harness
After installation:
 Version with Dynamic Drive: If necessary, carry out initial Dynamic Drive operation

STEERING GEAR
2005 BMW 645Ci
NOTE: Procedure is described in 32 13 060 REMOVING AND INSTALLING / REPLACING

POWER STEERING GEAR.
system.
After installation:
 Version with Dynamic Drive: If necessary, carry out initial operation for Dynamic Drive, refer to 37 10
001 INITIAL OPERATION WITH TEST RUN OF DYNAMIC DRIVE .
 Remove power steering gear from front axle carrier, raise at sides and secure
Place fluid sump underneath for hydraulic fluid.
Release screws (2).
Remove Servotronic converter (3).

2005 BMW 645Ci

Installation:
Replace O-ring.
Align Servotronic converter (3) to opening in power steering gear, press by hand into power steering gear up to
stop, insert screws (2) and tighten down.
STEERING ARMS, TIE RODS, STEERING DAMPER

For replacing gaiter for steering gear on left or right, refer to 32 11 100 REPLACING GAITER FOR
STEERING GEAR ON LEFT OR RIGHT.
2005 BMW 645Ci
After installation:
 Perform chassis alignment check, refer to 32 00 150 STANDARD CHASSIS / WHEEL ALIGNMENT
WITH DIN LOAD or 32 00 155 CHASSIS / WHEEL ALIGNMENT WITHOUT LOAD.
ADJUSTMENT FOR ACTIVE FRONT STEERING or connect vehicle to BMW diagnosis system.
Installation:
2005 BMW 645Ci
Fig. 34: Removing Tie Rod End From Swivel Bearing

Installation:
Check gaiter, replace if necessary.

2005 BMW 645Ci
Fig. 35: View Of Tie Rod End

 32 3 160
 Remove tie rod end from swivel bearing, refer to 32 21 151 REPLACING LEFT OR RIGHT TIE
ROD.
 Remove gaiter from power steering gear and slide back, refer to 32 11 100 REPLACING GAITER
FOR STEERING GEAR ON LEFT OR RIGHT.
possible.
2005 BMW 645Ci
Fig. 36: Unscrewing Tie Rod With From Rack Of Power Steering Gear
Clean rack.
Check surface of rack for damage (e.g. corrosion).
Replace O-ring (1).
Grease rack and O-ring (1).

2005 BMW 645Ci
Fig. 37: Replacing O-Ring

Remove clamping ring (1) and clamping nut (2).
Push gaiter (4), band clamp (3), clamping nut (2) and clamping ring (1) onto tie rod.

2005 BMW 645Ci
Fig. 38: Identifying Rack Pinion Components

After installation:

STEERING COLUMN
32 31 ... OVERVIEW OF STEERING WHEEL / CASING COMPONENTS / LOCK CYLINDER
2005 BMW 645Ci
Fig. 39: Identifying Steering Wheel And Column Components


COLUMN TRIM
 Remove lower section of trim, refer to 32 31 020 REMOVING AND INSTALLING / REPLACING
LOWER SECTION OF STEERING COLUMN TRIM.

2005 BMW 645Ci
Fig. 40: Unclipping Steering Column Cover From Upper Section Of Trim
Unfasten screws.
Installation:

2005 BMW 645Ci
Fig. 41: Identifying Expansion Rivets

2005 BMW 645Ci

Installation:

2005 BMW 645Ci


COLUMN TRIM
Detach front section of trim.

2005 BMW 645Ci
Fig. 44: Detaching Front Section Of Trim

Installation:

2005 BMW 645Ci


COLUMN TRIM

Release screw.
Unclip lower section of trim (1) and pull downwards.

2005 BMW 645Ci
Fig. 46: Unclipping Lower Section Of Trim (1) And Pulling Downwards
Installation:
Installation:

2005 BMW 645Ci


2005 BMW 645Ci
Fig. 48: Removing Lower Section Of Trim

32 31 070 REMOVING AND INSTALLING OR REPLACING LOWER SECTION OF STEERING

SPINDLE
gear, this can result in damage to the contact ring when the steering wheel is
turned.
After installation:
 Move steering wheel to straight-ahead position and turn ignition key to position 0

2005 BMW 645Ci
Installation:
Steering spindle lower section and steering gear can only be joined in one position.
Remove trim panel for pedal assembly.
When reinstalling lower section of steering spindle: Mark position of universal joint in relation to steering
column.
Turn ignition key to position 1.

2005 BMW 645Ci
Turn steering wheel approx. 45°, hold securely and release clamping screw (1).
Turn steering wheel back and turn ignition key to position 0.
Detach lower section of steering spindle from steering column and remove.
Installation:
Clamping screw must rest in groove of steering column.
Fig. 50: Detaching Lower Section Of Steering Spindle From Steering Column
32 31 082 REMOVING AND INSTALLING/REPLACING STEERING ANGLE SENSOR

2005 BMW 645Ci
After installation:
 Replacement only: Carry out programming/coding.

 Carry out steering angle sensor adjustment/initial operation for active front steering, refer to 32 10 005

32 31 090 REMOVING AND INSTALLING / REPLACING COMPLETE STEERING COLUMN

 Remove trim panel for pedal assembly.
 Remove steering spindle lower section from steering column, refer to 32 31 070 REMOVING AND
INSTALLING OR REPLACING LOWER SECTION OF STEERING SPINDLE.
 Replacement only: Remove fixture for steering column stalk, refer to 61 31 006 REMOVING AND
INSTALLING (REPLACING) FIXTURE FOR STEERING COLUMN STALK .
 Remove upper section of trim
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.
Vehicles (up to 09/2005) with automatic transmissions: Remove interlock cable (1) from steering lock
positioning unit.

2005 BMW 645Ci

NOTE: As from 09/2004 the new steering column with a 6-pin plug connection and
Installation:
If necessary, disconnect plug connection (3) at drive for electric steering column adjustment.
Vehicles up to 09/2005: Remove interlock cable (1) from steering column.
2005 BMW 645Ci
Fig. 52: Removing Wiring Harness From Steering Column And Place To One Side
Installation:
Unfasten screws.
2005 BMW 645Ci

Release screws (1).
Installation:
2005 BMW 645Ci
Fig. 54: Identifying Steering Column (2) And Screws (1)

Replacement only:
Remove ignition starter switch.
Remove ring antenna.
Remove lock cylinder.
 Remove lower section of steering spindle, refer to 32 31 070 REMOVING AND INSTALLING OR
REPLACING LOWER SECTION OF STEERING SPINDLE.
2005 BMW 645Ci
ACCELERATOR PEDAL MODULE .
Installation:
Fig. 55: Removing Sleeve From Bulkhead

After installation:
2005 BMW 645Ci
STEERING LOCK
Fig. 56: Identifying Steering Wheel And Column Components

32 32 050 REMOVING AND INSTALLING/REPLACING STEERING LOCK CYLINDER
 32 3 110

2005 BMW 645Ci
 Remove airbag unit, refer to 32 34 020 REMOVING AND INSTALLING / REPLACING AIRBAG
UNIT.
 Remove steering column trims
 Remove ring antenna
Fig. 57: Sliding End Cap (1) To Ignition Key And Removing With Special Tool 32 3 110
2005 BMW 645Ci
Pull out lock cylinder with end cap (1) and ignition key, turn ignition key forward and back if necessary.
Installation:

09/2005)

After installation:
 Adjusting interlock cable.

2005 BMW 645Ci
Fig. 58: Releasing Screw Bracket


2005 BMW 645Ci
Fig. 59: Removing Interlock Cable From Steering Column

Replacement only:
STEERING WHEEL
2005 BMW 645Ci
Fig. 60: Identifying Steering Wheel Components

 Remove airbag unit, refer to 32 34 020 REMOVING AND INSTALLING / REPLACING AIRBAG
UNIT.
Move steering wheel/front wheels to straight-ahead position.
Pull out lead(s), slide a small screwdriver at outside centre into plug connection(s) and carefully pull out plug(s)
using lead(s).
Release screw (1).

2005 BMW 645Ci
Remove steering wheel.
Fig. 61: Removing Steering Wheel

Installation:
Locking pin (1) must engage in recess of driver (2).

2005 BMW 645Ci
Fig. 62: Ensuring Locking Pin Engages In Recess Of Driver

Steering wheel can only be installed in one position on steering spindle (serration).
Replacement only:
Remove steering wheel retaining plate.
Version with Sequential Manual Gearbox/Transmission: remove shift paddles.
STEERING WHEEL FOR AIR BAG

2005 BMW 645Ci
Fig. 63: Identifying Steering Wheel Components

WARNING: Note airbag safety instructions! Incorrect handling may result in the
airbag unit being triggered and thereby cause injury.
Insert T25/T27 Torx screwdriver (1) from below into hole (2) until a springy resistance can be felt through
annular spring (3) of airbag unit.
2005 BMW 645Ci
Fig. 64: Removing Airbag Unit

IMPORTANT: Airbag unit may only be set down with the airbag itself facing upwards.

2005 BMW 645Ci

Remove airbag unit and set down with impact pad facing upwards in luggage compartment.
Installation:
Check installation position of lead, correct if necessary.
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!

2005 BMW 645Ci

1. Regulations
Gas generators are pyrotechnical objects belonging to danger class T1.

BMW Service.
 minute for vehicles from 9/93
2005 BMW 645Ci
Danger of injury: The airbag module may only be set down with the airbag itself facing upwards.

3. Transport
4. Storage
regulations.
PUMP AND OIL SUPPLY

system.
After filling:
 Version with Dynamic Drive: Carry out initial Dynamic Drive operation, refer to 37 10 001 INITIAL
OPERATION WITH TEST RUN OF DYNAMIC DRIVE .
 Thoroughly clean fluid reservoir and its immediate surroundings

 Open and remove fluid reservoir cap
CHF Pentosin CHF11S

2005 BMW 645Ci
Fig. 66: Identifying Fluid Reservoir Caps

1. Topping up when engine stationary:

 Top up fluid reservoir to "MAX" mark on dipstick
2. Bleeding:
 Start engine.
 Turn steering wheel twice each as far as left and right lock.
3. Oil level check with engine off:

 Check fluid level
 If necessary, top up hydraulic fluid to "MAX" level
4. Check:

2005 BMW 645Ci
 32 1 260
NOTE: The work steps are show on assorted components. Ear clip must always be
replaced.
Fig. 67: Removing An Ear Clip

2005 BMW 645Ci
Fig. 68: Identifying Earclip

2005 BMW 645Ci
Fig. 69: Attaching Hook Fastener And Press Ear With Special Tool 32 1 260
2005 BMW 645Ci
Fig. 70: Identifying Side Cutter Of Special Tool 32 1 260


2005 BMW 645Ci
Fig. 71: Identifying Clip Gap

 32 4 000
 32 4 004
2005 BMW 645Ci
 32 4 006
 32 4 011
 32 4 012
Fig. 72: Identifying Special Tool (1 Of 4)

2005 BMW 645Ci

2 sealing rings.
2005 BMW 645Ci

2005 BMW 645Ci

32 41 ... NOTES ON HYDRAULIC LINE WITH QUICK-RELEASE COUPLING
1. Quick-release coupling with ID marking

2005 BMW 645Ci
Fig. 76: Identifying Quick-Release Coupling With ID

Removing:
Push quick-release coupling (1) against pipe (4) (thereby relieving strain on spring (2)).
Press plastic ring (3) into quick-release coupling (1) and remove coupling (1).
Installing:
Push quick-release coupling (1) onto pipe (4) until a "click" can clearly be heard.
To check that quick-release coupling (1) has been installed correctly, pull it back forcefully.
2. Quick-release coupling with indication pins

2005 BMW 645Ci
Fig. 77: Identifying Quick-Release Coupling With Indication Pins

Removing:
Press plastic ring (2) into quick-release coupling (1) and remove coupling (1).
Installing:
Push quick-release coupling (1) onto connector (3) until both indication pins (4) can be seen and felt to
point outwards at outside diameter of housing.
To check that quick-release coupling (1) has been correctly fitted, feel indication pins (4) at outside
CAUTION: Coupling is not correctly engaged if both indication pins (4) fail to
32 41 ... OVERVIEW OF LINES FOR POWER STEERING (SHOWN ON VEHICLE WITH

DYNAMIC DRIVE) (N62)
2005 BMW 645Ci
Fig. 78: Identifying Oil Lines Of Power Steering

system.
After installation:
2005 BMW 645Ci

 If necessary, carry out initial operation for Dynamic Drive, refer to 37 10 001 INITIAL OPERATION
 Draw off and dispose of hydraulic fluid
Fig. 79: Detaching Fluid Reservoir From Holder

2005 BMW 645Ci
32 41 ... REPLACING PRESSURE LINE I FOR POWER STEERING (VEHICLE WITH DYNAMIC
DRIVE) (N62)
system.
After installation:
Place fluid sump underneath for residual fluid.
Release banjo bolt (1).
Disconnect pressure line (2) from power steering pump.

2005 BMW 645Ci
Fig. 80: Disconnecting Pressure Line From Power Steering Pump

Installation:
Release union nut (1).
Disconnect pressure line (2) and remove towards bottom.

2005 BMW 645Ci
Fig. 81: Disconnecting Pressure Line (2)

Installation:
Make sure pressure line I is laid without tension and with sufficient spacing to adjoining components.
32 41 ... REPLACING PRESSURE LINE II FOR POWER STEERING (VEHICLE WITH DYNAMIC
DRIVE) (N62)
system.
After installation:
 Version with active front steering: Carry out adjustment for active front steering, refer to 32 10 005
2005 BMW 645Ci

 Release union nut of pressure line I at junction
Unscrew nut (1).
Disconnect pressure line (2) from holder.
Fig. 82: Disconnecting Pressure Line From Holder

Unscrew nut (1).

2005 BMW 645Ci
Disconnect pressure line (2) from holder.
Fig. 83: Disconnecting Pressure Line From Holder

Unclip wiring harness.
Release screw (1).

2005 BMW 645Ci
Fig. 84: Releasing Screw (1)

Disconnect pressure line (2) from power steering gear (3) and remove towards front.
2005 BMW 645Ci
Fig. 85: Releasing Banjo Bolt, Pressure Line From Power Steering Gear
Installation:
Make sure pressure line II is laid without tension and with sufficient spacing to adjoining components.
 32 4 000
power steering gear for leaks. Adhere to the utmost cleanliness. Do not allow
2005 BMW 645Ci
After installation:
 Disconnect pressure line from vane pump, refer to 32 41 033 REMOVING AND
INSTALLING/REPLACING POWER STEERING PUMP FOR POWER STEERING GEAR
WITH ACTIVE FRONT STEERING (N62), 32 41 037 REMOVING AND
INSTALLING/REPLACING POWER STEERING PUMP FOR POWER STEERING GEAR
WITH DYNAMIC DRIVE (N62) or 32 41 060 REMOVING AND INSTALLING/REPLACING
VANE PUMP FOR POWER STEERING (N62).
Version with Dynamic Drive only:

2005 BMW 645Ci
Fig. 86: Identifying Dynamic Drive Assembly Component

Connect special tool 32 4 000 (refer to Notes on use) with new sealing rings to vane pump and pressure line,
refer to 32 41 ... INSTRUCTIONS FOR USING SPECIAL TOOL 32 4 000.

2005 BMW 645Ci

1. Close valve (A).

2. Open valve (B).
2005 BMW 645Ci
Fig. 88: Identifying valves (A) And (B)

3. Fill and bleed hydraulic system, refer to 32 13 006 BLEEDING POWER STEERING UNIT.
4. Start engine.
Replace vane pump if the nominal pressure is exceeded by more than 10%.
Check belt tension if the nominal pressure is undershot by more than 10%. Replace vane pump if belt
tension is OK.

STEERING GEAR WITH ACTIVE FRONT STEERING (N62)
2005 BMW 645Ci
system.
After installation:
 Remove power steering pump belt pulley

 If necessary, remove deflection pulley on alternator
 Disconnect suction line from power steering pump
 Detach pressure line from power steering pump

2005 BMW 645Ci
Fig. 89: Disconnecting Connector

Release screws (1...2).
Remove power steering pump (3) towards front.

2005 BMW 645Ci
Fig. 90: Removing Power Steering Pump


STEERING GEAR WITH DYNAMIC DRIVE (N62)
system.
After installation:
2005 BMW 645Ci

 Move engine into installation position and secure
 Disconnect intake line from power steering pump
 Disconnect pressure line for Dynamic Drive with bracket from power steering pump
 Disconnect pressure line for power steering gear from power steering pump
Version with active front steering: Disconnect connector (1).
Release screw (2).
Fig. 91: Disconnecting Pressure Line For Power Steering Gear From Power Steering Pump
2005 BMW 645Ci
Fig. 92: Removing Power Steering Pump (1 Of 2)


(N62)
system. Seal off pipe connections with plugs.
After installation:
2005 BMW 645Ci

 Disconnect intake line from power steering pump
 Disconnect pressure line from power steering pump

2005 BMW 645Ci
Fig. 93: Remove Power Steering Pump

After installation:

Release screws (1).

2005 BMW 645Ci
Fig. 94: Removing Belt Pulley

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",
refer to 11 28 010 REPLACING ALTERNATOR DRIVE BELT (N62) .
If necessary, remove front assembly underside protection.
Slacken screws (1)

2005 BMW 645Ci
Remove screws (1).
Remove belt pulley (2) from power steering pump and remove towards bottom.
Fig. 95: Removing Belt Pulley From Power Steering Pump

Installation:

STEERING
 32 1 260
2005 BMW 645Ci
After installation:
 M54, N52:
 Remove intake filter housing
 N62:
 Release coolant expansion tank and place to one side, refer to 17 11 100 REMOVING AND
INSTALLING/REPLACING COOLANT EXPANSION TANK (N62) .
 S85:
 Remove right intake filter housing
Release screw (1).

2005 BMW 645Ci
Fig. 96: Releasing Screw (1)

hose clamps.
Disconnect suction and return lines from fluid reservoir, check and if necessary replace.


2005 BMW 645Ci
 M54, N52:
 Remove intake filter housing
 M57TU, M57T2, N62:

 Release coolant expansion tank and place to one side, refer to 17 11 100 REMOVING AND
INSTALLING/REPLACING COOLANT EXPANSION TANK (N62) .
Unscrew nuts.
Remove shims.
Installation:

2005 BMW 645Ci
Fig. 97: Replacing Self-Locking Nuts

If necessary, disconnect plug connection at level switch. Remove hose clamps if necessary with special tool 32
1 260.
Disconnect suction line and radiator return line from fluid reservoir.
NOTE: Lift out fluid reservoir.

2005 BMW 645Ci

Replacement:
After installation:
 If necessary, carry out initial Dynamic Drive operation, refer to 37 10 001 INITIAL
OPERATION WITH TEST RUN OF DYNAMIC DRIVE .
32 41 332 REPLACING PRESSURE LINE FOR POWER STEERING (N62)

2005 BMW 645Ci
system.
After installation:
Installation:
Disconnect pressure line (3) from power steering pump (2).
Release screw (4).

2005 BMW 645Ci
Fig. 99: Disconnecting Pressure Line From Power Steering Pump

Shown on vehicle with Dynamic Drive:
Unclip wiring harness.
Release screw (1).

2005 BMW 645Ci
Fig. 100: Unclipping Wiring Harness

Disconnect pressure line (2) from power steering gear (3) and remove towards front.
Installation:
Make sure pressure line is laid without tension and with sufficient spacing to adjoining components.

2005 BMW 645Ci

32 41 341 REPLACING RETURN LINE/RADIATOR RETURN LINE FOR POWER STEERING (N62)
 32 1 260
After installation:
2005 BMW 645Ci

 Detach fluid reservoir from holder, raise and remove sideways
Unclip cooler return line (1) from pipe holder (2).
Remove Clic clamp with special tool 32 1 260.
Disconnect cooler return line (1) from fluid reservoir.

2005 BMW 645Ci
Fig. 102: Disconnecting Cooler Return Line From Fluid Reservoir

Unfasten quick-release coupling (1).
Unclip cooler return line (2) from pipe holder (3) and remove towards bottom.
2005 BMW 645Ci
Fig. 103: Unfastening Quick-Release Coupling

Installation:
Make sure radiator return line is laid without tension and with sufficient spacing to adjoining components.
32 41 351 REPLACING RETURN LINE FOR POWER STEERING (N62)
After installation:
2005 BMW 645Ci

 If necessary, remove left intake duct
 Remove left steering gear cover
Unfasten quick-release coupling (1).
Remove return line (2) from pipe holder and place to one side.
Fig. 104: Removing Return Line (2) From Pipe Holder

2005 BMW 645Ci
Installation:
Make sure return line is laid without tension and with sufficient spacing to adjoining components.
Fig. 105: Identifying Banjo Bolt (1)

Installation:
Unscrew nut (1).

2005 BMW 645Ci
Remove return line (2) towards top.
Fig. 106: Removing Return Line (2)

Installation:
Make sure return line is laid without tension and with sufficient spacing to adjoining components.
ELECTRONIC POWER STEERING


2005 BMW 645Ci
 after the battery has been disconnected or electrical plug connections on

the steering column switch cluster have been disconnected
 AL control unit
Select and carry out adjustment for active front steering under Service functions.
32 43 010 REMOVING AND INSTALLING / REPLACING CONTROL UNIT FOR ACTIVE FRONT
STEERING
DISCHARGE) .
After installation:
 Replacement only: Carry out coding, refer to DIAGNOSIS PROGRAMMING/CODING.

 Replacement/coding only: Carry out adjustment for active front steering, refer to 32 10 005
 Remove right entrance strip

 Remove right front seat
 Remove side trim in front right footwell
 Fold back front right floor trim
 Remove kickplate in footwell in front of and next to control unit; if necessary, cut along specified lines
with knife and secure later with adhesive tape
Release screws (1).

2005 BMW 645Ci

Lay grounding cable to one side.
Installation:
Remove active front steering control unit.

2005 BMW 645Ci


STEERING
DISCHARGE) .
 Remove left front seat

2005 BMW 645Ci
Release screws (1).
Fig. 109: Removing Yaw Sensor

TROUBLESHOOTING
TROUBLESHOOTING ON STEERING
Fault Cause Remedy
Excessive steering wheel Screws at lower section of steering Replace screws and tighten down
play/steering wheel shake spindle to steering gear/steering (refer to 32 31 070 REMOVING
column loose AND INSTALLING OR
REPLACING LOWER
2005 BMW 645Ci
SECTION OF STEERING
SPINDLE)
joint/double joint, to lower section (refer to ... Double joint / universal
of steering spindle/steering joint)
gear/steering column loose
Journal of tie rod end deformed Replace steering gear and tie rod
ends
Tie rod end worn Check steering gear rack; if
necessary, replace steering gear
Check tie rods, replace if
necessary
Replace tie rod end
Refer to Troubleshooting on front axle
Steering wheel inclination Tie rod Replace tie rod end
end worn Front axle alignment incorrectly Carry out chassis/wheel alignment
Refer to Troubleshooting on front axle
2005 BMW 645Ci
2004-05 BODY & ACCESSORIES Sliding/Tilt Roof - Repair Instructions - E63
2004-05 BODY & ACCESSORIES
Sliding/Tilt Roof - Repair Instructions - E63
SUNROOFS
54 0 ... REPAIR INSTRUCTIONS FOR BONDED SEALS
1. General information on handling rubber seal profiles:

 IF seals reveal partly detached protective film on delivery, they must not be bonded.
 Store seals at 15°C to 25°C.
 If, during the handling, the protective film has come off before bonding, it can still be bonded.
 Bonding at room and object temperature > 20°C. Temperatures between 40 and 50°C significantly
increase initial adhesion.
 Seals, which are subjected to temperatures above 80°C after gluing, will be very difficult to
remove.
2. Damage pattern and repair
2.1 Partially detached bond (rubber-adhesive tape or adhesive tape-paint)
 Up to 120 mm for retouching without auxiliary resources
 Up to 200 mm repaired with pressing-on tools on straight surfaces
DAMAGE PATTERN AND REPAIR

a. Cleaning damaged  Degrease bonded area
areas: with adhesive cleaner
and remove other
residues.
NOTE:
Use necessary cotton- or
fluff-free paper towel once
only.
When using solvent:
expose repair area to air for
at least 2 minutes.
b) Applying adhesive: With a fine nozzle,

apply a wafer-thin bead
to adhesive tape.
NOTE:
Use contact adhesive (e.g.
Terokal 2444)
CAUTION:
2005 BMW 645Ci
Avoid contact to skin!

Do not apply adhesive to
visible painted surfaces.
c) Pressing on rubber  Press down seal using

seal: contact pressure (forced
pressure not necessary)
for at least 1 minute.
CAUTION:
Load can only be applied to
the bond after a period of 2
minutes. This waiting time is
absolutely essential.
2.2 Larger defects (mechanical damage and larger separations of seal)

 A complete replacement of the rubber seal is necessary.
LARGER DEFECTS (MECHANICAL DAMAGE AND LARGER SEPARATIONS OF

SEAL) AND THEIR REPAIR
a. Peeling off damaged  Pull off rubber seal
rubber seal: slowly at an angle of 15
to 25.
NOTE:
Make sure the connection
between adhesive tape and
seal is retained.
If the connection between
adhesive tape and seal is
detached: Carefully and
slowly detach adhesive tape
at an angle of 15 to 25° from
roof opening or lid.
If, in the case of older seals,
you are peeling off using a
hot air blower: Do not
damage paintwork. Do not
detach rubber-adhesive tape
connection if at all possible.
b) Cleaning bonded  Degrease bonded area

area: with adhesive cleaner
and remove other
residues.
NOTE:
Use necessary cotton- or
2005 BMW 645Ci
fluff-free paper towel once

only.
When using solvent:
expose repair area to air for
at least 2 minutes.
c) Detaching protective  Detach protective film

film from bonded area: from rubber seal in
sections.
CAUTION:
Once the protective film has
been removed, do not under
any circumstances touch
the exposed bonded area.
d) Applying rubber seal:  Apply rubber seal on

roof opening edge
beginning at rear centre.
Use upper lip as
application edge. Press
on seal continuously by
hand. Carefully unwrap
seal at radii without
tension and press down
(critical area).
NOTE:
If positioned incorrectly, the
seal can still be pulled off,
repositioned and pressed on
again.
e) Establishing seal  Mark contact point at

joint: joint by pressing down
loose end on seal of
already bonded end.
Then cut and press
down loose end at same
height.
NOTE:
Small areas of seal can
remain stuck to adhesive
tape of loose end.
f) Pressing on seal:  Press on seal using a

roller
 Adhesive tape width up
2005 BMW 645Ci
to 5 mm Application
pressure approx. 5 N
 Adhesive tape width up
to 10 mm Application
pressure approx. 10 N
Seal on sliding sunroof E83  Press against seal
only: strongly with a roller.
Application pressure
approx. 70 N.
Seal on sliding sunroof E36  Application pressure
only: approx. 30 N.
 Tear off tear-off lip at
rear and side in area of
narrower flange.
NOTE:
Firm thumb pressure has
approx. 35 N/cm2
3. Checking rubber seal

 Check the bonded seals for correct positioning and perfect adhesion. The bonding can be checked
by pressing back the sealing lip.
 The force required to peel off the seal immediately after gluing must be greater than 10 N/cm.
54 10 004 ADJUSTING GLASS TILT SUNROOF LID
 00 9 315
 00 9 341
2005 BMW 645Ci

2005 BMW 645Ci

 Remove gaiter on left and right, refer to 54 10 1140 REMOVING AND INSTALLING/REPLACING
GAITER FOR GLASS TILT SUNROOF .
 Close glass tilt sunroof lid completely
 Check glass tilt sunroof for correct adjustment
Gap adjustment only:
 Remove roofliner, refer to 51 44 005 REMOVING AND INSTALLING/REPLACING ROOFLINER

(VERSION WITHOUT GLASS TILT SUNROOF) .
If the glass tilt sunroof is outside the adjustment tolerances, adjust as follows:
2005 BMW 645Ci
Height adjustment:
Carry out the following step on one side first and then the other (left, right or vice versa):
 Slacken Torx screws (1) on left/right so that sunroof lid (2) can still just be adjusted.
 Move sunroof lid as required.
 Make sure all screws are tightened down.
 Tightening torque, refer to 54 10 5AZ in SLIDE/TILT ROOF AND CONVERTIBLE TOP -
TIGHTENING TORQUES - E63 .
 Repeat work steps on the other side.
Fig. 3: Slacking Torx Screws On Left/Right For Adjusting Sunroof Lid

Checking height:
2005 BMW 645Ci
Press glass lid (1) at front and rear towards top or bottom until ideal position is reached.
Height:
 Front - glass lid flush to 2 mm lower

 Rear - glass lid flush to 2 mm higher
Check function and adjustment.
Gap adjustment:
 Slacken Torx screws (1) so that sunroof lid (2) can still just be adjusted.
Fig. 4: Slacking Torx Screws For Sunroof Lid Adjustment

 Move sunroof lid as required.

2005 BMW 645Ci
 Make sure all screws are tightened down.

 Tightening torque, refer to 54 10 5AZ in SLIDE/TILT ROOF AND CONVERTIBLE TOP -
Checking gap:
Check same gap (A) in relation to body with special tool 00 9 341, refer to Fig. 2 .
Slide special tool 00 9 341 or similar between seal and insert. It must be possible to slide the card against the
same level of resistance.
Slide glass lid towards front or rear until ideal position is reached.
54 10 008 SETTING GAP ADJUSTMENT FOR GLASS TILT SUNROOF LID
NOTE: This operation is described in section on:
 Adjusting glass tilt sunroof, refer to 54 10 004 ADJUSTING GLASS TILT SUNROOF LID .
54 10 1.. REMOVING AND INSTALLING/REPLACING OUTER GAITER FOR GLASS TILT

SUNROOF
IMPORTANT: Handle the gaiter with extreme care throughout the work procedure. This soft
component is highly susceptible to tearing.
 Remove trim strip from roof frame

 Remove glass tilt sunroof lid, refer to 54 10 100 REMOVING AND INSTALLING GLASS TILT
SUNROOF LID .
Unlock clips (1) and remove.

2005 BMW 645Ci
Fig. 5: Identifying Clips (1)

Remove gaiter.
Installation:
If necessary, replace faulty gaiter.
Mount gaiter first on glass sunroof lid.
54 10 100 REMOVING AND INSTALLING GLASS TILT SUNROOF LID
 Remove front trim, refer to 54 10 130 REMOVING AND INSTALLING/REPLACING FRONT

TRIM .
NOTE: The following steps must be carried out on the opened glass sunroof panel as
otherwise the Torx screws will not be completely released.
This also facilitates access for removal.

2005 BMW 645Ci
Open floating roofliner fully.
Make sure that grease on the rails and the mechanism does not come into contact with the roofliner.
Remove and dispose of the Torx screws (1) securing the glass panel to the front holders.
Fig. 6: Removing Torx Screws Securing Glass Panel To Front Holders

Remove and dispose of the Torx screws (1) securing the glass panel to the front lifting mechanism.
IMPORTANT: A second person is required to help in removing and installing the glass tilt
sunroof lid!
2005 BMW 645Ci
Fig. 7: Removing Torx Screws Securing Glass Panel To Front Lifting Mechanism
Raise sunroof lid at rear (1) uniformly until access from side (2) is possible.
2005 BMW 645Ci
Fig. 8: Raising Sunroof Lid At Rear

Lift out sunroof lid.
Installation:
Tape off installation area on left and right at roof aperture with fabric adhesive tape.
Insert sunroof lid carefully and uniformly.
Tighten Torx screws only to such an extent that sunroof lid can still just be adjusted.
Close slide/tilt sunroof lid, check for correct alignment and adjust if necessary, refer to 54 10 004 ADJUSTING
GLASS TILT SUNROOF LID .
Tighten down Torx screws.

2005 BMW 645Ci
Tightening torque, refer to 54 10 5AZ in SLIDE/TILT ROOF AND CONVERTIBLE TOP -

54 10 1140 REMOVING AND INSTALLING/REPLACING GAITER FOR GLASS TILT SUNROOF
IMPORTANT: Handle the gaiter with extreme care throughout the work procedure.
Soft components and plastic protective strip are highly susceptible to tearing
and kinking respectively.
Detach gaiter (1):
1. from lower
2. from upper guide.
Fig. 9: Detaching Gaiter

2005 BMW 645Ci
Installation:
Gaiter has a plastic connection strip.
Check that plastic connection strip is firmly seated on guide.
If necessary, replace faulty gaiter.
54 10 120 REPLACING SEAL FOR GLASS SLIDE/TILT SUNROOF LID
 Remove glass slide/tilt sunroof lid, refer to 54 10 100 REMOVING AND INSTALLING GLASS TILT
SUNROOF LID .
NOTE: Follow repair instructions for bonded seals on glass slide/tilt sunroof, refer to
54 0 ... REPAIR INSTRUCTIONS FOR BONDED SEALS .
Detach seal (1) for glass sunroof from body.
Installation:
Partially pull off protective film from adhesive tape (2).
Press seal (1) without stretching (squashing).
Stick on seal (1) in stages.

2005 BMW 645Ci
Fig. 10: Detaching Seal For Glass Sunroof From Body

IMPORTANT: Do not touch bonding surface. Surface temperature are equal to or greater than
20°C. Incorrect bonding of the seal will result in leakage.
54 10 130 REMOVING AND INSTALLING/REPLACING FRONT TRIM
 Remove gaiter on left and right, refer to 54 10 1140 REMOVING AND INSTALLING/REPLACING
GAITER FOR GLASS TILT SUNROOF .
Unclip trim (1).

2005 BMW 645Ci
Fig. 11: Unclipping Trim

Installation:
Replace trim (1) if clips are faulty.
Locator prevents incorrect installation of trim (1).
54 10 150 REMOVING AND INSTALLING/REPLACING FRONT FLOATING ROOFLINER
SUNROOF LID .
IMPORTANT: Make sure that grease on the rails does not come into contact with the floating
2005 BMW 645Ci
Open roofliner (1) to such an extent that screws (2) are still accessible.
Loosen screws (2).

Fig. 12: Opening Roofliner

Slide roofliner (1) uniformly towards front.
If necessary, raise slider (2) for roofliner.
Move slider (2) back until there is no longer any contact with the roofliner.
2005 BMW 645Ci
Fig. 13: Raising Slider For Roofliner

2005 BMW 645Ci
Fig. 14: Removing Floating Roofliner

54 10 155 REMOVING AND INSTALLING/REPLACING REAR FLOATING ROOFLINER
 Remove front roofliner
IMPORTANT: Make sure that grease on the rails does not come into contact with the floating
roofliner.
Move rear floating roofliner (1) towards front (close).
Loosen screws (2).

2005 BMW 645Ci
Fig. 15: Moving Rear Floating Roofliner Towards Front


Slide roofliner (1) uniformly towards front.
If necessary, raise slider (2) for front and rear floating roofliners.
Move slider (2) back until there is no longer any contact with the roofliner (1).
2005 BMW 645Ci
Fig. 16: Sliding Roofliner Uniformly Towards Front

2005 BMW 645Ci
Fig. 17: Removing Rear Floating Roofliner

54 10 200 REMOVING AND INSTALLING COMPLETE GLASS TILT SUNROOF

SUNROOF LID .
IMPORTANT: A second person is required to help in removing the glass tilt sunroof. Cover
door sill with protective covers (risk of damage). Do not damage any
surrounding parts when removing slide/tilt sunroof (5).
2005 BMW 645Ci
Fig. 18: Identifying Complete Glass Tilt Sunroof

 Unlock and disconnect plug for drive unit for floating roofliner (1) and glass tilt sunroof lid (2).
 Unclip wiring harness (3).
 Glass tilt sunroof is inserted into body in area (4) and thus secured against falling out.
 Secure glass tilt sunroof in front area against falling out by supporting it.
 Release screws in marked area from rear towards front.

 Remove slide/tilt sunroof (5) completely (through front door).
Installation:
Do not crush any cables when fitting the glass slide/tilt sunroof.
Initialise glass slide/tilt sunroof, refer to 54 0 ... NOTES ON PANORAMA GLASS ROOF
2005 BMW 645Ci
54 10 201 REPLACING GLASS TILT SUNROOF LID
Removing glass tilt sunroof lid, refer to 54 10 100 REMOVING AND INSTALLING GLASS TILT
SUNROOF LID .
54 10 210 REPLACING GLASS TILT SUNROOF
 Remove complete glass tilt sunroof, refer to 54 10 200 REMOVING AND INSTALLING
COMPLETE GLASS TILT SUNROOF .
 Remove drive motors, refer to 67 61 005 REMOVING AND INSTALLING/REPLACING DRIVE
WITH GEAR (FRONT) FOR ACTUATING SLIDE/TILT SUNROOF or 67 61 007 REMOVING
AND INSTALLING/REPLACING DRIVE WITH GEAR (REAR) FOR SLIDE/TILT SUNROOF .
ELECTRICAL SUN ROOF COMPONENTS

54 0 ... NOTES ON PANORAMA GLASS ROOF (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 panorama glass roof are recorded
and stored for correct operation of the anti-trapping mechanism.
NOTE: Then carry out an initialization:
 if the panorama glass roof has been mechanically moved by means of the emergency actuator
 in the event of malfunctions, e.g. no one-touch function, no opening or no comfort function possible
 after disengagement of the drive unit
 after work is carried out on the mechanism of the panorama glass roof
2005 BMW 645Ci
 after the control unit has been replaced
WARNING: There is no anti-trapping protection during initialization.
NOTE: Starting situation in accordance with following description:
 Panorama glass sunroof closed

 Floating roofliner completely open
Normalization:
 Press and hold the switch in the "Lift" direction

 In the event of delayed starting or sudden stopping of the panorama glass roof, continue pressing the
switch in the "Lift" direction
Fig. 19: Pressing Switch In "Lift" Direction

2005 BMW 645Ci
 After reaching the lift end position (A), keep the switch pressed for approx. 15 seconds further
Fig. 20: Identifying Panorama Glass Roof In Lift End Position (A)
 Normalization is completed when the panorama glass roof in lift end position (A) presses again briefly in
the direction of position (B).
Learning characteristic curve:
E53/E61/E83 only:
The curve is learnt manually in the following steps:
 After normalization, keep switch pressed in "Lift" direction.

 The panorama glass roof stops for 5 seconds in the final raise position after normalization.
 Floating roofliner closes completely.
 Floating roofliner opens completely.
 The panorama glass roof then moves into the "Closed" position (learning of the "Closing from raising"
curve)
2005 BMW 645Ci
"Closed" position (learning of the "Closing" curve).

 Release switch.
Fig. 21: Locating Switch

E63 only:
The curve is learnt manually in the following steps:
 After normalization, keep switch pressed in "Lift" direction.

 The panorama glass roof stops for 5 seconds in the final raise position after normalization.
 Floating roofliner opens completely.
 The panorama glass roof then moves into the "Closed" position (learning of the "Closing from raising"
curve)
2005 BMW 645Ci
 Release switch.
Fig. 22: Locating Switch

NOTE:  The entire operation lasts approx. 75 seconds

 Learning of the curve is terminated when the switch is released
 If the switch is released in the meantime, the entire procedure must be
repeated
 On completion of successful initialization, the corresponding messages in
the check control and the control display go out
 Carry out function check (tip function, anti-trapping protection and, if
necessary, comfort function)
2006 BMW 650i
SUSPENSION
00 GENERAL
 Headaches
 Dizziness
 Stomach aches
 Vomiting
 Diarrhoea
 Cramps/fits
 Unconsciousness

First aid measures:
Danger of injury!

2006 BMW 650i
 Impaired sight

First aid measures:

Recycling:

2006 BMW 650i

contact points.
necessary.

points!

2006 BMW 650i


2006 BMW 650i


2006 BMW 650i


2006 BMW 650i



2. Steering gear
4. Control arm
6. Swivel bearing
7. Tie rod end
8. Tie rod
2006 BMW 650i
Facts:
Consequence:
Procedure:

bristles!
procedure:
Troubleshooting
2006 BMW 650i

OK carrier
tie rod end is
deformed

bearing
and swivel bearing
Replace tie rods
2006 BMW 650i

Procedure:


2006 BMW 650i



2006 BMW 650i


SHOCK ABSORBER)

system.

2006 BMW 650i
support arm
TORQUES .

TORQUES -- 650I .


2006 BMW 650i


After installation:

2006 BMW 650i
centering pin.

Installation:

Replacement:
All except M5:

2006 BMW 650i
Installation:
Replacement:


2006 BMW 650i
Installation:
Replace screws (1).

M5 only:
Installation:
2006 BMW 650i

Release screws (1).
Installation:

2006 BMW 650i
11 FRONT SUB-FRAME

system.

front axle carrier.

2006 BMW 650i
Installation:

After installation:

 00 2 030
 00 2 040
 31 4 012
 33 3 274

system.
2006 BMW 650i


TORQUES -- 650I .

TORQUES -- 650I .
2006 BMW 650i

TORQUES -- 650I .



2006 BMW 650i

Installation:
2006 BMW 650i

Release screw.

TORQUES -- 650I .

After installation:

2006 BMW 650i



Unscrew nut (1).

2006 BMW 650i
Installation:

After installation:


2006 BMW 650i
Installation:

Installation:
 31 3 031
 31 3 032
2006 BMW 650i


Installation:
2006 BMW 650i
5°.

Installation:


 31 2 230

2006 BMW 650i
PULSE GENERATOR .
tension struts.
Installation:

Replacement:
wheel.
After installation:
2006 BMW 650i
bearing.



2006 BMW 650i
Installation:
Replace screws.
31 SPRING STRUT
2006 BMW 650i

Facts:
2006 BMW 650i
Procedure:
ABSORBER
M5:
2006 BMW 650i
Unscrew nuts.
Installation:

2006 BMW 650i

After installation:
centering pin.
 31 2 210
 31 3 341
 31 3 354
 31 3 355
springs.
2006 BMW 650i
Removing:

354 !

2006 BMW 650i

Take off cap.

Assembly:

2006 BMW 650i
pad (2).

2006 BMW 650i
spring plate.

After installation:
centering pin.

DOME


2006 BMW 650i





Release screws (1).

2006 BMW 650i
Installation:
Replace screws.


 31 2 210
 31 3 341
 31 3 354
 31 3 355
springs.
2006 BMW 650i

Removing:

354 !

2006 BMW 650i

Take off cap.

2006 BMW 650i

Assembly:
pad (2).


2006 BMW 650i
spring plate.

After installation:
centering pin.
2006 BMW 650i


FRONT SPRING STRUT
 31 2 210
 31 3 341
 31 3 354
 31 3 355
springs.
corrosion breakage!
2006 BMW 650i
entered.
shock absorber.
Removing:

354 !

2006 BMW 650i

Take off cap.

2006 BMW 650i

Assembly:

354 !
2006 BMW 650i
tool 31 3 355 .

pad (2).
spring end.
2006 BMW 650i

spring plate.

2006 BMW 650i
After installation:
centering pin.
35 STABILIZER BAR

Installation:

2006 BMW 650i

Replacement:

Installation:

2006 BMW 650i


ROD/STABILIZER
Release screw (2).

Unscrew nut (1).

2006 BMW 650i
Installation:


AXLE CARRIER
stabilizer.
Installation:
oil and grease.
2006 BMW 650i
90 TROUBLESHOOTING

Fault Cause Remedy
Radial/lateral rim
runout
Radial/lateral rim
runout
Rubber mount of
control arm faulty
worn
Rubber mount of
strut worn
Rubber mount of
control arm faulty
2006 BMW 650i
worn
Rubber mount of
play/steering wheel
strut worn
plate loose
PLATE)
loose
Replace bolt & nut
worn
strut worn
Rubber mounts for
faulty
link(s) worn
Front or rear axle
adjusted

Fault Cause Remedy
(bottoming)
2006 BMW 650i
auxiliary spring
SPECIAL TOOLS
2005 BMW 645Ci
2004-07 SUSPENSION Front - 6-Series (E63/64)i
2004-07 SUSPENSION
Front - 6-Series (E63/64)i
DESCRIPTION
All models use MacPherson strut front suspension systems, which consist of vertically mounted strut assemblies
directly attached to steering knuckles. Steering knuckles are connected to the axle carriers (crossmember)
through lower control arms. A stabilizer bar is attached to either the strut assembly or the lower control arm. For
information on electronic air suspension system, see appropriate ELECTRONIC article.
ADJUSTMENTS & INSPECTION

RIDING HEIGHT
NOTE: Riding height may be affected by faulty electronic suspension system. If height
is not correct, see appropriate ELECTRONIC article.
NOTE: To identify installed spring, refer to parts microfiche, contact parts supplier, or
remove spring and find BMW number on end of spring. Springs are allocated by
vehicle type and, where applicable, by special equipment such as air
conditioning, sports suspension, etc. and by date of production launch.
1. Ensure vehicle is on a level surface. Place front seats in center positions and load each with 150 Lbs. (68
kg). Load center of rear seat with 150 Lbs. (68 kg). Load luggage compartment with 46 Lbs. (21 kg).
Ensure fuel tank is full.
2. Determine actual ride-level height (A) by measuring from wheel arch lower edge (1) to rim flange (2) at
wheel center height. See Fig. 1. Bounce vehicle up and down. Determine average value for each wheel
and establish average value for axle.
3. Ride height measurement must be within .04" (10 mm) of specification. See RIDE HEIGHT
SPECIFICATIONS.
4. If ride height is not to specification, replace both coil springs even though only one may be defective. See
COIL SPRING & SHOCK ABSORBER under REMOVAL & INSTALLATION.
2005 BMW 645Ci
2005 BMW 645Ci
Fig. 1: Measuring Ride Level Height

RIDE HEIGHT SPECIFICATIONS

Application In. (mm)
17" Rim 24.7 (627)
18" Rim 25.2 (640)
19" Rim 25.7 (652)
20" Rim 26.2 (665)
INITIALIZING ACTIVE FRONT STEERING (AFS)
NOTE: Active Front Steering (AFS) must be adjusted after work is carried out on
steering system.
1. Connect vehicle to BMW DIS or MoDIC diagnostic tester or equivalent. Call up SERVICE
FUNCTIONS, CHASSIS, STEERING, ACTIVE FRONT STEERING. Select item AFS START-UP /
ADJUSTMENT.
2. Set total steering angle on steering gear to ZERO.
3. If necessary, carry out wheel alignment. See SPECIFICATIONS & PROCEDURES article in WHEEL
ALIGNMENT.
4. Work through test module. Test module contains the following steps:
 Reset motor position angle.
 Steering angle sensor adjustment.
 Adjustment of total steering angle sensor.
INITIALIZING DYNAMIC DRIVE
WARNING: Vehicle will perform strong rolling motions during initial operation run.
Keep wheel arches clear. Vehicle must stand on level ground. DO NOT,
under any circumstances, carry out initial operation on a lifting platform.
No persons are permitted inside or directly around the vehicle. Avoid
heavy loads. Failure to comply with specified instructions may result in
personal injury and damage to vehicle.
NOTE: Systems must be in normal temperature range.
1. Check fluid level in hydraulic tank and top up to MAX while engine is stopped.
2. Start engine and run at idle for at least one minute.
3. Turn steering wheel left and right to full lock twice. Move steering wheel to straight-ahead position.
4. Stop engine and check fluid level again. Top up to MAX.
5. Connect vehicle to DIS or MoDIC.
2005 BMW 645Ci
6. Observe warning. Start initial operations in SERVICE FUNCTIONS. Follow instructions in DIS to
initialize Dynamic Drive.
7. Check fluid level in tank (engine off). Top up to MAX.
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
NOTE: See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.
TROUBLE SHOOTING
To trouble shoot most symptoms, see TROUBLE SHOOTING.
Whether a spring strut has to be replaced can only be ascertained by checking while it is installed with a Boge
shock tester or, while it is removed, with a shock absorber test machine.
TROUBLE SHOOTING
Symptom Probable Cause Remedy
Body Swinging Long After Shock Absorber Effect Insufficient Replace Shock Absorbers.
Driving Over Rough Road
Grinding Noise (Louder When Wheel Bearings Faulty Replace Wheel Bearings
Cornering)
Flattened Areas On Tire Profile Shock Absorber Faulty Replace Shock Absorbers
Rattling Noise Ball Joints Of Control Arms Worn Replace Control Arm
Rattling Noise Ball Joint On Tension Strut Worn Replace Tension Strut
Rattling Noise Stabilizer Rubber Mounts Worn Replace Rubber Mounts
Rattling Noise Ball Joint On Stabilizer Link Worn Replace Stabilizer Link
Rattling Noise Front Axle Support Screws Tighten Screws (Check Threads)
Connection With Body Loose
Rattling Noise Shock Absorber In Swivel Bearing Check Mount & Tighten Screws
Loose
Rising Of Body When Shock Absorber Effect Insufficient Replace Shock Absorbers
Accelerating
Skidding In Bends Due To Poor Shock Absorber Effect Insufficient Replace Shock Absorbers
Track Holding
Steering Wheel Shake Wheels Out Of Balance Balance Wheels
Steering Wheel Shake Radial Rim Or Axial Runout Replace Rims If Necessary
Steering Wheel Shake Shock Absorber Effect Insufficient Replace Shock Absorbers
Steering Wheel Shake Excessive Play In Steering Gear Determine Pressure Point &
Replace Steering Gear
Steering Wheel Shake Rubber Mount Of Tension Strut Replace Traction Strut Bearing
Defective
Vehicle Skidding When Braking Shock Absorber Effect Insufficient Replace Shock Absorbers
2005 BMW 645Ci
Vibration Radial Rim Or Axial Runout Replace Rims If Necessary

Vibration Tires Have Radial Runout Match Or Replace Tires
Wheels Jumping Even On Shock Absorber Effect Insufficient Replace Shock Absorbers
Normal Road Surfaces
Whipping Of Body When Shock Absorber Effect Insufficient Replace Shock Absorbers
Driving Over Successive Rough
Road Surfaces

CONTROL ARM
1. Raise and support vehicle. Remove front wheel. Remove underbody protection at front and rear. Remove
steering gear cover at side.
2. On vehicles equipped with ride-height sensor, remove nut for control rod on ride-height sensor control
arm located on right side. See Fig. 2. Remove control rod (1) from control arm. Unlock and disconnect
plug (2) from ride-height sensor.
3. Remove lower control arm-to-subframe nut (1). See Fig. 3. Remove bolt.
4. On right side, if necessary, remove holder with ride-height sensor.
5. Remove lower control arm-to-spindle nut (2). See Fig. 3. Remove control arm from front axle carrier. If
necessary, grip ball joint with Torx socket. Remove control arm from swivel bearing.
6. To install, reverse removal procedure. Ensure ball pin and bore are free of grease. Replace self-locking
nuts and tighten to specification. See TORQUE SPECIFICATIONS.
7. Perform chassis alignment check. See SPECIFICATIONS & PROCEDURES article in WHEEL
ALIGNMENT.
2005 BMW 645Ci
Fig. 2: Removing Control Rod From Control Arm

2005 BMW 645Ci
Fig. 3: Removing Control Arm

FRONT AXLE CARRIER
Removal
1. Raise and support vehicle. Remove front wheels. Remove acoustic cover. Move engine hood into service
position.
2. Remove air filter housing. Remove microfilter.
3. Remove tension strut on spring strut dome. See TENSION STRUTS.
4. Remove expansion tank fasteners and place expansion tank to one side. DO NOT disconnect coolant
hoses. Remove servo fluid reservoir and place to one side.
5. Assemble Special Tool (00 0 200) with Special Tools (00 0 201/202/203/204/208) and install. See Fig.
4.Secure special tool (11 0 000) to front and rear engine lifting eyes and to special tool (00 0 200).
Supports (1) of special tool (00 0 208) must rest on screw connection (2) of both side panels. See Fig. 5.
6. Tighten screws (1, 2). See Fig. 6.
7. Release engine mounts at top left and right. Raise engine with Special Tool (00 0 200) about .4" (10 mm).
8. Remove stabilizer bar link on spring strut. See FRONT STABILIZER BAR.
9. Remove left and right brake calipers and tie back to body. Lines remain connected. To avoid damaging
2005 BMW 645Ci
10. Release screws (1) and remove reinforcement plate. See Fig. 7.
11. On convertible only, remove front tension struts. See TENSION STRUTS.
12. Remove lower section of steering spindle from steering gear. See STEERING SPINDLE LOWER
SECTION.
13. Remove return line for power steering/Dynamic Drive from radiator. If necessary, unlock and disconnect
plug from ride-height sensor.
14. On vehicles with Dynamic Drive, draw off and dispose of hydraulic fluid from fluid reservoir. Observe
all waste disposal regulations. Remove nut (1) for Dynamic Drive return line. See Fig. 8. Remove nut (2)
for Dynamic Drive pressure line. Remove nuts (3) for pressure lines to front axle oscillating motor.
Release cable ties for wiring harness (4).
15. On vehicles with active front steering, unlock plug (1) and remove. See Fig. 9. Remove line from retainer
(2). Unlock and disconnect plugs (3) and (4).
16. Insert Special Tools (31 4 012) into corresponding receptacles of Special Tool (00 2 040). Align Special
Tool (00 2 040) as illustrated to front axle support. See Fig. 10. Ensure when raising that Special Tools
(31 4 012) are correctly inserted in rear recesses on front axle carrier. Support front axle carrier in rear
area by raising Special Tool (00 2 030). Position Special Tool (33 3 274) on floor jack mounting.
17. Remove front axle carrier screws (1) and (2). See Fig. 11.
18. Carefully lower front axle carrier using Special Tool (00 2 030). Pay attention to power steering hoses
and lines when lowering. Hoses and lines must not be tensioned or bent. Lowering dimension (A) is
dependent on equipment specification and is about 7.9" (20 cm) between front axle carrier (1) and engine
carrier (2). See Fig. 12.
2005 BMW 645Ci
Fig. 4: Installing Engine Lifting Tool

2005 BMW 645Ci
Fig. 5: Resting Supports On Screw Connection

2005 BMW 645Ci
Fig. 6: Locating Support Screws

2005 BMW 645Ci

2005 BMW 645Ci
Fig. 8: Locating Nuts For Dynamic Drive

2005 BMW 645Ci
Fig. 9: Locating Lines & Plugs On Active Front Steering

2005 BMW 645Ci
Fig. 10: Supporting Front Axle Carrier

2005 BMW 645Ci
Fig. 11: Locating Front Axle Carrier To Engine Carrier Screws

2005 BMW 645Ci
Fig. 12: Identifying Lowering Dimension

Installation
1. Raise front axle into place. Tighten both front screws (1) first. See Fig. 11. Tighten rear screws (2). If
threads are damaged, they may be repaired with Helicoil thread inserts. Install inserts so they are flush
with original thread. Tighten to specification. See TORQUE SPECIFICATIONS.
2. To complete installation, reverse removal procedure. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS.
3. Install lower section of steering spindle to steering gear. See STEERING SPINDLE LOWER
SECTION.
4. On convertible, install tension struts. See TENSION STRUTS.
5. Install engine underguard and reinforcement plate. Tighten screws to specification. See TORQUE
SPECIFICATIONS.
6. Top up hydraulic fluid reservoir to MAX mark on dipstick. Start engine. Turn steering wheel twice from
2005 BMW 645Ci
7. Check pipe connections for leaks.

8. If necessary, carry out initial operation for Active Front Steering (AFS). See INITIALIZING ACTIVE
FRONT STEERING (AFS) under ADJUSTMENTS.
9. If necessary, carry out initial operation for Dynamic Drive. See INITIALIZING DYNAMIC DRIVE
under ADJUSTMENTS.
FRONT STABILIZER BAR
1. Raise and support vehicle. Remove front wheel.

2. Remove front underbody protection.
3. Remove nuts (1, 2) and remove stabilizer link. See Fig. 13. If necessary, grip ball joint with Torx Socket.
4. Remove stabilizer bar clamping nut (1) and screw (2) on both sides. See Fig. 14. Remove front stabilizer
bar.
5. If replacing, remove retaining bracket at both ends. Remove rubber mount at both ends.
6. To install, reverse removal procedure. Keep retaining bracket, rubber mount and stabilizer free from
grease. Replace self-locking nuts and tighten to specification. See TORQUE SPECIFICATIONS.
2005 BMW 645Ci
Fig. 13: Removing Stabilizer Link

2005 BMW 645Ci
Fig. 14: Removing Front Stabilizer

RUBBER MOUNTS ON TENSION STRUTS
CAUTION: Always replace both rubber mounts. Rubber mounts of tension struts may
only be changed once.
1. Remove tension struts. See TENSION STRUTS.

2. Mark tension struts with a punch mark in area (A). See Fig. 15. If tension struts already have a mark,
replace both tension struts.
3. Remove rubber mount with a press and special tool (31 3 031/032). See Fig. 16.
4. Ensure rubber mount and tension strut bore are free of grease. Press in new rubber mount with special
tool (31 3 031/032). Marking on rubber mount points towards marking on tension strut. Maximum
torsional tolerance (A) is within 5 degrees. See Fig. 17.
2005 BMW 645Ci
6. Install tension strut. See TENSION STRUTS.
Fig. 15: Marking Tension Strut

2005 BMW 645Ci
Fig. 16: Pressing Out Rubber Mount

2005 BMW 645Ci
Fig. 17: Installing Rubber Mount

2005 BMW 645Ci
Fig. 18: Identifying Rubber Mount Protrusion

STRUT WITH COIL SPRING
NOTE: If no centering pin is fitted, it is necessary to mark the position of the studs in
relation to the wheel arch to maintain approximately original camber. Only one
nut may ever be removed for marking.
Removal
1. Remove swivel bearing. See SWIVEL BEARING.

2. If no centering pin is fitted, mark position of studs in relation to wheel arch.
3. Secure spring strut from falling out. Remove strut-to-wheel arch nuts. See Fig. 19.
4. Remove spring strut downwards out of wheel arch.
2005 BMW 645Ci
Fig. 19: Locating Spring Strut Nuts

Disassembly
WARNING: You will be exposed to a high risk of injury if you fail to comply with the
following points:
 Follow instructions for using spring tensioner.

 Use only specified special tools.
 DO NOT use a protective insert for Special Tool (31 3 354).
NOTE: Replace coil springs in pairs only. Fit each axle with the same part number. Coil
springs are allocated according to vehicle type, launch date and optional extras.
1. Clamp Special Tool (31 4 341) at guide (1) in vice. See Fig. 20. Position Spring Retainer (31 3 355) with
protective insert (31 3 365) and spring retainer (31 3 354) without protective insert from above on Special
Tool (31 3 341) until locking pin (2) can be felt and heard to snap into place. Check secure seating of
2005 BMW 645Ci
2. Clean coil spring to remove heavy contamination. Insert upper spring plate in Special Tool (31 3 354).
See Fig. 21. Place lower coil of coil spring in Special Tool (31 3 355). Twist spring strut until end of coil
spring is flush with end of Special Tool (31 3 355). Tension coil spring.
3. Remove cap by removing nut with Special Tool (31 2 210). See Fig. 22. If necessary, use Allen wrench
to hold piston rod at hexagon socket to keep it from turning. Remove support bearing with shim. Remove
strut from coil spring.
4. Relieve tension on coil spring and remove from Special Tools (31 3 354) and (31 3 355). Remove spring
plate with spring pad.
5. Remove auxiliary spring (1), gaiter (2) and spring pad (3). See Fig. 23.
Fig. 20: Clamping Special Tool In Vice

2005 BMW 645Ci
Fig. 21: Placing Coil Spring In Special Tool

2005 BMW 645Ci
Fig. 22: Removing Coil Spring Cap

2005 BMW 645Ci
Fig. 23: Identifying Auxiliary Spring, Gaiter & Spring

Assembly
1. To assemble, reverse disassembly procedure. Check all components and replace, if necessary. Replace
self-locking nuts and tighten to specification. See TORQUE SPECIFICATIONS.
2. Coil spring must fit positively in lower spring plate/spring pad. See Fig. 24.
3. If replacing support bearing and original support bearing (2) was fitted without centering pin (1),
centering pin (1) of new support bearing (2) must be driven out. See Fig. 25.
2005 BMW 645Ci
Fig. 24: Fitting Coil Spring In Lower Spring Pad

2005 BMW 645Ci
Fig. 25: Locating Centering Pin

Installation
1. To install, reverse removal procedure. Replace self-locking nuts. If no centering pin is fitted, align
support bearing using markings to wheel arch. If centering pin is fitted, align spring strut using centering
pin to bore in wheel arch or using studs to wheel arch and push upwards. On all vehicles, tighten nuts to
specification. See TORQUE SPECIFICATIONS.
2. Align front axle. See SPECIFICATIONS & PROCEDURES in WHEEL ALIGNMENT article.
STABILIZER BAR LINK HOLDER
1. Raise and support vehicle. Remove front wheel.

2. Remove stabilizer bar link from holder (1). See Fig. 26. Unscrew bolt (2).
3. Remove nut (1). See Fig. 27. Remove holder (2) for brake hose, brake pad sensor and pulse generator.
4. To install, reverse removal procedure. Replace self-locking nuts and tighten fasteners to specification. See
TORQUE SPECIFICATIONS.
2005 BMW 645Ci
Fig. 26: Removing Stabilizer Link From Holder

2005 BMW 645Ci
Fig. 27: Removing Holder For Stabilizer Link

STEERING SPINDLE LOWER SECTION
CAUTION: If lower section of steering spindle is separated from power steering gear,
the result can be damage to contact ring when steering wheel is turned.
DO NOT allow steering wheel to turn when spindle is disconnected from
steering gear.
Removal
1. Move steering gear to straight-ahead position and turn ignition key to "0" position. Remove steering gear
cover on both sides.
2. Remove clamping screw. Remove lower section of steering spindle from power steering gear. See Fig.
28.
3. Working under dash, remove trim panel for pedal assembly. Mark position of universal joint in relation to
steering column.
2005 BMW 645Ci
4. Turn ignition key to "1" position. Turn steering wheel about 45 degrees. Hold securely and release
clamping screw (1). See Fig. 29.
5. Turn steering wheel back to straight-ahead position and turn ignition key to "0" position. Remove lower
section of steering spindle from steering column.
2005 BMW 645Ci
Fig. 29: Removing Lower Section Of Steering Spindle

Installation
1. To install, reverse removal procedure. Replace clamping screw (1). See Fig. 29. Steering spindle lower
section and steering gear can only be joined in one position. Clamping screw must rest in groove of
steering column. Make sure universal joint is correctly seated. Tighten universal joint coupling to steering
gear/steering spindle to specification. See TORQUE SPECIFICATIONS.
2. If necessary, carry out initial operation for Active Front Steering (AFS). See INITIALIZING ACTIVE
FRONT STEERING (AFS) under ADJUSTMENTS.
3. If necessary, carry out initial operation for Dynamic Drive. See INITIALIZING DYNAMIC DRIVE
under ADJUSTMENTS.
SWIVEL BEARING

2005 BMW 645Ci
2. Remove brake disk (brake line remains connected) and ABS pulse sensor. See BRAKES - REPAIR
INSTRUCTIONS .
3. Remove tension strut from swivel bearing. See TENSION STRUTS.
4. Remove control arm from swivel bearing. See CONTROL ARM.
5. Remove holder for stabilizer link. See STABILIZER BAR LINK HOLDER.
6. Support swivel bearing (1) from below with workshop jack and a suitable mount. See Fig. 30. Expand
swivel bearing with Special Tool (31 2 230). Lower swivel bearing with workshop jack. Remove swivel
bearing.
7. To install, reverse removal procedure.
Fig. 30: Removing Swivel Bearing

TENSION STRUTS
1. Raise and support vehicle. Remove appropriate front wheel. Remove front underbody protection. Remove
2005 BMW 645Ci
steering gear cover at side.

2. Remove tie rod nut. See Fig. 31. If necessary, keep tie rod ball joint from turning by holding ball joint
with Torx socket. Remove tie rod end from swivel bearing.
3. Unscrew tension rod-to-front axle nuts (1). See Fig. 32. Pull out screw (3). Remove ball joint nut (2). If
necessary, hold ball joint with Torx socket to aid in removing nut. Twist swivel bearing a little. Remove
tension strut from swivel bearing.
4. Installation is reverse of removal. Ensure ball pin and bore are free of grease. Replace self-locking nuts.
Tighten nuts to specification. See TORQUE SPECIFICATIONS.
Fig. 31: Locating Tie Rod Nut

2005 BMW 645Ci
Fig. 32: Removing Tension Struts

WHEEL BEARING
NOTE: When clamping swivel bearing unit, make sure it is only clamped at wheel
bearing.
1. Remove swivel bearing. See SWIVEL BEARING.

2. Clamp swivel bearing as illustrated. See Fig. 33.
3. Remove screws and remove swivel bearing upwards. See Fig. 34.
4. Keep tapped holes (1) clean and free from grease. See Fig. 35. Keep contact surface (2) of wheel bearing
and swivel bearing clean and free from grease.
5. To install, reverse removal procedure. If wheel bearing is not replaced, all tapped holes in wheel bearing
must be reconditioned. Tighten fasteners to specification. See TORQUE SPECIFICATIONS.
2005 BMW 645Ci
Fig. 33: Clamping Swivel Bearing Unit

2005 BMW 645Ci
Fig. 34: Detaching Swivel Bearing From Wheel Bearing

2005 BMW 645Ci
Fig. 35: Exploded View Of Wheel Bearing

Bracket For Stabilizer Link On Swivel Bearing 44 (59)
Brake Caliper-To-Steering Knuckle 81 (110)
Control Arm-To-Front Axle Support (1)
Step 1 74 (100)
Step 2 Additional 75-105 Degrees
2005 BMW 645Ci
Front Axle Carrier-To-Engine Carrier 74 (100)

Hydraulic Lines Connecting Nuts
Pressure/Control 22 (30)
Return 26 (35)
Reinforcement Plate-To-Front Axle Support/Engine Carrier (1)
Step 1 41 (56)
Shock Absorber Piston Rod On Thrust Bearing 47 (64)
Spring Strut Mount To Wheel Arch
18 mm 18 (24)
21 mm 25 (34)
Spring Strut Shock Absorber-To-Pivot Mount 60 (81)
Stabilizer Link-To-Stabilizer/Bracket 48 (65)
Tension Strut-To-Front Axle Support (1)
Step 1 74 (100)
Tie Rod Clamping Nut 38 (51)
Tie Rod End Nut 24-30 (32-40)
Universal Joint/Coupling-To-Steering Gear/Steering Spindle 16 (22)
(1)
Wheel Bearing Unit On Swivel Bearing 81 (110)

Wheel Lug Bolts 81-96 (110-130)
(1) Replace nuts/screws.
2006 BMW 650i
SUSPENSION
Rear - 650i, M6
00 GENERAL
 Headaches
 Dizziness
 Stomach aches
 Vomiting
 Diarrhoea
 Cramps/fits
 Unconsciousness

First aid measures:
Danger of injury!

2006 BMW 650i
 Impaired sight

First aid measures:

Recycling:

2006 BMW 650i

contact points.
necessary.

points!


differential cover!
2006 BMW 650i


2006 BMW 650i

Facts:
Consequence:
2006 BMW 650i
Procedure:

bristles!
2006 BMW 650i

THE FOLLOWING WORK



2. Swinging arm
2006 BMW 650i
3. Integral link
5. Control arm
6. Guide arm


2006 BMW 650i


2006 BMW 650i

10 FINAL DRIVE

Check oil level.
2006 BMW 650i

Installation:

2006 BMW 650i

Time-Oil" sticker.
Recycling:
DATA .
Installation:
2006 BMW 650i

No oil drain plug:
2006 BMW 650i

Installation:

2006 BMW 650i

E63 N52 188L / 188LW
N62, N62TU 215K
S85 215 with lock
E64 N52 188L / 188LW
N62, N62TU 215K
K Compact
L Light-running



bent).
2006 BMW 650i

Unfasten screws.

2006 BMW 650i


about noise.
TOOLS .

2006 BMW 650i

After installation:

Release screws (1).
Unscrew screws (2).
Remove cover.
Installation:
2006 BMW 650i

Release screw (1).
Unscrew screws (2).
Remove cover.
Installation:

2006 BMW 650i



2006 BMW 650i
rear differential.

 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
2006 BMW 650i
TOOLS .
 33 1 150
 33 1 341
 33 3 440
 33 3 470
 33 3 480

differential!

2006 BMW 650i

215K / with lock:

188K/L:

2006 BMW 650i



2006 BMW 650i

Fit drive flange.
can be screwed on.

2006 BMW 650i



After installation:

2006 BMW 650i
Installation:

Installation:
REAR AXLE .
2006 BMW 650i

Replacement:
After installation:
 00 5 010
 00 5 500
 32 1 060
 33 1 308
 33 3 400
 33 4 240
 33 4 250
TOOLS .

2006 BMW 650i

diameter).
00 5 500 + 33 3 400 : 168K/L - 78x44x10
00 5 500 + 33 4 240 : 188K/L/LW - 90x44x10
00 5 500 + 33 4 250 : 215K/L/LW, 220K to 230K - 100x50x10
33 5 030 : 210, 215 with lock - 76x50x10

2006 BMW 650i
After installation:
damage.

Series .
 188L / 188LW
 215K
 215 with lock
After installation:

 33 3 312
 33 4 161
 33 4 162
 33 4 166
 33 4 311
 33 4 312
 33 4 465
2006 BMW 650i


2006 BMW 650i

go.


FRONT (M6)
 33 3 312
 33 4 161
 33 4 162
 33 4 466
2006 BMW 650i

2006 BMW 650i

 33 4 281
 33 4 282
 33 4 283
 33 4 284
 33 4 465
2006 BMW 650i

as it will go.
2006 BMW 650i


(M6)
 33 4 281
 33 4 282
 33 4 283
 33 4 284
 33 4 465
2006 BMW 650i

Circolight

will go.
2006 BMW 650i
21 OUTPUT SHAFTS
 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

the output shaft.
2006 BMW 650i


070 .
2006 BMW 650i


tools 33 2 202 and 33 5 070 .
2006 BMW 650i

070 .


2006 BMW 650i

tools 33 2 202 and 33 5 070 .

2006 BMW 650i


Apply handbrake.
Remove rear wheel .
Unscrew collar nut.
Installation:

2006 BMW 650i

Installation:

2006 BMW 650i

After installation:
Remove rear wheel.

2006 BMW 650i

2006 BMW 650i
 21 2 120
 26 1 110
Clean output shaft.
Installation:

2006 BMW 650i
Remove circlip (4).
Installation:
joint.


2006 BMW 650i

Installation:

2006 BMW 650i
Installation:
Pull new gaiter on.

electric inscriber.
2006 BMW 650i
31 REAR SUB-FRAME
 00 2 030
 00 2 040
 33 4 232
system.



2006 BMW 650i
Installation:

2006 BMW 650i

After installation:

system.

2006 BMW 650i

After installation:


 00 2 030
 00 2 040
 33 3 274
 33 4 232
2006 BMW 650i




2006 BMW 650i
Installation:

2006 BMW 650i


LINK

Installation:

2006 BMW 650i

After installation:

check.


2006 BMW 650i

Installation:

2006 BMW 650i

Installation:

Unfasten nut.
Installation:

2006 BMW 650i

After installation:

2006 BMW 650i
Installation:

Unscrew nut (1).

2006 BMW 650i
Installation:

Replacement:
After installation:
Variants:
2006 BMW 650i

Unscrew nut (1).
Installation:

2006 BMW 650i

Installation:

2006 BMW 650i

After installation:
 33 3 333
 33 4 191
 33 4 192
 33 4 193

2006 BMW 650i

Remove circlip (1).
Installation:

2006 BMW 650i

After installation:

CARRIER
Remove rear wheel .
collar nut.
Unscrew collar nut.
Release handbrake.
Installation:

2006 BMW 650i

REAR BRAKE DISCS .
Replacement:
2006 BMW 650i

33 AXLE MOUNTING

Risk of damage!

Release screws (2).
Installation:

2006 BMW 650i

 33 4 153
 33 4 154
 33 4 155
 33 4 271
 33 4 272
 33 4 274

necessary.
2006 BMW 650i

observed.
2006 BMW 650i

41 WHEEL BEARINGS
 33 2 116
 33 2 160
 33 2 201
Apply handbrake.
Remove rear wheel .
Unscrew collar nut.

2006 BMW 650i
Installation:

bearing.
2006 BMW 650i
be reused!
Installation:
After installation:
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
inner race.
2006 BMW 650i
Inner Race


2006 BMW 650i

Installation:

2006 BMW 650i
52 SHOCK ABSORBER
Facts:
Consequence:
Procedure:
ABSORBER

Release screw.
2006 BMW 650i
Installation:
Replace screw.

Unscrew nuts (1).
Installation:

2006 BMW 650i


 31 3 341
springs.
2006 BMW 650i

Version with EDC:
Removing:
snap into place.

2006 BMW 650i




2006 BMW 650i

Assembly:
2006 BMW 650i
2006 BMW 650i


2006 BMW 650i

After installation:
Control (EDC).
 31 3 341
springs.
2006 BMW 650i
Version with EDC:
Removing:
snap into place.


2006 BMW 650i

(Arrow)
2006 BMW 650i

Assembly:
2006 BMW 650i
2006 BMW 650i


2006 BMW 650i

SHOCK ABSORBER

2006 BMW 650i

 31 3 341
springs.

2006 BMW 650i
Removing:
into place.


2006 BMW 650i

(Arrow)

2006 BMW 650i

Assembly:


2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
Absorber

2006 BMW 650i

MODEL)
absorber.
55 STABILIZER BAR
Installation:

2006 BMW 650i

Replacement:
Installation:
oil and grease.
2006 BMW 650i

Installation:
Installation:

2006 BMW 650i

90 TROUBLESHOOTING

2006 BMW 650i
Fault Cause Remedy

suspension faulty
faulty
or guide arm faulty
faulty
suspension faulty

Fault Cause Remedy
spring
2006 BMW 650i

tube
defective
on tyre profile
effect)
effect)
effect)
2005 BMW 645Ci
2004-05 SUSPENSION Rear - 645Ci
2004-05 SUSPENSION
Rear - 645Ci
DESCRIPTION
The 645Ci (E65) uses independent rear suspension. The rear axle carrier, the control arms and the swinging
arms are made of aluminum. All the bushings used on the rear axle are rubber bushings. Tension struts serve to
increase body rigidity. The stabilizer bar is fitted behind the rear axle carrier. The ride level sensors have been
moved forward.
Spring struts with coil springs and twin-tube gas-pressure dampers are used on rear axle. The sports suspension
available as an option is 15 mm lower at the front and rear axles compared with the standard suspension. The
sports suspension has been equipped with harder springs, sportier damper tuning and stiffer stabilizer bars.
ADJUSTMENTS
RIDE HEIGHT
See RIDE HEIGHT SPECIFICATIONS under RIDING HEIGHT ADJUSTMENT in SPECIFICATIONS &
PROCEDURES article in WHEEL ALIGNMENT.
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
See WHEEL ALIGNMENT PROCEDURES in SPECIFICATIONS & PROCEDURES article in WHEEL

ALIGNMENT.
TROUBLE SHOOTING
To trouble shoot most symptoms, see TROUBLE SHOOTING table.
Whether a spring strut shock absorber has to be replaced can only be ascertained by checking while it is
installed with a shock absorber tester or while it is removed with a shock absorber test machine.
TROUBLE SHOOTING
Fault Cause Remedy
Drumming Noise Rubber Mount Of Rear Axle Replace Rubber Mount
Carrier Faulty
Drumming Noise Rubber Mount On Final Drive Replace Rubber Mount
Suspension Faulty
Drumming Noise Rubber Mount Of Control Arm Replace Control Arm
Faulty
Drumming Noise Rubber Mount On Traction Strut Replace Traction Strut
Faulty
Drumming Noise Rubber Mounts Of Swinging Replace Swinging Arm
2005 BMW 645Ci
Arms Faulty
Grinding Noise Only When Wheel Bearings Faulty Replace Wheel Bearing
Driving In Curves
Poor Handling Or Direction Rubber Mount Of Control Replace Control Arm/Traction
Stability Arm/Traction Strut Unserviceable Strut
Poor Handling Or Direction Rubber Mount Of Rear Axle Replace Rubber Mount
Stability Carrier Faulty
Poor Handling Or Direction Rear Axle Geometry Not OK Perform Chassis Alignment Check
Stability
Excessive Tire Wear Rear Axle Geometry Not OK Perform Chassis Alignment Check
Rattling Noise Rubber Mount On Rear Axle Replace Rubber Mount
Carrier Faulty
Rattling Noise Ball Joint In Wheel Carrier Faulty Replace Ball Joint In Wheel
Carrier
Unsteady Taking Of Curves Due Rubber Mount On Rear Axle Replace Rubber Mount
To Self-Steering Or Poor Rear Carrier Faulty
End Track Stability
Unsteady Taking Of Curves Due Rubber Mount Of Final Drive Replace Rubber Mount
To Self-Steering Or Poor Rear Suspension Faulty
End Track Stability
Unsteady Taking Of Curves Due Shock Absorber Action Replace Shock Absorbers
To Self-Steering Or Poor Rear Inadequate
End Track Stability
Vibration Wheels Unbalanced Balance Wheels
Vibration Rims Have Lateral/Radial Runout Replace Rims If Necessary
Vibration Tires Have Radial Runout Match Or Replace Tires

AXLE CARRIER
NOTE: On vehicles with Dynamic Drive, draw off and dispose of hydraulic fluid from
power steering fluid reservoir. To bleed system, top off reservoir to MAX mark.
Start engine. Turn steering wheel twice each time lock-to-lock. Check oil level
with engine off. Top off as necessary.
Removal
1. Remove rear wheels. Remove complete exhaust system. See EXHAUST SYSTEM. Remove propeller
shaft from rear differential. See AXLE SHAFTS in DRIVE AXLES article. On vehicles with Dynamic
Drive, disconnect pressure lines at junction. See PRESSURE LINE FOR OSCILLATING
2005 BMW 645Ci
Detach plug connection on both sides for pulse generator at rear and expose line up to control arm.
2. Detach plug connection for brake pad wear sensor on right and expose line up to control arm. Remove
brake caliper on both sides of wheel carrier and tie back. Remove brake discs on both sides. Disconnect
hand brake cable on both sides of wheel brake and remove from hanging hook. See REAR BRAKES .
3. If necessary, disconnect plug connection from sensor. Remove spring strut shock absorber on both sides
from wheel sensor.
4. Insert Special Tools (33 4 233) and (33 4 232) into corresponding mountings of Special Tool (00 2 040).
Align Special Tool (00 2 040) to rear axle carrier. Support rear axle carrier by raising Special Tool (00 2
030). See Fig. 1.
5. Remove screws (1). Remove stop plate (2). Lower rear axle carrier (3) using Special Tool (00 2 030). See
Fig. 2.
Fig. 1: Preparing Rear Axle Carrier For Removal

2005 BMW 645Ci
Fig. 2: Lowering Rear Axle Carrier

Installation
1. To install, reverse removal procedure. Damaged threads in body-side bushes can be repaired with Helicoil
thread inserts. Thread inserts must be installed so that they are flush with original thread.
2. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
AXLE CARRIER RUBBER MOUNTS

2005 BMW 645Ci
heat shield. On convertible, remove cross strut. Remove tension strut on both sides and reinsert screws for
rear axle carrier. See AXLE CARRIER TENSION STRUT. Remove hand brake cable on both sides
from hanging hook. On version with Dynamic Drive, detach pressure lines for rear axle oscillating motor
on floorpan and remove bracket from rear axle carrier.
2. Insert Special Tools (33 4 233) and (33 4 232) into corresponding mountings of Special Tool (00 2 040).
Align Special Tool (00 2 040) to rear axle carrier. Support rear axle carrier by raising Special Tool (00 2
030). See Fig. 3.
3. Release screws (1). Remove stop plate (2). Lower rear axle carrier (3) using Special Tool (00 2 030). See
Fig. 4.
4. To remove a rubber mount, assemble Special Tools (33 4 154), (33 4 155), (33 4 272), (33 4 274) and (33
4 275). See Fig. 5. Check installation position of Special Tool (33 4 274) to rubber mount and (33 4 272)
to bearing bushing. Correct as necessary. Using a hot air blower, heat bushing to a maximum of 1112°F
(600°C). Pull out rubber mount by turning Special Tool (33 4 155).
5. To install rubber mount, install a marking to Special Tool (33 4 272). Coat rubber mount with Circolight
anti-friction agent and insert in Special Tool (33 4 272). Ensure arrows or stops (2) of inner sleeve points
in vehicle longitudinal direction when rubber mount is installed. See Fig. 6. Maximum deviation (A) is 0-
14 degrees. Align rubber mount using arrows or stops (2) to marking on Special Tool (33 4 272).
6. Assemble Special Tools (33 4 154), (33 4 155), (33 4 271) and (33 4 272). See Fig. 7. Check installation
position of rubber mount to marking on Special Tool (33 4 272). Correct as necessary. Align Special Tool
(33 4 272) using marking to vehicle longitudinal direction. Install on rear axle carrier and screw on
Special Tool (33 4 273). Check installation position of Special Tools (33 4 272) and (33 4 273). Correct
as necessary. Draw in rubber mount by turning Special Tool (33 4 154).
2005 BMW 645Ci
Fig. 3: Supporting Rear Axle

2005 BMW 645Ci
Fig. 4: Lowering Rear Axle Carrier

2005 BMW 645Ci
Fig. 5: Assembling Special Tools

2005 BMW 645Ci
Fig. 6: Aligning Rubber Mount

2005 BMW 645Ci
Fig. 7: Assembling Special Tools

AXLE CARRIER TENSION STRUT
1. On convertible, remove rear tension strut. On all models, if necessary, remove fuel tank cover.
2. On right side in version with Dynamic Drive, unscrew nut (1). See Fig. 8. Remove pressure lines from
rubber mount. On all models, insert Special Tools (33 4 233) and (33 4 232) into corresponding
mountings of Special Tool (00 2 040).
3. Align Special Tool (00 2 040) to rear axle carrier. See Fig. 9. If necessary, lower Special Tool (33 3 274).
Support rear axle carrier by raising Special Tool (00 2 040).
4. Remove screw (1) and bolt (2). See Fig. 10. Remove tension strut sideways. Secure rear axle carrier by
2005 BMW 645Ci
5. To install, reverse removal procedure. Tighten to specification. See TORQUE SPECIFICATIONS.
Fig. 8: Removing Nut

2005 BMW 645Ci
Fig. 9: Aligning Special Tool To Rear Axle Carrier

2005 BMW 645Ci
Fig. 10: Removing Screws & Bolts

EXHAUST SYSTEM
Support exhaust system with Special Tool (31 2 220). See Fig. 11. Unscrew nuts (1, 2). See Fig. 12. Unscrew
nut (1). See Fig. 13. Unscrew hanger nuts. See Fig. 14. Unfasten screws and remove reinforcement plate (1).
See Fig. 15. Lower exhaust system. To install, reverse removal procedure.
2005 BMW 645Ci
Fig. 11: Supporting Exhaust System With Special Tool

2005 BMW 645Ci
Fig. 12: Removing Nuts

2005 BMW 645Ci
Fig. 13: Locating Nut (Left Side Shown)

2005 BMW 645Ci
Fig. 14: Removing Exhaust System Hanger Nuts

2005 BMW 645Ci
Fig. 15: Detaching Suspension On Front Muffler From Body

PRESSURE LINE FOR OSCILLATING MOTOR/REAR AXLE
CAUTION: Ensure work area is clean. Do not allow any dirt to enter the hydraulic
1. Remove right underbody paneling. Remove right tank cover.

2. Remove nuts. Remove screws (1). See Fig. 16. Unfasten screws (1). See Fig. 17. Remove nuts (1) on
both sides. See Fig. 18. Place fluid sump underneath for residual fluid. Remove nuts (1, 2). See Fig. 19.
Feed pressure lines at top around rear axle carrier and remove toward rear.
2005 BMW 645Ci
different thread sizes.

4. Align pressure lines to rear axle carrier. Check anti-friction bearings on both sides for damage. Replace
stabilizer as necessary. Pressure lines can only be positioned and secured to stabilizer before stabilizer is
installed. Use Special Tool (33 0 170) to position pressure lines. Screw in pressure lines using nuts
loosely installed into stabilizer. Do not tighten. Clamp Special Tool (33 0 170) to pressure lines and
secure. Ensure side with notches points in direction of oscillating motor. Tighten nuts. Remove special
tool. See Fig. 20.
5. After installation, fill and bleed power steering hydraulic system. To bleed system, top off reservoir to
MAX mark. Start engine. Turn steering wheel twice each time lock-to-lock. Check oil level with engine
off. Top off as necessary.
Fig. 16: Removing Screws

2005 BMW 645Ci

2005 BMW 645Ci
Fig. 18: Removing Nuts On Both Sides

2005 BMW 645Ci
Fig. 19: Disconnecting Pressure Lines

2005 BMW 645Ci
Fig. 20: Installing Pressure Lines

PUSH ROD/INTEGRAL LINK
CAUTION: On vehicle with air suspension, disconnect fuse on air supply system so
that there is no unintentional system regulation. See FUSES & CIRCUIT
BREAKERS article.
1. Remove rear wheel. Remove output shaft from rear differential. See AXLE SHAFTS under DRIVE
AXLES. Remove swinging arm nut. See Fig. 21. Remove screw toward rear. Press swinging arm
downward. Remove screw. Remove integral link (1). See Fig. 22.
2. To install, reverse removal procedure. Replace nut. Mount swinging arm until it is hand tight, then tighten
bolts to specification. See TORQUE SPECIFICATIONS.
2005 BMW 645Ci
Fig. 21: Removing Swinging Arm Nut

2005 BMW 645Ci
Fig. 22: Removing Integral Link

RIDE HEIGHT SENSOR
NOTE: Numbers and letters in text refer to numbers and letters in figures.
Disconnect electrical connector from ride height sensor. Remove nut (1). See Fig. 23. Disengage control rod.
Unfasten screws (2). Remove ride height sensor. To install, reverse removal procedure.
2005 BMW 645Ci
Fig. 23: Removing Ride Height Sensor

SPRING STRUT SHOCK ABSORBER ASSEMBLY
NOTE: Numbers and letters in text refer to numbers and letters in figures.
BREAKERS article.
1. Remove rear wheel. Remove rear luggage compartment wheel arch trim. Remove control arm from wheel
carrier. See UPPER CONTROL ARM. Remove stabilizer link from swing arm. See STABILIZER
LINK FOR STABILIZER BAR.
2005 BMW 645Ci
carrier. Unscrew nuts (1). See Fig. 24. Remove screw. See Fig. 25. Remove rear spring strut shock
absorber from wheel carrier. Press wheel carrier downwards, guide rear spring strut shock absorber
downward between guide arm and control arm and then remove in upwards direction. See Fig. 26.
3. To install, reverse removal procedure. Replace self-locking nuts and tighten to specification. See

2005 BMW 645Ci
Fig. 25: Removing Bolt

2005 BMW 645Ci

Overhaul
WARNING: It is essential to use Special Tool inserts (31 3 368 ) and (31 3 357). Failure
to use protective inserts exposes the risk of the spring detaching from the
spring retainers during the tensioning/relieving operation. Never tighten
or untighten special tools with an impact tool.
WARNING: Coils of coil spring must be located completely in recess of Special Tools
(31 3 357) with protective insert (31 3 368) when tensioned.
1. Remove spring shock absorber assembly. See SPRING STRUT SHOCK ABSORBER ASSEMBLY.
Clamp Special Tool (31 3 341) in vise. Position Special Tools (31 3 357) with protective inserts (31 3
368) from above on Special Tool (313 3 341) until locking pins can be felt and heard to snap into place.
See Fig. 27. Check that Special Tools (31 3 357) are securely seated and correct as necessary.
2005 BMW 645Ci
Fig. 28.
3. Starting from a stud, mark installation position of support bearing on spring strut shock absorber. See Fig.
29. Compress coil spring until stress on piston rod is relieved.
4. Release nut (gripping piston in the process). See Fig. 30. Remove shim and support bearing with spring
pad. Remove spring strut shock absorber with thrust washer, damper and lower spring pad sideways from
tensioned coil spring. Remove thrust washer, damper (1) with protective tube and lower spring pad (2). If
necessary, relieve tension on coil spring.
5. To reassemble, check lower spring pad (2). If necessary, replace and position on spring plate. Check
damper (1) with protective tube, if necessary replace and attach to piston rod. See Fig. 31. Attach thrust
washer to piston rod.
6. If necessary, carry over marking from spring strut shock absorber to new component. Insert spring strut
shock absorber in tensioned coil spring and align to end of coil spring using lower spring pad. See Fig.
32.
NOTE: Ensure end of coil spring is precisely seated in lower spring pad. See Fig.
33 and Fig. 34 .
7. Check support bearing and replace as necessary. Attach support bearing to piston rod. Use lower spring
pad to align support bearing to end of coil spring.
8. Attach shim to piston rod. Replace self-locking nut and screw on as far as possible to avoid damaging the
piston rod when relieving tension on the coil spring. Align support bearing by way of a stud to marking
on spring strut shock absorber. See Fig. 29.
9. Relieve tension on coil spring slightly. Tighten down nut (gripping piston rod in the process). See Fig. 30.
Fully relieve tension on coil spring. Ensure lower and upper coils of coil spring rest completely in recess
of spring plate or support bearing.
2005 BMW 645Ci
Fig. 27: Clamping Special Tool (31 3 341) In Vise

2005 BMW 645Ci
Fig. 28: Placing Upper & Lower Coils Of Coil Spring Between Spring Retainers
2005 BMW 645Ci
Fig. 29: Marking Installation Position Of Support Bearing

2005 BMW 645Ci
Fig. 30: Removing Spring Strut Shock Absorber Nut

2005 BMW 645Ci
Fig. 31: Checking Damper With Protective Tube

2005 BMW 645Ci
Fig. 32: Inserting Spring Strut Shock Absorber In Tensioned Coil Spring
2005 BMW 645Ci
Fig. 33: Ensuring End Of Spring Is Seated In Rubber Mount (1 Of 2)

2005 BMW 645Ci
Fig. 34: Ensuring End Of Spring Is Seated In Rubber Mount (2 Of 2)

STABILIZER BAR
1. Remove rear wheel. Remove stabilizer link from stabilizer. See STABILIZER LINK FOR
STABILIZER BAR. Release nuts at both ends. Remove stabilizer sideways. Check rubber mount on
both sides for damage; if necessary, remove retaining bracket and replace rubber mount. See Fig. 35.
2. To install, reverse removal procedure. Keep retaining bracket, rubber mount and stabilizer free from
grease. Wet retaining bracket with low-surface tension water. Tighten bolts to specification. See
2005 BMW 645Ci
Fig. 35: Checking Rubber Mount At Stabilizer Bar

STABILIZER BAR RUBBER MOUNTS
Release nuts (1) on both sides. See Fig. 36. Turn stabilizer bar in downward direction. Remove retaining
bracket (2) on both sides. Remove rubber mount (3) on both sides. To install, reverse removal procedure. Keep
retaining bracket (2), rubber mount (3) and stabilizer bar/anti-friction bearing free from grease. Moisten
retaining bracket (2) with low surface-tension (soapy) water.
2005 BMW 645Ci
Fig. 36: Removing Rubber Mounts For Stabilizer Bar

STABILIZER LINK FOR STABILIZER BAR
To remove stabilizer link from stabilizer, release nut (1). See Fig. 37. If necessary, grip at Torx socket. To
remove stabilizer link from swinging arm, release nut (2). If necessary, grip at Torx socket. To install, reverse
removal procedure. Replace self-locking nuts. Tighten bolts to specification. See TORQUE
SPECIFICATIONS.
2005 BMW 645Ci
Fig. 37: Removing Stabilizer Link From Stabilizer & Swinging Arm
STEERING KNUCKLE/WHEEL CARRIER
CAUTION: On vehicles with air suspension, disconnect fuse on air supply system so
BREAKERS article.
1. Apply hand brake. Unclip hub cover. Unscrew collar nut (1). See Fig. 38. Remove rear wheel. Remove
rear brake disc. Disengage parking brake Bowden cable from wheel brake. See 34 41 120 REMOVING
2005 BMW 645Ci
AND INSTALLING / REPLACING BOTH HANDBRAKE BOWDEN CABLES . Remove stabilizer

link for stabilizer at rear STABILIZER LINK FOR STABILIZER BAR. Remove rear spring strut
shock absorber/rear shock absorber from wheel carrier/swinging arm. See SPRING STRUT SHOCK
ABSORBER ASSEMBLY. Remove swinging arm from wheel carrier. See SWING ARM. Press output
shaft out of wheel carrier. See AXLE SHAFTS article. Remove upper control arm from wheel carrier.
See UPPER CONTROL ARM. Remove guide arm from wheel carrier. See TRACTION STRUT.
2. Remove support for parking brake shoe. See PARKING BRAKE . Remove brake guard plate. Remove
integral link.
3. To install, reverse removal procedure. Secure collar nut by peening on flat areas of output shaft. Replace
collar nut. Tighten collar nut to specification. See TORQUE SPECIFICATIONS.
Fig. 38: Removing Collar Nut

STEERING KNUCKLE/WHEEL CARRIER BALL JOINT

2005 BMW 645Ci
1. Remove push rod/integral link. See PUSH ROD/INTEGRAL LINK. Remove stabilizer link from
swinging arm. See STABILIZER LINK FOR STABILIZER BAR. Remove spring strut shock
absorber/shock absorber carrier/swinging arm. See SPRING STRUT SHOCK ABSORBER
ASSEMBLY.
2. Cut highlighted area out of Special Tool (33 4 191) and then deburr. See Fig. 39. Remove circlip (1).
Assemble Special Tools (33 4 191), (33 4 192), (33 4 193) and (33 3 333). See Fig. 40. Slotted side of
Special Tool (33 4 191) must point to wheel carrier. Remove ball joint by turning nut on Special Tool (33
3 333).
3. Draw in new ball joint (1) with Special Tools (33 4 191), (33 4 192), (33 4 194) and (33 3 333) as far as it
will go. See Fig. 41. Install new circlip (1). Tighten bolts to specification. See TORQUE
SPECIFICATIONS.
Fig. 39: Reconditioning Special Tool By Removing Highlighted Area

2005 BMW 645Ci
Fig. 40: Assembling Special Tools (33 4 191, 33 4 192, 33 4 193 & 33 3 333)
2005 BMW 645Ci
Fig. 41: Drawing In New Ball Joint With Special Tools

SWING ARM
BREAKERS article.
1. Remove rear wheel. If necessary, remove control rod for ride-height swinging arm. Remove stabilizer
link from swinging arm. See STABILIZER LINK FOR STABILIZER BAR.
2. Mark position of eccentric bolt to rear axle carrier with colored paint to simplify reassembly. See Fig. 42.
3. Unscrew nut (1). Remove eccentric disc. See Fig. 43. Unscrew and remove eccentric bolt. Unfasten nut
2005 BMW 645Ci
and pull out bolt.

4. Support wheel carrier with jack. Unfasten nut. Pull out bolt. See Fig. 44. Remove swinging arm toward
bottom. See Fig. 45.
5. To install, reverse removal procedure. Replace self-locking nuts. Install eccentric disc (2). See Fig. 43.
Note insertion direction of eccentric bolts so bolt head points in direction of travel. Tighten bolts to
specification. See TORQUE SPECIFICATIONS.
Fig. 42: Marking Position Of Eccentric Bolt To Rear Axle Carrier

2005 BMW 645Ci
Fig. 43: Identifying Nut & Eccentric Disc

2005 BMW 645Ci
Fig. 44: Removing Nut & Pulling Out Bolt

2005 BMW 645Ci
Fig. 45: Removing Swinging Arm Toward Bottom

TRACTION STRUT
1. Remove rear wheel.

2. Release nuts (1). See Fig. 46. Grip hexagon head if necessary. Remove guide arm from wheel carrier.
Unscrew nut (1). Remove eccentric disc (2). See Fig. 47. Pull out eccentric bolt (3). Remove guide arm.
3. To install, reverse removal procedure. Replace self-locking nuts. Ensure tapered pin and bore are free of
grease. Note insertion direction of eccentric bolt (3). See Fig. 47. Bolt head points in opposite direction to
direction of travel. Tighten to specification. See TORQUE SPECIFICATIONS.
2005 BMW 645Ci

2005 BMW 645Ci
Fig. 47: Removing Eccentric Disc

UPPER CONTROL ARM
BREAKERS article.
1. Remove rear wheel. Unclip line for pulse generator (1) from holder (2). See Fig. 48. On right side, unclip
line for brake pad sensor (3) from holder (2).
2005 BMW 645Ci
carrier. Unscrew nut (1). Pull out bolt (2). See Fig. 50. Remove control arm at top.
3. To install, reverse removal procedure. Replace self-locking nut (1). Keep tapered pin and bore free from
grease. Note insertion direction of bolt (2). Tighten to specification. See TORQUE SPECIFICATIONS.
Fig. 48: Unclipping Line For Pulse Generator (1) & Brake Pad Sensor (3) From Holder (2)
2005 BMW 645Ci
Fig. 49: Releasing Nut By Gripping At Hexagon Head

2005 BMW 645Ci
Fig. 50: Unscrewing Nut (1) & Pulling Out Bolt (2)
WHEEL BEARING
1. Remove drive flange for rear axle shaft. See AXLE SHAFT DRIVE FLANGE under REMOVAL &
INSTALLATION in AXLE SHAFTS article. Remove bolts. Remove wheel bearing. See Fig. 51.
2. To install, reverse removal procedure. Keep tapped holes (1) and mating surfaces (2) of wheel bearing
and wheel carrier clean and free from grease. See Fig. 52. Use a new wheel bearing.
2005 BMW 645Ci
Fig. 51: Removing Wheel Bearing

2005 BMW 645Ci
Fig. 52: Identifying Tapped Holes & Mating Surfaces

Bearing Unit On Wheel Carrier 74 (100)
Collar Nut
M22 Thread 148 (200)
M27 Thread 310 (420)
Compression Strut On Body 33 (45)
Control Arm To Rear Axle Support (Tighten In Normal Position) 48 (65)
Control Lines To Oscillating Motor 22 (30)
2005 BMW 645Ci
Dynamic Drive Pressure Line Circuit To Valve Block 26 (35)

Hydraulic Line Connecting Nut 22 (30)
Hydraulic Line Connecting Nut Return 26 (35)
Integral Link On Front Wheel Carrier 74 (100)
Rear Axle Carrier To Body 122 (165)
Return Line To Valve Block 30 (40)
Shock Absorber To Trailing Arm 122 (165)
Shock Absorber Piston Rod On Thrust Bearing 20 (27)
Stabilizer Bar To Rear Axle Support Retaining Bracket 21 (28)
Stabilizer Link On Anti-Roll Bar/Swinging Arm
M10 48 (65)
M12 74 (100)
Support On Body/Rear Axle Carrier 21 (28)
Swinging Arm Screw Connection 177 (240)
Swinging Arm To Rear Axle Support 122 (165)
Traction Strut To Wheel Carrier 48 (65)
Trailing Arm To Rear Axle Carrier (Tighten In Normal Position) 49 (67)
Upper Control Arm To Axle Carrier 74 (100)
Upper Control Arm To Wheel Carrier 122 (165)
Wheel Lug Bolt 89 (120)
INCH Lbs. (N.m)
Control Rod/Jointed Rod To Ride Height Sensor 71 (8)
Control Rod To Swinging Arm 71 (8)
Lateral Acceleration Sensor To Body 71 (8)
Line Holder/Pipe Holder 71 (8)
Ride Level Sensor To Holder 44 (5)
Ride Level Sensor To Rear Axle Carrier 71 (8)
Valve Block To Holder 71 (8)
Valve Block To Body Holder 71 (8)
2006 BMW 650i
TRANSMISSION Transfer Case - Service Information - 650i
TRANSMISSION
Transfer Case - Service Information - 650i
00 TRANSFER CASE, GENERAL

 Headaches
 Dizziness
 Stomach aches
 Vomiting
 Diarrhoea
 Cramps/fits
 Unconsciousness

First aid measures:
Danger of injury!

2006 BMW 650i
TRANSMISSION Transfer Case - Service Information - 650i
 Impaired sight

First aid measures:

Recycling:
2006 BMW 650i
SUSPENSION Wheel And Tires - SI Techniques - All Models
SUSPENSION
Wheel And Tires - SI Techniques - All Models
KINEMATIC DIAGNOSIS SYSTEM AND ENVIRONMENT

BMW KDS (Beissbarth)
Fig. 1: Identifying Kinematic Diagnosis System And Environment

1. FOREWORD
1.1 Objectives
Wheel alignment has become an increasingly complex subject. The aim of this BMW Service Technology
bulletin, therefore, is to achieve several objectives:
 Creation of guidelines for working with the BMW Kinematic Diagnosis System (KDS).
2006 BMW 650i
 Familiarization with wheel alignment technology for current vehicles and clarifying any questions which
arise in this connection.
 Transparency and clarification of different terms.
 Clarification of the causes of errors in the past, such that they can be avoided after reading this document.
 Creation of conditions for dealing safely with the BMW KDS.
1.2 Further development of the BMW Kinematic Diagnosis System
 The BMW Kinematic Diagnosis System is an integrated part of automotive system concepts. It ensures
that work is carried out in a particularly rational manner which is appropriate for BMW requirements,
such that you can also be certain of being prepared for future technological developments. As far as
precision and performance in wheel alignment and tuning is concerned, BMW, together with leading
manufacturers, has made the best of what is technically feasible: the BMW Kinematic Diagnosis System.
 The BMW Kinematic Diagnosis System manufactured by Beissbarth is more than just the further
development of conventional wheel alignment equipment. It sets new standards in precision,
performance, speed and handling. It is a guarantor for the perfection which BMW service customers rely
on.
 Ride comfort, road safety and tyre wear depend to a large extent on the perfect interplay of the vehicle's
kinematic functions. BMW is constantly launching new generations of chassis which are even better than
their predecessors. This is why there are fewer kinematics system adjusting points and narrower
tolerances when measuring and tuning the chassis.
 With the use of the multi-link rear suspension and the E36, the electronic wheel alignment devices are no
longer suitable for BMW wheel alignment purposes. This applies to both the measuring procedure and
measuring precision. The generation of equipment which was approved with the E36 series still fulfils all
the requirements placed on a modern wheel alignment device, including the use of the latest computer
technology.
 Only BMW Kinematic Diagnosis Systems manufactured by Beissarth and Bosch may be used for wheel
alignment.
1.3 Technical Data

2006 BMW 650i
Fig. 2: Technical Data Display

BMW KINEMATIC DIAGNOSIS SYSTEM - TECHNICAL DATA SPECIFICATIONS

1) Display - 17" graphic screen with high-resolution graphics (640x480
pixels with 256 colours)
2) On-screen text - In the appropriate national language
3) Wheel dimensions - 12"...20"
4) Vehicle memory locations - Unlimited
5) Rotating plates - Load bearing capacity 1000 kg, angle of rotation +/- 360°,
450 x 450 x 50 mm (L x W x H), sliding range +/- 50 mm,
weight 18 kg
6) Sliding plates - Loadbearing capacity 1000 kg, angle of rotation +/- 10°,
450x450 x 50mm (L x W x H)
7) Electrical connection - 100...115 V/220...240V 50/60 Hz, 0.5 kW (other
connections on request)
2006 BMW 650i
1 - PC display device with graphic screen, graphical tablet, small or large equipment cabinet including
automatic charging station, DIN A4 dot matrix printer
4 - Measuring sensors with CCD camera technology and infrared data transmission with built-in power supply
1 - Cable set (comprising 4 cables)
1 - Brake clamping device
1 - Steering lock device
2 - Electronic precision rotating plates with integrated sensor without access ramps
2 - Sliding plates without access ramps
4 - BMW quick-clamping units, comprising a P8-68 locating bell and P267 01 quick-acting clamp including
coated holding claws
1 - Operating instructions for BMW KDS (8 languages)
1 BMW software and the BMW vehicle set-point data with setting screens as well as text for the measurement
preparations
1.5 Accessories Required
2 Locating rods for positioning the vehicle
1 Set of sand bags for the prescribed loading
1.6 Accessories recommended
4 - Quick-clamping units
2 - Sets of access ramps
1 - Remote control display
1 - Trolley (for ballast bags, rotating and sliding plates and 4 quick-acting clamps)
2. MEASURING OPTIONS USING THE BMW KINEMATIC DIAGNOSIS SYSTEM
2.1 Front Axle
 Toe-in (single and total toe-in in relation to the geometrical drive axis)
 Camber (with steering wheel pointing straight ahead)
 Wheel displacement (in relation to the left-hand front wheel)
2006 BMW 650i
 Castor, kingpin inclination and toe-differential angle
2.2 Rear Axle
 Toe-in (single and total toe-in in relation to the longitudinal centre plane of the vehicle -> previously
called symmetrical axis)
 Geometrical drive axis
 Camber
2.3 Other Measuring Options
 Rear Wheel Displacement

 Wheelbase Difference
 Lateral Displacement On Right
 Lateral Displacement On Left
 Track Difference
 Axial Displacement
3. SYSTEM DESCRIPTION
3.1 BMW Kinematic Diagnosis System 1, Based On The Beissbarth ML4000

2006 BMW 650i
Fig. 3: BMW Kinematic Diagnosis System Concept Chart

The KDS 1 is available in two different designs at no extra charge:
1. Mobile Workstation
2006 BMW 650i
Fig. 4: Identifying Mobile Workstation

2. Mobile Compact Cabinet

2006 BMW 650i
Fig. 5: Identifying Mobile Compact Cabinet

The larger workstation offers a small storage area for accessories, whilst the compact cabinet is mobile and
ideal for restricted working areas. Both variants can be supplied as a cableless measuring system (infrared).
From the point of view of measuring technology, there is only a difference in the handling and equipping of the
system. For both designs, the four measuring sensors are stored in integrated inserts with rechargeable battery
charging points. When automatically charged over night, the measuring sensor batteries provide enough power
for 10 hours of continuous use.
3.2 Computer
The KDS 1 system comprises tested and reliable industrial components. The computer is an IBM-compatible,
32-bit Intel processor with CD ROM drive to the industry standard.
2006 BMW 650i
Fig. 6: Identifying System Comprises Tested And Reliable Industrial Components

3.3 Graphical Tablet
All functions are shown in graphical form on a "pictogram" panel. The panel is protected by a plexiglass cover.
It can easily be replaced if more extensive design modifications are necessary. The operator interface has no
membrane and is thus protected against damage. The main functions are activated by clicking the icon with the
digital pen.
2006 BMW 650i
Fig. 7: Identifying Graphical Tablet

3.4 Equipment Cabinet
The PC with graphic monitor and removable operating panel, supports for the measuring sensors, the remote
control and the A4 printer are integrated into the workstation. The charging station is located in the cabinet and
can also be connected to the measuring sensors and the remote control using the plug-in cables (operating while
simultaneously charging the batteries).
2006 BMW 650i
Fig. 8: Identifying Equipment Cabinet

3.5 Remote Display
A cableless remote display can be supplied on request. The remote control keys are only active during
measuring and adjustment (not for customer data input, or if selecting a vehicle or editing the setpoint data etc.).
The following displays are supported by the remote control:
 Measured value with setpoint/actual comparison and tolerance bar

 Steering graphics for steering routines
 Live overview of the track/camber values with a setpoint/actual comparison
 Rim run-out compensation
2006 BMW 650i
Fig. 9: Identifying Remote Display

3.6 Measuring Sensors With CCD Camera
The measuring sensors are each equipped for automatic measurement with two CCD cameras and their own
processor for the cableless infrared transmission of data with integrated batteries. Benefits:
 No temperature deviation
 Very high measuring resolution (the track
 Single track range of more than +/- 9 degrees for the constant display of toe-in when changing the tie-rod
ends
 Exact system accuracy, i.e. when carrying out measurements at the vehicle following rim run-out
compensation, the toe-in and camber measurements are accurate to 2 angular minutes
2006 BMW 650i
Fig. 10: Measuring Sensors With CCD Camera

3.7 BMW Quick-Acting Clamp
BMW quick-acting clamp for holding the measuring sensors precisely in position and measuring without rim
run-out compensation.
NOTE: Any existing quick-acting clamps, e.g. from older F1600s or ML-3000s, must not
be used on the BMW KDS.
2006 BMW 650i
Fig. 11: Measuring BMW Quick-Acting Clamp For Holding

3.8 Rotating/Sliding Plates
 Electronic precision rotating plates for the front wheels with integrated sensor (360 degree measuring
range)
 Stable sliding plates for the rear wheels with a swivelling/rotating top plate
 Accessories: Cover hood for aluminum rotating plates
2006 BMW 650i
Fig. 12: Identifying Rotating/Sliding Plates

3.9 Sensor Pins
 A new BMW light alloy wheel (styling no. 18) has been available as optional equipment from April 1993.
When measurements are being made on vehicles with these wheels, new sensor pins are required for the
quick-acting clamps of the recommended wheel alignment equipment.
 The new sensor pins are included in the scope of supply for new deliveries of KDS 1 (order number: BS
90 19 11).
2006 BMW 650i
Fig. 13: Identifying Sensor Pins

3.10 Spoiler Adapter
 In the case of vehicles with very low spoilers, the sensor beam may be broken by the spoiler between the
measuring sensors. This primarily occurs in front of the front axle.
 The spoiler adapter is used here as a connecting element between the measuring equipment clamp and the
measuring sensor. Thanks to the adapter, the sensors are placed 50 mm lower, thus allowing the sensor
beam to move freely below the spoiler.
2006 BMW 650i

3.11 Quick-Clamping Units
 Quick-clamping units for wheel alignment on non-BMW vehicles with rim run-out compensation.
2006 BMW 650i
Fig. 15: Identifying Quick-Clamping Units For Wheel Alignment Non-BMW

3.12 Retainers
 The most varied clamping options for the measuring equipment are possible thanks to the versatile
retainers and the rubber-coated thrust pieces, even on exotic light-alloy rims.
2006 BMW 650i
Fig. 16: Identifying Retainers

4. WORKSTATION
4.1 Environment
All lifting platforms currently recommended by BMW (see Workshop Equipment Planning documentation,
Issue 11) for wheel alignment meet the requirements for the BMW KDS.
No particular requirements have to be met in respect of the location at which the BMW KDS is used. The
measuring device can be installed over working pits or on lifting platforms.
Requirements:
 Wheel alignment pits

 Pillar-type lifts with set-down device
 2 plunger-type lifting platforms with set-down device
 Repair stands with set-down device
 One measuring area (approx. 4.5 m x 7.0 m).
 The rotating plates must be pinned to the platform
The support surfaces for the rotating and sliding plates may only display the following maximum height
difference:
 from left to right +/- 0.5 mm

 from front to back +/- 1.0 mm
2006 BMW 650i
 diagonally +/- 1.0 mm.
Fig. 17: Cutaway View Of For Rotating And Sliding Plates

NOTE: A difference in the height of the rotary plates of +/- 2 mm from left to right
results in a measuring error of 4.8° in the camber.
As a comparison: The camber tolerance on the E36 is +/- 10'. The tyre tread
difference or varying tyre pressure cause measuring errors of the same
magnitude.
4.2 Preconditions For Alignment
When carrying out the wheel alignment, the front and rear wheels must be centred on the rotating and sliding
plates in order that all wheel suspensions remain free of tension during the steering routine and adjustment
work. As a result, the rotating and sliding plates for the relevant wheel bases and track widths of the vehicle to
be aligned must be moved.
4.3 Measuring Tolerance
All measuring tolerances are system tolerances. This means that the sum of all individual tolerances gives the
value shown in the example. Example of camber: Quick-acting clamp + measuring sensor + computer = 1' at a
measuring range of +/- 3° (all BMW vehicles are within this measuring range).
4.4 Levelling The Measuring Station
The manufacturers of the BMW KDS (Beissbarth/Bosch) are able to measure the measuring area to the required
accuracy using levelling devices. Any "normal" water level is not suitable for this. Lifting platforms must be
levelled under load so that the uneven deflection in the travel rails is taken into account.
2006 BMW 650i
IMPORTANT: Adjustment work for the lifting platform concerned must be executed by a
specialist (manufacturer's after-sales service).
5. CHASSIS-RELATED TERMS
5.1 Toe-Differential Angle
Description:
 The toe-differential angle (a) is the angular position of the internal wheel on the curve in relation to the
external wheel on the curve when driving round bends. The steering is designed such that the angular
position of the wheels in relation to each other changes as the steering angle increases.
 In ideal cases, the wheel axes meet at point D in any steering position (except for straight ahead).
Fig. 18: Identifying Toe-Differential Angle

2006 BMW 650i
5.2 Camber
 The camber is the angle of inclination of the wheel in relation to the vertical.
2006 BMW 650i
2006 BMW 650i
Fig. 19: Identifying Camber Angle

5.3 Toe-In
 The toe-in is the reduction in the distance between the front of the wheels and the rear. The toe-in
prevents the wheels from moving apart whilst driving (wobbling and grinding).
Fig. 20: Identifying Toe-In Angle

5.4 Caster
 The castor is the kingpin angle seen from the side in the opposite direction of travel. The line through the
centre of the spring strut mount and control arm ball joint corresponds to the kingpin.
2006 BMW 650i
Fig. 21: Identifying Castor Angle

5.5 Geometrical Drive Axis/Symmetrical Axis
 (1) The geometrical drive axis is the line bisecting the angle of the overall rear wheel toe. The
measurements of the front wheels relate to this axis.
 (2) The symmetrical axis represents the centre line through the front and rear axes.
2006 BMW 650i
Fig. 22: Identifying Geometrical Drive Axis Angle

5.6 Wheel Displacement Angle
 The wheel displacement angle is the angular deviation of the connecting line of the wheel contact points
in relation to a line running at 90° to the geometrical drive axis. The wheel displacement angle is positive
if the right-hand wheel is displaced to the front, and is negative if it is displaced to the rear.
2006 BMW 650i
Fig. 23: Identifying Wheel Displacement Angle

5.7 Kingpin Offset
 The kingpin offset is the distance from the centre of the wheel contact point to the contact point of the
kingpin extrapolation.
2006 BMW 650i
Fig. 24: Identifying Kingpin Offset Angle

6. WHEEL SUSPENSION
Those parts which connect the wheel to the mostly load-bearing floor elements of the bodywork and guide it in
the required direction belong to the wheel suspension. They are connected by axles or other comparable
structures and guided by the arms. The wheel suspension plays a decisive role in the handling characteristics of
a vehicle. Two main groups have to be distinguished: 1. Rigid axle suspension and 2. Independent wheel
suspension.
2006 BMW 650i
RIGID AXLE SUSPENSION SPECIFICATIONS

Description Advantages Disadvantages
The rigid axle suspension has a In the event of deflection taking Non-driven rear axles may also
rigid connection between both place, there are no changes to the acquire negative camber as well as
wheels or wheel pairs. Any change camber or wheel toe. This means: increasing tyre lateral guidance,
in one wheel is more or less less tyre wear and good track thus increasing tyre wear.
transferred to the other. It is now stability.
only fitted as a rear axle, if at all.
However it is frequently used for
lorries or busses.
6.2 Independent Wheel Suspension
INDEPENDENT WHEEL SUSPENSION DESCRIPTION

Description Advantages Disadvantages
State-of-the-art individual wheel Wheels suspended independently Depending on the type, changes
suspension is available on BMW from each other have no mutual may occur in the camber, wheel
vehicles on the front and rear influence on each other. toe, track width, castor and
axles. This development has its wheelbase.
cause in mass inertia, as a
reduction in the non-suspended
mass improves wheel and ground
contact, and the wheel stays better
on the road. Control arms and
trailing arms, which have to
absorb high longitudinal and
lateral forces to some extent, are
required for guiding independently
suspended wheels.
7. WHEEL ALIGNMENT PROCEDURE
7.1 Measuring Options
An overview of all measuring options and values (VA = front axle, HA = rear axle) is shown below.
MEASURING OPTIONS SPECIFICATIONS

Measuring options Measuring accuracy In measuring range Total measuring range
Total wheel toe (VA + +/- 2' +/-2° +/-18°
HA)
Single wheel toe (VA + +/-2' +/-2° +/-9°
HA)
Camber (VA + HA) +/-1' +/-3° +/-10°
Wheel displacement +/-2' +/-2° +/-9°
(VA)
2006 BMW 650i
Geometrical drive axis +/-2' +/-2° +/-9°

Castor +/-4' +/-18° +/-22°
Kingpin inclination +/-4' +/-18° +/-22°
Toe-differential angle +/-4' +/-20° +/-20°
Maximum steering angle +/-4' +/-60° +/-300°
(VA)
Maximum steering angle +/-4' +/-9° +/-9°
(HA)
Castor correction range +/-4' +/-7° +/-10°
NOTE: The measuring accuracy details only apply when using the precision rotating
and sliding plates as well as the BMW quick-acting clamps.
7.2 Preparatory Work
Before commencing the measurement, preparatory work must be carried out at the measuring area and on the
vehicle (see BMW KDS operating instructions). Preparatory work includes:
 Easy-running rotating and sliding plates

 Aligning the rotating and sliding plates in relation to the track width and wheelbase
 Centering the vehicle on the plates
 Applying the parking brake
 Removing the lock pins on the plates to prevent tension in the chassis under loading
 Checking the rim and tyre size, tread depth, tyre pressure, steering wheel play, wheel bearings and
condition of suspension and shock absorbers
 Fastening the measuring equipment to the wheels
 Loading the vehicle according to BMW KDS specifications
 Rock the vehicle firmly with the brakes released to ensure a stable centre position
 Lock the service brake using the brake clamping device
7.3 Initial/Final Measurement
This measurement can be carried out as a program-guided measurement in the same way as any subsequent
adjusting work and the final measurement. The sequence of the chassis measuring points to be called up is
specified and controlled by the system software. The individual steps comprise:
 Driving straight ahead to correctly record the wheel toe and camber values for the rear axle
 Steering routine for recording the castor, kingpin inclination and toe-differential angle
 Recording the wheel toe and camber of the front axle (adjust the steering centre point in advance)
 Steering routine for measuring the maximum steering angle on the left/right
 Checking the overview of measured values with the setpoint and actual comparison of all measured
values
2006 BMW 650i
7.4 Printing Out The Data
Fig. 25: Specification Data

The report printout from the integrated DIN A4 printer is subdivided into three sections:
 Header lines with customer and vehicle identification data --> the customer data entered before beginning
the measurement as well as vehicle data are printed out here.
 Centre section with vehicle data -> this includes the make, type, model and vehicle model year defined
when the setpoint data record was selected. The values previously measured for height level, tyre pressure
and tread depth are also printed in this section.
 The end section with all vehicle alignment values comprises the 3 columns initial measurement, setpoint
values and output measurement. The measured values are recorded separately in these three columns.
8. SPECIAL FEATURES
8.1 Free Wheel Alignment

2006 BMW 650i
following points must be observed for attaining the correct measurement results:
 Carry out all work in the same way as with the program-guided measurement.
 Before measuring the wheel toe and camber values for the rear axle, the steering must be in the "straight
ahead" position to ensure that it is perfectly aligned in relation to the longitudinal centre plane of the
vehicle.
 Before measuring the single wheel toe values on the front axle, the centre of steering must be established
to ensure the correct position of the steering wheel.
8.2 System Settings
The following settings must only be entered or set once: language, display format, date/time, advertising text,
remote control with display, rotating plate selection and printer settings. They remain stored.
9. BMW KINEMATIC DIAGNOSIS SYSTEM COMPARISON (BOSCH - BEISSBARTH)
BMW KINEMATIC DIAGNOSIS SYSTEM SPECIFICATIONS

Bosch Beissbarth
Measured value recording Infrared CCD camera
Data transmission Cable Infrared / cable
Measuring sensor power supply Cable Battery/ cable
Remote control Infrared Infrared
Remote control with measured Cable Infrared
value display
Setpoint data memory Floppy disk Hard disk
Measured value memory Always the last vehicle Unlimited vehicle memory
measured
Operating system -- MS-DOS
Languages English and one language on EN, DE, NI, SV, IT, FR, SP (further
request languages can be called up)
Update 3.5" floppy disk 3.5" floppy disk using TIS/DIS
Monitor 20" 17"
Computer -- Pentium
Disk drives 2 x floppy disk 1 x floppy, 1 x CD ROM
10. CONTROL MODIFICATION (MENU)
10.1 Remote Control With Display
The following steps show how the remote control with display is activated:
1. Call up the "Service" menu in special functions ("S" key)

2. Call up the "Remote control" sub-menu in the "Service" menu.
2006 BMW 650i
retained.
IMPORTANT: In the case of equipment without remote control, this must be configured to
"No remote control".
10.2 Brief Operating Instructions
1. Activate the remote control with the "ON" button (it may also be switched on during alignment). The title
page will appear on the LCD.
2. Select "Straight ahead" of the "Initial measurement", "Adjustment work" or "Final measurement" at the
measuring equipment cabinet. The steering graphics for "Straight ahead" will appear on the LCD.
3. Use the "Forward arrow" to change to the next measurement image. Display blocks will appear on the
LCD with the designation of the measured value and tolerance bar with the measured value. If the
measured value is within the tolerance range, it is shown in dark figures against a light background. If the
measured value is outside the tolerance range, it will be shown in inverse video (light figures against a
dark background).
4. By pressing the "F" key shortly, you can move alternately between the designation of the measured value
and the setpoint value with the tolerance inside the display blocks.
5. You can scroll through the measured values using the "Forward arrow", "Backward arrow" and
"Cancel" (red dot) keys. The function of these keys is identical to that of the keys on the graphics panel.
6. Even with "Free alignment", it is possible to scroll through the measured values in the same way as with
"Program-guided alignment".
7. During measurement, the report print-out can be initiated using the "Printer" key. The remote control keys
are only active during measurement and adjustment (not during customer data input, vehicle selection
etc.).
10.3 Display Support
 Measured values with a setpoint/actual comparison and tolerance bar (setpoint figures can be displayed
with the "F" key).
 Steering graphics for steering routines.
 Overview of measured values with current setpoint/actual comparison
 Rim run-out compensation.
 With all other functions (e.g. customer input), the title illustration appears on the LCD display.
If the data transmission from the remote control to the computer is interrupted, the remote control icon in the
bottom right-hand corner of the screen changes colour from green to red and the illustration on the LCD display
is shown inversely - black turns to white, white to black. This change does not take place in the title illustration.
Once the line-of-sight connection has been re-established, the remote control continues to operate from the
point of interruption in the program. A continuous visual connection during alignment is therefore not
necessary.
 The "Hour glass" icon in the LCD display means: "Please wait".
2006 BMW 650i
been reached.
 To switch off the remote control: press the "F" key for 5 seconds, then return it to its charging unit or
connect it to a charge cable. The title illustration will again appear as a charging check.
 If, during the measurement, the remote control has been placed back in the charging unit, it must be
switched on again using the "ON" button.
11. UPDATING THE SOFTWARE/SETPOINT DATA
Floppy disks will no longer be sent to BMW partners who have acquired a "BMW KDS (Beissbarth/Bosch)".
For cost-related reasons, you can create these disks yourself on the "DIS-tester" or on the "TIS/EPC server".
The data for this is regularly updated on the TIS CD.
11.1 Requirements
 BMW KDS (Beissbarth/Bosch)

 TIS CD program status (Beissbarth): from CD 12/95
 EPC program status: from 12/95
 TIS CD program status (Bosch): from CD 08/97
 DIS program status: from V6.0
 3.5" diskettes, 1.44 MB (Beissbarth 5 diskettes/Bosch 1 diskette)
11.2 Procedure (Beissbarth)
1. Go to the "Administration" screen

2. Select the KDS button
3. Select Beissbarth
4. Insert "Diskette 1" on request and confirm with "OK" (program diskette 1 of 2 is created, label it)
5. Insert "Diskette 2" on request and confirm with "OK" (program diskette 2 of 2 is created, label it)
6. Insert "Diskette 3" on request and confirm with "OK" (setpoint data diskette 1 of 3 is created, label it)
9. Perform update and/or setpoint data on the KDS in the usual manner with the diskettes which have just
been created.
11.3 Procedure (Bosch)
1. Go to the "Administration" screen

2. Select the KDS button
3. Select Bosch
4. Label "Diskette 3.1", insert it into the drive on request and confirm with "OK" (2x) --> Setpoint data is
copied to the diskettes.
5. Insert setpoint data diskette 3.1 into the 3.1 floppy disk drive, insert operating system diskette 3.0 into the
2006 BMW 650i
3.0 drive.
6. Switch on the machine in the usual manner.
IMPORTANT: When creating the KDS diskettes, all data on the diskettes used is overwritten.
NOTE: In the event of an error, a corresponding message is shown and the program is
cancelled completely. The procedure must be run from the beginning again and
all data on the diskette will be deleted. A new diskette may have to be used.
12. CREATING, COPYING AND EDITING SETPOINT DATA
12.1 Copying
 Press the "C" button and select the vehicle to be copied.

 Select the "Edit setpoint data" menu item from the special functions. Create a new vehicle in the usual
manner. The setpoint values for the last vehicle selected will appear in the data input screen. Enter the
data and save the data record.
12.2 Creating
 Press the "C" button and select the "Edit setpoint data" menu item from the special functions. Create a
new vehicle in the usual manner. An empty data input screen will appear. Enter the data and save the data
record.
12.3 Editing
 Factory-programmed setpoint data can neither be deleted nor modified. If this data does need to be
modified, a new vehicle with modified setpoint data must be created. New vehicles created by the user are
identified by a "+" in the selection menu. These vehicles can be deleted by the user using the "-" key or
modified using the "< >" key. These keys only appear if vehicles have been entered by the user.
13. SPECIAL FUNCTIONS
13.1 Customer-Specific Printer Report Header
The sub-item "Customer-specific text" must be called up in the "Special functions" menu. An input screen
will appear on the monitor. This input screen must be filled out with the name and address and stored with the
"S" screen key. The text entered is inserted into the report header.
13.2 Adjusting Options
 Call up the "Service" menu in the special functions ("S" key).

 Select the "Wheel toe adjustment" item or the "Camber adjustment" item from the "Adjustment"
sub-menu. The toe and camber adjustment program will guide the user step by step through the
adjustment using text and images. The measuring deviation for each measuring sensor will be shown on
2006 BMW 650i
 You can store the adjustment values in the measuring sensor using the "Store" key or you can quit the
program with the "Red dot key" without saving them (check). The adjustment values can be printed out.
13.3 Rotating Plate Test
 Call up the "Service" menu in the special functions ("S" key).

 Call up the "Rotating plate" item in the "Service" menu. Turn the left-hand and right-hand rotating
plate and check the display on the screen. Important: The measuring range is +/- 306 degrees.
13.4 Viewing And Deleting Customer Entries From Database
 Call up the menu item "Delete" in the "Database" menu in the special functions. The data input screen
will appear. Fill in the search fields with the data to be deleted.
 Use the "-" button to delete this data record. A new data record can then be highlighted and deleted with
the digital pen.
 You can scroll through the entire database with the "Arrow up" and "Arrow down" keys.
14. MODIFICATIONS WITHIN PROGRAM
Further modifications were carried out within the program which only slightly change the program sequence but
which optimise the alignment in respect of comfort and speed. This is described below:
 Optimisation of the rim run-out compensation in respect of speed.

 Optimisation of the steering routines: Highlighted values within the gate can still be corrected. The
message "Rotating plates not connected" no longer causes the steering routine to be cancelled. Further
measurements can be carried out after the rotating plates have been connected.
 Standardisation of screen colours with the colours on the tablet.
 Addition of texts in several foreign languages.
 Elimination of program-related and cosmetic faults.
 Electronic water level.
 Omission of kingpin inclination measurement.
15. FAULTS
15.1 Tyre Faults
TYRE FAULTS SPECIFICATIONS

Fault Effect
1) Wheel toe, camber, toe-differential angle 1) Severe tyre squeaking even at relatively
and castor not correct low speeds
2) Excessive toe-in and excessive positive 2) Tyres are worn down on one outside edge
camber in the longitudinal direction
3) Excessive negative camber 3) Tyre wear on inside edge
2006 BMW 650i
4) Worn front-axle suspension on front- 4) Increased noise / Vehicle pulls on one side
wheel-drive vehicles when accelerating
5) Incorrect wheel alignment 5) Wheels scrubbing / Tyre surface shows
feathering in the tread
6) Play in the suspension due to mechanical 6) Washout / Wobbling of front wheels
parts (suspension, steering)
7) Tyre pressure too low 7) Outside tyre surface wear
15.2 Front Axle Faults
FRONT AXLE FAULTS SPECIFICATIONS

Fault Cause Remedy
1. Toe deviation a. Vehicle not in normal a. Correct height level
position b. Replace tie rod(s)
b. Tie rod(s) bent c. Replace tie rod(s)
c. Tie rod ball joints worn d. Replace control arm
d. Rubber mount in control
arm defective
2. Camber deviation: The camber a. Rubber mount in control a. Replace control arm
is fixed during the design stage arm defective
and cannot be adjusted. b. Replace control arm
b. Control arm deformed c. Replace spring strut
c. Spring strut deformed d. Replace control arm
d. Traction strut worn e. Replace coil spring, height
e. Spring deflection too great level
f. Front axle carrier deformed f. Replace front axle carrier
g. Spring strut mount g. Repair forward structure
deformed h. Repair body
h. Distortion in the floor
assembly (engine bracket)
3. Castor deviation: The castor is a. Rubber mount for tension / a. Replace rubber mount
fixed during the design stage and traction strut defective
cannot be adjusted. b. Replace tension / traction
b. Tension / traction strut strut
deformed c. Replace control arm
c. Control arm deformed d. Replace spring strut
d. Spring strut deformed e. Repair forward structure
e. Wheelhouse deformed f. Repair body
(spring strut mount)
f. Distortion in the floor
assembly (engine bracket)
2006 BMW 650i
are correct a. Set wheel toe on left and

right to identical values
a. Tie rods unevenly adjusted
5. Wheel displacement deviation Requirement: Front wheels have a. Replace front axle carrier
same single toe in relation to the
geometrical axis b. Repair body
c. Replace control arm
a. Front axle carrier deformed d. Replace tension / traction
b. Engine bracket deformed strut
c. Control arm deformed
d. Tension / traction strut
deformed
15.3 Rear Axle Faults
REAR AXLE FAULTS SPECIFICATIONS

Fault Cause Remedy
1. Camber deviation a. Vehicle not in normal a. Correct height level
position: spring deflection b. Replace rubber mount
too great
c. Check rear axle carrier and
b. Rubber mount on rear axle replace, if necessary
c. Rear axle carrier deformed d. Check control arm and
d. Control arm deformed replace, if necessary
e. Traction strut deformed e. Check traction strut and
f. Distortion in the floor replace, if necessary
assembly f. Repair body
g. Swinging arm deformed g. Replace swinging arm
2. Rear wheel position is not a. Rear axle carrier has been a. Check the rubber mounts on
correct shifted laterally the rear axle carrier and
b. Distortion in the floor replace, if necessary
assembly b. Repair body
3. Toe deviation a. Vehicle not in normal a. Correct height level
position, i.e. spring b. Replace rubber mount
deflection too great
c. Replace control arm
b. Rubber mount in rear axle
carrier defective d. Replace swinging arm
c. Control arm deformed e. Check rear axle carrier and
replace, if necessary
d. Rubber mount and swinging
arm defective f. Check traction strut and
replace, if necessary
e. Rear axle carrier deformed
f. Traction strut deformed
2006 BMW 650i
4. Deviation from the geometrical Requirement: Total wheel toe is a. Repair body
drive axis correct
a. Distortion in the floor

assembly
Further details on the "Kinematic Diagnosis System" can be found in the operating instructions for the
BMW KDS (Beissbarth/Bosch).
Functional and system descriptions are not subject to change. Parts availability and immediate ordering
availability cannot be derived from this information. The specialist departments will be providing further
details at the relevant time.
RUNFLAT INDICATOR
All models
Fig. 26: Identifying Runflat Indicator

INTRODUCTION
The Run Flat Indicator (RPA) monitors the tyre pressure throughout the journey.
2006 BMW 650i
drop, the tyre will gradually "cave in". The resulting flexing means that the defective tyre will quickly receive
additional damage. The tyre could burst.
Some 80 % of all flat tyres are caused by small holes (e.g. caused by nails). The holes result in a gradual loss of
pressure in the affected tyre. Many "tyre blowouts" can be traced back to preliminary damage caused by a
gradual loss of pressure.
A gradual loss of pressure in one tyre may remain unnoticed for a long time. The lack of pressure only makes
itself clearly felt when driving when the tyre is almost completely empty.
As tyre pressure drops, the radius of the wheel and with it the tyre's 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
RPA 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.
IMPORTANT: 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 pressure at the same rate, the wheel speeds will also change at the same rate. The RPA 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)
IMPORTANT: Correct function of the Run Flat Indicator is not guaranteed when the
emergency wheel is fitted.
As the emergency wheel has a much smaller diameter, the correct operation of the RPA 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.
RPA button (E46, E53, E83, E85) The RPA button is only needed for initializing the PRA.
2006 BMW 650i
(RPA initialisation means "teaching the system the tyre pressures".
CID: Central Information Display Vehicles that are equipped with CID are initialized using the CID.
On-board computer button and rocker switch on turn-signal/main-beam switch (E87, E90, E91)
Initialisation is performed on the LCD display, using the BC button and the rocker switch on the turn-
signal/main-beam switch. The on-board computer functions are selected with the rocker switch.
The RPA software is in the following control units, depending on model series:
 RPA Control Unit (E46 all-wheel drive)
The E46 All-wheel drive has a separate RPA control unit.
The 4 wheel-speed sensors measure the wheel speeds. The DSC control unit sends the signals through 4
direct wires to the RPA control unit.
Alternatively
 DSC control unit with additional software for Run Flat Indicator (E46, E53, E60, E61, E63, E64,
E83, E85, E87, E90, E91)
With DSC Mk60 and DSC 8, the RPA is integrated into the DSC control unit through additional software.
Alternatively
 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 functions of the Run Flat Indicator:
 CAS: Car Access System E60, E61, E63, E64, E65, E66, E87, E90, E91
The CAS control unit provides input signals relating to terminal status (e.g. terminal 15 ON).
 GM: Basic Module E46, E53, E83, E85
The general module provides input signals relating to terminal status (e.g. terminal 15 ON).
 JBE: Junction Box Electronics E87, E90, E91

2006 BMW 650i
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 electrical distribution centre.
 KGM: Body-Gateway Module E60, E61, E63, E64 from 09/2005
The body-gateway module replaces the safety and gateway module (SGM). The KGM forms the data
interface (= gateway) between the K-CAN and the PT-CAN.
 M-ASK/CCC: Multi-Audio System Controller/Car Communication Computer The M-ASK/CCC

will emits an acoustic warning through the loudspeakers if tyre pressure drops. (On vehicles without M-
ASK or CCC, the instrument cluster 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
The signals from the on-board computer button and from the rocker switch are recorded and processed in
the SZL. The data are transmitted to the instrument cluster through a direct wire (on-board computer).
 ZGM: Central Gateway Module E65, E66 until 03/2004
The ZGM forms the data interface (= gateway) between the K-CAN and the PT-CAN.
 KOMBI and CID:Instrument Cluster and Central Information Display A fault in the RPA or drop in
tyre pressure will be indicated by the RPA indicator and warning light in instrument cluster. At the same
time, the symbol will light up in the LC display.
Faults registered by the RPA are indicated as follows by the RPA indicator and warning light (for
variations, please refer to national version):
 The RPA indicator and warning light lights up:
 Red (with acoustic signal): Drop in tyre pressure more than approx. 30 % +/- 10 %. Driving
safety is no longer guaranteed.
 Yellow: RPA failed
Information about the Check-Control message can be called up in the CID (CID is fitted depending on the
vehicle's equipment).
RPA Indicator And Warning Lights And Central Information Display
The Run Flat Indicator (RPA) has the following displays in the instrument cluster:
2006 BMW 650i
 RPA Indicator And Warning Light

 Symbol In LC Display
Fig. 27: Identifying Runflat Indicator (E83 Shown)

2006 BMW 650i
Fig. 28: Identifying RPA Warning In Central Information Display

How It Works RPA fault is displayed as follows:
 Via the RPA indicator and warning light The RPA indicator and warning light lights up:
 Red (with acoustic signal): Drop in tyre pressure more than approx. 30 % +/- 10 %. Driving safety
is no longer guaranteed.
 Yellow: The RPA has developed a fault.
 Indicator or symbol in LC display (yellow or red).

 Check control message in Central Information Display (CID) with additional information text.
If the RPA should fail, the following Check-Control messages are possible (for example):
RPA FAILURE MESSAGES & EXPLANATIONS

Check Control Message In CID Status Bar Further Information
Flat tyre! Flat tyre
2006 BMW 650i
Stop the vehicle carefully.

Please refer to the Owner's Handbook for how to
change a wheel.
Tyres with emergency-running characteristics
(RSC): The journey can be continued for a limited
distance at speeds up to max. 80 km/h, please refer
to the Owner's Handbook.
Have the tyres checked by the nearest BMW
Service
Run Flat Indicator failure! Run Flat Indicator
Run Flat Indicator failed Flat tyres cannot be
detected.
Have the problem checked by BMW Service as
soon as possible.
SYSTEM FUNCTIONS
The Run Flat Indicator (RPA) comprises the following functions:
 Self-test
 Initialisation
 Detects drop in tyre pressure
 Visual and acoustic warning
Self-Test
The RPA performs a self-test when terminal 15 is switched ON. A fault in the RPA is indicated by the RPA
indicator and warning light and by a symbol in the LCD display.
Initialisation
Initialisation is started manually (e.g. by pressing the RPA button). Then (after the journey has started),
initialisation will run as a fully automatic calibration sequence. 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.
2006 BMW 650i
Detects Drop In Tyre Pressure
The RPA records the wheel speeds using the wheel-speed sensors from the DSC. The RPA 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 pressure in one tyre of approx. 30 % +/- 10 % from the initial value is indicated by the RPA indicator
and warning light. In addition, an acoustic signal sounds.
Signal output: Depending on the model concerned, either via the instrument cluster or the multi-audio system
controller (M-ASK)/Car Communication Computer (CCC).
NOTE: DSC malfunction

The sensors used by the RPA are all monitored by the DSC. If DSC detect a
fault, the RPA will also register a malfunction.
SPECIAL CONDITIONS FOR SYSTEM FUNCTION
The following operating 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 RPA 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
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 RPA.
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.)
2006 BMW 650i
Initialisation and snow chains will cause incorrect adaptation values.
 Trailer towing
Initialisation should be performed when a trailer with a weight greater than approx. 300 kg is being
towed.
Repeat the initialisation process after detaching or unloading 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 RPA is no longer guaranteed.
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 initialized using the following control elements:
 RPA button
 On-board computer button on turn-signal/main-beam switch
 With iDrive in the Central Information Display (CID) with the controller
IMPORTANT: Always perform initialisation immediately after correcting the tyre pressure,
especially if a tyre 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.
IMPORTANT: Responsibility resides with the driver at all times.

2006 BMW 650i
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 RPA 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 RPA button

 Press and hold the RPA button until the RPA indicator and warning light lights up yellow for a few
seconds
 Vehicles with BC button (on-board computer function)
 In the on-board computer function select "RPA" and "INIT" (LCD display) with the rocker switch
on the turn-signal/main-beam switch. Press the BC button to confirm.
 Press and hold the BC button for approx. 5 seconds, until a box with a tick appears behind the
"INIT" display.
 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.
Preconditions For Activation
The Run Flat Indicator (RPA) is automatically activated when terminal 15 is switched ON. The RPA cannot be
switched off manually.
2006 BMW 650i
General information:
General information for Service staff on the Run Flat Indicator The following general information on the
Run Flat Indicator (RPA) is given for Service staff:
 Wheel-Speed Sensor Failure

 Read Off Status Of Initialisation Phase
Wheel-Speed Sensor Failure If no signal is received from one of the wheel-speed sensors, the RPA will switch
to "inactive" mode after approx. 2 minutes. The RPA indicator and warning light lights up yellow. The fault is
indicated with a check control message. A fault is recorded in the fault memory of the RPA control unit.
If the RPA is integrated into the DSC, a fault will be recorded in the DSC control unit. If the signal returns after
a signal failure, the RPA will be active again after driving for approx. 30 minutes. The fault will remain stored
in the fault memory.
Read off status of initialisation phase The status of the initialisation phase can be displayed in the service
functions for the control unit concerned (e.g. DSC control unit).
Diagnosis:
Encoding/Programming The Run Flat Indicator
 Encoding At the factory, the Run Flat Indicator (RPA) software is adapted to the model series concerned
(encoding data). The RPA is encoded with the encoding data. Here, different parameters specific to the
various vehicle models are written into the control unit.
 Programming The RPA is automatically programmed with the software for the Dynamic Stability
Control (DSC).
US NATIONAL VERSION
A flat tyre is indicated as follows:
 E53, E83, E85
Yellow RPA indicator and warning light without acoustic signal
 E60, E61, E63, E64, E65, E66, E90, E91
Yellow RPA indicator and warning light with acoustic signal
An RPA failure is indicated as follows:

2006 BMW 650i
 Yellow RPA indicator and warning light without acoustic signal
Subject to alteration due to misprints, errors and technical modifications.
TYRES WITH EMERGENCY RUNNING CHARACTERISTICS AND TYRE

PRESSURE WARNING SYSTEMS
All models
GENERAL INFORMATION
Warning Systems
BMW AG offers two different systems to warn the driver of a drop in tyre pressure.
WARNING SYSTEMS SPECIFICATIONS

System Description Measuring principle
RDC Tyre pressure control Tyre pressure/temperature
RDW Tyre pressure warning Comparison of wheel speeds
Emergency Running Systems
In addition to the warning systems, two emergency running systems are also employed to prevent a
depressurised tyre from caving in:
Components of emergency running system with self-supporting tyres:
EMERGENCY RUNNING SYSTEM COMPONENTS (WITH SELF-SUPPORTING TYRES)

RDW (standard equipment) Tyre pressure warning
RDC (available as option from 03/2000) Tyre pressure control
SST Self Supporting Tyre
EH2 disc wheel Disc wheel with Extended Hump 2
Components of emergency running system with integrated support ring:
EMERGENCY RUNNING SYSTEM COMPONENTS (WITH INTEGRATED SUPPORT RING)

Support ring NOTE:
In the future, only for heavy safety vehicles (E38/3)
RDC (optional) Tyre pressure control
H2 disc wheel Standard disc wheel with Hump 2
TYRE PRESSURE CONTROL (RDC)

2006 BMW 650i
RDC permanently monitors the tyre pressure and the temperature in the tyres, both while the vehicle is being
driven and when it is stationary. Data is transmitted via data telegram by the wheel electronic units to the
antennas installed in the wheel housing and on to the RDC control unit. There, the data received is compared
with the stored limit values.
After correcting the air pressure with the engine off and the ignition on, press the Set button and hold (approx. 6
seconds) until the words "Set tyre pressure" appear in the instrument cluster (instrument cluster high) or the
yellow LED lights up (basic instrument cluster).
If the limit values are exceeded, the driver will be warned via the instrument cluster in two stages, as follows:
RDC WARNING SYSTEM (LOSS OF TIRE PRESSURE)

Loss of tyre pressure Warning
Drop in tyre pressure of 0.2 to 0.4 bar Yellow LED on basic instrument cluster, or
Text: "Check tyre pressure" on instrument cluster
high
Gong: no
Drop in tyre pressure of more than 0.4 bar Red LED on basic instrument cluster, or
Text: "Tyre failure" on instrument cluster high
Gong: yes
Advantages of RDC
ADVANTAGES OF RDC
1) Safety  early warning in the event of rapid loss of
pressure
 warning of loss of tyre pressure through
normal diffusion
2) Comfort unchanging ride comfort

 instruction to check tyre pressure as necessary

3) Service life, economy  minimisation of tyre wear
 minimisation of fuel consumption
4) New developments  allow tyres with emergency running
characteristics to be fitted
 no spare wheel if tyres with emergency
running characteristics are fitted (saves
weight)
RDC System Layout

2006 BMW 650i
Fig. 29: RDC System Layout

Component Description
RDC Control Unit
Fully diagnosis-compatible
Task:
Evaluates the following telegrams from the wheel electronic units:
 Tyre Pressure
 Tyre Air Temperature
2006 BMW 650i
 Identification Number Of Wheel Electronic Unit

 Remaining Service Life Of Wheel Electronic Unit Battery
Fig. 30: Identifying RDC Control Unit

If required, information or a warning is transmitted.
Wheel Electronic Unit With Valve
Components:
 Pressure Sensor
 Temperature Sensor
 Transmitter
Frequencies According To Country
2006 BMW 650i
 Power Supply
 Service Life: Approx. 7 Years
 Not Exchangeable
Fig. 31: Identifying Wheel Electronic Unit With Valve

Installation Location Of Wheel Electronic Unit In Disc Wheel
The wheel electronic unit (1) is screwed to the valve (2) on the disc wheel (3)
Identifying feature: Metal Tyre Valves
NOTE: Different valves have to be used to allow for the different disc wheel sizes. The
valves are colour-coded. The correct coding can be taken from the spare parts
2006 BMW 650i
catalogue.
Fig. 32: Identifying Installed Position Of Wheel Electronic Unit In Disc Wheel
Antenna
There is an antenna in each wheel housing.
Task: Receives telegrams and forwards these to the RDC control unit.
2006 BMW 650i
Fig. 33: Identifying RDC Antenna

Set Button
Installed in the instrument panel to the right of the steering wheel. (E46: in the centre console)
Symbol: tyre cross-section
Task: initialisation after resetting cold tyre pressure or after changing tyre or wheel location.
2006 BMW 650i
Fig. 34: Identifying RDC Set Button

Display Element In Instrument Cluster
Indicator lamp lights up yellow:
 drop in tyre pressure of 0.2 to 0.4 bar
Indicator lamp lights up red:
 drop in tyre pressure of greater than 0.4 bar

2006 BMW 650i
Fig. 35: Identifying RDC Indicator In Instrument Cluster Display

TYRE PRESSURE WARNING RDW
RDW System Description
RDW measures the wheel speeds on all four wheels, using the wheel speed sensors of the ABS/ASC or
ABS/DSC system. It compares the wheel speeds of the diagonally opposite wheels and of the average speed.
In the event of a drop in tyre pressure, the dynamic diameter of a wheel will change, leading to a changed wheel
speed.
A drop in tyre pressure of 30 +/- 10 % can be detected on all wheels from about 15 km/h (10 mph) up to the
vehicle's top speed.
If this value is exceeded, the driver will be warned via the instrument cluster as follows:
RDW SYSTEM DESCRIPTION

Loss of tyre pressure Warning
Loss of tyre pressure of 30 +/- 10 % Red LED
Text: "Tyre failure"
Gong: yes
The vehicle is not to be driven faster than 80
km/h (50 mph).
2006 BMW 650i
NOTE: A cautious driving style with moderate forward and transverse acceleration will
help to prolong the service life of the defective tyre.
Advantages of RDW
With two exceptions, the advantages of RDC also apply to RDW.
Exceptions:
 no warning of loss of tyre pressure through normal diffusion

 tyre pressure still have to be checked regularly, every 14 days
RDW System Layout

2006 BMW 650i
Fig. 36: RDW System Layout

RDW Control Unit
Fully diagnosis-compatible
Task:
 evaluates wheel speeds.

 a warning is transmitted as required.
Fig. 37: Identifying RDW Control Unit

2006 BMW 650i
Set Button
Installed in the dashboard to the right of the steering wheel. Symbol: tyre cross-section with warning triangle.
Task: initialisation after resetting cold tyre pressure or after changing tyre or wheel location.
Fig. 38: Identifying Set Button

Display Element In Instrument Cluster
Indicator lamp lights up red:
 drop in tyre pressure 30 +/- 10 %

2006 BMW 650i
Fig. 39: Identifying RDW Indicator Lamp

EMERGENCY RUNNING SYSTEMS
Introduction
Tyres with emergency running characteristics can still be used for a certain distance even if they suffer a
complete loss of pressure. There are two different systems which meet these requirements:
 emergency running system with self-supporting tyres

 emergency running system with integrated support ring
Emergency Running Systems Setup
Emergency Running System With Self-Supporting Tyres
The side walls of the self-supporting tyre are reinforced. In conjunction with a special disc wheel, the tyre can
still be used for a certain distance even if it suffers a complete loss of pressure.
Mobility is retained for the following distances up to a speed of 80 km/h (50 mph) and with a cautious, suitably
adapted driving style:
EMERGENCY RUNNING SYSTEM DESCRIPTION

Unloaded vehicle max. 500 km (300 miles)
2006 BMW 650i
Fully loaded vehicle max. 50 km (30 miles)
Self-supporting tyres demand permanent monitoring of the tyre pressure to ensure that the driver is given
adequate warning if pressure is lost during a journey. For this reason, these tyres are only available in
conjunction with the warning system RDW and from 03/2000 also with RDC.
To prevent the self-supporting tyres from becoming detached from the disc wheel in the event of a complete
loss of tyre pressure, they must be fitted to newly developed wheels with modified disc wheel humps, but with
unchanged tyre seating (= standard disc wheel).
However, the new wheels can also be used for standard tyres of the same size.
Comparison Standard Tyres/Self-Supporting Tyres
Standard Tyres, Unpressurised
Fig. 40: Identifying Unpressurised, Standard Tyres

Self-supporting tyres, unpressurised
Envulcanised reinforcement (1) made of a temperature-resistant rubber compound.

2006 BMW 650i
Fig. 41: Identifying Unpressurised, Self-Supporting Tyres

Disc Wheels
H2 Disc Wheel (Standard Disc Wheel) For Emergency Running System With Integrated Support Ring
(1) Hump 2 of standard disc wheel

2006 BMW 650i
Fig. 42: Identifying H2 Disc Wheel

EH2 Disc Wheel For Emergency Running System With Self-Supporting Tyre
2006 BMW 650i
Fig. 43: Identifying EH2 Disc Wheel

1. Extended Hump 2 of disc wheel

2. Drop centre relocated a few millimetres to the centre (precentring on outside)
NOTE: The new EH2 disc wheels (extended Hump 2 inner and outer) will be used more
frequently on BMW vehicles in the future as they can also help to delay
standard tyres from being lost in the event of a drop in tyre pressure.
Example: from current 1.1 bar to 0.6 bar (X5 or Landrover disc wheel)
Emergency Running System With Integrated Support Ring
(In the future, primarily on heavy safety vehicles)
The support ring is made of a high-strength resilient plastic and is fitted on the disc wheel inside the tyre. The
2006 BMW 650i
support ring can only be removed using special tools which have been specially approved by BMW. It can only
be removed after destroying the tyre.
Emergency running systems with integrated support ring are used in particular on heavy safety vehicles. They
allow the vehicle to be driven away from a potential danger without dropping speed even if the tyres have
suffered a complete loss of pressure (flight situation).
It is possible as an option to have the tyre pressure monitored by an RDC system. The RDC is installed by
pressing the components into the support ring before it is fitted.
Wheel Structure With Integrated Support Ring
Emergency Running System With Integrated Support Ring
Fig. 44: Identifying Support Ring And Tyre

2006 BMW 650i
1. Tyre
2. Support ring
Installation Location Of RDC Wheel Electronic Unit
Fig. 45: Identifying Wheel Electronic Unit And Support Ring

1. Wheel electronic unit

2. Support ring
For further information on the subject of "Tyre pressure warning systems and tyres with emergency
running characteristics", please refer to the vehicle Owner's Handbook.
2006 BMW 650i
Functional and system descriptions are not subject to change. Parts availability and immediate ordering
availability cannot be derived from this information. The specialised departments will inform the
markets with further details at the appropriate time.
STORING WHEELS AND TYRES

All Models
WHEELS/TYRES - GENERAL NOTES
The service of storing a customer's wheels is one which is now almost taken for granted. For this reason, we
have published this BMW Technical Service bulletin to provide a uniform storage concept, which will prevent
damage being caused due to incorrect storage.
The tyre's rubber will age under the influence of sunlight, heat, humidity, movements in the air and ozone, and
will thus lose some of its stability and elasticity. For this reason, tyres should never be stored in the open-air. If
open-air storage cannot be avoided, the wheels/tyres must be stored in a clean and dry condition and covered
with waterproof material. It is essential that wheels/tyres are protected against rain, snow and sunlight, but due
to the risk of corrosion they must not be stored in tyre sacks. For more information on protective covers for
wheels and tyres, see SI 36 01 88 (864).
Wheels/tyres with tyre pressure control (RDC) must not be cleaned with high-pressure cleaning equipment. For
general information on RDC, TYRES WITH EMERGENCY RUNNING CHARACTERISTICS AND
TYRE PRESSURE WARNING SYSTEMS.
Storage Requirements
The following requirements apply in general to storage in enclosed rooms:
STORING WHEELS AND TYRES SPECIFICATIONS

cool 15...25 °C / sources of heat screened, or 1 m
minimum distance from source of heat
dry Prevent water and condensation
Avoid contact with mineral lubrication products
dark Protect from direct sunlight and high-UV artificial
light
moderate ventilation Avoid a supply of oxygen and ozone
In short, the storage room should be cool and dry. It is not necessary to heat the room during the winter. In the
summer, the doors and windows should be kept closed to ensure that no air can circulate. In addition, the
windows can also be coated with sun protection paint.
The storage room should not contain any working electric machinery, welding equipment, distribution boxes
etc. as electrical sparks generate ozone which can have a serious impact on the surface of the tyre (ozone
cracks).
2006 BMW 650i
Tyres should not be allowed to come into contact with oil, petrol, or other mineral lubricants as these dissolve
rubber, making the tyre porous.
Preparing Wheels/Tyres
1. Before removing a wheel, mark its position on the vehicle.

2. Whenever possible, keep the tyre on its wheel (complete wheels).
3. Correct the inflation pressure and recheck every 2 months.
4. Ensure that tyres are stored at a sufficient distance above the ground. Wheels/tyres should never be stored
on the ground.
5. Complete the storage forms. These should contain the following data:
 Type and size of tyre
 Condition and tread depth
 Customer's address
 Date and signature of customer
Wheel/Tyre Storage Requirements
A. Tyre fitted to wheel
Do not store upright, ...
NOTE: If storing the wheels upright cannot be avoided, the inflation pressure
must be increased to 3.5 bar.
2006 BMW 650i
Fig. 46: Use Care When Storing Wheel/Tyre Storage In Upright Position (Tyre Fitted To Wheel)
... but rather hang ...

2006 BMW 650i
Fig. 47: Preferred: Store Tyres In Hanging Position (Tyre Fitted To Wheel)
... or stack.
NOTE: Never store tyres on the ground.

Use a wooden palette or similar.
2006 BMW 650i
Fig. 48: Storing Tyres In Stacked Position (Tyre Fitted To Wheel)

B. Tyres Not Fitted

2006 BMW 650i
Do not stack, ...

2006 BMW 650i
2006 BMW 650i
... do not hang, ...
Fig. 50: DO NOT Store Wheel/Tyre In Hanging Position (Tyres Not Fitted)
... but rather store them upright and turn them every 4 weeks.
NOTE: Never store tyres on the ground.

Use commercially available shelves.
2006 BMW 650i
Fig. 51: Preferred: Store Tyres In Staked Position (Tyres Not Fitted)
2009 BMW 650i
SUSPENSION Wheels & Tires - Repair - 650i, M6
SUSPENSION
Wheels & Tires - Repair - 650i, M6
10 WHEELS
36 10 209 CHECKING FRONT AND REAR WHEEL FOR FACE AND RADIAL RUNOUT
 36 1 030 . See WHEEL AND TIRES - SPECIAL TOOLS .
 Check wheel bearings
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 .
2009 BMW 650i
Fig. 2: Checking Wheel With Special Tool (36 1 030)

If applicable, remove balance weights.
Check lateral runout of rim with special tool 36 1 030 (measuring fixture).
Fig. 3: Using Special Tool (36 1 030)

Check radial runout of rim with special tool 36 1 030 (measuring fixture).
2009 BMW 650i
Fig. 4: Checking Radial Runout Of Rim With Special Tool (36 1 030)
36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL
 36 1 120
 36 1 250
IMPORTANT: Observe safety instructions on raising the vehicle .

Follow instructions on initializing Run Flat Indicator (RPA). See TIRE
PRESSURE MONITOR SYSTEMS . After completing installation, check again
that all wheel bolts are tightened to specified torque. Tightening torque 36 10
1AZ . See WHEEL AND TIRES - TIGHTENING TORQUES .
Observe the following procedure to prevent shift errors and imbalance:
 Loosen wheel bolts.

 Wheel positioned with valve facing down.
 If several wheels are removed simultaneously, mark the installation locations of the wheels on the tires
(e.g. with chalk).
 Mark out wheel to wheel hub.
 Mark out lockable wheel bolt in relation to wheel.
 Release wheel bolts, remove wheel.
2009 BMW 650i
Fig. 5: Locating Wheel Bolts

IMPORTANT: Contact surfaces between:
 brake disk and disk wheel,

 brake disk and wheel hub,
must be free from grease.
Remove dirt, grease residues and corrosion from contact face (1) with a drill and special tool 36 1 250 .
IMPORTANT: Do not operate special tool 36 1 250 with an impact screwdriver!
NOTE: Degrease contact face with BMW universal cleaner.
NOTE: If there are grease residues in the area of the wheel stud bore, the brake disk
must be removed and cleaned.
2009 BMW 650i

Remove dirt, grease residues and corrosion from contact face (1) with a drill and special tool 36 1 250 .
NOTE: Degrease contact face with BMW universal cleaner.

Check brake disk retaining bolt (1) for secure seating.
IMPORTANT: Mounting bolt (1) must not under any circumstances protrude over contact
surface (2) between brake disk and disk wheel.
Tightening torque brake disk retaining bolt:

2009 BMW 650i
Front axle 34 11 1AZ.
Rear axle 34 21 1AZ. . See WHEEL AND TIRES - TIGHTENING TORQUES .
Fig. 8: Identifying Mounting Bolt And Contact Surface Between Brake Disk And Disk Wheel
Apply a thin coat of grease to wheel centering (1) in disk wheel.
NOTE: Refer to BMW Service Operating Fluids. See OPERATING FLUIDS - WHEELS
AND TIRES .
Fig. 9: Wheel Centering

Wheel studs with taper:
a. Wheel bolt - galvanized

2009 BMW 650i
c. Wheel bolt - black chrome plated and lockable

d. Lockable wheel stud with adapter, black chrome-plated
NOTE: To release and tighten down lockable wheel stud, use a matching adapter from
Fig. 10: Identifying Wheel Studs With Taper

Clean wheel bolts and check threads for damage, replace, if necessary.
Replace rusty wheel bolts.
IMPORTANT: Do not apply oil to new wheel bolts.
Before inserting, wipe threads and tapers of used wheel bolts with an oil cloth.
IMPORTANT: You may use an impact or power screwdriver to insert the wheel bolts and join
the wheel until a tightening torque of 20 Nm is obtained.
Do not under any circumstances use an impact or power screwdriver to tighten
down the wheel bolts (in diagonal sequence); this must be done by hand.
Tighten down wheel bolts with a calibrated torque wrench to prescribed tightening torque.
Tightening torque 36 10 1AZ. . See WHEEL AND TIRES - TIGHTENING TORQUES .
IMPORTANT: Disk wheel must rest uniformly against brake disk.

2009 BMW 650i
Fig. 11: Tightening Wheel Bolts With Calibrated Torque Wrench

NOTE: For wheels with Styling 90 wheel cover.
The wheel cover can be removed for cleaning and removal of foreign objects.
Fit special tool 36 1 120 (3) as shown on rim (1) (near valve).
Engage removal fork of special tool 36 1 120 (3) in wheel cover (2).
Pull off wheel cover (2) with handle of special tool 36 1 120 (3).
Fig. 12: Identifying Wheel Cover With Special Tool (36 1 120)
36 10 508 STATIONARY WHEEL BALANCING

2009 BMW 650i
 36 1 010
 Remove wheel
IMPORTANT: Use only BMW-approved balance weights.
Remove any fitted balancing weights, stones in tread pattern and larger contaminants.
Check tire pressure, check tire for condition, damage, flat spots (out-of-round caused by e.g. stopping the car
with hot tires); if necessary, check wheel and tire for radial and lateral runout .
Fig. 13: Identifying Fitted Balancing Weights, Stones In Tread Pattern And Larger Contaminants
Use BMW-approved centering elements of relevant balancing machine manufacturers.
1. Basic flange
2. Wheel centering element
3. Type flange
4. Clamping nut
2009 BMW 650i
Fig. 14: Identifying Basic Flange, Wheel centering Element And Clamping Nut
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 tire side wall with special tool 36 1 020 at appropriate point from rim flange.
2. Install retaining clip (1).
3. Remove special tool 36 1 020 .
Fig. 15: Identifying Retaining Clip 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.
2009 BMW 650i

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. imbalance per wheel. . See WHEEL AND TIRES - TECHNICAL DATA
Fig. 17: Identifying Spring Retainer And Balance Weight

NOTE: When using adhesive weights, proceed as follows:
1. Carefully remove any adhesive weights. Do not damage rim when doing
2009 BMW 650i
2. Select suitable location for fitting.

3. Clean adhesive area thoroughly.
IMPORTANT: On the E87 with 16" tires, do not use stick-on weights; use only clamp-on
weights instead.
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
 Remove wheel.
Mount wheel in balancing machine.
To avoid retooling errors, fit the wheel on the balancing machine in the same way as it is also fitted on the car
(valve position facing down).
Fig. 18: Balancing Wheels

2009 BMW 650i
Use suitable wheel centering element supplied with corresponding balancing machine.
1. Basic flange
3. Type flange
4. Clamping nut
Fig. 19: Identifying Basic Flange, Wheel Centering Element And Clamping Nut
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
2009 BMW 650i
Position special tool 36 1 030 on tire tread.
Turn wheel by hand and measure max. radial tire runout . See WHEEL AND TIRES - TECHNICAL DATA .
NOTE: Measuring device must be vertical to tire tread.
Fig. 21: Checking Radial Tire Runout

Position special tool 36 1 030 on tire side wall.
Turn wheel by hand and measure max. lateral tire runout . See WHEEL AND TIRES - TECHNICAL DATA
NOTE: Measuring device must be vertical to tire side wall.
Never measure on printed text on tire!

2009 BMW 650i
If necessary, check disk wheel (rim) for radial and face runout . See WHEEL AND TIRES - TECHNICAL
DATA .
Fig. 22: Checking Lateral Tire Runout

36 10 715 CHECKING RIM FOR FACE AND RADIAL RUNOUT
 Remove wheel
 Checking front and rear wheel for face and radial runout . See WHEEL AND TIRES - TECHNICAL
DATA .
 Pull tire off rim
 Remove fitted balance weights
 Remove dirt from rim well and rim flange
IMPORTANT: Disk wheels must not be repaired!
Mount disk wheel in balancing machine.

2009 BMW 650i
Fig. 23: Mount Disk Wheel In Balancing Machine

1. Basic flange
3. Type flange
4. Clamping nut
Fig. 24: Identifying Basic Flange, Wheel Centering Element And Clamping Nut
Place dial gauge sensor on rim shoulder.
Turn wheel by hand and measure max. radial runout . See WHEEL AND TIRES - TECHNICAL DATA .
Carry out measurement on both rim shoulder sides.

2009 BMW 650i
Fig. 25: Dial Gauge Sensor On Rim Shoulder

Position sensor on rim flange.
Turn wheel by hand and measure max. lateral runout . See WHEEL AND TIRES - TECHNICAL DATA .
Carry out measurement on both rim flanges.
NOTE: Dial gauge must be vertical to rim flange.
Fig. 26: Dial Gauge Vertical To Rim Flange

IMPORTANT: Avoid transformation errors during subsequent installation tasks.
11 DISC WHEELS (RIMS)

36 11 500 INITIALIZING RUN FLAT INDICATOR (RPA)
2009 BMW 650i
NOTE: Checking the tire pressure is based on monitoring the speeds of the wheels in
relation to each other. A tire puncture is detected and signalled by way of a
deviation in specific speed ratios.
The four tires mounted on the vehicle are monitored while the vehicle is moving.
Initialization must be carried out in each case immediately after tire pressures have been corrected, after
tires/wheels have been replaced and after repairs to the air spring system.
IMPORTANT: The Run Flat Indicator does not function when the vehicle is driven with the
compact spare wheel.
Please refer to the relevant Owner's Handbook for details of the initialization procedure.
36 11 503 RDC RESETTING
NOTE: RDC monitors the tire inflation pressure in the four wheels.
Each tire incorporates an electronic wheel circuit, which constantly monitors the tire inflation pressure.
The system signals when the inflation pressure drops in one or more tires.
Resetting must be carried out in each case immediately after tire pressures have been corrected, after
tires/wheels have been replaced and after repairs to the air spring system.
Please refer to the relevant Owner's Handbook for details of the initialization procedure.
12 TIRES
36 12 001 CHANGING A TIRE (ON FRONT, REAR OR SPARE WHEEL)
2009 BMW 650i
Fig. 27: Identifying Tire Changer Machine

Refer to the operating manual of the relevant fitting equipment manufacturer for details on how to fit the tire
correctly. The equipment must be in perfect condition to exclude the risk of damaging the disc wheel and the
tire.
NOTE: Comply with approved tires, tire sizes and optional extra.
Follow instructions on initializing Run Flat Indicator (RPA). See TIRE
PRESSURE MONITOR SYSTEMS .
NOTE: Pay attention to different tire markings:
 Item (1) Marking denoting BMW-approved tires. Ensure that only BMW-
approved tires are fitted.
 Item (2) RSC is the abbreviation for R unflat S ystem C omponent (runflat
tires).
 Item (3) Outside. The tire must be fitted so that the wording Outside is
always situated on the outside of the rim.
2009 BMW 650i
IMPORTANT: Many tires are directional!

The arrow on the tire must point in the direction of travel for each wheel!
Fig. 28: Identifying Tire Markings

Models with M Mobility system
If the wheel was inflated with the M Mobility system after a puncture, observe the following: Before removal,
drill a hole of approx. 25 mm dia. in the tire sidewall. Drain sealing compound from this hole and dispose of
this compound in an environmentally responsible manner. Clean the disc wheel after removing the tire.
Tire removal with a fitting machine:
Unscrew valve insert, discharge air, force off tire bead from rim flange with pressing-off horn of device on
outside and inside.
If tire beads are stuck, first release the tire with the pressing-off horn at several points of the wheel before
actually pressing off, apply tire mounting paste between tire and rim flange and press off the tires 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.

2009 BMW 650i
Fig. 29: Clamp Wheel On Mounting Machine

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 tire iron from damaging
the RDC wheel electronics.
Raise tire bead with tire iron over mounting finger.
Fig. 30: Raising Tire Bead With Tire Iron

2009 BMW 650i
NOTE: On aluminum rims, it is best to use a tire 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 tire bead can slide fully onto mounting
finger.
Then let fitting machine run forward in stages (clockwise).
Fig. 31: Fitting Machine Running Backward And Forward

In so doing, always check whether the lower bead is fully resting in the well and allow the tire 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 tire iron.
Let machine run back a short distance again and then forward (clockwise) briefly until there is complete
separation of the tire from the rim.

Tire bead must not press onto RDC wheel electronics.
2009 BMW 650i
Fig. 32: Lift The Bottom Bead Over The Mounting Finger With The Tire Iron
Release lock and tilt back or swing away mounting pillar.
Unclamp and clean rim.
Replace valve.
Coat rim flange and tire beads with mounting paste.

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 a valve is loose, the complete valve
must be replaced.
Keep wheel electronics free of tire mounting paste.
Clamp rim on fitting machine, valve must be located at 180° to mounting head.
Slide on tire with lower bead partially over rim flange.

2009 BMW 650i
Fig. 33: Sliding On Tire 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 tire under mounting finger by hand.
Tire bead must seat in rollers next to mounting finger.
Let fitting machine run forward (clockwise) a short distance.
Lower tire bead will drop into well.

Fit lower tire bead so that no pressure forces are exerted on RDC wheel
electronics.
Fig. 34: Identifying Adjustment Of Mounting Finger

2009 BMW 650i
Turn wheel again into fitting position so that valve is at 180 ° to mounting head.
Press upper tire 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 tire bead
remains in the well.

Fit upper tire bead so that no pressure forces are exerted on RDC wheel
electronics.
Fig. 35: Pressing Upper Tire Bead Under Mounting Finger

After mounting, first release clamps and then inflate tire (without valve).
Increase pressure up to 3.3 bar (330 kPa) in steps (jumping pressure).
If the tire bead does not slip on all round at the rim edge, do not increase pressure further but rather drain off air.
Press off tire bead again, coat rim flange again with tire mounting paste, 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
tire.
Screw in valve insert and correct tire pressure.

2009 BMW 650i
Fig. 36: Releasing Clamps And Inflate Tire

36 12 005 REPLACING A RUNFLAT TIRE
Follow the fitting machine manufacturer's operating instructions.
It is absolutely essential to ensure that the equipment is in proper working condition and that there is no damage
to the disc wheel and tire.
After completion of work, balance wheels .
IMPORTANT: Only fitting machines which are approved for fitting runflat tires may be used!
Please refer to the operating instructions of the respective fitting machine for
details of the exact fitting procedure.
Use only BMW-approved plastic-covered tire irons.
Use only BMW-approved tire mounting paste.
NOTE: Pay attention to different tire markings:
 Item (1) Marking denoting BMW-approved tires. Ensure that only BMW-
approved tires are fitted.
 Item (2) RSC is the abbreviation for Runflat System Component (runflat
tires).
 Item (3) Outside. The tire must be fitted so that the wording Outside is
always situated on the outside of the rim.
IMPORTANT: Many tires are directional!

The arrow on the tire must point in the direction of travel for each wheel!
2009 BMW 650i

After completing fitting, first release clamping claws.
Inflate with air (without valve insert).
Increase pressure up to 3.3 bar in stages (jumping pressure).
If the tire bead does not slip fully past the rim edge all round, do not under any circumstance increase the
pressure.
Release air and force off tire bead again.
Coat rim flange with tire mounting paste again.
Inflate tire again up to 3.3 bar.
When tire beads are resting perfectly on rim shoulders, increase inflation pressure to max. 4.0 bar to "settle"
tire.
Screw in valve insert and correct tire pressure.
Follow instructions on initializing Run Flat Indicator (RPA). See TIRE PRESSURE MONITOR SYSTEMS .
2009 BMW 650i
Fig. 38: Releasing Clamps And Inflate Tire

IMPORTANT: Advise the customer to avoid heavy acceleration in the initial period.
The mounting paste can cause the tire to turn on the rim and give rise to
imbalance.
36 12 084 REPLACING SEALANT BOTTLE OF M-MOBILITY SYSTEM
Raise luggage compartment floor at rear. Remove M-Mobility system (1). Remove sealant bottle underneath.
Fig. 39: Removing M-Mobility System
Check expiry date (1) on sealant bottle, replace if necessary.

2009 BMW 650i
Fig. 40: Checking Expiration Date
13 MOUNTING
36 13 SUBSEQUENT INSTALLATION OF WHEEL-BOLT LOCK
Loosen wheel bolts.
Raise car so that wheel can be turned freely.
Release wheel studs to such an extent that the wheel can move freely on the wheel hub.
Turn wheel so that valve is face down.
Remove top wheel stud and insert wheel stud lock.
Fig. 41: Locating Wheel Bolts

Possible play in wheel center and wheel weight could cause imbalance.
2009 BMW 650i
This imbalance is reduced to a minimum by installing the somewhat heavier wheel-bolt lock in the top wheel-
bolt position.
In this position - wheel stud lock at top, valve at bottom - tighten wheel studs hand-tight in diagonal sequence.
Lower car and tighten wheel bolts crosswise.
Tightening torque 36 10 1AZ . See WHEEL AND TIRES - TIGHTENING TORQUES .
If this sequence of fitting the wheel stud lock is followed by a customer complaint about wheel imbalance, it
will be necessary to finish-balance the wheels.
Fig. 42: Tightening Wheel Bolts With Torque Wrench

2005 BMW 645Ci
2004-05 SUSPENSION Wheels & Tires - Repair Instructions - E63
2004-05 SUSPENSION
Wheels & Tires - Repair Instructions - E63
WHEEL
36 10 209 CHECKING FRONT AND REAR WHEEL FOR FACE AND RADIAL RUNOUT
NOTE: For special tools, refer to WHEEL & TIRES - SPECIAL TOOLS - 645CI (E63) .
 36 1 030
 Check wheel bearings
Lift vehicle.
Check wheel with special tool 36 1 030 (measuring fixture) for lateral runout, refer to 36 10 WHEELS ONE-
PART ALLOY WHEELS , 36 10 WHEELS STEEL AND ALUMINUM STRIP WHEELS or 36 10
WHEELS TWO-PART ALLOY WHEELS .
2005 BMW 645Ci
Fig. 1: Measuring Tyre Lateral Runout

Check wheel with special tool 36 1 030 (measuring fixture) for radial runout, refer to 36 10 WHEELS ONE-
2005 BMW 645Ci
Fig. 2: Measuring Tyre Radial Runout With Special Tool 36 1 030

If applicable, remove balance weights.
Check lateral runout of rim with special tool 36 1 030 (measuring fixture), refer to 36 10 WHEELS ONE-
2005 BMW 645Ci
Fig. 3: Measuring Rim Lateral Runout With Special Tool 36 1 030

Check radial runout of rim with special tool 36 1 030 (measuring fixture), refer to 36 10 WHEELS ONE-
2005 BMW 645Ci
Fig. 4: Measuring Rim Radial Runout With Special Tool 36 1 030

36 10 Wheels One-Part Alloy Wheels
WHEELS ONE-PART ALLOY WHEELS

Max. radial runout of tire Rim with tire max. mm 1.1
Max. axial runout or tire Rim with tire max. mm 1.3
Max. radial runout out rim max. mm 0.3
Max. axial runout of rim max. mm 0.3
Max. imbalance for each side (before balancing) max. g 90 for clamp weights 120
for stick-on weights
Permissible residual imbalance for each side (after max. g 4
balancing)
Elimination of imbalance: Up to 60 g with one
weight or more than 60 g with two weights
2005 BMW 645Ci
36 10 Wheels Steel And Aluminum Strip Wheels
WHEELS STEEL AND ALUMINUM STRIP WHEELS

Max. radial runout out rim max. mmmax. mm 0.8
balancing)
36 10 Wheels Two-Part Alloy Wheels
WHEELS TWO-PART ALLOY WHEELS

Max. radial runout out rim max. mm 0.5
balancing)
36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL
 36 1 120
 36 1 250
 36 1 300
IMPORTANT: Wheel was balanced electronically.
PLATFORM .
2005 BMW 645Ci
Follow instructions on initializing Run Flat Indicator (RPA), refer to 36 11 000 INITIALIZING TYRE
DEFECT INDICATOR (RPA) .
Observe the following procedure to prevent shift errors and imbalance:
 Loosen wheel bolts.

 Wheel positioned with valve facing down.
 If several wheels are removed simultaneously, mark the installation locations of the wheels on the tires
(e.g. with chalk).
 Mark out wheel to wheel hub.
 Mark out lockable wheel bolt in relation to wheel.
 Release wheel bolts, remove wheel, refer to 36 10 300 REMOVING OR INSTALLING FRONT OR
REAR WHEEL .
2005 BMW 645Ci
Fig. 5: Removing Wheel Bolts And Wheel

IMPORTANT: Contact surfaces between:
 brake disk and disk wheel,

 brake disk and wheel hub,
must be free from grease.
Remove dirt, grease residues and corrosion from contact face (1) with a drill and special tool 36 1 250.
NOTE: Degrease contact face with universal cleaner.
NOTE: If there are grease residues in the area of the wheel stud bore, the brake disk
must be removed and cleaned, refer to 34 11 220 REMOVING AND
INSTALLING/REPLACING BOTH FRONT BRAKE DISKS or 34 21 320 REMOVING
AND INSTALLING OR REPLACING BOTH REAR BRAKE DISKS .
Remove dirt, grease residues and corrosion from contact face (1) with a drill and special tool 36 1 250
2005 BMW 645Ci
Fig. 6: Removing Dirt, Grease Residues And Corrosion From Contact Face (1) With A Drill And Special
Tool 36 1 250
NOTE: Degrease contact face with universal cleaner.

2005 BMW 645Ci
Fig. 7: Degrease Contact Face With Universal Cleaner

Check brake disk retaining bolt (1) for secure seating.
IMPORTANT: Mounting bolt (1) must not under any circumstances protrude over contact
surface (2) between brake disk and disk wheel.
Tightening torque brake disk retaining bolt:
Front axle, refer to 34 11 1AZ in WHEEL AND TIRES - TIGHTENING TORQUES - 645CI .
Rear axle, refer to 34 21 1AZ in WHEEL AND TIRES - TIGHTENING TORQUES - 645CI .
2005 BMW 645Ci
Fig. 8: Checking Brake Disk Retaining Bolt For Secure Seating

Apply a thin coat of grease to wheel centering (1) in disk wheel.
NOTE: Refer to OPERATING FLUIDS - WHEELS AND TIRES - ALL MODELS .

2005 BMW 645Ci
Fig. 9: Locating Grease Applying Point

Wheel studs with taper:
a. Wheel bolt - galvanised

b. Wheel bolt - black chrome plated
c. Wheel bolt - black chrome plated and lockable
d. Lockable wheel stud with adapter, black chrome-plated
NOTE: To release and tighten down lockable wheel stud, use a matching adapter from
2005 BMW 645Ci
Fig. 10: Identifying Wheel Studs With Taper

Clean wheel bolts and check threads for damage, replace, if necessary.
Replace rusty wheel bolts.
IMPORTANT: Do not apply oil to new wheel bolts.
Apply a thin coating of engine oil to threads and tapers of used wheel studs before insertion.
IMPORTANT: Under no circumstances use pneumatic or power screwdrivers to install and

tighten the wheel bolts.
Screw in wheel studs and, to center disk wheel, tighten down by hand diagonally and evenly.
2005 BMW 645Ci
Using torque wrench, firmly tighten wheel studs in diagonal and even sequence.
Tightening torque refer to 36 10 1AZ in WHEEL AND TIRES - TIGHTENING TORQUES - 645CI .
IMPORTANT: Disk wheel must rest uniformly against brake disk.
Fig. 11: Installing Wheel Studs To Center Disk

NOTE: For wheels with Styling 90 wheel cover.
The wheel cover can be removed for cleaning and removal of foreign objects.
Fit special tool 36 1 120 (3) as shown on rim (1) (near valve).
Engage removal fork of special tool 36 1 120. (3) in wheel cover (2).
2005 BMW 645Ci
Pull off wheel cover (2) with handle of special tool 36 1 120 (3).
Fig. 12: Installing Special Tool On Rim

36 10 508 BALANCING WHEEL DYNAMICALLY (WHEEL REMOVED)
 36 1 010
 36 1 020
Remove wheel, refer to 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL .

2005 BMW 645Ci
IMPORTANT: Use only BMW-approved balance weights.
Remove any fitted balancing weights, stones in tread pattern and larger contaminants.
Check tire pressure, check tire for condition, damage, flat spots (out-of-round caused by e.g. stopping the car
with hot tires); if necessary, check wheel and tire for radial and lateral runout, refer to 36 10 WHEELS ONE-
Fig. 13: Installing Wheel In Balancing Machine

Use BMW-approved centering elements of relevant balancing machine manufacturers.

2005 BMW 645Ci
Fig. 14: Identifying BMW-Approved Centering Elements

1. Basic flange
3. Type flange
4. Clamping nut
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 tire sidewall with special tool 36 1 020 at appropriate point from rim flange.
2. Install retaining clip (1).
2005 BMW 645Ci
Fig. 15: Installing Retaining Clip With Special Tool 36 1 020

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.
2005 BMW 645Ci
Fig. 16: Raising Retaining Clip With Special Tool 36 1 010

Arrangement of balance weights for light-alloy rims with distinctive J-shape rim flanges.
1. Spring retainer
2. Balance weight
2005 BMW 645Ci
Fig. 17: Identifying Balance Weights Arrangement For Light-Alloy Rims

Adhesive weights must be used on all other light-alloy rims.
Max. imbalance per wheel, refer to 36 10 WHEELS ONE-PART ALLOY WHEELS , 36 10 WHEELS
STEEL AND ALUMINUM STRIP WHEELS or 36 10 WHEELS TWO-PART ALLOY WHEELS .
NOTE: When using adhesive weights, proceed as follows:
1. Carefully remove any adhesive weights. Do not damage rim when doing so.
2. Select suitable location for fitting.
2005 BMW 645Ci
3. Clean adhesive area thoroughly.
IMPORTANT: On the E87 with 16" tyres, do not use stick-on weights; use only clamp-on
weights instead.
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
Mount wheel in balancing machine.

2005 BMW 645Ci
Fig. 18: Mounting Wheel In Balancing Machine

To avoid retooling errors, fit the wheel on the balancing machine in the same way as it is also fitted on the car
(valve position facing down).
2005 BMW 645Ci

1. Basic flange
3. Type flange
4. Clamping nut
Use special tool 36 1 030 for testing.
Special tool 36 1 030 consists of:

2005 BMW 645Ci

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.

2005 BMW 645Ci
Fig. 21: Positioning Special Tool On Tire Tread

Turn wheel by hand and measure max. radial tire runout, refer to 36 10 WHEELS ONE-PART ALLOY
WHEELS , 36 10 WHEELS STEEL AND ALUMINUM STRIP WHEELS or 36 10 WHEELS TWO-
PART ALLOY WHEELS .
NOTE: Measuring device must be vertical to tire tread.
Position special tool 36 1 030 on tire sidewall.

2005 BMW 645Ci
Fig. 22: Positioning Special Tool On Tire Sidewall 36 1 030

Turn wheel by hand and measure max. lateral tire runout, refer to 36 10 WHEELS ONE-PART ALLOY
PART ALLOY WHEELS .
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

 Check front or back wheel for face and radial runout, refer to 36 10 WHEELS ONE-PART ALLOY
2005 BMW 645Ci
TWO-PART ALLOY WHEELS .

 Pull tire off rim.
 Remove fitted balance weights.
 Remove dirt from rim well and rim flange.
Mount disk wheel in balancing machine.
Fig. 23: Mounting Disk Wheel In Balancing Machine

2005 BMW 645Ci

1. Basic flange
3. Type flange
4. Clamping nut
Place dial gauge sensor on rim shoulder.
Turn wheel by hand and measure max. radial runout, refer to 36 10 WHEELS ONE-PART ALLOY
PART ALLOY WHEELS .
Carry out measurement on both rim shoulder sides.
NOTE: Dial gauge must be vertical to rim shoulder.

2005 BMW 645Ci
Fig. 25: Placing Dial Gauge Sensor On Rim Shoulder

Position sensor on rim flange.

2005 BMW 645Ci
Turn wheel by hand and measure max. lateral runout, refer to 36 10 WHEELS ONE-PART ALLOY
PART ALLOY WHEELS .
Carry out measurement on both rim flanges.
NOTE: Dial gauge must be vertical to rim flange.
Fig. 26: Measuring Wheel Maximum Lateral Runout

IMPORTANT: Avoid transformation errors during subsequent installation tasks, refer to 36 10

508 BALANCING WHEEL DYNAMICALLY (WHEEL REMOVED) .
DISC WHEELS (RIMS)

2005 BMW 645Ci
NOTE: Checking the tyre pressure is based on monitoring the speeds of the wheels in
relation to each other. A tyre puncture is detected and signalled by way of a
deviation in specific speed ratios.
The four tyres mounted on the vehicle are monitored while the vehicle is moving.
Initialization must be carried out in each case immediately after tyre pressures have been corrected, after
tyres/wheels have been replaced and after repairs to the air spring system.
IMPORTANT: The tyre defect indicator does not function when the vehicle is driven with the
compact spare wheel.
Please refer to the relevant Owner's Manual for details of the initialization procedure.
TYRES
36 12 001 CHANGING A TIRE (ON FRONT, REAR OR SPARE WHEEL)
2005 BMW 645Ci
Fig. 27: Identifying Automatic Tyre Changing Machine

Refer to the operating manual of the relevant fitting equipment manufacturer for details on how to fit the tire
2005 BMW 645Ci
correctly. The equipment must be in perfect condition to exclude the risk of damaging the disk wheel and the
tire.
NOTE: Comply with approved tires, tire sizes and optional extra. Follow instructions on
initializing tyre defect indicator (RPA), refer to 36 11 000 INITIALIZING TYRE
Models with M Mobility system
If the wheel was inflated with the M Mobility system after a puncture, observe the following: Before removal,
drill a hole of approx. 25 mm dia. in the tire sidewall. Allow the sealing fluid to flow out of this hole and
dispose of it in an environmentally responsible manner. Clean the disk wheel after removing the tire.
Tire removal with a fitting machine:
Unscrew valve insert, discharge air, force off tire bead from rim flange with pressing-off horn of device on
outside and inside.
If tire beads are stuck, first release the tire with the pressing-off horn at several points of the wheel before
actually pressing off, apply tire mounting paste between tire and rim flange and press off the tires 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.

2005 BMW 645Ci
Fig. 28: Removing Tyre With Fitting Machine

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 tire iron from damaging
the RDC wheel electronics.
2005 BMW 645Ci
Raise tire bead with tire iron over mounting finger.
Fig. 29: Raising Tyre Bead With Tyre Iron Over Mounting Finger (1 Of 3)
NOTE: On aluminum rims, it is best to use a tire 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 tire 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 tire time to move.
If the bead clamps, stop the machine and let it run back slightly.
2005 BMW 645Ci
If the upper bead is pulled off the rim, also lift the bottom bead over the mounting finger with the tire iron.
Let machine run back a short distance again and then forward (clockwise) briefly until there is complete
separation of the tire from the rim.
IMPORTANT: Vehicles with RDC: Tire bead must not press onto RDC wheel electronics.
2005 BMW 645Ci
Release lock and tilt back or swing away mounting pillar.
Unclamp and clean rim.
Replace valve.
Coat rim flange and tire beads with mounting paste.

2005 BMW 645Ci
Fig. 32: Removing Tyre From Rim

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 a valve is loose, the complete valve must be replaced. Keep
wheel electronics free of tire mounting paste.
Clamp rim on fitting machine, valve must be located at 180° to mounting head.
2005 BMW 645Ci
Fig. 33: Clamping Rim On Fitting Machine

Slide on tire with lower bead partially over rim flange.
Swing or tilt mounting pillar into position and lock.
Check adjustment of mounting finger, readjust if necessary, and clamp.
Press tire under mounting finger by hand.
Tire bead must seat in rollers next to mounting finger.
Let fitting machine run forward (clockwise) a short distance.
Lower tire bead will drop into well.

2005 BMW 645Ci
IMPORTANT: Vehicles with RDC: Fit lower tire 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 tire 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 tire bead
remains in the well.
IMPORTANT: Vehicles with RDC: Fit upper tire bead so that no pressure forces are exerted
on RDC wheel electronics.
Fig. 34: Pressing Upper Tyre Bead Under Mounting Finger

2005 BMW 645Ci
After mounting, first release clamps and then inflate tire (without valve).
Fig. 35: Releasing Clamps

Increase pressure up to 3.3 bar (330 kPa) in steps (jumping pressure).
If the tire bead does not slip on all round at the rim edge, do not increase pressure further but rather drain off air.
Press off tire bead again, coat rim flange again with tire mounting paste 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 tire.
Screw in valve and correct tire pressure.
36 12 005 REPLACING A RUNFLAT TYRE
Follow the fitting machine manufacturer's operating instructions.

2005 BMW 645Ci
It is absolutely essential to ensure that the equipment is in proper working condition and that there is no damage
to the disc wheel and tyre.
After completion of work, balance wheels, refer to 36 10 508 BALANCING WHEEL DYNAMICALLY
(WHEEL REMOVED) .
IMPORTANT: Only fitting machines which are approved for fitting runflat tyres may be used!
Please refer to the operating instructions of the respective fitting machine for
details of the exact fitting procedure. Use only BMW-approved plastic-covered
tyre irons. Use only BMW-approved tyre mounting paste. For approved
wheel/tyre combinations, tyre makes and optional extras, refer to KSD CD.
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!
2005 BMW 645Ci

After completing fitting, first release clamping claws.
Inflate with air (without valve insert).
Increase pressure up to 3.3 bar in stages (jumping pressure).
If the tyre bead does not slip fully past the rim edge all round, do not under any circumstance increase the
pressure.
Release air and force off tyre bead again.
Coat rim flange with tyre mounting paste again.
Inflate tyre again up to 3.3 bar.
When tyre beads are resting perfectly on rim shoulders, increase inflation pressure to max. 4.0 bar to "settle"
tyre.
2005 BMW 645Ci
Screw in valve insert and correct tyre pressure.
Follow instructions on initializing Run Flat Indicator (RPA), refer to 36 11 000 INITIALIZING TYRE
IMPORTANT: Advise the customer to avoid heavy acceleration in the initial period. The
mounting paste can cause the tyre to turn on the rim and give rise to
imbalance.
MOUNTING
36 13 SUBSEQUENT INSTALLATION OF WHEEL-BOLT LOCK
Loosen wheel bolts.
Raise car so that wheel can be turned freely.
Release wheel studs to such an extent that the wheel can move freely on the wheel hub.
Turn wheel so that valve is face down.
Remove top wheel stud and insert wheel stud lock.

2005 BMW 645Ci
Fig. 37: Removing Wheel Bolts

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.
In this position - wheel stud lock at top, valve at bottom - tighten wheel studs hand-tight in diagonal sequence.
Lower car and tighten wheel bolts crosswise.
Tightening torque, refer to 36 10 1AZ in WHEEL AND TIRES - TIGHTENING TORQUES - 645CI .
2005 BMW 645Ci
If this sequence of fitting the wheel stud lock is followed by a customer complaint about wheel imbalance, it
will be necessary to finish-balance the wheels.
Fig. 38: Tightening Bolts

2006 BMW 650i
2006 SYSTEM WIRING DIAGRAMS BMW - 650i
2006 SYSTEM WIRING DIAGRAMS

2006 BMW 650i
2006 BMW 650i
Fig. 1: Air Conditioning, Dual A/C Circuit (1 of 3)

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
Fig. 4: Air Conditioning, Single A/C Circuit (1 of 2)

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
Fig. 6: Cool Box Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 7: Independent Heating Circuit
ANTI-LOCK BRAKES
2006 BMW 650i
2006 BMW 650i
Fig. 8: Anti-lock Brakes Circuit
ANTI-THEFT
2006 BMW 650i
2006 BMW 650i
Fig. 9: Access/Start Circuit (1 of 3)

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
Fig. 12: Anti-theft & Central Locking Circuit (1 of 2)

2006 BMW 650i
2006 BMW 650i
BODY CONTROL MODULES

2006 BMW 650i
2006 BMW 650i
Fig. 14: Body Control Modules Circuit
COMPUTER DATA LINES

2006 BMW 650i
2006 BMW 650i
Fig. 15: Data Bus Circuit (1 of 2)

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
Fig. 17: Data Link Connector Circuit
COOLING FAN
2006 BMW 650i
2006 BMW 650i
Fig. 18: Cooling Fan Circuit
CRUISE CONTROL
2006 BMW 650i
2006 BMW 650i
Fig. 19: Cruise Control Circuit
DEFOGGERS
2006 BMW 650i
2006 BMW 650i
Fig. 20: Defoggers Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 21: Electronic Power Steering Circuit
ELECTRONIC SUSPENSION
2006 BMW 650i
2006 BMW 650i
Fig. 22: Air Suspension Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 23: Dynamic Drive Suspension Circuit
ENGINE PERFORMANCE
4.8L
2006 BMW 650i
2006 BMW 650i
Fig. 24: 4.8L, Engine Performance Circuit (1 of 6)

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
EXTERIOR LIGHTS
2006 BMW 650i
2006 BMW 650i
Fig. 30: Back-up Lamps Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 31: Exterior Lamps Circuit (1 of 2)

2006 BMW 650i
2006 BMW 650i
GROUND DISTRIBUTION
2006 BMW 650i
2006 BMW 650i
Fig. 33: Ground Distribution Circuit (1 of 7)

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
HEADLIGHTS
2006 BMW 650i
2006 BMW 650i
Fig. 40: Adaptive Front Lighting Circuit, W/ Directional Headlights

2006 BMW 650i
2006 BMW 650i
Fig. 41: Adaptive Front Lighting Circuit, W/O Directional Headlights

2006 BMW 650i
2006 BMW 650i
Fig. 42: Headlamps Circuit (1 of 2)

2006 BMW 650i
2006 BMW 650i
HORN
2006 BMW 650i
2006 BMW 650i
Fig. 44: Horn Circuit
INSTRUMENT CLUSTER
2006 BMW 650i
2006 BMW 650i
Fig. 45: Display Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 46: Instrument Cluster Circuit
INTERIOR LIGHTS
2006 BMW 650i
2006 BMW 650i
Fig. 47: Courtesy Lamps Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 48: Instrument Illumination Circuit
MEMORY SYSTEMS
2006 BMW 650i
2006 BMW 650i
Fig. 49: Driver"s Memory Seat Circuit, Convertible (1 of 2)

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
Fig. 51: Driver"s Memory Seat Circuit, Coupe

2006 BMW 650i
2006 BMW 650i
Fig. 52: Passenger"s Memory Seat Circuit, Convertible (1 of 2)

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
Fig. 54: Passenger"s Memory Seat Circuit, Coupe

2006 BMW 650i
2006 BMW 650i
Fig. 55: Steering Column Memory Circuit
NAVIGATION
2006 BMW 650i
2006 BMW 650i
Fig. 56: Navigation Circuit (1 of 3)

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
Fig. 59: Parking Assistant Circuit
POWER DISTRIBUTION
2006 BMW 650i
2006 BMW 650i
Fig. 60: Power Distribution Circuit (1 of 6)

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
POWER DOOR LOCKS

2006 BMW 650i
2006 BMW 650i
Fig. 66: Power Door Locks Circuit (1 of 2)

2006 BMW 650i
2006 BMW 650i
POWER MIRRORS
2006 BMW 650i
2006 BMW 650i
Fig. 68: Electrochromic Mirror Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 69: Power Mirrors Circuit, W/ Solid State Mirror

2006 BMW 650i
2006 BMW 650i
Fig. 70: Power Mirrors Circuit, W/O Solid State Mirror
POWER SEATS
2006 BMW 650i
2006 BMW 650i
Fig. 71: Heated Seats Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 72: Heated Steering Wheel Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 73: Power Seats Circuit
POWER TOP/SUNROOF
2006 BMW 650i
2006 BMW 650i
Fig. 74: Convertible Top Circuit (1 of 2)

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
Fig. 76: Panoramic Roof Circuit
POWER WINDOWS
2006 BMW 650i
2006 BMW 650i
Fig. 77: Power Windows Circuit (1 of 2)

2006 BMW 650i
2006 BMW 650i
RADIO
2006 BMW 650i
2006 BMW 650i
Fig. 79: Radio Circuit, W/ HIFI Radio (1 of 3)

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
Fig. 82: Radio Circuit, W/ Stereo Radio (1 of 2)

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
Fig. 84: Radio Circuit, W/ Top HIFI Radio (1 of 3)

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
SHIFT INTERLOCK
2006 BMW 650i
2006 BMW 650i
Fig. 87: 6-Speed SMG Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 88: A/T Circuit
STARTING/CHARGING
2006 BMW 650i
2006 BMW 650i
Fig. 89: Charging Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 90: Starting Circuit
SUPPLEMENTAL RESTRAINTS
2006 BMW 650i
2006 BMW 650i
Fig. 91: Supplemental Restraints Circuit (1 of 2)

2006 BMW 650i
2006 BMW 650i
TRUNK, TAILGATE, FUEL DOOR

2006 BMW 650i
2006 BMW 650i
Fig. 93: Trunk & Fuel Door Release Circuit
WARNING SYSTEMS
2006 BMW 650i
2006 BMW 650i
Fig. 94: Warning Systems Circuit
WIPER/WASHER
2006 BMW 650i
2006 BMW 650i
Fig. 95: Wiper/Washer Circuit

2006 BMW 650i
2006 SYSTEM WIRING DIAGRAMS

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
Fig. 6: Cool Box Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 7: Independent Heating Circuit
ANTI-LOCK BRAKES
2006 BMW 650i
2006 BMW 650i
Fig. 8: Anti-lock Brakes Circuit
ANTI-THEFT
2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
BODY CONTROL MODULES

2006 BMW 650i
2006 BMW 650i
Fig. 14: Body Control Modules Circuit
COMPUTER DATA LINES

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
Fig. 17: Data Link Connector Circuit
COOLING FAN
2006 BMW 650i
2006 BMW 650i
Fig. 18: Cooling Fan Circuit
CRUISE CONTROL
2006 BMW 650i
2006 BMW 650i
Fig. 19: Cruise Control Circuit
DEFOGGERS
2006 BMW 650i
2006 BMW 650i
Fig. 20: Defoggers Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 21: Electronic Power Steering Circuit
ELECTRONIC SUSPENSION
2006 BMW 650i
2006 BMW 650i
Fig. 22: Air Suspension Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 23: Dynamic Drive Suspension Circuit
ENGINE PERFORMANCE
4.8L
2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
EXTERIOR LIGHTS
2006 BMW 650i
2006 BMW 650i
Fig. 30: Back-up Lamps Circuit

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
GROUND DISTRIBUTION
2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
HEADLIGHTS
2006 BMW 650i
2006 BMW 650i
Fig. 40: Adaptive Front Lighting Circuit, W/ Directional Headlights

2006 BMW 650i
2006 BMW 650i
Fig. 41: Adaptive Front Lighting Circuit, W/O Directional Headlights

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
HORN
2006 BMW 650i
2006 BMW 650i
Fig. 44: Horn Circuit
INSTRUMENT CLUSTER
2006 BMW 650i
2006 BMW 650i
Fig. 45: Display Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 46: Instrument Cluster Circuit
INTERIOR LIGHTS
2006 BMW 650i
2006 BMW 650i
Fig. 47: Courtesy Lamps Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 48: Instrument Illumination Circuit
MEMORY SYSTEMS
2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
Fig. 51: Driver"s Memory Seat Circuit, Coupe

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
Fig. 54: Passenger"s Memory Seat Circuit, Coupe

2006 BMW 650i
2006 BMW 650i
Fig. 55: Steering Column Memory Circuit
NAVIGATION
2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
Fig. 59: Parking Assistant Circuit
POWER DISTRIBUTION
2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
POWER DOOR LOCKS

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
POWER MIRRORS
2006 BMW 650i
2006 BMW 650i
Fig. 68: Electrochromic Mirror Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 69: Power Mirrors Circuit, W/ Solid State Mirror

2006 BMW 650i
2006 BMW 650i
Fig. 70: Power Mirrors Circuit, W/O Solid State Mirror
POWER SEATS
2006 BMW 650i
2006 BMW 650i
Fig. 71: Heated Seats Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 72: Heated Steering Wheel Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 73: Power Seats Circuit
POWER TOP/SUNROOF
2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
Fig. 76: Panoramic Roof Circuit
POWER WINDOWS
2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
RADIO
2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
SHIFT INTERLOCK
2006 BMW 650i
2006 BMW 650i
Fig. 87: 6-Speed SMG Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 88: A/T Circuit
STARTING/CHARGING
2006 BMW 650i
2006 BMW 650i
Fig. 89: Charging Circuit

2006 BMW 650i
2006 BMW 650i
Fig. 90: Starting Circuit
SUPPLEMENTAL RESTRAINTS
2006 BMW 650i
2006 BMW 650i

2006 BMW 650i
2006 BMW 650i
TRUNK, TAILGATE, FUEL DOOR

2006 BMW 650i
2006 BMW 650i
Fig. 93: Trunk & Fuel Door Release Circuit
WARNING SYSTEMS
2006 BMW 650i
2006 BMW 650i
Fig. 94: Warning Systems Circuit
WIPER/WASHER
2006 BMW 650i
2006 BMW 650i
Fig. 95: Wiper/Washer Circuit

BMW Series 6 E63 E64 Service Repair Workshop Manual Cu Diagrame

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2004-2010 BMW 645Ci BMW 650i

Commonly Used Abbreviations

* PLEASE READ THIS FIRST *

Air Bag Restraint System

A/C Cycling Switch

Air Charge Temperature Sensor

Air Injection Reactor

Air Injection System

Air Suction Control Solenoid

Air Bag System Diagnostic Module

Air Suction Valve

Automatic Temperature Control

After Top Dead Center

Automatic Transmission Fluid

Air Temperature Sensor

Automatic Transaxle Overdrive (Ford Models Only)

By-Pass Air Control

Barometric Absolute Pressure Sensor

Barrel (Example: 4-Bbl.)

Body Control Module

Barometric and Manifold Absolute Pressure Sensor

Brake On-Off Switch

Barometric Pressure Sensor

Before Top Dead Center

British Thermal Unit

Bimetallic Vacuum Switching Valve

California Air Resources Board

Closed Bowl Distributor

Computer Command Control

Computer Controlled Dwell

Cycling Clutch Orifice Tube

Capacitor Discharge Ignition

Computerized Engine Control

Cubic Inch Displacement

Camshaft Position Sensor

Crankshaft Position Sensor

Coolant Temperature Sensor

Constant Vacuum Control

Check Valve or Constant Velocity

Computer Controlled Coil Ignition

Computer Controlled Catalytic Converter

Direct Current Or Discharge

Dual Diaphragm Distributor

Diagnostic Energy Reserve Module

Digital Fuel Injection

Diagnostic Trouble Code

Driver Information Center

Distributorless Ignition System

Data Link Connector

Double Overhead Cam

Diagnostic Readout Box

Electric Air Control Valve

Electronic Automatic Transaxle

Electronic Brake Control Module

Electronic Back Light

Engine Control Module

Engine Coolant Temperature Sensor

Electronic Distributorless Ignition System

Electronic Engine Control

Evaporative Emission Control System

Electronically Erasable PROM

Early Fuel Evaporation

Exhaust Gas Oxygen Sensor

Exhaust Gas Recirculation