Important Safety Notice i i

Foreword i v
Index rea r of manual

0 General Data and 001 Warning s and Cautions 00 3 Symptoms and Field Observations
002 Vehicl e Identification and VIN 01 0 Product Familiarization
Maintenance Decoder 02 0 Maintenance

100 Engine-Genera l 13 0 Fuel Injection (M54 Engine)

110 Engin e Removal and Installation 13 1 Fuel Injection (N52 Engine)
113 Cylinde r Head Removal 13 2 Fuel Injection (N54 Engine)
and Installation 13 3 Fuel Injection (V8 Engine)
Engine
1 117 Camshaf t Timing Chain 16
119 Lubricatio n System 17
120 Ignitio n System 18
121 Battery , Starter, Alternator
0
0
0
Fuel Tank and Fuel Pump
Radiator and Cooling System
Exhaust System

2
200 Transmission-Genera l 24 0 Automatic Transmission
210 Clutc h 25 0 Gearshift Linkag e
Transmission 230 Manua l Transmission 26 0 Driveshafts
231 Sequentia l Manual Gearbox (SMG) 27 0 Transfer Case

3
Suspension, 300 Suspension , Steering and
Brakes-General
320 Steerin g and Wheel Alignment

Steering and 310 Fron t Suspension

330 Rea r Suspension
331 Rea r Axle Differential

Brakes 311 Fron t Axle Differential 340 Brake s

4 Body 400 Body-Genera l

410 Fenders , Engine Hood
411 Door s
412 Trun k Lid, Tailgate

5 Body Equipment
510 Exterio r Trim, Bumpers
512 Doo r Windows
513 Interio r Trim
515 Centra l Locking and Anti-theft
520 Seat s
540 Sunroo f

6
600 Electrica l System-General 630 Light s

Electrical System 611 Wiper s and Washers

612 Switche s
640 Heatin g and Air-conditioning
650 Radi o
620 Instrument s

7 Equipment an d
Accessories
720 Sea t Belts
721 Airba g System (SRS)

ECL ECL Electrica l Component Location s

ELE ELE Electrica l Wiring Diagrams

OBD OBD On-Boar d Diagnostics

 001-1

001 Warnings and Caution s

PLEASE REA D THES E WARNING S AN D CAUTION S

BEFORE PROCEEDIN G WITH MAINTENANC E AN D REPAI R WORK.

WARNINGS—
See also CAUTIONS
• Rea d the important safet y notic e on the copyright page a t the Do not attempt to work on your car i f you d o no t feel well. You
beginning of the book . increase the dange r o f injury to yourself and other s i f you ar e
• Som e repairs may be beyond your capability. If you lack the skills, tired, upset or have taken medication or any other substance tha t
tools and equipment o r a suitable workplace for any procedure may keep you from being fully alert.
described i n this manual, w e suggest you leave such repair s to Illuminate your work area adequately but safely. Use a portabl e
an authorized BM W deale r service department or other qualified safety light for working inside or under the car. Make sure the bul b
shop. is enclosed b y a wire cage. The ho t filament of an accidentally
• Thoroughl y read each procedur e an d the WARNINGS and broken bul b ca n ignit e spilled fuel, vapors o r oil.
CXcXCxzcxz Catch draining fuel , oil, o r brake fluid in suitable containers . D o
not use food or beverage containers that might mislead someon e
into drinking from them. Store flammable fluids away fro m fire
• I f any procedure, tightening torque , wear limit, specification or hazards. Wip e up spills at once, but do not store the oil y rags ,
data presented in this manua l doe s not appear t o be appropriate which can ignite an d burn spontaneously.
for a specific application, contac t the publisher o r the vehicle Observe good workshop practices. Wear goggles whe n yo u
manufacturer for clarification befor e using the informatio n in operate machine tool s or work with battery acid. Wea r glove s or
question. other protective clothing whenever the job require s workin g with
• D o not reuse an y fasteners that are worn or deformed. Man y harmful substances .
fasteners are designed to be used only once and become Greases, lubricants and other automotive chemicals contain toxic
unreliable and may fail when used a second time. This includes , substances, many of which are absorbed directly throug h the
but is not limited to, nuts, bolts , washers, self-locking nuts or skin. Rea d the manufacturer's instructions and warning s
bolts, circlips and cotte r pins . Replace these fasteners with new carefully. Use hand and eye protection. Avoid direct skin contact.
parts.
Disconnect the battery negativ e (-) termina l whenever yo u work
• D o not work under a lifted car unless i t is solidly supporte d o n on the fuel system or the electrical system. D o not smoke or work
stands designe d fo r the purpose. Do not support a car on cinder near heater s or other fire hazards . Keep an approved fir e
blocks, hollow tile s or other prop s that may crumble unde r extinguisher handy .
continuous load . Do not work under a car that is supported solely
Friction materials (such as brake pads and shoes or clutch discs)
by a jack. D o not work unde r the car while the engine i s running.
contain asbestos fibers or other friction materials. D o not create
• I f you are going t o work unde r a car on the ground, mak e sure dust by grinding, sanding , or by cleaning wit h compressed air.
that the ground is level. Block the wheels to keep the car from Avoid breathing dust . Breathing any friction material dus t ca n
rolling. Disconnec t th e battery negative (-) termina l to prevent lead to serious diseases and may result in death.
others from starting the ca r while you are unde r it.
Batteries give off explosive hydrogen gas during charging. Keep
• D o not run the engin e unles s th e work area is well ventilated. sparks, lighted matche s an d open flame away from the top of the
Carbon monoxide kills. battery. If hydrogen gas escaping from the cap vents is ignited, it
• Remov e rings , bracelets an d other jewelry so that they canno t may ignite gas trapped in the cells and cause the battery to
cause electrica l shorts, get caught in running machinery, or be explode.
crushed b y heavy parts . The air-conditioning system is filled with chemical refrigerant ,
• Tie long hair behind you r head. Do not wear a necktie, a scarf, which is hazardous. Mak e sure the system is serviced only by a
loose clothing, or a necklace when you work near machine tool s trained technician using approved refrigerant recovery/recyclin g
or runnin g engines. I f your hair, clothing, or jewelry were to ge t equipment, trained in related safety precautions, and familiar with
caught i n the machinery , sever e injury could result. regulations governing the discharge and disposal o f automotive
chemical refrigerants.

Continued on next page

001-2 Warning s and Cautions

WARNINGS (continued )

• D o not expose an y par t o f the A/C system t o high temperature s Be mindful of the environment an d ecology. Before you drain the
such as open flame . Excessiv e heat increase s syste m pressure crankcase, fin d out the prope r wa y to dispose o f the oil . D o not
and may cause th e syste m to burst. pour oi l onto the ground, dow n a drain, or into a stream, pon d or
• Som e aerosol tir e inflators are highly flammable. B e extremely lake. Dispos e of waste in accordance wit h federal, state an d
cautious when repairin g a tire that may have been inflate d usin g local laws .
an aerosol tire inflator. Keep sparks, open flame or other sources The control module for the anti-lock brak e system (ABS) canno t
of ignition away from the tire repai r area. Inflat e and deflate the withstand temperatures from a paint-drying booth or a heat lam p
tire at least four times befor e breaking th e bead from the rim . in excess o f 203° F (95° C). D o not subject to temperatures in
Completely remov e the tire from the ri m before attempting an y excess o f 185°F (85° C) for more than two hours .
repair.
Before doing an y electrical welding o n cars equipped with ABS,
• Car s covered b y this manua l ar e equipped wit h a supplementa l disconnect th e battery negativ e (- ) termina l (groun d strap) and
restraint system (SRS ) that automaticall y deploy s airbag s an d the ABS control modul e connector .
pyrotechnic seat bel t tensioner s i n case o f a frontal or side
Make sur e ignition is switched OFF befor e disconnecting battery.
impact. These ar e explosiv e devices. Handle d improperly or
without adequate safeguards , the y ca n b e accidently activate d Label batter y cables befor e disconnecting. O n some models ,
and cause seriou s injury . battery cables ar e not color coded .

• Th e ignition system produce s hig h voltage s tha t can be fatal. Disconnecting th e battery may erase fault code(s) stored in control
Avoid contact wit h exposed terminal s an d us e extreme car e module memory. Usin g special BMW diagnostic equipment, check
when working on a car with the engine running o r the ignitio n for fault codes prior to disconnecting th e batter y cables. If the
switched ON. malfunction indicator light (MIL) is illuminated, see OBD On-Board
Diagnostics at the bac k of this manual. (This light may be
• Plac e jack stands only at locations specified by the manufacturer.
identified as the Check Engin e ligh t or the Service Engine Soon
The vehicle lifting jack supplied with the vehicle is intended for tire light.) I f any othe r syste m fault s ar e detecte d (indicated by a n
changes only . Use a heavy dut y floo r jack to lif t vehicle before illuminated warnin g light), see an authorized BM W dealer .
installing jack stands. See 020 Maintenance.
If a normal or rapid charger i s used to charge battery, disconnec t
• Batter y acid (electrolyte) can cause sever e burns. Flus h contact the battery remov e it from the vehicle i n order to avoid damagin g
area with water, then see k medica l attention . the vehicle.
• Aeroso l cleaners and solvents may contain hazardou s or deadly Do not quick-charge th e batter y (fo r boost starting) for longer
vapors and are highly flammable . Us e only i n a well ventilated than on e minute. Wai t a t least on e minut e befor e boosting the
area. D o not use on ho t surfaces (engines , brakes , etc.). battery a second time .
• Du e to risk of personal injury , be sure th e engine i s cold before Connect an d disconnect a battery charger only with the battery
beginning work on the cooling system . charger switched OFF .
Sealed o r "maintenance free " batteries shoul d b e slow-charged
CAUTIONS— only, at an amperage rat e that i s approximately 10 % of the
See also WARNINGS battery's ampere-hour (Ah ) rating .
• I f you lack the skills, tools and equipment, o r a suitable workshop Do not allow battery charging voltag e to exceed 16.5 volts. If the
for any procedure described i n this manual, leave such repairs to battery begins producin g ga s o r boiling violently, reduce the
an authorized BMW dealer or other qualified shop. charging rate . Boosting a sulfated battery a t a high charging rat e
• BM W is constantly improving it s cars and sometimes thes e can cause a n explosion.
changes, bot h in parts and specifications, are made applicable to Do not use steel fasteners on engine components mad e of
earlier models . Any part numbers liste d i n this manua l ar e for aluminum-magnesium alloy . Use aluminum fastener s only. Test
reference only. Check with your authorize d BM W dealer parts fasteners for aluminum compositio n wit h magnet .
department for the latest information.
Replace aluminu m bolt s each time they are loosened. Follo w
• Befor e starting a job, mak e certai n tha t you have the necessary torque instructions , including angl e of rotation specifications,
tools and parts on hand. Read all the instructions thoroughly, and when installin g aluminum fasteners .
do not attempt shortcuts. Use tools appropriate t o the work and
use only replacement parts meeting BMW specifications.
• Us e pneumatic an d electric tools onl y to loosen threade d part s
and fasteners. Do not use these tool s to tighten fasteners,
especially o n light alloy parts . Us e a torque wrench to tighten
fasteners to the tightening torqu e specification listed .
 002-1

002 Vehicl e Identification and

VIN Decode r
Some o f the informatio n in this manual applie s onl y to cars of a particular mode l year or range of years. For example,
2004 refer s to the 2004 model year but does no t necessarily matc h the calendar yea r in which the car was
manufactured o r sold. To be sure of the model year of a particular car, check the vehicle identification number (VIN ) on
the car.

The VI N i s a unique sequence of 1 7 characters assigned by BMW to identify each individual car . When decoded, th e
VIN tells the country and year o f manufacture; make, mode l and serial number; assembl y plant an d even some
equipment specifications.

The BM W VIN i s on a plate mounted on the top of the dashboard, on the driver's side where the number can be seen
through the windshield. The 10th character is the model year code. Example: 4 for 2004. Fo r 2010, A is used. The tabl e
below explains some of the codes in the VIN for 2004 through 2010 BMW E6 0 and E6 1 5 Series cars covered b y this
manual.

Sample VIN : [WBA||NA53||5|0|4|B|

VIN Description Decoding information

position
1 -3 Country of WBA BMW, AC. Munich, Germany
manufacture WBS BMW Motorsports GmbH, Munich. Germany
4-7 Vehcle code NA53 525i 2004 - 2005 (2003/09/0 1 to 2005/02/28)
NE53 525i 2006 - 2007 (2005/03/01 to 2007/02/28 )
NU53 528i 2008 - 201 0 (2007/03/01 to 2009/1 2/31 )

NA73 530i 200 4 - 2005 (2003/01/0 1 t o 2005/08/27 )

NE73 530i 2006 - 2007 (2005/03/01 to 2007/02/28)
NW13 535i 2008 - 2010 (2007/03/01 t o 2009/12/31)

NB33 545i 2004 - 2005 (2003/09/01 t o 2005/08/31)

NB53 550i 2006 - 2007 (2005/09/0 1 to 2007/02/28)
NW53 550i 2008 - 2010 (2007/03/01 t o 2009/12/31)

NF33 525xi 2006 - 2007 (2005/04/0 1 to 2007/02/28 )

NV13 528xi 2008 - 2010 (2007/03/01 t o 2009/12/31)
NF73 530xi 2006 - 2007 (2005/04/01 to 2007/02/28)
NV93 535xi 2008 - 2010 (2007/03/01 to 2009/12/31)

NN73 530xi Sport Wagon 2006 - 2007 (2005/04/01 t o 2007/02/28)

PT73 535xi Sport Wagon 2008 - 201 0

NB93 M5
8 Restraint sys- 5 Multiple restraint system
tem
9 Check digit 0 - 9 or X, calculated by NHTSA
10 Model year 4 2004
5 2005
6 2006
7 2007
8 2008
9 2009
A 2010
11 Assembly B, C Munich, Germany
plant
12-17 Serial number Sequential production number for specific vehicle
 003-1

003 Symptom s and Field Observations

GENERAL 003- 1 4 BOD Y 003-17

0 GENERA L DAT A AN D MAINTENANCE 003- 2 5 BOD Y EQUIPMEN T 003-18

1 ENGIN E 003- 5 6 ELECTRICA L SYSTEM 003-19

2 TRANSMISSIO N 003-1 2 7 EQUIPMEN T AND ACCESSORIES . 003-24

3 SUSPENSION , STEERIN G AN D BRAKES. . 003-14

GENERAL
This repair group includes a list of symptoms, field observations, an d
suggested fixe s for common problem s and issues found on BM W 5
Series (E60, E61) vehicles.

The informatio n is organized by sections that correspond t o th e

layout of the repai r manual. Additional information (when available)
can be found in the repai r group associated with the specifi c issue :
• 0 Genera l Dat a and Maintenance
• 1 Engin e
• 2 Transmission
• 3 Suspension , Steerin g and Brakes
• 4 Bod y
• 5 Bod y Equipmen t
• 6 Electrica l System
• 7 Equipmen t and Accessories

This informatio n was developed from varied sources, rangin g from

professional BM W technician feedback to manufacturer-issue d
technical servic e bulletins (TSBs) . The content i s intended to
complement the repai r informatio n found in this repai r manual .

CAUTION—
• The information contained in this section is inherently dated
material. It was applicable and relevant at the time this manual
went to press. A/ways check BMW factory repair information at
www.bmwtechinfo.com or the publisher's website at
www. com for information that may
supersede any information included in this section.
003-2 Symptom s and Field Observations

0 GENERA L DAT A AND MAINTENANCE

Additional
Topic Notes information
(when available)
Exiting a vehicle tha t i s double- Never lock a vehicle from outside the car with an someone insid e the
locked from the outsid e car!
In the unlikely that someone get s double-locke d insid e th e car , the
person insid e th e car can exit the vehicle using the following 2-step
procedure:
• Pres s the central unloc k butto n to disable "double-lock" .
• Pul l the door handl e twic e to open door .

NOTE—
• For vehicles with the factory alarm, opening the door will
activate the alarm.

Engine oil, topping u p Oil residue ma y collect on the cylinder hea d cove r near the oi l filler
cap a few days afte r topping u p or refilling the engine oil .
When oi l is added, th e filler cap i s laid partiall y upsid e down . I n this
position, engine oil seeps into the area of the oil cap that is not seale d
by the gasket. When th e cap is reinstalled, the oil leaks fro m the
unsealed are a onto the cylinder head cove r surface.
020
If investigating an oil leak in this area, confirm that it is not oil from the
cap.

Replacing spark plugs, servic e ti p When servicing spark plugs, a standard socket may fit too tightly into
the spark plu g bor e i n the cylinder head . I f this i s the case , remov e
the heat shield inside plug hole (arrow) before servicing spark plugs .

020

Special tool for spark plug removal ) Th e N5 4 engine use s a new design spar k plu g from Bosch tha t
consists of a 12mm thread (compared to the 14m m design on the
N52) and a 12-point hex . The plug require s a special too l (BM W
special tool part no . 83 30 0 495 560). The special socke t i s a thin-
wall design to facilitate acces s i n the confined are a of the N5 4
cylinder head . 020
 Symptoms and Field Observations 003- 3

0 GENERA L DAT A AN D MAINTENANCE (CONTINUED )

Additional
Topic Notes information
(when available)
Engine oi l level , checking after oil Always perfor m the dynamic oi l level measurement (approx . 5
change - dynamic chec k minutes driving time) after an oil change. The oil level could be
(engine running) misinterpreted as the oil level last stored is initially displayed after an
oil change.

NOTE—
• There is no oil level initially stored after replacing or
CD reprogramming the engine control unit ("Oil level below min" is
§ displayed). The correct oil level is indicated after running the
CM
engine for approx. 5 minutes.
2 020
- Star t engine.
o
•a - Select on-board computer function - OIL usin g rocker switch. Press
o BC switch in once. Oil level check begins . A clock symbol (arrow)
may appear while the leve l measurement i s running.

NOTE—
• The clock symbol appears for up to 50 seconds after starting
the engine when there is no measured value or the last stored
value is not within the tolerance range of the currently
measured oil level.
V8 engine A/C belt removin g and On the V8 engines, there is no tensioner o n the A/C belt. To install a
installing. new belt, a special tool (BMW par t # 90 88 6 641 040) is required to
A/C belt installatio n tool guide the belt onto the pulley.

020

When installin g a new battery, it must be "registered" to the

vehicle to notify the vehicle powe r management software
(engine electronics and intelligent battery sensor) that a new
battery was fitted. This operatio n require s a BMW scan tool.

Without ne w battery registration, various electrical problems as

121
well odd electrical system behavio r can occur.
003-4 Symptom s and Field Observations

0 GENERA L DAT A AND MAINTENANCE (CONTINUED )

Additional
Topic Notes information
(when available)
No communication wit h BMW sca n When performing diagnosis o n a vehicle with the BMW scan tool, the
__ .
tool o n DCAN message "Connec t diagnostic connecto r an d switch ON ignitio n
(Terminal 15)! " is displayed .
plug
• D-CA N failure in vehicle.

Before diagnosing D-CA N in the vehicle, try communicating wit h

another vehicle . If communication cannot be established on othe r
vehicle, try a different scan tool. I f communication resume s o n the
other vehicle, us e the following steps to diagnose DCAN .

— Disconnec t vehicl e powe r supply / charger (if connected) .

— Disconnec t battery.

— Chec k resistanc e of D-CA N circuit across OB D socke t Pi n 6 020, 60 0

(D_CAN_H) an d Pi n 1 4 (D_CAN__L). A good D-CA N measure s
60 ohms. The D-CAN circui t is fitted with two 120 ohm terminal
resistors. One is fitted in wiring near OBD socket. The secon d is
fitted in gateway module o f vehicle (KG M or SGM) .

— I f resistance reading is 0 ohms, the D-CA N wires are shorte d

together. Check circui t for shorts as per wiring diagram.

— I f resistance reading i s Mega ohms , the D-CA N wiring ha s a n

open circuit. Check circuit for opens a s per wiring diagram .

— I f resistance reading i s 12 0 ohms, on e o f terminal resistor s i s

faulty. Check resistanc e of both resistor s for an open circui t and
replace as necessary .

Intelligent battery sensor (IBS) , The Intelligen t Battery Senso r (IBS ) is an electronic devic e
service precaution s connected directly to the negative battery terminal.The IB S is very
sensitive to mechanical stres s and strain. Particular attention shoul d
be paid to the following points:
• D o not make any additional connections at the negative terminal of
the battery .
• Do not modify the battery groun d cable.
• D o not make any connections betwee n th e IBS and the senso r
screw.
• D o not use force when disconnectin g the ground terminal from the
battery. 121
• Never pul l on the ground cable.
• D o not use the IB S as a pivot poin t to lever off the ground terminal .
• D o not use the connections o f the IBS as a lever.
• Use only a torque wrench as described in the repair manual during
installation.
• Do not release or tighten the sensor screw .

NOTE—
•A replacemen t IB S includes th e ground cable. The groun d
cable als o serves as a heat dissipate r for the IBS .
 Symptoms and Field Observations 003- 5

1 ENGIN E
Additional
Topic Notes information
(when available)

Engine knoc k fault code s Engine knoc k fault codes indicat e tha t the engin e i s knocking .
Detonation or knock i s an erratic form of combustion that can cause
head gasket failure as well as other engine damage. Prolonge d or
heavy detonatio n ca n be very damaging. Th e hammer-lik e shock
waves created by detonation subject the hea d gasket , piston, rings, 120
spark plug and rod bearings to severe overloading. As a first remedy,
try highe r octan e hig h detergent fuel or switch brands . I f the faults
codes continue to return, contact your authorized BMW dealer.

Diagnosing electri c cooling fan From 03 / 2007 production vehicles : A revised power supply rela y
for the electric coolant fan power supply was use d on these vehicle s
Coolant fa n powe r supply rela y K9137 is located i n the bac k of the
rear fuse box. Connector (B ) provides contro l signals for relay
activation (KLSO g from the rea r fuse box/power distributio n box and
local ground KL31).
On cars with inoperative electri c coolant (wit h symptoms o f A/C 170, EL E
malfunction, engine overheating, or fault code 2EFE "Cooling fan
activation" stored in the DME), check the power supply relay operation:
Check that both B + connections (A) are threaded o n tight and free of
corrosion.
Check KLSOg (B+) an d KL31 (ground ) signals (B) for correc t
operation.

E-box water ingres s Water leak s into the E-box may cause variou s drivability complaints,
loss of power or the "Service Engine Soon " lam p to illuminate while
driving.
Water can enter through the grommet for the ground connection X 6
on the front of the E-box.
If water is present, check that all drains and water channels are clear.

No crank, n o start Engine doe s no t crank. Only the SRS (Supplemental Restrain t
System) an d re d brake lights show i n the instrumen t cluster with
ignition on. FC A111 (ELV voltage supply fault) is stored in CAS (Ca r
Access System) .

NOTE—
•Asa result of a change in government requirements, the ELV was
deleted on most 2007 and later models. Anti-theft protection 121
continues to be provided by drive-away protection in EWS.

Disconnect th e IB S connector (3-pi n connecto r wit h 2 wires) at the

negative batter y terminal. Follo w the white/blue and gray wires from
the IB S to locate the connector .
Now try startin g the vehicle. I f the vehicle starts, replace faulty IBS .
003-6 Symptom s and Field Observations

1 ENGINE (CONTINUED )
Additional
Topic Notes information
(when available)
Ignition coil fuel/ oil contaminatio n When working on the fuel system, i t is important t o ensure tha t the
ignition coils are no t fouled by fuel or oil (especially critical for N5 4
engines). The resistanc e of the silicone materia l is significantly
reduced by fuel contact. This can cause spark over at the spark plug
and misfires .
120
Before servicing the fuel system, remove the ignition coils and cover
the spark plug hole with a cloth.
Ignition coils heavily fouled by fuel must b e replaced .

Valvetrain service not e When diagnosing engin e noise , do not rule out worn timing chai n
components. Thi s i s especially applicabl e t o high mileag e engines
and engines with extended oil change intervals.

117

Valve cover gasket leak s When replacing valve cover gasket, take extr a caution when
tightening fasteners and sealing at metal joining points. For example
front timing cover to cylinder head. There i s a small are a wher e
silicone should b e applied to seal where the gasket ma y not.
Applies to all engines.
113

VANOS and silicone sealan t When working around VANOS units kee p area clean and free of
silicone sealant. Even a small amount o f silicone introduce d int o
VANOS actuator or solenoid can cause a fault.

117
 Symptoms and Field Observations 003- 7

1 ENGIN E (CONTINUED )
Additional
Topic Notes information
(when available)

Sticky VANOS solenoi d sets cam A sticky / jammed VANO S solenoid ca n set a camshaft position
position (CMP ) sensor code s (CMP) senso r fault (tooth error).
Models with N52, N52KP, N54 and V8 engines ma y be difficult to
start, run rough and have the Service Engin e Soo n lamp illuminate d
with one or more of the following stored faults:
• Cam sensor, inlet signal - signal invali d for synchronization
• Crankshaft-inlet camshaft , correlation
• VANO S intak e - stiff, jammed mechanicall y 117
• Cam sensor, exhaust signa l - signal invalid for synchronization
• Crankshaft - exhaust camshaft, correlation
• VANO S exhaust - stiff, jammed mechanicall y

Remove VANOS solenoid, intake or exhaust, depending on fault codes

stored and, using shop air, gently blow out any visible particles and
reinstall. If fault returns, try swapping solenoids between banks to see if
fault follows solenoid. Replac e solenoid if fault cannot be corrected.

Do not overfill cooling system Be careful not to overfill cooling system during servic e or when
topping up . V8 engine coolan t caps hav e a tendency to not release
when pressur e exceeds maximum. An overfilled cooling system can
amplify this problem.

170
0)
00

Coolant pipe leak The coolant pip e located in valley of V8 engine ca n develop leaks at
the end O-ring seals. To replace the pipe with the OEM pipe, the front
Coolant pipe
of the engine mus t be fully disassembled , requirin g engine removal
under mos t circumstances.
Aftermarket options ar e available (threade d expanding pipe , is one
c example) that significantly reduce the time and cost require d to do
0)
00 the job.

Oil leak - alternator bracke t profil e An oil leak from the alternator area i s usually b e caused b y a faulty
gasket alternator bracket profil e gasket. To replace the gasket , remov e
alternator and bracket.
Profile
0)
c gasket
"5>
121
0)
00
003-8 Symptom s an d Fiel d Observation s

1 ENGINE (CONTINUED )
Additional
Topic Notes information
(when available)
Vacuum pump diaphrag m fail s A rupture d vacuum pum p diaphrag m result s in oil being sucke d int o
causing oil leak and brake booster the brake booster. Remov e brak e booster vacuum hos e to inspect. If
failure oil is present in hose, replac e vacuum pump . I f large amounts o f oi l
are found inspect brak e booster, replacement ma y be needed.

133

Throttle housin g (EDK ) fault code s Fault codes :

• 2CF8 - Throttl e valv e potentiometer, signa l
• 2CF9 - Throttle valve potentiometer 1 , signa l
• 2CFA - Throttle valve potentiometer 2, signal

133
In most cases, DSC fault 5F77 (DME invalid data) will also be stored.
These faults are sporadic an d usually no t reproducible .
The cause is an intermittent interruption of the ED K signal t o the
DME due to a resistance fluctuation in the ED K harness connector .
Replace ED K harness with updated par t #12 51 7 602 973 .

An occasional ticking or rattling noise from hydraulic valve adjuster s

(HVA) element s may occur during col d engine starts or frequent
short-distance driving.This condition will not cause an y damage to
the engine, and usually remedies itself with a longer driving distance
or operating times a t full operatin g temperature.
In this situation, the lifter s can bleed dow n or have trapped ai r
causing ticking/rattling noise and may require bleeding, as described
below. The bleed time ma y take anywhere from two minute s t o a
maximum of 30 minutes.
Procedure preconditions :
• Engin e runnin g at operating temperature
• Vehicle stationary on a level surface in a properly ventilated are a
• Engine oil level correct - no t underfilled o r overfilled
113
1. Bring engine up to an operating speed (no load) of 2000-3000 rpm
and maintain thi s speed for three minutes .
2. Let engine idle for 15-30 seconds. Listen for whether the noise is
still present :
• I f engine i s quiet, procedur e is finished.
• If engine noise still present, repeat procedure; perform steps 1 and
2 u p to a maximum o f 5 times.

If the noise remains after performing the bleeding procedure 5 times:

proceed by performing the procedure for a final time, also at an
engine operatin g speed of 2000-3000 rpm , but for a total tim e
duration of 1 5 minutes. If noise return s after multipl e bleedings , th e
cylinder hea d may be faulty an d require replacement.
 Symptoms an d Field Observation s 003- 9

1 ENGIN E (CONTINUED )
Additional
Topic Notes information
(when available)
Faulty valvetronic motor linked to If diagnosing a faulty DME , be sure to check that the valvetronic
DME failure motor was not the roo t cause of the damage to DME control unit.
If a new control unit i s installed an d the valvetroni c motor is bad
(excessive current draw), the ne w DME will be damaged .

0)
130
CM
m
Z

Cylinder-assigned hig h pressure On N54 engines, mar k the cylinder locations o n the fuel injectors
injectors when removin g them.
As part of injector manufacturing, tolerance ranges for injection
quantity ar e determined and specified in a six-digit number
combination. Thes e values are used b y the DM E to compensate for
variations i n the individua l injectors .
130
NOTE—
• When replacing an Injector, it is essential to carry out an
injector adjustment using the BMW scan tool.

Servicing hig h pressure fuel Working on the HPI system must only be carried out after the engin e
injection system - safety precaution has cooled down. D o not attempt to open any fuel lines or
connections o n the HP I injection system unti l the coolant
temperature is below 40° C (approx. 104°F )
If the engin e i s not cool, there i s danger o f residua l fuel pressur e
0)
spray in the high-pressure system . 130
«f
in When working on the high-pressure fue l system, take particular care
to ensure conditions o f absolute cleanliness an d follow the work
sequences describe d in the repai r instructions. Eve n the smallest
contaminants and/o r damage t o the threads on the high-pressure
lines can cause leaks .
High pressur e fue l system faults Service Engin e Soon ligh t illuminated, engin e enter s fail-safe mod e
with reduced power.
Scan tool data shows fault codes 1073 7 (P3283, P3284) , and/o r
10738 (P3003, P3090 ) - "Hig h fuel pressure system , plausibility "
stored in MSD80 (DME ) control module. These faul t codes all relate
c to the high pressur e fuel system. 160
m
t
in The possibl e cause s are : incorrect adaptation value s o f the hig h
pressure pump contro l valv e or failure of the high-pressur e fuel
pump. Begi n b y resetting adaptations fo r engine management . If
fault codes retur n immediately afte r adaptation, th e fuel pump may
be faulty.
003-10 Symptom s an d Field Observation s

1 ENGINE (CONTINUED )
Additional
Topic Notes information
(when available)
High pressur e fue l injector, Always replace the teflon O-ring (arrow ) when fitting and removin g
replacing replac e teflon sea l the fuel injector. This also applie s t o an injector that ha s just bee n
fitted and ha s to be removed again afte r an engine start.
A new injector with a new teflon O-ring should b e fitted as quickly as
possible as the Teflon sealing rin g could swell up.

Also, be sure that the injector is correctly seated when installing . Th e 130
injector hold-down mus t res t on both injecto r tabs, otherwis e th e
necessary forc e is not applied.

Do not clean th e nozzle-needl e tip of the piezo-injector.

High pressur e fue l pum p extende d On 2007 - 2009 models with N54 engines, BM W emissions warrant y
warranty coverag e of the high pressur e fuel pump (HDP ) ha s been extende d fro m 4
years or 50,000 miles to 10 years or 120,000 miles, whichever come s
first.
Vehicles with a faulty fuel pump ma y have the Service Engine Soo n
lamp illuminate d wit h various low fuel pressure-related fault s stored
in the engine control module (DME) . Affected vehicles ma y 160
experience long cranking times o r reduced engin e performanc e
(engine in failsafe mode) whe n the HD P malfunctions .
If the hig h pressur e fuel pump o f a MY 2007- 200 9 exhibit s th e
symptoms listed above, it should b e replaced with the improve d part .

Fuel injector faults On cars with faulty fuel injectors , various fault codes relate d to fuel
injectors may be stored i n the DM E control module (Servic e Engin e
Soon light is illuminated). The engine may lack power, idle erratically,
or have poor throttle response. Faults code s suc h a s injector,
cylinder 1-6 , short circui t or line break, DM E internal fault; Injector
driver circuit failure ban k 1 -3; bank 4-6 or Misfiring, several cylinder s 130
may indicate a bank o f 3 faulty injectors. Consult you r authorize d
dealer regardin g injector replacement a s it applies to BM W Servic e
Bulletin SIB 1 2 02 08 (date d October 2008) .

EML light illuminated, lim p home In the event of a failure, malfunction or an implausible signa l from any
mode, n o boost pressur e contro l of the sensors listed below, activation of the wastegate valves is shut
down an d the valve flaps are fully opened. Turbocharging ceases at
this point .
• High-pressur e fuel system
• Inle t or exhaust VANOS
• Crankshaft position sensor
• Camshaft position sensor
• Boost-pressur e sensor
• Knock sensor s
• Intake-ai r temperature senso r

If the ELM L ligh t is illuminated, interrogate fault memory and correct

any problems found.
 Symptoms and Field Observations 003-1 1

1 ENGIN E (CONTINUED )
Additional
Topic Notes information
(when available)
Rattle noise from turbocharger area A metallic nois e from the exhaus t syste m near the engine or
turbocharger area can occur during deceleratio n from approx. 3,500
RPM or during a high engin e spee d withou t a drive gear bein g
engaged.
0)
c In this situation, the wastegate valve does no t completely clos e due
'5> to mechanical tolerance s of the wastegate actuator and results in the
cu wastegate valve rattling against it s seating surface.
180
"3-
Do not replace the turbocharger o r adjust the existing wastegate
actuator control rod . Instea d reprogra m the DME . I f after
programming, th e noise is no longer present, take no further action .
If th e nois e is still present, replace both of the turbocharger
wastegate actuators .
Coolant contac t wit h magnesiu m During service procedures which involve coolant, such as cylinder
components head replacement, the bol t holes mus t be blown dry immediately. To
a> prevent corrosion, do not allow an y traces o f coolant to remai n in
<D holes.
c
"01
Q)
*fr 113
in

Damaged connector a t throttle When connecting throttle module connector, it is possible to twist the
module connector before plugging i t in, causing damag e to the harnes s an d
the connector. Be sure to install connector carefully to avoid damage.

CM
in
Electric coolan t pump precautions Particular care must b e taken to ensure that the coolant pump does
(0 not run dry. When the pump is removed, it should be stored filled with
<u coolant. The pum p bearing s could seize i f the pum p i s not filled with
'5) coolant. A inoperative coolant pump coul d cause seriou s engine
0) damage.
^s- 170
in If the pump shoul d ever run dry, the pum p impelle r should be turned
CM by han d to ensure the pum p i s not seized befor e connecting th e
in coolant hoses. The system should then be immediately filled with
coolant.
003-12 Symptom s an d Field Observation s

2 TRANSMISSIO N
Additional
Topic Notes information
(when available)
SMG Transmission require s specifi c An extra deep socke t is used to remove the 41 mm nut on the SM G
socket to remove output flange. output flange. BMW part number 8 3 30 0 493 421.
41 m m deep socket

B510003001

ATF service recommendatio n The automatic transmission flui d in the both th e ZF and G M unit s
should b e changed a t service interval s no greater than 100,00 0
miles. 6 0 to 80k miles should b e considered a more acceptabl e
maximum interval .
When checking the fluid level, it is critical that the temperature o f the
240
fluid be maintained a t approximately 30° C (86°F) . (The factory
specification i s 30 - 50°C.) Checkin g the temperature can b e don e
using an infrared temp gun or a more correctly, with a BMW scan tool.

Vibration or noise i n drive trai n One or more of the following may be heard while driving slowly,
coming to a stop or at highway speeds:
• A clunk can be heard while rolling slowly and downshifting from 2nd
to 1s t gear coming t o a stop.
• Loa d reversa l causes a slight clunk noise .
• A clunk nois e ca n be heard while shiftin g into forward or reverse
gear fro m park or neutral.
240

Check for a deterioration or separation o f the rubbe r i n the universa l

joint locate d between the transmission an d drive shaft assembly .
To check if the noise i s caused by a defective universal joint th e
driveshaft mus t first be removed. Once removed , check i f any o f the
metal collars are loose and/or rubbe r cracking is found. Replace the
universal joint if any faul t are found .
Mechatronic sealin g sleev e leakin g Transmission fluid can be seen leaking from transmission oi l pan, or
more specificall y from the Mechatroni c sealing sleeve .
This repai r requires replacing the sealing sleev e and the
transmission oil pan gasket. Refe r to BMW Service Bulletin SI B 24
08 06 (dated February 2009 ) fo r parts an d repai r information ,
including prope r sleeve installatio n instructions . 240

NOTE—
<3mn • After installation of the new sleeve, the correct distance
between the transmission harness connector and the housing
surface should not exceed 3 mm.
 Symptoms and Field Observation s 003-1 3

2 TRANSMISSION (CONTINUED )
Additional
Topic Notes Information
(when available)
Transmission/transmission contro l Various complaints associated wit h inoperative transmission
complaints controls. At times the vehicle will not start, gear indicato r display not
present, transmission failsafe light is on, or there is a transmission
failsafe message i n the check control. Durin g diagnosi s with scan
tool, EGS cannot be identified.
The transmission harnes s connecto r ma y have a loose or pushe d
back pin(s) . This condition ca n cause various complaint s and man y
different faults to be stored.
Disconnect the battery and check the transmission connector X8500
240
for loos e or pushed back pins. It may be possible when the connector
is removed for the pin to move forward, so check that all the pins ar e
tight and locked in place by using a blunt tool like a pick. Loo k
carefully - a pushed i n pin may appear a s an open slot.

NOTE—
• It may be necessary to remove the exhaust and lower the back
of the transmission to properly inspect plug. If this step is
necessary be careful to not bend shifter cable bracket
otherwise shifter cable operation will be compromised.
Transmission in failsafe mode with This is caused by highly-sensitive EGS software. The fault normall y
stored fault (CF33) sets during a 5-4 downshift in vehicles with a replacement
(from 02/2006 to 08/2007 production transmission, or after a reset of the adaptation values .
with 6HP19TU auto, trans.)*
Do not replace an y parts. Usin g the factory scan tool (version 49.0
and higher) to run a short test and perform the following test module :
Reset learnin g functions - available usin g th e following diagnosti c
240
path: Service Functions / Transmission Contro l / Calibrations / Reset
leaning functions
Afterwards, turn ignition of f / loc k vehicle / let vehicle enter sleep
mode. I t should then b e possible t o clear the fault.
'This problem is planned to be corrected with August 2007 and later
production vehicles equipped with these ZF transmissions.
003-14 Symptom s and Field Observations

3 SUSPENSION , STEERIN G AND BRAKES

Additional
Topic Notes information
(when available)

Rear coil spring repai r procedure s For repair procedures that requir e removal o f the rea r coil springs ,
the spring seats mus t be properly cleaned prio r to reinstallin g th e
springs. Dirt, pebbles, and debris left on the spring pads can becom e
trapped betwee n the spring pads an d the lowe r coil of the springs .
This can damage th e protective coating o f the springs an d rus t may
form on the spring. Over time, rust formation on the spring combine d
with vehicle operating conditions ma y cause th e spring t o break . 330

xDrive front pinion seal lea k Front pinio n seal leak s (arrow ) should b e addressed promptly . Th e

r front differential has a low fluid capacity and any size lea k ca n pos e
an immediate problem.

311

Brake pad wear sensor, us e care whe n The brak e pad wear sensor is easily damage durin g installatio n
installing / removin g owing to the 90° design. Be careful not to break the sensor whe n
during installation and removal.

340

Brake squeal from pa d wear senso r Under ligh t / moderate brake applications, brake squeal ca n b e
caused by contact between the brake pad wear sensor and the brake
rotor (fron t or rear brakes).
The geometry of the pa d wear sensor, combined with individua l
driving habits , can result in a wear pattern that causes a squeaking
and/or squealing nois e when the brake s are applied wit h ligh t to
moderate force.
If the nois e i s coming fro m the brak e system, inspec t the brak e pa d
wear sensor of the affected axle. If the sensor i s in contact with th e
rotor/disc, remov e the senso r and drive the vehicle. I f the nois e i s
eliminated, replac e the brake pads and wear sensor of the affected
axle. I f the nois e i s not eliminated, further diagnosis i s required to
determine the caus e of the noise .
 Symptoms an d Field Observation s 003-1 5

3 SUSPENSION , STEERIN G AND BRAKES (CONTINUED)

Additional
Topic Notes information
(when available)
Wheel alignmen t (track), resettin g On cars with the optional activ e steering (optio n SA 214), the front
(cars with active steering ) track ha s to be reset after work on the steering . The procedur e for
adjusting track on a vehicle with active front steering (total steering
angle sensor) is not the same as that for a vehicle with a conventional
power-assisted steering system .

320

• ••* • - J
'• x • ,"

510003027

ELV (Electric Steerin g Lock ) warning ELV light on with intermittent no-crank, no-start situation o r ELV
shown i n the Instrumen t Cluste r solenoid i n locked position . This fault i s usually cause d b y low
voltage durin g vehicle cranking / starting.
Troubleshooting shoul d b e carried ou t using BM W scan tool .

NOTE— 320

• If terminal KL15 is not switched on, scan tool communication will

be inhibited. In this case, start diagnostics by selecting the vehicle
manually. Then follow the diagnostics path: Drive/Engine start/
Comfort start/button to get into the scan tool test plan.
Front whee l bearin g wear Worn wheel bearing s can often produce a knocking sound whil e
driving. Not e that special press tools ar e neede d t o replace the
bearings.
• Check the front wheel bearings for wear with the vehicle raised. Th e
bearing will feel tight when spinning th e wheel.
310
• Pu t the vehicle on the ground, pull and push on top of wheel / tire to
check for looseness in wheel bearing. Initiall y it may feel tight. Roc k
steering wheel bac k and forth to situate the bearing . Bearin g will
then feel loose when pushing / pulling o n top of tire.

Active steering, reinitializin g afte r Active steering must b e reinitialized after the batter y has bee n
battery disconnect disconnected. Reinitialize as follows :
• Start engine (the "Active Steering Inactive" Check-Control messag e
appears)
1 Turn steering wheel as far as it will go counter clockwise and then
as far as i t will go clockwise.
003-16 Symptom s and Field Observations

3 SUSPENSION , STEERIN G AND BRAKES (CONTINUED )

Additional
Topic Notes information
(when available)
Clicking or cracking nois e fro m rea r The differential input flange mating surface with the input drive pinion
differential is insufficiently greased.

This is not a failure of the differential assembly. Do not replace the

complete differential.
Remove the differential drive flange.
Apply lubrican t P/ N 83 23 0 443 864 on the input flang e matin g
surface (A) , as described in the illustration.
Before complete reassembly, replac e the input flange seal and collar
nut retaining plat e

Tire pressure monitor , damage d whee l The tire pressure monitor (TPM) system use d on 2007 and later cars
electronics (2007-2010 vehicles ) measures the tire pressures at each of the four wheels. Th e syste m
utilizes a warning lamp, mounted in the instrument cluster to alert the
driver of a low tire pressure condition. The TPM system use s
separate wheel electronic s mounted at the base of each tire valve
inside the wheel. Extra care mus t be taken when changing tire s to
avoid damaging th e wheel electronics. A damaged whee l electroni c
can cause the tire warning indicato r to illuminate .
When diagnosin g a n illuminated TPM warning lamp , the tires and
wheels should be inspected for damage and/or prior replacement .

NOTE—
• The last four digits of the tire's DOT number indicate the
calendar week, followed by the year in which the tire was
produced. This information can be used to determine if one or
more tires have been recently replaced.
Flat tire monitoring / tire pressur e The warning lamp is illuminated when the tire pressure decreases by
monitoring, illuminated warnin g lam p approximately 25%. Temperatur e fluctuations can cause changes i n
tire pressure. For every 10° F change in ambient temperature, the tire
pressure can change b y 1 psi. Therefore, the tire warning indicato r
may be illuminated by a large change i n temperature combined wit h
a low pressure condition.
Inspect tires regularly for physical damage an d check tire pressure s
when the tire warning i s illuminated. BMW recommends checking tire 020
inflation pressures every two weeks and before long trips.

CAUTION—
• Driving on a significantly under-inflated tire causes the tire to
overheat and can lead to tire failure.
• Under-inflation reduces fuel efficiency and tire tread life, and
may affect the vehicle's handling and stopping ability.
 Symptoms an d Field Observations 003-1 7

4 BOD Y
Additional
Topic Notes information
(when available)
Multiple electrical faults caused b y Electrical components mounted in spare tir e well may becom e
water leak int o trun k damaged b y water leaking int o trunk. Inspec t trunk rubber seal an d
in particular, the larg e rubbe r washers at the bumper fasteners (as
viewed from inside trunk).

Noisy wiper blades , blade s chatte r Wiper blades in good condition may make noise during operation, or
may not clean the windshield properly . This ma y be caused by
contaminants on the glass or blades, or by the blades or arms bein g
out of adjustment.
The first step is to make sure the glass and the blades ar e clean and
free of contaminants. Common contaminant s tha t are not removed
by conventional glas s cleaners can be removed with BON AMI®, a
household cleanser.
The cleanser shoul d b e applied on a wet cloth o r sponge and the
windshield mus t be thoroughly an d evenly scrubbed . Wip e off the
residue with a clean, dry cloth before the cleanser dries on the glass. 611

If there is evidence of heavy overspra y o f waxes or silicones on th e

glass, a wax and silicone remove r can be used to remov e them.
Clean th e wiper blades with a clean clot h soaked i n rubbing alcohol
Once the blades and glass have been cleaned, check the adjustment
of the wiper arms.

NOTE—
• To properly adjust the wiper arms, special BMW adjustment
gauges and tools are required. Se e 611 Wipers and Washers .
003-18 Symptom s and Field Observation s

5 BOD Y EQUIPMEN T
Additional
Topic Notes information
(when available)
Squeaking noise from B-pillar A squeaking or grating noise may be heard from the top of the B-pillar
when driving over rough road s at very cold ambient temperatures .
This nois e typically occurs only belo w approximately 20°F.(Fo r
noises from this area at high temperatures, refer to BM W Servic e
Bulletin SI B51 02 05).
This i s caused by a bad bond betwee n the B-pilla r trim an d the rea r
door seal.
Replace the door seal with an updated part , which use s a softer
rubber compound .

Sunroof move s i n small steps or Slide/tilt sunroof requires initialization.

interior light s no t working
The moto r of the slide/tilt sunroof use s 2 Hall sensors. The y ar e
located on the moto r shaft and offset by 90 degrees with respec t to
each other. When the motor is running, this result s in two offse t Hal l
signals that are used to register the direction o f rotation and for the
anti-trapping protection function.

NOTE—
• The control button must remain pressed during the entire
initialization procedure. The initialization procedure must be
repeated if the button is released.
• If the power supply is interrupted during initialization the
procedure must be repeated.

Press and hol d sunroof button i n the sunroof tilt direction. After
approx. 1 5 seconds, the initializatio n begins b y storing the tilt -
position end stop, then the full open end stop position , etc .
Initialization takes about 12 0 seconds.
Initialization is erased under th e following conditions:
• Remova l of the voltage suppl y to sunroof control modul e
• Hal l sensor fault detected
• Sunroo f position implausibl e
• Modified/change d vehicle coding or coding data faulty
Tailgate opens slow at low ambient Tailgate opens slowly o r does not fully open under its own power .
temperatures
In low ambient temperatures, the gas pressure in the tailgate strut s
(Sports Wagon)
is reduced. The resul t is a less powerful strut. Conversely, a t very
high ambient temperatures, the gas pressure is higher, thus allowing
the tailgate to open quicker. This is a normal condition and the struts
are not faulty.
However, to ensure that excessive friction is not present in the hinges
due to lack of lubrication, be sure to lubricate tailgate and gas stru t
hinges with grease.
 Symptoms an d Field Observation s 003-1 9

5 BOD Y EQUIPMEN T (CONTINUED)

Additional
Topic Notes information
(when available)
Front an d rear door s d o not unlock at Intermittently, when the vehicle i s unlocked usin g either the remote
same tim e key or the central locking button, th e rea r doors d o not unlock at the
same time as the front doors. This situation is unaffected by whether
or no t selective locking i s active.
For the rea r door s t o unlock, th e unloc k procedure mus t b e
performed an additional time .
A Hig h Rat e of Battery Discharge chec k control message may also
be displayed.
This condition occurs when an excessive closed-circuit current draw
is detected. When a n excessive draw is detected, the 30gf rela y is
switched, disconnectin g th e basic body modul e (KBM ) from the
power supply.

6 ELECTRICA L SYSTEM
[ Additiona l
Topic Notes information
(when available )
Changing / setting dat e format (mm/dd To change Persona l Profil e settings:
or dd/mm) in the Persona l Profile
• Pres s rocker switch in direction indicator stalk, u p or down unti l
settings
"Personal Profile " function (key with a check mark) appears, ac -
(vehicles without Navigation )
companied b y the word SET in the instrumen t cluster.
• Pres s Board Compute r (BC) button on steering column stalk.
• Pres s rocke r switch , u p or down, unti l "tt/mm" or "mm/tt" is shown .
• Pres s the BC button.
• Us e the rocker switch to make the selection/change.
• Pres s the BC button to confirm and accept the selection/change.

NOTE—
• This will also change the date format in the radio display.

The following display format s and unit s of measure ca n be

selected/changed i n the same way.
• Fue l consumption (1/100km , mpg, km/I)
• Distanc e (km, mis)
•Time format (12h/24h )
• Temperature (°C, °F )
• Rese t of display formats / units o f measure (factory/defaul t setting)
003-20 Symptom s and Field Observations

6 ELECTRICA L SYSTE M (CONTINUED)

Additional
Topic Notes information
(when available)
Closed-circuit current (parasitic draw ) Increased closed-circuit currents may occur permanently o r
specification intermittently and cause the battery to discharge. Th e increas e in
closed-circuit current may be caused by a faulty control unit , or by the
installation of a non-approved accessory .
121
E60, E61 : 40 mA after 60-70 minutes wit h TCU (telematics
control unit ) (30 minutes withou t TCU)
In general, closed-circuit current consistently over 50 m A mus t b e
investigated.
Stabilant 22A electrical contac t Connectors carrying low current are particularly susceptible t o the
enhancer formation of deposits. These deposit s affec t the resistanc e o f the
circuit and, dependin g o n the sensitivity of the particular circuit, can
cause system malfunctions (ver y often intermittent), and the
activation of warning lamp s an d check control indicators.
In difficult to solve electrical resistance situations, Stabilant 22 A ma y
help to enhance electrica l contact. Stabilant 22 A evaporates and
leaves a thin polymer film which i s conductive betwee n the mating
surfaces, while staying non-conductive between adjacent pins . At the
same time it prevents the formation of any further harmfu l deposits.

NOTE—
• Read and understand any Stabilant 22A safety precautions
provided by the manufacturer.
• Do not use Stabilant 22A on Oxygen sensor or SRS
connectors.
Check Control message: Vehicl e If the off-loa d current exceeds 80 m A after 68 minutes of the ke y
Battery! Increased Batter y Discharg e being off, the engine managemen t system outputs the CC messag e
"Vehicle Battery! Increased Battery Discharge " the nex t tim e
Terminal 15 is switched on. This happens regardless of the batter y
state of charge.
In the event of the abov e situation, check the vehicle for non -
approved electrical equipment installations.
Retrofitted after-market equipment (e.g. , hands-free systems,
navigation systems, GPS or entertainment systems) may have been
121
incorrectly connected to Terminal 30, Terminal 30g-f or directly to the
battery.

NOTE—
• The intelligent battery sensor (IBS) monitors the battery's
discharge current while the vehicle is off. The measures values
are transmitted to the DME through the bit-serial data (BSD)
interface. Therefore, equipment or accessories must only be
connected to Terminal 15 or Terminal 30g, unless otherwise
specified in the installation instructions of the BMW retrofit kit.
 Symptoms an d Field Observations 003-2 1

6 ELECTRICA L SYSTE M (CONTINUED )

Additional
Topic Notes information
(when available)
Windshield washer, lo w or no volume Windshield washers spray a very low volume of fluid, or no fluid at all.
The straine r (arrow) on the windshield washe r fluid pump may
become clogged by debris or an algae-like substance .
The algae-like substance is typically caused b y using non-approve d
washer fluid or straight water i n the washer fluid reservoir.

To replace the strainer :

611
• Remov e the washer fluid pump, locate d in lower part right front
wheel well.
• Drai n existing washer fluid in the reservoir an d properly discard.
• Replac e the strainer, which is installed on the end of the pump. An
updated straine r has a larger mes h to avoid future occurrences.
• Refil l the washer fluid reservoir wit h BMW washer fluid at the spec-
ified concentration.
Gong warnin g withou t visual check A gong warning sounds approximatel y 10-1 5 seconds after the
control messag e engine is started. There is no check control warning in the instrument
cluster and n o faults are stored .
515
This can be caused by a center door lock button (permanently closed
contacts). Test the functionality of the center doo r lock button an d
replace as necessary.
Remote ke y not workin g The radi o remote control function is inoperative:
• The vehicle canno t b e unlocked o r locked with the remote key.
• The check control messag e "Replac e Remot e Contro l Battery" is
displayed.
• Faul t Code 9308BO - I D transmitter: Battery undervoltage is stored.

Test remot e ke y using BMW scan tool.

Instrument cluste r mileag e displa y The instrumen t cluster mileage displa y switche s to kilometers after
switches to kilometer s whe n key Is switching keys. This situation occurs only u p to 1 6 minutes after the
switched vehicle i s switched off (vehicle not yet asleep) .
Do not replace any parts or perform any software updates to correct
this situation. The problem can be corrected by letting the vehicle go
to sleep (longe r than 1 6 minutes after the ke y is OFF).
Consumption i s Set to mpg UK instead Usin g iDriv e menu change settin g unde r Displa y Settings .
of mp g U S

• B51000300 4
003-22 Symptom s an d Field Observation s

6 ELECTRICA L SYSTE M (CONTINUED)

Additional
Topic Notes information
(when available)
A/C blows warm after an extended driv e Th e air conditioning stop s cooling an d starts to blow warm air. This
usually happens when the weather is very humid o r there i s a high
level of air pollution. Norma l operation is restored after the syste m is
turned off for approximately 1 5 minutes .
The air conditioning system temperature regulation is calibrated
between 33.4°F (0.8°C) and 34.5°F (1.4°C). Under certai n
environmental conditions , ic e may form on the evaporator, causin g
loss of air conditioning performance. A software update i s required to
remedy this problem. Progra m usin g BM W scan tool.
Blower moto r stays o n with ke y OF F Occasionally after a long drive, the blower motor stay s on at a
reduced speed from the last setting on the control panel, for up to 1 6
minutes after the vehicle was turned off .
DME fault code 2DED Batter y Power Management ma y also be
stored. This complaint will not cause the battery to be discharged .
This is caused b y a blower motor LIN-Bus communication error
(blower i n emergency mode). A software update i s required t o
remedy this problem. Progra m using BM W scan tool.
A/C compressor does no t switch O N IHKA (Integrate d Heating and Air Conditioning) faul t 9C6A -
Compressor Coupling i s stored.
Check for a loose ground connection at compressor. I f the groun d
connection is not loose, continue troubleshooting fault using BM W
scan tool test plan

Testing automatic recirculatio n (AUC) Us e the following steps to diagnose AUC-relate d fault codes.
sensor.
— Remov e AUC sensor from mounting point . Electrica l connector
remains connected.

— Tur n ignition key on, mak e sure IHK A system i s on .

640
— Blo w into AUC sensor air intake. Fresh air flap should slam shut .

— I f flap does no t close, check voltage supply to sensor . I f voltage

supply i s good, replac e AUC sensor.
 Symptoms and Field Observations 003-2 3

6 ELECTRICA L SYSTE M (CONTINUED)

Additional
Topic Notes information
(when available)
Eyebrow light s inoperativ e after If eyebrow lights (arrow) fail to work after vehicle programming,
programming reprogram complete vehicle usin g BM W scan tool with latest
software.

Xenon lamp bulbs differ i n color afte r Replacement xenon bulbs have a yellow-white appearance when
replacement compared with the bluish-whit e o f the original bulb.
New Xenon bulbs requir e a burn-in period, which causes a gradual
color change from yellow to blue. The greatest color occurs in the first
5 minutes of use, and stabilizes after approximately 100 hours of use.
LED flashing o n headlight switch, no With the ligh t switch switched to the automatic position, the LE D on
faults store d the headlam p switc h is flashing and AH L (Activ e Headlights) is
deactivated.
Using the BMW scan tool, carry out a short test to identify any faults
related to AHL system. If no faults are stored and LED is still flashing,
problem ma y be caused by stuck stepper motor i n the headlamp .
AHL i s integrated int o BU S network and relie s on communicatio n
with other modules to function. Select: "Control Unit
Functions/AHL/Component Activation .
Activate each of the AHL functions in turn unti l the proble m is
identified and replac e faulty components .

Automatic headlights , adjustin g Headlights switch on too earl y or too late , even in daylight, with
sensitivity headlight switch set to automatic position .
The factor y default for the rain/light sensor i s set to "sensitive". With
this setting, the rain/ligh t sensor i s set for optimum operation.
There ar e three setting options :
• Norma l (reduced sensitivity)
• Sensitiv e (factory default)
• Highl y sensitiv e (mos t sensitive).

If th e preferenc e i s to hav e sensor settin g either mor e or less

sensitive, the setting can b e changed usin g BMW scan tool.
003-24 Symptom s an d Field Observation s

6 ELECTRICA L SYSTE M (CONTINUED )

Additional
Topic Notes information
(when available)

Key falls out of , or gets stuck i n key Remote key is not adequately retaine d in the key slot and sometime s
holder falls out. There ar e also situations wher e the remot e key gets stuc k
in the ke y slot and cannot easily be removed.
Under these situations, the ke y slot should b e replaced wit h an
updated par t (improve d mechanism fo r gripping the remot e key).
Updated par t were introduced in 9 / 2005 .
The date code on the part is in day/year format. Improved part s have
date code 248/05 o r later. Illustratio n shows E9 0 ke y holder, EG O is
similar.

B510003008

7 EQUIPMEN T AND ACCESSORIES

Additional
Topic Notes information
(when available)
OC3 (occupancy) ma t installation tips . When a new OC3 seat mat has been installe d us e the following tips
to avoid activation problems:
• With the ne w seat mat installed in the vehicle, eliminate any tensio n
in the seat ma t caused by the installatio n process by having a n
adult sit in the seat .
p Remov e all weight from the seat .
1 Using BM W sca n tool, enable the sea t mat.

NOTE—
• OC3 mat warranty has been extended to 10 years / unlimited
mileage on vehicles produced to 11 / 2005.
B510003005

Both rea r belt tensioners deplo y i n In the case of an accident that would trigger the rea r belt tensioners,
accident both tensioners will deploy, regardles s of whether the rea r seats are
occupied, or not. This a normal condition as the rea r belt buckle s
have no switch.

WARNING —
• Always rep/ace deployed airbag components and confirm MRS 721
operational status using BMW scan tool.
 010-1

010 Produc t Familiarization

GENERAL 010-1 TRANSMISSIONS 010-1 8

Manual transmissions 010-1 8
PRODUCT OVERVIEW 010- 1
Sequential Manual Gearbox (SMG ) 010-1 9
Technical data 010- 3
Automatic transmissions 010-1 9
BMW 5 Series specification s (2004 Sedan ) . . . 010- 3
BMW xDrive 010-2 0
MODEL YEA R HIGHLIGHT S 010- 5
SUSPENSION, STEERIN G AND BRAKES . . . 010-2 0
Model year 2004 010- 5
Front suspension 010-2 0
Model yea r 200 5 010- 6
Rear suspension 010-2 1
Model yea r 2006 010- 7
Dynamic drive (activ e stabilizers) 010-2 2
Model yea r 200 7 010- 8
Steering 010-2 2
Model year 2008 010- 8
Brakes 010-2 3
Model yea r 200 9 010- 9
Dynamic stabilit y control (DSC) 010-2 4
Model yea r 2010 010-1 0
BODY 010-2 5
ENGINES 010-1 0
Sports Wagon (E61 ) 010-2 6
M54 engine (200 4 - 2005) 010-1 0
Interior 010-2 7
N52 engine (200 6 - 2007) 010-1 1
Airbag systems 010-2 8
N52K engine (200 8 -2010 ) 010-1 3
N54 engine (200 8 - 2010) 010-1 4 ELECTRICAL SYSTE M 010-2 8
Valvetronic V8 engines (200 4 - 2010) 010-1 6 Power management an d voltage supply 010-2 9
Dashboard and controls overvie w 010-3 1

GENERAL
The informatio n in this section is based on introductory material for
2004 through 2010 BM W 5 Series vehicles sold in the US A and
Canada. The reference materia l provide d i s intended to serve a s a
product familiarization guide and is subject to change .

WARNING —
• Check BMW factory repair information at www. bmwtechinfo. com
or the publisher's website at www. com for
information that may supersede information in this section.

PRODUCT OVERVIEW
The 5th generation 5 Series (E60 ) wa s introduced i n the U S in
model year 2004 a s a replacement for the 199 7 - 2003 5 Serie s
(E39) an d was produce d through model year 2010.

The rear-whee l drive Sedan was introduced first. Sports Wago n

(E61) and all wheel xDriv e (Sedan and Sports Wagon) version s
were introduced in 2006.
010-2 Produc t Familiarization

2004 mode l introduction

525i (184 hp, 6 cylinder)
£60 4-door Seda n 530i (225 hp, 6 cylinder)
545i (325 hp, V8)

The E60 5 Series is a larger car than the corresponding E39 chassis
it replaced, addin g bot h interio r passenger roo m and wheelbas e
length.

Body dimensions wer e increased to improve roominess in the rear

compartment (additiona l 1.9 7 in knee room ) an d to increase the
luggage compartmen t capacit y (a t 520 L the larges t capacity of all
the BMW vehicles, including the E65).

Compared to the outgoing model, more generous exterior dimensions

ensure even greater spaciousness and comfort for all passengers. At
178.0 inches, the length increased by 2.5 inches . The width at 72.7
inches increased by 1.8. Vehicle height i s 57.8 inches, an increase of
1.3 inches. The wheelbase is 2.3 inches longer at 113.7 inches.

5 Series seda n
with xDriv e

BentfeyPublishers B510010006
 Product Familiarization 010- 3
Technical data

Technical data
BMW 5 Series specifications (2004 Sedan )
525i 530i 545i
Exterior

Doors 4 4 4

Height (A ) 58.0 in (1473mm) 58.0 in (1473 mm) 58.0 in (1473 mm)

Front track (B) 61.3 in (1558 mm) 61.3 in (1558 mm) 61.3 in (1558 mm)
Rear track (C) 62.3 in (1582 mm) 62. 3 in (1582mm) 62.3 i n (1582 mm)
Width (D) 72. 7in (1846 mm) 72. 7 in (1846mm) 72. 7 in (1846mm)
Wheelbase (E) 113.7 in (2888 mm ) 11 3. 7 in (2888mm) 11 3.7 in (2888 mm )
Length (F) 190. 6in (4841 mm) 190. 6in (4841 mm) 190. 6in (4841 mm )

Interior

Front headroo m 39.1 i n (993 mm) 39.1 i n (993 mm) 39.1 in (993 mm)
Rear headroo m 38.1 in (967 mm) 38.1 in (967 mm) 38.1 i n (967 mm)
Front legroom 41 .5 in (1054mm) 41. 5 in (1054mm) 41. 5 in (1054 mm)
Rear legroo m 36.0 in (915 mm) 39.1 in (993 mm) 36.0 in (915 mm)
EPA passenger compartmen t 99.1 cu ft (2806 liters ) 38.1 in (967 mm) 99.1 c u ft (2806 liters )
vol.
Cargo (trunk ) capacity 14.0 cuft (39 6 liters ) 41.5 i n (105 4 mm ) 14.0 c u ft (39 6 liters)

Engine

Engine configuration,
cylinders / valves per cyl. 2.5 liter in-line 6/ 4 3.0 liter in-line 6/ 4 4. 4 liter V8 / 4
Displacement 2494 cc (15 2 cu in) 2979(182) 4398 (268 )
Stroke / bore (mm ) 84.0/75.0 88.0/85.0 92.0/82.7
Rated power 184 @ 6000 rp m 255 @ 6600 rp m 325 © 610 0
Max. torque (Ib-ft) 175 © 350 0 rp m 220 © 2750rp m 330 © 360 0
Compression 10.5 : 1 10.2 : 1 10.5 : 1
Fuel requiremen t Premium unleade d Premium unleade d Premium unleade d

General

Final driv e ratio 3.15 : 1 (MT);3.73: 1 (AT ) 2.93 : 1 (MT); 3.46 : 1 (AT) 2.93 : 1 (MT); 3.3 8 : 1 (AT)
Fuel tank capacit y 18.5 U S gal 18.5 U S gal 18.5 U S gal
Unladen weight (manual) 3428 I b 3472 I b 3803
Gross vehicle weight (GWR) 4530 Ib 4575 I b 4905 I b
Coefficient o f drag (C d) 0.29 0.29 0.29
Max. roo f loa d 100 IDS . 100lbs. 100lbs.
Acceleration ( 0 - 60 mph ) 7.8 sec (est) 6.6 sec (est ) 5.7 sec (est)
010-4 Produc t Familiarization
BMW 5 Series specifications (2004 Sedan)

Vehicle dimension s

BentieyPublfsfters
 Product Familiarizatio n 010- 5
Model year 2004

MODEL YEAR HIGHLIGHT S

Below are the 5 Series year-to-year highlights throug h mode l yea r
2010. Majo r change s ar e detailed late r in this repair group .

Model yea r 200 4

The E6 0 sedan was introduced wit h many ne w features (som e
optional. Mos t notabl e were the following:
• Innovativ e lightweight construction with an aluminum front end and
an all-aluminum suspension . iDriv e control with available head-u p
display that project s important informatio n i n the form of a virtual
image directl y into the driver's field of vision.
• Directiona l headlights that adapt continuously to the steering angle
to illuminat e around th e bend i n the road .
010-6 Produc t Familiarizatio n
Model year 2005

Additional feature s for 2004:

6-speed Steptroni c transmissio n
• Choice of a 2.5- and 3.0-liter inlin e 6-cylinder engines or a 4.4-liter
Valvetronic V 8 engine.
• Choic e of 6-speed transmissions : manual, STEPTRONI C
automatic and Sequential Manua l Gearbo x (SMG) .
• Revised chassis features (suspension, steering, brakes) .
• Automatic headlight control and rain-sensing windshiel d wipers
standard o n all models .
• iDriv e control system for many features an d functions
• Active cruise control (ACC).
• Voice command system (included with optional navigation system)
• Fla t tire monitor (FTM) monitor s tir e pressures whil e vehicle is
Bentley driven.
B309010002
• Run-fla t tires with all sport packages.
• Adaptive brake lights, enlarged brak e ligh t area unde r heav y
braking.
• Sport package with active front steering , active rol l stabilization
and run-on flat performanc e tires (standar d o n 545i 6-speed
manual, otherwis e optional).
• Germa n built; production o f 530i began July 1, 2003, other model s
September 1 , 2003.

Model year 2005

New for 2005 wa s the launch o f the 4th generatio n E60 M5.

The 5.0 liter 500 horsepower V1 0 engine wa s mate d to a seven-

speed SMG transmission. Wit h this new powertrain, the M5 offered
the best power-to-weight ratio in its class. I n the tradition of BMW M,
the chassis was engineered t o kee p u p with the power while the
exterior treatment was distinctively subtle .

M5 (S65) engine specifications

Configuration 90° V10 with high-pressure dou-
ble VANOS, steplessly variable
valve timing, 1 0 individua l
electronically controlled throttles
Construction Aluminum bloc k and head s
Displacement (lite r / cid) 4.999/305.1
Bore x stroke (mm ) 92.0x75.2
Power outpu t (bh p / kW) @ rpm 500 / 373 @ 7750 rpm
Torque (N m / ft-lb) @rp m 520/383 @ 610 0
Maximum engine spee d 8250
Compression rati o 12.0: 1
Valves / cyl 4
Engine managemen t MSS65
0 - 6 0 mph 4.6s
 Product Familiarization 010- 7
Model year 2006

Model year 2006

2006 was a significant update year for the 5 Series: Valvetronic
6-cylinder engines, a more powerful 4.8 liter V8 engine, the
introduction of all-wheel drive, and a Sports Wagon body styl e are
the most notable updates .

6-cylinder all-wheel drive model s with new badge designation s

525xi and 530xi.

6-cylinder models were powered by BMW's advanced N52 engines.

• Ne w generation 6-cylinder engines, called N52, both with 3.0-liter
displacement:
- 525i: 215 hp @ 6250 rpm, 185 Ib-ft. torque @ 2750 rpm, single -
stage induction system .
- 530i: 255 h p @ 6600 rpm, 220 Ib-ft . torque @ 2750 rpm , 3-stage
induction system.
- Magnesium-aluminu m composite construction, Valvetronic
variable valve lift, electric coolant pump and many other
innovations.

The new Sports Wagon, an appealing concept combining 5 Series

sophistication with enhanced load-carrying versatility, was
introduced as an all-wheel drive mode l for 2006.

BentleyPuffitShets
-'' - r'- " - -'-•"••

550i model with 4.8-liter Valvetronic V8 engine, 360 hp, 360 Ib-ft.
torque, a 35 hp increase over the previous 545i.
010-8 Produc t Familiarizatio n
Model year 2007

Additional features for 2006

Start Stop butto n replaces former key switch; new-typ e remote
control.
• Comfor t access system (can be ordered as an option as of
September 2005 production ) featuring keyless access.
• Numericall y higher final drive ratio s for the 6-cylinder models .
• Xenon adaptive headlight s standard on 530i and 530xi models.
• All models fitted with chrome vertical grill e slats (previousl y 545i
only).

Model year 200 7

Night vision became an available an option. The system uses a
thermal-imaging camera that constantly monitor s the road ahead
and displays images accordin g to their temperature o n the iDrive
screen.
• Tire pressure monitor, replacing previou s fla t tire monitor,
constantly monitor s tire pressures an d displays a warning on the
iDrive screen when i t detects a significant change in tire pressure.
• Hig h definition (HD) radi o available as an option; offers CD quality
FM and raises AM reception to the sam e leve l as analog F M
broadcast.
• Rea l time traffic informatio n for navigation system , for up-to-the-
minute report s on local traffic conditions.
• Auxiliary input for iPod or MP3 player i s now standard; located
between the two power sockets at rear of center console.
• Revise d sport package wit h 20-way multi-contou r seats. Seats
include articulated upper backrest, adjustable-widt h backrest ,
adjustable thigh support and 4-way lumbar support. Sport package
also added 3-spoke steerin g wheel.

Model year 2008

The biggest visual change for 2008 (a s of 03 / 2007 production) was
the mid-life update, called Life Cycle Impuls e (LCI ) by BMW.

LCI exterior updates included :

Reconfigured optical headlight lense s emphasized with chromed

tubes.
• New front air dam with reshaped opening and up turned ends.
• Relocate d amber DO T lenses; headlight are a i s completely white.

B5100100igl
 Product Familiarization 010- 9
Model year 2009

Taillights include new white design wit h fewer reflectors, re d lines in

optical lenses.
• Reshaped rea r bumper , wit h revised diffuse r belo w bumper .

Model yea r 2008 introduce d new models with new engines:

• 528i and 528xi Sedan and Sports Wagon replaced 525i and 525xi.
These models received a more powerful 3.0-liter inline six-cylinder
engine, generating 230 hp and 200 Ib-f t of torque, for an increase
of 1 5 hp and 1 5 Ib-ft over the previou s engine, ,
• 535I and 535xi Sedan and Sports Wagon replaced 530i and 530xi.
These models were fitted with the N54 3.0-liter twin-turbocharged
inline 6-cylinde r engine producin g 300 hp and 400 Ib-f t of torque,
an increase of 45 h p and 80 Ib-ft .

Additional features for 200 8

• Active cruis e contro l (optional ) wit h stop-and-go brakin g function
• Bi-xeno n headlights
• Optional lane departure warnin g

Freshened interior with additional leather and extended wood tri m

for a more elegant look .
• Ergonomi c changes include d mor e convenient window switches,
relocated console ashtra y an d electronic shifter .
• Technically update d STEPTRONIC automatic transmission wit h
shift-by-wire electroni c shifter ( a no-cost option in 2008).
• Optiona l Sport automatic transmission included steering-whee l
paddle shifters and rpm-matching during downshifts, with Spor t
button for quicker, more dynamic shifting (beginning 0 6 / 2007
production).

Model year 2009

For 2009, the BMW 5 Series had very few changes: ne w standard
wheels on the 528i an d 528i xDriv e model s (17" double-spoke
wheels with all-season tires), and on the 535i and 535i xDrive
models (17" V-spoke wheels with all-season tires) .
010-10 Produc t Familiarizatio n
Model year 2010

Model year 2010

For 2010, the BM W 5 Series experienced two significant changes:

4th-generation iDrive system with ne w graphics an d controls on

vehicles equipped with optional on-boar d navigatio n system.
High-resolution 8.8 in. control display .
Optimized menus , expanded rang e o f functions.
Greater convenience and more intuitive operation vi a direct-select
buttons at controller, plus mor e programmable memor y keys .

Available M Sport Packag e included anthracite headliner, exterio r

aerodynamic packag e wit h Shadowline trim , M-specific wheels,
door sills, footrest, gearshift lever, and steering wheel. Some M
exterior colors were also available on vehicles with M Sport
Package.

ENGINES
There are 4 variants of the 6-cylinder engines an d two variants of the
V8 engines of the used in the 5 Series. See 100 Engine-General for
a full engine application chart .

M54 engine (2004 - 2005)

2004 and 2005 525i and 530i model s are fitted with the M54 engine.
This aluminium-block engine features overhead camshafts, four valves
per cylinder, hydraulic valve adjustment an d double-VANOS system
(variable valv e timing) to optimize torque , power and emissions.

M54 engine specifications

Displacement (cm 3)
525i 2494
530i 2979
Bore x stroke (mm )
525i 84.0 x 75.0
530i 84.0 x 89. 6
Power output (bhp ) @ rpm
525i 184 @ 5900 RP M
530i 225 @ 5800 RPM
Torque (N m / ft-lb) @rp m
525i 175 @ 3500
530i 214 @ 3500
Compression ratio
525i 10.5: 1
530i 10.2 : 1
Valves / cyl 4
Engine management Siemens MS 45.1
drive-by-wire throttl e
 Product Familiarization 010-1 1
N52 engine (2006 - 2007)

The double-VANOS system is a combined hydraulic and mechanica l

camshaft contro l device controlled by the Siemens engine
management system .

The VANOS system uses camshaft adjusters to continuously modif y

intake and exhaust camshaf t timing as a function of accelerato r
pedal positio n and engine speed .

Double-VANOS significantly enhance s emissio n management ,

increases output and torque, and offers better idling quality and fuel
economy.

N52 engine (2006 - 2007)

In 2006, the new generation N52B3 0 in-lin e 6-cylinder engin e was
N52 3.0 liter introduced. Thi s engine featured many innovations , includin g a
Valvetronic engin e
composite crankcase, Valvetronic system and the 3-stage DIS A
intake manifold . The oil level dipstick was eliminated .

The same basi c 3. 0 liter engine was shared o n the 525i and 530i ,
with the difference in power ratings being achieve d wit h intak e
manifold tuning and DM E software.

N52 engine specifications

Displacement (cm 3) 2996
Bore x stroke ore (mm ) 85.0 x 88.0
Power output bhp) @rpm
525i 215 @ 6250 RP M
530i 255 @ 6600 RP M
B309010030
Torque (N m / ft-lb) @rp m
525i 185 @ 2750
530i 220 @ 2750
Maximum engin e spee d 7000
Compression rati o 10.7: 1
Valves / cyl 4
Engine weigh t (kg ) 161 kg (355 Ib)
Engine managemen t Siemens MSV70
Emission complianc y ULEV2

The N5 2 engine weighe d 22 Ibs. less than it s predecessor M5 4

Magnesium allo y
composite crankcas e engine. The primar y weigh t saving s cam e from the composite
magnesium allo y crankcase an d the lightweight exhaus t manifold .

B309010036
010-12 Produc t Familiarizatio n
N52 engine (2006 - 2007)

The magnesium bedplat e and cylinder head cover also played a role
in overall weight reduction .

C
The traditional belt driven coolant pum p fro m previous engines was
replaced by an electric coolant pump. This allowed for the addition of
a single belt drive.

Additional N5 2 engine features:

• Trapezoidal connecting rod s (weigh t optimized) .
1. Bedplate inlays
2. Bedplat e • Aluminum silico n (AluSil) cylinder hea d
• Timing cas e integrated in crankcase an d cylinder hea d
• Cylinder head gasket with silicon sealing li p
• Weight-optimized double VANOS
• Crankcase ventilatio n with integrated heate r
• Volumetric flow controlled oil pum p
B309010029

Valvetronic replace s the conventional throttl e butterfly with an

electromechanical system that control s the amoun t o f lif t of the
individual intake valves . Th e Valvetronic engine is able to breath e
freely, delivering bette r performance while usin g les s fuel.

Valvetronic valvetrain uses a stepper moto r to control a secondary

eccentric shaf t fitted with a series o f intermediate rocker arm s tha t
3,
control the degree of valve lift. The throttle butterfly is no longer needed
as a means of controlling the air supply, though for safety reasons it is
still fitted as an emergency back-up. Valvetronic improves cold start
behavior, lowers exhaust emissions and provides smoother, more
immediate power.
1 . Actuato r
2. Wor m shaf t
3. Retur n spring
4. Gat e block
5. Intak e camshaft
6. Ram p
7. Hydrauli c valve adjuster (HVA) , intak e
8. Intak e valv e
9. Rolle r cam follower
10. Intermediat e lever
11. Eccentri c shaft
12. Wor m gear
B309010031

The compact VANOS units use vane-type construction which is less

complex and easier to service than previou s VANO S designs. Th e
VANOS units have integrate d sprockets and are attached t o the
camshaft via a central bolt.

NOTE—
• Due to the different spread ranges for the intake and exhaust
camshaft, the VANOS units cannot be interchanged. Doing so
would cause engine damage.
 Product Familiarization 010-1 3
N52K engine (2008 -2010)

To mee t the oiling requirements of the N52, a volumetric-flow

controlled oil pump i s utilized. Systems such as VANOS requir e a
large volum e of oil, particularl y at low engine speeds .

This pump only delivers as much oil as each operating rang e of the
engine requires. A conventional oi l pump woul d hav e to be
approximately three times the size of that in the N52 engine. A larger
oil pump would also consume excess energy and therefore the new
pump desig n allows :
• Increase d power outpu t
• Reduce d weigh t
• Optimized fuel consumption
• Reduced exhaus t emission s

B309010033

N52K engine (2008-2010 )

For 2008, the N5 2 base engin e from the 525i was replace d by the
more powerful N52K engine (230 hp vs. 215 hp). The N52 K engin e
was an improved and cost-optimized versio n of the N52 and was first
available i n the 528 i and 528xi from March 2007 production .

There are not many changes to the emission system s o n this

engine. The N52K P continued to use the composite magnesium -
aluminum allo y engine block from the existing N52.

The technical highlight s o f the N52K P include:

• New engine management (MSV80 )
• Ne w hot film mass ai r flow sensor (digital HFM)
• EGAS 8 throttle with magnetoresistive position feedback
• Plasti c valve cover with integrate d crankcase vent valve and oil
separation
• Stronge r connecting rods
• Exhaus t valve stem increased to 6 mm
• Second-generatio n electri c coolant pum p
• Lightweigh t camshafts (hydroformed)

N52K engin e specifications

Displacement (cm 3) 2996
Bore x stroke (mm ) 85.0x88.0
Power output (bhp ) @ rpm 230 @ 6250 RP M
Torque (ft-lb ) @rp m 200 @ 3000
Maximum engin e spee d 7000
Compression rati o 10.7: 1
Valves / cyl 4
Engine managemen t Siemens MSV8 0
Emission complianc y ULEV2
010-14 Produc t Familiarizatio n
N54 engine (2008 -2010)

N54 engine (2008 -2010)

The N54 engine used in the 2008 and later 535 i models is the high-
performance powerplant utilizin g twin-turbo technology and high-
pressure direct gasoline injection .

The N54 delivers uncompromising respons e an d high torque output

in a unit that is about 150 pounds lighter than a V8 engine. The new
technology use d in the N5 4 allows for maximu m efficienc y and the
low exhaust emissions t o meet ULE V I I guidelines .

N54 3.0 liter

turbocharged engine

High-pressure
fuel fump

Piezo injector s

Turbochargers
:

Bentley Publishers
B309010040

The N5 4 is officially referre d to a s the N54B30OO . The "O"

N54 engin e
designates th e "upper" output rang e an d the "0' indicates th e first
generation i n this series.

BentieyPublishers
B309010034
 Product Familiarizatio n 010-1 5
N54 engine (2008 -2010)

. Th e N5 4 uses HP I injection system , whic h i s capable of pressures

piezo injector of u p to 200 ba r (2900 psi). This system features piezo injector
technology with outward opening injectors .

Developing 300 hp and peak torque of 400 Nm or 295 Ib-ft, this new
engine offer s the highes t standar d of spontaneous and superior
power and performance.

N54 engine specifications

Displacement (cm3 ) 2979
Bore x stroke (mm ) 84x89.6
Power output (k w / bhp) 225 / 300 @ 5800 RP M
Torque (Nm ) @rp m 400 @ 1 300 - 5000
BwnleyPublishers
B309010039 Maximum engin e spee d 7000
Compression rati o 10.2: 1
Valves / cyl 4
Engine weigh t 187 kg (41 2 Ib)
Engine managemen t MSD80, MSD8 1
Emission compliancy ULEV2
Injection syste m type HPI (D l 2)

The 3.0 liter N5 4 engine feature s the following :

• Exhaus t driven twin turbocharger
•Air to air intercooler
• Second generation direc t injection (HPI ) wit h piezo injector s
• Ne w engine managemen t (MSD80 , MSD81)
BentleyPubiisNirs • Bi-VANOS
• All aluminum crankcas e with iron cylinder liners
(similar dimensions to N52)
• Externa l oil cooler
• New high output electric coolant pum p (400 W)
• Aluminum cylinder hea d with plastic valve cover
• Steel crankshaft

B309010042
010-16 Produc t Familiarizatio n
Valvetronic V8 engines (2004 - 2006)

Valvetronic V8 engines (200 4 - 2006)

The 2004 through 2010 V8 models wer e fitted with the new
generation Valvetronic engines. Ther e ar e two variants of the N62
Valvetronic motor:
• 2004 - 2005 model s had a 325-hp 4.4 liter version calle d the N62
• 2006 - 2010 models had 360-hp 4.8 liter version called the N62 TU

N62 and N62 TU motors are mated to either a 6-speed automati c

transmission or a 6-speed manual .

N62 and N62 TU engine specifications

Displacement (cm3)
N62 (2004 - 2005) 4398
N62TU (200 6 -2010) 4799
Bore x stroke (mm)
N62 (2004 - 2005) 92 x 82.7
N62TU (200 6 -2010) 93 X 88.3
Power output (bhp) @ rpm
N62 (2004 - 2005) 325 @ 610 0
N62TU (200 6 -2010) 360 @ 6300
Torque (Nm ) @rp m
N62 (2004 - 2005) 330 @ 3600
N62TU (200 6 -2010) 360 @ 3400
Compression rati o
N62 (2004 - 2005) 10.0: 1
N62TU (200 6 -2010) 10.5: 1
Valves / cyl 4
Engine managemen t
N62 (2004 - 2005 ) Bosch ME 9.2
N62TU (2006-2010 ) Bosch ME 9.2.2
Emission complianc y ULEV2

N62 engine (2004 - 2005)

545i model with 4.4-liter V8 engine, 33 0 hp , 325 Ib-ft. torque.

N62 engine features :

• Valvetronic
• Full y variable intake manifol d
• Bi-VANOS

Valvetronic is a patented BMW system that varies valve lift to control

engine power. Instead of a conventional throttle, Valvetronic varies
valve lift all the way from 0.3 mm (for idling) to 9.7 mm (for full-power
operation). By eliminating pumpin g losse s associate d wit h a throttle
plate, Valvetronic plays a major role in boosting power on the 4.4 liter
engine. I t also help s make the engin e smoother.
 Product Familiarization 010-1 7
Valvetronic V8 engines (2004 - 2006)

Valvetronic operatio n

Intermediate leve r (roller bearing ) Intake camshaf t

Transmits cam lobe movement
to roller cam follower

Exhaust camshaf t
Eccentric shaf t
Adjusts position of
intermediate lever
Pull-back sprin g Roller cam

Roller cam
follower

Hydraulic lifte r

Hydraulic lifte r

Valve spring Valve spring

Intake valv e
Fully variable — Exhaust valv e
valve lif t
Spark plug
Publishers
BX56010013

The Valvetronic mechanism sits atop the intake valves on both of the
V8 cylinder banks. Eac h o f the engine's 32 valves ( 4 valves pe r
cylinder) i s actuated a s the camshaft lob e deflects a finger-type
rocker arm with hydraulic clearance adjustment. O n the intake sid e
there is an additional element between the cam lobe and rocker arm,
called an intermediate lever.

Upon contac t b y the camshaft lobe, the intermediate lever actuates

the rocker arm and, i n turn, the valve. The intermediate leve r is held
in place b y an eccentric shaf t that is rotated b y an electric serv o
motor. Th e eccentric shaft positio n determines the intermediate
lever's pivot point , and therefore valve lift . Eccentri c shaf t position
commands com e fro m the Bosch engin e management system i n
response to accelerator peda l movements .

V8 engines emplo y a steplessly variabl e intak e manifol d that

optimizes performance acros s the entire engine speed range .
010-18 Produc t Familiarizatio n
Manual transmissions

In addition t o Valvetronic, the N6 2 engine also use s a double

VANOS system similar t o that used o n the 6-cylinder engine. This
arrangement varie s valve timing b y rotating the intak e an d exhaust
camshafts steplessl y to optimize engine power , emissions an d fuel
efficiency. The combination of VANOS an d Valvetroni c is exclusive
to the new N family of power plants .

Bentley Publishers BX56010009

N62 TU engine (2006-2010 )

N62 The 550i Sedan , replacin g th e 545 i i n 2006, is powered b y 4.8-liter

Valvetronic V 8 engine. Thi s engin e i s very similar to the 4.4 lite r
Valvetronic engine. Th e greater displacement an d other mino r
engineering improvement s mak e thi s uni t eve n mor e powerful : 360
hp and 360 Ib-ft . o f torque, up from the previou s 4.4-lite r engine' s
325 h p / 330 Ib-ft .

This engin e utilize s Bosch M E 9.2.2 an d maintains Valvetroni c and

dual-VANOS controls.

TRANSMISSIONS
In the E60 5 Series model s covere d by this manual, al l transmission
choices are 6-speed .

Manual transmissions
The 6-speed manual gearbox , standard on all models, is engineered
6-speed manual transmission
to provide precis e control an d a high leve l o f driving pleasure. The
manual transmissio n ha s a lifetime oil fill. Bot h Getrag and ZF
manufactured units are installed on the 5 Series cars covered by this
manual. Se e 200 Transmission-General for application
information.

• • ; - ; ; ; • . : ;DM: ;; -•'•,
 Product Familiarization 010-1 9
Sequential Manual Gearbox (SMG)

Sequential Manual Gearbox (SMG )

Available as an option, the sequential manual gearbo x (SMG )
Sequential Manua l
functions like a clutchless manual transmission. Clutch operation i s
Gearbox (SMG ) handled via a computer controlled hydraulic uni t to engage an d
disengage th e clutch, as well as shift gears. Se e
200 Transmission-General for application information.

B510010036

Automatic transmissions

6-speed automati c A 6-spee d automatic transmission is available fo r 5 Series cars .

Compared to the 5-spee d unit it replaces, i t is 10% lighter, has a
more efficient torque converter and operates with fewer internal
clutches. See 200 Transmission-General for application
information.

The automati c transmission is controlled by the mechatronic s

module tha t i s made u p of a combination of the valve bod y an d
electronic transmission control uni t (EGS) . Th e drive range switch
(for drive range s P , R, N and D ) is located i n the mechatronic s
module, which is mounted i n the ATF sump. I t is operated b y th e
selector lever i n connection wit h a bowden cable assembly .

The Steptronic feature offers Normal, Spor t and Manual modes. The
Sport mode , i n which shifts occur at higher engin e speeds , i s
engaged b y moving the lever from D; from here, the Manual mod e is
engaged whe n the driver manually choose s a gear b y tipping the
lever forward (for downshifts) or rearward (for upshifts).

The torque converter use s an integrated torsion dampe r whic h

Torque converter avoids unnecessar y sli p and power loss. The converter clutc h is
closed immediatel y after the vehicle starts off. In this way , it feels
similar t o a manual transmission , with short response an d shift
times. With precis e contro l and a low level of converter slip, the
6-speed automatic transmissio n also improve s fuel economy ,
particularly a t highway speeds when 6th gear is in use .
010-20 Produc t Familiarizatio n
BMWxDhve

BMW xDriv e
xDrive is BMW's intelligent all-wheel drive system. It was introduced
Transfer cas e with
on the E6 0 and E6 1 cars in model year 2006.
variable torqu e
distribution xDrive optimizes traction, while enhancing stabilit y o n slippery roa d
J surfaces. Via the same type of logic tha t DS C employs t o recognize
and correct for excessive over- or understeer, xDrive adjusts the
front to rear torque split to avoid thes e tendencies .

NOTE—
• 2009 and later models with all-wheel drive no longer carry xi on the
trunk badge. Instead, there is an xDrive badge on the front fender
designating the all-wheel drive configuration.

xDrive operates as follows:

B510010039
• Drivin g torque is always transmitte d t o the front and rear wheels.
• The portion of torque transmitted to the front wheels i s controlle d
by a multi-disc clutch attached to the transfer box. The torque split
between front and rear wheels is steplessly variable.
• Engagemen t pressur e o n the multi-dis c clutc h i s directed by an
electronic control syste m i n response t o actual roa d and driving
conditions.

SUSPENSION, STEERIN G AN D BRAKE S

E60 and E61 cars feature a highly evolved chassis, including front and
rear aluminum suspensio n system s for low unsprung weight and
outstanding handling and ride comfort. The front and rear suspension
also includ e accommodations for active stabilizer bars as part o f the
dynamic driv e system (optional equipment , Spor t package).

The steering is an engine-speed-sensitive variable-assist powe r

rack-and-pinion design . Als o available a s an option was active
steering, which electromechanically varie s the steering ratio on the
basis of vehicle speed and other driving conditions.

Standard equipment include s four-wheel ventilated brake rotors and

a new generation dynami c stabilit y contro l (DSC ) system .

Front suspensio n
The aluminum fron t suspension utilize s a double pivo t axle with
MacPherson struts . All models benefi t from the reduced sprung and
unsprung weight of aluminum for optimal suspension responsiveness.
• Unsprun g aluminu m components :
Both lower arm s (tw o per side)
Steering knuckle s
Strut tubes
• Sprung aluminu m components :
Spring pad s
Subframe
Front end reinforcement plate
Steering rack

Other aluminum component s furthe r contribute to overall weight

BentleyPubSishers savings: engine mounting brackets, transmission crossmemberan d
mounting brackets, and power steerin g pump housing.
 Product Familiarizatio n 010-2 1
Rear suspension

BMW E6 0 aluminum
suspension system

Front activ e
stabilzer ba r ,

Aluminum
subframe

Aluminum
reinforcement
plate
Aluminum Aluminum
subframe driveshaft

Rear activ e
stabilizer bar

B510010040

Rear suspensio n
Sedan rea r The rea r axle is designed aroun d BMW' s highly sophisticated multi -
suspension link Integra l system .

As in the front suspension, aluminum is extensively use d in the rea r

suspension.
• Sprung aluminum components:
Subframe
Spring pad s
• Unsprung aluminum components:
All link s of the 4-link Integra l system
Shock absorbe r tube s

The aluminum rea r subframe, which carries the entire rea r

suspension system and final drive (differential), i s mounted t o the
main structure with four large rubber bushings tha t help absorb roa d
shocks. The final drive uni t is mounted to the subframe through it s
own rubbe r bushings. Wit h these two stages of vibration and nois e
absorption, the differential is acoustically decoupled from the body,
minimizing gear and driveline noise .
010-22 Produc t Familiarizatio n
Dynamic drive (active stabilizers)
Air suspension (Sport s Wagon )
Sports Wago n
E61 cars are equipped with an automatic self-levelling air
suspension (EHC ) a t the rea r axle. This suspensio n system is a
variant of BMW's integra l link rea r axl e an d was specificall y
developed for the Sports Wagon t o facilitate a completely fla t
luggage compartment floor while providing a very large through-
load space .

Rear air suspension i s particularly advantageous o n vehicles with

high payload (such as the Sports Wagon) as the load at the rear axle
changes when loadin g an d unloading th e car.

With conventional steel springs, a change in axle loa d affects not

only th e rid e height but also vehicle vibration and suspension
geometry. There is a change in rear wheel camber at high payloads .
Bent This can result i n increased load at the inne r shoulder s of the tires,
B510010050
in turn reducing the load bearing capacity of the tires. EHC
eliminates man y of these problem s b y maintaining a constant rear
ride height regardles s o f the load .

Rear air springs and shock absorber s ar e supported independentl y

on the floor pan of the cargo compartment .

The ai r supply syste m is located on the underbod y betwee n the

spare wheel well and battery box.

Dynamic driv e (activ e stabilizers )

BMW's innovative dynamic driv e (als o calle d activ e stabilizers or
ARS) ensures that under - o r oversteering is reduced, resulting in
enhanced safety , greater comfort and an impressivel y dynamic
driving experience. Dynami c driv e minimize s bod y rol l and

1 distributes it between both axles, ensurin g a comfortable flat ride .

Dynamic driv e i s fitted to the 5 Series as part of the Sport Package .

In the dynamic driv e system, fron t and rea r hydraulically-actuate d
active stabilizer bars replace conventional soli d stabilize r bars.

During cornering, the active bars counteract the vehicle's tendenc y

to roll in a corner. By working together with acceleration and position
sensors, a n electronic managemen t system and other components,
the system ensures a high degre e o f agility a t all speeds, balance d
reactions to load changes and precise steering.

The system continually adapt s t o driving conditions . For example,

when driving straight ahead, dynami c drive reduces the pressure on
the active stabilizer bars, treating them individually. This results in a
highly comfortable ride.

Additional informatio n o n dynamic drive , includin g syste m

troubleshooting, can be found in 300 Suspension, Steerin g and
Brakes-General.

I • • ,nttfy Publishers

Steering
The vehicle-speed-sensitive variable-assist power rack-and-pinio n
steering system was standard on all models. Togethe r with the
redesigned suspensio n an d subframe, the steering reactio n to
inputs i s precise and sharp .
 Product Familiarizatio n 010-2 3
Brakes
Active steerin g
Active fron t steerin g
Active steering is a revolutionary development from BMW (include d
in Sport Packag e option , rear-wheel-driv e models). Activ e steerin g
offers man y benefits:
• Wide variable steering ratio; steering-wheel movement s fo r
parking maneuvers, U-turns an d sharp corner s are greatly
reduced for amazing agility.
• Vehicle stabilization; in critical situations, can intervene to preserve
stability. For example, if the driver applies the brakes while drivin g
on a surface on uneven tractio n (one side of the roa d slippery, th e
other grippy), active steerin g can steer against th e instability.
B309010065

This sophisticated system electronicall y varies th e degree to which

the front wheels tur n i n relation to steering inpu t from the driver .
Under norma l drivin g conditions a t low and medium speed s th e
steering ratio becomes mor e direct, meaning the wheels turn mor e
in relation to input from the driver, reducing the amount th e steering
wheel mus t b e turned. Fewe r than 2 turns are needed to mov e th e
steering wheel from one loc k to the other.

At hig h speeds, o n highways for instance, the steering gea r rati o

becomes increasingly more indirect. The simultaneously increasin g
steering wheel torque leve l prevent s unintentional steerin g
movements an d the drive r can feel an improvement i n directional
tow speed
stability.
B510010044

Brakes
The E60 has a hydraulic dual-circui t brake system wit h front to rear
split. The electri c precharge pump for the DS C function is no longer
used. The brakes use ventilated cast iron rotors all around, an d
aluminum calipers at the front as a contribution to balanced weigh t
distribution. Braking power is enhanced b y large diameter rotors .

A new coating eliminates rustin g on portions o f the rotors no t swept

by the brake pads.Separat e front and rear pad wear sensors allo w
the mileage remainin g o n the front and rear pads t o be displaye d
and appropriate service scheduled. See 020 Maintenance fo r
accessing the CBS (conditio n base d service ) menu .

Some models use lightweight compound brake rotors made of two

components: th e high-carbon cast iron outer portion , which
functions conventionally, and an aluminum ha t in the cente r
Advantages include :
• Reduce d unsprun g weight , complementin g th e aluminum
suspension system . Actual reductions are approximately 2. 2 Ib. at
the front , 1. 5 Ib . at the rear .
• Reduce d rotor deformation under har d braking, meanin g les s
tendency o f the brake s to vibrate when very hot.
010-24 Produc t Familiarizatio n
Dynamic stability control (DSC)

btive front steering control module 2 . Yaw sensor 3. Active fron t steering actuatin g uni t B510010045

Dynamic stabilit y contro l (DSC )

The 5 Series dynamic stabilit y control (DSC) syste m is referred to as
DSC senso r DSC8 (DSC8+ o n later models). The DS C control uni t uses vehicle
speed, steering angle and latera l acceleration signals to calculate
vehicle yaw while cornering . DSC intervention is performe d
depending o n whether the vehicle i s oversteering or understeering.
The DS C function can b e deactivated b y means of the DS C button.

The DS C sensor i s a key component i n the DSC 8 system. It is

installed unde r the front passenger's seat nex t to the transmission
tunnel. The DSC sensor contains th e yaw rat e sensor (Q), a
transverse acceleration sensor (ay) , a longitudinal acceleration
sensor (ax) fo r the drive-off assistant function.

The following advanced functions contribute to increased directiona l

stability, optimized comfort, enhanced syste m availability an d
response plu s reduce d brakin g distance .

• ABS Antilock braking syste m

• ASC Automatic stability control
• MSR Engin e dra g torque contro l
B51001004 • DS C dynamic stabilit y control
 Product Familiarization 010-2 5
Dynamic stability control (DSC)

• DBC Dynamic brake control

Active wheel speed senso r
• CBC Cornering brake control
• ECD Electronically controlled deceleration (active cruise control
AB C only)
• EB V Electronic brake-force distribution
• DTC Dynamic tractio n contro l
• RP A Tire defect indicator
• BBV Brake-pad wea r indication

There are additional DSC8+ functions for 2006 and late r cars: Dry
braking, brak e standby, automatic soft-stop, fading warning and
assistance, drive-off assistant , hill descent control
A. Sensor rin g
B. Sensor integrate d Additional xDrive DSC (also called OCX ) functions:
circuit wit h Hall senso r
• TCC Transfer case control (control of multi-disc clutch in transfe r
C. Sensor housin g
case)
• ASC-X Automatic stability control X (special function for all-wheel
Publishers drive vehicles )
B510010047
• ADB-X Automatic differential brake X (special function for all-wheel
drive vehicles)
• HOC Hill descent contro l

BODY
A ne w BMW platform always means exciting new technology an d
innovative, meaningful features. The most noteworthy feature of the
E60 body is the lightweight aluminum chassis technology.

In order to make the E6 0 significantly lighter, BMW designe d a

reduced weight aluminum front end (GRAV). The front end consist s
almost entirel y of aluminum (blu e shading) while the transition to
steel occurs i n the front bulkhead area.

The weight savin g at the front end not only reduces the total weigh t
of the vehicle but is also a significant factor in the E6 0 attaining the
ideal axle load distribution o f 50 / 50.

The transition from the aluminum fron t engine support rai l to the
steel rail section joint is produced by bonding and punch riveting. To
increase conductivity, ground points are located on the two rails and
are connected with a ground strap.

In addition t o the underhoo d strut tower reinforcement brace, the

bumper carrier an d an aluminum front end reinforcement pane l
provide additional reinforcemen t and structural rigidity.

1. Spring Support 5. Bulkhead Cros s Membe r

2. Engine Suppor t 6. Bulkhea d
3. Bulkhead carrie r suppor t 7. Inner A-pilla r (steel)
4. Outer connectio n (steel) B510010055
010-26 Produc t Familiarizatio n
Sports Wagon (E61)

GRAV (aluminum front end )

Bentiey Publishers B510010049

Sports Wagon (E61 )

The Sports Wagon offers essentially the same accommodations
and features as the Sedan, includin g th e aluminum fron t end. Front
and rea r leg room are identical for the two bod y styles; the Sports
Wagon's standar d split folding rea r seats offer essentially the sam e
functions and benefits as those tha t ar e optional i n the Sedan.

The bi g difference is aft of the rea r seats where, in terms of load-

carrying ability and versatility, the Sports Wago n offer s many
advantages ove r the Sedan, suc h a s a high-lift tailgate and
separately opening rea r window, for convenient loadin g without
opening the tailgate.

The rea r hatch i s set at a low level in the interest s of a low loadin g
sill. The tailgate is comprised of two segments (th e rear window can
be opened separately) . An indentation in the rea r bumper reduce s
the heigh t of the loading sil l for easier loading.
 Product Familiarizatio n 010-2 7
Interior
Interior
On the inside, the 5 Series continues the harmonious balance
between sportiness and elegance, with an ergonomically designe d
cockpit for the driver and purposeful materials carefully chosen t o
Crash sensitiv e please the senses.
head restraint
Some o f the interio r highlights include:
• Greater space for passengers and cargo compared t o perviou s
5 Series: 0. 5 in. more shoulder roo m and 0.3 in . more hea d roo m
for front-seat occupants. 1. 3 in. more shoulder room , 0.7 in . more
60mm head room , 1. 8 in. more le g room for rear-sea t passengers an d a
26% increas e in trunk volume.
• Evolve d iDrive system with optional Navigation: A simplifie d
version of the iDrive system first seen in the 7 Series, with a 6.5-in.
color monitor * displaying 256 colors at 400 x 240-pixel resolution.
*2010 models with the navigation used a larger screen.
• Refine d automatic climat e control , standard rain-sensin g
windshield wipers.
-- • Advanced safet y and security systems, including front and rea r
B309010027 head protection, and optional active (crash sensitive) hea d
restraints.
010-28 Produc t Familiarizatio n
Airbag systems

Airbag systems
The latest generations o f the airbag systems provide enhanced
passive protection for vehicle occupants i n case of a serious
collision. Two system variants were use d on the EG O and E61 cars,
depending o n model year.
• Advanced Safety Electronic s (ASE) on 2004 - 2005 models
• Advanced Crash and Safety Management (ACSM ) on 2006 - 2010
models.

The differences betwee n th e two systems relate mainly t o the

updated electrical plan on he 2006 and late r cars. These
B510010053 sophisticated safety systems differ from previous MR S systems in
that the reaction time is decreased and accuracy is increased due to
the addition o f the door pressure sensors an d crash sensors in the
engine compartment. Se e 721 Airbag Syste m (SRS) for additional
information.

ELECTRICAL SYSTEM
Multiple control modules are involved in the operation of the vehicle
electrical system. BMW calls this the distributed functions approach .
There are several systems (i.e. central locking, power windows and
interior lighting) whose functions are distributed across multiple
control modules .

The primary contro l module s are :

• SGM Safety gateway modul e (200 4 - 2006)
• TMFA Driver' s door module (200 4 - 2005 )
• TMBF Passenge r door module (200 4 - 2005)
• MP M Micro powe r modul e (200 4 - 2005 )
• KGM Body gatewa y modul e (2006 - 2010)
• CA Comfort access (2006 -2010 )
• KBM Body basi c modul e
• CAS Car access system
• LM Light modul e

Distributive function
Opening of rear window at driver's door switc h

Ppwer
window switc h

TMFA SGM KBM

byteflight K-CAN

Power windo w
motor
Publishers
B510010056
 Product Familiarizatio n 010-2 9
Power management and voltage supply

Power managemen t and voltage supply

Supply voltag e i s monitored during bot h driving an d parke d
conditions to reduce the possibility of unwanted closed current
draws and insur e that adequate batter y power is available fo r
starting. Th e state of charge (SoC ) an d the state of health (SoH) o f
the batter y are determined continuousl y wit h the E6 0 powe r
management system .

The powe r supply syste m consists of the following components :

• Vehicle ground points: Owing to the aluminum fron t end
construction, additional groundin g techniques ar e employe d
improves the electromagnetic compatibilit y (EMC) o f the vehicle .
• Batter y and battery cable.
• Intelligen t battery sensor (IBS) with ground lead: A sensor installed
directly at the negativ e batter y terminal. It constantly measure s
battery terminal voltage, battery charge / discharge current ,
battery acid temperature and reports this information to the DME .
• Terminal 30 g relay prevents increased closed-circuit current
consumption by switching off electric loads in a defined manner. This
happens approx. 60 minutes after turning the ignition OFF (termina l
R off). Terminal 30g rela y is actuated by car access system (CAS) .
• Micr o power module (200 4 - 2005 only) : In the same wa y a s with
terminal 30g, th e micro power modul e (MPM ) facilitate s define d
deactivation o f electric loads. The MP M i s installed i n the spar e
wheel recess.
• DME : Powe r management softwar e i s contained i n the DME .
When the vehicle i s at rest, the IB S is partially responsibl e fo r
power management .
• Car access syste m (CAS) : Responsible for ignition an d starter
functions, remot e key, immobilizer (EWS), central locking, powe r
windows, condition base d servic e (CBS), as well as man y othe r
distributive electrica l functions .

See 600 Electrical System-General for additional information on

the electrical system and buses.
010-30 Produc t Familiarizatio n
Power management and voltage supply

Typical voltage supply for 6-cylinder models

0
-; :• ; _ ~
,H
^,-» ...I-
HOI

1. Intelligen t battery senso r (IBS ) 5. Alternato r 9. Fron t fuse an d rela y panel

2. Batter y 6. Starte r 10. Ca r access syste m (CAS)
3. Ignitio n and starter switch (ZAS ) 7. Starte r relay 11. Micr o powe r modul e (200 4 - 2005)
4. DM E 8. Rea r fuse and relay panel with
terminal 30g
 Product Familiarizatio n 010-3 1
Dashboard and controls overview

Dashboard and controls overview

1. Ligh t switc h 19. Remote ke y slot

2. Cruis e control stalk switch 20. START STOP switch
3. Paddl e shifter 21. Parking brake handl e
4. Speedometer , fuel gauge 22. iDrive main menu butto n
5. Instrumen t cluster LCD scree n 23. iDrive controller
6. Tachometer , engin e coolan t temperature gaug e 24. Gear shift switch (GWS)
7. Wipe r and washer stalk switc h 25. Center console switch cluster
8. Navigatio n and iDrive display screen 26. Radio and navigation contro l
9. Centra l locking and anti-theft alarm indicator 27. Climate control knobs
10. Hazard warning and central locking switch
11. Center air outlets adjuster NOTE—
12. Side air outlet adjuster • Features and equipment may vary from the illustration.
13. Side window defroster outlet
14. Trunk lid or tailgate release button
15.OBD II plug cover
16. Engine hoo d releas e
17. Horn, airbag
18. Multifunction steering wheel switches
010-32 Produc t Familiarization

B510010057
 020-1

020 Maintenanc e

GENERAL 020- 2 Antifreeze concentration, checking 020-3 0

Warnings, Cautions and Notes 020- 2 Cooling system hoses , inspectin g 020-3 1
CONDITION BASE D SERVIC E (CBS) 020- 3 ELECTRICAL SERVIC E 020-3 1
CBS basics 020- 3 ENGINE ACCESSOR Y BELT SERVIC E 020-3 2
Service recognition 020- 4 Accessory belt , replacin g (M54 , N52 ) 020-3 2
CBS items, viewing 020- 4 Accessory belt , replacing (N54) 020-3 4
CBS items, resettin g 020- 6 Accessory belt, replacin g (V8 ) 020-3 6
Car information computer (CIC) 020- 7 A/C belt , replacing (M5 4 engine) 020-3 7
RECOMMENDED MAINTENANC E 020- 7 A/C belt , replacing (V8 engine) 020-3 8
BASIC SERVIC E INFORMATIO N 020- 9 ENGINE OIL SERVIC E 020-3 9
Diagnostic trouble codes (DTCs) , accessin g . . . . 020- 9 Engine oil , checkin g leve l 020-3 9
Non-reusable fastener s 020- 9 Engine oil and filter, changing (6-cylinder ) 020-4 1
Tightening fastener s 020-1 0 Engine oil and filter, changing (V8) 020-4 2
Buying part s 020-1 0 FUEL FILTE R 020-4 3
Service 020-1 1
Tools 020-1 2
POWER STEERIN G FLUI D SERVIC E 020-4 3
Power steering fluid, checking level 020-4 3
IDENTIFICATION PLATE S AN D LABELS . . . . 020-12
SPARK PLU G SERVICE 020-4 4
RAISING VEHICL E 020-1 4 Spark plugs , replacin g 020-4 4
Raising vehicle safely using floor jack 020-1 4
Raising vehicl e using hydraulic lif t 020-1 4
OTHER MECHANICA L MAINTENANC E 020-4 5
Working unde r vehicle safely 020-1 5 Differential oi l level, checking 020-4 6
Drive axle joint (CV joint) boots, inspecting 020-4 7
EMERGENCIES 020-1 5 Exhaust system, inspecting 020-4 7
Indicator and warning light s 020-1 6 Fuel tank and fuel lines, inspecting 020-4 7
Flat tire indication 020-1 6 Idle speed 020-4 7
Jump starting 020-1 7 Oxygen sensors 020-4 8
Tire change 020-1 7 Suspension and steering, inspecting 020-4 8
Towing 020-1 8 Tires, checking inflatio n pressure 020-4 8
ENGINE COMPARTMEN T 020-1 9 Tires, rotating 020-4 8
Engine compartment inspectio n 020-1 9 Transmission service 020-4 8
M54 engine compartment 020-1 9 Wheels, alignin g 020-4 9
N52 engine compartmen t 020-2 0 BODY AN D INTERIO R MAINTENANC E 020-4 9
N62 engine compartmen t 020-2 0 Body, hinges, locks , lubricating 020-4 9
Engine uppe r covers (M5 4 engine) , removin g . . . 020-21 Exterior washing 020-4 9
Engine upper cove r (N5 2 / N54 engines), Interior care 020-5 0
removing 020-2 2 Leather upholster y and trim 020-5 0
Engine uppe r cover s (N62 / N62TU engines), Seat belt s 020-5 0
removing 020-2 2 Special cleanin g 020-5 0
Engine lower covers (splash shields), removing . 020-23 Underbody visua l inspection 020-5 1
AIR FILTE R SERVIC E 020-2 4 Washing chassis 020-5 1
Air filte r element, replacing (6-cylinde r engines) . 020-2 4 Waxing 020-5 1
Air filter element, replacing (V8 engines) 020-2 4 Windshield wiper blade maintenanc e 020-5 1
BATTERY SERVIC E 020-2 5 CHECK CONTRO L 020-5 2
Access to battery 020-2 5
Battery, checking 020-2 6 TABLES
BRAKE SERVIC E 020-2 6 a. CBS prompted service 020- 7
Brake fluid level, checking 020-2 6 b. Additional services 020- 8
Brake pa d and rotor wear, checkin g 020-2 7 c. Engine oil service 020- 8
Parking brake, checking 020-2 8 d. Vehicle check 020- 8
e. General bolt tightening torques in Nm 020-1 0
CABIN AIR MICROFILTE R 020-2 8 f. Engin e oil capacity (6-cylinder) 020-4 1
Cabin air microfilter, replacing 020-2 8 g. Engine oil capacity (V8) 020-4 3
Cabin air microfilter housing, removing 020-2 9 h. Spark plugs (100k change interval) 020-4 4
COOLING SYSTE M SERVIC E 020-3 0
Coolant level, checking 020-3 0
020-2 Maintenanc e
Warnings, Cautions and Notes

GENERAL
This repair group detail s service an d maintenance procedures for
the 2004 throug h 201 0 BM W 5 series (E6 0 and E61) .

BMW 5 Series vehicles ar e equipped with condition base d servic e

(CBS) capabilities that monitors many vehicl e system s an d
components an d suggests servic e based on the actual curren t
condition of components. Following the CBS recommended service
intervals helps ensure safe and dependable operation of the vehicle.

Aside from keeping your vehicle i n the bes t possibl e condition,

proper maintenance plays a role in maintaining ful l protection under
BMW's new-vehicle warrant y coverage . If in doubt about the term s
and conditions o f your vehicle' s warranty, an authorized BMW
dealer shoul d be able t o explain them.

BMW i s constantly updating thei r recommended maintenanc e

procedures and requirements. The information contained here may
not include updates or revisions made by BMW since the publication
of the documents supplie d wit h the vehicle . I f there i s any doubt
about wha t procedures apply to a specific mode l or model year, or
what interval s to follow, consult an authorized BMW dealer.

Warnings, Cautions an d Note s

Throughout thi s manual , ther e are numerous paragraph s with the
headings WARNING , CAUTION o r NOTE. Thes e heading s have
different meanings .

WARNING —
• Text under this heading warns of unsafe practices that are very
likely to cause injury, either by direct threat to the person(s)
doing the work or by increased risk of accident or mechanical
failure while driving.

CAUTION—
• Text under this heading calls attention to important precautions
to be observed during the repair work to help prevent
accidentally damaging the vehicle or its parts.

NOTE—
• A note contains information, tips, or pointers which help in doing a
better job and completing it more easily.

Read WARNING, CAUTION and NOTE heading s befor e you begin

repair work. See also 001 Warnings an d Cautions.
 Maintenance 020- 3
CBS basics

CONDITION BASED SERVICE (CBS)

CBS basics
The BMW maintenance system, called condition based service
(CBS) notifie s the driver of needed service based on the condition of
monitored components. In other words, CBS recommends
maintenance onl y for components tha t are worn.

CBS uses sensors and special algorithms to monitor vehicle drivin g

conditions, the n uses this data to calculate current and future
service requirements.

CBS tasks that are monitored are displayed in the instrument cluster
or the central control display. The display shows remaining times or
distances for the following maintenance tasks .
• Engine oi l and filter change
• Fron t brake pads replacement
• Rear brake pads replacemen t
• Brake fluid change
• Cabin microfilte r replacement*
• Spar k plug replacement*
• Vehicle check
• State / emissions inspections .
Service requirements * <• >
*The CB S instrument cluster display intervals fo r spark plugs an d
< Statu s >
cabin microfilter were discontinued as of 2008 models. These items
State inspection ~ still require periodic replacement. See maintenance tables in this
repair group.
Emission inspect.
Vehicle check CBS sorts service requirements accordin g t o date due and notifies
Rear brake pads the driver when the vehicle needs a service appointment. Mandatory
47000 mis emissions and safety inspection due dates may also be stored and
ront brake ad s displayed.
90.9 FM T! 12: 1 5pm
NOTE—
• Additional maintenance recommended by BMW is listed in
Table b and Table d , i n this repair group.

Service requiremen t information is stored in the remot e key while

Remote with integrated key
the vehicle i s driven. Thi s information can be accessed b y an
(2006 and later models) authorized BMW device center at the time of a service appointment .

For CBS to work correctly, make sure correct local date and time are
set in vehicle memory.

BentieyPublishers
.com B51002010001
020-4 Maintenanc e
Service recognition

Service recognitio n
The CBS system recognizes when a service is required using one of
the following three methods:

Adaptive. Sensor data and algorithms ar e use d to determine Yne

required maintenance interva l for a service based on individual user
driving style . Examples :
• Oil change interval is determined by engine oi l condition sensor
(OZS) monitorin g oil condition, oil level, and oil temperature; and
from additional algorithms using these parameters: engine load,
fuel consumption, tim e an d distance sinc e the last oil change.
• Fron t and rear brake pad replacement interval s ar e determined
from two-stage brake lining wear sensors on left front and right rear
brake pads; an d from algorithms usin g these input parameters:
travel distance, wheel speed, brakin g pressure, braking time, and
braking frequency .

Fixed time (months) determines the require d maintenanc e o f the

following:
• Brake fluid change
• Mandated safety and emissions inspection s

Fixed distance (miles) determines the required maintenance of the

following:
• Spark plug replacement (dependen t on engine)
• Air filter elemen t replacement
• Automatic transmissio n flui d change
• Microfilter replacemen t (dependent o n vehicle mode l and CBS
version)
• Oxygen sensor s replacemen t
• Vehicle check

CBS items, viewin g

The instrument cluste r contro l modul e communicates servic e
requirements t o the central dashboar d display where data can be
displayed with graphics an d text.

NOTE—
• This procedure is for 2004 - 2009 5 series cars with CID (central
information display). Procedure may vary slightly on 2010 and later
models fitted the high-definition CIC (car information computer)
system and multi-button iDrive controller.

— Switc h ignition ON .

^ Onc e main screen appears, press down on iDrive controller (arrow)

to select Inf o sources I Settings menu .

NOTE—
• Press menu button anytime to return to initial menu.
 Maintenance 020- 5
CBS items, viewing

Turn iDriv e controller to select Service.

Display of f
Display settings
Entertainment settings
Vehicle setting s
Service
Communication settings

A. Faste n safety belt s

B510020006

Service requirements » Turn iDriv e controller to select maintenance items .

• Servic e items highlighte d in green: No service currentl y require d
< Statu s >
• Servic e items highlighted i n yellow: Service deadline i s approaching
A Engin e oil • Servic e items highlighte d i n red: Service deadline ha s passe d
Hi Brake fluid
OK Stat e inspectio n
OK Emissio n inspect.
-130 mis OK Vehicle chec k

Press down on controller to access additional informatio n for eac h

listed task.

-130 mis Example: Selec t Engine oi l then press down controller to enter
Engine oi l screen. Here you can see engine oi l service i s overdue
by 13 0 miles .
Engine oil
Service overdue !
{ Pleas e make a n appointmen t wit h
| yonr BM W cente r as soon as possible!

Push forward (1), then dow n (2 ) on controller to retur n to Servic e

Info menu .
020-6 Maintenanc e
CSS items, resetting

CBS items , resetting

After carrying out maintenance tasks, e.g . changing engine oil, rese t
CBS item to its full service interval. This can be done using the BMW
factory scan tool, or manually using the instrument cluster set / reset
button as described below.

— Ente r vehicle and close all doors.

— Switc h ignitio n ON, bu t do not start engine .

• Mak e sure lower displays in cluster shows cloc k and mileage.

^C Pres s and hold instrument cluste r se t / reset butto n fo r 10 seconds

(arrow) to enter CBS rese t mode .
• Lowe r LCD display: Remainin g driving distance an d date of next
scheduled servic e shown. Servic e requirement s ar e displayed i n
order of priority.
• Q indicates that Check Control messages are stored. See Check
Control i n this repai r group .

— Pres s set / reset button repeatedly to scroll through CBS icons. Hold
button until RESET? appears . Press button again and hold unti l
distance / time display i n the lowe r window changes to dashes.

— T o confirm reset, press BC button while looking a t CBS rese t icon.

Acknowledgment of reset is shown wit h OK.

1. Vehicl e check. See Tabled.

2. Nex t oil change due . See Engine oil
service in this repair group.
3. Nex t safety inspectio n and road test
due.
4. Nex t emissions inspection due.
5. Nex t front brake service due. See Brake
Service in this repair group . See also
340 Brakes.
6. Nex t rear brake service due. See Brake
Service in this repair group. See also
340 Brakes.
7. Nex t brake fluid change due. See
340 Brakes.

NOTE—
• On 2004 - 2007'cars, a sparkplug icon and a cabin microlilter icon
are displayed in the CBS menu. On 2008 and later cars, these
items are deleted from the display.
 Maintenance 020- 7
Car information computer (CIC)

Car informatio n computer (CIC)

2010 models with navigation option are equipped with a new version
of iDriv e with multiple men u buttons. The displa y for this system is
known as car information computer (CIC). Functionally, system
operations ar e similar t o the earlier version .

RECOMMENDED MAINTENANC E
Table a lists maintenance services prompted by CBS .
Table b lists service and maintenance required at specified mileag e
intervals (not prompted by CBS).
Table c gives the details of an engine oi l service.

CAUTIOM—
• The publisher of this manual recommends that engine oil and
filter be replaced a intervals not exceeding 7500 miles or one
year, whichever comes first.

Table d lists other recommended periodic vehicle inspection tasks.

The number i n the "additional repair information " colum n refers to

the repai r group i n this manual wher e additional informatio n can be
found.

« I
•LI
Table a . CBS prompted servic e II!
Engine oi l service (CBS prompt s base d o n engine oi l condition. ) 020
Front brak e pads : Replace. (CBS prompt s base d on pad thickness. ) 340

Rear brake pads : Replace . (CB S prompt s based on pad thickness. ) 340
Brake fluid: Change / flush every 2 years. (CBS prompt s based on elapsed time since las t change) 340

Spark plugs : Replace . (CBS prompts based on elapsed mileage.) * 020

Cabin microfilter : Replace. (CBS prompts based on elapsed mileage.) * 020

State inspection : Emissions (CBS prompts base d o n elapsed mileage , pe r state law.)
State inspection : Safety (CB S prompt s base d o n elapsed mileage, per state law. )
Vehicle check (CB S prompt s after ever y second oil change.)
Items discontinued from CBS menu as of 2008 models.
• Spark plugs : Replace every 100,00 0 mile s
• Cabin microfilter : Replace at every engine oil service, or approximately every 15,000 miles .
020-8 Maintenanc e
Car information computer (CIC)

c
w. 2
C* ^
o *

Table b. Additional service s

Every 3rd engine oi l service o r 45,000 mile s
Air filter element : Replace. Reduc e change interval in dusty conditions . 020
Every 100,000 miles
Oxygen sensors, (N62 engine) : Replace . 180
Automatic transmission fluid (ATF): Replace. 240

Every 120,00 0 mile s

Oxygen sensors (M54, N52 , N54, N62T U engines) : Replace. 180
Note: BMW states that engine coolant, manua l transmission fluid, differential fluid and transfer case fluid are life-time fluids and do not
require replacement .

information
Additional
repair
Table c. Engine oil servic e
Engine oil and oil filter, change. See 119 Lubrication System. 020
Brief diagnosti c tests:
• Check Control : Check messages .
• Indicato r and warning lights : Sca n fo r fault codes usin g BM W scan tool or equivalent .
020
• CBS display: Reset engin e oil service interval .
• Tires: Check tread , adjust pressures.
• Tire pressure monitor: Rese t (wher e applicable, 200 6 an d later cars).
Parking brake: Check operation, adjus t a s necessary. 340
Washer fluid, top off

(D . i

Table d. Vehicle chec k

Horn, headlight flasher , hazard warnin g flasher: Check operation,
Instrument cluster and control lighting , heate r blower: Check operatio n
Lighting syste m (dome lights, glov e compartmen t light , flashlight, trunk or cargo compartment lights , turn signals , hazar d
630
warning flasher, back-up lights , brake lights , license plat e lights): Check operation .
Safety belts : Check conditio n an d function. 720

Wipers and washers: Check . 611

Body: Chec k for corrosion.

Tires: Chec k tread depth , wea r pattern , condition, inflation pressure, correct pressure as necessary.
Run-flat indicator/tir e pressure monitor : Initialize 300

Battery: Check state of charge, charge as required. 121

Power steerin g fluid : Check fluid level. 020, 32 0

 Maintenance 020- 9
Diagnostic trouble codes (DTCs), accessing

information
Additional
repair
Table d. Vehicle check (continued)
Airbags: Inspec t fo r torn covers, damage o r attached stickers. 721
Mirrors: Inspect . 510
Engine coolant : Check leve l and concentration . 020,170
Windshield washer : Intensiv e cleanin g system, check protectio n level, fluid level , top of f if necessary.
Brake system connections and lines: Check for leaks, damage an d correct positioning.
Underbody (transmission , rear axle, fuel lines, exhaust system): Check for damage, leak s and corrosion.
Steering components: Check fo r clearance, leaks , damag e and wear.
Road test: Check fo r performance , braking, steering, suspension , noises .

BASIC SERVICE INFORMATIO N

Diagnostic trouble codes (DTCs), accessin g
Diagnostic trouble codes (DTCs) tha t ar e stored in the engine
control module (ECM) or other electronic modules ma y be accessed
as follows:

Place transmission selecto r leve r i n PARK or NEUTRAL. Engag e

parking brake. Make sur e ignition i s OFF .

Connect BM W sca n tool to OBD I I plug o n left doo r post. Plu g is

behind plastic trim .

Turn ignition ke y on.

Follow sca n tool instruction s as they appear on scan too l screen .

For a listing of scan tool suppliers, see Tools in this repair group. For
additional information, see OB D On-Boar d Diagnostic s .

Non-reusable fastener s
Many fasteners used on the vehicles covered by this manua l mus t
be replaced with new ones once they are removed. These includ e
but are not limited to: bolts, nuts (self-locking, nylock, etc.), roll pins,
clips and washers. Us e genuine BM W replacement part s for this
purpose.

Some bolts, known as torque-to-yield fasteners, are designed to

stretch during assembl y an d are permanently altered, renderin g
them unreliabl e once removed . Replac e thes e wher e instructe d to
do so. Failure to replace these fasteners could cause personal injury
or vehicle damage .

Many component s on the later 6-cylinde r engines are assembled

using aluminum bolts i n order t o reduce electrochemica l corrosion.
Most aluminum bol t heads are painted blue. These fasteners also
stretch in use; replace with new during reassembly. Always use
aluminum bolts wher e specified.
020-10 Maintenanc e
Tightening fasteners

Tightening fastener s
Tighten fasteners o n a component graduall y and evenly t o avoid
misalignment o r over-stressing any on e portion o f the component.
For components sealed with gaskets, this method help s to ensure
that the gasket seals correctly.

Where ther e ar e several fasteners , tighten them i n a sequenc e

alternating betwee n opposit e sides o f the component. Repea t the
sequence until all the fasteners are evenly tightene d to the proper
specification.

For some repair s a specific tightenin g sequence is necessary, o r

particular order of assembly is required. Such special conditions are
noted in the text, and the necessar y sequence i s described or
illustrated. Where no specific torque is listed, use Table e as a
general guide for tightening fasteners.

NOTE—
• Metric bolt classes or grades are marked on the bolt head.
B001FNG I • Do not confuse wrench size with bolt diameter.
• Values in Table e are for reference only.

Table e. General bol t tightening torque s i n Nm

(max. permissible )
Bolt Class (according t o DI N 267)
Bolt diamete r 8.8 10.9 12.9
M5 6 8 10
M6 10 14 17
M8 24 34 40
M10 47 66 79
M12 82 115 140
M14 130 180 220

Buying part s
Many of the maintenance and repair task s i n this manual call for the
installation of new parts, o r the us e of new gaskets an d other
materials when reinstallin g parts. Mak e sur e the parts that are
needed are on hand before beginning th e job. Read the introductory
text and the complete procedur e to determine which parts are
needed.

For some bigger jobs, partial disassembly an d inspection is required

to determine a complete parts list. Read the procedure carefully and,
if necessary , make other arrangements t o ge t the necessary parts
while your vehicl e i s disassembled.
 Maintenance 020-1 1
Service

Genuine BM W parts
Genuine BM W replacement part s from an authorized BMW deale r
are designed an d manufactured to the same hig h standards a s the
original parts. They are the correct material, manufactured to the
same specifications, and guaranteed to fit and work as intended .
Most genuin e BM W parts carr y a limited warranty .

Many independent repair shops make a point of using genuine BMW

parts. They kno w the value of doing the job right with the right parts .
Parts from other sources may be as good as BMW parts, particularly
if manufactured by one of BMW's original equipment suppliers, but it
is often difficult t o know.

BMW is constantly updatin g and improving their vehicles, ofte n

making improvements durin g a given model year. BM W may
recommend a newer, improve d part as a replacement, and you r
authorized dealer's part s department will know about it . The BM W
parts organization is best equipped to deal with your BMW parts
needs.

Non-returnable part s
Some parts cannot be returned. The best example is electrical parts.
Buy electrical parts carefully, and be as sure a s possible tha t a
replacement is needed, especiall y for expensive part s such a s
electronic control modules. It may be wise to let an authorized BM W
dealer o r other qualified sho p confir m your diagnosis befor e
replacing a non-returnable part .

Model and model year

When ordering parts it is important that you know the correct mode l
and engine designatio n for your vehicle. This manual cover s
5 Series sedan and wagon body styles with multipl e engine variant s
in both rear wheel drive and xDrive. For information on engine codes
and engine applications, see 100 Engine-General.

Model year i s not necessarily the same as date o f manufacture or

date of sale. A 2007 model ma y have been manufacture d i n late
2006 and perhap s not sold unti l early 2008. I t is still a 2007 model.
Model year s covered by this manua l are 2006 to 2010.

Service
BMW dealers are uniquely qualified to provide service for BMW
vehicles. Their authorize d relationshi p with the larg e BM W service
organization means that they have access to special tool s and
equipment, together with the latest and most accurate repai r
information.

The BMW dealer's service technicians are highly trained and very
capable. Authorize d BMW dealers ar e committed to supporting th e
BMW product. On the other hand, there are many independen t
shops tha t provid e quality repair work. Checking with other BM W
owners for recommendation s o n service facilities i s a good wa y to
learn of reputable BM W shops i n your area .
020-12 Maintenanc e
Tools

Tools
Most maintenance can be accomplished wit h a small selectio n of
tools. Tools range in quality from inexpensive junk, which may break
at first use, to very expensive and well-made tools for the
professional. Th e best tools for most do-it-yourself BM W owners li e
somewhere i n between .

Many reputabl e tool manufacturers offer good quality, moderatel y

priced tools with a lifetime guarantee. These are your best buy. They
cost a little more, but they are good quality tools that will do what is
expected of them. Sears' Craftsman® lin e is one such source of
good quality tools.

Some of the repairs covered in this manual require the use of special
tools, such as a custom puller o r specialized electrica l test
equipment. These special tools are called out in the text and can be
purchased through an authorized BMW dealer . As an alternative,
some specialty and scan tools may be purchased from the following
tool manufacturers or distributors :

Specialty tool supplier s

Assenmacher Specialt y Samstag Sale s
Tools, Inc. 615-735-3388
800-525-2943 www.samstagsales.com
www.asttool.com
Autologic Diagnostic s (UK) Baum Tool s Unlimited , Inc.
44-1865-870050 800-848-6657
www.autologic-diagnos.co.uk www.baumtools.com
Tool Source ZDMAK Tools
888-220-8350 (877) 938-665 7
www.toolsource.com www.zdmak.com

IDENTIFICATION PLATES AND LABELS

Vehicle identification numbe r (VIN ) . This is a combination of
letters and numbers that identif y the particula r vehicle. The VIN
appears on the state registration document and on the vehicle itself.
One location is on the right front strut tower in the engin e
compartment, anothe r i n the lowe r lef t corne r o f the windshield.

For additional information, see 002 Vehicle Identification and VIN

Decoder.

Vehicle identification
number (VIN)
 Maintenance 020-1 3
Tools

Model and date of manufacture. This informatio n may be

necessary when ordering replacement parts or determining if any of
the warranty recall s are applicable to your vehicle. The VIN plate on
the driver door jamb belo w the door striker also specifies model ,
month and year the vehicle was built.

Engine code. 5 Series vehicles covered in this manual are powered

by either 6-cylinder or V8 engines. For information on engine code s
and engine applications, see 100 Engine-General .

Transmission code . The transmission type with its identifying code

may be important when buying parts such as seals or gaskets. For
information on transmission codes and applications, see
200 Transmission-General.

Tire pressures. Recommende d tire pressures as well as wheel

size, tire size, gross vehicl e weight, an d carrying capacit y are listed
on a sticker on the driver door jamb.

NOTE—
• Observe tire pressure monitor (or flat tire monitor) sticker (arrow).
On-board system should be reinitialized whenever tire pressure is
adjusted. Reinitialize FT M o r TPM. See 300 Suspension ,
Steering and Brakes-Genera l o r your owner's manual for
instructions.

Engine seria l number i s on left side of engine block behin d an d

under intake manifold. 6 cylinder engine shown.
020-14 Maintenanc e
Raising vehicle safely using floor jack

RAISING VEHICL E
Raising vehicle safel y using floor jack

WARNING —
• When raising the vehicle using a floor jack or hydraulic lift,
carefully position the jack pad to prevent damaging the vehicle
body.
• Watch the jack closely. Make sure it stays stable and does not
shift or tilt.

For safety and to avoid damaging vehicle, us e jack only at four

jacking pad s (arrows) just behind front wheels and just in front of
rear wheels. Jack pad locations are marked by small molded arrow s
on rocker panel cover.

CAUTION—
• Check to make sure the hard rubberized jack pads have not
fallen off the vehicle. Do not jack the car up if the pad is missing.
Damage to the vehicle may result.

— Par k vehicle o n flat, level surface .

— I f changing a tire, loose n lu g bolt s befor e raising vehicle. Se e

Changing a tire in this repair group.

— Us e wheel chocks to block wheel that i s opposite and farthest from

jack to prevent vehicle fro m unexpectedl y rolling.

WARNING —
• Do not rely on the transmission or the parking brake to keep the
vehicle from rolling. They are not a substitute for positively
blocking the opposite wheel.

Place floor jack into position, making sure base o f jack is resting on
flat, solid surface. Us e a board o r other suppor t t o provide a firm
surface for jack, if necessary.

Raise vehicle slowly while constantly checking position of jack an d

vehicle.

Raising vehicle usin g hydrauli c lif t

Place lifting pads unde r jacking pads (arrows ) just behind front
wheels an d just in front of rear wheels. Rais e vehicl e carefully ,
checking to make sure that i t is solidly balance d o n lift .
 Maintenance 020-1 5
Working under vehicle safely

Working under vehicle safely

WARNING —
• A jack is a temporary lifting device. Do not use a jack alone to
support the vehicle while you are under it.
• Do not work under a lifted vehicle unless it is solidly supported
on jack stands that are intended for that purpose.
• Do not use wood, concrete blocks or bricks to support a vehicle.
Wood may split. Blocks and bricks, while strong, are not
designed for that kind of load and may break or col/apse.
• Use care when removing major (heavy) components from one
end of the vehicle. The sudden change in weight and balance
can cause vehicle to tip off the lift or jack stands.
• Do not support vehicle at engine oil pan, transmission, fuel
tank, or on front or rear axle. Serious damage may result.

Disconnect negative (-) cable from battery so that vehicle cannot be

started. Le t others know what you are doing .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given i n 001 Warnings and Cautions
Jack stands
Raise vehicle slowly. See Raising vehicle safely using floor jack
in this repair group .

Use at least two jack stand s to support vehicle . Use jack stand s
designed for the purpos e o f supporting a vehicle.

Place jack stands o n firm, solid surface. If necessary, us e a flat

board or similar solid object to provide a firm footing.

Lower vehicle slowly until its weight is fully supported by jack stands.
Watch t o make sure that the jack stand s do not tip or lean as the
vehicle settles on them.

Observe jacking precautions agai n when raisin g vehicl e t o remov e

jack stands .
0024408

EMERGENCIES
The following i s a list of emergency procedure s and where they are
covered in this manual :
• Flat tire warning. See Flat tire indicatio n in this repai r group .
• Fuel flap manual release. See 515 Central Locking and Anti-
theft.
• Jump start . See Jump startin g in this repair group.
• Sunroof manua l closing. See 540 Sunroof.
• Trunk emergenc y opening . Se e 412 Trunk, Tailgate.
• Tire change. Se e Tire chang e i n this repair group.
• Towing. See Towing i n this repair group.
020-16 Maintenanc e
Indicator and warning lights

Indicator an d warning light s

Many vehicle systems ar e self-monitored for faults while driving .
Generally, a red warning light that illuminates while driving should be
considered serious. I f you cannot immediately determine th e
seriousness of the warning light, stop the vehicle i n a safe place and
switch engine OFF as soon as possible. Consult the owner's manua l
for additional information on the warning light and the recommended
action.

If the malfunction indicato r light (MIL) (Servic e Engin e Soo n warnin g

light) come s on or flashes, it generally indicate s a n emissions -
related fault in the engine managemen t system . Fault s suc h as a
bad oxygen sensor or a faulty fuel injecto r can cause exhaust or
evaporative emissions to exceed a specified limit . When these limits
are exceeded, the MIL illuminates. The engine ca n be safely driven
with the ligh t on, but the faults should b e interrogated with a scan
tool as soon as possible. See OBD On-Board Diagnostics for
more information on the MI L and the on-boar d diagnosti c system.

Flat tire indication

Tire air pressure is automatically checked by either the flat tire
monitor (FTM) system or the tire pressure monitoring (TPM) system,
depending o n model year and equipment installed .

The FT M system uses ABS wheel speed s sensor s to calculate tire

pressure. TPM system use s electronics i n wheels to measure tire
pressure.

If a flat tire or substantial loss of tire pressure is detected, warning

lights in yellow and red illuminate i n the instrument cluster and a tire
failure message appear s i n Check Contro l an d the center
dashboard display. In addition, a n acoustic signa l sounds.

WARNING —
• In case of run-on flat tire failure, drive cautiously and do not
exceed a speed of 50 mph or 80 km/h. With tire pressure loss,
vehicle handling changes. This includes reduced tracking
stability in braking, extended braking distance and altered
steering characteristics.
• If unusual vibration or loud noises occur while driving on a
damaged tire, this may be an indication that the tire has failed
completely. Reduce speed and pull over as soon as possible at
a suitable location. Otherwise parts of the tire could come
loose, resulting in an accident. Do not continue driving.

Avoid sudden brakin g an d steering maneuvers . A t the next

opportunity, check air pressure in all four tires. Tir e pressur e
specifications ar e given on a sticker o n the driver doo r jamb .

If all four tires are inflated to the correct pressures , reinitializ e FTM
or TPM. Initializatio n is covered in 300 Suspension, Steerin g an d
Brakes-General.

If warning light s illuminate in yellow an d a tire failure messag e

appears in Check Control, FTM or TPM has a malfunction. Have the
system checked as soon as possible.
 Maintenance 020-1 7
Jump starting

Jump starting
Jump start the vehicle with a discharged or dead battery usin g the
good batter y from another vehicle. See owner's manual fo r proper
instruction on jump starting.

Attach jumper cables to engine compartment B+ terminal (flip cover

Battery B + down t o access) and ground lug.
erminal cover
WARNING —
• Do not jump-start the engine if you suspect that the battery is
frozen. Trapped gas may explode. Allow the battery to thaw first.

CAUTION—
• To avoid damage to vehicle electronics, make sure the 12V
battery on the car giving assistance is approximately the same
capacitance (in Amp-hours) as the dead battery in your
5 Series. This information can be found on the battery.
• Do not quick-charge the battery (for boost starting) for longer
than one minute, and do not exceed 16.5 volts at the battery
with the boosting cables attached. Wait at least one minute
before boosting the battery a second time.

Tire change
The following details a procedure for changing a tire using floor jack
and hand tools. See owner's manual for instructions on using th e
vehicle-supplied jack.

NOTE—
• On vehicles equipped with run-on flat tires, there is no need to
change a wheel immediately in case of a puncture. See owner's
manual for safe driving speed and distance for a run-flat tire with
no air pressure.
• On cars with run-on flat tires, there is no spare tire or tire changing
tools.

— Choc k wheel diagonally opposite to the one bein g changed .

WARNING —
• Do not rely on the transmission or the parking brake to keep the
vehicle from rolling. They are not a substitute for positively
blocking the opposite wheel.

Loosen lug bolts while vehicl e is on ground, but leave them a little
snug.

Place jack under jacking point nearest wheel being changed. Us e a

board to provide a firm footing for jack if ground is soft. Raise vehicle
only far enough so that the wheel is fully off ground and then remove
lug bolts and wheel.

Install ne w wheel. Instal l lu g bolts and tighten hand-tight using lug

wrench.
020-18 Maintenanc e
Towing

Lower vehicle. With all wheels on ground, full y tighten lug bolts i n a
crisscross pattern. Chec k inflatio n pressure o f newly installed tire.

Tightening torque
Wheel t o wheel hub 120± 10Nm
(89 ± 7 ft-lb)

B001FNQ

Towing
The safest technique fo r towing vehicles covered b y this manua l
(rear wheel drive or xDrive, manual o r automatic transmission ) is by
using flat bed equipment .

WARNING—
• Do not tow with rear wheel lifted and front wheels on the
ground. There is no steering lock on some vehicles. Vehicle
may self-steer and sway dangerously from side to side.

CAUTION—
• Rear wheel drive: Do not tow with sling-type equipment. Use a
lift bar. Do not use tow hook to tow faster than 30 mph (50 kph)
or for a distance greater than 95 miles (150 km).
• Rear wheel drive with automatic transmission: Automatic
transmission fluid (ATF) does not circulate when the vehicle is
on rear wheels. Severe transmission damage may result. Use
flat bed equipment.
• xDrive: Do not tow with front or rear axle raised individually. Do
not use tow hook or cable except for very short distances to
winch it to a safe place. Use flat bed equipment.
• Winch or tow vehicle with transmission lever in N (neutral).

To access front threaded towing eye socket, press on lower edge of

cover (arrow ) o n front bumpe r unti l cover disengages .

To access rea r threaded towing eye socket, press on lower edge of

cover (arrow) on rear bumper unti l cove r disengages .

— Remov e towing eye from cargo compartment too l kit and fully screw
into threaded hole i n bumper until tight.

— Us e towing eye for winchin g vehicl e on flat bed .

BentleyPubfishers
 Maintenance 020-1 9
Engine compartment inspection

ENGINE COMPARTMEN T
Engine compartment inspection
Remove upper an d lower engine cover s as required an d chec k
engine compartment fo r signs of fluid leaks. Flui d leak s attrac t dust
making them easier to spot. Expensiv e repair s can be avoided by
prompt repai r of minor flui d leaks.

Working from below, visually inspect for oil and ATF leaks at engin e
and transmission. Also inspect cooling, fuel, heating and air -
conditioning system s for leakage. Visually inspect hoses and hos e
connections for leaks, worn areas , porosit y an d brittleness.

Check tha t fluid levels are between MI N and MAX marks.

The following illustrations show representative engine compartment

layouts. There may be minor differences among model years, such as
engine cover configuration.

M54 engine compartment

1. Hoo d alarm switch
2. Stru t tower brac e
3. Cabi n microfilter, right (under cover)
4. A/ C refrigerant port
5. Oi l filler cap
6. Engin e oil dipstick
7. Batter y B + junction
8. Brak e fluid reservoir
(under cabin microfilter housing)
9. Powe r steering fluid reservoir
10. Ground lug
11. ABS / DSC control modul e
12. Coolant reservoi r cap
13. Intake VANOS solenoid
14. Oil filter housin g
15. Alternator (Generator)
16. Mass air flow sensor
17. Windshield washer reservoir cap
18. Intake air filter housing
020-20 Maintenanc e
N52 engine compartment

N52 engine compartmen t

1. Hoo d alarm switch
2. Stru t tower brace
3. Cabi n microfilter, righ t (under cover)
4. A/ C refrigerant port
5. Oi l filler cap
6. Batter y B+ junction
7. Brak e fluid reservoir
(under cabin microfilter housing)
8. Powe r steering fluid reservoir
9. Groun d lug
10. ABS / DSC control modul e
11. Coolant reservoir cap
12. Valvetronic motor (under cover)
13. Oil filter housing
14. Engine oi l cooler
15. Alternator (Generator )
16. Mass air flow sensor
17. Windshield washer reservoir cap
18. Intake air filter housing

N62 engine compartmen t

1. Stru t tower brac e

2. Hoo d alarm switch
3. Powe r steering fluid reservoir
4. A/ C refrigerant port
5. Cabi n microfilter, right (under cover )
6. Valvetroni c motor , right (under cover )
7. Valvetroni c motor, left (under cover)
8. Batter y B+junction
9. Brak e fluid reservoir
(under cabin microfilter housing)
10. Ground lug
11. ABS / DSC control module
12. Coolant reservoi r ca p
13. Oil filler cap
14. Mass air flow sensor
15. Windshield washer reservoir cap
16. Intake air filter housing
 Maintenance 020-2 1
Engine upper covers (M54 engine), removing

Engine upper covers (M54 engine) , removing

Open engin e hood .

Remove cabi n microfilte r housings . Se e Cabin microfilte r

housing, removing in this repair group.

Unfasten wire harness duc t from strut tower brace :

• Uncli p front of wiring harness cover and slide u p and off.
• Remov e rivet s (lef t and right side) holdin g cabl e ducting to strut
tower brace an d uncli p ductin g from brace .

Remove cove r above fuel injectors :

• Remov e plasti c tri m covers (arrows).
• Remov e cover hold down bolts beneath covers and remove cover.

Remove cove r above ignitio n coils :

• Remov e oil filter cap (A).
• Remov e plasti c tri m covers (arrows) .
• Remov e cover hold dow n bolt s beneath covers and remove cover .
• Reinstal l oil filler cap to cylinder hea d cover.
020-22 Maintenanc e
Engine upper cover (N52 / N54 engines), removing

Engine upper cover (N52 / N54 engines),

removing
— Ope n engin e hood .

— Remov e cabin microfilte r housings. Se e Cabi n microfilte r

housing, removin g in this repai r group .

^ Unfaste n wire harness duc t from strut tower brace:

• Unclip front of wiring harnes s cover an d slide up and off (inset) .
• Remov e rivet s (arrows) holding cabl e ducting to strut tower brace
and unclip ducting from brace.

Remove cove r fastener s (arrows ) an d lift u p cover.

• N5 2 engine with metallic cover shown, N52 K an d N54 engines
similar.

Engine upper cover s (N6 2 / N62TU engines),

removing
N62 engine: Remov e cover fasteners (arrows) and lif t off upper
cover.
 Maintenance 020-2 3
Engine lower covers (splash shields), removing

N62 TU engine: Remove cover fasteners (arrows) and lif t off upper
cover.

Unclip side cover from grommets on valve cover and remove. When
installing, make sure pin s on cover fully engage grommets i n valve
cover (arrows) . If necessary, use a small amoun t o f lubricant t o
ease installation .

Engine lowe r covers (splash shields) ,

removing
Engine splash shield: Unscrew fasteners (arrows) and lower rear of
cover and pull out of bumper cover.

Transmission splas h shield : Unscrew fasteners (arrows). Rotate

cover around lu g to remove.
020-24 Maintenanc e
Air filter element, replacing (6-cylinder engines)

AIR FILTE R SERVIC E

Air filter element, replacin g
(6-cylinder engines )
M54 / N52 engines:
• Disconnec t connector from mass ai r flow sensor (A) .
• Loose n hos e clamp (B ) at mass air flow sensor an d disconnect
intake pip e from air cleaner housing.
• Uncli p sprin g clamps (C) .
• Lif t off upper sectio n of air filter housing .
• Lif t out air filter element an d discard.
• Thoroughly clean filte r housing an d install ne w element.
• Installation is reverse of removal

N54engines:
• Uncli p spring clamps (arrows).
• Lif t off upper section of air filter housing .
• Lif t out air filter elemen t an d discard .
• Thoroughly clea n filter housing an d install ne w element.
• Installatio n is reverse of removal

Air filter element, replacin g (V 8 engines )

N62 / N62 TU engines :
• Uncli p spring clamps (arrows) .
• Carefull y lif t up upper section of air filter housin g and lift out air filter
element and discard .
• Thoroughly clea n filter housing an d install new element.
• Installatio n is reverse of remova l
 Maintenance 020-2 5
Access to battery

BATTERY SERVIC E
Battery remova l i s described i n 121 Battery, Starter, Alternator.

Be sure to reinitialize electrical systems and reset vehicle readines s

anytime the battery i s disconnected. See 121 Battery, Starter ,
Alternator.

Access t o batter y
The batter y is in right rear of trunk or cargo compartment .

Working in trunk, twist plastic fasteners 90° in right side pane l and
remove fasteners (arrows). Rais e floor mat together wit h cover
beneath it. Pull panel ou t from lower right corner.

Battery access is similar on Sports Wagon models . Remov e cargo

compartment floo r panel. See 513 Interior Trim. Afte r removing
right sid e panel, remove scre w (arrow) securing plasti c storag e
shelf (A) . Remove plastic storage shelf fastener s (inset) an d
remove plasti c storage shelf.

Battery terminals ar e fitted with battery safet y terminal (BST ) an d

intelligent battery sensor (IBS).

WARNING —
• The BST is and explosive device. Handle with care. Do not pry
on the BST to remove the battery terminal.
• Batteries give off explosive hydrogen gas during charging.
Keep sparks, lighted matches and open flame away from the
top of the battery.
Battery safet y Intelligent • Battery acid (electrolyte) can cause severe burns. Flush
terminal (BST ) battery
sensor (IB S contact area with water, then seek medical attention.

CAUTION—
• The IBS is a delicate electronic device handle gently. Do not pry
on the IBS to remove the battery terminal.
• The battery is held in place by a hold-down bracket and bolt. A
secure battery hold-down is important in order to prevent
vibrations and road shock from damaging the battery.
020-26 Maintenanc e
Battery, checking

Battery, checkin g
The original equipment BM W battery i s equipped with built-i n
hydrometer "magi c eye" .

Battery condition is determined by magic eye color :

• Green : Adequate charg e
• Black : Inadequat e charge , recharg e
• Yellow: Defectiv e battery, replac e

See 12 1 Battery , Starter, Alternator for additional topics:

• Batter y removal and installation
• Replacemen t batter y registratio n
• Batter y reconnection notes

CAUTION—
• Do not charge battery with conventional charger. Use vehicle
power supply device for recharging.

BRAKE SERVICE
Routine maintenance o f the brak e system include s checkin g brake
pads for wear, checking parking brake function, and inspecting the
system fo r fluid leaks o r other damage :
• Chec k that brake hoses ar e correctly routed t o avoid chafing or
kinking.
• Inspec t union s an d brake caliper s for signs o f fluid leaks.
• Inspec t rigi d lines for corrosion, dents, o r other damage .
• Inspec t flexible hoses for cracking.
• Replac e faulty hoses or lines.

WARNING —
• Incorrect installation or overtightening of hoses, lines and
unions may cause chafing or leakage. This can lead to partial
or complete brake system failure.

Note that brak e fluid level and brak e pa d thickness are monitored
and replacement interval s recommende d by condition base d
service (CBS) system. Se e Condition Base d Servic e (CBS) in this
repair group .

Brake fluid level, checkin g

The brake fluid reservoir is located on the driver's side near the base
of th e windshield underneat h th e cabi n microfilte r housing.

WARNING —
• Brake fluid is poisonous. Do not ingest. Wash thoroughly with
soap and water if it comes into contact with skin.

Working in engine bay , remov e left (driver's side) cabin microfilte r

housing to access brak e fluid reservoir. See Cabin ai r microfilter
housing, removin g i n this repai r group .
 Maintenance 020-2 7
Brake pad and rotor wear, checking

CAUTION—
• Use only new, previously unopened brake fluid conforming to
DOT 4.
• Do not let brake fluid come in contact with paint. Wash
immediately with soap and water.
• Brake fluid absorbs moisture from the air. Store in an airtight
container,
• Do not use DOT 5 (silicone) brake fluid.
• Do not fill brake fluid above MAX in fluid reservoir.
• Do not mix mineral oil products such as gasoline or engine oil
with brake fluid. Mineral oil damages rubber seals in the brake
system.
• Dispose of brake fluid as a hazardous waste.

Check that fluid level is between MIN and MA X mark s molde d o n

brake fluid reservoir. Fluid level drops slightly as brake pad material
wears.

Brake fluid applicatio n

BMW preferred fluid Low viscosity DOT 4 brake fluid
Low viscosity DOT 4 brake fluid may be used in all E60 vehicles.
DOT 4 and low viscosity DOT 4 brake fluid can be mixed.

Brake fluid absorbs moisture easily. This affects brake performance

and reliability. To eliminate moisture , BMW recommends replacin g
the brake fluid every two years. When replacin g o r adding brak e
fluid, us e only ne w fluid from previously unopened containers . D o
not use brake fluid that has been ble d from the system , even if it is
brand new .

See 340 Brakes for brake fluid flushing and bleeding .

Brake pa d and roto r wear , checking

Disc brake s are fitted at all four wheels. Although th e brakes ar e
equipped with a brake pa d warning system , th e system onl y
monitors on e wheel pe r axle. Check brak e pad thickness wheneve r
wheels ar e off or brake wor k i s being done .

Disc brak e pad wear can b e checked through opening i n caliper:

• Remov e road wheel
• Measur e distance (A ) of brake pad "ear" to brake rotor . Compare
to specification below.

Brake pad lining minimu m thicknes s

Dimension A 3.0 m m (0.12 in)

Unbolt caliper from caliper carrie r to properly inspect. See

340 Brakes for additional technique s fo r checking brakes and for
brake pad, roto r and caliper replacement procedures .
020-28 Maintenanc e
Parking brake, checking

Parking brake, checking

The parkin g brak e system is independent o f the mai n brakin g
system and may require periodic adjustmen t depending on use.
Adjust th e parking brake if the brake lever can be pulled up more
than 8 clicks. Check that the cable moves freely. See 340 Brakes for
parking brak e adjustment procedure .

The parking brake may lose some of its effectiveness if it is not used
frequently. This is due to rust build-up on the parking brake drum. To
remove rust , appl y the parking brake just until it begins to grip, then
pull the lever up one more sto p (click). Driv e the vehicl e
approximately 40 0 meter s (1,300 ft.) and releas e the brake .

CABIN AIR MICROFILTER

The cabin air microfilters filter out dust and pollen fro m the
passenger compartment . There ar e two filte r elements, located at
the rea r of the engin e compartment, lef t an d righ t sides.

Cabin air microfilters, replacing

Open engine hood.

Remove microfilter cover:

• Turn quick-releas e fastener (A) approx. 90 ° counterclockwise .
• Right side filter : disconnect harness connector at hood alarm
contact switch (B) .
• Pr y filter cover spring clip off cover (C).
• Remov e microfilter cover by lifting up and out of rear clips
(arrows).

Unclip filte r element fro m cover and replace .

Installation is reverse of removal. Mak e sure filter is correctly seate d

in cover prio r to installation .

Clean filter housing usin g a disinfectant wheneve r the filter is

replaced. I f necessary, remove housin g for a thorough cleaning .
See Cabin air microfilter housing, removing .
 Maintenance 020-2 9
Cabin air microfilter housing, removing

Cabin air microfilter housing, removing

Open engin e hood.

Remove cabin filter s together with covers. See Cabi n ai r filters,

replacing.

Remove cente r trim from housings. Pres s dow n o n lockin g cli p (A )

and slid e of f i n direction o f arrow.

Peel out rubbe r gutter tri m piece s from left and righ t sides .

Unclip lef t an d righ t ends an d pee l of f bulkhead weathe r stripping .

Remove housin g fastene r (arrow).

^ Workin g a t left (driver' s side ) housing , turn quick-releas e fasteners

(arrows) approx. 90 ° counterclockwise to unlock .

— Lif t ou t lef t cabi n ai r filte r housin g working from center o f engin e

compartment.

— Remov e righ t housing usin g instruction s fo r lef t housing removal .

— Installatio n i s reverse of removal . Instal l righ t (passenge r side )

housing first .
020-30 Maintenanc e
Coolant level, checking

COOLING SYSTEM SERVIC E

Antifreeze raises the boilin g point and lower s the freezing point of
coolant. BMW recommends engine coolant that is a 50 / 50 mixture
of distilled water and ethylene glycol-based antifreeze.

Routine cooling system maintenanc e consists o f maintaining the

coolant leve l and inspecting hoses .

For additional cooling system information and repai r procedures,

see 170 Radiator and Cooling System .

Coolant level, checking

WARNING —
• Allow cooling system to cool before opening or draining the
cooling system.

With engine fully cooled off, open radiator expansion tank cap. Note
that arrows on cap and tank line up when cap clicks into fully closed
position.

"^C Floa t in expansion tank indicate s coolant leve l when cold .

• When uppe r mark on float (MIN) i s level with top of filler neck,
coolant i s at minimum allowabl e level .
• When lowe r mark on float (MAX) is level with top of filler neck,
coolant i s at maximum level .

— To p of f coolan t i f necessary.

CAUTION—
• Use only BMW approved phosphate-free, nitrite-free and
am/no-free antifreeze when filling the cooling system.

Antifreeze concentration, checking

Use a coolant hydrometer to determine antifreez e concentration.

Coolant mixtur e recommendation s

Concentration Cold protectio n
50% antifreez e -35°C(-31°F)
60% antifreez e -40°C (-40°F)

Do not use a higher concentration of antifreeze than a 60% mixture,

as the hea t transfer quality o f the coolant decrease s wit h higher
antifreeze concentrations.
 Maintenance 020-3 1
Cooling system hoses, inspecting

Cooling syste m hoses , inspecting

Inspect hoses by first checking that all connections ar e tight and dry.
Coolant seepag e indicate s that either the hos e clamp i s loose, th e
hose i s damaged, o r the connectio n i s dirty or corroded. Drie d
coolant has a chalky appearance.

Check hose condition b y a visual and tactile inspection, making sur e

it i s firm and springy. Replac e hose s that exhibit conditions note d
below. (Illustratio n courtesy of Gates Rubbe r Company, Inc. )
• Leakage : Dripping , moisture, o r seepage nea r clamp s o r
connectors.

Abrasion damage Ozone damage

CAUTION—
• When installing or reinstalling coolant hoses, use clamps
specified by BMW.

• Electromechanica l degradation : Difficul t to see, bu t detectable b y

Oil damag e Heat damage squeezing hos e an d feeling for cracks, weak areas , an d voids .
• Oi l damage: Soft and spongy to touch, visible bulges an d swelling.
• Abrasion damage: Wear, abrasion, or scuffing, often due to contact
with components i n engine compartment .
• Hea t damage: Internal and external damage, generall y due to high
under hoo d temperatures or overheating. Internal hea t damage i s
often indicate d b y swelling with external damage marke d b y
hardened an d cracked areas.
• Ozon e damage : Small , paralle l cracks in outer layers , bu t without
hardening. Du e to exposure to atmospheric conditions .

— A s a preventative measure, replac e coolant hose s every 4 years.

ELECTRICAL SERVIC E
See the following repair groups for detailed informatio n on vehicle
electrics:
• 12 1 Battery, Starter, Alternator for engine electrical component s
• 600 Electrical System-General for basic electrica l
troubleshooting information
• ECL Electrical Componen t Location s for fuse, relay and control
module information
• ELE Electrical Wiring Diagram s fo r detailed electrica l
schematics.
020-32 Maintenanc e
Accessory belt, replacing (M54, N52)

ENGINE ACCESSORY BEL T SERVIC E

The accessor y bel t and pulleys transfer power from the engine
crankshaft to the alternator, A/C compressor an d powe r steering
pump. Not e that engine cooling fan i s electric. On 2006 an d later
6-cylinder engines, the coolant pump is also electric.

Inspect belt with engine OFF. I f belt shows signs of wear, cracking,
glazing, or missing sections, replac e immediately . To reduce the
chance o f belt failure while driving, replac e belt every four years.

When the bel t is replaced with a new one, stor e the old one in the
trunk for emergency use .

If accessory belt, power steering pump pulley or front axle carrier are
found to be damaged, replac e these part s as well as the left engine
mount with updated parts .

CAUTION—
• To avoid electrochemical corrosion to engine components
made of aluminum-magnesium alloy, do not use steel
fasteners. Use aluminum fasteners only.
• For reliable identification, test fasteners for aluminum
composition with magnet.
• Replace aluminum bolts each time they are loosened.
• Follow torque instructions, including angle of rotation
specifications, when installing aluminum fasteners.

Accessory belt , replacin g (M54 , N52 )

If plannin g to reinstal l old belt, be sure to mar k direction of rotation.
If replacin g the belt , keep the ol d bel t fo r emergenc y use .

— Ope n engine hood .

— Fo r additional clearance, remove radiator cooling fan cowl with

integral fan. See 17 0 Radiato r an d Coolin g System .

— M5 4 engine: Remov e A/C compressor belt . See A/C belt,

replacing (M54 engine) i n this repai r group .

^ M5 4 engine: pry cover from tensioner .

 Maintenance 020-3 3
Use Torx socke t to rotate belt tensioner clockwis e (arrow). Thi s
releases bel t tension .

If applicable, loc k tensioner in released position usin g appropriat e

diameter pin (BMW specia l tool 11 3 340) .

WARNING —
• Observe care when working with tensioner. Personal injury
could result if tensioner springs back into position uncontrolled.

— Wor k bel t off pulleys an d remove .

M54 engine: Instal l belt usin g accompanying diagra m a s guide. If

reinstalling used belt, follow direction-of-rotation mark mad e
previously.
020-34 Maintenanc e

N52 engine: Install belt using accompanying diagram as guide. If

reinstalling use d belt , follow direction-of-rotation mark mad e
previously.
1. A/ C compressor pulle y
2. Vibratio n damper (crankshaf t pulley)
3. Tensione r pulle y
4. Powe r steering pump pulle y
5. Alternato r pulley
6. Idle r pulle y

— Releas e tensioner .

— Th e remainde r o f installation i s reverse of removal. Run engine an d

check for proper bel t installation .

Accessory belt , replacin g (N54 )

— Ope n engin e hood .

— Fo r additional clearance , remov e radiato r coolin g fan cowl with

integral fan. See 170 Radiator and Coolin g System .

— Remov e engine splash shield. Se e Engin e lowe r covers (splash

shields), removin g in this repair group .

— I f planning to reinstal l old belt , be sur e t o mar k direction of rotation.

^V Workin g at left side o f engine compartment :

• Loose n hos e clamp A and detach ai r duct from air filter housing .
• Rotat e quick-release clamp B 90° on boost pressur e duct.
Separate ai r ducts.

Working underneath radiator , unclip lin e A from clip B in direction of

arrow.
 Maintenance 020-3 5
Accessory belt, replacing (N54)

Working at top front of cylinder head , disconnect coolant hos e A

from bracke t B.

Remove air duct bracket mounting bolts (A) a t front of engine. Fol d
air duct (B ) down without disconnecting or removing .

Use Torx socket to rotate belt tensioner (A) clockwise (arrow). This
releases belt tension.

Lock tensioner in released position using appropriate diameter pi n

(BMW special tool 1 1 3 340).

WARNING —
• Observe care when working with tensioner. Personal injury
could result if tensioner springs back into position uncontrolled.

— Wor k belt off pulley s an d remove.

B309020108!
020-36 Maintenanc e
Accessory bell, replacing (V8 engines)
k Instal l belt usin g accompanyin g diagra m a s guide. If reinstalling
1 23 4 5 used belt, follow direction-of-rotation mar k mad e previously .
1. Vibratio n damper (crankshaf t pulley)
2. Tensione r pulley
3. Tensioner-idle r pulle y
4. Idle r pulle y
5. Alternato r pulley
6. Idle r pulle y
7. Powe r steering pump pulle y
8. A/ C compressor pulle y

— Releas e tensioner.

— Th e remainde r o f installation i s reverse of removal. Ru n engine an d

B309020102 check fo r proper bel t installation.

Accessory belt, replacing (V8 engines)

If planning t o reinstall old belt, be sure to mar k directio n of rotation.
If replacin g the belt , keep the ol d bel t for emergency use .

— Ope n engine hood.

— Fo r additional clearance , remov e radiato r coolin g fa n cowl with

integral fan. Se e 170 Radiator an d Cooling System .

^ Us e Torx socket (T60) to rotate belt tensioner full y clockwise

(arrow). This releases belt tension.

— Wit h tensioner i n fully released position , inser t loc k or appropriate

diameter pin (BMW specia l tool 11 3 340) int o bore i n bottom of
tensioner.

WARNING —
• Observe care when working with tensioner. Personal injury
could result if tensioner springs back into position uncontrolled.

— Wor k bel t off pulley s an d remove .

^V Instal l belt using accompanying illustratio n as a guide. If reinstalling

used belt, follow direction-of-rotation mark mad e previously .

— Releas e tensioner.

— Th e remainde r o f installation is reverse o f removal. Ru n engine and

check for proper belt installation .

Hey 1 tJti s ' • -r'^ 3

 Maintenance 020-3 7
A/C belt, replacing (M54 engine}

A/C belt, replacing (M54 engine )

Two belts are use d t o drive engin e accessories :
• Outer (front ) belt: A/ C compressor
• Inne r (rear ) belt: Alternator, coolant pump , steerin g pump

If plannin g to reinstal l old belt(s) , be sure to mar k directio n o f

rotation.

M54 engine accessor y belt s

1. Crankshaf t pulle y
2. A/ C belt tensioner
3. A/ C compresso r pulle y
4. Coolan t pump pulle y
5. Alternato r pulley
6. Accessor y bel t tensione r
7. Idle r pulle y
8. Powe r steering pum p pulle y

To remov e A/C compresso r belt :

• Us e hex head (A) or Torx socket to rotate A/C belt tensioner in
direction of arrow.
• Sli p belt off pulleys and remove belt .
• Check bel t for cracks an d coolant or oil residue. Replac e i f
necessary.

To reinstall A/C compresso r belt :

• Rotat e A/C bel t tensioner i n direction of arrow.
• Rout e belt ove r pulley s an d release tensioner .

When reinstallin g belt, check tha t i t is correctly positioned on

pulleys. I f reinstalling old belt , pa y attention t o directio n o f rotatio n
marks mad e previously .

Tightening torques
Fan clutch t o coolant pum p (left - hand thread )
• With BM W tool 1 1 5 040 30 N m (2 2 ft-lb )
• Without BM W tool 1 1 5 040 40 N m (29 ft-lb)
020-38__Maintenance
A/C belt, replacing (V8 engine)

A/C belt, replacing (V 8 engine)

Two belts are used to drive engine accessories:
• Outer (rear ) belt : Alternator, coolan t pump, steerin g pum p
• Inne r (front ) belt: A/ C compressor

- I f planning t o reinstall old belt, b e sure to mark direction of rotation

If replacing th e belt, kee p the old bel t for emergency use .

— Ope n engine hood .

- Remov e accessor y belt. See Accessor y belt , replacin g

(V8 engines) in this repair group.

- Remov e engine splash shield. Se e Engin e lowe r covers

(splash shields), removing, i n this repai r group.

> Rotat e engine at crankshaft bol t usin g socke t in direction of engine

rotation. A t the same time, pull off A/C belt (A) using clean ran (B) in
direction o f arrow.

Place belt in position and clamp bel t to pulley wit h clam p

(BMW specia l tool 64 1 040).

, Rotat e engine at crankshaft bol t usin g socke t i n direction of engine

rotation unti l A/C belt is fully seated on pulley. Remove BMW special
tool 64 1 040.

If reinstalling used belt, follow direction-of-rotation mar k mad e

previously.

CAUTION—
• If belt is contaminated with hydraulic fluid, do not reinstall.
Install new belt.

The remainder of installation is reverse o f removal. Run engine and

check for proper bel t installation.
 Maintenance 020-3 9
Engine oil, checking level

c -\ F
ENGINE OIL SERVIC E
x—

A, CAUTION—
30 -
- 80 ^
20 -
• Use BMW specified oil to top off engine between oil changes.
- 60
10 -
o
•* • Do not use engine oil additives.
40 5
to I
o
0 -— ^ I g
- 20
oj LO
BMW high performanc e synthetic oil is recommended fo r use i n the
—
-10 - 3 cars covered by this manual.

u
LO
- 0 — i
-20 - I

30 - -20 •f Engine oil specification

/ \ BMW high performanc e syntheti c API rating SM
SAE 5 W - 30 or 5W - 40 or highe r
( '*-— B309020077

Engine oil, checking leve l

2004 - 2005 models :
• Check oi l level wit h car on level surface, afte r engine has bee n
stopped fo r at leas t a few minutes.
• Pul l out dipstick an d wipe i t clean. Reinser t dipstick fully and the n
withdraw i t again .
• Oi l leve l is correct if it is between two mark s a t end o f dipstick .
• O n 6-cylinder engines , red-handle d dipstick i s at front left of
engine.

2006 - 2010 models: There i s no dipstick. Engin e oi l level and other

oil characteristics are monitored electronicall y by the oi l conditio n
sensor (OZS) an d displayed vi a the center dashboar d displa y whe n
called u p through th e iDriv e system. See 119 Engine Lubricatio n
for detai l o f OZS operation .

On 2006 an d later 6-cylinde r engines, the dipstick wa s eliminated .

2006 and later V8 engines hav e dipsticks throughout th e productio n
range, but oil level can also be checked through iDriv e check control
as described below .

Monitoring engin e oi l level electronically ensure s tha t the oil doe s

not reach critically low levels. Overfilling the engine wit h oil can
cause leaks ; a corresponding warnin g is therefore given .

2006 - 2009 model s

• Star t engine .
• Pres s down on iDrive MENU butto n to open star t menu. Selec t Info
sources.

. Pres s down on iDriv e controller, then select Service Info .

90.9 FM 4 9T l 12:12p»
020-40 Maintenanc e
Engine oil, checking level

Turn controller until Service requirement s i s selected and press

controller. Change t o upper fiel d on screen i f necessary .
• Turn controller until Engine oil level is selected and press
controller. Change t o second field on screen if necessary.
Measurement normall y takes abou t 3 minutes if the vehicle is at a
standstill on a level surface, or about 5 minutes i f the vehicl e is
underway.
• One of the following messages i s displayed
Engine oi l level O.K.
No measured valu e available: Updatin g engin e oi l level
measurement...
Engine oil level at the minimum! Refil l with 1 quart of engine oil.
Engine oil level too high. Have this checked immediately .
Please observ e recalculate d service interval for engine oil.

To check oi l level o n 2010 models :

• Start engine.

Using iDrive controller , selec t Vehicle Information through mai n

Main menu No signal
menu.
CD/Multimedia • Select Vehicle status and then select Engin e oil level.
Radio Measurement normally takes about 3 minutes if the vehicle is at a
Telephone standstill on a level surface, or about 5 minutes i f the vehicle is
underway.
Navigation
• One of the following messages i s displaye d
Contacts
Engine oil level OK
BMW Services Measurement no t possible as this time
Vehicle information Measuring engine oi l level.. .
Settings Engine oil level below minimum. Ad d 1 quart!
Engine oil level too high! Have this checked.
Measurement inactive. Hav e this checke d

If oil level is low, add oil at oil filler (arrow). Use correct viscosity an d
grade oil.
 Maintenance 020-4 1
Engine oil and filter, changing (6-cylinder)

Engine oi l and filter, changing (6-cylinder )

CAUTION—
• When changing the oil, make sure the engine oil drain plug is
started and torqued using hand-tools. Power tools can strip the
threads of the plug and the oil pan.

A complete oil change require s new oil, a new filter inser t ki t and a
new drain plu g sealin g washer . Run engine for a few minutes t o
warm engine oil . Switch engin e OFF.

^V Us e oil filter wrench to loosen and remove oil filter housing cover
(arrow). Remov e filter cartridge and discard O-ring.

— Rais e vehicle and suppor t safely .

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Working underneath engin e sump, open service door i n engine

splash shiel d (arrow ) to expose drain plug.

Place drain pan under oil drain plug. Usin g a socket or box wrench,
loosen drai n plug. Remov e plu g by hand and le t oil drain int o pan .

WARNING —
• Pull the loose plug away from the hole quickly to avoid being
scalded by hot oil. It will run out quickly when the plug is
removed. If possible, use gloves to protect your hands.

When oil flow ha s diminished t o an occasional drip , reinstal l drain

plug with a new metal sealin g washer and torque plug .

Tightening torque
Engine oi l drain plug to oil pan 25 M m (18ft-lb )

Lubricate and install new oil filter O-ring and new filter cartridge in oil
filter housin g cover . Install and tighten housing cover .

Tightening torque
Cover to oil filter housin g 25Nm(18ft-lb)

Sealing
— Refil l crankcase with oil. Oil capacity i s listed i n Table a.
O-rings
Table a. Engine oi l capacity (6-cylinder)
Engine Approx. capacity (incl.oil filter)
Filter
element 6-cylinder: M54 , N52, N5 4 6.5 liter s (6.9 US qt)

Start engin e an d check that oil pressure warning light immediatel y

goes out. Check for any leaks.
B309020064

Check for correct oil level. Se e Engine oil , checking level, i n this
repair group.
020-42 Maintenanc e
bngine oil and filter, changing (V8)

Engine oil and filter, changing (V8)

CAUTION—
• When changing th e oil, make sure th e engine oi l drain plug is
started and torqued using hand-tools. Power tools can strip the
threads of the plug and the oil pan.

On V8 engines, the oil filter is in the bottom of the engine (A) and the
engine oil drain plu g i s in the center o f the oi l pan (B).

A complete oil change require s new oil, a new filter insert kit and a
new drain plug O-ring. Run engine for a few minutes t o warm engine
oil. Switch engine OFF.

Open engine hoo d and remov e oil filler cap. Store in safe place.

Raise vehicle and support safely.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Working underneath engin e sump , ope n servic e door (arrow) in

engine splash shield to expose filter cover.

Place drain pan under oil drain plug . Us e 6mm alien wrench to
loosen drain plug (A) from oil filter cover. Remove plug by hand and
let oil drain into pan. Remove oil pan drai n plug (B ) and let oil drain
into pan.

WARNING —
• Pull the loose plug away from the hole quickly to avoid being
scalded by hot oil. It will run out quickly when the plug is
removed. Use gloves to protect your hands.

When oil flow has diminished t o an occasiona l drip , use an oil filter
wrench to loosen and remove the oil filter cover.

Remove filter cartridge and pick off and discar d larg e O-ring from
cover.

Lubricate and install ne w oil filter O-ring (B) and new filter cartridge
(C) i n oil filter housing cover. Install and tighte n cover.

Tightening torque
Oil filter cover to oil sump 25 M m (1 8 tt-lb)

— Reinstal l drain plug (A) with a new O-ring and torque plug .

Tightening torque
Engine oi l drain plug to oil pan 10 Mm (89in-lb)
 Maintenance 020-4 3
Power steering fluid, checking level

— Refil l crankcase with oil. Oil capacity is listed in Table b .

Table b . Engine oi l capacity (V8)

Engine Approx. capacity (incl. oil filter)
V8: M62 , M6 2 TU 8.0 liter s (8. 5 US qt )

Start engine and check that oil pressure warning ligh t immediatel y
goes out. Check for any leaks.

Check for correct oil level. See Engine oil , checking level , given
earlier.

FUEL FILTE R
Models covered by this manua l are equipped with a life-time fuel
filter with no specified replacement interval.

The filter i s located in left lobe of the fuel tank, integral with the fuel
level sender and fuel pressure regulator. I t is available as a
replacement par t from BMW. See 160 Fuel Tank and Fue l Pump .

POWER STEERIN G FLUI D SERVICE

Power steering fluid, checking level
The power steering system is permanently filled with either CH F or
ATF hydraulic fluid. Routinely adding fluid is not required unles s the
system i s leaking.

CAUTION—
• Power steering reservoir cap is marked with the type of fluid
being used — ATF or CHF. Do not mix.

^C T o check powe r steering fluid level in fluid reservoir:

• Par k vehicle on level ground with engine OFF.
• Leve l is correct if it is between MI N and MAX mark s o n dipstick.
• I f level i s below MIN mark, add fluid to reservoir to bring leve l up.

— Hand-tighte n reservoir cap.

See 320 Steering and Wheel Alignment for power steering system
bleeding.
020-44 Maintenanc e
Spark plugs, replacing

SPARK PLU G SERVIC E

All £60 5 Series engines use a coil-over-spark plug configuration,
with one ignition coil above each spark plug .
x'/ Turbocharged (N54 ) engin e spark plugs are particular t o that
engine. A special thin-walled 12-point spark plug socket, BM W part
no. 83 30 0 495 560, is needed for servicing these spark plugs.

Table c. Spark plugs (100k mil e change interval)

Manufacturer Bosch NGK
M54 FGR7DQP BKR6EQUP
N52 engine FR7NPP332 ILZFR6D11
N54 engine (turbo ) ZGR6STE2 not availabl e
N62 / N62T U FGR7DQP BKR6EQUP
unecK tor correct applications with authorized BMW dealer parts
department.

Spark plugs, replacing

WARNING —
• To avoid personal injury, be sure the engine is cold before
beginning work in the engine compartment.

— Remov e ignition coil covers. See Engine uppe r covers , removin g

in this repair group.

- Remov e ignition coil. See 120 Ignition System .

*\k (curved arrow) ignition coil connector. Pul

connector of f coil.

Slide rod-shape d ignition coi l straight ou t of spark plug hole.

CAUTION—
• Do not allow fuel or oil to contact the ignition coils. Fuel or oil
residue can cause a breakdown in the electrical resistance of
silicone used in production, resulting in ignition coil failure.
 Maintenance 020-4 5
Sparkplugs, replacing

Remove spark plugs :

• N52 engine: Us e thin-walled spark plug socket.
• N54 (turbo) engine : Us e special 12-poin t spark plug socket .

N52 engine: i f thin-walled spark plug socket is not available ,

carefully remov e slotted ignitio n coil sleeves from cylinder hea d
cover holes, then remov e spark plugs .

Inspect spark plug electrodes . Light grey indicates norma l

combustion.

Installation i s reverse of removal, bearing i n mind th e following:

• Lightl y lubricat e new spark plug threads wit h copper-based anti -
seize compound .
• Thread plug s int o cylinder head b y hand t o prevent cross -
threading.
• N5 2 engine: reinser t or replace slotted ignition coil sleeves, if
removed.
• Carefully insert ignition coil s i n spark plug wells and reattach
electrical connectors. B e sure to reattach all removed ground s

Tightening torque
Spark plug to cylinder hea d 23±3Nm(18±2ft-lb )
020-46 Maintenanc e
Differential oil level, checking

OTHER MECHANICA L MAINTENANC E

Differential oil level, checking
The front (if applicable) an d rear differentials are filled with lifetime oil
that ordinarily does not need to be changed. BM W recommend s
using only a specially formulated synthetic gea r oil (SAF-XO) that is
available throug h an authorized BMW dealer part s department. For
additional informatio n on this lubricant an d any other lubricants that
may be compatible, contac t an authorized BM W dealer service
department.

Front differential:
• Remov e engine splash shield. See Engine lower covers (splas h
shields), removin g in this repair group.
• Remov e front reinforcement plate. See 310 Front Suspension .
• Check oil at fill plug (arrow) .

B510311009

Rear differential: Check oil level at fill plu g (arrow).

All: Chec k lubricant leve l with vehicle level :

• Us e 1 4 mm or 1 7 mm Allen socket to remov e filler plug.
• Leve l is correct when fluid just reaches edg e of filler hole.
• I f necessary, top up fluid.
• Replac e filler plug sealing ring .
• Instal l and tighten oil filler plug when oi l level is correct.

Tightening torque
Fill / drain plug to rea r differential housing:
• Plu g with sealing O-ring (replace O-ring ) 65 Nm (4 8 ft-lb )
• Plu g without sealing O-ring (replace plug ) 60 Nm (44 ft-lb)

See also 311 Front Axle Differential or 331 Rea r Axle

Differential.
 Maintenance 020-4 7
Drive axle joint (CV joint) boots, inspecting

Drive axl e joint (C V joint) boots , inspectin g

Inspect C V joint protective boo t (arrow) for cracks an d damage. If
the rubbe r boot fails, water and dirt that enter the joint quickly
damage it .

Areas where leaks are most likely to occur are around driv e shaft
and drive axl e mountin g flanges .

CV boo t replacemen t i s covered in 331 Rea r Axle Differential.

Exhaust system , inspectin g

Exhaust system lif e varies widely according to driving habit s an d
environmental conditions. If short-distance driving predominates,
moisture and condensation in the system does not fully dry out. This
leads to early corrosion damage an d more frequent replacement .

Scheduled maintenance o f the exhaust system i s limited t o

inspection.

Check to see that hangers (arrow) ar e in place an d properl y

supporting the system an d that part s of the exhaust system do not
contact the body .

Check for restrictions due to dents or kinks.

Check fo r weakness o r perforation du e to rust .

See 180 Exhaust System.

Fuel tank an d fuel lines , inspectin g

Inspect fuel tank and fuel lines for damage or leaks .

Check for fuel leaks in engine compartment or fuel odors in

passenger compartment .

Check for evaporative emissions hose s that may have become

disconnected. Chec k carefully at charcoal canister and leakag e
diagnosis pump. Se e 130 Fuel Injectio n and 160 Fuel Tank an d
Fuel Pum p fo r component location s and additional information.

Idle spee d
Idle speed i s electronically adaptive an d no t adjustable.
020-48 Maintenanc e
Oxygen sensors

Oxygen sensors
Replacement o f oxygen sensors a t specified interval s ensures that
the engine and emission control system continue to operate as
designed. Extendin g the replacement interva l may void the emission
control warranty coverage. Oxygen senso r replacemen t i s covered
in 180 Exhaus t System .

Suspension and steering, inspectin g

Check suspension an d steering movin g part s for wear an d
excessive play. Inspect ball joint and tie-rod rubber seals an d boots
for cracks or tears that allow the entry o f dirt and water.

See also :
• 310 Front Suspension .
• 311 Fron t Axle Differential
• 320 Steering and Wheel Alignment
• 330 Rear Suspensio n
• 331 Rear Axle Differential

Tires, checking inflation pressure

Correct tire pressure s are important to handlin g an d stability, fuel
economy, and tire wear. Tire pressur e change s wit h temperature.
Check tire pressures often during seasona l temperatur e changes.

Correct inflatio n pressures can be found on driver door pillar. Note

that tire pressure specifications are higher when the vehicle i s more
heavily loaded .

WARNING —
• Do not inflate any tire to a pressure higher than maximum
inflation pressure listed on the sidewall. Use care when adding
air to warm tires. Warm tire pressures can increase as much as
4 psi (0.3 bar) over their cold pressures.

Tires, rotating
Due to the vehicle's suspension design , BMW does not recommend
tire rotation . Rotating used o r worn tires ma y adversely affect roa d
handling an d tire grip.

Transmission service
Automatic and manual transmission s ar e filled with lifetime
lubrication. N o oil change i s required fo r the entir e service life of
these transmissions. I f repairs have to be made to the transmission
or transmission oil cooler, use only the approved lifetim e lub e oil .

Transmission fluid, automatic

The automatic transmissio n i s not equipped with a dipstick .
Checking ATF level includes measurin g an d maintaining a specified
ATF temperature durin g the checking procedure .

For ATF service information, including checkin g AT F level and ATF

filter replacement procedures , see 240 Automatic Transmission .
 Maintenance 020-4 9
Wheels, aligning

Transmission fluid, manual

The manua l transmission s i s filled with a special lifetim e fluid. For
manual transmissio n fluid checking and replacement procedures ,
see 230 Manual Transmission .

Wheels, aligning
BMW recommends checking the front and rea r alignment once a
year and whenever ne w tires are installed. See 320 Steerin g an d
Wheel Alignment .

BODY AN D INTERIO R MAINTENANC E

Body, hinges, locks, lubricating
— Lubricat e door locks and lock cylinders with an oil that contains graphite.

— Lubricat e body an d door hinges, hood latch and doo r check rod s
with SAE 3 0 or SAE 40 engine oil.

— Lubricat e sea t runner s with multipurpos e grease .

— Lubricat e door weather-strips with silicone spray or talcum powder .

— Lubricat e engine hoo d releas e and hood releas e cable wit h spray
grease.

CAUTION—
• Do not apply oil to rubber parts.
• Use an absolute minimum of winter lock deicer spray. Alcohol
in deicer washes grease out of lock assemblies and may cause
locks to corrode internally or to become difficult to operate.

Exterior washing
The longe r dirt is left on the paint, the greater the ris k of damagin g
the glossy finish, either b y scratching or by the chemica l effec t dirt
particles may have on the painted surface .

Wash with a mixture of lukewarm water and vehicle was h product.

Rinse using plenty o f clear water.

Wipe body dr y with a soft cloth towel or chamois t o preven t water-

spotting.

CAUTION—
• Do not wash the vehicle in direct sunlight.
• If the engine hood is warm, allow it to cool.
• Beads of water not only leave spots when dried rapidly by the
sun or heat from the engine, but also can act as small
magnifying glasses and burn the finish.
020-50 Maintenanc e
Interior care

Interior car e
Remove dirt spots on upholstery with lukewarm soapy water or dry
foam cleaner .

Use spot remove r for grease and oil spots. D o not pour cleanin g
liquid directl y on carpet or fabric. Dampen clea n clot h an d rub
carefully, starting at edge o f the spot an d working inward .

WARNING —
• Do not use gasoline, naphtha, or other flammable substances.

Leather upholster y an d tri m

Clean leathe r upholstery and trim periodically .

Use slightly damp cotton or wool cloth to get rid of dirt in creases and
pores that can cause brittleness and prematur e aging .

On heavily soiled areas, use a mild detergent (suc h as Woolite®) or

a specially formulate d leathe r cleaner .

Dry trim and upholstery completely usin g a soft cloth. Regular use
of a good quality leather conditioner reduce s drying and cracking of
leather.

Seat belt s
Dirt and other abrasiv e particle s damag e sea t belt webbing.

To clean sea t belts , us e a mild soa p solution .

WARNING —
• Do not clean the seat belt webbing using dry cleaning
chemicals, bleach or other strong cleaning agents.
• Allow wet belts to dry before allowing them to retract.

Inspect conditio n o f belt webbing an d function of retractor

mechanisms.

Special cleanin g
Remove tar and insect spots with a bug and tar remover. Do not use
gasoline, kerosene, nail polish remover, or other unsuitable solvents .

A bit of baking soda dissolved i n the wash water facilitates removal.

This method can also b e used to remov e tree sap spots.
 Maintenance 020-5 1
Underbody visual inspection

Underbody visua l inspection

Inspect the following for leaks or damage:
• Engine
• Transmission
• Fue l system
• Cooling and heating systems
• Brake system
• Exhaus t system

A small amount o f dampness i s considered normal in some cases ,

especially around axle and pulley seals since the leaking fluid helps
the seal work properly. On the other hand, expensive repairs can be
avoided b y prompt repai r of minor fluid leaks. Judgement an d
experience are required to distinguish among the differen t kinds of
fluid leaks.

Inspect underside of vehicle for damage caused by normal wear and

tear or by driving over road debris. Whenever vehicle is raised on a
lift, inspec t underbody, wheel wells and sill or rocker panels fo r
damage t o underbody sealants and coatings. Also inspec t after
major repairs to vehicle systems.

Repair damage o r defects found. Only us e wax-based or tar-based

anti-corrosion compounds a s specified. Do not use oil-based anti -
corrosion sprays due to possible incompatibility with factory applied
protection.

Washing chassi s
Periodically wash underside o f vehicle, especially i n winter, to help
prevent accumulation o f road salt and rust.

The best time to wash the underside is just after the vehicl e ha s
been driven in wet conditions. Spray the chassis with a powerful jet
of water. Commercial or self-service vehicle washes may not be best
for this, as they may recycle the salt-contaminated water.

Waxing
For a long-lasting, protectiv e and glossy finish, apply a hard wax
after the vehicle has been washed and dried. Us e carnauba or
synthetic based products.

Waxing is not needed after every washing. You can tell when waxing
is required by looking at the finish when i t is wet. I f the wate r coat s
the paint i n smooth sheet s instead of forming beads that roll off, a
new coat of wax i s needed. D o not apply wax to black trim pieces,
rubber, or other plastic parts .

Windshield wiper blad e maintenanc e

Common problem s with windshield wipers include streaking or
sheeting, water drops after wiping, and blade chatter. Streaking i s
usually caused when wiper blades are coated with road film or
vehicle wash wax. Clean the blade s usin g soap y water. If cleaning
the blades doe s not cure the problem, replace them. BM W
recommends replacin g th e wiper blades twice a year, befor e and
after the cold season .
020-52 Maintenanc e
Check Control

Check tension spring that forces wiper against glass. Replace wiper
arm i f spring tension i s weak.

Drops that remai n behin d after wiping are caused b y oil, road film,
or diesel exhaus t coating the windshield. Us e an alcohol or
ammonia solution or a nonabrasive cleanser to clean the windshield.

Wiper blade chatte r ma y be caused by dirty or worn blades, b y a

dirty windshield, o r by bent or twisted wiper arms. Clean the blade s
and windshield a s described above . Adjus t the wiper arm so that
there is even pressure along the blade , an d s o that the blade is
perpendicular t o the windshield a t rest. Lubricate th e wiper linkage
with a light oil. Th e linkage is located under the hood on the driver's
side. I f the proble m persists , the blade s are excessively aged or
worn and should b e replaced.

Wiper blade replacemen t i s covered i n 611 Wipers an d Washers.

CHECK CONTRO L
Check Control monitors vehicle functions and alerts the driver to
malfunctions using indicator an d warning lights in a variety of colors
in the instrument cluster . In some circumstances , acousti c signals
as well as text messages ar e given .

Q indicate s that Check Contro l messages are stored.

Check Contro l
message ico n

To view Check Control messages i n central dashboar d display:

Press down iDrive controller to brings up Info sources | Settings
menu.

NOTE—
• Central dashboard display menus vary slightly on 2010 models.
 Maintenance 020-5 3
Check Control

Pull back iDriv e controller to enter middle screen , then rotat e

lnfosources> controller to Service Info .

X Pres s down controller to enter Service Info (or Service

requirements) submenu .

- Rotat e controller to Check Control messages .

Press down controlle r to enter Check Contro l messages .

 100-1

100 Engine-Genera l

GENERAL 100- 1 Intake manifold 100-1 1

Engine I D tag 100- 2 Lubrication, vacuum and
Engine applications 100- 3 cooling systems 100-1 3

M54 ENGIN E OVERVIE W 100- 4 N54 ENGIN E OVERVIE W 100-1 4

Engine introduction 100-1 4
Engine introduction 100- 4
Cylinder block and crankshaft 100- 4 Turbochargers 100-1 4
Connecting rod s and pistons 100- 4 Intercooler 100-1 4
Cylinder hea d and valvetrain 100- 4 Crankcase breathing 100-1 5
Double VANOS 100- 5 Engine oil, vacuum and fuel pump drive . . . . 100-1 5
Intake system 100- 6 N62 ENGIN E OVERVIE W 100-1 6
Exhaust manifold s 100- 6 Engine introduction 100-1 6
Cooling system 100- 7 Valvetronic principles 100-1 8
Lubrication system 100- 7 Valvetronic components 100-1 8
N52 ENGIN E OVERVIE W 100- 8 Valvetronic operation 100-1 9
Engine introduction 100- 8 Valvetronic electronic control 100-1 9
Crankcase components 100- 8 TABLE
Cylinder hea d and valvetrain 100-1 0
a. 5 Series engine applications and specifications 100- 3

GENERAL
This section covers general informatio n on engines an d engin e
components. Se e Table a for engine application informatio n an d
specifications.

For specific repai r procedures, refer to:

• 020 Maintenanc e fo r engine compartmen t views an d accessor y
belt service, oil change an d air filter service
• 11 0 Engine Remova l and Installation
• 113 Cylinder Hea d Remova l an d Installation
• 117 Camshaft Timing Chai n
• 11 9 Lubrication Syste m for lubrication system descriptio n an d
crankcase sea l service
• 12 0 Ignition Syste m fo r ignition coil, camshaft sensor, crankshaf t
sensor and knoc k sensor service
• 130,131,132,133 Fuel Injection for engine managemen t syste m
description and component replacemen t (based o n engine type )
• 17 0 Radiator and Cooling Syste m for radiator, coolant pump and
coolant service
• 18 0 Exhaust Syste m fo r exhaust manifold, oxygen senso r an d
turbocharger servic e
100-2 Engine-Genera l
General

Engine ID tag
M54 engine I D tag with engine serial numbe r i s on left side of
engine block , above engine oil pan.

B510100024

N52 and N54 engine I D tag with engine seria l number is on left side
of engin e block, underneath intak e manifold .

N62 engine ID tag with engine serial number i s on left side of engine
block, below cylinder head .
 Engine-General 100- 3
General

Engine application s

Table a. 5 Series engine applications and specifications

Displacement Bore x stroke Comp. Torque Horsepower Engine
Year, model Engine code, type cc (cid ) mm (in ) ratio Ib-ft @ rpm hp @ rp m management
2.5 liter 6-cylinder
2004 - 2005 M54B25, double VANOS 2494(152) 84x75 10.5: 1 175 @ 3500 1 84 @ 5900 Siemens DM E
525i (3.31 x2.95 ) MS 45.1
3.0 liter 6-cylinder (normally aspirated)
2004 - 2005 M54B30, double VANOS 2979(182) 84 x 89.6 10.2: 1 214 @ 3500 225 @ 5800 Siemens DM E
530i (3.31 x3.53) MS 45.1
2006 - 200 7 N52B30, 2996(183) 85.0 x 88.0 10.7: 1 185 @ 2750 215 @ 6250 Siemens
525i, 525xi VANOS, Valvetronic (3.35 x 3.46) MSV70
Sports Wagon
2006 - 2007 N52B30, 2996(183) 85.0x88.0 10.7 : 1 220 @ 2750 255 @ 6600 Siemens
530i, 530xi, VANOS, Valvetronic (3.35 x 3.46) MSV70
Sports Wago n
2008-2010 N52KB30, 2996(183) 85.0 x 88.0 10.7: 1 200 @ 2750 230 @ 6500 Siemens
528i, 528xi VANOS, Valvetronic (3.35 x 3.46) MSV80
Sports Wago n
3.0 liter 6-cylinder (turbocharged)
2008-2010 N54B30 Turbo, 2979(182) 84.0 x 89.6 10.2 : 1 300 @ 3500 300 @ 5800 Siemens
535i, 535xi VANOS (3.31 x3.53) MSD80 (u p to
535xi Sports 03/2008)
Wagon MSD81 (fro m
03/2008)
4.4 liter V8
2004 - 2005 545 i N62B44, 4398 (268) 92 x 82.7 10.0: 1 330 @ 3600 325 @ 6100 Bosch DM E
VANOS, Valvetronic (3.62 x 3.26) ME 9.2, wit h
valvetronic
control unit
4.8 liter V8
2006-20105501 N62B48TU, Valvetronic, 4799 (293) 93 x 88.3 10.5: 1 360 @ 3400 360 @ 6300 Bosch DM E
VANOS (3.66 x 3.48) ME 9. 2. 2
100-4 Engine-Genera l
M54 Engine Overview

M54 ENGIN E OVERVIEW

Engine introductio n
525i and 530i E60 and E61 (Sedan and Sports Wagon) models were
introduced in 2004 i n the North American marke t equipped wit h the
3-liter in-line 6-cylinder normally-aspirated M5 4 engine. Two levels
of performance were available :
• Low output engin e i n 525i model s
• Hig h outpu t engin e i n 530i models

Cylinder bloc k an d crankshaf t

The cylinder bloc k is cast aluminum allo y (AISi 9Cu3) with cast iron
cylinder liners. The cylinders are exposed on all sides to circulating
coolant.

Connecting rods and pistons

The forged steel connecting rod s us e replaceabl e split-shell
Top compression rin g
1.5 m m rectangular " bearings at the crankshaft end and solid bushing s at the
piston pin end. Connecting rods weight classe s are indicated by a
Center compressio n ring
1.5 mm taper fac e
color code system.

Oil scrape r rin g •~~~~ The piston s are equipped wit h three ring s with two upper
compression ring s and a lower one-piece oi l scraper ring. Full
Color code
floating piston pins are retained wit h circlips.

Graphite coating is used on piston skirts to reduce friction and noise.

B510100010a

Cylinder hea d and valvetrai n

M54 cylinder head cross section
Cooling passages i n the M5 4 cylinder head are designed for
+I 1 1 , + optimum coolant circulation, allowing th e hea d to operate at lower
temperatures than the cylinder block .

The aluminum cylinde r head use s chain-driven doubl e overhea d

camshafts and four valves per cylinder. The cylinde r hea d employ s
a crossflow design for greater power and efficiency. Intake air enters
the combustion chambe r fro m one side whil e exhaust gasse s exi t
from the other. The spark plugs are centrally located dow n th e
middle o f the cylinder head .
 Engine-General 100-5
M54 Engine Overview

Double VANOS

M54 engines ar e equipped with compact, infinitely variable vane -

VANOS
assemblies type VANOS unit s for both intake and exhaust camshafts. Th e
VANOS system (fro m the German words VAriable NOckenwe/len
Steuerung) electrohydraulicall y adjusts valve timing for enhanced
mid-range performanc e and improved emissions. VANO S is
controlled by the engine control module (ECM), using engine speed ,
engine load and engine coolant temperatur e a s the primary inputs.
Engine oi l pressure is used for powering camshaft adjustment .

B510100009a

i Engin e oi l pressure is used to position the VANOS actuators. Oil

Double VANOS components pressure is fed from the engine oil pump up to the VANOS solenoids;
oil drains bac k to the sump a s the camshafts are adjusted durin g
engine operation .

With the engine off , the base settin g of the camshafts is as follows:
• Intak e camshaft : Retarde d
• Exhaus t camshaft: Advanced
;3attery (+}
terminal 15 \ •;{"-' " c\x- j
W Js%1 1 This i s also the fail-safe position in case of an electronic control

**?*fa -, . <*-—
failure. Bot h camshafts are held in these positions by oil pressur e

^VAN-,5?aM>*A.'
- - ^ ^r : •• \
: Soteno e
from the engine oil pump. The exhaust camshaft i s held additionally
by a spring i n the VANOS actuator.
^ <9 I Engine
ECM 1L = When the engine is started, the camshafts remain in these position s
ipply B510100015 a
until the EC M detects the position s of the camshafts fro m the
camshaft sensors (approximately 50 revolutions or 2 - 5 seconds).
The engine i s equipped with static Hall-effect camshaft sensor s s o
that camshaft position s ar e recognized as soon a s the ignitio n is
switched ON, befor e the engine i s started.

Once camshaft positions are recognized , the EC M makes a n initia l

camshaft timing adjustment based on oil temperature, oil pressure
and engine rpm. Following this initial setting, engine rpm , throttl e
position signal, intak e air temperature and engine coolan t
temperature are used to adjust camshaft timing.

When th e ECM detects that the camshafts ar e in the desired

position, the solenoids ar e modulated at 10 0 - 220 Hz , maintainin g
oil pressure on both sides of the actuators to maintai n camshaf t
timing.

In addition to increasing engine power output, double VANOS offer s

the following advantages:
• Increase d torque at lower and medium rpm ranges
• Mor e efficient combustion an d improved idle quality
• Interna l EGR in part-load range for lower NOX emission s
• Quicke r warm-up cycle for catalytic converter and faster reduction
in emission s
• Overal l improve d fuel economy

See 11 7 Camshaft timing chain for Vanos system repairs.

100-6 Engine-Genera l
M54 Engine Overview

^Ramtube r-Mai n manifold Intake syste m

Low to mid-range
(< 3750 rpm)
cylinder 1 The intak e manifold , made of molded plastic , i s configured as two
intake valves sets of three runners. This design enhance s lo w end torque by
open changing the intake air flow configuration for varying engine speeds.
This helps achieve optimum torque throughout the entire rpm range.

During engine operation, a closed resonance valve gives the intake

air charge the dynamic effec t of long intak e runner s at low to mid-
range engine speeds (u p to 3750 rpm). This helps increase torque.

During mid-range to high speed operation (abov e 4100 rpm), the

solenoid is de-energized and the resonanc e valv e is sprung open.
This allows intake air to be drawn through both resonanc e tubes,
providing the air volume necessary for additional power at the upper
rpm range.
Low to mid-rang e
(< 3750 rpm )
cylinder 1 The rpm for resonance valve activation varies slightly depending on
intake valves clos e temperature.
cylinder 5
intake valve s open
In addition, when the valve is closed, a dynamic effec t is produced.
For example, as intake air is flowing into cylinder 1 , intak e valves
rSCI close. This blocks onrushing air. Cylinder 1 air flow stops and
expands backwar d (resonance back pulse ) t o fill cylinder 5. The
resonance wave along with the intake velocit y enhances cylinder
filling.

B5101000163

Combustion chamber desig n The intake manifol d includes intak e turbulence ports. The 5.5 mm
Exhaust camshaft intake camshaft
(0.217 in.) turbulence ports channel idl e and low speed air directly
from the idle speed control valve to one intak e valve of each
Secondary cylinder.
air injection Intake Throttl e
valve
Routing intake air to one intak e valve pe r cylinder causes the air
charge to swirl in the cylinder. Together with the high flow rate of
\- - H
Intake U
intake air across the small (5.5 mm ) port, intak e fluctuations are
reduced for more stable combustion .
valve

B510100017a

r Exhaust manifold assembly Exhaust manifold s

Precatalyst oxygen sensor s
Each exhaust manifold assembly incorporates a catalytic converter.
The converter s are mounte d clos e to th e engin e for faster heat u p
and light off . Pre- and post-catalyst oxygen sensors are a mounte d
in each exhaust manifold.
Post-catalyst
oxygen
sensors
Catalytic
converters

B510100012a
 Engine-General 100- 7
M54 Engine Overview

Cooling syste m
The cooling system i s designed so that coolant flows directly fro m
the coolant pum p t o the cylinder head . Th e coolant i s fed from the
coolant pump through a cast coolant feed passage to the rear of the
cylinder head. From there it flows forward to the thermostat housing ,
radiator and heate r valve .

525i and 530I models ar e equipped with a DME-controlled electric

cooling fan. See 170 Radiator and Cooling Syste m fo r additiona l
information

Lubrication syste m
The lubrication system is pressurized whenever the engine is
running. The oil pump draws oil through a pickup in the bottom of the
oil pan, then forces it through a replaceable oi l filter and int o the
engine oil passages .

Oilways i n the cylinder hea d provide lubricatio n fo r the camshaft s

and valvetrain.

The chain-driven oi l pump i s bolted to the botto m of the cylinder

block insid e the oil pan. A pressure relie f valv e limits the maximu m
system pressure. A bypass valve prevents the oil filter from bursting
and insures engine lubricatio n should the filter become plugged .

See 119 Lubrication Syste m fo r additional information .

100-8 Engine-Genera l
N52 Engine Overview

N52 engine
N52 ENGIN E OVERVIE W
Engine introduction
Beginning with 2006, 5 Series models were equipped wit h 3-liter in-
line 6-cylinder normally-aspirated N5 2 engine. 2-whee l drive and 4-
wheel drive models wer e offered:
• Lo w output engine i n 525i or 525xi models
• Hig h outpu t engine i n 530i o r 530xi models

Beginning wit h 2008, 5 Series models wer e fitted with the N52KP
engine. 2-whee l drive and 4-wheel drive (xDrive ) models wer e
offered:
• 528i or 528i xDriv e models
• 530I or 530i xDrive models

The N52 engine family features the following:

• 4-valves-per-cylinder friction-optimized components
B510100001
• Two-piece crankcase
• Composit e magnesium-aluminum engine bloc k structure
• Trapezoidal weight-optimized connectin g rod s
• Aluminum silicon (AluSil ) cylinder hea d
• Timing cas e integrate d i n crankcase an d cylinder hea d
• Cylinder head gasket wit h silicon sealing lip
• Valvetronic system
• Weight-optimized double VANO S syste m
• Volumetric flow-controlled oil pum p
• Electricall y controlled coolant pum p
• Crankcase ventilation with integrated heate r
• 3-stage variable intake manifol d or DIS A

The weight reduction in these systems an d components, as

compared to the M54 engine, led to increased power-to-weight ratio,
reduced emissions and decreased fue l consumption.

Crankcase component s
Crankcase

The upper section of the crankcase consists of an aluminum / silicon

Timing chai n (AluSil) insert cast in a magnesium alloy . The timing cover is cast as
housing an integral part of the engine block .
 Engine-General 100- 9
N52 Engine Overview

The AluSil cylinder bores are not equipped with iron cylinder liners.
Therefore, the cylinder bores cannot be machined, bu t the dec k
surface may be planed .

F~~ The AluSil insert has threaded bores for transmission, cylinder hea d
and crankshaft main bearing bolts.

The inser t provides coolant passages as well. This i s to preven t

coolant contact with the magnesium portio n of the engine block .

The lower section of the crankcase is a bedplate structure made of

magnesium with sintered steel inlays (arrow) for mai n bearin g
support. The magnesiu m structur e is used to increase crankcas e
rigidity and the steel inlays take up forces which ar e no t suitable for
magnesium alone.

A liqui d sealant is injected under high pressure int o a machine d

groove between upper and lowe r crankcase sections. This detai l is
critical to understand i n service applications. A s an example, whe n
the crankcase main seals are replaced, a special sealant is injected
into the seal grooves an d crankcase seams .
100-10 Engine-Genera l
N52 Engine Overview

Crankshaft
The crankshaft is cast iron with 7 main bearin g journals. The trigger
wheel for the crankshaft sensor i s between cylinder s 5 and 6. Due
to the design o f the timing chain housin g (on e piece wit h the
crankcase), the crankshaft snout is modified to facilitate timing chain
module remova l an d installation durin g service .

Connecting rod s
The big end of each connecting ro d is cracked t o allow centering of
the bearing cap without the use of dowel pins. This contributes to the
overall weight reduction .

Pairing codes (arrows ) are stamped o n each connectin g ro d to

match the correct rod cap to the connecting rod.

The small en d of the ro d is tapered, reducin g weigh t without

affecting strength.

The connecting rod s are separated int o weight categories and can
only b e replaced as a set.

Pistons
The piston s are manufactured from aluminum an d have 4 valve
reliefs. The underside s o f the piston s ar e coole d with oil spray jets.

Cylinder hea d an d valvetrain

Cylinder hea d
The N5 2 engine use s an AluSil cylinder hea d wit h a cast bridge to
mount the Valvetronic actuator motor .
 Engine-General 100-1 1
N52 Engine Overview

Variable camshaft timin g (VANOS )

VANOS uni t
N52 engines ar e equipped wit h compact, infinitel y variable vane -
type VANOS units for both intake and exhaust camshafts. Th e
VANOS system (from the German words VAriable NOckenwe/len
Steuerung) electrohydraulicall y adjusts valve timing fo r enhance d
mid-range performanc e and improve d emissions. VANO S i s
controlled by the engine control module (ECM), using engine speed,
engine load and engine coolan t temperature as the primar y inputs .
Engine oil pressure i s used for powering camshaft adjustment .

Front vie w Rear view

Valvetronic

N52 engine loa d is controlled via the valve timing gear. This system,
Valvetronic moto r called Valvetronic, varies valve lift rathe r than throttle valve openin g
to control engine powe r an d torque. It offers the following:
• Increase d engine efficiency .
• Improve d emission values .
Eccentric • Top engine speed t o 7,000 rpm .
shaft
• Powe r output o f 85 hp / lite r displacement.
• Engin e torque of 100 Nm / liter displacement ove r a broad engin e
speed range .
• Reduce d CO 2 emissions .

Intake
camshaft

Intake manifol d
Variable intake manifold (DISA )
5 Series models wit h N52 engines are equipped wit h 3-stag e
variable intake runners in a system know n a s DISA .

Valves in the intake manifold are driven by DISA electric motor s and
gear mechanisms . DIS A actuators are driven b y pulse width-
modulated signals fro m the engine control modul e (ECM) . Eac h
valve has only two possibl e positions: Open o r closed .
DISA actuator 1

DISA actuator 2

B510100013
100-12 Engine-Genera l
N52 Engine Overview

Switched-length intake manifold runners help achieve a high torque

Throttle valve over the entire engine speed rang e usin g two DISA valves and an
(always open)
overflow pipe i n the intake .
• Stage 1 : Idl e and low engine speed range . Both DIS A valves
closed. Intake air flows past throttle valve into resonance pipe . Air
flow is split i n resonance pip e an d i s further routed vi a collector
runner and intake resonatin g runner s int o individual cylinders . In
this way, a relatively large air mass is made available to cylinders.
• Stage 2: Medium engine speed range . DISA valve 2 open. (I n this
example, cylinder 1 intake valves ar e just closing.) Air flow
produces pressure peaks at closing intak e valves. This resonates
to next cylinder in firing order, thus improvin g charge of next
DISA valve
cylinder.
DISA valve 2 Low rPm • Stage 3: High engine speed range . Bot h DISA valves open.
(Again, I n this example, cylinder 1 intake valves are just closing.)
oooooo loooooo
Pressure peaks ahead o f closing intake valves are also utilize d in
this case. Intake air mass i s now route d via resonance , overflow
and manifold runners .

Mid-range rp m

High rpm
 Engine-General 100-1 3
N52 Engine Overview

Lubrication, vacuum and cooling system s

Lubrication and vacuum systems

VANOS requires a large volume of oil, particularly at low engin e
speeds. T o meet the oilin g requirements of the engine , a hig h
volume volumetric-flow controlled oil pump i s utilized. The pum p is
designed to provide the high volume when needed, but drop back its
flow at higher engine speeds when it is not needed. Se e 119 Engin e
Lubrication.

Valvetronic engin e loa d contro l requires a wide open throttl e unde r

most engine operating conditions, resulting in minimal intake
manifold vacuum. In order to operate the brake vacuum booster , an
auxiliary vacuum pump i s fitted to the engine .

A chain assembly i s used to drive the oil pump an d brak e booste r

auxiliary vacuum pum p sprockets.

1. Auxiliar y vacuum pump sprocke t bolt

12
2. Crankshaf t sprocket
3. Auxiliar y vacuum pum p driv e sprocket
4. Auxiliar y vacuum pump
5. Oi l pump sprocket bolt
6. Oi l pump drive sprocket
7. Oi l pump

B510100018

Cooling system
The cooling system utilizes a DME-controlled electric coolan t pum p
which minimizes engin e powe r losses and allows for increased fuel
economy b y a more efficient method of engine hea t managemen t
 100-14 Engine-Genera l
N54 Engine Overview

N54 ENGIN E OVERVIE W

Engine introduction
N54 engine Beginning i n 2008 the 535i Sedan and Sports Wagon model s were
equipped wit h the turbocharged in-lin e 6-cylinder N5 4 engine .
Available as a 3.0 lite r engine, i t shares th e following features with
the N5 2 engine:
• Doubl e VANOS
• Aluminum cylinde r head with plastic cylinde r hea d cover
• Stee l crankshaft

The following features are specific to the N5 4 engine:

• Exhaus t driven twin turbochargers (bi-turbo )
• Air to air intercooler
• Hig h output (40 0 W) electric coolant pum p
• Direc t injection (high pressure injection or HPI) with piezo injectors
• Bosc h MSD8 1 engin e managemen t
• Externa l oil cooler
• All aluminum crankcas e with iro n cylinder liner s

12 3 4 5 6
Turbochargers
1. Wastegat e actuator, bank 2
2. Turbocharger , bank 2
3. Exhaus t manifold, bank 2
4. Exhaus t manifold, bank 1
5. Turbocharger , bank 1
6. Coolan t retur n
7. Catalyti c converter , bank 2
8. Catalyti c converter , bank 1
9. Wastegat e actuating leve r
10. Plana r broad-band oxygen sensor, ban k 2
11. Plana r broad-band oxyge n sensor, ban k 1
91 01 1 12
12. Coolan t supply
JI.....M.I ..<!.••

Wastegate
actuators
intercooler
The charg e air i s greatly heated whe n i t is compressed in the
turbochargers, making i t necessary fo r the air to be cooled again i n
an intercooler.

Turbochai

Intercooler
BS10100002
 Engine-General 100-1 5
N54 Engine Overview

Crankcase breathin g
The turbocharged engine crankcase breather valve system i s
designed so that when the engine is in turbocharged mode ,
increased manifol d pressure does no t adversely affec t crankcas e
venting. Instea d of a crankcase ventilation valve, the engin e
breathing system consists of small cyclone separators integrate d
into the plastic cylinder hea d cover. The flow of crankcase gases is
metered through a series of restrictions which control crankcas e
pressure.

As with the N52 engine, the turbo engine oil pump and auxiliary
vacuum pump are driven by a single chain powered by a sprocket at
the front of the crankshaft. In addition, the hig h pressure fuel pum p
is tandem mounted to the rea r of the vacuum pump.

1. Auxiliar y vacuum pump sprocket bolt

2. Crankshaf t sprocket
3. Auxiliar y vacuum pump-high pressur e
fuel pump drive sprocket
4. Auxiliar y vacuum pump
5. Hig h pressure fuel pump
6. Oi l pump sprocket bolt
7. Oi l pump drive sprocket
, •.,. \e oil, vacuum and fuel pump drive
8. Oi l pump
100-16 Engine-Genera l
N62 Engine Overview

N62 ENGIN E OVERVIEW

Engine introductio n
545i and 550i model s ar e equipped with the V8 N62 engine wit h
Valvetronic.

N62 engine from the front:

2 3 4 5
1. Valvetroni c actuator
2. Throttl e unit
3. Thermosta t housin g
4. VANO S solenoi d
5. Evaporativ e emissions valv e
6. Starte r with hea t shield
7. Brak e booster vacuum pum p
8. Water-coole d alternato r
 Engine-General 100-1 7
Engine introduction

N62 engine fro m the rear :

12 34
1. Camshaf t sensors, lef t ban k
2. Valvetroni c eccentri c shaft position sensor , lef t ban k
3. Valvetroni c eccentric shaf t position sensor , righ t ban k
4. Camshaf t sensors , righ t ban k
5. Secondar y ai r injection valves
6. Variabl e intake manifol d servomotor

65
B510100003a

In addition t o Valvetronic technology, th e N6 2 engine i s equipped

Valvetronic actuators with double VANOS .

Bi-VANOS units 1
B510100023a

, Doubl e VANOS allows for variable timing on both intake and exhaust
camshafts. Th e VANOS uni t is designed a s an integra l componen t
of the chain driv e and i s secured to the respectiv e camshaf t wit h a
central bolt.
100-18 Engine-Genera l
Engine introduction

Valvetronic principle s
The Valvetronic system uses hardware and software to eliminate the
conventional throttle mechanism. Instea d o f a throttle valve, intake
air is regulated by adjusting valve lift. BMW claims that removing the
throttle valve as an obstruction result s i n 10% fuel savings by
minimizing pumpin g losses.

In order to diagnose and repai r the Valvetroni c system, b e sure to

have access to BM W scan tool.

Valvetronic component s
1. BoltM5x12m m
2. BoltM5x30m m
3. Valvetroni c actuator
4. O-rin g
5. Space r
6. Oi l spray tube
7. Lockin g clip
8. BoltM7x8m m
9. Bridg e suppor t
10. Eccentric shaft
11. Needle bearin g
12. Eccentric shaft magnetic pulse
generator
13. Bolt M6x 20 mm
14. BoltMSx 16m m

15. Eccentric shaft position sensor

16. BoltMSx 50 mm
17. Intermediate lever
18. Valve rocker (with roller)
19. Valve keeper
20. Upper valve spring seat
21. Hydraulic valve adjuster (HVA)
22. Valve spring
23. Valve stem seal
24. Intake valve
25. Retainer spring
26. Spring support
27. Torx bolt M7 x 44 mm
28. Sealing O-ring
29. Intake camshaft
30. Camshaft position pulse generator
wheel
31. Allen bolt M14x 19m m
 Engine-General 100-1 9
Engine introduction

12 3 4 1 2 3 Valvetronic operation
1. Retaine r spring
2. Intermediat e leve r
3. Intak e camshaft
4. Ca m gear operated b y Valvetronic actuator
5. Eccentri c shaf t
6. Intak e valve
7. Hydrauli c valve adjuster (HVA)
8. Valv e rocker (with roller)

B510100020a

The Valvetronic actuator in each cylinder bank operates an eccentric

Valvetronicl shaft. Lobe s o n shaft press on intermediate levers between intak e
Sensor actuator camshaft lobe s and each cylinder' s pair of intake valv e rockers.
Intake . " *»
camshaft Depending o n position of eccentric shaft lobes, the siz e of intak e
Eccentric
shaft
1
valve opening ranges from about 0.3 to 9.85 mm.
•=••" .:>•= :*

Valvetronic electronic contro l

, Electrica l and electroni c controls for the Valvetroni c system consis t
Valvetronic Integrated voltage of:
control module supply module (IVM • Valvetronic control module in E-box
• Engin e control modul e (ECM ) i n E-box
• DM E and Valvetronic relays i n integrated voltage suppl y modul e
(IVM) i n E-box
• Valvetronic actuators
• Eccentri c shafts position sensors
• Eccentri c shafts magnetic puls e generators

The Valvetronic DC motors (actuators ) which adjust th e eccentri c

shafts are operated at 16 kHz for exact control of valve lift. Once th e
target valve opening i s attained, as determined b y the ECM, polarit y
is briefly reversed to generate braking forc e and to posit/on motors
exactly. Adjustment tim e required to move motors from minimum t o
maximum valve lift is approximately 300 ms. Motor draw can peak at
100 amperes .

When the engine i s stopped, self-stopping motors and worm gea r

drives prevents position changes. Whe n restarted, if automatic valv e
opening adjustmen t i s not detected, a fault i s recorded and motor s
are moved bac k to the target positions.
 110-1
110 Engin e Removal and Installation

GENERAL 110-1 ENGIN E REMOVA L AND INSTALLATIO N

Warnings and Cautions 110-2 (N52 , N5 4 ENGINE ) 110- 6
N52, N5 4 engine, removin g and installing . . . . 110- 6
ENGINE REMOVA L AND INSTALLATION
(M54 ENGINE ) 110-3 ENGIN E REMOVA L AND INSTALLATIO N
M54 engine, removin g and installing 110-3 (V 8 ENGINE ) 110- 8
V8 engine, removin g and installing 110- 8

GENERAL
This repair group includes an overview of M54, N52 , N5 4
(6-cylinder) an d N6 2 (V8) engine removal and installation .

Transmission removal is required before the engine can be removed.

See also:
• 020 Maintenance for engine cover s remova l
• 10 0 Engine-General for engine codes and applications
• 12 1 Battery, Starter, Alternator
• 170 Radiator and Cooling System
• 180 Exhaust System
• 230 Manual Transmission
• 231 Sequential Manua l Gearbox (SMG)
• 240 Automatic Transmissio n
• 260 Driveshafts
• 310 Front Suspension
• 410 Fenders, Engin e Hoo d
110-2 Engin e Removal and Installation
Warnings and Cautions

Warnings and Cautions

WARNING —
• The fuel system is designed to retain pressure even when the
ignition is OFF. When working with the fuel system, loosen fuel
lines slowly to allow residual fuel pressure to dissipate. Avoid
spraying fuel.
• Before beginning any work on the fuel system, place a fire
extinguisher in the vicinity of the work area.
• Fuel is highly flammable. When working around fuel, do not
disconnect any wires that could cause electrical sparks. Do not
smoke or work near heaters or other fire hazards.
• Loosen the fuel tank cap to release pressure in the tank before
working on the tank or lines.
• When disconnecting a fuel hose, wrap a shop towel around the
end of the hose to prevent fuel spray.
• Do not use a work light with an incandescent bulb near any fuel.
Fuel may spray on the hot bulb causing a fire.
• Make sure the work area is properly ventilated.

CAUTION—
• If the MIL (malfunction indicator light, also called Check Engine
or Service Engine Soon light) is illuminated, see
OBD On-Board Diagnostic s fo r DME fault code information.
• If other system faults are indicated by an illuminated ABS, SRS
or DSC warning light, see the appropriate repair group in this
manual or an authorized BMW dealer for more information on
fault codes.
• Magnesium crankcase requires aluminum fasteners.
• Steel fasteners may not be used in place of aluminum fasteners
due to the threat of corrosion.
• Aluminum fasteners may be marked with blue paint. Use a
magnet to identify.
• Replace aluminum fasteners each time they are loosened.
Engine Removal and Installation 110- 3
M54 engine, removing and installing

ENGINE REMOVA L AND INSTALLATION

(M54 ENGINE )
Be sure to cover painted surface s before beginning th e remova l
procedure. As an aid to installation, label components, wires an d
hoses before removing them. Do not reuse gaskets, O-rings or seals
during reassembly .

WARNING —
• Due to risk of personal injury, be sure the engine is cold before
beginning the removal procedure.

M54 engine, removing and installing

— Plac e hood i n service position. Se e 410 Fenders , Engin e Hood .

— Remov e exhaus t system . Se e 180 Exhaust System .

— Secur e engine with BMW special tool 00 6 000 engin e support

or equivalent.

— Disconnec t negative (-) cabl e from battery .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions in 001 Warnings an d Cautions.

— Remov e transmission. Se e 230 Manua l Transmission,

231 Sequential Manual Gearbox (SMG ) o r 240 Automati c
Transmission

— Drai n engine oil .

— Drai n engin e coolant .

— Remov e air cleaner housing an d fresh air ducts. See 13 0 Fue l

Injection.

— Remov e fan cowl with electri c cooling fan. See 17 0 Radiator an d

Cooling System.

— Remov e radiator . See 170 Radiator an d Cooling System .

— Remov e coolant expansion tank. See 170 Radiator and Coolin g

System.

— Remov e intak e manifold . Se e 130 Fuel Injection .

"^ Workin g in E-box, detach engine wirin g harness connector s fro m

ECM, transmission control module, engin e electronic s fuse carrie r
and other connectors (arrows).

— Disconnec t electrical connectors and harness from ignition coils and

lay harness aside.
110-4 Engin e Remova l and Installatio n
M54 engine, removing and installing

— Disconnec t positiv e batter y cabl e (arrow ) at intake manifold .

— Remov e vacuum line from brake booster .

— Disconnec t vapo r line from fuel tank ven t valve.

— Remov e pre-catalyst and post-catalys t oxygen sensors.

See 180 Exhaust System .

— Workin g at right side engine mount bracket, remov e groun d cable.

— Remov e engin e accessory belt . See 020 Maintenance.

— Remov e powe r steering pump with bracket. See 320 Steering and
Wheel Alignment .

^C Remov e A/C compressor mounting bolt s (arrows) and lift A/C

compressor off its mounting bracket without disconnecting,
distorting, o r deforming refrigeran t lines. Suspen d fro m body usin g
stiff wire.

^ Vehicl e with dynamic drive (activ e stabilizer bar):

Working at front stabilizer bar , remove hydrauli c line (A).

— Workin g above engine, remov e engine moun t fasteners.

Engine Remova l an d Installation 110- 5
M54 engine, removing and installing

Install engine lifting device (BMW 1 1 0 000 or equivalent) to the front

and rea r engine support s an d raise engine unti l its weight i s
supported.

Carefully rais e engine ou t of engine compartment , checking for any

wiring, fuel lines, or mechanical parts that migh t become snagge d
as engine is removed.

Installation is reverse of removal, noting the following:

• Replac e gaskets, O-rings an d seals.
• Us e new fuel injector seals.
• Chec k that engine driv e belts properly engage pulle y grooves.
• Inspec t O-ring seal betwee n mass ai r flow sensor an d air filter
housing. T o facilitate reassembly, coat seal with acid-free grease.
• Change engin e oi l and filter and check all other fluid levels. Se e
020 Maintenance .
• Refil l and bleed cooling system. See 170 Radiator and Coolin g
System.

CAUTION—
• Use new fasteners for reinstalling front end reinforcement.
• When reattaching throttle assembly harness connector,
connector is fully tightened when arrows on connector and plug
line up.
110-6 Engin e Removal and Installation
N52, N54 engine, removing and installing

ENGINE REMOVA L AND INSTALLATION

(N52, N5 4 ENGINES )
Be sure to cover painted surfaces before beginnin g the removal
procedure. A s an aid to installation, labe l components , wire s and
hoses before removing them. Do not reuse gaskets, O-rings or seals
during reassembly .

WARNING —
• Due to risk of personal injury, be sure the engine is cold before
beginning the removal procedure.

N52, N54 engine, removin g and installin g

Place hood i n service position. Se e 410 Fenders , Engin e Hood .

Remove exhaust system . See 18 0 Exhaus t System .

Remove transmission . Se e 230 Manua l Transmissio n o r 240

Automatic Transmission .

Drain engine oil .

Drain engine coolant .

Disconnect negativ e (- ) cabl e from battery.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings an d Cautions.

— Remov e ai r cleaner housin g and fresh ai r ducts. See 131 or 132

Fuel Injection.

— Remov e fan cowl with electric cooling fan . See 170 Radiator an d
Cooling System.

— Remov e radiator. See 17 0 Radiato r an d Coolin g System .

— Remov e thermostat. Se e 17 0 Radiato r an d Coolin g System .

— Remov e all cooling syste m hoses from vehicle.

— Remov e intake manifold . Se e 13 1 o r 13 2 Fue l Injection.

— Remov e vacuum lin e from brake booster .

— Disconnec t electrical connectors and harness from ignition coils and

lay harness aside .

— Disconnec t engine electrical harness and lay aside.

— Turb o engine: Remov e fuel supply lin e to hig h pressur e fuel pump .
See 160 Fuel Tank an d Fuel Pum p fo r high pressur e fuel pum p
removal an d installation.

^ Remov e A/C compressor (A) from engine an d set on front axl e

carrier an d secure with stiff wire . D o not disconnect A/ C lines or
discharge system .
Engine Remova l an d Installatio n 110- 7
A/52, A/5 4 engine, removing an d installing

Remove powe r steerin g pum p (A) , set on front axle carrie r an d

secure with stif f wire . Do not disconnect hydrauli c lines .

Vehicles wit h dynami c driv e (activ e stabilizer bar) :

Working a t front stabilizer bar, remove hydrauli c lin e (A) .

Install engine to w hoo k (fro m tool kit in trunk) to front of engine (A) .
Attach BMW special too l 1 1 0 020 to engine usin g onl y specifie d
mounting place s (B) .
110-8 Engin e Remova l an d Installatio n
V8 engine, removing and installing

If equipped with automatic transmission : Rais e engine 1 0 cm ( 4 in)

and remov e fasteners (A) for ATF cooler line s (B) .

Remove engine from vehicle usin g engine hois t attache d t o BMW

special hook 1 1 0020.

Raise engine slowly while watching carefully to make sure no lines,

wires or hoses becom e snagged .

Installation i s reverse of removal . Remembe r to :

• Replac e aluminum fasteners.
• Check for fuel leaks .
• Check and clear any fault codes usin g BMW scan tool .
• Refil l and bleed cooling system. Se e 170 Radiator and Cooling
System.

CAUTION—
• Use new fasteners for reinstalling front end reinforcement.

ENGINE REMOVA L AND INSTALLATIO N

(V8 ENGINE )
Be sure to cover painted surfaces before beginning th e remova l
procedure. A s an aid to installation, label components, wire s an d
hoses before removing them. D o not reuse gaskets, O-rings or seals
during reassembly.

WARNING —
• Due to risk of personal injury, be sure the engine is cold before
beginning the removal procedure.

V8 engine, removin g an d installin g

— Plac e hood in service position. See 410 Fenders , Engine Hood .

— Remov e exhaust system. See 18 0 Exhaus t System.

— Secur e engin e with BM W special tool 00 6 000 engine suppor t

or equivalent .

— Disconnec t negativ e (- ) cabl e from battery.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings an d Cautions .

Remove transmission. Se e 230 Manual Transmission ,

231 Sequential Manua l Gearbo x (SMG) or 240 Automati c
Transmission.

Drain engine oil .

Drain engine coolant.

Remove air cleaner housing and fresh air ducts. Se e 13 3 Fuel

Injection.

— Remov e radiator . See 17 0 Radiator an d Coolin g System .

Engine Remova l an d Installatio n 110- 9
V8 engine, removing and installing

— Remov e coolant expansion tank. Se e 170 Radiator and Coolin g

System.

— Remov e intake manifold. Se e 133 Fuel Injection.

'A. Workin g near righ t front strut tower, remove ground cable (arrow) .

Working in E-box, detach engin e wiring harness connector s fro m

ECM, transmission control module, engine electronic s fuse carrier
and other connectors (arrows) .

Disconnect electrical connectors and harness from ignition coils and

lay harness aside .

Disconnect jump start terminal cable (arrow).

110-10 Engin e Remova l an d Installatio n
V8 engine, removing and installing

Remove clamp (A ) and discard. Remov e line (B). Remove hose

clamps (black arrows ) an d hoses. Remov e vacuu m line (white
arrow).

'X Workin g at fuel tank vent valve (B) , remove electrical connecto r (A)
and emission lines (arrows) .

— Remov e pre-catalys t and post-catalyst oxygen sensors. Se e 180

Exhaust System .

— Workin g at right side engine moun t bracket , remov e engine groun d

cable.

— Remov e engine accessor y belt . See 02 0 Maintenance .

— Remov e vibration damper (crankshaf t pulley) . Se e 11 7 Camshaft

Timing Chain .

— Remov e power steering pump with bracket. See 320 Steering an d

Wheel Alignment.

— Remov e A/C compresso r idler pulley .

^ Remov e A/C compressor mounting bolt s (arrows ) and lif t A/C

compressor of f its mounting bracket without disconnecting,
distorting, or deforming refrigeran t lines. Suspen d from body usin g
stiff wire .
Engine Remova l and Installatio n 110-1 1
V8 engine, removing and installing

Remove lowe r steering shaft universal joint (arrow).

k Vehicle s with dynamic driv e (active stabilizer bar):

Working at front stabilizer bar , remove hydraulic lin e (A) .

— Workin g above engine , remov e engine mount fasteners .

. Instal l engine liftin g device (BMW 11 0 000 or equivalent) t o the front

and rear engine support s an d rais e engine unti l it s weight i s
supported.

Carefully rais e engine out of engine compartment, checkin g fo r any

wiring, fuel lines, or mechanical part s that migh t becom e snagge d
as engine i s removed.
110-12 Engin e Removal and Installation
V8 engine, removing and installing

Installation i s reverse of removal, noting the following:

• Replac e gaskets, O-rings and seals.
• Check that engine drive belts properly engage pulley grooves.
• Change engine oil and filter and check all other fluid levels. See
020 Maintenance .
• Chec k and clear any fault codes usin g BMW scan tool.
• Refil l and bleed cooling system. Se e 170 Radiator and Cooling
System.

CAUTION—
• Use new fasteners for reinstalling front end reinforcement.
• When reattaching throttle assembly harness connector,
connector is fully tightened when arrows on connector and plug
line up.
 113-1

113 Cylinde r Hea d

Removal and Installatio n

GENERAL 113- 2 CYLINDER HEA D (N54 ENGINE ) 113-2 7

Engine identificatio n 113- 2 Cylinder head cove r components
Warnings an d Cautions 113- 3 (N54 engine) 113-2 7
Cylinder hea d cover , removing and installin g
CYLINDER HEA D (M54 ENGINE ) 113- 4 (N54 engine) 113-2 7
Cylinder head cover, removing and installin g Cylinder hea d and timing chain
(M54 engine ) 113- 4 (N54 engine) 113-3 1
Cylinder hea d remova l and installation Cylinder head , removin g and installin g
(M54 engine ) 113- 5 (N54 engine) 113-3 2
Cylinder head , removin g (M5 4 engine) 113- 5 Cylinder head , removin g (N54 engine) 113-3 2
Cylinder head , installin g (M5 4 engine) 113-1 0 Cylinder head, installing (N54 engine) 113-3 5
CYLINDER HEA D (N52 ENGINE ) 113-1 4 CYLINDER HEA D (V8 ENGINE ) 113-3 9
Cylinder hea d cove r component s Cylinder hea d cover component s
(N52 engine ) 113-1 4 (V8 engine) 113-3 9
Cylinder hea d cover , removing and installin g Cylinder head cover, removing and installin g
(N52 engine) 113-1 4 (V8 engine) 113-3 9
Cylinder hea d an d timing chain Cylinder hea d (V 8 engine) 113-4 2
(N52 engine ) 113-1 7
Cylinder head an d timing chain
Cylinder head , removin g an d installing (V8 engine) 113-4 2
(N52 engine) 113-1 7
Cylinder hea d remova l and installatio n
Cylinder head , removin g (N5 2 engine) 113-1 8 (V8 engine) 113-4 2
Cylinder head, installing (N52 engine) 113-2 2 Right cylinde r head, removing
(V8 engine) 113-4 3
Right cylinder head , installing
(V8 engine) 113-4 7
Left cylinder head , removin g
(V8 engine) 113-5 3
Left cylinder head , installin g
(V8 engine) 113-5 5
113-2 Cylinde r Hea d Remova l and Installatio n
bngine identification

GENERAL
Cylinder head :
N52 6-cylinder engine , Thi s repai r group provide s remova l an d installatio n procedure s for
the cylinder hea d and associated components .

The cylinder head i s equipped wit h variable camshaft timin g

(sometimes referre d to as VANOS, from the German words VAriab/e
NOckenwellen Steuerung). Specia l tool s and procedures ar e
required to remove and install camshaft adjustment unit s and to time
camshafts. B e sure to read each procedure through before starting
work.

See also:
• 020 Maintenanc e
• 100 Engine-General for engine cod e an d application information.
• 117 Camshaft Timin g Chai n for camshaft timin g chain an d
camshaft adjuster (VANOS ) servic e
• 130, 131,132,13 3 Fuel Injection for air filter housing and intak e
B510113007 manifold removal
• 170 Radiator and Cooling Syste m

Engine identification
Engine applications and specifications are detailed in
100 Engine-General.

Table a. Engine identification

Engine
designation Year, model Identifying feature
M54 2004 - 2005 2 upper engine covers
525i, 530i
N52 2006 - 2007 Aluminum-
525i, 525xi magnesium cylinde r
530i, 530x i head cover
530xi Sports Wago n
N52KP 2008-2010 Black plastic cylinder
528i, 528xi head cove r
530i, 530xi
528i xDrive
530i xDrive
N54 2008-2010 Twin-turbo chargers
535i, 535x i
535xi Sport s Wagon
535i xDrive
535i Sport s Wago n
535i xDrive Sports Wagon
N62 2004 - 2005 545 i V-style engine wit h
2006 -2010550 i two valvetronic
motors

Fasteners and fastener torques differ amon g th e versions. Rea d

torque specifications carefully.
Cylinder Head Removal and Installation
Warnings and Cautions

Warnings and Cautions

WARNING —
• To avoid personal injury, be sure the engine is cold before
beginning work on engine components.
• Use extreme caution when draining and disposing of engine
coolant. Coolant is poisonous and lethal to humans and pets.
Pets are attracted to coo/ant because of its sweet smell and
taste. Seek medical attention immediately if coolant is ingested.
• The fuel system is designed to retain pressure even when the
ignition is OFF. When working with the fuel system, loosen fuel
lines slowly to allow residual fuel pressure to dissipate. Avoid
spraying fuel. Use shop towels to capture leaking fuel.
• Before beginning work on the fuel system, place a fire
extinguisher in the vicinity of the work area.
• Fuel is highly flammable. When working around fuel, do not
disconnect wires that could cause electrical sparks. Do not
smoke or work near heaters or other fire hazards.
• Wear eye protection and protective clothing to avoid injuries
from contact with fuel.
• Unscrew the fuel tank cap to release pressure in the tank before
working on fuel lines.
• Do not use a work light with an incandescent bulb near fuel.
Fuel may spray on the hot bulb causing a fire.
• Make sure the work area is properly ventilated.

CAUTION—
• To avoid electrochemical corrosion to engine components
made of aluminum-magnesium alloy, do not use steel
fasteners. Use aluminum fasteners only.
• The end faces of aluminum fasteners are usually painted blue.
For reliable identification, test fasteners for aluminum
composition with magnet.
• Replace aluminum bolts each time they are loosened.
• Follow torque instructions, including angle of rotation
specifications, when installing aluminum fasteners.
^M3-4^Cylinder Head Removal andjnstallatior^
Cylinder head cover, removing and installing (M54 engine)

CYLINDER HEA D (M54 ENGINE)

Cylinder head cover, removing and installinq
(M54 engine)
- Mak e sure ignition is OFF. Remov e ignitio n key.

— Remov e air intake hood above radiator.

- Remov e upper engine covers. See 020 Maintenance.

^ Workin g at left front of cylinder head cover , pinc h crankcas e

^
breather hos e clip (arrows) . Detach hos e from cover.

. Remov e ignition coils:

• Disconnect ignitio n coil harness connectors .
• Remove coil mountin g fasteners .
• Remove coils.
• Remov e ground straps.
• Set coil harness to side of engine compartment .

CAUTION—
• Note location of all ground wires. Failure to reinstall grounds
can result in permanent damage to engine control module or
ignition system components.

Remove cylinder hea d cover mountin g fasteners an d remove

cylinder head cover .

NOTE—
• Make note of arrangement of fasteners during removal so that they
can be reinstalled in their original locations.

Inspect cylinder head cover fasteners. Replac e a s necessary .

1. Ca p nut
2. Washe r
3. Rubbe r seal

Clean gasket residue fro m cylinder head sealing surface Appl y thin
beads o f 3-Bond 1209 ® or equivalent sealer at timing chain cover
B701113011; seams.

Remove inner and outer gaskets from cylinder head cover and clean
gasket residue from grooves .

Coat cylinder head cover grooves with thin layer o f antifriction

compound such as glycerine. Press inner and outer gaskets in
place, makin g sure gaskets are no t stretched at any point .

Use a small amount of 3-Bond 1209 ® or equivalent sealer at corners

of half-moo n seals .
Cylinder Hea d Remova l and Installatio n 113- 5
Cylinder head, removing (M54 engine)

— Reinstal l cylinder hea d cover.

• Coat cylinder hea d and gasket contact surfaces with thin laye r of
anti-friction compound suc h as glycerine.
• Check for correct seating of half-moon seals i n back of cylinde r
head cover.
• Instal l cylinder hea d cover fasteners and tighten gradually i n
crisscross pattern, starting with inside fasteners .

— Remainde r o f assembly i s reverse of removal .

CYLINDER HEA D REMOVA L AND

INSTALLATION (M54 ENGINE )
The 6-cylinde r engine cylinde r head is equipped wit h doubl e
VANOS. To remove the cylinder head, special tools and procedure s
are require d for removing th e VANOS unit. Rea d the entir e
procedure before beginning th e repair.

CAUTION—
• Disassembly, removal and assembly of camshafts or cylinder
head without special tools poses the risk of damage or
breakage. The valves may be bent by contact with the piston
crown; camshafts may break if stressed incorrectly during
removal or installation.

NOTE—
• VANOS or variable camshaft timing is from the German words
VAriable NOckenwelle n Steuerung.
• VANOS service i s covered i n 117 Camshaft Timing Chain .

Cylinder head remova l an d installation procedure s ar e describe d

separately. Remove the intak e manifold before removing th e
cylinder head. Se e 13 0 Fuel Injection .

If you remov e a cylinder hea d and determine that i t require s

significant reconditionin g work, a remanufactured cylinder hea d is
available from an authorized BMW dealer .

Cylinder head, removing (M54 engine )

WARNING —
• Due to risk of personal injury, be sure the engine is cold before
beginning the removal procedure.

— Disconnec t negative (-) cabl e from battery .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings and Cautions .

Remove air intake hoo d above radiator .

Remove upper engin e covers . See 020 Maintenance .

Detach air hose and vacuum lin e from secondary ai r valve o n righ t
side o f cylinder head .
113-6 Cylinde r Head Removal and Installation
Cylinder head, removing (M54 engine)

Working above engine , disconnec t th e following:

• Vent line from cylinder head cover. To remove, pinch clip (arrows).
• Electrica l harness connector from VANO S solenoid valve (A).

— Remov e both exhaust manifolds. Se e 18 0 Exhaus t System . Afte r

removing exhaust manifolds, reinstall engine suppor t ar m and
engine mount .

— Remov e air filter housing and ducts . Se e 13 0 Fuel Injection .

— Remov e cylinder head cover. See Cylinder hea d cover , removin g

and installing (M54 engine) in this repair group.

— Remov e spark plugs . Plu g spark plu g bore s to prevent debris from
falling into engine.

— Remov e intake manifold . See 13 0 Fue l Injection. Plu g cylinder

head intake ports to prevent debris from falling into engine.

WARNING —
• Unscrew the fuel tank cap to release pressure in the tank before
working on the fuel line.
• Wrap shop towels around fuel line fitting before disconnecting.
• Plug open fuel lines and fittings.

— Rais e car an d suppor t safely.

WARNING —
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Drain engine coolant :

• Remov e expansion tank cap on radiator .
• Plac e a 3 gallon pail underneat h engine t o capture coolant.
• Remov e coolant drain plug (arrow ) located on exhaust side of
cylinder 2 on engine block.

Drain radiator into a 3 gallon pai l b y removing plastic drain plu g

(arrow) completely.

— Remov e engine coolin g fan and radiator . See 17 0 Radiator and

Cooling System.
 Cylinder head, removing (M54 engine)

Remove thermostat housing:

Disconnect electrica l harness connector at thermostat housing
hoses from thermostat housing by releasing locks

Unbolt ( 4 bolts) and remove thermostat housing.

Remove fasteners (arrows ) from heater bypass tube Pul l tube out
of cyhnder head and set to side, leaving heater hos e connected

'i l pressure line banjo bolt and careful|y

Remove oil baffle cover from above intake camshaft.

Remove banjo bolt from VANOS unit oil pressure line Us e banio
bolt toattec h BM W special too, 1 1 3 450P(COmpressed afrfitt^) to

dnppin9 not aii°w

502113856
113-8 Cylinde r Hea d Removal an d Installation
Cylinder head, removing (M54 engine)

Cover oil bore (arrow) i n VANOS uni t with shop towel to capture oil
which sprays when compressed ai r i s applied.

Connect compressed air line to air fitting. Apply air pressure set to
2 - 8 bar (30-115 psi).

With compressed air line connected, use crankshaft vibratio n

damper bol t to rotat e engine i n direction o f rotation (clockwise) at
least twice, until cylinder 1 intake and exhaust camshaft lobes face
each other (arrows) in top dead center (TDC) positio n for cylinder 1 .

CAUTION—
• Do not rotate engine counterclockwise to reach TDC. If engine
rotates past TDC, complete another two complete rotations.

Remove sealing plu g from special too l bor e on lower left side of
engine block nea r flywheel . Secur e crankshaft in TDC position with
BMW special tool 1 1 2 300 (arrow).

Unscrew and remov e two cylinder head cover studs

(arrows) at rear of cylinder head.
Cylinder Hea d Remova l and Installation 113- 9
Cylinder head, removing (M54 engine)

^. Secure camshafts i n TDC position usin g BMW special tool set

11 3 240 (include s 1 1 3 241 and 1 1 3 244).

— Remov e VANOS unit from front of cylinder head. Se e

117 Camshaft Timin g Chain .

— Remov e crankshaft locking tool from transmission bell housing .

Lift primar y chain and hold under tension. Use crankshaft vibratio n
damper bol t to rotate engine in direction opposite to normal rotatio n
(counterclockwise) approximately 30°.

CAUTION—
• By turning crankshaft 30° counterclockwise, pistons are moved
away from TDC. This prevents piston-to-valve interference
during camshaft servicing.

Remove camshaft locking tools (BMW special tool set 1 1 3 240)

from rea r of cylinder head.

Remove camshafts and camshaft bearing carriers.

See 117 Camshaft Timing Chain.

, Remov e intake camshaft sensor (arrow) from side of cylinder head .

Remove secondary chain lower guide bolts (arrow). Remove chai n

guide.
113-10 Cylinde r Hea d Remova l an d Installation
Cylinder head, installing (M54 engine)

Remove bolt s (arrows ) holdin g timing chain cover to cylinder head.

(Photo shows camshafts and camshaft bearin g caps in place).

^ Usin g BMW special tool 11 2 250 or equivalent, loosen cylinder head

51 11 39 7 1 bolts i n several stages, in sequence shown . Discar d head bolts.

NOTE—
• BMW special tool 11 2 250 is a thin-walled Torx E12 socket with an

oo oooo
O G O O O O O extended reach. The cylinder head bolts are recessed into the
head below the camshaft carriers with little working space.
Q0 O 0 0 Q O — Lif t off cylinde r head.

10 1 41 26 4
5021138573

Cylinder head , installin g (M54 engine )

Clean cylinde r head and gasket surface s o f cylinder bloc k and
timing chain covers.

CAUTION—
• Remove foreign matter and liquid from bolt holes. Trapped oil or
coolant in bolt holes can cause damage to the engine block.
• Do not use a metal scraper or wire brush to clean the aluminum
cylinder head or pistons. If necessary, use a hard wooden or
plastic scraper. Also available are abrasive discs to be used in
conjunction with an electric drill. Be sure to use the correct disc
for the type of metal being cleaned.

— I f the cylinder head i s machined, us e a special cylinder head gasket

available from an authorized BMW dealer. The gasket is 0.3 mm
(0.011 in) thicker than standard and i s marked accordingly.

— Lubricat e camshafts, camshaft carriers, bearing caps , hydraulic

lifters and friction washers with assembly lubrican t before
installation.

^ Chec k that two cylinder head aligning sleeves (arrows) are correctly
positioned i n block and are not damaged .

— Appl y elastic sealing compound 3-Bon d 1209 ® to corner joints an d

seam o n cylinder bloc k to timing chain cover.

— Plac e new cylinder head gasket on cylinder block .

 Cylinder Head Removal and Installatio n 113-1 1
Cylinder head, installing (M54 engine)

NOTE—
• The word "OBEN" or "TOP", printed on the gasket, faces up. The
cylinder head gasket fits correctly in only one orientation.

Set cylinder head in position, guiding primary chain through cylinde r

head opening.

Prior to installin g cylinder head bolts , kee p in mind th e following:

• D o not reuse cylinder hea d bolts. The y are stretch-type bolts an d
are replace d whenever loosened.
• Cylinder head bol t lengt h for aluminum engine bloc k =110 mm.
• Check that head bol t washer s are in place before installin g th e
bolts. Some washers are staked to the cylinder head.

Lightly lubricate new cylinder head bolts and washers with oil. Install
cylinder head bolts and bolts for cylinder head to lower timing chai n
cover finger tight.

26 8 1 4 Tighten cylinder head bolt s in correct sequence ( 1 - 14) .

12 1 04

p\i ( t I
I1 i *
CAUTION—
• Tighten the bolts in three stages, as listed below. The final
)o oo o )
o o OO O O
stages require the use of a BMW special tool 112 110 or a
suitable protractor to tighten the bolts to a specified torque

? f ' I f t s <4
angle.

yI M\ 3 9
\ Tightening torque
Cylinder hea d to engine bloc k
• Stag e 1 1 1
40 N m (3 0 ft-lb)
13 7 5
502113857b
• Stage 2 +90°
• Stage 3 +90°

Install intake camshaft sensor (arrow) .

502113Q53
113-12 Cylinde r Head Remova l and Installatio n
Cylinder head, installing (M54 engine)

Install lowe r secondary chai n guide . Tighte n tor x bolts (arrows) to

specifications. Bolt on intake camshaft sid e i s long and extends into
engine block .

Tightening torque
Secondary chain guide to cylinder hea d (M6) 10Nm(89in-lb)

Tighten bolts (arrows) for cylinder head to lower timing chain cover.
(Photo shows camshafts in place) .

Tightening torque
Cylinder head to lowe r timing chain cover 10Nm(89in-lb)
(M6)

— Reinstal l camshafts. See 11 7 Camshaft Timin g Chain .

CAUTION—
• Make sure the crankshaft, which was rotated approximately 30°
opposite the direction of engine rotation from TDC, is still in that
position before reinstalling the camshafts. This ensures that
pistons are out of TDC position and prevents piston-valve
interference when the camshafts are installed.
• After the camshafts are installed, a minimum waiting time is
required for the hydraulic lifters to bleed down before bringing
the crankshaft and pistons back to TDC. When the camshafts
are removed, the hydraulic lifters may expand. This expansion
can cause increased valve lift when the camshafts are bolted
down, possibly resulting in piston-valve interference.

— Reinstal l double VANOS unit. See 11 7 Camshaf t Timing Chain .

^ Instal l coolant pipe fasteners at base o f cylinder head and tighten

fasteners (arrows).

NOTE—
• Use new sealing O-ring on coolant pipe.

— Attac h oil line to VANOS unit using banj o bol t with new seals.

Tightening torque
Oil line to VANOS unit (banjo bolt) 32 Nm (24 ft-lb)
Cylinder Head Removal an d Installation 113-1 3
Cylinder head, installing (M54 engine)

Install intake camshaft cover and cylinder head cover. See Cylinde r
head cover, removing and installing (M5 4 engine) i n this repair
group.

Tightening torque
Cylinder head cover to cylinder head (M6) 10 N m (8 9 in-lb)

Install exhaust manifolds using new gaskets and nuts. Coat manifold
studs with copper past e prior to installing nuts. See 18 0 Exhaus t
System.

Tightening torque
Exhaust manifold to cylinder head (M7) 20 N m (15ft-lb )

— Instal l electrica l harness connectors for oil pressure sende r an d

coolant temperature sensor befor e installing intake manifold.

— Reinstal l intake manifold . See 13 0 Fuel Injection.

CAUTION—
• When reattaching throttle assembly harness connector,
connector is fully tightened when arrows on connector and plug
line up.

Installation of the remainin g parts is reverse or removal, notin g th e

following:
• Refil l and bleed cooling system. See 170 Radiator and Coolin g
System.
• Chang e engine oil and filter. See 020 Maintenance .
• Reconnec t battery .

CAUTION—
• To prevent damaging engine electronic systems, install ground
wires previously removed, including the ground wires for the
ignition coils.
• Prior to starting engine, be sure to remove crankshaft lock tool.

Tightening torque
Coolant drain plug to cylinder block 25 N m (18ft-lb)
Radiator cooling fan to coolant pump 40 N m (30 ft-lb)
Radiator drain screw to radiator 2.5 N m (22 in-lb)
Spark plug to cylinder head 25 Nm (18 ft-lb)
113-14 Cylinde r Head Remova l and Installation
Cylinder head cover components (N52 engine)

CYLINDER HEA D (N52 ENGINE)

Cylinder hea d cover components (N5 2 engine)
Cylinder head cover fo r 2006 N52 engine is made of aluminum-
magnesium alloy . Aluminum stretch bolts and fasteners are used .
Replace them wheneve r the cover i s removed .

Cylinder hea d cover for 2007 an d late r N5 2 engine i s made of

plastic. Stee l fasteners may be used an d they can be reused.
1. Valvetroni c motor mountin g bol t (M 6 x 1 6 mm)
•Tighten to 1 0 M m ( 7 ft-lb)
2. Valvetroni c motor
3. Gaske t
4. Cylinde r hea d cover
5. Cylinde r head cove r fastener
6. Bracke t (N52 engine only )
7. Cylinde r head cove r gasket-outer
8. Cylinde r hea d cover gasket-inner (spark plu g holes )
9. Crankcas e breathe r hos e

Cylinder hea d cover , removing an d installing

(N52 engine )
— Us e scan tool to rea d out and recor d ECM fault memory.

— Switc h ignition OFF an d remov e key.

— Remov e cabin microfilter uppe r an d lowe r housings. Se e 64 0

Heating an d Air-conditioning.

— Remov e righ t strut tower brace .

— Remov e ignition coil cover (uppe r engin e cover) . See

020 Maintenance.

— Detac h ignition coi l connectors. Unclip ignitio n coil harness from

cylinder hea d cover an d lift aside.

— Remov e ignition coils. Se e 12 0 Ignitio n System .

^, Working at cylinder head cover :

• Detach crankcas e breather hose .
• I f applicable: Pul l off metal bracket .
• Remov e valvetronic motor mountin g bolt s (A). To disengage
valvetronic motor , see 131 Fuel Injection .
Cylinder Head Removal and Installation 113-1 5
Cylinder head cover, removing and installing (N52 engine)

^. Remove cylinde r head cover fastener s (A , B). Discard if aluminum

(blue head) .
• Measur e and record lengths and positions of bolts and studs .
Different fastener length s are determined b y shapes o f bushings .

NOTE—
• The end laces of aluminum fasteners are usually painted blue. For
reliable identification, test fasteners for aluminum composition with
magnet.

— Lif t of f cylinder hea d cover and discar d old gaskets.

Clean gaske t residu e fro m cylinder head and cylinder hea d cove r
sealing surface s (A, B) .

CAUTION—
• To avoid gouging the cover, do not use metal scraping tool.

Remove and replace slotte d ignitio n coil sleeves in cylinder hea d

cover.

Coat cylinder head cove r grooves with thin laye r of anti-friction

compound suc h as glycerine. Pres s gaskets i n place, makin g sur e
they are no t stretched at any point.
113-16 Cylinde r Hea d Remova l an d Installatio n
Cylinder head cover, removing and installing (N52 engine)

Reinstall cylinder hea d cover.

• Coat cylinde r hea d contac t surface s with thin laye r of anti-friction
compound suc h a s glycerine.
• Plac e small quantity o f silicone sealan t at metal-to-metal seams
(such a s timing cove r to engine block ) an d half moo n gaske t area .
• Replac e aluminum fasteners . Install i n correct locations as noted
previously.
• Tighten graduall y i n crisscross pattern , startin g with inside
fasteners.

Tightening torques
N52 engine cylinde r head cover to cylinde r
head (aluminum-magnesium allo y cover, use
new aluminum M7 fasteners )
• Stage 1 7 N m (6 3 in-lb)
• Stage 2 additional 90°
N52KP or N51 engine cylinde r hea d cover to 9 N m (7 ft-lb)
cylinder head (plasti c cover, steel M7
fasteners)

— Reinstal l valvetronic motor.

Tightening torque
Valvetronic moto r to cylinder head cove r 10Nm(7ft-lb)
(M6x 1 6 mm bolts)

Remainder o f assembly i s reverse of removal . Mak e sur e cabin

microfilter housing seal s correctly.

Tightening torques
Ignition coil cover to cylinder head cover (M6 ) 4 Nm (35 in-lb)
Cylinder Head Removal and Installatio n 113-1 7
Cylinder head and timing chain (N52 engine)

Cylinder head and timing chain (N52 engine )

1 Camshaft adjustment unit mounting bol t
(M1 O x 94 mm)
• Fteplac e with new
• Tighten in 2 stages
Stage 1:20 Mm (15 ft-lb)
Stage 2: Additional 180 °
2. Camshaf t impulse wheel
3. Exhaus t camshaft adjustment uni t
4. Chai n tensioner (M22 x 1.5)
• Tighten to 55 Nm (41 ft-lb)
5. Sealin g O-ring
• Install new
6. Chai n tensioner rail
7. Chain module mounting bolt s
(M6x35 mmTorx)
• Tighten to 8.5 Nm (6 ft-lb)
8. Timin g chain
9. Cylinde r head with camshafts
10. Intake camshaft adjustment uni t
11. Chain tensioner rail mounting bol t (M8 )
• Tighten to 20 Nm (15 ft-lb)
12. Crankshaft sprocket
13. Chain guide
14. Chain guide mounting bolt (M7)
•Tighten to 14Nm (10 ft-lb)

Cylinder head, removin g and installin g

(N52 engine)
When removin g and installing the cylinder head, special tool s and
procedures are required to remove and install camshaft adjustmen t
units and valvetronic eccentric shaft and to time camshafts. Rea d
the entire procedure before beginning repairs .

CAUTION—
• Disassembly, removal and assembly of camshafts, camshaft
adjustment units or cylinder head without spec/a/ tools poses
the risk of damage or breakage: Valves may be bent by contact
with the piston crowns.

NOTE—
• Camshaft timing is covered in 117 Camshaft Timing Chain .

Cylinder hea d remova l and installation procedure s are describe d

separately.

If yo u remov e a cylinder hea d an d determine that i t require s

significant reconditioning work, a remanufactured cylinder head is
available from an authorized BMW dealer.
113-18 Cylinde r Head Remova l and Installatio n
Cylinder head, removing (N52 engine)

Cylinder head , removin g (N5 2 engine )

The cylinder head stretch bolts are aluminum . Replac e them any
time they ar e removed. Us e angle protractor to torque.

WARNING—
• To avoid personal injury, be sure the engine is cold before
beginning the removal procedure.

— Disconnec t negativ e (- ) cabl e from battery.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings an d Cautions .

— Rais e vehicle and suppor t safely .

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Remov e engine compartment splash shield. See 020 Maintenance.

— Wit h exhaust system fully cooled off , remove exhaus t system an d

both exhaust manifolds . Se e 180 Exhaus t System .

— Drai n engine coolant . Se e 17 0 Radiato r an d Coolin g System .

— Drai n engine oil. Se e 020 Maintenance .

— Remov e ignition coi l cover (upper engin e cover) . See

020 Maintenance .

— Remov e air filter housing, engin e ai r intak e duct s and intak e

manifold. See 131 Fue l Injection .

WARNING —
• Unscrew the fuel tank cap to release pressure in the tank
before working on fuel lines.

— Remov e cylinder head cover. See Cylinder hea d cover, removing

and installing (N5 2 engine) in this repai r group.

— Detac h coolant hoses from cylinder head .

"^ Usin g vibration damper bolt , rotate crankshaft to place cylinder 1 in

TDC firin g position. In this position , cylinder 1 intake camshaft lobe
points upwar d at an angle.

Cyl 1 intake
camshaft lob e
Cylinder Head Removal and Installatio n 113-1 9
Cylinder head, removing (N52 engine)

Make sure intake and exhaust camshaft part number s (A ) poin t up .

Cylinder 1 in TDC firin g position: Cylinder 6 exhaust camshaf t lob e

(A) points downward at an angle (dashed line). Cam follower (B) is
not actuated.

NOTE—
• Use a mirror to check exhaust camshaft lobe position.

Working underneath engine, slide out protective plug at lower left of

engine bell housing flange. Install BM W special tool 1 1 0 300
(crankshaft lockin g tool) through bel l housing flange por t int o
flywheel (A) hole . If necessary, roc k flywheel slightly bac k an d forth
to line up holes with tool. This lock s crankshaft at TDC .

CAUTION—
• Automatic transmission model: A short distance before the
flywheel special tool bore for TDC position, there is a large bore
which can be confused with the special tool bore. If the flywheel
is locked using the correct bore, the engine can no longer be
rotated at the vibration damper bolt.
Ijjj^CyjinderJHead Removal and Installation
Cylinder head, removing (N52 engine)

Using BMW special too l set 1 1 4 280, loc k down camshafts.

, Remov e intake and exhaust camshaft adjustmen t units:

• Loosen an d remove adjustmen t unit mounting bolts (A) Discar d
bolts.
• Remove timing chain tensioner (B). B e prepared to catch drippin g
oil with a shop towel. D o not allow oil to contaminate accessory
belt.
• Disengage timin g chain from camshaft adjustmen t unit sprockets .
Remove adjustment unit s and set aside.

NOTE—
• Illustration does not show special tool set 11 4 280 in place.

Working at front of cylinder head:

• Remov e timing chain modul e mountin g bolts (A).
• Uncli p chain modul e (B) at junction (C ) and lift out.
• Plac e timing chain in cylinder head opening.

CAUTION—
• Do not remove crankshaft locking tool. Rotating crankshaft may
cause the timing chain to jam or jump teeth.
Cylinder Hea d Removal and Installatio n 113-2 1
Cylinder head, removing (N52 engine)

Unbolt an d remove valvetroni c eccentric shaft sensor mountin g

bolts (A) . Slide sensor (B ) forward (arrow) to remove .

Remove eccentric shaft magne t wheel mountin g bol t (A) . Slid e

magnet wheel (B ) forward (arrow) to remove .

CAUTION—
• Magnet wheel mounting bolt is non-magnetic. Do not allow it to
fall into engine.
• Magnet wheel is highly magnetic. Protect against metal filings
by storing in sealed plastic bag.

Pretension eccentric shaf t (arrow) . Remov e stop scre w betwee n

cylinders 1 and 2 (A).
113-22 Cylinde r Head Removal and Installatio n
Cylinder head, installing (N52 engine)

Remove cylinder head bolt s (A , B ) to timing chain housing . Press

timing chain rail forward slightly to remove bolt B. Discard aluminu m
bolts.

CAUTION—
• Use mechanical gripper to prevent lower bolt(s) from falling
down inside crankcase.
• Measure and note down different bolt lengths for correct
reinstallation.

Use BMW special tools 1 1 4 420 (Tor x T50) and 1 1 8 580 (Torx T60)
to loosen and remove M9 and M10 cylinder hea d bolts. (Intake and
exhaust camshafts removed for purpose o f illustration.)
• Loose n M9 bolts first.
• Loose n M10 bolts in crisscross pattern, startin g with outside bolts.
• Not e different bolt lengths .
• Discar d aluminum bolts .

Bolt liftin g handles to cylinder head. Lif t off hea d with help of
assistant.

CAUTION—
• Cylinder head weighs approx. 40 kg (88 Ib).
• Place cylinder head on work bench on its side. Putting it down
on sealing surface risks damage to the valves.
• Be sure to clean antifreeze out of cylinder head bolt holes in
1: /£ 0 t*4 >
crankcase immediately.
...BSi 01130381

Cylinder head, installing (N52 engine)

Before cleaning engin e block sealing surface, insert plugs (BMW
special tools 1 1 4 430 o r equivalent) int o oil passages .
• Not e cylinder head gasket I D at right front edge of gasket.

Clean cylinder head and gasket surfaces of engine block and timing
chain housing .

CAUTION—
• Remove foreign matter and liquid from bolt holes. Trapped oil or
coolant in bolt holes can cause damage to the engine block.
• Do not use a metal scraper or wire brush to clean sealing
surfaces. If necessary, use a hard wooden or plastic scraper.
Also available are abrasive discs to be used in conjunction with
an electric drill. Be sure to use the correct disc for the type of
metal being cleaned.

— Inspec t cylinder head for visible crack s o r other defects .

Cylinder Head Removal and Installation 113-2 3
Cylinder head, installing (N52 engine)

To check cylinder head fo r warpage:

• Remov e intake and exhaust camshafts and intermediate intak e
levers.

CAUTION—
• Keep components in separate compartments and mark them
for reassembly in their original positions.

Use straight edge to check evenness of cylinder head sealin g

surface i n longitudinal direction.

'A. Us e straight edg e to check evennes s of cylinder head sealin g

surface i n transverse direction.

Cylinder head warpage specifications

Maximum warpage allowe d
• Longitudina l 0.10 m m (0.003 9 in )
• Transverse 0.05 m m (0.002 0 in )

— Hav e cylinder head tested for coolant leaks an d cracks .

— I f cylinder head is warped but otherwise sound , machine a

maximum of 0.3 m m (0.01 1 in ) off sealing surface.

— Reassembl e cylinde r head , o r us e reconditioned BM W cylinde r

head. Se e 117 Camshaft Timing Chain .

Tightening torques
Oil spray nozzle to valvetronic guide block 10Nrn(7fWb)
(M6 x 30 m m bolt)
Valvetronic guide bloc k to timing chain 10Nm(7ft-lb)
housing (M6 x 23 mm bolt)

Valvetronic torsion sprin g t o cylinder hea d 10Nm(7ft-lb)

(M6 x 20 bolt)
Camshaft bearin g strip to camshaft
( M 7 x 7 0 m m 10. 9 steel bolt)
• Stage 1 8 Nm (71 in-lb)
• Stage 2 additional 60 °

CAUTION—
• Once assembled with valves and camshafts, place cylinder
head dcwn on work bench on its side. Putting it down on
sealing surface risks damage to the valves.
113-24 Cylinde r Head Remova l and Installation
Cylinder head, installing (N52 engine)

^ Chec k that two cylinder head aligning sleeves (arrows) are correctly
positioned i n engine bloc k and ar e no t damaged .

— Replac e cylinder head gasket.

- I f cylinder hea d i s machined, us e a special cylinde r hea d gaske t

available fro m an authorized BMW dealer . Th e gasket i s 0.3 mm
(0.011 in) thicker than standar d an d i s marked accordingly .

— Plac e cylinde r hea d on engine bloc k an d fit to aligning sleeves .

Insert new aluminum cylinde r hea d bolts :

• Bolt s 1 - 10: M1 Ox 12 5 mm
• Bolt s 11 -14: M9 x 95 mm and M9 x 125 mm. Inser t correct length
bolts, as marked previously.

NOTE —
• Graphic shows intake and exhaust camshafts removed.

Use BMW special too l 1 1 8 850 (Tor x T60) t o tighten bolt s 1 - 10 in

sequence show n below .

Use BMW special tool 11 4 420 (Torx T50) t o tighten bolts 11 -14 in
sequence show n below .

Tightening torques and sequence

Cylinder head to engine block :
• Stag e 1 : All bolts, 1 - 1 4 30 Nm (2 2 ft-lb)
• Stag e 2: All bolts, 1 - 14 additional 90 °
• Stag e 3 : Only bolt s 1 - 1 0 additional 90 °
• Stage 4: All bolts 1 - 14 additional 45°

CAUTION—
• Stage 3 applies to M10 bolts (1 - 10) only.
Cylinder Hea d Removal an d Installation 113-2 5
Cylinder head, installing (N52 engine)

. Us e ne w aluminum bolt s (A , B ) to attac h cylinde r hea d to timing

chain housing. Pres s timing chain rai l forward slightly to install lowe r
bolt(s).

CAUTION—
• Use mechanical gripper to prevent lower bolt(s) from falling
down inside crankcase.
• Place different bolt lengths in correct bores.

Tightening torques
N52 engine cylinde r hea d to timing chai n
housing (M 9 x 30 m m or M 9 x 70 mm) :
• Stage 1 15 Nm (1 1 ft-lb )
• Stage 2 additional 90°
N52K engin e cylinde r hea d t o timing chai n
housing (M 9 x 30 mm) :
• Stage 1 10Nm(7ft-lb)
• Stage 2 additional 90 °
N52K engin e cylinde r hea d to timing chain
housing (M 9 x 70 mm) :
• Stag e 1 10Nm(7ft-lb)
• Stage 2 additional 135°

— Reinstal l eccentric shaft stop screw.

Tightening torque
Eccentric shaft stop scre w to cylinder hea d 10Nm (7 ft-lb)
(M6)

Replace eccentric shaf t magnet wheel .

Reinstall eccentri c shaft sensor.

Use wire hook t o retriev e timing chain fro m inside timin g chai n
housing. Place chain over chain module and clip module to lowe r
chain rail. Reinstall chain modul e mountin g bolts .

Tightening torque
Chain modul e t o cylinder hea d 8.5 N m (6 ft-lb)
(M6 x 35 m m Torx)

Use new bolts to reattach camshaft adjustment (VANOS) units . Not e

that exhaust and intake unit s are different and so marked. Camshaf t
sensor impulse wheel for intake and exhaust ar e the same.

CAUTION—
• Use special tools shown i n 117 Camshaft Timing Chain to
lock down camshafts.

Tightening torque
Camshaft adjustmen t (VANOS ) uni t to
camshaft (us e ne w M1 0 x 94 m m bolt):
• Stag e 1 20 N m (1 5 ft-lb)
• Stage 2 additional 180 °
B510113023
113-26 Cylinde r Hea d Removal and Installation
Cylinder head, installing (N52 engine)

Install chain tensioner and set camshaft timing . See 117 Camshaft
Timing Chain .

CAUTION—
• If chain tensioner is reused, drain its oil chamber. Place
tensioner on level working surface and compress slowly.
Repeat twice.
• No seal ingring is fitted to chain tensioner at the factory. When
reassembling engine, be sure to use new sealing O-ring.

Tightening torque
Timing chain tensioner to cylinder hea d 55 N m (41 ft-lb)
(M22 x 1 .5) (us e new sealing O-ring )

Remainder of installation is reverse of removal. Remembe r to:

• Remov e camshaft and crankshaft locking tools.
• Assemble cylinder head cover with new gasket .
• Reattac h and tighten an y ground cable s removed .
• Reassembl e fuel rail using new O-ring seals .
• Change engin e oi l and filter. Se e 020 Maintenance .
• Fil l and bleed coolin g system . Se e 170 Radiator an d Coolin g
System.
Cylinder Head Removal and Installation 113-2 7
Cylinder head cover components (N54 engine)

CYLINDER HEA D (N54 ENGINE)

Cylinder head cover components (N54 engine)
1. Cylinde r head cove r bolt (M6 x 38 mm )
• Quantity: 2
•Tighten to 8.5 M m (75 in-lb )
2. Cylinde r head cove r
3. Threade d stu d
• Quantity: 3
• Remov e using BMW special tool 1 1 8 620 or equivalent dee p
10 mm socket wrench .
4. Cylinde r hea d cove r bol t (M 6 x 32.5 mm )
• Quantity: 26
• Tighten to 8.5 Nm (75 in-lb)
5. Cylinde r hea d cover gaske t

B510113004

Cylinder hea d cover, removing and installing

(N54 engine)
Disconnect negativ e (- ) battery cable and cover batter y termina l t o
keep cable fro m accidentally contactin g terminal.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given i n 001 Warnings an d Cautions .

— Us e scan tool to read out and recor d EC M fault memory .

— Switc h ignition OFF an d remov e key.

— Remov e upper an d lowe r cabin microfilte r housings . Se e 64 0

Heating an d Air-conditioning

— Remov e righ t stru t tower brace .

— Remov e ignition coi l cover (upper engin e cover) . Se e

020 Maintenance .

— Remov e ignition coils . Se e 12 0 Ignition System .

— Uncli p fue l injector and ignitio n coil wiring harness an d se t aside .

113-28 Cylinde r Hea d Remova l and Installatio n
Cylinder head cover, removing and installing (N54 engine)

Loosen high pressure fuel line junctions (arrows).

WARNING—
• Fuel in the fuel line is underpressure (approx. 200 bar or 2900
psi) and may be expelled forcibly. Do not smoke or work near
heaters or other fire hazards. Keep a fire extinguisher handy.
• Work only on fuel system when engine temperature is below
40°C (104°F).
• Unscrew the fuel tank cap to release pressure in the tank before
working on the fuel line.
• Plug open fuel lines and fittings.
• Wrap a clean shop towel around fitting before disconnecting.
Residual fuel pressure is present in the fuel line.
• To reduce fuel pressure, place towel over injector and carefully
tap with a wrench.

CAUTION—
• Maintain a dean work area when servicing high pressure fuel
system. Contaminants can cause a system malfunction.
• Fuel residue can break down the electrical resistance qualities
of silicone used in ignition coil production, resulting in coil
failure.
• Replace high pressure fuel lines if tightened 10 times.

— Remov e injector lines and mar k them i n order.

— Remov e injectors an d mark them in order. Plug fuel injector bores to

prevent debris from entering engine. Se e 13 2 Fuel Injection.

^C Workin g at left front of cylinder head :

• Detac h vacuum hoses (A) from vacuum lines .
• Uncli p vacuum line s (B) from cylinder hea d cover.

Working at right front of cylinder head :

• Detach vacuu m hoses (A) from vacuum lines .
• Uncli p vacuum line s (B) and set aside .
 113-29
Cylinder head cover,

< Us e BMW special tool 1 1 8 62C or equivalent dee p 1 0 mm socket

wrench t o loosen and remove threaded stud s (arrow) i n center o f
cylinder head cove r valley.
• Quantity: 3 studs

Remove cylinder head cove r bolts (arrow).

• M 6 x 38 mm bolts, quantity: 2
• M 6 x 32.5 m m bolts, quantity: 26

NOTE—
• Make note of arrangement of fasteners during removal so that they
can be reinstalled in their original locations.

- Remov e cylinder head cover and discard gasket .

- Inspec t cylinde r hea d cover fasteners. Replac e as necessary.

< Clea n gaske t residu e from cylinder head sealing surface and fro m
cylinder head cover grooves . '
Gasket
grooves CAUTION—
• To avoid gouging the cover, do not use metal scraping tool.
'—

Coat cylinde r head cover groove s with thin layer of anti-friction

compound such as glycerine. Press gasket in place, making sure it
is not stretched a t any point .

-.

B510113006
113-30 Cylinde r Hea d Remova l and Installatio n
Cylinder head cover, removing and installing (N54 engine)

Reinstall cylinde r hea d cover.

• Coa t cylinder head and gasket contact surfaces with thin layer of
anti-friction compound suc h as glycerine.
• Plac e smal l quantity of silicone sealant a t metal-to-metal seams
(such as timing cove r to engine block) .
• Instal l cylinder head cover fasteners in correct locations as note d
previously.
• Tighten gradually i n crisscross pattern , starting with insid e
fasteners.
• Replac e fuel injector PTFE sealin g rings . See 132 Fuel Injection.

Tightening torque
Cylinder head cover to cylinder hea d (M6) 8.5 N m (75 in-lb)

Reinstall high pressure fuel lines an d injector s in correct locations,

as marked previously . See 132 Fuel Injection .
• Coat nut threads with gear oil.
• Connect high pressur e line (A) finger tight.
• Hig h pressur e lin e ma y only be retightened 1 0 times.

If fuel lines cannot be easily installed , rock injector (arrows) to allow

fuel line nipple threads to be started b y hand .
• Tighten hold-down bracket fastener (A).

Tightening torque
Hold-down bracket to cylinder head 13Nm(9 5 ft-lb)

To tighten injector lines:

• Tighten nut (A) usin g special tool 37 1 151 while holding injector
with wrench (C).
• Tighten nut (B) using special tool 37 1 151.

Tightening torque
High pressure lin e to injector 23 Nm (17 ft-lb)

High pressure line to fuel rail 23 Nm (17 ft-lb)

 Cylinder Hea d Removal an d Installation 113-3 1
Cylinder head and timing chain (N54 engine)

— Clea n al l fuel from ignition coil hole.

— Remainde r o f assembly i s reverse of removal . Kee p i n mind th e

following:
• Mak e sure cabin microfilte r housing seal s correctly.
• Check fuel line s for leaks once engine starts.

Tightening torque
Ignition coil cover to cylinder head cover (M6) 4 N m (35 in-lb)
Strut tower brac e to bulkhead (replac e M12
bolt)
• Stage 1 100 M m (74ft-lb )
• Stage 2 additional 90°
Strut tower brac e to strut tower (replace M10
bolt)
• Stage 1 40 N m (3 0 ft-lb)
• Stage 2 additional 60 °

Cylinder head and timing chain (N54 engine )

1. Camshaf t adjustment unit mounting bol t
(MlOx 94 mm)
1 2 3 4 5 6 7 8
• Replac e with new
• Tighten in 2 stages
Stage 1: 20 Nm (15 ft-lb)
Slage 2: Additional 180 °
2. Camshaf t impulse whee l
3. Exhaus t camshaft adjustment uni t
4. Chai n tensioner (M22x 1.5 )
•Tighten to55 Nm (41 ft-lb)
5. Sealin g O-rin g
• Instal l new
6. Chai n tensioner rai l
7. Chai n module mounting bolts
(M6 x 35 mm Torx)
• Tighten to 8.5 Nm (6 ft-lb)
8. Timin g chain
9. Cylinde r head with camshafts
10. Intake camshaft adjustment uni t
11. Chain guide mounting bol t (M8)
• Tighten t o 20 Nm (15 ft-lb)
12. Crankshaft sprocke t
13. Chain guide
14. Chain guide mounting bolt (M7)
•Tighten to 14Nm (10ft-lb)
 Cylinder Head Removal an d Installation 113-3 1
Cylinder head and timing chain (N54 engine)

— Clea n al l fuel from ignition coil hole.

— Remainde r of assembly i s reverse of removal. Kee p i n mind th e

following:
• Mak e sure cabin microfilte r housing seals correctly.
• Chec k fuel lines for leaks onc e engine starts.

Tightening torque
Ignition coil cover to cylinder hea d cover (M6) 4 Nm (3 5 in-lb )
Strut towe r brac e to bulkhead (replace M1 2
bolt)
• Stag e 1 100 Nm (74ft-lb )
• Stage 2 additional 90 °
Strut tower brace to strut tower (replace M10
bolt)
• Stage 1 40 N m (30 ft-lb)
• Stage 2 additional 60°

Cylinder head and timing chai n (N54 engine )

1 Camshaft adjustment unit mounting bolt
(M10x94mm)
1 2 3 4 5 6 7 8
• Replac e with new
• Tighten in 2 stages
Stage 1 : 20 Nm (15 ft-lb)
Stage 2: Additional 180 °
2. Camshaf t impulse whee l
3. Exhaus t camshaft adjustment uni t
4. Chai n tensioner (M22 x 1.5)
•Tighten to 55 Nm (41 ft-lb)
5. Sealin g O-ring
• Instal l new
6. Chai n tensioner rail
7. Chai n module mounting bolt s
13 1 4 (M6 x 35 mm Torx)
B510113008|
• Tighten to 8.5 Nm (6 ft-lb)
8. Timin g chain
9. Cylinde r head with camshafts
10. Intake camshaft adjustmen t unit
11. Chain guide mountin g bolt (M8 )
• Tighten t o 20 Nm (15 ft-lb)
12. Crankshaft sprocket
13. Chain guid e
14. Chain guide mountin g bol t (M7 )
• Tighten to 14 Nm (10 ft-lb)
113-32 Cylinde r Hea d Remova l an d Installation
Cylinder head, removing and installing (N54 engine)

Cylinder head, removing and installing

(N54 engine)
To remove the turbo engine cylinder head, first remove the engine .
Special tools and procedures are require d to remove and install
camshaft adjustment unit s and to time camshafts . Rea d the entir e
procedure before beginnin g repairs .

CAUTION—
• Disassembly, removal and assembly of camshafts, camshaft
adjustment units or cylinder head without special tools poses
the risk of damage or breakage:
-Valves may be bent by contact with the piston crowns.
-Camshaft may snap in two if bent by valve springs.

NOTE —
• Camshaft timing i s covered i n 117 Camshaft Timin g Chain .

Cylinder hea d remova l an d installation procedure s are describe d

separately.

If you remov e a cylinder hea d an d determin e tha t i t requires

significant reconditionin g work, a remanufactured cylinde r head is
available from an authorized BM W dealer .

Cylinder head, removing (N54 engine)

The cylinder hea d stretch bolts ar e aluminum. Replac e them any
time they ar e removed . Us e angle protracto r to torque.

WARNING —
• To avoid personal injury, be sure the engine is cold before
beginning the removal procedure.

— Disconnec t negativ e (- ) cabl e fro m battery.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings an d Cautions.

— Remov e ignition coil cover (uppe r engine cover). See

020 Maintenance .

— Wit h engine fully cooled off, drain engin e coolant. See 170 Radiator
and Cooling System.

— Remov e engine. Se e 11 0 Engin e Remova l an d Installation.

— Remov e cylinder hea d cover. See Cylinder hea d cover , removin g

and installin g (N5 4 engine ) i n this repai r group .

^, Using vibration damper bol t to rotate crankshaft , plac e cylinde r 1 in

TDC firin g position. In this position , lobe s for cylinder 6 (rear of
engine) intak e and exhaust camshaft s (A , B ) point away from eac h
other and down. Cylinder 6 camshaft lobe s do not contact roller cam
followers.
Cylinder Hea d Removal an d Installation 113-3 3
Cylinder head, removing (N54 engine)

NOTE—
' Use a mirror to check cylinder 6 cam lobe positions.

Working underneat h engine, slide out protective plu g at lower lef t of

engine bel l housing flange . Install BMW special tool 1 1 0 300
(crankshaft lockin g tool) through bell housing flange port int o
flywheel (A ) hole. If necessary, roc k flywheel slightly back and forth
to line up holes with tool. This lock s crankshaft at TDC.

CAUTION—
• Automatic transmission model: A short distance before the
flywheel special tool bore for TDC position, there is a large bore
which can be confused with the special tool bore. If the flywheel
is locked using the correct bore, the engine can no longer be
rotated at the vibration damper bolt.

Remove intake and exhaust camshaft adjustment units .

See 117 Camshaft Timin g Chain.

Use BMW special tool set 1 1 4 280 to lock down camshafts .

Remove intake an d exhaust camshaft adjustment units :

• Loose n and remove adjustment unit mounting bolt s (1) . Discar d
bolts.
• Remove timing chain tensioner (2) . Be prepared to catch dripping
oil with a shop towel. Do not allow oil to contaminate accessor y
belt.
• Disengag e timing chai n from camshaft adjustment uni t sprockets .
Remove adjustment unit s and set aside.

NOTE—
• Illustration does not show special tool set 114 280 in place.
113-34 Cylinde r Head Removal and Installation
Cylinder head, removing (N54 engine)

Working at front of cylinder head:

• Remov e timing chain modul e mountin g bolt s (A).
• Uncli p chai n modul e (C ) at junction (B ) and lif t out.
• Place timing chain in cylinder head opening.

CAUTION—
• Do not remove crankshaft locking tool. Rotating crankshaft may
cause the timing chain to jam or jump teeth.

Remove cylinder hea d bolt s (A) to timing chain housing . Pres s

timing chai n rai l forward slightly t o remov e lower bolt(s).

CAUTION—
• Use mechanical gripper to prevent lower bolt(s) from falling
down inside crankcase.
• Measure and note down different bolt lengths for correct
reinstallation.

Use BMW special tool 11 4 420 (Torx T50) to loosen and remove M9
cylinder head bolts.
• Not e different bolt lengths .
• Discar d al l aluminum bolts .
Cylinder Head Removal and Installation 113-3 5
Cylinder head, installing (N54 engine}

Use BMW special too l 1 1 8 850 (Torx T60) to loosen an d remov e

M1 1 cylinder head bolt s (A).
• Star t a t outer corners and loosen bolts in crisscross pattern .
• Discar d all aluminum bolts .

Use magnet (A ) to lif t out cylinder hea d bolt washers (B ) betwee n

surface of cylinder head an d camshaft bearing strip.

Bolt liftin g handle s t o cylinder head. Lif t off hea d wit h help of
assistant.

CAUTION—
• Cylinder head weighs approx. 40 kg (88 Ib).
• Place cylinder head down on work bench on its side. Putting it
down on sea/ing surface risks damage to the valves.
• Be sure to clean antifreeze out of cylinder head bolt holes in
crankcase immediately.

Cylinder head, installing (N54 engine)

Before cleaning engine bloc k sealing surface, inser t plug s (BM W
special tools 1 1 4 430 or equivalent) into oil passages .

Clean cylinder head and gasket surfaces of engine bloc k and timing
chain housing .

CAUTION—
• Remove foreign matter and liquid from bolt holes. Trapped oil or
coolant in bolt holes can cause damage to the engine block.
• Do not use a metal scraper or wire brush to clean the aluminum
cylinder head or pistons. If necessary, use a hard wooden or
plastic scraper. Also available are abrasive discs to be used in
conjunction with an electric drill. Be sure to use the correct disc
for the type of metal being cleaned.

— Inspec t cylinder hea d for visible cracks or other defects.

113-36 Cylinde r Hea d Remova l an d Installatio n
Cylinder head, installing (N54 engine)

To check cylinde r hea d for warpage :

• Remov e intake and exhaust camshafts an d roller cam followers.
• Remov e valve lifter s and valves.

Use straight edge to check evennes s o f cylinder head sealin g

surface in longitudinal direction .

Use straight edge to check evenness o f cylinder hea d sealin g

surface i n transverse direction.

Cylinder hea d warpage specifications

Maximum warpage allowe d
• Longitudina l 0.10 m m (0.0039 in)
• Transverse 0.05 m m (0.0020 in)

— Hav e cylinder head tested for coolant leak s an d cracks.

— I f cylinder hea d is warped but otherwise sound, machine a

maximum of 0.3 m m (0.011 in) off sealin g surface.

— Reassembl e cylinder head, o r us e reconditione d BMW cylinder

head.

Tightening torque
Camshaft bearin g strip to camshaft
(M7x70mm 10.9 steel bolt)
• Stage 1 8 N m (71 in-lb)
• Stage 2 additional 60 °

CAUTION—
• Once assembled with valves and camshafts, place cylinder
head down on work bench on its side. Putting it down on
sealing surface risks damage to the valves.

^ Chec k that two cylinder head aligning sleeves (arrows) are correctly
positioned in engine bloc k and are not damaged .

— Replac e cylinder head gasket .

— I f cylinder head i s machined, us e a special cylinde r hea d gasket

available from an authorized BMW dealer. Th e gaske t i s 0.3 mm
(0.011 in) thicker than standard and i s marked accordingly .

— Plac e cylinder head on engine bloc k an d fit to aligning sleeves.

Cylinder Hea d Remova l and Installation 1 13-37
Cylinder head, installing (N54 engine)

Insert ne w aluminum cylinde r hea d bolts:

•Bolts 1 - 10: M11 x 135m m
• Bolt s 1 1 - 1 4: M9 x 95 mm and M9 x 1 25 mm. Insert correct lengt h
bolts, as marked previously .
• Where necessary, use magnet to fit bolt washer.

NOTE—
• Graphic shows intake and exhaust camshafts removed.

Use BMW special tool 1 1 8 850 (Torx T60) to tighten bolts 1 - 10 in

sequence show n below.

Use BMW special too l 1 1 4 420 (Torx T50) to tighten bolts 1 1 - 14 in

sequence shown below.

Tightening torques and sequence

Cylinder head to engine block:
•Stage 1 : All bolts, 1 - 1 4 30 Nm (22 ft-lb)
• Stage 2: All bolts, 1 - 1 4 additional 90°
•StageS: Only bolts 1 - 1 0 additional 90°
• Stage 4: All bolts 1 - 1 4 additional 45 °

CAUTION—
• Stage 3 applies to M11 bolts (1 - 10) only.

Install cylinder head bolts to timing chain housing (A). Press timing
chain rail forward slightly to install lower bolt(s).

CAUTION—
• Use mechanical gripper to prevent lower bolt(s) from falling
down inside crankcase.
• Place different bolt lengths in correct bores.

Tightening torque
Cylinder hea d to timing chain housin g 22 N m (16 ft-lb)
(M9 x 30 mm or M9 x 70 mm)

Use wire hook to retriev e timing chain from inside timing chain
housing. Plac e chain ove r chain modul e and clip modul e t o lower
chain rail . Reinstall chai n modul e mountin g bolts .

Tightening torque
Chain modul e t o cylinder hea d 8.5 Nm (6 ft-lb)
(M6 x 35 m m Torx)
113-38 Cylinde r Head Removal and Installation
Cylinder head, installing (N54 engine)

Use new bolts to reattach camshaf t adjustmen t units. Note that

exhaust and intake units ar e different an d so marked. Camshaf t
sensor impuls e wheel for intake an d exhaust ar e the same.

CAUTIOH—
• Use special tools shown in 117 Camshaft Timin g Chain t o
lock down camshafts.

Tightening torque
Camshaft adjustmen t uni t to camshaft (use
new M10 x 94 mm bolt):
• Stage 1 20Nm(15ft-lb)
• Stage 2 additional 180°

Install chai n tensionerand set camshaft timing . See 117 Camshaft

Timing Chain.

B510113023 CAUTION—
• If chain fens/oner is reused, drain its oil chamber. Place
tensioner on level working surface and compress slowly.
Repeat twice.
• No sealing ring is fitted to chain tensioner at the factory. When
reassembling engine, be sure to use new sealing O-ring.

Tightening torque
Timing chain tensioner to cylinder hea d 55 Nm (41 ft-lb)
(M22 x 1.5 ) (use ne w sealing O-ring)

Remainder o f installation is reverse o f removal. Remember to:

• Remov e camshaft and crankshaft locking tools.
• Assemble cylinder hea d cover with new gasket.
• Reattac h and tighten any ground cables removed.
• Reassemble fue l rail using ne w O-ring seals .
• Change engine oil and filter. See 020 Maintenance.
• Fill and bleed cooling system . Se e 170 Radiator and Cooling
System.
Cylinder Head Removal and Installation 113-3 9
Cylinder head cover components (V8 engine)

CYLINDER HEA D (V8 ENGINE )

Cylinder hea d cove r components (V 8 engine)
Cylinder hea d cover for V8 engines i s made of plastic. Replace
gaskets, seals and O-rings whenever the cover i s removed.
1. Cylinde r head cover
2. Pressur e regulating valve
3. Valvetroni c motor spacer
4. O-rin g
5. Valvetroni c motor
6. Ca p nut
7. Rubbe r seal
8. Bol t
9. Gaske t ring
10. Cylinde r head cover gasket

Cylinder hea d cover, removing and installin g

(V8 engine )
— Us e scan tool to read out and recor d ECM fault memory.

— Switc h ignition OFF an d remov e key.

— Remov e upper engine cover . See 020 Maintenance .

— Remov e ignition coil cover. See 02 0 Maintenance .

'X. Uncli p wiring harness and holder from (A) from cylinder head cover.
Remove fuel tank vent valve (B) off mounting bracket (C).
1 1 3-40 Cylinde r Hea d Removal an d Installation
Cylinder head cover, removing and installing (V8 engine)

Disconnect electrical connectors (A).

k Remov e fasteners (arrows). Remove wiring harness bulkhead seal

(A) and discard, remov e sensors (B) .

— Remov e ignition coils. See 120 Ignition System .

"X. Remov e ground straps (arrows). Unclip and remove wiring harness
duct (A).

— Remov e valvetronic motor. See 13 3 Fuel Injection.

Cylinder Hea d Removal and Installation 113-4 1
Cylinder head cover, removing and installing (V8 engine)

^k Remov e valvetronic motor spacer fasteners (arrows) and

spacer (A) . Discard valvetronic motor spacer seal upon removal.

— Remov e fuel injector rail. Se e 13 3 Fuel Injection .

, Remov e fasteners (A, B, C and D). If necessary remove dipstick. Lif t

and remove cylinder head cover.

To reinstall cylinder head cover.

• Coa t cylinder hea d contact surfaces with thin laye r of anti-friction
compound suc h as glycerine.
• Plac e small quantity of silicone sealan t at metal-to-metal seams
(such as timing cover to engine block) and half moon gasket areas.
• Instal l spark plug domes i n cylinder head cover before installation.
• Replac e cylinder hea d cover gaskets, seals and O-rings .
• Reinstal l valvetronic motor.
• Tighten cylinder hea d cover bolts gradually in crisscross pattern,
starting with inside fasteners.

Tightening torque s
Cylinder head cover to cylinder hea d
M6 bolts
M7 bolts 10Nm(7ft-lb)
15 M m (1 1 ft-lb )
• M8 bolts
17 Nm (12.5 ft-lb )

— Remainde r of assembly i s revers e of removal.

113-42 Cylinde r Hea d Remova l and Installation
Cylinder head and timing chain (V8 engine)

CYLINDER HEA D (V8 ENGINE )

Cylinder head and timing chain (V8 engine)
1. Dowe l
2. Scre w plu g
3. Valvetroni c motor flange
4. Scre w plu g
5. O-rin g
6. Scre w plug
7. Scre w plu g
8. Cove r
9. Cylinde r hea d bolt
10. Spark plu g dom e
11. Cylinder head assembly
12. Timing chain rail
13. Timing chai n
14. Timing chain guide
15. Bearing bolt
16. Cylinder hea d bolt
17. Connector
18. Timing chain tensioner
19. Timing chain guide
20. Timing chain guid e bearing
21. VANOS adjuste r
22. Check valv e
23. Cylinder head gasket

Cylinder head removal and installation

(V8 engine)
V8 engine cylinder heads are equipped with VANOS. To remove the
cylinder heads, special tools an d procedures are required for
removing the VANOS units . Rea d the entire procedure befor e
beginning the repair .

CAUTION—
• Disassembly, removal and assembly of camshafts or cylinder
head without special tools poses the risk of damage or
breakage. The valves may be bent by contact with the piston
crown; camshafts may break if stressed incorrectly during
removal or installation.

NOTE —
• VANOS or variable camshaft timing is from the German words
VAriable NOckenwelle n Steuerung.
• VANOS removal i s covered in 117 Camshaft Timin g Chain .
Cylinder Head Removal an d Installation 113-4 3
Right cylinder head, removing (V8 engine)

Right and left cylinder head remova l and installation procedures are
given separately. Remov e the intake manifold before removin g
either cylinder head. See 133 Fuel Injection.

If you remove a cylinder head and determine that it requires

significant reconditionin g work , a remanufactured cylinder hea d is
available fro m an authorized BM W dealer.

Right cylinder head , removin g (V8 engine)

WARNING —
• Due to risk of personal injury, be sure the engine is cold before
beginning the removal procedure.

— Disconnec t negativ e (-) battery cable.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings an d Cautions.

— Rais e car an d suppor t safely.

WARNING—
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

— Remov e right exhaust manifold . Se e 18 0 Exhaust System .

NOTE—
• To remove exhaust manifolds, secure engine in the installation
position with special tool and lower front axle bracket. Once
manifolds have been removed Reinstall front axle bracket and
remove special tool for securing engine in installation position.

— Ope n engine coolant drai n plug at right side of engine block . B e

prepared to catch draining coolant . Drain remaining engine coolan t
from radiator . Se e 170 Radiator and Cooling System .

— Remov e ignitio n coil cover. Se e 020 Maintenance.

— Remov e ignition coils. See 120 Ignition System .

— Remov e valvetronic motor. Se e 13 3 Fuel Injection.

— Remov e right cylinder hea d cover. See Cylinder hea d cover ,

removing and installing (V8 engine) in this repair group.

— Remov e intak e manifold. Plu g intake manifold ports to preven t

debris from entering engine Se e 133 Fuel Injection .

— Remov e upper righ t timing cover . Se e 117 Camshaft Timin g

Chain.

— Disconnec t electrica l connectors and la y engine wirin g harnes s

aside.

— Remov e spar k plugs . Plug spark plug bores t o prevent debris from
entering engine . Se e 020 Maintenance.
113-44 Cylinde r Hea d Remova l and Installatio n
Right cylinder head, removing (V8 engine)

— Remov e right cylinder hea d vent hose .

^k Workin g at rear of right side cylinder head , remov e secondary air

hose (A) . Remove check valve fasteners (B ) and remove check
valve (C ) with tube (D). Uncli p wiring harness (E) and lay aside.

— Remov e intake and exhaust camshaft adjustmen t (VANOS ) units.

See 117 Camshaft Timing Chain.

Loosen timing chain tensioner (A) by 1 turn (360°) .

Rotate eccentric shaft at dihedral hea d to reduce tension on torsion

spring (A). Using a strap (B) carefully pull torsion spring (A) off roller
(C) i n direction of arrow.
Cylinder Head Remova l and Installation 113-4 5
Right cylinder head, removing (V8 engine)

Rotate eccentric shaft at dihedral hea d in direction o f arrow to

minimum strok e postion .

Remove spring moun t fasteners (arrows) and feed spring moun t

(A) upward s out of locating pin .

Remove eccentric shaf t sensor fasteners (arrows). Remove

eccentric shaft sensor (A) from cylinder head .
113-46 Cylinde r Hea d Remova l an d Installation
Right cylinder head, removing (V8 engine)
Remove timing chain guide fastener (arrow).

Remove cylinder hea d to timing cover fasteners (arrows).

Loosen cylinder hea d fasteners 1 turn (360° ) i n sequence 1 0 - 1.

Cylinder Head Removal and Installation 113-4 7
Flight cylinder head, installing (V8 engine)

Rotate eccentric shaft at dihedral hea d in direction of arrow to

remove cylinder head bolt 7 (A) and discard.

Rotate eccentric shaft at dihedral hea d in direction of arrow to

minimum strok e postion .

Remove remaining cylinde r head fasteners and discard.

Lift off cylinder head with help o f assistant.

CAUTION—
• Cylinder head weighs approx. 40 kg (88 Ib).
• Place cylinder head on work bench on its side. Putting it down
on sealing surface risks damage to the valves.
• Be sure to clean antifreeze out of cylinder head bolt holes in
crankcase immediately.

Remove and discard cylinder hea d gasket .

Right cylinder head , installin g (V8 engine)

Clean cylinder head and gasket surfaces of engine bloc k and timin g
chain housing .

CAUTION—
• Remove foreign matter and liquid from bolt holes. Trapped oil or
coolant in bolt holes can cause damage to the engine block.
• Do not use a metal scraper or wire brush to clean sealing
surfaces. If necessary, use a hard wooden or plastic scraper.
Also available are abrasive discs to be used in conjunction with
an electric drill. Be sure to use the correct disc for the type of
metal being cleaned.

— Inspec t cylinder head for visible cracks or other defects .

113-48 Cylinde r Head Remova l and Installatio n
Right cylinder head, installing (V8 engine)

Remove timing chai n tensioner (A) and discard tensioner seal.

Slowly compres s timin g chain tensioner pisto n on a level surface .

Repeat procedure two times.

B5101130021

Install timing chai n tensione r (A ) with new seal finger tight.

Cylinder Head Removal an d Installation 113-4 9
Right cylinder head, installing (V8 engine)

Coat joint (arrows ) between engine block and timing cover with
3-Bond 1209® .

Inspect dowel sleeves (A ) for damage, replace if necessary .

Install new cylinder head gasket .

Place cylinder head onto engine block, being careful not to damag e
cylinder hea d gasket.

Install new cylinder head fasteners finger tight. Do not wash coatin g
on new cylinder hea d fasteners.

NOTE—
• Cylinder head fastener 7 will be installed in next step.
113-50 Cylinde r Head Removal and Installation
Right cylinder head, installing (V8 engine)

Rotate eccentric shaft at dihedral head in direction of arrow to install

cylinder head bolt 7 (A).

Rotate eccentric shaft at dihedral hea d in direction o f arrow to

minimum stroke postion.

Tighten cylinder head fasteners in sequence 1-10.

Tightening torques and sequence

Cylinder head to engine block:
•Stage 1: All bolts, 1 - 10 30 Nm (22 ft-lb)
• Stage 2: All bolts, 1 - 1 0 additional 90°
• Stage 3: All bolts 1 -10 additional 90 °
Cylinder Hea d Removal and Installation 113-5 1
Right cylinder head, installing (V8 engine)

Install and tighten cylinde r hea d to timing cover fastener s (arrows) .

Tightening torques and sequence

Cylinder hea d to timing cover: 10Nm (7.3ft-lb)

Install and tighten timing chain guide fastene r (arrow) .

Install eccentric shaft spring mount (A). Align locating pin with bore
in cylinder head. Instal l and tighten fasteners (arrows).
113-52 Cylinde r Head Removal and Installatio n
Right cylinder head, installing (V8 engine)

Rotate eccentric shaft at dihedral hea d to reduce tension on torsion

spring (A). Using a strap (B) carefully install torsion spring (A) onto
roller (C ) in direction o f arrow.

Rotate eccentric shaft at dihedral hea d in direction o f arrow to

minimum stroke postion .

Install eccentric shaft sensor (A) onto cylinder head and tighten
eccentric shaft sensor fasteners (arrows).
Cylinder Head Removal and Installation 113-5 3
Left cylinder head, removing (V8 engine)

Tighten timin g chain tensione r (A).

Tightening torques and sequenc e

Timing chain tensioner t o cylinder hea d 65 Nm (48 ft-lb)

Install intake an d exhaust camshaft adjustment (VANOS ) units . See

117 Camshaft Timin g Chain.

Remainder o f installation i s reverse of removal. Remember to:

• Remov e camshaft an d crankshaft lockin g tools .
• Assemble cylinde r hea d cover with new gasket.
• Reattac h and tighten any ground cables removed.
• Reassembl e fue l rai l using new 0-ring seals.
• Change engin e oi l and filter. See 020 Maintenance.
• Fill and bleed cooling system. See 170 Radiator and Coolin g
System.

Left cylinder head , removin g (V8 engine)

WARNING —
• Due to risk of personal injury, be sure the engine is cold before
beginning the removal procedure.

— Disconnec t negative (-) battery cable.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions in 001 Warnings and Cautions.

— Rais e car an d suppor t safely.

WARNING —
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

— Remov e left exhaust manifold. See 18 0 Exhaust System.

NOTE—
• To remove exhaust manifolds, secure engine in the installation
position with special tool and lower front axle bracket. Once
manifolds have been removed Reinstall front axle bracket and
remove special tool tor securing engine in installation position.

— Ope n engin e coolan t drai n plug a t left side o f engine block. Be

prepared to catch draining coolant . Drain remaining engine coolant
from radiator. See 170 Radiator and Cooling System.

— Remov e ignition coil cover. See 02 0 Maintenance.

— Remov e ignition coils. Plug spark plug bores to prevent debris from
entering engine. See 120 Ignition System .

— Remov e valvetronic motor. See 13 3 Fue l Injection.

— Remov e left cylinder head cover. See Cylinder hea d cover ,

removing an d installin g (V 8 engine) i n this repai r group .
113-54 Cylinde r Hea d Removal and Installation
Left cylinder head, removing (V8 engine)

— Remov e intake manifold. Plug intak e manifold ports to prevent

debris from entering engine. See 133 Fuel Injection .

— Remov e upper left timing cover . See 117 Camshaft Timing Chain.

— Disconnec t electrical connectors and lay engine wiring harnes s

aside.

— Remov e spark plugs. Se e 02 0 Maintenance.

— Remov e right cylinder head vent hose.

'X. Working a t rear of left side cylinder head, remove secondary air
hose (A) . Remov e check valve fasteners (B ) and remove check
valve (C) with tube (D) . D o not remove dipstick tube (E) .

— Remov e intak e and exhaust camshaf t adjustment (VANOS) units.

See 117 Camshaft Timin g Chain.

Remove eccentric shaft sensor fasteners (arrows). Remove

eccentric shaft sensor (A) from cylinder head .

Remove timing chain guide fastener (arrow).

Cylinder Hea d Removal and Installation 113-5 5
Left cylinder head, installing (V8 engine)

Remove cylinder head to timing cover fasteners (arrows).

Remove an d discard cylinder head fasteners in sequence 1 0 - 1 .

Lift off cylinder head with hel p of assistant.

CAUTION—
• Cylinder head weighs approx. 40 kg (88 Ib).
• Place cylinder head on work bench on its side. Putting it down
on sea/ing surface risks damage to the valves.
• Be sure to clean antifreeze out of cylinder head bolt holes in
crankcase immediately.

— Remov e an d discard cylinder head gasket .

Left cylinder head, installing (V8 engine)

Clean cylinder head and gasket surface s of engine block and timing
chain housing.

CAUTION—
• Remove foreign matter and liquid from bolt holes. Trapped oil or
coolant in bolt holes can cause damage to the engine block.
• Do not use a metal scraper or wire brush to clean sea/ing
surfaces. If necessary, use a hard wooden or plastic scraper.
Also available are abrasive discs to be used in conjunct/on with
an electric drill. Be sure to use the correct disc for the type of
metal being cleaned.

— Inspec t cylinder head for visible cracks or other defects.

^ Coa t joint (arrows ) between engin e bloc k and timing cover with
3-Bond 1209®
113-56 Cylinde r Hea d Removal and Installation
Left cylinder head, installing (V8 engine)

k Inspec t dowel sleeves (A) for damage, replace if necessary.

— Instal l new cylinder head gasket.

— Plac e cylinder head onto engine block, being careful not to damage
cylinder head gasket.

— Instal l new cylinder head fasteners finger tight. Do not wash coating
on new cylinder head fasteners.

Tighten cylinder head fasteners in sequence 1-10 .

Tightening torques and sequence

Cylinder head to engine block:
•Stage 1 : All bolts, 1 - 10 30 N m (22 ft-lb)
• Stage 2: All bolts, 1 - 1 0 additional 90 °
• Stage 3: All bolts 1 - 10 additional 90°

Install and tighten cylinder head to timing cover fasteners (arrows).

Tightening torques and sequence

Cylinder head to timing cover : 15Nm(11 ft-lb)
Cylinder Hea d Removal and Installation 113-5 7
Left cylinder head, installing (V8 engine)

If replacing cylinder head, transfer screw plug (A ) fro m old cylinder

head to new. Failure to replace scre w plug will result in a VANOS
malfunction.

Install and tighten timing chain guide fastener (arrow) .

Install eccentric shaf t sensor (A) onto cylinder head and tighten
eccentric shaft sensor fasteners (arrows).

Install intake and exhaust camshaft adjustment (VANOS) units. See

117 Camshaft Timing Chain .

Remainder of installation i s reverse of removal. Remember to :

• Remov e camshaft an d crankshaft lockin g tools.
• Assemble cylinder hea d cover with new gasket.
• Reattac h and tighten any ground cables removed.
• Reassembl e fuel rail using new O-ring seals.
• Change engine oil and filter. See 020 Maintenance.
• Fil l and bleed cooling system. See 170 Radiator and Coolin g
System.
 117-1

117 Camshaf t Timing Chai n

GENERAL 117- 1 TIMING CHAIN SERVIC E

Warnings 117- 2 (N52, N5 4 ENGINE ) 117-5 1
Camshaft timing chai n component s
VIBRATION DAMPE R 117- 3 (N52, N54 engine) 117-5 1
Vibration damper , removin g an d installing
Camshaft timing chain, removing and installing
(M54 engine) 117- 3
(N52, N5 4 engine) 117-5 2
Vibration damper, removing an d installing
Camshaft timing, adjusting (N52, N54 engine) 117-6 1
(N52, N5 4 engine) 117- 4
Timing chai n tensioner (N52 , N54 engine) . . . 117-6 4
Vibration damper, removin g and installing
(V8 engine) 117- 5 VANOS UNIT S (N52, N5 4 ENGINE ) 117-6 5
TIMING CHAI N SERVIC E (M54 ENGINE) . . . 117- 6 VANOS units,
removing an d installing (N52 , N54 engine) . 117-6 5
Double VANOS unit components
(M54 engine) 117- 6 TIMING CHAIN SERVICE (V 8 ENGINE ) 117-5 9
Double VANO S unit, removing (M54 engine) . 117- 7 Timing chai n component s (V 8 engine) 117-6 9
Double VANO S unit, installing (M54 engine) . 117-1 0 Right camshaft timing, adjustin g (V8 engine) . 117-6 9
Timing chai n components (M5 4 engine) . . . . 117-1 3 Left camshaft timing, adjusting (V8 engine) . . 117-7 7
Timing chains, removing (M54 engine) 117-1 4 Timing chain tensioner (V8 engine) 117-8 4
Timing chains, installing (M5 4 engine) 117-2 0
VANOS UNIT S (V8 ENGINE ) 117-3 4
Camshaft timing, checking an d adjusting
(M54 engine) 117 - 28 Right VANOS unit, removing (V8 engine) . . . 117-8 4
Right VANOS unit, installing (V8 engine) . . . . 117-8 9
CAMSHAFT SERVIC E (M54 ENGINE) 117-3 5 Left VANOS unit, removin g (V8 engine) . . . . 117-9 0
Camshafts, removin g (M54 engine) 117-3 5 Left VANOS unit, installing (V 8 engine) 117-9 4
Camshafts, installing (M54 engine) 117-4 1

GENERAL
This repair group provides remova l and repair informatio n fo r
crankshaft vibratio n damper, engine timin g chain and camshaf t
adjustment (VANOS) units. Camshaf t timin g procedur e i s also
included.

Repair procedure s i n this repair grou p assume tha t the engine is

installed in the engine bay.

The 5 Series engine cylinder head is equipped with variable

camshaft timing or VANOS (from the German words VAriab/e
NOckenwellen Steuerung). Special tools and procedures are
required to remove and install camshaft adjustment units and to time
camshafts. Be sure to read each procedure through before starting
work.
117-2 Camshaf t Timing Chai n
Warnings

See also:
• 020 Maintenance
• 100 Engine-General for engine cod e and application information .
• 113 Cylinder Hea d Remova l an d Installatio n fo r cylinder head
cover removal
• 130,131,132,133 Fuel Injection for air filter housing and intake
manifold remova l
• 170 Radiator an d Cooling Syste m fo r radiator drain and refill

Warnings

WARNING —
• Due to risk of personal injury, be sure the engine is cold before
beginning work on engine components.
• Use extreme caution when draining and disposing of engine
coolant. Coolant is poisonous and lethal to humans and pets.
Pets are attracted to coolant because of its sweet smell and
taste. Seek medical attention immediately if coolant is ingested.
• Fuel is highly flammable. When working around fuel, do not
disconnect wires that could cause electrical sparks. Do not
smoke or work near heaters or other fire hazards.
 Camshaft Timing Chain 117- 3
Vibration damper, removing and installing (M54 engine)

VIBRATION DAMPER
Vibration damper, removing and installing
(M54 engine )
The M54 engine uses a 1-piece crankshaft vibration damper ,
integrated with the hub .

— Rais e fron t of vehicle and support i n a safe manner .

CAUTION—
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Remov e splas h guard under engine. See 020 Maintenance.

— Remov e electric cooling fan and cooling fan cowl. See 170 Radiator
and Cooling System .

NOTE—
• Protect radiator from damage with a piece of wood.

— Wit h engin e full y coole d off , mark direction of rotation o n engin e

accessory belts . Remove belts . See 020 Maintenance.

^ Bol t BM W special tools 1 1 8 190 and 11 8 200 together. Inser t

fingers of special tool 1 1 8 200 in vibration damper openings. Use
this tool setup to counterhold vibration damper hu b while loosenin g
vibration damper mountin g bol t (arrow).

CAUTION—
• Make sure an assistant holds special tool.
• If assistant is not available to grip the tool, rest handle of tool on
front subframe. Protect subframe from damage with a piece of
wood.
• Do not use flywheel locking tool to hold crankshaft stationary to
loosen or tighten vibration damper mounting bolt.

— Remov e vibratio n dampe r mountin g bolt and discard.

— Pul l off vibration damper usin g BMW special tool s 1 1 8 210 an d

11 8 200.

CAUTION—
• Avoid damaging radiator.
• If using a different puller than the BMW special tools, be careful
to avoid damaging crankshaft threads.

Inspect front crankshaft seal for leaks. For seal replacement, se e

119 Lubrication System .
117-4 Camshaf t Timing Chai n
Vibration damper, removing an d installing (N52, A/5 4 engine)

When reinstalling :
• Align vibratio n damper groov e t o crankshaft woodruff key.
• Insert new vibration damper mounting bolt and washer.

CAUTION—
• Inspect woodruff key for damage before installing vibration
damper. Replace if necessary

Use BMW special tools 11 1 8 190 and 1 1 8 200 to counterhol d

vibration damper whil e tightening mounting bolt .

CAUTION—
• Do not use flywheel locking tool to hold crankshaft stationary to
loosen or tighten vibration clamper mounting bolt. Use only the
recommended special tools, or equivalent tools for
counterholding the pulley.

Tightening torque
Vibration damper to crankshaft 410Nm(300ft-lb)
(replace damper bolt)

Vibration damper , removin g an d installin g

(N52, N54 engine)
The crankshaft vibration dampe r i s also referre d to as the front
pulley.

WARNING —
• To avoid personal injury, be sure the engine is cold before
beginning the procedure.

— Rais e vehicle an d suppor t safely .

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.
_.,

— Remov e engine compartmen t splas h shield . See 020 Maintenance .

— Remov e electric cooling fan and cooling fan cowl. See 170 Radiator
and Cooling System .

NOTE —
• Protect radiator from damage with a piece of wood.

— Wit h engine full y cooled off, mark direction o f rotation o n engin e

accessory belt. Remov e belt. Se e 020 Maintenance .

^. Remov e vibration damper mounting Torx bolts (A) and discard. Lift
off vibratio n damper .

CAUTION—
• Do not remove vibration damper hub bolt (B). If this bolt is
removed, the timing chain drive sprocket becomes free to
rotate, resulting in valve damage.
 Camshaft Timing Chain 117- 5
Vibration damper, removing and installing (V8 engine)

— Installatio n is revers e of removal.

Tightening torque
Vibration damper t o hub 35 N m (2 6 ft-lb )
(replace damper M 8 x 1 6 mm Torx bolts)

Vibration damper, removing and installin g

(V8 engine)
— Rais e fron t o f vehicle an d support i n a safe manner .

CAUTION—
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Remov e splash guard unde r engine. See 020 Maintenance .

— Remov e electric cooling fan and cooling fan cowl. See 170 Radiato r
and Cooling System .

NOTE—
• Protect radiator from damage with a piece of wood.

— Wit h engine full y cooled off, mark direction of rotatio n on engin e

accessory belts. Remove belts. See 020 Maintenance .

^ Remov e vibration damper mounting bolts (arrows) and discard. Lift

off vibratio n damper (A).

CAUTION—
• Do not remove vibration damper hub bolt (B).

Installation i s reverse of removal.

• Align vibration damper wit h locating pin (A) on damper hu b (B).

Tightening torque
Vibration damper t o hub 22 N m (16. 2 ft-lb)
(replace damper bolts )
117-6 Camshaf t Timing Chain
Double VANOS unit components (M54 engine)

TIMING CHAIN SERVICE (M54 ENGINE)

The M54 engine use s a pair of chains to drive the camshafts. A
primary chai n i s driven off the crankshaft an d drives the primar y
sprocket on the exhaust camshaft . The secondary chai n drives the
intake camshaft. Eac h chain is tensioned by a hydraulic tensioner .

Intake and exhaust camshaft timing i s variable and i s controlled by

the engine control module (ECM). This system is known as double
VANOS.

Camshaft timing chain service and repai r requires the removal of

front crankshaft vibration damper, double VANOS unit, engine oil
pan and timing chain housing cover. Be sure to read the procedures
before starting work.

Double VANO S unit components (M5 4 engine )

1. Bolt(M6 )
2. Exhaus t camshaft sensor
3. Sealin g ring
4. Camshaf t end sealing plug
•Tighten to50Nm (37ft-lb)
5. Camshaf t seal cap
6. VANO S hydraulic piston set screw
• Left hand threa d
Tighten to 10Nm (7 ft-lb)
7. Nut(M7 )
• Tighten to 14 Nm (10 ft-lb)
8. Engin e liftin g hook
9. Stud(M7 )
10.Nut(M6)
• Tighten to 10Nm (7 ft-lb)
11. Gasket
12. Cylinder head
13. Sealing rin g
14. Intake camshaft sensor
15. Bolt (M6)
16. VANOS unit
17. Copper sealing ring
18. VANOS oil feed line
19. Banjo bolt
• Tighten to 32 Nm (24 ft-lb)
 Camshaft Timing Chai n 117- 7
Double VANOS unit, removing (M54 engine)

Double VANOS unit, removing (M54 engine )

WARNING—
• Due to risk of personal injury, be sure the engine is cold before
beginning the removal procedure.

CAUTION—
• Special BMW service tools are required to remove and install
the VANOS unit. Read the procedure through before starting
the job.
• If the camshafts are not properly timed, the pistons can contact
the valves, causing engine damage.

— Disconnec t negativ e (- ) cabl e from battery.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings an d Cautions.

Remove air filter housing wit h mass air flow sensor. See 130 Fuel
Injection.

Remove electri c cooling fan and cooling fan cowl. See 170 Radiato r
and Cooling System .

NOTE—
• Protect radiator from damage with a piece of wood.

Remove engin e covers and cylinder head cover . Se e 113 Cylinder

Head Remova l an d Installation.

Remove spark plugs. Plu g spark plug bores to prevent debri s from
falling int o engine .

Remove oil baffle cover from above intake camshaft.

Remove banjo bolt from VANOS unit oil pressure line. Use banjo bolt
to attach BM W special too l 1 1 3 450 (compressed air fitting) to
VANOS unit.
• Be prepared to catch spraying oil. D o not allow oil to contaminate
accessory belts.
117-8 Camshaf t Timing Chai n
Double VANOS unit, removing (M54 engine)

Cover oil bore (arrow) i n VANOS uni t with shop towel to capture oi l
which sprays when compressed ai r is applied .

Connect compresse d ai r line to air fitting. Apply air pressure se t to

2 - 8 bar (30-115 psi) .

. Wit h compressed air lin e connected, us e crankshaft vibration

damper bolt to rotate engin e in direction of rotation (clockwise) a t
least twice, until cylinder 1 intake and exhaus t camshaf t lobe s face
each other (arrows) in top dead center (TDC ) positio n for cylinder 1.

CAUTION—
• Do not rotate engine counterclockwise to reach TDC. If engine
rotates past TDC, continue another two complete rotations.

Remove sealing plug from special tool bore on lower left side of
engine block at flywheel bellhousing. Secur e crankshaft i n TDC
position with BMW special tool 1 1 2 300 (arrow) .

Unscrew an d remove two cylinder head cover stud s

(arrows) at rear of cylinder head .
 Camshaft Timing Chai n 117- 9
Double VANOS unit, removing (M54 engine)

Secure camshafts in TDC position using BM W special tool set

11 3 240 (include s 1 1 3 241 and 1 1 3 244).

Disconnect compresse d air line, leavin g compressed air fitting

attached to VANOS unit.
• B e prepared to catch drippin g oil . Do not allow oil to contaminat e
accessory belts.

Unscrew sealing plug s (arrows ) from VANOS unit .

Be prepared to catch dripping oil. Do not allow oil to contaminat e

accessory belts.

Pull sealing caps straight out of VANOS unit with BMW special tool
11 6 170, or with short needle-nose d pliers .
• Additional oil may drain fro m VANOS unit.
117-10 Camshaf t Timing Chai n
Double VANOS unit, installing (M54 engine)

Remove se t screws o n ends of intake and exhaust camshafts .

CAUTION—
• Set screws have left hand threads. Unscrew clockwise.

Detach harness connectors at exhaust camshaf t position sensor

and exhaust camshaft VANOS contro l valv e (arrows) .

Remove VANOS unit:

• Remov e fasteners fro m engine support eye.
• Remov e VANOS mounting nuts (arrows) from cylinder head . Slid e
VANOS unit and metal gasket off .
• The VANOS unit contains residua l oil . Plac e shop towels
underneath when removing .

CAUTION—
• Do not crank the engine with VANOS unit removed. Damage to
engine may result from piston-to-valve interference.

.021.13832,

Double VANO S unit, installin g (M54 engine )

Clean contact edges of cylinder hea d face and VANOS unit an d
apply a thin coat of permanently elasti c 3-Bond 1209® or equivalent
to surfaces.

CAUTION—
• Check locating dowel (Aj and dowel sleeve (B) at top of cylinder
head for damage or incorrect installation.
• Make sure gasket material is removed from face of cylinder
head. Clean sealing face and keep free of oil. If foreign material
is present on the sealing surface, camshaft timing will be
incorrect.
 Camshaft Timing Chai n 117-1 1
Double VANOS unit, installing (M54 engine)

Using ne w gasket, instal l VANO S unit to cylinder head .

• Reinstal l engine suppor t eye.

Tightening torques
VANOS unit to cylinder hea d
• M6 nut 10Nm(7ft-lb)
• M7 nut 14 Nm (1 0 ft-lb)

Insert and tighten VANOS hydraulic piston set screws on intake an d

exhaust camshafts.

Tightening torque

Hydraulic piston to splined shaft 10Nm(7ft-lb)

(Left-handed set screw)

CAUTION—
• Set screws have left-hand threads. Tighten counterclockwise.

Replace sealing cap s insid e VANO S unit with BM W special too l

11 6 17 0 or short needle-nose d pliers .

Insert and secure VANOS sealing plug s (arrows) , using ne w

sealing O-rings.

Tightening torque
Sealing plug to VANOS uni t 50 Nm (37 ft-lb)

— Remov e compressed ai r fitting from VANOS unit.

— Fi t VANOS oil line banjo bol t with new seals. Attach oil lin e t o
VANOS unit.

Tightening torque
Oil line to VANOS uni t (banjo bolt) 32 Nm (24 ft-lb)

Connect electrical harness connectors to camshaft position sensors

and VANOS solenoid valves .

If double VANO S unit i s replaced, or i f repair operations ar e

completed that may change camshaf t timing, rechec k an d adjus t
camshaft timing. See Camshaft timing , checking an d adjustin g
(M54 engine) i n this repai r group.
117-12 Camshaf t Timing Chain
Double VANOS unit, installing (M54 engine)

Remove BMW special locking tools from rear of cylinder head.

Remove crankshaft lockin g tool and replace sealin g plug.

Install intak e camshaf t baffl e and cylinder hea d cover .

• Check for correct seating of half-moon seal s (A) in back of cylinder
head cover.
• Us e a small amount of 3-Bond 1209 ® or equivalent sealant at
corners (B) of half-moon cutouts.
• Similarly, seat gasket and seal corners in front of cylinder head , at
VANOS unit.

Tightening torque
Cylinder head cover to cylinder head (M6 ) 10Nm(7ft-lb)

— Remainde r o f installation is reverse o f removal .

Tightening torques
Spark plug to cylinder head 25 Nm (18 ft-lb)

After completing work, check VANO S operation usin g BMW scan

tool.
 Camshaft Timing Chain 117-1 3
Timing chain components (M54 engine)

Timing chain component s (M54 engine )

1. Impuls e wheel mounting nut
2. Exhaus t camshaft impulse wheel
3. Sprin g plate
4. Thrus t spacer
• Thickness (T) =3.5 mm
5. Spline d shaft
6. Tor x screw
7. Exhaus t secondary sprocke t
8. Secondar y timing chain
9. Spline d sleev e
10. Primary sprocket
11. Threaded locating stud
12. Secondary chain tensione r
13. Secondary chain lower guide
14. Sprocket mounting nu t
15. Spring plate
16. Splined shaft
17. Intake camshaft sprocke t
18
18. Locating stud
16 19. Thrust spacer
20. Intake camshaft impulse wheel
21. Chain tensioner rail
22. Crankshaft sprocke t
23. Primary chain tensioner
24. Primary chai n
25. Locating stud
26. Guide rail
27. Locating stu d
28. Woodruff key
117-14 Camshaf t Timing Chain
Timing chains, removing (M54 engine)

Timing chains, removing (M54 engine)

When removin g camshaft timin g chains, first remove the oil pan.
See 11 9 Lubrication System . Also required i s removal of the
VANOS unit and disassembly o f the intak e and exhaust camshaf t
sprocket assemblies. Se e Double VANO S unit, removin g (M5 4
engine) i n this repai r group.

Special BMW service tools are needed for timing chain removal and
installation. These tools assure proper timing o f the valvetrain.
Precise marks to set the timing on the camshafts are not provided
for reassembly . Read the procedures throug h befor e beginning th e
job.

WARNING—
• Due to risk of personal injury, be sure the engine is cold before
beginning the removal procedure.

CAUTION—
• Special BMW service tools are required to remove and install
the VANOS unit and time the camshafts. Read the procedure
through before starting the job.
• If the camshafts are not properly timed, the pistons can contact
the valves, causing engine damage.

— Disconnec t negative (-) cabl e from battery .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings and Cautions.

Remove air intake hood above radiator .

Remove air filter housing . See 130 Fuel Injection .

Remove viscous clutch cooling fa n and fan shroud. See

170 Radiator and Cooling System .

CAUTION—
• The radiator cooling fan nut (32 mm wrench) has left- hand
threads.

— Mar k direction of engine rotation on accessory belts . Remov e belts.

See 020 Maintenance.

— Remov e coolant pum p pulley .

— Remov e engine covers an d cylinder head cover. See 113 Cylinder

Head Remova l and Installation .

— Remov e spark plugs. Plu g spar k plug bores to prevent debris fro m
falling into engine.

— Remov e VANOS unit. See Doubl e VANO S unit, removin g (M5 4

engine) i n this repair group.
 Camshaft Timing Chain 117-1 5
Timing chains, removing (M54 engine)

Raise car and support safely.

WARNING —
• Make sure the car is stable and well supported at a/I times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

— Drai n engin e cooling system. Se e 170 Radiator and Coolin g

System.

— Drai n engine oi l and remov e oil pan. See 119 Lubrication System .

^C Mak e sure camshafts are locked in TDC position using BMW special
tool set 1 1 3 240. See Double VANO S unit, removin g (M5 4
engine) i n this repair group.

Make sure crankshaft is still locked with BMW special tool 11 2 300 .
See Double VANO S unit, removin g (M54 engine) i n this repai r
group.

Remove primar y camshaft chai n tensioner (arrow ) from timing

chain cover.

CAUTION—
• Chain tensioner piston is under spring pressure.
117-16 Camshaf t Timing Chai n
Timing chains, removing (M54 engine)

Press down on secondary chain tensioner and lock into place usin g
BMW special too l 11 3 292 or a similar size pin tool.

Remove exhaust camshaft impulse wheel mounting nuts (arrows).

Remove impulse wheel (A).

~j H . Remov e spring plate (A).

Remove intake camshaft sprocket mounting nut s (arrows ) an d

remove spring plate (labeled FRONT) .
 Camshaft Timing Chain 117-1 7
Timing chains, removing (M54 engine)

Remove tor x bolt s (arrows) fro m exhaust camshaf t sprocket.

Lift off exhaust an d intake sprockets wit h secondary chain , thrust

spacer (A ) and splined shaf t (B) .

CAUTION—
• Intake and exhaust camshaft splined shafts share the same
part number. Be sure to mark splined shafts so they can be
reinstalled in their original positions.

Remove exhaust camshaf t spline d sleeve (A ) and shaft (B) .

117-18 Camshaf t Timing Chain
Timing chains, removing (M54 engine)

Remove secondary chain tensioner mounting bolts (arrows).

Remove tensioner while keeping locking pin in place.

Remove primary chain sprocket mounting studs (arrows) on

exhaust camshaft.

. Lif t primary chain sprocket off exhaust camshaft. Remove sprocket

from chain.
 Camshaft Timing Chain 117-1 9
Timing chains, removing (M54 engine)

Hang timing chain on exhaust camshaft end .

Working in cylinder head cavity, remove timing chain cove r bolts

(arrows).

"A. Remov e secondary chain lowe r guide mounting bolt s (arrows) .

Remove chain guide.

NOTE—
• Bolt on intake camshaft side is long and extends into timing chain
cover.

— Remov e crankshaft vibration damper. See Vibration damper ,

removing and installing (M5 4 engine) i n this repai r group .

CAUTION—
• Do not use flywheel locking tool to hold crankshaft stationary to
loosen or tighten vibration damper mounting bolt. Use only the
special tools specified, or equivalent hub ho/ding tool.
• Do not allow crankshaft to rotate while timing chains are
loosened or removed. The pistons can contact the valves,
causing engine damage.

Using a 5 mm or smaller drift , drive two locating dowel s

(insets) in lower timing cover toward rear of car.
117-20 Camshaf t Timin g Chain
Timing chains, installing (M54 engine)

Remove timing cove r mounting bolt s (arrows) . Slide cover with

coolant pum p forwar d to remove .

CAUTION—
• Use care when removing the cover from the cylinder head
gasket. If the cover is stuck, use a sharp knife to separate it from
the head gasket.
• If cylinder head gasket is damaged, remove cylinder head and
replace head gasket. Se e 113 Cylinder Hea d Remova l an d
Installation.
• Use care when detaching front timing cover from coo/ant pipe
at rear of cover.

NOTE—
• For clarity, front timing cover is illustrated with coolant pump
removed.

B11126 — Pus h primar y chai n tensioner guid e rail aside and remove chain.

Timing chains, installing (M54 engine )

^. Make sure camshafts are locked in TDC position using BMW special
tool set 11 3 240 .

— Inspec t timing chain sprockets . Inspec t guid e rai l and tensioner rail
for damage. Replace any part that is worn o r damaged.

NOTE—
• If any sprockets are replaced due to wear, also replace chain.
 Camshaft Timing Chai n 117-2 1
Timing chains, installing (M54 engine)

Primary timing chain assembly

1. Primar y chain tensioner
2. Chai n tensioner rai l
3. Crankshaf t sprocke t
4. Exhaus t camshaft sprocke t
5. Primar y chain
6. Ancho r bolt
7. Guid e rail
8. Ancho r bolt
9. Woodruf f key

Install primary timing chain to crankshaft sprocket and han g upper

end from exhaust camshaft.

If necessary, replac e crankshaft front seal in timing chain cover. Se e

119 Lubrication System.

To install lower timing chain cover:

• Clean cover and cylinder block sealing surfaces.
• Us e new gaskets and coolant pipe 0-ring.
• Remov e timing chai n cove r dowel pins from engine block .
0021085
• Drive dowels into cover until they just protrude slightly from sealing
surface.
• Apply a small bead of silicon sealer (3-Bon d 1209® or equivalent)
to corners of cylinder head where timing cover meets cylinder head
and engine block.
• Tap cover int o position until firmly seated .
• Install all bolts hand tight, including two Torx bolts from above .
• Install secondary chai n lower guide .
• Tighten cove r mounting bolts alternatel y and in stages.

Tightening torque
Lower timing cover to cylinder block (M6) 10 Nm (7 ft-lb)

— Instal l oil pan wit h ne w gasket. See 11 9 Lubrication System.

Tightening torques
Oil pan to engine block (M6)
• 8.8 grade 10Nm(7ft-lb)
• 10.9 grad e 12 Nm (9 ft-lb)
117-22 Camshaf t Timing Chai n
Timing chains, installing (M54 engine)

Reinstall crankshaft vibration damper. Se e Vibration damper ,

removing and installing (M5 4 engine) in this repai r group.

CAUTION—
• Do not use BMW special tool 11 2 300 to hold crankshaft
stationary to tighten vibration damper mounting bolt. Use only
the special tools specified, or equivalent hub holding tool.
• Have a second person hold special tool 11 8 190 while
tightening vibration damper mounting bolt.

Tightening torque
Vibration damper hub to crankshaft 410Nm(300ft-lb)
(use ne w bolt)

Remove crankshaft locking tool (arrow) .

Fit top sprocket to primary timing chai n an d install o n exhaust

camshaft so that pointe r on sprocket (arrow) lines up with cylinder
head sealing surfac e (dashed line) .

— Positio n sprocket s o that chain slack i s on tensioner rai l side.

Insert BMW special too l 1 1 4 220 i n cylinder hea d and screw in

adjustment screw by hand just unti l it contacts tensioning rail and
chain slack i s removed .

NOTE —
• BMW special tool 11 4 220 is an adjustable dummy tensioner that
simulates the function of the primary chain tensioner.

Make sur e that arrow on upper primar y sprocke t still lines u p with
upper edg e o f cylinder head. Reposition sprocket if necessary .

Install and tighten down threaded locatin g studs (arrows) i n end of

exhaust camshaft.

Tightening torque
Exhaust camshaf t locating stu d 20 Nm (15ft-lb)
 Camshaft Timing Chain 117-2 3
Timing chains, installing (M54 engine)

Install secondary chain tensioner on cylinder hea d (arrows) . Keep

tensioner compressed using BMW special tool 11 3 291 or suitable
pin tool.

Fit exhaust camshaft splined sleeve, aligning gap in sleeve spline s

with corresponding gap on camshaft splines (arrows).

Slide splined shaft on exhaust camshaft. Be sure that locating tooth

of shaft fits into spline gaps of camshaft and splined sleev e
(arrows).
• Pus h splined shaft in further to rotate splined sleeve until three
threaded holes in primary chain sprocket are centered i n splined
sleeve slots (dashed lines).
117-24 Camshaf t Timing Chain
Timing chains, installing (M54 engine)

Place intake an d exhaust sprocket s i n BMW special tool 11 6 180.

11 6180 Position spline gap on intake sprocke t (arrow) as shown and place
secondary chain on sprockets .

BX56113006

Remove chain and sprockets from tool and slide sprockets on

camshafts. Confirm that gap in intake sprocke t splines line s up with
corresponding gap in camshaft spline s (arrow).

CAUTIOM—
• Do not alter position of sprockets with respect to chain when
removing from special tool 116 180.

Align locating tooth of splined shaft with gaps on camshaft and

sprocket. Slide spline d shaft onto intake camshaf t until approx.
1 m m (0.04 in) of splines (arrows) are visible.

A = approx. 1 mm (0.04 in) |

''

Install intake camshaft spring plate so that FRONT mar k is visible.

Install mountin g nut s (arrows) finger tight .
 Camshaft Timing Chain 117-2 5
Timing chains, installing (M54 engine)

Insert sprocket mounting bolt s (arrows) on exhaust side camshaft

assembly.
• Initiall y tighten to approx. 5 Nm (44 in-lb) and then back off by half
a turn.

Fit thrust spacer (A ) on exhaust camshaft .

Install spring plate (A) to exhaust camshaft. Mak e sure that F mark
is visible.

NOTE—
•IfF mark is no longer visible, install spring plate as shown in inset:
convex side facing forward.
117-26 Camshaf t Timing Chai n
Timing chains, installing (M54 engine)

Install exhaust camshaft impuls e wheel, aligning pointer (B) with top
edge of cylinder hea d (A). Install mounting nuts (arrows) finger
tight.

^V Pul l out exhaust camshaft splined shaft to stop (arrow).

— Pres s down on secondary chain tensioner and remov e tensioner

lock-down tool.

Preload primary chain:

• Tighten adjusting screw on BMW special tool 11 4 220 to specified
torque.

Tightening torque
Primary chain tensioner preload 0.7 N m (6 in-lb)

Preload exhaust camshaft spring plate by pressing on impulse

wheel while tightening mountin g nuts (arrows ) finger tight .
 Camshaft Timing Chai n 117-2 7
Timing chains, installing (M54 engine)

Install BMW special tool 1 1 6 150 (VANOS setup bracket) to front of

cylinder head timing case. Instal l nuts (arrows) finger tight , the n
tighten dow n uniformly unti l special tool is in full contact wit h cylinder
head.

CAUTION—
• Make sure gasket material is removed from face of cylinder
head. Clean sea/ing face and keep free of oil. If foreign material
is present on the sea/ing surface, camshaft timing will be
incorrect.

Secure camshaf t sprocket s and impulse wheels:

• Tighten mounting screws (A) on exhaust camshaft impuls e wheel
to approx. 5 Nm (44 in-lb).
• Tighten mounting nut s (B) on exhaust and intake sprocket
assemblies to approx. 5 Nm (44 in-lb).
• Torque dow n mountin g screws (A) and nuts (B ) to final
specifications.

Tightening torques
Sprocket assembly wheel to camshaft
(initial torque) 5 Nm (44 in-lb)
Sprocket assembly whee l to camshaf t
• M7 torx screws (A ) 20 Nm (15ft-lb)
• M6 mounting nuts (B) 10Nm(8ft-lb

— Remov e crankshaft locking too l so that crankshaft i s no longe r

secured i n TDC position.

— Remov e camshaft lockin g tools from cylinder head.

^ Tur n engine over twice in direction o f rotation until cylinder 1 intake

and exhaust camshaft lobes (arrows ) face each other .

— Secur e crankshaft in TDC positio n with BMW special too l 11 2 300 .

Place BM W special tool set 1 1 3 240 over camshafts and measure

clearances.
• Du e to flexible sprocket design, VANOS unit tolerances and play in
the VANOS splines, whe n the camshaft timing is set correctly, the
intake side of special tool 1 1 3 240 (B) may be up to 1 mm (0.0 4
in) above th e surface o f the cylinder head. Thi s is normal .
Reassemble engine .
• Otherwise, reset camshaft timing. Se e Camshaft timing ,
checking an d adjusting (M54 engine) in this repai r group.

CAUTION—
• If the exhaust side of the tool (A) is not flush with the cylinder
head, camshaft timing is incorrect. Reset camshaft timing.

— Remov e BM W special tool 1 1 6 150 from front o f cylinder head.

117-28 Camshaf t Timing Chain
Camshaft timing, checking and adjusting (M54 engine)

Reinstall VANOS unit. Se e Double VANOS unit, installin g (M5 4

engine) i n this repair group.

Remove BMW special tool 11 4 220 (adjustabl e dummy tensioner).

Reinstall primary chai n tensioner .

Tightening torque
Primary chain tensioner to timing chain
cover (M26 x 1 .5) 70 Nm (52 ft-lb)

— Instal l intake camshaft oi l baffle .

^V, Instal l cylinder head cover:

• Check for correct seating of half-moon seals (A) in back of cylinder
head cover.
• Use a small amount o f 3-Bond 1209® or equivalent sealant at
corners (B ) of half-moon cutouts. Seal corners i n front of cylinde r
head at VANOS unit.

Tightening torque
Cylinder hea d cover to cylinder hea d 10Nm(7ft-lb)

Remainder o f assembly i s reverse of removal, notin g the following :

0021075J
• Secure all coolant hoses , thermostat housing, engin e coolant
drains.
• Instal l ne w engine oil filter and oil. See 119 Lubrication System .
• Refill and bleed cooling system. Se e 170 Radiator an d Cooling
system.
• Us e scan tool to check VANOS operation with engine idling.

Tightening torques
Coolant drain plug to cylinder block 25 Nm (18 ft-lb)
Radiator drain screw to radiato r 2.5 Nm (22 in-lb)
Vibration dampe r hu b to crankshaf t 410Nm (300 ft-lb)
(use new bolt )

Camshaft timing , checking and adjusting

(M54 engine)
Remove engine top covers and cylinder hea d cover. See 113
Cylinder Hea d Remova l and Installation.

Remove oil baffle cover from above intake camshaft.

Remove engine driv e belts and cooling fan. See 170 Radiator an d
Cooling System.

Remove spark plugs. Plu g spark plug bores to prevent debris fro m
falling into engine.

53502113821
 Camshaft Timing Chai n 117-2 9
Camshaft timing, checking and adjusting (M54 engine)

Remove primary camshaft chain tensioner cylinder (arrow).

CAUTION—
• Chain tensioner piston is under spring pressure.

Insert BM W special tool 1 1 4 220 in cylinder hea d an d screw in

adjustment screw by hand just until it contacts tensioning rai l an d
chain slack is removed.

NOTE-
• BMW special tool 114 220 is an adjustable dummy tensioner that
simulates the function of the primary chain tensioner.

Preload primary chain tensioner rail:

• Tighten adjusting screw on BMW special tool 1 1 4 220.

Tightening torqu e
Primary chain tensioner preloa d 0.7 N m (6 in-lb)

Remove banjo bolt from VANOS unit oil pressure line. Use banjo bolt
to attach BMW special tool 113 450 (compressed air fitting) to
VANOS unit.
• B e prepared to catch dripping oil . Do not allow oil to contaminat e
accessory belts.
117-30 Camshaf t Timing Chain
Camshaft timing, checking and adjusting (M54 engine)

Cover oil bore (arrow) in VANOS unit with shop towel to capture oil
which spray s when compressed ai r is applied .

Connect compresse d ai r line to air fitting. Apply air pressure set to

2 - 8 bar (30-115 psi).

With compressed ai r line connected, us e crankshaft vibration

damper bol t to rotat e engine i n direction o f rotation (clockwise) at
least twice, until cylinde r 1 intake an d exhaust camshaft lobes face
each other (arrows) in top dead center (TDC ) positio n for cylinder 1.

CAUTION—
• Do not rotate engine counterclockwise to reach TDC. If engine
rotates past TDC, complete another two complete rotations.

Remove sealing plu g from special too l bor e on lower lef t side of
engine bloc k near flywheel. Secure crankshaft in TDC position with
BMW special too l 1 1 2 300 (arrow).

Unscrew an d remove tw o cylinder head cover stud s

(arrows) at rear of cylinder head.
 Camshaft Timing Chai n 117-3 1
Camshaft timing, checking and adjusting (M54 engine)

Place BMW special tool set 11 3 240 over camshafts and measure
clearances.
• Du e to flexible sprocket design, VANOS unit tolerances and play in
the VANOS splines, whe n the camshaft timing is set correctly, th e
intake sid e of special tool 1 1 3 240 (B) may be up to 1 mm (0.0 4
in) above the surface of the cylinder head. Thi s i s normal .
Reassemble engine .
• Otherwise, continu e with camshaft timin g adjustment procedure .

CAUTION—
• If the exhaust side of the tool fAj is not flush with the cylinder
head, camshaft timing is incorrect. Reset camshaft timing.

Remove double VANOS unit. See Double VANOS unit, removin g

(M54 engine) i n this repair group.

Press down on secondary chain tensioner and lock into place usin g
BMW special too l 1 1 3 292 or equivalent pin or drift.

Loosen intake camshaft sprocket mounting nut s (arrows) by 1 turn.

Loosen exhaust camshaft sprocket mounting fasteners:

• Release bolt s A Vz turn .
• Release nut s B 2 turns.
117-32 Camshaf t Timing Chain
Camshaft timing, checking and adjusting (M54 engine)

Pull out intake camshaft splined shaf t ou t so that approx.

1 m m (0.04 in ) of splines (arrows ) can b e seen .

Pull out exhaust camshaft spline d shaft t o stop (arrow) .

Make sure camshafts are secured i n TDC positio n usin g BMW

special tools 11 3 240 and 1 1 3 244.

Make sure chain tensioning rai l is preloaded .

Tightening torque
Primary chain tensioner preloa d 0.7 N m (6 in-lb)

Preload exhaust camshaft spring plat e b y pressing on impulse

wheel. Tighten mounting nut s (arrows) by hand. Do not tighten fully.

•HE 5021138791
 Camshaft Timing Chai n 117-3 3
Camshaft timing, checking and adjusting (M54 engine)

Install BMW special tool 1 1 6 1 50 (VANOS setup bracket ) t o front of

cylinder head timing case. Tighten nuts (arrows) by hand, and then
tighten down uniforml y until special tool contacts cylinder hea d
firmly.

CAUTION—
• Make sure gasket material is removed from face of cylinder
head. Clean sealing face and keep free of oil. If foreign material
is present on the sealing surface, camshaft timing will be
incorrect.

Secure camshaf t impulse sprockets an d wheels:

• Pretighte n Tor x screws (A ) on exhaust camshaft impuls e wheel to
approx. 5 Nm (44 in-lb).
• Pretighte n mountin g nuts (B ) on exhaust an d intake sprocket
assemblies to approx. 5 Nm (44 in-lb).
• Torque down Torx screws (A) and nuts (B) to final
specifications.

Tightening torques

Sprocket assembly to camshaft

(initial torque) 5 Nm (44 in-lb)
Sprocket assembly t o camshaf t
• M7 Torx screw (A) 20 Nm (15ft-lb)
• M6 mounting nut (B) 10 Nm (7ft-lb)

— Remov e flywheel lockin g tool from transmission bellhousin g so that

crankshaft i s no longer locked.

— Remov e camshaft locking tools from rear of cylinder head .

— Us e crankshaft vibratio n damper bolt to crank engin e over twice b y

hand in direction of rotatio n until cylinder 1 intake and exhaus t
camshaft lobe s face each other again.

— Secur e crankshaf t wit h BMW special tool 1 1 2 300 .

^. Plac e BMW special too l set 11 3 240 over camshafts and measure
clearances.
• Du e to flexible sprocket design, VANOS unit tolerances and play in
the VANOS splines, whe n the camshaft timing is set correctly, the
intake side of special tool 11 3 240 (B) may be up to 1 mm (0.0 4
in) above the surface of the cylinder head . This i s normal .
• Otherwise, repeat camshaft timing adjustmen t procedure .

CAUTION—
• If the exhaust side of the tool (A) is not flush with the cylinder
head, camshaft timing is incorrect. Reset camshaft timing.

— Remov e camshaf t locking tools from rea r o f camshafts .

117-34 Camshaf t Timing Chai n
Camshaft timing, checking and adjusting (M54 engine)

Remove BM W special tool 11 4 220 (adjustable dummy tensioner) .

Reinstall primary chain tensioner.

Tightening torque
Primary chai n tensione r t o timing chai n 70 Nm (52 ft-lb )
cover (M26x 1.5)

— Remov e crankshaft lockin g tool from transmission bellhousing .

Reinstall sealin g plug .

— Remov e VANOS setup bracke t from front of cylinder head.

- Instal l VANOS unit. See Double VANO S unit , installing (M5 4

engine) in this repair group .

— Remov e compressed ai r lin e adapter (BM W special tool

11 3 450) from VANOS unit.

— Fi t VANOS oil line banjo bol t with new seals. Attach oil line to
VANOS unit .

Tightening torque
Oil line to VANOS unit (banjo bolt) 32 Nm (24 ft-lb)

Remainder of installation i s reverse of removal. Note the following:

• Install spark plugs.
• Instal l intake camshaft plastic baffle prior to installing cylinder head
cover. Instal l ignition coi l packs an d connect electrical harness
connectors.
• Install accessory belts, radiator coolin g fa n and cooling fan shroud.
• Instal l uppe r engine covers .
Tightening torques
Cylinder head cove r to cylinder hea d 10Nm(7ft-lb)
Spark plu g to cylinder head 25 Nm (18 ft-lb)
 Camshaft Timing Chain 117-3 5
Camshaft sprockets assembly (M54 engine)

CAMSHAFT SERVICE (M54 ENGINE )

Camshaft sprockets assembly (M54 engine )
1. Impuls e wheel mounting nut
2. Exhaus t camshaft impulse wheel
3. Sprin g plate, exhaust
4. Thrus t spacer (T = 3.5 mm)
5. Spline d shaft
6. Tor x screw
7. Exhaus t camshaft secondary sprocket
8. Secondar y timing chain
9. Spline d sleeve
10. Primary sprocket
11. Threaded locatin g stud
12. Secondary chain tensioner
13. Secondary chain lower guide
14. Sprocket mounting nut
15. Spring plate, intake
16. Splined shaft
17. Intake camshaft sprocket
18. Locating stud
19. Thrust spacer
20. Intake camshaft impulse wheel

Camshafts, removing (M54 engine )

WARNING —
• Due to risk of personal injury, be sure the engine is cold before
beginning the removal procedure.

CAUTION—
• Special BMW service tools are required to remove and install
the camshafts and VANOS units. Read the procedure through
before starting the job.
• If the camshafts are not properly timed, the pistons can contact
the valves, causing engine damage.

— Disconnec t negativ e (- ) cabl e from battery.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings an d Cautions.

— Remov e air filter housing and ducts. Se e 130 Fuel Injection.

117-36 Camshaf t Timing Chai n
Camshafts, removing (M54 engine)

Remove electric cooling fan and cooling fan shroud. See

170 Radiator and Cooling System .

Remove engine cover s and cylinder head cover. See

113 Cylinder Hea d Remova l and Installation.

Remove spark plugs. Plug spark plu g bores to prevent debris from
falling into engine.

Remove VANOS unit. See Double VANO S unit, removing (M54

engine) i n this repair group.

Remove primary camshaft chai n tensioner cylinde r (arrow).

CAUTION—
• Chain tensioner piston is under spring pressure.

Press down on secondary chain tensioner and lock into place using
BMW special tool 1 1 3 291, or a thin drift or pin.

Remove exhaust camshaf t impulse wheel mountin g nut s (arrows).

Remove impulse whee l (A) .
 Camshaft Timing Chai n 117-3 7
Camshafts, removing (M54 engine)

Remove spring plat e (A).

Remove intake camshaft sprocke t mountin g nut s (arrows) and

remove spring plate (labele d FRONT) .

Remove torx bolt s (arrows) from exhaust camshaft sprocket .

Lift off exhaust and intake sprockets together wit h secondary chain,
thrust spacer (A) , and splined shaf t (B) .

CAUTION—
• Intake and exhaust camshaft splined shafts share the same
part number. Be sure to mark splined shafts so they can be
reinstalled in their original positions.
117-38 Camshaf t Timing Chain
Camshafts, removing (M54 engine)

Remove exhaust camshaft splined sleev e (A) and shaft (B).

Remove secondary chain tensioner mounting bolts (arrows) and

remove tensioner with retaining pi n in place.

Remove sprocket mounting studs (arrows ) from exhaust camshaft.

1

Camshaft Timing Chain 117-3 9

Camshafts, removing (M54 engine)

Lift primary chai n sprocket off exhaust camshaft. Remov e sprocket

from chain.

< Place timing chain on end of exhaust camshaft.

^C Remov e locating studs (arrows) from intake camshaft. Lift off intake
camshaft thrust spacer (A ) and impulse wheel (B) .

< Do not remove Torx® screws (arrows) from camshafts.

117-40 Camshaf t Timing Chain
Camshafts, removing (M54 engine)

Remove cylinde r head cover mountin g studs (arrows) from cente r

of cylinder head.

— Remov e crankshaft locking tool.

Lift primary chai n and hold under tension. Use crankshaft vibratio n
damper bolt to rotate engin e i n direction opposit e to normal rotatio n
(counterclockwise) approximatel y 30°.

CAUTION—
• By turning crankshaft 30° counterclockwise, pistons are moved
away from top dead center. This prevents piston-to-valve
interference during camshaft servicing.

Remove camshaft locking tools (BM W specia l tool set 1 1 3 240)

from rear of cylinder head .

Remove intake camshaft bearing cap 1 fasteners (arrows). Remove

bearing cap.

CAUTION—
• Do not remove camshaft bearing caps 2 - 6 at this time.

Fit BMW special tools 11 3 260 and 1 1 3 270 to cylinder hea d and
screw long bolts (arrows) int o spark plug threads. Align tensioning
pins on tool with bearing caps on camshaft.

CAUTION—
• Do not overtighten bolts in spark plug holes.

11 3260

11 3270 BX56113005
 Camshaft Timing Chain 117-4 1
Camshafts, installing (M54 engine)

^C Rotat e eccentric shaft of special tool (arrow) to pretension intak e

camshaft bearing caps. Remove remaining intake camshaft bearin g
cap fasteners.

— Slowl y release tension on eccentric shaft and remov e BM W special

tools. Remov e bearing cap s an d set aside i n order. Remov e
camshaft and store safely.

— Repea t procedur e fo r exhaust camshaft .

If cylinder hea d i s being removed , secure hydraulic lifters in lifte r

bores usin g BMW special too l set 1 1 3 250, or remove lifter s usin g
a magnetic pick-u p tool . Wit h lifters secure or removed, lif t ou t
camshaft bearin g carriers from cylinder head.

CAUTION—
• Do not let hydraulic litters fall out as camshaft carrier is
removed.
• Mark hydraulic lifters so that they can be reinstalled in their
original lifter bores.
• Store hydraulic lifters in an upright position.

Camshafts, installin g (M54 engine)

Lubricate camshafts , camshaft carriers, bearing caps, hydrauli c
lifters and friction washers with assembly lubricant befor e
installation.

Before installing camshaf t carriers, examine hydraulic lifte r bor e

bearing points (arrows) on underside of camshaft carriers for signs
of wear.

Center camshaft carrier with hydraulic lifter s on pins (arrows ) at

bearing positions 2 and 7.
117-42 Camshaf t Timing Chain
Camshafts, installing (M54 engine)

Note marks on camshaft carriers: E for intake side and A for exhaust
side.

Lift timing chain an d place exhaus t camshaft o n exhaust camshaft

carrier. Plac e intake camshaft on intak e camshaft carrier.

Place bearing caps on camshafts and install retaining nuts (arrows)

finger tight.
• Not e that each bearing cap is marked (inset):
E1 to E 7 for intake (front to rear)
A1 to A7 for exhaust (front to rear )

CAUTION—
• Make sure the crankshaft, which was rotated approximately 30°
opposite the direction of engine rotation from TDC, is still in that
position before reinstalling the camshafts. This ensures that
pistons are out of TDC position and prevents piston-to-valve
interference when the camshafts are installed.

Fit BMW special tools 11 3 260 and 1 1 3 270 to cylinder head and
screw lon g bolts (arrows) into spark plug threads. Align tensioning
pins on tool with bearing caps on intake camshaft.

CAUTION—
• Do not overtighten bolts in spark plug holes.

11 3260

11 3270

Rotate eccentric shaft of special tool (arrow ) to pretension bearing

caps. Torque bearing cap nuts.

Tightening torque
Camshaft bearing ca p to cylinder head (M7) 14 Nm (10 ft-lb)

— Releas e tension on eccentric shaft and remov e special tools.

 Camshaft Timing Chain 117-4 3
Camshafts, installing (M54 engine)

— Repea t procedure for exhaust camshaft.

CAUTION—
• After the camshafts are installed, a minimum waiting time is
required for the hydraulic lifters to bleed down before bringing
the crankshaft and pistons back to TDC. When the camshafts
are removed, the hydraulic lifters may expand. This expansion
can cause increased valve lift when camshafts are bolted down,
possibly resulting in piston-to-valve interference.

Hydraulic lifter bleed down waiting times

68° F (20° C) and higher 4 minutes
500-68°F(100-20°C) 1 1minutes
32 0 -50°F(0 0 -10°C) 30 minutes

In procedure steps that follow, use 27 mm open-end wrench to rotate

camshaft into position. I f necessary, grind off outer edges o f wrench
jaws to prevent damag e to cylinder head .

Rotate camshafts unti l intake and exhaust lobe s for cylinder 1 face
each other (arrows) .

Secure camshafts in TDC position using BMW camshaft TDC tools

11 3 241. Align camshafts so that camshaft TDC tools rest solidly on
cylinder hea d uppe r surface. Lock down with special tool 1 1 3 244
bolted to a spark plug bore.
117-44 Camshaf t Timing Chain
Camshafts, installing (M54 engine)

,;
Lift timing chain and hold under tension.

While maintaining tension o n timing chain, us e crankshaft vibratio n

damper bol t to rotate crankshaf t i n direction o f rotation (clockwise)
until cylinder 1 is at TDC position. O|T (arrow) on front pulley line s
up with boss on lower timing chain cover.

Secure crankshaft i n TDC position with BM W special tool 11 2 300

(arrow).

Slide impulse wheel on intake camshaft, aligning boss with raised

portion on camshaft (arrow).
 Camshaft Timing Chain 1 1 7-45
Camshafts, installing (M54 engine)

Fit thrust spacer (A) to intake camshaft (B ) and tighten dow n wit h
threaded locatin g studs. Plac e longer threaded en d of studs int o
camshaft (arrows).

Tightening torqu e
Impulse whee l studs to intake camshaft 20 N m (15ft-lb)

. Fi t primary sprocket to primary timing chain and instal l on exhaus t

camshaft so that pointer on sprocket (arrow) lines u p with cylinder
head sealing surfac e (dashe d line) .

< Inser t BMW specia l tool 1 1 4 220 int o timing chain tensione r bor e
and bring center spindle int o contact with tensioning rail. Tighte n
until slack i s removed, but do not pretension timing chain .

NOTE—
• BMW special tool 114 220 is an adjustable dummy tensionerand
simulates the function of the primary chain tensioner.

Make sure that arrow on upper primary sprocket still lines u p with
upper edge o f cylinder head . Repositio n sprocket if necessary .

Insert and tighten dow n threaded locatin g stud s (arrows ) in end of

exhaust camshaft. Note installe d positio n of studs.

Tightening torqu e
Exhaust camshaft locatin g stu d 20Nm(15ft-lb)
117-46 Camshaf t Timing Chai n
Camshafts, installing (M54 engine)

Install secondary chai n tensioner on cylinder head (arrows) . Kee p

tensioner compressed using BM W special tool 11 3 291 or suitable
pin tool.

Install exhaust camshaft splined sleeve . Confirm that gap in sleeve

splines aligns with corresponding ga p in camshaft splines (arrows) .

Slide splined shaft on exhaust camshaft. Be sure that locating tooth

of shaft fits into spline gaps o f camshaft an d splined sleev e
(arrows).
• Pus h splined shaf t in further to rotat e splined sleeve until three
threaded holes in primary chain sprocke t are centered in splined
sleeve slot s (dashed lines) .

502113868|
 Camshaft Timing Chai n 117-4 7
Camshafts, installing (M54 engine)

Place intake an d exhaust sprocket s i n BMW special tool 1 1 6 180 .

11 6180 Position spline ga p on intake sprocket (arrow) as shown an d plac e
secondary chain on sprockets.

0 o o a o 9

Remove chai n and sprockets from tool and slide sprockets on

camshafts. Confirm that gap in intake sprocket splines line s u p with
corresponding ga p in camshaft splines (arrow).

CAUTION—
• Do not alter position of sprockets with respect to chain when
removing from special tool 11 6 180.

Align locating tooth o f splined shaft with gaps o n camshaft an d

sprocket. Slide splined shaf t onto intake camshaft until approx. 1
mm (0.04 in) of splines (arrows ) are visible.

Install intake camshaf t sprin g plate so that FRON T mark is visible.

Install mountin g nuts (arrows ) finger tight.
117-48 Camshaf t Timing Chain
Camshafts, installing (M54 engine)

Insert sprocke t mountin g bolt s (arrows ) on exhaust side camshaft

assembly.
• Initiall y tighten to approx. 5 Nm (44 in-lb) and then bac k off by half
a turn.

Fit thrust spacer (A) on exhaust camshaft.

Install spring plat e (A ) to exhaust camshaft. Mak e sure that F mark

is visible.

NOTE—
•IfF mark is no longer visible, install spring plate as shown in inset:
convex side facing forward.

Install exhaust camshaft impulse wheel, aligning pointer (B) with top
edge of cylinder head (A). Instal l mounting nuts (arrows ) finger
tight.
 Camshaft Timing Chai n 117-4 9
Camshafts, installing (M54 engine)

Pull out exhaust camshaft spline d shaft to stop (arrow).

Press dow n on secondary chai n tensioner and remov e tensione r

lock-down tool.

Preload primar y chain:

• Tighten adjusting screw on BMW special tool 11 4 220 to specified
torque.

Tightening torque
Primary chain tensioner preload 0.7 Nm (6 in-lb)

. Preloa d exhaust camshaft sprin g plate by pressing o n impuls e

wheel while tightening mountin g nut s (arrows) finger tight .

Install BMW special tool 11 6 150 (VANOS setup bracket) to front of

cylinder hea d timin g case. Instal l nut s (arrows) finger tight, the n
tighten down uniformly until special tool is in full contact with cylinder
head.

CAUTION—
• Make sure gasket material is removed from face of cylinder
head. Clean sealing face and keep free of oil. If foreign material
is present on the sea/ing surface, camshaft timing will be
incorrect.
117-50 Camshaf t Timing Chain
Camshafts, installing (M54 engine)

Secure camshaf t sprockets and impulse wheels:

• Tighten mountin g screws (A) on exhaust camshaft impulse whee l
to approx. 5 Nm (44 in-lb).
• Tighten mounting nuts (B) on exhaust and intake sprocket
assemblies t o approx. 5 Nm (44 in-lb) .
• Torque down mountin g screw s (A ) and nuts (B ) to final
specifications.

Tightening torques

Sprocket assembl y wheel to camshaft-

(initial torque) 5 N m (44 in-lb)
Sprocket assembly wheel to camshaf t
• M7 torx screws (A) 20Nm(15ft-lb)
• M6 mounting nut s (B) 10Nm(8ft-lb)

— Remov e crankshaft lockin g too l so that crankshaft i s no longer

secured in TDC position .

— Remov e camshaf t locking tools from cylinder head.

^. Turn engine over twice i n direction of rotation until cylinder 1 intake

and exhaust camshaft lobe s (arrows ) face each other .

— Secur e crankshaft in TDC positio n wit h BMW specia l too l 1 1 2 300.

Place BMW special too l set 1 1 3 240 ove r camshafts and measure
clearances.
• Du e to flexible sprocket design , VANO S unit tolerances and play in
the VANOS splines, when camshaft timin g i s set correctly, the
intake sid e of special tool 11 3 240 (B ) may be up to 1 mm (0.0 4
in) above the surfac e of the cylinde r head . Thi s is normal.
• Otherwise, reset camshaft timing. Se e Camshaft timing ,
checking and adjusting (M54 engine) in this repai r group .

CAUTION—
• If the exhaust side of the tool (AJ is not flush with the cylinder
head, camshaft timing is incorrect. Reset camshaft timing.

— Remov e BM W special tool 11 6 150 from front of cylinder head .

- Reinstal l VANOS unit. See Double VANOS unit , installin g (M54

engine) i n this repai r group.

— Remov e camshaft and crankshaft locking tools.

— Reassembl e engine. Be sure to top off and bleed cooling system

 Camshaft Timing Chain 117-5 1
Camshaft timing chain components (N52, N54 engine)

TIMING CHAIN SERVICE

(N52 ENGINE, N54 ENGINE )
Camshaft timing chain components
(N52, N5 4 engine)
Camshaft timing chain, vibration damper (front pulley) an d
associated components of N52 and N54 engines are similar.

1. VANO S unit mounting bolt (M1 Ox 94

mm)
• Replace with new
• Tighten in 2 stages
Stage1:20Nm(15ft-lb)
Stage 2: Additional 180°
2. Camshaf t impulse wheel
3. VANO S unit
• Different intake and exhaust
adjustment unit s
4. Chai n tensioner (M22 x 1.5)
•Tighten to55 Nm (41 ft-lb)
5. Sealin g O-ring
6. Chai n tensioner rail
7. Chai n assembly mountin g bolts
(M6 x 35 mm Torx)
• Tighten to 8.5 Nm (6 ft-lb)
8. Timin g chain
9. Chai n assembly
10. Chain guide
11. Chain guide mounting bolt (M7 )
• Tighten to 14 Nm (10 ft-lb)
15 1 6 1 7 11 8 1 9
12. Cylinder head with camshafts
• N52 cylinder hea d illustrated
13. Vibration damper hub mounting bol t
(M16x80mm)
• Replace with new
• Tighten i n 2 stages
Stage 1:100 Nm (74 ft-lb)
Stage 2: Additional 360°
14. Vibration damper mounting bol t
(M8x 16 mm Torx)
• Tighten to 35 Nm (26 ft-lb)
15. Vibration damper (front pulley)
16. Vibration damper hub
17. Chain tensioner rail mounting bolt (M8)
• Tighten to 20 Nm (15 ft-lb)
18. Crankshaft front seal
19. Crankshaft sprocket
117-52 Camshaf t Timing Chai n
Camshaft timing chain, removing and installing (N52, N54 engine)

Camshaft timing chain, removing and installing

(N52, N54 engine)
When removing an d installing the camshaft timin g chain, special
tools and procedures ar e required to remove an d install VANOS
units and to time camshafts. Rea d the entire procedure befor e
beginning repairs .

WARNING —
• To avoid personal injury, be sure the engine is cold before
beginning the procedure.

CAUTION—
• Disassembly, removal and assembly of camshafts or VANOS
units without special tools poses the risk of damage or
breakage: Valves may be bent by contact with the piston
crowns,
• Throughout this procedure, unless otherwise specified,
crankshaft and camshafts remain locked against rotation using
BMW special tools.

— Us e scan tool to rea d out and recor d ECM fault memory.

— Switc h ignitio n OFF and remov e key .

— Remov e upper an d lower cabin microfilter housings. Se e

640 Heating and Air-conditioning.

— Remov e strut tower brace.

— Remov e ignition coil cover (upper engine cover). See

020 Maintenance .

— Detac h ignition coil connectors. Lif t ignition coil harness off cylinde r
head cove r and set aside.

— Remov e ignition coils. See 12 0 Ignition System.

— Remov e cylinder head cover. See 11 3 Cylinder Head Removal

and Installation .

— Remov e spark plugs .

^ N5 2 engine: Usin g vibration damper bolt, rotate crankshaft to place

cylinder 1 in TDC firing position . In this position, cylinde r 1 intake
camshaft lobe points upwar d at an angle (dashed line).
 Camshaft Timing Chai n 117-5 3
Camshaft timing chain, removing and installing (N52, N54 engine)

, N5 2 engine: Cylinder 1 in TDC firin g position: Cylinde r 6 exhaus t

camshaft lobe (A) points downwar d at an angle (dashed line) . Cam
follower (B) i s not actuated .

NOTE—
• Use a minor to check exhaust camshaft lobe position.

N54 engine: Usin g vibration damper bolt to rotate crankshaft, place

cylinder 1 in TDC firing position. In this position, lobes for cylinder 6
(rear of engine) intak e and exhaust camshafts (A, B ) poin t awa y
from each other and down. Cylinder 6 camshaft lobe s do not contact
roller cam followers.

NOTE—
• Use a mirror to check cylinder 6 cam lobe positions.

^. Working at right front of cylinder head, remov e timing chai n

tensioner (B). B e prepared to catch dripping oil with a shop towel.
Do not allow oi l to contaminate accessory belt .

— Rais e vehicle and suppor t safely.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Remov e engine compartment splash shield. See 020 Maintenance .

— Remov e engin e accessory belt. See 020 Maintenance .

— Remov e vibration damper (fron t pulley). Se e Vibration damper ,

removing and installing (N52, N5 4 engine) i n this repai r group .

— Remov e crankshaft front seal. See 119 Lubrication System .

117-54 Camshaf t Timing Chain
Camshaft timing chain, removing and installing (N52, N54 engine)

Working underneath engine , slide out protective plug at lower left of

engine bel l housing flange . Instal l BMW special too l 11 0 300
(crankshaft lockin g tool) through bel l housin g flang e port int o
flywheel (A) hole. If necessary, roc k flywheel slightly back and forth
to line up holes with tool. This locks crankshaft at TDC .

CAUTION—
• Models with automatic transmission: In the flywheel (torque
plate), a short distance before the bore for TDC position, there
is a large bore which can be confused with the special tool bore.
If the flywheel is locked using the correct bore, the engine can
no longer be rotated at the vibration damper bolt.
• If special tool 11 0 300 does not slide easily into the bell
housing flange bore, sand paint off the tool. Do not enlarge the
bore.

Remove vibration damper hub :

• Bol t BMW special tool 11 9 280 (counter hol d tool) to hub .
• With help of assistant counter holding hub, loose n and remove hub
bolt (A) . Discard bolt .
• Pul l hub off crankshaft, sliding i t out of timing chain lower sprocket.

CAUTION—
• Counter hold hub securely. Do not rely on flywheel lock (special
tool 11 0 300) to counter hold against crankshaft rotation.

Unscrew plug (arrow ) at upper lef t of timing chain housing.

 Camshaft Timing Chain 117-5 5
Camshaft timing chain, removing and installing (N52, N54 engine)

^V, Unscre w plug (arrow ) at lower right of timing chain housing.

Remove chain guide mounting bol t (arrow) at upper lef t of timing

chain housing.

Remove chain tensioning rail mounting bolt (arrow) at lower right of

timing chain housing .
117-56 Camshaf t Timing Chain
Camshaft timing chain, removing and installing (N52, A/54 engine)

Use BMW special tool se t 1 1 4 280 to lock down camshafts.

Remove intake and exhaust VANO S units :

• Loose n an d remove VANOS unit mountin g bolts . Discar d bolts.
• Disengag e timing chain from VANOS uni t sprockets.
• Remov e VANOS units (arrows) and set aside. See VANOS units,
removing and installin g (N52 , N5 4 engine) i n this repair group.

NOTE—
• Illustration does not show special tool set 114 280 in place.

Working at front of cylinder head :

• Remov e timing chain assembly mountin g bolts (A).
• Lif t timing chain, timing chain assembl y an d crankshaft sprocket
straight u p (arrow) out of timing chain housing.
 Camshaft Timing Chai n 117-5 7
Camshaft timing chain, removing an d installing (N52, A/5 4 engine)

'X. Chain , chain assembly and crankshaft sprocket. VANOS unit s

shown installed on assembly fo r purposes of illustration .
VANOS
units Timing — Disengag e timing chain from guide and rail assembly and crankshaft
chain sprocket and fit new chain .

Chain Chain
rail guide

Crankshaft
sprocket

B309117008

Fit crankshaft sprocket to chain in orientation shown, with colla r

pointing t o engine .

CAUTION—
• Incorrect sprocket assembly results in engine damage.

N54 engine: Not e that friction plates (arrows) are fitted betwee n
timing chain sprocke t an d oil pump drive sprocket.

CAUTION—
• If N54 engine is operated without friction plates, engine
damage results.
117-58 Camshaf t Timing Chain
Camshaft timing chain, removing and installing (N52, N54 engine)

^V N5 4 engine: Make sure oil pump driv e sprocket friction plate (A ) is

in correct position .

NOTE—
• B and C are oil pump and oil pump chain guide mounting bolts.

— Pul l timing chain taut until sprocket engages chain guide. Instal l
timing chain and chain assembly i n chain housin g i n this position,
holding chain unde r tensio n at all times.

— Instal l and torque timing chain assembly, rai l and guid e bolts.

Tightening torques
Timing chain guid e to cylinder head (M7) 14Nm(10ft-lb)
Timing chain assembly to cylinder head 8.5 Nm (6 ft-lb)
(M6 x 35 m m Torx)
Timing chai n rail to crankcase (M8) 20Nm(14ft-lb)

. N5 4 engine: Slide friction plate (arrow ) on vibration damper hu b

shaft prior to inserting hub in crankcase bore .

B309117012'

Line up timing chain and oil pump chain sprockets (A) inside
crankcase bore, then insert vibration damper hu b (B), sliding it
through chain sprockets. Using ne w vibration damper bolt, attach
hub finger tight to crankshaft.

To achieve final torque on vibration damper hub, follo w one of

several alternative procedure steps for preventing crankshaft
rotation recommended b y BMW.

CAUTION—
• Do not rely on flywheel lock (special tool 11 0 300) to counter
hold against crankshaft rotation.
 Camshaft Timing Chain 117-5 9
Camshaft timing chain, removing and installing (N52, N54 engine)

Remove bel t tensioner and screw in special tool 1 1 4 362.

• Bol t special tool 1 1 5 200 to vibration damper hub.
• Bol t specia l tool 1 1 9 280 to tool 1 1 5 200. Rest tool 1 1 9 280
against tool 1 1 4 362.
• Tighten t o initial tightening torque.

Tightening torqu e
Vibration damper hu b to crankshaft
• Stage 1 100 M m (74ft-lb )

Mark special tool 1 1 9 280 and socket wrench with pain t (A).
• Tighten hu b bolt to final torque with assistant helping to counter
hold tool 11 9280.

Tightening torque
Vibration damper hu b to crankshaft
• Stage 2 Additional 360°
_,

Alternate method for manual transmissio n vehicle:

• Moun t special tool 11 8 180 on transmission usin g bolt s A .
• Slide lock handle up (arrow) and tighten bol t B.
117-60 Camshaf t Timing Chain
Camshaft timing chain, removing and installing (N52, N54 engine)

Alternate method for automatic transmissio n vehicle:

• Secure flywheel with special tool 1 1 8 660 through transmission
bell housing opening .

Alternate method i f transmission i s removed:

• Secur e flywheel with special tool 1 1 9 260.

Use angle protractor (BMW special too l 00 9 140 or equivalent) to

torque hub bolt.

Tightening torque
Vibration damper hub to crankshaf t
• Stage 1 100Nm(74ft-lb)
• Stage 2 Additional 360 °

— Instal l crankshaft front seal. See 11 9 Lubrication System .

 Camshaft Timing Chain 117-6 1
Camshaft timing, adjusting (N52, N54 engine)

Use new bolts to reattach VANOS units. Note that exhaust an d

intake unit s are different and so marked. Camshaft sensor impuls e
wheel for intake an d exhaust ar e the same. Se e VANOS units ,
removing an d installin g (N52 , N5 4 engine) i n this repai r group .

Tightening torque
VANOS unit to camshaf t
(use ne w M10 x 94 m m bolt) :
• Stage 1 20 N m (15ft-lb )
• Stage 2 additional 180°

Install chai n tensioner. See Timing chai n tensioner (N52 , N5 4

engine) in this repai r group .

CAUTION—
• If chain tensioner is reused, drain its oil chamber. Place
tensioner on level working surface and compress slowly.
Repeat twice.
• No sealing ring is fitted to chain tensioner at the factory. When
reassembling engine, be sure to use new sea/ing O-ring.

Tightening torque
Timing chain tensione r t o cylinder hea d 55 N m (4 1 ft-lb )
(M22 x 1 .5) (us e new sealing O-ring)

Remove crankshaft and camshaft lockin g tools and rotat e engine 2

full revolutions. Then check and, if necessary, reset camshaft timing .
See Camshaft timing, adjusting (N52, N5 4 engine) in this repair
group.

CAUTION—
• Remove crankshaft and camshaft locking tools before rotating
or starting engine.

Reassemble engine .

Camshaft timing, adjusting (N52, N54 engine)

WARNING —
• To avoid personal injury, be sure the engine is cold before
beginning the procedure.

— Us e scan tool to rea d out an d recor d EC M fault memory .

— Switc h ignition OF F an d remov e key .

— Remov e uppe r an d lowe r cabin microfilte r housings. Se e

640 Heating and Air-conditioning .

— Remov e strut tower brace .

— Remov e ignition coil cover (uppe r engin e cover). See

020 Maintenance .

Detach ignition coil connectors. Lift ignition coil harness off cylinder
head cove r an d set aside .
117-62 Camshaf t Timing Chain
Camshaft timing, adjusting (N52, N54 engine)

— Remov e ignitio n coils. See 120 Ignition System .

— Remov e cylinder head cover. See 11 3 Cylinder Hea d Removal

and Installation.

— Rais e vehicle and suppor t safely.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Remov e engine compartment splash shield. Se e 020 Maintenance.

^k N5 2 engine: Using vibration damper bolt , rotate crankshaft to place

cylinder 1 in TDC firing position. I n this position , cylinde r 1 intake
camshaft lobe points upwar d at an angle (dashe d line) .

B309113024

N52 engine: Cylinder 1 in TDC firing position : Cylinde r 6 exhaust

camshaft lobe (A) points downward at an angle (dashed line). Cam
follower (B ) i s not actuated.

NOTE—
• Use a mirror to check exhaust camshaft lobe position.

N54 engine: Usin g vibration damper bolt to rotate crankshaft, place

cylinder 1 in TDC firing position. In this position, lobes for cylinder 6
(rear of engine) intak e and exhaus t camshaft s (A, B) point away
from each other and down. Cylinder 6 camshaft lobes do not contact
roller cam followers.

NOTE—
• Use a mirror to check cylinder 6 cam lobe positions.
 Camshaft Timing Chain 117-6 3
Camshaft timing, adjusting (N52, N54 engine)

Working underneath engine, slide out protective plug at lower lef t of

engine bel l housing flange. Instal l BM W special tool 1 1 0 30 0
(crankshaft lockin g tool) through bell housing flange port int o
flywheel (A) hole . If necessary, rock flywheel slightly back and forth
to line up holes with tool. This locks crankshaft at TDC .

CAUTION—
• Models with automatic transmission: In the flywheel (torque
plate), a short distance before the bore for TDC position, there
is a large bore which can be confused with the special tool bore.
If the flywheel is locked using the correct bore, the engine can
no longer be rotated at the vibration damper bolt.
• If special tool 11 0 300 does not slide easily into the bell
housing flange bore, sand paint off the tool. Do not enlarge the
bore.

Use BMW specia l tool set 1 1 4 280 to lock down camshafts .

With crankshaft locked, if special tool 1 1 4 281 fits, camshaft timing

is correct. Remove special tools and reassemble engine.

If special too l 1 1 4 281 doe s no t fit, use hexagon casting a t rea r of

camshafts to rotate camshafts until tool fits. Proceed with camshaft
timing procedure below.

Working at front of camshafts:

• Loose n exhaust and intake camshaft adjustment (VANOS ) unit
mounting bolt s (A, B) .
• Discar d bolts and replace with new.
• Tighten bolt s finger tight.
117-64 Camshaf t Timing Chain
Timing chain tensioner (N52, N54 engine)

Install BM W special tool 1 1 8 520.

• Plac e tool u p against VANO S unit sensor gears .
• Rotat e sensor gears (arrows) until locating pins on tool line up with
bores in sensor gears.
• Pus h tool firmly agains t sensor gears and lock down with
M6 x 45 m m bolts (A).

Working at front of cylinder head:

• Remov e timing chain tensioner (A) . Be prepared to catch dripping
oil. D o not allow oil to contaminate accessor y belt .
• Screw BMW special tool 1 1 9 340 (dummy chai n tensioner ) int o
cylinder head .
• Usin g BMW special tool 00 9 250 (lo w torque torque-wrench),
rotate stud of special too l 1 1 9 340 to pretension timin g chai n to
0.6 Nm (5.3 in-lb).
• Tighten VANO S unit mounting bolt s (B) .

Tightening torque
VANOS unit to camshaft:
• Stage 1
• Stage 2 20Nm(15ft-lb)
additional 180 °

Remove special tools and assemble engine . Reinstal l chain

tensioner using ne w sealing O-ring . Se e Timing chain tensione r
(N52, N5 4 engine) in this repair group.

Tightening torque
Timing chain tensione r to cylinder hea d 55 Nm (41 ft-lb)
(M22 x 1 .5) (us e new sealing O-ring)

Timing chai n tensioner (N52 , N5 4 engine )

The timing chain tensioner i s screwed int o the righ t front of the
cylinder head . When i t is removed be sure to catch any dripping oil
in a shop towel. Do not allow oil to contaminate accessory belt.

If chain tensioner is reused, drain it s oil chamber. Place tensioner

vertically on level working surface and compress slowly (arrow) .
Repeat twice.

CAUTION—
• No sealing ring is fitted to chain tensioner at the factory. When
reassembling engine, be sure to use new sealing O-ring.

Tightening torque
Timing chain tensioner to cylinder hea d 55 N m (41 ft-lb)
(M22 x 1 .5) (us e new sealing O-ring )
B309117023
 Camshaft Timin g Chain 117-6 5
VANOS units, removing and installing (N52, N54 engine)

VANOS UNIT S (N52, N54 ENGINE )

VANOS units, removing an d installin g
(N52, N5 4 engine)
Special tools and procedures are required to remove and install
VANOS units and to time camshafts. Read the entire procedure
before beginning repairs .

WARNING —
• To avoid personal injury, be sure the engine is cold before
beginning the procedure.

CAUTION—
• Disassembly, removal and assembly of VANOS units without
special tools poses the risk of damage or breakage: Valves may
be bent by contact with the piston crowns.
• Throughout this procedure, unless otherwise specified,
crankshaft and camshafts remain locked against rotation using
BMW special tools.
• Keep VANOS components free of silicone sealant. A small
amount of silicone introduced into VANOS actuator or solenoid
can set faults.

— Us e scan tool to read out an d recor d ECM fault memory .

— Switc h ignition OF F an d remov e key.

— Remov e upper an d lowe r cabin microfilte r housings. Se e

640 Heating an d Air-conditioning.

— Remov e stru t tower brace .

— Remov e ignition coil cover (upper engine cover). See

020 Maintenance.

— Detac h ignition coil connectors. Lift ignition coil harness off cylinder
head cover and set aside.

— Remov e ignition coils. See 120 Ignition System.

— Remov e cylinder head cover. See 113 Cylinder Head Remova l

and Installation .

— Rais e vehicle and suppor t safely.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Remov e engine compartment splash shield. See 020 Maintenance .

^. N52 engine: Usin g vibration damper bolt, rotate crankshaft to place

cylinder 1 in TDC firing position. I n this position, cylinde r 1 intake
camshaft lobe points upwar d at an angle.
117-66 Camshaf t Timing Chai n
VANOS units, removing an d installing (N52, A/5 4 engine)

N52 engine: Cylinder 1 in TDC firin g position: Cylinder 6 exhaust

camshaft lobe (A) points downward a t an angle (dashed line). Cam
follower (B) i s not actuated .

NOTE—
• Use a mirror to check exhaust camshaft lobe position.

N54 engine: Usin g vibration damper bolt to rotate crankshaft, place

cylinder 1 in TDC firing position. I n this position, lobes for cylinder 6
(rear of engine) intak e and exhaus t camshafts (A , B ) point away
from each other and down. Cylinder 6 camshaft lobes do not contact
roller cam followers.

NOTE—
• Use a mirror to check cylinder 6 cam lobe positions.

Working underneath engine, slide out protective plug at lower left of

engine bell housing flange. Instal l BM W special tool 11 0 300
(crankshaft lockin g tool) through bel l housin g flange port into
flywheel (A) hole . I f necessary, rock flywheel slightly back and forth
to line up holes with tool. This lock s crankshaft at TDC.

CAUTION—
• Models with automatic transmission: In the flywheel (torque
plate), a short distance before the bore for TDC position, there
is a large bore which can be confused with the special tool bore.
If the flywheel is locked using the correct bore, the engine can
no longer be rotated at the vibration damper bolt.
• If special tool 110 300 does not slide easily into the be/I
housing flange bore, sand paint off the tool. Do not enlarge the
bore.
 Camshaft Timing Chain 117-6 7
VANOS units, removing and installing (N52, N54 engine)

Use BMW specia l too l set 1 1 4 280 to loc k down camshafts.

Working a t right front of cylinder head , remov e timing chai n

tensioner (B) . B e prepared t o catch drippin g oi l with a shop towel.
Do not allow oil to contaminate accessor y belt .

Working a t front of camshafts :

• Loosen and remove exhaus t an d intake VANOS uni t mounting
bolts (A , B) . Discard bolts .
• Disengag e timin g chai n from camshaft adjustmen t uni t sprockets .
• Tilt VANOS unit s dow n t o remove.
117-68 Camshaf t Timing Chain
VANOS units, removing and installing (N52, N54 engine)

Use new bolts to reattac h VANO S units .

• Not e that exhaust and intake unit s are different and so marked.
• Camshaf t sensor impuls e whee l for intake an d exhaust ar e the
same.
• VANOS units and sensor wheel s ma y be installed in any positio n
initially. Finger-tighten mountin g bolt s for now.

B309113023

Press chain int o chain tensione r rai l (arrow) by hand t o make sure
it is routed correctly. (Chain assembly an d VANO S units show n
removed from engine fo r purpose of illustration.)

Adjust camshaft timing. See Camshaft timing , adjustin g (N52 ,

N54 engine) i n this repai r group. The n torqu e VANOS mountin g
bolts.

Tightening torque
VANOS unit to camshaft (use ne w M10 x 94
mm bolt) :
• Stage 1 20Nm(15ft-lb)
• Stage 2 additional 180 °

Install chain tensioner. See Timing chai n tensione r (N52 , N5 4

engine) i n this repai r group .

CAUTION—
B309117039 • If chain tensioner is reused, drain its oil chamber. Place
tensioner on level working surface and compress slowly.
Repeat twice.
• No sealing ring is fitted to chain tensioner at the factory. When
reassembling engine, be sure to use new sealing O-ring,

Tightening torque
Timing chain tensione r t o cylinder hea d 55 Nm (41 ft-lb)
(M22 x 1 .5) (us e new sealing O-ring )

— Reassembl e engine.

CAUTION—
• Remove crankshaft and camshaft locking tools before rotating
or starting engine.
 Camshaft Timing Chain 117-6 9
Timing chain components (V8 engine)

TIMING CHAI N SERVICE (V8 ENGINE )

Timing chai n components (V8 engine )
1. Timin g chain rail
2. Camshaf t adjuster (VANOS) unit
3. Timin g chain guide
4. Suppor t stud
5. Timin g chain tensioner
6. Timin g chain guide
7. Timin g chain guide bearing
8. Timin g chain

B5101130008a

Right camshaft timing, adjustin g (V8 engine)

— Remov e right side valvetronic motor. See 133 Fuel Injection .

— Remov e spark plugs. Plu g spark plug bores to prevent debris from
entering engine.

— Remov e right side cylinder head cover. See 11 3 Cylinder Hea d

Removal and Installation.

— Remov e engine cooling fan and cooling fan shroud. Se e 17 0

Radiator and Cooling System.

— Remov e air filter housing and ducts . See 133 Fuel Injection .

^C Workin g at front of right cylinder head:

• Remov e clamp (A) and remove line (B) .
• Loose n hose clamps (blac k arrows).
• Detach vaccum line (white arrow).
117-70 Camshafnimirig^hai n
Right camshaft timing, adjusting (V8 engine)

Remove vaccu m pump fasteners (arrows ) and vacuum pump (A)

with bracket (B).

Disconnect electrical connectors from VANOS adjuster solenoid s

(A). Remove fasteners (B), brackest (arrows) and remove actuator
solenoids (A) . Discard actuator solenoids O-rings .

Remove vacuum line s from bracke t (arrow) .

 Camshaft Timin g Chain 117-7 1
Right camshaft timing, adjusting (V8 engine)

Remove upper timing chain cove r fasteners (A) and remov e uppe r
cover (B) .

Remove banjo bolt (A) . Unclip oi l line (B) from retianers (C ) and
remove.

CAUTION—
• Do not misplace oil line banjo bolt.

Using vibration damper cente r bolt, turn engine i n direction of

rotation to cylinder 1 TDC position.

NOTE—
• Cylinder 1 exhaust lobe points upwards at an angle.
Cylinder 1 intake lobe points downwards at an angle.
117-72 Camshaf t Timing Chai n
Right camshaft timing, adjusting (V8 engine)

Using BMW special tool 11 9 190, loc k engine in cylinder 1 TDC

position.

To avoid incorrect timing adjustment, chec k VANO S adjustment uni t

locking usin g the following steps .

Grip hexagon (black arrow) of intake camshaft and attempt to rotate

intake camshaft carefull y in direction opposit e (whit e arrow) to
engine rotation . I f there i s no fixed connection betwee n intake
camshaft and intake VANOS unit, rotate intake camshaft in direction
opposite t o engine rotatio n a s far as i t will go.

Grip hexagon (blac k arrow ) o f exhaust camshaft an d attempt to

rotate exhaust camshaf t carefully in the direction of engine rotatio n
(white arrow). If there i s no fixed connection between exhaust
camshaft and exhaust VANOS unit , rotat e exhaust camshaft in the
direction of engine rotation as far as it will go.
 Camshaft Timing Chain 117-7 3
Right camshaft timing, adjusting (V8 engine)

Grip each camshaft at hexagon and loosen VANOS adjuster bolt s

(arrows). D o not remov e VANOS adjuster bolts.

Install BM W special tool 1 1 9 461 on intake camshaft so that it rests

flush on cylinder head.

Install BMW special tool 11 9 463, secure holder (A) in thread for oil
line hand tight.
117-74 Camshaf t Timing Chai n
Right camshaft timing, adjusting (V8 engine)

Grip intake camshaft a t hexagon and tighten intake VANOS adjuster

bolt (A).

Tightening torque
VANOS adjuster t o camshaft 80 Nm (59 ft-lb)
(replace bolt )

Remove holde r (A) and BMW special tools 11 9 461, 1 1 9 463.

Install BMW special tool 1 1 9 462 o n exhaust camshaft so that it

rests flush on cylinder head .
 Camshaft Timing Chai n 117-7 5
Right camshaft timing, adjusting (V8 engine)

Install BMW special tool 1 1 9 463 and secure holder (A ) i n oil lin e
thread han d tight.

Grip exhaust camshaft at hexagon and tighten exhaust VANO S

adjuster bolt (A).

Tightening torque
VANOS adjuster to camshaf t 80 N m (59 ft-lb)
(replace bolt )

Remove holder (A ) and BMW special tools 1 1 9 462, 11 9 463.

117-76 Camshaf t Timin g Chai n
Right camshaft timing, adjusting (V8 engine)

Remove BMW special tool 11 9 190. Using vibration damper center

bolt turn engine 2 full rotations. Usin g BM W special tool 11 9 190
lock engine in cylinder 1 TDC position.

" Plac e BM W special tool 11 9 461 o n intake camshaft an d chec k

timing. Timing is correctly adjusted when BMW special tool 11 9 461
rests flat on cylinder hea d or protrudes by up to 0.5 mm to exhaust
side.

NOTE—
• Due to flexible sprocket design, VANOS unit tolerances and play in
the VANOS units, when the camshaft timing is set correctly, the
exhaust side of special tool 11 9461 may be up to 0.5 mm (0.02
in) above the surface of the cylinder head. This is normal.

— Remov e special tool 11 9 461 fro m inlet camshaft.

. Plac e BMW special too l 1 1 9 462 o n exhaust camshaft and chec k

timing. Timing is correctly adjusted when BMW special tool 11 9 461
rests flat on cylinder head or protrudes by up to 0.5 mm to exhaust
side.

NOTE—
• Due to flexible sprocket design, VANOS unit tolerances and play in
the VANOS units, when the camshaft timing is set correctly, the
exhaust side of special tool 11 9 462 may be up to 0.5 mm (0.02
in) above the surface of the cylinder head. This is normal.

— Remov e special tool 11 9 462 from exhaust camshaft .

— Reassembl e engine.

— Remembe r to replace :
• VANOS unit bolts .
• VANOS solenoid O-rings.
 Camshaft Timing Chain 117-7 7
Left camshaft timing, adjusting (V8 engine)

Left camshaft timing, adjusting (V8 engine)

Remove lef t side valvetronic motor. See 133 Fuel Injection.

Remove spar k plugs . Plug spark plu g bores to prevent debri s from
entering engine.

Remove lef t side cylinder head cover. See 113 Cylinder Hea d
Removal an d Installation.

Remove engine cooling fan and fan shroud. Se e 170 Radiator an d

Cooling System.

Remove air filter housing and ducts. See 133 Fuel Injection .

Disconnect negative (-) cabl e from battery.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions in 001 Warnings an d Cautions.

Remove banjo bol t (A). Uncli p oil line (B ) from retainers (C ) and
remove.

CAUTION—
• Do not misplace oil line banjo bolt.

Using vibration damper center bolt, turn engine i n direction of

rotation to cylinder 1 TDC position.

NOTE—
• With cylinder 1 in TDC position, cylinder 5 camshaft intake and
exhaust camshaft lobes point upwards at an angle (arrows).

Using BMW special tool 1 1 9 190, lock engine i n cylinder 1 TDC

position.
117-78 Camshaf t Timing Chai n
Left camshaft timing, adjusting (V8 engine)

To avoid incorrect timing adjustment, chec k VANOS adjustment unit

locking using the following steps.

Grip hexagon (blac k arrow) of intake camshaft an d attempt to rotate

intake camshaft carefully in direction opposite (white arrow) to
engine rotation . If there i s no fixed connection between intak e
camshaft and intake VANOS unit, rotate intake camshaft in direction
opposite to engine rotatio n as far as it will go.

Grip hexago n (black arrow ) o f exhaust camshaft an d attempt t o

rotate exhaust camshaft carefully in the direction o f engine rotation
(white arrow). I f there is no fixed connection between exhaus t
camshaft and exhaust VANO S unit, rotat e exhaust camshaft in the
direction o f engine rotatio n as far a s it will go.

^ Disconnec t electrical connectors from VANOS adjuster solenoids

(A). Remove fasteners (arrows), brackest (B ) and remove actuato r
solenoids (A). Discard actuato r solenoids O-rings.

— Remov e alternator belt. See 020 Maintenance .

 Camshaft Timing Chain 117-7 9
Left camshaft timing, adjusting (V8 engine)

Remove alternator fastener s (A ) and lay alternator (B) aside .

Remove fastener (arrow) and bracket (A). Unclip wiring harness (B )

from bracket .

Remove upper timing chain cover fasteners (A) an d remov e cover

(B).
117-80 Camshaf t Timing Chain
Left camshaft timing, adjusting (V8 engine)

Grip each camshaft at hexagon an d loose n VANOS adjuster bolts

(arrows). Do not remove VANO S bolts.

Install BMW special tool 11 9 461 on intake camshaft so that it rests

flush on cylinder head .

Install BM W special tool 1 1 9 463 an d secure holder (A) i n oil lin e

thread hand tight.
 Camshaft Timing Chain 117-8 1
Left camshaft timing, adjusting (V8 engine)

Grip intake camshaft at hexagon and tighten intake VANOS adjuster

bolt (A).

Tightening torque
VANOS adjuste r t o camshaf t 80 Nm (59 ft-lb)
(replace bolt)

Remove holder (A ) and BMW special tools 11 9 461, 1 1 9 463.

Install BMW special tool 11 9 462 on exhaust camshaft so that it

rests flush on cylinder head .
117-82 Camshaf t Timing Chain
Left camshaft timing, adjusting (V8 engine)

Install BMW special tool 1 1 9 463 and secure holder (A) in oil line
thread hand tight.

Grip exhaust camshaft at hexagon and tighten intake VANOS

adjuster bolt (A).

Tightening torque
VANOS adjuster t o camshaft 80 Nm (59 ft-lb)
(replace bolt)

Remove holder (A) an d BMW special tools 11 9 462, 11 9 463.

 Camshaft Timing Chain 117-8 3
Left camshaft timing, adjusting (V8 engine)

Remove BMW special tool 11 9 190. Usin g vibration dampe r cente r

bolt turn engine 2 full rotations. Using BM W special tool 11 9 1 90
lock engine i n cylinder 1 TDC position .

" Plac e BM W special tool 1 1 9 461 o n intake camshaft an d chec k

timing. Timing is correctly adjuste d when BMW special tool 11 9 461
rests flat on cylinder head or protrudes b y up to 0.5 mm to exhaus t
side.

NOTE—
• Due to flexible sprocket design, VANOS unit tolerances and play in
the VANOS units, when the camshaft timing is set correctly, the
exhaust side of special tool 11 9 462 may be up to 0.5 mm (0.02
in) above the surface of the cylinder head. This is normal.

— Remov e special tool 11 9 461 from inlet camshaft.

" Plac e BMW specia l tool 1 1 9 462 o n exhaust camshaft an d chec k

timing. Timing is correctly adjusted when BMW special tool 11 9 461
rests flat on cylinder hea d or protrudes by up to 0.5 m m to exhaust
side.

NOTE—
• Due to flexible sprocket design, VANOS unit tolerances and play in
the VANOS units, when the camshaft timing is set correctly, the
exhaust side of special tool 11 9 462 may be up to 0.5 mm (0.02
in) above the surface of the cylinder head. This is normal.

— Remov e special tool 11 9 462 from exhaust camshaft.

— Reassembl e engine .

— Remembe r t o replace:
• VANOS unit bolts.
• VANOS solenoid O-rings.
117-84 Camshaf t Timing Chai n
Timing chain tensioner (V8 engine)

Timing chai n tensioner (V 8 engine)

A timing chain tensioner is screwed into the left front of each cylinder
head. When i t is removed b e sure to catch any dripping oil in a shop
towel. D o not allow oi l to contaminate accessory belt .

If chain tensioner is reused, drain it s oil chamber. Plac e tensioner

vertically on level working surface and compress slowly (arrow) .
Repeat twice.

CAUTION—
• When reassembling engine, be sure to use new sealing O-ring.

Tightening torque
Timing chain tensioner to cylinder hea d 65 Nm (48 ft-lb)
(M22 x 1 .5) (us e new sealing O-ring )

B309117023

VANOS UNIT S (V8 ENGINE )

Right VANOS unit, removing (V 8 engine )
— Remov e righ t side valvetronic motor. See 133 Fuel Injection.

— Remov e spark plugs . Plu g spark plu g bore s to prevent debris from
entering engine.

— Remov e righ t side cylinder head cover. Se e 113 Cylinder Head

Removal an d Installation.

— Remov e engine cooling fan and coolin g fan shroud. See

170 Radiator and Cooling System .

— Remov e ai r filter housin g and ducts. See 133 Fuel Injection .

^. Working at front of right cylinder head :

• Remov e clamp (A) and remove lin e (B) .
• Remove hos e clamp s (blac k arrows) .
• Remove vaccum line (white arrow).

^ Remov e vaccum pump fastener s (arrows ) and vacuum pump (A)

with bracket (B).
 Camshaft Timin g Chai n 117-8 5
Right VANOS unit, removing (V8 engine)

Disconnect electrica l connectors from VANOS adjuste r solenoid s

(A). Remove fasteners (B), brackest (arrows) and remove actuator
solenoids (A). Discard actuator solenoids O-rings.

Remove vacuu m lines from bracke t (arrow) .

B510117006

Remove upper timin g chain cove r fasteners (A) and remov e uppe r
cover (B) .
117-86 Camshaf t Timing Chai n
Right VANOS unit, removing (V8 engine)

Remove banjo bolt (A) . Uncli p oil line (B ) from retainers (C) and
remove.

CAUTION—
• Do not misplace oil line banjo bolt.

Using vibration damper cente r bolt , turn engine i n direction of

rotation t o cylinder 1 TDC position.

NOTE—
• Cylinder 1 exhaust lobe points upwards at an angle.
Cylinder 1 intake lobe points downwards at an angle.

Using BMW special tool 1 1 9 190, loc k engine in cylinder 1 TDC

position.
 Camshaft Timin g Chai n 117-8 7
Right VANOS unit, removing (V8 engine)

To avoid incorrect timing adjustment, chec k VANOS adjustment unit

locking using the following steps .

. Gri p hexagon (black arrow) of intake camshaft and attempt to rotate

intake camshaf t carefully i n direction opposite (whit e arrow) to
engine rotation. If there i s no fixed connection betwee n intak e
camshaft and intake VANOS unit, rotate intake camshaft in direction
opposite t o engine rotatio n as far as it will go.

Grip hexago n (blac k arrow) of exhaust camshaft an d attemp t t o

rotate exhaust camshaf t carefully in the direction of engine rotatio n
(white arrow). I f there i s no fixed connection betwee n exhaust
camshaft an d exhaust VANOS unit, rotate exhaust camshaft i n the
direction o f engine rotatio n a s far as it will go.

Using vibration damper center bolt, turn engine in direction opposite

to rotatio n to 45° before cylinder 1 TDC position .
117-88 Camshaf t Timing Chain
Right VANOS unit, removing (V8 engine)

^V Gri p eac h camshaf t a t hexagon an d loosen VANOS adjuster bol t

(arrows). Fo r now, do no t remov e VANOS bolts.

— Remov e intak e VANO S adjuster bolt and discard .

^V Compres s tensioner rai l (A) several time s to remove oil from

tensioner. Remov e intake VANOS adjuste r (B) .

— Remov e exhaust VANOS adjuster bolt and discard.

Remove exhaust VANOS adjuster (A) . Secure timing chain to

prevent i t from falling into timing cover.
 Camshaft Timing Chai n 117-8 9
Right VANOS unit, installing (V8 engine)

Right VANOS unit, installin g (V 8 engine )

Use new bolts to reattach VANOS units .
• Exhaus t and intake units are different and so marked.
•VANOS units may be installed i n any position initially.
Finger-tighten mounting bolt s for now.

B309113023

Exhaust VANOS adjuster has a metal clip (A) for driving vacuum
pump.

Pull timing chain u p and place ove r exhaus t VANO S sprockets .

Install VANOS adjuster bolt hand tight, then loosen b y 1 /2 turn.
 17-90 Camshaf t Timing Chai n
Left VANOS unit, removing (V8 engine)

^V, Compres s tensione r rai l (A) and place chain over sprockets (B) .
Install VANOS adjuster bolt hand tight, then loosen b y 1 /2 turn

NOTE—
• If tensioner rail cannot be compressed enough to instal chain
loosen timing chain tensioner 3 turns.

— Chec k and adjust camshaft timing. Se e Righ t camshaft timing,

adjusting (V 8 engine) i n this repai r group.

— Reassembl e engine.

Tightening torque
VANOS adjuster to camshaft 80 N m (59 ft-lb)
(replace bolt)
Timing chain tensioner to cylinder hea d 65 N m (48 ft-lb )

Left VANO S unit, removing (V8 engine)

Remove lef t side valvetronic motor. Se e 133 Fuel Injection .

Remove spark plugs . Plug spark plug bores to prevent debri s from
entering engine.

Remove left side cylinder head cover. See 11 3 Cylinder Hea d

Removal an d Installation.

Remove engine cooling fan and cooling fan shroud. Se e 170

Radiator and Cooling System .

Remove air filter housing and ducts. See 13 3 Fuel Injection.

Disconnect negative (- ) cabl e from battery.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions in 001 Warnings an d Cautions.

Remove banj o bol t (A) . Unclip oil line (B) from retainers (C ) and
remove.

CAUTION—
• Do not misplace oil line banjo bolt.

Using vibration damper center bolt , turn engine in direction of

rotation to cylinder 1 TDC position.

NOTE—
• With cylinder 1 in TDC position, lobes of intake and exhaust
camshafts at cylinder 5 point upwards at an angle (arrows).
 Camshaft Timin g Chain 117-9 1
Left VANOS unit, removing (V8 engine)

Using BMW special tool 1 1 9 1 90, lock engine in cylinder 1 TDC

position.

To avoid incorrect timing adjustment, check VANOS adjustment uni t

locking using the following steps .

Grip hexagon (black arrow) of intake camshaft and attempt to rotate

intake camshaft carefully in direction opposite (white arrow) to
engine rotation. If there is no fixed connection between intake
camshaft and intake VANOS unit, rotate intake camshaft i n direction
opposite to engine rotatio n as far as it will go.

Grip hexagon (black arrow) of exhaust camshaft and attempt t o

rotate exhaust camshaft carefully in the direction of engine rotation
(white arrow). I f there i s no fixed connection between exhaust
camshaft and exhaust VANOS unit, rotate exhaust camshaft i n the
117-92 Camshaf t Timing Chai n
Left VANOS unit, removing (V8 engine)

^V Disconnec t electrica l connector s fro m VANOS adjuster solenoid s

(A). Remove fasteners (arrows), brackest (B) and remove actuator
solenoids (A) . Discard actuator solenoid s O-rings .

— Remov e alternator belt. See 02 0 Maintenance .

Remove alternator fasteners (A) an d la y alternator (B ) aside.

Remove fastener (arrow) and bracket (A). Unclip wiring harness (B)
from bracket.
 Camshaft Timin g Chain 117-9 3
Left VANOS unit, removing (V8 engine)

Remove uppe r timin g chai n cover fasteners (A) an d remov e cove r

(B).

Using vibration damper cente r bolt, turn engine in direction opposit e

to rotation t o 45° before cylinder 1 TDC position.

'X. Gri p each camshaft a t hexagon an d loosen VANOS adjuste r bol t

(arrows). Fo r now, do no t remov e VANOS bolts.

— Remov e and exhaus t VANO S adjuster bolt.

117-94 Camshaf t Timing Chai n
Left VANOS unit, installing (V8 engine)

'X, Compres s tensioner rail (A) several time s to remove oil from
tensioner. Remov e exhaust VANOS adjuster (B).

— Remov e intake VANOS adjuster bolt and discard.

Remove intake VANOS adjuster (A). Secure timing chain to prevent

it from falling into timing cover.

Left VANOS unit, installing (V8 engine)

Use new bolts to reattac h VANOS units .
• Exhaus t and intake VANOS units are different and so marked.
•VANOS units may be installed in any positio n initially. Finger-
tighten mounting bolt s for now.
 Camshaft Timin g Chai n 117-9 5
Left VANOS unit, installing (V8 engine)

Pull timing chain up and place chain over sprocket (A). Install
VANOS adjuster bolt hand tight, then loosen by 1 /2 turn.

'X. Compres s tensioner rail (A) and place chain over sprocket (B).
Install VANOS adjuster bol t hand tight, the n loosen b y Vz tur n

NOTE—
• If tensioner rail cannot be compressed enough to install chain
remove timing chain tensioner. Remember to replace sealing O-
ring.

— Chec k and adjust camshaf t timing. Se e LLeft camshaft timing ,

adjusting (V8 engine) i n this repair group.

— Reassembl e engine.

Tightening torque
VANOS adjuster to camshaft 80 N m (59 ft-lb)
(replace bolt)
Timing chain tensioner 65 Nm (48 ft-lb)
 119-1

119 Lubricatio n Syste m

GENERAL 119-2 CRANKSHAFT SEALS (M54 ENGINE ) 119-1 1

Warnings an d Cautions 119-2 Crankshaft front oil seal, replacing
(M54 engine) 119-1 1
ENGINE LUBRICATION 119-3
Crankshaft rea r main seal, replacin g
Engine lubricant 119-3 (M54 engine) 119-1 2
Engine lubrication (M54 engine ) 119-3
Engine lubricatio n (N52, N5 4 engine) 119-3 CRANKSHAFT SEALS
Engine oi l pump (N52, N5 4 engine) . . 119-4 (N52, N5 4 ENGINE ) 119-1 4
Engine lubricatio n (V8 engine) 119-4 Crankshaft front seal, removin g and installin g
(N52, N5 4 engine) 119-1 4
OIL PRESSUR E WARNING SYSTE M 119-5 Crankshaft rea r mai n seal, removin g an d installing
Oil pressure, checking 119-5 (N52, N5 4 engine) 119-1 7
Oil pressure warning switch, CRANKSHAFT SEALS (V8 ENGINE ) 119-2 1
replacing 119-7
Crankshaft front seal, removin g and installin g
OIL MONITORIN G 119-8 (V8 engine) 119-2 1
Oil level and temperature sensor Crankshaft rea r main seal ,
[M54, V8 engine (t o 2006)] 119-8 removing and installing (V 8 engine) 119-2 4
Oil condition sensor (OZS ) OIL PA N AND OIL PUM P (M54 ENGINE ) . . 119-2 6
[N52, N54 , V8 engine (fro m 2006)] 119-8
Oil pan, removin g an d installing (M54 engine) 119-2 6
OZS operation, (N52, N54 , V8 engine) . . . 119-9
Oil pump, removin g an d installing
OZS fault evaluation 119-9
(M54 engine) 119-2 8
Oil level and temperature sensor , replacing
Oil pressure relie f valve (M54 engine) 119-2 9
(M54 engine) 119-9
OZS, replacin g (N52, N54 , V8 engine) 119-10
119-2 Lubricatio n System
Warnings and Cautions

GENERAL
This repair group covers lubrication system troubleshooting and
crankshaft sea l replacement. Oil pan removal and oil pump
replacement for M54 engine are also covered.

See also:
• 020 Maintenance for oil and oil filter change
• 10 0 Engine-General for engine identificatio n and application

Warnings an d Cautions

WARNING —
• Due to risk of personal injury, be sure the engine is cold before
beginning work on engine components.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions in 001 Warnings and Cautions.
• To avoid electrochemical corrosion to engine components
made of aluminum-magnesium alloy, do not use steel fasteners.
Use aluminum fasteners only. For reliable identification, test
fasteners for aluminum composition with magnet.
• Replace aluminum bolts each time they are loosened.
• Follow torque instructions, including angle of rotation
specifications, when installing aluminum fasteners.
• Cover alternator with shop towel to protect from oil drips.
 Lubrication Syste m 119- 3
Engine lubricant

ENGINE LUBRICATION
Engine lubricant

Engine oil specification

M54 engine: BMW high performanc e API ratin g SJ / CF
synthetic or higher
• S A E 5 W - 3 0 o r 15W-4 0
N52, N54 , V8 (N62) engine : BMW long-life API
rating (LL-01 ) synthetic oil s for US market: rating S M
• Castrol Synte c Europea n Formul a or highe r
SAE O W - 3 0
• Mobi l 1 SAE OW - 40
• Pennzoi l Platinum Europea n Formul a Ultra
SAE 5 W - 30
• Valvoline SynPowe r SAE 5W - 30

Engine oil capacity

Engine Approximate capacity (incl. oil filter)
M54 7.5 liter s (8. 0 U S qt)
N52, N5 4 6.5 liters (6.9 US qt)
V8 (N62 ) 8 liter s (8.45 U S qt)

Engine lubrication (M54 engine )

Oil pressure is generated by a gear-type pump bolte d to the botto m
of the engine block . The oi l pump i s chain driven off the front of the
crankshaft.

The oil pressure warning syste m consists of an oil pressure switc h

mounted i n the oil circuit and an instrument panel warning light .
Other safet y features include :
• Filte r bypass t o provide lubricatio n should the oil filter becom e
clogged.
• Oil pump pressur e relie f valve to prevent excessive syste m
pressure.

VANOS Engine lubrication (N52, N5 4 engine)

units
To meet the oiling requirement s o f N52 and N54 engines, a chain-
driven volumetric-flow controlled oil pump i s utilized. The VANO S
system require s a large volume of oil, particularly at low engine
speeds.

The volumetric-flow controlled pum p desig n allows:

• Increase d powe r output
• Reduced weight
• Optimized fuel consumptio n
• Reduced exhaust emissions

Oil pum p
119-4 Lubricatio n System
Engine oil pump (N52, N54 engine)

Engine oil pump (N52, N5 4 engine)

1 2 3 4
1. Slidin g vane valve
2. Pivotin g rotor housin g
3. Bevele d control pisto n
4. Compressio n spring
5. Pivo t pin
6. Roto r
7. Pum p shaft

The volumetric-flow controlled oi l pump delivers only as much oil as

is necessary. N o surplus quantities o f oil are delivered in low load
operating ranges . This reduce s th e fuel consumption of the engine
and slows down the oil wear rate .

The pump is designed with sliding vane valves. The pump shaft and
rotor are positioned off-cente r i n the pivotin g roto r housing and the
5 6 7 vanes ar e displaced radiall y durin g rotation . The vanes form
B309119003
chambers of differing volume dependin g o n the position of the roto r
housing.

When the pum p rotates , oil pressure act s on the control piston
against the force of the compression spring . The beveled piston
varies the position o f the pivotin g housing .

When the housin g i s centered o n the rotor , changes in intake an d

output chamber volume s ar e small: Delivere d oil volume i s low.
When the rotor housing i s off-center in relation to the rotor, changes
in input an d output chambe r volume s ar e greater: Delivered oil
volume is high .

When the oil volume require d b y the engine increases , for example
during VANOS operation, oil pressure i n the lubricating system
drops, reducin g pressure on the bevele d piston . In response, the
compression sprin g presses th e beveled piston against the pivotin g
housing contro l dog, forcing the housin g further off-center and
increasing oil volume. The opposit e occur s as engine oil pressure
increases and the need for delivered oil volume drops .
Pivoting
housing B309119004

Engine lubrication (V 8 engine)

Oil pressure is generated b y a two-stage gear-type pump with two
parallel switched gear clusters. It is bolted to the bottom o f the
engine bloc k at an angle. The oi l pump i s chain driven off the front
of the crankshaft.
1. Oi l pum p
2. Oi l filter
3. Profil e gasket
4. O-rin g
5. Oi l pump inle t
6. Oi l pip e
7. Oi l pump driv e chai n
8. Oi l pump drive gea r
9. Oi l deflector
 Lubrication System 119- 5
Oil pressure, checking

Engine oi l i s supplied b y the oi l pump t o lubrication point s i n the

engine block and is pumped int o the cylinder heads. Three oil check
valves are installed i n each cylinde r head. This prevent s engin e oi l
from draining out of the cylinder head and VANOS units. The chec k
valves ar e serviceable from the outside casting of the cylinder head.
1. Intak e VANOS check valve
2. Exhaus t VANOS check valve
3. Cylinde r hea d oi l supply check valve

OIL PRESSUR E WARNING SYSTE M

CAUTION—
• If the red oil pressure warning light comes on or flashes on while
driving, assume that the oil pressure is low. Stop the engine
immediately and make arrangements to test oil pressure.

Oil pressure, checking

Test oil pressure b y removing oi l pressure switch and installin g oi l
pressure gauge i n its place .

— 6-cylinde r engine: Loose n oi l filter cover to allow engin e oil to drain

back down into oil pan. Tighten cover.

^ M5 4 engine : Acces s to oil pressure warning switch (arrow) is

restricted (intake manifold removed for purposes o f photo) .
119-6 Lubricatio n System
Oil pressure, checking

N52, N5 4 engine: Detac h harnes s connecto r (arrow) from oil

pressure switch. If necessary, remov e ignition coil cover. See 02 0
Maintenance.

V8 engine: Working at front of righ t cylinder head , detach electrical

connector (A ) from oil pressure switch (B) .

Remove switch. Be prepared to catch leaking oil with a shop towel.

CAUTION—
• Thoroughly clean around the oil pressure switch before
removing it.

Install pressure gauge i n place of oil pressur e switch. If necessary,

use BMW special adapter 11 4 050 i n place of oil pressure switch.

With gauge installed, start engine an d allow to reach operating

temperature. Check oil pressure. See Table a.

NOTE—
• For the most accurate test results, make sure the engine oil and
filter are new and the oil of the correct grade.

Table a. Engine oil pressur e

At idle , engine at operating
temperature
M54 engine 0.5 ba r ( 7 psi)
N52, N5 4 engin e 1.5bar(22psi)
V8 engine 1.0 bar (14.5 psi)
Maximum regulated pressure,
engine at operating temperature
M54 engine 4 ± 0.5 bar (58 ± 7 psi)
N52, N5 4 engine 4.0 - 6.0 bar (58 - 87 psi)
V8 engine 4.0 - 6.0 ba r (5 8 - 87 psi)
 Lubrication System 119- 7
Oil pressure warning switch, replacing

Remove pressur e gaug e and reinstall pressure switch wit h new

sealing washer.

Tightening torque
Oil pressure switch to oil filter housing
M54 engine (M1 2 x 1.5 ) 27 Nm (20 ft-lb)
Oil pressure switch to oil filter housing 20 N m (15 ft-lb)
N52, N5 4 engine (M 1 2 x 1. 5) additional 16°
Oil pressure switch to cylinder head
V8 engine (M12 x 1.5) 27 N m (20 ft-lb)

If testing shows low oil pressure, one or more of the following

conditions may be indicated:
• Worn or faulty oil pump o r faulty pump pressure relie f valve
• Worn or damaged engin e bearing s
• Severe engine wear

Any of these conditions indicate the need for major repairs .

Oil pressure warning switch, replacing

M54 engine: Access t o oil pressure warning switc h (arrow ) i s
restricted (intake manifold removed for purposes of photo).

N52, N54 engine: I f necessary, remove ignition coil cover. See 02 0

Maintenance.
119-8 Lubricatio n Syste m
Oil level and temperature sensor [M54, V8 engine (to 2006)]

V8 engine: Oi l pressur e switc h (B ) i s located at right front cylinder

head.

6-cylinder engine: Loose n oi l filter cap to allow engine oil to drain

back down int o oil pan .

Disconnect harnes s connecto r from oil pressure switch and remov e

switch. B e prepared t o catch leakin g oi l with a shop towel.

CAUTION—
• Thoroughly clean around the oil pressure switch before
removing it.

Installation i s reverse of removal. Tighten oil filter housing cap and

top of f oil, i f necessary.

Tightening torque
Oil pressure switch to oil filter housing
M54 engine (M12 x 1.5 ) 27 M m (2 0 ft-lb )
Oil pressure switch to oil filter housin g 20Nm(15ft-lb)
N52, N5 4 engine (M 1 2 x 1.5) additional 16 °
Oil pressure switc h to cylinder hea d
V8 engine (M 1 2 x 1.5) 27 N m (20 ft-lb)

OIL MONITORIN G
Oil level and temperature sensor
[M54, V8 engine (to 2006)]
Engine oil leve l and temperature i s measured b y the oil level and
temperature sensor and indicated in the instrument cluster or central
information display.

Oil condition informatio n i s processed b y the engine control modul e

(ECM), then routed via PT-CAN and K-CAN buses to the instrument
cluster and central information display . Th e EC M software
determines the optimal tim e for oil change interval.

Checking oil leve l is covered i n 020 Maintenance .

Oil condition sensor (OZS)

[N52, N54, V8 engine (from 2006)]
Engine oi l level is measured b y the oi l condition sensor (OZS) an d
indicated in the instrument cluster o r central information display.
Engine oil temperature and condition are also monitored by the
OZS. N52 , N5 4 engines ar e not equipped with a dipstick .

Oil condition information is processed by the engine control module

(ECM), then route d via PT-CAN and K-CAN buses to the instrumen t
Oil condition cluster and central informatio n display . The EC M uses condition
sensor (OZS )
engine based service (CBS) software to determine optima l oil chang e
interval.

Checking oil level is covered in 020 Maintenance.

 Lubrication System 119- 9
OZS operation, (N52, N54, V8 engine)

OZS operation, (N52, N54 , V 8 engine)

1. Housin g
2. Oute r metal tub e
3. Inne r metal tub e
4. Engin e oi l (maximum )
5. Engin e oi l (average)
-£:*-
6. Engin e oi l (minimum )
7. Oi l pan
8. Oi l temperature sensor
9. Senso r electronics
10. Senso r connector

OZS consists of two cylindrical capacitors arranged on e above th e

other. Oil condition is determined b y the lower , smaller capacitor .
Two metal tubes (1 , 2), arranged one inside the other, serv e as
capacitor electrodes. The dielectric is the engine oil between the
electrodes. The electrical property of engine oil changes wit h ag e
9— and break-down of oil additives, changing the OZS capacitance .
This chang e i s processed i n the sensor electronics (9) an d
converted to a digital signal . The digital sensor signal i s transferred
to the ECM , which use s i t to calculate the next oil change servic e
due.

Engine oil level i s determined b y the capacitor of the OZS . A s oi l

level drops, sensor capacitanc e changes accordingly. This change
is processed in the sensor electronics (9) and converted t o a digital
signal. The digital sensor signa l i s transferred to the EC M an d
displayed to the driver.

A platinu m temperature sensor (8 ) is installed a t the bas e o f the oi l

condition sensor .

Engine oil level, temperature an d condition are monitore d

continuously a s long a s voltage i s applied a t terminal 15 (ignition
ON). OZS is powered via terminal 87.

OZS fault evaluation

OZS electronic circuitry features a self-diagnosis function. In case of
a fault in the sensor, an error message i s sent to the ECM . Th e fault
can be viewed using a BMW scan tool.

Oil level an d temperature sensor , replacin g

(M54 engine)
Oil level warning switch is located at bottom of engine oi l pan.

Raise vehicle and support safely.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splas h shield underneath engine. Se e 020 Maintenance.

Drain engine oil . See 020 Maintenance .

119-10 Lubricatio n System
OZS, replacing (N52, A/54, V 8 engine)

k Disconnec t electrical connector an d remov e mounting nuts

(arrows). Lower level sensor, be prepared to catch dripping oil.

— Whe n reinstalling, replac e sealing O-ring.

— B e sure to refill engine an d check for leak s after work is completed.

OZS, replacing (N52, N54, V8 engine)

N52 engine shown. Other engines are similar.

Raise vehicle and support safely.

WARNING—
• Make sure the vehicle is stable and well supported at a/I times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splash shield underneath engine . Se e 020 Maintenance .

Drain engine oil. See 020 Maintenance .

With engine fully cooled off, disconnect OZS electrical connector (A)
and remove mounting nuts (B). Lower leve l sensor. Be prepared to
catch dripping oil.

- \n reinstalling, replace sealing (J-nng.

Tightening torque
OZS to oil pan
• Stage 1 2 M m (18lb-in )
• Stage 2 8.5 Nm (75 Ib-in)

— Refil l engine with oil and check for leak s afte r work is completed.
 Lubrication System 119-1 1
Crankshaft front oil seal, replacing (M54 engine)

CRANKSHAFT SEALS (M54 ENGINE)

Crankshaft front oil seal, replacin g
(M54 engine )
With engine fully cooled off, remove electric cooling fan, engin e
accessory belt s and crankshaft vibration damper and pulley. Be sure
to mar k belts with direction of rotation. See 117 Camshaft Timing
Chain.

Install ca p (BM W special tool 1 1 2 383) on end of crankshaft.

Install seal guide (BM W special tool 11 2 385) ove r end of

crankshaft. Be sure to align groov e with keyway on crankshaft
(arrow).

Install oil seal puller (BMW special tool 1 1 2 380) and screw in body
of pulle r until it contacts seal . Tighten bolt in center of tool to draw
seal ou t of cover.
119-12 Lubricatio n Syste m
Crankshaft rear main seal, replacing (M54 engine)

^V Coa t ne w seal with oil and position i n timing chain cover. Use BMW
special tool 1 1 3 280 and crankshaft cente r bolt to draw seal in flush
with timing case cover.

— Reinstal l crankshaft vibration dampe r and pulley .

Tightening torque
Vibration damper hu b to crankshaft 410Nm(302ft-lb)
(use new bolt)

— Remainde r of installatio n is reverse of removal , notin g the following:

• Instal l engin e accessor y belts . Se e 020 Maintenance .
• Instal l cooling fan. See 170 Radiator an d Cooling System .

Crankshaft rear main seal, replacing

(M54 engine )
Crankshaft rea r main seal (flywhee l seal) replacemen t requires
removal of the transmission an d flywheel.

— Remov e transmission. Se e 23 0 Manua l Transmission ,

231 Sequential Manua l Gearbo x (SMG ) or 240 Automatic
Transmission.

— Manua l transmission vehicles: Remov e clutc h pressure plate an d

disc. See 210 Clutch.

— Remov e flywheel. See 210 Clutch or 240 Automati c

Transmission.

— Drai n engine oil.

^C Remov e seal carrier bolts from oil pan (arrows) . Loose n all oil pan
bolts.

502119556

Remove remaining seal carrier bolts (arrows) and carefully remove

seal carrier without damaging oi l pan gasket.

CAUTION—
• After removing seal carrier, check oil pan gasket for damage. If
gasket is damaged during removal, remove oil pan and rep/ace
gasket. See Oil pan, removing an d installing (M54 engine) in
this repair group.

NOTE—
• BMW offers the rear main seal carrier and seal in a kit. A plastic
installation sleeve, required for sliding the seal over the crankshaft,
is included with the kit.
 Lubrication System 119-1 3
Crankshaft rear main seal, replacing (M54 engine)

Install ne w seal carrier to crankcase. Remember to :

• Check locatin g sleeve s and bores in lower seal housin g for
damage.
• Replac e gaske t betwee n rear mai n seal carrier and crankcase .
• Apply thin coat of 3 Bond® 120 9 or equivalent sealant t o oil pan
gasket sealing surfaces .
• Lubricate crankshaft seal contact surface .

CAUTION—
• Do not kink or damage the sealing lip. Do not touch with fingers.

^C Us e plastic support bushin g (A) that comes wit h seal kit as an

installation guid e whe n fitting seal over end of crankshaft. Use care
to push seal carrier and installation sleeve on straight, without tilting
sideways. Remov e installation sleeve.

— Instal l sea l carrier bolts and torqu e to specifications.

"^ Us e new bolts (arrows ) at base of seal carrier. Coat threads wit h
sealing compound befor e installing.

— Instal l and tighte n oi l pa n bolts .

— Remainde r of assembl y i s revers e of disassembly.

• Instal l flywheel, clutch o r torque converter and transmission .
• Fil l engine wit h oil.
• Ru n engine and check for leaks.

Tightening torques
Oil drain plu g to oil pa n (M12) 25 N m (18ft-lb )
Oil pan to engine bloc k or seal carrier
• M 6 (8.8 grade) 10Nm(89in-lb)
•M6 (10. 9 grade) 12Nm(9ft-lb)
• M 8 (8.8 grade) 22 N m (16ft-lb )
Rear main seal carrier to crankcase
•M6 10 Nm (89in-lb )
•M8 22Nm(16ft-lb)
119-14 Lubricatio n System
Crankshaft front seal, removing and installing (N52, N54 engine)

CRANKSHAFT SEALS (N52, N54 ENGINE )

Crankshaft front seal, removin g an d installing
(N52, N54 engine)

WARNING —
• To avoid personal injury, be sure the engine is cold before
beginning the procedure.

CAUTION—
• When the crankshaft seal is replaced, its grooves and
crankcase seams are filled with special Loctite® sealant to
avoid oil leaks. Be sure to read the entire procedure before
starting work.

— Rais e vehicle and suppor t safely .

WARNING—
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splash shiel d underneat h engine . Se e 020 Maintenance .

Remove engine accessor y belt . Se e 020 Maintenance .

Remove vibration damper (front pulley). Se e 117 Camshaft Timing

Chain.

CAUTION—
• Do not remove vibration damper hub bolt. If this bolt is
removed, the timing chain drive sprocket becomes free to
rotate, resulting in valve damage.

Place BMW special tool 1 1 9 221 against vibration damper hub and
tighten dow n usin g bolts (specia l tool 1 1 9 224). This pushe s
crankshaft seal inwar d approx. 1 mm, thus loosening it for
subsequent removal.

Tightening torque

Special tool 1 1 9 221 to vibration damper hub 20Nm(15ft-lb)

— Remov e special tools.

 Lubrication System 119-1 5
Crankshaft front seal, removing and installing (N52, N54 engine)

Screw BM W special too l 1 1 0 371 into crankshaft seal with approx .

80 Nm (59 ft-lb) of torque. Then rotate specia l tool 11 0 371
clockwise to pul l out seal. Repea t process if necessary.

Carefully saw seal at dashed lin e an d peel of f tool.

B309117028

. Workin g at crankcase opening :

• Clean crankshaft seal seating surfac e (A).
• Degreas e thoroughl y area aroun d crankcas e seam (arrows) .
• Lightl y oil sealing surfac e (B) on vibration damper hub .
119-16 Lubricatio n Syste m
Crankshaft front seal, removing an d installing (N52, A/54 engine)

Attach BM W special too l 1 1 9 232 to vibration damper hub usin g

bolts (specia l tool 1 1 9 234).

Place crankshaft seal an d installation sleev e ove r tool and against

crankcase opening.
• Plasti c sleev e i s supplied wit h seal and is used as installatio n
guide.
• Mak e sure seal grooves center o n crankcase seam (arrows).
• Coat both grooves on seal with Loctite ® 171000 (primer). Allow to
dry for approx. 1 minute.

Use BMW special tools 1 1 9 231 an d 1 1 9 233 to press in seal.

 Lubrication System 119-1 7
Crankshaft rear main seal, removing and installing (N52, N54 engine)

Use brush to coat seal groove s and crankcase seams (A ) with

Loctite® 17100 0 (primer).

Use injector kit to fill seal groove s and crankcase seams (A ) wit h
Loctite® 12835 7 (sealant) .

Coat sealed areas with Loctite® 171000 (primer) to bind sealant.

Reinstall crankshaf t vibratio n damper .

Tightening torque
Vibration damper t o vibration damper hub 35 N m (26 ft-lb )
(M8 x 1 6 mm Torx )

— Remainde r of assembly i s reverse of disassembly .

Crankshaft rea r main seal ,

removing and installing (N52, N5 4 engine)
Crankshaft rea r main sea l (flywhee l seal) replacemen t requires
removal of the transmission and flywheel.

CAUTION—
• When the crankshaft seal is replaced, its grooves and
crankcase seams are filled with special Loctite® sealant to
avoid oil leaks. Be sure to read the entire procedure before
starting work.

Remove transmission. Se e 230 Manual Transmission,

231 Sequential Manua l Gearbo x (SMG) or 240 Automati c
Transmission.

Manual transmission vehicles: Remove clutch pressur e plat e and

disc. Se e 210 Clutch.
119-18 Lubricatio n Syste m
Crankshaft rear main seal, removing and installing (N52, N54 engine)

— Remov e flywheel. See 210 Clutc h o r 240 Automati c

Transmission.

— Drai n engine oil .

^k Crankshaf t rear main seal ha s six removal opening s (inset) . If

necessary, scrape off rubber coating t o expose openings.

..X"

B30911901:

Fit BMW seal puller , special tool 1 1 9 200, t o seal.

• Inser t sheet meta l screws (arrows ) into seal remova l openings.
Tighten snugly bu t do not overtighten .
• Screw in seal remover spindle (A ) slowly to pull out seal.

Before installing ne w seal:

• Clean seal seating surfac e (A).
• Degreas e crankcase seams (arrows) thoroughly.
• Apply light coal of engine oi l to seal li p running surface (B) on
crankshaft flange.
 Lubrication Syste m 119-1 9
Crankshaft rear main seal, removing and installing (N52, N54 engine)

Place crankshaft sea l (A ) and installation sleev e (B) agains t

crankcase opening .

CAUTION—
• Do not kink or damage the sealing lip. Do not touch with fingers.

• Plasti c installation sleeve i s supplied with seal and i s used as

installation guide.
• Mak e sure seal grooves (C) center on crankcase seam s (D).
• Coat bot h grooves on seal with Loctite® 171000 (primer). Allow to
dry for approx. 1 minute.
• Pres s i n seal a s far a s possibl e by hand, then remov e installatio n
sleeve.

Fit BM W special tool s 11 9 182 and 1 1 9 184 to crankshaf t flange .

• Fi t spacer rin g (A) ove r seal. Space r ring is supplied wit h seal .

B309119019

Use BMW specia l tools 1 1 9 181 and 1 1 9 183 to pres s i n seal.

11 9 181 11 9 183 — Remov e special tools and space r ring.

63091190201
119-20 Lubricatio n System
Crankshaft rear main seal, removing an d installing (N52, A/54 engine)

^ Us e brus h to coat seal grooves and crankcase seams (A) wit h

Loctite® 171000 (primer).

^ Us e injecto r kit to fill seal grooves an d crankshaft seams (A) with

Loctite® 128357 (sealant).

— Coa t sealed area s with Loctite® 171000 (primer) to bind sealant .

— Remainde r of assembly i s revers e of disassembly .

• Instal l flywheel, clutch or torque converter and transmission.
• Fil l engine with oil.
• Run engine and check for leaks .
 Lubrication System 119-2 1
Crankshaft front seal, removing and installing (V8 engine)

CRANKSHAFT SEALS (V 8 ENGINE )

Crankshaft front seal, removing and installing
(V8 engine)

WARNING —
• To avoid personal injury, be sure the engine is cold before
beginning the procedure.

CAUTION—
• Be sure to read the entire procedure before starting work.

— Rais e vehicle and suppor t safely.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splash shiel d underneat h engine. See 020 Maintenance .

Remove engine accessor y belt. See 020 Maintenance .

Remove vibration damper (fron t pulley). See 117 Camshaft Timin g

Chain.

Working at front of engine:

• Instal l BM W special tool 1 1 9 451 to vibration damper hu b and
BMW special tool 11 9 452 to oil sump.
• Remov e vibration damper hu b bolt (A) and discard .
• Remov e vibration damper hub .

Install BM W special too k 1 1 9 410 onto crankshaft. Rotat e puller

levers (A ) to grab behind crankshaft seal (B).

Tighten cente r bolt of BMW specia l tool 1 1 9 410 and remov e

crankshaft seal (B) .
119-22 Lubricatio n System
Crankshaft front seal, removing and installing (V8 engine)

A support sleev e (A ) i s included wit h a new crankshaft seal. The

support sleev e remain s i n crankshaft seal until installation. Do not
remove prior to installation .

CAUTION—
• Do not touch the sealing li p with your fingers it is highly
sensitive and is easily kinked .

— Remov e support sleeve from crankshaft seal.

B510119012

Place crankshaft seal (A) into timing cover by hand.

Using BM W special tool 1 1 9 420, tur n he x (A) to press crankshaf t

seal into timing cover unti l it is flush.

— Instal l vibration dampe r hu b b y hand o n crankshaft.

 Lubrication System 119-2 3
Crankshaft front seal, removing and installing (V8 engine)

^k Instal l BMW special tool 1 1 9 451 to vibration damper hub and BMW
special tool 1 1 9 452 to oil sump .

Install BMW special too l 1 1 3 460 to end of crankshaft .

Place pointe r o n BMW special too l 1 1 3 454 to 0° (arrow).

Tighten dampe r bol t to specified torque and angle .

Tightening torque
Vibration damper hu b to crankshaft
(replace bolt) (MlQx 1.5 )
• Stage 1 100 Mm (73.7ft-lb )
• Stage 2 Additional 60 °
• Stage 3 Additional 60°
• Stage 4 Additional 60 °

Remainder o f assembly i s reverse of disassembly .

• Instal l vibration damper .
• Fil l engine wit h oil .
• Ru n engine an d check fo r leaks.
119-24 Lubricatio n System
Crankshaft rear main seal, removing and installing (V8 engine)

Crankshaft rea r main seal,

removing and installing (V8 engine)
Crankshaft rea r main sea l (flywhee l seal) replacemen t require s
removal of the transmission and flywheel. Crankshaft rear main seal
is integral par t of rea r cover.

— Remov e transmission. Se e 23 0 Manua l Transmission,

231 Sequential Manual Gearbo x (SMG ) o r 240 Automatic
Transmission.

— Manua l transmissio n vehicles: Remov e clutc h pressur e plate and

disc. Se e 210 Clutch .

— Remov e flywheel. Se e 210 Clutch or 240 Automati c

Transmission.

— Drai n engine oil .

^C Workin g at rear of engine block , remov e fastener s (A).

A support sleeve (A ) i s included wit h ne w crankshaft rear mai n

seal.The sleeve remains i n crankshaft rea r main seal during
installation.

CAUTION—
• Do not touch the sealing lip with your fingers. It is highly
sensitive and is easily kinked.
 Lubrication Syste m 119-2 5
Crankshaft rear main seal, removing and installing (V8 engine)

Inspect cover alignment dowel s (A) for correct installation. Keep

sealing area free from oil (arrows).

Lightly oil crankshaft. Plac e cover (B) and support sleeve (A ) over
crankshaft and carefully push on.

When installing:
• Instal l fasteners (A) finger tight
• Instal l fasteners (B) finger tight
• Tighten fasteners (A) .
• Tighten fasteners (B).

Remainder of assembly i s reverse of disassembly .

• Instal l flywheel, clutch or torque converter and transmission.
• Fil l engine with oil.
• Ru n engine and check for leaks.
119-26 Lubricatio n System
Oil pan, removing and installing (M54 engine)

OIL PA N AND OIL PUM P (M54 ENGINE)

Oil pan, removing and installing (M54 engine)
Disconnect negativ e (- ) battery cable .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions in 001 Warnings and Cautions.

— Remov e air filter housing. See 130 Fuel Injection.

— Rais e engine hoo d int o assembly position . See 410 Fenders,

Engine Hood .

— Rais e car and suppor t safely.

WARNING —
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

— Drai n engine oil. See 020 Maintenance.

— Remov e dipstick guide pipe.

— Remov e splash shiel d and front end reinforcemen t from under

engine.

^C. Instal l engine suppor t brace across engin e bay . Raise engine
slightly to release loa d on engine mounts .

— Workin g underneath engine, remov e righ t and lef t engine mount

upper nuts (arrow).

— Lowe r front subframe. See 310 Front Suspension .

 Lubrication Syste m 119-2 7
Oil pan, removing and installing (M54 engine)

Detach electrical harness connector (arrow) at oil level sensor .

Automatic transmission: Disconnec t transmission oil cooler line s

from transmission and oil pan.

Remove oil pan screws. Slide oil pan backward to remove .

CAUTION—
• If the oil pan does not separate easily from the engine cylinder
block, tap lightly with a rubber mallet to break it free. Do not use
prying tools.

Clean sealing surface of engine block, then apply beads of 3-Bond®

1209 or equivalent approx . 3 mm high and 2 mm wide (arrow ) to
timing cover and rea r main sea l carrier seams.

When reinstalling oil pan:

• Thoroughly clean ol d gasket material from oil pan sealing surface
and use a new gasket.
• Insert oi l pan bolts.
• Tighten front oil pan bolts first.
• Tighten transmission bellhousin g bolt s last .

Remainder of installation is reverse of removal. Fil l engine with oil,

run engine an d check for leaks.

CAUTION—
• Follow correct installation procedure for front end reinforcement
/n310 Front Suspension .

NOTE—
• It is not necessary to realign the front end after this procedure.
119-28 Lubricatio n System
Oil pump, removing and installing (M54 engine)

Oil pump, removing and installing

(M54 engine)
The M54 engine oil pump is located on the underside o f the engine
block, insid e the oil pan. I t is driven b y the crankshaft via chain and
sprocket assembly. To remove the oi l pump , lowe r the front
suspension and remove the oil pan. Rea d the procedure through
before starting work.

6-cylinder engine oi l pump assembly :

1. Driv e chain
2. M1 0 x 1 nut (lef t han d threads)
• tighten to 25 Nm (18ft-lb)
3. Oi l pump sprocket
4. Inne r pump rotor
5. Oute r pump rotor
6. Pressur e relief valve
7. M 8 bolt
• tighten to 23 Nm (17ft-lb)
8. Oi l pump housin g
0021375 9. Locatin g dowel s
10. Pick-u p tube sealing O-rin g
11. Pick-u p tube
12. Picku p tube mountin g bolts (M6 )
•Tighten to 10Nm(7ft-lb )

Remove oil pan. Se e Oil pan, removing an d installing (M5 4

engine) in this repair group .

Remove oil pump sprocket mountin g nu t (arrow).

CAUTION—
• Oil pump sprocket nut has left hand threads. Turn clockwise to
loosen.

— Lif t sprocket off pump togethe r with drive chain.

— Unbol t oil pump from engine block.

• Remov e oil pump pick-u p tube bolt s and remove pick-up tube
before removin g pump .
• Remov e mounting bolts from oil pump. Withdra w pump.
• Be sure to record locatio n of spacers between pum p an d engine
block, if applicable .

— Spi n oil pump shaf t and check that gear s turn smoothly. Replac e
pump i f gears spin with difficulty.

— Inspec t oil pressure relief valve. See Oil pressure relie f valve (M54
engine) i n this repai r group.
 Lubrication Syste m 119-2 9
Oil pressure relief valve (M54 engine)

Installation is reverse of removal, noting the following:

• Inspec t pump locatin g dowels for damage and correct positioning .
• Replac e oil pick-up and return tube sealing O-rings.
• Align sprocket splines to oil pump shaft splines befor e tightening
sprocket nut .

CAUTION—
• Oil pump sprocket nut has left hand threads. Turn
counterclockwise to tighten.

Tightening torques
Oil pump sprocket to oil pump shaf t
(M10x 1 ) (left han d thread) 25Nm(18ft-lb)
Oil pump to crankcase (M8 ) 23Nm(17ft-lb)

— Fil l engine with oil, run engine an d check for leaks .

Oil pressure relie f valv e (M54 engine )

— Remov e oil pump. Se e Oi l pump , removin g and installin g (M5 4
engine). The oil pump pressure relief valve is held in the side of the
oil pump with a circlip.

*\t oil pump relie f valve components and bore for scoring or
Oil pressure relief valve assembly 5 other damage .
(M54 engine) 4
1. Contro l plunge r
2. Sprin g
3. Sealin g O-rin g
4. Sleeve
5. Circli p

— Instal l using a new circlip.

 120-1

120 Ignitio n System

GENERAL 120- 1 CAMSHAFT SENSO R SERVIC E 120-1 6

Ignition firing order 120- 2 Intake camshaft sensor, replacing
Disabling ignitio n system 120- 2 (M54 engine) 120-1 6
Warnings and Cautions 120- 3 Exhaust camshaft sensor, replacing
(M54 engine ) 120-1 7
DIGITAL MOTO R ELECTRONIC S (DME) Intake camshaft sensor, replacing
IGNITION SYSTE M 120- 4 (N52, N5 4 engine) 120-1 7
Ignition coils 120- 4 Exhaust camshaft sensor, replacing
Crankshaft sensor 120- 6 (N52, N54 engine) 120-1 8
Camshaft sensors 120- 7 Camshaft sensor, replacing
Knock sensors 120- 8 (V8 engine) 120-1 8
Troubleshooting 120- 9 KNOCK SENSO R SERVIC E 120-1 9
On-board diagnostics 120- 9 Knock sensors, replacin g
Misfire detection 120- 9 (M54 engine ) 120-1 9
Oscilloscope diagnostic diagrams 120- 9 Knock sensors, replacing (N52 engine) 120-2 0
IGNITION COIL SERVICE 120-1 2 Knock sensors, replacing (N54 engine) 120-2 1
Ignition coil, replacing (M54 engine) 120-1 2 Knock sensor, replacing (V8 engine) 120-2 2
Ignition coil, replacing (N52 , N54 engine ) . . . 120-1 2 TABLE
Ignition coil, replacing (V8 engine) 120-1 3
a. Ignition firing order 120- 2
CRANKSHAFT SENSO R SERVIC E 120-1 4 b. 5 Series engine managemen t applications . . 120- 4
Crankshaft sensor, replacin g c. Ignition secondar y voltage diagnostics 120- 9
(M54 engine ) 120-1 4
Crankshaft sensor, replacin g
(N52, N5 4 engine) 120-1 5
Crankshaft sensor, replacin g
(V8 engine) 120-1 5

GENERAL
This repai r group covers ignition component troubleshooting and
replacement.

See also:
• 020 Maintenance for spark plug replacement
• 100 Engine-General for engine applications
• 130, 131 , 132, 133 Fuel Injection
• ECL Electrical Component Location s
• ELE Electrical Wiring Diagrams
• OBD On-Board Diagnostics
120-2 Ignitio n System
Ignition firing order

Ignition firing order

Table a. Ignition firing order
6-cylinder engin e 1-5-3-6-2-4
V8 engine 1-5-4-8-6-3-7-2

S-cylinder engine: Cylinde r 1 is at the front of the engine.

V8 N62 engine :
• Cylinder 1 is at right (passenge r side ) front .
• Cylinders 1 - 4 are the right bank
• Cylinders 5 - 8 are the left bank.

Disabling ignition system

The ignition system operates i n a lethal voltag e range. Disable th e
ignition system any time engine servic e o r repair work is being done
that requires the ignition to be switched ON.

One way of disabling th e ignition is by removing the DME main relay.

The rela y is located in the electronics box (E-box) in the right rear of
the engine compartment. DME fuse, relay and power supply
information is in 130,131,132, 133 Fuel Injection or
ECL Electrical Component Locations .

CAUTION—
• Relay locations vary. Use care when identifying relays. See
ECL Electrical Componen t Locations .
 Ignition System 120- 3
Warnings and Cautions

Warnings and Cautions

WARNING —
• Do not touch or disconnect any cables from the ignition coils
while the engine is running or being cranked by the starter.
• The ignition system produces high voltages that can be fatal.
Avoid contact with exposed terminals. Use extreme caution
when working on a car with the ignition switched ON or the
engine running.
• Connect and disconnect the DME system wiring and test
equipment leads when the ignition is OFF.
• Before operating the starter without starting the engine (for
example when testing compression), disable the ignition. See
Disabling ignition system in this repair group.

CAUTION—
• Do not attempt to disable the ignition by removing the coils from
the spark plugs.
• Do not connect any test equipment that delivers a 12-volt power
supply to terminal 15 (+) of the ignition coil. The current flow
may damage the engine control module (ECM). Connect test
equipment only as specified by BMW or the equipment maker.
• Connect or disconnect ignition system wires, multiple wire
connectors and ignition test equipment leads only while the
ignition is OFF. Switch multimeter functions or measurement
ranges with test probes disconnected.
• Do not disconnect the battery while the engine is running.
• Prior to disconnecting the battery cables, read the battery
disconnection cautions i n 001 Warnings and Cautions.
• Wait at least 1 minute after switching the ignition OFF before
removing the ECM connector. If the connector is removed
before this time, residual power in the system relay may
damage the control module.
• Use a digital multimeter for electrical tests. Use an LED test
light for quick tests.
• To avoid electrochemical corrosion to engine components
made of aluminum-magnesium alloy, do not use steel fasteners
in place of aluminum. For reliable identification, test fasteners
with a magnet for aluminum composition.
• Replace aluminum fasteners each time they are loosened.
• Follow torque instructions, including angle of rotation
specifications, when installing aluminum fasteners.
120-4 Ignitio n System
Ignition coils

DIGITAL MOTOR ELECTRONIC S (DME )

IGNITION SYSTEM
BMW 5 Series models are equipped with digital motor electronics
(DME), also known as Motronic. In these systems, fuel injection and
ignition are controlled by an integrated engine control modul e
(ECM). Applicatio n information for DME systems i s in Table b.

Most DME functions are described i n 130, 131,132 , 13 3 Fuel

Injection. I n the topics that follow, functions that are traditionally
associated wit h ignition are given fulle r treatment.

Table b. 5 Series engine management applications

Year, model Engine Engine Features
code management
2004-2005
Sedan: 525i , 530 i M54 Siemens DM E Dual VANOS
MS 45.1
Sedan; 545 i N62 Bosch DM E Valvetronic,
ME 9.2.1 VANOS
2006-2007
Sedan, Sport s N52 Siemens MSV7 0 Valvetronic,
Wagon: SULEVII VANOS
525i, 525xi , 530i ,
530xi
Sedan: 550 i N62TU Bosch DME Valvetronic,
ME 9.2. 2 VANOS
2008-2010
Sedan, Sports N52KP Siemens MSV8 0 Valvetronic,
Wagon: 528i, 528xi, ULEV II VANOS
Sedan, Sport s N54 Siemens MSD8 1 VANOS
Wagon: 535i, 535x ,
535i xDrive
Sedan: 550 i N62TU Bosch DM E Valvetronic,
ME 9.2.2 VANOS

Ignition coils
5 Series engines use a distributorless ignition system with individual
ignition coils (numbered) for each cylinder . There is no distributor
cap or ignition rotor. (N52 engin e shown i n photo.)
 Ignition Syste m 120- 5
Ignition coils

Each coi l i s separately controlle d an d monitored b y the ECM .

Igniton coi l
control (1 per cyl.)
DME
(ignition management)

b3091200005

When th e ignition is switched ON , the ECM receives wake-u p

(KL 15w) via the bus network an d a hardwire KL1 5 wake-up signa l
A8680 directly fro m the car access system (CAS) . It then energizes the
Engine ECM main rela y to supply power to the engine electronics fus e
electronics 30A I carrier and to the ignition coils.
fuse carrier

CAUTION—
• Maintain a high level of cleanliness when servicing ignition
coils. Fuel/oil residue can cause a breakdown in the electrical
to other
Ignition coils resistance qualities of silicone used in production. This in turn
can result in ignition coil failure.

NOTE—
Ignition • Schematic diagrams shown are for illustrative purposes only. See
coil ELE Electrical Wiring Diagrams fo r engine management specific
wiring information.

A6000
Engine control
module (ECM )

B5101200001

Ignition timing i s electronically mapped and not adjustable. Th e

ECM uses engine load , engin e speed, coolant temperature, knoc k
detection, an d intake ai r temperature as the basic input s fo r timing
control.

A three-dimensional map similar to the one shown is digitally stored

in the ECM. The initial ignition point is determined b y the crankshaft
sensor durin g cranking. Once the engine i s running, th e ECM refers
to the stored map to continually adjust ignitio n timing based on
operating conditions.

^oaa e^
_0011539 _ _ J
120-6 Ignitio n Syste m
Crankshaft sensor

Crankshaft senso r
The crankshaft senso r detect s crankshaft positio n and rotation
speed vi a a toothed pulse whee l mounted on flywheel. I f the ECM
does not receive an impulse signa l fro m the crankshaft sensor
during cranking, the engine does no t start. If the OBD I I system
misfire detection protocol detects a catalyst damaging fault due to a
malfunction in crankshaft senso r components, the malfunction
indicator light (MIL) i s illuminated.

The crankshaft position sensor i s supplied 1 2 volts from the engine

electronics fuses and ground fro m the ECM . I t produces a 5 volt
square wave signal to the ECM .

M54 engine: Crankshaft sensor (arrow) is at left rear of cylinder

block below starter.

N52, N5 4 engine: Crankshaf t senso r (arrow ) is at left rear of

cylinder bloc k belo w starter .

V8 engine: Crankshaft sensor (arrow) is on right of transmission bell

housing.

The crankshaft sensor i s also referred t o as engine spee d /

reference sensor.
 Ignition System 120- 7
Camshaft sensors

Camshaft sensor s
Each camshaf t sensor respond s to an impulse wheel mounted a t
the end of the camshaft. The signal from camshaft sensors are use d
by the EC M for cylinder recognition, spark timing, sequentia l fue l
injection, VANOS (camshaft timing) an d Valvetronic (variable valve
lift) control. I f a fault with the camshaft senso r is detected th e
malfunction indicato r ligh t (MIL) i s illuminated

The camshaft positio n sensor is supplied 12 volts from the engine

electronics fuses an d ground from the ECM. I t produces a 5 volt
square wave signal to the ECM .

. M5 4 engine intake camshaft sensor (arrow): Underneath crankcase

breather hose , left side of cylinder head.

M54 engine exhaust camshaft sensor (arrow): Right front of cylinder

head.

N52, N5 4 engine:
• Intake camshaft sensor (B): Lef t front of cylinder head.
• Exhaus t camshaf t senso r (C): Righ t front of cylinder head .

NOTE—
• A/52, N54 engine: A malfunctioning o r sticking VANOS solenoid
may set camshaft position sensor fault codes. If you suspect this,
swap VANOS solenoid from bank with fault code to the other bank.
If the camshaft position sensor fault code follows the location of the
solenoid, the solenoid is at fault.

The camshaft sensor is also called the cylinder identification sensor.

V8 engine: Intake (A) and exhaust (B) camshaft sensors are located
on the front top of each cylinde r head .
120-8 Ignitio n System
Knock sensors

Knock sensors
Knock sensors monitor the combustion chambers fo r engine-
*« ' • u p damaging knock. A knock sensor is a piezoelectric microphon e
tuned to the frequencies o f engine knock o r detonation. If engine
knock is detected, ignitio n spar k i s retarded b y the ECM . I f a faul t
with the knock sensor is detected th e malfunctio n indicator ligh t
(MIL) i s illuminated

M54 engine: Knoc k sensors ar e bolte d to lef t side of cylinder block

under intake manifold.

, N52 , N5 4 engine: Knoc k sensors ar e bolted to left side of cylinder

block unde r intake manifold (arrows) . They share an electrica l
connector and have to be replaced a s a pair.

V8 engine: 4 sensors (A) , 2 per bank o f cylinders, are under intak e

manifold.
i i IL i t, xf -\V$
." • , *•.. ? y ,*' . |
 Ignition System 120- 9
On-board diagnostics

TROUBLESHOOTING
On-board diagnostic s
. I f faults arise, or if the malfunctio n indicator light (MIL ) i s illuminated ,
begin troubleshooting by connecting a BMW scan tool to the data
link connector (DLC or OBD I I plug). Fo r information on ho w t o
access diagnostic troubl e code s (DTCs) , see 020 Maintenance .

Misfire detectio n
Engine misfir e in one or more cylinders may be caused b y
malfunctions i n various subsystems. The OBD II system
incorporated into the engine management systems is designed to
detect an d warn of misfire faults during engin e operation . Se e
OBD On-Board Diagnostics .

WARNING —
• Ignition misfires can cause high hydrocarbon exhaust emissions
and catalytic converter damage. For this reason, if a severe
misfire is detected, the fuel injector to the specific cylinder is
switched OFF and the MIL is illuminated. A misfire may also
overheat the catalytic converter(s), a fire hazard.

Oscilloscope diagnosti c diagram s

One way to diagnose faulty engine management components or
functions is to use an oscilloscope to analyze spar k quality with the
engine running .

BMW engines covered i n this manual use a rod type ignition coil.
127050 Install BMW special tool 1 2 7 050 in series with coil to tes t
secondary ignitio n voltage .
••- -. .
See Table c for a list of common ignition coil voltage faults and
related causes .

Table c. Ignition secondary voltage diagnostics

Secondary Secondary
voltage low voltage high
Spark plug electrode gap Too small Too big
Spark plu g electrod e Worn / burn t
condition

B510120005 Spark plug electrode Too high Too low

temperature
Engine compression Too low Too high
Spark plug wires Faulty
Fuel air mixtur e Too lea n
120-10 Ignitio n Syste m
Oscilloscope diagnostic diagrams

Normal scop e trace of spark at idle

1. Star t of ignition voltage pea k
2. Leve l of ignition voltage
3. Leve l of combustion voltag e
KV
4. Perio d of combustion
5. Combustio n curve characteristics

MS
6. Star t of spark deca y
7. Terminatio n oscillations
15r
3 Ignition spar k a t idle spee d
1. Norma l ignitio n voltag e peak: Good spar k plu g
-20
2. Lo w voltage peak : Closed plu g gap
3. Hig h voltage peak: Open plug gap

^ Lon g combustion period : Small spar k plu g gap

Mk

Short combustion period: Large spark plug gap

30

*V •,«)

[10

E
Jo

-H30 Normal combustion perio d at idle

HM
•
I
-- o

^-V
Normal oscilloscope pattern for ignition system at idl e

-jl o
F
--15
 Ignition System 120-1 1
Oscilloscope diagnostic diagrams

Ignition voltage peaks at idle

1. Norma l ignition peaks
2. Downwar d peak (arrow) shortened: Ignition coil defective
3. Downwar d peak (arrow) missing completely: Ignitio n coil
defective

, Defectiv e ignition coil

1. Shor t spark period
10 20
2. Spar k voltage line (arrow) with very slight drop

10

_T0

. Defectiv e ignition coil

1. Norma l combustion period
2. Spar k voltage line (arrow) absen t

Normal secondary voltage patterns (4-cylinder pattern shown)

2 isj ,

4 '••( ,

3, ,

1r -m

Ignition voltage peaks in response to sudden acceleration load:

1 5 : - •• 30
1. Norma l ignition pattern. Beginnin g of dying out pattern i s not
.. much higher than ignition voltage peak.
2. Beginnin g of dying out pattern considerably higher than ignition
voltage peak. Fault in injection system:
• Lean fuel mixture
sL • Defective fuel injector
• Lo w compression in cylinder
120-12 Ignitio n Syste m
Ignition coil, replacing (M54 engine)

IGNITION COIL SERVICE

There is a separate ignition coil above each spark plug. Spark plug
replacement is covered in 020 Maintenance .

CAUTION—
• Maintain a high level of cleanliness when servicing ignition
coils. Fuel/oil residue can cause a breakdown in the electrical
resistance qualities of silicone used in production. This in turn
can result in ignition coil failure.

Ignition coil, replacing (M54 engine)

Make sure ignitio n is switched OFF.

Remove ignitio n coils cover . Se e 020 Maintenance.

Lift u p on lock (A) and release ignition coil electrical connector.

Remove fasteners (B). Not e position o f coil ground wire.

^V Remov e ignition coil by pulling straigh t up and off spark plug.

— Installatio n i s reverse of removal. B e sure to reattach ground cables

or wires.

— Chec k and clear fault codes from ECM memory.

Ignition coil, replacing (N52 , N5 4 engine)

Make sure ignition i s switched OFF.

Remove ignition coi l cover. See 020 Maintenance.

Unlock (curve d arrow) ignition coil connector. Pull (straight arrow )

connector of f coil.
 Ignition Syste m 120-1 3
Ignition coil, replacing (V8 engine)

Slide rod-shape d ignitio n coil straight out of spark plug hole .

Installation i s reverse of removal.

Check and clear fault codes fro m ECM memory .

Ignition coil, replacing (V 8 engine)

— Mak e sure ignition is switched OFF.

— Remov e ignition coils cover. Se e 020 Maintenance.

'X. Remov e ignition coil hold-down bracke t fasteners (A ) and remov e

hold-down bracket s (arrows) . Left side shown, righ t is similar.

Unlock (curved arrow) ignition coil connector. Pull (straight arrow)

connector off coil.
120-14 Ignitio n System
Crankshaft sensor, replacing (M54 engine)

^V Slid e rod-shaped ignition coil straight out of spark plug hole.

— Installatio n i s reverse of removal .

— Chec k and clea r fault codes fro m EC M memory.

"•'' B510120001J J

CRANKSHAFT SENSOR SERVIC E

Crankshaft sensor , replacin g
(M54 engine )
Crankshaft senso r i n M54 engine is on left rear of engine block ,
underneath intak e manifol d and starter motor.

Make sure ignition is OFF.

Raise car and support i n a safe manner .

WARNING —
• Make sure the car is stable and we/1 supported at a/1 times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

— Remov e front end reinforcement plate. See 310 Front Suspension .

^C Workin g underneath starter:

• Cut off wire tie securing crankshaft sensor harnes s connecto r
(arrow) to sensor.
• Disconnect harness connector .

Remove sensor mounting fastener (arrow) and remove sensor from

cylinder block .

Installation is reverse of removal.

• Use new sealing O-rin g when installing sensor.
• Replac e self-locking mounting bolt.
• B e sure wiring is rerouted as before.

Tightening torque
Crankshaft senso r t o engine block 10Nm(7ft-lb)
(M6, replac e with new )

— Chec k an d clear fault codes from ECM memory .

 Ignition Syste m 120-1 5
Crankshaft sensor, replacing (N52, N54 engine)

Crankshaft sensor, replacing (N52, N54 engine)

Crankshaft sensor is on left rear of engine block, underneat h intake
manifold and starter motor .

Make sure ignitio n is OFF.

Raise car and support in a safe manner.

WARNING —
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

— Remov e front end reinforcement plate. See 310 Front Suspension.

^C, Working underneath starter :

• Disconnect crankshaf t senso r harnes s connector (A ) from senso r
(B).

— Remov e sensor mounting fastener (arrow) and remove sensor from

cylinder block. Be prepared to catch dripping oil.

— Installatio n i s reverse of removal . Remember to :

• Use new sealing O-rin g when installing sensor.
• Replac e mounting bolt .
• Be sure wiring is routed as before.
• Check an d clear fault codes from ECM memory.

Tightening torque
Crankshaft sensor t o engine bloc k 8 N m (6 ft-lb)
(M6, replac e with new)

Crankshaft sensor , replacin g (V 8 engine)

Crankshaft sensor is on right botto m of transmission housing .

Make sure ignition i s OFF.

Raise car and support in a safe manner.

WARNING —
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

— Remov e front end reinforcement plate. See 310 Front Suspension .

^ Disconnec t crankshaft sensor harnes s connector (A ) from senso r

(B).

— Remov e sensor mounting fastener (arrow) and remove sensor fro m

cylinder block . B e prepared to catch dripping oil.
120-16 Ignitio n Syste m
Intake camshaft sensor, replacing (M54 engine)

Installation is reverse of removal . Remember to:

• Use new sealing O-rin g when installin g sensor.
• Replace mounting bolt .
• B e sure wiring is routed as before.
• Check and clear fault codes from ECM memory.

Tightening torque
Crankshaft sensor to engine bloc k 8 Nm (6 ft-lb)
(M6, replace wit h new)

CAMSHAFT SENSO R SERVIC E

Intake camshaft sensor , replacin g
(M54 engine )
Intake camshaft sensor on M54 engin e is mounted at left side of
cylinder hea d near front.

Make sure ignition is OFF.

Remove upper engin e covers . See 020 Maintenance .

Remove air filter housing and ducts. See 130 Fuel Injection.

Working at left side of cylinder head:

• Detach engine ven t hose from cylinder head cover by pinching
spring clips (arrows) .
• Detach VANOS solenoid electrica l connector (A).
• Unscrew VANOS solenoid.
• I f necessary, unfasten oil supply line on VANOS adjustment unit.
Be prepared to catch dripping oil.

Remove camshaft sensor mounting bolt. Remove sensor (arrow)

from cylinder head .

— Reac h under intak e manifold to disconnect camshaf t sensor

harness.

NOTE—
• Prior to removal, attach a stiff piece of wire to connector to aid in
routing of harness during reinstallation.
 Ignition System 120-1 7
Exhaust camshaft sensor, replacing (M54 engine)

Installation is reverse of removal. Remember to:

• Replac e camshaf t senso r mountin g bolt.
• Us e new sealing O-ring s when installing sensor, VANOS solenoi d
and VANOS oil supply line .
• Be sure senso r harness is rerouted a s before.

Tightening torques
Intake camshaft sensor t o cylinder hea d 10Nm (7ft-lb)
(M6, replac e bolt )
Oil supply line to VANOS uni t (banjo bolt ) 32 Nm (24 ft-lb)
VANOS solenoi d t o VANOS uni t 30 N m (22 ft-lb)

— Chec k an d clear fault codes from EC M memory .

Exhaust camshaf t sensor, replacin g

(M54 engine )
Exhaust camshaft sensor on M54 engine is mounted a t right sid e of
cylinder hea d nea r front.

— Mak e sur e ignition is OFF .

^ Workin g at front of engine on exhaust (right ) side , detac h exhaus t

camshaft senso r electrica l harnes s connector (arrow) .

— Remov e sensor mountin g bolt an d remov e sensor. Be prepared t o

catch drippin g oi l

— Installatio n is reverse of removal .

• Replac e camshaft senso r mountin g bolt .
• Use new sealing O-ring when installing sensor .

Tightening torque
Exhaust camshaft senso r to cylinder hea d 10Nm(7ft-lb)
(M6, replac e bolt )

— Chec k an d clear fault codes from EC M memory .

Intake camshaft sensor, replacing

(N52, N5 4 engine)
Intake camshaft sensor is mounted to left front of cylinder head.

— Mak e sur e ignitio n is OFF .

— Remov e uppe r engine covers. Se e 020 Maintenance.

— Remov e ai r filter housin g and ducts. See 131, 132 Fuel Injection.

^ Detac h camshaft senso r electrical connector (A).

— Remov e camshaft sensor mountin g bol t (arrow). Remove senso r

(B) from cylinder head . B e prepared to catch dripping oil.
120-18 Ignitio n System
Exhaust camshaft sensor, replacing (N52, N54 engine)

Installation is reverse of removal. Remember to:

• Replace camshaft sensor mounting bolt.
• Use new sealing O-rings when installing sensor .
• B e sure sensor harness is routed as before.
• Check and clear fault codes from ECM memory.

Tightening torques
Intake camshaft sensor to cylinder hea d 9 Nm (6.5 ft-lb)
(M6, replace with new)

Exhaust camshaft sensor, replacin g

(N52, N5 4 engine)
Exhaust camshaft sensor is mounted to right front of cylinder head.

Make sure ignition is OFF.

Remove upper engine covers. See 020 Maintenance.

Remove air filter housing an d ducts. Se e 131, 132 Fuel Injection.

Detach camshaft sensor electrical connecto r (A).

Remove camshaft sensor mounting bol t (arrow). Remov e sensor

(B) from cylinder head . Be prepared t o catch dripping oil.

Installation i s reverse of removal. Remember to:

• Replace camshaft sensor mounting bolt.
• Us e new sealing O-rings when installing sensor.
• Be sure sensor harness i s routed as before.
• Check and clear fault codes from ECM memory.

Tightening torques
Intake camshaft sensor to cylinder hea d 9 Nm (6.5 ft-lb)
(M6, replace bolt)

Camshaft sensor , replacin g

(V8 engine)
V8 engine: Intake and exhaust camshaft sensors are located on the
front top of each cylinder head . Right side intake camshaft sensor
replacement is shown. Others are similar.

Make sure ignition is OFF.

Remove upper engine covers. See 020 Maintenance.

Intake camshaft sensor

Detach camshaft sensor electrical connector (A).

Remove camshaft sensor mounting bolt (arrow). Remov e sensor

(B) from cylinder head. Be prepared to catch dripping oil.
 Ignition System 120-1 9
Knock sensors, replacing (M54 engine)

Detach camshaft sensor electrical connector (A).

Remove camshaft sensor mounting bol t (arrow). Remove sensor

(B) from cylinder head . B e prepared to catch dripping oil.

Installation is reverse of removal. Remember to:

• Replace camshaft sensor mountin g bolt .
• Use new sealing O-rings when installing sensor.
• B e sure sensor harness is routed as before.
• Check and clear fault codes from ECM memory.

rv
B51£120g012J

KNOCK SENSOR SERVIC E

Knock sensors, replacing (M54 engine )
M54 engine knoc k sensors are under the intake manifol d o n the left
side of the cylinder head .

Disconnect negative (-) battery cable and cover battery terminal to

keep cable from accidentally contactin g terminal.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given in 001 Warnings and Cautions .

With engine full y cooled, remov e intake manifold . Se e 130 Fue l

Injection.

Disconnect knoc k senso r electrica l harness connecto r (A ) on left

side of engine block .
• Remove knock sensor mounting bolt s (arrows ) on side of cylinder
block.
• Remove sensors.

CAUTION—
• Note the installed angle of the knock sensor on the block before
removing it. Reinstall the sensor in the same position. Be sure
to use a torque wrench when lightening the sensor mounting
bolt.

Clean knock sensor contac t surfac e on engine block and sensor

(arrows) before installing knoc k sensor.

CAUTION—
• Do not overtighten knock sensors.

Tightening torque
Knock sensor to engine block (M8) 20 Nm (15 ft-lb)

— Chec k an d clear fault codes from ECM memory.

120-20 Ignitio n System
Knock sensors, replacing (N52 engine)

Knock sensors , replacin g (N52 engine)

N52 engine knock sensors ar e under th e intake manifold o n the left
side of the cylinder head.

Disconnect negativ e (- ) battery cable an d cover battery terminal t o

keep cable fro m accidentally contacting terminal .

| CAUTION— H
Prior to disconnecting the battery, read the battery
disconnection cautions given in 001 Warnings an d Cautions.

With engine fully cooled, remov e intak e manifold. See 131 Fuel
Injection.

Disconnect knock sensor electrical harnes s connector.

• Remov e knock sensor mounting bolts (arrows) on side of cylinder
block. Remov e sensors .

CAUTION—
• Note the installed angle of the knock sensor on the block before
removing it. Reinstall the sensor in the same position. Be sure
to use a torque wrench when tightening the sensor mounting
bolt

Clean knoc k sensor contac t surfac e o n engine block and senso r

(arrow) before installing knoc k sensor.

CAUTION—
• Do not overtighten knock sensors.

Tightening torques
Knock sensor to engine block (use ne w
aluminum M8 fasteners)
• Stage 1 7 Nm (63 in-lb)
• Stage 2 additional 90 °

Installation is reverse of removal. Remembe r to :

• Replace knoc k senso r mounting bolt .
• Be sure sensor harness is routed as before.

— Chec k an d clear fault codes from ECM memory.

 Ignition Syste m 120-2 1
Knock sensors, replacing (N54 engine)

Knock sensors , replacin g (N5 4 engine )

N54 engine knoc k sensors are under the intake manifold o n the lef t
side of the cylinder head.

Disconnect negativ e (- ) battery cable and cover battery terminal t o

keep cable from accidentally contacting terminal.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given in 001 Warnings and Cautions.

With engine fully cooled, remov e intake manifold . See 132 Fuel
Injection.

Disconnect electrica l connector s (A) , remove and seal hig h

pressure fuel pump fuel supply line connections. Be prepared to
catch dripping fuel.

WARNING —
• The fuel system is designed to retain pressure even when the
ignition is OFF. When working with the fuel system, remove fuel
lines slowly to allow residual fuel pressure to dissipate. Avoid
spraying fuel, Use shop towels to capture leaking fuel
• Electric fuel pump starts automatically when door is opened.
• Carry out installation work on fuel system with coolant
temperature below 40°C (104°F).

CAUTION—
• When working with high pressure fuel lines observe clean
working habits. Any dirt or debris introduced into system will
cause malfunctions.

Disconnect knoc k sensor electrica l connector (A) o n left side of

engine block .
120-22 Ignitio n System
Knock sensor, replacing (V8 engine)

'X. Remov e knock sensor mounting bolt s (arrows) o n side of cylinder

block. Remove sensors .

CAUTION—
• Note the installed angle of the knock sensor on the block before
removing it. Reinstall the sensor in the same position. Be sure
to use a torque wrench when tightening the sensor mounting
bolt.

Clean knock sensor contact surface on engine bloc k and sensor

(arrow) befor e installing knock sensor .

CAUTION—
• Do not overtighten knock sensors.

Tightening torques
Knock sensor to engine bloc k (us e ne w
aluminum M 8 fasteners)
• Stage 1 7 N m (6 3 in-lb)
• Stage 2 additional 90 °
Fuel lin e nu t to high pressure pum p 30 N m (22 ft-lb)
(coat thread with transmission fluid )
Fuel lin e mounting bracket to engine bloc k 8 N m (87. 5 in-lb)

Installation i s reverse of removal . Remembe r to:

• Replac e knock sensor mountin g bolt .
• B e sure sensor harness i s rerouted as before.
• Chec k for fuel system leaks.
• Check an d clear fault codes from EC M memory.

Knock sensor, replacing (V8 engine)

V8 engine i s equipped with 4 sensors, 2 per bank o f cylinders,
installed under intak e manifold .

Disconnect negative (- ) battery cabl e and cover battery terminal t o

keep cable from accidentally contactin g terminal.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given i n 001 Warnings and Cautions .

With engine fully cooled, remove intak e manifold. See 133 Fuel
Injection.
 Ignition System 120-2 3
Knock sensor, replacing (V8 engine)

Disconnect knock senso r electrical harnes s connector .

• Remov e knock sensor mounting bolt s (arrows) o n side of cylinder
block. Remov e sensors (A).

CAUTION—
• Note the installed angle of the knock sensor on the block before
removing it. Reinstall the sensor in the same position. Be sure
to use a torque wrench when tightening the sensor mounting
bolt.
l_

Clean knoc k sensor contact surface on engine block and sensor

(arrow) before installing knock sensor.

CAUTION—
• Do not overtighten knock sensors.

Tightening torques
Knock sensor t o engine bloc k
(M8 replace with new) 21 N m (14.7ft-lb )

Installation is reverse of removal. Remembe r to :

• Replac e knock sensor mountin g bolt.
• B e sure sensor harness i s routed as before.
J^ b309120001 5|
• Check an d clear fault codes from ECM memory.
 121-1

121 Battery , Starter, Alternator

GENERAL 121- 1 STARTER

Engine electrical system 121- 1 Starter troubleshootin g
Troubleshooting 121- 2 CAS module, removin g an d installing
Warnings and Cautions 121- 2 Starter, removing an d installing (M5 4 engine )
Starter, removin g and installing
BATTERY 121- 4 (N52, N5 4 engine)
Battery basic s 121- 4
Starter, removin g an d installing (V8 engine) .
Battery location and connections 121- 4
Battery safety terminal (BST) 121- 4 ALTERNATOR AN D CHARGING SYSTEM . . 121-18
Intelligent batter y sensor (IBS) 121- 5 Alternator basic s 121-18
Battery, testin g 121- 7 Alternator interfac e 121-18
Electronic batter y testing 121- 7 Charging syste m troubleshootin g 121-19
Hydrometer testin g 121- 7 Charging system quick-check 121-19
Battery open-circuit voltage test 121- 8 Charging system , checking 121-19
Battery load voltage test 121- 8 Alternator, removin g and installing
Battery parasiti c draw, testing 121- 9 (M54 engine ) 121-21
Battery charging note s 121- 9 Alternator, removin g an d installing
(N52 engine) 121-22
Battery, chargin g 121-1 0
Alternator, removing and installing
Battery, removin g and installin g 121-1 0
(N54 engine) 121-23
Replacement batter y registratio n 121-1 2
Alternator, removin g and installing
Battery reconnection note s 121-1 2 (V8 engine) 121-25

GENERAL
This repair group covers the battery, alternator , starter an d
associated components o f the electrical system.

See also:
• 020 Maintenance fo r accessory belt replacement an d routin e
battery service.
• 600 Electrical System-General for bus system information,
power reset procedure an d general electrical troubleshootin g
• 721 Airbag System (SRS) for battery safet y terminal (BST )
• ECL Electrical Componen t Location s
• ELE Electrical Wirin g Diagram s

Engine electrical system

The alternator and starter are wired directly to the battery. To prevent
accidental short s that migh t blo w a fuse or damage wire s and
electrical components, disconnect the negative (-) batter y cable
before working on the electrical system.
121-2 Battery , Starter, Alternator
Troubleshooting

Different versions o f alternators, starter s and batteries are use d i n

5 Series models. Replace components according to the original
equipment specifications .

Troubleshooting
Basic battery , starter and charging syste m troubleshootin g
information is in Table a.

Table a . Battery, starter and charging system troubleshooting

Symptom Probable cause Corrective action
Engine does no t crank. Fault i n car access system (CAS). Try another ignitio n key . I f problem persists , contact
your authorized BM W dealer.
Engine cranks slowly or Battery cables loose , dirty o r corroded . Clean or replace cables . Se e 020 Maintenance.
not at all, solenoi d clicks
Battery discharged . Charge batter y and test . Replac e i f necessary.
when starter i s operated .
Battery to body ground cable i n trunk loose, Inspect groun d cable . Clean , tighte n o r replac e if
dirty or corroded necessary.
Poor connectio n at starter moto r terminal X6512. Check connection s at starter motor.
Starter moto r o r solenoid faulty. Test starter .
Battery doe s no t sta y Short circuit draining battery, (parasitic draw ) Test for excessive current drain with everything
charged more than a few electrical off.
days.
Short driving trips and high electrical drain on Evaluate driving style. Where possible , reduc e
charging syste m does not allow battery to electrical consumption whe n makin g short trips .
recharge.
Engine accessory belt loose, wor n or damaged . Inspect or replace accessory belt. See
020 Maintenance.
Battery faulty. Test batter y and replac e i f necessary.
Battery cables loose , dirty or corroded. Clean o r replace cables. Se e 020 Maintenance.
Alternator faulty. Test alternator.

Warnings and Cautions

WARNING —
• Wear goggles, rubber gloves and a rubber apron when working
around the battery or battery acid (electrolyte).
• Battery acid contains sulfuric acid and can cause skin irritation
and burning. If acid is spilled on your skin or clothing, flush the
area at once with large quantities of water. If electrolyte gets
into your eyes, flush them with large quantities of clean water
for several minutes and call a physician.
• A battery that is being charged or is fully charged gives off
explosive hydrogen gas. Keep sparks and open flames away.
Do not smoke.
• Battery lead and battery acid are both hazardous materials.
When disposing of an old battery, follow federal, state and local
regulations on hazardous waste disposal.
 Battery, Starter, Alternator 121- 3
Warnings and Cautions

CAUTION—
• Use a digital multimeter when testing automotive electrical
components.
• If a repair procedure specifies disconnecting the battery, follow
the instruction for safety reasons.
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings and Cautions .
• Disconnecting the battery cables may erase fault codes stored
in ECM memory.
• Using a conventional battery charger to jump start the vehicle
may damage electronic control modules. Use an electronic
vehicle power supply or another 12-volt battery for jump-
starting. Jump starting i s covered in 020 Maintenance.
• Disconnect the negative (-) battery cable first and reconnect it
last. Cover the battery post with an insulating material
whenever the cable is removed.
• Do not disconnect battery, alternator or starter wires while the
engine is running.
• Do not reverse the battery cables. Even a momentary wrong
connection can damage the alternator or other electrical
components.
• Do not depend on insulation color to tell battery positive and
negative cables apart. Label cables before removing.
• Power windows and sunroof may fail to function properly after
disconnecting and reconnecting the battery. Reinitialize
windows and sunroof. See Battery reconnection notes i n this
repair group.
• Do not make any additional connections at the negative
terminal of the battery.
• Do not modify the battery ground cable.
• Do not make any connections between the intelligent battery
sensor (IBS) and the sensor screw.
• Do not use force when disconnecting the ground terminal from
the battery.
• Do not pull at the ground cable.
• Do not use the IBS as a pivot point to lever off the ground
terminal.
• Do not use the connections of the IBS as a lever.
• Use a torque wrench when reinstalling the battery ground
cable.
• Do not release or tighten the IBS screw (screw with Torx head).
• To avoid electrochemical corrosion to engine components
made of aluminum-magnesium alloy, do not use steel
fasteners. Use aluminum fasteners only. Use a magnet to
identify aluminum fasteners.
• Replace aluminum fasteners each time they are loosened.
• Follow torque instructions, including angle of rotation
specifications, when installing aluminum fasteners.
121-4 Battery , Starter, Alternator
Battery basics

BATTERY
Battery basic s
The wet-cell lead-acid batter y is rated by ampere / hour s (Ah) and
cold cranking amps (CCA) liste d on the battery.

Battery location and connections

The batter y is mounted i n the righ t side o f the trunk or cargo
compartment, underneath th e floor trim.

For rear power distribution pane l details , se e EC L Electrica l

Component Locations .

Underneath th e vehicle a t the batter y bo x are two power transfer

points for the two cables that ru n to the engine compartment .
• One cable goes to the jump star t terminal i n the engin e
compartment an d then connects to the starter and alternator.
• The second cable is used to supply powe r to engine electronic s
(DME an d Valvetronic).
• The power cables are routed in a protected area underneath the
If*..... i ,i body of the vehicle .

Engine compartment
electrical supply wires B5101210002

Battery safety terminal (BST )

12 3
1. Positiv e battery terminal (B+)
2. BS T igniter connector
3. B + to rear power distributio n box (A46 )
4. BS T cover retainin g clip

m& 5. B + to starter and alternator

The battery safety termina l (BST) i s controlled by the multiple

restraint system (MRS) control module . Th e system disconnects
electrical power to the engine compartmen t i n case of a significant
ttif-""^ crash. MRS fires an encapsulated pyrotechnic device in the positive
(+) battery terminal that disconnects powe r to the engin e
compartment bu t maintains power to the exterio r lights an d interior
of the vehicle.

See also 721 Airbag Syste m (SRS) .

B301121003
 Battery, Starter, Alternator 121- 5
Intelligent battery sensor (IBS)

Intelligent battery senso r (IBS )

. Intelligen t battery senso r (IBS) i s connected to the negative battery
terminal.
1. Batter y ground cabl e
2. B + connection to IBS
3. Bit-seria l data (BSD) interfac e
4. Intelligen t batter y sensor (IBS )

The IBS is sensitive to mechanical stres s and strain. See Warnings

and Cautions in this repair group .

Replace IBS as a complete uni t with the battery ground cable . Th e

ground cable serves as a heat sink for the IBS .

If IBS is replaced, allow vehicle to rest unused at least 3 hours. Only

then can the ne w IBS determine battery status.

The IBS microprocessor monitors and measures battery condition s

such as:
• Terminal voltage vi a measurement from B+ to ground
• Charge / discharge curren t via integrated shunt resisto r
• Temperature of battery acid via integrated temperature senso r
1. B + battery positiv e termina l
2. Batter y ground terminal
3. Voltag e measuremen t
4. Temperatur e measuremen t
5. Integrate d shunt resistor
6. Curren t measuremen t
7. IB S microprocessor
8. Engin e control modul e (ECM )

IBS components:
1. Copperplat e
2. Gul l win g tabs
3. P C board with evaluation electronic s
12 4 2 1
4. Housin g
5. Mangani n coppe r alloy resistor maintains constant temperatur e
regardless of current flow, used to measure curren t flow.

IBS evaluation function

IBS electronics continuously measur e the following values under all
vehicle operatin g conditions :
•Voltage (6 vto 16. 5 v)
• Starting curren t ( 0 A to 1000 A)
• Charging curren t (20 A to 200 A)
• Temperature (-40° C to 105°C or -40°F to 221 °F)
B309121007 • Parasiti c draw o r closed circuit curren t ( 0 A to 10 A)
121-6 Battery , Starter , Alternato r
Intelligent battery sensor (IBS)

When th e vehicle is stationary, th e IB S is programmed t o wake up

every 40 seconds and makes battery condition measurements
within approx . 50 ms in order to save power. The measured values,
communicated to the engine control module (ECM) via binary serial
data (BSD) interface, are used to calculate the following:
• State of charge (SoC) shows the current charge of the battery. SoC
is used during key OFF periods to insure that the battery maintain s
a sufficient charge to start the engine a t least one more time.
• State of health (SoH) tracks the history of the battery in the vehicle.
Charge / discharge cycles and times are monitored. SoH helps the
ECM determine correc t battery charging rates and anticipated
battery life . Internal resistance of the battery is calculated b y IBS
from current and voltage dro p during engin e start . These values
are used b y the EC M to calculate th e So H of the battery.

Software contained in the IBS microprocessor utilizes the measured

values to calculate battery So C during vehicle slee p mode and
compares this informatio n with that receive d from the ECM
pertaining to the battery So C / SoH during the period between
engine OFF and deactivation of the DM E main relay.

Battery data i s stored every 2 hours over a 6 hour time frame,

providing three snapshots o f battery So C information. The stored
information / snapshot data is overwritten every 6 hours. Whenever
the ignition is activated, IB S updates the ECM with the current
closed circuit histogram / battery status information . The ECM
evaluates the ne w data and, i f a parasitic dra w (closed-circuit
current draw ) i s identified, a fault i s stored in fault memory .

IBS diagnosis
A fault code i s stored in the EC M whe n the IB S is defective. Th e
ECM boosts idl e speed in order t o sufficiently charg e the battery.

The IBS can only be diagnosed throug h th e ECM. The self-

diagnosis function checks the voltage, current , temperature,
terminal 1 5 wake up signal a s well as system errors i n the IBS .

Voltage measurement
If IB S is shorted to ground, EC M fault code display s "Voltage Faul t
DME ON". The IB S is unable t o wake u p the ECM.

If IBS is shorted to B+, ECM fault code displays "Voltage Fault, DME
not ON". The vehicle does NO T enter slee p mode.

Current measurement
Current measurement is a dynamic process . I f an implausibl e
current flow value is detected, EC M fault code displays "Current
Fault".

IBS wake-up
The IB S constantly monitors battery SoC, eve n when the vehicle is
asleep. A wake-up signal is sent to the ECM if the SoC falls below a
predetermined threshold. Upo n wake-up , the EC M switches OFF
auxiliary electrica l load s i n order t o preserve batter y charge .

IBS wakes up the vehicle once during a key-off cycle . Once

awakened, th e vehicle return s t o sleep mode.
 Battery, Starter, Alternator 12 1 -7
Battery, testing

Wake-up signal faults

The IB S detects wake-up line faults under the following conditions:
• ECM switched ON.
• Ignitio n switched ON (voltage high at IBS).
• Terminal 1 5 running via alternator output at BSD.

If voltages at IBS terminal 1 5 and terminal 1 5 via th e BS D ar e no t

equal, a fault is indicated eithe r in the BSD line or the IBS.

Battery, testin g
BMW batteries are rated as follows:
• A h rating is determined b y the average amount o f current the
battery can deliver over time without dropping below a specifie d
voltage.
• CCA rating is determined by the battery's ability to deliver startin g
current at 0° F (-18° C) without dropping below a specified voltage.

Battery testing determines battery condition and state of charge.

Before testing the battery, check that the battery cables are tight and
free of corrosion.

Electronic battery testin g

. Electroni c battery testers such as Midtronics®MCR 717 ar e
recommended for testing all battery types.

Hydrometer testin g
On conventional or low-maintenance batteries, check th e specific
gravity o f the electrolyte using a hydrometer. Th e mor e dens e the
concentration of sulfuric acid in the electrolyte, the highe r th e stat e
of charge.

Before hydrometer testing, loa d the battery with 15 amperes for one
minute. I f the batter y i s installed i n the vehicle, this ca n b e done b y
switching the headlights O N for about one minute without the engine
running. The state of battery charge based on specific gravity values
are in Table b.

Note that electrolyte temperature affects hydrometer reading. Check

the electrolyte temperature with a thermometer. Add 0.004 t o the
MBC05410002
hydrometer reading for every 6°C (10°F) that the electrolyte is above
27°C (80°F) . Subtract 0.004 from the reading for every 6°C (10°F )
that the electrolyte is below 27°C (80°F) .

Table b. Specific gravity of battery electrolyte at 27° C (80 F )

Specific gravity State of charge
1.265 Fully charged
1.225 75% charged
1.190 50% charged
1.155 25% charged
1.120 Fully discharge d
121-8 Battery , Starter, Alternator
Battery open-circuit voltage test

If the specific gravity is at or above 1.22 5 but the battery lacks power
for starting, determine th e battery's service conditio n with a load
voltage test. Se e Battery loa d voltage tes t in this repai r group .

If the average specific gravit y o f the six cells is below 1.225 , charge
battery and retest. See Battery charging note s in this repair group.

Battery open-circuit voltage tes t

Before testing , loa d battery with 1 5 amperes for one minute with
battery load-tester or switch headlights O N for about on e minute
without engine running . Connect digita l voltmete r across battery
terminals. Open-circuit voltage level s are given i n Table c.

Table c. Open-circuit voltage and battery charge

Open-circuit voltage State of charge
12.6 o r mor e Fully charged
12.4 75% charge d
12.2 50% charged
12.0 25% charged
11.7 or less Fully discharged

If open-circuit voltag e is OK but battery still lacks powe r fo r starting,

perform a load voltage test. See Batter y load voltage test i n this
repair group .

If open-circuit voltage is below 12. 4 volts, recharge battery an d

retest. See Battery chargin g notes in this repair group .

Battery load voltage test

A batter y load tester is required for a load voltage test. The test is
made by applying a high resistive load to the battery terminals and
simultaneously measuring batter y voltage. Fo r the most accurate
results, make sure the battery is fully charged. Disconnect battery
cables before making the test. Replac e th e batter y if the voltage is
below that listed i n Table d.

WARNING —
• Wear protective goggles and clothing when performing a load
test.

Table d . Battery load test-minimum voltag e

Ambient temperature Voltage*
27° C (80° F) 9.6

16°C(60°F) 9.5

4° C (40° F) 9.3

-7°C(20°F) 8.9

-18°C(0°F) 8.5

* Measur e after applying a 200 am p loa d for 1 5 seconds .

 Battery, Starter, Alternator 121- 9
Battery parasitic draw, testing

Battery parasiti c draw, testing

If the vehicle battery i s discharged for an unknown reason , perform
the parasiti c draw test designed to detect excessive current flow
from the battery when everything in the vehicle is shut down. This is
also known as a closed circuit current measurement.

— Chec k that batter y voltage is 1 2 volts or higher . If lower, recharg e

battery

^V Remov e negative cable and install battery isolation switch (OTC too l
7645 or equivalent).

— Clos e switch. Connect digital multimeter in series across switch. Set

meter to milliamp (mA ) scale.

— Tur n trunk loc k t o locked position using screwdriver o r similar

(simulates trunk lid being closed) .

— T o simulate normal parasiti c draw conditions: Switch ignitio n O N

and activate all electrical consumers, including an y accessories .
Switch ignition OFF . Open and close driver's door (simulate s
somebody gettin g out). Lock car, arming alarm i f installed. Wit h
exception o f trunk, keep all other doors an d lids closed.

— Ope n batter y isolatio n switch an d monito r curren t draw.

• Vehicle without telematics (TCU): Wai t 30 minutes .
• Vehicle with telematics (TCU) : Wait 60 - 70 minutes.

— Maximu m allowable parasiti c draw after waiting: Approx. 40 mA .

— I f draw exceeds maximu m allowable, fin d consumer(s) a t fault b y

removing individual fuses and notin g change in parasitic draw.
Repair o r replace component(s) found at fault.

Fuse locations and applications are in ECL Electrical Componen t

Locations.

Battery charging note s

430-watt Deutroni c Consistent, clean voltage i s essential when charging th e batter y or

power supply maintaining battery charg e while codin g or programming control
modules. A transformer-based battery charger is inadequate fo r this
task. BM W recommends th e use of a vehicle powe r supply instea d
of a battery charger.

A power supply is a constant voltage, high-amperag e power statio n

with electronically controlled functions. It insure s clean DC voltage
and eliminates AC. It also provides fast, efficien t an d safe batter y
charging. Once proper battery voltage is obtained, the power supply
floats the charge t o maintain tha t voltage.

o
Battery chargin g voltag e
BMW recommendatio n 14.8v

Power supply unit s from different manufacturer s are illustrate d on

next page .

B309121013
121-10 Battery , Starter, Alternator
Battery, charging

If using a power supply, recharg e battery without removing it.

70-amp ACCTIVA Professional Otherwise, remove the battery from the trunk or cargo compartment
power supply during charging. See Battery, removing an d installing i n this
repair group .

Prolonged charging with a conventional charger can cause battery

electrolyte evaporation to a level that can damage. I t is best to use
a low-current charger (6 amperes or less) to prevent battery damage
caused by overheating.

WARNING —
• Hydrogen gas given off by the battery during charging is
explosive. Do not smoke. Keep open flames away from the top
of the battery, and prevent electrical sparks by turning off the
battery charger before connecting or disconnecting it.

CAUTION—
• Battery electrolyte (sulfuric acid) can damage the car. If
B3091210I4 electrolyte is spilled, clean the area with a solution of baking
soda and water.
• Allow a frozen battery to thaw before attempting to recharge it.
• Do not exceed 16.5 charging voltage at the battery.

Battery, charging
Connect vehicle power supply charge r t o engine compartment B +
and ground. Follow manufacturer's instructions for setting chargin g
voltage.

Battery, removing and installing

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given in 001 Warnings and Cautions.

Switch ignitio n OFF .

Working in trunk or cargo compartment, open battery compartment .

Sports Wagon: Remov e cargo compartment floo r panel.

See 513 Interior Trim.

Sports Wagon: Remove screw (arrow) securing plasti c storag e

shelf (A) . Remove plastic storage shelf fasteners (inset ) an d
remove plastic storage shelf.
 Battery, Starter, Alternator 121-1 1
Battery, removing and installing

Working at top of battery, remove protective bracket mountin g

fasteners (arrows) and lif t off bracket.

Working a t top of battery:

• Unloc k batter y safety terminal plastic cover and loosen batter y
cable fasteners (inset).
• Disconnec t negativ e cable first.
• Carefully lift positive cable , negative cable an d intelligent batter y
sensor off battery and la y aside .

CAUTION—
• Do not damage intelligent battery sensor (IBS), which is
attached t o ground cable. See Warnings and Cautions i n this
repair group.

• Disconnec t batter y ven t hos e at side of battery, i f applicable.

— Lif t batter y out o f trunk o r cargo compartment .

— Clea n awa y corrosion in and around batter y tray and o n cable s

ends.

— Whe n reinstallin g battery, reconnect negative cable last .

Tightening torques
Battery post pinch bol t
•M6 5 N m (4 4 in-lb)
•M8 15 Nm (11 ft-lb)

Once the battery i s reinstalled, th e following steps ar e necessary :

• I f higher rating battery is installed, recode CAS with correct battery
specifications.
• Registe r battery. See Replacement batter y registratio n i n this
repair group .
• Follo w Batter y reconnectio n notes in this repair group.
121-12 Battery , Starter, Alternator
Replacement battery registration

Replacement battery registration

After fitting a new battery, connect BM W scan too l and ru n service
r ; D'spbv histor y o f r.MrUr v reptoc«3>:ien t function "Register battery replacement" t o notify vehicle power
[2] Register battery replacemen t management (softwar e in the engine electronic s and intelligent
battery sensor) that a new battery i s fitted in the vehicle .

Without new battery registration, CA S and vehicle powe r

management doe s no t run properly an d this can lea d for example:
reduction o r deactivation o f individual consume r functions .

During batter y registration , the following operations ar e performed:

• Current mileage i s stored.
• Store d values fro m old battery (charg e status , current, voltage,
temperature, etc.) ar e deleted.
• Powe r management i s initialized.

Battery reconnection notes

In addition t o Warnings an d Caution s i n this repai r group and in
001 Warnings an d Cautions, observ e th e following whenever the
battery is disconnected o r accidentally discharge d an d then
reconnected.

Clock
Reset.

Radio
Enter presets.

Steering angle sensor

AFS (activ e front steering) only :

Adjust usin g BMW scan tool .

Active front steering

Initializing and commissioning, Se e 320 Steering an d Wheel
Alignment.

Active stabilizer
Commissioning, Se e 300 Suspension, Steerin g and Brakes-
General.

Automatic tailgate
Setting readiness, See 412 Trunk Lid, Tailgate .

Power window regulator motor s

Initialize as follows :

Switch ignitio n ON and open window completely.

Hold switch in Open one-touch operation positio n an d hol d for 1 5 to

25 seconds .
 Battery, Starter, Alternator 12 1 -13
Starter troubleshooting

— Releas e window button , then hol d switch in Close direction .

The window full y open s and then closes . Initializatio n is completed

once the window has closed.

— Chec k to make sure one-touch control, anti-trappin g and comfor t

functions are active .

See 512 Door Window s fo r additional information .

Sunroof
Initialize as follows (if applicable):

^C, Switc h ignition O N and press and hold sunroof switch in Raise d
direction (arrow).

- Afte r sunroo f reaches Raise d position, keep switch presse d for

approx. 1 5 seconds longer .
B510121U022

— Initializatio n is complete when sunroof attempts briefly to lif t again .

Compass in interior mirro r

Calibration (if applicable):

— Switc h ignition ON

^. Using thin bladed screwdrive r or equivalent tool, press push butto n

at base o f mirror until C appears i n compass display (oval).

— Driv e vehicle 2 - 3 times in a circle at approx. 1 0 mph.

— Calibratio n i s complete whe n directio n display appears .

8309121015

STARTER
Starter troubleshooting
M54, N52, N54 engine: Starter is bolted to engine bell housing under
intake manifold. Starte r wiring connects to solenoid, abov e starter,
as follows:
X6512 • Larg e wire (X6512 or B+ connector) is direct battery voltage.
B+ connecto r • Smaller wire (X6510) operate s starter solenoi d via ignition switch
from battery
and car access system (CAS) .
X6510
Connector from
car access
system (CAS)
121-14 Battery , Starter, Alternator
CAS module, removing and installing

N62 engine: Starte r is bolted t o engine bel l housin g unde r righ t

exhaust manifold. Starter wiring connects to solenoid, above starter,
X6510 as follows:
Connector from
car access • Larg e wire (X6512 or B+ connector) i s direct batter y voltage.
system (CAS) • Smaller wire (X6510) operates starter solenoid via ignition switch
and car access system (CAS) .

If starter an d solenoid clic k repeatedl y withou t starting vehicle:

• Chec k batter y state of charge.
• Inspec t battery an d starter cables , terminal s an d groun d
connections for good contact. I n particular, mak e sure groun d
connections betwee n battery, bod y an d engine ar e completely
X6512
clean and tight.
B+ connector • I f no faults are found, starter may be faulty and should b e replaced.
from battery
If starter fails to operate, chec k the following:
• Car access system (CAS) . Try another ignitio n key . If no faults can
be found, chec k operation of CAS using a BMW scan tool. CAS
replacement is covered in CAS module, removin g an d installin g
in this repair group .
• Clutch switch module (manual transmission). Make sure clutch is
pressed all the way to the floor. See 210 Clutch .

wore—
• Automatic transmission neutral safety switch function is built into
transmission mechatronics electronics. Failure of this function
causes a no-start condition.

Access to starter is difficult as i t is under th e intak e manifold. If

possible, chec k for battery voltag e (12. 6 volts) a t B+ terminal
(X6512).

Check for battery voltage a t terminal X651 0 of starter motor with

ignition in START position.
• I f voltage i s not present, check wirin g betwee n CAS and starte r
terminal.
• Check CAS and other input s that disrup t power to solenoid. See
ELE Electrical Wiring Diagrams .
• I f voltage is present and no other visible wiring faults can be found,
problem is most likely in starter motor .

CAS module, removin g an d installin g

CAUTION—
•CAS module is static sensitive. Static discharge may damage it
permanently. Handle using static prevention equipment and
techniques. Se e 600 Electrical System-General.

Remove lef t side dashboard lower tri m (pedal cluster trim) . See
513 Interior Trim.

Working to lef t of steering column :

• Detac h ribbon harness (A ) from CAS module.
• Detach harness connector (B) from CAS module.
 Battery, Starter, Alternator 121-1 5
Starter, removing and installing (M54 engine)

Remove module mountin g scre w (arrow) an d withdraw modul e t o

left an d down to remove from dashboard.

Inspect ribbon cable and replace if damaged. (Ribbo n cabl e

connects CA S to ignition key slot and START / STOP button. )

When installing , make sure CAS module guide fits correctly into
mounting slot.

After reassembly , carry out vehicle coding and programming . Se e

600 Electrical System-General.

Starter, removing and installing

(M54 engine)
The starter is removed from below. Access to starter bolts is difficult.
Be sure to have the proper tool s on hand befor e proceeding .

— Disconnec t negative (-) batter y cable.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings and Cautions .

— Rais e vehicle and suppor t safely.

WARNING —
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

— Remov e front suspension reinforcemen t plate.

"^ Workin g underneat h car , disconnect batter y positive (+ ) lead from

starter (arrow) .

NOTE —
• Note routing for cables. Cable routing can vary. When reinstalling,
make sure cables do not chafe.

Using a long extension an d universal joint from output end of

transmission, remove bolts (A) fastening starter to transmission bel l
housing an d engine block .

— Pul l starter out of transmission bell housing in direction of arrow an d

detach remaining starter wiring .

— Remov e starter from below.

121-16 Battery , Starter, Alternator
Starter, removing and installing (N52, N54 engine)

Check starter pinio n gea r an d flywheel teeth for damage.

Installation i s reverse of removal .

Tightening torques
Starter t o transmission bell housing 45 Nm (33 ft-lb)
Wire terminals to starter
•M5 5 N m (44 in-lb)
•M6 7 N m (62 in-lb)
•M8 13Nm(10ft-lb)

Starter, removing and installin g

(N52, N5 4 engine )
Switch ignition OFF. Disconnec t negativ e (-) batter y cable and
cover battery terminal t o keep cable fro m accidentally contacting
terminal.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings an d Cautions .

Remove upper an d lower cabin ai r microfilte r housings . Se e

020 Maintenance .

Remove engine ai r filter housing an d ducts . See 131, 13 2 F:uel

Injection.

Remove ignition coil cover . Se e 020 Maintenance .

Remove intake manifold. See 131 , 13 2 Fuel Injection.

CAUTION—
• Do not detach fuel lines or injectors.

Working a t starter solenoid electrical connections:

• Remov e fastener (A) and detach B + cable from solenoid.
• Pres s in wire clip (arrow) to release solenoid wire connector .
 Battery, Starter, Alternator 121-1 7
Starter, removing and installing (V8 engine)

^V Remov e starte r mountin g bolts (arrows). Discard aluminum bolts .

(Aluminum bolt heads are not always marked with blue paint . Use a
magnet to identify them. )

— Lif t out starte r motor.

— Befor e installing new starter, rotate engine an d inspec t flywheel or

torque plate gear teeth through starter hole. Replace i f damaged.
See 210 Clutch o r 240 Automatic Transmission.

— Reinstal l starter and reattac h electrical connectors.

Tightening torques
B+ cable to starter (M8) 13Nm(10ft-lb)
Starter to bell housin g (turbo) 38 N m (28 ft-lb)
Starter to bell housing (non-turbo )
(replace M10 aluminum bolts)
• Stage 1 20Nm(15ft-lb)
• Stage 2 additional 180°

Starter, removing and installing (V 8 engine)

Switch ignition OFF. Disconnec t negative (-) batter y cable an d
cover battery terminal to keep cabl e from accidentally contactin g
terminal.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings and Cautions .
..
— Remov e righ t side exhaust manifold. Se e 180 Exhaus t System .

^ Remov e starter hea t shield fasteners (arrows) then remove hea t

shield (A).

Disconnect electrical connector (A). Remov e fastener (B) an d

remove starter cable (C).
 Battery, Starter, Alternator
Alternator basics

Remove starter mounting bolt s (arrows).

— Lif t out starte r motor .

— Befor e installing ne w starter, rotat e engin e an d inspec t flywhee l or

torque plate gear teet h through starte r hole . Replac e if damaged .
See 210 Clutch o r 240 Automatic Transmissio n

— Reinstal l starter and reattac h electrical connectors .

Tightening torques
B+ cable t o starter (M8) 13Nm(10ft-lb)
Starter to bell housing
(replace bolts ) 45 N m (33 ft-lb)
Starter heat shiel d 6Nm(4.4ft-lb)

ALTERNATOR AN D CHARGING SYSTE M

Alternator basic s
v Th e alternator is bolted to the lef t side o f the engine block. It is driven
by the engine accessor y belt . Accessory belt replacemen t i s
covered in 020 Maintenance .

Several versions of alternators are use d in E60 vehicles. B e sure

that the replacement alternato r is correct for the application .

Alternator interfac e
The alternator communicates wit h the engine control module (ECM)

I ftf.GN
™

m
"\ via bit-serial data (BSD) interface. This single wire connection allows
the EC M to adapt it s calculations an d contro l data to alternator
output. The EC M controls the following functions :
battery — Batter y
sensor ~n _ • Alternator activation and deactivation .
BSD
• Informin g the voltage regulato r o f the nomina l voltag e value to be
set.
• Alternator load respons e control .
( • BSD line diagnosis .
*] instrument • Alternator fault code storage .
1 • Charge indicato r ligh t activation i n instrument cluster.
1A6000 !"t"o ~ 1G643 0
g| [Engin e control J \ ]B+jum p

(
<"~!J> ,", J J

BSD

Sw
XI,
Tm G6524 ,-JL'i
Alternator i~
'
~~]M6510
| f?) B [Starte r
a
. ji ;

B309121008
 Battery, Starter, Alternator 121-1 9
Charging system troubleshooting

Charging system troubleshooting

Some charging system tests require special test equipment. I f the
test equipment i s not available, charging system fault diagnosis ca n
be performed by an authorized BMW dealer or other qualified repai r
shop. See Table a for general electrica l componen t troubleshooting .

Before checking the alternator, mak e sure the battery i s fully

charged and capable of holding a charge. Check that the batter y
terminals are clean and tight and the engine accessory drive belt is
properly tensioned and not severely worn. For drive belt service see
020 Maintenance .

Charging system quick-check

Use a digital multimeter to measure voltage across the batter y
terminals with ignition OFF and then again with engine running.
Battery voltage should b e about 12.6 volts with key OFF an d
between 13. 2 and 14.5 volts with engine running .

Run engine at about 2000 rpm and switch ON electrical loads (fans ,
lights, rea r window defroster, and wipers). With all accessories on,
battery voltage shoul d b e above 12. 6 volts.

The regulated voltage (engine running , battery charged,

accessories and lights OFF) i s usually between 13. 2 and 14.5 ,
depending on temperature and operating conditions. If the voltage is
higher tha n 14.8, the voltage regulato r i s most likel y faulty.

Charging system , checkin g

CAUTION—
• Do not disconnect the battery while the engine is running.
Damage to the alternator or engine electronic systems may
result.
• Only use a digital multimeter when testing charging system
components.

Switch ignition ON. Check that batter y warning ligh t comes ON for
self test. I f warning ligh t does no t come ON , check for fault codes .
121-20 Battery , Starter, Alternator
Charging system, checking

Check for battery voltage at alternator terminal 30 (B+):

• Pul l off insulating cover at terminal 30 (arrow) at rear of alternator.
• Connect voltmeter between terminal 30 and ground and check for
battery voltage . If voltage i s not present, check wiring for faults.

Connect oscilloscope across battery terminals to check alternator

function.

— Connectin g oscilloscope :
A • Positiv e test lead of oscilloscope t o positive batter y terminal.
• Negativ e test lead of oscilloscope to negative battery terminal
• Set oscilloscope to A/C volts and a time bas e of 500ms.

^C Norma l alternator pattern.

0,0

-1JO

-2.0

-3.0

B309121009

Alternator with defective diode.

0.0

-1.0

-2XJ

-3.0

0* 2.0 • 4,0 I
!,« 3,0
 Battery, Starter, Alternator 121-2 1
Alternator, removing and installing (M54 engine)

Alternator with broken winding.

iA If test indicate a defective alternator , replac e unit. Repair part s are

not available for the alternator.
3»

2,0

1.6

0.0

-1.0

-2t>

-3,0

-4jO

p^co fi.a a *4 .
-3* Ifl 3 *

Alternator, removing and installing

(M54 engine)
A replacement alternato r should have the same rating as the
original. Alternator manufacturer and ampere rating are normally
marked o n the alternator housing .

Switch ignition OFF. Disconnect negative (-) batter y cable and

cover battery terminal t o keep cable from accidentally contactin g
terminal.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions in 001 Warnings an d Cautions.

— Remov e air intak e duct and filter housing . See 13 0 Fue l Injection .

— Remov e engine accessory belt. See 020 Maintenance . Mar k

direction o f rotation on belt befor e removing.

^V, Workin g at rear of alternator, remove electrical connector (A ) an d

battery positiv e cabl e fastene r (B) .

Working at front of alternator (B) , remov e cover fro m idler pulley (A)
and remove alternator fasteners (arrows).

Rotate alternator forward and then u p and out of engine

compartment, using care to not damage radiator.

CAUTION—
• Protect radiator with heavy cardboard or sheet metal.
121-22 Battery , Starter, Alternato r
Alternator, removing and installing (N52 engine)

— Installatio n is reverse of removal.Remember to:

• Reinstal l accessory bel t usin g previousl y mad e direction-of -
rotation marks.
• Mak e sure accessory bel t grooves engag e pulley s correctly.

Tightening torques
Pulley t o alternator 70 Nm (44 ft-lb)
Terminal 3 0 (B+) wir e to alternator (M8 ) 13Nm(10ft-lb)
Alternator t o crankcase (M8 ) 21 Nm (15.4 ft-lb)

After reconnecting battery, see Batter y reconnectio n note s in this

repair group.

Alternator, removing and installin g

(N52 engine)
Switch ignitio n OFF. Disconnec t negative (-) batter y cabl e and
cover battery terminal to keep cable fro m accidentally contactin g
terminal.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions in 001 Warnings an d Cautions .

— Remov e engine accessory belt. See 02 0 Maintenance . Mar k

direction of rotation o n belt befor e removing .

— Remov e air intake duct an d filter housing . See 131 Fuel Injection.

^C Workin g a t rear of alternator :

• Detach harness connector (A )
• Remove nu t (B) and detach alternator cable.
• Remov e alternator mounting bolt s (arrows ) and discard
(aluminum bolts) .
• Lif t out alternator.

^C Wit h alternator on work bench :

• Remov e idler pulley (C ) fastener plastic cover , if applicable.
• Remov e idler pulley and transfer to new alternator.

Tightening torques
• Idler pulley to alternator housing 80 Nm (59 ft-lb)

Reinstall alternator using new aluminium bolts . Reattach electrical

harnesses.

Tightening torques
Alternator cable t o alternator (M8 ) 19Nm (1 4 ft-lb)
Alternator to engine bloc k (M8 x 82 mm
aluminum bolts , replace with new)
• Stage 1 10 Nm
• Stage 2 additional 180 °
 Battery, Starter, Alternato r 12 1 -23
Alternator, removing and installing (N54 engine)

Reassemble front of engine. Remember to :

• Reinstal l accessory bel t usin g previousl y made direction-of -
rotation marks.
• Mak e sure accessory bel t grooves engage pulley s correctly.
• Afte r reconnectin g battery , see Battery reconnection note s i n
this repai r group .

Alternator, removing an d installin g

(N54 engine )
Switch ignition OFF . Disconnect negativ e (- ) batter y cabl e and
cover battery terminal to keep cable from accidentally contactin g
terminal.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings and Cautions .

— Rais e vehicle and suppor t safely.

WARNING—
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splas h shield underneath engine compartment. See

020 Maintenance .

Remove electric fan cowl and fan. See 170 Radiator an d Coolin g
System.

Remove engine accessor y belt. See 020 Maintenance. Mar k

direction of rotation on belt before removing .

Remove air intake duct an d filter housing. Se e 132 Fue l Injection .

Remove lef t side charg e air duct. See 132 Fuel Injection .

Remove A/C compressor from mounting bracket an d han g aside .

See 640 Heating and Air-conditioning. Do not detach A/C
refrigerant lines .

Loosen A/C compressor bracke t bolts (arrows) a few turns. D o not

remove bracket .
121 -24 Battery , Starter, Alternato r
Alternator, removing and installing (N54 engine)

Working at rear of alternator:

• Detac h harnes s connecto r (A)
• Pul l off plastic protectiv e cover and remov e nu t (B) to detach
alternator terminal 30 (B+) cable.

Working at left side of engine :

• Remov e alternator mounting bolt s (arrows).
• Lif t out alternator with bracke t (A).

With alternator on work bench:

• Remov e idler pulley (B ) fastener plasti c cover , if applicable .
• Remov e idler pulley and transfer to new alternator.

Tightening torques
Idler pulley to alternator housing 80 Nm (59 ft-lb)

— Reinstal l alternator and reattac h electrica l harnesses.

Tightening torques
Alternator cable to alternator (M8) 19Nm(14ft-lb)
Alternator to engine block (M8) 19Nm(14ft-lb)

Tighten A/C compressor bracket bolts , then reinstal l compressor.

Tightening torque
A/C compressor bracket to engine block 19Nm(14ft-lb)

Reassemble front of engine. Remembe r to :

• Reinstal l accessory bel t using previousl y made direction-of-
rotation marks.
• Mak e sure accessory bel t grooves engag e pulley s correctly.
• Afte r reconnectin g battery , see Batter y reconnectio n note s in
this repai r group.
 Battery, Starter , Alternato r 12 1 -25
Alternator, removing and installing (V8 engine)

Alternator, removin g an d installin g

(V8 engine )
Switch ignition OFF. Disconnect negative (-) batter y cable an d
cover batter y termina l to keep cable from accidentally contacting
terminal.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings and Cautions .

— Remov e air intake duct and filter housing . See 13 3 Fue l Injection .

— Remov e electric fan cowl and fan. See 170 Radiato r an d Coolin g
System.

— Remov e alternator drive belt. See 020 Maintenance. Mark directio n

of rotation on belt before removing .

^ Disconnec t alternator electrical connecto r (B). Remov e fastener (A)

and alternator cable (C) .

^V Remov e alternator fasteners (A) and lift out alternator (B) .

• Remov e idler pulley (C ) fastener plastic cover, if applicable .
• Remov e idle r pulley and transfer to new alternator.

— Installatio n is reverse o f removal .

Tightening torques
Terminal 30 (B+) wire to alternator (M8) 13 M m (10ft-lb )
Idler pulle y to alternator 45 Nm (33 ft-lb)
Drive pulley to alternator 70 Nm (51 ft-lb )
Alternator t o crankcase 21 Nm (15. 4ft-lb)
 130-1

130 Fue l Injectio n MS45. 1

(M54 Engine )

GENERAL 130- 1 Air filte r housin g an d ducts,

removing and installing 130-1 3
DME applications 130- 2
Warnings and Cautions 130- 3 Mass air flow, measuremen t 130-1 4
Mass ai r flow sensor, replacin g 130-1 4
DRIVEABILITY TROUBLESHOOTIN G 130- 5 Throttle housin g (EDK) , replacin g 130-1 5
Basic engine settings 130- 5 Idle speed contro l valve, replacin g 130-1 7
System voltag e 130- 5 Fuel rail and injectors,
Main grounds 130- 6 removing and installing 130-1 8
On-board diagnostics 130- 6 Intake manifold, removin g and installing . . . . 130-2 1
ENGINE MANAGEMEN T FUSE S Crankcase breathe r valve components 130-2 4
AND POWE R SUPPLY COMPONENT S 130- 7 Engine coolan t temperatur e (ECT ) sensor ,
replacing 130-2 4
Power supply fuse s 130- 7
DME main relay , testing 130-2 5
SIEMENS DME MS45. 1 (M54 ENGINE ) . . . 130-8 ECM pin assignments
DME MS45.1 syste m descriptio n 130- 8 (Siemens DM E MS45.1) 130-2 7
Secondary ai r injection 130-1 0
TABLE
Secondary air injection syste m components . 130-1 1
a. 5 Series engine management
Secondary ai r injection illustration s 130-1 2
applications 130- 4
b. Siemens DM E MS45. 1 EC M
pin assignments 130-2 7

GENERAL
This repair grou p covers service an d repair o f engine management
system for 5 Series model s with M5 4 engine and Siemen s
DMEMS45.1.

See also:
• 020 Maintenance for air filter, fuel filte r and spark plug
replacement
• 100 Engine-General for engine identification
• 120 Ignition System for ignition coil, camshaft sensor, crankshaf t
sensor an d knock sensor servic e
• 160 Fuel Tank and Fuel Pump for fuel pump and fuel pump relay
service, fuel pressure tests and fuel pressure regulator
replacement
• 18 0 Exhaust System for oxygen sensor servic e
• ECL Electrical Component Locations
• ELE Electrical Wiring Diagrams
• OBD On-Board Diagnostics
130-2 Fue l Injection MS45.1 (M54 Engine)
DME applications

DME applications
BMW 5 Series models ar e equipped wit h digital moto r electronics
(DME), also known as Motronic. In these systems, fuel injection and
ignition are controlled by an integrated engine control modul e
(ECM). Application information for DM E system s is in Table a.

Table a. 5 Series engine management applications

Year, model Engine Engine Features
code management

2004-2005

Sedan: 525I , 530i M54 Siemens Double VANOS

MS 45.1

Sedan: 545i N62 Bosch DM E Valvetronic,

ME 9.2 with VANOS
Valvetronic
control modul e

2006 - 200 7

Sedan, N52 Siemens MSV7 0 Valvetronic,

Sports Wagon: VANOS
525i, 525xi,
530i, 530x i
Sports Wagon

2008-2010
Sedan, N52KP Siemens MSV80 Valvetronic,
Sports Wagon : VANOS
528i, 528xi

Sedan, N54 Siemens MSD80 VANOS,

Sports Wagon : (to 03 / 2008) turbocharged
535I, 535xi MSD81 (fro m
03 / 2008 )
2004-2005
Sedan: 545 i N62 Bosch DME Valvetronic,
ME 9.2 with VANOS
valvetronic
control unit

2006-2010
Sedan: 550 i N62TU Bosch DM E Valvetronic,
ME 9 . 2. 2 VANOS
Fuel Injection MS45.1 (M54 Engine) 130- 3
Warnings and Cautions

Warnings and Caution s

WARNING —
• The fuel system is designed to retain pressure even when the
ignition is OFF. When working with the fuel system, loosen the
fuel lines slowly to allow residual fuel pressure to dissipate.
Avoid spraying fuel. Use shop towels to capture leaking fuel.
• Fuel in fuel lines is underpressure (approx. 3 - 5 bar or 45 - 75
psi) and may be expelled forcibly. Do not smoke or work near
heaters or other fire hazards. Keep a fire extinguisher handy.
• Unscrew the fuel tank cap to release pressure in the tank
before working on fuel lines.
• Plug open fuel lines and fittings.
• Before beginning work on the fuel system, place a fire
extinguisher in the vicinity of the work area.
• Work only on the fuel system when engine temperature is
below 40°C(104°F).
• When disconnecting a fuel line, clamp off the line and wrap a
clean shop towel around the fitting before disconnecting.
Residual fuel pressure is present in the line.
• Fuel is highly flammable. When working around fuel, do not
disconnect wires that could cause electrical sparks. Do not
smoke or work near heaters or other fire hazards.
• Wear eye protection and protective clothing to avoid injuries
from contact with fuel.
• When working on an open fuel system, wear suitable hand
protection, as prolonged contact with fuel can cause illnesses
and skin disorders.
• Unscrew the fuel tank cap to release pressure in the tank
before working on fuel lines.
• Do not use a work light with an incandescent bulb near fuel.
Fuel may spray on the hot bulb causing a fire.
• Make sure the work area is properly ventilated.
• Due to risk of personal injury, be sure the engine is cold before
beginning work on engine components.
• The ignition system produces high voltages that can be fatal.
Avoid contact with exposed terminals. Use extreme caution
when working on a car with the ignition switched ON or the
engine running.
130-4 Fue l Injection MS45.1 (M54 Engine)
Warnings and Cautions

CAUTION—
• Renew fuel system hoses, clamps and O-rings any time they
are removed.
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings and Cautions .
• Connect and disconnect the DME system wiring and test
equipment leads only when the ignition is switched OFF.
• Wait at least 1 minute after switching the ignition OFF before
disconnecting engine control module (ECM) connectors. If the
connectors are removed before this time, residual power in the
system relay may damage the control module.
• Tests or repair procedures in this section may set fault codes
(DTCs) in the ECM and illuminate the MIL. After repairs are
completed, access and clear DTC memory using a BMW scan
tool. See On-board diagnostic s in this repair group.
• Fuel system cleaners and other chemical additives other than
those specifically recommended by BMW may damage
catalytic converters, oxygen sensors or other fuel supply
components.
• Do not connect any test equipment that delivers a 12-volt
power supply to terminal 15 (+) of the ignition coils. The current
flow may damage the ECM. Connect test equipment only as
specified by BMW or the equipment maker.
• Relay positions can vary. Be sure to confirm relay location and
function by identifying the wiring in the socket using the wiring
diagrams found in ELE Electrica l Wirin g Diagrams .
• Use a digital multimeter for electrical tests. Use an LED test
light for quick tests.
Fuel Injectio n MS45. 1 (M5 4 Engine) 130- 5
Basic engine settings

DRIVEABILITY TROUBLESHOOTIN G
The self-diagnostic DME engine management system s monito r an d
store diagnostic troubl e codes (DTCs) . If the malfunctio n indicato r
light (MIL) illuminates, it indicates that an emissions-related fault has
occurred and that one or more DTCs are stored in the engine control
module (ECM) .

If faults arise, or i f the MI L i s illuminated, begin troubleshooting b y

connecting BMW scan tool to the OBD II plug unde r the dashboard .

The capabilities o f OBD I I software has the potential to save hours of

diagnostic time and to help avoid incorrect component replacemen t
and possible damage t o system components. See On-boar d
diagnostics i n this repair group.

Basic engin e setting s

Idle speed, idle mixtur e (%CO), and ignition timing ar e not
adjustable. The DME system is adaptive and automaticall y
compensates fo r changes i n the engine due to age, minor wear or
small problems such as a disconnected vacuum hose . However , the
adaptive range is limited. Once the limits are exceeded, driveabilit y
problems become noticeable .

Poor initial driveability may be encountered when the batter y is

disconnected and reconnected. Whe n th e battery is disconnected,
ECM adaptive memor y may be reset. The system readapt s afte r
about ten minutes o f driving.

System voltag e
Digital motor electronic s (DME ) requires that the syste m (battery )
voltage be maintained withi n a narrow range of DC voltage. D C
voltage levels beyond or below the operating range, o r any A C
voltage in the electrical system can cause havoc .

• Whe n troubleshooting a n illuminate d MIL, make sur e the batter y i s

fully charged and capable o f delivering all its power t o the electrica l
system. An undercharge d batter y can amplify AC alternator outpu t
ripple.

• T o make a quick check o f batter y charge, measure voltag e acros s

battery terminals with all cables attached and ignitio n OFF. A fully
charged battery measures 12. 6 volts or slightly more , compare d t o
12.15 volts for a battery with a 25% charge.

The DME system operates a t low voltage and current levels, making
it sensitive to small increase s in resistance. The electrical system is
routinely subject to corrosion, vibration and wear, so faults or
corrosion in the wiring harness an d connectors are not uncommon .

Check battery terminals for corrosion or loose cable connections .

See 121 Battery, Starter , Alternator.
130-6 Fue l Injectio n MS45.1 (M54 Engine)
Main grounds

If a battery cable connectio n ha s no visible faults but is still suspect,

measure voltage drop across the connection. A large drop indicates
excessive resistance, meaning that the connection is corroded, dirty
or damaged. Clea n o r repair an d retest . See 600 Electrica l
System-General for voltage drop tes t procedure.

Visually inspect wiring, connectors, switche s and fuses. Loose o r

damaged connector s ca n cause intermitten t problems, especiall y
small terminals in ECM connectors. Disconnec t wirin g harness
connectors to check for corrosion, an d use electrical cleaning spray
to remove contaminants.

Main ground s
Good ground s ar e critical to prope r DM E operation . I f a ground
connection ha s n o visible faults but is still suspect, measure the
voltage drop across the connection. A large voltage drop means
high resistance . Clean or repair the connectio n and retest.

For voltage drop testing, see 600 Electrica l System-General.

For ground locations , se e EC L Electrica l Componen t Locations .

On-board diagnostic s
Second generation on-board diagnostic s (OB D II) software and
hardware is incorporated in the engin e managemen t systems . Th e
OBD II system monitors components tha t influenc e exhaust an d
evaporative emissions . I f a problem i s detected, th e OBD I I system
stores the associated diagnosti c troubl e code (DTC ) and condition .

If vehicle emissions level s exceed 1. 5 times Federall y mandate d

criteria, the OB D I I system illuminate s a malfunction indicator ligh t
(MIL) i n the instrumen t cluster.

Scan tool connected to OBD plug o n floor post below left

dashboard.

Professional diagnostic scan tools availabl e a t the time of this

printing include the BM W GT1, IST A and a small number of
aftermarket BMW-specifi c tools .

In addition to professional scan tools, there are inexpensive generic

OBD II scan tool software program s and handheld units available.
Although these have limited capabilities a s compared to the
dedicated tools, they ar e powerful diagnostic tools.

For the DI Y owner, a simple aftermarke t DTC reader is available

through http://www.peakeresearch.com . This tool i s capable of
checking for DTCs as well as switching the illuminated MIL OFF and
resetting service indicato r lights .

NOTE—
• OBD II DTC memory (including an illuminated MIL) can only be
reset using a BMW scan tool or equivalent. Removing the
connector from the ECM or disconnecting the battery does not
erase DTC memory.
r Fuel Injection MS45.1 (M54 Engine ) 130- 7
Power supply fuses

ENGINE MANAGEMEN T FUSE S

AND POWE R SUPPLY COMPONENT S
Power supply fuses
See EC L Electrical Componen t Location s fo r fuse panel access
information.

Rear distributio n panel (A46 ) in trunk, installed in right rea r fender :

• F9 0 200A: Powe r supply to fuse panel A41a.

A41a: fuse and relay panel behin d glove compartment :

• F8 60A:
Engine control module (ECM ) (A6000 )
ECM main rela y (K6300 )
Engine electronic s fuse carrier (A8680)
Engine electronic s fuse carrier (A8681)

See ECL Electrical Component Location s for specific vehicl e

fuse locations .

Engine electronic s fuse carrier A8680 (arrow).

130-8 Fue l Injection MS45.1 (M54 Engine)
DME MS45.1 system description

SIEMENS DM E MS45. 1 (M5 4 ENGINE )

DME MS45.1 system description
DME MS45.1 manage s an d monitor s th e following functions :

Air
• Idl e speed valv e
• Electroni c throttle
• Ho t film mass ai r flow senso r
• Resonance-turbulenc e intak e contro l

Fuel
• Fue l suppl y (returnless )
• Fue l injection

Ignition
• Direc t ignition
• Knoc k contro l
• Primary/secondar y ignition monitorin g

Emissions
• OBD II complianc e
• Secondary ai r injection and monitorin g
• Pre - and post-catalyst oxygen sensors
• Electricall y heated DME-mappe d thermosta t
• Misfir e detectio n
• Evaporativ e emissio n contro l and leak detectio n
• Ambient pressur e sensin g
• Malfunction indicator light (MIL )

Performance controls
• Doubl e VANOS control
• Electri c radiator coolin g fan
• E-box cooling fan
• CAN-bus communicatio n
• CA S (car access system ) - EWS 3.3
• Cruise contro l
• Comfort start
• ECM programming
• Alternator interface (BSD, IBS )
• Dynami c stabilit y control (DSC) interfac e
 Fuel Injectio n MS45.1 (M54 Engine) 130- 9
DME MS45. 1 system description

Engine control modul e (ECM)

The engin e contro l modul e (ECM ) (arrow ) is mounted i n the
electronics box (E-box) at righ t rea r of engine compartment .

, Th e MS45. 1 EC M is flash-programmable and features 5 electrica l

harness connector s wit h a total of 13 4 pins.
• Connector 1 : Voltages an d grounds
• Connector 2 : Ancillary signals (oxygen sensors, etc.)
• Connector 3 : Engine signal s
• Connector 4 : Vehicle signal s
• Connector 5 : Ignition signal s

The EEPRO M (chip ) i n the MS45. 1 EC M is coded t o the vehicle . It

can be flashed (reprogrammed ) u p to 1 3 times.

B70113004E

Fuel meterin g
The EC M meters pressurize d fue l by changing th e openin g tim e
(pulse width) of the fuel injectors. The exact amoun t of fuel injecte d
is determined b y the amoun t o f time the injector s are open . To
ensure that injector pulse width is the only factor that determines fuel
metering, fuel pump pressur e is maintained by a pressure regulator .
The injector s are mounted t o a common fue l rail .

The fuel-injectors inject fuel at an angle in a dual cone spray pattern .

The ECM monitors engine operating conditions to determine injecto r

opening duration . Eac h injecto r can be individually controlle d for
cylinder selective fuel trim.

Air intak e
Air enterin g the engine passe s throug h a pleated pape r elemen t i n
the air filter housing. Intak e air mass is then measured b y a mass ai r
flow sensor. A reference current i s used to heat a thin film i n the
sensor when th e engine i s running. The current needed t o hol d th e
temperature o f the film constant i s the basis of the electronicall y
converted voltage measuremen t correspondin g to the mas s of the
intake air.
130-10 Fue l Injectio n MS45. 1 (M5 4 Engine )
Secondary air injection

Idle speed control

Idle speed is electronically controlled via the idle speed control valve
by bypassing varyin g amounts o f air around the closed throttle
valve. Idle speed i s not adjustable. The EC M determines idl e speed
by controlling a dual-winding rotar y idl e control valve. The basic
functions and parameters of idle speed control are as follows:
• Contro l of cold air intake volume. Fo r example, at air temperatures
below 0°C (32°F) , electronic throttle control (EDK) i s also opene d
during idle.
• Smoot h idl e speeds regardles s of load and inputs
• Smoot h transition from acceleration to deceleration

Idle speed stabilizatio n is active during the following conditions:

• Engine war m up
• Heatin g or A/C activation
• Driv e gear selected (automatic transmission )
• Varying engine cooling fan speeds

If the EC M detects a fault in the idl e control valve, i t increases or

decreases air flow, depending o n the natur e of the fault:
• I f the fault causes decreased air flow (idle control valve closed), the
electronic throttle control compensates t o maintain idle.
• I f the fault causes increased air flow (idle control valve failed open),
VANOS and knock control are deactivated. This reduces engine
performance noticeably.

Throttle control
In order to integrate the driver's wish with the requirements of the
traction control system (DSC) and cruise control, DME systems
feature electronic throttle control (EDK). There is no throttle cable
between the accelerator pedal an d the throttle housing

Knock (detonation) contro l

Knock sensors monitor and control ignitio n knock through the ECM.
Knock sensors function like microphones an d are able to convert
mechanical vibratio n (knock ) into electrical signals . The EC M is
programmed to react to frequencies that are characteristic of engine
knock and adapt th e ignition timing poin t accordingly.

Knock sensor replacement i s covered i n 120 Ignition System.

Secondary air injectio n

The secondary air system pumps ambien t ai r into the exhaust
stream after a cold engine start to reduc e catalytic converter warm-
up time and to reduce HC and CO emissions. The ECM controls and
monitors the secondary air injection system .

The electric air pump draws in ambient ai r and supplies i t to the

secondary ai r valve. The air injection valve i s opened b y a solenoid
using engine vaccum and is closed b y an internal spring .

The secondary air valve is bolted to the righ t front of the cylinder
head. Cas t passageways within the cylinder hea d duct the
secondary air directly into the cylinder head exhaust ports.
 Fuel Injection MS45.1 (M54 Engine) 130-1 1
Secondary air injection system components

Secondary air injection system components

1. Ai r pump
2. Filte r air duct
3. Ai r pump mount
4. Ai r pump bracket
5. Ai r pump filter
6. O-rin g
7. Ai r pump mini mass air flow senso r
8. Pressur e hose
9. Secondar y air valve
10. Vacuum pipe
11. Vacuum hose (3.3 mm)
12. Vacuum solenoid (ECM controlled)
13. Mounting nut M6
14. Gasket
15. Cylinder head
16. Intake manifold
17. Check valve

A miniature mass air flow sensor in the secondary air system detects
the air mass supplied b y the secondary air pump. This function
monitors the secondary ai r system for OBD I I compliance .

When the mini mass air flow sensor detects no or insufficient air flow,
a fault is stored in the ECM and the malfunction indicator ligh t (MIL )
is illuminated.

b3091300008

Secondary ai r injection illustration s

Secondary ai r pump i s in right front fender behind whee l wel l liner.
Secondary air injection illustrations

B2606 Mini mass air flow sensor .

Secondary air valve is bolted to righ t front of cylinder head.

Fuel Injection MS45.1 (M54 Engine) 130-1 3
Air filter housing and ducts, removing and installing

Air filter housing and ducts,

removing and installing
For air filter servicing, se e 020 Maintenance.

Disconnect mass air flow sensor connector (arrow) .

^V Loose n hose clamp (A ) and remove air filter housing fastener s

(arrows).

— Remov e air filter housing by liftin g up and ou t i n direction of arrow.

— Workin g at throttle body, loosen duct clamp. Remove duct from

throttle body.

— Installatio n is revers e of removal .

— Afte r reinstalling, chec k and clear fault codes from ECM memory.
130-14 Fue l Injection MS45.1 (M5 4 Engine )
Mass air flow, measurement

Mass air flow, measuremen t

The mass air flow sensor, incorporating an electrically heated film in
the air flow stream, sends to the EC M a varying voltage (approx. 0.5
- 4.5 volts) representin g the mas s o f the intak e air.

The EC M provides operating voltage an d ground to the air flow

sensor. As air flows through th e sensor , the film is cooled. To
maintain the film at a constant temperature, additional current is
necessary. I t is this additional curren t tha t is the basi s for the air
mass signal .

If there i s no output signal from the ai r flow sensor, the EC M

operates the engine using throttle position and engine rp m inputs. A
faulty air flow sensor illuminate s th e MIL .

B51013000016

The intake air temperature sensor (inset) is integrated into the mass
air flow sensor. The sensor is an NTC thermistor which receives a 5
volt referenc e current and ground fro m the ECM .

A faulty air flow sensor ca n produc e th e following problems:

• Difficul t to restart when engine i s hot.
• Engin e starts then stalls.
• Engin e start s and runs only wit h accelerator pedal depressed .

B51013000017

Mass air flow sensor, replacin g

— Switc h ignition OFF an d remov e key.

^C Workin g at left front of engine compartmen t at air filter housing :

• Detac h mass air flow sensor electrica l connector (A).
• Remov e fasteners (arrows).
• Remov e mass air flow sensor (B) .

— Chec k intake ducts for cracks and vacuu m leaks.

 Fuel Injection MS45.1 (M54 Engine) 130-1 5
Throttle housing (EDK), replacing

Installation i s reverse of removal.

• Inspec t O-ring (arrow ) and replace if necessary. Kee p O-rin g an d
duct sealing are a free from oil.

After reinstalling , check an d clear fault codes from ECM memory .

Tightening torques
Mass ai r flow sensor t o housing 3 N m (2 6 in-lb)

B51013000015

Throttle housing (EDK), replacing

There i s no mechanical (cable ) lin k between the accelerator peda l
and the throttle plate.

The accelerato r pedal module (PWG ) a t the peda l assembl y

communicates peda l positio n directl y to the ECM . The modul e
PWG modul e
(Hall sensors)
provides two variable voltag e signal s (via two Hall sensors) t o th e
ECM for pedal position and rat e of movement.

The EC M provides an independent voltag e and ground suppl y for

each Hal l sensor. Eac h Hal l sensor is provided with 5 volts an d
ground. As the accelerator pedal i s moved from rest to full throttle,
the sensors produc e a variable voltage signal .

The output of the Hall sensors is checked for plausibility. The voltage
range of Hall sensor 1 is approximately 0.5 to 4.5 volts. Hal l sensor
2 range s from approximately 0. 5 to 2.5 volts.

The throttle housing uni t ED K i s nonadjustable. I f found to b e faulty,

replace as a complete unit .

After replacing th e throttle housing , us e BMW scan too l to rese t

adaptation values .

CAUTION—
• If the adaptation process is not completed correctly, the engine
does not start.

— Switc h ignition OFF an d remov e key.

— Remov e air filter housing an d ai r intake ducts . Se e Ai r filter

housing an d ducts, removin g an d installing i n this repair group .
130-16 Fue l Injection MS45.1 (M54 Engine)
Throttle housing (EDK), replacing

. Working a t side of intake manifold, disconnect electrica l connectors:

• Intak e manifold resonance valv e (A)
• Idl e speed control valv e (B)

Disconnect electrical connectors at oil pressure sender an d oil

temperature sender at base of oil filter housing .

Working at left side and underneath intak e manifold :

• Detach electrica l connector (A) at fuel tank venting valve.
• Disconnec t hose at quick disconnect fittin g (arrow).
• Remov e valv e from manifold and set aside.

^V. Remov e wiring harness housing mounting fasteners

(arrows) and pull housin g away from throttle assembly.

— Remov e engine oil dipstick tube.

Fuel Injection MS45.1 (M5 4 Engine) 130-1 7
Idle speed control valve, replacing

Working at throttle housing, unscrew harness plug counterclockwise

(arrow) to disconnect .

, Remov e throttle housing mountin g fasteners (arrows) and pul l

assembly of f manifold.

— Installatio n is revers e of removal .

• Replac e profile gasket (sealin g O-ring) between throttle assembl y
and intake manifold .
• Reattac h throttle assembly connector with care. Arrow on fully
tightened connector must lin e u p with corresponding arro w o n
throttle assembly housing .

— Usin g BM W sca n tool:

• Check and clear fault codes fro m ECM memory .
• Rese t throttle adaptation .

Idle speed control valve, replacing

The idl e speed contro l valve, mounte d directl y above th e throttle
housing, regulate s idl e speed b y redirecting air around the throttle
valve. Th e valve, supplied wit h batter y voltage fro m the DM E main
relay, incorporates a two-coil rotary actuator. Coil ground s ar e
pulsed simultaneously b y the ECM . The duty cycle of each circuit is
varied to achieve the require d idl e speed.

A faulty idle speed contro l valve sets a DTC. The MI L illuminate s if

OBD I I fault criteria are exceeded .

Switch ignition OF F and remov e key.

Disconnect batter y negativ e (- ) cable i n cargo compartment .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings and Cautions.

Remove air filter housing an d air intake ducts. See Air filte r
housing an d ducts, removin g an d installin g in this repai r group .
130-18 Fue l Injection MS45.1 (M54 Engine )
Fuel rail and injectors, removing and installing

Working at side o f intake manifold :

• Disconnec t electrical connector to intake manifold resonance valve
(A).
• Disconnec t electrical connector t o idle speed contro l valve (B).
• Remov e upper wiring harness housin g mountin g fastener (C). Pull
harness housin g bac k slightly .
• Remov e idle speed valve mountin g bracke t screw s (D).
• Pul l idle regulator off intake manifold. I t is fitted to manifold using a
sealing grommet .

When reinstalling, replace rubber grommet. Coat grommet o n inside

with assembly lubricant , then install in manifold. Pres s idle valve into
place.
1. Intak e manifold
2. Intak e manifold resonanc e valv e
3. Sealin g grommet
4. Idl e speed contro l valv e
5. Mountin g bracke t
6. Rubbe r mounting

— Reattac h wiring harnesses. Reinstal l air filter assembly and ducts .

6-
— Chec k and clea r fault codes fro m EC M memory.

Z02130015

Fuel rail and injectors , removing and installing

Fuel injectors are electrically controlled solenoid valves that provid e
precisely metere d and atomized fue l into the engine intake ports.

Injectors receiv e voltage from the DM E mai n relay . The engin e

control module (ECM ) control s injecto r openin g by activating the
ground circuit for the injector valve solenoids . Th e ECM varies the
duration (i n milliseconds) of injector opening t o regulate air/fuel
ratio.

— T o access injectors , remove engine covers . See 020 Maintenance .

— Fo r a quick check o f injectors, ru n engine and touch each injecto r

with a screwdriver or stethoscope. You should feel a vibration or
hear a buzzing. Switc h engine OFF .

— Disconnec t battery negative (-) cable.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings an d Cautions.

— Remov e upper engine covers. See 02 0 Maintenance .

Fuel Injection MS45.1 (M54 Engine) 130-1 9
Fuel rail and injectors, removing and installing

Working above engine , detac h the following :

• B Resonance valve electrical connector
• C Oxygen senso r connectors
• D Electrical connector for intake ai r temperature senso r
• E Manifold vacuum lin e
• F VANOS solenoid electrica l connector

CAUTION—
• Be sure to mark oxygen sensor connectors so that they can be
reassembled as before.

Disconnect fue l injector electrical connectors from injectors :

• Use small screwdriver to pry one corner o f wire loc k clip on fuel
injector 1 connector.
• Repea t for all injectors.
• Lif t off connector loom and set aside.

Unscrew Schraede r valve cap (arrow) from fuel rail .

• Unscrew fue l tank cap to release pressure .
• Usin g a brief burs t of compressed air (maximum o f 3 bar or 43.5
psi), blow fuel back int o fuel tank.

WARNING —
• Wrap a clean shop towel around fitting before connecting.
Residual fuel pressure is present in the fuel rail.
130-20 Fue l Injectio n MS45.1 (M54 Engine)
Fuel rail and injectors, removing and installing

Working a t rear of manifold , us e BM W special tool 16 1 050 or

equivalent to press locking clip inside end of fuel line fitting (arrow)
to disconnect fuel supply line from fuel rail.

WARNING—
• Wrap a clean shop towel around fitting before disconnecting.
Residual fuel pressure is present in the fuel line.

Remove fuel rai l mounting bolt s (arrows).

• Carefull y pry fuel rail and injectors of f manifold.
• Separate fuel line support bracke t at rear of intake manifold .
• Guid e fuel line(s) out of rear of engine compartmen t whil e liftin g
fuel rail out.

Remove individual injectors:

• Pr y retaining clip from injector (1).
• Pul l injecto r from rail (2).

Installation is reverse of removal . Remembe r to:

• Fi t new sealing O-rings when installin g injectors . For ease of
installation, lightly lubricat e O-rings wit h assembly lubricant .
• Check that injecto r electrical connections ar e correctly fitted and
that injector s are fully seated prio r to installin g fuel rail mounting
bolts.
• Check fuel line rubber O-rings and replace as necessary. For ease
of installation, lightly lubricate O-rings with assembly lubricant.
• Replac e wire ties.

Tightening torque
Fuel rail to cylinder hea d 10Nm(7ft-lb)

— Chec k and clea r fault codes from ECM memory .

Fuel Injection MS45. 1 (M54 Engine) 130-2 1
Intake manifold, removing and installing

Intake manifold, removing and installing

Switch ignition OFF and remov e key.

Disconnect batter y negativ e (- ) cable.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings and Cautions .

— Remov e upper engine covers. See 020 Maintenance .

^V Workin g above engine, detac h the following:

• A B+ lead bracket
• B Resonance valve electrical connector
• C Oxygen sensor connector s
• D Electrical connector for intake air temperature senso r
• E Manifold vacuum lin e

CAUTION—
• Be sure to mark oxygen sensor connectors so that they can be
reassembled as before.

Working at left side o f cylinder head :

• Detac h engine ven t hos e from cylinder head cove r by pinching
spring clip s (arrows) .
• Detac h VANOS solenoid electrica l connector (A).

Detach fuel injector electrical connectors from injectors :

• Us e small screwdrive r to pry one corner of wire lock clip o n fuel
injector 1 connector.
• Repea t for all injectors.
• Remov e two mai n harnes s hold-dow n fasteners. Lift off entire
harness and la y aside .
130-22 Fue l Injectio n MS45.1 (M5 4 Engine )
Intake manifold, removing and installing

Working a t left side an d underneat h intak e manifold :

• Detac h electrica l connecto r (A ) at fuel tank ventin g valve .
• Disconnec t hos e a t quick disconnec t fittin g (arrow).
• Remov e valve from manifold an d set aside .

"X. Disconnec t electrica l connector (arrow ) at idle spee d contro l valve.

— Remov e throttl e housing. Se e Throttle housing (EDK) , replacin g

in this repair group .

Unscrew Schrsede r valve ca p (arrow ) from fuel rail.

• Unscre w fuel tank ca p to release pressure .
• Usin g a brief burst o f compressed ai r (maximum of 3 bar or 43. 5
psi), blow fuel back int o fue l tank.

WARNING —
• Wrap a clean shop towel around fitting before connecting.
Residual fuel pressure is present in the fuel rail.
Fuel Injection MS45.1 (M54 Engine) 130-2 3
Intake manifold, removing and installing

Working at rear of manifold, us e BMW special tool 16 1 050 o r

equivalent to press locking clip inside end of fuel line fitting (arrow)
to disconnect fue l supply lin e from fuel rail.

WARNING —
• Wrap a clean shop towel around fitting before disconnecting.
Residual fuel pressure is present in the fuel line.

Working underneath car , remov e lower intake manifol d suppor t

mounting bolt (arrow), located adjacent to lef t engine mount .

Detach knock sensor connector fro m bracket at base of manifold .

Remove manifold lower support nuts.

Remove intake manifol d mounting nuts (arrows).

Remove intake manifold from cylinder head while carefully checking

for electrica l connections or hoses that might becom e snagged .

CAUTION—
• Plug open intake ports to prevent parts or debris from falling into
the engine intake.

Note intake manifol d brackets and mounts:

1. Manifol d mounting nut s
•tighten to 1 5 Nm (11 ft-lb)
2. Fue l pip e bracke t
3. Fue l pipe bracke t
4. Vacuu m pump bracke t
5. Manifol d mounting bracke t
6. Tan k venting valve bracket
7. Mountin g bracke t to manifold bolt (M6)
•tighten to 10N m (7 ft-lb)
8. Mountin g bracket to engine bloc k nut (M10)
• tighten to 47 Nm (33 ft-lb)
130-24 Fue l Injection MS45.1 (M54 Engine )
Crankcase breather valve components

Intake manifol d installatio n i s reverse of removal.

• Us e new fuel injector seals .
• Carefull y check intak e manifold gaskets an d replac e i f necessary.
• Check condition of rubber seals at throttle housing and idle speed
control valve . Replace a s necessary .
• Inspec t O-ring sea l between mas s ai r flow sensor an d air filter
housing. To facilitate reassembly, coa t sea l wit h assembly fluid .

CAUTION—
• When reattaching throttle assembly harness connector, make
sure arrows on connector and plug line up when fully tightened.

Tightening torques
Intake manifol d to cylinder head (M7) 15Nm(11 ft-lb )
Mounting bracke t to engine bloc k (M10 ) 47 N m (33 ft-lb)
Mounting bracke t to intake manifol d (M6) 10 M m ( 7 ft-lb)

Crankcase breathe r valv e component s

1. Cylinde r head cove r
2. Connectin g hos e
3. Oi l return hose
4. Breathe r valv e
5. Vacuu m hos e
6. Dipstic k guide tube vent hos e
7. Dipstic k guide tub e
8. Ven t pipe
9. Scre w

The M54 engine crankcase is ventilated by breather valve under the

BX56130049!
intake manifold. If the diaphrag m valv e i n the breathe r housing
leaks, full intake vacuum may be applied to the crankcase, resulting
in excessive oil consumption, irregula r idle , whistling or howlin g
noises or oil smoke i n the exhaust .

To gain access to breather valve, remove air filter housing and

ducts. See Throttle housing , removin g an d installing i n this
repair group.

Engine coolant temperatur e (ECT ) sensor,

replacing
, Th e EC T sensor i s an NTC (negativ e temperatur e coefficient)
sensor. As coolant temperature rises, resistance through the sensor
decreases.

25T 24 YX60003 The EC M varies ignitio n timing an d air / fuel mixture base d on
engine coolant temperature. The EC T sensor i s supplied a 5 volt
reference voltage. The voltage drop acros s the sensor varies as the
coolant temperature (sensor resistance ) changes .

> \
Engine coolant
temperature (ECT)
sensor
202130009
Fuel Injectio n MS45. 1 (M5 4 Engine) 130-2 5
Radiator outlet coolant temperature sensor

If the EC T sensor inpu t i s faulty or not plausible, th e MI L i s

illuminated. The ECM assumes a substitute value (80° C /176°F) to
maintain engin e operation . Th e ignition timing is set to a safely
conservative basic setting.

The ECT sensor i s located below cylinder 6 intake port at the rear of
the engine, underneat h th e intak e manifold.

With engine fully cooled off, remove intake manifold. Se e Intak e

manifold, removin g an d installin g i n this repai r group .

Disconnect EC T sensor connecto r (arrow) .

Unscrew EC T sensor fro m cylinder head. B e prepared t o catc h

small amoun t o f coolant .

Installation is reverse of removal :

• Us e new copper sealin g washe r when installin g sensor .
• Replac e lost coolant.
• Check and clear fault code s from EC M memory.

Tightening torque
Temperature senso r to cylinder hea d 13 M m (10ft-lb )

Radiator outle t coolant temperature sensor

The radiato r outlet temperatur e sensor (inset ) i s an NTC (negativ e
temperature coefficient ) sensor. As coolant temperature rises ,
resistance through th e sensor decreases.

The EC M varies cooling fa n speed base d on radiator outle t coolant

temperature. The radiato r outle t coolan t temperatur e senso r i s
supplied a 5 volt referenc e voltage. The voltage dro p acros s th e
sensor varie s as the coolant temperatur e (senso r resistance )
changes.
130-26 Fue l Injection MS45.1 (M54 Engine )
DME main relay, testing

DME main relay, testing

The DME main relay is energized via the EC M and supplies battery
positive (B+) powe r to the following :
•ECM
• Ignitio n coils
• Fue l injectors
• Fue l tank lea k detection pum p
• Idl e air control valv e
• Camshaft sensors
• Evaporativ e emissions valv e
• Mas s air flow sensor
• Fue l pump relay
• Oxygen sensor heater s

If the DM E mai n rela y is faulty, the engine doe s no t start.

With ignition off, remove DM E main rela y (K6300) (arrow ) in

electronics bo x (E-box) at right rear of engine compartment .

NOTE—
• Relay locations can vary. Confirm relay identification by matching
wiring colors an d terminal numbers. Se e ELE Electrical Wiring
Diagrams.

*\k for voltage at terminal 6 of relay socket (corresponds to

DME main relay circui t terminal 30 on relay).
B+ junction point
(battery voltag e at all times)
— I f battery voltage i s present, continue testing .

K6300 — I f battery voltage i s not present , check th e following :

DME

G main relay • Larg e red wire in relay socket

• A2076 (battery positive junction) i n E-box, righ t rear of engine
compartment
• Fus e F 8 in fuse and relay panel above glov e compartment. See
Power supply fuse s i n this repai r group .
• See ELE Electrical Wiring Diagram s fo r more details

— Chec k for ground at relay socket 4 (correspond s to terminal 85 o n

A8680 [ relay).
Engine I IIF04 I IF°3 | F0 2 IF01I
electronics I NSOA I I20A U30A I30AI — I f ground is present, continue testing.
fuse carrier'
in E-box ' — B51 01 300008 — I f ground i s not present, signal fro m ECM i s missing. Chec k wire
between rela y and EC M 24-pin connector X60002 . Se e EC M pin
assignments (Siemen s DM E MS45.1) in this repai r group .

— I f no faults are found :

• Check EC M grounding.
• EC M may be defective.
 Fuel Injection MS45.1 (M54 Engine) 130-2 7
ECM pin assignments (Siemens DME MS45.1)

With ignition ON and rela y installed, chec k for battery voltag e a t

relay sockets 2 and 5 (correspond to terminals 87 on relay).

NOTE—
• In some models there is only one terminal 87.

If batter y voltag e i s present, relay has energized and i s functionin g

correctly.

If battery voltage i s not present and all earlier tests are OK , rela y is
faulty. Replace .

If n o faults are found during rela y testing but power is not reachin g
ECM or other components, chec k fuses in engine electronics fus e
carrier (A8680) in E-box. See fuses in ECL Elelctrical Componen t
Locations.

When finished testing, check for DTCs and clear and rese t EC M
memory.

ECM pin assignments (Siemens DME MS45.1 )

The engine control module (ECM ) (arrow) i s located in the right rear
of the engine compartmen t i n the E-box .

The EC M has 5 electrical connectors with a total of 134 pins :

• Connector 1 (X60001), 9 pins: Powe r and ground s
• Connector 2 (X60002), 24 pins: Ancillary signals (oxygen sensors,
CAN-bus, etc.)
• Connector 3 (X60003), 5 2 pins: Engin e signal s
• Connector 4 (X60004), 40 pins: Vehicle signal s
• Connector 5 (X60005), 9 pins: Ignitio n signals

ECM pin assignments for Siemens DME MS45.1 are given i n Table
45 b. This informatio n can be helpful when diagnosing fault s to or from
the ECM.

Generally, absence o f voltage o r continuity means ther e i s a wiring

or connector problem . Test results with incorrect values d o not
necessarily mea n tha t a component i s faulty. Check fo r loose ,
broken or corroded connections an d wiring before replacin g
components. Fo r engine managemen t syste m electrical
schematics, see ELE Electrical Wiring Diagrams .

When making checks at the ECM, use a break-out box to allow tests
to be made wit h the connector attached to the ECM . Thi s prevent s
damage t o the small terminal s in the connector. As an alternative ,
the connector housin g ca n be separated so that electrica l checks
can b e made from the back of the connector.

CAUTION—
• Wait at least one minute after switching the ignition OFF before
removing the connector from the ECM. If the connector is
removed before this time, residual power in the system relay
may damage the ECM.
• Connect or disconnect the control module connector and meter
probes with the ignition OFF.
 130-28 Fue l Injectio n MS45. 1 (M5 4 Engine )
ECM pin assignments (Siemens DME MS45.1)

Table b. Siemens DME MS45.1 ECM pin assignment s

Connector X60001 9-pi n (power, grounds)
Pin Type Component or function Note
1 Not used
2 - Not used
3 input / output TXD signa l Solder connecto r
4 ground ECM
5 ground ECM
6 ground ECM
7 input Power supply (termina l 30) Battery voltag e (B+) a t all times, fuse F10 5
8 input Terminal 87 , fuse F2 Voltage suppl y
- Not use d

Connector X6000 2 24-pi n (ancillary signals)

Pin Type Component or function Note
1 output Oxygen senso r heate r (pre-catalyst cyl. 1-3 ) Negative activatio n
2 output Oxygen senso r heate r (pre-catalys t cyl. 4-6) Negative activatio n
3 - Not use d
4 - Not use d
5 - Not used
6 output Oxygen senso r heate r (post-catalyst cyl. 1-3 ) Negative activatio n
7 input Oxygen senso r (pre-catalyst , cyl. 1-3 ) Negative Signa l
8 input Oxygen senso r (post-catalyst , cyl. 4-6) Negative Signa l
9 input Oxygen senso r (pre-catalyst , cyl. 4-6) Negative Signa l
10 input Oxygen senso r (post-catalyst , cyl. 1-3 ) Negative Signa l
11 - Not use d
12 output Oxygen senso r heate r (post-catalys t cyl. 4-6) Negative activatio n
13 input Oxygen senso r (pre-catalyst , cyl. 1-3 ) Signal
14 output Oxygen senso r (post-catalyst , cyl. 4-6) Signal
15 output Oxygen senso r (pre-catalyst , cyl. 4-6) Signal
16 output Oxygen senso r (post-catalyst , cyl. -3) Signal
17 - Not used
18 - Not use d
19 input Oxygen senso r (pre-catalyst , cyl. 1-3 ) Signal
^20 input Oxygen senso r (pre-catalyst , cyl. 1-3 ) Signal
21 input Oxygen senso r (pre-catalyst , cyl. 4-6) Signal
22 input Oxygen sensor (post-catalyst, cyl. 4-6 ) Signal
23 input DME system power supply, terminal 87 Battery voltage fro m DME main relay
Not use d
 Fuel Injectio n MS45.1 (M5 4 Engine ) 130-2 9
ECM pin assignments (Siemens DME MS45.1)

Connector X6000 3 52-pin (engine signals)

Pin Type Component or function Note
1 input Mass airflow sensor Signal
2 - Not use d

3 input Crankshaft sensor Signal

4 output Mass airflow sensor Voltage suppl y

5 output Throttle valve (EDK) Voltage suppl y

6 output Fuel injector 2 Pulsed groun d

7 output Fuel injector 4 Pulsed groun d

8 output Fuel injector 6 Pulsed ground

9 output VANOS solenoid exhaus t Signal

10 output VANOS solenoid intake Signal

11 output Fuel injector 5 Pulsed groun d
12 output Thermostat heating Signal

13 output Fuel injector 1 Pulsed groun d

14 ground Mass airflow senso r
15 ground Throttle valve (EDK)

16 ground Oil pressure switch

17 - Not used

18 - Not used

19 input / outpu t Alternator BS D Interface

20 - Not use d

21 output Fuel tank vent valv e Signal

22 output Idle speed control valve Signal
23 output Idle speed control valve Signal

24 - Not used

25 - Not used

26 output Fuel injecto r 3 Pulsed groun d

27 input Intake air temperature sensor Signal

28 input Coolant temperature sensor Signal

29 input Camshaft positio n sensor 1 Signal
30 input Camshaft position sensor 2 Signal
31 input Throttle position signal Throttle valv e (EDK)
32 input Throttle position signal Throttle valve (EDK)
33 input Knock sensor Double knock senso r
34 input Knock sensor, cyl. 4 - 6 Signal
35 ground Coolant temperatur e sensor

36 ground Camshaft positio n sensor 1

37 ground Crankshaft positio n senso r
 130-30 Fue l Injectio n MS45. 1 (M54 Engine )
ECM pin assignments (Siemens DME MS45.1)

Connector X60003 52-pi n (engine signals) (continued)

Pin Type Component or function Note
38 - Not use d
39 output Secondary ai r injection vacuum solenoi d Signal
40 output DISA changeover valv e Signal
41 - Not used
42 output Throttle valve (EDK) Signal
43 output Throttle valve (EDK) Signal
44 input Oil temperature sensor Signal
45 ground Oil temperature sensor Signal
46 input Knock sensor Double knoc k senso r
47 input Knock senso r Double knoc k sensor
48 - Not used
49 ground Camshaft positio n sensor 2
50 input Oil level sensor Signal
51 - Not used
52 - Not use d

Connector X60004 40-pin (vehicle signals)

Pin Type Component or function Note
1 - Not use d
2 output Diagnostic modul e tank leak (DM-TL) detection Signal
3 output Secondary ai r injection pump rela y Signal
4 input Electric cooling fan Signal
5 ground Mass ai r flow sensor
6 - Not use d
"7
ground Pedal positio n sensor
^8 input Pedal positio n senso r 1 Signal
9 output Pedal positio n sensor Voltage suppl y
10 output Fuel pum p rela y Signal
11 - Not use d
12 ground Pedal positio n senso r
13 input Pedal positio n senso r 2 Signal
14 output Pedal positio n sensor Voltage suppl y
15 Input Mass ai r flow sensor Signal
16 - Not use d
17 output Crankshaft speed signa l OBD I I connector o r 20-pin DL C
18 - Not use d
19 output E-box cooling fan Signal
 Fuel Injectio n MS45. 1 (M5 4 Engine ) 130-3 1
ECM pin assignments (Siemens DME MS45.1)

Connector X60004 40-pin (vehicle signals) (continued)

Pin Type Component or function Note
20 output Diagnostic modul e tan k lea k (DM-TL ) detectio n Signal
21 output Radiator shutter solenoi d Signal
22 input Wheel speed senso r Signal
23 input Clutch pedal positio n switc h Signal
24 input Brake light switch Signal
25 - Not use d
26 input Terminal 15 , fuse F3 1 (wake up signal) Switched powe r
27 - Not used
28 input Brake light switch Signal
29 - Not use d
30 input Fuel tank leakage diagnosi s pum p (DM-TL ) Signal
31 - Not use d

32 - Not use d
33 input EWS (electronic immobilizer ) Car access syste m
34 - Not used
35 - Not use d
36 input/output CAN-bus hig h Signal
37 input/output CAN-bus low Signal
38 ground Radiator coolant outlet temperature senso r

39 input Radiator coolant outlet temperature sensor Signal

40 input Start signa l Car access syste m

Connector X60005 9-pin (ignition signals)

Pin Type Component or function Note
1 output Ignition coil 5 Signal
2 - Not used
3 - Not use d
4 output Ignition coil 3 Signal
5 ground ECM groun d
6 ground Ignition coi l 1
7 output Ignition coil 2 Signal
8 output Ignition coi l 4 Signal
9 output Ignition coil 6 Signal
 131-1

131 Fue l Injection MSV70, MSV80

(N52 Engine )

GENERAL 131- 1 Mass air flow sensor, replacing 131-1 2

DME applications 131- 2 Throttle housing (EDK), replacing 131-1 3
Warnings and Cautions 131- 3 Valvetronic motor , removing and installing . . 131-1 4
Fuel rail and injectors,
DRIVEABILITY TROUBLESHOOTING 131- 5 removing and installing 131-1 5
Basic engine settings 131- 5 Intake manifold, removing and installing . . . . 131-1 7
System voltage 131- 5 Crankcase breather valve 131-2 0
Main grounds 131- 6 Crankcase breather heating 131-2 0
On-board diagnostics 131- 6 Engine coolant temperature (ECT) sensor,
ENGINE MANAGEMEN T FUSES replacing 131-2 2
AND POWER SUPPL Y COMPONENT S 131- 7 Radiator outlet coolant temperature sensor . . 131-2 2
Power supply fuses 131- 7 DME main relay, testing 131-2 3
ECM pin assignments 131-2 5
SIEMENS DME MSV70 , MSV80
(N52 ENGINE ) 131- 8 TABLE

DME engine management a. 5 Series engin e managemen t application s 130- 4

system description 131- 8 b. Siemens DME MSV70 MSV80 ECM
Air filter housing and ducts, pin assignments 130-2 5
removing and installing 131-1 1
Mass air flow, measurement 131-1 2

GENERAL
This repai r group covers service and repair o f engine managemen t
systems for 5 Series model s wit h N52 engine and Siemens DME
MSV70 or MSV80.

See also:
• 020 Maintenance for air filter, fuel filter and spark plu g
replacement
• 100 Engine-General for engine identification an d applicatio n
information
• 120 Ignition System for ignition coil, camshaft sensor, crankshaf t
sensor and knock sensor service
• 160 Fuel Tank and Fuel Pump for fuel pump and fuel pump rela y
service, fuel pressure test s and fuel pressure regulato r
replacement
• 180 Exhaust System for oxygen sensor servic e
• ECL Electrical Component Location s
• ELE Electrical Wiring Diagram s
• OBD On-Board Diagnostics
131 -2 Fue l Injection MSV70, MSV80 (N52 Engine)
DME applications

DME applications
BMW 5 Series models ar e equipped wit h digital motor electronic s
(DME), also known as Motronic. In these systems, fuel injection and
ignition are controlled by an integrated engine control module
(ECM). Application informatio n for DME systems is in Table a.

Table a. 5 Series engine management applications

Year, model Engine Engine (Feature s
code management

2004-2005
Sedan: 525i, 530i M54 Siemens Double VANOS
MS 45.1
Sedan: 545i N62 Bosch DME Valvetronic,
ME 9.2 with VANOS
Valvetronic
control modul e

2006 - 2007
Sedan, N52 Siemens MSV7 0 Valvetronic,
Sports Wagon : VANOS
525I, 525xi,
530I, 530xi
Sports Wagon
2008-2010
Sedan, N52KP Siemens MSV80 Valvetronic,
Sports Wagon: VANOS
528i, 528x i
Sedan, N54 Siemens MSD80 VANOS,
Sports Wagon : (to 03 / 2008 ) turbocharged
535i, 535x i MSD81 (fro m
03 / 2008)
2004-2005
Sedan: 545i N62 Bosch DME Valvetronic,
ME 9.2 with VANOS
valvetronic
control uni t
2006-2010
Sedan: 550 i N62TU Bosch DM E Valvetronic,
ME 9. 2. 2 VANOS
Fuel Injection MSV70, MSV80 (N52 Engine) 131- 3
Warnings and Cautions

Warnings and Caution s

WARNING —
• The fuel system is designed to retain pressure even when the
ignition is OFF. When working with the fuel system, loosen the
fuel lines slowly to allow residual fuel pressure to dissipate.
Avoid spraying fuel. Use shop towels to capture leaking fuel.
• Fuel in fuel lines is underpressure (approx. 3 - 5 bar or 45 - 75
psi) and may be expelled forcibly. Do not smoke or work near
heaters or other fire hazards. Keep a fire extinguisher handy.
• Unscrew the fuel tank cap to release pressure in the tank
before working on fuel lines.
• Plug open fuel lines and fittings.
• Before beginning work on the fuel system, place a fire
extinguisher in the vicinity of the work area.
• Work on the fuel system only when engine temperature is
below 40°C(104°F).
• Fuel is highly flammable. When working around fuel, do not
disconnect wires that could cause electrical sparks. Do not
smoke or work near heaters or other fire hazards.
• Wear eye protection and protective clothing to avoid injuries
from contact with fuel.
• When working on an open fuel system, wear suitable hand
protection, as prolonged contact with fuel can cause illnesses
and skin disorders.
• Unscrew the fuel tank cap to release pressure in the tank
before working on fuel lines.
• Do not use a work light with an incandescent bulb near fuel.
Fuel may spray on the hot bulb causing a fire.
• Make sure the work area is properly ventilated.
• Due to risk of personal injury, be sure the engine is cold before
beginning work on engine components.
• The ignition system produces high voltages that can be fatal.
Avoid contact with exposed terminals. Use extreme caution
when working on a car with the ignition switched ON or the
engine running.
131-4 Fue l Injection MSV70, MSV8Q (N52 Engine )
Warnings and Cautions

CAUTION—
• Renew fuel system hoses, clamps and O-rings any time they
are removed.
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings and Cautions.
• Connect and disconnect the DME system wiring and test
equipment leads only when the ignition is switched OFF.
• Wait at least 1 minute after switching the ignition OFF before
disconnecting engine control module (ECM) connectors. If the
connectors are removed before this time, residual power in the
system relay may damage the control module.
• Tests or repair procedures in this section may set fault codes
(DTCs) in the ECM and illuminate the MIL. After repairs are
completed, access and clear DTC memory using a BMW scan
tool. SeeOn-board diagnostics i n this repair group.
• Fuel system cleaners and other chemical additives other than
those specifically recommended by BMW may damage
catalytic converters, oxygen sensors or other fuel supply
components.
• Do not connect any test equipment that delivers a 12-volt
power supply to terminal 15 (+) of the ignition coils. The current
flow may damage the ECM. Connect test equipment only as
specified by BMW or the equipment maker.
• Relay positions can vary. Be sure to confirm relay location and
function by identifying the wiring in the socket using the wiring
diagrams found in ELE Electrical Wiring Diagrams .
• Use a digital multimeter for electrical tests. Use an LED test
light for quick tests.
Fuel Injectio n MSV7Q , MSV8 Q (N52 Engine ) 131- 5
Basic engine settings

DRIVEABILITY TROUBLESHOOTING
The self-diagnostic DME engine management system s monito r and
store diagnostic troubl e codes (DTCs) . If the malfunctio n indicato r
light (MIL) illuminates, it indicates that an emissions-related faul t has
occurred and that one or more DTCs are stored in the engine control
module (ECM) .

C I f faults arise, or i f the MI L i s illuminated, begin troubleshooting b y

connecting BM W scan tool to the OBD II plug under the dashboard .

The capabilities of OBD I I software has the potential to save hours of

diagnostic tim e and to help avoid incorrect component replacemen t
and possible damag e t o system components. See On-board
diagnostics i n this repair group.

Basic engin e setting s

Idle speed , idl e mixture (%CO), and ignition timing are not
adjustable. Th e DM E system is adaptive and automaticall y
compensates for changes i n the engine due to age, mino r wea r or
small problems such as a disconnected vacuum hose . However, the
adaptive range i s limited. Onc e the limits are exceeded, driveabilit y
problems becom e noticeable .

Poor initial driveability may be encountered when th e batter y is

disconnected and reconnected . When the battery is disconnected ,
ECM adaptive memor y may be reset. The system readapt s afte r
about ten minute s o f driving.

System voltag e
Digital motor electronic s (DME ) require s that the system (battery)
voltage be maintained withi n a narrow range of D C voltage. D C
voltage levels beyon d or below th e operating range, o r any AC
voltage i n the electrical system can cause havoc .

• Whe n troubleshooting a n illuminate d MIL, mak e sure the batter y is

fully charged an d capable o f delivering all its power to the electrical
system. An undercharge d batter y can amplify AC alternator outpu t
ripple.

To make a quick check o f battery charge, measure voltage across

battery terminals wit h all cables attached an d ignition OFF. A fully
charged batter y measures 12. 6 volts or slightly more , compare d t o
12.15 volts for a battery with a 25% charge.

The DME system operates at low voltage and current levels , makin g
it sensitive to small increase s in resistance. The electrical system i s
routinely subject to corrosion, vibration and wear, so faults or
corrosion in the wiring harness an d connectors are no t uncommon .

Check batter y terminals for corrosion or loose cable connections .

See 12 1 Battery, Starter , Alternator.
131-6 Fue l Injection MSV7Q , MSV8Q (N52 Engine )
Main grounds

If a battery cable connection ha s no visible faults but is still suspect,

measure voltage drop across the connection. A large drop indicates
excessive resistance, meaning tha t the connection is corroded, dirty
or damaged. Clean or repair and retest. Se e 600 Electrical
System-General fo r voltage dro p test procedure .

Visually inspec t wiring, connectors, switches and fuses. Loose or

damaged connector s can cause intermitten t problems , especially
small terminal s i n ECM connectors. Disconnec t wirin g harnes s
connectors to check for corrosion, and us e electrical cleaning spray
to remove contaminants.

Main ground s
Good grounds are critical to proper DM E operation . I f a ground
connection has no visible faults bu t is still suspect, measure the
voltage dro p across the connection. A large voltage drop means
high resistance. Clean or repair the connection and retest .

For voltage drop testing, see 600 Electrica l System-General .

For ground locations, se e ECL Electrica l Componen t Locations .

On-board diagnostic s
Second generation on-boar d diagnostics (OB D II ) software an d
hardware is incorporated i n the engin e managemen t systems . Th e
OBD II system monitor s components that influence exhaus t an d
evaporative emissions. I f a problem i s detected, the OB D I I system
stores the associated diagnosti c troubl e code (DTC) an d condition.

If vehicle emissions level s exceed 1. 5 times Federall y mandate d

criteria, the OBD II system illuminate s a malfunction indicato r ligh t
(MIL) in the instrumen t cluster .

Scan tool connected to OBD I I plug belo w lef t dashboard.

Professional diagnostic sca n tools availabl e a t the time of this

printing includ e the BMW GT1, IST A and a small number of
aftermarket BMW-specific tools.

In addition to professional scan tools, there are inexpensive generic

OBD I I scan tool software programs an d handhel d unit s available.
Although these hav e limited capabilities a s compared to the
dedicated tools, they are powerful diagnosti c tools.

For the DI Y owner, a simple aftermarke t DTC reader is available

through http://www.peakeresearch.com. Thi s tool is capable of
checking for DTCs as well as switching the illuminated MIL OFF and
resetting service indicator lights.

NOTE—
• OBD II DTC memory (including an illuminated MIL) can only be
reset using a BMW scan tool or equivalent. Removing the
connector from the ECM or disconnecting the battery does not
erase DTC memory.
Fuel Injectio n MSV70 , MSV8 0 (N5 2 Engine ) 131- 7
Power supply fuses

ENGINE MANAGEMEN T FUSES

AND POWE R SUPPLY COMPONENTS
Power suppl y fuse s
See EC L Electrical Componen t Location s for fuse panel acces s
information.

^ Rea r distribution pane l (A46 ) in trunk, installed in right rea r fender:

• F9 0 200A: Powe r supply t o fuse panel A41a.

A41a: fuse and relay panel behin d glove compartment :

• F8 60A:
Engine contro l module (ECM ) (A6000)
ECM main rela y (K6300 )
Engine electronic s fuse carrier (A8680)
Engine electronics fuse carrier (A8681)

See ECL Electrical Component Location s for specific vehicle fuse

locations.

Engine electronics fuse carrier A8680 (arrow).

131 -8 Fue l Injection MSV70, MSV80 (N52 Engine)
DME engine management system description

SIEMENS DME MSV70 , MSV80

(N52 ENGINE )
DME engine management syste m description
The DM E manages an d monitors the following functions:

Air

• Electroni c throttle
• Mas s airflo w
• Resonance-turbulenc e intak e contro l
• Valvetronic II

Fuel
• Fue l suppl y
• Fue l injectio n

Ignition
• Direc t ignitio n
• Knoc k contro l
• Primar y / secondary ignitio n monitorin g

Emissions
• OBD II complianc e
• Pr e and post-catalyst oxygen sensor s
• Electricall y heate d DME-mappe d thermosta t
• Misfire detectio n
• Evaporativ e emissio n contro l and leak detectio n
• Malfunctio n indicato r ligh t (MIL )

Performance controls
• Dua l VANO S contro l
• Output of injection signal (Tl) for fuel economy gauge
• Output o f engine rpm (TD) fo r tachomete r
• A/C compressor contro l
• Electri c radiato r coolin g fan
• CAN-bus communicatio n
• Dynami c stabilit y control (DSC) interfac e
• CA S (car access system ) - EWS 3.3
• Cruise control
• EC M programming
 Fuel Injection MSV70, MSV8 0 (N52 Engine ) 131- 9
DME engine management system description

Engine control module (ECM)

. Th e engin e control module (ECM ) (arrow) is mounted i n th e
electronics box (E-box) at the righ t rear of the engin e compartment.

The EC M is flash-programmable and features 2 main electrica l

harness connectors, one with 4 modular connections an d the other
with 3 for a total of 7 subconnectors and 14 7 pins .
\ 23 4 ^\ ^5 6 1 4 26 \r~ :"";A;;:;;:
E __ • A: X60001 (signals )
1•
7 121 42
2
6
2 _, « 1 1 3
• B: X60002 (signals)
Bt
\ "2 f*"** ' """i5 /
u— m m m m P g , ^, K««»KK«St* G M HI M

J 2 1 6 1 i y • C: X60003 (voltage , ground supply)

• D: X60004 (valvetronic)
• E: X60005 (signals)
b3091300002
• F : X60006 (ignition coils)
• G: X60007 (signals)

The EEPRO M (chip ) i n the EC M is coded to the vehicle. The EC M

cannot be swapped for testing purposes.

Fuel metering

The ECM meters pressurized fuel by changing th e opening tim e

(pulse width) of the fuel injectors. The exact amount of fuel injected
is determined b y the amount of time the injectors are open . To
ensure that injector pulse width is the only factor that determines fuel
metering, fuel pump pressure is maintained by a pressure regulator.
The injectors are mounted to a common fuel rail.

The fuel injectors are mounted into a machined bor e i n the cylinder
head. This design allows the fuel injectors to be closely mounte d to
the intak e valves.

The injectors are a compact desig n manufactured by Deka with a

resistance value of approximately 1 2 ohms each.

The ECM monitors engine operating conditions to determine injector

opening duration. Each injecto r can be individually controlled for
Intake valve cylinder selective fue l trim.
I

b3091300003
131-10 Fue l Injection MSV70, MSV80 (N52 Engine)
DME engine management system description

Air intake
Air enterin g the engine passe s through a pleated paper element in
Valvetronic H the air filter housing. Intake air mass is then measured by a mass air
flow sensor. A reference current is used t o heat a thin film in the
1 sensor when the engine is running. The current needed t o hold the
/" ! I ~%
HFM
. , .;• • —\
: : v '
temperature of the film constant is used to calculate the mass of the
intake air.
1. Ai r mass measurement (HFM )
2. Throttle valve
3. Intake manifold
4. Variabl e intake valve lift (Valvetronic )
5. Residua l oxygen measurement i n exhaust
ECM
6. Intak e manifol d vacuum
7. Engin e speed
b3091300004
8. Injectio n timing

Idle speed control

The EC M controls Idle speed by varying intak e valve lif t via the
Valvetronic system.
1. Valvetroni c motor
2. Retur n spring
3. Intak e camshaft
4. Intermediat e lever
5. Intak e rocker arm
6. Intak e valve

Idle speed is not adjustable. The basi c functions and parameters of

idle speed control are as follows:
• Contro l of cold air intake volume.
• Smooth idle speeds regardles s of load and inputs.
• Smooth transition from acceleration to deceleration.

Idle speed stabilization is active during the following conditions:

• Engin e warm up
!'..if'II 300006
• Heatin g or A/C activation
• Driv e gear selected (automatic transmission)
• Varying cooling fan speeds

Throttle control
The throttle module (EDK ) is not needed for engine load control.
Which i s carried out by the Valvetronic function of the ECM .
However, the throttle ma y be slightly closed to allow sufficient
manifold vacuum for the crankcase ventilation an d canister purge
systems.
Fuel Injectio n MSV70, MSV8 0 (N52 Engine ) 131-1 1
Air filter housing and ducts, removing and installing

Knock (detonation) control

Knock sensors monitor and control ignition knock through the ECM .
The knoc k sensors function like microphones an d are able to
convert mechanica l vibratio n (knock ) int o electrical signals. Th e
ECM is programmed to react to frequencies that are characteristic of
engine knock an d adapt the ignition timing point accordingly.

Knock sensor replacemen t is covered in 120 Ignition System .

Air filter housin g and ducts,

removing an d installin g
For air filter element replacement, see 020 Maintenance.

"X. Workin g a t air filter housing :

• Loose n hos e clamp (A ) at mass air flow sensor an d detach ai r
intake duc t (B ) from filter housing.
• Remov e filter housing mounting bolts (arrows) and lift housing out
of engin e compartment .

^ Disconnec t hos e (A) from duct. Loose n duc t clamp (B) . Remov e
duct (C ) from throttle body.

— Installatio n is reverse of removal .

— Afte r reinstalling , check and clea r fault codes from EC M memory .

131 -12 Fue l Injection MSV70, MSV8 0 (N52 Engine )
Mass air flow, measurement

Mass ai r flow, measuremen t

3 Series non-turb o engine s utiliz e two different ai r mas s
measurement systems .

Analog mas s air flow sensor i s used i n models produce d t o

09 / 2006. The sensor, incorporating an electrically heated film in the
air flow stream, send s t o the EC M a varying voltage (approx . 0.5 -
4.5 volts) representin g the mass o f the intak e air.

The EC M provides operatin g voltage an d ground t o the air flow

sensor. As air flows through the sensor , th e film i s cooled. To
maintain the film at a constant temperature , additiona l curren t is
necessary. It is this additional current tha t i s the basi s for the input
signal.

If there i s no output signal from the ai r flow sensor , the EC M

B510130Q0016 operates the engine using throttle position and engine rpm inputs. A
faulty air flow sensor illuminates the MIL .

Digital mas s air flow sensor i s used i n models fro m 09 / 2006. In

this system, a duty cycle signal corresponds t o changes i n intake air
mass. This eliminate s th e need for signal conversio n i n the ECM.

The intake air temperature sensor is integrated into the mass air flow
sensor. The sensor i s an NTC thermistor whic h receive s a 5 volt
reference current and ground from the ECM .

A faulty air flow sensor can produc e th e following problems:

• Difficul t to restart when engin e i s hot.
• Engine starts then stalls.
• Engin e starts and runs only with accelerator peda l depressed.

B51013000017

Mass ai r flow sensor, replacin g

— Switc h ignition OF F an d remov e key.

^V Workin g at left front of engine compartmen t a t air filter housing:

• Detac h mas s ai r flow sensor electrical connector (A) .
• Remov e fasteners (arrows) .
• Remov e mass ai r flow sensor (B) .

— Chec k intake ducts for cracks and vacuu m leaks .

 Fuel Injectio n MSV70, MSV8 0 (N5 2 Engine ) 131-1 3
Throttle housing (EDK), replacing

'X, Installatio n i s reverse of removal.

• Inspec t O-ring (arrow) and replace if necessary.

— Afte r reinstalling, check and clea r fault codes from ECM memory .

Tightening torques
Mass air flow sensor to housing 3 N m (26 in-lb )

Throttle housin g (EDK) , replacin g

The throttle housing (EDK) i s not used for engine loa d control.
Which is carried out by the valvetronic function of the ECM .
However, th e throttle ma y be slightly closed to allow sufficien t
manifold vacuum for the crankcase ventilation and canister purg e
systems. There is no mechanical (cable ) lin k between the
accelerator pedal and the throttle plate .

The accelerator pedal modul e (PWG ) at the peda l assembl y

communicates peda l position directly t o the ECM. Th e module
PWG modul e
(Hall sensors ) provides two variable voltage signals (via two Hall sensors ) t o the
ECM for pedal positio n and rat e of movement.

The ECM provides an independent voltag e and ground suppl y for

each hall sensor. Eac h Hal l sensor is provided with 5 volts and
Accelerator ground. As the accelerator peda l i s moved from res t to full throttle ,
j peda l the sensors produc e a variable voltage signal.

Power The output of the Hall sensors is checked for plausibility. The voltage
to PWG range of Hall sensor 1 is approximately 0.5 to 4.5 volts . Hal l senso r
module
2 range s from approximately 0.5 to 2.5 volts.

The throttle housing uni t is nonadjustable. If found to b e faulty,

ECM replace as a complete unit .
b309 13000 17
After replacin g the throttle housing, us e BMW scan too l o r
equivalent to reset adaptation values .

CAUTIOtt-
• If the adaptation process is not completed correctly, the engine
does not start.

— Switc h ignitio n OF F an d remov e key.

— Remov e air filter housing and ai r intake ducts. See Ai r filter

housing and ducts, removing an d installing in this repair group.
131-14 Fue l Injection MSV70, MSV80 (N52 Engine )
Valvetronic motor, removing and installing

^k Workin g at left side of intake manifold :

• Disconnec t electrica l connector (A).
• Remov e fasteners (arrows) and remove throttle housin g (B).

— Installatio n i s reverse of removal .

— Replac e profil e gasket (sealin g O-ring) betwee n throttl e assembly

and intake manifold .

Tightening torques
Throttle housin g to intake manifol d 9 Nm (8 0 in-lb)

Reattach throttle assembly connector with care. It is possible to twist

the connector before pluggin g i t in. This can cause damage t o the
harness and connector.

After reinstalling, chec k and clear faul t codes fro m ECM memory .
Reset throttle plate adaptation values following scan tool on-screen
instructions.

Valvetronic motor, removing and installing

Switch ignitio n OFF and remov e key.

Remove uppe r and lower cabin microfilte r housings. See

020 Maintenance .

Remove ignitio n coil cover. See 020 Maintenance .

Disconnect batter y negative (- ) cable.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings an d Cautions.

Disconnect ignitio n coil electrical connectors and remove ignition

coil overlay harness (arrows) .

Gently screw valvetronic moto r i n clockwise direction (arrow) until

you feel resistance of the eccentri c shaft stop.
Fuel Injection MSV70, MSV80 (N52 Engine) 131-1 5
Fuel rail and injectors, removing and installing

Remove valvetronic moto r fasteners (arrows) and Valvetronic moto r

support bracke t fastener (inset).

Gently screw valvetronic motor in counterclockwise direction whil e

sliding moto r out of cylinder head cover (arrow) .

Installation i s reverse of removal. Remembe r to :

• Replac e aluminum fasteners.
• Rout e ignition harness correctly

Tightening torque
Valvetronic motor to cylinder hea d 4Nm (2 9 ft-lb)

— Afte r reinstalling, check and clear fault codes from EC M memory.

Fuel rai l and injectors, removin g an d installin g

Fuel injectors are electrically controlled solenoid valves that provide
precisely metere d and atomized fuel into the engine intak e ports .

Injectors receiv e voltage from the DM E main relay . The engin e

control module (ECM) control s injector opening by activating the
ground circui t for the injector valve solenoids. The EC M varies the
duration (in milliseconds) o f injector opening to regulat e ai r / fuel
ratio.

— Switc h ignitio n OFF and remov e key.

— Remov e upper an d lowe r cabin microfilte r housing. Se e

020 Maintenance .

— Remov e ignitio n coil cover. See 020 Maintenance.

— Fo r a quick check o f injectors , run engine and touch each injecto r

with a screwdriver or stethoscope. You should feel a vibration or hear
a buzzing. Switch engine OFF .
131-16 Fue l Injection MSV70, MSV80 (N52 Engine )
Fuel rail and injectors, removing and installing

— Disconnec t batter y negativ e (- ) cable .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings and Cautions.

Working above engine, detach oxyge n senso r connector s (A ) and

unclip wiring harness from holder .

CAUTION—
• Be sure to mark oxygen sensor connectors so that they can be
reassembled as before.

Unscrew schraeder valve cap (arrow) from fuel rail. Connect air line
adapter (A) to fitting.
• Unscre w fuel tank cap to release pressure .
• Usin g a brief burst o f compressed air (maximum o f 3 bar or 43.5
psi), blow fuel back int o fuel tank.

WARNING—
• Fuel in the fuel line is under pressure (approx. 3 - 5 bar or 45 -
75 psi) and may be expelled forcibly. Do not smoke or work near
heaters or other fire hazards. Keep a fire extinguisher handy.
• Unscrew the fuel tank cap to release pressure in the tank before
working on the fuel line.
• Plug open fuel lines and fittings.

Working above engine :

• Remov e and detach fue l line (A) .
• Disconnec t connecto r stri p (B ) in direction o f arrow.
• Remov e fasteners (arrows).
• Remov e fuel rail (C).

WARNING —
• Wrap a clean shop towel around fitting before disconnecting.
Residual fuel pressure is present in the fuel line.
Fuel Injection MSV70, MSV80 (N52 Engine ) 131-1 7
Intake manifold, removing and installing

Remove individual injectors:

• Pr y retaining clip from injector (A).
• Pul l injector from rail (arrow).

Installation i s reverse of removal . Remember to:

• Fi t new sealing O-ring s when installin g injectors. For ease of
installation, lightl y lubricat e O-rings with assembly lubricant .
• Check that injector electrical connections are correctly fitted and
that injector s are fully seated prio r to installing fuel rai l mounting
bolts.
• Replac e wire ties.

b3091300022
Tightening torque
Fuel rail to cylinder hea d 10Nm(7ft-lb)

After reinstalling , check and clear fault codes from ECM memory .

Intake manifold, removing and installing

Disconnect batter y negativ e (- ) cable in cargo compartment .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings and Cautions.

— Remov e upper engine covers . See 020 Maintenance .

— Remov e air filter housing and ai r intake ducts. Se e Ai r filter

housing an d ducts, removin g an d installing i n this repai r group .

"^ Remov e and discard tension strut fasteners (arrows). Remove

tension strut (A).

Working at left side and underneat h intak e manifold :

• Ope n harness holder (B).
• Disconnec t electrica l connector (A).
• Releas e bot h crankcase breathe r connections (C,D).
131-18 Fue l Injection MSV70, MSV80 (N52 Engine)
Intake manifold, removing and installing

Working a t left side an d underneat h intak e manifold:

• Disconnec t electrica l connectors (A,C) .
• Remov e fastener s (D) .
• Detac h engin e wirin g harness (B ) from intake manifol d an d lay
aside.

Disconnect electrica l connector (A ) a t oil pressure switc h (B).

Working above engine , detac h oxyge n senso r connectors (A) and

unclip wiring harness from holder.

CAUTION—
• Be sure to mark oxygen sensor connectors so that they can be
reassembled as before.
Fuel Injection MSV70, MSV80 (N52 Engine) 131-1 9
Intake manifold, removing and installing

Working above engine :

• Remov e and lay fuel rail (B) aside. D o not disconnect fue l line .
• Remov e fastener (A).
• Remov e nut s (C).

Raise intak e manifol d approximatel y 1 0 cm ( 4 in). Working

underneath:
• Disconnec t electrica l connector (A).
• Releas e fuel tank ven t line (arrow) behind throttl e valve assembly .
• Rais e and remove intak e manifold .

CAUTION—
• Plug open intake ports to prevent parts or debris from falling
into the engine intake.

— Installatio n i s reverse of removal . Remembe r to replac e al l seals .

Tightening torque
Manifold to cylinder hea d 15 N m (1 1 ft-lb )
Tension strut to body (M8)
replace fasteners 30.5 N m (22.4 ft-lb)
131-20 Fue l Injectio n MSV70 , MSV80 (N5 2 Engine )
Crankcase breather valve

Crankcase breather valve

N52 engine crankcase is ventilated b y either a breather valve under
the intake manifold or a breather valv e integrate d i n the cylinder
head cover. Engine s wit h a metal cylinde r hea d cover utiliz e an
external breather valve, engines wit h a plastic valve cover utilize an
internal breather valve.

External crankcase breather

, Th e crankcas e ventilation system ha s an electrically heate d
crankcase breathe r valve. The pressure contro l valve and cyclonic
oil separator are combined int o on e unit . The assembl y i s located
under the intake manifol d (arrow).

The pressure control valv e varie s th e vacuum applie d to the

crankcase breather depending o n engine load . The valve is
balanced betwee n spring pressure an d the amount o f manifold
vacuum.

At idl e when the intak e manifold vacuu m i s high, vacuu m reduce s

the valve opening, allowin g a small amoun t o f crankcase vapor s to
be drawn into the intak e manifold .

At part to full load conditions when intak e manifol d vacuum i s lower,

the spring opens the valve an d additional crankcase vapors are
b3091300031 drawn into the intake manifold .

Crankcase breathe r heatin g

Integrated into the design o f the crankcas e breathe r valve is an
electric heatin g system (arrow ) designed t o prevent moisture
buildup. Moistur e buildu p ca n eventuall y lea d to ice at low ambien t
temperatures leadin g t o malfunctions o f the crankcase breather
valve. The crankcase breathe r valv e i s insulated by a protective
foam covering to provide additional shelter from low ambient
temperatures.

The heating elements are integrated int o the crankcase ventilatio n

valve and hose assemblies. Ther e i s a junction point on the intake
manifold which provides a connection poin t for the individual heating
elements.

There is also a heating element locate d on the centrally located port

on the intake manifold. This por t i s also provide d with a separate
heating circui t controlled by a PTC thermistor. For wiring schematic
ELE Electrical Wiring Diagrams .
b3091300029
 Fuel Injection MSV70, MSV80 (N52 Engine) 131-2 1
Crankcase breather heating

Integrated crankcase breathe r

. Th e interna l crankcas e ventilation system is integrated int o th e
plastic cylinder hea d cover. The crankcase breather valve i s part of
the cylinder hea d cover and is not serviceable as a separat e
component.

Oil separation i s carried out via a labyrinth system and two cyclon e
separators incorporate d int o the cylinder head cover. By having the
system components integrate d into the cylinder hea d cover , th e
crankcase gases ar e heate d by the engine rathe r tha n a n electric
heater as on the external system. However , there is still one electri c
heating element at the manifold inlet. Once the liquid oil is separated
/ Integrate d from the crankcase vapors, the oil is allowed to drain bac k throug h
crankcase breathe r check valves back int o the engine.

If the diaphragm valv e in the breathe r housing leaks , full intake

vacuum ma y be applied to the crankcase, resultin g i n excessive oi l
consumption, irregula r idle, whistling or howling noises o r oil smok e
in the exhaust .

Crankcase pressur e specifications for N52 engine s

The pressure control valve sets the following pressure range :
• N5 2 24 to 28 mbar
• N52 K 28 to 32 mbar

Deviation to the current ambient pressure : +20 mbar to -60 mba r

A faulty crankcase breather valve causes significant deviations from

the specified value:
• Crankcase ventilation clogged: Ambien t pressure +100 mba r
• Crankcase ventilation interna l leak: ambient pressur e -17 0 mba r

To gain access to external breather valve, remov e throttl e housing .

See Throttle housing , removin g and installing i n this repai r
group.

To replace internal breather valve. Replace cylinder head cover. See

113 Cylinder Head , Remova l and Installation .
131-22 Fue l Injectio n MSV70, MSV80 (N52 Engine)
Engine coolant temperature (EOT) sensor, replacing

Engine coolant temperature (ECT ) sensor,

replacing
The engine coolan t temperature (ECT ) sensor i s an NTC (negative
temperature coefficient) sensor. A s coolant temperatur e rises ,
resistance through the sensor decreases .

The EC M varies ignition timing an d ai r / fuel mixture based on

engine coolant temperature. The EC T sensor i s supplied a 5 volt
reference voltage. The voltage drop across the sensor varies as the
coolant temperature (senso r resistance) changes .

If the EC T sensor inpu t i s faulty or no t plausible , th e MI L is

illuminated whe n OBD I I fault criteria are exceeded . Th e EC M
assumes a substitute value (80 ° C / 176°F ) to maintain engin e
operation. The ignitio n timin g is set to a safely conservative basic
setting.

The ECT sensor is located in the lef t front of the engine near oil filter
housing.

With engine fully cooled off, disconnect EC T sensor connector (A).

Unscrew EC T sensor (B ) from cylinder head. B e prepared to catch

small amount o f coolant.

Installation is reverse of removal :

• Us e new copper sealin g washer when installing sensor.
• Replac e los t coolant.

Tightening torque
Temperature sensor to cylinder hea d 18Nm(13ft-lb)

— Afte r reinstalling , check and clea r fault codes fro m EC M memory .

Radiator outlet coolan t temperature senso r

N52 engine to 03 / 2007: Radiato r outlet temperature sensor (inset)
is NTC (negative temperature coefficient) sensor. As coolant
temperature rises , resistanc e through sensor decreases.

ECM varies cooling fan speed base d on radiator outlet coolant

temperature. Radiator outlet coolant temperature sensor is supplied
a 5 volt reference voltage. Voltag e dro p across sensor varies as
coolant temperature (senso r resistance ) changes.
 Fuel Injection MSV70, MSV80 (N52 Engine) 131-2 3
DME main relay, testing

DME main relay, testing

The DM E main rela y is energized via the EC M and supplies batter y
positive (B+ ) powe r to the following:
•ECM
• Ignitio n coil s
• Tailpipe flap
• Mas s airflo w senso r
• Fue l tank lea k detectio n pum p (DMTL )
• Crankshaft senso r
• Camshaft sensor s
• Evaporativ e emission s valve
• Crankcas e breathe r valve heate r
• Oil condition senso r
• Variable intake manifol d (DISA) controllers
• Electri c coolant pum p
• Thermostat
• Oxyge n sensor heater s

If the DM E main rela y i s faulty, the engin e doe s no t start .

With ignition off, remove DME main relay (K6300) i n electronics box
(E-box) a t right rear of engine compartment .

NOTE—
• Relay locations can vary. Confirm relay identification by matching
wiring colors an d terminal numbers. Se e ELE Electrical Wirin g
Diagrams.

^ Chec k for voltage at terminal 6 of relay socket (correspond s to

DME main relay circuit terminal 30 on relay).
B+ junction point
(battery voltage at all times)
— I f battery voltage i s present, continu e testing.
6

30 K6300 — I f battery voltage i s no t present , check the following:

1 DME

M main relay • Larg e red wire in relay socket

n- \ A
87 87
• A2076 (battery positive junction ) i n E-box, right rear of engine
85
| compartment
4 j 2

23 1 f]F6 ! • Fus e F 8 in fuse and relay pane l behin d glove compartment. Se e

J10A| Power suppl y fuse s i n this repair group.
r -r' v "JA600 0 i
l©l lEC M l .1 • See ELE Electrical Wiring Diagrams for more detail s

. liilj 3 5 7 1 - Chec k for ground at relay socket 4 (corresponds to terminal 85 on

A8680 T -•• ^» "* 1 relay).
Engine 1 F3 F4 f F1 I
electronics 1 30A J20A J30A I 30AI — I f ground i s present, continue testing.
fuse carrier ' I
in E-box ' — b309 300033 |
— I f ground i s not present , signal from ECM i s missing. Chec k wir e
between rela y and EC M 44 pin connector X60005. Se e EC M pi n
assignments i n this repair group.
131 -24 Fue l Injection MSV70, MSV80 (N52 Engine)
DME main relay, testing

— I f no faults are found :

• Check ECM grounding.
• EC M may be defective.

— Wit h ignition ON and relay installed, check for battery voltage at

relay sockets 2 and 5 (correspond to terminals 87 on relay).

NOTE—
• In some models there is only one terminal 87.

— I f battery voltage i s present, relay ha s energize d an d i s functioning

correctly.

— I f battery voltage is not present and al l earlie r tests ar e OK , rela y is

faulty. Replace .

— I f no faults are found during rela y testing bu t powe r is not reachin g

ECM or other components, chec k fuse s i n engine electronic s fuse
carrier (A8680 ) in E-box and Fron t fuse panel (A41) . See Power
supply fuses in this repai r group.

— Whe n finished testing, chec k and clear faul t code s fro m ECM
memory.
 Fuel Injectio n MSV70 , MSV8 0 (N52 Engine ) 131-2 5
ECM pin assignments

ECM pin assignment s

The engine control module (ECM) (arrow) i s located in the right rear
of the engine compartmen t in the E-box .

. Th e EC M has 2 main electrical harness connectors, one wit h 4

modular connections and the other with 3 for a total of 7 sub
connectors and 14 7 pins.
\ft*
~«~ ,"*I";A;;I,,—:s..-
6 , 1 4 2E &
'I &2 3 ...1^ - . - • A: X6000 1 (signals )
_D_ r~ " 2 2 _C_ fT
• B: X60002 (signals)
7 121 42 6 ^•»*» - . ««J^ P

VI 2 1 . 1 3 1 1* ^ • C: X60003 (voltage , ground supply)

• D : X60004 (valvetronic )
• E: X60005 (signals )
b3091300002
• F : X60006 (ignitio n coils)
• G: X60007 (signals )

ECM pin assignments for non-turbo engines are give n i n Table b.

This information can be helpful when diagnosing faults to or from the
ECM.

Generally, absence o f voltage or continuity means ther e i s a wiring

or connector problem. Test results with incorrect values do not
necessarily mea n that a component i s faulty. Check fo r loose,
broken or corroded connections an d wiring befor e replacing
components. For engine managemen t syste m electrical
schematics, see EL E Electrical Wiring Diagrams.

When making checks at the ECM, use a break-out box to allow tests
to b e made wit h the connector attached to the ECM . This prevent s
damage t o the small terminals in the connector. As an alternative,
the connector housin g ca n be separated so that electrica l check s
can be made from the bac k of the connector.

CAUTION—
• Wait at least one minute after switching the ignition OFF before
removing the connector from the ECM. If the connector is
removed before this time, residual power in the system relay
may damage the ECM.
• Connect or disconnect the control module connector and meter
probes with the ignition OFF.
131-26 Fue l Injection MSV70, MSV80 (N52 Engine)
ECM pin assignments

Table b. Siemens DM E MSV70 MSV8 0 ECM pin assignment s

Connector X60001 26-pin (signals)
Pin Type Component or function Note
1 input/output Signal PT-CA N low Powertrain CAN-bu s
2 input Start signa l Car access syste m

3 input/output BSD signa l Battery sensor

4 input Brake ligh t signal Brake light switch
5 output Exhaust flap signal Exhaust flap
6 input Radiator outlet temperature sensor signal Temperature sensor at radiator outlet
7 input Accelerator pedal modul e signa l Accelerator peda l modul e
8 output Electric fan signal Electric engin e coolin g fan
9 output Radiator shutter solenoid Signal
10 ground Accelerator pedal modul e Accelerator pedal modul e
11 output Accelerator pedal modul e supply voltage Accelerator pedal modul e
12 - Not use d
13 - Not use d
14 input/output Signal PT-CA N high Powertrain CAN-bu s
15 input EWS signal to 03/200 7 Car access syste m
PA bus signal from 03/2007
16 input Brake light test signal Brake light switch
17 input Right rea r wheel speed sensor signal Connector X1 01 86 (right rear wheel speed sensor)
18 input Clutch switc h signal Clutch switch modul e
19 input Radiator outlet temperature sensor signal Temperature sensor a t radiato r outlet
20 input Accelerator pedal modul e signal Accelerator pedal modul e
21 input/output TD signa l TD signal connecto r
22 input Not used to 03/200 7
Signal RXI N Car access syste m
23 ground Accelerator pedal modul e Accelerator pedal modul e
24 output Accelerator pedal modul e supply voltage Accelerator pedal modul e
25 - Not use d
26 output E-box fan signal E-box fa n

Connector X60002 26-pin (signals)

Pin Type Component or function Note
1 input Wake u p signal, terminal 15 Terminal 1 5 wake u p connector
2 - Not use d
3 - Not use d
4 - Not use d
5 input Oxygen senso r signal Bank 2 sensor 1
6 input Oxygen senso r signal Bank 1 sensor 1
 Fuel Injection MSV70, MSV8 0 (N5 2 Engine ) 13 1 -27
ECMpin assignments

Connector X60002 26-pi n (signals) (continued)

Pin Type Component or function Note
7 input Oxygen sensor signal Bank 2 sensor 1

8 input Oxygen sensor signa l Bank 1 sensor 1

9 input Oxygen sensor signa l Bank 2 sensor 1

10 ground Oxygen sensor Bank 1 sensor 1
11 ground Oxygen sensor Bank 2 sensor 1
12 input Oxygen sensor heatin g Bank 1 sensor 1

13 input Oxygen sensor heatin g Bank 2 sensor 1

14 - Not used

15 input DMTL valve signa l Diagnosis modul e for fuel tank leakag e

16 input DMTL pump signa l Diagnosis modul e for fuel tank leakag e
17 input DMTL heatin g signa l Diagnosis modul e for fuel tank leakag e
18 input Oxygen sensor signa l Bank 1 sensor 1

19 input Oxygen sensor signal Bank 2 sensor 2

20 input Oxygen sensor signal Bank 1 sensor 2

21 - Not used
22 - Not used

23 ground Oxygen sensor Bank 1 sensor 2

24 input Oxygen senso r Bank 2 sensor 2

25 input Oxygen sensor Bank 2 sensor 2

26 output Oxygen sensor Bank 1 sensor 2

Connector X60003 6-pi n (voltage, ground supply)

Pin Type Component or function Note

1 input Terminal 30 B+ potential distributor

2 input Terminal 87 Fuse F0 3

3 ground Ground Ground poin t

4 ground Ground Ground poin t

5 ground Ground Ground point

6 ground Ground Ground poin t

Connector X60004 6-pi n (valvetronic)

Pin Type Component or function Note
1 input Terminal 87 VVT rela y
2 input Terminal 87 VVT rela y
3 output Valvetronic actuato r signa l Valvetronic actuator timing actuator
4 output Valvetronic actuator signal Valvetronic actuator timing actuato r
5 output Valvetronic actuator signa l Valvetronic actuator timing actuato r
6 output Valvetronic actuator signal Valvetronic actuator timing actuator
131 -28 Fue l Injection MSV70, MSV80 (N52 Engine )
ECM pin assignments

Connector X60005 44-pin (signals)

Pin Type Component or function Note
1 - Not used
2 - Not use d
3 - Not use d
4 - Not use d
5 - Not use d
6 - Not use d
7 - Not used
8 - Not use d
9 - Not use d
10 - Not use d
11 - Not used
12 output Crankcase breathe r valve heating activation Crankcase breathe r valve heating rela y
13 output DME main rela y activation DME main rela y
14 output Throttle valve voltage suppl y Throttle valv e
15 input Throttle valve signa l Throttle valve
16 input Throttle valve signal Throttle valve
17 - Not use d
18 output DISA changeover valve signal DISA controller 2
19 input Knock sensor signal Knock senso r
20 input Knock sensor signal Knock sensor
21 - Not use d
22 - Not use d
23 output Fuel tank vent valve signa l Fuel tank ven t valv e
24 - Not used
25 output Mass ai r flow sensor voltage supply Mass ai r flow senso r
26 input Mass ai r flow sensor signal Mass ai r flow senso r
27 ground Mass air flow senso r Mass air flow senso r
28 input Intake air temperature sensor signa l Intake air temperature senso r
29 input Crankshaft position sensor signa l Crankshaft positio n senso r
30 ground Crankshaft positio n sensor Crankshaft positio n senso r
31 output Intake manifold pressur e sensor voltage supply Intake manifold pressure sensor
32 ground Intake manifold pressur e senso r Intake manifold pressure senso r
33 input Intake manifold pressure sensor signa l Intake manifol d pressur e senso r
34 - Not used
35 input/output BSD signal BSD signal connector
36 input Throttle valve signal Throttle valve
37 input Throttle valve signal Throttle valve
 Fuel Injectio n MSV70 , MSV8 0 (N5 2 Engine ) 131-2 9
ECM pin assignments

Connector X60005 44-pin (signals) (continued)

Pin Type Component or function Note

38 ground Throttle valve Throttle valve

39 - Not used

40 output DISA changeover valve signa l DISA controller 1

41 input Knock sensor signal Knock sensor

42 input Knock sensor signal Knock sensor

43 - Not used

44 - Not used

Connector X60006 12-pi n (ignition coils)

Pin Type Component or function Note

1 output Ignition coil signal Ignition coil signal 1

2 output Ignition coil signal Ignition coil signal 2

3 output Ignition coil signal Ignition coil signal 3

4 output Ignition coil signal Ignition coil signal 4

5 output Ignition coil signal Ignition coil signal 5

6 output Ignition coil signal Ignition coil signal 6

7 - Not used

8 - Not used

9 - Not used

10 - Not used

11 - Not used

12 - Not used

Connector X60007 26-pin (signals)

Pin Type Component or function Note

1 output Fuel injector signal Fuel injecto r 1

2 output Fuel injector signal Fuel injecto r 2

3 output Fuel injector signal Fuel injecto r 3

4 input Engine coolant temperature signal Engine coolan t temperature sensor

5 output Intake VANOS solenoid signal Intake VANOS solenoi d

6 input Eccentric shaft sensor signal Eccentric shaft sensor

7 input Eccentric shaft sensor signa l Eccentric shaft sensor

8 input Eccentric shaft sensor signal Eccentric shaft sensor
9 input Eccentric shaft sensor signa l Eccentric shaf t sensor
10 ground Wire shieldin g Eccentric shaf t sensor
11 input Camshaft positio n sensor 1 signal Camshaft positio n sensor 1
12 input Camshaft position senso r 2 signa l Camshaft positio n sensor 2
13 input Oil pressure switch signa l Oil pressure switch
131-30 Fue l Injection MSV70 , MSV8 0 (N52 Engine)
ECM pin assignments

Connector X6000 7 26-pin (signals) (continued)

Pin Type Component or function Note
14 output Fuel injecto r signa l Fuel injecto r signal 4
15 output Fuel injector signa l Fuel injecto r signal 5
16 output Fuel injecto r signa l Fuel injecto r signal 6
17 ground Engine coolan t temperatur e senso r Engine coolan t temperatur e senso r
18 output Exhaust VANO S solenoi d signa l Exhaust VANO S solenoi d
19 input Thermostat signa l Thermostat
20 ground Eccentric shaf t sensor Eccentric shaf t senso r
21 output Eccentric shaf t senso r voltag e suppl y Eccentric shaf t senso r
22 input Eccentric shaft sensor signa l Eccentric shaf t senso r
23 output Valvetronic actuato r rela y signa l Valvetronic actuato r rela y
24 ground Camshaft positio n sensor 1 Camshaft positio n senso r 1
25 ground Camshaft positio n senso r 2 Camshaft positio n senso r 2
26 input/output BSD signa l Electric coolant pum p
 132-1

132 Fue l Injectio n MSD80 , MSD8 1

(N54 Engine )

GENERAL 132- 1 Charge air duct pressure sensor,

DME applications 132- 2 replacing 132-1 7
Warnings an d Cautions 132- 3 Intake manifold charge air pressure sensor,
replacing 132-1 8
DRIVEABILITY TROUBLESHOOTIN G 132- 5 Throttle housin g (EDK) , replacing 132-1 9
Basic engin e setting s 132- 5 Fuel injector servic e 132-2 0
System voltag e 132- 5 Fuel injectors, removing 132-2 1
Main ground s 132- 6 Injector bore , cleaning 132-2 4
On-board diagnostic s 132- 6 Fuel injecto r PTFE seal , replacing 132-2 4
ENGINE MANAGEMEN T FUSE S Fuel injectors , installing 132-2 7
AND POWE R SUPPL Y COMPONENT S 132- 7 Fuel injector adaptation 132-2 9
Power supply fuse s 132- 7 Fuel rail , removin g 132-3 0
Fuel rail , installing 132-3 2
SIEMENS DME MSD80 , MSD8 1 Intake manifold , removing an d installing . . . . 132-3 4
(N54 ENGINE ) 132- 8 Crankcase breathe r valve 132-3 7
DME engine managemen t Engine coolan t temperature (ECT) sensor ,
system description 132- 8 replacing 132-3 8
Air filte r housing an d ducts , Radiator outlet coolant temperature sensor . . 132-3 8
removing an d installin g 132-1 1
DME main relay , testing 132-3 9
Charge air ducts, lef t side ,
ECM pin assignments 132-4 1
removing and installin g 132-1 2
Charge air ducts, righ t side , TABLE
removing and installin g 132-1 4
a. 5 Series engin e managemen t application s 132- 2
Mass air flow, measurement 132-1 7
b. Siemens DM E MSD8 0 / 81 EC M pi n assignments . . 132-42

GENERAL
This repai r grou p cover s servic e an d repair of engine managemen t
systems fo r turbocharged N5 4 engines wit h Siemens DME MSD8 0
orMSD81.

See also:
• 020 Maintenance for air filter, fuel filter and spark plug
replacement
• 100 Engine-General for engine identificatio n an d application
• 12 0 Ignition System fo r ignition coil , camshaft sensor , crankshaf t
sensor an d knock senso r servic e
• 160 Fuel Tank and Fuel Pump for fuel pump and fuel pum p relay
service, fuel pressure tests and fuel pressure regulator
replacement
• 18 0 Exhaust Syste m for oxygen senso r servic e
• EC L Electrical Componen t Location s
• EL E Electrical Wirin g Diagram s
• OBD On-Board Diagnostic s
132-2 Fue l Injectio n MSD80 , MSD8 1 (N5 4 Engine)
DME applications

DME applications
BMW 5 Series models ar e equipped wit h digital moto r electronics
(DME), also known as Motronic. In these systems, fuel injection and
ignition are controlled by an integrated engin e control modul e
(ECM). Application information for DM E systems is in Table a .

Table a . 5 Series engine management applications

Year, model Engine Engine Features
code management
2004-2005
Sedan: 525i , 530i M54 Siemens Double VANOS
MS 45.1
Sedan: 545I N62 Bosch DM E Valvetronic,
ME 9. 2 with VANOS
Valvetronic
control modul e
2006 - 200 7
Sedan, N52 Siemens MSV70 Valvetronic,
Sports Wagon : VANOS
525i, 525xi,
530i, 530xi
Sports Wagon
2008-2010
Sedan, N52KP Siemens MSV8 0 Valvetronic,
Sports Wagon : VANOS
528i, 528x i
Sedan, N54 Siemens MSD80 VANOS,
Sports Wagon : (to 03 / 2008 ) turbocharged
535I, 535xi MSD81 (fro m
03 / 2008 )
2004-2005
Sedan: 545 i N62 Bosch DM E Valvetronic,
ME 9.2 with VANOS
valvetronic
control uni t
2006-2010
Sedan: 550 i N62TU Bosch DM E Valvetronic,
ME 9. 2. 2 VANOS
Fuel Injection MSD80, MSD81 (N54 Engine ) 132- 3
Warnings and Cautions

Warnings an d Caution s

WARNING —
• The fuel system is designed to retain pressure even when the
ignition is OFF. When working with the fuel system, loosen the
fuel lines slowly to allow residual fuel pressure to dissipate.
Avoid spraying fuel. Use shop towels to capture leaking fuel.
• Fuel in fuel lines is underpressure (approx. 3 - 5 bar or 45 - 75
psi) and may be expelled forcibly. Do not smoke or work near
heaters or other fire hazards. Keep a fire extinguisher handy.
• Unscrew the fuel tank cap to release pressure in the tank
before working on fuel lines.
• Plug open fuel lines and fittings.
• Before beginning work on the fuel system, place a fire
extinguisher in the vicinity of the work area.
• Work only on the fuel system when engine temperature is
below 40°C(104°F).
• Fuel is highly flammable. When working around fuel, do not
disconnect wires that could cause electrical sparks. Do not
smoke or work near heaters or other fire hazards.
• Wear eye protection and protective clothing to avoid injuries
from contact with fuel.
• When working on an open fuel system, wear suitable hand
protection, as prolonged contact with fuel can cause illnesses
and skin disorders.
• Unscrew the fuel tank cap to release pressure in the tank
before working on fuel lines.
• Do not use a work light with an incandescent bulb near fuel.
Fuel may spray on the hot bulb causing a fire.
• Make sure the work area is properly ventilated.
• Due to risk of personal injury, be sure the engine is cold before
beginning work on engine components.
• The ignition system produces high voltages that can be fatal.
Avoid contact with exposed terminals. Use extreme caution
when working on a car with the ignition switched ON or the
engine running.
132-4 Fue l Injection MSD80, MSD81 (N54 Engine)
Warnings and Cautions

CAUTION—
• Renew fuel system hoses, clamps and O-rings any time they
are removed.
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings and Cautions .
• Connect and disconnect the DME system wiring and test
equipment leads only when the ignition is switched OFF.
• Wait at least 1 minute after switching the ignition OFF before
disconnecting engine control module (ECM) connectors. If the
connectors are removed before this time, residual power in the
system relay may damage the control module.
• Tests or repair procedures in this section may set fault codes
(DTCs) in the ECM and illuminate the MIL. After repairs are
completed, access and clear DTC memory using a BMW scan
tool. See On-board diagnostic s i n this repair group.
• Fuel system cleaners and other chemical additives other than
those specifically recommended by BMW may damage
catalytic converters, oxygen sensors or other fuel supply
components.
• Do not connect any test equipment that delivers a 12-volt
power supply to terminal 15 (+) of the ignition coils. The current
flow may damage the ECM. Connect test equipment only as
specified by BMW or the equipment maker.
• Relay positions can vary. Be sure to confirm relay location and
function by identifying the wiring in the socket using the wiring
diagrams found in ELE Electrical Wiring Diagrams .
• Use a digital multimeter for electrical tests. Use an LED test
light for quick tests.
Fuel Injection MSD80, MSD81 (N54 Engine ) 132- 5
Basic engine settings

DRIVEABILITY TROUBLESHOOTIN G
The self-diagnostic DME engine management syste m monitors an d
stores diagnostic troubl e codes (DTCs). If the malfunctio n indicato r
light (MIL) illuminates, i t indicates that an emissions-related fault has
occurred and that one or more DTCs are stored in the engine contro l
module (ECM) .

If faults arise, or i f the MI L i s illuminated, begi n troubleshooting b y

connecting BMW scan tool to the OBD II plug under the dashboard.

The capabilities o f OBD I I software have the potential to save hour s

of diagnosti c tim e and to help avoi d incorrect component
replacement and possible damage to system components. Se e On-
board diagnostic s i n this repair group.

Basic engine setting s

Idle speed, idl e mixtur e (%CO), and ignition timing are not
adjustable. The DM E system i s adaptive an d automaticall y
compensates for changes in the engine due to age, mino r wear or
small problems such as a disconnected vacuum hose . However , the
adaptive rang e i s limited. Once the limits are exceeded, driveabilit y
problems becom e noticeable .

Poor initial driveability may be encountered when the batter y i s

disconnected an d reconnected. Whe n the battery is disconnected ,
ECM adaptive memor y ma y be reset . The system readapt s afte r
about ten minute s o f driving .

System voltag e
Digital moto r electronics (DME ) require s that the system (battery )
voltage b e maintained withi n a narrow range of DC voltage. D C
voltage level s beyon d or below the operating range, or any AC
voltage in the electrical system can cause havoc .

When troubleshooting an illuminated MIL , make sur e the batter y i s

fully charged and capable o f delivering all its power to the electrical
system. An undercharged batter y can amplify AC alternator output
ripple.

To make a quick check of battery charge, measure voltage acros s

battery terminals with all cables attached and ignition OFF . A fully
charged batter y measure s 12. 6 volts or slightly more , compare d t o
12.15 volts for a battery with a 25% charge .

The DME system operates a t low voltage and current levels, makin g
it sensitive to small increase s i n resistance. The electrical syste m is
routinely subject to corrosion, vibratio n and wear, so faults or
corrosion in the wiring harness an d connectors are no t uncommon .

Check batter y terminals fo r corrosion or loose cable connections .

See 121 Battery, Starter, Alternator .
132-6 Fue l Injection MSD80, MSD8 1 (N54 Engine)
Main grounds

If a battery cable connection ha s n o visible faults but is still suspect,

measure voltage drop across the connection. A large drop indicates
excessive resistance, meaning that the connection i s corroded, dirty
or damaged. Clea n o r repair and retest . See 600 Electrica l
System-General for voltage dro p tes t procedure .

Visually inspect wiring, connectors, switche s an d fuses. Loose or

damaged connector s can cause intermittent problems , especiall y
small terminals i n ECM connectors. Disconnec t wirin g harness
connectors to check for corrosion, and use electrical cleaning spray
to remov e contaminants .

Main grounds
Good grounds ar e critical to proper DM E operation. I f a ground
connection ha s no visible faults bu t is still suspect, measure th e
voltage drop across the connection. A large voltage dro p mean s
high resistance . Clean or repair the connectio n an d retest .

For voltage drop testing, se e 600 Electrica l System-General .

For ground locations , se e EC L Electrica l Componen t Locations .

On-board diagnostic s
Second generation on-board diagnostics (OB D II ) software and
hardware is incorporated in engine management systems . The OBD
II system monitor s components tha t influenc e exhaust an d
evaporative emissions. I f a problem i s detected, the OBD I I system
stores the associated diagnosti c troubl e code (DTC) and condition.

If vehicle emissions level s exceed 1. 5 times Federall y mandate d

criteria, the OB D I I system illuminates a malfunction indicator light
(MIL) i n the instrumen t cluster.

>. Sca n tool connected t o OB D I I plug belo w lef t dashboard .

Professional diagnostic sca n tools available a t the time of this

printing include th e BM W GT1, IST A and a small number of
aftermarket BMW-specifi c tools.

In addition to professional scan tools, there are inexpensive generic

OBD I I scan tool software programs an d handhel d unit s available.
Although these have limite d capabilities a s compared to the
dedicated tools , they are powerful diagnosti c tools.

For the DI Y owner, a simple aftermarke t DT C reader is available

through http://www.peakeresearch.com. This tool is capable of
checking for DTCs as well as switching the illuminated MIL OFF and
resetting service indicator lights.

NOTE—
• OBD II DTC memory (including an illuminated MIL) can only be
reset using a BMW scan tool or equivalent. Removing the
connector from the ECM or disconnecting the battery does not
erase DTC memory.
Fuel Injectio n MSD80 , MSD8 1 (N5 4 Engine ) 132- 7
Power supply fuses

ENGINE MANAGEMEN T FUSE S

AND POWE R SUPPLY COMPONENT S
Power supply fuses
See ECL Electrical Componen t Location s fo r fuse pane l acces s
information.

Rear distribution pane l (A46 ) i n trunk, installed i n right rea r fender:

• F9 0 200A: Powe r supply t o fuse panel A41a.

A41a: fuse and rela y panel behin d glov e compartment :

• F8 60A:
Engine contro l module (ECM ) (A6000 )
ECM main rela y (K6300 )
Engine electronic s fuse carrier (A8680)
Engine electronic s fuse carrier (A8681)

See ECL Electrical Component Location s for specific vehicle fuse

locations.

Engine electronic s fus e carrier A8680 (arrow) .

132-8 Fue l Injectio n MSD80, MSD8 1 (N5 4 Engine )
DME engine management system description

SIEMENS DME MSD80 , MSD8 1

(N54 ENGINE )
DME engine management system descriptio n
The DM E manages an d monitors th e following functions:

Air
• Twin-turbo chargers
• Electronic throttle
• Charge ai r intercoolers

Fuel
• Fue l suppl y
• Direc t fuel injection

Ignition
• Direct ignitio n
• Knoc k control
• Primar y / secondary ignitio n monitorin g

Emissions
• OBD I I compliance
• Pre - and post-catalyst oxyge n sensor s
• Electrically heated DME-mapped thermostat
• Misfir e detection
• Evaporativ e emission contro l and leak detectio n
• Malfunctio n indicator light (MIL )

Performance controls
• Doubl e VANOS control
• Outpu t o f injection signal (Tl ) for fuel economy gauge
• Output of engine rp m (TD) fo r tachomete r
• A/C compressor contro l
• Electri c radiator cooling fan
• CAN-bus communicatio n
• Dynami c stabilit y control (DSC ) interfac e
• Car access system (CAS ) with EW S 3.3
• Cruise contro l
• ECM programming
 Fuel Injectio n MSD80 , MSD8 1 (N5 4 Engine ) 132- 9
DME engine management system description

Engine control module (ECM )

The engine control modul e (ECM ) (arrow) is mounted i n the
electronics box (E-box) at the righ t rear of the engine compartment .

, Th e EC M i s flash-programmable and features 2 main electrical

harness connectors, one with 4 modular connections an d the other
with 3 for a total of 7 subconnectors and 14 7 pins.
£2-.3.. .....::: E:::: A • A: X60001 (signals)
1 22 C ?"" " 1
7 121 4 26 14 • B: X60002 (signals )
:: F :;:::.:::G BUZ"
• C: X60003 (voltage , ground supply)
• D : X60004 (ignitio n coils)
• E: X60005 (signals )
b3091300002
• F: X60006 (fue l injectors)
• G: X60007(signals )

The EEPRO M (chip ) in the EC M is coded to the vehicle .

Fuel meterin g

The EC M meters pressurized fuel by changing th e openin g tim e

(pulse width) o f the fuel injectors. The exact amount of fuel injected
is determined b y the amount o f time the injectors are open .

5 Series mode l wit h N54 engine utilize s direct fuel injection. Eac h
fuel injector (arrow) is mounted int o a machined hole in the cylinder
head near the spark plug .

A direct injection turbocharged engine achieves a higher

compression rati o when compared to ones utilizin g manifol d
injection. At the same time, the exhaust gas temperature i s reduced
under ful l load. Anothe r advantage o f this injection process i s
improved efficiency in part-load operation.

The ECM monitors engine operating conditions to determine injector

opening duration. Eac h injecto r can be individually controlled for
cylinder selective fuel trim.
132-10 Fue l Injectio n MSD80, MSD8 1 (N5 4 Engine)
DME engine management system description

Air intak e
Air intake ducting plays a significant role due to the requirement s of
12 3 4 5 6 a turbocharged engine. In principle, the energy of escaping exhaust
gases i s utilized to precompress the inducte d fres h air and thus
introduce a greater air mass int o the combustion chamber . Thi s is
only possibl e i f air intak e ductin g i s leak free and installe d properly.
1. Heate r for blo w b y gases (PTC )
2. Recirculate d air line, bank 2
3. Connectio n t o throttle valve
4. Ai r filter housin g
5. Recirculate d air line, ban k 1
6. Ai r intake snorkel

13 1 2 11 10
7. Charg e air pressure line
8. Charg e air suction line, bank 1
b3091300035
9. Charg e air intercooler
10. Charg e air manifold
11. Turbocharger , ban k 1
12. Turbocharger , ban k 2
13. Charg e air suction line , ban k 2

Fresh air is drawn i n via the ai r cleaner (1 ) and charge-air suction

lines (2, 3) to the turbochargers (4, 5) and compressed. Because the
o (• turbochargers can get very hot during operation, they are connected
UJ <
to the engine coolant and engine oil circuits. The charge air is greatly
heated when compressed i n the turbocharger, making i t necessary
for th e ai r to be cooled i n an intercoole r (6).

The compressed an d cooled charge ai r is routed from the

intercooler via the throttle valve (7 ) into the intake manifold. The
system is equipped wit h several sensors and actuators in order to
ensure that the volume of air i s optimally adapted to engine
operating conditions.

b3091300036

Idle speed contro l

The ECM controls idle speed by varying throttle valve actuation. Idl e
speed is not adjustable. The basi c function s and parameters of idle
speed control are as follows:
• Control of cold air intake volume .
• Smooth idle speeds regardless of load and inputs.
• Smooth transition from acceleration to deceleration.

Idle speed stabilizatio n is active during th e following conditions:

• Engin e warm-up
• Heating or A/C activation
• Driv e gear selected (automatic transmission )
• Varying cooling fan speeds
Fuel Injectio n MSD80, MSD8 1 (N5 4 Engine ) 132-1 1
Air filter housing and ducts, removing and installing

Throttle control

The N5 4 engine features electroni c throttle control (EDK). There is

no throttle cable between the accelerator pedal an d the throttle
housing. EDK integrates driver commands with the requirements of
the traction control syste m (DSC ) and cruise control.

Knock (detonation ) contro l

Knock sensors monitor and control ignition knock through the ECM .
Knock sensors functio n like microphone s an d are able t o conver t
mechanical vibration (knock) int o electrical signals. The EC M is
programmed to react to frequencies that are characteristic of engin e
knock an d adapt the ignition timing poin t accordingly.

Knock sensor replacemen t i s covered in 120 Ignition System .

Air filte r housin g and ducts ,

removing and installing
^C Workin g at top of engine, detach air intake duct (arrow ) and lif t ou t
of radiato r support.

— Remov e upper engin e covers . See 020 Maintenance .

Remove complet e air cleaner housing, disconnecting and labeling

connectors, ducting and hoses a s necessary:
• Air duct hose clamp (arrow) .
• Disconnec t lin e (A) and detach from air intake housing (B) .
132-12 Fue l Injection MSD80, MSD81 (N54 Engine)
Charge air ducts, left side, removing and installing

Loosen clam p (arrow ) and remov e air intak e hose .

• Pul l u p wiring harness rubbe r mount s (B ) to detach.
• Detac h intak e filte r housin g (A) from rubber mounts, then lif t and
remove.

— Installatio n is reverse of removal .

CAUTION—
• Turbocharger failure may result if charge air ducts are not
installed dry and free of grease. Install using antiseize
compound only.

— Afte r reinstalling , check and clear faul t codes from ECM memory.

Charge air ducts, left side,

removing and installin g
Remove air filter housing and ducts. Se e Air filter housing an d
ducts, removin g and installin g i n this repair group.

Turn quick releas e coupling lock s (A ) 90 ° to disconnect. Detach

recirculated air hoses (B) an d la y aside. Not e position of arrows on
quick connector for reinstallation .

Working at lef t charge air duct:

• Loose n clamp (arrow) and remove charge air hose (A) from duct
(B).
Fuel Injectio n MSD80, MSD8 1 (N5 4 Engine ) 132-1 3
Charge air ducts, leftside, removing and installing

Disconnect electrical connector (A) and place harness aside.

^V Remov e fastener (arrow) .

• Unloc k quick connect (A) and remove charge air duct (B ) from
throttle valve.

— Rais e vehicle and suppor t safely.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Remov e splash shiel d underneath engine. See 020 Maintenance .

^. Working under vehicle at right front air charge duct:

• Unloc k quick connect (arrow) an d disconnect charge air duct (A)
from intercoole r (B).
132-14 Fue l Injection MSD80, MSD81 (N54 Engine)
Charge air ducts, right side, removing and installing

^ < Feed ai r charge duct (A ) through to p an d remove.

— Installatio n i s revers e of removal .

CAUTION—
• Turbocharger failure may result if charge air ducts are not
installed dry and free of grease. Install using antiseize
compound only.

— Afte r reinstalling , check an d clea r faul t codes fro m EC M memory .

Charge air ducts, righ t side,

removing and installing
— Drai n coolant an d remov e coolant expansio n tank .
See 170 Radiator and Cooling System.

— Remov e splash shield underneat h engine . Se e 02 0 Maintenance .

^ Workin g in right front engine compartment :

• Labe l and detach vacuu m line s (A) from canisters.
• Remov e fasteners (arrows).

— Rais e bracke t slightly. Label an d detac h vacuu m hose from bottom

of canisters. Remov e assembly .
Fuel Injection MSD80, MSD8HN54jnqine)_jl32-15
Charge air ducts, right side, removing and installing

Working a t right strut tower, remove nut s (arrows) and remove hea t
shield (A ) i f equipped .

Working above turbocharger, loosen clamp (arrow) and remove

charge air duct (A).

Working above turbocharger, loosen clamp (arrow) and remove

charge air duct (A).
132-16 Fue l Injection MSD80, MSD81 (N54 Engine)
Charge air ducts, right side, removing and installing

Working beneat h righ t front of vehicle:

• Unloc k quick connect an d remove radiato r hose (A).
• Unloc k quick connect (arrow ) and remov e charg e ai r duct (B).

When reinstallin g charge air duct to intercoole r us e BMW special

tool 1 1 8 670.

^V Coa t charge air duct O-rin g (arrow ) with antiseiz e before

reinstalling.

— Remainde r o f installatio n i s reverse of removal .

CAUTION—
• Turbocharger failure may result if charge air ducts are not
installed dry and free of grease. Install using antiseize
\ compound only.

— Afte r reinstalling, chec k an d clea r faul t codes from ECM memory .

b3091300054
 Fuel Injectio n MSD80 , MSD8 1 (N5 4 Engine) 132-1 7
Mass air flow, measurement

Mass air flow, measuremen t

The N5 4 engine utilize s a calculated air mass system. Thi s
calculation makes us e of the following signals:
• VANOS setting (load acquisition)
• Throttle settin g
• Intak e air temperature (ai r density correction)
• Engin e temperature (air density correction)
• Engin e speed (cylinde r charge)
• Intak e manifol d pressur e (throttl e correction)
• Ambient pressur e (air density, altitude correction)

"V TThe
r calculated air mass i s adjusted with the oxygen senso r signa l
(mixture
(rr ratio ) an d injecto r timing and corrected if necessary .
ill B £.. ^__^&T ' "^'""jgaBm'
,% /
t //^^*>*~ aw»-*'"'"*m
1. Intake air temperature sensor
j~ T [c^ s yp^p , , _, . ,>- . "> ::"::;\^»v V ^ 1
2. Throttle valve positio n

r
[4] 3. Intake manifold
^J
I —— 1 LI ! 1 ./. ' I
[ej
i 4. Residual oxygen measurement i n exhaust

m •;
"Moil Intake manifold vacuum
_J 5.
6. Engine spee d
7. ECM with charge calculatio n mode l
*— <MMM#* ^^ ^ I I[ j 8. Injection timin g
ECM EI™i > U
In the event of an oxygen sensor failure, a fault code is stored i n the
b3091300014
ECM
E( (air mass plausibility) . The calculated air mass i s not adjuste d
in this case.

Charge air duct pressur e sensor , replacing

Switch ignition OF F and remov e key.

Remove air filter housing an d ducts. See Air filter housin g an d

ducts, removing an d installin g i n this chapter .

Working at throttle body charg e ai r duct:

• Detac h senso r electrical connecto r (A).
• Remov e fasteners (arrows).
• Remov e sensor (B).
132-18 Fue l Injectio n MSD80 , MSD81 (N5 4 Engine)
Intake manifold charge air pressure sensor, replacing

Installation i s reverse of removal.

• Inspec t sealing O-ring (arrow) and replace in necessary.

After reinstalling , check and clear fault codes from ECM memory.

Tightening torques
Sensor to charge air duct 3.5 N m (3 1 in-lb)

b3091300056

Intake manifold charg e ai r pressure sensor ,

replacing
— Switc h ignition OFF an d remov e key.

— Remov e uppe r engin e covers. Se e 02 0 Maintenance .

"^ Workin g at rear of intake manifold:

• Detac h senso r electrical connector (B).
• Remove fasteners (arrows) .
• Remov e sensor (A).

Installation i s reverse of removal .

• Inspec t sealing O-ring (arrow) and replac e if necessary.

After reinstalling, check an d clear fault codes fro m ECM memory.

Tightening torques
Sensor to intake manifol d 3.5 N m (3 1 in-lb)

b3091300056
 Fuel Injection MSD80, MSD81 (N54 Engine) 132-1 9
Throttle housing (EDK), replacing

Throttle housin g (EDK) , replacing

There is no mechanical (cable ) link between the accelerator peda l
and the throttle plate .

. Th e accelerato r peda l modul e (PWG ) a t the peda l assembl y

communicates peda l positio n directly to the ECM. The modul e
r vysj j i Muuuit: \ l sensors) \ f
provides tw o variable voltage signals (via two Hal l sensors) t o th e
ECM for peda l positio n an d rat e of movement .
\H ff
The EC M provides a n independent 5 V and ground suppl y for each
COT
i

Hall sensor. A s the accelerator peda l is moved from res t to full

T\\ Accelerator
pedal
throttle, the sensors produc e a variable voltage signal.

The output of the Hall sensors is checked for plausibility. The voltag e
Power * * M l range of Hall sensor 1 is approximately 0.5 to 4.5 volts. Hal l senso r
to PWG ""s^s^^r ft \ I
module ' \ fr E I I \
2 range s from approximately 0. 5 to 2.5 volts.

,»Xu / ' jk
ECM r^(^"
\3
The throttl e housing uni t i s non-adjustable. I f found t o b e faulty,
replace as a complete unit.

'\
After replacin g the throttle housing, use BMW scan too l or
^-^~ b30 9 13000 17
equivalent to rese t adaptation values .

CAUTION—
• If the adaptation process is not completed correctly, the engine
will not start.

— Switc h ignition OF F an d remov e key.

— Remov e air filter housing an d ducts. See Air filter housin g an d

ducts, removing an d installin g i n this chapter.

— Remov e charge air ducts. Se e Charge ai r ducts, lef t side ,

removing and installin g i n this chapter.

^C Workin g at side o f throttle assembly, disconnect lin e (arrow) .

132-20 Fue l Injection MSD80, MSD81 (N54 Engine)
Fuel injector service

Working unde r throttle assembly , disconnec t electrica l connector

(A).
• Remov e fasteners (arrows) and remove throttl e housin g (B).

Replace profil e gasket (sealin g O-ring ) betwee n throttl e assembl y

and intake manifold .

Tightening torques
Throttle housin g t o intake manifol d 8 N m (7 0 in-lb)

Installation is reverse of removal .

Reattach throttle assembl y connecto r wit h care.

CAUTION—
• It is possible to twist the connector before plugging it in. This
can cause damage to the harness and connector.

After reinstalling , chec k an d clear faul t codes fro m EC M memory.

Reset throttle plat e adaptatio n value s followin g BMW scan tool on-
screen instructions .

Fuel injector service

Fuel injectors are electrically controlled solenoid valves that provid e
precisely metere d an d atomized fue l int o th e engine intak e ports.
The N5 4 turbocharged engin e utilize s a high precision injection
(HPI) direc t fuel injection system .

The HP I system use s piezo-electri c fuel injectors . These injector s

open i n an outward direction , which form s a precise tapered spra y
pattern. With the aid of high syste m pressur e (200 bar), th e HPI
system i s capable o f providing a high level of efficiency.

Voltage from the EC M controls injecto r openin g b y activating the

injector valve piez o element. The EC M varies the duration (in
milliseconds) of injector opening t o regulat e air / fuel ratio.

b3091300059
Fuel Injection MSD80, MSD81 (N54 Engine) 132-2 1
Fuel injectors, removing

. Durin g manufacture, the tolerance range s fo r injector-quantity

adjustment ar e determined an d specified in a six-digit numbe r
combination. Mak e note of tolerance numbers. They are required for
fuel injector adaptation. See Fuel injecto r adaptation in this repai r
group.

Information on the lif t performance of the injector is also adde d for

injector voltage adjustment. Injecto r adjustment is required because
of the individual voltage demand of each piezo actuator. This data is
programmed i n the ECM. During engine operation, these values are
used to compensate fo r deviations in fuel metering .

When replacin g an injector , it is essential to carry out a n injector

adjustment usin g BMW factory scan tool or equivalent .

If a fault is diagnosed i n the system, such as failure of the hig h

pressure sensor, the fuel-supply control valve i s de-energized; fue l
then bypasses int o the rail . I n the event of limp-home mode ,
turbocharging is deactivated b y an opening of the wastegate valves.

Additional causes o f limp-home mod e can be:

• Implausibl e high-pressure senso r value s
• Failur e of the fuel-supply control valve
• Leakag e i n the high-pressure system
• Failur e of the high-pressure pump
• Failur e of the high-pressure sensor

Fuel injectors, removing

Disconnect batter y negative (- ) cable i n cargo compartment .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings an d Cautions.

— Remov e upper engine covers. See 020 Maintenance .

— Remov e ignition coil at corresponding cylinde r o f fuel injector

service. See 120 Ignition System .

CAUTION—
• Maintain a high level of cleanliness when servicing ignition
coils. Fuel, oil residue can break down the electrical resistance
qualities of silicone used in ignition coil product/on, resulting in
coil failure.
132-22 Fue l Injectio n MSD80 , MSD8 1 (N5 4 Engine )
Fuel injectors, removing

Remove fuel line to corresponding fue l injecto r (A).

WARNING —
• Fuel in the fuel line is underpressure (approx. 200 bar or 2900
psi) and may be expelled forcibly. Do not smoke or work near
heaters or other fire hazards. Keep a fire extinguisher handy.
• Work only on fuel system when engine temperature is below
40°C (104°F).
• Unscrew the fuel tank cap to release pressure in the tank before
working on the fuel line.
• Plug open fuel lines and fittings.
• Wrap a clean shop towel around fitting before disconnecting.
Residual fuel pressure is present in the fuel line.
• To reduce fuel pressure, place towel over injector and carefully
tap with a wrench.

CAUTION—
• Maintain a clean work area when servicing high pressure fuel
system. Contaminants can cause a system malfunction.
• Seal open fuel system lines with protective caps.
• Replace high pressure fuel lines if tightened 10 times.

NOTE—
• If several injectors are removed, ensure that each injector is
reinstalled in its original location (cylinder).

Unlock an d remove electrical connector (A) . Remove fastener and

remove hold-down bracke t (B) . Remov e injecto r (C).

Seal injector (A) with cap and fuel rai l connections with plug from
special tool ki t 32 1 270.
 Fuel Injection MSD80, MSD81 (N54 Engine) 132-2 3
Fuel injectors, removing

Seal high pressure fuel lines (A) with caps from special tool kit
32 1 270.

32 1 270
b3091300082

The followin g procedure can b e used if of an injecto r is stuck i n the

cylinder head .

Install special tool 130 18 0 on injector (A).

130180

Install special tool 1 3 5 250 (slide hammer) and carefully knock fuel
injector (A ) out.
132-24 Fue l Injection MSD80, MSD81 (N54 Engine)
Injector bore, cleaning

Once injecto r (C ) is removed, instal l sealin g cap s to fuel lin e

connection (B ) and injecto r tip (A). Caps ar e available from BMW
dealer part s department .

b3091300065

Injector bore, cleaning

Only us e the following procedure i f injector bores are dirty.

To clean injector bore, slide injector, without uncoupling element (A)

but with new PTFE sealing rin g (B), i n and ou t of injector bores
several times. Replac e PTF E sealin g rin g after cleaning.

Clean contact surfaces of uncoupling elemen t an d cylinder head.

Replace uncoupling elemen t (A) .

Fuel injecto r PTF E seal , replacin g

Before replacing PTF E sealing rin g (A) mak e sure your hands an d
work surface are clean and free of oil. Avoid mechanical contact with
injector tip (B) .

b3091300067
 Fuel Injection MSD80, MSD8 1 (N5 4 Engine ) 132-2 5
Fuel injector PTFE seal, replacing

Using special too l 1 3 0 190 , remov e PTF E sealin g rin g (A ) from

injector (B). Us e a lint-free cloth to remove combustion residue from
cylindrical par t of injector tip. D o not clean injecto r tip.
130190

f
r

b3091300068

Slide ne w PTFE sealin g rin g (A ) on mounting taper 1 3 0 195 .

130195

Using finger s and mounting tape r (13 0 195 ) install PTF E sealin g
ring (A) on injector (B) .
132-26 Fue l Injectio n MSD80 , MSD8 1 (N5 4 Engine)
Fuel injector PTFE seal, replacing

To bring the PTF E sealing rin g to it s installation dimension , slide

three mounting sleeve s (A ) with decreasing diameter s on injector
(B).

First slide 1 3 0 192 (large diameter sleeve ) on injecto r (A). The n

slide mounting sleev e 130 19 3 on injector (A).
1 3 0 1 9 2 / 1 3 0 1 93

Next press injecto r (A) int o mountin g sleev e 130 19 4 (small

diameter). Instal l injector within 10 minutes o f removing mountin g
sleeve.

,130194

b3091300073
Fuel Injection MSD80, MSD81 (N54 Engine) 132-2 7
Fuel injectors, installing

Fuel injectors, installin g

Remember to:
• Replac e uncouplin g elemen t (A).
• Replac e PTF E sealin g rin g (B).
• Remov e PTFE protective cap a maximum of 1 0 minutes befor e
installing. Sealin g rin g swells up once cap i s removed.
• I f injector adaptation is needed, not e injector tolerance rang e
numbers fo r each corresponding cylinder.

b3091300066

Working at cylinder head :

• Instal l injector (A ) into cylinder head .
• Instal l hold-down bracke t (B). Fastene r (arrow ) should be finger
tight allowing injecto r (A) to be adjusted.
• Instal l electrical connector (C) .

Check that hold-dow n bracke t (A) i s correctly installed (arrows).

132-28 Fue l Injection MSD80, MSD81 (N54 Engine)
Fuel injectors, installing

Copper seal s on high pressure lines installed a t factory are no

longer needed. Remov e and discard .

b3091300076

Connect high pressure line (A) finger tight.

• I f reusing high pressure line, coat nu t threads with gear oil.
• High pressur e lin e may only be retightened 10 times.
• I f both nuts on line cannot be installed easil y b y hand, adjust
position of injector using following step .

^V I f fuel line union cannot be easily installed by hand, rotate injector in

direction of arrows until high pressure lin e nuts can be easily
tightened b y hand .

— Tighte n fastene r for hold-down bracke t (arrow).

Tightening torque
Hold-down D racket to cylinder head 13 Nm (9.5 ft-lb)
 Fuel Injectio n MSD8Q, MSD81 (N5 4 Engine ) 132-2 9
Fuel injector adaptation

Use following tightening sequence:

• Tighten nu t (A) usin g specia l tool 37 1 151 while holdin g injector
with wrench (C).
• Tighten nu t (B) usin g special tool 37 1 151.

— Clea n all fuel from ignition coil hole .

— Chec k fuel system for leaks.

— Perfor m injector adaptation. Se e Fue l injecto r adaptation i n this

repair group.

— Chec k an d clear fault codes from ECM memory .

Tightening torqu e
High pressur e line to injector 23 N m (17ft-lb )
High pressure line to fuel rai l 23 Mm (17ft-lb)

Fuel injecto r adaptatio n

Connect BM W scan tool and perfor m following tasks:
• Identif y vehicle.
• Selec t Function selection .
• Select Service functions.
• Selec t Adjustment programs .
• Selec t Adjust injectors.
• Change Tes t schedule .

For each replaced injector, enter fuel injector tolerance rang e (inset )
to corresponding cylinder.

Confirm correct tolerance rang e (inset ) ha s been entere d fo r each

"sirs of matchin g injector.
• Cylinder 1: 59 0 22 ?
I Cylinde r Z: 57 4 20 6
ytinderS: 58 8 22 0
Blinder 4: 58 5 23 7
|Cylinder5: 57 5 21 6
Cylinders: S8 t 22 5
132-30 Fue l Injection MSD80, MSD8 1 (N54 Engine)
Fuel rail, removing

Fuel rail , removing

Disconnect batter y negative (-) cable i n trunk or cargo compartment.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings an d Cautions .

Remove upper engin e covers. Se e 020 Maintenance .

Remove ignition coils . Se e 120 Ignition System .

CAUTION—
• Maintain a high level of cleanliness when servicing ignition
coils. Fuel or oil residue causes a breakdown of the electrical
resistance qualities ofsilicone used in production. Resulting in
failure of the ignition coil.

Label positio n an d remove hig h pressur e fue l lines :

• Using special tool 37 1 151 loosen nut (A) while holding injecto r
with wrench.
• Usin g specia l too l 37 1 151, loose n nu t (B).

WARNING —
• Fuel in the fuel line is underpressure (approx. 200 bar or2900
psi) and may be expelled forcibly. Do not smoke or work near
heaters or other fire hazards. Keep a fire extinguisher handy.
• Work only on fuel system when engine temperature is below
40°C(104°F).
• Unscrew the fuel tank cap to release pressure in the tank before
working on the fuel line.
• Plug open fuel lines and fittings.
• Wrap a clean shop towel around fitting before disconnecting.
Residual fuel pressure is present in the fuel line.
• To reduce fuel pressure, place towel over injector and carefully
tap with a wrench.
• Protect alternator from dripping fuel and oil.

CAUTION—
• Maintain a clean work area when servicing high pressure fuel
system. Contaminants can cause a system ma/function.
• Seal all fuel system opening with protective caps.
• Replace high pressure fuel lines if tightened 10 times.

Seal injector (A ) with cap and fuel rail connections with plu g from
special tool kit 32 1 270.

b309I300081l
 Fuel Injection MSD80, MSD81JN54 Engine) 132-3 1
Fuel rail, removing

Seal high pressure fuel lines (A) with caps from special tool kit
32 1 270.

32 1 270
53091300082

X, Unloc k and remove electrical connector (A) from fuel rail.

- Remov e electrical connector bracket s from fuel rail.

Detach fuel rail pressure sensor electrica l connector (arrow) .

Working at fuel injector rail :

• Loose n fuel line unio n nu t (A).
• Plu g open fuel lines and fittings.
• Wrap a clean shop towel around fitting before disconnecting.
Residual fuel pressure is present in fuel line.
• Remov e fasteners (B ) and remove fuel rail (C).
• Seal connections at high pressure line (A) and fuel rail (C).
132-32 Fue l Injection MSD80, MSD8 1 (N5 4 Engine )
Fuel rail, installing

Fuel rail, installing

Install high pressur e rail:
• Connect fue l line union (A) finger tight.
• Instal l fasteners (B) finger tight.
• Install electrical connector (C) .

Copper seals on high pressur e lines installed a t factory are no

longer needed . Remove an d discard.

Connect high pressure line (A) finger tight.

• If reusing high pressure line, coa t nu t threads with gear oil.
• Hig h pressure lin e may only b e retightened 1 0 times.
Fuel Injection MSD8Q, MSD81 (N54 Engine) 132-3 3
Fuel rail, installing

"^V. I f fuel lines cannot b e easily installe d b y hand :

• Loosen fastener (arrow )
• Rotat e injector in direction of arrows until high pressure lin e nut s
can b e easily tightened b y hand.

— Tighte n fastener for hold-down bracke t (arrow).

Tightening torque
Hold-down bracket to cylinder hea d 13 Mm ( 9 5 ft-lb)

Tighten fuel injector rai l (C) fasteners (B).

Tighten fue l line nu t (A).

Tightening torque
Fuel injector rai l to cylinder head 13Nm (9. 5ft-lb)
High pressure lin e to fuel rail 30 N m (22 ft-lb)

Use following tightening sequence :

• Tighten nu t (A) using special tool 37 1 151 while counter holdin g
injector with wrench (C).
• Tighten nut (B) using special tool 37 1 151.

Clean al l fuel from ignition coi l hole and install ignitio n coil.

Check fuel system for leaks .

Check an d clear fault codes fro m ECM memory.

Tightening torque
High pressur e lin e to injector 23 N m (17 ft-lb)
High pressur e line to fuel rail 23 Nm (17 ft-lb)
132-34 Fue l Injection MSD80, MSD81 (N54 Engine)
Intake manifold, removing and installing

Intake manifold, removing and installing

Disconnect batter y negative (-) cable in trunk or cargo compartment.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings an d Cautions .

— Remov e upper engin e covers. Se e 02 0 Maintenance .

— Remov e complete ai r filter housing an d air intak e ducts . Se e Air

filter housing and ducts, removing and installing in this repai r
group.

"> Disconnec t crankcas e breathe r lin e (A ) at cylinder hea d cover if

equipped.

NOTE—
• Not all models have additional line.

^ Exampl e of N54 engin e without additional crankcase breather line.

There is a plug (arrow) i n its place.

- Remov e throttle housing. See Throttle housin g (EDK), replacing

in this repair group.
Fuel Injection MSD80, MSD81 (N54 Engine) 132-3 5
Intake manifold, removing and installing

Working at right side underneat h intak e manifold :

• Disconnec t vacuu m hos e (A) , if equipped.
• Remov e fuel tank vent valve (B) from mounting bracket .
• Remov e vacuum hos e (C) and lay aside.

Slide wiring harnes s junction bo x (A) off bracket under intak e

manifold.

Disconnect electrical connector (A ) at oil pressure switc h (B)

132-36 Fue l Injection MSD80, MSD8 1 (N54 Engine)
Intake manifold, removing and installing

Working a t top of intake manifold , unhoo k electrical harness

retainers (A ) an d place harness ou t of way.

Remove electrica l connector (arrow) and remove fasteners (A).

Working at backside of intake manifold :

• Cut cable tie (A).
• Disconnec t electrical connector (B) , if equipped

CAUTION—
• Plug open intake ports to prevent parts or debris from falling
into the engine intake.

Installation is revers e of removal . Remembe r t o replace intak e

manifold seals (C ) i f necessary.

Tightening torque
Manifold to cylinder hea d 15 Mm (11 ft-lb)
Fuel Injection MSD80, MSD81 (N54 Engine ) 132-3 7
Crankcase breather valve

Crankcase breathe r valv e

, The crankcase breather valve is part of the cylinder head cover an d
is not serviceable as a separate component .

Oil separation is carried out via a labyrinth system and two cyclon e
separators incorporate d int o the cylinder head cover. B y having th e
system components integrate d into the cylinder head cover , the
crankcase gases are heated b y the engine.

However, there is one electric heating element at the manifol d inle t

(arrow). Onc e the liquid oil is separated from the crankcase vapors,
the oil is allowed to drain bac k through check valves bac k int o th e
engine.

If the diaphrag m valv e i n the breathe r housing leaks , ful l intak e

vacuum ma y be applied to the crankcase, resultin g in excessive oil
consumption, irregula r idle, whistling or howling noises o r oil smok e
in the exhaust .

Intake vacuum specifications for N54 engines

The breather valve set s a pressure range o f 7 to 1 1 mbar.

A faulty crankcase breather valve causes significant deviations from

the specified value:
• Crankcase ventilation clogged: Ambient pressur e +100 mbar
• Crankcase ventilation interna l leak : Ambient pressure -17 0 mba r
132-38 Fue l Injection MSD80, MSD81 (N54 Engine)
Engine coolant temperature (EOT) sensor, replacing

Engine coolan t temperature (ECT) sensor,

replacing
The engine coolant temperature (ECT) sensor i s a negative
temperature coefficient (NTC) sensor . As coolant temperature rises,
resistance through the sensor decreases .

The ECM varies ignitio n timing and air / fuel mixtur e base d on
engine coolant temperature. The EC T sensor i s supplied a 5 volt
reference voltage. The voltage dro p across the sensor varies as the
coolant temperature (senso r resistance) changes .

If the ECT sensor input is faulty or not plausible, the MIL is

illuminated when OBD I I fault criteria are exceeded. The ECM
assumes a substitute value (80° C / 176°F) to maintain engin e
operation. Ignition timing is set to a safely conservative basic setting.

The ECT sensor i s located at front of cylinder head .

. Wit h engine full y cooled off, remove fastene r (arrow) an d line (A).

CAUTION—
• Be prepared to catch any dripping coolant

Remove electrical connector (A) . Unscrew ECT sensor (B) from

cylinder head. B e prepared t o catch small amount o f coolant.

Installation is reverse of removal:

• Use new copper sealin g washer when installin g sensor.
• Replac e O-rings on coolant line .
• Replac e lost coolant.

Tightening torque
Temperature sensor to cylinder hea d 19Nm(14ft-lb)
Coolant pipe to cylinder hea d 19Nm(14ft-lb)

— Afte r reinstalling , chec k and clea r fault codes from ECM memory.

Radiator outlet coolant temperature sensor

^ Th e radiato r outlet temperature sensor (inset ) is a negative
temperature coefficien t (NTC) sensor. As coolant temperature rises ,
resistance through the sensor decreases.

The ECM varies cooling fan speed base d on radiator outlet coolant
temperature. The radiato r outlet coolant temperature sensor is
supplied a 5 volt reference voltage. Th e voltage drop across the
sensor varies as the coolant temperature (senso r resistance )
changes.
 Fuel Injectio n MSD80, MSD8 1 (N5 4 Engine) 132-3 9
DME main relay, testing

DME main relay, testing

The DME main rela y is energized via the ECM and supplies batter y
positive (B+) power to the following:
•ECM
• Ignitio n coil s
• Tailpipe flap
• E-box coolin g fan
• Fuel tank lea k detection pum p
• Crankshaft senso r
• Camshaft sensor s
• Evaporativ e emissions valv e
• Crankcas e breathe r valve heater
• Oil condition senso r
• Electri c coolant pum p
• Thermostat
• Oxygen sensor heater s

If the DM E main relay i s faulty, th e engine does not start.

. Wit h ignition off, remove DME mai n relay (K6300) in electronics box
(E-box) a t right rear of engine compartment .

NOTE—
• Relay locations can vary. Confirm relay identification by matching
wiring colors and terminal numbers. Se e ELE Electrical Wirin g
Diagrams.

'A Chec k for voltage at terminal 6 of relay socket (corresponds t o

DMEE main relay circuit terminal 3 0 on relay) .
B+ junction point
(battery voltage a t all times ) — I f battery voltage i s present, continue testing.
6
30 K6300 — I f battery voltag e is not present, chec k the following:
DME

G
[ main rel ;iy • Larg e re d wire in relay socke t
i— ]~

NMHMHMI
"
• A2076 (batter y positive junction) in E-box, right rea r of engin e
85 87 1
compartment
4 2 5
'|F6 ! • Fus e F 8 in fuse and relay panel behin d glove compartment. Se e
23
1

I10AI Power suppl y fuse s i n this repai r group.

~T^ 1A600 0 i
j©] « ECM • Wiring can vary. See ELE Electrical Wiring Diagrams fo r mor e
details.
L rU j 3 5 7 1

/\8680 f "
L-». i— >-
•* i — Chec k fo r ground at relay socket 4 (corresponds to terminal 85 on
Eingine 1 [ F3 F4 F1 I relay).
e lectronics 1 I 30A I 20A [
30A 1
30AI
f use carrier ' i
i — I f ground i s present, continu e testing.
b309 1300033

— I f ground i s not present, signa l fro m ECM i s missing. Chec k wir e

between rela y and ECM 44-pin connector X60005. See EC M pin
assignments in this repair group .
132-40 Fue l Injectio n MSD80 , MSD8 1 (N5 4 Engine )
DME main relay, testing

— I f no faults are found :

• Check ECM grounding.
• EC M may be defective.

— Wit h ignition O N and rela y installed, chec k fo r batter y voltage at

relay sockets 2 and 5 (correspond to terminals 8 7 on relay).

NOTE—
• In some models there is only one terminal 87.

— I f battery voltage i s present, rela y ha s energize d an d i s functioning

correctly.

— I f battery voltage i s not present and al l earlie r tests are OK , rela y is

faulty. Replace.

— I f no faults are found during rela y testing but powe r i s not reaching
ECM or other components , chec k fuse s in engine electronic s fuse
carrier (A8680) i n E-box. See Powe r suppl y fuses i n this repai r
group.

— Whe n finished testing, check an d clea r fault codes fro m EC M

memory.
 Fuel Injection MSD80, MSD81 (N54 Engine) 132-4 1
ECM pin assignments

ECM pin assignment s

The engine control module (ECM ) (arrow) i s located in the right rear
of the engine compartmen t i n the E-box.

The EC M has 2 main electrica l harness connectors, one with 4

modular connections an d the other with 3 for a total o f 7 sub
connectors and 14 7 pins.
A fl 23 44 s* /5 6 14 .....A
>III,,J • A: X60001 (signals )
12 2 _C_ T"""" " "13
-U~ 7 121 42 6 • B: X60002 (signals)
~; F I" *"'"1G"".I ^. _ . J=f
kj 7 1 6 1 w ...^ • C: X60003 (voltage , ground supply)
• D : X60004 (ignitio n coils)
• E: X60005 (signals)
b3091300002
• F : X60006 (fue l injectors)
• G: X60007(signals)

ECM pin assignments for turbo engines are given i n Table b . This
information can be helpful when diagnosing faults to or from the
ECM.

Generally, absence o f voltage or continuity means ther e i s a wiring

or connector problem. Test results with incorrec t value s do not
necessarily mea n that a component is faulty. Check fo r loose ,
broken or corroded connections an d wiring before replacing
components. For engine management syste m electrica l
schematics, see EL E Electrical Wiring Diagrams.

When making checks at the ECM, use a break-out box to allow tests
to be made with the connector attached to the ECM . Thi s prevent s
damage to the small terminals i n the connector. As an alternative,
the connector housin g ca n be separated so that electrica l check s
can b e made fro m the bac k o f the connector.

CAUTION—
• Wait at least one minute after switching the ignition OFF before
removing the connector from the ECM. If the connector is
removed before this time, residual power in the system relay
may damage the ECM.
• Connect or disconnect the control module connector and meter
probes with the ignition OFF.
132-42 Fue l Injectio n MSD80 , MSD8 1 (N5 4 Engine )
ECM pin assignments

Table b. Siemens DME MSD80 / 81 ECM pin assignments

Connector X60001 26-pi n (signals)
Pin Type Component or function Note
1 input/output Signal PT-CA N low Powertrain CAN-bu s
2 input Start signal Car access system
3 input/output BSD signal Battery senso r
4 input Brake ligh t signal Brake light switc h
5 - Not use d
6 input Radiator outlet temperature sensor signal Temperature sensor a t radiator outle t
7 input Accelerator peda l module signa l Accelerator peda l module
8 output Electric fan signal Electric engine coolin g fan
9 - Not used
10 ground Accelerator pedal modul e Accelerator pedal modul e
11 output Accelerator pedal modul e supply voltage Accelerator pedal modul e
12 - Not used
13 - Not used
14 input/output Signal PT-CA N high Powertrain CAN-bu s
15 input EWS signal Car access system
16 input Brake light test signal Brake light switch
17 input Right rea r wheel spee d senso r signa l Connector X 1 01 86 (right rear wheel speed sensor )
18 input Clutch switch signal Clutch switch modul e
19 input Radiator outle t temperature sensor signa l Temperature senso r at radiator outlet
20 input Accelerator pedal modul e signal Accelerator pedal modul e
21 input/output TD signa l TD signal connecto r
22 - Not use d
23 ground Accelerator pedal module Accelerator pedal modul e
24 output Accelerator pedal modul e suppl y voltage Accelerator peda l modul e
25 - Not used
26 - Not use d

Connector X60002 26-pin (signals)

Pin Type Component or function Note
1 input Wake up signal, terminal 15 Terminal 1 5 wake up connector
2 - Not used
3 - Not use d
4 - Not use d
5 input Oxygen sensor signa l Bank 2 sensor 1
6 input Oxygen sensor signal Bank 1 sensor 1
7 input Oxygen sensor signal Bank 2 sensor 1
 Fuel Injection MSD80, MSD8 1 (N54 Engine) 132-4 3
ECM pin assignments

Connector X60002 26-pi n (signals) (continued)

Pin Type Component or function Note

8 input Oxygen sensor signa l Bank 1 sensor 1

9 input Oxygen sensor signal Bank 2 sensor 1

10 ground Oxygen sensor Bank 1 sensor 1

11 ground Oxygen sensor Bank 2 sensor 1

12 input Oxygen sensor heating Bank 1 sensor 1

13 input Oxygen sensor heating Bank 2 sensor 1

14 - Not used

15 - Not used

16 input DMTL pump signal Diagnosis module for fuel tank leakage
17 input DMTL heating signal Diagnosis modul e for fuel tank leakage

18 input Oxygen sensor signal Bank 1 sensor 1

19 input Oxygen sensor signal Bank 2 sensor 2

20 input Oxygen sensor signal Bank 1 sensor 2

21 - Not used
22 - Not use d

23 ground Oxygen sensor Bank 1 sensor 2

24 input Oxygen sensor Bank 2 sensor 2

25 input Oxygen sensor Bank 2 sensor 2

26 output Oxygen senso r Bank 1 sensor 2

Connector X60003 6-pin (voltage, ground supply)

Pin Type Component or function Note

1 input Terminal 30 B+ potential distributor

2 input Terminal 87 Fuse F0 3

3 ground Ground Ground poin t

4 ground Ground Ground point

5 ground Ground Ground point

6 ground Ground Ground point

Connector X60004 6-pin (ignition coils)

Pin Type Component or function Note
1 output Ignition coil signal Ignition coil signal 1
2 output Ignition coil signal Ignition coil signal 2
3 output Ignition coil signal Ignition coil signal 3
4 output Ignition coil signa l Ignition coil signal 4
5 output Ignition coi l signal Ignition coil signal 5
6 output Ignition coil signal Ignition coil signal 6
132-44 Fue l Injectio n MSD80 , MSD8 1 (N5 4 Engine )
ECM pin assignments

Connector X6000 5 44-pin (signals )

Pin Type Component or function Note
1 - Not used
2 - Not use d
3 output Volume contro l valve Control signal
4 - Not use d
5 - Not use d
6 - Not use d
7 output Low pressure fuel sensor groun d Low pressure fue l senso r
8 output Low pressure fuel sensor voltage supply Low pressure fuel sensor
9 input Boost pressure senso r signa l Boost pressure senso r
10 input Boost pressur e senso r signal Boost pressure sensor
11 output Boost pressure sensor voltag e supply Boost pressur e senso r
12 - Not use d
13 output DME main rela y activation DME main rela y
14 output Throttle valve voltage suppl y Throttle valve
15 input Throttle valv e signal Throttle valv e
16 input Throttle valve signal Throttle valve
17 input Intake air temperature signal Integral to boost pressur e sensor
18 Not use d
19 input Knock sensor signa l Knock senso r
20 input Knock senso r signa l Knock senso r
21 - Not use d
22 Not used
23 output Fuel tank vent valve signal Fuel tank ven t valv e
24 - Not use d
25 - Not use d
26 - Not use d
27 - Not use d
28 - Not use d
29 input Crankshaft position sensor signa l Crankshaft position sensor
30 ground Crankshaft positio n sensor Crankshaft positio n senso r
31 output Intake manifol d pressure sensor voltage supply Intake manifold pressur e senso r
32 ground Intake manifol d pressure sensor Intake manifold pressure senso r
33 input Intake manifol d pressur e sensor signa l Intake manifol d pressure senso r
34 input Low pressure fuel sensor signal Low pressure fuel senso r
35 input/output BSD signal BSD signal connecto r
36 input Throttle valve signa l Throttle valve
37 input Throttle valv e signa l Throttle valve
 Fuel Injectio n MSD80 , MSD8 1 (N5 4 Engine ) 132-4 5
ECM pin assignments

Connector X60005 44-pin (signals) (continued)

Pin Type Component or function Note

38 ground Throttle valve Throttle valve

39 - Not used

40 - Not use d

41 input Knock sensor signa l Knock sensor

42 input Knock senso r signa l Knock senso r

43 - Not used
44 - Not use d

Connector X60006 12-pi n (ignition coils)

Pin Type Component or function Note

1 output Fuel injector voltage suppl y Fuel injecto r 1

2 output Fuel injector voltage suppl y Fuel injecto r 2

3 output Fuel injecto r voltage suppl y Fuel injecto r 3

4 output Fuel injector voltage suppl y Fuel injecto r 4

5 output Fuel injector voltag e supply Fuel injector 5

6 output Fuel injector voltage suppl y Fuel injecto r 6

7 output Fuel injector trigge r Fuel injector 1

8 output Fuel injector trigger Fuel injecto r 2

9 output Fuel injector trigger Fuel injecto r 3

10 output Fuel injecto r trigger Fuel injecto r 4

11 output Fuel injector trigge r Fuel injector 5

12 output Fuel injecto r trigger Fuel injecto r 6

Connector X60007 26-pi n (signals)

Pin Type Component or function Note
1 - Not used
2 - Not use d

3 - Not use d
4 input Engine coolan t temperature signa l Engine coolan t temperature senso r
5 output Intake VANOS solenoid signa l Intake VANO S solenoi d
6 - Not use d
7 output Wastegate contro l valve signa l Wastegate contro l valve
8 input Fuel rai l pressure sensor signa l Fuel rai l pressure sensor
9 output Fuel rai l pressure sensor signa l Fuel rai l pressure senso r
10 output Fuel rai l pressure sensor voltage suppl y Fuel rai l pressur e sensor
11 input Camshaft positio n sensor 1 signal Camshaft positio n senso r 1
12 input Camshaft positio n senso r 2 signa l Camshaft positio n sensor 2
13 input Oil pressure switch signal Oil pressure switch
132-46 Fue l Injectio n MSD80 , MSD81 (N5 4 Engine )
ECM pin assignments

Connector X60007 26-pin (signals) (continued )

Pin Type Component or function Note
14 output Wastegate control valve signal Wastegate control valve signal
15 - Not used
16 - Not use d
17 ground Engine coolant temperature sensor Engine coolant temperatur e sensor
18 output Exhaust VANOS solenoid signal Exhaust VANOS solenoid
19 input Thermostat signal Thermostat
20 - Not use d
21 - Not used
22 - Not use d
23 - Not use d
24 ground Camshaft positio n sensor 1 Camshaft position sensor 1
25 ground Camshaft positio n sensor 2 Camshaft position sensor 2
26 input/output BSD signal Electric coolant pum p
 133-1

133 Fue l Injection M E 9.2, M E 9.2.2

(V8 Engine)

GENERAL 133- 1 Secondary ai r injection system components . 133-1 6

DME applications 133- 2 Secondary air injection illustrations 133-1 6
Warnings an d Cautions 133- 3 Air filte r housing and duct,
removing an d installing 133-1 8
DRIVEABILITY TROUBLESHOOTIN G 133- 5 Mass airflow , measurement 133-1 8
Basic engin e setting s 133- 5 Mass air flow sensor, replacing 133-1 9
System voltage 133- 5 Throttle housing (EDK) , replacing 133-1 9
Main grounds 133- 6 Valvetronic motor , removing and installin g . . 133-2 1
On-board diagnostics 133- 6 Fuel rail and injectors,
ENGINE MANAGEMEN T FUSE S removing and installing 133-2 2
AND POWE R SUPPL Y COMPONENTS 133- 7 Intake manifold , removing and installing . . . . 133-2 4
Power supply fuse s 133- 7 Engine coolant temperatur e (ECT) sensor,
replacing 133-2 5
Integrated voltage suppl y modul e
(IVM) (A6009 ) 133- 8 Radiator outlet coolant temperature sensor . . 133-2 6
Vacuum pump , removin g an d installing 133-2 6
BOSCH DME M E 9.2 , M E 9.2. 2 133- 9 Bosch M E 9.2, M E 9.2.2 ECM
Bosch DME introduction 133- 9 pin assignments 133-2 7
Integrated voltage suppl y modul e
(IVM) relay s 133-1 0 TABLE

DME engine managemen t a. 5 Series engine management application s 133- 2

system description 133-1 1 b. Fuses applications, Integrate d voltage supply modul e
Secondary air injection 133-1 5 (IVM) (A6009 ) (V8 engine) 133- 8

GENERAL
This repai r group covers service and repair of engine managemen t
systems for 5 Series models with V8 engine and Bosch DM E ME 9.2
and ME 9.2.2.

See also:
• 020 Maintenance fo r air filter, fuel filter and spark plu g
replacement
• 100 Engine-General for engine identification and application
• 120 Ignition System for ignition coil , camshaft sensor, crankshaft
sensor and knock sensor service
• 160 Fuel Tank and Fuel Pum p for fuel pump and fuel pump relay
service, fuel pressure test s and fuel pressure regulato r
replacement
• 18 0 Exhaust System fo r oxygen sensor service
• ECL Electrical Componen t Location s
• ELE Electrical Wiring Diagram s
• OBD On-Board Diagnostic s
133-2 Fue l Injectio n ME 9.2, ME 9.2.2 (V 8 Engine )
DME applications

DME applications
BMW 5 Series models are equipped with digital motor electronics
(DME), also known as Motronic. In these systems, fuel injection and
ignition ar e controlled b y an integrated engine contro l module
(ECM). Application informatio n for DM E systems is in Table a.

Table a. 5 Series engine management applications

Year, model Engine Engine Features
code management
2004-2005
Sedan: 525i , 530 i M54 Siemens Double VANOS
MS 45.1
Sedan: 545 i N62 Bosch DM E Valvetronic,
ME 9.2 with VANOS
Valvetronic
control modul e
2006 - 200 7
Sedan, N52 Siemens MSV70 Valvetronic,
Sports Wagon : VANOS
525i, 525xi,
530i, 530x i
Sports Wago n
2008-2010

Sedan, N52KP Siemens MSV8 0 Valvetronic,

Sports Wagon: VANOS
528i, 528xi
Sedan, N54 Siemens MSD80 VANOS,
Sports Wagon : (to 03 / 2008) turbocharged
535i, 535x i MSD81 (fro m
03 / 2008 )
2004-2005
Sedan: 545i N62 Bosch DME Valvetronic,
ME 9.2 with VANOS
Valvetronic
control modul e
2006-2010
Sedan: 550i N62TU Bosch DM E Valvetronic,
ME 9. 2.2 VANOS
Fuel Injectio n ME 9.2, M E 9.2.2 (V 8 Engine ) 133- 3
Warnings and Cautions

Warnings and Cautions

WARNING —
• The fuel system is designed to retain pressure even when the
ignition is OFF. When working with the fuel system, loosen the
fuel lines slowly to allow residual fuel pressure to dissipate.
Avoid spraying fuel. Use shop towels to capture leaking fuel.
• Fuel in fuel lines is underpressure (approx. 3 - 5 bar or 45 - 75
psi) and may be expelled forcibly. Do not smoke or work near
heaters or other fire hazards. Keep a fire extinguisher handy.
• Unscrew the fuel tank cap to release pressure in the tank
before working on fuel lines.
• Plug open fuel lines and fittings.
• Before beginning work on the fuel system, place a fire
extinguisher in the vicinity of the work area.
• Work only on the fuel system when engine temperature is
below 40°C(104°F).
• Fuel is highly flammable. When working around fuel, do not
disconnect wires that could cause electrical sparks. Do not
smoke or work near heaters or other fire hazards.
• Wear eye protection and protective clothing to avoid injuries
from contact with fuel.
• When working on an open fuel system, wear suitable hand
protection, as prolonged contact with fuel can cause illnesses
and skin disorders.
• Do not use a work light with an incandescent bulb near fuel.
Fuel may spray on the hot bulb causing a fire.
• Make sure the work area is properly ventilated.
• Due to risk of personal injury, be sure the engine is cold before
beginning work on engine components.
• The ignition system produces high voltages that can be fatal.
Avoid contact with exposed terminals. Use extreme caution
when working on a car with the ignition switched ON or the
engine running.
133-4 Fue l Injection ME 9.2, ME 9.2.2 (V8 Engine )
Warnings and Cautions

CAUTION—
• Renew fuel system hoses, damps and O-rings any time they
are removed.
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings an d Cautions .
• Connect and disconnect the DME system wiring and test
equipment leads only when the ignition is switched OFF.
• Wait at least 1 minute after switching the ignition OFF before
disconnecting engine control module (ECM) connectors. If the
connectors are removed before this time, residual power in the
system relay may damage the control module.
• Tests or repair procedures in this section may set fault codes
(DTCs) in the ECM and illuminate the MIL. After repairs are
completed, access and clear DTC memory using a BMW scan
tool. See On-board diagnostic s i n this repair group.
• Fuel system cleaners and other chemical additives other than
those specifically recommended by BMW may damage
catalytic converters, oxygen sensors or other fuel supply
components.
• Do not connect any test equipment that delivers a 12-volt
power supply to terminal 15 (+) of the ignition coils. The current
flow may damage the ECM. Connect test equipment only as
specified by BMW or the equipment maker.
• Relay positions can vary. Be sure to confirm relay location and
function by identifying the wiring in the socket using the wiring
diagrams found in ELE Electrica l Wirin g Diagrams .
• Use a digital multimeter for electrical tests. Use an LED test
light for quick tests.
Fuel Injectio n M E 9.2, M E 9.2.2 (V 8 Engine) 133- 5
Basic engine settings

DRIVEABILITY TROUBLESHOOTING
The self-diagnostic DME engine management systems monitor and
store diagnostic troubl e codes (DTCs) . If the malfunction indicator
light (MIL) illuminates, it indicates that an emissions-related fault has
occurred and that one or more DTCs are stored in the engine contro l
module (ECM) .

If faults arise, or i f the MI L i s illuminated, begin troubleshooting b y

connecting BM W scan tool to the OBD I I plug on lef t door post .

The capabilities of OBD II software has the potential to save hours of

diagnostic time and to help avoid incorrect component replacement
and possible damage t o system components . See On-boar d
diagnostics i n this repai r group.

Basic engine setting s

Idle speed, idl e mixture (%CO), and ignition timing are not
adjustable. The DM E system is adaptive and automatically
compensates for changes i n the engine due to age, mino r wear or
small problems such as a disconnected vacuum hose. However, the
adaptive range is limited. Once the limit s are exceeded, driveability
problems become noticeable .

Poor initial driveability may be encountered when the batter y i s

disconnected and reconnected. When the battery is disconnected ,
ECM adaptive memor y may be reset. The system readapt s afte r
about ten minutes of driving.

System voltage
Digital motor electronic s (DME) requires that the system (battery )
voltage b e maintained within a narrow range of DC voltage. D C
voltage level s beyond or below the operating range, or any AC
voltage in the electrical system ca n cause havoc.

When troubleshooting an illuminated MIL, make sur e the batter y i s

fully charged and capable o f delivering all its power to the electrical
system. An undercharged batter y can amplify AC alternator output
ripple.

To make a quick check o f battery charge, measure voltage acros s

battery terminals with all cables attached and ignitio n OFF . A fully
charged battery measures 12. 6 volts or slightly more, compared t o
12.15 volts for a battery with a 25% charge.

The DME system operates at low voltage and current levels, making
it sensitive to small increases i n resistance. The electrical system is
routinely subjec t to corrosion, vibration and wear, so faults or
corrosion in the wiring harness and connectors are not uncommon .

Check batter y terminals for corrosion or loose cable connections .

See 121 Battery , Starter, Alternator.
133-6 Fue l Injection ME 9.2, ME 9.2.2 (V8 Engine)
Main grounds

If a battery cable connection has no visible faults but is still suspect,

measure voltage drop across the connection. A large drop indicates
excessive resistance, meaning that the connection is corroded, dirt y
or damaged. Clea n o r repair and retest . See 600 Electrica l
System-General for voltage drop tes t procedure.

Visually inspec t wiring, connectors, switche s an d fuses. Loose or

damaged connector s can cause intermitten t problems, especiall y
small terminals i n ECM connectors. Disconnec t wirin g harnes s
connectors to check for corrosion, and use electrical cleaning spray
to remove contaminants .

Main grounds
Good ground s ar e critical to proper DM E operation . I f a ground
connection has no visible faults but is still suspect, measure the
voltage drop across the connection. A large voltage drop mean s
high resistance . Clean or repair the connection an d retest.

For voltage drop testing, see 600 Electrica l System-General.

For ground locations , see EC L Electrica l Componen t Locations.

On-board diagnostic s
Second generation on-boar d diagnostics (OB D II ) software and
hardware is incorporated i n the engine managemen t systems. Th e
OBD I I system monitors component s tha t influenc e exhaust an d
evaporative emissions. I f a problem i s detected, the OBD I I system
stores the associated diagnosti c troubl e code (DTC) and condition .

If vehicle emissions level s exceed 1. 5 times Federally mandate d

criteria, the OBD I I system illuminate s a malfunction indicator light
(MIL) i n the instrumen t cluster .

Scan tool connected t o OBD I I plug belo w lef t dashboard.

Professional diagnostic scan tools availabl e at the time of this

printing include th e BM W GT1 , IST A and a small number of
aftermarket BMW-specifi c tools.

In addition to professional scan tools, there are inexpensive generic

OBD I I scan tool software programs an d handhel d units available.
Although these hav e limite d capabilities a s compared to the
dedicated tools , they are powerful diagnosti c tools.

For the DI Y owner, a simple aftermarke t DTC reader is available

through http://www.peakeresearch.com. This tool is capable of
checking for DTCs as well as switching the illuminated MIL OFF and
resetting service indicator lights .

NOTE—
• OBD II DTC memory (including an illuminated MIL) can only be
reset using a BMW scan tool or. Removing the connector from the
ECM or disconnecting the battery does not erase DTC memory.
Fuel Injectio n ME 9.2, M E 9.2.2 (V 8 Engine) 133- 7
Power supply fuses

ENGINE MANAGEMEN T FUSE S

AND POWE R SUPPLY COMPONENT S
Power supply fuses
See EC L Electrical Component Location s for fuse panel acces s
information.

Rear distribution panel (A46) in trunk, installed in right rear fender:

• F9 0 200A: Powe r supply to fuse and relay panel behin d glov e
compartment (A41a) .
• F9 1 100A: Powe r supply to fuse panel Integrate d voltage suppl y
module (IVM ) (A6009) .

A41a: fuse and rela y panel behin d glove compartment:

• F 8 60A: Integrate d voltage supply modul e (IVM ) (A6009 )

See ECL Electrical Componen t Location s for specific vehicle fuse

locations.
133-8 Fue l Injection ME 9.2, ME 9.2.2 (V8 Engine)
Integrated voltage supply module (IVM) (A6009)

Integrated voltage supply module (IVM) (A6009)

The integrated voltage supply module (IVM) (A6009 ) i s in the E-box,
right rea r engine compartment , unde r th e plenu m cover . See also:
• Integrated voltag e suppl y modul e (IVM ) relay s in this repai r
group fo r IV M relay informatio n
• ECL Electrical Component Locations for E-box access
information.

IVM fuse rating s are in Table b

Table b. Fuse applications, integrated voltage supply module

(IVM) (A6009 )
Rating
Fuse in amps Protected circuits
F001 30 Engine control modul e (ECM ) (A6000 )
Fuel injector s 5 - 8 (Y610 5 - Y6108)
Valvetronic control modul e (A60210 )
Sequential manua l gearbo x (SMG ) (A70010 )
F002 20 Camshaft sensors , lef t ban k (B62241 , B62242 )
Ignition coils 5 - 8 (T6155 - T 6158)
VANOS solenoids, lef t ban k (Y6283 , Y6284)
Fuel tank ven t solenoi d (Y6120 )
F003 20 Ignition coil s 1 - 4 (T6151 - T6154)
F004 20 Ignition coils 5 - 8 (T6155 - T6158)
F005 30 Camshaft sensors, righ t bank (B62141, B62142 )
Crankshaft sensor (B6203 )
Thermostat, characteristi c ma p (Y6279)
VANOS solenoids, righ t bank (Y6281, Y6282)
Mass ai r flow sensor (B6207 )
F006 20 Fuel injector s 1 - 4 (Y610 1 - Y6104)
F007 20 Engine contro l module (ECM ) (A6000))
Sequential manua l gearbo x (SMG) (A70010)
F008 30 Oil quality sensor (B62540 )
Oxygen senso r heater s
F009 10 Fuel pum p rela y (K96)
Tailpipe flap (Y 1 98)
Radiator shutter solenoi d (Y13864 )
E-box fan (M6506 )
DMTLpump(M119a)
Secondary ai r pum p rela y (K6304)

F010 40 Valvetronic contro l modul e (A60210 )

F011 40 Valvetronic contro l module (A60210)
 Fuel Injectio n ME 9.2, M E 9.2.2 (V 8 Engine ) 133- 9
Bosch DME introduction

BOSCH DME M E 9.2, M E 9.2. 2

5 series models t o 09 / 2005: N6 2 V8 engine wit h Vaivetronic (4. 4
liter) i s equipped wit h Bosch DM E ME 9.2 engine management .

5 series model s from 09 / 2005: N62T U V8 engine with Vaivetronic

(4.8 liter) i s equipped wit h Bosc h DM E ME 9.2.2 engin e
management.

Both DME engine managemen t system s for N62 and N62T U V 8

engine ar e similar an d will be covered together unles s otherwis e
noted.

For a description of the N6 2 engine, se e 100 Engine-General.

Bosch DM E introductio n
The Bosc h DM E engine managemen t syste m meets stringen t
emission requirements in addition to reducing fuel consumption an d
increasing driving performance . A flash EEPROM i s used a s th e
storage mediu m for program data, DT C memory and adaptatio n
values. The engine control module (ECM) works in combination wit h
the Vaivetronic control module :
• ECM : Overall engin e managemen t
.Vaivetronic • Vaivetronic control module : Variabl e intake valve lif t
"control modul e
The ECM , Vaivetronic control module and integrated voltage supply
module (IVM ) are in the E-bo x at the right rea r of the engin e
compartment.

The EC M controls an electric cooling fan (arrow) i n the bas e o f th e

E-box to draw i n cool air from the passenger compartment.

The 13 4 pin ECM is manufactured by Bosch to BMW specifications .

The EC M uses the SKE (standard shell construction) housing an d
has 5 modular connectors.

12 45
133-10 Fue l Injection ME 9.2, M E 9.2.2 (V 8 Engine)
Integrated voltage supply module (IVM) relays

Integrated voltag e suppl y modul e (IVM) relay s

When ignitio n i s switched ON, the EC M activates a ground path to
energiiie relays 1 - 3 in the IVM .

1. Powe r to ECM
2. Powe r to fuel injectors

1. Powe r to oxygen sensor heaters

• CAS activates relay 4.
2. Powe r to ignition coils
• Additional relays in IVM supply power
to the Valvetronic system and
automatic transmission control
module.

BX56130035

See also Engin e Managemen t Fuse s and Power Suppl y

Components i n this repai r group .
Fuel Injection ME 9.2, ME 9.2.2 (V8 Engine) 133-1 1
DME engine management system description

DME engine management system description

The DM E manages an d monitor s th e following functions :

Air

• Electroni c throttl e
• Mas s airflo w
• Variable intak e manifol d
• Valvetronic

Fuel
• Fue l suppl y
• Fue l injectio n

Ignition
• Direc t ignitio n
• Knoc k control
• Primar y an d secondary ignitio n monitoring

Emissions
• OBD II compliance
• Pre - and post-catalyst oxyge n sensors
• Electricall y heated DME-mapped thermostat
• Misfir e detection
• Evaporativ e emissio n control and leak detection
• Secondar y ai r injection syste m (to 03 / 2005)
• Malfunctio n indicator light (MIL)

Performance controls
• Dua l VANOS contro l
• Outpu t o f injection signal (Tl ) for fuel economy gaug e
• Outpu t of engine rp m (TD) for tachometer
• A/C compressor contro l
• Electri c radiator cooling fan
• CAN-bu s communicatio n
• Dynami c stabilit y control (DSC ) interface
• CAS (car access system ) with EWS 3.3
• Cruis e contro l
• ECM programming
133-12 Fue l Injectio n M E 9.2, M E 9.2.2 (V 8 Engine )
DME engine management system description

Fuel meterin g
The EC M meters pressurized fuel by changing th e opening time
(pulse width ) o f the fuel injectors. The exac t amount of fuel injected
is determined b y the amoun t o f time the injector s are open. To
ensure that injector pulse width is the only factor that deteroalaes fuel
metering, fuel pump pressure is maintained by a pressure regulator.

The fuel injectors are positioned clos e to the intake valves resulting
in large injection spray angles. Greater fuel spray atomization leads
to optimum fue l mixing and thereby reduce s fuel consumption an d
exhaust emissions .

A service port (arrow) in the non-retur n fue l rail is for fuel pressure
tests.

The Siemens fue l injectors hav e a coil resistanc e o f approximately

12 fieach .

The Bosc h DM E system uses 8 individual fue l injector circuit s so

that any one or multiple injectors can be deactivated, i f needed. I f the
ECM detects a catalyst-damaging fault, it deactivates all the
injectors.

Variable intake manifold

The variable intake manifold is operated b y turning a rotor.
Intake manifol d

Rotor

BX56130039

Adjustments to the intak e manifol d are carried out by the EC M

controlling a drive unit. The driv e uni t is mounted on the rea r of the
intake manifold.

The drive unit consists of a 12 V electric motor with worm gears and
an integral potentiometer for intake manifold position feedback. If the
Intake manifol d
pressure senso r j drive unit fails, the system remains in its current position. The driver
may notice a loss in power and a fault code may be stored i n the
ECM.

Variable
manifold driv e

B5101330021
 Fuel Injection ME 9.2, ME 9.2.2 (V 8 Engine) 133-1 3
DME engine management system description

Valvetronic system

The Valvetronic control system varies intake valve opening tim e and
valve lif t according t o engine spee d and load . Exten t of valve lif t i s
based on a request from the ECM . Two Valvetronic actuators adjus t
the two eccentric shafts in the cylinder heads, affecting valve lift. See
100 Engine-General for additional information.

Faults i n the Valvetronic system are detected by the Valvetroni c

control module and transmitted via CAN-bus to the ECM where they
are stored for diagnostics.

Idle speed control

The EC M controls idle speed b y varying intake valve lif t via th e

Valvetronic system.
1. Valvetroni c motor
2. Retur n spring
3. Intak e camshaft
4. Intermediat e lever
5. Intak e rocke r arm
6. Intak e valve

Idle speed is not adjustable. The basic functions and parameters o f

idle speed control are as follows:
• Control of cold air intake volume.
• Smoot h idle speeds regardles s of load and inputs.
• Smoot h transition from acceleration to deceleration.

Idle speed stabilization is active during the following conditions:

• Engin e warm up
b3091300006
• Heating or A/C activation
• Driv e gear selected (automati c transmission)
• Varying cooling fan speeds

Throttle control

The throttle module (EDK ) is not needed for engine loa d control .
Which is carried out by the Valvetronic functio n of the ECM .
However, the throttle may be slightly closed to allow sufficien t
manifold vacuum for crankcase ventilation an d canister purg e
systems.

The ECM provides operating voltage and ground to the throttle valve
for openin g and closing the throttle plate .

BentteyPublishers
85101330022
133-14 Fue l Injection ME 9.2, ME 9.2.2 (V8 Engine)
DME engine management system description

Knock (detonation) control

Knock sensors monitor and control ignition knoc k through the ECM.
The knoc k sensors function lik e microphone s an d are able to
convert mechanical vibratio n (knock ) int o electrical signals. The
ECM is programmed to react to frequencies that are characteristic of
engine knoc k and adapt the ignition timing poin t accordingly .

Four knock sensors (arrows ) are bolted to the cylinder head s

between cylinders 1 & 2, 3 & 4, 5 & 6 and 7 & 8. If the signal valu e
exceeds the programmed threshold , th e ECM identifies knock and
retards the ignition timing for that cylinder .

If a fault is detected with the sensor(s), the EC M deactivates knock

control. Then the ignition timing is set to a conservative basic setting
based on intake ai r temperature an d a DTC is stored.

Knock sensor replacement i s covered i n 120 Ignition System .

Evaporative emissions
Control of evaporative fuel vapors fro m the fuel tank continues
through tighter controls of fuel tank venting and refinements in the
leak detection system (DM-TL).

On-board refuelin g vapor recover y (ORVR)

The ORVR system recover s and stores hydrocarbo n (fuel) vapor s
during refueling. When refueling , the pressur e of the fuel entering
the tank forces hydrocarbon vapors through the tank refuelling
breather hose to the liquid / vapor expansio n tank and into the
activated charcoal canister. The vapor s ar e stored in the caniste r
and the system ca n then breathe through the DM-TL and the air
filter.

Oxygen sensor s
In order to control exhaust emissions, 4 oxygen sensors are utilized,
2 before and 2 after the converters .

The post-catalyst sensors are conventional heate d zirconia units

which produce a low and relativel y stable voltage (approx.
700 - 800 mV ) when the system is stable an d operating normally.
Fuel Injection ME 9.2, ME 9.2.2 (V8 Engine) 133-1 5
Secondary air injection

The precatalyst units are Bosch LS U planar wideband oxyge n

sensors. This compact senso r use s thin layers of zirconium dioxid e
(ZrO2) ceramic films. The laminate structure allows the integration of
several functions including th e heating element which ensure s tha t
the minimu m operatin g temperatur e (750°C / 1382°F ) i s reache d
rapidly.
1. Zirconiu m cerami c film
2. Platinu m electrode , pum p cel l
3. Platinu m electrode, referenc e cell
4. Exhaus t gas port
5. Referenc e cell
6. Pum p cel l
7. Pum p curren t (/P)
8. Referenc e voltage (l/ ref)
9. Referenc e air channe l
10. Heatin g voltag e (ly

The wideband oxygen sensor can measure mixture in a wide range ,

from rich to extremely lean , ver y rapidly.

To operate effectively, the oxygen sensor requires ambient ai r as the

reference gas inside. This ambien t ai r reaches the insid e of the
sensor through the harness connector and the electrical harness. I n
case o f oxygen sensor malfunction , check the connector and clea n
contamination as necessary. Also , disconnect and reconnect th e
harness connector to remov e oxidation from the connector pins .

Secondary ai r injectio n
5 series V8 engine models manufacture d to 03 / 2005 (545i): The
secondary air system pump s ambien t air into the exhaus t strea m
after a cold engine star t to reduce catalytic converter warm-up tim e
and to reduc e HC and CO emissions. The EC M controls an d
monitors the secondary air injection system.

The electric air pump draw s in ambient air and supplies it to th e

secondary air valve. The ai r injection valve is opened b y a solenoi d
using engin e vacuum an d i s closed b y an internal spring .

The secondary ai r valve is bolted to the right front of the cylinde r

head. Cas t passageway s withi n the cylinder head duc t the
secondary air directly into the cylinder head exhaust ports .
133-16 Fue l Injection ME 9.2, ME 9.2.2 (V8 Engine)
Secondary air injection system components

Secondary ai r injection system component s

1. Ai r pump
2. Filte r air duct
3. Ai r pump mount
4. Air pump bracket
5. Air pump filter
6. O-rin g
7. Ai r pump mini mass air flow sensor
8. Pressur e hose
9. O-rin g
10. Cylinder head air intake tube
11. Secondary air valve
12. Gasket

A miniatur e mass air flow sensor i n the secondary air system

detects the air mass supplied by the secondary air pump. This
function monitors the secondary ai r system for OBD I I compliance.

When the mini mass air flow sensor detects no or insufficient air flow,
a fault is stored in the ECM and the malfunction indicator light (MIL)
is illuminated.

b3091300008

Secondary air injection illustration s

Secondary air pump is in right front fender behind wheel well liner.
Fuel Injection ME 9.2, ME 9.2.2 (V8 Engine) 133-1 7
Secondary air injection illustrations

B2606 Min i mas s air flow sensor.

Secondary air valves (arrows ) are bolted to the rea r of each of

cylinder head .
133-18 Fue l Injectio n ME 9.2, M E 9.2.2 (V 8 Engine )
Air filter housing and duct, removing and installing

Air filter housin g an d duct ,

removing and installing
For air filter element replacement, see 020 Maintenance ,

— Remov e uppe r engine covers. See 020 Maintenance.

^C Workin g at air filter housing :

• Disconnec t mas s air flow sensor electrical connector (A).
• Remove filte r housin g mounting bolts (arrows) .

^V Loose n hose clamp (A) at throttle housing an d detach vacuum line

(arrow) from air intake duct .

— Remov e ai r filter housing and duct fro m vehicle.

— Installatio n i s reverse of removal .

— Afte r reinstalling, chec k and clea r fault codes fro m ECM memory .

Mass air flow, measuremen t

The air volume input signal is produced electronicall y by the hot film
mass ai r flow sensor whic h use s a heated metal film in the air flow
stream to detect the mas s of the air flowing past.

The sensor is mounted in the air inlet pipe between the air filter and
the throttle valve. As air flows through th e sensor, the ho t film is
cooled, changing th e resistanc e which affects current flow (voltage
drop) through the circuit. The EC M monitors thi s change an d
regulates the amount of fuel injected .

The mass ai r flow sensor contain s an integral air temperatur e

sensor. The signal from this negative temperature coefficient (NTC)
sensor is needed b y the ECM to correct the air volume inpu t signal .
Changes in intake air temperature (ai r density) affect the amount of
fuel injected, ignitio n timing and secondary ai r injection activation.
Fuel Injection ME 9.2, ME 9.2.2 (V8 Engine) 133-1 9
Mass air flow sensor, replacing

Mass air flow sensor, replacing

Switch ignition OFF an d remov e key.

Working at air filter housing :

• Disconnec t mas s ai r flow sensor electrical connector (A) .
• Uncli p filter housing li d (arrows).
• Loose n air duct clamp (A ) and remove air filter housin g lid from
vehicle.

Remove fasteners (arrows) and remov e mass ai r flow sensor fro m

air filter housing .

— Chec k intake ducts for cracks and vacuu m leaks .

— Installatio n i s reverse of removal .

• Inspec t O-ring an d replac e i f necessary.

— Afte r reinstalling , check an d clear fault codes from EC M memory .

Throttle housing (EDK), replacing

Accelerator pedal position module (PWG)
The accelerator pedal position module (PWG) provides tw o variable
voltage signals to the ECM that represent accelerator peda l positio n
and rate of movement. The ECM activates the Valvetronic system
based on this input .

Dual Hall sensors ar e used in the PWG . The EC M compares th e

values from the two for plausibility. I f the signals ar e not within th e
plausible range , the EC M uses the lowe r of the two signals as the
driver reques t input. Acceleration response in that case i s slower
because maximu m Valvetroni c opening i s reduced.

After replacin g th e throttle housing, us e BMW scan too l to rese t

BX56130037 adaptation values .

CAUTION—
• If the adaptation process is not completed correctly, the engine
does not start.
133-20 Fue l Injectio n M E 9.2, ME 9.2.2 (V8 Engine )
Throttle housing (EDK), replacing

— Switc h ignition OF F an d remov e key.

— Remov e upper engin e covers. See 02 0 Maintenance .

^C Workin g at air filter housing:

• Disconnec t mass air flow sensor electrica l connector (A) .
• Remov e filter housing mountin g bolt s (arrows).

X Loose n hos e clamp (A ) at throttle housing and detach vacuum line

(arrow) from air intake duct.

— Remov e air filter housing an d duc t from vehicle.

Working at left side of intake manifold:

• Disconnect electrica l connector (A) .
• Remove fasteners (arrows) an d remove throttle housing .

Installation i s reverse of removal.

Replace profil e gasket (sealing O-ring) between throttle assembly

and intake manifold.

After reinstalling , check an d clear faul t codes fro m ECM memory

Reset throttle plate adaptation values following scan tool on-scree n
instructions.
Fuel Injection ME 9.2, MEj.2.2jy8jngine^jl33-21
Valvetronic motor, removing and installing

Valvetronic motor , removing and installin g

Right side valvetroni c moto r shown. Left side is similar.

- Switc h ignition OFF and remov e key.

- Remov e upper engine covers. See 020 Maintenance.

— Disconnec t battery negative (- ) cable.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings and Cautions .

Disconnect valvetronic motor electrica l connecto r (arrow) .

Locate BMW roundel (logo) at back o f valvetronic motor. Usin g a

small pick, chisel cente r area of roundel to expose Allen hea d
(inset).

X. Remov e valvetronic motor fastener s (arrows) .

- Usin g a 4 mm Allen, gentl y rotate valvetronic motor shaf t

counterclockwise until released from eccentric shaft splines .

— Remov e valvetronic moto r i n direction of arrow.

— Installatio n is reverse o f removal . Remembe r to:

• Rout e ignition harnes s correctly

— Afte r reinstalling, check and clear fault codes from ECM memory .
133-22 Fue l Injection ME 9.2, ME 9.2.2 (V8 Engine)
Fuel rail and injectors, removing and installing

Fuel rai l and injectors, removing and installing

Fuel injectors are electrically controlled solenoid valves that provide
precisely metere d and atomized fuel into the engine intak e ports .

Injectors receiv e voltage from the DM E main relay . The engin e

control modul e (ECM ) controls injector opening b y activating th e
ground circuit for the injector valve solenoids . Th e EC M varies the
duration (in milliseconds) o f injector openin g t o regulate ai r / fuel
ratio.

— Switc h ignition OFF an d remov e key .

— Remov e upper engin e covers. Se e 02 0 Maintenance .

— Fo r a quick chec k o f injectors , run engin e an d touch each injecto r

with a screwdriver or stethoscope. Yo u should feel a vibration or hear
a buzzing. Switch engine OFF .

— Disconnec t battery negative (-) cable .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings an d Cautions.

Working above engine , disconnec t valvetroni c motor electrical

connectors (A) . Disconnect knoc k sensor electrica l connector s
(arrows) and uncli p wiring harness fro m holder (B).

CAUTION—
• Be sure to mark oxygen sensor connectors so that they can be
reassembled as before.

Disconnect the following electrical connectors :

1. Fue l injecto r electrical connectors at fuel rail, left and right side.
2. Throttl e housing .
3. Bot h temperature sensors .
4. Al l electrical solenoids.
5. Alternator .
6. Manifol d pressure sensor .
7. Intak e manifol d drive unit.
8. Camshaf t positio n sensors, lef t and righ t side.
9. Lef t eccentric shaft sensor .

Remove wiring harness bracke t fastener s (arrows). Lif t u p and lay

wiring harness aside .
Fuel Injection ME 9.2, ME 9.2.2 (V 8 Engine) 133-2 3
Fuel rail and injectors, removing and installing

Unscrew Schraeder valve cap (arrow) fro m fuel rail. Connect air line
adapter (A ) to fitting.
• Unscre w fuel tank cap to release pressure .
• Usin g a brief burst o f compressed ai r (maximum of 3 bar or 43. 5
psi), blow fuel back int o fuel tank.

WARNING —
• Fuel in the fuel line is underpressure (approx. 3 - 5 bar or 45 -
75 psi) and may be expelled forcibly. Do not smoke or work near
heaters or other fire hazards. Keep a fire extinguisher handy.
• Unscrew the fuel tank cap to release pressure in the tank before
working on the fuel line.
• Plug open fuel lines and fittings.

Working abov e engine :

• Remov e fuel rail fasteners (arrows).
• Lif t lef t and right side fuel rail up and off engine.

Using a small fla t blade screwdriver , remove fuel lin e lockin g colla r
(B). Unlock fue l line b y pushing coupler (A) i n direction o f arrow.
Remove fuel line with from fuel rail from vehicle.

WARNING—
• Wrap a clean shop towel around fitting before disconnecting.
Residual fuel pressure is present in the fuel line.
133-24 Fue l Injection ME 9.2, ME 9.2.2 (V8 Engine)
Intake manifold, removing and installing

Disconnect fue l injector electrica l connectors (arrow). Pry retaining

clip from injector (A) .

. Remov e individual injectors :

• Pul l injecto r from rail (arrow).

Installation i s reverse o f removal. Remembe r to :

• Fi t new sealing O-ring s whe n installin g injectors. Fo r ease of
installation, lightl y lubricate O-ring s wit h assembly lubricant .
• Check that injecto r electrical connection s ar e correctly fitted and
that injectors are fully seated prio r to installin g fuel rail mountin g
bolts.
• Replac e wire ties.

Tightening torque
Fuel rai l to cylinder hea d 10Nm(7ft-lb)

— Afte r reinstalling , check an d clea r faul t codes from ECM memory .

Intake manifold, removing and installing

— Disconnec t battery negative (- ) cable i n cargo compartment.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings an d Cautions.

— Remov e upper engin e covers . See 02 0 Maintenance .

— Remov e air filter housing an d ai r intak e ducts. See Air filter

housing an d ducts, removin g and installing in th'is repair group.

"^ Remov e and discard tension stru t fasteners (arrows). Remove strut
brace (A) .

— Remov e fuel rail. See Fue l injectors , removin g an d installin g in

this repai r group .
Fuel Injection ME 9.2, M E 9.2.2 (V 8 Engine) 133-2 5
Engine coolant temperature (EOT) sensor, replacing

Disconnect crankcas e vent hos e (A ) from valve covers (arrows) .

Remove from intake manifold .

Remove intak e manifold fasteners (arrows) . With help from a n

assistant, lif t intak e manifol d u p and off engine.

Installation is reverse of removal. Remembe r to:

• Instal l new gaskets to intake manifold before installing.
• Clean sealing surfaces.
• Replac e all seals.

Tightening torque
Manifold to cylinder hea d
•M6 10Nm(7.3ft-lb)
•M7 15 M m (1 1 ft-lb )
•M8 22Nm(16.2ft-lb)
Tension strut to bod y
(replace fasteners) 30.5 N m (22. 4 ft-lb )

Engine coolan t temperatur e (ECT ) sensor ,

replacing
The engine coolan t temperature (ECT ) sensor i s an NTC (negativ e
temperature coefficient) sensor. As coolant temperature rises ,
resistance through the sensor decreases .

The ECM varies ignition timing and air/fuel mixture based on

engine coolant temperature. The EC T sensor i s supplied a 5 volt
reference voltage. The voltage drop across th e sensor varies as the
coolant temperature (senso r resistance) changes .

If the EC T sensor inpu t i s faulty or not plausible , the MI L i s

illuminated when OBD II fault criteria are exceeded. Th e EC M
assumes a substitute valu e (80 ° C / 176°F ) to maintain engin e
operation. The ignitio n timin g i s set to a safely conservative basi c
setting.

The EC T sensor i s located o n the front of the engine nea r

thermostat housing .
133-26 Fue l Injection ME 9.2, ME 9.2.2 (V 8 Engine)
Radiator outlet coolant temperature sensor

With engin e full y cooled off, disconnect EC T sensor connector (A).

Unscrew EC T sensor (B ) from cylinde r head . B e prepared to catch

small amount o f coolant.

Installation i s reverse of removal :

• Us e new copper sealin g washer whe n installin g sensor.
• Replac e lost coolant.

Tightening torque
Temperature sensor to cylinder hea d 13Nm(9.5ft-lb)

After reinstalling , chec k an d clear fault codes fro m ECM memory.

Radiator outlet coolant temperature sensor

The radiato r outlet temperature senso r (inset ) i s an NTC (negative
temperature coefficient) sensor. A s coolant temperatur e rises,
resistance through the sensor decreases .

The ECM varies cooling fan speed based o n radiator outlet coolan t
temperature. The radiato r outlet coolan t temperatur e senso r is
supplied a 5 volt referenc e voltage. Voltag e drop across the senso r
varies as coolant temperatur e (senso r resistance ) changes.

Vacuum pump, removing and installing

— Pum p brak e pedal 1 0 times to reduc e vacuu m pressur e in brake
booster.

— Remov e uppe r engin e covers . See 02 0 Maintenance .

— Remov e intake air ducts. Se e Ai r filte r housing an d ducts ,

removing and installin g in this repai r group.

"^C Remov e clamp (A ) and vacuum lin e from pump (arrows).

Fuel Injection ME 9.2, ME 9.2.2 (V8 Engine) 133-2 7
Vacuum pump, removing and installing

^k Remov e vacuum pump fasteners (arrows).

B5101330027

Remove vacuum pump (A ) from engine.

Installation is reverse of removal . Remember to:

• Replace vacuu m pum p O-ring .
• Properl y align pump to camshaft slot (arrow).
133-28 Fue l Injectio n M E 9.2, M E 9.2.2 (V 8 Engine )
Bosch ME 9.2, ME 9.2.2 ECM pin assignments

Bosch M E 9.2, M E 9.2.2 EC M pin assignment s

The engine contro l module (ECM ) (arrow ) is located in the right rear
of the engine compartmen t i n the E-box .

iiValvetronic " 1
8 control modul e H

The EC M has 5 main electrica l harnes s connectors , for a total 13 4

pins.
• 1: X60001 (voltage , ground supply )
• 2: X60002 (oxygen sensors )
• 3: X60003 (signals )
• 4: X60004 (signals )
• 5: X60005 (ignitio n coils)

12 45

B701130045

ECM pin assignments fo r V8 engine s ar e given in Table c. This

information can b e helpful when diagnosing fault s to or from the
ECM.

Generally, absence o f voltage o r continuity mean s there is a wiring

or connector problem . Test results with incorrect values do not
necessarily mea n that a component i s faulty. Check for loose,
broken or corroded connections and wiring before replacing
components. Fo r engine managemen t syste m electrical
schematics, see EL E Electrical Wirin g Diagrams.

When making checks at the ECM, us e a break-out box to allow tests

to be made with the connector attached to the ECM. This prevents
damage t o the small terminals in the connector . As an alternative,
the connector housin g ca n be separated s o that electrical checks
can b e made from the bac k of the connector.

CAUTION—
• Wait at least one minute after switching the ignition OFF before
removing the connector from the ECM. If the connector is
removed before this time, residual power in the system relay
may damage the ECM.
• Connect or disconnect the control module connector and meter
probes with the ignition OFF.
 Fuel Injectio n M E 9.2, ME 9.2.2 (V 8 Engine ) 133-2 9
Bosch ME 9.2, ME 9.2.2 ECM pin assignments

Table c. Bosch ME 9.2 ME 9.2.2 EC M pin assignments

Connector X60001 9-pi n (signals)
Pin Type Component or function Note

1 - Not used

2 - Not used
3 input/output TXD signal Integrated voltage supply module (IVM )
4 ground ECM ground Integrated voltag e suppl y modul e (IVM )

5 - Not used

6 ground ECM ground Integrated voltag e supply module (IVM )

7 input Terminal 30 Integrated voltag e suppl y module (IVM )
8 input Terminal 8 7 Integrated voltage supply module (IVM )
9 - Not used

Connector X60002 24-pi n (signals)

Pin Type Component or function Note
1 output Signal, oxygen senso r heatin g Bank 1 sensor 1
2 output Signal, oxygen sensor heatin g Bank 2 sensor 1
3 - Not used

4 - Not used

5 - Not used

6 output Oxygen sensor heatin g Bank 1 sensor 2

7 ground Oxygen sensor Bank 1 sensor 1

8 ground Oxygen sensor Bank 2 sensor 2

9 ground Oxygen sensor Bank 2 sensor 1

10 ground Oxygen sensor Bank 1 sensor 2

11 - Not used

12 output Oxygen sensor heating Bank 2 sensor 2

13 input Oxygen sensor signa l Bank 1 sensor 1

14 input Oxygen sensor signal Bank 2 sensor 2

15 input Oxygen sensor signa l Bank 2 sensor 1

16 input Oxygen sensor signal Bank 1 sensor 2
17 - Not use d
18 - Not use d
19 input Oxygen senso r signa l Bank 1 sensor 1
20 input Oxygen sensor signal Bank 1 sensor 1
21 input Oxygen sensor signa l Bank 2 sensor 1
22 input Oxygen sensor signa l Bank 2 sensor 1
23 input Terminal 87 Integrated voltage supply module (IVM )
24 - Not used
133-30 Fue l Injection ME 9.2, ME 9.2.2 (V8 Engine)
Bosch ME 9.2, ME 9.2.2 ECM pin assignments

Connector X6000 3 52-pi n (signals )

Pin Type Component or function Note
1 input Mass ai r flow sensor signa l Mass ai r flow senso r

2 input Intake pip e pressur e sensor signal Intake pipe pressur e sensor
3 input Mass ai r flow sensor signal Mass ai r flow senso r
4 output 5 volt referenc e voltage Mass airflo w senso r
5 -
6 output Fuel injecto r signal Fuel injecto r signal 4
7 output Fuel injecto r signal Fuel injecto r signal 5
8 output Fuel injecto r signa l Fuel injecto r signal 6
9 output VANOS solenoid signa l VANOS solenoid intake , ban k 2
10 output VANOS solenoid signa l VANOS solenoid intake , bank 1
11 output Fuel injecto r signal Fuel injecto r signal 7
12 output Thermostat heatin g Characteristic MA P thermostat
13 output Fuel injecto r signal Fuel injecto r signal 1
14 ground Ground Connector X646 0
15 - Not use d
16 input Camshaft positio n sensor signa l Camshaft positio n sensor, exhaus t ban k 1
17 input Camshaft positio n sensor signa l Camshaft positio n sensor , exhaust bank 2
18 input /output Valvetronic control module Valvetronic control module
19 input /output BSD signal Connector X603 8
20 output VANOS solenoi d signal VANOS solenoid, bank 1
21 output Fuel tan k vent valve signal Fuel tank vent valv e
22 - Not used
23 output VANOS solenoid signal VANOS solenoid exhaust , bank 2
24 output Fuel injecto r signal Fuel injecto r signal 2
25 output Fuel injecto r signa l Fuel injector signal 8
26 output Fuel injecto r signa l Fuel injecto r signal 3
27 output Crankshaft positio n sensor signa l Crankshaft positio n senso r
28 input Engine coolant temperature senso r signa l EEngine coolant temperatur e sensor
29 input Camshaft position senso r signa l Camshaft position sensor , intak e bank 1
30 input Camshaft positio n sensor signa l Camshaft positio n sensor , intake bank 2

r input Throttle valve signal Throttle valve

32 input Throttle valve signa l Throttle valv e
33 input Knock sensor signa l Knock sensor 1
34 input Knock sensor signa l Knock sensor 1
35 input Knock sensor signa l Knock senso r 2
36 input Knock sensor signa l Knock sensor 2
37 ground Ground Connector X645 0
 Fuel Injectio n ME 9.2, M E 9.2.2 (V 8 Engine) 133-3 1
Bosch ME 9.2, ME 9.2,2 ECM pin assignments

Connector X60003 52-pin (signals) (continued)

Pin Type Component or function Note
38 input / outpu t Signal PT-CAN high Valvetronic control module
39 - Not used

40 output Variable intake manifold changeover valve signal

41 output Variable intake manifold changeover valve signal Knock sensor

42 output Throttle valve signal Throttle valve

43 output Throttle valve signal Throttle valve

44 - Not used

45 input Variable intake manifold changeover valve signal

46 input Knock sensor signal Knock sensor 1

47 input Knock sensor signal Knock sensor 1

48 input Knock sensor signal Knock sensor 2

49 input Knock sensor signal Knock sensor 2

50 output Throttle valve signal Throttle valve

51 input / output Signal PT-CAN high Valvetronic control module

52 ground Throttle valve signal Throttle valve

Connector X60004 40-pin (signals)

Pin Type Component or function Note
1 - Not used
2 input DMTL signal Diagnostic modul e for fuel tank leakag e

3 output Secondary air pump rela y Secondary air pump

4 output Engine cooling fan signal Engine coolin g fan

5 input Secondary ai r mass air flow signal Secondary air mass air flow sensor

6 - Not used

7 ground Accelerator pedal modul e Accelerator peda l modul e

8 input Accelerator pedal modul e signal Accelerator peda l module

9 output Accelerator pedal modul e Accelerator pedal modul e

10 output Fuel pump relay activatio n Fuel pump relay

11 - Not used
12 ground Accelerator pedal modul e Accelerator pedal modul e

13 input Accelerator pedal modul e Accelerator pedal module

14 output Accelerator pedal module Accelerator pedal modul e

15 ground Secondary air mass air flow sensor Secondary ai r mass air flow senso r
16 output Tailpipe flap signal Tailpipe flap

17 output TD signal Connector X243

18 output Tailpipe flap signal Tailpipe flap

19 output E-box cooling fan signal E-box cooling fan

133-32 Fue l Injection M E 9.2, ME 9.2.2 (V8 Engine)
Bosch ME 9.2, ME 9.2.2 ECM pin assignments

Connector X60004 40-pin (signals) (continued)

Pin Type Component or function Note
20 input DMTL signa l Diagnostic modul e for fuel tank leakage
21 output Radiator shutter signal Radiator shutte r
22 input Processed wheel speed Right rear wheel
23 input Clutch switch signal Clutch switch
24 input Brake light switch Connector X1 81
25 input Oil pressure switch signal Oil pressure switch
26 input Terminal 15 Wake up signal
27 - Not use d
28 input Brake light switch signal Test signal
29 - Not used
30 input DMTL signal Diagnostic modul e fo r fuel tank leakage
31 - Not used
32 - Not use d
33 input EWS signa l Car access system (CAS)
34 - Not use d
35 - Not use d
36 input / output Signal PT-CA N high CAN bus connector
37 input/ output Signal PT-CA N high CAN bus connector
38 input Engine coolant temperature sensor signal Engine coolant temperature sensor, radiator outlet
39 input Engine coolant temperature sensor signal Engine coolant temperature sensor, radiator outlet
40 input Start signal Car access system (CAS)

Connector X60005 9-pin (ignition coils)

Pin Type Component or function Note
1 output Ignition coil signal Ignition coil signal 3
2 output Ignition coil signal Ignition coil signal 4
3 output Ignition coil signal Ignition coil signal 1
4 output Ignition coil signal Ignition coil signal 7
5 ground Ground
6 output Ignition coil signal Ignition coil signal 8
7 output Ignition coil signal Ignition coil signal 2
8 output Ignition coil signal Ignition coil signal 6
9 output Ignition coil signal Ignition coil signal 5
 160-1

160 Fue l Tank and Fuel Pum p

GENERAL 160- 2 FUEL PUM P AND FUEL LEVEL SENDER S . ieo-1 9

Fuel tank 160- 2 Accessing fuel pump an d fuel level senders . 160-1 9
Fuel delivery system s 160- 2 Fuel pum p and fuel level sender (right side),
Electric fuel pump 160- 3 removing 160-1 9
Fuel system schematic (M54 , N62 engines) . . 160- 3 Fuel pump an d fuel level sender (right side),
Fuel syste m schematic (N5 2 engine) 160- 4 installing 160-2 1
Fuel system schemati c (N5 4 engine) 160- 5 Fuel filter and fuel level sender (left side),
removing 160-2 2
Warnings and Cautions 160- 6
Fuel filter and fuel level sender (left side),
FUEL TANK EVAPORATIV E CONTRO L installing 160-2 3
SYSTEM 1 eo-7 High-pressure fuel pump,
Evaporative system troubleshooting 160- 7 removing (N54 engine) 160-2 4
Evaporative system lea k test 160- 8 High-pressure fuel pump,
installing (N54 engine) 160-2 6
FUEL SYSTE M TROUBLESHOOTING ieo- 9
Fuel pump fuse and rela y (M54, N62 engines) 160- 9 FUEL SUPPLY COMPONENT S 160-2 8
Fuel pump fuse and modul e Fuel tank, draining 160-2 8
(N52, N54 engines) 160- 9 Fuel filter 160-2 9
Operating fuel pump for tests Fuel pressur e regulato r 160-2 9
(M54, N6 2 engines) 160-1 0 Fuel pum p (EKP ) module,
Operating fuel pump for tests removing and installing (N52 , N54 engines) 160-2 9
(N52, N54 engines) 160-1 0 Activated carbon canister,
Fuel pump electrica l circuit, testing 160-1 1 removing and installing 160-3 0
Fuel pump power consumption, testing Fuel tank lea k detectio n modul e (DMTL) ,
(M54, N62 engines) 160-1 2 removing and installing 160-3 0
Fuel pump power consumption, testing TABLE
(N52, N5 4 engines) 160-1 3
Fuel pressur e gauge, installing 160-1 4 a. Fuel tank capacity for 5 Series models 160- 2

Fuel pressure regulator 160-1 6

Fuel delivery, testing 160-1 7
160-2 Fue l Tank and Fue l Pump
Fuel tank

GENERAL
This repai r group covers service informatio n for the fuel supply
system.

See also:
• 100 Engine-General for model year, engine code , an d DME
applications
• 130 Fuel Injectio n (M5 4 Engine )
• 131 Fuel Injectio n (N5 2 Engine )
• 132 Fuel Injection (N54 Engine )
• 133 Fuel Injectio n (V8 Engine)
• ECL Electrical Component Locations for fuel pump fuse and
relay access informatio n

Fuel tan k
The saddle-shaped plasti c fue l tank i s mounted underneat h th e
center of the car (underneath the rear seat). Mounted in the fuel tank
are the electric fuel pump, fue l level sending unit s an d suction jet
pump. Connecting lines for the evaporative emissio n control system
are also attached t o the tank.

Fuel tank capacity for 5 Series models i s listed in Table a.

Table a. Fuel tank capacity for 5 Series models

Tank capacit y 70 liters (18. 5 US gal)
Reserve capacity 10 liters (2. 6 US gal)

Fuel deliver y system s

5 Series model s us e two main fuel delivery systems . Naturally
aspirated M54, N52 , V8 (N62) engine s us e only an electric fuel
pump. Turbocharged N5 4 engine model s us e an electric and
mechanical fuel pump.

M54 and N62 engine fuel injectors are installe d in machine-bored

holes in the intak e manifold. An in-tan k electri c fuel pump delivers
pressure-regulated fuel to the fuel rail . The fuel pump is controlled
by the DME via a fuel pump rela y (K96). I t operates at a pressure of
3.5 bar (50.7 psi).

N52 engine fuel injectors are installed in machine-bored holes in the

cylinder head. An in-tan k electric fue l pum p delivers pressure-
regulated fuel to the fuel rail. The fue l pump i s a variable spee d
pump controlled by the EKP (electric fuel pump control) module and
delivers only the amount o f fuel needed for engine operation . Thi s
eliminates excess fuel delivery an d reduce s pum p wear. It can
operate at up to 5 bar (72. 5 psi ) an d 9 5 liters (2 5 gallons) pe r hour.

N54 engine direct fuel injection allows fo r precise meterin g of

mixture and higher compression. This i s made possibl e b y locatin g
a fuel injector for each cylinder centrally between th e valves. Th e
electric fuel pump delivers fuel to a high pressur e fue l pump. Th e
high pressur e fuel pump i s driven b y a chain an d can provid e fuel
pressure from 5 bar (72.5 psi) up to 200 ba r (2900 psi).
 Fuel Tank and Fuel Pum p 160- 3
Electric fuel pump

Electric fue l pum p

An electric fuel pump is mounted in the fuel tank in tandem wit h th e
right side fuel level sender and suction jet pump. A suction jet pump
is located in the lef t side of the tank to transfer fuel to the righ t side.
The combined fue l filter / pressure regulato r delivers pressurize d
fuel to the fuel injection system. The system is a non-return design;
there is one fuel line to the fuel injectors and excess fuel flows
directly from the fuel filter / pressure regulator back int o the tank.

Fuel pum p self-diagnostic s ar e built int o the DME . A failure in the

fuel pump circuit may set a fault code.

Fuel system schemati c (M54, N6 2 engines)

1. Electri c fuel pump
2. Fue l supply line
3. Chec k valve
4. Fue l filter
5. Fue l supply line to engine
6. Fue l injector
7. Pressur e regulator
8. Chec k valve
9. Lef t suction jet pum p
10. Right suction jet pump
11. Pump initial filling valve
12. Fuel baffle
13. Fuel level sender
14. Refueling line connector
15. Refueling ventilation line
16. Refueling ventilation nipple
17. Left operation ventilation valve
18. Right operation ventilation valve
19. Operation ventilation line
20. Diagnosis pump for tank leakage
(DMTL)
21. Fresh air vent line
22. Activated carbon canister
23. Fuel tank vent valve
24. Engine control module (ECM )
25. Fuel pump relay (K96)
160-4 Fue l Tank and Fuel Pump
Fuel system schematic (N52 engine)

Fuel system schematic (N52 engine)

1. Electri c fuel pump
© 24
2. Fue l supply lin e
3. Chec k valv e

u ©
4. Fue l filter
5. Fue l supply lin e to engine
6. Fue l injector
7. Pressur e regulato r
8. Chec k valve
9. Lef t suction jet pum p
10. Suction jet pump
11. Pump initial filling valve
12. Fuel baffle
13. Fuel level sender
14. Refueling line connector
15. Refueling ventilation line
16. Refueling ventilation nipple
17. Left operation ventilation valve
18. Right operation ventilation valve
19. Operation ventilation line
20. Diagnosis pump for tank leakage
(DMTL)
21. Fresh air vent line
22. Activated carbon canister
23. Fuel tank vent valve
24. Engine control modul e (ECM )
25. Fuel pump module (EKP)
 Fuel Tank and Fuel Pum p 160- 5
Fuel system schematic (N54 engine)

Fuel system schematic (N54 engine )

1. Electri c fuel pump
2. Fue l supply lin e
3. Chec k valv e
4. Fue l filter
5. Fue l supply line to engine
6. Hig h pressure fuel pump
7. Fue l injector
8. Pressur e regulator
9. Chec k valve
10. Left suction jet pum p
11. Suction jet pump
12. Pump initial filling valve
13. Fuel level sender
14. Refueling line connector
15. Refueling ventilation line
16. Refueling ventilation nipple
17. Left operation ventilation valv e
18. Right operation ventilation valve
19. Operation ventilation line
20. Diagnosis pump for tank leakag e
(DMTL)
21. Fresh air vent line
22. Activated carbon canister
23. Fuel tank vent valve
24. Engine control module (ECM )
25. Fuel baffl e
26. Fuel pump module (EKP )
160-6 Fue l Tank and Fuel Pump
Warnings and Cautions

Warnings and Cautions

WARNING —
• The fuel system is designed to retain pressure even when the
ignition is OFF. When working with the fuel system, loosen the
fuel lines slowly to allow residual fuel pressure to dissipate.
Avoid spraying fuel. Use shop towels to capture leaking fuel.
• Before beginning work on the fuel system, place a fire
extinguisher in the vicinity of the work area.
• Work only on the fuel system when engine temperature is
below 40°C(104°F).
• Electric fuel pump starts each time a door is opened.
• Fuel is highly flammable. When working around fuel, do not
disconnect wires that could cause electrical sparks. Do not
smoke or work near heaters or other fire hazards.
• Wear eye protection, face shield and protective clothing to
avoid injuries from contact with fuel.
• When working on an open fuel system, wear suitable hand
protection, as prolonged contact with fuel can cause illnesses
and skin disorders.
• Unscrew the fuel tank cap to release pressure in the tank
before working on fuel lines.
• Do not use a work light with an incandescent bulb near fuel.
Fuel may spray on the hot bulb causing a fire.
• Make sure the work area is properly ventilated.
• Due to risk of personal injury, be sure the engine is cold before
beginning work on engine components.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given in 001 Warnings and Cautions.
• Before making any electrical tests with ignition switched ON,
disable the ignition system a s described i n 120 Ignition
System. Be sure the battery i s disconnected when replacing
components.
• To prevent damage to the ignition system or other DME
components, including the engine control module (ECM),
connect and disconnect wires and test equipment with ignition
OFF.
• Cleanliness is essential when working with the fuel system.
Thoroughly clean the fuel line unions before disconnecting any
of the lines. Plug open fuel lines and ports.
• Use only clean tools. Keep removed parts clean and sealed or
covered with a clean, lint-free cloth, especially if completion of
the repair is delayed.
• Do not move the car while the fuel system is open.
• Avoid using high pressure compressed air to blow out lines and
components. High pressure can rupture internal seals and
gaskets.
• Use new seals, O-rings and hose clamps when replacing fuel
system components
• Replace aluminum fasteners when loosened.
• For reliable identification test fastener with magnet for
aluminum composition.
 Fuel Tank an d Fuel Pum p 160- 7
Evaporative system troubleshooting

FUEL TANK EVAPORATIV E CONTROL SYSTEM

Evaporative control, also referre d to as runnin g losse s control, is
designed to prevent fuel system evaporative losses from venting into
the atmosphere. The component s of this system allow control an d
monitoring of evaporative losses by on-board diagnostic (OB D II )
software incorporate d into the engine control module (ECM).

Listed below ar e the mai n component s of the evaporative contro l

system and their functions:
• Carbo n canister stores fuel vapors.
• Plumbin g ducts vapors from fuel tank to canister and from canister
to intak e manifold .
• Carbo n canister purge valve is controlled by engine control module
(ECM).
• Pressur e regulator shunts excess fuel volume directly back to fuel
tank before i t circulates through fuel lines.
• Lea k detectio n uni t (DMTL) pressurize s fuel tank and evaporativ e
system to monitor system leaks .

Evaporative syste m troubleshootin g

Start by accessing diagnosti c troubl e codes (DTCs) usin g a BM W
scan tool.
• Fo r purposes o f OBD II emissions compliance , the DM E syste m
sets a diagnostic troubl e code (DTC ) when it detects a leak i n the
evaporative control system.
• Malfunctio n indicator ligh t (MIL ) i s illuminated upo n secon d
recurrence of fault. See OB D On-Board Diagnostics .

When lea k testing, observ e the following conditions to obtai n

plausible results :
• Fue l tank 1 /4 to 3 /4 full.
• Vehicle parked for at least 2 hours to allow fuel to reac h ambien t
temperature. Idea l fuel temperature is 10°-20° C (50° -68°F) .
• D o not refuel immediately befor e leak test.

If a leak i s detected, chec k th e following areas:

• Fue l filler cap leaking or off.
• Fue l tank ventilation line s leaking a t fuel tank or activated carbo n
canister.
• Tank ventilation valve leaking (i n engine compartment) .
• Fue l level sensor and fuel pump assembly cove r leaking .

For evaporative system componen t replacement , see Fue l Suppl y

Components i n this repai r group.
160-8 Fue l Tank and Fuel Pump
Evaporative system leak test

Evaporative system leak test

Use the following leak test when diagnosing evaporativ e system leak
fault codes .

Working underneat h lef t rea r bumper: gai n acces s t o activated

carbon canister . See Activated carbo n canister , removin g an d
installing i n this repai r group.

Remove fresh air line (inset ) fro m DMTL pump .

"> Instal l BMW test adapter 83 30 0 433 207 (B) (or suitable substitute)
at DMT L fres h air connection (A) .

— Connec t evaporative system smoke machine (C) to test adapter (B).

BMW recommends VACUTE C 625-522 B (nitroge n pressure swin g
absorption technology) .

— Remov e fuel filler cap.

— Activat e smoke machin e and fil l fuel system with smoke unti l it
escapes fro m fuel filler neck .

— Shu t off smok e machine .

WARNING —
• Use only smoke machine that utilizes nitrogen to pressurize
fuel system.
• The fuel system may release a substantial amount of fuel-rich
gasoline vapors during testing. Work in a well ventilated area.

Reinstall fuel filler cap.

Reactivate smoke machine an d fill fuel system with smoke.

WARNING —
• Do not exceed a maximum fuel system pressure of 0.3 bar
(4 psi) when using smoke machine.

Examine fue l system component s fo r signs o f escaping smoke .

Repair o r replace fault y components .

After completing tests:

• Attach DMT L fresh air line.
• Check an d clear fault codes fro m ECM memory.
 Fuel Tank and Fuel Pump 160- 9
Fuel pump fuse and relay (M54, N62 engines)

FUEL SYSTEM TROUBLESHOOTING

Fuel pum p fus e and relay (M54, N6 2 engines)
A46 Rea r fuse holder Begin troubleshooting tuel system faults by checking fuel pump fuse
and relay. Also, check DME main relay and integrated voltage supply
module (IVM) . The fuel pump rela y is located behin d the glov e
compartment. Se e ECL Electrical Component Locations for
access information.

Fuel pump suppl y circuit i s fuse-protected by:

• M5 4 engine: fuse F50 in the rea r fuse holder:
K96
Fuel pump relay • N62 engine (to 05/2009): fuse F5 0 in the rear fuse holde r
• N6 2 engine (fro m 05/2009): fus e F72 in the rear fuse holde r

CAUTION—
Fuel pum p
• Relay and fuse positions and wire colors vary. A good way to
verify a relay position or wire colors is to compare the wiring
colors at the relay socket to the colors indicated on the wiring
diagrams in ELE Electrical Wiring Diagrams .

B5101600001
The engine control module (ECM) supplies switched ground to relay.
During starting, th e fuel pump run s as long as ignition switc h i s in
START position and continues to run once engine starts. If electrical
A46 system faults interrupt power t o fuel pump, th e engine does not run .
Rear fuse holde r
f~ioIFSO
>F72
Fuel pump fuse and module (N52, N5 4 engines)
Begin troubleshooting fuel system faults by checking fue l pump fuse.
Ter 15 I CA N L
wake u p I | The fuel pump fuse is located i n the rear fuse holder. Se e EC L
Electrical Componen t Location s fo r access information .
16J 'I
Fuel pump control
(EKP) , Fue l pump circuit is fuse-protected by:
• N52 engine (to 05/2009): Fuse F50
• N52 engine (fro m 05/2009): Fus e F72
• N54 engine: Fus e F72

Fuel pump
CAUTION—
• Relay and fuse positions and wire colors vary. A good way to
verify a relay position or wire colors is to compare the wiring
b510160002 colors at the relay socket to the colors indicated on the wiring
diagrams i n ELE Electrical Wirin g Diagrams.

The ECM calculates the amount of fuel required at the given point in
ECM
time and the electric fuel pump is activated as required. The tota l
volume required is transmitted as a message to the EK P control
< module via PT-CAN .
o
The EK P module converts this messag e int o an output voltage
k!15 which controls the fuel pump. The fuel pump is capable of delivering
EKP module CAS up to 95 liters (25 gallons) per hour at a pressure of 5 bar (72. 5 psi) .
»k!30 On turbo engine models, i f the EC M detects a fault in the lo w
pressure fuel sensor, the fuel pump i s activated to 100 % or 5 bar
(72.5 psi) .

IMI
160-10 Fue l Tank and Fuel Pump
Operating fuel pump for tests (M54, N62 engines)

Operating fuel pump fo r tests

(M54, N6 2 engines)
This procedure explains how to operate the fuel pump for
purposes without having to ru n the engine .

Remove fue l pump rela y (K96) locate d in relay panel behind the
glove compartment. See ECL Electrical Component Location s for
access information .

^V Connec t relay socket terminal 30 to relay socket terminal 87 with

fused jumper wire .
• Us e 14 ga wire to make jumper and includ e an in-line fuse holder
with a 15A fuse. To avoid rela y socket damage fro m repeated
connecting and disconnecting, also includ e a toggle switch in
jumper harness.
• Fuel pum p operate s a s soon as jumper wir e is attached.

— I f pump does not run with jumper installed, faul t could be in 1uel
pump, fuse F50, or wiring to pump. Chec k pump, fuses and its
wiring. See Fuel pump electrical circuit , testing in this repair
group.

— Afte r completing tests , remove jumper harnes s an d install relay.

Operating fuel pump for tests

(N52, N5 4 engines)
This procedure explain s ho w to operate th e fuel pump for testin g
purposes without having to run the engine .

^C, Usin g BMW scan tool:

• Identif y vehicle
• Select Nex t (arrow )
• Select Control Modul e Function s
• Select Complete Vehicle
• Select Drive
• Select DME (Motor Electronics)
• Select Component Activation
• Select Fuel Pum p

^ Fue l pump will run at 100% (5 bar) for 20 seconds.

 Fuel Tank and Fuel Pump 160-1 1
Fuel pump electrical circuit, testing

Fuel pum p electrical circuit , testing

If fuel pump does no t operate or there is no fuel pressure, first test
fuel pum p electrical circuit.

Remove rea r seat to access fuel pump an d fuel leve l sender. See
Accessing fuel pump an d fuel level senders i n this repai r group .

Slide electrical connector loc k (in direction of arrow) and remov e

connector from fuel pump and fuel level sender.

^V Connec t voltmeter between fue l pump leads (arrows) on connector .

— Activat e fuel pump. See Operating fuel pump for tests in this
repair group.

— Us e digital multimete r to test for battery voltage at fuel pump

connector leads.

— I f voltage an d groun d ar e present , fuel pump i s probably faulty . If

there i s no voltage, check wirin g betwee n fue l pump and fuel pump
module.

— Afte r completing tests, reconnect fuel pump harness connector .

160-12 Fue l Tank and Fuel Pum p
Fuel pump power consumption, testing (M54, N62 engines)

Fuel pump power consumption, testing

(M54, N62 engines )
Remove rear seat to access fuel pum p and fuel level sender. See
Accessing fuel pum p an d fuel leve l senders in this repair group .

. Disconnec t harness connector from fuel pump.

Make sure battery voltage a t fuel pum p connecto r is 12. 6 volts.

Charge battery if necessary.

Attach digital ammeter between pum p lea d an d harness. Connect

jumper wire between pump and harness .

CAUTION—
• Do not allow the test leads to short to ground.

Activate fuel pump. See Operating fue l pump for tests (M54, N62
engines) i n this repai r group.

Compare ammete r reading with specification liste d i n table.

Fuel pum p curren t (M54, N62 engines )

Current consumption 8 - 1 3 amps

Higher tha n normal power consumption b y fuel pum p ma y indicate

a worn pump, causing intermitten t fuel starvation due to pump
overheating and seizure. Replace pump.

Lower than norma l power consumption ma y indicate blockage in a

fuel line. Before replacing fuel pump, be sure to check that return line
and pump picku p (inside fuel tank) ar e no t obstructed.

b8D9160029
 Fuel Tank and Fuel Pump 160-1 3
Fuel pump power consumption, testing (N52, N54 engines)

Fuel pump power consumption, testing

(N52, N5 4 engines )
If fuel delivery is erratic or poor, o r if fuel pump makes abnormall y
loud noises , test pump powe r consumption.

Using BMW factory scan tool or equivalent:

• Identify vehicl e
• Selec t Next (arrow)
• Select Functio n Selectio n
• Selec t DME (Motor Electronics )
• Select Fue l Pum p
• Select Contro l Curren t
• Selec t Next (arrow)

Follow steps on screen to monito r fuel pump current.

Fuel pump current (N52, N5 4 engines)

Current consumption (fue l pump
activated wit h BM W scan tool ) 8 - 1 3 amps

An alternate method is to install a digital ammeter i n fuel pum p

circuit usin g the following steps.

— Remov e rear seat to access fuel pump and fuel level sender. Se e
Accessing fuel pump an d fuel level senders i n this repai r group.

^C Slid e locking connector i n direction o f arrow and remov e electrica l

connector from fuel pump .

— Mak e sure battery voltage a t fuel pump connector i s 12. 6 volts.

Charge batter y i f necessary .
160-14 Fue l Tank an d Fuel Pum p
Fuel pressure gauge, installing

Attach digital ammete r betwee n pum p lead and harness. Connect

jumper wir e between pum p an d harness .

CAUTION—
• Do not allow the test leads to short to ground.

Activate fuel pump. Se e Operating fue l pump for tests (N52, N5 4

engines) i n this repai r group .

Compare ammete r readin g with specification liste d in table.

Fuel pump current (N52, N5 4 engines)

Current consumption (fue l pum p
activated with scan tool) 8 - 1 3 amps

— Highe r tha n norma l powe r consumption b y fuel pump ma y indicat e

a worn pump, causin g intermitten t fue l starvation due to pum p
overheating and seizure. Replac e pump .

— Lowe r than normal powe r consumption ma y indicate blockage in a

fuel line. Before replacing fuel pump, be sure to check that return line
and pump picku p (insid e fuel tank) ar e not obstructed.

Fuel pressur e gauge, installin g

Working in engine compartment , instal l fue l pressure gauge a t
Schraeder valve on fuel rail.

— Remov e upper engine covers . Se e 02 0 Maintenance .

Use a fuel pressure gauge wit h a minimum rang e of 0 to 7 bar

(Oto 100psi).

WARNING—
• The fuel system is designed to retain pressure even when the
ignition is OFF. When working with the fuel system, loosen fuel
lines slowly to allow residual fuel pressure to dissipate. Avoid
spraying fuel. Use shop towels to capture leaking fuel.
• Fuel pump starts each time door is opened.
• Make sure the fuel pressure gauge is securely connected to the
fuel rail to prevent it from coming loose under pressure.

— Remov e engine to p cover. See 02 0 Maintenance .

M54 engine

^. Remov e Schraeder valve cap (arrow) at fuel rail and connect fuel
pressure gauge .
 Fuel Tank and Fuel Pump 160-1 5
Fuel pressure gauge, installing

N52 engine
Remove Schraader valve cap (arrow ) at fuel rail and connect fue l
pressure gauge.

N54 engine
Working at left side engine compartmen t near strut tower,
disconnect fuel line (arrow).

Install compatibl e T-styl e test adapter and install fuel pressur e

gauge.

b309160032
160-16 Fue l Tank an d Fuel Pum p
Fuel pressure regulator

V8 engin e
Remove Schraeder valve ca p (arrow ) a t fuel rai l and connect fuel
pressure gauge .

Fuel pressure regulator

Fuel pressure is created by the fuel pump and maintained by the fuel
pressure regulator .

Fuel pressur e regulato r i s integrated int o the fuel filter assembly.

Fuel pressur e regulato r

B510160003
 Fuel Tank and Fuel Pump 160-1 7
Fuel delivery, testing

Fuel delivery, testing

Checking fue l delivery is a fundamental par t of troubleshooting an d
diagnosing th e DM E system. Fuel pressure directl y influences fue l
delivery. There are two significant fuel delivery values to be
measured:
• Syste m pressur e i s created b y fuel pump an d maintained by
pressure regulator. System pressure i s adjustable only by the
ECM.
• Residua l pressure i s pressure maintained i n closed syste m after
engine an d fuel pum p are shut off.

System pressure

Attach fuel pressure gauge. Se e Fuel pressur e gauge, installin g

in this repai r group.

Activate fuel pump. Se e Operating fuel pump for tests i n this

repair group. Compar e fue l pressure to specifications i n
accompanying table.

Fuel system pressure specification

M54, V8 (N62) engin e 3. 5 ±0.2 bar (50. 76 ±2. 9 psi)
N52, N5 4 engine 5 ±0.2 bar (72. 5 +2. 9 psi)

CAUTION—
• The fuel pump is capable of developing a higher pressure than
that regulated by the pressure regulator. Do not allow pressure
to rise above 6.5 bar (94 psi). Damage to the fuel lines or fuel
system components could result.

After completing test s without running engine, check for fault codes
and rese t ECM memory.

. N54 engine: Compare fuel pressure on gauge to data value on BMW

scan tool.

If pressure does no t match , replac e fuel pressure regulator . Se e

Fuel pump , removin g an d installin g i n this repai r group .
Lov.'-picsstirc fuel value
Low-cicc-susc" fuel valu e After completing tests , note the following:
• M54 , N52 , V8 (N62) engine : replac e Schrasde r valve cap .
• N54 engine: reassembl e fue l line.
• Check an d clear fault codes from ECM memory.
160-18 Fue l Tank and Fuel Pump
Fuel delivery, testing

Residual pressur e
For quick restarts and to avoid vapor lock when the engine is hot, the
fuel injection system retain s fuel pressure after the engine is shirt oil
This residua l pressur e is primarily maintaine d b y the fuel pressure
regulator and a check valve at the fuel pump outlet .

Attach fuel pressure gauge. Se e Fue l pressur e gauge , installin g

in this repai r group.

Start engin e an d allow it to ru n for approximately on e minute . Not e

fuel pressure reading. Shu t OFF engine.

Note fuel pressure after approximately 20 minutes. Mak e sure

pressure does no t drop mor e tha n 0.5 bar from system pressure.

Fuel system pressure specification

M54, V 8 (N62) engines :
System pressure , engine no t
running 3.5 ±0.2 ba r (50.76 ±2 . 9 psi)

N52, N54 engines :

System pressure , engine no t
running 5 +0.2 bar (72.5 ±2. 9 psi)

CAUTION—
• The fuel pump is capable of developing a higher pressure than
that regulated by the pressure regulator. Do not allow pressure
to rise above 6.5 bar (94 psi). Damage to the fuel lines or fuel
system components could result.

When finished, disconnec t pressure gauge and fitting, an d replace

Schroder valve cap.

If fuel system doe s no t maintain pressure :

• Visually check for leaks in fuel lines and unions.
• Check for leaking injector(s).
• Check for faulty fuel pump chec k valve .
 Fuel Tank and Fuel Pump 160-1 9
Accessing fuel pump and fuel level senders

FUEL PUM P AND FUEL LEVE L SENDERS

Accessing fuel pump and fuel level senders
NOTE—
• Right side fuel pump / fuel level sender shown. Accessing left side
fuel level sender is similar.

— Remov e rea r seat cushion. See 520 Seats .

— Pee l back carpet to expose fuel sender service cover.

^ Workin g at ride side fuel tank:

• Remov e fasteners (A).
• Remov e fuel pump access cover (B).

— Installatio n is reverse of removal.

Fuel pump and fuel level sender (righ t side),

removing
Drain fuel tank. Se e Fue l tank, draining in this repair group.

Disconnect negative cable from battery.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given in 001 Warnings and Cautions .

Remove left side fuel filter and level sender. See Fuel filter and fuel
level sender (lef t side), removing in this repair group .

Remove fuel pump acces s cover. See Accessing fuel pump an d

fuel leve l senders in this repai r group.

Slide electrical connector lock in direction of arrow, remov e

connector and fuel lines if equipped.

WARNING —
• When disconnecting fuel hose, wrap shop towel around end of
hose to prevent spray of fuel under pressure.
160-20 Fue l Tank and Fue l Pump
Fuel pump and fuel level sender (right side), removing

^V Usin g BM W special tool 1 6 1 020, remov e fuel pump service cap.

— Secur e a stiff wir e to hos e pack through lef t side fuel tank service
opening. This will help with installation .

Carefully raise and to remove sending uni t with hose pac k from fuel
• tank, being careful not spill fuel from charge container (A) . Remove
and discard sending uni t sealing O-ring .

CAUTION—
• Do not bend fuel sender arm.
• Be prepared to catch any dripping fuel.

To replace fuel level sender us e following step.

Remove wire from holders and disconnect electrica l connector (A).

Carefully unlock tabs (B) and pul l fuel level sensor off in direction of
arrow.

Installation of fuel level sender i s reverse of removal. See Fue l

pump and fuel level sende r (righ t side), installing in this repair
group for fuel pump installation .

BS10160009
 Fuel Tank and Fuel Pump 160-2 1
Fuel pump and fuel level sender (right side), installing

Fuel pump an d fuel level sende r (righ t side),

installing
Working insid e fuel tank carefully install fuel pump an d fuel leve l
sender. I f necessary rotat e hos e pack and tilt toward fuel leve l
sender.

CAUTION—
• To avoid kinking hoses be sure to rotate sensor unit and hoses
in the same direction.
• Do not bend fuel sender arm.

< Whe n installing chec k to see that servic e cap lug (A) engages with
corresponding slot (B ) of fuel tank.

— Instal l service cap han d tight.

Using BMW special too l 16 1 020 tighten service cap unti l notc h o n
service cap (A) point t o notch o n fuel tank (B) .

Tightening torque
Service ca p to fuel tank 45 ±5 M m (33±3.6ft-lb )

X, Connec t electrical connector by sliding lock in direction of arrow and

connect fuel line i f equipped .

— Instal l fue l tank acces s cover .

CAUTION—
• After finishing repairs but before starting engine, be sure there
is at least 5 liters (1.5 gallons) of fuel in the tank. The fuel pump
is damaged if run without fuel.
160-22 Fue l Tank and Fuel Pump
Fuel filter and fuel level sender (left side), removing

Fuel filter and fuel level sender (left side),

removing
Drain fuel tank. See Fuel tank , drainin g i n this repair group .

Disconnect negativ e cabl e from battery .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given i n 001 Warnings an d Cautions .

Remove lef t side fuel sender acces s cover . See Accessing fuel
pump an d fuel level senders i n this repai r group .

Disconnect electrical connector (i f equipped). Usin g only your

fingers press tabs (inset ) together an d pull fuel supply (B ) line
straight up.

^ Usin g special tool 1 6 1 020, remov e fue l pump service cap.

— Carefull y lift sender out of tank with hose pack. Remove and discard
fuel tank seals (O-rings) .

Disconnect line (A) at fuel filter in direction of arrow and seal

connection at fuel filter. Disconnec t suctio n jet pump from fuel filter
by pressing catch (B) downwards, then detac h suction jet pump .
 Fuel Tank and Fuel Pump 160-2 3
Fuel filter and fuel level sender (left side), installing

Unlock and disconnect electrical connector (A ) on sending unit.

Remove sending unit from vehicle .

To replace fuel level sender, use following step.

Squeeze plug (A) tabs an d remove in direction of arrow. Release

catches (B) and pull fuel level sensor out of sender unit. Disconnec t
wires from pressure regulato r an d feed out of wire gland.

Installation o f fuel level sender is reverse of removal. See Fue l

pump an d fuel leve l sender (right side), installin g i n this repair
group for fuel pump installing.

B510160010

Fuel filter and fuel level sender (left side),

installing
^ Whe n installing check to see that service cap lug (A) engages with
corresponding slot of fuel tank (B).

— Instal l service cap han d tight.

160-24 Fue l Tank and Fuel Pump
High-pressure fuel pump, removing (N54 engine)

Using BM W special too l 1 6 1 020 tighten servic e cap until notch on

service ca p (A) points t o notch on fuel tank (B).

Tightening torque
Service ca p to fuel tank 45 +5 M m (33±3.6ft-lb )

Connect electrica l connecto r (i f equipped) an d fuel lin e (inset) .

Install fue l tank acces s cover .

CAUTION—
• After finishing repairs but before starting engine, be sure there
is at least 5 liters (1.5 gallons) of fuel in the tank. The fuel pump
is damaged if run without fuel.

High-pressure fuel pump , removin g

(N54 engine )
Remove intak e manifold . Se e 13 2 Fue l Injectio n (N54 Engine).

. Workin g at side o f engine block , remov e electrica l connectors (A )

and lay harness aside .
 Fuel Tank and Fuel Pump 160-2 5
High-pressure fuel pump, removing (N54 engine)

Remove aluminu m fastener (arrow) and discard. Detac h fue l lin e

(A). Seal fuel lines with BM W special tools 1 3 5 281 and 1 3 5 282 .
Remember to replac e aluminum fastene r (arrow) wit h new.

WARNING —
• Wear gloves and face shield when loosening fuel lines.

Loosen fuel lin e union nut (A, B ) in this order. Remov e fuel lin e
bracket fastener (C) and remov e fuel line (D). Seal fuel lin e
connections with matching plugs from BMW special tool kit 32 1 270.

WARNING —
• Wear gloves and face shield when loosening fuel lines.

Remove high-pressure fuel pump mountin g fastener s (arrows) and

remove high-pressure fuel pump. B e prepared to catch any dripping
oil with shop cloth .
High-pressure fuel pump, installing (N54 engine)

High-pressure fue l pump, installin g (N54

engine)
Replace high-pressure fue l pump O-ring (A) and clean mounting
surfaces.

When installing, rotate pump (A ) in direction of arrow until flush with

mounting surface.

Install high-pressur e fuel pump fasteners (arrows ) finger tight.

 Fuel Tank and Fuel Pum p 160-2 7
High-pressure fuel pump, installing (N54 engine)

Prior to installing high-pressure fue l lines, dispose of any coppe r

sealing ring s installe d a t factory. They ar e no longer needed .

b3091300076

Use the following sequence when installing the fuel line.

• Coat fuel line connections wit h transmission fluid.
• Preinstal l fuel line A.
• Tighten unio n nut s B, C finger tight.
• Tighten nut B to proper torque.
• Tighten unio n nu t C to proper torque.
• Tighten fuel line bracket fastener D.

Tightening torques
Fuel line to high-pressure fuel pump 30 Nm (22 ft-lb)
Fuel lin e to fuel rail 30 N m (22 ft-lb)
Fuel line mount to cylinder hea d 1 3 Nm (9.5 ft-lb)

'X, Befor e installing high-pressur e fuel pump supply line , confirm it has
updated elastomer mounting clamp (arrow). If it has a soldered hol d
down clamp, replac e fuel supply line with updated part .
160-28 Fue l Tank and Fuel Pump
Fuel tank, draining

Use the following sequence whe n installin g the fuel supply line.
• Coat fuel line connections wit h transmission fluid.
• Pre-install fuel line (A) .
• Tighten union nu t B and mount fastene r (arrow ) finger tight.
Remember t o replace fue l line bracket aluminum fastener with
new.
• Connect fuel line C to fuel supply lin e A. Liste n for audible click.
• Tighten nut B to proper torque.
• Tighten fuel line bracket fastener (arrow).

Tightening torques
Fuel line to high-pressure fuel pump 30 Nm (22 tt-lb)
Fuel line bracket to engine
• Stage 1 10 Mm (7.3ft-lb)
• Stage 2 Additional 90° ± 15°

— Reassembl e engine.

— Chec k fuel system fo r leaks.

— Chec k and clear fault codes from ECM memory .

FUEL SUPPL Y COMPONENT S

Fuel tank, drainin g
When draining fuel tank, use a safe storage unit and an approved
fuel pumping device.

WARNING —
• Before starting to work on tank removal, make sure hot
components, such as the exhaust system, are completely
cooled down.
• Fuel may be spilled. Do not smoke or work near heaters or
other fire hazards.

— Star t engine and allo w to ru n 1 0 - 1 5 seconds to fill fuel

compensating siphon assembly. This allow s both lobes of fuel tank
to be drawn off through fuel filler pipe.

— Disconnec t negative cable from battery.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given i n 001 Warnings and Cautions.

— Remov e fuel tank filler cap .

— Slid e suction hose int o filler neck about 13 0 cm (5 1 in), twisting as

necessary. Withdra w fue l into storage unit.
 Fuel Tank and Fuel Pum p 160-2 9
Fuel filter

Monitor fuel level reduction i n both lobes :

• Remov e rear seat cushio n an d access bot h fuel tank sende r
harness connectors. See Accessing fuel pum p an d fuel leve l
senders i n this repai r group .
• Us e multimeter to measure resistanc e at both senders. Resistanc e
should dro p a s fuel level drops.

If siphoning mechanis m i s faulty, drain lef t tank lob e separatel y b y

removing sende r cove r an d pumpin g fuel directly out of left lobe .

Remove suction hos e fro m tank filler neck carefully to avoi d

damaging fille r neck baffle plate.

CAUTION—
• After finishing repairs but before starting engine, be sure there
is at least 5 liters (1.5 gallons) of fuel in tank. The fuel pump is
damaged if run without fuel.

Fuel filter
The fue l filter i s a lifetime filter. I t is integrated into the lef t sid e fuel
level sender. Se e Fue l leve l sender (lef t side), removin g i n this
repair group .

Fuel pressur e regulato r

The fuel pressure regulator is integrated into the lef t side fue l level
sender. See Fuel leve l sender (lef t side), removin g i n this repai r
group.

Fuel pum p (EKP) module,

removing and installing (N52, N54 engine )
Remove righ t side luggag e compartmen t trim panel .
See 412 Trunk Lid , Tailgate.

Working at fuel pump (EKP ) module:

• Remov e electrical connectors (A).
• Remov e fasteners (arrows) and remove EKP module (B).

Installation is reverse of removal.

• Remembe r to code / program fuel pump (EKP) module i f replaced .
See 600 Electrical System-General fo r information on coding and
programming.

Tightening torques
Fuel pum p (EKP) modul e to body 8 M m (5 9 ft-lb)

— Chec k and clear fault codes fro m EC M memory.

160-30 Fue l Tank and Fuel Pump
Activated carbon canister, removing and installing

Activated carbon canister,

removing and installing
The carbon caniste r i s on the righ t side behin d the righ t rea r wheel
well liner.

- Rais e rea r end of car and suppor t safely .

CAUTION—
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

— Remov e righ t rea r wheel .

— Remov e right rea r wheel wel l liner .

^ Remov e activated carbon canister :

• Remov e lin e connections a t leak detectio n pum p (A) .
• Disconnect electrical connector (B) .
• Remov e fasteners (arrows ) and remove carbo n caniste r from
vehicle.

— Installatio n i s reverse of removal .

Fuel tank leak detection module (DMTL),

removing and installing
The DMT L i s mounted t o the activate d carbo n canister.

Raise car and support safely .

WARNING —
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

— Remov e activated carbon canister. See Activated carbon canister,

removing an d installing i n this repai r group.

^ Remov e fastener s (A) and pull DMTL unit out of carbon canister in
direction of arrow.

— Installatio n i s revers e of removal .

 170-1

170 Radiato r and Cooling Syste m

GENERAL 170- 1 Thermostat, removing and installing

Coolant pum p 170- 2 (M54 engine ) 170-1 4
Electrically heate d thermostat 170- 2 Thermostat, removin g and installing
(N52, N54 engines) 170-1 5
Radiator and expansion tan k 170- 2
Thermostat, removing an d installing
Electric cooling fan 170- 3
(V8 engine) 170-1 5
Automatic transmission flui d (ATF) cooler . . . . 170- 3
Coolant pump , removin g and installing
Warnings and Cautions 170- 4 (M54 engine ) 170-1 6
TROUBLESHOOTING 170- 5 Coolant pump, removin g and installin g
Cooling system inspectio n 170- 5 (N52, N54 engines) 170-1 7
Cooling system pressure test 170- 6 Coolant pump , removin g and installin g
(V8 engine) 170-1 8
Combustion chambe r lea k test 170- 6
Automatic transmission fluid (ATF) cooler,
Thermostat 170- 7
removing and installing 170-1 9
COOLING SYSTE M SERVIC E 170- 7 Power steering cooling loop,
Coolant, drainin g an d filling 170- 7 removing and installing 170-2 0
Cooling system, bleeding (M54 , V8 engines) . . 170- 9 Intercooler, removin g and installing
Cooling system, bleeding (N52, N54 engines) 170-1 0 (N54 engine) 170-2 1
Radiator, removing an d installing 170-1 1 TABLE
Electric cooling fa n and cowl,
a. Cooling system test pressure s 170- 6
removing and installin g 170-1 2
b. Cooling system capacities 170- 8
Coolant expansion tank ,
removing and installin g 170-1 3

GENERAL
This repai r group covers componen t repair information for the
engine cooling system .

See also:
• 020 Maintenance fo r coolant hose inspection
• 100 Engine-General for engine cod e an d application information
• Fuel Injectio n (M54 Engine ) fo r engine coolant temperature
(ECT) senso r servic e
• 131 Fuel Injectio n (N52 Engine ) fo r engine coolant temperature
(ECT) sensor servic e
• 132 Fuel Injectio n (N5 4 Engine ) fo r engine coolant temperature
(ECT) senso r service
• 133 Fuel Injection (V8 Engine) for engine coolant temperature
(ECT) senso r service
170-2 Radiato r an d Cooling Syste m
Coolant pump

Coolant pump
M54, V8 (N62) engine s
A centrifugal coolant pump is mounted to the front of the engine. The
belt-driven pum p circulate s coolan t throug h th e system whenever
the engine i s running .

N52, N54 engine s

An externally mounte d electri c coolant pum p i s bolted to the right
front of the engine block . The electric pum p allows for more efficient
heating an d cooling of the engine. I t can operat e regardless of
whether the engin e i s ON or OFF .

A low coolant flow rate is used during cold start situations to spee d
engine warm-up. A high flow rate (including flo w with engine OFF) is
used for rapid cool-down. In this way the electric coolant pump help s
ensure engine efficienc y and longevity .

The pump i s DME controlled. The DM E use s engin e load , engine

operating range and various temperature sensors t o determin e
coolant pum p operation and speed .

The electric coolant pum p i s self-diagnosable and can identify and

B510170001 store the following faults:
• Impelle r spee d deviatio n
• Stif f operatio n o r blocked b y foreign objects
• Incorrec t mixtur e ratio coolant / water
• Air in cooling syste m

Electrically heate d thermosta t

An electrically heated, DME-controlle d thermostat i s externally
mounted above the coolant pump . Th e engine contro l module
(ECM) activate s the thermostat to maintai n engin e coolant
temperature within a narrow range .

If the electronics fail, the mechanical functio n of the thermostat acts

as a fail-safe.

Radiator and expansion tank

The radiato r is a cirossflow design. An expansion tank provides for
coolant expansio n at higher temperatures an d easy monitoring of
the coolant level .

Automatic transmission fluid (ATF) is circulated through a n

additional heat exchange r (AT F cooler).
 Radiator and Cooling Syste m 170- 3
Electric cooling fan

Electric coolin g fan

Models covered by this manual us e an electric cooling fan mounte d
on the engine side of the radiator.

The electric cooling fan is controlled by the engine control module

(ECM) via the output final stage .

The output final stage is mounted on the fan housing, next to the fan
motor. The fan is operated using a pulse width modulated signal .
Fan circuit wiring is protected by a high-amp fuse. Electric fa n
activation is based on the following inputs to the ECM :
• Radiato r outlet temperature
• Calculated catalytic converter temperature
• Vehicle speed
• Batter y voltage
• Calculated refrigerant pressure

B510170003! When the vehicle is first started, the ECM activates the electric fan
briefly at 20% of its maximum speed, then switches OFF. This is for
diagnostic monitoring. The voltage generated by the fan when it
slows down (actin g as a generator) mus t match the stored rp m
values in the fan output stage to confirm that the fan i s operating
correctly.

NOTE—
• If the ECM fault memory indicates a cooling fan fault, check that
the fan is not seized and that it spins freely.
• When A/C is switched ON, the electric fan is not immediately
turned on.
• After the engine is switched OFF, the fan may continue to run at
varying speeds for up to 10 minutes, based on calculated catalyst
temperature.

Automatic transmissio n fluid (ATF) coole r

ATF lines connect the transmission to the ATF cooler (hea t
exchanger) at back of radiator.

On cold engine start-up, the engine coolant is heated mor e quickl y

than the transmission fluid. Heat from engine coolant i s used to
warm up the ATF faster, reducin g drag in the transmission an d
improving fuel mileage .

Once ATF reaches normal operating temperature, it is hotter tha n

the engine coolant. The ATF heat exchanger then acts as a cooling
device.
170-4 Radiato r and Cooling System
Warnings and Cautions

Warnings and Cautions

Observe the following warnings and cautions whe n working on the
cooling system.

WARNING —
• At normal operating temperature the cooling system is
pressurized. Allow the system to cool as long as possible
before opening (a minimum of one hour), then release the cap
slowly to allow safe release of pressure.
• Releasing cooling system pressure lowers the coolant boiling
point. The coolant may boil suddenly. Use heavy gloves and
wear eye and face protection to guard against scalding.
• Use extreme care when draining and disposing of engine
coolant. Coolant is poisonous and lethal to humans and pets.
Pets are attracted to coolant because of its sweet smell and
taste. Seek medical attention immediately if coolant is ingested.

CAUTION—
• Avoid adding cold water to the coolant while the engine is hot
or overheated. If it is necessary to add coolant to a hot system,
do so only with the engine running and coolant pump operating.
• To avoid excess silicate gel precipitation in the cooling system
and loss of cooling capacity, use BMW coolant or equivalent
low silicate antifreeze.
• If oil enters the cooling system, the radiator, expansion tank and
heating circuit must be flushed with cleaning agent. BMW
recommends removal of the radiator and expansion tank to
flush.
• When working on the cooling system, cover the alternator to
protect it against coolant drips.
• Prior to disconnecting the battery, read the battery
disconnection cautions given in 001 Warnings and Cautions.
• Replace aluminum fasteners when loosened.
• For reliable identification test fastener with magnet for
aluminum composition.
Radiator an d Cooling System 170- 5
Cooling system inspection

TROUBLESHOOTING
Begin the diagnosis o f cooling syste m problems wit h a thorough
visual inspection . I f no visual fault s are found, check th e engin e
control module (ECM ) faul t memory for stored diagnostic troubl e
codes (DTCs ) usin g BM W scan tool.

Common coolin g system faults can be grouped int o one of 4

categories:
• Cooling system leak s
• Poo r coolant circulatio n
• Radiato r cooling fan faults
• Electrica l / electronic fault s

Cooling system inspection

Check operation o f electric radiato r fan:
• Start engine, turn A/C on, MAX setting. Electri c fan should run .

Check coolant hoses for cracks or softness. Chec k clamp s for

looseness. Chec k coolan t leve l and check for evidence o f coolan t
leaks from engine.

Check that radiato r fins are no t blocked with dirt o r debris. Clea n
radiator usin g low-pressure water or compressed air. Blo w outward
from engine side out .

To check mechanica l coolant pump:

• Remov e cooling fan. See Electric coolin g fan , removing an d
installing in this repair group.
• Remov e accessory bel t from coolant pump pulley . See
020 Maintenance .
• Firml y grasp opposit e side s of pulley and check fo r play i n all
directions.
• Spin pulle y and check that shaf t runs smoothly withou t play .

NOTE—
• The coolant provides lubrication for the pump shaft, so an
occasional drop of coolant leaking from the pump is acceptable. If
coo/ant drips steadily from the vent hole, replace the pump.

Check operation o f electric coolant pump :

• Turn ignition key on.
• Adjust hea t to max. setting.
• Pres s accelerator pedal to floor.
• Pum p shoul d audibl y ru n after about 1 0 seconds .

At normal operating temperature, cooling system is pressurized. This

raises boiling point o f coolant. Leaks may prevent system from
becoming pressurized. Pressure test cooling system to help pinpoint
hard-to-find leaks. See Cooling syste m pressure test.
170-6 Radiato r and Cooling System
Cooling system pressure test

If cooling system i s full of coolant an d hold s pressure:

• Use an appropriate scan tool to interrogate engine control modul e
(ECM) for radiator fan or DM E contro l circuit faults.
• Check for failed thermostat or coolant pum p impeller.
• Check for clogged / plugged radiato r o r coolant passages .

Cooling system pressure test

A cooling system pressur e teste r is used to test for coolant leaks ,
including internal ones. Commo n source s of internal coolant leaks
are a faulty cylinder head gasket, a cracked cylinder head , o r a
cracked engine block .

WARNING —
• At normal operating temperature the cooling system is
pressurized. Allow the system to cool before opening. Remove
the cap slowly to allow safe release of pressure.

With engine cold, instal l pressure tester (BMW specia l tools

170 10 1 / 1 70 11 3 or equivalent) t o expansion tank. Pressurize
system t o specification listed in Table a.
• Pressur e should no t drop mor e than 0.1 ba r (1.45 psi) for at least
two minutes.
• I f pressure drops rapidly and there i s no sign o f external leakage,
cylinder head gasket ma y be faulty. Perform compression an d
leak-down tests.
• Test expansion tank cap using pressure tester with correct adapter
(BMW specia l tool 170 114 or equivalent). Replac e faulty cap or
cap gasket.

CAUTION—
• Exceeding the specified test pressure could damage the
radiator or other system components.

Table a. Cooling syste m test pressure s

Component Test pressur e
Radiator 1.5 ba r (21. 75 psi)
Radiator cap 2 bar (29 psi)

Combustion chamber lea k tes t

If you suspect that combustion chamber pressur e is leaking into the
cooling system pas t the cylinder hea d gasket, use an exhaust gas
analyzer to test the vapors risin g fro m the coolant at the expansion
tank.

CAUTION—
• Use an extension tube above th e reservoir neck to maintain
distance between the top of the coo/ant and the gas analyzer
nozzle. The gas analyzer is easily damaged if it is allowed to
inhale liquid coolant.
• While running engine to check for causes of overheating,
observe coolant temperature carefully in order to avoid engine
damage.
 Radiator and Cooling System 170- 7
Thermostat

Thermostat
If the engine overheats or runs too cool and no other cooling syste m
tests indicat e trouble, the thermostat may be faulty.

The electricall y heated thermostat is monitored by the OB D I I

diagnostic software . The fault may lie in the DM E software or
hardware, or it may lie in the wiring to the thermostat. See OBD On -
Board Diagnostics .

COOLING SYSTEM SERVICE

Coolant, draining and filling

WARNING —
• Allow the cooling system to cool before opening or draining the
cooling system.

— Rais e front of ca r an d suppor t safely .

WARNING —
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Remove splash shiel d from under engine. See 020 Maintenance .

Radiator expansion
tank cap Remove cap from radiator expansion tank.

Place 5-gallon pail underneath radiator .

Loosen drain plug (arrow) o n petcock a t bottom of radiator an d

allow coolant to drain .

NOTE—
• For radiators without drain plug, remove lower hose to drain
radiator.

WARNING —
• Coolant is poisonous. It is especially lethal to pets. Clean up
spills immediately and rinse the area with water. If coolant is
ingested, immediately seek medical attention.
170-8 Radiato r and Cooling Syste m
Coolant, draining and filling

M54 engine bloc k drain plug i s located on right side of engine block
near cylinder 2. V8 engine bloc k drain plug (A) is located on left side
of engin e block.

Place 5-gallon pail underneat h engin e bloc k coolant drai n plug .

Remove engine bloc k coolant drain plu g and drain coolant .

Before refilling radiator:

• Switch ignitio n ON. Do not start engine.
• Set temperature controls to full warm.
• Set blower control to low.
• Set seat hea t control to maximum.

Using a coolant mixture of 50% antifreez e and 50% distilled water,

fill expansion tank slowly. Continue unti l coolant emerges from bleed
screw. Cooling system capacities ar e i n Table b.

NOTE—
• Tap water may cause corrosion of radiator, engine and coolant
hoses.
• Coolant can be reused provided it is clean and less than two years
old. Do not reuse coolant when replacing damaged engine parts.

Bleed cooling system. See Cooling system, bleeding in this repair

group.

Table b. Cooling system capacities

Engine Capacity
M54:
• Automatic transmission 10.6L(11.2USqt)
• Manual transmission 101(10.56 US qt)
N52, N54 :
• Manual transmissio n 10.6L(11.2USqt)
• Automatic transmission 1 01(10.56 US qt)
V8 (N62):
• Automatic transmission 14.21(15 U S qt)
• Manual transmission 13.81(14.58 US qt)

Tightening torques
Block drain plug to engine block :
•M14x1.5 25Nm(18ft-lb)
•M16x1.5 35 N m (26 ft-lb)
• M 1 8 x 1.5 40 N m (30 ft-lb)
Radiator and Cooling System 170- 9
Cooling system, bleeding (M54, V8 engines)

Cooling system, bleeding (M54, V 8 engines)

Trapped air in the cooling system can prevent proper coolan t
circulation and cause overheating. Whenever the coolant is drained
and filled, bleed th e cooling system.

CAUTION—
• Carry out this procedure when replacing cooling system
components or refilling the cooling system. Failure to follow this
procedure may result in incomplete filling of cooling system,
overheating and engine damage.

Before refillin g radiator:

• Switc h ignition ON. (Do not start engine).
• Se t temperature controls to full warm.
• Set blower control to low.
• Set seat hea t control to maximum.

Using a coolant mixture of 50% antifreeze and 50% distilled water,

fill expansion tank slowly to MAX .

CAUTION—
• Use genuine BMW coolant or its equivalent to avoid the
formation of harmful, clogging deposits in the cooling system.

Start engine and run at idle speed for one minute (cap open). Adjust
coolant leve l to MAX (A). Close cap.
• Ru n engine unti l it reaches operatin g temperature.
• After engin e ha s cooled, rechec k coolant level.
• Top up so that coolant leve l indicator is at MAX.
• I f trapped air cannot b e bled manually , pressure-blee d syste m
using cooling system pressur e tester.

Cooling system capacitie s

Engine Capacity
M54:
• Automatic transmission 10.61(11.2 USqt )
• Manua l transmissio n 10L(10.56USqt)

V8 (N62):
• Automatic transmissio n 14.2L(15USqt)
• Manual transmissio n 13.81(14.58 USqt )
170-10 Radiato r and Cooling Syste m
Cooling system, bleeding (N52, N54 engines)

Cooling system, bleeding (N52 , N54 engines)

Trapped air in the cooling system can preven t proper coolant
circulation and cause overheating. Whenever the coolant is drained
and filled, bleed the cooling system .

5 series models equipped with N52 and N54 engines feature an

electric coolant pump. The bleeding procedur e operates the coolant
pump for approximately 12 minutes t o remov e trapped ai r an d
ensure that the cooling system i s filled to capacity.

CAUTION—
• Carry out this procedure out when replacing cooling system
components or refilling the cooling system. Failure to follow this
procedure may result in incomplete filling of cooling system,
overheating and engine damage.

Before refillin g radiator :

• Switch ignition ON . (Do not start engine) .
• Set temperature controls to full warm .
• Se t blower control to low.
• Set seat hea t control to maximum .

Using a coolant mixtur e of 50% antifreeze and 50% distilled water,

fill expansion tank slowly to MAX.

CAUTION—
• Use genuine BMW coolant or its equivalent to avoid the
formation of harmful, clogging deposits in the cooling system.

Radiator expansion Close cap on coolant expansion tan k and perfor m the following
tank cap steps:
1. Connec t vehicle power supply. Se e 600 Electrical System-
General.
Switch ignitio n ON.
Set heater to MAX temperature an d turn fan to lowest speed.
Press accelerator pedal to floor for 1 0 seconds.
Bleeding procedur e begin s whe n accelerator pedal i s pressed
and takes approximately 1 2 minutes . (Electri c coolant pum p
turns ON and OFF automatically after approx . 1 2 minutes).

CAUTION—
• Do not open expansion tank cap while electric coolant pump is
ON.

6. Fil l coolant expansion tank 10 0 ml above MA X (dimension A) .

7. Chec k coolin g syste m for leak s
8. I f leaks are found, remove ignition ke y and wait approximately
3 minutes befor e repeating coolin g system bleedin g procedure .
 Radiator and Cooling System 170-1 1
Radiator, removing and installing

When bleeding procedure is complete, close coolant expansion tank

cap unti l marks on cap and tank (arrows) lin e up.

Cooling system capacities

Engine Capacity
N52, N54:
• Manual transmissio n 10.61(11.2 USqt)
• Automatic transmission 10L(10.56 USqt)

Radiator, removing and installing

Raise car and support safely

WARNING—
• Make sure the car is stable and well supported at a/I times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

— Remov e splash shiel d from under engine.

— Drai n radiator. See Coolant draining and filling in this repair

group.

WARNING —
• Allow cooling system to cool before opening or draining
system.

— Remov e fan cowl. See Electri c cooling fan an d cowl , removing

and installing in this repair group.

— Unloc k coolant hose s an d detac h from radiator.

^ Automati c transmission: Unloc k catch (A) in direction of arrow.

Remove ATF heat exchange r (B ) from radiator in direction of arrow.

— Installatio n i s reverse of removal . Remember to:

• Blee d cooling system
• Check cooling system for leaks.
170-12 Radiato r and Cooling System
Electric cooling fan and cowl, removing and installing

, Carefull y lif t radiato r (A ) u p and out of engine compartment .

N52 engine shown , other engines similar .

Installation i s reverse of removal. Mak e sure :

• Radiato r seats firmly in lower mounts .
• Electri c cooling fan cowl clips securel y at bottom.
• Refil l and bleed cooling system. Se e Cooling system, bleedin g
in this repair group.
• Check cooling system for leaks .

Electric cooling fan and cowl,

removing and installin g
. Workin g above radiato r remov e cente r panel fasteners (arrows) .

Lift center panel towards engine. Be careful not to kink hood release
bowden cable. La y center panel t o one side.

WARNING —
• Do not place center panel on or near jump start terminals.

Remove Torx screws (arrows) from radiator cove r and pull radiator
cover u p and off.

^V Disconnec t electrica l connectors fro m AUC sensor (where

applicable) and fan motor (A) .

— Rais e cooling fan cowl (B ) 3 cm (1. 1 in)

 Radiator and Cooling System 170-1 3
Coolant expansion tank, removing and installing

^ Fol d in retaining tab (arrow) on left (driver's ) side of fan housing.

— Remov e cooling fan cowl b y lifting up and out .

— Installatio n is reverse of removal . Remember to:

• Correctly route all electric harnesses .
• Check and clear fault codes fro m EC M memory.

Coolant expansio n tank ,

removing and installing
Drain coolin g system. Se e Coolant, draining an d filling i n this
repair group .

WARNING —
• Allow cooling system to cool before opening or draining
system.

Release clamps o n coolant hose s (A).

Remove expansion tan k fasteners (arrows).

Raise tank slightly (i f necessary) an d release electrical connector for

coolant leve l switch (inset ) and remove expansion tank .

Installation i s reverse of removal. Remember to :

• Mak e sure locatin g pin at bottom o f tank fits securely int o rubbe r
grommet.
• Fil l and bleed coolin g system. Se e Cooling system , bleedin g in
this repai r group.
• Chec k cooling syste m for leaks.

Tightening torque
Expansion tank to body 8 Nm (71 in-lb)
170-14 Radiato r and Cooling System
Thermostat, removing and installing (M54 engine)

Thermostat, removing and installing

(M54 engine )
The electrically-heated thermostat i s an integral par t ol the
thermostat housing. The operation of the thermostat is monitored by
the ECM. If a faulty thermostat is suspected, interrogat e the ECM for
stored fault codes using a BMW scan tool.

Thermostat housing assembly

\t thermostat housing assembly
1. BoltM 6
2. Bol t M8
3. Housin g wit h heated thermosta t
4. Gaske t

Drain radiator an d engine block. See Coolant, draining and filling

in this repai r group.

WARNING —
• Allow cooling system to cool before opening system.

0021212 Remove cooling cowl . See Electric coolin g fa n and cowl,

removing and installin g i n this repai r group .

Disconnect electrica l harnes s connector fro m thermostat housing.

Cover alternator to prevent damage fro m coolant.

Lever out retaining clips (arrows) and pul l hos e fittings off housing .

Unbolt and remove thermostat housing from front of engine. Loose n

nut at top of engine liftin g eye to facilitate removal .

Installation i s reverse of removal, notin g the following:

• Keep sealing faces free of oil .
• Use new sealing gasket.

Fill system wit h coolan t and bleed. See Coolant, draining and
filling in this repair group.

Tightening torques
Block drain plu g to engine block :
• M 1 4 x 1.5 25Nm(18ft-lb)
•M16X1.5 35 Nm (2 6 ft-lb)
• M 1 8 x 1.5 40 Nm (30 ft-lb)
Radiator drain plug to radiator 2.5 N m (22 in-lb)

Cooling syste m capacitie s

Engine Capacity
M54:
• Automatic transmissio n 10.6L(11.2USqt)
• Manual transmission 10L (10.56 U S qt)
 Radiator and Cooling System 170-1 5
Thermostat, removing and installing (N52, N54 engines)

Thermostat, removing and installing

(N52, N54 engines)
Remove splash shield from under engine.

Drain cooling system . See Coolant, draining an d filling i n this

repair group.

WARNING —
• Allow cooling system to cool before opening or draining
system.

Working above engin e coolan t pump, release hose clamps (A , B )

and disconnect hoses.

Unlock fasteners (C , D) and remove hoses .

Disconnect electrica l connector (E).

Remove bolts (F) and remov e thermostat (G).

Installation i s reverse of removal. Remembe r to :

• Refil l and bleed cooling system . Se e Cooling system, bleedin g
in this repai r group.
• Chec k cooling system for leaks.

Tightening torques
Thermostat to coolant pump :
• N52 engine 9 M m (8 0 in-lb )
• N54 engine 8 N m (7 1 in-lb)

Thermostat, removing and installing

(V8 engine)
— Remov e splash shield from under engine .

— Drai n cooling system. Se e Coolant , drainin g an d fillin g i n this

repair group.

"^ Workin g below coolant pump :

• Disconnec t electrical connector (A).
• Unloc k and remove hose (B) .
• Remov e fasteners (arrows).
• Remov e thermostat (C).

— Installatio n i s reverse of removal . Remembe r to:

• Replac e sealing O-ring .
• Refil l and bleed cooling system . Se e Cooling system , bleedin g
in this repair group .
• Check cooling system for leaks.

Tightening torque
Thermostat to coolant pump 10 Nm (88 5 in-lb)
170-16 Radiato r and Cooling System
Coolant pump, removing and installing (M54 engine)

Coolant pump, removing and installing

(M54 engine)
— Remov e cooling cowl. See Electri c coolin g fan and cow\
removing and installing in this repair group.

— Drai n cooling system. See Coolant, drainin g an d filling in this

repair group.

WARNING —
• Allow cooling system to cool before opening or draining
system.

— Remov e alternator drive belt. See 020 Maintenance. Mar k direction

of rotatio n on belt.

— Cove r alternato r to prevent damag e from coolant.

— Remov e coolant pum p pulle y bolts an d remov e pulley from pump.

'A. Remov e coolant pump fasteners (arrows).

Insert two M6 screws (arrows) i n tapped bore s and tighten uniformly

until pump is free from timing chain cover .

Installation i s reverse of removal . Remembe r to:

• Replac e sealing O-ring and gaskets.
• Coa t O-ring with lubricant during installation .
• Refil l and bleed cooling system. Se e Cooling system, bleedin g
(M54, N6 2 engines) i n this repai r group .
• Chec k cooling syste m for leaks

Tightening torques
Coolant pump to timing chain cover 10Nm(89in-lb)l
Coolant pump pulley to coolant pump 10 Mm (89in-lb)
 Radiator and Cooling Syste m 170-1 7
Coolant pump, removing and installing (N52, N54 engines)

Coolant pump , removin g and installin g

(N52, N5 4 engines)
— Remov e splash shiel d from under engine.

— Drai n cooling system. Se e Coolant, drainin g an d filling i n this

repair group .

WARNING —
• Allow cooling system to cool before opening or draining
system.

— Cove r alternator to preven t damage from coolant.

— Remov e coolant thermostat. See Thermostat, removin g an d

installing i n this repair group.

^, Release hos e clamps (1) and disconnect coolant hoses from back
of pump .

— Disconnec t electrical connector (4) at front of pump.

— Remov e bolts (5) and remov e pump from side of engine .

CAUTION—
• If coolant pump is to be reused, fill with mixture of 50%
antifreeze and 50% distilled water immediately after removing,
and plug openings to avoid contamination.

— Installatio n is reverse of removal . Remember to :

• Replac e aluminum fastener s (fasteners with heads painte d blue)
with new.

CAUTION—
• Do not use steel fasteners in place of aluminum.
Electrochemical corrosion will result.

• Reinstall thermostat.
1 Refil l and blee d cooling system . See Coolin g system , bleedin g
in this repai r group .
• Check cooling system for leaks .

Tightening torques
Thermostat to coolant pum p
• N52 engine 9 N m (80 in-lb)
• N54 engine 8 Nm (7 1 in-lb)
Coolant pump to engine bloc k
(replace aluminum fasteners with new 10 Nm (8 9 in-lb)
and observe torque angle) + 90° turn
170-18 Radiato r and Cooling Syste m
Coolant pump, removing and installing (V8 engine)

Coolant pump , removing an d installing

(V8 engine)
Remove cooling cowl. See Electric coolin g fa n and cowl,
removing and installing i n this repai r group .

Drain cooling system. See Coolant, drainin g an d filling i n this

repair group.

WARNING—
• Allow cooling system to cool before opening or draining
system.

— Remov e alternator drive belt. See 020 Maintenance. Mark direction

of rotatio n on belt.

— Cove r alternator to prevent damag e from coolant.

^. Working at coolant pump :

• Disconnec t electrical connectors (A).
• Remov e vacuum lin e holder (arrow).
• Unloc k and remove coolant hose.
• Remov e drive belt pulle y (B) fasteners (arrows).

— Remov e crankshaft damper. Se e 11 7 Camshaft Timing Chain.

. Remov e coolant pump (A ) fastener s (arrows).

Installation is reverse of removal. Remember to:

• Clea n all sealing surfaces.
• Replac e coolant pipe (A ) located behind coolant pump.
• Rotat e coolant pump impeller one full revolution before installing.
• Refil l and bleed cooling system. See Cooling system, bleedin g
in this repai r group.
• Check cooling system for leaks.

Tightening torques
Coolant pum p to engine block :
•M6 10Nm (89in-lb)
•M7 15 M m (11 ft-lb)
•M8 22 N m (16 . 2 ft-lb)
B510170023
 Radiator and Cooling System 170-1 9
Automatic transmission fluid (ATF) cooler, removing and installing

Automatic transmission fluid (ATF) cooler,

removing and installing
— Remov e splas h shiel d from under engine.

— Drai n cooling system . See Coolant , draining and filling i n this

repair group .

CAUTION—
• Cover alternator when working on oil, coolant or fuel circuits to
protect from damage.

— Remov e coolant hose s from ATF cooler.

'X Us e BMW special tool 17 0 030 to unlock transmission fluid from

hydraulic line s from cooler.

Unlock catch (A) i n direction of arrow. Remove ATF heat cooler (B )

from radiato r i n direction o f arrow.

Installation i s reverse o f removal . Remember to :

• Check automatic transmission fluid level. Se e 240 Automatic
Transmission.
• Refil l and bleed coolin g system. See Cooling system , bleedin g
in this repai r group.
• Chec k cooling system for leaks.
170-20 Radiato r and Cooling System
Power steering cooling loop, removing and installing

Power steering cooling loop ,

removing and installin g
— Rais e car an d suppor t safely

WARNING —
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

— Remov e splash shiel d from under engine .

— Drai n radiator. See Coolan t drainin g an d fillin g i n this repair

group.

WARNING —
• Allow cooling system to cool before opening or draining
system.

— Remov e fan cowl. See Electri c coolin g fan an d cowl, removin g

and installin g i n this repair group .

— Remov e radiator. See Radiator , removin g an d installin g in this

repair group .

— Plac e a suitable container beneath powe r steerin g cooling loop

connections to catch dripping fluid . Dispos e o f properly.

— Usin g a fluid recovery machine, suctio n flui d from power steering

fluid reservoir.

— Pres s hydraulic lin e towards cooling loop . Pull back on locking ring
and remove line.

— Secur e A/C condenser i n place to protec t from falling and damage .

CAUTION—
• Do not disconnect A/C refrigerant lines.

Press lock (A ) and remove bracke t (B ) downwards. Illustration

shows left bracket. Sam e procedur e applie s to opposite side.
 Radiator and Cooling System 170-2 1
Intercooler, removing and installing (N54 engine)

Remove cooling modul e carrie r (A ) towards bottom .

^V Releas e cooler line mountin g catc h (A). Remove fasteners (blac k

arrows).

— Carefull y press coolin g loop (B) on right toward s front, then unclip
on left and remov e from modul e carrie r (C) .

— Installatio n is reverse o f removal . Remembe r to :

• Mak e sur e cooling loo p hydrauli c line s connect securely .
• Check that cooling loop lines snap securely into holder (A) .
• Refil l and bleed coolin g system. Se e Cooling system , bleedin g
in this repair group.
• Refil l and bleed powe r steering system. See 320 Steering an d
Wheel Alignment .
• Chec k cooling system for leaks.

Intercooler, removin g an d installin g

(N54 engine )
— Rais e ca r and suppor t safel y

WARNING —
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

— Remov e splash shield fro m under engine .

— Disconnec t intak e air duct from left and right side of intercooler. Se e
132 Fuel Injectio n (N54 engine) .

^. Release screws. (Pictur e show s righ t side). Ope n quick-connec t

couplings on charge-air hoses .

— Remov e intercoole r from cooling module carrier.

170-22 Radiato r and Cooling System
Intercooler, removing and installing (N54 engine)

When installing, coa t sealing ring s of intake air ducts with antiseize
paste.

NOTE—
• Fitting air ducts to intercooler without antiseize paste is nearly
impossible.

Reattach intake air ducts usin g BM W special tool 1 1 8 670. Duct s

must snap audibl y int o place.

CAUTION—
• Special clamping jaws (special tool 118 670) are strongly
recommended for proper installation and to prevent damage to
air ducts.
• Right side shown. Left side is similar.
 180-1

180 Exhaus t System

GENERAL iso- 1 Exhaust manifol d (cylinder s 1 - 4)

Warnings an d Cautions 180- 2 removing and installing (V8 engine) 180-2 3
Exhaust manifold (cylinders 5 - 8)
EXHAUST SYSTEM 130- 2 removing an d installing (V8 engine) 180-2 4
Exhaust system, removin g and installing
(M54, N5 2 engines) 180- 2
OXYGEN SENSORS 180-2 5
Exhaust system, removing and installin g Oxygen sensors, removin g and installing
(N54 engine) 180- 5 (M54, N52 engines) 180-2 5
Exhaust system, removing and installing Oxygen sensors, removing and installing
(V8 engine) 180- 7 (N54 engine) 180-2 6
Exhaust syste m components , removin g an d installing Oxygen sensors, removing and installing
(M54, N5 2 engines) 180- 9 (V8 engine) 180-2 8
Exhaust system components, CATALYTIC CONVERTERS 1 30-29
removing an d installing (N54 engine) 180-1 0 Near engine catalytic converters
Exhaust system components, (M54, N52 , V8 engines) 180-2 9
removing and installing (V 8 engine) 180-1 1 Near engine catalytic converters
EXHAUST MANIFOLDS 130-1 3 (N54 engine ) 180-2 9
Exhaust manifold (cylinders 1- 6), Downstream catalyti c converters 180-3 1
removing an d installing (M54 engine) 180-1 3 EXHAUST SYSTEM COMPONENTS iso-3 2
Exhaust manifold (cylinders 1- 3), Exhaust system component s (M5 4 engine) . . 180-3 2
removing and installing (N5 2 engine) 180-1 4
Exhaust system components (N52 engine) . . 180-3 3
Exhaust manifol d (cylinder s 4 - 6),
Exhaust system components (N54 engine) . . 180-3 4
removing and installing (N52 engine) 180-1 4
Exhaust syste m component s (V 8 engine) . . . 180-3 5
Exhaust manifold and turbocharger (cylinders 1- 3),
removing an d installing (N54 engine) 180-1 5
Exhaust manifol d an d turbocharger (cylinders 4 - 6),
removing and installing (N5 4 engine) 180-1 9

GENERAL
This repair group covers removal and replacement of the exhaust
system, includin g exhaust manifolds , turbocharger s an d oxygen
sensors.
180-2 Exhaus t System
Warnings and Cautions

Warnings and Caution s

WARNING —
• Exhaust gases are colorless, odorless, and very toxic. Run the
engine only in a well-ventilated area. Immediately repair any
leaks in the exhaust system or structural damage to the car
body that might allow exhaust gases to enter the passenger
compartment.
• The exhaust system and catalytic converter operate at very
high temperatures. Allow components to cool before servicing.
Wear protective clothing to prevent burns. Do not use
flammable chemicals near a hot catalytic converter.
• Corroded exhaust system components crumble easily and
often have exposed sharp edges. To avoid injury, wear eye
protection and heavy gloves when working with old exhaust
system parts.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given i n 001 Warnings and Cautions.
• Replace aluminum fasteners when loosened.
• For reliable indentification, test fastener with magnet for
aluminum composition.
• Use care not to drag or bang oxygen sensors. Oxygen sensor s
are easily damaged.
• When detaching and reattaching oxygen sensor connectors,
make sure front and rear connectors are not mixed up.
• The exhaust system is heavy. Work with an assistant.

EXHAUST SYSTEM
The exhaust system is designed t o b e maintenance free, although
regular inspection is warranted due to the harsh operatin g
conditions. Unde r norma l conditions, catalytic converters do not
require replacement unless damaged

Use new fasteners, clamps , rubbe r mount s an d gaskets when

replacing exhaust components. A libera l application of penetrating
oil to the exhaust system nuts and bolt s in advance may make
removal easier.

Exhaust system, removin g and installin g

(M54, N52 engines)
Remove exhaust system as a complete unit .

Once the complete system is removed from the car, replace

individual pipes and mufflers. Rear muffler can be replaced withou t
removing exhaust system.

— Rais e vehicle and suppor t safely.

WARNING—
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.
 Exhaust System 180- 3
Exhaust system, removing and installing (M54, N52 engines)

— Suppor t exhaust system using BM W special tool 31 2 220 o r

equivalent an d suitable jack.

NOTE—
• Exhaust system weighs approximately 40 kg (88 Ibs).

^ Remov e fasteners (arrows ) and remov e front muffler mount (A) .

Remove exhaust pipe flang e fasteners (arrows) and discard.

Remove front pipe support fasteners (arrows) and remov e suppor t

(A).
180-4 Exhaus t Syste m
Exhaust system, removing and installing (M54, N52 engines)

Working next to rear differential, remove exhaus t syste m

subframemount fastener (arrow) .

Working at rear subframe, remov e exhaust system mount fasteners

(arrows).

^V Workin g above rear muffler, remove exhaust system mount fastener

(arrow).

— Carefull y lower complete exhaust system and remove .

— Installatio n is reverse of removal . Remembe r to:

• Us e new gaskets an d hardware. Coa t hardwar e threads with
anti-seize paste .
• Mak e sure there is sufficient clearance betwee n exhaust system
and vehicle underbod y a t every point.
• Loosely instal l exhaust syste m mountin g hardware and hangers
before tightening fasteners t o their final torque.

Tightening torques I
Exhaust pip e to manifold flange 45 Nm (33 ft-lb)
Front exhaust pip e support to transmission 20Nm(15ft-lb)
Exhaust syste m hanger to rear subframe 20 Nm (15 ft-lb )
Exhaust system hange r to rear subfram e 20 N m (1 5 ft-lb )

— Chec k exhaus t syste m for leaks .

 Exhaust System 180- 5
Exhaust system, removing and installing (N54 engine)

Exhaust system, removing and installing

(N54 engine )
The remova l of the exhaus t system as a complete uni t i s
recommended. Onc e the complete syste m is removed fro m the car,
individual pipes and mufflers can be more easily replaced. Rea r
muffler ca n be replaced without removing exhaus t system .

— Rais e vehicle and suppor t safely.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Support exhaust syste m usin g BM W special tool 31 2 220 or

equivalent and suitable jack.

Remove fasteners fo r front exhaust pip e at exhaust manifold flange

(arrows).

Remove fastener (arrow) and front support bracket (A).

Remove reinforcemen t plat e bolts an d remove plat e (A) .

B510180011
180-6 Exhaus t System
Exhaust system, removing and installing (N54 engine)

Working at rear differential, remov e exhaust system hanger fastener

(arrow).

Working at rear subframe, remove exhaust system mount fasteners

(arrows).

CAUTION—
• Exhaust system is heavy. Lower with the help of an assistant.

^V Workin g at rear muffler, disconnect tailpipe flap vacuum hose

(arrow) and remove exhaust mount fastener (A).

— Carefull y lowe r complete exhaus t system and remove.

CAUTION—
• Exhaust system is heavy. Lower with the help of an assistant.
 Exhaust System 180- 7
Exhaust system, removing and installing (V8 engine)

Installation i s reverse of removal . Remember to:

• Us e new gaskets and hardware. Coat hardware threads wit h
anti-seize paste.
• Make sur e there i s sufficient clearanc e betwee n exhaus t syste m
and vehicle underbod y a t every point.
• Loosel y install exhaust system mounting hardware and hanger s
before tightening fastener s to their final torque.
• Check exhaus t syste m for leaks .

Tightening torques
Exhaust pip e to manifold flange 21 Nm(15ft-lb )
Front exhaust pipe clamp to transmission 21 Nm(15ft-lb )
Exhaust system hanger to rear differential 35 N m (2 6 ft-lb )
Exhaust system hange r to wheel carrier 21 Nm (15 ft-lb)
Exhaust system hange r to rear chassis 21 Nm (15 ft-lb)

Exhaust system, removing and installing

(V8 engine)
Remove exhaust system as a complete unit.

Once the complete system i s removed from the car, replac e

individual pipe s and mufflers. Rea r muffler can be replaced without
removing exhaus t system .

— Rais e vehicle and suppor t safely.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Support exhaust system using BM W special tool 31 2 220 or

equivalent and suitable jack.

Remove mounting bracket (A ) fasteners (arrows). Remove exhaus t

pipe flange fasteners (B).
180-8 Exhaus t Syste m
Exhaust system, removing and installing (V8 engine)

Working at rear differential, remove exhaust system hanger fastener

(A).

Working at rear subframe, remove exhaus t syste m moun t fasteners

(arrows)

Working at rear muffler , disconnect tailpip e flap vacuum hose (A )

and remove exhaust moun t fastene r (arrow )
 Exhaust System 180- 9
Exhaust system components, removing and installing (M54, N52 engines)

Remove reinforcemen t plate (A ) fasteners (arrows)

Carefully lower complete exhaus t system and remove.

CAUTION—
• Exhaust system is heavy. Lower with the help of an assistant.

Installation is reverse o f removal. Remembe r to :

• Use new gaskets and hardware. Coa t hardware thread s with
anti-seize paste.
• Mak e sure there is sufficient clearance between exhaust syste m
and vehicle underbody at every point .
• Loosely instal l exhaust system mountin g hardwar e and hangers
before tightening fasteners to their final torque.
• Check exhaust system for leaks.

Tightening torques
Exhaust pipe to manifold flange 45 N m (33 ft-lb)
Front exhaust pipe suppor t t o transmission 21 N m (15 ft-lb)
Exhaust syste m hange r to rear differentia l 35 Nm (26 ft-lb)
Exhaust syste m hange r to wheel carrie r 21 Nm (15 ft-lb)
Exhaust syste m hange r to rear chassis 21 N m (15 ft-lb)

Exhaust system components ,

removing an d installing (M54, N52 engines)
BMW offers individua l exhaus t components as replacemen t parts .
Originally installe d exhaus t components are welded togethe r at the
factory and mus t b e cut off to be replaced.

Front silencer replacement i s best accomplished by first removin g

the complete exhaust system. Rea r muffler can be replaced without
removing exhaust system. See Exhaust system, removin g an d
installing in this repair group .

Working at rear muffler, measure old exhaust system part s against

replacement parts to locate cuttin g point .

Use exhaust pipe cutter (BMW special tool 00 2 210 o r equivalent)

to cut pipe(s). Deburr cu t pipe end(s) .
180-10 Exhaus t Syste m
Exhaust system components, removing and installing (N54 engine)

Assemble pipes usin g band clamps.

Installation is reverse of removal. Remember to:

• Mak e sure there is sufficient clearance between exhaust system
and vehicle underbody at every point.
• Check exhaust system for leaks.

Tightening torque
Band clam p to exhaus t pipes 45 Nm (33 ft-lb)

Exhaust syste m components ,

removing an d installing (N5 4 engine )
BMW offers individual exhaust components a s replacement parts .
Originally installed exhaust components ar e welded together at the
factory and mus t be cut off to be replaced.

Component replacemen t i s best accomplished by first removing the

complete exhaust system. See Exhaust system, removing and
installing in this repair group.

NOTE—
• Rear muffler can be replaced without removing exhaust system.

. Cu t lines for exhaust components are designated by notches in the

535i exhaust syste m shown .
1. Rea r catalytic converter , lef t
2. Rea r catalytic converter , righ t
3. Cente r muffle r
4. Rea r muffler, left
5. Rea r muffler, right

Use exhaust pipe cutter (BM W special tool 00 2 210 or equivalent )

to cut pipe(s). Deburr cut pipe end(s).
 Exhaust Syste m 180-1 1
Exhaust system components, removing and installing (V8 engine)

Assemble pipes usin g ban d clamps.

Installation i s reverse of removal. Remember to:

• Mak e sure there is sufficient clearance between exhaust system
and vehicle underbod y a t every point.
• Check exhaust system for leaks.

Tightening torque
Band clamp to exhaust pipe s 45 Nm (33 ft-lb)

Exhaust system components,

removing and installing (V8 engine)
BMW offers individual exhaust components as replacement parts .
Originally installed exhaus t component s ar e welded together at the
factory and mus t be cut off to be replaced.

Component replacemen t i s best accomplished by first removing the

complete exhaust system. Se e Exhaust system, removing an d
installing in this repai r group .

Cut lines for exhaust components are designated by notches in the

exhaust system . Mark exhaust cuttin g line s with aid of replacement
parts.

Front muffler: Mark lengt h A with aid of replacement muffler.

B510180021

Center muffler . Mar k length s A and B with aid of replacement

muffler.
180-12 Exhaus t System
Exhaust system components, removing and in stalling (V8 engine)

^V. Rea r muffler: Mark length of dotted area wit h aid of replacemen t
muffler
--!*
--J ^ H»| ^:

"' ' "'

\J! ' : . \"v*

B510180020

Use exhaust pipe cutter (BM W specia l tool 00 2 210 or equivalent )

to cut pipe(s). Deburr cut pipe end(s).

Assemble pipes using band clamps.

Installation i s reverse of removal . Remembe r to :

• Make sure there is sufficient clearanc e between exhaus t syste m
and vehicle underbod y a t every point.
• Check exhaus t system for leaks.

Tightening torque
Band clam p to exhaust pipes 45 N m (33 ft-lb)
 Exhaust System 180-1 3
Exhaust manifolds (cylinders 1 - 6), removing and installing (M54 engine)

EXHAUST MANIFOLDS
Exhaust manifolds (cylinders 1 - 6),
removing and installing (M54 engine)
The M54 engine uses two exhaust manifolds. Each manifold
includes an integral catalytic converter. Should the catalyst nee d
replacing, replac e the appropriate exhaus t manifold / catalyst unit .
See Exhaust System Components in this repai r group .

— Remov e engine cover . See 020 Maintenance .

^ Suppor t engine from above with suitable hoist.

— Remov e lower engine covers. See 020 Maintenance.

— Remov e complete exhaust system. See Exhaust system,

removing and installing (M54, N52 engine) in this repair group .

— Remov e oxygen sensors. Se e Oxygen sensors, removin g an d

installing (M54, N5 2 engine) in this repair group .

_ _X_ J—-TiT_;=rg ^^Ljff_B5W\SSOXj

- Remove fasteners (A) and remove engine mount support (B).

---r^,_^.^_~_~_"*-
,!-=&:.
* - • * . „ «-•. . „•„ w ^ • __

»™—'">i'_ ^-:-_ ;""***-«(

r,v Remove exhaust manifol d fasteners (C) and remove exhaus t
^ 7C * -f --,--:- -t.
-i>¥i-^1 manifolds.
,*•"»*," ^^-^S,—-
t~.rj---r-tw *-=

Installation is reverse of removal. Remember to :

• Clean sealing surfaces and replace gaskets.
• Replace manifold and front pipe mounting nuts.
• Coat fastener threads with anti-seize paste.

Tightening torques
Exhaust manifold to cylinder hea d
(replace with new M7 nuts) 15 Mm (11 ft-lb)
Front pipe to exhaust manifold
(replace with new M10 nuts) 45 Nm (33 ft-lb)
Oxygen sensor to exhaust pipe or catalytic
converter (M18) 50 N m (37 ft-lb)
180-14 Exhaus t System
Exhaust manifold (cylinders 1 - 3), removing and installing (N52 engine)

Exhaust manifol d (cylinder s 1 - 3),

removing an d installing (N52 engine)
The N52 engine uses two exhaust manifolds. Eac h manifold
includes a n integral catalytic converter. Should the catalyst need
replacing, replac e the appropriate exhaus t manifold / catalyst unit.
See Exhaust System Components i n this repair group.

Remove rear exhaust manifold. See Exhaust manifold (cylinder s

4 - 6), removing and installing (M54, N52 engine) in this repair
group.

Remove oxygen sensors. See Oxygen sensors, removing and

installing (M54 , N52 engine) in this repair group.

Remove fasteners (arrows) from front exhaust manifold (A) and

remove manifold.

Installation i s reverse of removal. Remembe r to:

• Clean sealing surfaces of manifold and cylinder head.
• Us e new gaskets and hardware.
• Chec k exhaust system for leaks.

Tightening torqu e
Exhaust manifold to cylinder head 20Nm(15ft-lb)

Exhaust manifol d (cylinders 4 - 6),

removing an d installing (N52 engine )
Remove engine cover. See 020 Maintenance .

Remove lower engine covers. See 020 Maintenance.

Remove complete exhaust system. See Exhaust system,

removing and installing (M54, N52 engine) in this repair group.

Remove oxygen sensors. See Oxygen sensors, removing and

installing (M54, N52 engine) in this repair group.

Remove fasteners (arrows) from rear exhaust manifold (A) and

remove manifold.

Installation is reverse of removal. Remember to:

• Clean sealing surfaces of manifold and cylinder head.
• Use new gaskets and hardware.
• Check exhaust system for leaks.

Tightening torque
Exhaust manifold to cylinder hea d 20Nm(15ft-lb)
 Exhaust System 180-1 5
Exhaust manifold and turbocharger (cylinders 1- 3), removing and installing (N54 engine)

Exhaust manifol d and turbocharger

(cylinders 1- 3), removing and installin g
(N54 engine)
The N5 4 engine i s equipped wit h two exhaust manifolds eac h wit h
an integral turbocharger. A catalytic converter is attache d
downstream of each turbocharger . Should the catalyst nee d
replacing, i t is removable an d available separately. See Exhaust
System Components i n this repair group.

— Remov e both near engine catalyti c converters. See Nea r engin e

catalytic converter s (N54 engine ) in this repair group.

— Remov e intercooler . See 170 Radiato r an d Cooling System .

— Drai n engin e coolant an d remov e coolant expansion tank .

See 170 Radiator and Cooling System.

— Remov e thermostat. See 17 0 Radiato r and Cooling System .

— Remov e coolant pump. Se e 17 0 Radiator and Cooling System .

— Remov e turbocharge r vacuum reservoirs. Se e 132 Fuel Injection

MSD80, MSD8 1 (N54 Engine) .

— Remov e air box and air intake duct. See 132 Fuel Injection MSD80 ,
MSD81 (N54 Engine) .

— Remov e right side tie rod from steering rack. Se e 320 Steering and
Wheel Alignment .

^C Workin g below turbo chargers: Remov e fasteners on oil return line

(A) an d oil return line bracke t (B). Gently pull oil return line out of
engine bloc k in direction o f arrow.

Working betwee n turbochargers, remove fasteners (A) an d remove

coolant supply lines (B) .

NOTE—
• If necessary grasp coolant supply line flange with pliers to remove.
Do not use pliers on pipes.
180-16 Exhaus t Syste m
Exhaust manifold and turbocharger (cylinders 1- 3), removing and installing (N54 engine)

Remove fasteners (A) at coolant inle t pip e (B ) and remove pipe.

Remove coolant return pipe fasteners (A, C) and remove return pipe
(D).

NOTE—
• If necessary grasp coolant return line flange (B) with pliers to
remove. Do not use pliers on pipes.

Remove fasteners (A) at retaining plate (B) . Remov e heat shield

fasteners (C).
 Exhaust System 180-1 7
Exhaust manifold and turbocharger (cylinders 1- 3), removing and installing (N54 engine)

Carefuly remove heat shield (A) in direction of arrow so heat shield

and coolant pipe s ar e not damaged.

Remove fasteners (A) from bracket (B) . La y bracket o n top of

cylinder head .

Remove oil supply lin e bracket (B ) fastener (A). Remove oi l supply

line in direction of arrow.
180-18 Exhaus t Syste m
Exhaust manifold and turbocharger (cylinders 1- 3), removing and installing (N54 engine)

Remove fastener (A ) and remove oi l supply line.

NOTE—
• If necessary grasp oil supply line flange (B) with pliers to remove.
Do not use pliers on pipes.

Remove exhaust manifol d fasteners (A). Detac h vacuum hose from

wastegate valv e and lif t out exhaust manifol d an d turbocharger
towards the top.

NOTE—
• Take care not to damage wastegate valve linkage.

If replacin g turbocharger, remov e fastener (B ) fo r oil supply lin e (C )

and install supply lin e on new unit. Always replac e graphite gasket s
(A).
 Exhaust Syste m 180-1 9
Exhaust manifold and turbocharger (cylinders 4 - 6), removing and installing (N54 engine)

Remainder of installatio n i s reverse of removal. Remember to :

• Us e new O-rings, gasket s an d hardware. Coat hardwar e thread s
with anti-seize paste.
• Check an d clear fault codes fro m ECM .
• Check ai r intake syste m for leaks.
• Check exhaust system fo r leaks.

Tightening torques
Bracket to cylinder hea d 9 Nm (7 ft-lb)
Coolant suppl y lin e to crankcase 9 N m ( 7 ft-lb)
Coolant retur n lin e to crankcase 8 Nm ( 6 ft-lb)
Coolant retur n line to turbocharge r 8 N m ( 6 ft-lb)
Coolant supply line to coolant lin e 8 N m ( 6 ft-lb)
Exhaust manifol d hea t shield to crankcase 8 N m (6 ft-lb)
Oil supply lin e to crankcase 20 N m (15 ft-lb)
Oil pressure line to turbocharger 8 N m (6 ft-lb)
Oil return line to crankcas e 8 N m ( 6 ft-lb)
Oil return line to turbocharge r 8 N m ( 6 ft-lb)
Turbocharger to exhaust manifold 20 N m (1 5 ft-lb)

Exhaust manifol d an d turbocharge r

(cylinders 4 - 6), removing an d installin g
(N54 engine)
— Remov e both Nea r engin e catalyti c converters. See Nea r engin e
catalytic converters (N54 engine) i n this repair group .

— Releas e right side tie rod from steering rack. See 320 Steering and
Wheel Alignment .

— Remov e intercooler. See 17 0 Radiato r and Cooling System .

— Drai n engine coolan t an d remov e coolant expansio n tank . Se e

170 Radiator and Cooling system .

— Remov e thermostat. See 17 0 Radiato r and cooling system.

— Remov e coolant pump . Se e 17 0 Radiator and coolin g system .

— Remov e turbocharger vacuum reservoirs . See 13 2 Fue l Injectio n

MSD80, MSD8 1 (N54 Engine). .

— Remov e air box and air intake duct. See 132 Fuel Injection MSD80 ,
MSD81 (N5 4 Engine).

^. Remove fasteners on oil return lin e (A) and oil return line bracke t
(B). Gentl y pul l oi l retur n line out of engine bloc k i n direction o f
arrow.
180-20 Exhaus t System
Exhaust manifold and turbocharger (cylinders 4 - 6), removing and installing (N54 engine)

Working betwee n turbochargers , remove fasteners (A ) and remov e

coolant supply lines (B) .

NOTE—
• If necessary grasp coolant supply line flange with pliers to remove.
Do not use pliers on pipes.

Remove fasteners (A) at coolant inlet pipe (B ) and remove pipe.

Remove fastener (A) at coolant retur n line clamp and remove line.

NOTE—
• If necessary grasp coolant return line flange with pliers to remove.
Do not use pliers on pipes.
 Exhaust System 180-2 1
Exhaust manifold and turbocharger (cylinders 4 - 6), removing and installing (N54 engine)

Remove fastener (A) and remove coolant return line (B) and coolant
supply lin e (C).

NOTE—
• If necessary, grasp flange with pliers to remove. Do not use pliers
on pipes.
• Take care not to damage wastegate valve linkage.

Remove fasteners (A ) at retaining plate (B) . Remov e hea t shield

fasteners (C).

Carefully swing out hea t shields (A ) i n direction of arrow. Coolan t

supply pipe (B ) can be removed along with hea t shield .
180-22 Exhaus t Syste m
Exhaust manifold and turbocharger (cylinders 4 - 6), removing and installing (N54 engine)

Remove fasteners (A) from bracket (B) . La y bracket on top of

cylinder head .

Remove oi l supply line bracket (B) fastener (A), Remov e oil supply
line in direction of arrow.

Remove exhaust manifold fasteners (A). Detach vacuum hose from

wastegate valve and lif t out exhaust manifol d an d turbocharger
towards the top.

NOTE—
• Take care not to damage wastegate valve linkage.
 Exhaust Syste m 180-2 3
Exhaust manifold (cylinders 1 - 4), removing and installing (V8 engine)

If replacing turbocharger, remove fastener (B) for oil supply line (C)
and install supply line on new unit. Always replace graphite gaskets
(A).

Remainder o f installation is reverse of removal. Remembe r to :

• Us e new O-rings, gaskets and hardware. Coat hardwar e threads
with anti-seize paste.
• Chec k and clear fault codes from ECM .
• Check ai r intake system fo r leaks .
• Check exhaus t system fo r leaks.

Tightening torques
Bracket to cylinder hea d 9 N m (7 ft-lb)
Coolant supply lin e t o crankcase 9 Nm (7 ft-lb)
Coolant return lin e to crankcas e 8 Nm (6 ft-lb)
Coolant retur n line to turbocharger 8 Nm (6 ft-lb)
Coolant supply line to coolant lin e 8 Nm (6 ft-lb)
Exhaust manifold hea t shield to crankcase 8 Nm (6 ft-lb)
Oil supply line to crankcas e 20 Nm (15 ft-lb)
Oil pressure line to turbocharger 8 N m ( 6 ft-lb)
Oil return line to crankcas e 8 Nm (6 ft-lb)
Oil return line to turbocharger 8 N m ( 6 ft-lb)
Turbocharger t o exhaust manifol d 20 N m (15 ft-lb)

Exhaust manifold (cylinders 1 - 4), removin g

and installing (V8 engine)
Remove pre- and post-catalyst oxygen sensors. See Oxygen
sensors, removing and installing (V8 engine) i n this repair group.

Remove complet e exhaust system. Se e Exhaust system ,

removing an d installing (V8 engine) in this repair group.

Secure engin e in place using engine support .

Lower front subframe. Se e 310 Front Suspension .

Remove right side engine moun t and engine moun t support .

Remove exhaust manifol d fasteners (arrows). Remove exhaust

manifold towards bottom, pull outwards toward rear.
180-24 Exhaus t Syste m
Exhaust manifold (cylinders 5 - 8), removing and installing (V8 engine)

Remainder o f installation is reverse of removal. Remember to:

• Us e new gaskets and hardware. Coa t hardwar e threads with anti-
seize paste .
• Check exhaus t system for leaks.

Tightening torques
Exhaust manifold t o cylinder hea d
• M6 nuts 10Nm (7.3ft-lb )
• M7 nuts 15 M m (11 ft-lb)
• M8 nuts 23Nm(16.9ft-lb)

Exhaust manifol d (cylinder s 5 - 8), removing

and installing (V8 engine)
Remove pre - and post-catalyst oxygen sensors. See Oxyge n
sensors, removin g and installing (V8 engine) in this repair group .

Remove complete exhaus t system . Se e Exhaust system ,

removing an d installing (V 8 engine) in this repai r group.

Secure engine in place usin g engine support .

Lower front subframe. See 310 Front Suspension .

Remove steering knuckle. See Steerng and Wheel Alignment .

Remove exhaus t manifold fasteners (arrows) . Remove exhaust

manifold towards bottom , pull outwards toward rear .

Remainder of installation is reverse o f removal. Remembe r to :

• Us e new gaskets and hardware. Coat hardwar e threads with anti-
seize paste.
• Check exhaus t syste m fo r leaks.

Tightening torques
Exhaust manifol d to cylinder head
• M6 nuts 10 Mm (7.3 ft-lb)
• M7 nuts 15 Mm (1 1 ft-lb)
• M8 nuts 23 Nm (16 . 9 ft-lb)
 Exhaust System 180-2 5
Oxygen sensors, removing and installing (M54, N52 engines)

OXYGEN SENSOR S
Oxygen sensors, removin g and installing
(M54, N52 engines )
Oxygen sensors are installed at the front and rear of the catalyti c
converters. Prior to sensor removal, use BMW scan tool to read an d
clear ECM fault codes.

CAUTION—
• Use care not to drag or bang oxygen sensors. Oxygen sensors
are easily damaged.
• To avoid possible engine damage, do not mix up oxygen sensor
connectors. Mark connectors before disassembling.

Remove upper engin e covers . Se e 020 Maintenance .

Raise vehicle and support safely .

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Remov e front end reinforcement. Discar d mounting bolts.

See 310 Front Suspension .

— Labe l oxygen sensor harnes s connectors then disconnect .

Pre-catalyst oxygen sensor s

^ Workin g a t right side of engine above exhaus t manifolds , remove
oxygen senso r usin g slotted 22 mm socket (BM W specia l tool
11 7 020 or equivalent). M54 engine shown, N5 2 is similiar,

Post-catalyst oxygen sensors

*\e oxyge n senso r usin g crow-foo t wrench
11 7 030 or equivalent) .

— Installatio n is reverse of removal . Remembe r to:

• Apply a small amount of anti-seize compound to sensor threads.
• Mak e sure sensor electrical harness connectors are routed as
before and connected correctly.

r CAUTION—
• Do not overuse anti-seize paste. Do not contaminate tip of
sensor with paste or lubricants.

Tightening torques
* r l l I .»-%. :

6510180045. Oxygen senso r to exhaust pipe:

• Usin g BM W special tool 1 1 7 030 47 Nm (35 ft-lb)
• Usin g BMW special tool 1 1 7 020 50 Nm (37 ft-lb)
180-26 Exhaus t System
Oxygen sensors, removing and installing (N54 engine)

Oxygen sensors, removing and installin g

(N54 engine )
Oxygen sensor s are installed at the front an d rear o f the catalyti c
converters. Prior to sensor removal, use BMW scan tool to read and
clear EC M fault codes.

CAUTION—
• Use care not to drag or bang oxygen sensors. Oxygen sensors
are easily damaged.
• To avoid possible engine damage, do not mix up oxygen sensor
connectors. Mark connectors before disassembling.

Remove uppe r engine covers. Se e 020 Maintenance.

Raise vehicle and support safely .

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove front end reinforcement. Discar d mountin g bolts .

See 310 Front Suspension .

Label oxyge n sensor harnes s connector s then disconnect.

Pre-catalyst oxygen sensors

Release right side tie rod from steering rack . See 320 Steering and
Wheel Alignment .

Pre-catalyst oxygen senso r (A) for cylinders 1 - 3 shown with BMW

special tools 11 7 030 and 1 1 9 150.

NOTE—
• Cylinders 1 - 3 harness connector colored black.

Pre-catalyst oxygen sensor (A ) for cylinders 4 - 6 shown with BMW

special tools 1 1 7 030 and 1 1 9 150.

NOTE—
• Cylinders 4 - 6 harness connector colored grey
 Exhaust System 180-2 7
Oxygen sensors, removing and installing (N54 engine)

Installation i s reverse of removal. Remember to:

• Apply a small amoun t o f anti-seize compound to sensor threads.
• Mak e sure sensor electrical harnes s connectors ar e routed as
before and connected correctly.

CAUTION—
• Do not overuse anti-seize paste. Do not contaminate tip of
sensor with paste or lubricants.

Tightening torques
Oxygen sensor to exhaust pipe:
• Using BMW special tool 1 1 7 030
together with 11 9 150 47 Nm (35 ft-lb)
• Usin g BMW special tool 1 1 7 020 50 N m (37 ft-lb )

NOTE—
• When tool 11 7 030 is used together with swivel tool 119 150,
reduce tightening torque by 3 Nm to 47 Nm (35 ft-lb).

Post-catalyst oxyge n sensors

. Post-catalys t oxygen sensor (A) for cylinders 1 - 3 shown with BM W

special tools 1 1 7 030 and 1 1 9 150.

NOTE—
• Cylinders 1 - 3 harness connector colored black.

. Post-catalys t oxygen sensor (A) for cylinders 4 - 6 shown with BM W

special tool 1 1 7 020.

NOTE—
• Cylinders 4 - 6 harness (B) connector colored grey.

Installation is reverse of removal. Remember to:

• Apply a small amount of anti-seize compound to sensor threads .
• Mak e sure sensor electrical harness connectors are routed as
before and connected correctly.

CAUTION—
• Do not overuse anti-seize paste. Do not contaminate tip of
sensor with paste or lubricants.

Tightening torques
Oxygen sensor to exhaust pipe:
• Using BMW special tool 1 1 7 030
together with 11 9 150 47 N m (35 ft-lb)
• Using BMW special tool 1 1 7 020 50 Nm (37 ft-lb)

NOTE—
• When tool 11 7 030 is used together with swivel tool 11 9 150,
reduce tightening torque by 3 Nm to 47 Nm (35 ft-lb).
180-28 Exhaus t Syste m
Oxygen sensors, removing and installing (V8 engine)

Oxygen sensors , removin g an d installing

(V8 engine )
Oxygen sensors are installed a t the front and rear of the catalytic
converters. Prior to sensor removal , us e BMW scan tool to read and
clear ECM fault codes.

CAUTION—
• Use care not to drag or bang oxygen sensors. Oxygen sensors
are easily damaged.
• To avoid possible engine damage, do not mix up oxygen sensor
connectors. Mark connectors before disassembling.

Remove uppe r engin e cover. Se e 020 Maintenance .

Raise vehicle and support safely .

WARNING —
• Make sure the vehicle is stable and well supported at a/I times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Remov e front end reinforcement . Discar d mountin g bolts.

See 310 Front Suspension .

— Labe l oxygen sensor harnes s connectors the n disconnect.

Pre-catalyst oxygen sensors

^k Pre-catalys t oxygen sensor (A ) for cylinders 1 - 4 shown, cylinders
5 - 8 are similiar. Remov e usin g BMW special tool 1 1 7 030.

— Installatio n i s reverse of removal . Remembe r to :

• Apply a small amount o f anti-seize compoun d to sensor threads .
• Make sure senso r electrical harness connectors ar e routed as
before and connected correctly.

CAUTION—
• Do not overuse anti-seize paste. Do not contaminate tip of
sensor with paste or lubricants.

Tightening torques
Oxygen sensor to exhaust pipe :
• Using BMW special tool 1 1 7 030 50 Nrn (37 ft-lb)
 Exhaust System 180-2 9
Near engine catalytic converters (M54, N52, V8 engines)

Post-catalyst oxygen sensors

Remove lower engine cover .

Post-catalyst oxygen sensor (A) for cylinders 1 - 4 shown, cylinders

5 - 8 are similiar.. Remove using BMW special too l 1 1 7 030.

Installation is reverse of removal. Remember to:

• Apply a small amount o f anti-seize compound t o sensor threads .
• Make sure sensor electrical harness connectors are routed as
before and connected correctly.

CAUTION—
• Do not overuse anti-seize paste. Do not contaminate tip of
sensor with paste or lubricants.

Tightening torques
Oxygen sensor to exhaust pipe:
• Usin g BM W special tool 1 1 7 030 50 Nm (37 ft-lb)

CATALYTIC CONVERTER S
Catalytic converter s ar e used i n the exhaust syste m t o forc e
oxidation o r conversion o f unburned hydrocarbons , carbo n
monoxide an d nitrogen oxides .

Near engine catalytic converters

(M54, N52, V8 engines)
M54, N52 and N62 engines include an integral catalytic converte r in
each exhaust manifold. T o replace catalyst, see Exhaust manifol d
in this repai r group.

Near engine catalytic converters (N54 engine)

N54 engines include a separate catalytic converter clamped to each
turbocharger. To replace N54 near engine catalyst, follow the
procedures below.

— Remov e lower engine cover. See 02 0 Maintenance .

— Remov e exhaust system. See Exhaus t system, removing an d

installing (N54 engine) i n this repair group.

— Workin g at side o f transmission: Remove holder for oxygen senso r

wiring harness.

— Remov e oxygen sensors. See Oxygen sensors, removin g an d

installing (N5 4 engine) in this repai r group.

— xDriv e models: Remove righ t side front drive axle bearing block .
180-30 Exhaus t Syste m
Near engine catalytic converters (N54 engine)

Near aneign ecatalytic converter, cylinders 1 - 3

(N54 engine)

Remove nut s (arrows ) from catalytic converte r bracket.

Remove bolt s (arrows) fro m catalytic converte r bracke t (A).

While supporting catalytic converter: Loose n clam p (arrow) an d

lower converter (A) to remove .
 Exhaust System 180-3 1
Downstream catalytic converters

Installation i s reverse of removal. Remember to:

• Clean sealing surfaces and replace seal betwee n converter and
turbocharger.
• Hol d catalytic converter in position using BM W special tool
180 11 0 or equivalent an d install clamp.
• Chec k exhaust system for leaks.

Tightening torque
Catalytic converter to turbocharger
13Nm(10ft-lb)

Near engine catalytic converter, cylinders 4 - 6

(N54 engine)

Remove near engine catalyti c converter for cylinders 1 - 3.

Remove oxygen sensors. See Oxygen sensors, removin g and

installing i n this repai r group.

While supporting catalytic converter: Remove clamp (arrow) an d

lower converter (A) to remove .

Installation is reverse o f removal. Remembe r to:

• Clea n sealing surfaces and replace seal between converter an d
turbocharger.
• Hol d catalytic converter in position using BMW special tool
18 0 110 or equivalent and instal l clamp.
• Chec k exhaust system for leaks.

Tightening torqu e
Catalytic converter to turbocharger 13 Nm (10ft-lb )

Downstream catalyti c converter s

N52 and N54 engines includ e downstream catalytic converters that

are welded into the originally installed exhaust system and must be
cut of f to be replaced .

To replace N52 or N54 engine downsrea m catalyst, See Exhaus t

system components, removing and installing i n this repai r
group.
180-32 Exhaus t Syste m
Exhaust system components (M54 engine)

EXHAUST SYSTEM COMPONENT S

Exhaust syste m component s (M54 engine )
1. Exhaus t manifold, cy l 1 -3
2. Exhaus t manifold, cyl 4-6
3. Pre-catalys t oxygen sensor, cyl 1 -3
4. Pre-catalys t oxygen sensor, cyl 4-6
5. Post-catalys t oxyge n sensor, cyl 1 -3
6. Post-catalys t oxygen sensor, cyl 4-6
7. Bracke t

1. Gaske t
2. Bol t
3. Exhaus t pipe support, lower
4. Exhaus t pip e support, upper
5. Washe r
6. Bracke t
7. Vibratio n damper
8. Hange r
9. Clam p
10. Center muffle r

1. Muffle r
2. Dua l clamp
3. Bracke t
4. Bracke t hanger
5. Bracket , front
6. Bracket , rear
7. Tailpip e tip
 Exhaust System 180-3 3
Exhaust system components (N52 engine)

Exhaust syste m components (N52 engine )

1. Exhaus t manifold, cyl 1 -3
2. Exhaus t manifold, cyl 4-6
3. Pre-catalys t oxygen sensor , cyl 1-3
4. Pre-catalys t oxyge n sensor , cyl 4-6
5. Post-catalys t oxygen sensor, cyl 1 -3
6. Post-catalys t oxygen sensor, cyl 4-6
7. Bracke t

B510180060 |

1. Gaske t
2. Bol t
3. Exhaus t pip e support, lowe r
4. Exhaus t pipe support, uppe r
5. Bracke t
6. Washe r
7. Downstrea m catalyti c converter, cy l 1 -3
8. Downstrea m catalytic converter , cyl 4-6
9. Hange r
10. Center muffler
11. Clamp
12.Hanger

1. Muffle r
2. Dua l clam p
3. Bracke t
4. Bracke t hanger
5. Bracket , front
6. Bracket , rea r
7. Tailpip e tip
180-34 Exhaus t Syste m
Exhaust system components (N54 engine)

Exhaust system components (N54 engine)

1. Exhaus t manifold/turbocharger,
cyl 1 -3
2. Exhaus t manifold / turbocharger,
cyl 4-6
3. Hea t shield
4. Bracke t
5. Hea t shiel d
6. Gaske t

1. Nea r engine catalytic converter, cyl 1 -3

2. Nea r engine catalytic converter, cyl 4-6
3. Pre-catalys t oxygen sensor, cyl 1 -3
4. Pre-catalys t oxygen sensor, cyl 4-6
5. Post-catalys t oxyge n sensor, cyl 1 -3
6. Post-catalys t oxygen sensor, cyl 4-6
7. Bracke t

1. Gaske t
2. Bol t
3. Exhaust hanger, lower
4. Exhaust hanger, upper
5. Bracke t
6. Washe r
7. Downstrea m catalyti c converter, cyl 1 -3
8. Downstrea m catalytic converter, cyl 4-6
9. Vibratio n damper
10. Center muffler
11. Clamp
12. Hanger
 Exhaust System 180-3 5
Exhaust system components (V8 engine)

1. Muffler , left
2. Muffler , right
3. Dua l clamp
4. Hange r
5. Bracke t
6. Tailpip e trim
7. Edg e protecto r
8. Tailpip e flap

Exhaust syste m component s (V 8 engine)

1. Exhaus t manifold, cyl 1 -4
2. Exhaus t manifold , cy l 5-8
3. Gaske t
4. Nu t
5. Bracke t
6. Oxyge n sensor bracke r connecto r
7. Pre-catalys t oxygen sensor, cyl 1-4
8. Pre-catalys t oxygen sensor, cyl 5-8
9. Post-catalys t oxygen sensor, cyl 1 -4
10. Post-catalyst oxygen sensor, cyl 5-8
11. Bolt

1. Nu t
2. Hange r
3. Bracke t
4. Vibratio n dampe r
5. Bol t
6. Resonato r
7. Dua l clamp

B510180066j
180-36 Exhaus t Syste m
Exhaust system components (V8 engine)

1. Dua l clamp
2. Cente r muffler
3. Rea r pipe and mufflers
4. Nu t
5. Bracke t
6. Hnage r
7. Tailpip e flap
8. Tailpip e trim
 200-1

200 Transmission-Genera l

GENERAL 200- 1 DRIVETRAIN LUBRICANT S 200- 6

Clutch fluids 200- 5
DRIVETRAIN 200- 2
Transmission fluids 200- 6
MANUAL TRANSMISSIO N 200- 2 Transfer case fluid 200- 7
6-speed manual transmission and clutch 200- 2 Differential oil 200- 8

SEQUENTIAL MANUA L GEARBOX (SMG) .. 200- 3 TABLES

Paddle shift 200- 4
a. 5 Series manual transmissio n application s (6-speed ) 200- 3
AUTOMATIC TRANSMISSION 200- 4 b. 5 Series SMG applications 200- 3
6-speed automatic transmission 200- 4 c. 5 Series automatic transmission applications 200- 4
d. SMG clutch fluid 200- 6
XDRIVE 200- 5 e. Manual an d SMG transmission fluids 200- 6
Transfer case 200- 5 f. Automati c transmission fluid 200- 6
xDrive clutch . 200- 5 g. Transfer case fluid specification 200- 7
h. Differential oil (lifetime) 200- 8

GENERAL
This section provides general information for drivetrain components
such as clutch, transmission, driveshafts and xDrive transfer case.

See also:
• 119 Lubrication Syste m fo r rear main seal replacemen t
• 210 Clutch for clutch mechanical and hydraulic repairs and
flywheel replacement
• 230 Manual Transmission fo r manual transmissio n flui d service ,
seal replacement and transmission replacemen t
• 231 Sequential Manua l Gearbox (SMG) for basic SM G service
• 240 Automatic Transmission fo r ATF change an d transmission
replacement
• 260 Driveshafts for front and rear driveshaft repair s
• 270 Transfer Cas e for xDrive transfer case replacemen t
• 311 Fron t Axle Differential for front differential, front drive axles
and front CV joints
• 331 Rear Axle Differential fo r rear differential, rea r drive axle s
and rear CV joints
200-2 Transmission-Genera l
6-speed manual transmission and clutch

DRIVETRAIN
5 Series models ar e equipped wit h a longitudinal drivetrain. The
transmission i s bolted directly t o the rea r of the engine.

In rear-wheel drive models, a driveshaft connect s the output shaft of

the transmission t o the rear differential .

On xDrive models, a transfer case i s mounted to the rear of the

transmission, with drive shafts leading to front and rear differentials.
Individual drive axles with integrated constant velocity joints transfer
rotational power from the differentials to the drive wheels.

1. Fron t drive axle

5 series 1 2. xDriv e transfer cas e
xDrive
3. Rea r driveshaft
4. Rea r drive axl e
5. Fron t differential
6. Fron t driveshaf t
7. Transmissio n
8. xDriv e clutch (VTG) actuator
9. Rea r differentia l

1 5 6 7 8 49
B510200003

MANUAL TRANSMISSIO N
6-speed manual transmission and clutch
A 6-speed manual transmission is available on all models.
 Transmission-General 200- 3
6-speed manual transmission and clutch

"X. Manua l transmission vehicles are equipped with a single-disc clutch

and dual-mass flywheel.
1. Pilo t bearing
2. Dual-mas s flywheel
3. Clutc h disc
4. Clutc h pressure plate
5. Clutc h release bearin g

For further information, see 210 Clutch.

Manual transmission has a metal ID plate mounted on side of

transmission. Do not rely on numbers cast on transmission cas e for
identification. Fo r transmission applications, see Table a.
BX06200008
Transmission gear ratio information is in 230 Manual
Transmission.

Table a. 5 Series manual transmission applications (6-speed)

Model (engine) Year BMW designation Manufacturer designatio n
525i (M54) 2004 - 2006 GS6-37BZ / DZ ZF6HP19type H
530i (M54, N52) 2004 - 2007 GS6-37BZ / DZ ZF6HP19typeH
525i, 528i (N52) 2006-2010 GS6-17BG Getrag type I
525xi, 528xi, 530xi (N52) 2006-2010 ^GS6X37BZ7D7^ ZF6HP19typeH

535i (N54) 2008-2010 GS6-53BZ/DZ ZF 6HP26 type G

535xi (N54) 2008-2010 GS6X53DZ ZF 6HP26 type G

545i, 550i 2004-2010 GS6-53BZ ZF 6HP26 type G

(N62, N62TU)

SEQUENTIAL MANUAL GEARBOX (SMG)

Available as an option, the 6-speed sequential manual gearbox
Sequential manual (SMG) functions lik e a clutchless manual transmission. Clutc h
gearbox (SMG ) operation is handled via a computer controlled hydraulic unit that
engages and disengages th e clutch automatically, as well as
physically shifting the transmission into gear.

SMG application information is in Table b.

Table b. 5 Series SMG applications

Model (engine) Year Transmission
525i, 530i (M54) 2004 - 2005 GS6S37BZ
530i (N52) 2006 - 2007 GS6S37BZ
545i (N62) 2004 - 2006 GS6S53BZ

B510200001
200-4 Transmission-Genera l
Paddle shift

Paddle shift
In addition t o the traditional floor-mounte d selector lever, SMG
models are equipped with paddle shifters above the steering wheel
spokes. Pulling or pushing either paddle result s i n transmission
upshift or downshift.

AUTOMATIC TRANSMISSIO N
6-speed automatic transmission
The automatic transmissio n i s a 6-speed Steptronic that offers a
choice of Normal, Sport, and Manual mode. Sport mode is engaged
by moving the shift lever out of Drive and into the Sport / Manual shift
gate. I n Sport mode , shifts occur at a higher rp m than normal .
Additionally, th e driver can tip the lever forwar d (downshifts) or
backward (upshifts) to manually select a gear. Automatic
transmission applications are i n Table c.

Table c, 5 Series automatic transmission applications

Model (engine) Year Transmission
525i, 525xi, 530i, 530xi, 2004 - 2007 GA6HP19Z
(M54, IN52)
545i, 550i 2004 - 2007 GA6HP26Z
(N62, N62TU )
B309020003 5281, 528xi, 535i, 535xi, 2008 - 2000 GA6HP19ZTU
(N52, N54 )
550i (N62TU ) 2008 - 2009 GA6HP26ZTU
 Transmission-General 200- 5
Transfer case

XDRIVE
xDrive
transfer case
Transfer case
BMW's advanced all-wheel drive system is known as xDrive. I t
includes a transfer case with electronically controlled clutch that
regulates the front to rea r torque split for best traction.

The xDrive transfer case, bolted to the rear of the transmission ,

directs power from the transmission t o both the front and rea r
differentials via driveshafts. The transfer case is permanentl y
engaged to drive all four wheels all of the time.
1. Transfe r case input shaft
B309200010 2. Transmissio n an d transfer case mount
3. Fil l plug
4. Fron t driveshaft outpu t
5. Rea r driveshaft output
6. xDriv e clutch actuator

xDrive clutc h
In the xDrive system, an electronically controlled clutch i n the
Clutch
transfer case allows for infinitely variabl e distributio n o f front to rear
Rear torque for best traction.
Front driveshaft
driveshaft xDrive functions ar e integrated with ABS / DSC. Under norma l
driving conditions, 60% of engine power goes to the rear axle, 40%
to the front . I f a wheel begins to slip or if the DC S steering angle
sensor and acceleration sensors signal excessive yaw (rotational
acceleration) i n the vehicle, xDrive reacts by transferring power to
the wheel or wheels with best traction, usually before a wheel is able
to spin. This significantly reduce s the risk of under- or oversteer ,
improving agility and safety on the road.

Torque and engine power are redistributed by xDrive within a few

milliseconds. As a result, the driver normally does not notice a
change in power distribution.
Clutch actuato r B510200008
In addition t o controlling powe r distribution, xDrive and DS C may
intervene via braking. I f a wheel starts to spin without transmittin g
power, the brakes are applied a t that wheel. In this case, th e
differential automatically supplies more power to the opposite
wheel.

For additional information on xDrive and DS C functions, see

270 Transfer Case and 340 Brakes.
200-6 Transmission-Genera l
Clutch fluids

DRIVETRAIN LUBRICANTS
Clutch fluid s

Manual transmission clutch fluid

Manual transmission hydraulic clutc h is operated using brake fluid.
Brake fluid level checking and topping off is covered in
020 Maintenance. Hydrauli c clutch bleeding i s covered in
210 Clutch.

SMG clutch fluid

. Clutc h fluid reservoir (A ) i s at side o f transmission. Clutch fluid
checking and topping of f is covered in 231 Sequential Manua l
Gearbox (SMG).

SMG clutch flui d requiremen t i s in Table d .

Table d . SMG clutch fluid

Hydraulic fluid PentosinCHF 11 S

Transmission fluid s
Manual, SM G and automatic transmissions are filled with lifetime
lubrication. N o oil change i s required fo r the entire service life of the
transmission. I f repairs hav e to be made t o the transmission o r
transmission oi l cooler, us e only the recommended lifetim e fluid to
refill. See Table e or Table f .

Table e. Manual and SMG transmission fluids

Transmission Year range Fluid type
ZF GS6-37BZ 2004 - 2005 MTF-LT-2
ZF GS6S37BZ (SMG) from 2006 MTF-LT-3
ZF GS6X37BZ (xDrive)
ZF GS6-53BZ
ZF GS6S53BZ (SMG)
ZF GS6X53BZ (xDrive)
MTF-LT-2 (Lifetime fluid) BMW part no. 83 22 0 309 031
MTF-LT-3 (Lifetime fluid) BMW part no. 83 22 0 409 878

Table f. Automatic transmission flui d

Type BMW part no. Manufacturer par t no.
GA6HP19Z 83220142516 Shell M-1 375.4
GA6HP19ZTU
GA6HP26Z
GA6HP26ZTU
 JYansmission-General 200- 7
Transfer case fluid

, A label on manual transmission specifies original lubrican t use d at

the factory.

For manual transmission fluid service, see 230 Manual

Transmission.

For SMG fluid service, se e 231 Sequential Manua l Gearbo x

(SMG).

. AT F is specified on colored label on automatic transmission sump .

For automatic transmission fluid service, including checkin g flui d

level and ATF filter replacement, see 240 Automatic
Transmission.

Transfer cas e fluid

Transfer case fluid specification for xDrive models i s in Table g .

Table g. Transfer case fluid specificatio n

Type BMW part no. Manufacturer par t no.
xDrive (all) 83 22 0 397 244 Shell TF0870

For transfer case fluid service, see 270 Transfer Case.

200-8 Transmission-Genera l
Differential oil

Differential oi l
Differentials are filled with lifetim e lubrication . No oil change is
required for the entire service lif e of the differential. If repairs have to
be made to the differential, us e only the recommended lifetime oil to
refill. See Table h .

Table h. Differential oil (lifetime )

BMW specification SAF-XO Synthetic

Front differential i n xDrive models is bolted to left side of engine oil

pan.

For front differential oil service, see 311 Front Axle Differential.

Rear differential is supported at rear suspension subframe using

three rubber bushings (arrows) .

For rear differential oil service, see 331 Rea r Axle Differential.
 210-1

210 Clutc h

GENERAL 210- 1 CLUTCH MECHANICAL 210- 7

Clutch system overview 210- 1 Clutch, removing 210- 8
Cautions 210- 2 Clutch components, inspecting 210- 9
Clutch, installin g (new SAC components) . . . 210-1 0
CLUTCH HYDRAULICS 210- 2
Clutch, installing (used SAC components) . . . 210-1 1
Clutch hydraulic system,
bleeding an d flushing 210- 3 Self-adjusting clutch (SAC), breaking in 210-1 3
Clutch maste r cylinder, replacin g 210- 4 Flywheel, removing and installing 210-1 4
Clutch switch, replacing 210- 6 Transmission pilo t bearing, replacin g 210-1 5
Clutch slave cylinder, replacing 210- 7

GENERAL
This repair group covers replacement of manual transmission clutc h
mechanical and hydraulic components .

See also:
• 200 Transmission-General for transmission application
information
• 230 Manual Transmissio n fo r transmission remova l
• 270 Transfer Cas e for xDrive transfer case removal

Clutch system overview

Clutch assembly an d hydraulics

SAC pressure plat e Ball
stud From brake I . Clutch switch
fluid reservoir ~~--- J

Engine
flywheel

Pilot
bearing

Crankshaft

Clutch disc Pressur e plate Releas e

release lever leve r B510210008J
210-2 Clutc h
Cautions

Cautions

CAUTION—
• When performing any repair which involves separating the
engine and transmission, check that the be/I housing dowels
are undamaged and properly in place before reassembly. If the
alignment of the engine flywheel to the transmission input shaft
or torque converter is incorrect any of the following complaints
may result: Clutch slipping, shudder, or poor disengagement;
noise from transmission input shaft; transmission popping out
of gear; difficulty changing gears; or internal damage to the
transmission.
• When removing interior trim clips, avoid damaging trim pieces
by using a plastic prying tool or a screwdriver with the tip
wrapped with masking tape.
• Brake fluid is poisonous, highly corrosive and dangerous to the
environment. Wear safety glasses and rubber gloves when
working with brake fluid. Do not siphon brake fluid with your
mouth. Immediately clean away any fluid spilled on painted
surfaces and wash with water, as brake fluid removes paint.
• Use new brake fluid from a fresh, unopened container. Brake
fluid absorbs moisture from the air. This can lead to corrosion
problems in the hydraulic systems, and also lowers the brake
fluid boiling point. Dispose of brake fluid properly.
• To avoid electrochemical corrosion to engine components
made of aluminum-magnesium alloy, do not use steel
fasteners. Use aluminum fasteners only.
• The end faces of aluminum fasteners are usually painted blue.
For reliable identification, test fasteners for aluminum
composition with magnet.
• Replace aluminum fasteners each time they are loosened.
• Follow torque instructions, including angle of rotation
specifications, when installing aluminum fasteners.

CLUTCH HYDRAULIC S
The clutch is hydraulically actuated by the master and slave
cylinders. Clutc h disc wear i s automatically taken u p through the
self-adjusting clutc h (SAC ) pressur e plate springs, makin g periodic
adjustments unnecessary .

A soft or spongy feel to the clutch pedal, long pedal free-play, o r

grinding noises fro m the gears while shifting can all indicate
problems with clutch hydraulics . In these circumstances i t is best to
start with a clutch fluid flush, followed, i f necessary, b y replacemen t
of the hydraulic parts.

The clutch hydraulic syste m shares the fluid reservoir and fluid with
the brake hydraulic system.
210-6 Clutc h
Clutch switch, replacing

Working at clutch master cylinder mounting pins :

• Use screwdriver to remove locking clip (A).
• Pry out mounting pins (B).

•w • Lowe r master cylinder and detach fluid supply line.

i-:?:'''S!!?r:::" ••••-¥nsi;r;| i CAUTION—

• Do not pull supply line completely into vehicle interior.

Remove switch module from master cylinder.

• Pres s locking butto n (A) to release harness connector .
• Pul l harness connector (B ) off switch module.
• Us e screwdriver to lever switch module (C) off master cylinder.

Installation i s reverse of removal. Keep in mind the followino:

• Make sure switch module snaps audibly into place on master
cylinder housing .
• Reattach fluid supply hose before placing mastr, cylinde r in place
on pedal cluster .
• Pres s in master cylinder mounting pins uni.il locking clips snap into
place.

Reattach fluid supply hos e to brake fluid '^servoir. Fill reservoir with
clean fluid and bleed clutch hydraulics . Se e Clutch hydrauli c
B510210006 system, bleeding and flushing i n this repai r group .

Clutch switch, replacin g

The clutch switch module is attached to the clutch master cylinder. It
performs both cruise control and starter immobilization functions.

Working at pedal cluster , remove lower left trim panel unde r

dashboard (peda l cluster trim). See 513 Interior Trim .

. Remov e switch module fro m master cylinder .

• Press locking button (A) to release harness connector (B).
• Use screwdriver to lever off switch module (C).

Installation is reverse of removal. Mak e sure switch module snap s

audibly into place on master cylinder housing.

B510210006
 Clutch 210- 5
Clutch master cylinder, replacing

. Workin g underneat h lef t side dashboard a t pedal cluster , detach

clutch peda l retur n spring (arrow).

Using screwdriver, remov e retainin g clip (arrow), then push out pin
mounting maste r cylinder pus h ro d to clutch pedal .

Use thin screwdriver to remove fluid pressure line retaining clip

(arrow). Detac h fluid line from clutch master cylinder.

CAUTION—
• To prevent brake fluid spill, wrap clutch master cylinder with
shop towels when removing hydraulic fluid lines from master
cylinder.
• Brake fluid damages paint and stains carpets. Clean off any
brake fluid on or in the vehicle immediately.
 Clutch 210- 3
Clutch hydraulic system, bleeding and flushing

Clutch hydrauli c system ,

bleeding an d flushing
If the clutch and brake fluid is murky or muddy, o r has not been
changed within the last two years, flush the system using a brake
system pressure bleeder .

— Rais e vehicl e and support safely .

WARNING—
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Remov e splash shield under transmission . Se e 020 Maintenance.

— Workin g at left rea r of engine compartment , remove left cabi n

microfilter cover and housing. See 020 Maintenance .

"^ Remov e brake fluid reservoir cap. Using a clean syringe, remov e
brake fluid from reservoir. Refill reservoir with clean DOT 4 lo w
viscosity brake fluid .

— Attac h pressure brake bleeder to fluid reservoir and pump bleede r a

few times to pressurize hydraulic fluid system.

CAUTION—
• Do not exceed2 bar (29 psi) pressure at the fluid reservoir when
bleeding or flushing the hydraulic system.
• Brake fluid is poisonous, highly corrosive and dangerous to the
environment. Wear safety glasses and rubber gloves when
working with brake fluid. Do not siphon brake fluid with your
mouth. Immediately clean away any fluid spilled on painted
surfaces and wash with water, as brake fluid removes paint.
• Use new brake fluid from a fresh, unopened container. Brake
fluid absorbs moisture from the air. This can lead to corrosion
problems in the hydraulic systems, and also lowers the brake
fluid boiling point. Dispose of brake fluid properly.

Clutch hydraulics, bleedin g

Connect a length of hose from clutch slave cylinder bleede r valv e
(arrow) t o a container.

Open bleeder valve and allow brake flui d to expel until clean fluid
comes out free of air bubbles .

Close bleede r valve and disconnect pressur e bleedin g equipment

from fluid reservoir. Hose on bleeder valve remains connected .

Slowly operate clutch pedal about 1 0 times. Fill reservoir with clea n
fluid as necessary .
210-4 Clutc h
Clutch master cylinder, replacing

Clutch hydraulics, bleeding usin g

BMW special tool 21 5 030
^C Workin g underneath vehicle, unbolt slave cylinder from
transmission. Fit BMW special tool 21 5 030 to slave cylinder. Rotate
threaded too l spindle to press slave cylinder pushrod completel y
into slave cylinder.

— Attac h pressure brake bleeder t o fluid reservoir .

— Hol d slave cylinder so that bleeder valve is at highest point.

• Open bleeder valve.
• If bubble-free brake fluid emerges, us e tool spindle t o retract slave
Slave cylinder 2 1 5 03 0
cylinder push rod slightly, then press in again.
• I f bubbles appear, repeat procedure until fluid runs clear and
without bubbles.
• Once brake fluid appears without air bubbles, close bleeder valve,
release pressure bleede r an d detach special tool . Disconnec t
bleeder hose.

CAUTION—
• Do not detach special tool from slave cylinder if fluid is
pressurized. The slave cylinder push rod can blow out of th&
cylinder.

Reinstall slave cylinder to transmission. Ad d clean brike fluid to

reservoir as necessary. Check clutch operation.

Tightening torqu e
Clutch slave cylinder t o transmissio n 22Nm(16ft-lb) 1

Clutch maste r cylinder, replacing

The clutch master cylinder is mounted to the pedal assembly directl y
above the clutch pedal.

— Workin g at left rear of engine compartment , remov e left cabi n

microfilter cover and housing. See 020 Maintenance.

^, Remove brake fluid reservoir cap. Using a clean syringe , remove

brake fluid from reservoir.

— Disconnec t clutc h fluid supply lin e from brake fluid reservoir. Place
a pan under hose to catch dripping fluid.

— Workin g at pedal cluster , remov e lowe r left trim panel unde r

dashboard (pedal cluster trim). See 513 Interio r Trim.

— Remov e light module. Se e 630 Lights .

r'-cntleyPublishers
.cor
 Clutch 210- 7
Clutch slave cylinder, replacing

Clutch slave cylinder, replacing

The clutch slave cylinder i s bolted to the left side of the transmission
housing clos e to the clutch bell housing.

— Workin g at lef t rea r of engine compartment, remove left cabi n

microfilter cover and housing . Se e 020 Maintenance .

— Us e hos e pinch tool 1 3 3 010 or equivalent to pinc h off clutc h flui d

supply line at brake fluid reservoir .

— Rais e vehicle an d suppor t safely.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove lower engine and transmission splash shields a s

necessary. See 020 Maintenance.

. Workin g underneath transmission:

• Loose n unio n nu t A to disconnect fluid line fro m slave cylinder .
Place pan under line to catch dripping fluid.
• Loose n unio n nu t B to detach metal line from fluid supply hose .
• Remov e slave cylinder mounting nut s (arrows) fro m clutch bel l
housing and remov e cylinder.

Installation is reverse of removal. Not e the following :

• Check for wear on slave cylinder push rod. Any wear except on tip
is caused b y misalignment o f clutch components.
• Lightly coat pushrod tip with molybdenu m disulfid e greas e
(Molykote® Longter m o r equivalent).
• Durin g installation be sure pushrod tip engages reces s i n clutch
release lever .
• Fil l brake fluid reservoir with clean fluid and bleed clutc h
hydraulics. Se e Clutch hydraulic system, bleeding an d
flushing in this repair group .

Tightening torques
Clutch slave cylinder to transmission 22 N m (16ft-lb )
Fluid line to slave cylinder 14.5Nm (1 1 ft-lb)

CLUTCH MECHANICA L
Clutch replacement requires removal o f the transfer case (xDriv e
models) an d transmission.

Clutch disc, pressure plate and release bearing are usually replace d
during a clutch overhaul . Check flywheel for wear and scoring .
Replace i f necessary.

Be sure to check the bottom of the bell housing for oil. If engine oil is
found, check for faulty rear crankshaft (rear main) oi l seal. Rear
main sea l replacemen t i s covered in 119 Lubrication System .
210-8 Clutc h
Clutch, removing

/n
The SAC pressure plate uses a wedge ring which rotates against the
diaphragm springs to accommodate fo r clutch disc wear. The wedge
Flywheel —
ring adjusts by means of spring tension. Special tools are needed to
apply and relieve spring tensio n a s the clutch pressur e plate is
removed and installed .

8510210009
Clutch, removin g
Disconnect negativ e (-) batter y cable an d cover battery terminal t o
keep cable from accidentally contactin g terminal .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warning s an d Cautions.

— Rais e vehicle and suppor t safely .

WARNING—
• Make sure the vehicle is stable and we/I supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splash shiel d unde r engin e an d transmission. Se e

020 Maintenance.

Remove front en d reinforcement . Discar d mounting bolts.

Remove complete exhaus t system. See 18 0 Exhaust System.

WARNING—
• Make sure exhaust system is fully cooled off before starting
removal.

Remove heat shields unde r transfer case (xDriv e models) an d rea r

driveshaft.

Detach fron t (xDriv e models ) an d rea r driveshaft s and tie to side.

See 260 Driveshafts .

Remove transmission from engine. See 230 Manual

Transmission.

Lock flywheel i n position using BMW special tool 119 260 or

equivalent.
 Clutch 210- 9
Clutch components, inspecting

Loosen 6 clutch mounting bolt s (arrows) evenly.

Remove pressure plat e and clutch disc.

WARNING —
• Friction material in the clutch disc produces dangerous dust. Do
not breathe in dust. Use water to wet down components and
collect dripping mixture in a shop towel.

Remove clutc h release bearing and lever modul e (A): Remov e

module from spring cli p an d tilt off transmission inpu t shaft i n
direction of arrow.

CAUTION—
• To avoid installing incorrectly, do not remove bearing from
release module.

Clutch components, inspecting

Inspect clutc h dis c fo r wear, cracks, loose rivets , contamination o r
excessive runou t (warping) . Replace i f necessary.

Measure dept h o f clutch lining a t lining rivets. If shallowest rivet

depth i s less than 1 mm (0.04 in) , replace clutch disk .

Inspect flywheel for scoring, hot spots, cracks or loose or worn guide
pins. Replac e flywhee l if any faults are found. See Flywheel ,
removing and installing in this repair group.

CAUTION—
• If flywheel is removed from engine, reinstall using new bolts.

Release leve r — Chec k t o mak e sur e transmissio n pilot bearing rotate s smoothly
ball stud
without play. Replac e i f faulty. See Transmission pilo t bearing ,
replacing in this repair group.

— Inspec t and clea n releas e bearin g module .

Release lever -
spring retainer ^, Check releas e leve r ball stu d and spring retainer. Replace if
Release bearing damaged o r worn.
210-10 Clutc h
Clutch, installing (new SAC components)

— Clea n releas e bearing guide sleeve .

CAUTION—
" Do not grease release bearing module or guide sleeve. If guide
sleeve is greased, release bearing may stick to it.

Clutch, installing (new SAC components)

The SAC pressure plate, when new, come s from the factory with a
lock plat e at the center which maintain s sprin g tension on the self-
adjusting springs. D o not remove this lock plat e until the pressur e
plate is securely installe d on the flywheel with clutch disk in place.

CAUTION—
• Avoid contaminating clutch friction surfaces with oil or grease.
Do not touch these surfaces.

Center clutc h disc on flywheel usin g the appropriate BMW (or

equivalent) centering tool.

21 2 201 CAUTION—
• Be sure clutch disc is facing the correct way. The disc is marked
21 2 230 "engine side" or "transmission side".
21 2 250 J

NOTE—
• The large bolt in the clutch disc centering tool is used to install and
remove the tool only. Once the disc is in place on the flywheel,
remove the bolt to make room for the SAC pressure plate.

Lock flywheel in position usin g BM W specia l too l 1 1 9 260 or

J3309210040j
equivalent.

Install SAC pressure plat e on flywheel dowe l pins. Instal l clutc h

mounting bolt s and tighten each one tur n at a time until pressure
plate is fully seated. Torque to specification i n 2 stages.

Tightening torque
Clutch to flywheel (use new M8 ZNS bolts )
• Stage 1 15 M m (11 ft-lb)
• Stage 2 additional 90° ± 5°

Use 1 4 mm Allen wrench to unscre w (clockwis e or

counterclockwise) lock plate in center of pressure plate.

NOTE—
• The spring lock plate may make snapping noises while being
unscrewed.

Using large bolt , pul l out clutch disc centering tool.

Remove flywheel lockin g tool.

Inspect and clean clutch release bearing and leve r module .

 Clutch 210-1 1
Clutch, installing (used SAC components)

V. Instal l clutc h releas e modul e (A ) b y lilting over transmission inpu t

shaft (arrow) . B e sure it clips securely to retainin g spring clip.

— Instal l transmission . Se e 230 Manua l Transmission.

CAUTION—
• Replace aluminum bolts each time they are loosened.
• Follow torque instructions, including angle of rotation
specifications, when installing aluminum fasteners.

Tightening torques
Front en d reinforcemen t to front end (us e
new fasteners):
• Stag e 1 56 N m (4 1 ft-lb )
• Stage 2 additional 90°
Slave cylinder to transmission 22 N m (1 6 ft-lb)
Transmission rea r support to body (M8) 19Nm (14 ft-lb)
Transmission moun t t o rea r support (M8) 19Nm(14ft-lb)
Transmission to engine (us e new
aluminum bolts) :
• M1 0 x 30 mm 20 Nm
Stage 1 additional 90 ° - 110 °
Stage 2
• M1 0 x 85 mm 20 Nm
Stage 1 additional 180 ° - 200°
Stage 2
•M12 25 N m
Stage 1 additional 130 ° + 20°
Stage 2
Vibration damper to transmission rea r 38 N m (2 8 ft-lb)
support (M10 )

Clutch, installing (used SAC components)

When reinstallin g a previously used self-adjusting clutch (SAC),
special tools are needed to reset the self-adjusting ring to its original
position.

— Plac e SAC pressur e plat e on clean work surface.

^. Plac e BMW special too l 21 2 180 on pressure plate.

21 2 180 • Not e that locating hooks of special tool engage pressur e plat e
adjusting rin g openings (inset) .
• Grip tool firmly and squeeze specia l too l handles together.
• Tighten dow n specia l too l knurle d screws (arrows).
• SAC adjustment ring is now in its original position.

Tool
handles
210-12 Clutc h
Clutch, installing (used SAC components)

Install BM W special tool 21 2 170 on SAC pressure plate.

• Fi t fingers of special tool in slots abov e dowe l pin bores.
• Tighten down knurled nut (arrow) finger-tight.
• Scre w in T-handle until pressure plat e diaphrag m sprin g is
pretensioned to stop.

CAUTION—
• Avoid contaminating clutch friction surfaces with oil or grease.
Do not touch these surfaces.

Center clutch disc on flywheel using th e appropriate BM W (or

equivalent) centerin g tool.

21 2 201 CAUTION—
• Be sure clutch disc is facing the correct way. The disc is marked
21 2 230 "engine side" or "transmission side".
21 2 250
NOTE—
• The large bolt in the clutch disc centering tool is used to install and
remove the tool only. Once the disc is in place on the flywheel,
remove the bolt to make room for the SAC pressure plate.

Lock flywheel in position usin g BM W specia l too l 1 1 9 260 or

equivalent.

Install SA C pressure plate on dowel pin s a t flywheel. Instal l clutch

mounting bolt s and tighten each one turn at a time until pressure
plate i s fully seated. Torque to specification i n 2 stages.

Tightening torque
Clutch to flywheel (use new M8 ZNS bolts)
• Stag e 1 15 M m (1 1 ft-lb)
• Stage 2 additional 90° ± 5°

Using large bolt, pull ou t clutch disc centerin g tool.

Remove flywheel locking tool.

Inspect an d clean clutch release bearin g an d leve r module.

Install clutch release module (A ) b y tilting over transmission input

shaft (arrow) . B e sure i t clips securely to retainin g spring clip.
 Clutch 210-1 3
Self-adjusting clutch (SAC}, breaking in

— Instal l transmission. Se e 23 0 Manua l Transmission .

CAUTION—
• Replace aluminum bolts each time they are loosened.
• Follow torque instructions, including angle of rotation
specifications, when installing aluminum fasteners.

Tightening torques
Front end reinforcemen t to front end (use
new fasteners):
• Stag e 1 56 N m (4 1 ft-lb )
• Stage 2 additional 90 °
Slave cylinde r to transmission 22 N m (16 ft-lb)
Transmission rea r support t o bod y (M8) 19 N m (1 4 ft-lb)
Transmission moun t to rear support (M8) 19Nm(14ft-lb)
Transmission t o engine (us e new
aluminum bolts) :
• M1 0 x 30 mm 20 Nm
Stage 1 additional 90 ° - 110°
Stage 2
• M10x8 5 mm 20 N m
Stage 1 additional 180 ° -200°
Stage 2
•M12 25 N m
Stage 1 additional 130 ° + 20°
Stage 2
Vibration damper t o transmission rea r 38 N m (2 8 ft-lb)
support (M10)

Self-adjusting clutc h (SAC) , breakin g i n

In normal driving, approx. 800 to 100 0 gearshifts are neede d fo r a
new SAC clutch lining to be fully broke n in . To ensure correc t
operation and long life, break i n the SAC gradually, wit h ligh t to
medium loads . Fas t sports-styl e driving and abrupt clutc h
engagement ma y destroy a new clutch.The following procedur e
helps t o break in the clutch.

Drive at 20 mph (30 kph) on level grade. Start, upshift and downshift
through the gears at approx. 2000 rpm.

Increase speed. Upshif t and downshift through the gears at approx.

3500 - 4000 rpm.

On medium grad e (approx . 12% and up): Start off at approx. 250 0
rpm 3 - 5 times.
210-14 Clutc h
Flywheel, removing and installing

Flywheel, removin g and installing

This procedur e is for vehicle wit h manua l transmission. Flywhee l
and torque plate remova l fo r automatic transmissio n vehicl e is
covered in 240 Automatic Transmission .

Disconnect negativ e (- ) batter y cabl e an d cover batter y terminal to

keep cable from accidentally contactin g terminal .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warning s an d Cautions.

— Rais e vehicle and support safely .

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splash shiel d unde r engin e an d transmission. See

020 Maintenance .

Remove front end reinforcement. Discard mountin g bolts .

Remove complete exhaus t system . Se e 18 0 Exhaust System.

WARNING —
• Make sure exhaust system is fully cooled off before starting
removal.

— Remov e heat shield s unde r transfe r case (xDriv e models) and rea r
driveshaft

— Detac h front (xDrive models) and rea r driveshaft s and tie to side.
See 260 Driveshafts.

— Remov e transmission fro m engine. Se e 23 0 Manual

Transmission.

— Remov e clutch. Se e Clutch , removin g in this repai r group.

— Inspec t flywheel for scoring, hot spots, cracks or loose or worn guide
pins. Replac e flywheel if any faults are found .

^C Workin g at flywheel:
• Loc k flywhee l in position usin g BM W special tool 1 1 9 260 or
equivalent.
• Us e BMW special too l 1 1 4 180 or equivalent (Tor x T60 socket ) t o
loosen and remov e flywheel mounting bolts .
• Remov e flywheel.

— Clea n flywheel bolt threads i n crankshaft .

 Clutch 210-1 5
Transmission pilot bearing, replacing

Check flywheel location dowel sleeve (arrow) for damage an d

correct installation .

BX06210022

. Whe n reinstallin g flywheel, positio n dowel sleev e next to tw o

locating notches (arrows) .

— Instal l flywheel using new self-locking bolts .

Tightening torque
Flywheel to crankshaft
(use ne w self-locking bolts) 120 M m (89ft-lb )

CAUTION—
• Use new self-locking bolts to install flywheel. Do not reuse the
old stretch-type bolts. Do not install bolts with Loctite® or
similar thread-locking compound.

Transmission pilo t bearing , replacin g

Disconnect negativ e (-) batter y cable and cover battery terminal to
keep cable from accidentally contacting terminal.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings and Cautions .

— Rais e vehicle and suppor t safely.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splash shiel d unde r engine and transmission. See

020 Maintenance.

Remove front end reinforcement . Discard mounting bolts.

Remove complete exhaust system. See 180 Exhaust System .

WARNING —
• Make sure exhaust system is fully cooled off before starting
removal.
210-16 Clutc h
Transmission pilot bearing, replacing

— Remov e heat shields under transfer cas e (xDrive models) and rea r
driveshaft.

— Detac h front (xDrive models ) an d rea r driveshafts and tie to side .

See 260 Driveshafts.

— Remov e transmission fro m engine. Se e 230 Manua l

Transmission.

— Remov e clutch . Se e Clutch, removin g i n this repai r group .

— Remov e flywheel. See Flywheel , removin g an d installin g i n this

repair group .

*\e hydraulic pres s and BMW special too l 21 2 051 to press

transmission pilo t bearin g ou t of dual-mass flywheel. Pres s from
engine sid e of flywheel.

CAUTION—
• Do not drive bearing in or out using a chisel or punch.

Place new pilot bearing o n BMW specia l too l 21 2 052. Use

hydraulic press to press bearing int o flywheel as far as it will go.
Press from clutch sid e o f flywheel.
 230-1

230 Manua l Transmissio n

GENERAL 230- 1 Transmission input shaft seal , replacin g 230- 6

Manual transmission applications Transmission output shaf t seal , replacing 230- 7
and gear ratio s 230- 2 TRANSMISSION REMOVA L
Cautions 230- 2 AND INSTALLATION 230-1 0
TRANSMISSION FLUI D SERVICE 230- 2 Transmission, removing and installing 230-1 0
Transmission fluid level, checking 230- 3
TABLES
Transmission fluid, replacing 230- 3
a. Manual transmissio n application s 230- 1
TRANSMISSION EXTERNA L SERVICE 230- 4 b. Manual transmission gear ratios 230- 2
Back-up ligh t switch , replacin g 230- 4 c. Manual transmission fluids 230- 3
Selector shaft seal, replacing 230- 5 d. Manual transmissio n flui d capacities 230- 4

GENERAL
This repair group covers manual transmission external service,
including transmission removal and installation. Internal
transmission repair is not covered. Special tools and procedures are
6-speed manual required to disassemble and service the internal geartrain.
transmission
(GS6-37BZ) See also:
•210 Clutc h
• 250 Gearshift Linkag e
• 260 Driveshafts
• 270 Transfer Case

Manual transmissio n application s

and gear ratio s
, Severa l manual transmission are used in 5 Series models . See
Table a . Gear ratio s ar e in Table b.

Table a. Manual transmission applications

Model (engine) Year BMW Manufacturer
designation designation
525i (M54) 2004 - 2006 GS6-37BZ / DZ ZF6HP19type H
530i (M54, N52) 2004 - 2007 GS6-37BZ/DZ ZF6HP19typeH
525i, 528i (N52 ) 2006 - 200 9 GS6-17BG Getrag typ e I
525xi, 528xi , 530x i 2006 - 2009 GS6X37BZ/DZ ZF6HP19typeH
(N52)
535I (N54) 2008 - 2009 GS6-53BZ / DZ ZF6HP26typeG
535xi (N54) 2008 - 2009 GS6X53DZ ZF 6HP26 typ e G
545i, 550i 2004 - 2009 GS6-53BZ ZF 6HP26 type G
(N62, N62TU )
230-2 Manua l Transmission
Cautions

Table b. Manual transmission gear ratios

Getrag ZF GS6-37BZ / DZ ZF GS6-53BZ / DZ
Gear GS6-17BG ZF GS6X37BZ / DZ ZF GS6X53DZ
1st 4.32 1 4.35 : 1 4.06 : 1
ond
2.46 1 2.50 : 1 2.40 : 1

3rd 1.66 1 1.66 : 1 1.58 : 1

4th
1.23 1 1.23: 1 1.19: 1

5th 1.00 1 1.00 : 1 1.00 : 1

6th 0.85 1 0.85 : 1 0.87 : 1

Reverse 3.94 1 3.93 : 1 2004 - 2005: 3.77 : 1

2006 - 2009: 3.68 : 1

Cautions

CAUTION—
• When performing any repair which involves separating the
engine and transmission, check that the bell housing dowels
are undamaged and properly in place before reassembly. If the
alignment of the engine flywheel to the transmission input shaft
or torque converter is incorrect any of the following complaints
may result: Clutch slipping, shudder, or poor disengagement:
noise from transmission input shaft; transmission popping out
of gear; difficulty changing gears; or internal damage to the
transmission.
• When removing interior trim clips, avoid damaging trim pieces
by using a plastic prying tool or a screwdriver with the tip
wrapped with masking tape.
• To avoid electrochemical corrosion to engine components
made of aluminum-magnesium alloy, do not use steel
fasteners. Use aluminum fasteners only.
• The end faces of aluminum fasteners are usually painted blue.
For reliable identification, test fasteners for aluminum
composition with magnet.
• Replace aluminum fasteners each time they are loosened.
• Follow torque instructions, including angle of rotation
specifications, when installing aluminum fasteners.
• Fill manual transmission only with BMW approved synthetic oil.
Filling with incorrect lube could cause the following damage
— Premature synchromesh ring wear.
— Reduced service life of bearings.
— Tooth profile damage.
— Faster wear of selector forks.
— Damage to radial shaft oil seals.

TRANSMISSION FLUID SERVICE

Manual transmissions in 5 Series models are provided with lifetime
lubrication. N o oil change is required for the entir e service life of
these transmissions. If repairs have to be made to the transmission,
use only the recommende d lifetime fluid t o refill .
 Manual Transmission 230- 3
Transmission fluid level, checking

Usually, the transmission fluid sticker near the fill plug identifie s th e
lifetime transmission fluid used at the factory.

Table c. Manual transmission fluids

Transmission Year rang e Fluid type
GetragGS6-17BG 2004 - 2005 MTF-LT-2
ZF GS6-37B Z from 2006 MTF-LT-3
ZF GS6X37B Z
ZF GS6-53B Z
ZF GS6X53B Z
MTF-LT-2 (Lifetime fluid) BMW part no. 83 22 0 309 031
MTF-LT-3 (Lifetime fluid) BMW part no. 83 22 0 409 878

Transmission fluid level, checking

Drive vehicle for a few miles t o warm transmission.

Raise and safely support vehicl e to access transmissio n

filler plug. Mak e sure vehicle i s level.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Remov e plastic splash shiel d unde r transmission. Se e

020 Maintenance .

X, Remov e fill plug (B) . B e prepared to catch dripping fluid .

— Inser t gloved finger i n fill hole to check fluid level.

• I f fluid level is up to botto m of fil l hole (finger is wetted by
transmission fluid), level is correct.
• I f level is low, slowly fil l transmission with fluid until fluid overflows
fill hole.

— Instal l and torqu e fill plug .

Tightening torque
Drain or fill plu g t o transmission case :
•M12x1.5 25Nm(18ft-lb)
• M 1 8 x 1.5 35 N m (2 6 ft-lb )

Transmission fluid, replacing

Drive vehicle for a few miles t o warm transmission.

Raise an d safely support vehicl e to access transmission drai n plug .

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove plasti c splash shiel d under transmission. Se e

020 Maintenance .
230-4 Manua l Transmission
Back-up light switch, replacing

Place drain pa n unde r transmissio n an d remov e drain plug (A) at

bottom of transmission .
• Drai n fluid.
• Instal l and torque drain plug .
• Remov e fill plug (B) from side o f transmission .

X • Slowl y fill transmission with fluid unti l flui d overflows fill hole .

fSE/J \i
Table d. Manual transmission fluid capacities
Initial fill, new or
\A Transmission rebuilt uni t Fluid change
GetragGS6-17BG 1.4 liter (1. 5 U S qt) 1.3 liter (1.4 USqt)
ZF GS6-37B Z 1.6 lite r (1. 7 USqt ) 1.5 lite r (1. 6 USqt )
BS102300C1 ZF GS6-53D Z 1.6 lite r (1. 7 US qt) 1.5 lite r (1.6 USqt )

— Instal l and torqu e fluid fill plug .

Tightening torque
Drain or fill plug t o transmission case :
•M12x 1.5 25 N m (18ft-lb )
•M18x1.5 35 N m (2 6 ft-lb)

TRANSMISSION EXTERNA L SERVIC E

GS6-17BG
GS6-37BZ / DZ Back-up light switch, replacing
Back-up ligh t switch location on manua l transmissio n varies.

Getrag GS6-17B G or ZF GS6-17BZ / D Z transmission. Back-up

light switch (arrow) on righ t side of transmission toward rear.

^V Z F GS6-53BZ / D Z transmission. Back-u p ligh t switch (arrow) on

right side of transmission towar d rear .

— Rais e and safel y support vehicle t o acces s back-u p light switch.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove plasti c splash shiel d unde r transmission . Se e

020 Maintenance .

Detach back-up ligh t switch harness connector . Unscre w switch

from transmission.
 Manual Transmission 230- 5
Selector shaft seal, replacing

— Instal l ne w switch and reconnec t harness connector.

Tightening torque
Back-up light switch to transmission 16 Nm (13 ft-lb)

Check transmission fluid level before lowering vehicle. Top off a s

necessary. See Transmission Flui d Service in this repai r group.

Selector shaft seal , replacin g

This repai r can be performed with transmission installed i n vehicle.

Place transmission int o secon d gear .

Raise vehicle and support safely.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove underbod y splash shields.

Remove exhaust system . See 180 Exhaust System.

WARNING —
• Make sure exhaust system is fully cooled off before removing.

Remove exhaus t heat shields.

xDrive models: Remov e front drive shaft. See 260 Driveshafts.

All models: Remove rea r driveshaf t from output flange:

• Remov e driveshaf t cente r bearin g support fasteners . Suppor t
center o f driveshaft .
« Detach rear driveshaft flex-disc fro m transfer case .
• Lowe r center o f driveshaft sufficientl y t o disengage flex-disc fro m
transfer case flange. Tie driveshaft to side.

CAUTION—
• To prevent damage to rear driveshaft CV joint, do not allow
driveshaft to hang down unsupported.

Free harnesse s fo r oxygen sensor s an d back-up ligh t switch fro m

rear transmission support.

Support end of transmission with suitable jack. Remov e mountin g

fasteners (arrows ) for rea r transmission support.
230-6 Manua l Transmissio n
Transmission input shaft seal, replacing

Working at top rea r of transmission a t shifter console, pry locking

spring (A) out of groove and press pin (B) out of shift coupling.
• Detac h shift coupling and shift linkage from selector shaft and tie
aside.

Carefully pr y out selector shaf t oil seal with BM W special too l

23 0 210, or with a narrow seal remover or small screwdriver.

Coat new selector shaft seal with transmission fluid. Drive new seal
in flush with housing. Us e BMW specia l sea l installation tool
23 0 220 or equivalent and a soft-faced (plastic) hammer.

Remainder of installation is reverse of removal. Chec k transmissio n

and transfer case oil level, topping up as necessary .

Tightening torques
Transfer case to transmission 43 Nm (31 ft-lb)

BX06230008 j

Transmission input shaft seal , replacin g

Remove transmission fro m vehicle. Se e Transmission, removin g
and installin g in this repai r group .

Remove clutch release bearing / release lever module fro m inside

bell housing . See 210 Clutch .

Remove bolt s (arrows ) for clutch release-bearin g guide sleeve.

Remove guide sleeve.

BX06230009
 Manual Transmission 230- 7
Transmission output shaft seal, replacing

Two covered remova l hole s (1 ) are present i n seal. Thread BMW

special tool 23 0 490 or equivalent slide hammer sea l puller into one
hole and remove seal.

To install ne w seal :
• Pus h radia l seal on BMW special tool 23 0 320.
• Coat sealing li p of new seal with transmission oil.
1 23032 0
• Slid e tool onto inpu t shaft .
• Us e plastic hamme r to drive in seal until fully seated .

Thoroughly clea n clutc h release bearing guide sleev e mountin g

bolts, sealing surfaces, an d threads. Appl y Loctite®24 3 o r
equivalent thread lockin g compound t o guide sleeve bolts . Reinstall
guide sleeve and spacer (i f equipped) .

Tightening torque
Guide sleev e to transmission housing
• M8 X 30 25 Nm (18ft-lb )
•M8X22 1 8 Nm ( 1 3 ft-lb)
•M6 10Nm(7ft-lb)

— Replac e clutc h releas e bearin g / release leve r module . Se e

210 Clutch.

— Reinstal l transmission.

Transmission outpu t shaft seal, replacin g

— Disconnec t negative (- ) cable from battery.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given in 001 Warnings an d Cautions .

— Rais e and safely suppor t vehicle.

WARNING—
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Remov e underbod y splash shields .

230-8 Manua l Transmissio n
Transmission output shaft seal, replacing

— Remov e complete exhaust system. See 18 0 Exhaust System.

WARNING—
• Make sure exhaust system is fully cooled off before removing.
I

— Remov e exhaust system heat shields.

— Remov e rear driveshaft from output shaft :

• Remove driveshaft center bearing suppor t fasteners. Suppor t
center of driveshaft .
• Detac h rear driveshaft flex-disc from transfer case .
• Lower center of driveshaft sufficiently to disengage flex-dis c from
transfer case flange. Tie driveshaft to side.

CAUTION—
• To prevent damage to rear driveshaft CV joint, do not allow
driveshaft to hang down unsupported.

— xDriv e models: Remove transfer case. See 270 Transfe r Case.

^ Counterhol d output flange with BMW special tool 23 0 020 and

release flange collar nut using BMW special tool 23 1 210.

Remove output flange using BMW special tool 33 1 150 or suitable

puller.
 Manual Transmissio n 230- 9
Transmission output shaft seal, replacing

Remove output shaf t seal usin g BMW special tool 00 5 011 or

suitable sea l puller .

When installin g ne w seal, coa t seal lips with transmission fluid . Use
BMW special tool 24 0 110 and plastic hammer to drive seal in flush.

Remainder of installation is reverse of removal. Remember to :

• Replac e collar nut with new.
• Us e Loctite®431 on output shaft threads when installing colla r nut.
• Follo w 3 step tightening procedure (tighten, release, tighten down).
• Check transmissio n fluid level and check syste m for leaks .

Tightening torque
Transmission outpu t flange to transmission
(GS6-17BG and GS6-37BZ transmission )
• Pretension 170Nm (125ft-lb )
• Releas e Release tension
• Tighten dow n 120Nm (89ft-lb )
Transmission output flang e to transmission
(GS6-53DZ transmission )
• Pretension 200 Nm (148ft-lb)
• Release Release tensio n
• Tighten down 140Nm (103ft-lb )
230-10 Manua l Transmission
Transmission, removing and installing

TRANSMISSION REMOVA L AND INSTALLATION

Removal an d installation of the transmission is best accomplishe d
with the vehicle o n a lif t and usin g a transmission jack. Support
engine usin g equipment whic h allow s th e engin e t o pivo t on its
mounts to access the upper bolt s a t the transmission bel l housing .

WARNING—
• The removal of the transmission may upset the balance of the
vehicle on a lift.

Transmission, removing an d installin g

Disconnect negative (-) cable from battery .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given i n 001 Warnings and Cautions.

— Rais e an d safely suppor t vehicle.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove underbody splash shields. Se e 020 Maintenance .

Remove front end reinforcement plate.

Remove complete exhaus t system . Se e 18 0 Exhaust System.

WARNING—
• Make sure exhaust system is fully cooled off before removing.

Remove exhaust system hea t shields .

xDrive models: Remov e front drive shaft . See 260 Driveshafts.

Disconnect harnes s connecto r from back-up ligh t switch on

transmission. See Back-up ligh t switch, replacing i n this repai r
group.

Remove fasteners (A) and remove exhaus t bracket (B).

 Manual Transmissio n 230-1 1
Transmission, removing and installing

Remove underbody splash shield s brackets (arrows).

Disconnect oxyge n sensor harness connectors (A) and remov e

fasteners (B) from connector bracket (C).

Unclip oxygen sensor harnes s (A ) from bracke t (B) . Remov e

fastener an d remove bracke t (C ) from transmission.
230-12 Manua l Transmission
Transmission, removing and installing

Support transmission o n transmission jack . Secure transmission to

jack.

Remove mounting fasteners (arrows) for rear transmission support.

xDrive models : Detac h xDriv e servomotor harnes s connector s at

transfer case.

Lower transmission jac k slowly, allowing engin e an d transmissio n

assembly to tilt back and down slightly.

CAUTION—
• Tilting the engine to lower the transmission can lead to damage
to engine compartment components due to lack of clearance at
rear of engine. Lower transmission carefully while checking
engine rear clearance.

All models: Remove rea r driveshaft from outpu t flange:

• Remov e driveshaf t cente r bearing support fasteners. Suppor t
center o f driveshaft.
• Detac h rear driveshaft flex-disc from transmission or transfer case
output flange.
• Lowe r center of driveshaft sufficiently to disengage flex-disc from
output flange. Tie driveshaft to side .

CAUTION—
• To prevent damage to rear driveshaft CV joint, do not allow
driveshaft to hang down unsupported.

Unbolt clutc h slave cylinder from side of transmission. D o not

disconnect fluid hose. Suspen d slav e cylinde r from chassis usin g
stiff wire.

CAUTION—
• Unbolt clutch slave cylinder slowly to prevent air being drawn
into hydraulic system.
• Do not operate clutch pedal with slave cylinder removed from
transmission.
 Manual Transmission 230-1 3
Transmission, removing and installing

^ Remov e shift rod clip (arrow ) and disconnec t shift linkage fro m
selector shaf t coupling .

NOTE—
• A new, more secure, shin rod clip is fitted as of 04 / 2008. Use new
specification shift rod clip when reassembling.

— Disconnec t shift console from top o f transmission. Se e

250 Gearshift Linkage .

— Suppor t front of engine with tall jack stand or hydraulic jack.

Release locking clips (arrows ) and lif t out shift arms.

B510230010

Remove transmission mounting Torx-head bolts (arrows). Note

length and location o f bolts.

CAUTION—
• Number, size and location of fasteners varies with transmission
installed.

Remove transmissio n by pulling backward unti l transmission input

shaft clears clutc h dis c splines, then pull downwards. Lowe r
transmission jack to remov e transmission.

CAUTION—
• Do not allow transmission to hang from input shaft.

B309230032
230-14 Manua l Transmission
Transmission, removing and installing

Be sure bell housing alignmen t dowe l sleeves (arrows) ar e located

correctly. Replac e damage d sleeves .

Inspect clutch, clutch release bearing and flywheel. See 210 Clutch.
Repair a s necessary.

Check an d repair transmission seals . Se e Transmission Externa l

Service i n this repai r group.

Reinstall transmission and xDrive transfe r cas e (i f equipped),

keeping in mind the following:
• I f installing a new transmission, be sure to transfer parts from old
transmission.

BX06230012
• Thoroughly clean inpu t shaft and clutch dis c splines . Lightl y
lubricate transmission input shaft splines before installing .

CAUTIOM—
• Replace aluminum bolts each time they are loosened.
• Follow torque instructions, including angle of rotation
specifications, when installing aluminum fasteners.

Tightening torques

Front end reinforcement to front end (use

new fasteners):
• Stage 1 56 Nm (41 ft-lb)
• Stage 2 additional 90 °
Slave cylinder to transmission 22 Nm (16 ft-lb)
Transmission rea r support t o body (M8) 19Nm(14ft-lb)
Transmission mount to rear support (M8) 19Nm(14ft-lb)
Transmission to engine (us e new
aluminum bolts) :
• M10x30 mm 20 Nm
Stage 1 additional 90° - 110°
Stage 2
• M10x 85 mm 20 Nm
Stage 1 additional 180 D -200°
Stage 2
•M12 25 N m
Stage 1 additional 130° + 20°
Stage 2
Vibration dampe r to transmission rea r 38 Nm (28 ft-lb)
support (M10)
 Manual Transmission 230-1 5
Transmission, removing and installing

Reinstall transmission support. Center rear of transmission i n

driveshaft tunnel befor e tightening support bracket bolts (arrows).

Tightening torques
Transfer case to transmission 43 N m (3 1 ft-lb)
Transfer cas e suppor t
• To chassis (M10) 42 N m (30 ft-lb)
• To transfer case rubber mount (M12) 74 N m (55 ft-lb )

Reinstall driveshafts using ne w self-locking nuts. Se e

260 Driveshafts.

CAUTION—
• To avoid damaging flex-disc rubber, be sure to hold bolts
stationary while tightening nuts.

Tightening torques
Front driveshaf t flex-dis c t o front differentia l 60 Nm (44 ft-lb )
flange (replac e fasteners) (M1 0 10.9 )
Rear driveshaft flex-dis c to transfer case 100 Nm (74 ft-lb)
output flang e

— xDriv e models: Refill transfer case . Se e 270 Transfer Case .

Tightening torque
Fill plug to transfer case 33 N m (2 4 ft-lb)

Refill transmission before starting or towing vehicle. Se e

Transmission Flui d Service i n this repai r group .

Tightening torque
Drain or f II plug to transmission case:
• M12 x 1 5 25 Nm (18 ft-lb)
•M18 x 1 5 35 Nm (26 ft-lb)
 231-1

231 Sequentia l Manua l Gearbox (SMG)

GENERAL . 231- 1 TRANSMISSION REMOVA L

SMG application s and gear ratio s . 231- 1 AND INSTALLATIO N 231-1 4
SMG overview . 231- 2 Transmission, removing and installing 231-1 4
Cautions 231-12
TABLES
TRANSMISSION FLUI D SERVICE 231-12
a. SMG applications 231- 1
Transmission fluid level, checking 231-12 b. SMG gea r ratio s 231- 1
Transmission fluid, replacing 231-13 c. SMG fluids 231-1 2
Clutch hydraulic fluid, filling 231-13 d. SMG fluid capacities 23 1 -13

GENERAL
This repai r group covers sequential manual gearbo x (SMG )
description and operation, a s well as transmission remova l and
installation. Transmission repair i s not covered .

See also:
• 230 Manual Transmission fo r transmission seal replacemen t
• ECL Electrical Component Location s for SMG component s

SMG applications and gear ratio s

SMG application informatio n is in Table a . Gear ratio s are i n
Table b.

Table a. SMG applications

Model (engine) Year Transmission
525i, 530i (M54 ) 2004 - 2005 GS6S37BZ
530i (N52) 2006 - 2007 GS6S37BZ
545I (N62 ) 2004 - 2006 GS6S53BZ

Table b. SMG gear ratios

Gear ZF GS6S37B Z ZF GS6S53BZ
1st 4.35 : 1 4.06 : 1
nnd
2.50 : 1 2.40 : 1
3rd 1.66 : 1 1.58: 1
4th
1.23: 1 1.19 : 1
5th 1.00: 1 1.00 : 1
6th 0.85 : 1 0.87 : 1
Reverse 3.93 : 1 3.77 : 1
231-2 Sequentia l Manua l Gearbox (SMG )
SMG overview

SMG overview
Introduction
The sequential manual transmission (SMG) ha d its origins in racin g
cars. Modified for use in street vehicles, it was available a s an option
in selected 200 4 - 2007 5 Series rear-wheel drive models .

In contrast to a conventional manual transmission , SM G clutch

control is automated. By driver choice, shiftin g is either manua l o r
automatic. A computerized electrohydraulic syste m operates th e
clutch and can take over gearshifts as well.

For SMG. 6-speed manua l transmission housing s fo r GS637BZ an d

GS653B2' transmissions were modified to accommodate th e
following components :
• Hydrauli c uni t with actuators for engaging an d disengaging the
clutch an d for switching gears .
• Additional sensors: Shif t travel sensor, selector angl e sensor,
inductive senso r for transmission inpu t speed .

The construction of the transmission and the clutch remai n

unchanged. Th e version used i n V8 models (GS6S53BZ ) is
equipped with a more powerfu l clutc h actuator .

SMG maximum torque capabilities

GS6S37E3Z 370 N m (27 3 Ib-ft )
GS6S53E3Z 600 N m (443 Ib-ft )

GS6S37BZ external views

">, HRight
I side :
1 2 3 „
J%xr,,,, 1.
1. Assembl y port (access to selector shaft, gearshift and selector
angle actuator)
'! ' % k 2. Shift travel sensor
" •;. : --5(:--" ^i--'. "- /"%>.

3. Selector angle sensor

'" s . i
• ; -'x x'
4.
,4 Gearshift an d selector angl e actuator
5. Hydraulic unit
• ;i , ' •• rjr^ 6. Transmission inpu t speed senso r
4 .- | ? • //-- ^
,»- J '* vi —b
7. Hydraulic pum p
/I * ~ 8. Expansion tank
"', f : • 'D •
7- 7
/
' r1&*^ ft
r --- ' " ' •
O ' .,.: - ,

B510231005
 Sequential Manua l Gearbo x (SMG ) 231- 3
SMG overview

Left side:
12 3
1. Selecto r angle sensor
2. Shif t travel sensor
3. Assembl y por t (acces s to selector shaft, gearshif t an d selector
angle actuator)
4. Gearshif t an d selector angle actuator
5. Hydrauli c pum p powe r supply connector
6. Hydrauli c uni t component s electrica l connector ( 4 solenoi d
II valves, hydraulic pressur e sensor)
7. Clutc h travel sensor
8. Clutc h actuator
10
9. Selecto r angl e sensor connecto r
11
12 10. Pressur e accumulator
11. Hydrauli c uni t
12. Shif t travel sensor connector

GS6S53BZ externa l views

Right side :
1 . Selecto r angl e sensor
2. Shif t travel sensor
3. Assembl y port (access to selector shaft, gearshift and selector
angle actuator )
4. Transmissio n inpu t speed sensor
5. Hydrauli c pum p
6. Gearshif t and selector angle actuato r
7. Expansio n tank
8. Hydrauli c unit

Left side:
1 2 3 4
1. Selecto r angle sensor
2. Shif t travel sensor
3. Assembl y port (access to selector shaft , gearshif t and selector
angle actuator)
4. Gearshif t an d selector angl e actuato r
5
5. Clutc h actuato r
6 6. Hydrauli c pum p powe r supply connector
7
7. Clutc h travel senso r
8
9 8. Hydrauli c uni t components electrica l connector ( 4 solenoi d
10 valves, hydraulic pressur e sensor)
9. Selecto r angle senso r connector
11
10. Shif t travel sensor connecto r
B510231008 11. Pressur e accumulator
12. Hydrauli c unit
231-4 Sequentia l Manua l Gearbo x (SMG )
SMG overview

Selector leve r
SMG can be shifted usin g eithe r the center-console-mounte d
selector leve r or steering-wheel-mounted shif t paddles .

SMG operation modes are controlled by the selector lever (A) . The
gear positio n display (B ) indicate s th e mode s tha t ca n be selected:
• N = Neutral position .
• R = Reverse gear. With foot on brake pedal, pres s selector down,
left and forward.
• + or - = Manual mode. Flic k selector forward o r backward to
change gears .
• D = Automatic mode .

Pressing the SPORT button (C) in either manual or automatic mode

engages dynami c drivin g control (FDC). Thi s interventio n in engine
and transmission controls reduce s gea r shif t times. In automatic
mode, up-shift s occur at higher engin e speeds .
B
The SPORT button also switches the steering system Servotronic or
active steering settin g to sports mode .

The selector lever assembly i s equipped wit h shiftlock function.

Shift paddles
The steering wheel with 2 gearshift paddles allow s manual gear
changes without the driver havin g to take hand s of f the steerin g
wheel. Pull one or both of the paddles to shift up a gear. Press one
or both of the paddles t o shift down a gear.

The two gearshift paddle s are identical in construction and are wired
in parallel.

Power is supplied to the gearshift paddles from the steering column

switch cluster (SZL).
 Sequential Manual Gearbox (SMG) 231- 5
SMG overview

Manual mode
Gears are selected sequentially by briefly pressing the selector leve r
or shift paddle(s) in + or - direction. Gears ca n be skipped by rapidl y
pressing the shifter repeatedly.

Gears ar e changed whe n a shift pulse i s transmitted electricall y to

the SMG control module. Wit h the shift-by-wire gearshift method ,
there is no mechanical linkage between th e gear lever or gearshift
paddles an d the transmission.

There i s no clutch pedal. Th e clutc h is operated automatically .

Automatic mod e
When the selector leve r i s in D, shift point s are automatically
controlled according t o characteristic curves and adapted t o the
driving situation .

SMG control module

. Th e SM G control module, i n E-box at right rea r of engin e
SMG hydraulic SM G control : i(i ¥
pump rela y modul e jit s compartment, compute s solenoid actuation for clutch operation an d
gear change. Th e control module also communicates wit h othe r
control modules (fo r example, ECM) .

The SMG control module can be programmed and coded .

Hydraulic uni t
The hydraulic unit assembly , bolted to the bottom of the
transmission sump, is precharged and tested. Within thi s assembl y
are the actuators for transmission operation .
1. Valv e block
2. Solenoi d MV2 : 2nd, 4th, 6th gear shifts
3. Solenoi d MV1 : 1 st, 3rd, 5th gear shifts
4. Solenoi d MVO: Clutch actuator
5. Expansio n tan k
6. Transmissio n inpu t speed inductiv e sensor
7. Hydrauli c pum p
8. Gearshif t an d selector angle actuator
9. Shif t level senso r
10. Selecto r angle senso r
16
B510231009 11. Pressur e accumulato r
12. Solenoi d MV3: Selecto r angle brake, pressur e relief valve
13. Hydrauli c pressur e sensor
14. Clutc h actuato r wit h clutch travel sensor
15. Hydrauli c pump powe r supply
16. Hydrauli c uni t components electrica l connector (4 solenoid
valves, hydraulic pressur e sensor)
231-6 Sequentia l Manua l Gearbo x (SMG )
SMG overview

Gearshift an d selector angl e actuato r

GS6S37BZ
The gearshift and selector angl e actuato r shift s the selector shaft
along its longitudinal axis and turns the selector shaft to change shift
gate.

Gearshift and
selector angl e
actuator

Shift travel sensor and selector angle sensor

GS6S53BZ The gear engaged i s recognized from the shift travel sensor and the

e
selector angl e sensor :
• The shift travel sensor detects the forward and backward
Selector movements of the selector shaft i n the shift gate .
l^^Ljjfangle senso r • The selector angle senso r detects how far the selector shaft turns,
:4:W/ shif t and so recognizes a change of shift gate .
V!i
i
nf travel senso r

}V , GS6S53BZ transmissio n illustrated . GS6S37B Z transmissio n is

similar.

Pressure accumulator

The pressure accumulator , fitted on the lowe r lef t of the

transmission, ensures that there i s always sufficient oil pressure for
a gearshift to b e executed.

A freely moving pisto n subdivides th e pressur e accumulator into 2

chambers. One chamber is permanently charged wit h nitroge n a t
approx. 27 bar and -25°C. The othe r chambe r fill s with oil from the
hydraulic pump . Durin g transmissio n operation , the oil exerts
pressure on one side of the piston , compressin g th e nitrogen and
maintaining oil pressure during shifting.

Hydraulic pressur e senso r

The hydraulic pressure sensor is installed directly on the hydraulic

unit valve bloc k and report s the current oi l pressure to the SMG
control module. Th e hydrauli c pum p i s switched O N and OFF as
required.
 Sequential Manual Gearbox (SMG) 231- 7
SMG overview

Clutch actuator with clutch travel sensor

GS6S37BZ
The clutch actuator executes clutch operations. The clutch trave l
sensor register s clutc h release travel .

/ f'JI
.

Clutch actuator
Clutch travel senso r
B510231012

Hydraulic pump with electric motor

The hydraulic pum p wit h electric motor generates 55 bars (79 8 psi )
of system pressure for gearshifts. The pump is actuated b y the SM G
control module .

Transmission inpu t speed sensor

The SMG control modul e compares transmissio n speed , measured

by the sensor, with engine spee d and computes clutch closing
speed (i.e., how fast the clutch can establish the optimal powe r flow
between the engine an d the transmission).

Expansion tank
The expansion tan k ensures that there is always sufficient hydrauli c
fluid available i n the system. There are MAX and MIN marks o n the
expansion tan k for adjusting oi l level.

Valve block
The valve block contains the solenoid valves, the hydraulic pressur e
sensor, the pressure accumulator and a check valve.

Solenoid valves
Four solenoid valves are installe d in the valve block:
• Solenoid MVO controls clutc h actuator (A) .
• Solenoid MV1 (shif t travel valve) controls shifting for 1st , 3rd, 5th
and reverse gears.
• Solenoid MV2 controls shifting for 2nd, 4th , and 6th gears.
• Solenoid MV3 :
—Controls selector angle brak e for switching shift gate (B).
—Serves as pressure relie f valve for hydraulic system.

Pressurized flui d to solenoid valves i s supplied by a hydraulic pump

(C).
231 -8 Sequentia l Manual Gearbox (SMG)
SMG overview

Back-up light function

Back-up light s are switched ON based o n messages from the SMG
control module to the ligh t module (LM) .
• To 09 / 2005: SMG control modul e -> PT-CAN -> safety and
gateway modul e (SGM ) -> K-CAN - > LM
• Fro m 09 / 2005: SMG control modul e -> PT-CAN -> body-gateway
module (KGM ) -> K-CAN -> LM

Instrument cluster display

The following information is displayed o n the instrument cluster LCD
display:
1. Engage d gear
2. SPOR T button activated for dynamic driv e control (FDC)
3. Engage d drive position
4. Tim e
5. Ambien t temperature
6. Warnin g triangle indicates Check Contro l message ar e
f) 98. 5 kml h present. See 020 Maintenance fo r an explanation o f Check
Control.
oobte 888. 8
f. /•! .=••• /;; .-"V f~> # ™ s ;' 4 |
- „ ;f"•- •

7. Tota l mileage
8. Tri p mileage

Details of SMG display i n LCD :

oe
1. Clutc h overheated
Select N position, then depress brak e to start engine

O
Select gear again (yello w symbol )
4HIHI*
2. Transmissio n in N: Vehicle can rol l (yellow symbol)
s<5—Q] 3. Emergenc y program (limp-home mode ) activated:
Transmission malfunction (yellow o r re d symbol)
4. Revers e gea r
5. Neutra l (idle)
6. Automati c mod e (D 1 - D6)
7. Manua l mode : Steptroni c (1 st - 6th gear)
8. Chec k Control message(s) present

Fault message s (from SMG control modul e vi a PT-CAN, SGM or

B510231015 KGM and K-CAN) illuminat e Chec k Contro l warning. Check Contro l
messages are displayed i n the uppe r LC D display when the Check
Control button on the turn-signal stalk switc h is pressed .

Brake light switch

The brake light switch signal is transmitted vi a PT-CA N bv Vne ECW\
For safety reasons, the signal is also transmitted by a direct wire
from the brake light switc h to the SMG control module. Th e modul e
uses the signal for the following:
• Shift leve r loc k (shift-lock ) release .
• Brak e application detection.
• Shift to N when engin e i s shut down.
Sequential Manual Gearbox (SMG) 23 1 -9
SMG overview

Starter inhibito r
Car access system (CAS) enables the starter when the SMG control
module satisfies the following conditions :
• Gea r shift lever in position N (neutral). Instrumen t cluste r LCD
shows N, indicating tha t transmission i s also i n neutral .
• Clutch i s disengaged.

SMG functions
SMG functions include the following:
• Engin e start
• Gearshif t
• Drivin g in gear lever position D (automatic mode)
• Launc h contro l (acceleration assist system)
• Roc k free (e.g., fro m snow )
• Vehicle standstill
• Gear lever position N and ignition OFF
• Emergency progra m (limp-hom e mode )

Engine start. T o start the engine, th e gear leve r an d transmission

are in N (neutral). When the engine is started, sufficient syste m
pressure immediatel y build s up to disengage the clutch. For this
reason, the SM G control module i s activated by a wake-up signal
from CAS when the vehicle is unlocked.

The SMG control modul e measures syste m pressur e vi a the

hydraulic pressure sensor. If system pressure is too low , the
hydraulic pump i s actuated and builds pressure. When syste m
pressure is reached, the control module switches the hydrauli c
pump OF F again .

With the prompt signal, the gear lever position indicator i n the center
console is activated. I f terminal 15 (wake-up wire) is not activate d
approx. 1 5 minutes afte r vehicle unlocking, th e gear leve r positio n
display is switched OFF again .

Gearshift. If a gearshift is initiated in manual or automatic mode , th e

SMG control module actuates the corresponding solenoid valv e in
the valve block. The pressurized hydraulic fluid flows into the clutch
actuator and opens o r closes the clutch.

At the same time, the SMG control module sends informatio n to the
ECM that a gearshift i s initiated and that engine torque i s to b e
reduced.

In the nex t step, the gearshift and selector angle actuator is

actuated. At the same time, the gearshift and selector angle actuator
executes forward, backward and side-to-side movements o f the
selector shaft.

During the gearshift, engine speed may be raised as require d t o

allow clutch engagemen t t o be completed more quickly and mor e
smoothly.

When th e gear is engaged, the clutch automaticall y engages. Th e

SMG control module receives precise clutch position from the clutch
travel sensor .
231 -10 Sequentia l Manual Gearbo x (SMG)
SMG overview

After the gear change, the solenoid valve s are actuated without the
use of current. The course of the entir e gearshift depends o n
accelerator pedal position , road speed , engin e speed and other
factors (e.g. , engine oil temperature).

Just before the vehicle reaches a standstill, SM G shifts into 1 st gear

and disengages the clutch. The transmission of power betwee n
engine and transmission i s broken.

Gearshifts tha t result in an excessively hig h or low engine speed are

suppressed.

Gear leve r position D (automatic mode) :

• Constant-speed travel. Continuous change s o f accelerator pedal
position (openin g an d closing th e throttle) ar e registered i n the
SMG control module. Th e control module suppresse s a pendulum
shift between adjacent gears (up and down, e.g., on a highway with
constantly changing speed).
• Upshift suppression. Based on accelerator pedal position, the
SMG control module recognize s when the throttle is closed rapidly,
e.g. before applying the brake. The module suppresses the upshift.
This ensures tha t engine braking stays in effect.
• Drivin g uphill. Th e SMG control module recognize s when the
vehicle is driving uphill from the data from the wheel speed sensors
and accelerator pedal position The module prevents unnecessar y
upshifts and irritating pendulum shift s (e.g., at constantly hig h
engine speed an d foot taken off the accelerato r pedal) .
• Driving downhill. The SMG control module recognizes when the
vehicle is driving downhill from throttle valve potentiometer (load),
wheel speed sensor and brak e ligh t switc h signals. T o maintain
and increase engine braking effect, the control modul e shift s dow n
a gear as road speed increases .
• Brakin g deceleration and automatic downshift. The SMG control
module recognizes brakin g deceleration from brak e ligh t switch ,
wheel speed sensor and accelerator pedal position sensor signals.
The control module shift s down accordin g to road speed to
maintain engine braking effect. When this happens, severa l gear s
may be skipped. Th e correct gear i s automatically selected when
the vehicle accelerates again.
• Manua l intervention i n automatic operation. When the gearshift
lever or the gearshift paddles ar e operated i n automatic mode, the
system automatically changes to manual mode . If automatic mode
is required, th e driver select s it again.

Launch contro l (acceleration assis t system) . Launch control

enables optimu m vehicle acceleration from standstill . Upshifts ar e
automatic eve n in manual mode whe n launc h control is active. This
prevents the engine from reachin g critica l speeds .

Preconditions for launch contro l consis t o f the following:

• High-grip roa d surface.
• Dynamic stability control (DSC ) deactivate d (DSC butto n pressed
for longe r than 3 seconds).
• SPORT butto n pressed.
• Accelerator pedal pressed to floor (kick dow n position )
Sequential Manual Gearbox (SMG) 23 1 -11
SMG overview

To deactivate launch control:

• Releas e accelerator pedal (releas e from kick down position) .
• Manua l shif t request.
• Switc h OFF dynamic drivin g control (FDC) using SPORT button .
• Activate DSC .

CAUTION—
• During the running-in phase of a new vehicle, do not accelerate
the vehicle using launch control.
• Frequent use of launch control leads to increased component
wear.

Rocking free. To rock the vehicle free (e.g., from snow) mov e
gearshift leve r rapidl y from 1st to R and then back. Complete th e
gearshift withi n the space of 0.8 seconds. Otherwis e the gear leve r
lock (shift-lock ) becomes activated.

Vehicle standstill. The clutch is disengaged and 1st gear selected

when the SMG control module detects that the vehicle i s stationary.
Vehicle standstil l i s detected b y means of the accelerato r peda l
position, wheel speeds and engine speed. The clutch is disengage d
and 1s t gear selected irrespective of the drive program (manua l o r
automatic mode).

An audible warnin g i s triggered immediately i f the drive r door i s

opened whil e the engine is running and the transmission is not in
position N or P . At this time, N also flashes nine times i n the
instrument cluste r LCD .

If, despite these warnings, neither the pedals, the gearshift paddle s
nor the gearshift leve r are moved, the selected gear is automatically
cancelled after approx . 2 seconds.

Gear leve r position neutra l and ignition OFF . When th e gear

lever is in N (neutral) and ignitio n is switched OFF, N flashes in the
instrument cluster LCD . I n addition, the audio system controlle r
(M-ASK) emit s an acoustic warning.

Emergency program . I n the emergency progra m (limp-hom e

mode), the vehicle remain s operational, bu t with limitations. Onl y
gearshift positions R, N and 1 st - 3rd gears are available. Dependin g
on the type of transmission fault, the vehicle ma y n o longer b e
operational afte r a vehicle standstill.
231 -12 Sequentia l Manual Gearbox (SMG)
Cautions

Cautions

CAUTION—
• When performing any repair which involves separating the
engine and transmission, check that the be/I housing dowels
are undamaged and properly in place before reassembly. If the
alignment of the engine flywheel to the transmission input shaft
is incorrect, any of the following complaints may result:
—Clutch slipping, shudder, o r poor disengagement.
—Noise from transmission input shaft.
—Transmission popping out of gear.
—Difficulty changing gears.
—Internal damage t o transmission.
• To avoid electrochemical corrosion to engine components
made of aluminum-magnesium alloy, do not use steel
fasteners. Use aluminum fasteners only.
• The end faces of aluminum fasteners are usually painted blue.
For reliable identification, test fasteners for aluminum
composition with magnet.
• Replace aluminum fasteners each time they are loosened.
• Follow torque instructions, including angle of rotation
specifications, when installing aluminum fasteners.
• Fill manual transmission only with BMW approved synthetic oil.
Filling with incorrect lube could cause the following damage:
— Premature synchromesh ring wear.
— Reduced service life of bearings.
— Tooth profile damage.
— Faster wear of selector forks.
— Damage to radial shaft oil seals.
• When removing interior trim clips, avoid damaging trim pieces
by using a plastic prying tool or a screwdriver with the tip
wrapped with masking tape.

TRANSMISSION FLUID SERVICE

SMG transmissions installed in 5 Series models use lifetime manual
transmission fluid and do not require periodic fluid changes.

Table c. SMG fluids

Transmission Year range Fluid type
ZF GS637SBZ 2004 - 2005 MTF-LT-2
ZF GS6S53B Z from 2006 MTF-LT-3
MTF-LT-2 (Lifetime fluid) BMW part no. 83 22 0 309 031
MTF-LT-3 (Lifetime fluid) BMW part no. 83 22 0 409 878
Clutch hydraulic fluid Pentosin CHF 11 S

Transmission fluid level, checkin g

Checking the transmission fluid level involves removin g the side fill
plug and inserting a gloved finger into the hole to check the fluid
level. If the fluid level is up to the botto m of the fil l hol e (finger is
wetted by transmission fluid), the leve l is correct.
Sequential Manual Gearbox (SMG) 23 1 -13
Transmission fluid, replacing

Transmission fluid, replacing

— Driv e vehicle for a few mile s to warm transmission.

— Rais e and safely support vehicl e to access drain plug .

CAUTION—
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Place a drain pa n underneath transmissio n and remov e drain plu g

(A) a t bottom o f transmission .
• Drai n fluid.
• Instal l and torque drai n plug .
• Remov e fill plu g (B ) from side of transmission.
• Slowl y fill transmission wit h fluid until fluid overflows fill hole.

Table d. SMG fluid capacities

Initial fill, new or

Transmission rebuilt unit Fluid change
ZF GS6S37B Z 1.6 liter (1.7 US qt) 1.5 lite r (1. 6 U S qt)
ZF GS6S53D Z 1.6 liter (1.7 US qt) 1.5 lite r (1.6 USqt )

— Instal l and torqu e fluid fill plug.

Tightening torque
• Drain or fil plug to transmission housing 35 Nm (26 ft-lb)

Clutch hydraulic fluid, filling

The clutch i n the SMG system is operated via hydrauli c fluid .

— Switc h ignition ON withou t starting vehicle.

— Us e BM W sca n tool t o depressurize clutch hydraulic system .

^k Workin g at side of transmission, open hydraulic fluid expansion tan k

(A) an d fil l to MAX leve l with Pentosi n CH F 11 S hydraulic fluid .
231 -14 Sequentia l Manual Gearbox (SMG)
Transmission, removing and installing

TRANSMISSION REMOVA L
AND INSTALLATIO N
Removal and installation o f the transmissio n i s best accomplishe d
with the vehicle on a lift and using a transmission jack. Suppor t
engine using equipment which allow s the engine to pivot on its
mounts to access the uppe r bolts a t the transmission bel l housing.

WARNING —
• The removal of the transmission may upset the balance of the
vehicle on a lift.

Transmission, removing and installin g

Disconnect negativ e (-) cable from battery.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given i n 001 Warnings and Cautions.

— Rais e an d safel y support vehicle .

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove underbody splash shields .

Remove front en d reinforcement plate.

Remove complete exhaust system. Se e 180 Exhaust System.

WARNING —
• Make sure exhaust system is fully cooled off before removing.

Remove oxygen sensors and store i n safe location .

Working underneat h vehicle, remov e hea t shields (A , B)

Sequential Manual Gearbox (SMG) 23 1 -15
Transmission, removing and Installing

Working at crankshaft sensor:

• Detach electrical connector (A).
• Remov e mounting bolt (B) and remove crankshaft sensor.

Detach electrical connector (arrow ) fro m oil level sensor. Uncli p

harness from harness suppor t clips.

Detach electrical connector (arrow) fro m hydraulic uni t component s

electrical plug.
231 -16 Sequentia l Manual Gearbox (SMG )
Transmission, removing and installing

Press in retaining lug s (A ) with screwdrive r (B ) and remove cable

duct (C) . Tie wire loom to one side .

Remove transmissio n bell housing bolts (arrows) .

Support transmission with BM W special tools 00 2 030, 23 0 123 ,

23 0 131, 23 0 134, an d 21 0 135 .
Sequential Manual Gearbox (SMG) 231-1 7
Transmission, removing and installing

Remove transmission mounting fasteners (A). Remov e

transmission rea r support fasteners (B). Remov e support .

Remove rea r driveshaft fro m transmission outpu t flange :

• Remov e driveshaft center bearing support fasteners. Suppor t
center of driveshaft .
• Unbol t rea r driveshaft flex-disc from transmission flange .
• Lowe r center of driveshaft sufficiently to disengage flex-dis c fro m
transmission output flange. Tie driveshaft to side.

CAUTION—
• To prevent damage to rear driveshaft CVjoint, do not allow
driveshaft to hang down unsupported.

Disconnect electrical harness connectors (A ) and (B) .

Cut wire tie (C) .

Disconnect electrical harness connectors (A , B),

uncoupling harness from bracket .
231 -18 Sequentia l Manual Gearbox (SMG)
Transmission, removing and installing

Disconnect electrica l harness connector (arrow ) from clutch travel

sensor.

Disconnect electrical harness connector (arrow) from sensor .

Remove bell housing to engine block mounting bolts (arrows ) and

slide transmission off engine .

CAUTION—
• Do not allow transmission to hang on input shaft while removing
and installing as the clutch disc can be damaged.
• Tilling the engine to lower the transmission can lead to damage
to various components in the engine compartment due to lack
of clearance.
 Sequential Manual Gearbox (SMG) 231-1 9
Transmission, removing and installing

Before installing transmission, make sure bell housing centerin g

dowels (arrows) are intact and lined up correctly. Replac e if
damaged.

Remove and clean release bearing and release lever .

21 2 240 • Push grease scraper, BMW special tool 21 2221, on input shaft (A)
21 2 221 as far as i t will go.
• Grease splines of input shaft, using Unirex S2 grease.
• Slide grease scraper off input shaft.

B5102310301
231-20 Sequentia l Manua l Gearbo x (SMG )
Transmission, removing and installing

Installation is reverse of removal, keeping in mind the following:

• When installing a new transmission, be sure to transfer parts from
old transmission, if applicable .
• Install driveshaft and preload center bearin g bracket. Us e new nuts
when mounting driveshaft t o transmission flex disc and final drive.
See 260 Driveshafts .
• Refil l transmission with appropriate lubrican t befor e starting or
towing car. See Transmission Flui d Service in this repair group.
• Check and clear fault codes from ECM and SMG control module
memory.

Tightening torques
Front end reinforcement to front end (us e
new fasteners):
• Stage 1 56 Nm (41 ft-lb)
• Stage 2 additional 90°
Slave cylinder t o transmission 22 Nm (16 ft-lb)
Transmission rear support to body (M8 ) 19Nm(14ft-lb)
Transmission moun t t o rear support (M8 ) 19Nm(14ft-lb)
Transmission to engine (us e new
aluminum fasteners):
• M 1 0 x 3 0 mm
Stage 1 20 Nm
Stage 2 additional 90 ° -110°
• M10x85 mm
Stage 1 20 Nm
Stage 2 additional 180° -200°
•M12
Stage 1 25 Nm
Stage 2 additional 130 ° + 20°
Vibration damper to transmission rear 38 N m (28 ft-lb)
support (M10 )
 240-1

240 Automati c Transmission

GENERAL 240- 1 TRANSMISSION REMOVA L

Automatic transmission applications 240- 2 AND INSTALLATION 240-17
Automatic transmission assembly 240- 2 Transmission, removing and installing
Automatic transmission features 240- 2 (6HP19Z transmission, M54 engine) . . . . 240-17
Automatic transmission functions 240- 5 Transmission, removing and installin g
Torque converter 240- 8 (6HP19Z transmission, N52 , N54 engines) 240-23
Transmission, removing and installing
Cautions 240- 9
(6HP19Z xDrive transmission) 240-31
TROUBLESHOOTING 240- 9 Transmission, removin g and installin g
Mechatronics service notes 240-1 0 (6HP26Z, V8 engine) 240-39
Visible fluid leaks 240-1 0 TORQUE CONVERTE R SERVIC E 240-46
AUTOMATIC TRANSMISSIO N FLUI D Torque converter, removing and installing . 240-46
(ATF) SERVIC E 240-1 2 Torque converter oil seal,
ATF level, checking 240-1 2 removing and installing 240-46
ATF, drainin g an d filling 240-1 3 Torque plate and flywheel,
removing and installing 240-48
ATF sump, removing and installing 240-1 4
TABLES
a. Automatic transmission applications 240- 2
b. Automatic transmission flui d (ATF ) 240-1 4

GENERAL
This repair group covers maintenance and replacemen t of the
automatic transmission.

Automatic transmission internal repairs are not covered.

Transmission repair s require specia l servic e equipment and
knowledge. I f transmission interna l servic e i s required, consul t an
authorized BM W dealer abou t a factory reconditioned uni t or a
transmission rebuild .

See also:
• 119 Lubrication System for crankshaft rear main (flywheel ) seal.
• 170 Radiator and Cooling Syste m for ATF cooler and hea t
exchanger.
• 200 Transmission-General for drivetrain information .
• 250 Gearshift Linkage for manual override of gearshift lock
• 260 Driveshafts for front (xDrive) and rear driveshaft.
• 270 Transfer Cas e for xDrive equipped models .
240-2 Automati c Transmission
Automatic transmission applications

Automatic transmission applications

The 6-speed automatic transmission in 5 Series vehicles was jointly
developed b y BMW and ZF (Zahnradfabrik Friedrichshafen).
Application informatio n is in Table a.

Table a . Automatic transmission applications

Model (engine) Year Transmission Max. torque
5251, 530i (M54 ) 2004 - 2005 GA6HP19Z 350 Nm (258 Ib-ft)
5251, 525xi, 5301, 530xi, 2006 - 2007 GA6HP19Z 400 N m (295 Ib-ft)
(N52)

545i, 550i (N62, N62TU) 2004 - 2007 GA6HP26Z 600 N m (443 Ib-ft)
528i, 528xi, 535i, 535xi, 2008* - 2000 GA6HP19ZTU 400 N m (295 Ib-ft)
(N52K, N54 )
550i (N62TU ) 2008* - 2009 GA6HP26ZTU 650 N m (479 Ib-ft)
* 2008 model year starts with 03 / 2007 production.

Automatic transmission assembly

1. Torqu e converte r
• Capable of torque multiplication
2. Multi-plat e clutch pack s
3. Planetar y gear assembly
4. Mechatronic s module
• Valve body (hydraulic unit)
• Transmission control module
(A7000a)

NA

BX06240018

Automatic transmission features

The 6-speed automatic transmissio n syste m features the following
components or signals:
• Mechatronics modul e
• Steptronic shift lever (2004 - 2007)
• Gear shift switch (GSW) (2008 - 2009)
• Gearshif t paddles (2008 - 2009)
• Instrument cluste r display of gear rang e
• Brak e light switch signal
• ECM signal
• DSC signal
• Accelerator pedal signal
• Bus connections
 Automatic Transmission 240- 3
Automatic transmission features

Mechatronics module
Mechatronics
module Transmission Mechatronics modul e is inside the transmission housing , combinin g
control module hydraulic uni t (valv e body ) and transmission contro l module (TCM )
(A7000a)
(A7000a). TCM operatin g software i s known as electronic
transmission control (EGS) .

The TCM include s the following components and functions:

• Powe r supply for solenoid valves and electronic pressure contro l
valves.
• Transmission senso r system:
— Transmission input speed sensor.
— Transmission output speed sensor.
— Transmission oil temperature sensor.
• Mechatronic s connecto r for connection to vehicle wirin g harnes s

Steptronic shift lever

Steptronic shif t lever i s equipped with positions P(ARK) ,
R(EVERSE) an d N(EUTRAL ) as well as D(RIVE) for automatic
mode and M/ S for manual and Steptronic mode.

The Steptroni c function makes it possible to shift the automati c

transmission manually. Manua l mod e is engaged whe n the shift
lever is moved left from automatic gate into manual gate . In manua l
mode, pressin g the shift lever forwar d or backward close s electrical
contacts, resultin g in upshift or downshift.

Gear shift switch (GWS )

In models buil t from 03 / 2007 (200 8 mode l year) , the shift leve r is
configured a s a control modul e referred to as gear shift switc h or
GWS. Transmission gear range selection in these model s i s
actuated electronically instead of via shift cable.

From 06 / 2007, a Sport automatic transmission is also available ,

featuring a SPORT button on the shifter console. Dynamic drivin g
control (FDC) i s activated wit h the SPORT button : Gearshif t time s
are shortened an d shift characteristic s ar e made more sporty .
240-4 Automati c Transmission
Automatic transmission features

Gear shift paddles

From 06 / 2007 (2008 model year), the Sport automatic transmission
also features gearshif t paddles . I n addition to sequential gear
selection with the shift lever, the gear s can also be selected using
gearshift paddle s on the steering wheel.

A shift pulse is transmitted electrically to the TCM. Wit h this

shift-by-wire method ther e is no mechanical linkag e between the
gearshift paddles an d the transmission.

Pull one of the gearshift paddle s briefly to change UP a gear. Pres s

one of the gearshift paddles briefl y to change DOW N a gear.

Instrument cluster displa y

Instrument cluster displays transmission gear rang e as well as
Check Control messag e via K-CAN. Check Contro l also alert s the
driver wit h acoustic signals. See 020 Maintenance for a discussion
of Chec k Control.

Brake light switch signal

Brake light switch signal affect s function of shiftlock and adaptiv e
transmission control.

Engine control module (ECM) signal

Engine control module (ECM) signal s engin e speed, torque an d
other parameters. TCM signals current transmission operating
status back t o ECM .

Dynamic stability control (DSC) signa l

DSC control module signals cornering , acceleration and traction
data.

Accelerator pedal signa l

Accelerator pedal modul e signals drive r power demand data .

Bus connections
Bus connections are used to handle electrical complexity throughou t
the 5 Series chassis. See 600 Electrical System-Genera l fo ?
details of bus systems.
 Automatic Transmission 240- 5
Automatic transmission functions

Automatic transmissio n function s

Automatic transmission function s include the following:
• Adaptive transmission control (AGS )
• Overlap control
• Starter inhibitor
• Parking lock
• Warm-up program
• Engine interventio n
• Downshift inhibitor
• Revers e gear inhibitor
• Shift lever lock (shiftlock )
• Standstill decouplin g
• Interlock
• Emergency program (limp-home mode)

Adaptive transmission control (AGS)

The transmission offer s the choice between a comfort program and
a sport program. AGS (a component of EGS) adapts transmissio n
shift characteristics to the driver and the driving situation.

In both programs, AGS can switch from a basic shift map to a

performance-orientated map, taking the following conditions int o
account:
• Comfort program (shift lever position D) uses 2 maps: XE (extreme
economy) and E (economy).
• Sport program (shift lever position M/S ) produces dynamic, sport y
shift characteristics. There is a basic S (sport) map and a
performance-orientated XS (extreme sport) map .

Other AGS functions are as follows:

Adaptation to driver. AGS adapts to different driving style s usin g

the following criteria:
• Kick-fast. If the accelerator pedal is depressed rapidly, the shift
program is changed to E in comfort program and XS in sport
program.
• Cornering detection reacts to lateral acceleration with an indirect
adaptation to the driver type. Lateral acceleration is considered an
indirect statemen t of preferred driving dynamics and does not
cause an immediate gearshift response (shifts when cornering
could adversely affect driving stability). Lateral acceleration is
calculated fro m wheel-speed, yaw rate and road speed sensor
signals.
• Braking is evaluated in a similar way to kick-fast. Braking
deceleration i s measured and compared with threshold values i n
theTCM.
• Drive r adaptation is restarted each time the vehicle pulls away from
a standstill.

Driving uphill or trailer towing function is based on a compariso n

of vehicle acceleration with a nominal value. Fro m the curren t
engine operating situation, acceleration with normal load on a level
surface is calculated. I f the actual acceleration is significantly below
240-6 Automati c Transmission
Automatic transmission functions

the theoretical value, driving uphill or trailer towing function is

activated.

Driving downhill. I f the TCM detects downhill driving, it

automatically shif t down a gear if vehicle speeds up. This enhances
the engine brakin g effect. A downshift onl y occurs i f the engin e
speed is below the maximum speed of the lower gear.

TCM detects downhill driving from signals from the throttle valve
potentiometer (load) , wheel speed sensors (road speed) an d brake
light switch (brake activation).

Braking deceleratio n an d automatic upshift . To decelerate the

vehicle, the foot is taken off the gas and the brake depressed a s
necessary. The gearshift map triggers an upshift when the throttle is
closed. These gearshifts are not necessary in conjunction with brake
applications a s they prevent the engine brakin g effec t from being
exploited.

The intention to apply the brakes is anticipated fro m the accelerator

pedal being rapidly released to the zero position. If such an action is
detected, transmission upshif t i s suppressed for as long as the
accelerator pedal is in the zero position and the vehicle is in overrun
mode.

Winter program (only with shift lever in position D ) is automatically

activated if the drive wheels start to spin, eve n at a low rate of
acceleration. The winter program ensures better traction by not
using 1s t gear. Early upshifts reduc e the reactions caused by load
changes. Winter program is deactivated if the wheels do not spin for
several seconds despite hig h drive torque.

Overlap control
Overlap control provides gentle shift characteristics as follows:
During a shift, pressure is reduced in the active multi-plate clutch
and at the same time built u p in the clutc h that is about to be
activated. Gradual reduction and build-up o f pressure is maintaine d
until the shift is complete. Overlap control is active for all gearshifts
from 1 st to 6th gear and from 6th to 1 st gear.

Starter inhibitor
It is only possible to start the engin e when vehicle is in P or N. Car
access system (CAS) with electronic imrnobilize r (EWS) evaluates
signals from the TCM via direct wire or CAN-bus signal indicating
that shift lever is in P or N.

Parking lock
Parking lock feature locks the transmission output shaft so that the
vehicle i s prevented from rolling unexpectedly. Parking lock is
designed to provide a reliable brak e on gradients u p to 32%.

2004 - 2007 models: When the vehicle i s stationary, parkin g lock is

engaged purely mechanically via Bowden cable from shift lever to
mechatronics module.

, 200 8 - 2009 models: The parking lock is signalled electronically via

a button on the gear shift switch (shift lever). I t is actuated via a
mechanical spring and cable system.
 Automatic Transmission 240- 7
Automatic transmission functions

Parking lock i s activated under the following conditions :

• Pressur e on shift lever button and road speed signal les s than 1. 2
mph (2 kph).
• Ignition key removed fro m ke y slot and road speed signal of 0.
• Engin e ON.
—Shift leve r in D or R.
—Driver door open .
—Drivers seat belt not fastened in belt buckle.
—Pedals not depressed [road speed signal les s than 2 mph
(3 kph)].
• START / STOP butto n pressed while engine is ON.
—Shift leve r in D or R .
—Road speed signal 0.

Parking lock i s only release d when the engine is ON becaus e

hydraulic pressur e is required to open the parkin g lock. I n case of
power failure (such as dead battery ) parkin g lock can b e release d
manually. See 250 Gearshift Linkage .

Warm-up program
If the engin e i s started and coolant temperature is lower than
approx. 176° F (60°C), the warm-up program i s activated. Until the
engine warms up , the transmission remains in performance ma p E
or XS, shifting gears at higher speeds. This enables the engine an d
catalytic converter s t o reach operatin g temperature more quickly.

Up to a transmission oi l temperature o f approximately 95°F (35°C) ,

the torque converter lockup clutch i s neither controlled no r closed.

Engine intervention
During a gearshift, the TCM emits signals to retard ignition timin g for
a few milliseconds. This action briefly reduces the torque, improves
shift quality, reduces transmission loa d and shortens shif t time.

Downshift inhibitor
TCM program prevents shifting to a lower gear until engine spee d is
below maximum speed for the next gear down. Engine speed signa l
is transmitted by the ECM to the TCM. The downshift inhibito r
prevents damage t o the engine and transmission.

Reverse gear inhibito r

Shifting int o revers e gea r i s inhibited when th e vehicle is moving
forward at speeds abov e 3 mph (5 kph) .

Shift lever loc k (shiftlock)

The shift leve r is locked in positions P or N by an electromagne t
actuated by the TCM. Shiftlock engages with shift lever in P or N and
ignition ON. Shifting from P or N into a drive gear or reverse i s only
possible at road speeds less than 3 mph (5 kph) an d brake applie d
at engine speed below 2500 rpm .
240-8 Automati c Transmissio n
Torque converter

Standstill decouplin g
The torque converter is decoupled when the vehicle is at a standstill.
Thus onl y a minimum loa d remain s o n the engine and fuel
consumption i s reduced. Decoupling i s effected by clutch action
within the transmission.

Interlock
2004 - 2007 models : The ignitio n loc k is mechanically linke d to the
shift leve r by a Bowden cable . Interloc k allow s the ignitio n ke y to be
removed only when the shif t lever i s in P. Conversely, the shif t lever
can only be moved from P when the ignition key is in the ignition lock
and turned at least to ignition ON.

2008 - 2009 models: The remote key (ignition key) ca n only b e

removed when CA S registers a road spee d signal belo w 0.6 mph
(1 kph). I f the remote control is removed from the ignition slot after
the engine is switched OFF, the parkin g loc k automatically applies .

Emergency progra m
The emergency program (limp home mode) activates if transmission
management fails or detects a malfunction that could lead to critical
driving conditions. In limp home, th e vehicle remains operational but
with limitations.

If TCM fails, the following forward gears ca n b e engaged:

• Failur e in 1st - 3rd gear: Emergenc y 3rd gear activated.
• Failure i n 4th - 6th gear: Emergency 5th gear activated .
• Engin e restar t is possible i n 3rd gear.

Torque converte r

Torque i s transmitted fro m the engine to the transmission by a

Torque
converter hydro-dynamic torqu e converter (flui d coupling). The converter is
lock-up equipped wit h slip-controlle d lock-u p clutch .
clutch

Engine sid e Transmission

side
 Automatic Transmission 240- 9
Cautions

Cautions

CAUTION—
• When performing any repair which involves separating the
engine and transmission, check that be/1 housing dowels are
undamaged and in place before reassembly. If the alignment of
the engine flywheel to the transmission input shaft or torque
converter is incorrect, any of the following complaints may
result:
—Noise from transmission input shaft.
—Internal damage t o the transmission.
• When removing interior trim clips, avoid damaging trim pieces
by using a plastic prying tool or a screwdriver with the tip
wrapped with masking tape.
• To avoid electrochemical corrosion to engine components
made of aluminum-magnesium alloy, do not use steel
fasteners. Use aluminum fasteners only.
• The end faces of aluminum fasteners are usually painted blue.
For reliable identification, test fasteners for aluminum
composition with magnet.
• Rep/ace aluminum fasteners each time they are loosened.
• Follow torque instructions, including angle of rotation
specifications, when installing aluminum fasteners.
• Fill transmission only with BMW approved synthetic oil. Filling
with incorrect lube could cause the following damage
— Premature wear.
— Reduced service life of bearings.
— Tooth profile damage.
— Damage to radial shaft oil seals.

TROUBLESHOOTING
Minor automatic transmission problems may be corrected by
changing the automatic transmission flui d (ATF) and filter. See
Automatic Transmission Flui d (ATF) Service on this repair group .

Begin b y checking ATF level and condition. Check t o see i f the fluid
is dirty or has a burned odor indicating overheated fluid. The burne d
odor may be the result s of burned discs in the clutch packs . Th e
friction material from the burned disc can clog valve body passages.

Software i n the transmission control module (TCM) monitor s

transmission operation for faults and alerts the driver by illuminatin g
the transmission faul t indicator o n the instrument panel . The self -
diagnostic software stores diagnostic troubl e codes (DTCs ) whic h
may be accessed as follows:

Connect BM W scan tool to OBD 2 plug on left door post . (Plu g is

behind plastic trim. )

Place transmission shif t leve r in P or N . Engage parking brake.

Switch ignition ON. Follo w scan tool on-screen instructions.

For a listing of scan too l suppliers, see 020 Maintenance .

240-10 Automati c Transmissio n
Mechatronics service notes

Mechatronics service note s

The mechatronic s electrica l connection i s delicate. Use care when
removing and replacing the multi-pin connector. If pins are
damaged, replac e the complete mechatroni c module .

Leaks around the mechatronics sleeve can be misdiagnosed a s

coming from the transmission pa n gasket . I f a leak a t the
mechatronics sleev e is confirmed, replac e th e sleeve .

An incorrectly installed mechatronic s sleeve can cause damage d

connector pins and intermittent transmission communication faults.
Example of faults include:
• Seria l wire message missin g (BM W faul t code 5079) .
• Seria l line signal plausibility (BM W faul t code 507A) .
• Transmission emergency progra m light illuminated.
• Transmission entering failsafe mode .

Push sealing sleeve (arrow ) into mechatronics housing. Use new

O-rings an d lubricate sleeve with transmission fluid.

Reattach mechatronics connector , making sure connecto r pin s are

not damaged. Clos e white locking tab o n connector. D o not use
excessive force. Excessive force indicates a n incorrectly installe d
sleeve.

With harness connector installed and locked, make sure distance

between connector and housin g surfac e (A) doe s no t exceed '/» "
(3 mm).

If distance between connector and housin g surface (A) measure s

approximately 14 " - Y. (," ( 7 - 8 mm), sealin g sleev e installation is
incorrect and may permanently damage connector pins .

Visible fluid leak s

If visual inspection reveals oil drops o r other evidence of oil leak s
from transmission, check the following:

Check transmission sump gaske t fo r leaks at spots marked with

arrows.
 Automatic Transmissio n 240-1 1
Visible fluid leaks

Check transmission outpu t shaf t seal (arrow) for leaks .

Check mechatronic s connecto r sleev e (arrow) for leaks .

Check selector shaft bearin g sea l (arrow ) for leaks .

240-12 Automati c Transmission
ATF level, checking

AUTOMATIC TRANSMISSION FLUI D (ATF)

SERVICE
5 Series automati c transmission fluid (ATF ) has a condition-based
service (CBS ) interva l of approximately 100,00 0 miles (160,00 0
km). Fo r an explanation of condition-based service , see
020 Maintenance .

Check ATF level if there is evidence o f a leak, a complaint relate d to

fluid level or after transmission repairs . I f service o r repair s hav e to
be made t o the transmission o r ATF cooler, us e only the approve d
transmission fluid .

The automatic transmission is not equipped with a dipstick. Chec k

ATF level while monitoring ATF temperature with special equipment .
Make sure transmission i s at operating temperatur e and vehicle is
level throughout tests.

Be sure necessary equipment, catch bin, transmission fluid and fluid

pump are available before starting the fluid level checking
procedure.

ATF service interval

Condition-based: chec k instrumen t cluster approximately
to monitor servic e interval. 100,000 mile s
See 020 Maintenance.

ATF level, checkin g

Transmission fluid expands with temperature. BMW requires that
the ATF be checked whe n flui d temperature i s between 30 - 50°C
(86- 122°F) .

— Driv e vehicle to warm u p ATF to operatin g temperature.

^ Connec t BMW scan tool and call up "Service function s (drive)." Set
scan tool to measure AT F temperature.

— Wit h engine running , switch on air-conditioning to increase engine

idle speed .

— Appl y parking brake.

— Whil e applying foot brak e firmly move gea r shif t leve r through al l
gear positions, pausin g i n each gea r briefly.

— Rais e and safel y support vehicle. Place oil drip pan underneath.

CAUTION—
• Make sure th e vehicle is stable and well supported a t all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Remov e splash shields unde r transmission . See 020 Maintenance .

 Automatic Transmission 240-1 3
A TF, draining and filling

With engine running , shift lever in P and ATF temperature as

specified, remove AT F fill plug (arrow).
• Fo r best results, check fluid level at 30°C (85°F) .
• A n accurate level check is not possible if fluid temperature rise s
above 50°C (120° F).

ATF level checking

Fluid temperature 30° - 5 0 C C ( 8 6 & - 122°F )

Level is correct i f small stream o f fluid runs out of fill hole.

If n o fluid runs out, add flui d until it starts to overflow.

CAUTION—
• Do not mix BMW transmission oils, and do not replace with
another oil.

Automatic transmission fluid (ATF)

BMW recommended fluid BMW part no . 83 22 0 14251 6
Shel M-1375.4

— Instal l fill plu g usin g new sealin g ring.

Tightening torque
Fill plug to transmission housing 35 Nm (26 ft-lb)

Press on brake pedal. With engine running at idle speed , shif t

through gear s several times. Shift to P.

Connect BM W scan tool and call u p "Service functions (drive). "

Follow on-screen instructions to complete ATF level check .

ATF, draining and filling

Drive vehicle to warm u p ATF to operating temperature.

Raise vehicle and support safely.

WARNING —
• Make sure the vehicle is stable and well supported at a/I times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splash shiel d underneat h transmission. Se e

020 Maintenance. I f necessary t o improve access , remove splash
shield and exhaust brackets.

Place 5-gallon drain pan underneath transmission sump .

Remove ATF drain plu g (arrow ) and allow to drain.

WARNING —
• Use gloves to protect your hands. Hot ATF scalds.
240-14 Automati c Transmission
ATF sump, removing and installing

— Replac e drain plu g and tighten .

Tightening torque

Drain plug to plastic sump 8 Nm (6 ft-lb)

Remove ATF fill plug (arrow). Fill transmission unti l ATF flows out of
fill hole.

Table b. Automatic transmission fluid (ATF )

BMW recommended flui d BMW part no . 83 22 0 14 2 516
Shell M-1375. 4
Fill capacity approx. 9 - 10 liters (9.5 - 10.6 US qt)

CAUTION—
• Do not overfill with ATF. Transmission fill capacity given in
specifications includes torque converter volume. Torque
converter does not drain when transmission is drained using
drain plug.
• ATF expands when transmission is warmed up. Final fluid level
is set with ATF at a temperature of 30° - 50°C (86° - 122°F).

— Instal l fill plug.

— Pres s on brake pedal. Wit h engine runnin g a t idl e speed , shift

through gears several times. Shift to P.

— Connec t BM W sca n tool and call u p "Service functions (drive).'

Follow on-screen instructions to complete ATF level check. See ATF
level, checking i n this repair group .

— Reinstal l fill plug usin g ne w sealing ring .

Tightening torques
Fill plu g to transmission housin g 35 Nm (26 ft-lb)

ATF sump, removing and installin g

Raise and safely suppor t vehicle. Place oil drip pan underneath.

CAUTION—
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splash shield underneath transmission . See

020 Maintenance. I f necessary t o improve access , remov e splash
shield an d exhaust brackets .
 Automatic Transmission 240-1 5
ATF sump, removing and installing

Remove ATF drain plug and allow to drain. Reinstall and torque
drain plug. See ATF, draining and filling i n this repai r group .

WARNING —
• Use gloves to protect your hands. Hot ATF scalds.

Tightening torque
Drain plug to plastic sum p 8 Nm (6 ft-lb)

Remove ATF sump retainin g bolts (arrows) and lower sump.

. AT F sump components :
1. Oi l pickup tube sealing O-ring
2. M 6 bolt
• I t necessary, replace with M6 x 28.5 mm Torx T4 0
•Tighten to 10Nm ( 7 ft-lb)
-3 3. Gaske t
4. AT F sump (plastic )
5. Drai n plug
-4 • Tighten t o 8 Nm (6 ft-lb)

Remove and discard old sump gasket and oil pickup tube sealin g
O-ring. Us e shop towels to clean sump interior and seal and gasket
grooves.
-5 |
B510240022 CAUTION—
• Do not degrease sump with cleaning agent.

— Instal l new sealing O-ring .

"^ Mak e sure locating tab (arrow) on new gasket mates correctly wit h
bore at edge of sump.

— Reinstal l sump. Instal l retaining bolts hand-tight. Tighten bolts

gradually an d in crisscross pattern.

Tightening torque
ATF sump to transmission housing 10 Nm ( 7 ft-lb)
240-16 Automati c Transmission
ATF sump, removing and installing

Remove ATF fill plug (arrow). Fill transmission unti l ATF flows out of
fill hole.

Automatic transmission fluid (ATF )

BMW recommended flui d BMW par t no. 83 22 0 14 2 516
Shell M-1375. 4

Fill capacit y approx. 9 - 1 0 liters (9. 5 - 10. 6 U S qt)

CAUTION—
• Do not overfill with ATF. Transmission fill capacity given in
specifications includes torque converter volume. Torque
converter does not drain when transmission is drained using
drain plug.
• ATF expands when transmission is warmed up. Final fluid level
is set with ATF at a temperature of 30° - 50"C (86° - 122°F).

— Instal l fil l plug.

— Pres s on brake pedal. With engine running at idle speed, shift

through gears several times. Shift to P.

— Connec t BM W sca n tool and cal l u p "Service function s (drive). "

Follow on-screen instructions to complete ATF level check. See ATF
level, checking in this repair group.

— Reinstal l fil l plug usin g new sealin g ring .

Tightening torque s
Fill plug t o transmission housin g 35 Nm (26 ft-lb)
 Automatic Transmission 240-1 7
Transmission, removing and installing (6HP19Z transmission, M54 engine)

TRANSMISSION REMOVA L AND INSTALLATIO N

Removal and installation o f the transmission is best accomplishe d
on an automotive lift using a transmission jack. Use caution and safe
workshop practices when working underneath vehicle and lowerin g
transmission. Be sure to have appropriate tools on hand befor e
starting th e job.

CAUTION—
• Replace aluminium fasteners each time they are released. Do
not use steel fasteners in place of aluminium. Electrochemical
corrosion will result.

Transmission, removin g an d installing

(6HP19Z transmission, M5 4 engine)

WARNING —
• Allow engine and transmission to cool down before starting
work on the transmission.

Transmission, removin g (M54 engine )

Disconnect negativ e (- ) cable from battery.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given in 001 Warnings and Cautions .

Support engine from above with suitable hoist.

Raise an d safely suppor t vehicle .

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Remov e splash shield s an d supporting bracket s under engin e an d

transmission. See 020 Maintenance.

— Remov e fron t en d reinforcement . Discar d mounting bolts. Se e 31 0

Front Suspension .

— Remov e complete exhaust system. See 18 0 Exhaus t System .

CAUTION—
• To avoid damaging oxygen sensors, transport and store
exhaust system carefully.

Remove heat shield s (A , B).

240-18 Automati c Transmission
Transmission, removing and installing (6HP19Z transmission, M54 engine)

Working a t shift cable connectio n o n lef t side of transmission:

• Counterhold clamping sleev e (A ) and loosen nu t (B). Use a
screwdriver t o pry off retainer clip (C) and pull cable (D) out of
support bracket .

Support transmissio n with transmission jack . Illustratio n show s

BMW special tools.

Remove transmission rea r support fasteners (A , B). Remove rear

support.

Detach rea r driveshaft from transmission :

• Remov e driveshaft center bearing suppor t fasteners . Support
center of driveshaft .
• Unbol t rear driveshaf t flex-dis c fro m transmission flange .
• Lowe r cente r o f driveshaft sufficiently to disengage flex-disc fro m
transmission output flange. Ti e driveshaf t to side with stiff wire.
See 260 Driveshafts .

CAUTION—
• To prevent damage to rear driveshaft CVjoint, do not allow
driveshaft to hang down unsupported.
 Automatic Transmissio n 240-1 9
Transmission, removing and installing (6HP19Z transmission, M54 engine)

Working a t rear of transmission housing :

• Twist mechatronics electrical connector bayonet lock in direction of
curved arrow (A) to release.
• Carefull y pull connector off pins (B).
• Inser t BM W special tool 24 2 390 in place of mechatronics
connector to protect delicate pins.

CAUTION—
• Do not touch pins.

Working at ATF cooler lines (A) o n lef t side of transmission:

• Remov e fluid lin e bracke t hold-down bolt (B)
• Detach flui d lines from transmission housing .

CAUTION—
• Be prepared to catch dripping fluid.
• Remove and discard fluid line O-ring seals. Be sure to use new
ones when reassembling.

If necessary, remov e small cover over torque plat e mounting bolt s

access hole.

Rotate engine by hand in direction of rotation using bol t o n

crankshaft vibration damper unti l torque plate mounting bol t (arrow )
is visible throug h acces s hol e in engine bel l housing flange.
• Loosen an d remove bolt.
• Rotat e engine to gain access to and remove remaining torque
plate bolts.
240-20 Automati c Transmission
Transmission, removing and installing (6HP19Z transmission, M54 engine)

Use BMW special too l 24 4 16 0 or equivalent to secure torque

converter in bell housing befor e you separate transmissio n fro m
engine. This prevents torque converter from pulling of f transmission
input shaft an d damaging torque converter oil seal.
• Inser t tool in bell housing opening an d secure in place lightl y using
knurled knob A.
• Twist in knurled knob B and tighten.
• Tighten down knob A.

Remove transmission bell housing bolts (arrows). Discar d

aluminum bolts.

Remove transmission b y pulling bac k an d down. Lowe r jack slowly

while watching carefull y t o make sur e no lines, hoses or wires
become snagged .

WARNING—
• Be sure the vehicle is properly supported. The removal of the
transmission may upset the balance of the vehicle on the lift.

CAUTION—
• Tilting the engine to remove the transmission can lead to
damage to engine compartment components due to lack of
clearance.
• Do not allow the torque converter to fall off the transmission
input shaft.

Blow out oil cooler lines with low-pressure compressed air and flush
cooler with clean ATF twice.

CAUTION—
• Wear safety glasses when working with compressed air.
• Do not reuse ATF used for flushing.

Inspect engine torque plate and flywhee l for cracks or elongated

holes. Replac e if necessary.

If torque converter seal is leaky, or torque converte r position on

transmission input shaf t was disturbed durin g removal , replace
torque converte r seal . Se e Torque converter oil seal, removing
and installin g i n this repair group .
 Automatic Transmissio n 240-2 1
Transmission, removing and installing (6HP19Z transmission, M54 engine)

Transmission, installin g
. Rotat e engine unti l torque plat e bore for mounting bol t (arrow) i s
accessible through opening in engine bell housing.

"X, Chec k that bel l housin g dowe l sleeves (arrows) ar e in good shap e
and correctl y seated. Replac e if needed.

— Chec k that torque converte r is seated correctly in transmission .

— Rotat e torque converte r unti l threaded mountin g hol e in converter is

lined u p with bore i n torque plate.

— Joi n transmission to engine. Mak e sure torque converter and torqu e

plate bolt bore s ar e lined up by installing one bolt finger-tight.

Using ne w aluminum bolts , tighten bell housing fastener s to initia l

torque.
• Us e torque angl e tool (BM W specia l tool s 00 9 120 / 00 9 130 or
equivalent) an d tighten fasteners to final torque angle .
• Install and tighten remaining torque converte r bolts .

Tightening torques
Torque converter to torque plate:
•M10x10.9 56 N m (4 1 ft-lb)
Transmission rear support to body (M8 ) 19Nm(14ft-lb)
Transmission rea r support to transmission 19Nm (1 4 ft-lb)
Transmission t o engine (M1 2 aluminum) :
• Initial torqu e 25 Nm (18 ft-lb)
• Torque angle + 130 °
Transmission to engine (M10 x 3 0 aluminum):
• Initia l torque 20 N m (1 5 ft-lb )
• Torque angl e + 90-110°
Transmission t o engine (M1 0 x 85 aluminum) :
• Initial torqu e 20 N m (1 5 ft-lb)
• Torque angl e + 1 80 - 200°
240-22 Automati c Transmission
Transmission, removing and installing (6HP19Z transmission, M54 engine)

— Remainde r o f installation i s reverse o f removal . Remembe r to:

• Instal l ne w sealing washer s or O-rings o n ATF cooler lin e fittings.
• Adjust gearshif t mechanism. See 250 Gearshift Linkage.
• Driveshaf t tightening torque s are i n 260 Driveshafts. To avoid
damaging driveshaft flex-disc, counterhol d flex-disc bolt head s
while tightening nuts .
• Fil l transmission with clean ATF. See ATF, draining an d filling in
this repai r group .
• Us e new bolts to reinstall fron t end reinforcemen t plate. See
310 Front Suspension.

Tightening torque s
Drain plu g t o plastic sum p 8 N m (6 ft-lb)
Fill plu g to transmission housin g 35 N m (2 6 ft-lb)

Automatic transmission fluid (ATF)

BMW recommended flui d BMW par t no . 83 22 0 142 516
Shell M-1 375.4
Fill capacit y approx. 9 - 1 0 liters (9.5 - 10. 6 US qt)

CAUTION—
• Do not overfill with ATF. Transmission fill capacity given in
specifications includes torque converter volume.
• ATF expands when transmission is warmed up. Final fluid level
is set with ATF at a temperature of 30° - 50°C (86° - 122°F).
 Automatic Transmission 240-2 3
Transmission, removing and installing (6HP19Z transmission, N52, A/54 engines)

Transmission, removing and installin g

(6HP19Z transmission, N52, N54 engines )

WARNING —
• Allow engine and transmission to cool down before starting
work on the transmission.

Transmission, removin g (N52, N54 engines)

— 200 8 - 2009 model s (startin g production date 03 / 2007): Releas e
parking lock manually. Se e 250 Gearshift Linkage.

— Disconnec t negative (-) cable from battery .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given in 001 Warnings and Cautions.

Support engine from above wit h suitable hoist .

Raise and safely support vehicle .

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splas h shields and supporting brackets under engine and

transmission. Se e 020 Maintenance .

Remove front end reinforcement . Discard mounting bolts . See

310 Front Suspension .

— Remov e complet e exhaust system. Se e 180 Exhaust System .

CAUTION—
• To avoid damaging oxygen sensors, transport and store
exhaust system carefully.

Remove hea t shields (A, B).

240-24 Automati c Transmission
Transmission, removing and installing (6HP19Z transmission, N52, N54 engines)

Separate oxygen sensor electrical connector s (A). Remove

fasteners (B) and remove retaining plate (C).

Use BMW special tool 00 9 010 (Tor x E18 socket) t o remov e

aluminium fastener nex t to electrical connector brackets. Discar d
fastener.

B309240018I

N52 engine: Working at front exhaust pipe flanges, remov e heat

shield bracke t fasteners (A) and remove bracket (B).
 Automatic Transmission 240-2 5
Transmission, removing and installing (6HP19Z transmission, N52, N54 engines)

N54 engine: Workin g at front exhaust pipe flanges:

• Detac h electrical harness from bracket (A).
• Remov e wire bracket mounting fastener (B) .
• Remov e bracket (C).

2006 - 2007 models : Workin g at shift cable connection on left side

of transmission:
• Counterhold clamping sleeve (A) and loosen nut (B). Us e a
screwdriver to pr y off retaine r clip (C) and pul l cable (D ) ou t of
support bracket .

">. 200 8 - 2009 models: Workin g a t parking loc k cable o n left side of
transmission:
• Remov e cable bracke t fastener (A).
• Disengag e cabl e end from parking lock lever (B) .

— Suppor t transmissio n with transmission jack. Secure transmission to

jack with suitable strap .
240-26 Automati c Transmission
Transmission, removing and installing (6HP19Z transmission, N52, N54 engines)

Remove transmission rea r suppor t fastener s (A, B) . Remov e rear

support.

Detach rea r driveshaft from transmission :

• Remov e driveshaf t center bearing support fasteners. Suppor t
center o f driveshaft.
• Unbol t rea r driveshaft flex-disc from transmission flange .
• Lowe r center of driveshaft sufficiently to disengage flex-dis c from
transmission outpu t flange. Tie driveshaf t to side usin g stiff wire .
See 260 Driveshafts.

CAUTION—
• Jo prevent damage to rear driveshaft CV joint, do not allow
driveshaft to hang down unsupported.

Working a t rear of transmission housing :

• Twist mechatronics electrical connector bayone t loc k in direction of
curved arrow (A) to release .
• Carefully pul l connecto r of f pins (B) .
• Inser t E3M W special tool 24 2 390 i n place o f mechatronic s
connector to protect delicat e pins .

CAUTION—
• Do not touch pins.

Working at ATF cooler line s (A ) o n lef t side o f transmission:

• Remov e fluid lin e bracke t hold-down bol t (B)
• Detac h fluid lines from transmission housing .

CAUTION—
• Be prepared to catch dripping fluid.
• Remove and discard fluid line O-ring seals. Be sure to use new
ones when reassembling.

-*•• laailEMinigil
 Automatic Transmission 240-2 7
Transmission, removing and installing (6HP19Z transmission, N52, N54 engines)

-TT7- Remove transmission fluid cooler line bracket mounting bol t (arrow)
at engine oil pan .

"X. Rotat e engine b y hand in direction of rotation using bolt on

crankshaft vibration damper until torque plate mounting bolt (arrow )
is visible through access hole i n engine bell housing flange .
• Loose n and remove bolt.
• Rotat e engine to gain access to and remove remaining torque
plate bolts.

Use BMW special tool 24 4 16 0 or equivalent to secure torqu e

converter in bell housing befor e you separate transmission from
engine. This prevents torque converter from pulling of f transmission
input shaft and damaging torqu e converter oil seal.
• Inser t tool in bell housing opening and secure in place lightl y using
knurled knob A.
• Twist in knurled knob B and tighten.
• Tighten down knob A.
240-28 Automati c Transmission
Transmission, removing an d installing (6HP19Z transmission, A/52 , A/5 4 engines)

Remove transmission bell housin g bolt s (arrows). Discar d

aluminum bolts .

Remove transmission by pulling bac k an d down. Lowe r jack slowly

while watching carefully t o make sure n o lines, hoses or wires
become snagged.

WARNING—
• Be sure th e vehicle is properly supported. Th e removal of the
transmission may upset the balance of the vehicle on the lift.

CAUTION—
• Tilting the engine to remove the transmission can lead to
damage to engine compartment components due to lack of
clearance.
• Do not allow the torque converter to fall off the transmission
input shaft.

Blow out oil cooler lines with low-pressure compressed air and flush
cooler with clean ATF twice.

CAUTION—
• Wear safety glasses when working with compressed air
• Do not reuse ATF used for flushing.

Inspect engine torque plate an d flywheel for cracks or elongated

holes. Replac e if necessary.

If torque converter seal i s leaky, o r torque converter position on

transmission input shaft was disturbed durin g removal, replace
torque converter seal. Se e Torque converte r oil seal, removin g
and installing i n this repai r group.

Transmission, installing (N52, N54 engines)

. Rotat e engine unti l torque plate bor e for mounting bolt (arrow) is
accessible through opening i n engine bel l housing.
 Automatic Transmissio n 240-2 9
Transmission, removing and installing (6HP19Z transmission, N52, N54 engines)

^V Chec k that bel l housing dowe l sleeves (arrows ) are i n good shap e
and correctl y seated. Replac e if needed .

— Chec k that torque converter is seated correctly in transmission .

— Rotat e torque converter until threaded mounting hol e in converter i s

lined u p with bore in torque plate.

— Joi n transmission to engine. Make sure torque converter and torque

plate bol t bores ar e line d u p by installing one bol t finger-tight.

Using new aluminum bolts , tighte n bell housin g fastener s t o initia l

torque.
• Us e torque angl e too l (BMW specia l tools 00 9 120 / 00 9 130 or
equivalent) an d tighten fasteners to final torque angle .
• Instal l and tighten remainin g torqu e converter bolts .

Tightening torques
Torque converter to torque plate :
• M 1 0 x 10.9 56 N m (4 1 ft-lb )
Transmission rea r support to body (M8) 19 N m (1 4 ft-lb)
Transmission rea r support t o transmissio n 19 N m (1 4 ft-lb)
009120 ^|C ^ Transmission to engine (M1 2 aluminum) :
• Initia l torque 25 N m (1 8 ft-lb)
• Torque angl e + 130°
Transmission to engin e
(M10 x 30 aluminum) :
• Initia l torque 20 N m (1 5 ft-lb)
• Torque angl e + 90-110°
Transmission t o engin e
(M10 x 85 aluminum) :
• Initia l torqu e 20 N m (1 5 ft-lb)
• Torque angl e + 180-200 °
240-30 Automati c Transmission
Transmission, removing an d installing (6HP19Z transmission, A/52 , A/5 4 engines)

Remainder o f installation is reverse of removal . Remember to:

• Instal l new sealing washers or O-rings on ATF cooler line fittings.
• 2006 - 2007 models: Adjus t gearshift mechanism. See
250 Gearshift Linkage .
• 2008 - 2009 models : Adjust parking loc k cable free play. See 250
Gearshift Linkage .
• Driveshaf t tightening torques are in 260 Driveshafts . To avoid
damaging driveshaf t flex-disc, counterhold flex-dis c bolt heads
while tightening nuts.
• Fil l transmission with clean ATF. See ATF, draining and filling in
this repai r group.
• Us e new bolts to reinstall front end reinforcement plate. See
310 Front Suspension.

Tightening torques
Drain plu g to plastic sum p 8 N m ( 6 ft-lb)
Fill plug to transmission housin g 35 N m (26 ft-lb)

5 Series automatic transmission fluid (ATF )

BMW recommended flui d BMW par t no. 83 22 0 142 516
Shell M-1375. 4
Fill capacity approx. 9 - 10 liters (9.5 - 10.6 US qt)

CAUTION—
• Do not overfill with ATF. Transmission fill capacity given in
specifications includes torque converter volume.
•ATF expands when transmission is warmed up. Final fluid level
is set with ATF at a temperature of 30° - 50°C (86° - 122°F).
 Automatic Transmission 240-3 1
Transmission, removing and installing (6HP19Z xDrive transmission)

Transmission, removing and installin g

(6HP19Z xDriv e transmission )

WARNING —
• Allow engine and transmission to cool down before starting
work on the transmission.

Transmission, removing (xDrive transmission)

— 200 8 - 2009 models (starting production date 03 / 2007): Release
parking loc k manually . Se e 250 Gearshift Linkage.

— Disconnec t negative (-) cable from battery.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given in 001 Warnings and Cautions .

Support engine fro m above with suitable hoist.

Raise and safely support vehicle.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Remov e splas h shield s an d supporting brackets under engin e an d

transmission. Se e 020 Maintenance .

— Remov e front end reinforcement . Discard mounting bolts . Se e 31 0

Front Suspension .

— Remov e complete exhaust system . See 18 0 Exhaus t System .

CAUTION—
• To avoid damaging oxygen sensors, transport and store
exhaust system carefully.

Remove hea t shield s (A , B) .

240-32 Automati c Transmissio n
Transmission, removing and installing (6HP19Z xDrive transmission)

. Separat e oxyge n senso r electrica l connectors (A) . Remove

fasteners (B) and remove retaining plate (C) .

Use BMW special too l 00 9 010 (Tor x E1 8 socket) to remove

aluminium fastene r nex t to electrical connecto r brackets . Discard
fastener.

N52 engine: Workin g a t front exhaust pip e flanges, remov e heat

shield bracke t fasteners (A) and remov e bracke t (B).
 Automatic Transmission 240-3 3
Transmission, removing and installing (6HP19ZxDrive transmission)

N54 engine: Working at front exhaust pipe flanges:

• Detac h electrica l harnes s fro m bracket (A) .
• Remov e wire bracket mountin g fastene r (B) .
• Remove bracket (C) .

N54 engine: Workin g at front exhaust pipe flanges :

• Remov e wire bracket mountin g fastene r (A).
• Remove bracket (B) .

2006 - 2007 models: Working at shift cable connection on lef t side

of transmission:
• Counterhold clamping sleeve (A) and loosen nut (B). Us e a
screwdriver to pry off retainer cli p (C) and pull cable (D) out of
support bracket.
240-34 Automati c Transmissio n
Transmission, removing and installing (6HP19ZxDrive transmission)

2008 - 2009 models : Workin g a t parking loc k cable on left side of

transmission:
• Remov e cable bracke t fastener (A) .
• Disengag e cabl e en d from parking loc k leve r (B).

— Suppor t transmission with transmission jack. Secure transmission to

jack wit h suitable strap.

Working underneath transmissio n a t front of transfer case:

• Remov e front driveshaft mounting bolts (arrows) and tie driveshaft
to one side.
• Remov e mounting bolt s (A) and remove exhaus t bracke t (B).

— Detac h rear driveshaft fro m transfer case:

• Remov e driveshaft center bearing suppor t fasteners . Support
center of driveshaft.
• Unbol t rear driveshaft flex-disc from transfer case flange.
• Lowe r center of driveshaft sufficiently to disengage flex-disc from
transfer case output flange . Ti e driveshaf t t o side. See 260
Driveshafts.

CAUTION—
• To prevent damage to rear driveshaft CV joint, do not allow
driveshaft to hang down unsupported.

Working underneath vehicle at rear of transfer case:

• Remov e transmissio n rear support mounting bolts (A) . Remov e
support.
• Detac h transfer case electrical connectors (B) .
 Automatic Transmission 240-3 5
Transmission, removing and installing (6HP19ZxDrive transmission)

Working at rea r o f transmission housing :

• Twis t mechatronics electrical connector bayonet lock in direction of
curved arrow (A ) to release.
• Carefully pull connecto r off pins (B) .
• Inser t BM W special tool 24 2 390 in place o f mechatronic s
connector t o protect delicate pins.

CAUTION—
• Do not touch pins.

Working at ATF cooler lines (A ) on lef t side of transmission :

• Remov e fluid lin e bracket hold-dow n bolt (B)
• Detach fluid lines from transmission housing.

CAUTION—
• Be prepared to catch dripping fluid.
• Remove and discard fluid line O-ring seals. Be sure to use new
ones when reassembling.

Remove transmission fluid cooler line bracket mounting bol t (arrow)

at engine oil pan .
240-36 Automati c Transmission
Transmission, removing and installing (6HP19ZxDrive transmission)

Rotate engine by hand in direction of rotation using bol t on

crankshaft vibration damper unti l torque plate mounting bolt (arrow)
is visible throug h access hole i n engine bel l housin g flange.
• Loose n and remove bolt.
• Rotat e engin e t o gain access to and remove remaining torqu e
plate bolts .

Use BMW special too l 24 4 16 0 or equivalent to secure torque

converter in bell housin g before you separate transmission from
engine. This prevents torqu e converter from pulling off transmission
input shaft and damaging torqu e converte r oi l seal.
• Inser t tool in bell housing opening an d secure in place lightly using
knurled knob A .
• Twist in knurled knob B and tighten.
• Tighten down knob A.

Remove transmission bell housing bolt s (arrows) . Discar d

aluminum bolts .

Remove transmission by pulling bac k an d down. Lower jack slowly

while watchin g carefull y t o make sur e no lines, hoses or wires
become snagged .

WARNING —
• Be sure the vehicle is properly supported. The removal of the
transmission may upset the balance of the vehicle on the lift.

CAUTION—
• Tilting the engine to remove the transmission can lead to
damage to engine compartment components due to lack of
clearance.
• Do not allow the torque converter to fall off the transmission
input shaft.
 Automatic Transmission 240-3 7
Transmission, removing and installing (6HP19Z xDrive transmission)

Blow out oil cooler lines with low-pressure compressed air and flush
cooler with clean ATF twice.

CAUTION—
• Wear safety glasses when working with compressed air.
• Do not reuse ATF used for flushing.

Inspect engine torque plate and flywheel for cracks or elongate d

holes. Replac e i f necessary.

If torque converter seal i s leaky, or torque converter position o n

transmission inpu t shaft was disturbed durin g removal , replac e
torque converter seal. See Torque converte r oil seal, removin g
and installin g i n this repai r group.

Transmission, installing (xDrive transmission)

, Rotat e engin e until torque plat e bore for mounting bolt (arrow ) i s
accessible through opening i n engine bel l housing .

V—J B510240035 1

^C Chec k tha t bell housing dowel sleeve s (arrows ) ar e in good shap e

and correctl y seated. Replac e if needed.

— Chec k that torque converte r i s seated correctl y i n transmission.

— Rotat e torque converter until threaded mounting hole in converter i s

lined u p with bore i n torque plate.

— Joi n transmission to engine. Make sure torque converter and torqu e

plate bolt bores ar e lined u p by installing one bol t finger-tight.

B510240036
240-38 Automati c Transmissio n
Transmission, removing and installing (6HP19Z xDrive transmission)

Using ne w aluminum bolts , tighten bell housin g fasteners to initial

torque.
• Us e torque angl e too l (BMW special tool s 00 9 120 / 00 9 130 or
equivalent) an d tighten fasteners to final torque angle.
• Install and tighten remaining torque converter bolts .

Tightening torques
Torque converter t o torque plate:
• M 1 0 x 10.9 56 N m (4 1 ft-lb )
Transmission rea r support to body (M8 ) 19Nm(14ft-lb)
Transmission rear support to transmission 19Nm(14ft-lb)
Transmission to engine (M1 2 aluminum) :
• Initial torqu e 25 N m (1 8 ft-lb)
• Torque angle + 130°
Transmission to engine
(M1 Ox 30 aluminum):
• Initia l torque 20 N m (1 5 ft-lb )
• Torque angle + 90 - 1 1 0°
Transmission t o engine
(M10 x 85 aluminum) :
• Initial torque 20 N m (15 ft-lb)
• Torque angle + 180-200 °

Remainder o f installation is reverse o f removal. Remembe r to :

• Instal l new sealing washer s or O-rings on ATF cooler line fittings.
• 2006 - 2007 models : Adjust gearshift mechanism. See
250 Gearshift Linkage .
• 2008 - 2009 models : Adjust parking loc k cable free play. See
250 Gearshift Linkage.
• Driveshaf t tightenin g torques ar e in 260 Driveshafts. To avoid
damaging driveshaf t flex-disc, counterhold flex-dis c bolt heads
while tightening nuts .
• Fill transmission wit h clean ATF. See ATF, draining and filling in
this repair group.
• Use new bolts to reinstall front end reinforcement plate. See
310 Front Suspension .

Tightening torques
Drain plug to plastic sum p 8 N m ( 6 ft-lb)
Fill plug to transmission housing 35 Nm (26 ft-lb)

5 Series automatic transmission fluid (ATF)

BMW recommended flui d BMW part no. 83 22 0 142 516
Shell M- 1 375.4
Fill capacity approx. 9 - 10 liters (9.5 - 10.6 US qt)

CAUTION—
• Do not overfill with ATF. Transmission fill capacity given in
specifications includes torque converter volume.
• ATF expands when transmission is warmed up. Final fluid level
is set with ATF at a temperature o f 30° - 50°C (86" - 122°F).
 Automatic Transmission 240-3 9
Transmission, removing and installing (6HP26Z, V8 engine)

Transmission, removin g and installin g

(6HP26Z, V 8 engine )
Transmission, removin g (V8 engine)
- 200 8 - 2009 model s (startin g production date 03 / 2007): Releas e
parking loc k manually. Se e 250 Gearshift Linkage.

— Disconnec t negative (-) cable from battery .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given in 001 Warnings and Cautions .

Support engine from above wit h suitable hoist.

Raise and safely support vehicle.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splash shield s and supporting brackets under engin e an d

transmission. See 020 Maintenance.

Remove fron t end reinforcement. Discar d mountin g bolts. See

310 Front Suspension .

Remove exhaus t system from catalytic converter s back. Se e

180 Exhaust System .

Remove oxygen sensors and store them safely.

. Remov e hea t shield s (A, B) .

240-40 Automati c Transmission
Transmission, removing and installing (6HP26Z, V8 engine)

Working underneat h righ t side of engine bellhousing:

• Detach plu g (A) from crankshaft sensor .
• Remov e sensor mountin g screw (B) and remove speed sensor.

Working underneat h engin e oil pan :

• Detac h electrical connecto r (arrow ) from oil level sensor.
• Uncli p harnes s from harness support clips .

Working underneat h transmission bell housing, detach harnes s

connector (arrow) from cable loom. Uncli p loo m from transmission
housing and tie to one side.
 Automatic Transmission 240-4 1
Transmission, removing and installing (6HP26Z, V8 engine)

2006 - 2007 models : Workin g at shift cable connectio n o n lef t sid e

of transmission :
• Counterhold clamping sleeve (A ) and loosen nut (B). Us e a
screwdriver to pry of f retaine r clip (C) and pul l cabl e (D ) out of
support bracket .

2008 - 2009 models : Workin g at parking lock cable on left side of

transmission:
• Remov e cable bracke t fastener (A).
• Disengag e cabl e en d from parking loc k leve r (B) .

Support transmission wit h transmission jack. Secure transmission to

jack with suitable strap .

If necessary , remove fastener (arrow) and detac h transmissio n

ground strap .
240-42 Automati c Transmission
Transmission, removing and installing (6HP26Z, V8 engine)

Remove transmission rea r suppor t fastener s (A , B). Remove rea r

support.

Detach rea r driveshaft fro m transmission :

• Remov e driveshaft center bearing support fasteners. Suppor t
center of driveshaft.
• Unbol t rea r driveshaft flex-disc from transmission flange .
• Lowe r center of driveshaft sufficiently to disengage flex-dis c from
transmission outpu t flange . Tie driveshaft t o side usin g stif f wire.
See 260 Driveshafts.

CAUTION—
• To prevent damage to rear driveshaft CV joint, do not allow
driveshaft to hang down unsupported.

Working at rear of transmission housing :

• Twist mechatronics electrical connector bayonet lock in direction of
curved arrow (A) to release .
• Carefull y pull connector of f pins (B) .
• Inser t BM W special too l 24 2 390 in place o f mechatronic s
connector to protect delicate pins.

CAUTION—
• Do not touch pins.

Working at ATF cooler line s (A ) o n lef t side o f transmission:

• Remov e fluid lin e bracket hold-dow n bolt (B)
• Detac h fluid lines from transmission housing .

CAUTION—
• Be prepared to catch dripping fluid.
• Remove and discard fluid line O-ring seals. Be sure to use new
ones when reassembling.
 Automatic Transmission 240-4 3
Transmission, removing and installing (6HP26Z, V8 engine)

^ Rotat e engine by hand in direction of rotation using bolt on

crankshaft vibration damper until torque plate mounting bolt (arrow )
is visible through access hole in engine bell housing flange.
• Loosen and remove bolt.
• Rotat e engine t o gain access to and remove remaining torque
plate bolts .

Use BM W special tool 24 4 160 or equivalent to secure torqu e

converter in bell housing before you separate transmission from
engine. This prevents torque converter from pulling off transmission
input shaft and damaging torque converter oil seal.
• Insert tool in bell housing opening and secure in place lightly using
knurled knob A.
• Twist in knurled knob B and tighten.
• Tighten down knob A.

Remove transmission bell housing bolts (arrows). Discard

aluminum bolts.

Remove transmission b y pulling back and down. Lower jack slowly

while watching carefully to make sure no lines, hoses or wires
become snagged.

WARNING —
• Be sure the vehicle is properly supported. The removal of the
transmission may upset the balance of the vehicle on the lift.

CAUTION—
• Tilting the engine to remove the transmission can lead to
damage to engine compartment components due to lack of
clearance.
• Do not allow the torque converter to fall off the transmission
input shaft.
240-44 Automati c Transmission
Transmission, removing and installing (6HP26Z, V8 engine)

— Blo w out oil cooler lines with low-pressure compressed air and flush
cooler with clean ATF twice.

CAUTIOU-
• Wear safety glasses when working with compressed air.
Do not reuse ATF used for flushing.

Inspect engine torque plate an d flywheel for cracks or elongate d

holes. Replac e if necessary.

If torque converter seal is leaky, or torque converte r position o n

transmission inpu t shaft was disturbed durin g removal, replace
torque converter seal. See Torque converte r oil seal, removing
and installing i n this repair group.

Transmission, installing (V8 engine)

. Rotat e engine until torque plate bore for mounting bol t (arrow ) i s
accessible through openin g i n engine bell housing .

BS10240035

^V Chec k that bell housing dowe l sleeves (arrows ) ar e in good shape

and correctly seated. Replace if needed .

— Chec k that torque converter is seated correctly in transmission.

— Rotat e torque converter until threaded mounting hole in converter is

lined up with bore in torque plate .

— Joi n transmission to engine. Make sure torque converter and torque

plate bolt bores are lined up by installing one bolt finger-tight.
 Automatic Transmission 240-4 5
Transmission, removing and installing (6HP26Z, V8 engine)

Using new aluminum bolts, tighten bell housing fasteners t o initial

torque.
• Us e torque angle tool (BMW specia l tools 00 9 120 / 00 9 130 or
equivalent) an d tighten fastener s to final torque angle.
• Install and tighten remaining torque converte r bolts .

Tightening torques
Torque converte r t o torque plate :
• M10X10.9 56 M m (41 ft-lb)
Transmission rea r support to body (M8) 19 M m (14 ft-lb)
Transmission rea r support to transmission 19 Mm (14 ft-lb)
Transmission to engine (M12 aluminum):
• Initial torqu e 25 Nm (18 ft-lb)
• Torque angl e + 130 °
Transmission to engine
(M10 x 30 aluminum):
• Initial torque 20 Nm (15 ft-lb)
• Torque angl e + 90-110°
Transmission to engine
(M10 x 85 aluminum):
• Initial torque 20 Nm (15 ft-lb)
• Torque angl e + 180-200°

Remainder o f installation i s reverse of removal. Remember to :

• Install new sealing washers or O-rings o n ATF cooler line fittings.
• 2006 - 2007 models : Adjus t gearshift mechanism. Se e
250 Gearshift Linkage .
• 2008 - 2009 models: Adjust parkin g lock cable free play . See
250 Gearshift Linkage.
• Driveshaf t tightening torque s are in 260 Driveshafts. To avoid
damaging driveshaf t flex-disc, counterhold flex-disc bolt head s
while tightening nuts .
• Fill transmission with clean ATF. See ATF, draining and filling in
this repair group .
• Us e new bolts to reinstall front end reinforcement plate . Se e
310 Front Suspension .

Tightening torques
Drain plug to plastic sum p 8 N m ( 6 ft-lb)
Fill plug to transmission housing 35 Nm (26 ft-lb)

5 Series automatic transmission fluid (ATF )

BMW recommended fluid BMW part no. 83 22 0 14 2 516
Shell M-1375. 4
Fill capacity approx. 9 - 1 0 liters (9.5 - 10.6 US qt)

CAUTION—
• Do not overfill with ATF. Transmission fill capacity given in
specifications includes torque converter volume.
• ATF expands when transmission is warmed up. Final fluid level
is set with ATF at a temperature of 30° - 50°C (86° - 122°F).
240-46 Automati c Transmission
Torque converter, removing and installing

TORQUE CONVERTER SERVIC E

Torque converter, removing an d installin g
Remove transmission. Se e Transmission Remova l and
Installation in this repai r group.

Screw BMW special tool s 24 4 000 into torque converter . Pull

converter straight off transmission inpu t shaft.

CAUTION—
• When torque converter is removed, transmission fluid will drain
out. Be prepared to catch dripping fluid.

Remove torque converter slowly an d set down vertically to avoid

spilling additional transmission fluid .

Replace torque converter seal. See Torque converter oil seal,

removing and installing in this repair group.

Reinstall torque converter, taking care to not damage ne w seal.

Lightly oi l converter seal surface and rotate converter during
installation, applying slight pressure until recesses in converter
locate audibly i n ATF pump. Then pres s converter in firmly.

CAUTION—
• If torque converter is not installed correctly, impeller driver in
converter is destroyed when transmission is mated to engine.

Torque converter oil seal,

removing and installin g
ATF leaking from the torque converter seal usually collects at the
bottom of the bell housing and drips out.

Torque converter oil seal leakage i s often caused by a worn or

scored bushing in the torque converter hub. Check bushing when
replacing seal. A damaged bushing rapidl y wears the new seal.

Remove transmission. See Transmission Remova l and

Installation in this repair group.

Carefully slide torque converter off transmission inpu t shaft. Be

prepared to catch ATF as it flows out of torque converter. See
Torque converter, removing and installing in this repai r group.

Check converter hub bushing surface (arrow) fo r scoring or wear,

• Remove sharp edges and burrs with fine emery cloth .
• If hub is deeply scored , replace torqu e converter .
 Automatic Transmission 240-4 7
Torque converter oil seal, removing and installing

Use small screwdriver t o pry out seal retaining circlip (if equipped )
(arrow) from ATF pump a t front of transmission case .

Attach BMW special too l 24 2 353 or 24 2 354 (dependin g o n

transmission) to transmission input shaft (A) .

Screw BM W special too l 24 2 351 into seal. Us e BMW specia l too l

24 2 352 to gradually dra w out seal.

24 2 351

24 2 352
240-48 Automati c Transmission
Torque plate and flywheel, removing and installing

^V Coa t sealing lip s of new seal with transmission fluid . Use BMW
special tool 24 2 360 or 24 2 400 (dependin g o n transmission) an d
soft-faced hammer to drive seal (A) int o transmission as far as it will
go.

— Reinstal l retainin g circlip (if equipped) .

— Reinstal l torqu e converter , takin g care to not damage new seal.

Lightly oi l converter seal surface and rotate converter durin g
installation, applyin g slight pressure unti l recesse s i n converter
locate audibly i n ATF pump. Then pres s converter in firmly.

CAUTION—
• It torque converter is not installed correctly, impeller driver in
converter is destroyed when transmission is mated to engine.

Torque plate and flywheel,

removing and installing
Crankshaft rear main (flywheel) seal replacemen t i s covered in
119 Lubrication System.

Remove transmission. Se e Transmission, removin g an d

installing i n this repair group.

Use BMW special tool 11 9 260 or equivalent to lock flywheel .

Loosen an d remove flywhee l bolt s (arrows) an d discard .

— Remov e torque plat e and flywheel.

— Clea n bolt threads in crankshaft.

 Automatic Transmission 240-4 9
Torque plate and flywheel, removing and installing

When installing :
• Not e that flywhee l is located with dowel sleeve (arrow) .
• Mak e sur e torque converter mounting hole s in torque plat e an d
flywheel lin e up.
• Us e new flywheel bolts.

Tightening torque
Flywheel an d torque plat e to crankshaft
(M12 x 1.5) (use new bolts ) 130 Nm (96ft-lb )

— Reinstal l transmission .
 250 Gearshif t Linkage

GENERAL 250- 1 AUTOMATIC TRANSMISSIO N GEARSHIFT . . . 250- 7

Neutral safety switch function 250- 1 Steptronic gearshift assembly (2004 - 2007) . . 250- 7
Gearshift knob , removin g 250- 2 Gearshift mechanism , adjusting (2004 - 2007) 250-7
Caution 250- 2 Automatic shiftlock , checking functio n
(2004 - 2007) . 250- 8
TROUBLESHOOTING 250- 2 Automatic shiftlock, releasing manually
Shift leve r blocke d 250- 2 (2004 - 2007) . 250- 9
Transmission does no t shift to P 250- 3 Ignition interlock, checkin g functio n
MANUAL TRANSMISSION GEARSHIF T 250- 4 (2004 - 2006) . 250- 9
Manual gearshif t linkage 250- 4 Gear shift switch (GWS) (2008 - 2009) 250-10
Gearshift lever , removing and installing Parking lock cable bracket , adjusting
(manual transmission ) 250- 4 (2007 - 2008) 250-10
Parking lock , releasing manuall y
SMG GEARSHIF T 250- 7 (2008 - 2009) 250-10
SMG gearshift assembly 250- 7

GENERAL
This repair group covers transmission gearshift for manual,
sequential manual gearbox (SMG ) an d automatic transmission
models.

See also:
• 180 Exhaust System
• 260 Driveshafts
• 310 Front Suspension for front end reinforcement plate

Neutral safety switch function

In models with automatic transmission, starter operation is
prevented unless the gear position is (P)ARK or (N)EUTRAL.
250-2 Gearshif t Linkage
Gearshift knob, removing

Gearshift knob, removing

This procedur e applies to the following:
• Manual transmissio n model s
• Automatic model s to 2007

Make sur e the engine is OFF when removin g gearshift knob .

Pull gearshift knob straigh t u p (arrow) to remove . I t may require up

to 90 Ibs. of force to do this.

CAUTION—
• Automatic transmissions for2008 - 2009 models (starting with
03 / 2007 production) are equipped with gear shift switch
(GWS) instead of a shift lever. The procedure given here for
gearshift knob removal does not apply.
• Some versions of shift boot and knob are one piece. Release
boot from console before removing knob.
• To prevent damage to shift knob locating tabs, do not twist while
removing.

Caution

CAUTION—
• When removing interior trim clips, avoid damaging trim pieces
by using a plastic prying tool or a screwdriver with the tip
wrapped with masking tape.

TROUBLESHOOTING
Shift lever blocked
Automatic transmission: If shift lever (A) canno t be moved to P or is
otherwise blocke d from moving, check to see if coins (B) from coin
holder ar e lodged underneath shifter Bowde n cabl e (C ) pivots .
 Gearshift Linkag e 250- 3
Transmission does not shift to P

Transmission does no t shift to P

2008 - 2009 model s (startin g production dat e 0 3 / 2007) wit h
automatic transmission: Transmission parking lock is engaged using
a dedicated cable . Parkin g lock is triggered when P button is
pressed on shift lever.

If P button is pressed bu t transmission does no t shift into parkin g

lock (BM W faul t code 507B) , inspect positio n of parking loc k cable
end i n parking lock leve r (lef t side of transmission, underneath
vehicle):
• I f cable end button is centered in lever hook (dimension s A and B
are equal), parkin g lock lever is OK.
• I f cable en d button i s offset (dimensio n A an d B are unequal) ,
parking lock leve r is bent.
250-4 Gearshif t Linkage
Manual gearshift linkage

MANUAL TRANSMISSIO N GEARSHIF T

Manual gearshift linkag e
1. Rubbe r boot
2. Shif t lever bearing
3. MSnu t
4. Shif t arm support bearing
5. Loc k pin
6. Bushin g
7. Transmissio n housin g
8. Shif t arm
9. Bushin g
10. Lock ring
H.Circlip
6 58 9 1 0! 1 2
12. Shifter coupling
13. Selector rod
14. Shift lever
15. Dowel

BX06250001

Gearshift lever , removing an d installin g

(manual transmission)
Remove shift boo t and shift knob. Se e Gearshif t knob, removing
in this repair group.

CAUTION—
• Some versions of shift boot and knob are one piece. Re/ease
boot from console before removing knob.
• To prevent damage to locating tabs on shift knob, do not twist
while removing.

Remove sound insulatio n at base o f shift lever.

Raise and safely support vehicle.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splash shield under transmission. Se e 020 Maintenance.

Remove complete exhaust system. See 180 Exhaust System.

CAUTION—
• To avoid damaging oxygen sensors, transport and store
exhaust system carefully.
 Gearshift Linkag e 250- 5
Gearshift lever, removing and installing (manual transmission)

^V Remov e hea t shields (A, B).

— Suppor t transmissio n wit h a suitable jack. Remov e transmissio n

rear suppor t and lower transmissio n slightly to gain access to
gearshift lever.

Working above transmission , disconnec t selector rod :

• Pul l of f selector ro d retaining circlip (arrow) an d discard .
• Disengag e selecto r rod from shifter coupling to.

^. Releas e shift lever bearing from below using BMW special spanne r
25 1 120. Turn tool 90° ( % turn) counterclockwise.
• Pus h shif t leve r and bearing u p to remove from shift arm .

— Lowe r vehicle. Working from inside passenger compartment , pul l up

on shift leve r to remov e i t together wit h inne r rubbe r boo t an d shift
lever bearing .

— Clea n ol d grease fro m shif t leve r ball and mounting ring. Als o clea n
shift arm bowl. Lubricat e with molybdenum disulfid e grease.

— Inser t shif t leve r togethe r with inner boot an d bearing into shift arm .
250-6 Gearshif t Linkag e
Gearshift lever, removing and installing (manual transmission)

Pull inne r rubbe r boo t ove r shift arm bow l (arrows) to seal bas e of
shift lever . Install rubber boo t with arrow pointing towar d Iront of
vehicle.

When installin g shift lever bearing :

• Align lockin g tabs with slots (arrows) in shift ar m bowl .
• Mak e sure arrow on shift leve r bearing points t o front of vehicle.
• Pres s clown unti l bearing snap s int o place .

When reinstallin g selecto r rod, be sure to us e new shift ro d circlip

with locking tang (arrow).

B510250002
 Gearshift Linkage 250- 7
SMG gearshift assembly

SMG GEARSHIF T
SMG gearshift assembly
1. Shif t leve r knob
2. Shif t lever boot
3. Shiftloc k magneti c solenoid
4. M 6 x 35 mm bol t
5. Gearshif t housin g
6. Sealin g frame
7. Blin d rivet

AUTOMATIC TRANSMISSION GEARSHIFT

Steptronic gearshift assembly (2004 - 2007)
1. Clampin g bolt
2. Washe r
3. Transmissio n shift arm on side of
transmission
4. M 8 self-locking nut
5. Bushin g
6. Suppor t bracket
7. M6bol t
8. Steptroni c shif t mechanism
9. M 6 Torx screw
10. Cage nut
11. M8 self-locking nu t

BX06250002,

Gearshift mechanism, adjusting (2004 - 2007 )

Automatic gearshift mechanis m varies wit h model . Adjustment i s
similar.

Position gearshif t lever in P(ARK) .

Raise vehicle to gain acces s to shift linkage .

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose.
250-8 Gearshif t Linkag e
Automatic shiftlock, checking function (2004 - 2007)

Working at transmission selector lever a t side of transmission :

• Counterhold cable clamping bushing (A).
• Loosen cabl e clampin g nu t (B) .
• Pus h transmission shift arm forward toward engine (curve d
arrow) (PAR K position).
• Pus h shifter cable en d backward awa y from engine (arrow) .
Release pressure on cable .
• Tighten clampin g nut .

CAUTION—
• Do not overtighten the nut so that it twists the cable.

Tightening torque
Shift cabl e clampin g nu t 10 Mm (7ft-lb )

Automatic shiftlock , checkin g functio n

(2004 - 2007)
The automatic shiftlock uses an electric solenoid to lock the selector
lever in P(ARK) or N(EUTRAL). Depressin g th e foot brake with the
ignition O N energizes the solenoid, allowing th e lever to be moved
into R(EVERSE) or D(RIVE). Th e solenoid is energized only whe n
engine speed is below 2,50 0 rpm and vehicle speed is below 5 kph
(3 mph). The solenoid is mounted in the righ t sid e of the selecto r
lever housing .

Automatic shiftlock prevents drive gear selection until brake pedal is

depressed.
• With engine running and vehicle stopped , plac e selector lever in P.
• Without depressing brake pedal, check that selector leve r is locked
in P.
• Depres s brak e peda l firmly an d listen to solenoid clicking audibly.
• Check that selecto r leve r can no w be move d ou t of P.

NOTE—
• Perform the next test in an open area with the parking brake ON
and with extreme caution.

With selecto r leve r i n P and brake peda l depressed, rais e engine

above 2,500 rpm . Chec k that selector lever cannot be moved out of
P.

If any faults are found :

• Check electrical operation of shiftlock solenoi d
• Check for wiring faults to or from transmission control module
(TCM). See ECL Electrical Componen t Location s an d ELE
Electrical Wiring Diagrams .

NOTE—
• The solenoid is controlled via the transmission control module
(TCM), using brake pedal position, engine speed, and road speed
as control/ing inputs.
 Gearshift Linkag e 250- 9
Automatic shiftlock, releasing manually (2004 - 2007)

Automatic shiftlock, releasing manuall y

(2004 - 2007)
Normally, the automatic transmissio n shift lever can only b e move d
out of P if ignition is ON (o r engine running ) and brak e peda l
depressed. I n case of power failure (such as dead battery) , release
move gearshift manually and shift to N before moving vehicl e o r
working.

CAUTION—
• Attempting to move vehicle without taking transmission out ofP
may cause transmission damage.

— Engag e parkin g brake so that vehicle cannot roll .

— Uncli p an d pul l up shift lever bezel.

^ Workin g at shift lever:

• Switc h ignition O N to disengage ignitio n interlock pawl (curve d
arrow).
• Usin g thi n screwdriver, depress shiftlock solenoid plunge r an d
move shifter to N.

Ignition interlock , checkin g function

(2004 - 2006)
"^C Ignitio n interlock uses a cable between ignition switch and selecto r
lever to loc k lever in P(ARK ) position when ignition key is OFF o r
removed. This feature also prevent s key from being remove d from
ignition loc k unless selecto r leve r is in P.

— Shif t selector lever to P and switc h ignition OFF.

— Remov e ignition key. Check that selector lever cannot b e shifted out
ofP

— Switc h ignition ON and depress brake pedal. Chec k tha t selecto r

lever move s freely from gear to gear.

— Wit h selector lever in a gear positio n other than P , attempt t o turn

key to OFF position an d remove . Key should no t go int o OF F
position.

— I f any fault s are found :

• Chec k interloc k cable for kinks.
• Chec k cable attachment point s for damage o r faults.

NOTE—
• Make sure ignition key can only be removed with selector lever in
P(ARK).
• Do not kink shift interlock cable.
• Ignition interlock cable replacement i s covered in 320 Steerin g
and Wheel Alignment .
250-10 Gearshif t Linkage
Gear shift switch (GWS) (2008 - 2009)

Gear shif t switch (GWS ) (200 8 - 2009)

. I n models buil t from 03 / 2007 (2008 model year) , the shif t lever is
configured as a control modul e (referred to as gear shif t switc h or
GWS). Transmission gea r rang e selectio n i n these models i s
actuated electronically instea d o f via shif t cable.
1. Shif t leve r handl e
2. M 6 x 18 mm screw
3. Gea r shift switch (GWS ) housin g
4. Space r pi n
5. SPOR T switch

Parking loc k cable bracket , adjustin g

(2007 - 2008 )
On 2008 - 2009 model s (startin g productio n dat e 0 3 / 2007),
transmission parkin g lock i s engaged usin g a dedicated cable . To
adjust cable correctly:

Loosen cabl e bracke t fastener (k) an d slide bracke t to achieve

correct free play.

Parking lock cable end free play

GapB 1 m m ( 0 04 in)

See also Transmission does no t shift to P in this repair group.

Parking lock , releasing manuall y (200 8 - 2009 )

Normally, the automatic transmission shif t leve r can only be moved
out of P if ignition i s ON (o r engine running) an d brake peda l
depressed. I n case of power failure (suc h as dead battery), release
transmission parkin g lock before movin g vehicl e or working on
transmission.

CAUTION—
• Attempting to move vehicle without re/easing parking lock may
cause transmission damage.

Engage parkin g brake so that vehicle canno t roll .

Unclip and pull up shift lever bezel .

 Gearshift Linkag e 250-1 1
Parking lock, releasing manually (2008 - 2009)

'A. Inser t screwdriver into opening (A) . Pull screwdriver towar d rea r
until i t is heard to engage (B) . Leav e screwdriver inserted in
opening. Thi s release s transmission park lock .

— T o relock parkin g lock , pull out screwdriver.

 260-1

260 Driveshaft s

GENERAL 260- 1 Rear driveshaft, removin g 260- 6

Driveshafts overview 260- 1 Rear driveshaft, inspecting 260- 7
Cautions 260- 2 Rear driveshaft, installing 260- 8
Flex-disc, replacing 260- 9
TROUBLESHOOTING 260- 2
Center bearing assembly, replacing 260-1 0
Driveshaft problem s 260- 2
Front centering sleeve, replacing 260-1 1
FRONT DRIVESHAFT SERVICE 260- 4 Constant velocity (CV) joint, replacing 260-1 1
Front driveshaft, removing and installing 260- 4
TABLE
REAR DRIVESHAF T SERVIC E 260- 5 a. Rear driveshaft problems and causes 250-3
Rear driveshaft components 260- 5

GENERAL
This repair group covers repai r and replacement of front an d rea r
driveshafts and driveshaft components.

See also:
• 270 Transfer cas e
• 310 Front Suspensio n fo r front end component s
• 311 Fron t Axl e Differentia l for front drive axle repair s
• 331 Rea r Axle Differential for rear drive axle repair s

Driveshafts overview
xDrive model s are equipped with a transfer cas e bolted to the rea r
xDrive 1 2 345 6 78 of the transmission, with front and rear driveshaft s transferrin g
driveshafts power to front and rear differentials. Rear-drive models are
equipped with a single driveshaft attached directly to the rea r of the
transmission.
1. xDriv e transfer case
2. Flex-dis c
3. Rea r driveshaft
4. Cras h element (aluminu m driveshaf t only )
5. Cente r bearin g and moun t
6. Cente r universa l joint
7. C V joint
8. Rea r differentia l
9. Fron t differentia l
10. Universa l joint
11. Fron t driveshaf t

Front driveshaf t repair s are limited to replacement of the complet e

driveshaft. Rear driveshaft repairs consist of replacement of the flex-
disc, C V joint, and center mount an d bearing. I f the rea r driveshaft
universal joint i s defective, replac e the complete driveshaft .
260-2 Driveshaft s
Cautions

6-cylinder vehicles ar e equipped with aluminiu m o r hybrid

(aluminum-steel) rea r driveshafts, whereas V8 model rear
driveshafts are steel. Driveshaf t are mounted wit h ZN S (shiny zinc-
coated) fasteners. Be sure to replac e ZNS fasteners with same .

Cautions

CAUTION—
• Be sure the wheels are off the ground before removing the
driveshaft. Set the parking brake before removing the
driveshaft.
• Use only ZNS (zinc-coated) fasteners to mount driveshafts.
• ZNS fasteners are designed to be used only once. Replace
during reassembly.
• Do not move vehicle using engine power once a driveshaft is
removed.
• Driveshafts are balanced to close tolerances. Whenever a
driveshaft is removed or disassembled, mark mounting flanges
and driveshaft sections with paint before proceeding with work.
This ensures that the driveshaft can be reassembled and
installed in exactly the original orientation.
• Do not allow rear driveshaft to hang from flex-joint or rear CV
joint. The weight of the driveshaft may damage rubber joints or
boots.

TROUBLESHOOTING
Driveshaft problems
Sources of driveline vibrations and noise may be difficult to pinpoint.
Engine, transmission, front or rear axl e or wheel vibration s may be
transmitted through the driveshafts to the car body.

Noises in the interio r of vehicle may b e caused by:

• Differential problem s
• Fault y whee l bearing s
• Damaged drive axle(s )
• Worn o r improperly inflated tires

Driveshaft nois e or vibrations are usually caused b y worn or

damaged components.

To inspect o r remov e rear driveshaft, remov e exhaust system an d

exhaust heat shield . Se e 180 Exhaust System .
Center bearin g
rubber Check driveshaf t universa l joint for play. Pul l and twist driveshaft

*SK
"*V'r' '•'•• ' while watchin g universa l joint. Specified tolerance for p\a\ \ very
small, so almost any noticeable play indicates a problem.
SSJKSSSSSSB^^,

Universal joint play

Maximum allowabl e 0.15 m m (0.006 in )
Universal join t

— Chec k fastener torque at flange connections .

— Chec k rear driveshaf t flex-dis c an d center bearing rubber for

deterioration or tearing.
 Driveshafts 260- 3
Driveshaft problems

Check driveshaft for broken or missing balanc e weights. Weights

are welded tabs o n driveshaft tubes.

Use paint t o matchmark fron t and rear flanges. Remov e driveshaft.

See Rea r driveshaft, removin g i n this repair group.

Check rea r driveshaft universal joint for wear or binding. I f it is

difficult to move or binds, replac e driveshaft.

Check rea r driveshaft centering guide at output flange for damage

or misalignment .

Check runout at transmission or transfer case output flange an d

output shaft , and at rear differential input flange.

Driveshaft flange wear limits

Runout a t transfer case output flange
(max. allowable) :
• Axia l play 0 10 mm (0 004 in)
• Radia l play 0 07 mm (0 003 in)
Rear differential input flange radia l play 0 07 mm (0 003 in)
(measured a t driveshaft center lip )

Check bolt bores at transmission or transfer case output flange an d

front and rear differential input flange s for wear and elongation .

Spin rear driveshaft center bearing and check for smooth operatio n
without play.

If inspection reveals nothing wrong with driveshaft, it may need to be

rebalanced. This can be done by a speciality driveshaft repair shop .

Sometimes a minor rea r driveshaft vibration can b e corrected by

disconnecting at front flange and repositionin g i t 120° or 240° i n
relation to differential input flange.

Table a lists symptoms o f rear driveshaft problems an d their

probable causes. Mos t of the repai r information is contained within
this repair group. There are references to other repair groups, where
applicable.

Table a. Rear driveshaf t problem s and causes

Symptom Probable cause Corrective action
Vibration when starting off Center bearin g rubber deteriorated. Inspect center bearin g and rubber. Replac e if necessary.
(forward or reverse). See Center bearing assembly, replacing in this repair
group.
Flex-disc damaged o r worn. Inspect flex-disc. Replace if necessary. See Flex-disc,
replacing in this repai r group .
Engine o r transmission mounts faulty . Inspect engine and transmission mounts . Align or
replace, i f necessary .
Front centering sleeve worn, or driveshaft Check front centering sleeve and replac e i f necessary.
mounting flanges out of round. See Front centering sleeve, replacing in this repair
group. Also check runou t of driveshaft flanges.
Universal joint worn or seized. Check universa l joint play and movement. Replac e
driveshaft i f necessary.
260-4 Driveshaft s
Front driveshaft, removing and installing

Table a. Rear driveshaf t problems and causes (continued)

Symptom Probable cause Corrective action
Noise during o n / off Differential components worn or damage d Remove differential and repair. See 311 Front Axl e
throttle o r when engagin g (excessive pinion-to-ring-geiar clearance). Differential or 331 Rear Axle Differential.
clutch.
Drive axle or CV joint faulty. Inspect drive axles and C V joints. Repai r or replace as
necessary. See 31 1 Front Axle Differential or
331 Rear Axl e Differential.
Vibration at 25 to 30 mph Front centerin g sleev e worn, or driveshaft Check front centering sleeve an d replac e i f necessary.
(40to50kph). mounting flange s out of round or damaged. See Front centering sleeve, replacing in this repai r
group. Als o check runou t o f driveshaft flanges.
Universal join t worn or seized . Check universa l joint pla y an d movement . Replace
driveshaft i f necessary.
Flex-disc damaged or worn. Inspect flex-disc. Replac e if necessary. See Flex-disc,
replacing in this repai r group .
Center bearin g rubbe r deteriorated. Inspect center bearing. Replac e if necessary. See Center
bearing assembly, replacing in this repai r group .
Vibration, audible rumbl e Front centerin g sleeve worn, or driveshaft Check front centering sleeve an d replac e if necessary.
over 35 mph (6 0 kph) . mounting flange s out of round or damaged . See Front centering sleeve, replacing in this repair
group. Als o check runou t o f driveshaft flanges.
Mounting flang e bolts loos e or holes worn. Remove rear driveshaft and check input and output
flange bolt s and holes. Replace if necessary .
Rear driveshaf t unbalanced . Check driveshaft fo r loose or missing balance weights.
Have driveshaft rebalanced o r replac e if necessary.
Universal joint worn or seized. Check universa l joint pla y and movement . Replace rear
driveshaft i f necessary.
Rear driveshaft center bearing faulty. Replace center bearing. See Center bearing assembly,
replacing in this repai r group .
Rear differentia l rubbe r bushing(s) faulty. Inspect differential rubbe r bushing(s). Replace as
necessary. See 33 Rear Axl e Differential.

FRONT DRIVESHAF T SERVIC E

If detecting vibratio n o r noise from the front driveshaft, check front
universal joints for play. Pull and twis t driveshaft while watching
universal joint. Specified tolerance for pla y i s very small, so almost
any noticeable play indicates a problem .

Universal joint play

Maximum allowable 0.15 mm (0.006 in )

Front driveshaft, removing and installing

Raise car and support safely .

WARNING —
• Make sure the car is stable and we/I supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

— Remov e splas h shields underneath engine and transmission.

 Driveshafts 260- 5
Rear driveshaft components

— Remov e front end reinforcemen t plate. Discar d fasteners.

— I f driveshaft is to be reinstalled, matc h mark mounting flange s wit h

paint to preserve original orientation.

"^ Fron t driveshaft components:

1. Transfe r case
2. M 8 ZNS bolt (replace with new)
• Tighten to 20 Nm (15 ft-lb) + additional 45 C
3. Driveshaf t
4. Universa l join t

— Workin g at front differential inpu t flange, remove universal join t

bolts.

— Workin g at transfer case flange, remove universa l joint bolts an d

remove driveshaft.
B309260015]
— Installatio n is reverse of removal. Remembe r to:
• Observ e marks made previously (i f applicable).
• Replac e ZNS fasteners with new.

Tightening torque
Front driveshaft to transfer case or differential 20 Nm (15 ft-lb)
(use ne w M8 ZNS bolts) + additional 45°

REAR DRIVESHAF T SERVICE

Rear driveshaft components
1. Centerin g sleev e
2. Flex-dis c
3. ZN S bolt
• Replace with new
• Bolt size and torque values vary. See
torque table,
4. Fron t section
5. Bearin g mount
6. M 8 center bearing mounting bol t
•Tightento21 Nm (16ft-lb)
7. Universa l joint
8. Rea r section
9. M 1 O x 52 mm ZNS bolt
• Replace with new
• Torque to 20 Nm (15 ft-lb) + add'l 90°
10. Hose clamp
11. Reinforcement
9101112 1 31 4|
_B510260002J 12. Metal gasket
13.CVjoint
14. End cover
260-6 Driveshaft s
Rear driveshaft, removing

Rear driveshaft, removing

Raise vehicle an d support safely .

WARNING —
• Make sure the vehicle is stable and well supported at a/1 times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove exhaust system and exhaust heat shields. See

180 Exhaust System .

WARNING—
• Make sure exhaust system is fully cooled off before removing.

N54 engine: Suppor t transmissio n with transmission jack , the n

remove transmission rear support .

Match mar k driveshaft mountin g flanges an d sections wit h paint to

preserve origina l orientation .

Working at driveshaft front flex-disc, counterhold bolt heads

(arrows) and remove nut s at transmission or transfer cas e outpu t
flange. Discar d old fasteners.

CAUTION—
• To avoid damaging flex-disc rubber, be sure to hold bolts
stationary while loosening nuts.

— Han g driveshaft front section from body usin g stiff wire.

Working at rear differential flange, loosen and remove rear

driveshaft CV joint fasteners (arrows) .
 Driveshafts 260- 7
Rear driveshaft, inspecting

k, Us e screwdriver to pry C V joint off differential flange . Discard ol d

fasteners.

— Han g driveshaf t rea r section from body usin g stiff wire.

Remove driveshaft center bearing support mounting nuts (arrows) .

Lower driveshaft, releasin g fron t and rear sections fro m stiff wire.

Rear driveshaft, inspectin g

Check driveshaft universal joint, center bearing, CV joint and flex-
disc for defects. See Troubleshooting i n this repair group. Replac e
components a s needed .

Check driveshaft fron t centering sleev e for damage. Replac e if

Transmission Flex-disc necessary. See Front centering sleeve , replacin g i n this repai r
or transfer cas e group.

B510260008
260-8 Driveshaft s
Rear driveshaft, installing

Aluminum driveshaft : Check dimension of crash element ahead of

center bearing carrier. Replace driveshaft if crash element is
deformed shorter than specification .

Driveshaft crash element specificatio n

Dimension A minimum approx. 10 0 mm (4 in)

BS10260005|

Rear driveshaft, installing

— Appl y thin coat of molybdenum disulfide grease (Molykote Longterm
2 Plus® or equivalent) t o centering sleeve .

— Ben d driveshaft slightly at center universal joint to install.

— Alig n matchmarks on driveshaft to matchmarks on front and rear

flanges.
• Rear CV joint: Using new ZNS fasteners, alternately tighten two
opposite nuts to draw joint evenly into flange. Once seated, tighten
down remaining nuts.
• Fron t flex-disc: Attach to transmission or transfer case output
flange using new fasteners.

CAUTION—
• To avoid damaging flex-disc rubber, be sure to hold bolts
stationary while tightening nuts.

Tightening torques
Rear driveshaft CV joint to differential: 20 Nm (15ft-lb)
Replace M10 x 52 mm 10.9 grade ZNS + additional 90 °
fasteners with new
Rear driveshaft flex-disc to transfer case: 20Nm(15ft-lb)
Replace M10 x 47 mm 10.9 grade ZNS + additional 90°
fasteners with new
Rear driveshaft flex-disc to transmission: 55 Nm (41 ft-lb)
Replace M12 10.9 grade ZNS fasteners with + additional 90°
new
 Driveshafts 260- 9
Flex-disc, replacing

*\. D o not allow rea r driveshaft to hang from flex-joint or rear CV joint.
Driveshaft weight may damage rubber joints or boots (arrow) .

— Reinstal l cente r bearin g suppor t fasteners .

Tightening torque
Driveshaft center bearin g suppor t to body 21 Nm (15ft-lb )

— Instal l heat shields. Instal l exhaust system. See 180 Exhaus t

System.

— Roa d test vehicle t o check fo r noise or vibration.

Flex-disc, replacin g
Raise vehicle an d support safely.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove exhaust system and exhaust heat shields. See

180 Exhaust System .

WARNING —
• Make sure exhaust system is fully cooled off before removing.

Support transmissio n wit h transmission jack , then remov e

transmission rea r support.

Check flex-disc for cracks, tears, missing pieces or distortion. Check

for worn bolt holes i n flange.

Mark driveshaft mountin g flanges an d sections wit h pain t to

preserve original orientation.

Counterhold flex-disc bolt heads (arrows) an d remove nuts at

transmission o r transfer cas e output flange. Discar d old fasteners.

CAUTION—
• To avoid damaging flex-disc rubber, be sure to hold bolts
stationary while loosening nuts.

Remove driveshaft center bearing support fasteners. Support cente r

of driveshaft .

CAUTION—
• To avoid damaging rear driveshaft CV joint, do not allow
driveshaft to hang down unsupported.

Lower center of driveshaft sufficientl y to disengage flex-dis c fro m

transmission or transfer case flange. Tie driveshaft to side .
260-10 Driveshaft s
Center bearing assembly, replacing

— Remov e fasteners and detach flex-disc from driveshaft.

— Befor e reinstalling flex-disc , check driveshaf t front centering sleev e

for damage. Replace if necessary. See Fron t centering sleeve,
replacing i n this repair group .

— Appl y thin coat of molybdenum disulfid e grease (Molykote Longterm

2 Plus® or equivalent) to centering sleeve.

^C Reinstal l flex-disc using new ZNS fasteners.

• Molded arrow s (arrows) on coupling point toward flange arms.
• Counterhold bolts while tightening nuts .

Tightening torques
Rear driveshaft flex-disc to transfer case: 20Nm(15ft-lb)
Replace M10 x 47 mm 10.9 grade ZN S + additional 90°
fasteners with new
Rear driveshaft flex-disc to transmission: 55 Nm (41 ft-lb)
Replace M12 10.9 grade ZNS fasteners with + additional 90°
new
I

Center bearing assembly, replacing

The rear driveshaft center bearing assembly consist s o f a grooved
ball bearing in a rubber mount. The bearing assembly is pressed on
the driveshaft.

Remove driveshaft. Se e Rear driveshaft, removin g i n this repai r

group.

Use paint to matchmark front and rear driveshaft sections before

separating.

CAUTION—
• Do not scratch or punch marks in driveshaft metal.

Remove bolt (arrow) securing front and rear halves of driveshaft

and pull driveshaft apart.

Remove shim and dust shield (arrows), where fitted.

Use puller to remove center bearing assembl y fro m driveshaft.

On installation, drive new center bearing firmly to stop. Reassemble

driveshaft using matchmark s mad e prior to disassembly .

Clean threads and install bolt securing driveshaft halves. Us e thread

locking compound Loctite ® or equivalent .

Frightening torque
Driveshaft front half to rea r half 97 Nm (72 ft-lb)
(use thread locking compound)

Reinstall driveshaft. See Rear driveshaft, installing in this repair

group.
 Driveshafts 260-1 1
Front centering sleeve, replacing

Front centering sleeve , replacin g

Transmission /Flex-dis c
or transfer case / ^. The front centering sleev e center s the rear driveshaft in relation to
transmission o r transfer case flange. The guide is press-fit into a
Centering cavity in the flex-disc and slides on a dowel on the output flange.
dowel
Driveshaft No specifications ar e given for wear of the guide. Check to mak e
sure that the sleeve fits snugly over the dowel.

— Remov e rear driveshaft. See Rea r driveshaft, removing in this

repair group .

— Pac k cavity behind centerin g guide with heavy grease until grease
is flush with bottom edg e of guide.

— Inser t 14 mm (approximately VK, in) diameter mandrel (meta l rod)

into guide. Strik e mandrel wit h hammer to force centering guide out.
Make sure mandrel fit s snugly i n centering guide so that greas e
cannot escape around sides of mandrel.

— Remov e old grease from driveshaft, lubricate ne w centering guid e

with molybdenum disulfide grease (Molykote Longterm 2 Plus® or
equivalent) an d drive through cente r of flex-disc into driveshaft .

^. When installing ne w driveshaft centering guide, be sure sealin g lip

of guide faces outward. Driv e guide into driveshaft to a protrusion
depth of 4 - 6 mm (0.16 - 0.24 in).

— Appl y thin coat of molybdenum disulfid e grease (Molykote Longter m

2 Plus® or equivalent) to centering sleeve.

— Instal l driveshaft. Se e Rear driveshaft, installing in this repai r

group.

Constant velocity (CV) joint, replacin g

The CV joint at the rear of the rear driveshaft is available from BMW
as a separate part.

— Remov e rea r driveshaft. Se e Rear driveshaft, removin g i n this

repair group.

^C Us e screwdriver to pry end cover off CV joint. Discar d cover .

260-12 Driveshaft s
Constant velocity (CV) joint, replacing

^ Clea n grease off CV joint. Remov e retaining circlip (arrow) from CV

joint end of driveshaft. Discar d cli p

— Driv e out bolts from CV joint.

"X Remov e CV joint from driveshaft :

• Pry back protective boo t (A).
• Using BMW special tool 26 1 070 or 26 1 110 on inner race (B),
press or pull joint off shaft.

— Chec k protective boo t for damage. Replac e i f necessary.

— Instal l new C V joint:

• Working from both sides of joint, injec t approximatel y 8 0 grams of
CV joint grease into joint.
• Instal l ne w sealing gasket (C) on joint face that mates with
protective boot . Seal fits in groove on outer rac e of joint.
• Clean grease off driveshaft and mating splines on joint.
• Apply Loctite® 648 to driveshaft splines.
• Press new CV joint o n shaft as far as it will go.

CAUTION—
• Only press on inner CV joint race.

Install new retaining circlip to end of driveshaft. Install new end cover
with new sealing gasket.

Insert ne w CV joint mounting bolts. B e sure to reus e reinforcin g

washers.

Install driveshaft . See Rear driveshaft, installing in this repair

group.
 270-1

270 Transfe r Cas e

GENERAL 260-1 TRANSFE R CAS E SERVIC E 260- 5

xDrive overview. 260-1 Transfe r case fluid service 260- 5
Transfer case, removing and installing 260- 6

GENERAL
This repai r group cover s the all-wheel driv e (xDrive ) transfer case.
Internal transfer case repair is not covered. Special press tools an d
procedures are required to disassemble and service the interna l
geartrain.

See also:
• 180 Exhaust System
• 200 Transmission-Genera l
• 260 Driveshafts

xDrive overvie w
The BMW all-wheel drive (xDrive ) control system is integrated wit h
dynamic stability control (DSC) .

The xDrive transfer case, bolte d to the rear of the transmission,

directs powe r fro m the transmission to both the front and rea r
differentials via driveshafts. The transfer case is permanentl y
engaged to drive all four wheels all of the time.

1. xDriv e transfer case

• Active torque control (ATC) 300
2. Fron t differential
3. Fron t driveshaft
4. Transmissio n
5. Rea r driveshaft
: ;
6. Rea r differential
270-2 Transfe r Cas e
xDrive overview

Transfer cas e (ATC 300 )

1 2 3 4 5 6 7 89 1 0
The active torque control (ATC 300) transfe r case uses an L-shaped
series of spur gears t o transfer powe r to the front driveshaft .
1. Fron t driveshaft
2. Fron t output flang e
3. Fron t outpu t gea r
4. Idle r gear
5. Clutc h control cam
6. Driv e gea r
7. Contro l lever
8. Multi-dis c clutc h pac k
9. Rea r output flang e
11 121 3 10. Rea r driveshaft
11. Driv e pinion
12. Multi-dis c clutch disc pack
13. Clutc h actuato r driv e gea r
14. Clutc h actuato r (VTG ) servo moto r

Principles of operation (power flow)

When th e multi-disc clutch in the transfer cas e is disengaged, no
driving torque is transmitted to the front axle. All of the driving torque
is distributed to the rea r axle. This is because th e inpu t shaft is
splined to the rear driveshaft output, providing a permanent
connection to the rear axle.

The multi-dis c clutch couples th e driv e gear to the front driveshaft

output flange. Torque to the front axle i s increased or decreased by
regulating locking pressure of the multi-disc clutch, providin g a
stepless coupling o f the front axle to the drivetrain. This depends o n
DSC assessment o f driving situations and roa d conditions .

When the multi-disc clutc h i s fully engaged, th e front and rear axles
turn at the same speed. Torque distribution front to rear is based on
available tractio n at each axle. Fo r example, when traction is
identical o n the front and rear axles an d the driver accelerates from
a stop i n first gear a t full throttle, the rea r axle i s capable o f
B510270005
transferring greater torque to the roa d wheel s without slipping, a s
vehicle weight shifts from front to rear. The clutches disengage ,
transferring most o f the power t o the rea r axle.

Another example: I f the front axle i s on a high traction surface an d

the rear axle Is on ice, virtually 100 % of the available driving torque
is transmitted to the front axle. Based on available traction, virtually
no driving torque can be transferred to the driving wheels by the rear
axle. When mor e torque i s transmitted t o the front ax\e, torque to Xhe
rear axle is proportionally reduced due to lack of traction.

The advantages of variable distribution of drive torque at front and

rear axles are :
• Optimum utilizatio n of lateral cornering an d wheel periphera l
forces applie d at front and rear axles.
• Brak e interventions by DSC reduced, thu s increasin g overal l
comfort.
• Torque distribution front to rear wheels mor e closel y matched to
differing friction values at the front an d rea r axles .
 Transfer Cas e 270- 3
xDrive overview

Even when DS C i s switched OFF, transfer case control is active to

ensure maximum traction and vehicle dynamics.

Permanent all-wheel drive is cancelled to a large extent or

completely i n three situations :
• When negotiating extremely tight corners with little engine torque ,
in order t o allow spee d equalization between the front and rea r
axle (e.g. , when parking).
• At speeds i n excess of 180 kph (112 mph) .
• I n extreme understeer driving situations.

Transfer cas e control modul e

The transfer cas e (xDrive) contro l module i s installed under th e rug

forward of the passenge r front seat.
1. Kic k guar d
2. Transfe r case contro l module \. Passenge r sea t

The control module i s connected via powertrain CAN-bus

(PT-CAN) to the DSC control module, engine control module (ECM) ,
transmission control module (TCM) and body gatewa y modul e
(KGM).

The control module regulate s transfer case multi-dis c clutch

engagement to control the distribution of torque between fron t an d
rear axles. Torque adjustment requests are received from the DS C
control modul e an d trigger th e power electronics circuitry require d
for the clutch actuator drive . Control module pi n assignments ar e in
Table a and Table b.

In case of DSC failure, an emergency program (limp-home mode )

for locking up transfer cas e clutche s allow s all-wheel drive vehicle
operation to be continued.

Transfer case control module pi n assignment s

Table a . Pin assignments for connecto r X10594 to vehicle

electrical system via PT-CA N
Pin Type Description
1 Power Terminal 30
X10594 X8000 3
2 Ground Terminal 31
3 Input Terminal 15 wake-up wir e
4 not used
5 not used
6 Input /output PT-CAN hig h
7 Input/ output PT-CAN low
8 Power Terminal 30
270-4 Transfe r Case
xDrive overview

Table b. Pin assignments for connecto r X8003 to clutch

actuator (VTG) moto r
Pin Type Description
1 Input Classification resisto r
X10594 X8000 3
2 Input Temperature sensor i n VTG motor
3 Input Negative wire from VT G motor
4 Output Positive wire to VTG moto r
5 Input Negative lea d from incremental
sensor an d classification resistor
6 Input Positive lead for incrementa l
sensor

B510270013
7 Input Incremental sensor (indicate s
direction of VTG moto r rotation )
8 Input Incremental sensor (indicates VTG
motor position )

Classification resisto r

Because o f mechanical tolerance s i n production, th e characteristic

curve of the multi-dis c clutch locking torque varies slightly. At the
factory, once the actual locking torque is measured on the clutch test
bench, a resistor is attached to the clutch actuator. The resistor
value (classification) determines clutc h lockin g torque
characteristics.
1. Clutc h actuato r driv e gea r
2. Clutc h actuator (serv o motor)
3. Classificatio n resisto r

Each time the engine is started, th e transfer case control module

measures the resistor value once and selects the optimum progra m
map for transfer case engagement .

B510270006

Warning light s
In case of DSC or xDrive system failure, instrument cluster warning
lights and a gong war n the driver of malfunction(s). Use BMW scan
tool to read out and diagnose faults.
 Transfer Case 270- 5
Transfer case fluid service

TRANSFER CAS E SERVICE

Transfer cas e fluid servic e
xDrive transfer case oil monitoring is performed by the transfer case
control module t o determine whe n oil change i s due.

After performing work on transfer case, check fluid level. Be sure t o

use correct specification fluid.

Remove drain plug (arrow) to drain transfer case.

Tightening torque
Drain plug to transfer case (M22) 60 N m (44 ft-lb)

Fill case to lower edge o f filler plug (arrow) .

Transfer case fluid

Capacity 0.52 lite r (0.5 5 U S qt)
Fluid specificatio n BMW part no. 83 22 0 397 244

CAUTION—
• In order to prevent serious damage to transfer case, use only
the recommended fluid.

Tightening torque
Fill plu g to transfer case (M22) 60 Nm (44 ft-lb)
270-6 Transfe r Case
Transfer case, removing and installing

Transfer case, removin g and installing

CAUTION—
• If replacing transfer case with new or used unit, be sure to also
replace classification resistor corresponding to replacement
case.

— Rais e vehicle and suppor t safely.

WARNING —
• Make sure the vehicle is stable and we/I supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splash shield s underneat h engin e an d transmission.

Remove front end reinforcement plate. Discar d fasteners.

Remove exhaust system and exhaust heat shield. See 180 Exhaus t
System.

WARNING—
• Make sure exhaust system is fully cooled off before removing.

— Remov e support bracket s for hea t an d splas h shield s a s needed .

— Us e paint to match mark front and rea r driveshaft mounting flanges

to preserve original orientation .

^C. Remov e front driveshaft fasteners (arrows) at transfer case output

flange. Tie driveshaft to side.

— N5 4 engine: Suppor t transmission wit h transmission jack, then

remove transmissio n rear support.

— Matc h mark rea r driveshaft mounting flang e with paint to preserve

original orientation.

Working a t rear driveshaf t fron t flex-disc , counterhol d bolt head s

(arrows) and remov e nut s at transfer case outpu t flange. Discard
old fasteners.

CAUTION—
• To avoid damaging flex-disc rubber, be sure to hold bolts
stationary while loosening nuts.
 Transfer Case 270- 7
Transfer case, removing and installing

Remove driveshaft center bearing support fasteners. Support center

of driveshaft.

c/\ur/ow—
• T o prevent damage to rear driveshaft CV joint boot, do not allow
driveshaft to hang down unsupported.
l_

Detach rear driveshaft flex-dis c fro m transfer case. Hang driveshaf t

front section from body using stiff wire.

With transmission supporte d on transmission jack:

• Remove transmission rea r support mounting bolt s (A). Remov e
support.
• Detach transfer case electrical connector s (B).

While supporting transfer case, remove transfer case mounting

bolts from transmission housing .
1. Transmissio n housin g
o\\ / ^ 2. Dowe l pin
V* ?£ ' i\ 3. Transfe r case ATC 300
f, ?>'"' S • PY 4. M1 0 x 35 mm ZNS 8.8 grade bolt
: Srfl^S^ ^' • Tighten to 43 Nm (32 ft-lb)
'•',
5. M1 0 x 80 mm ZNS 8.8 grade bolt
• Tighten to 43 Nm (32 ft-lb)

Lower transfer case. Check carefully to make sure no lines, hose s

or wires become snagged .
270-8 Transfe r Cas e
Transfer case, removing and installing

When installing:
• Inspect dowel pin (arrow) and replace i f damaged.
• Transfer vents hose, covers and protective caps to new transfer
case
• Replace transfer case input shaft sealing O-ring, if applicable .
• Apply thin coat of Weicon® antiseize grease to dowel pin and input
shaft splines.

Tightening torques
Front driveshaft to transfer case or j 2 0 Nm (15 ft-ffa )
differential: Replac e new M8 ZNS bolts with + additional 45°
new
I
Rear driveshaft flex-disc to transfer case : 20Nm(15ft-lb)
Replace M1 0 x 47 mm 10.9 grade ZN S + additional 90°
fasteners with new
Transfer case to transmission (M1 0 x 35 mm 43 Nm (32 ft-lb)
or M10 x 80 mm ZNS 8.8 grade bolt )
Transmission rea r support to body (M8 ) 19Nm(14ft-lb)
Transmission rear support to transmission 19 Nm (14 ft-lb)

After completion of work, check and top off fluid level. See Transfer
case fluid service in this repai r group .

When installing front end reinforcement plate , use new bolts. See
310 Front Suspension .

After filling transfer case, drive vehicle approximately 200 meters

(600 ft) and recheck fluid level.

Use BMW scan tool to carry out "Repair" service function and
complete transfer case programing and coding. See 600 Electrical
System-General.
 300-1

300 Suspension , Steering and Brakes-

General

GENERAL 300- 1 BRAKE SYSTEM 300-1 1

Suspension, steering , brakes (xDrive Sedan). . 300- 1 Vacuum booster pump 300-1 1
Aluminum suspension component s 300- 2
WHEEL ALIGNMEN T 300-1 2
FRONT SUSPENSION 300- 2 WHEELS AN D TIRES 300-1 3
REAR SUSPENSION 300- 3 Flat tire monitor (FTM ) 300-1 3
Tire pressur e monito r (TPM) 300-1 5
ACTIVE STABILIZERS (DYNAMI C DRIVE ) . . . soo- 4
Active stabilize r component overview 300- 4 TABLE
Active stabilize r troubleshooting 300- 8 a. Active stabilizer troubleshooting 300- 9
STEERING 300-1 0 b. Driving distance with flat run-on-flat tire 300-1 5

Active steering 300-1 1

GENERAL
This repair group includes overview information for the front and rear
suspension, braking and steering systems. Also see:
• 200 Transmission-General fo r xDrive transfer case informatio n
• 600 Electrical System-Genera l fo r bus information
• ECL Electrical Component Locations

Suspension, steering, brakes (xDrive Sedan)

1. Steerin g rack
1 2 3 4 2. Fron t drive axle
3. Fron t strut and spring assembly
4. Fron t brake caliper
5. xDriv e transfer case
12
6. Rea r driveshaft
7. Thrus t rod
8. Rea r axle carrier (rear subframe)
9. Tractio n strut
10. Rear strut and spring assembly
11. Upper control arm
12. Rear drive axle
13. Front differential
14. Front end reinforcement
15. Front driveshaft
16. Rear brake caliper
9 1 0 1 6 1 1 12 17 1 8
B510300001
17. Rear differential
18. Stabilizer bar
300-2 Suspension , Steering and Brakes-General
Front Suspension

Aluminum suspension components

In order to reduce vehicle weight, aluminum suspension
components are used. A test with a magnet easily reveals the metal
used. When working with aluminum components, follow the
cautions below.

CAUTION—
• Due to the chemical and corrosion characteristics of aluminum,
do not bring into contact with battery acid.
• Do not use wire brushes with brass or iron bristles. Only use
brushes with stainless steel bristles.
• Do not expose to flying sparks from grinding or cutting
operations.
• Do not subject to steel welding splashes.
• Do not expose to temperatures over 80°C (176°F), even for
short periods. Temperatures in painting facilities are not a
problem.

FRONT SUSPENSION
i
^ xDriv e model right front suspension.

The 5 Series front suspension i s a double-pivot, strut-typ e design

with dual lower control arms. Many of its components are
manufactured from aluminum alloy. Overall benefits of this front
suspension design include :
• Increased vehicle agility.
• Improved comfort due to reduction of unsprung weight.
• Reduction in fuel consumption du e to lowering gross vehicle
weight and better axle load distribution.

The aluminum axle carrier (front subframe) is made of cast alloy

high tensile strength sections welded to extruded sections. It forms
Control arm - a rigid mounting platform for the front suspension arms, stabilizer
>«>•/ ; S bar, steerin g rack, engine mounts, hea t shields and underbody
Reinforcement panel
splash panels.

The lower control arms (known as control arm and tension strut) are
connected to the steering knuckles i n a double pivot configuration.
The tension struts (or thrust arms) are connected to the front
subframe using hydraulic mounts .

. Eac h front strut assembly includes a tubular strut and a coil spring.
The upper strut mount includes a bearing. Th e lower end of each
strut housing i s pinch-fitted to the steering knuckle.

On rear drive models, wheel bearings and hub assemblies are

bolted to the steering knuckles .

on xDrive models, wheel bearing are pressed into steering knuckles.

Use press tools to remove and install .
 Suspension, Steering and Brakes-General 300- 3
Rear Suspension

The aluminum thrust zone reinforcemen t panel , bolted to the front

subframe to increase transverse rigidity, improves handling , nois e
level and crash performance. BMW specifies the following:
• Do not drive the vehicle wit h the front end reinforcement removed.
• When reinstallin g th e panel after repairs, replac e panel mounting
fasteners with new.

The front suspension also includes provision s for active stabilizer

system (ARS) .

Front suspension repairs are covered in 310 Fron t Suspension .

The front differentia l i s bolted t o the left side o f the engine oil pan .
Drive axles with constant velocity (CV) joints at each en d driv e the
front wheels.

Front differentia l and drive axle repairs are covered in 311 Fron t
Axle Differential .

REAR SUSPENSION
— Differential Sports Wagon rea r suspension .
Body brace
The aluminum rea r subframe mounts to the body through four large
Stabilizer bar! bushings. Rear suspension components attac h t o the subframe.

The rea r suspension i s an integral multi-link design. Thre e contro l

arms o n each side locate the rear wheels. The lower contro l arm ,
called the swing arm, is attached to the wheel bearing carrier
through a pivoting integral link. Aluminum components reduc e
unsprung weight .

Sedan an d Sports Wago n rea r axl e design, though basically the

same, differ as follows:
• Sedan rear suspension use s conventional MacPherson struts and
coil springs .
• Sports Wago n i s equipped with self-leveling ai r springs, also
known as electronic height control (EHC). By separating the air
springs from the shock absorbers and placing the shock absorbers
at a lower level and more widely spaced , the Sports Wago n design
provides a larger and wider cargo space.

Rear suspension repair s are covered in 330 Rea r Suspension .

The rear differential mounts to the subframe usin g two rubbe r

bushings i n front and one hydromoun t at rear. Drive axles wit h
constant-velocity (CV) joints at both ends transfer power from the
differential to the roa d wheels.

Rear differential and drive axle repairs ar e covered in 331 Rear Axle
Differential.
300-4 Suspension , Steering and Brakes-General
Active Stabilizers (Dynamic Drive)

ACTIVE STABILIZERS (DYNAMIC DRIVE )

5 Series vehicles may be equipped with the optional active stabilizer
system (acrony m ARS) . The system, also referred to as dynami c
drive, is used to improve handling an d suspensio n comfort.

With this system, front and rea r stabilizer bars are split i n half, with
the halves connected to each other via hydraulic oscillatin g motors.
An electronic control module operates through a valve bod y to
control coupling of the two stabilizer bar halves. The stabilizer bar at
each wheel is non-interacting wit h the stabilizer o n the other wheel
of the same axle and the suspension syste m a s a whole does not
respond if only on e wheel i s deflected by an irregularit y in the road.

Suspension compliance adapts to suit driving conditions, varying

from performance-oriented during cornering to smooth and comfort-
oriented when the vehicle is proceeding i n a straight line. Durin g
vehicle operation, the system responds to suspension travel by
continuously cyclin g through closed-loo p hydraulic control pulse s
lasting only fractions of a second.

Front active stabilizer component replacement i s covered i n 310

Front Suspension. Rea r active stabilizer component replacement
is covered i n 330 Rea r Suspension .

Active stabilizer components overvie w

1. Rea r oscillating motor
2. Rea r stabilizer bar halves
3. Hydrauli c fluid reservoir
4. Tande m flui d pump
5. Fron t stabilizer bar halves
6. Hydrauli c fluid cooler
7. Hydrauli c lines
8. Latera l acceleration senso r
9. Dynami c drive control modul e
10. Valve bloc k
78 11 8510300013
11. Front oscillating motor
 Suspension, Steerin g and Brakes-General 300- 5
Active Stabilizers (Dynamic Drive)

Active stabilizer syste m inputs - outputs

1. Powe r supply, front fuse panel, behin d
glove compartmen t
Active
stabilizer 2. Hydrauli c fluid reservoir flui d level
(dynamic sensor
drive)
control 3. Latera l acceleration sensor, underneat h
module passenger sea t
j 4. Ca r access syste m (CAS) control
module, underneath lef t side dashboard
5. ABS/DS C module, engine
compartment
6. Steering-angl e sensor, steering column
PT-CAN switch cluster (SZL )
7. Valv e block, behind righ t front whee l
housing liner
8. Engin e control module (ECM )
9. Safet y and gateway module (SGM) ,
behind glov e compartment
byteflight
10. Instrument cluste r

10

Bei Jin tirs

Active stabilizer control modul e

The active stabilize r control module , located behind the passenger
kick-panel, is supplied with power via terminal 30 (ignition ON) an d
is protected by a 10A fuse. The modul e use s input signal s t o
calculate the operating commands for the valve block. Inpu t signal s
are also checked for plausibility and used for system monitorin g
purposes.

When the vehicle is started, the following electronic tests are

performed b y the control module :
• An authentication process compares the vehicle identificatio n
number from CAS with the vehicle identification number encode d
in the stabilizer module.
• Control module hardwar e and software are checked.
• Valv e block solenoids are checked for faults. In case of a fault, the
system switches to fail-safe mode.
• The control modul e switches off if there i s overvoltage .
• The control module learns the steering angle offset and the lateral
acceleration zero-point during start-u p and while driving.

If the control modul e i s replaced, use BMW scan tool to code an d

program the ne w unit.
300-6 Suspension , Steering and Brakes-General
Active Stabilizers (Dynamic Drive)

Lateral acceleration sensor

The lateral acceleration sensor, mounte d underneath the passenger
seat on the floor, supplies th e main senso r signa l t o the control
module. Whe n the vehicle corners, the sensor detect s lateral
acceleration up to a measuring range of approx. 1. 1 g.

.com B510310044

Tandem pum p
The tandem pump, driven by the engine via accessory belt, consists
of a radial piston pum p for the active stabilize r system and a vane
pump for power steering .

Valve block
The valve block i s behind th e righ t front wheel housin g trim.
1. Rea r axle pressure control valve
3 4 5
2. Fron t axl e pressur e contro l valve
3. Lin e 1 , front axl e oscillating motor
4. Lin e 2, front axle oscillating moto r
5. Fron t axle pressur e sensor
6. Rea r axle pressure senso r
7. Tande m pum p connectio n
8. Selecto r positio n recognition sensor
9. Fail-saf e valve
10. Directiona l valve
11. Lin e 2, rear axle oscillating moto r
11 1 21 3
BentieyPublishers 12. Hydrauli c reservoi r connection
B510310046
13. Lin e 2 , rear axle oscillating moto r

Pulse-modulated signals from the control modul e activate the valve

block.

Pressure control valve s adjust the actuation pressure s for the

front and rear axl e stabilizer bars .

Directional valve specifies the direction of high-pressure fluid flow

when vehicle is cornering lef t or right .

Fail-safe valve shuts off the front axl e oscillating motor in case of a
power failure or other detected fault. Thus th e front active stabilizer
bar behaves like a normal mechanica l stabilizer .
 Suspension, Steerin g and Brakes-General 300- 7
Active Stabilizers (Dynamic Drive)

Oscillating moto r
Oscillating Oscillating The activ e stabilizer ba r consists of the halve s of the stabilize r ba r
motor shaf t motor housing
mounted to the oscillating moto r and the oscillating moto r housing .

The oscillatin g motor ha s three functions:

• I t guides torque into the two halves of the stabilizer bar.
• I t decouples th e two halve s of the stabilizer bar.
• I n case of system failure (fail-safe mode), the front oscillatin g
motor create s sufficient damping via hydraulic fluid (hydrauli c
locking) so that the stabilizer works like a conventional stabilize r
bar.

Since one half of the stabilizer bar is connected to the shaft and th e
other to the housing, the two halves turn in opposite directions, thus
damping irregula r suspension movements .

If the oscillating motor chambers no longer contain an y fluid as a

result of a leak, the front axle stabilizer ba r can n o longer creat e
damping.

Pressure relief valves

When th e vehicle i s driven o n poor road surfaces, stabilizer ba r
movements give rise to cavitation in the fluid inside the oscillatin g
motors and this may produce rattlin g noises. The pressur e relie f
valves on the front oscillating motor eliminate these noise s b y
allowing filtered air to flow into the oscillating motor. This small
quantity of air is absorbed by the hydraulic fluid to form an emulsion ,
which is discharged durin g the nex t activations of the oscillatin g
motor. The ai r separates out in the hydraulic fluid reservoir.

Because noise s from the rea r axle cannot be heard insid e the
vehicle, pressure relief valves are not installed on the rea r stabilizer
bar oscillating motor.

pressure
relief valve s

Service note s
• I f the active stabilizer system fails, DSC can no longer b e
deactivated or i f it is already deactivated , it does no t switc h bac k
on automatically.
• Hydrauli c connections fo r each components are different in
dimensions an d lengths s o that they cannot b e swapped .
• When installing cables and fluid lines, make sure they are correctly
isolated and free of tension. Make sure they are covered by
underbody protection .

Steering angle adjustmen t

The active stabilizer system i s dependent o n the precis e settin g of
the steering angle sensor . Afte r working on steering or activ e
stabilizer components o r replacing steerin g column switch (SZL)
components, reset steering angle sensor. Connect vehicle to BMW
scan tool and carry out steering angle sensor adjustmen t syste m
function.
300-8 Suspension , Steering and Brakes-General
Active Stabilizers (Dynamic Drive)

Active stabilizer , commissioning

WARNING—
• During commissioning, the vehicle performs very strong and
rapid rolling motions. For this reason, make sure no persons
are near the vehicle, particularly in the proximity of moving
vehicle components. Also, make sure that there are no objects
underneath the vehicle or in the wheel housings.
• Make sure that commissioning is carried out with the vehicle
standing on a firm, flat surface with all four wheels on the
ground. Do not perform commissioning with the vehicle on a lift,
wheel alignment platform, shock absorber test platform, brake
testing platform or dynamometer.

The purpos e of commissioning i s to teach th e active stabilizer

control modul e the parameters an d zero point o f syste m
components. Commissio n th e system an y time the system is coded
and programmed, hydraulic s are opened or parts replaced .

Commissioning require s the us e of BM W scan tool . The process i s

divided int o 5 phases an d takes approx . 2 5 seconds :
• Check o f direction valve.
• Low pressure test .
• Fron t axle hig h pressur e test.
• Rea r axle high pressur e test.
• Pressur e contro l valv e test.

Before commissioning, mak e sure o f the following:

• Hydrauli c fluid temperature of 50° - 70°C (122° - 158°F).
• Vehicle parked leve l and on all four wheels .
• Vehicle unladen .
• Engin e at idle.
• Vehicle in rest status wit h doors close d and no persons inside .

40}' Active stabilizer troubleshootin g

The following may appear a s Check Contro l messages in iDrive
display screen :

Vehicle instability ico n i n yellow. Activ e stabilizer system disabled .

Vehicle leans mor e i n curves. T o continue driving :
• Chec k fluid level in power steering and active stabilizer reservoir.
• I f there is no significant fluid loss, continu e driving , but carefully
around corners .

Bring vehicle to qualified repai r facility as soon as possible .

Vehicle instability ico n in red. Flui d loss i n steering and active

stabilizer system. Do not continue t o drive. Hav e vehicle towe d for
diagnosis an d repairs .
 Suspension, Steering and Brakes-General 300- 9
Active Stabilizers (Dynamic Drive)

Table a lists commonly encountere d activ e stabilize r faults an d

suggested solutions .

Table a. Active stabilizer troubleshooting

Problem Possible cause Suggested solutions
Noises (banging , rattling ) during Front or rear suspension bolt s loos e Check front and rear suspension fastene r
straight-ahead drivin g and gentle torques.
steering through center . Stabilizer ba r lin k loose or defective Check stabilize r link ball joints fo r damage or
play. Tighten o r replace stabilizer link a s
necessary.
Stabilizer bar mount loos e Tighten stabilizer bar mount bolts .
Hydraulic line s distorte d Check hydrauli c lin e alignment. Mak e sur e tha t
lines ar e installe d in brackets tension-free, not
twisted.
Hydraulic line s fitted too closely o r hav e Check hydrauli c line alignment. Mak e sur e tha t
insufficient clearanc e (elasti c movemen t o f line lines ar e installed with sufficient clearance .
during pressure buildup )
Hydraulic lin e bracket s loose, missing or Check hydrauli c line bracket fasteners for
incorrectly fitted tightness and fit. Replace i f missing o r
damaged.
Hydraulic lin e rubbe r isolating element s Replace defective or missing rubbe r isolatin g
damaged o r missin g elements.
Valve block rubber isolating elements damage d • Replac e defective or missing rubbe r isolatin g
or missin g elements.
• Replac e valve block bracket .
Valve bloc k defective If after bleeding an d initialization , faults ar e
detected, replac e valve block.
Rattling noise s o n bump s an d Front or rea r suspension bolt s loos e Check front and rear suspension fastene r
straight-ahead driving (withou t torques.
altering steering wheel position) ; Stabilizer ba r link loose or defective Check stabilize r link bal l joints for damage or
noises to a large exten t play. Tighten o r replace stabilizer lin k a s
independent o f temperature necessary.
Stabilizer bar mount loos e Tighten stabilize r bar mount bolts .
Hydraulic line s distorte d Check hydrauli c line alignment. Mak e sur e that
lines ar e installe d in brackets tension-free , not
twisted.
Hydraulic line s fitted too closel y or have Check hydrauli c lin e alignment. Mak e sur e that
insufficient clearanc e (elastic movement of line lines ar e installed with sufficient clearance.
during pressur e buildup )
Hydraulic lin e brackets loose, missing o r Check hydrauli c line bracket fastener s for
incorrectly fitted tightness an d fit. Replace i f missing o r
damaged.
Hydraulic lin e rubbe r isolating element s Replace defectiv e or missing rubbe r isolatin g
damaged o r missin g elements.
Protective rubber cap (black ) not removed from Remove Y-connector rubber cap.
front fluid lines Y-connector
Vent valve leakin g If black plastic air filter element is filled with fluid,
replace vent valve and filter.
Valve bloc k defectiv e If after bleeding an d initialization, faults ar e
detected, replac e valve bloc k
300-10 Suspension , Steerin g and Brakes-General
Steering

Table a. Active stabilizer troubleshooting

Problem Possible cause Suggested solutions
Rattling noises on bumps and Valve block defective During test drive, chec k i f noises occu r during
straight-ahead driving (withou t straight-ahead drivin g or road bump s on one
altering steering wheel position); side. If after bleeding and initialization, faults are
noises only at higher ambien t detected, replac e valv e bloc k
temperature or when vehicle i s
heated up
Hissing noise Hydraulic lines damage d Check hydrauli c line s to see i f they are bent or
crushed. Repai r or replace as necessary.
Valve block fluid flow proble m Use BM W scan tool to diagnose system. If fault
in valve block i s detected, replac e valve block.
Whining noises durin g cornering Tandem pum p bel t problem Check whether noise s are fro m pump o r belt. If
necessary, install noise-optimize d belt pulley,
Pump noise from engine Fluid pressure line damage d Check fluid pressure line from tandem pump . If
compartment depending o n crushed o r bent, replac e line.
engine speed or only durin g Tandem pum p defective Check for pump damage. I f other causes ar e
cornering
ruled out, replac e pump .

STEERING
The rack-and-pinio n steerin g system i s powered b y an hydraulic
pump driven by the engine accessory belt .

Power assist to the steering system i s regulated in one of two ways:

• BM W Servotronic provides speed-sensitive variabl e powe r assist
to the steering gear an d i s regulated b y software in the safety and
gateway modul e (SGM) .
• Active steering (AS) incorporates Servotronic , but in addition
provides variable steering ratio.

The steering column i s electrically adjustable for length and height.

Seat and mirror memory contro l also adjusts steering wheel
position.

Seat, mirror an d
Steering column steerin g colum n
adjustment switch memor y contro l
 Suspension, Steering and Brakes-General 300-1 1
Brake System

Active steering
Active steering
actuator Active steering (AF S or AS), an option on 5 Series vehicles, allow s
variable steering ratio based on road speed and conditions suc h as
yaw and latera l acceleration.

Active steering manipulation o f steering ratio from 1 0 : 1 to 20 : 1 is

actuated by a planetary gear set driven by a 3-phase DC motor an d
controlled by the active steering control module.

Rack and pinio n

BRAKE SYSTEM
5 Series vehicles covered by this manual are equipped wit h power
disc brakes with integral antilock brake s (ABS) and dynamic stabilit y
control (DSC). See 340 Brakes for details.

The parking brake is a dual-drum system integrated with the rea r

brake rotors.

Lightweight brake rotors are two-piece: The braking surface is made

from grey cast iron , while the hubs are made from aluminum. The
two parts are riveted together.

Each disc brak e uses a caliper with a single hydraulic cylinder .

Brake pads in the left front and right rear contain wea r sensors .
When brake pads need replacement, the sensors illuminate a light
on the dashboard.

Power assist is provided by a vacuum booster when the engin e is

running. The brake pedal pushro d is connected directl y t o the
master cylinder, so failure of the vacuum booster doe s not normally
result in total brake failure.

Vacuum booster pump

In order to provide adequate vacuu m for the brake booster, a n
additional vacuu m pump is fitted, except in models with M54 engine.

In 6-cylinder models , the pum p is driven off the oi l pum p chain.

N52 or N52KP engine: Vacuum pump is attached t o rear of timing

chain housing .
300-12 Suspension , Steering and Brakes-Genera l
Wheel Alignment

N54 engine: Vacuum pump in tandem with high pressure fuel pum p
is attached to rear of timing chai n housing, below an d to righ t o )
alternator.

V8 engine: Vacuu m pump i s attached t o front of right timing chain

cover and driven off the righ t exhaust camshaft .

See 100 [Engine-General for additional information .

WHEEL ALIGNMENT
Use electronic alignment equipmen t t o check and set camber and
toe for all 4 wheels. B e sure to check an d adjust ride height prior to
attempting wheel alignment.

For ride height an d alignment specifications and procedures, se e

320 Steering and Wheel Alignment.
Suspension, Steering and Brakes-General 300-1 3
Wheels and Tires

WHEELS AND TIRES

Run-on-flat tires are optional on 5 Series cars covered by this
manual. Severa l different styles of wheels in 16, 17, 18 and 1 9 inch
diameters are available from an authorized BMW dealer.

Flat tire monitor (FTM )

Flat tire monitor (FTM) uses input from the ABS wheel speed
sensors to keep track of tire inflation pressure s a s the vehicle i s
driven. I n case of pressure loss in a tire, the rollin g radius an d
therefore the rotatio n speed of the wheel changes. This change is
detected and the system alerts the driver using warning light s in the
instrument cluster.

FTM electronic control is integrated in DSC control module.

FTM, initializing using iDrive

In order to assure reliability, us e iDrive controller and displa y to
initialize FT M system after tire pressures are set correctly .

B-pillar door sticker (inset) provide s factory-recommended tire

inflation pressures.

Repeat initialization eac h time tire inflation pressure s ar e correcte d

and afte r ever y tire or wheel change.

^C Wit h ignition ON , press down iDriv e menu button (arrow ) to open

Start menu.

wore—
• Early style iDrive shown. Later version iDrive operates similarly.

— Pres s iDrive controller to open inf o sources menu .

— Selec t Vehicle settings an d press controller .

300-14 Suspension , Steering and Brakes-Genera l
Wheels and Tires

^k Selec t FT M and press controller.

— Star t engine bu t d o no t drive.

— Selec t Se t tire pressure and press controller .

^k Selec t Yes and press controller.

— Star t to drive. The messag e Initializin g i s displayed .

— Initializatio n finishes during driving and Status: FT M active appears

again.

If driving is interrupted before initialization i s complete, initialization

continues automatically when driving resumes.

Do not initialize the system when driving with snow chains or

compact spar e tire.

Flat tire indication

^ I n case of a flat tire or extensive loss of air in a tire, the instrument
warning ligh t light s up red and a Check Contro l messag e appears .
In addition, an acoustic signal sounds .

— Reduc e speed. Sto p vehicle carefully. Avoid sudden brakin g and

steering maneuvers.

— Identif y damaged tire and replace . Se e 02 0 Maintenance .

Run-on-flat tires
In case of a flat tire warning i n the instrumen t cluster:

Cautiously reduc e spee d to below 50 mph (80 kph). Avoid sudden

braking and steering maneuvers. D o not exceed a speed of 50 mph
(80 kph).

WARNING —
• If the vehicle is not equipped with run-on-flat tires, do not
continue to drive. Continuing to drive with a flat tire could cause
a severe accident.

— A t the nex t opportunity, check air pressure i n all four tires.

— I f tire pressure i n all four tires is correct, FTM may not have initialized
correctly. Initializ e system.
 Suspension, Steering and Brakes-Genera l
300-15
Wheels and Tires

In case of complete tire pressure loss, use Table b to estimate safe

distance for continued driving .

Table b. Driving distance wit h flat run-on fla t tire

Condition Approx . safe distance to driv e j

1 - 2 persons, n o luggage 15 5 miles (25 0 km)
J2 persons, full luggag e 94 miles (15 0 km)
4 persons, n o luggage

Full loadT^TpeTsons.lull Iugga^epo7nites^(5ol<rn)

WARNING —
• In case of a completely flat run-on-flat tire, drive cautiously and
do not exceed a speed of 50 mph (80 kph).
• Vehicle hand/ing changes with a flat tire. This can mean
reduced tracking stability in braking, extended braking distance
and altered steering characteristics.
• If unusual vibration or loud noises occur while driving on a
damaged tire, this may be an indication that the tire has failed
completely. Reduce speed and pull over as soon as possible at
a suitable location. Otherwise parts of the tire could come
loose, resulting in an accident. Do not continue driving.

System limits

FTM cannot indicate sudden sever e tire damage caused b y outside

factors. It also does not detect an even pressure drop in all four tires.
In the following situations, the system could be delayed o r
malfunction:
• Uninitialize d system.
• Drivin g on snowy or slippery road surface.
• Sporty driving style leading to slip in the drive wheels, hig h latera l
acceleration.
• Drivin g with snow chains.
• Drivin g with compact spare.

Tire pressure monitor (TPM)

Beginning with 2006 models , tire pressures are automaticall y
monitored by the tire pressure monitorin g system (TPM) .

. A TPM antenna i n each wheel communicates tire pressure data to a

pick-up antenna i n each wheel housing.

TPM electroni c control is integrated in DSC control module.

Tire pressure
monitor antenna
300-16 Suspension , Steering and^rak^s-:Genejra|
Wheels and Tires

Tire pressure data from run-on-fla t tires is monitored by the tire

pressure monitorin g (TPM) system . If a substantial loss of tire
pressure is detected, warning lights in red illuminate in the
instrument cluster and a tire failure message appears in Chec k
Control display. In addition, an acoustic signal sounds.

WARNING—
• In case of a completely flat run-on-flat tire, drive cautiously and
do not exceed a speed of 50 mph (80 kph).
• Vehicle handling changes with a flat tire. This can mean
reduced tracking stability in braking, extended braking distance
and altered steering characteristics.
• If unusual vibration or loud noises occur while driving on a
damaged tire, this may be an indication that the tire has failed
completely. Reduce speed and pull over as soon as possible at
a suitable location. Otherwise parts of the tire could come
loose, resulting in an accident. Do not continue driving.
• TPM does not work correctly if it is not initialized.
• TPM cannot indicate a flat tire if a wheel without TPM
electronics is mounted.

Avoid sudden braking and steering maneuvers. At the nex t

opportunity, check air pressure in all four tires.

B-pillar door sticke r (inset) provides factory-recommended tir e

inflation pressures.

Immediately after correcting tire pressures or mounting a new

wheel, reset TPM .

TPM, resetting
— Switc h ignition ON.

"^ Pres s dow n iDrive controller (arrow) t o select Inf o source s |

Settings menu.

NOTE—
• Early style iDrive shown. Later version iDrive operates similarly.
 Suspension, Steerin g an d Brakes-General 300-1 7
Wheels and Tires

Rotate controller to Settings.

— Pres s down controlle r to select Settings, then rotat e to

Vehicle/Tires.

Press down controller t o select Vehicle/Tires. I n similar manner,

TPM * navigate to TPM screen.

Start engine, but do not drive off.

Select Rese t an d press controller .

Select Yes and press controller.

Start to drive. Initialization completes automatically while vehicle is

on the move. Correctly inflated tires show up as green o n iDriv e
display.
 310-1

310 Fron t Suspensio n

GENERAL 310- 1 Tension stru t bushing, replacin g 310-1 8

Front axl e descriptio n 310- 1 Tension stru t ball joint, replacing (xDrive) . . . 310-1 9
Front suspension component s STEERING KNUCKL E AND
(rear-wheel drive ) 310- 2 FRONT WHEEL BEARING 310-2 0
Front suspension component s (xDrive ) 310- 3
Steering knuckl e components
Front end reinforcemen t panel, (rear-wheel drive) 310-2 0
removing and installing 310- 3
Steering knuckle , removin g and installin g
Strut tower brace , removin g and installing . . . . 310- 4 (rear-wheel drive) 310-2 0
Warnings and Cautions 310- 5 Front whee l bearing , replacing
FRONT STRUT ASSEMBLY 310- 5 (rear-wheel drive ) 310-2 2
Front strut assembly, removin g and installing Steering knuckl e components (xDrive ) 310-2 3
(rear-wheel drive) 310- 6 Steering knuckle , removin g and installin g
Front stru t assembly, removin g and installin g (xDrive) 310-2 4
(xDrive) 310- 8 Front wheel bearing , replacin g (xDrive) 310-2 6
Front strut assembly component s 310-1 0 FRONT STABILIZER BA R 310-2 9
Front strut assembly, disassemblin g Active stabilizer ba r (dynamic drive) 310-2 9
and assembling 310-1 0
Hydraulic system, bleeding 310-3 0
FRONT SUSPENSION ARMS 310-1 3 Front stabilizer bar, removin g and installin g
Control arm, removin g and installing 310-1 3 (mechanical stabilizer) 310-3 0
Tension strut, removing an d installing Front stabilizer bar, removin g and installin g
(rear-wheel drive) 310-1 4 (active stabilizer) 310-3 2
Tension strut , removing an d installing Front stabilizer bar links, replacing 310-3 4
(xDrive) 310-1 7

GENERAL
This repai r grou p covers the repai r an d replacement of front
suspension components.

See also:
• 300 Suspension, Steering and Brakes-General for a general
description o f the suspension system
• 311 Fron t Axle Differentia l fo r front drive component s
• 320 Steering and Wheel Alignment for ride heigh t specifications

Front axle descriptio n

Most fron t axl e component s are mad e o f aluminum. Weight an d
space are saved and front axl e rigidit y increase d by the us e of an
aluminum reinforcemen t panel bolte d t o the front subframe . BM W
specifies th e following :
• D o not drive the vehicle with th e front end reinforcement removed .
• Whe n reinstallin g th e reinforcemen t pane l after repairs , replac e
mounting fasteners wit h new .
310-2 Fron t Suspensio n
Front suspension components (rear-wheel drive)

The suspension features double-pivot ball-joint s at the base of each

steering knuckl e and a MacPherson strut at the top.

All models are equipped with rack-and-pinion steering. During wheel

alignment, adjust toe at the tie rods . Correc t camber b y removing a
locating pin on the strut top bearing and rotatin g the strut top inside
the strut tower. See 320 Steering an d Wheel Alignment .

Front suspensio n component s

(rear-wheel drive )
1. Stru t assembl y
2. Stru t top bearin g
3. Stabilize r ba r link
4. Tensio n stru t
5. Stabilize r bar
6. Steerin g rack
7. Hydromoun t
8. Stabilize r lin k bracket
9. Whee l hub
10. Control arm
11. Front subframe (axle carrier)
12. Front end reinforcement
13. Ride level sensor
14. Steering tie rod
15. Steering knuckl e (swive l bearing) and
9101 1 12 13 1 03 1 4 15 wheel bearing carrier

B510310006
 Front Suspension 310- 3
Front suspension components (xDrive)

Front suspension components (xDrive)

1. Steerin g tie-rod
2. Tensio n stru t
3. Coi l spring
4. Stru t tube
5. Hydromoun t
6. Stabilize r bar moun t
7. Stabilize r bar
8. Fron t subframe
9. Fron t end reinforcement
10. Steering knuckle (swive l bearing) an d
wheel bearing carrier
11. Drive axle outer CV joint
12. Control arm
13. Stabilizer arm link
14. Drive axle
15. Drive axle inner CV joint

i *

Front end reinforcement panel ,

removing an d installin g
the aluminum fron t end reinforcement panel provide s additiona l
rigidity to the subframe (fron t axle carrier).

CAUTION—
• Do not drive the vehicle with the front end reinforcement panel
removed.

— Rais e vehicle and suppor t safely .

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Remov e underbod y splash shields. See 020 Maintenance.

310-4 Fron t Suspensio n
Strut tower brace, removing and installing

Remove fastener s (arrows) and remov e reinforcemen t panel.

Installation i s reverse of removal. B e sure to replace fasteners with

new.

Tightening torqu e
Front end reinforcement panel t o subfram e
(replace M1 0 x 35 mm 10. 9 grade ZN S bolt s
with new):
• Stag e 1 56 N m (4 1 ft-lb )
• Stage 2 + additional 90°
I

Strut tower brace , removin g and installing

A strut tower brace i n the engine compartmen t provid e additiona l
rigidity to the front suspension.

CAUTION—
• Do not drive the vehicle with strut tower brace removed.

Working in engine compartment , detach wiring harness an d remove

upper and lower cabin microfilte r housings on right and left . See
020 Maintenance .

If necessary , remove plastic strut tower covers. Remove plastic

shield over strut tower brace at bulkhead .

Remove strut tower brace fasteners (arrows ) and lif t of f brace.

When installing , replac e bolt s wit h new.

Tightening torque
Brace to strut tower or bulkhea d 30.5 N m (22 ft-lb)
(use ne w M8 Torx bolts)
 Front Suspensio n 310- 5
Warnings and Cautions

Warnings and Caution s

WARNING —
• Do not reuse self-locking fasteners. They are designed to be
used only once and may fail if reused. Replace with new.
• Pentosin fluid (in active stabilizer hydraulic system) is injurious
to skin and eyes. Wear protective gloves and eyewear.

CAUTION—
• Do not drive the vehicle with the front end reinforcement panel
removed. Se e Front end reinforcemen t panel, removin g
and installin g i n this repair group.
• When reinstalling the panel after repairs, replace panel
mounting fasteners with new.
• Due to the chemical and corrosion characteristics of aluminum,
follow these precautions when working with aluminum
components:
—Do not bring into contact with battery acid.
—Do not use wire brushes with brass or iron bristles. Only us e
brushes with stainless steel bristles.
—Do not expose t o flying sparks from grinding o r cutting
operations.
—Do not subject t o steel we/ding splashes.
—Do not expose t o temperatures over 80°C (176°F), even for
short periods. Temperatures in painting facilities are not a
problem.
• When filling or bleeding hydraulic system, do not allow
contamination of fluid or reservoir.

FRONT STRUT ASSEMBL Y

The front suspension shoc k absorbers are MacPherson struts . The
Strut top strut is a major component of the front suspension and supports the
bearing spring. Mos t strut assembly components ar e available a s
replacement parts .

If a shock absorbe r o r strut i s defective on one side of the vehicle ,

Wheel spee d Strut replace both shock absorbers on that axle. If a coil spring i s broken
sensor assembly due to corrosion, replac e both coil springs on the axle.

Front strut, strut top bearin g moun t or spring replacemen t is a two-

step procedure :
• Remova l of strut assembly fro m vehicle.
Steering
knuckle • Disassembl y an d replacement o f components on work bench.
Strut
pinch bolt Procedures for removal of the fron t strut assembly differ betwee n
rear-wheel drive and all-wheel drive (xDrive) models. B e sure to
B5103100051 read the complete procedur e before starting work.
310-6 Fron t Suspensio n
Front strut assembly, removing and installing (rear-wheel drive)

Front stru t assembly, removin g an d installin g

(rear-wheel drive )
— Rais e car an d remov e fron t wheel .

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Detac h fron t brake caliper from steering knuckle and suspend aside
using stif f wire . Do not detach brak e fluid hose. Se e 340 Brakes .

— Remov e brake rotor . Se e 34 0 Brakes .

— Remov e ABS wheel speed senso r fro m steerin g knuckle . Se e 340

Brakes.

— Detac h contro l ar m an d tension stru t fro m steering knuckle . See

Front Suspensio n Arm s in this repai r group.

— Detac h ti e rod end from steering knuckle . Se e 320 Steerin g an d

Wheel Alignment .

<^ Workin g a t top of steering knuckle:

• Remov e strut pinch bolt (A ) from uppe r steerin g knuckle.
• Remov e stabilizer lin k bracket bol t (B ) and detach bracke t from
steering knuckle.

If necessary, us e BMW special tool 31 2 230 to spread (curved

arrow) steering knuckle pinc h collar. Slid e steerin g knuckle
downward to disengage fro m strut tube.
• Not e locatin g bos s (arrow) for strut. During reassembly, bos s
slides i n steering knuckl e pinc h colla r gap .
 Front Suspension 310- 7
Front strut assembly, removing and installing (rear- wheel drive)

k Workin g in engine compartmen t at strut top bearing :

• Not e position of strut centering pin (A). If centering pin is missing ,
mark positio n of strut top bearing studs o n strut tower to maintain
original camber.
• Secur e strut against fallin g out.
• Remov e strut top bearing fasteners (arrows).

— Lowe r strut out o f wheel arch.

— I f replacing strut, coi l spring or strut top bearing, disassemble an d

reassemble strut assembly on bench. See Front strut assembly ,
disassembling an d assembling i n this repair group.

— Remainde r of installatio n i s reverse of removal. Note the following :

• Lette r on strut tube designates mountin g location. Struts are
marked R for right and L for left.
• Replace self-lockin g fasteners.
• Stru t top bearing without centering pin: Moun t strut top to strut
tower using mark s made previously.
• Mak e sure locating bos s on strut tube slides in steering knuckl e
pinch collar gap.
• Fac e strut pinch bol t head i n direction of travel.
• Make sur e steerin g knuckle contact s sto p on strut befor e
tightening pinch bolt .
• Clea n wheel speed senso r bore hole and lubricate with
Staburags® NBU 12/ K or equivalent grease.
• Align wheel s whe n job is complete .

Tightening torques
Brake caliper to steering knuckle 110 Mm (8 1 ft-lb)
replace M1 2 x 1 .5 x 43 mm ZNS bolts with
new)
Brake roto r to wheel hub 16Nm(12ft-lb)
(replace M 8 x 1 4 mm Alle n bolt with new)
Control arm to steering knuckl e 165 N m (122 ft-lb)
(replace M14 x 1.5 self-locking flange nut
with new )
Road wheel to hub 120± 10Nm
(89 ± 7 ft-lb)
Strut assembl y pinc h bolt 81 Nm (60 ft-lb)
(replace M12 x 10 0 mm 10. 9 grade bolt
with new)
Strut top bearing to strut tower 34 N m (25 ft-lb)
(replace M 8 flanged nut with new )
Tension stru t to steering knuckle 165Nm (122 ft-lb )
(replace M14 x 1 .5 self-locking flange nut
with new)
Tie ro d end to steering knuckle 1 65 Nm (12 2 ft-lb)
(replace M1 4 x 1.5 ZNS3 nut with new )
Wheel spee d sensor to steering knuckl e 8 Nm (6 ft-lb)
310-8 Fron t Suspensio n
Front strut assembly, removing and installing (xDrive)

Front stru t assembly , removin g and installing

(xDrive)
— Rais e car an d remov e front wheel.

WARNING—
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Using a suitable punch, straighten staked sides of wheel hu b collar

nut (arrows) .

With an assistant holding down brake pedal, remove colla r nut and
discard.

CAUTION—
• If necessary, reinstall road wheel and place vehicle on floor
before breaking collar nut free.

Detach front brake caliper from steering knuckle and suspend asid e
using stiff wire . Do not detach brake flui d hose. See 34 0 Brakes.

— Remov e brak e rotor . Se e 340 Brakes .

— Remov e wheel speed sensor from steering knuckle . See 34 0

Brakes. Detach senso r electrical harnes s fro m bracket on strut.

— Detac h control arm an d tension stru t from steering knuckle. See

_B510310010J
Front Suspension Arm s in this repai r group .

— Detac h tie ro d end from steering knuckle . Se e 320 Steering and

Wheel Alignment.

— Detac h stabilize r link from strut tube. Use Torx tool (T30 ) t o
counterhold shaft of stabilizer ba r lin k bal l joint while removing nut.

— Rotat e steering knuckle to one side and us e BMW special tools

32 2 200 or equivalent to press drive axle stub out of wheel bearing
hub. Tie up drive axle end usin g stif f wire.

CAUTION—
• In order to avoid damaging drive axle threads, do not drive out
stub axle using impact tool.

^ Workin g at strut top bearing:

• Not e position o f strut centering pin (A) . If centering pin is missing,
mark position of strut top bearin g stud s o n strut tower to maintai n
original camber .
• Support steering knuckl e with floor jack to secure assembly
against falling out.
• Remov e strut top bearing fasteners (arrows).

— Lowe r strut and steering knuckl e ou t o f wheel arch .

 Front Suspension 310- 9
Front strut assembly, removing and installing (xDrive)

— Workin g at top of steering knuckle, remove strut pinch bolt .

'X. I f necessary, use BMW special too l 31 2 230 to spread (curve d

arrow) steering knuckle pinc h collar. Slide strut tube out of steering
knuckle.
• Note locating bos s (arrow) for strut. During reassembly , bos s
slides in steering knuckle pinc h collar gap .

— I f replacing strut , disassemble an d reassemble strut assembly o n

work bench. See Front strut assembly, disassembling an d
assembling i n this repai r group.

— Installatio n is reverse of removal. Note the following :

• Letter on strut tube designates mountin g location . Strut s are
marked R for right and L for left.
• Make sure locating boss on strut tube slides in steering knuckle
pinch colla r gap .
• Make sure steering knuckle contacts stop on strut before
tightening pinch bolt. Fac e strut pinch bolt head in direction of
travel.
• Replace self-locking fasteners.
• Strut top bearing without centering pin: Mount strut top to strut
tower usin g marks made previously.
• Use Torx tool (T30) to counterhold shaft of stabilizer bar link ball
joint while tightening nut .
• Clean ABS wheel speed sensor bore hole and lubricate with
Staburags® NBU 12/K or equivalent grease.
• Oil collar nu t and wheel hub contact surfaces lightly. Do not allow
oil to contaminate drive axle threads. Final tightening with wheel on
ground. Stake collar nut after final tightening.
• Align wheels when job is complete.

Tightening torques
Brake caliper to steering knuckle (replace 110Nm(81 ft-lb)
M12x 1.5 x43 m m ZNS bolts with new)
Brake rotor to wheel hub 16Nm(12ft-lb)
(replace M8 x 14 mm Allen bolt with new)
Control arm to steering knuckle (replace 1 65 Nm (122 ft-lb)
M14x 1 .5 self-locking flang e nut with new)
Drive axle to wheel hub 420 Nm (310 ft-lb)
(replace M27 x 1 .5 collar nu t with new)
Road wheel to hub 120±10Nm
(89 ± 7 ft-lb)
Stabilizer lin k to strut tube 65 Nm (48 ft-lb)
(replace M10 ZNS3 nut with new)
Strut assembly pinc h bolt (replac e M12 x 100Nm (74 ft-lb)
1 .5 x 80 mm ZNS3 bolt with new)
Strut top bearing to strut tower 34 Nm (25 ft-lb)
(replace M 8 flanged nut with new)
Tension strut to steering knuckl e bal l joint 1 65 Nm (122 ft-lb)
(replace M14 x 1 .5 self-locking flange nut
with new)
Tie rod end to steering knuckl e 1 65 Nm (122 ft-lb)
(replace M1 4 x 1.5 ZNS3 nut with new)
Wheel speed sensor to steering knuckle 8 Nm (6 ft-lb)
310-10 Fron t Suspensio n
Front strut assembly components

Front strut assembly components

1. Ca p
2. Uppe r strut self-locking nut
• Use new nut
• Tighten to 64 Nm (47 ft-lb)
3. Stru t top bearing mounting nut
• Use new nut
• Tighten to 34 Nm (25 ft-lb)
4. Stru t top bearing
5. O-rin g seal
6. Washe r
10 7. Uppe r spring seat

I 8. Uppe r spring pad

9. Coi l spring
10. Rubber bump stop
11. Dust boo t
12. Lower spring pad
13. Strut wit h lower spring seat

Front strut assembly, disassemblin g

and assemblin g
If replacing strut, uppe r stru t mount o r coil spring, first remove the
strut assembly fro m the vehicle. See Front strut assembly,
removing an d installing (rear-wheel drive) or Front stru t
assembly, removin g and installing (xDrive) i n this repair group .

BMW recommends th e use of BMW spring compressor (special tool

31 3 340). A number of different spring compressor tools are
available. Photos in this section illustrat e the function of one such
tool in use.

WARNING—
• Do not attempt to disassemble the strut assembly without a
spring compressor designed specifically for this job.
• Prior to each use, check special tool for functionality.
• Do not use a damaged tool.
• Do not make any modifications to tool,
• Use correct size spring retainers when compressing coil spring.
• When assembling BMW spring compressor (special tool
31 3 340), make sure spring retainer plates are felt and heard
snapping into place. Check seating of spring retainers carefully.

Clamp sprin g compressor in shop vise.

Spring retainers
 Front Suspensio n
Front strut assembly, disassembling and assembling

Position coil spring between spring retainers s o that 3 coils lie

between retainer s (arrows) . Compress spring.

WARNING —
• Make sure that when tensioned, the spring coil rests completely
in the spring holder recess.
1 Do not tighten or loosen spring compressor with an impact tool.
• Tighten down the coil spring until stress on the strut top bearing
is relieved.
• Only loosen upper strut nut if spring coils are completely
inserted in the spring holder grooves. If necessary, loosen
compressor, reposition and recompress.

Use BMW special too l 31 2 210 or equivalent to remove uppe r strut

nut. Counterhold strut shaft using 6 mm Allen wrench.

CAUTION—
• Do not remove strut nut with impact tool.

— Remov e uppe r stru t bearing an d related components .

— I f a new coil spring is being installed, relieve tension o n spring

compressor and remove coil spring.

— Chec k strut dust boot, rubber stop and spring pads. Replac e a s
necessary.

— Replac e strut , upper strut mount or spring, as needed. If one sprin g

is corroded o r damaged, replace bot h springs as a matched pair .

"^k Reassembl e components with spring held compressed.

Front strut top • Us e a new upper strut self-locking nut (A). Tighten nu t fully before
releasing sprin g compressor.
• Illustration shows a typical BM W strut assembly. 5 Series model s
are similar but not identical.

Do not tighten strut nut with impact tool.

Tightening torque s
Strut shaft to strut top bearing 64 Nm (47 ft-lb)
(replace self-locking nut with new)

Be sure coil spring ends and upper an d lower spring pads are
correctly installe d to spring seat s before releasing spring
compressor. Se e following illustrations.

502310732
310-12 Fron t Suspensio n
Front strut assembly, disassembling and assembling

Upper coil spring end:

• Make sure spring pad aligns correctly wit h indentation in upper
spring seat.
• Place coil spring en d in spring pa d stop (inset) .

1 < Rear-wheel drive lower coil spring end :

• Align lower end of coil spring (inset) to spring pad as illustrated.
• Check installation positio n of dust boot and correct folds if
necessary.

Note that end of coil spring doe s no t rest against shoulde r o f spring
pad. Reces s in pad serves to reinforce and correctly seat lower
spring pa d and does not serve as a stop for the spring end .

^V xDriv e lower coil spring end:

• Make sure spring end (arrow) rest s on spring pa d stop.
• Check installation position of dust boot an d correct folds if
necessary.

— Releas e spring compressor carefull y an d evenly, allowing spring to

expand slowly.

— Reinstal l strut assembly in vehicle.

— Hav e vehicle professionally aligne d when job is complete.

 Front Suspension 310-1 3
Control arm, removing and installing

FRONT SUSPENSION ARM S

Control arms and tension struts are collectively known as
suspension arms. Tension struts are sometimes called thrust arms
or thrust rods.

Control arms and tension struts are attached to the front subframe
through rubber bushings an d to the steering knuckles by ball joints.

Note that steering wheel vibration during braking (usually at road

speeds of 50 to 60 mph) ma y be caused by faulty suspension ar m
bushings, no t out-of-true brake rotors.

Inspect ball joints for wear and looseness. Inspect bushings fo r wear
or fluid leaks. On xDrive vehicles, the tension strut ball joint is
available a s a separate part. Otherwise, ball joints can only be
replaced as part o f an entire suspension arm assembly. Tensio n
strut hydromount bushings ar e available as replacement parts .
Replace bushings in pairs.

Special tools may be required to remove suspension arm s an d to

replace bushings. Read the procedure through before beginning the
job.

Control arm, removing and installing

Raise car and remov e front wheel.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splash shield underneat h vehicle front. See

020 Maintenance .

Remove suspension side splash shield screws (insets). Remove

side splash shield.

Working at control arm:

• I f equipped, detach ride height sensor link rod (A).
• Remov e control arm fastener (B) at subframe. Lightly tap mountin g
bolt out of subframe.
• I f necessary, counterhold ball joint shaft with Torx T40 socket while
loosening ball joint nut (C).
• xDrive: For space reasons , back off ball joint nu t 3 - 4 threads
before using special tool to break loose ball joint press fit.
310-14 Fron t Suspension
Tension strut, removing and installing (rear-wheel drive)

Use BMW special tool 31 2 240 or equivalent to separate ball joint

from steering knuckle .

Inspect control arm ball joint and bushing. Replace bot h contro l
arms if defects are found.

Installation is reverse of removal. Remembe r to :

• Make sure thread bores, bolts, nuts and mating surfaces are clean.
• Instal l bushing end of control arm to subframe using new
fasteners. Bolt head points to front of vehicle. Do not fully tighten
nut at this time.
• Install control arm ball joint to steering knuckl e usin g ne w self-
locking nut . Tighten fully .
• If equipped, reattac h ride height senso r link rod to control arm.
• Instal l wheel and lower car.
• Tighten bushing end of control arm to subframe with car on ground
and loaded. Bounc e suspensio n a few times before final
tightening.
« Use BMW scan tool to carry out steering angle senso r alignment .
• Align wheels when job is complete.

Tightening torques
Control arm to steering knuckl e 165Nm(122ft-lb)
(replace M14 x 1.5 self-locking flange nut
with new)
Control arm to subframe (replace M12 x
1 .5 x 1 00 mm 1 0.9 grade bolt with new)
• Stage 1 100Nm(74ft-lb)
• Stage 2 additional 90 ° ± 15°
Road wheel to hub 120 ± 1 0 Mm
(89 ± 7 ft-lb)

Tension strut, removing and installing

(rear-wheel drive )
— Rais e car and remov e wheel.

WARNING—
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splash shield underneath vehicle front. See

020 Maintenance.

Detach stabilizer link from stabilizer bar . Us e Torx tool (T30) to

counterhold shaft of stabilizer bar link ball joint while loosening nut.

Detach control arm from steering knuckle. See Control arm,

removing and installing in this repair group.
 Front Suspension 310-1 5
Tension strut, removing and installing (rear-wheel drive)

Working at tension strut:

• Remov e tension strut bushing fastener (A). Lightly tap tension strut
bushing bol t out of front subframe.
• Remove tension strut ball joint nu t (B).

If necessary, counterhol d bal l joint shaf t with Torx tool (T40 ) whil e
loosening ball joint nut.

Support steering knuckle using floor jack. Working at top of steering

knuckle, remov e strut pinch bol t (arrow).
310-16 Fron t Suspension
Tension strut, removing and installing (rear-wheel drive)

. I f necessary, us e BM W specia l tool 31 2 230 to spread (curved

arrow) steering knuckle pinch collar. Slide stru t tube out of steering
knuckle approx . 1 inch (2.5 cm).
• Not e locating boss (arrow ) for strut. Durin g reassembly , boss
slides i n steering knuckle pinc h colla r gap.

Detach tension strut ball joint from steering knuckl e and remove
tension strut.

Inspect torsion strut ball joint and bushing.

• I f ball joint is defective, replace bot h torsion struts .
• I f bushing is defective, replace both bushings , bu t this may only be
done once per torsion strut. See Tension stru t bushing ,
replacing i n this repai r group.

Installation is reverse of remova l

• Mak e sure thread bores, bolts, nuts and mating surfaces are clean.
• Install bushing end of tension strut to subframe usin g new
fasteners. D o not fully tighten nu t at this time.
• Install tension strut ball joint to steering knuckle using ne w self-
locking nut. Tighten fully.
• Slide steering knuckle up in strut tube and tighten pinch bolt. Mak e
sure steering knuckle contacts stop on strut before tightening pinch
bolt. Face stru t pinc h bolt head in direction of travel .
• Us e Toirx tool (T30) to counterhold shaf t o f stabilizer ba r link ball
joint while tightenin g nut.
• Instal l wheel and lower car.
• Tighten bushin g en d of tension strut to subframe with car on
ground and loaded. Bounc e suspensio n a few times before final
tightening.
• Use BMW scan too l to carry ou t steering angl e sensor alignment .
• Align wheels whe n job is complete.

Tightening torques
Control arm to steering knuckl e 165 M m (122ft-lb )
(replace M14 x 1.5 self-locking flange nut
with new)
Road wheel to hub 120±10Nm
(89 ± 7 ft-lb)
Stabilizer lin k t o stabilizer bar 65 Nm (48 ft-lb)
(replace M10 ZNS3 nut with new)
Strut assembly pinc h bolt 81 Nm (ft-lb)
(replace M1 2 x 100 mm 10.9 grad e bol t
with new)
Tension stru t to steering knuckl e 165 Nm (122 ft-lb)
(replace M14 x 1 .5 self-locking flange nut
with new)
Tension strut to subframe (replace M1 2 x
1 .5 x 1 00 mm 10. 9 grade bolt with new )
• Stage 1 1 00 Nm (7 4 ft-lb )
• Stage 2 additional 90°
 Front Suspension 310-1 7
Tension strut, removing and installing (xDrive)

Tension strut, removing and installing

(xDrive)
— Rais e car an d remov e wheel.

WARNING —
• Make sure the vehicle is stable and we/I supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Remov e splash shiel d underneat h vehicl e front. See

020 Maintenance .

— I f equipped, detac h rid e height senso r link ro d from tension strut .

^ Workin g at tension strut :

• Remov e torsion strut bushin g fastene r (A).
• Remov e bal l joint nut. I f necessary, counterhol d ball joint shaft wit h
Torx tool while loosenin g nut .
• Us e ball joint pres s tool BMW special tool 31 2 240 or equivalent
to separate tension stru t from steering knuckle.

— Inspec t torsion stru t ball joint an d bushing.

• I f ball joint is defective, replace bal l joint. See Tension stru t bal l
joint, replacin g (xDrive ) in this repair group .
• I f tension stru t bushing i s defective, replace both bushings, bu t this
may only b e done onc e pe r torsion strut. See Tension stru t
bushing, replacin g i n this repai r group.

— Installatio n is revers e o f remova l

• Mak e sure thread bores, bolts, nut s and mating surfaces are clean.
• Instal l bushing en d of tension stru t to subframe using ne w
fasteners. D o not fully tighten nut at this time.
• Instal l tension strut to steering knuckle ball joint usin g ne w self-
locking nut. Tighten fully.
• Instal l wheel and lower car.
• Tighten bushing end of tension strut to subframe with car on
ground and loaded. Bounc e suspensio n a few times befor e final
tightening.
• Us e BMW scan tool to carry out steering angle senso r alignment .
• Align wheels when job i s complete.

Tightening torques
Road wheel to hub 120 + 10 Mm
(89 ± 7 ft-lb)
Strut assembly pinch bolt (replace M12 x 100 Nm (74 ft-lb )
1 .5 x 80 m m ZNS3 bol t with new)
Tension strut to steering knuckle ball joint 165 N m (12 2 ft-lb)
(replace M1 4 x 1 .5 self-locking flange nut
with new)
Tension strut to subframe (replac e M1 2 x
1 .5 x 1 00 mm 10. 9 grade bol t with new)
• Stage 1 100Nm (74 ft-lb)
• Stage 2 additional 90 °
310-18 Fron t Suspensio n
Tension strut bushing, replacing

Tension strut bushing , replacing

Replace tension strut bushings i n pairs. Bushing ma y only be
replaced once on a tension strut .

— Rais e car an d remov e wheel.

WARNING —
• Make sure that the car is firmly supported on jack stands
designed for the purpose. Place jack stands underneath
structural chassis points. Do not place jack stands under
suspension parts.

Rear-wheel drive : Test tension stru t bal l joint. I f defective, replace

both tension struts. If ball joint i s ok, procee d with bushing
replacement procedure.

Remove tension strut. See Tension strut , removing an d installing

(rear-wheel drive ) or Tension strut , removin g an d installing
(xDrive) in this repai r group .

Check circled area (arrow ) o f tension strut for punch mark :

• I f strut was previously punch-marked , replace both tension struts.
• I f not, punch mar k strut to indicat e bushin g replacement .

Using a service pres s an d appropriate press tools, pres s bushin g

out of tension strut.

CAUTION—
• Make sure press tools are exactly flush with walls of bushing
bore.

Make sure bushing bor e and new bushing ar e clean and grease-
free.

Press i n new bushing. Make sure mark on bushing (smal l arrow) is

aligned with mark on tension strut. Maximum deviation
allowed = ± 5°.

CAUTION—
• T o avoid damaging th e new bushing, press only o n the outer
steel sleeve during installation.
 Front Suspension 310-1 9
Tension strut ball joint, replacing (xDrive)

Press bushing i n so it protrudes equally (dimensio n A ) fro m both

sides o f tension strut .

I Install tension strut. See Tension strut, removin g and installing

(rear-wheel drive) or Tension strut , removing and installin g
A (xDrive) in this repai r group .

t CAUTION—
• Tighten the tension strut bushing through-bolt to its final torque
only with the vehicle on the ground and the suspension loaded.
*
A

t
B510310018

Tension stru t ball joint, replacing (xDrive )

— Rais e ca r and remov e wheel .

WARNING —
• Make sure that the car is firmly supported on jack stands
designed for the purpose. Place jack stands underneath
structural chassis points. Do not place jack stands under
suspension parts.

Detach tensio n stru t from ball joint. See Tension strut , removin g
and installing (xDrive) i n this repair group .

Remove ball joint mounting bolt s (A).

Remove ball joint from steering knuckle. If necessary, us e slid e

hammer t o drive bal l joint ou t of seat.

CAUTION—
• Do not reuse ball joint once it has been forcibly removed from
steering knuckle.

— Instal l new bal l joint using ne w self-locking bolts.

Tightening torque
Ball joint to steering knuckl e 60 N m (44 ft-lb)
(replace M10 x 20 m m 10. 9 grade ZN S self -
locking bolt s with new)

— Attac h tensio n strut to ball joint using new self-locking nut .

Tightening torque
Tension strut to steering knuckle ball joint 165 N m (12 2 ft-lb)
(replace M1 4 x 1 .5 self-locking flange nut
with new)
310-20 Fron t Suspension
Steering knuckle components (rear-wheel drive)

STEERING KNUCKLE AND

FRONT WHEEL BEARING
The steering knuckle (also called swivel bearing ) serve s as the
outboard attachmen t poin t for the suspensio n arm s and as the
wheel hub / wheel bearing carrier . Th e wheel bearing s ar e
permanently sealed an d require no maintenance .

Steering knuckle components

(rear-wheel drive )
The wheel bearing and hub assembly is bolted to the steerin g
knuckle.
1. M6 x 16 mm 8.8 grade ZNS3 bol t
•Tightento8Nm(6ft-lb)
2. ABS wheel speed senso r
• Lubricate with Staburags ® NB U 12/K or equivalent grease
before installing.
3. M12 x 1. 5 x 55 mm Z1 bearin g hu b bol t
• Replac e with new
•Tighten to 11 0 M m (8 1 ft-lb)
4. Electrical harness bracket
5. Steering knuckle (swive l bearing)
6. Stabilizer bar link bracket
7. M10 x 20 m m 10. 9 grade bol t
8. M12 x 100 m m 10. 9 grade strut pinc h bolt
• Replac e with new
• Tighten to 81 Nm (60 ft-lb)
9. M12 x 1.5 x ZNS3 self-locking collar nut
10. Whee l bearing hub

Steering knuckle , removin g and installin g

(rear-wheel drive )
— Rais e car an d remov e front wheel .

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Detac h front brake caliper from steering knuckle and suspend aside
using stiff wire . Do not detach brak e fluid hose. See 340 Brakes.

— Remov e brak e rotor. Se e 340 Brakes .

— Remov e wheel speed sensor from steering knuckle . Se e

340 Brakes

— Detac h control arm an d tension stru t from steering knuckle. See

Front Suspension Arm s in this repai r group .

— Detac h tie ro d end from steering knuckle. Se e 320 Steering an d

Wheel Alignment .
 Front Suspensio n 310-2 1
Steering knuckle, removing and installing (rear-wheel drive)

Working at top of steering knuckle:

• Remov e strut pinch bolt (A) from upper steering knuckle .
• Remove stabilizer lin k bracke t bol t (B) and detach bracke t fro m
steering knuckle .

If necessary, us e BMW special tool 31 2 230 to spread (curve d

arrow) steering knuckle pinc h collar . Slide steering knuckle
downward to disengage fro m strut tube.
• Not e locating bos s (arrow ) for strut. During reassembly , bos s
slides in steering knuckle pinc h colla r gap.

Replace wheel bearin g i f necessary. See Front whee l bearing ,

replacing (rear-wheel drive) in this repai r group .

Installation i s reverse of removal. Note the following :

• Replac e self-lockin g fasteners .
• Mak e sur e locating boss o n strut tube slides in steering knuckle
pinch colla r gap.
• Fac e strut pinch bol t head in direction of travel.
• Mak e sure steering knuckl e contacts stop on strut before
tightening pinch bolt .
• Clean wheel speed sensor bor e hol e and lubricate with
Staburags® NBU 12/ K or equivalent grease.
• Align wheels when job is complete.

Tightening torques
Brake caliper to steering knuckl e (replac e 110Nm(81 ft-lb)
M12 x 1 .5 x 43 m m ZNS bolt s with new)
Brake rotor to wheel hub (replace M 8 x 1 4 16Nm (12 ft-lb)
mm Allen bolt with new)
Control arm to steering knuckle (replace 165 M m (12 2 ft-lb)
M14 x 1 .5 self-locking flange nu t with new)
Road wheel to hub 120 ± 10 Nm
(89 ± 7 ft-lb)
Strut assembly pinch bolt (replace M1 2 x 81 Nm (60 ft-lb)
1 00 mm 1 0.9 grade bol t with new)
Tension strut to steering knuckle (replace 165Nm (12 2 ft-lb)
M14x 1.5 self-locking flange nut with new)
Tie rod end to steering knuckl e (replace 165Nm (12 2 ft-lb)
M14x 1. 5 ZNS3 nut with new )
Wheel spee d sensor t o steering knuckl e 8 Nm (6 ft-lb)
310-22 Fron t Suspension
Front wheel bearing, replacing (rear-wheel drive)

Front wheel bearing, replacin g

(rear-wheel drive)
— Rais e car an d remov e front wheel.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove steerin g knuckle. Se e Steering knuckle, removing an d

installing (rear-wheel drive) in this repai r group.

Clamp wheel bearin g hub in shop vise as illustrated.

CAUTION—
• Make sure unit is only clamped at bearing hub.

Remove bearing hub mounting bolts (arrows) . Lif t off steering

knuckle.
 Front Suspension 310-2 3
Steering knuckle components (xDrive)

When installing :
• Kee p bearing hub contact area (grey) clean an d grease-free.
• I f reusing bearing hub, tap mounting bol t threaded holes (arrows) .
• Replac e mountin g bolt s wit h new.

Tightening torque
Bearing hub to steering knuckle 110 Mm (81 ft-lb)
(replace M1 2 x 1.5x55 m m Z1 bolt with new)

Steering knuckle components (xDrive )

The wheel bearing is pressed o n the steering knuckl e an d require s
special tools to remove . The wheel bearing i s destroyed when th e
wheel hub is removed .
1. AB S wheel spee d sensor
• Lubricat e with Staburags® NBU 12/K or equivalent greas e
before installing .
2. M12 x 1. 5 x ZNS3 self-lockin g collar nut
3. Steerin g knuckl e (swive l bearing)
4. Brak e hose bracket
5. Whee l bearin g
6. M1 2 x 1. 5 x 80 m m ZNS stru t pinch bol t
• Replac e with new
•Tighten to 10 0 M m (7 4 ft-lb)
7. Circli p
8. Dus t shield
9. Hu b
10. M27 x 1. 5 collar nut
• Replac e with new
• Tighten (wit h wheel on ground) to 420 Nm (310 ft-lb)
310-24 Fron t Suspension
Steering knuckle, removing and installing (xDrive)

Steering knuckle , removin g an d installing

(xDrive)
— Rais e car and remov e front wheel .

WARNING —
• Make sure the vehicle is stable and well supported at a/I times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

^C. Usin g a suitable punch , straighte n stake d side s of wheel hub collar
nut (arrows).

With a n assistant holdin g dow n brak e pedal , remov e collar nut and
discard.

CAUTION—
• The drive axle collar nut is tightened to a high torque. If
necessary, reinstall road wheel and place vehicle on floor
before breaking collar nut free.

— Detac h front brake caliper from steering knuckle and suspend aside
using stif f wire . Do not detach brak e flui d hose . Se e 340 Brakes.

— Remov e brak e rotor . See 34 0 Brakes .

— Remov e whee l speed sensor from steerin g knuckle. Se e 340

Brakes. Detac h senso r electrica l harnes s fro m bracket on strut.

— Detac h contro l ar m an d tension stru t from steering knuckle. See

Front Suspension Arm s i n this repai r group .

— Detac h tie ro d end from steering knuckle. Se e 320 Steering an d

Wheel Alignment .

— Detac h stabilize r lin k from strut tube. Us e Tor x tool (T30) to

counterhold shaft o f stabilizer bar link ball joint while removing nut .

— Rotat e steering knuckle to one side and pres s drive axle stub out of
wheel bearin g hub . Ti e u p drive axl e en d usin g stif f wire .

CAUTION—
• In order to avoid damaging drive axle threads, do not drive out
stub axle using impact tool.

— Suppor t steerin g knuckl e wit h floor jack. Workin g a t top o f steerin g

knuckle, remov e strut pinch bolt .
 Front Suspension 310-2 5
Steering knuckle, removing and installing (xDrive)

If necessary , us e BM W special too l 31 2 230 to spread (curve d

arrow) steerin g knuckle pinch collar. Slid e steering knuckle down
and off strut tube.
• Not e locatin g bos s (arrow ) for strut. During reassembly , bos s
slides i n steering knuckl e pinc h collar gap.

If necessary, replace torsion strut ball joint. See Tension strut bal l
joint, replacin g (xDrive) .

If necessary , replac e wheel bearing . Se e Fron t wheel bearing ,

replacing (xDrive ) in this repair group.

Installation i s reverse o f removal . Not e the following:

• Mak e sur e locating bos s o n strut tube slide s i n steering knuckl e
pinch colla r gap .
• Mak e sure steering knuckl e contact s stop on strut befor e
tightening pinc h bolt . Fac e stru t pinch bolt head in direction o f
travel.
• Replac e self-lockin g fasteners.
• Us e Torx tool (T30 ) t o counterhold shaft of stabilizer ba r link bal l
joint while tightening nut .
• Clea n AB S wheel spee d senso r bor e hole and lubricate wit h
Staburags® NBU 12/ K or equivalent grease .
• Oil and wheel hub contact surface s lightly. Do not allow oi l to
contaminate drive axle threads. Fina l tightening with wheel o n
ground. Stak e collar nut after final tightening .
• Align wheels when job is complete.

Tightening torques
Brake caliperto steering knuckl e (replace 110 Mm (8 1 ft-lb )
M1 2 x 1.5x43 m m ZNS bolt s with new)
Brake roto r to wheel hu b 16Nm(12ft-lb)
(replace M 8 x 1 4 mm Allen bol t wit h new)
Control arm to steering knuckl e (replac e 1 65 Nm (12 2 ft-lb)
M14 x 1 .5 self-locking flange nut with new)
Drive axle to wheel hu b 420 N m (310 ft-lb)
(replace M2 7 x 1 .5 collar nu t with new)
Road wheel to hub 120 ± 1 0 Nm
(89 ± 7 ft-lb)
Stabilizer link to strut tub e 65 N m (4 8 ft-lb)
(replace M1 0 ZNS3 nut with new)
Strut assembly pinc h bol t (replac e M1 2 x 100 N m (74 ft-lb )
1 .5 x 80 mm ZNS3 bolt wit h new )
Tension strut to steering knuckle bal l joint 165 N m (12 2 ft-lb)
(replace M14 x 1.5 self-locking flange nut
with new)
Tie rod end to steering knuckl e 165Nm (122 ft-lb)
(replace M14 x 1. 5 ZNS3 nut with new)
Wheel spee d senso r t o steering knuckl e 8 N m ( 6 ft-lb)
310-26 Fron t Suspensio n
Front wheel bearing, replacing (xDrive)

Front wheel bearing, replacing (xDrive)

— Rais e car an d remov e front wheel.

WARNING—
• Make sure the vehicle is stable and well supported at a/I times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Using a. suitable punch, straighten staked sides o f wheel hu b collar

nut (arrows).

With an assistant holding down brak e pedal, remov e collar nut and
discard.

CAUTION—
• The drive axle collar nut is tightened to a high torque. If
necessary, reinstall road wheel and place vehicle on floor
before breaking collar nut free.

— Detac h front brake caliper from steering knuckl e and suspend aside
using stiff wire . Do not detach brak e fluid hose. See 340 Brakes.

— Remov e brake rotor . See 34 0 Brakes .

. Attac h slide hammer hu b puller to bearing hub flange using 5 wheel

bolts. Drive hub off wheel bearing.

Note that wheel bearing inne r race is removed with flange, thus
destroying bearing. Separate race from flange and discard race. Do
not damage flange.

Remove steering knuckle. See Steering knuckle , removing and

installing (xDrive) in this repai r group. Clam p in shop vice with
aluminum jaws.
 Front Suspension 310-2 7
Front wheel bearing, replacing (xDrive)

Squeeze wheel bearing retaining circlip using needle-nosed plier s

and lif t out of hub.

Jfrll'HPI'EH

Use bearing remova l tools (arrows ) or shop pres s to remov e

bearing from steering knuckle.

Before installing ne w bearing:

• Clea n press-fit surface in steering knuckle and keep free of oil and
grease.
• Coat 50% of press-fit surface in steering knuckle with Loctite® 638 .

Use bearing installation tools or shop press to pres s in new wheel

bearing. Make sure wide champfer on bearing (arrow) points t o
steering knuckle .

CAUTION—
• Press only on outer race when installing bearing in steering
knuckle.

Reinstall bearin g retaining circli p usin g needle-nosed pliers. Mak e

sure circlip is seated firmly i n steering knuckle groove.
310-28 Fron t Suspensio n
Front wheel bearing, replacing (xDrive)

Use bearing installation tools (arrows) or shop press to press wheel

hub flange into new bearing.
• Mak e sure dust shield i s intact. Replac e if necessary.

CAUTION—
• Press only on inner race when installing hub in wheel bearing.

Install steerin g knuckle. See Steering knuckle, removin g and

installing in this repair group.

Draw front axle int o steering knuckle.

Install front brake rotor and caliper. Se e 340 Brakes.

Apply light coating o f oil to contact surfaces . With an assistant

holding down brake, tighten axle collar nut to specified torque.

Tightening torques
Drive axle to wheel hub 420 Nm (310ft-lb)
(replace M2 7 x 1.5 collar nu t with new)
Road wheel to hub 120 ±10 M m
(89 ± 7 ft-lb)

Using a suitable drift , stake side of axle collar nu t to stub axle.

Align wheels when job is complete .

 Front Suspension 310-2 9
Active stabilizer bar (dynamic drive)

FRONT STABILIZER BA R
Active stabilizer ba r (dynamic drive)
5 Series vehicles may be equipped with the optional active stabilizer
system (acronyms ARS). The system is also referred to as dynamic
drive.

With this system, front and rear stabilizer bars are split in half, with
the halves connected to each other via hydraulic oscillatin g motors .
An electronic control module operates through a valve body to
control coupling of the two stabilizer bar halves.

For additional details, including active stabilizer troubleshooting and

commissioning, see 300 Suspension, Steering and Brakes-
General.

Active stabilizer bar components, front

1. Stabilize r bar link
1 2
2. Fron t ride-height sensor
3. Activ e stabilizer valve block
4. Rea r oscillating motor pressure lines
5. Stabilize r bar mount
6. Fron t oscillating motor pressure lines
7. Fron t oscillating motor
8. Ven t hose
\h
9. Stabilize r bar

srs
5 6 7 8 5
310-30 Fron t Suspension
Hydraulic system, bleeding

Hydraulic system , bleeding

CAUTION—
• When filling or bleeding hydraulic system, do not allow
contamination of fluid or reservoir.
• Using contaminated equipment to add fluid may introduce dirt
particles into the fluid reservoir and significantly reduce the
service life of system components.

Active stabilizer system and power steerin g share the fluid reservoir
and fluid cooler. The reservoir ca p indicates the fluid to be used.

Active stabilizer system fluid

Hydraulic flui d for tandem pump system Pentosin C

Thoroughly clea n fluid reservoir and its immediate surrounding s

before opening reservoir cap . Chec k and top off fluid level with fluid
temperature at approx. 20°C (68°F) and the engine stopped .

Make sur e reservoir ca p is fully screwe d in before checkin g flui d

level. Check that fluid level is at MAX mark. Top off with correct fluid
if necessary .

CAUTION—
• With fluid at operating temperature (50°-60°C or 122°-140°F),
full fluid level is approximately 15 mm ( 5A in) above MAX
marking. Do not siphon out fluid in that situation.

— Star t engine.

— Tur n steering wheel left and right twice in each direction t o full lock,
if necessary, to p off hydraulic fluid again.

— Mov e steering wheel to straight-ahead positio n an d switch engine

OFF. Check an d correct fluid level.

— T o make sure all air is out of system, drive vehicle on a short trip,
then perform bleed procedure again .

— Chec k hydraulic syste m for leaks. I f extreme air or fluid leaks are
detected, o r rattling noises continue in the front end, replac e th e
pressure relie f valves and fluid lines, the n bleed system again.

Front stabilizer bar , removing an d installin g

(mechanical stabilizer )
The front stabilizer is attached to the front subframe.

— Rais e front of vehicle an d support safely .

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Remov e engine splash shield and fron t end reinforcemen t panel.

 Front Suspension 310-3 1
Front stabilizer bar, removing and installing (mechanical stabilizer)

Detach stabilizer links on both sides fro m stabilizer bar Us e Torx

tool (T30) t o counterhold shaft of stabilizer bar link ball joint whil e
loosening nut.

Rear-wheel driv e righ t side: Remov e power steering line bracke t

mounting bolt (arrow) fro m stabilizer ba r mount.

Remove stabilizer bar mount fasteners (arrows) an d lowe r bar.

Check rubbe r moun t mount s for damage. Replac e if necessary .

Installation is reverse of removal. Note th e following .

• Replace self-lockin g fasteners .
• Us e Torx tool (T30) to counterhold shaft of stabilizer bar lin k bal l
joint while tightening nut.
• Instal l front end reinforcement using new fasteners. See Front end
reinforcement panel, removing an d installing i n this repai r
group.

Tightening torques
Stabilizer ba r mount t o front subframe 30.5
(replace M8 fasteners wit h new)
Stabilizer link to stabilizer bar 65 Nm (48 ft-lb )
(replace M1 0 ZNS3 nu t with new)
310-32 Fron t Suspension
Front stabilizer bar, removing and installing (active stabilizer)

Front stabilizer bar , removing and installing

(active stabilizer)
The front stabilizer is attached t o the front subframe .

Raise front of vehicle and support safely.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

— Remov e engine splash shield and front end reinforcemen t panel.

'X Detac h stabilize r links on both side s from stabilizer bar. Use Torx
tool (T30 ) to counterhold shaft of stabilizer ba r link bal l joint while
loosening nut.

Working at front stabilizer oscillating motor , pull vent lin e out of

Y-connector (arrow) .

CAUTION—
• Do not detach or disassemble pressure relief valves.

Note carefully installation position s of fluid pressure lines and

brackets at oscillating motor. Then detach pressur e line union s
(arrows) from motor. Be prepared t o catch dripping hydraulic fluid
and dispose i n a safe manner .

CAUTION—
• Do not allow dirt to enter hydraulic lines. Plug fluid line
openings.

To avoid confusion when installing, pressur e line s are different

dimensions an d the union s hav e different threads.

BentleyPublisners
.com
 Front Suspension 310-3 3
Front stabilizer bar, removing and installing (active stabilizer)

"X, Righ t side: If necessary, remove hydraulic line bracket mounting bolt
(arrow) from stabilizer bar mount.

— Lef t side: I f necessary, detach hydrauli c line bracke t from stabilizer

bar mount .

Remove stabilizer bar mount fasteners (arrows) and lowe r bar.

Separate stabilizer bar mount brackets and rubber mount s from

roller bearings .
Rubber
mount / c. • Check rolle r bearings fo r free movement. Sligh t discharg e of
Mount grease fro m bearing is acceptable. Replac e stabilize r bar if a
bracket bearing bind s or is otherwise damaged.
• Replac e rubbe r mount s if damaged. Keep rubbe r grease-free .

When installing , not e the following.

• Replac e self-locking fasteners.
• To prevent stabilizer bar distortion, instal l lef t mount bracket first
(without elongated holes). Then install right moun t bracket (wit h
elongated holes) .
• Us e Jorx too l (T30) t o counterhold shaft of stabilizer ba r link bal l
joint while tightening nut.
BentieyPublishers
Tightening torques
Stabilizer bar mount to front subframe 30.5 N m (22 ft-lb)
(replace M 8 fasteners with new)
Stabilizer lin k to stabilizer bar 65 N m (48 ft-lb)
(replace M10 ZNS3 nut with new)
310-34 Fron t Suspensio n
Front stabilizer bar links, replacing

Attach fluid pressure line s an d brackets . Mak e sure pressure lines

do no t contact stabilizer bar . Minimu m distance = 5 mm (1 4 in) .

Tightening torque
Fluid pressur e lin e to oscillating moto r 30 N m (22 ft-lb)
(union nut)

New stabilizer ba r is equipped wit h ne w pressur e relie f valves. Use

new vent hose s and Y-connection.
• Remov e plugs from pressure relie f valves. Loose n valv e unio n nut.
• Yello w vent hos e i s toward fron t of vehicle. Blac k hos e i s at rear.
• Slid e vent lines int o pressur e relie f valve s u p to middle o f marks
and tighten unio n nuts .

Tightening torques
Vent hos e to vent valve 5 Nr n (4 ft-lb)
Vent valve to oscillating moto r 14Nm(10ft-lb)

Fill hydraulic flui d reservoir (same a s power steering flui d reservoir).

Active stabilizer system fluid

Hydraulic fluid for tandem pump system Pentosin CHF 11S

Use BMW scan tool to bleed ai r out o f active stabilizer system . See
Hydraulic system , bleedin g i n this repai r group . Chec k line s and
connections for leaks.

Install front end reinforcemen t usin g ne w fasteners. See Front en d

reinforcement panel , removin g an d installin g i n this repair group.

Carry out commissioning procedure . Se e 300 Suspension ,

Steering an d Brakes-General.
BenticyPurjIisii Ir s
B510310045

Front stabilizer bar links, replacin g

The stabilize r bar links attach the stabilize r ba r to the strut
assemblies.
• Rear-whee l drive: Stabilizer ba r link uppe r bal l joint attaches to
separate triangula r bracke t whic h bolts to steering knuckle.
• xDrive : Stabilizer bar link upper bal l joint bolts directly to strut tube.

Replace stabilizer ba r links in pairs.

Raise fron t of vehicle and remove front wheels .

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift o r jack stands designe d for
the purpose. A floor jack is not adequate support.
 Front Suspension 310-3 5
Front stabilizer bar links, replacing

^> Detac h stabilizer links on both sides from stabilizer bar. Us e Torx
tool (T30 ) t o counterhold shaft o f stabilizer bar link ball joint while
loosening nut .

— Similarly , detach stabilizer ba r link from steering knuckle bracke t or

strut tube on each side.

— Installatio n is reverse of removal . Replace self-locking fasteners.

Tightening torques
Road wheel to hub 120+ 10N m
(89 ± 7 ft-lb)
Stabilizer lin k to stabilizer ba r or upper link 65 Nm (48 ft-lb)
mount (replac e M10 ZNS3 nu t with new)
 311-1

311 Fron t Axl e Differentia l

GENERAL 311- 1 FRONT DIFFERENTIA L 311- 9

Front differential an d drive axle s 311- 1 Front driv e components 311- 9
Front axl e description 311- 2 Front differential oil level, checking 311-1 0
Warnings an d Cautions 311- 2 Front differential oil, draining and filling 311-1 0
Front differential, removing and installing . . . 311-1 1
DRIVE AXLE S 311- 2
Right axle bearing pedestal ,
Front driv e axle , removin g and installing 311- 2
removing and installing 311-1 4
Front drive axl e flange seal, replacing 311- 5
Front differential inpu t flange seal, replacin g . 311-1 5
CV joint boots, replacin g 311- 6
TABLES

a. Differential flui d 311- 9

GENERAL
This repair grou p covers servic e an d replacement of front driv e
axles an d front differential . Fron t differentia l interna l repai r i s not
covered.

See 300 Suspension, Steering and Brakes-General for a general

description of the front suspension.

See also:
• 260 Driveshafts for front driveshaft remova l
• 310 Front Suspension

Front differentia l an d drive axle s

1. Steerin g knuckle (swivel bearing)

1 2 2. Stru t assembly
3. Stabilize r bar link
4. Fron t end reinforcement panel
5. Fron t driveshaft flange
6. Oute r CV joint
7. Fron t drive axle
8. Inne r CV joint
9. Righ t side bearing pedestal
10. Front subframe (axl e carrier )
11. Front differentia l

10
6510311001
311 -2 Fron t Axle Differential
Front axle description

Front axle descriptio n

The front axle differentia l an d the righ t side bearing pedestal bol t to
each side of the oil pan. Powe r i s transmitted to the front differential
from the xDrive transfer case via the front driveshaft, then to front
drive hub s through two drive axles. The right drive axle inne r
constant velocity (CV) joint shaf t extends throug h the right side
bearing pedesta l and the oil pan int o the front differential.

Warnings an d Cautions

WARNING—
• Do not reuse self-locking fasteners. They are designed to be
used only once and may fail if reused. Replace with new.

CAUTION—
• Do riot drive the vehicle with the front end reinforcement panel
removed. Se e 310 Front Suspension .
• When reinstalling the reinforcement panel after repairs, replace
panel mounting fasteners with new.
• Due to the chemical and corrosion characteristics of aluminum,
follow these precautions when working with aluminum
components:
—Do not bring into contact with battery acid.
—Do not use wire brushes with brass o r iron bristles. Only use
brushes with stain/ess steel bristles.
—Do not expose t o flying sparks from grinding o r cutting
operations.
—Do not subject t o steel we/ding splashes.
—Do not expose t o temperatures over80°C (176°F), even for
short periods. Temperatures in painting facilities are not a
problem.

DRIVE AXLES
Front drive axles use two differen t types o f CV joint.
• Outer CV joint: Traditional ball-and-cage design allows power to be
delivered from axle to wheel hu b continuously while allowing
suspension and steering motion.
• Inne r joint: Triple roller bearing joint minimizes the amount of
vibration and noise transmitted back throug h vehicle drivetrain
while allowing axle to move in and ou t to compensate for
suspension travel.

To replace a CV joint or boot, remove the drive axle from the vehicle.

Front drive axle, removing an d installing

Raise ca r and remove fron t wheel .

WARNING—
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.
 . Usin g a suitable punch , straighte n staked sides o f wheel hu b colla r
nut (arrows).

, Wit h an assistant holdin g dow n brak e pedal, remov e colla r nu t an d

discard.

CAUTION—
• The drive axle collar nut is tightened to a high torque. If
necessary, reinstall road wheel and place vehicle on floor
before breaking collar nut free.

— Detac h front brake caliper from steering knuckle and suspend aside
using stif f wire . D o not detach brak e fluid hose. See 340 Brakes .

— Remov e brake disc. Se e 340 Brakes .

— Remov e ABS wheel spee d senso r fro m steering knuckle . Se e 34 0

Brakes. Detac h sensor electrica l harness from bracket on strut.

— Detac h control ar m an d tension stru t from steering knuckle. Se e

310 Front Suspension .

— Detac h tie rod end from steering knuckle . See 320 Steerin g an d
Wheel Alignment .

— Detac h stabilizer lin k from strut tube. Use Torx tool (T30 ) t o
counterhold shaft of stabilizer ba r link ball joint while removin g nut .

— Rotat e steering knuckle to one side and us e BM W specia l tools

32 2 200 or equivalent to press drive axle stub out of wheel bearing
hub. Tie up drive axle end usin g stif f wire .

CAUTION—
• In order to avoid damaging drive axle threads, do not drive out
stub axle using impact tool.

Remove splash shiel d an d front end reinforcement panel. Se e

310 Front Suspension .

. Us e BMW special too l 31 5 11 0 or equivalent prying too l to force

drive axle inner CV joint shaft out of front differential or right bearin g
pedestal outpu t flange. Be prepared to catch dripping oil .

Replace differential or bearing pedestal flange seal while axl e is

removed from vehicle. See Front drive axle flange seal, replacin g
in this repai r group.
311 -4 Fron t Axle Differentia l
Front drive axle, removing and installing

— Replac e CV joint boots as necessary. Se e C V joint boots,

replacing i n this repair group.

^ Replac e inne r CV joint locking circlip (arrow).

— Whe n installing drive axle inner end:

• Coat sealing lip of flange seal with transmission fluid.
• Pus h inner CV joint shaft into differential o r bearing pedestal flange
until locking circli p snaps i n place .

— Lightl y oil drive axle spline teeth and insert drive axle into wheel hub.

CAUTION—
• Do not oil axle or collar nut threads.

Installation is reverse o f removal. Not e the following:

• Replace self-locking fasteners .
• Us e Torx tool (T30) t o counterhold shaft of stabilizer ba r link bal l
joint while tightening nut.
• Clean ABS wheel speed sensor bor e hol e and lubricate with
Staburags® NBU 12/K or equivalent grease.
• Oil collar nut and wheel hub contact surfaces lightly . Do not allow
oil to contaminate drive axle threads. Final tightening with wheel on
ground. Stak e collar nu t after final tightening.
• Check fron t differential oil level when jo b i s complete. Se e Front
differential oil level, checking in this repair group .
• Install front end reinforcement pane l using new fasteners. Se e
310 Front Suspension .

Tightening torques
Brake calipe r to steering knuckle (replac e 110 Mm (81 ft-lb)
M12x 1. 5 x43 m m ZNS bolts with new)
Brake disc to wheel hu b 16Nm(12ft-lb)
(replace M 8 x 1 4 mm Allen bolt with new)
Control arm to steering knuckle (replac e 165Nm (122 ft-lb)
M14 x 1.5 self-locking flang e nut with new)
Drive axle to wheel hub 420 Nm (310 ft-lb)
(replace M27 x 1 .5 collar nut with new)
Front end reinforcement panel t o
subframe (replace M10 x 35 m m 10.9
grade ZNS bolts with new):
• Stage 1 56 Nrn (41 ft-lb)
• Stage 2 + additional 90°
Road wheel to hub 120±10N m
(89 ± 7 ft-lb)
Stabilizer link to strut tube 65 N m (4 8 ft-lb )
(replace M 1 0ZNS3 nu t with new)
Tension stru t t o steering knuckle ball joint 165Nm (122 ft-lb)
(replace M1 4 x 1 .5 self-locking flange nu t
with new )
Tie ro d end to steering knuckle 165Nm (12 2 ft-lb)
(replace M1 4 x 1 .5 ZNS3 nut with new)
Wheel spee d sensor t o steering knuckle 8 Nm (6 ft-lb)
 Front Axl e Differential 31 1 -5
Front drive axle flange seal, replacing

Front driv e axle flang e seal , replacin g

The left front drive axle is fitted to the front differential. The righ t front
drive axle is fitted to the right bearing pedestal. Se e Front driv e
components i n this repair group.

There i s a flange seal on each side , in the differential and i n the

bearing pedestal. I n case o f flange seal oil leaks, follow this
procedure to replace the seal(s).

— Rais e front of vehicle an d suppor t safely.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove front drive axle. See Fron t drive axle, removing an d

installing i n this repai r group.

Left side flange: Us e seal removal tool or screwdriver to pry (arrow)

flange seal out o f differential.

Right side flange: Us e seal remova l tool or screwdriver to pr y

(arrow) flange seal ou t of right bearing pedestal .

Remove protective sleeve from new flange seal and sav e for use
Prtective during drive axle installation. Seal is equipped with protective sleeve
sleeve to prevent sealing li p from damage durin g axl e installation .

Flange
seal

\3
311 -6 Fron t Axle Differential
CV joint boots, replacing

Use BM W specia l too l 3 1 3 13 0 o r equivalen t sea l drive r to driv e

flange seal int o differential or bearin g pedesta l as far as it will go.

Coat sealing lip of flange seal with transmission fluid.

Insert protectiv e sleeve into seal.

Replace inner CV joint lockin g circli p (arrow) .

Install drive axle:

• Inser t inboard end of drive axle partially into differential housing or
bearing pedestal .
• Withdraw protectiv e sleeve from sealing lip , cut protective sleeve
and remove.
• Continue pressing drive axle in until spring clip snaps audibly int o
place.

Installation i s reverse of removal . Not e the following:

• Replac e self-locking fasteners.
• Reinstal l drive axle stub in steering knuckle . See Front drive axle,
removing and installing i n this repai r group .
• Chec k front differential oil level when job i s complete. See Front
differential oil level, checking i n this repai r group.
• Instal l front end reinforcement panel usin g ne w fasteners. See
310 Front Suspension .

CV joint boots , replacing

When replacin g CV boots, us e a complete boo t repair kit. The kit
includes new boots, clamping bands, special lubricant and a new CV
joint shaft circlip.

Remove drive axle. See Front drive axle, removing and installing
in this repair group.
Outer
CV joint Place axle in shop vice with aluminum jaws.

Inner
CV joint
 Front Axle Differential 31 1 -7
CV joint boots, replacing

^k, Releas e retaining clamps (arrows) from both ends of outer CV boot.
Cut off boot and discard.

— Usin g a soft-faced hammer, poun d outer CV joint off drive axle.

— Inspec t outer CV joint carefully.

• Loo k for galling, pitting and other signs of wear or physical
damage.
• Polishe d surfaces or visible ball tracks alone are not necessarily
cause for replacement.
• Discoloratio n (overheating) of balls indicates lack of lubrication.
Replace joint.

Using a flat blade screwdriver, pry spring clip (arrow ) off drive axle
splines.

— Clea n ol d lubrican t off axle splines.

Release retaining clamps (arrows) from both ends of inner CV boot.

Cut off boot and discard .

B510311007
311 -8 Fron t Axle Differential
CV joint boots, replacing

Inner C V joint (triple-roller ) component s

1. Locikin g circlip
2. Inne r C V joint housing
3. Circli p
4. Tripl e rolle r bearing
5. Clam p
6. Inne r CV joint boot
7. Driv e axle shaft
8. Clam p

Slide housin g (2 ) off triple-roller bearing.

Clean ol d lubricant off axle and tripl e roller bearing.

Pack triple roller bearing and boo t with fresh CV joint grease.

CV joint lubricant capacity

Inner CV joint 80 grams (2.8 oz )

— Instal l new inner CV joint boot ove r outer axl e end.

^. I f triple-roller bearing i s removed from axle shaft, note that it is

installed with flat side of joint facing retainin g circlip.

— Inser t triple roller bearing int o inne r C V joint housing .

— Secur e boot to housing and axl e shaft usin g clamps supplie d with
boot kit. Pinch clamps tight using special clamp pliers.

— Plac e new clamping band s an d oute r C V boo t over drive axle.

— Replac e spring clip on splined en d o f drive axle.

— Appl y Loctite® 270 or an equivalent heavy-duty locking compound t o

drive axle splines.

CAUTION—
• Do not let locking compound contact balls in joint. Apply only a
thin coat to cover splines.

— Pac k joint with fresh CV joint grease.

CV joint lubricant capacity

Outer C V joint 80 grams (2.8 oz )

Tap CV joint onto splined en d of drive axl e until spring clip snap s
audibly int o place.

Using clamp pliers , secure retaining clam p int o position tightly

sealing large end of boot against C V joint.
 Front Axle Differential 311- 9
Front drive components

Before installing smal l boo t clamp :

• Fle x CV joint a s far over as it will go.
• Inser t smal l screw-driver betwee n boo t and axle-shaft t o "burp" air
from boot.

With outer boot ful l of grease an d any air eliminated fro m boot,
secure small en d of boot o n CV joint by pinching clamp wit h pliers .

Remainder o f installation is reverse of removal. See Fron t driv e

axle, removin g and installing in this repair group .

Check front differential oil leve l and top of f i f necessary. See Fron t
differential oil level, checking i n this repair group.

FRONT DIFFERENTIA L
The fron t differential, bolted to the lef t side of the engin e oi l pan, is
filled with lifetime oil that ordinaril y does no t need to be changed. I f
service i s required, BM W recommends using onl y a speciall y
formulated synthetic gea r oil (SAF-XO).

Axle flange seal replacement i s covered in Front drive axle flange

seal, replacin g i n this repair group.

Replacement of O-ring seal betwee n engine oil pan and front

differential is covered i n Front differential , removin g and
installing i n this repair group.

Replacement of O-ring seal between engine oi l pan and righ t sid e

bearing pedestal is covered in Right axle bearing pedestal ,
removing an d installin g i n this repair group.

Table a. Differential fluid

Capacity 0.6 lite r (0.6 3 US qt)
BMW specification SAF-XO Synthetic

Front driv e component s

1. Oute r C V joint
1 23 4 5 6 3 2 1 2. Driv e axle shaft
3. Inne r CV joint
4. Righ t side bearing pedestal
5. Fron t differential
6. Fron t driveshaf t flange
311-10 Fron t Axle Differential
Front differential oil level, checking

Front differential oil level, checkin g

Drive vehicle a short distance to warm differentia l oil.

Raise vehicle and support safely.

WARNING—
• Make sure the vehicle is stable and well supported at a/1 times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splash shiel d and front end reinforcement . See 310 Fron t
Suspension.

With vehicle level, check oil at filler plug (arrow) :

• Plac e a drain pan under oil filler plug befor e removing.
• Oil level is correct when it just reaches edg e o f filler hole.

If necessary, to p up fluid with syntheti c gea r oi l (SAF-XO) .

Replace filler plu g sealing ring.

Install and tighten oil filler plug when oil level is correct.

Tightening torque
Oil drain / fill plu g to differential 60 Nm (4 4 ft-lb)

Front differentia l oil , draining and filling

Drive vehicl e a short distanc e t o warm differentia l oil.

Raise vehicle an d safely support .

WARNING—
• Make sure the vehicle is stable and we/I supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splash shiel d and front end reinforcemen t panel. See

310 Front Suspension.

With vehicle level:

• Plac e a drain pan under oi l drain plug.
u B • Remov e drain plug (A ) and allow oil to drain into pan.

f«. WARNING—
• Pull the loose plug away quickly to avoid being scalded by hot
oil. Use gloves to protect your hands.

j When oi l flow has diminished to an occasional drip, reinstal l drai n

JaKJiiifppr^
plug with new sealing ring.

Remove filler plug (B). Ad d synthetic gear oil (SAF-XO) and check
level. See Front differential oil level, checking in this repair group.

Tightening torque
Oil drain /fill plug to differential 60 N m (4 4 ft-lb)
 Front Axle Differentia l 311-1 1
Front differential, removing and installing

Front differential, removing and installing

Disconnect negativ e (- ) battery cable.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions i n 001 Warnings and Cautions .

— Rais e engine hood to service position. See 410 Fender, Engin e

Hood.

— Remov e air filter housing. Se e 13 0 Fuel Injection.

— Remov e uppe r engin e cover (ignitio n coil cover). Se e

020 Maintenance .

— Rais e vehicle and suppor t safely .

WARNING —
• Make sure the vehicle is stable and well supported at a/I times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splash shield and front end reinforcement panel from under
engine.

Remove suspension sid e splash shields.

Install engine support brace across engine bay .

^V Workin g underneath engine, remove right and lef t engin e moun t

"
upper nuts (arrow) . Rais e engine slightly (!4 - 1 /2 in) to releas e loa d
on engine mounts .

— Sipho n out powe r steering fluid.

311-12 Fron t Axle Differential
Front differential, removing and installing

Working underneat h engine , remov e pressur e lin e banj o bolt

(arrow) from power steerin g pump and detach pressure line. Catch
dripping fluid i n a shop towel .

— Detac h fluid line from transmission fluid cooler.

— Drai n front differential oil. See Fron t differentia l oil, draining and
filling i n this repair group .

— Driv e axles:
• Remov e lef t drive axle. See Front driv e axle, removin g and
installing i n this repai r group.
• Pul l right drive axle approx. 6 to 7 cm (2 1/2 - 3 in) out of front
differential.

— Remov e front driveshaft. See 26 0 Driveshafts .

Detach steerin g spindle from steering rack :

• Mov e steering wheel so that front wheels point straight ahead.
Vehicle with steering lock: Remov e ignitio n ke y and mak e sur e
steering locks i n straight ahead position .
• With front wheels pointing straight ahead , mak e sure steering
spindle pointer an d steering rac k pointe r lin e u p (arrows).
Remove lower steering spindle pinc h bol t and detach steerin g
universal joint from steering rac k shaft .

CAUTION—
Steering spindl e • While steering spindle is detached from steering rack, make
pinch bol t sure steering wheel is not rotated. Rotating the wheel may
damage the airbag and horn contact spring.

Support front subframe with transmission jack. Remove subframe

mounting bolt s (arrows) an d lowe r subframe sufficientl y to allow
access to front differential mounting bolts.

CAUTION—
• Do not bend or stretch fluid lines and hoses when lowering or
raising subframe.
• Automatic transmission vehicle: Disconnect transmission fluid
cooler lines from subframe.
 Front Axle Differentia l 311-1 3
Front differential, removing and installing

Remove bolts (arrows) and lower differential carefully, making sur e

that n o lines, hoses o r harnesses becom e snagged .
Vent port

CAUTION—
• Support differential as last bolt is removed.

^C Remov e sealing O-ring (arrow) between oil pan and differential an d

replace with new.

— Instal l differential to oi l pan.

;" piP^
Tightening torques
Front differential to oil pa n 65 N m (4 8 ft-lb)

Remainder of assembly i s reverse of removal. Kee p i n mind:

• Replac e drive axle flange seal befor e installing lef t drive axle .
• Replac e power steering fluid line banjo bol t sealing rings .
• Fil l and bleed powe r steering. Se e 320 Steering an d Wheel
Alignment.
• Fil l front differential with oil. See Front differential oi l level ,
checking i n this repair group.
• Instal l front end reinforcement panel usin g ne w fasteners. See
310 Fron t Suspension .
• Us e BMW scan tool to carry out steering angle senso r adjustment.

Tightening torques
Engine mount to engine bracke t (replace 56 N m (4 1 ft-lb)
M10 10.9 grade self-lockin g nuts with new )
Front en d reinforcemen t panel to subframe
(replace M10 x 35 mm 10. 9 grade ZNS bolt s
with new):
• Stag e 1 56 N m (4 1 ft-lb)
• Stag e 2 + additional 90 °
Front subframe to chassis (replac e M1 2 x 1.5
10.9 grade bolts wit h new):
• Stag e 1 100 N m (7 4 ft-lb )
• Stage 2 + additional 90 °
Steering fluid line banjo bol t to steering pump 33 - 35 N m
(M14 or M16, replac e sealin g O-rings ) (24 - 25 ft-lb )
Steering spindle universa l joint to steering
rack (pinc h bolt ) 22 N m (1 7 ft-lb)
311-14 Fron t Axle Differential
Right axle bearing pedestal, removing and installing

Right axle bearing pedestal ,

removing and installin g
— Rais e vehicle an d suppor t safely.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splash shiel d and front end reinforcemen t panel. See

310 Fron t Suspension .

Remove right front drive axle. See Front driv e axle, removing and
installing i n this repai r group.

Remove bearing pedestal mountin g bolt s (arrows) at side of oil pan.

Lift of f pedestal.

Replace sealing O-ring (arrow). Coa t O-rin g with assembly fluid .

Replace drive axle flange seal before installing drive axle. See Front
drive axle flange seal, replacin g i n this repai r group.

Installation i s reverse of removal . Remembe r t o replac e front end

reinforcement pane l fastener s with new.

Tightening torque s
Bearing pedestal to oil pan 21 Nm(16ft-lb )
Front end reinforcemen t panel to subfram e
(replace M10 x 35 mm 10.9 grade ZNS bolt s
with new):
• Stage 1 56 N m (4 1 ft-lb )
• Stage 2 + additional 90 °
 Front Axle Differential 311-1 5
Front differential input flange seal, replacing

Front differentia l inpu t flange seal , replacin g

Raise vehicl e and support safely .

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove splash shiel d and front end reinforcement panel. Se e

310 Front Suspension .

Remove front driveshaft. See 260 Driveshafts.

Pry out inpu t flange retainin g nu t lock plate.

Using a center punch , mar k relatio n of input flange retaining nu t to

shaft (arrows).

Counterhold input flange using BMW special tool 23 0 020 and

remove nut.

CAUTION—
• Do not place flange holder pins in threaded holes of flange.

Remove input flange using hub puller. Be prepared to catch drippin g

oil.
311 -16 Fron t Axle Differentia l
Front differential input flange seal, replacing
I
^V Usin g sea l puller or flat screwdriver, pry (arrow ) seal out of
differential housing .

— Coa t sealing edges of new seal with transmission fluid and drive into
differential housing usin g seal installe r (BM W specia l too l 31 5 130
or equivalent.

— Clea n inpu t flange and instal l into differential housing.

Install flange nut. Counterhold flang e an d tighten down nut until

punch marks (arrows ) align . Instal l ne w input flange retainin g nut
locking plate.

CAUTION—
• Do not torque input flange retaining nut beyond match marks.
Over-torquing can damage differential internals.
• Do not rep/ace input flange or input flange locking nut.

Remainder of installation is reverse o f removal . Kee p in mind :

• Check front differential oil level and top off if necessary. See Front
differential oil level, checking i n this repair group.
• Instal l front end reinforcement panel usin g ne w fasteners. See
310 Front Suspension.

Tightening torque
Front driveshaft to differential 20 N m (15ft-lb )
(replace M 8 ZNS bolt s with new) + additional 45°
Oil drain / fil l plu g to differential 60 N m (4 4 ft-lb )
 320-1

320 Steerin g and Wheel Alignment

GENERAL 320- 1 Power steering pump, removing and installing

Steering system 320- 2 (N54 engine) 320-1 8
Steering components 320- 2 Power steering pump, removing and installing
(V8 engine) 320-2 2
Servotronic 320- 2
Active steering 320- 3 MECHANICAL STEERIN G COMPONENT S . . 320-2 3
Active steering, adjusting 320- 4 Steering rack , removing and installing
Power steering fluid 320- 4 (rear-wheel-drive) 320-2 3
Hydraulic line quick disconnect coupling 320- 5 Steering rack , removing and installing
(xDrive) 320-2 6
Warnings and Cautions 320- 5
Tie rod end, replacing 320-2 9
TROUBLESHOOTING 320- 6 Tie rod, replacing 320-3 0
Corrosion damage 320- 6 Steering rack boot, replacing 320-3 1
Active steering faults 320- 7
WHEEL ALIGNMENT 320-3 2
STEERING WHEE L 320- 8 Preparing for alignment 320-3 2
Steering wheel components 320- 8 Normal loade d positio n 320-3 2
Sport steering wheel components 320- 8 Ride height 320-3 2
Steering angle sensor 320- 8 Front toe, setting 320-3 3
Steering wheel, removing and installing 320- 8 Front camber, adjusting 320-3 5
STEERING COLUMN 320-1 0 Rear camber, adjusting 320-3 6
Adjustable steering colum n 320-1 0 Rear toe, setting 320-3 6
Steering column components 320-1 0 Caster 320-3 6
Steering column, removing an d installing . . . 320-1 1 Alignment specifications 320-3 7

Steering shaft spindle , TABLES

removing and installing 320-1 3
a. Front ride height 320-3 3
POWER STEERIN G PUMP 320-1 4 b. Rear ride height, Sedan (E60) 320-3 3
Power steering system, bleeding and filling . . 320-1 4 c. Rear ride height, Sport s Wagon (E61) 320-3 3
Power steering pump , removin g and installin g d. Alignment specifications , Sedan (E60) 320-3 7
(M54 engine) 320-1 5 e. Alignment specifications, Sport s Wagon (E61) 320-3 8
Power steering pump, removin g and installin g
(N52 engine ) 320-1 6

GENERAL
This repai r group covers steering whee l and column remova l an d
steering system service, including wheel alignment information. For
additional information , see:
• 310 Front Suspension for active stabilizer
• 513 Interior Trim for steering column trim
• 612 Switches for steering column switch cluster (SZL) , ignition
switch and START /STOP switch
• 721 Airbag System (SRS) for driver airbag
320-2 Steerin g and Wheel Alignment
Steering system

Steering system
5 Series models are equipped with a power-assisted steering rack
mounted to an aluminum subframe . Powe r boost for the steering is
provided by an engine-driven hydrauli c pump.

The steering wheel connects to the steering rack via an adjustable

steering column which incorporates a sliding spindle to dampen
vibration and noise.

Power steering fluid is supplied from the fluid reservoir to the pump
and to the steering rack via rubber and metal lines. The retur n line
from the steering rack to the reservoir loops forward and connects to
the steering fluid cooler.

Steering components
1. Ti e rod end
12 3 456 7 8 9 1 0 11
2. Inne r tie rod
°":-'.:, 3. Steering rack boot
4. Steerin g fluid reservoir
5. Sealin g O-ring
• Replace with new
6. Banj o bolt M14 or M16
• Tighten to 33 - 35 Nm (24 - 26 ft-lb)
7. Steerin g rack gear housing with
servotronic valve
8. Steerin g spindle lower universal joint
• Rethread threads in pinch collar
• Replac e M8 Ton pinch bolt with new
• Tighten to 22 Nm (16 ft-lb)
9. Lowe r steering spindle
10. Steering spindle upper universal joint
12 13 3 2 1 13
• Rethread threads in pinch collar
• Replac e M8 Jon pinc h bolt with new
• Tighten to 22 Nm (16 ft-lb)
11. Steering column
12. Steering fluid cooler
13. Steering rack
14. Power steering pump.

Servotronic
The servotronic system uses an electrohydraulic valv e at the
steering rack to control the degree of steering assistance provided
by the power steering as a function of vehicle speed . Th e flow of
hydraulic fluid is restricted to a greater or lesser extent depending on
how the servotroni c valve is actuated electronically by the safet y
and gateway module (SGM).

The servotronic valve is actuated when terminal 1 5 is ON (ignition

ON). The vehicle speed signal from the DSC control module is used
by SGM software to modulate the servotronic valve signal.
 Steering and Wheel Alignment 320- 3
Active steering

Current supply to the servotroni c valve is interrupted by the faults

listed below. Under these circumstances, steering assistance is
limited to minimum:
• Vehicle speed signal from DSC control module incorrect ; or no
vehicle speed signal .
• Terminal status from CAS control module via K-CAN incorrect or
missing.
• Electrica l fault in servotronic valve circuit (exception : short-circuit
to positive) .

In case of a short-circuit to positive, full voltage is applied to th e

servotronic valve, activating it fully and increasing steering
assistance to maximum.

Active steering
, Th e optional active front steering system (acronyms AS, AFSor AL).
provides steering power assist with variable steering ratio. Steering
Active steering
gear housing ratio adapts to road speed and to the steering angle requested by
the driver. The steering is designed to be indirect at high speeds and
direct at low speeds.

At slow speeds and when parking, vehicle maneuverabilit y i s

significantly increase d so that the driver does not need to grip the
steering wheel excessively hard. When the vehicle i s stationary, 2
turns are enough t o move the steering wheel lock to lock.

At high speeds (abov e 75 mph /120 kph), active steering allow s a

more indirect steering gea r ratio than conventional steering .
Unintentional steerin g movements are prevented i n conjunction with
the increased steering torque level.

, The activ e steering control module is in the righ t footwell, attached

to the floor pan and protecte d by a kick plate.

In vehicles equipped with active steering, the Servotroni c valve is

activated by the active steering control module.

Active steering
control modul e
320-4 Steerin g and Wheel Alignment
Active steering, adjusting

Active steering, adjustin g

Use BMW scan tool to adjust (o r commission) active steering
system unde r th e following circumstances :
• If front suspension or steering components are repaired, modifie d
or aligned.
• I f battery is disconnected an d reconnected .
• I f electrical connections on the steering column switch cluster
(SZL) ar e disconnected an d reconnected.
• I f active steering or DSC electronic components are replaced,
coded or programmed.

Note that steering whee l position and the position o f the steered
wheels ar e synchronized a s soon as the engine i s started. Thi s
ensures that the positions o f the steering wheel and the road wheels
match if , for example, th e steering whee l was moved while the
vehicle wa s at a standstill with the ignition switched OFF .

The synchronization procedure can cause the steering wheel or the

vehicle's front wheels to move. Movements of the steering wheel or
the vehicle's front wheels might be perceptible while synchronization
is in progress. Synchronization also occurs while the vehicle is on
the move, but the process is extremely slow and virtually
imperceptible.

Power steering fluid

6-cyhnder engine compartmen t
The power steerin g syste m is permanently filled with either AT F or
Pentosin hydrauli c fluid. Routinely addin g fluid is not required unless
the system i s leaking.

Power steering CAUTION—

fluid reservoir Power steering reservoir cap is marked with the type of fluid
being used— ATF or CHF. Do not mix.

Hydraulic flui d
As recommende d on reservoir cap for power steering, active
steering, active stabilizer:
• Automatic transmission fluid (ATF)
•Pentosin CHF 11 S

For filling and bleeding procedure , see Power steering system,

V8 engine compartmen t bleeding an d filling i n this repai r group .

Power steerin g
fluid reservoir
 •

Steering and Wheel Alignment 320- 5

Hydraulic line quick disconnect coup/ing

Hydraulic lin e quick disconnect couplin g

To disconnect quick disconnect coupling (inset), press plastic rin g
into coupling (arrow) . B e prepared to catch dripping fluid.

To reconnect, push couplin g together until a distinct click is heard.

Attempt t o pull coupling apart forcefully to test for correct seating.

Warnings and Caution s

WARNING —
• The airbag mounted in the steering wheel is an explosive
device. Treat it with extreme caution. Follow the airbag removal
procedure i n 721 Airbag System (SRS).
• Serious injury may result if airbag system service is attempted
by persons unfamiliar with the BMW SRS and its approved
service procedures.
• Before performing any work involving airbags, disconnect the
negative (-) battery cable.
• Prior to disconnecting the battery, read the battery
disconnection cautions given in 001 Warnings and Cautions .
• BMW airbags are equipped with a back-up power supply inside
the airbag control module. Observe a 5 second waiting period
after disconnecting the battery cable to allow the reserve power
supply to discharge.
• Do not reuse self-locking nuts. They are designed to be used
only once and may fail if reused. Replace with new.
• Do not install bolts and nuts coated with undercoating wax, as
correct tightening torque cannot be assured. Clean the threads
with solvent before installation, or install new parts.
• Do not attempt to weld or straighten steering components.
Replace damaged parts.
• Power steering and hydraulic fluid (ATF or Pentosin) are
injurious to skin and eyes. Wear protective gloves and
eyewear.
• Follow local, state and federal regulations for safe disposal of
power steering fluid.
320-6 Steerin g and Wheel Alignment
Corrosion damage

CAUTION—
• When filling or bleeding steering and hydraulic system, do not
allow contamination of fluid or reservoir.
• Using contaminated equipment to add fluid may Introduce dirt
particles into the fluid reservoir and significantly reduce the
service life of system components.
• To avoid electrochemical corrosion to engine components
made of aluminum-magnesium alloy, do not use steel
fasteners. Use aluminum fasteners only.
• The end faces of aluminum fasteners are usually painted blue.
For reliable identification, test fasteners for aluminum
composition with magnet.
• Rep/ace aluminum bolts each time they are loosened.
• Follow torque instructions, including angle of rotation
specifications, when installing aluminum fasteners.
• To prevent marring interior trim, work with plastic prying tools or
wrap the tips of screwdrivers and pliers with tape before prying
out switches or trim.
• Static discharge may permanently damage an electronic
component such as control module or sensor. Handle
electronic components using accepted static prevention
equipment and techniques. Se e 600 Electrical System-
General.

TROUBLESHOOTING
Corrosion damage
Inspect tie rod ends and steering rack boots periodically fo r damage
or tears. Replace as necessary. Se e Tie ro d end, replacin g and
Steering rac k boot, replacin g i n this repai r group.

Note that rodent bite damage to rac k boot i s difficult to detect. Bite
marks are often small and only on one side. Leakage a t one rac k
boot can resul t in corrosion of rac k shaft metal at both ends.

If steering rack metal shows sign o f corrosion, replace complete

rack. See Steering rack , removing an d installin g (rear-wheel-
drive) or Steering rack, removin g and installing (xDrive) i n this
repair group.

Metal corrosion
Steering an d Wheel Alignmen t 320- 7
Active steering faults

Active steerin g fault s

, Th e drive r is alerted to active steering system faults b y a warnin g
icon and a Check Control warning triangle in instrument cluster.

Check Control message s i n center dashboard (iDrive ) displa y

details abou t active steering failure and instruction on ho w to
proceed.
320-8 Steerin g and Wheel Alignment
Steering wheel components

STEERING WHEEL
5 Series vehicles are equipped wit h on e o f two differen t styles of
steering wheel :

Steering wheel component s

1. Multifunctio n switches
2. M1 2 mounting bolt
•Tighten to 63 N m (4 6 ft-lb)
3. Airba g unit and horn butto n

.corn B510320010

Sport steering wheel component s

1. M1 2 mountin g bolt
• Tighten t o 63 Nm (46 ft-lb)
2. Multifunctio n switche s
3. Plasti c trim
4. Mountin g plat e
5. Airba g unit and horn butto n

Steering angle sensor

The steering angle sensor is integral with the steering column switch
cluster (SZL) . Fo r more information , including remova l and
installation of the SZL, se e 612 Switches .

To reset steering angle sensor , connect vehicle to BMW scan too l

and carry out steering angl e senso r adjustmen t syste m function.

Steering wheel, removing and installing

Center steering wheel. Make sur e front wheels are pointed straight
ahead.

Extend steering wheel as far back an d a s low as possible.

Disconnect negativ e (- ) cable from battery.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given i n 001 Warnings and Cautions.
 Steering and Wheel Alignment 320- 9
Steering wheel, removing and installing

Remove driver airbag i n steering wheel. See 721 Airba g Syste m

(SRS).

WARNING —
• The steering wheel mounted airbag is an explosive device.
Treat with extreme caution. Follow the airbag removal
procedure i n 721 Airba g System (SRS).
• Airbag removal may set SRS fault codes. The SRS indicator
light remains ON until problems are corrected and fault memory
cleared.

Remove steering wheel center bolt (arrow) .

CAUTION—
• The SRS contact reel (also known as airbag contact ring/slip
ring) is integral with the steering column switch block. The
contact reel is a wound coil of wire that ensures continuous
electrical contact for the airbag and steering wheel electrical
components. When the steering wheel is removed the contact
reel is locked and its position must not be altered.

The steering column an d steering wheel are match marke d a t the

factory. Check for proper alignmen t o f steering column mark s
(arrows) befor e removing steerin g wheel.

— Remov e steerin g wheel.

— Whe n installin g steering wheel:

• Align steering wheel and column match marks .
• Align steering wheel to alignment pin s located on steering colum n
switch block.
• Instal l steering column cente r bolt. Do not over-torque.

Tightening torque s
Steering wheel to steering shaft (M1 2) 63 N m (4 7 ft-lb )

— Carefull y install airbag. Se e 72 1 Airbag System (SRS) .

320-10 Steerin g and Wheel Alignmen t
Adjustable steering column

Steering colum n STEERING COLUMN

adjustment switc h
Steering wheel Adjustable steerin g colum n
heater switc h
The steering column adjustment switch is used to control two motors
in the steering column, one for tilt and the other for extension.

Column positio n i s memorized and stored , along with driver seat

and outside rea r view mirror positions, i n the seat memor y module.

Steering colum n component s

i1 . Electri c steering loc k or ELV (2006 only)
Benliey Publishers
2. Steerin g column assembly
3. Uppe r steering shaft universal joint
1 - 4. Steerin g shaft spindle
5. Lowe r steering shaft universal joint
6. Steerin g column adjustment motors
 Steering and Wheel Alignment 320-1 1
Steering column, removing and installing

Steering column , removing and installin g

— Cente r steering wheel. Make sure front wheels are pointe d straight
ahead. Exten d steering wheel as far back and as low as possible .

— 200 4 - 2005 model : Remov e ignition key.

— Disconnec t negativ e (-) battery cable and cover battery terminal t o

keep cable from accidentally contacting terminal.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given i n 001 Warnings and Cautions.

— Remov e driver airbag. Se e 72 1 Airbag System (SRS) .

WARNING —
• The steering wheel mounted airbag is an explosive device.
Treat with extreme caution. Follow the airbag removal
procedure i n 721 Airbag System (SRS).

Remove steerin g wheel. See Steering wheel, removin g an d

installing i n this repair group.

CAUTION—
• Do not move front wheels from straight-ahead position while
steering wheel is off.
• Do not turn or twist the airbag and horn contact spring.

Remove steering column trim, left lower dashboard tri m an d lef t

dashboard panel . Se e 513 Interior Trim.

Remove airbag and horn contact spring and steering column switch
cluster (SZL) . See 612 Switches .

2004 - 2005 mode l wit h automatic transmission : Detach ignitio n

interlock cable en d (arrow) from steering lock.

Detach wiring harnesses an d cables from steering column an d

place to one side.
BentleyPuWiSbet
.com

Working i n left footwell, slide sleeve (arrow) fo r steering spindl e

upwards on steering column.
320-12 Steerin g and Wheel Alignment
Steering column, removing and installing

Remove steering shaf t uppe r universa l joint pinch bolt (arrow) .

Working underneat h steerin g column:

• Mar k installatio n positio n o f steering column .
• Loose n an d remove steering colum n fastener s (arrows). B e sure
to hav e an assistant suppor t colum n a s last bolts ar e removed.
• Guide colum n of f steering spindle universa l joint an d remove.

Installation i s reverse o f removal . Remembe r to :

• Recu t threads i n spindle universa l join t pinch collar .
• Slide universal joint splines ove r column shaft. Splines fi t only one
way. Instal l ne w Torx pinc h bolt . Pinc h bol t rest s in groove of
steering column shaft .
• Fi t spindle sleev e bac k int o opening in floorboard. Align mark s o n
sleeve and floorboard.
• Us e new bolts to mount colum n to dashboard an d dashboard
brace. Matc h positio n mark s mad e previously.

Tightening torques
Steering column to dashboard o r dashboar d 21 N m (15ft-lb )
brace (replace M 8 bolt with new)
Steering shaft spindle universa l joint pinc h 22Nm(16ft-lb)
bolt (recu t pinch collar threads, replac e M8
Torx bol t with new)

Check steerin g system for freedom o f movement throug h entire

steering column adjustmen t range .

Carry out steering angle sensor adjustment usin g BMW scan tool. If
replacing steering angle sensor , cod e usin g BMW scan tool before
performing steering angle offse t check .

If airbag warning ligh t illuminates, us e BMW scan tool to check and

clear fault codes .

— Tes t drive vehicle to check directional stability .

 Steering and Wheel Alignment 320-1 3
Steering shaft spindle, removing and installing

Steering shaf t spindle , removin g an d installin g

Raise front of car and suppor t safely.

WARNING—
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

Remove splash shiel d and front end reinforcement panel from

Steering spindle 1?* underneath engine . Als o remov e left side splash shield a t front
pinch bol t suspension.

Remove steering spindle lower pinch bolt and slide universal joint off
steering rac k shaft (arrow).

CAUTION—
• While steering spindle is detached from steering rack, make
sure steering wheel is not rotated. Rotating the wheel may
damage the airbag and horn contact spring.

Remove lef t lowe r dashboard trim (peda l cluste r trim). Se e 51 3

Interior Trim.

Working i n left footwell, slide sleev e (arrow ) fo r steering spindl e

upwards on steering column.

Remove steering shaf t uppe r universa l joint pinch bolt (arrow) an d

slide universa l down and off steering column shaft .

Installation is reverse of removal . Remembe r to:

• Rethrea d threads in spindle universa l joint pinch collars .
• Slid e universal joint splines over steering column and steering rack
shafts. Splines fi t only one way. Install new Torx pinch bolts. Pinc h
bolts res t in shaft grooves .
• Fi t spindle sleev e back int o opening i n floorboard. Align mark s o n
sleeve and floorboard.

Tightening torque
Steering shaft spindle universa l joint pinch 22 N m (16ft-lb )
bolt (recu t pinch colla r threads , replace M8
Torx bol t with new )

Check steering system for freedom of movement through entir e

steering column adjustmen t range . Check directional stability of
vehicle on test drive.

— Carr y out steering angl e senso r adjustment using BM W sca n tool .

320-14 Steerin g and Wheel Alignment
Power steering system, bleeding and filling

POWER STEERIN G PUM P

Power assist is provided b y a belt-driven pum p a t the lower left front
of the engine. Th e powe r steering fluid reservoi r i s located \r\e
engine compartment :
• 6-cylinde r model : Lef t side of engine compartmen t
• V8 models: Righ t side o f engine compartmen t

Power steering system, bleedin g an d filling

The powe r steering system i s permanently fille d with either CHF
(Pentosin hydrauli c fluid) o r ATF. Routinely adding fluid is not
required unles s the system is leaking .

CAUTION—
• Power steering reservoir cap is marked with the type of fluid
being used — CHF or ATF. Do not mix.

To check powe r steerin g fluid leve l i n fluid reservoir:

• Par k vehicle o n level ground wit h engin e OFF.
• Leve l i s correct if it is between MI N and MA X mark s on dipstick.
• I f level is below MI N mark, ad d fluid to reservoi r to bring level up.

CAUTION—
• Correct power steering fluid level can be as much as 10 mm
(0.4 in ) higher than MAX mark when engine i s at normal
operating temperature. D o not draw off fluid to MAX mark when
checking fluid with engine warmed up.

— T o bleed powe r steering system, star t engine . Turn steering wheel

twice to lef t loc k and righ t lock .

— Rechec k fluid level with engine off . Fill to MAX.

Power steering fluid application

Black labe l (chec k cap ) ATF Dexro n III
Green labe l (chec k cap) Pentosin CHF 1 1 S

— Hand-tighte n reservoi r cap.

 Steering and Wheel Alignment 320-1 5
Power steering pump, removing and installing (M54 engine)

Power steerin g pump , removin g and installin g

(M54 engine )
— Drai n power steering fluid reservoir using clean syringe. Do no t
reuse fluid.

— Mar k engine accessory belt directio n of rotation , then remov e belt.

See 020 Maintenance.

— Rais e front o f car an d suppor t safely.

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.
i i
Remove splash shield underneath front of engine. See
020 Maintenance .

Remove power steering pump pulley.

Remove alternator idler pulley.

Working at power steering pump , detac h fluid lines. B e prepared to

catch dripping fluid. Plug open flui d ports.
• Cut supply hose clamp (A ) and separate hose from pump inlet .
• Remov e banjo bolt (B) and remove pressure line.

BentleyPubiishers
B510320034

Remove pump mountin g bolts and lower pump.

• A = M8 x 70 mm ZNS bolt
•B = M8x 10 0 mm ZNS bolt
• C = M8 x 22 mm ZNS bolt

Installation is reverse of removal. Keep i n mind the following:

• Us e new O-ring seals a t pressure line banjo bolt . Rout e pressure
line tension-free and with sufficient distance to adjoining
components.
• Matc h marking s on supply lin e and pump connection. Us e new
hose clamp a t connection.
• Letterin g on pump pulle y faces forward.

Tightening torques
Pressure lin e to pump 35 Nm (26 ft-lb)
(M16 banjo bolt, use new O-ring seals)
Pulley to power steerin g pump 27 Nm (20 ft-lb)
(M8 x 1 4 mm 10. 9 grade bolts )
Power steering pump to engine bloc k 21 N m (16 ft-lb)
(M8 ZNS bolts)

Fill and bleed steering system with correct fluid. See Powe r
steering system , bleedin g an d filling in this repai r group .

— Ru n engine and chec k fluid connections for leaks .

320-16 Steerin g and Wheel Alignmen t
Power steering pump, removing and installing (N52 engine)

Power steering pump, removing and installing

(N52 engine)
— Drai n power steering fluid reservoir using clean syringe. Do not
reuse fluid.

— Rais e front of car an d suppor t safely.

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

— Remov e splash shield underneath fron t of engine. Se e

020 Maintenance .

— Remov e air filter housing. See 13 0 Fue l Injection .

^k Workin g from above on left side o f engine:

• Cut supply hose clamp (A) and separate hos e from pump inlet. Be
prepared to catch drippin g fluid. Plu g open fluid ports.
• Remov e steering pump rear bracke t mountin g bolts (B). Discard
aluminum bolts.

— Mar k engine accessory belt direction o f rotation , then remov e belt.

See 020 Maintenance .

— Workin g underneath front of vehicle, remove power steering pump

pulley.

Loosen union nu t (arrow) and detach pressur e line from pump. Be

prepared to catch dripping fluid. Plug open fluid ports.
' Steering and Wheel Alignment 320-1 7
Power steering pump, removing and installing (N52 engine)

^V Remov e pump mountin g bolt s (arrows) an d lower pump. Discar d

aluminum bolts.

. • "v^*., — Whe n installin g pump, replac e aluminium bolts with new, tighten
finger tight and observe the following tightening sequence :
f^o^mfftf.
1. Tighte n rea r bracket fasteners to 2 Nm (18 in-lb).
2. Tighte n fron t fasteners to 2 Nm (18 in-lb).
3. Tighte n front fasteners to final specification.
4. Loose n rea r bracket fasteners and make sure bracket i s flush
with engine block.
5. Tighte n rear bracket fasteners to final specification.

V:
BeptldtPublishers
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Tightening torque
Power steering pump to block (replace
M10 x 33 mm aluminum bolts with new)
20 Nm (15ft-lb )
additional 90°

Remainder of installatio n i s reverse of removal. Keep i n mind th e

following:
• Rout e fluid lines tension-free and with sufficient distance to
adjoining components.
• Matc h markings on supply lin e and pump connection. Use new
hose clamp a t connection.
• Letterin g on pump pulle y faces forward.

Tightening torques
Pressure line to pum p 36 N m (2 7 ft-lb)
Pulley to power steering pump 21 N m (20 ft-lb)
(M8 8.8 grade bolts)

Fill and bleed steering system with correct fluid. See Powe r
steering system, bleedin g and filling in this repai r group.

— Ru n engine and check fluid connections for leaks.

320-18 Steerin g and Wheel Alignment
Power steering pump, removing and installing (N54 engine)

Power steering pump, removin g and installing

(N54 engine )
— Disconnec t negativ e (- ) battery cable an d cove r battery terminal to
keep cable from accidentally contacting terminal .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given i n 001 Warnings an d Cautions.

— Mar k engine accessor y belt directio n o f rotation , then remov e belt.

See 020 Maintenance .

— Drai n powe r steerin g fluid reservoir usin g clea n syringe . Do not

reuse fluid.

— Rais e front of car an d remov e front wheels.

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

Remove splash shiel d and front end reinforcemen t pane l from

underneath engine. Als o remove sid e splash shields a t front
suspension.

Install engine suppor t brac e acros s engin e ba y and support weight

of engine .

Working underneath engine , remov e righ t and left engine mount

f upper nut s (arrow). Rais e engine slightl y ( 1/4 - 1 /2 in) to releas e load
on engine mounts.

Detach both tie rod ends from steering knuckles . See Tie rod end ,
replacing i n this repai r group.
, xDrive: Detach lef t and righ t contro l arm s from steering knuckles.
Detach left and right front stabilizer bar links from stabilizer bar. See
310 Front Suspension .
tie-Fit H?

Detach steering spindle from steering rack :

• Mov e steering wheel s o that fron t wheels poin t straight ahead.
Vehicle with steering lock: Remove ignitio n key and make sur e
steering lock s in straight ahead position .
• With front wheels pointing straight ahead, mak e sure steering
spindle pointer and steering rac k pointer lin e up (arrows) .
Remove lowe r steering spindle pinc h bol t an d detach steering
universal joint from steering rack shaft.

CAUTION—
Steering spindle
pinch bolt • While steering spindle is detached from steering rack, make
sure steering wheel is not rotated. Rotating the wheel may
damage the airbag and horn contact spring.
 Steering an d Wheel Alignmen t 320-1 9
Power steering pump, removing and installing (N54 engine)

If applicable, detach electrica l connectors at front suspension rid e

height sensor, Servotroni c sensor and engine mount vacuum line.

Vehicle with active stabilizers (dynamic drive):

• Remov e right front wheel housing liner . See 410 Fenders, Engin e
Hood.
• Separat e fluid lines to front stabilizer oscillating motor. Be prepared
to catch dripping fluid. Plug open fluid lines immediately .

Vehicle with active steering: Detac h activ e steering gearbo x

electrical connectors . Detac h wiring harness fro m front subframe.

Support front subframe with transmission jack. Remov e subfram e

mounting bolt s (arrows ) and lowe r subframe about 10 0 mm (4 in).

CAUTION—
• Do not bend or stretch fluid lines and hoses when lowering or
raising subframe.
• N54 with automatic transmission: Disconnect transmission fluid
cooler lines from subframe.

Working underneat h fron t of vehicle:

• Remov e powe r steerin g pump pulley bolts (A ) and take pulley off
pump.
AB • Remove pum p mounting bolts (B ) and pull pump forward. Discar d
aluminum bolts.
320-20 Steerin g and Wheel Alignmen t
Power steering pump, removing and installing (N54 engine)

Working at steering pump , detach flui d lines. Be prepared to catch

dripping fluid. Plug ope n fluid ports.
• Cu t supply hose clamp (A ) and separate hos e from pump inlet.
Note match mark s on supply hos e an d pump connection.
• Remov e banjo bol t (B) and remove pressur e line.
• Lowe r steering pump.

Attach fluid lines to new pump :

• Us e new O-ring seals at pressure line banj o bolt. Route pressure
line tension-free and with sufficient distance to adjoining
components.
• Matc h markings on supply line an d pump connection. Use new
hose clamp at connection.

Bentley Publishers}, Tightening torques

"' B510320039
Pressure line to pump 33 N m (2 4 ft-lb)
(M14 banjo bolt , us e new O-ring seals )

Raise pump int o position on engine block . Replace aluminium bolts

with ne w and tighten finger tight. Observe the following tightening
sequence:
1. Tighte n rea r fasteners to 2 Nm (18 in-lb).
2. Tighte n front fasteners t o 2 Nm (18 in-lb) .
3. Tighte n front fasteners to final specification.
4. Loose n rear fasteners and make sur e bracke t is flush wit h
engine block.
5. Tighte n rea r bracket fastener s t o final specification .

Tightening torque
Power steering pump to block (replace 38 N m (28 ft-lb)
M10 x 35 mm aluminum bolt s wit h new)

— Reinstal l pump pulley. Lettering on pum p pulle y faces forward.

Tightening torque
Pulley to power steering pump 22 Nm (1 6 ft-lb)
(M8 x 1 2 mm 8.8 grad e bolts)
 Steering and Wheel Alignment 320-2 1
Power steering pump, removing and installing (N54 engine)

— Remainde r o f installation i s reverse o f removal. Keep i n mind the

following:
• Rais e front subfram e int o place carefully, watching t o make sur e
fluid lines and electrical harnesse s are not crushed .
• Us e new fasteners as indicated in torque specifications table .

Tightening torques
Control arm to steering knuckle 165 Nm (122 ft-lb )
(replace M1 4 x 1 .5 self-locking flange nut
with new )
Engine mount to engine bracke t (replace 56 N m (4 1 ft-lb)
M10 10. 9 grade self-locking nuts with new)
Front en d reinforcement panel to subframe
(replace M10 x 35 mm 10.9 grade ZNS bolts
with new):
• Stage 1 56 N m (4 1 ft-lb)
• Stage 2 + additional 90°
Front subframe to chassis (replac e M1 2 x 1 .5
10.9 grade bolt s with new):
• Stage 1 100Nm (74 ft-lb)
• Stage 2 + additional 90 °
Road wheel t o hub 120 ± 10 Nm
(89 ± 7 ft-lb)
Stabilizer link to stabilizer bar 65 Nm (48 ft-lb)
(replace M10 ZNS3 nut with new )
Steering shaft spindle universa l joint pinch 22 N m (16 ft-lb)
bolt (recut pinc h collar threads, replac e M8
Torx bolt with new )
Tie ro d ball joint to steering knuckle 80 N m (59 ft-lb )
(replace M14x 1.5ZNS 3 nut with new)

Fill and bleed steering syste m wit h correct fluid. See Power
steering system , bleedin g and filling in this repair group.

Run engine and check fluid connections fo r leaks.

Carry out steering angle senso r adjustment usin g BMW scan tool.
320-22 Steerin g and Wheel Alignmen t
Power steering pump, removing and installing (V8 engine)

Power steering pump, removing and installing

(V8 engine)
— Drai n powe r steerin g flui d reservoir usin g clea n syringe . D o not
reuse fluid .

- Mar k engin e accessor y belt directio n o f rotation, then remove belt.

See 020 Maintenance .

— Rais e fron t o f car and support safely .

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

— Remov e splash shield underneath front o f engine. See

020 Maintenance .

— Remov e power steering pump pulley .

^ Workin g at steering pump, detac h flui d lines . B e prepared to catch

dripping fluid. Plug open fluid ports .
• Cut supply hos e clamp (A ) and separate hos e from pump inlet.
- - li f 1 1H
v 1 • Loose n unio n nut (B) and remove pressur e line.
• Remov e pump mountin g fastener s (C) and lower pump .

1 * 4 „1 — Installatio n is reverse o f removal. Kee p i n mind the following:

• Rout e pressure lin e tension-free and with sufficien t distanc e to
adjoining components.
• Match marking s o n supply line and pump connection. Us e new
hose clamp at connection.

s
• Letterin g on pump pulle y face s forward.

Tightening torques
B l - y B510320041
i l Pressure line to pum p 36 Nm (27 ft-lb)
Pulley to power steering pum p 27 N m (20 ft-lb)
(M8 x 14 mm 10. 9 grade bolts )
Power steering pump t o engine bloc k 21 Nm (16 ft-lb)
(M8 8.8 grade fasteners)

Fill and bleed steering system wit h correc t fluid. See Power
steering system , bleedin g and filling i n this repai r group.

— Ru n engine and chec k fluid connections for leaks.

 Steering and Wheel Alignment 320-2 3
Steering rack, removing and installing (rear-wheel-drive)

MECHANICAL STEERIN G COMPONENT S

Steering rack, removin g an d installing
(rear-wheel-drive)
— Disconnec t negativ e (-) battery cable an d cover batter y terminal to
keep cable fro m accidentally contacting terminal .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given in 001 Warnings an d Cautions.

— Drai n power steering fluid reservoir using clean syringe. Do no t

reuse fluid.

— Rais e front o f car and remov e fron t wheels .

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

Remove splash shield and front end reinforcement panel from

underneath engine. Also remove side splash shields at front
suspension.

Install engine support brace across engine bay.

Working underneath engine, remov e right and lef t engin e moun t

upper nut s (arrow). Rais e engine slightly (V* - 1/2 in) to releas e loa d
on engine mounts.

Detach bot h tie rod ends fro m steering knuckles . See Tie rod end ,
replacing i n this repai r group .

EientleyPLibiis
B51031101
320-24 Steerin g and Wheel Alignmen t
Steering rack, removing and installing (rear-wheel-drive)

Detach steering spindle from steering rack:

• Mov e steerin g wheel s o that front wheel s poin t straight ahead.
Vehicle wit h steering lock: Remove ignitio n key and make sure
steering locks i n straight ahead position .
• With front wheels pointing straight ahead , mak e sur e steering
spindle pointer and steering rack pointer lin e u p (arrows) .
Remove steering spindl e pinch bolt and detach steering universal
joint from steering rac k shaft .

CAUTION—
Steering spindle • While steering spindle is detached from steering rack, make
pinch bol t sure steering wheel is not rotated. Rotating the wheel may
damage the airbag and horn contact spring.

— I f applicable, detac h electrica l connector s a t front suspension rid e

height sensor , Servotronic senso r an d engine moun t vacuu m line.

— Vehicl e wit h active stabilizers (dynamic drive):

• Remove righ t front wheel housing liner. See 410 Fenders, Engin e
Hood.
• Separate fluid lines to front stabilizer oscillating motor. Be prepared
to catch dripping fluid. Plug open fluid lines immediately.

— Vehicl e wit h active steering : Detac h active steering gearbox

electrical connectors. Detach wirin g harness from front subframe .

^C. Suppor t front subframe with transmission jack. Remove subframe

mounting bolts (arrows ) and lowe r subfram e abou t 10 0 mm (4 in).

CAUTION—
• Do not bend or stretch fluid lines and hoses when lowering or
raising subframe.
• N54 with automatic transmission: Disconnect transmission fluid
cooler lines from subframe.

— Remov e lef t engine mounting bracket from subframe .

— I f necessary, remove heat shield from power steering rack.

Working a t steering rack , remov e banj o bolts (arrows ) and

disconnect fluid lines from rack gear box.
• B e prepared to catch dripping fluid. Plug open fluid ports.
• Discar d sealing O-rings.

ill -»• H

POMfshersJ
B510320027
 Steering and Wheel Alignment 320-2 5
Steering rack, removing and installing (rear-wheel-drive)

Remove steerin g rac k mountin g fasteners (arrows).

Vehicle with active steering: Detach electrical connectors a t rack

gear box.

Slide rack to right an d remove towar d rear . Check for wiring, fluid
lines o r mechanical part s that migh t becom e snagged a s rac k i s
removed.

When installing, use new mounting bolts and self-locking nuts.

Tighten in two stages.

Tightening torque
Steering rac k to front subframe
(replace M1 0 10.9 grad e fasteners with new )
""'"• • Stage 1 56 Nm (41 ft-lb)
.com B510320028 • Stage 2 additional 90 °

When reattachin g fluid lines:

• Replac e old banjo bolt on pressure line with new one fitted with
Old New check valve .
• Use new sealing O-rings .

Tightening torque
Steering fluid line banjo bolt to steering pump 33 - 3 5 N m
(M14 or M16, replac e sealin g O-rings) (24- 25 ft-lb )

Remainder of installation is reverse of removal. Make sure fluid lines

and electrical harnesses ar e routed as before and connected free of
stress. Kee p i n mind the following :
• Rais e front subframe into place carefully, watchin g to make sure
fluid lines and electrical harnesses ar e not crushed.
B510320029
• Us e new fasteners as indicated i n torque specifications table .
• Fil l and bleed steering and hydraulic system with correct fluid. See
Power steering system , bleedin g and filling in this repair group .
• Check fluid connections fo r leaks.
• Perfor m wheel alignment.
• Carry out steering angle senso r adjustment usin g BMW scan tool .
• I f necessary, adjust activ e steering. See Active steering ,
adjusting i n this repair group.
• If necessary, commissio n active stabilize r system. Se e 310 Front
Suspension.

Tightening torques
Engine mount to engine bracket (replac e 56 N m (41 ft-lb)
M10 10.9 grade self-lockin g nut s with new )
Front end reinforcement panel to subframe
(replace M10 x 35 mm 10.9 grade ZNS bolts
with new) :
• Stag e 1 56 N m (4 1 ft-lb)
• Stage 2 + additional 90 °
320-26 Steerin g and Wheel Alignment
Steering rack, removing and installing (xDrive)

Tightening torques
Front subframe to chassis (replace M'\2x'\.5
'\Q.9 grad e bolts with new):
• Stag e -\ Stage 2 100 Mm (74ft-lb)
+ additional 90 °

Road wheel to hub 120± 10 Mm

(89 ± 7 ft-lb)

Steering shaft spindle universal joint pinc h 22Nm(16ft-lb)

bolt (recu t pinch colla r threads, replac e M8
Torx bolt with new)
Tie rod ball joint to steering knuckl e 80 Nm (59 ft-lb)
(replace M1 4 x "1.5 ZNS 3 nu t with new)

Steering rack, removing and installing (xDrive)

Disconnect negativ e (- ) battery cable and cover battery terminal to
keep cable from accidentally contactin g terminal.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given i n 001 Warnings and Cautions.

— Drai n power steerin g flui d reservoir using clean syringe. Do not

reuse fluid.

— Rais e front of car and remov e fron t wheels .

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

Remove splash shiel d and front end reinforcemen t panel from

underneath engine . Als o remove side splash shields at front
suspension.

Install engine support brac e acros s engine bay.

, Workin g underneath engine, remove righ t and left engine mount

upper nut s (arrow). Raise engine slightl y ( 1/4 - 1 / 2 in) to release loa d
on engine mounts .

Detach lef t an d righ t tie ro d ends from steering knuckles. See Tie
rod end, replacing i n this repai r group .

Detach lef t an d righ t control arms from steering knuckles . Se e

310 Front Suspension .

Detach left and right front stabilizer bar links from stabilizer bar. See
310 Front Suspension .

B510311011
 Steering an d Wheel Alignmen t 320-2 7
Steering rack, removing and installing (xDrive)

^V. Detac h steering spindle from steering rack:

• Mov e steering wheel so that front wheels point straigh t ahead.
Vehicle with steering lock: Remov e ignition key and mak e sur e
steering lock s in straight ahead position .
• With front wheels pointin g straight ahead, mak e sur e steerin g
spindle pointe r and steering rack pointer line up (arrows).
Remove steering spindl e pinc h bol t and detach steering universa l
joint from steering rack shaft.

CAUTION—
Steering spindle • While steering spindle is detached from steering rack, make
pinch bolt
sure steering wheel is not rotated. Rotating the wheel may
damage the airbag and horn contact spring.

If applicable, detac h electrical connectors at front suspension rid e

height senso r and Servotronic sensor.

Support front subframe with transmission jack. Remov e subfram e

mounting bolt s (arrows ) and lowe r subframe until steering rac k
rests on front drive axle (abou t 10 0 mm or 4 in).

CAUTION—
• Do not bend or stretch fluid lines and hoses when lowering or
raising subframe.
• Make sure tension strut bushing cover is free to move.
• N54 with automatic transmission: Disconnect transmission fluid
cooler lines from subframe.

Working at steering rack, remove banj o bolts (arrows) and

disconnect fluid lines from rack gear box.
• B e prepared to catch dripping fluid . Plu g open fluid ports .
• Discar d sealing O-rings.
320-28 Steerin g and Wheel Alignmen t
Steering rack, removing and installing (xDrive)

^, Remove steering rac k mounting fasteners (arrows).

- Pus h front subframe forward and guide steering rack past drive axle.

— Lowe r subframe as much a s possible without damaging hose an d

lines. Slide rac k toward rear, rotate and remove from left side. Check
for wiring, fluid lines o r mechanical part s that migh t becom e
snagged as rack i s removed .

— Whe n installing, use new mounting bolt s an d self-lockin g nuts .

Tightening torque
Steering rack to front subframe 120Nm(89ft-lb)
(replace M12 10.9 grade fasteners with new )

When reattaching fluid lines:

• Replac e old banjo bolt o n pressure lin e with new one fitted with
Old New
check valve.
• Use new sealing 0-rings .

Tightening torque
Steering fluid line banjo bolt to steering pump 33 -35 Mm
(M14 or M16, replace sealing O-rings) (24- 25 ft-lb)

Remainder of installation is reverse of removal. Make sure fluid lines

and electrical harnesses are routed as before an d connected free of
stress. Keep in mind the following:
• Rais e front subframe int o plac e carefully , watching to make sure
fluid lines and electrical harnesses are not crushed.
B510320029 • Us e new fasteners as indicated i n torque specification s table.
• Fil l and bleed steering and hydraulic system with correct fluid. See
Power steerin g system , bleedin g and filling in this repai r group.
• Check fluid connections for leaks.
• Perfor m wheel alignment.
• Carry out steering angle senso r adjustmen t usin g BMW scan tool.

Tightening torques
Control arm to steering knuckle 1 65 N m (12 2 ft-lb)
(replace M1 4 x 1 .5 self-locking flange nut
with new )
Engine mount to engine bracket (replac e 56 Nm (41 ft-lb)
M10 10. 9 grade self-locking nuts with new)
Front end reinforcement panel t o subfram e
(replace M1 0 x 35 mm 10.9 grade ZNS bolts
with new):
• Stage 1 56 N m (41 ft-lb)
• Stage 2 + additional 90 °
Front subframe to chassis (replace M12x 1.5
10.9 grade bolts with new):
• Stage 1 100Nm (74 ft-lb)
• Stage 2 + additional 90 °
Steering and Wheel Alignment 320-2 9
Tie rod end, replacing

Tightening torques
Road wheel to hub 120± 1 0 Mm
(89 ± 7 ft-lb)
Stabilizer lin k to stabilizer bar 65 N m (48 ft-lb )
(replace M10 ZNS3 nu t with new)
Steering shaf t spindle universa l joint pinc h 22 Nm (16 ft-lb)
bolt (recu t pinch colla r threads, replace M8
Torx bolt wit h new )
Tie rod ball joint to steering knuckl e 80 Nm (59 ft-lb)
(replace M 1 4 x 1. 5 ZNS3 nu t with new)

Tie rod end, replacing

Raise front of car. Remove roa d wheel.

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

— Remov e splash shield underneath engine.

^(. Mak e reference measurement (A ) of outer tie rod end to tie rod .
Record measurement.
• Accurate measurement o f tie rod end with reference to tie rod
helps approximat e correc t whee l alignment when ne w parts are
installed.

Working at outer end o f tie rod:

• Remov e tie ro d end nu t (A) at steering knuckle. I f necessary,
counterhold ti e ro d ball joint shaf t with Torx tool.
• Loose n tie rod adjustment loc k nut (B).
320-30 Steerin g and Wheel Alignment
Tie rod, replacing

"X. Us e BMW special tool 32 3 090 or equivalent to press tie rod end out
of steerin g knuckle.

— Unscre w tie ro d end fro m tie ro d shaft .

— Chec k steering rack boot carefully fo r damage. Replac e if

necessary. See Steering rac k boot, replacin g i n this repai r group.

— Installatio n is reverse o f removal .

• Mak e sure threaded parts ar e clean.
• Us e anti-seize paste on inner tie ro d threads.
• Use new self-locking nuts where applicable .
• Us e previously made referenc e marks to set toe temporarily.

Tightening torques
Lock nut to tie rod end (^6x1.5) 51 N m (3 8 ft-lb)

Tie ro d ball joint to steering knuckle 80 Nm (5 9 ft-lb)

(replace M^4x^.5 ZNS 3 nu t with new)

After reassemblin g steering:

• Hav e car aligned.
• Adjust active steering (if applicable).
• Carry out steering angle sensor adjustmen t using BMW scan tool.

Tie rod, replacing

Raise front o f car. Remov e roa d wheel .

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

Make length reference mark on tie rod, the n remove outer tie rod
end. See Tie ro d end, replacing . Remov e lock nut.

Cut rac k boot clamps and slide boo t off. Check boot carefully for
damage. Replace if necessary. Se e Steerin g rack boot, replacing
in this repair group .

Use BMW special tool 32 3 160 or equivalent 38 mm crowfoot

wrench to loosen an d remove inne r tie rod shaft from steering rack.

CAUTION—
• To avoid damage to steering rack while removing tie rod, turn
steering until end of rack is as far as possible inside rack
housing.

Replace rack end sealing O-ring (arrow).

When reassembling , greas e ti e rod taper s o that rack boo t suppor t

buffer or small end of rack boot slides on tie ro d when tie ro d is
tightened, preventing rack boot from twisting.
Steering and Wheel Alignment 320-3 1
Steering rack boot, replacing

Installation i s reverse of removal, noting the following:

• Make sur e threaded part s are clean.
• Use anti-seize past e on inner tie rod threads.
• Use new self-locking nuts where applicable .
• Use previously made reference mark s to set toe temporarily.

Tightening torques
Lock nu t to tie ro d end (M1 6 x 1.5) 51 N m (3 8 ft-lb )
Tie rod ball joint to steering knuckl e 80 Nm (59 ft-lb )
(replace M1 4 x 1. 5 ZNS3 nu t with new)
Tie rod to steering rac k 110 Nm (81 ft-lb)

After reassemblin g steering:

• Hav e car aligned.
• Adjust active steering (i f applicable).
• Carr y out steering angle senso r adjustment using BMW scan tool .

Steering rac k boot, replacin g

Raise front of car. Remove road wheel.

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

— Remov e splash shiel d underneat h engin e and side splash shields .

— Mak e length referenc e mark on tie rod, the n remove outer tie ro d
end. See Tie rod end, replacing.

- Cu t rack boot ban d clamps and slide off boot. Inspec t boo t for any
sign of damage. Replac e if necessary. New rack boot kit comes with
new band clamps .

— Inspec t exposed ends o f steering rac k shaft. If polished surfac e

shows signs of corrosion, replace complete steering rack. Se e
Corrosion damag e i n this repai r group.

— Greas e tie rod taper so that small en d of rack boot slide s on tie ro d
when tie ro d is tightened, preventing rac k boot from twisting.

— Slid e new boot int o position an d replace ban d clamps . Reinstal l ti e

rod end using previousl y made referenc e marks.

Tightening torques
Tie ro d end to tie ro d (pinch bolt ) 40 Nm (30 ft-lb)

Tie ro d to steering knuckle (use ne w nut) 80 Nm (59 ft-lb)

After reassembling steering:

• Hav e car professionally aligned.
• Carry out steering angle senso r adjustment using BMW scan tool.
320-32 Steerin g and Wheel Alignment
Preparing for alignment

WHEEL ALIGNMENT
Proper handling , stability and driving ease depend upon the correct
alignment o f all four wheels. Th e fron t axle i s aligned in relation to
the rea r axle, then the front wheels ar e aligned in relation to one
another. Thi s i s known as a four-wheel or thrust-axis alignment .

BMW vehicles us e a sophisticated multi-lin k suspensio n a t the front

and rea r of the car. Proper alignmen t require s computerized
alignment equipment .

For front an d rear alignment specifications, see Alignment

specifications i n this repai r group .

Preparing for alignmen t

The following conditions ar e necessary befor e wheel alignment :
• Correc t wheels and identical tire s in good conditio n an d inflated
correctly. Tire tread depth fo r eac h axl e may differ lef t to righ t by
max. 1 - 2 mm (0.0 4 - 0.08 in).
• Steering and suspension part s an d bushings undamage d and
showing n o signs of abnormal wear .
• Wheel bearings i n good condition .
• Rid e height in accordance with specifications. See Ride heigh t i n
this repair group .
• Vehicle wit h electronic heigh t control (EHC): Remove EH C fuse to
prevent automatic heigh t adjustment . Se e ECL Electrica l
Component Locations.
• Vehicle with active steering: Remov e activ e steering fuse to
deactivate activ e steering. See ECL Electrical Component
Locations.
• Vehicle i n normal loade d position. Se e Normal loaded position in
this repai r group.

Normal loade d positio n

BMW defines vehicle normal loade d positio n as follows.

Normal loaded position

Each front seat, seats i n central positio n 68Kg(150lb)
Center of rea r seat 68 K g (150 lib )
Cargo compartmen t 21 K g (46 Ib )
Fuel tank Full

Ride heigh t

I
Measure rid e heigh t (A ) from center of fender arc h to bottom of
wheel rim .
• Car in normal loade d positio n o n the ground. Se e Normal loade d
position i n this repai r group.
• Specifie d tires and wheels, correct tire pressure, even tir e wear.
• Correct wheel bearin g play .

If ride heigh t i s outside specification s listed , instal l ne w springs.

Suspension spring removal and installation i s covered in 310 Front
BenHeyPybiishers Suspension and 330 Rear Suspension .
 Steering and Wheel Alignment 320-3 3
Front toe, setting

Table a. Front ride height (measurement A)

Ride height in mm (in )
Normal Sport Rough road Security xDrive
Wheel size suspension suspension package Long version version (E60, E61 )
16 inch 589(23.189) 574 (22.5984 ) 607 (23.8976 )
17 inc h 605(23.8189) 589(23.189) 622 (24.4882 ) 610(24.0157) 605(23.8189) 619(24.3701)
18 inch 617(24.2913) 602 (23.7008 ) 635 (25 ) 617(24.2913) 632 (24.8819 )
19 inch 630(24.8031) 614(24.5669) 648(25.5118)
Maximum combine d deviation from specification: 10 mm (0. 4 in)
Maximum differenc e between left and right : 1 0 mm (0.4 in)

Table b. Rear ride height, Sedan (E60) (measuremen t A)

Ride height in mm (in )
Normal Sport Rough road Security
Wheel size suspension suspension package Long version version xDrive
16 inch 573(22.5591) 558(21.9685) 589(23.189)
17 inch 588(23.1496) 573(22.5591) 604 (23.7795) 593 (23.3465 ) 588(23.1496) 599 (23.5827 )
18 inch 601 (23.6614 ) 585(23.0315) 617(24.2913) 600 (23.622) 611 (24.0551 )
19 inc h 613(24.1339) 598 (23.5433 ) 629 (24.7638) 612(24.0945)
Maximum combine d deviatio n from specification: 10 mm (0.4 in)
Maximum differenc e between left and right : 10 mm (0.4 in)

Table c. Rear rid e height, Sports Wagon (E61)

(measurement A)
Ride height in mm (in )
Normal Sport
Wheel size suspension suspension xDrive
16 inch 588(23.1496) 578 (22.7559)
17 inch 603 (23.7402 ) 593 (23.3465) 603 (23.7402 )
18 inch 615(24.2126) 605(23.8189) 616(24.252)
Maximum combined deviatio n from specification: 10 mm (0. 4 in)
Maximum difference between lef t and right : 1 0 mm (0. 4 in)

Front toe , settin g

Set front toe before adjusting camber . Camber an d toe influenc e
each other. Toe is the difference in the distance between the front of
the wheels and the rea r of the wheels . It is adjusted b y altering th e
length of the tie rods .

Make toe adjustments with vehicle in normal loaded position . See

Normal loade d positio n i n this repair group.

Center steering wheel. Make sure front wheels are pointed straigh t
ahead.
320-34 Steerin g and Wheel Alignment
Front toe, setting

— Rais e car an d suppor t safely .

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

— Remov e splash shield and front end reinforcement panel from under
engine.

— Remov e side suspensio n splas h shields .

'X, Workin g underneath vehicle, make sure steering spindle pointer and
steering rac k pointer line u p (arrows).

— Us e steering wheel holdin g too l to loc k steering wheel in centered

position.

— Workin g underneat h vehicle , clean thread s o n tie ro d shaft.

Counterhold tie ro d end and loose n tie ro d adjuster lock nut (A).
• To adjust toe, counterhold tie rod end and turn inner tie rod shaft
(curved arrow) to change length .
• To keep steering wheel centered, adjust both tie rods equa l
amounts.
• Loose n or remove rack boot small end clamp (B) so that rack boot
moves freely on tie ro d shaft and doe s not become twisted. .

Tightening torques
Lock nu t to tie rod end (M'lQxl 5) 51 M m (3 8 ft-lb )
 Steering and Wheel Alignment 320-3 5
Front camber, adjusting

Front camber, adjusting

Set front toe before adjusting camber. Camber an d toe influenc e
each other. Camber i s the deviatio n of each wheel from vertical. If
necessary, adjust camber b y removing front strut top centerin g pin.

CAUTION—
• Do not attempt to straighten out accident-caused changes in
axle geometry by adjusting the camber.

Working a t strut top bearing:

• Remov e centering pin (A) .
• Loose n strut top bearing mountin g nut s (arrows) 1 -11 /2 turns.

— Rais e vehicle until wheels ar e off ground. Suppor t vehicl e safely .

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

i
Working belo w vehicle, use compressed air to clean of f debris in
wheel housing nea r strut top bearing .

Fit BMW special tool 32 3 190 over inboar d stru t top nut.
• Turn knurled nut on tool (arrow) to adjust camber to specifie d
value.
• Replac e outboard strut top mountin g nuts with new, then tighte n
down.

Remove special tool and replace inboard strut top mounting nu t with
new, then tighten down .

Tightening torque
Strut top bearing to chassis 34 N m (2 5 ft-lb)
(replace M 8 shoulder nut s with new )

Check directional stability of vehicle. If necessary, reset toe. See

BentJeyiubiisnefs Front toe, setting .
.com
Vehicle with active steering: Us e BMW scan tool to zero steerin g
angle sensor an d commission active steering.
320-36 Steerin g and Wheel Alignment
Rear camber, adjusting

Rear camber, adjustin g

Adjust rea r camber befor e settin g toe. A camber chang e mean s a
toe chang e a s well. Camber i s the deviatio n o f each whee l from
vertical.

— Rais e vehicle and support safely.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Working at swing arm underneat h rea r suspension :

• Replac e nu t on swing arm eccentric bol t (arrow) with new. Tighten
to 5 Nm (finger tight).
• Lowe r vehicle on alignment rac k an d use eccentric bol t to adjust
camber (curve d arrow).
• Tighten swing arm eccentric bolt to specification with vehicle in
normal loade d position .

Tightening torque
Swing arm eccentric fastener to rea r 165Nm(122ft-lb)
subframe (replac e nut , tighten wit h
suspension loaded)

Rear toe, setting

Adjust rea r camber befor e setting toe. A camber chang e mean s a
toe change as well. Toe is the difference in the distance between the
front of the wheels an d the rea r of the wheels.

Working at guide link :

• Replac e nut (arrow) on eccentric bolt . Tighten to 5 Nm (finger
tight).
• Lowe r vehicle on alignment rack and use eccentric bol t to set toe
(curved arrow).
• Tighten guid e lin k eccentri c bol t t o specification with vehicle in
normal loade d position .

Tightening torque
Guide link eccentric fastener to rear subframe 65 N m (4 8 ft-lb)
(replace nut , tighte n wit h suspension loaded )

Caster
Front and rear caster ar e fixed and deviations ar e usually the resul t
of wor n or damaged suspension or body parts.

Check front suspension arm s an d bushings fo r wear, damage an d

deformation i f front caster problems are present .

Check rea r axle subframe an d traction struts if rear caster problem s

are present .
 Steering and Wheel Alignment 320-3 7
Alignment specifications

Alignment specification s
Table d. Alignment specifications, Sedan (E60)

Specifications
Standard Sport Rough roa d Long
Parameter suspension suspension suspension wheelbase xDrive
Front axl e
Total toe 0° 8' ± 12 ' 0 ° 8 ' ± 12 ' 0 ° 8 ' ± 12 ' 0° 12' ± 12 ' 0° 12 ' ± 12'
Adjustment total toe* 0° 8 1 ± 4' 0° 8' ± 4' 0° 8' ± 4' 0° 12 ' ± 4 ' 0° 12 ' ± 4'
Toe difference between right and left* * max 12 ' max 12 ' max 12 ' max 12 ' max 12 '
Camber (differenc e between lef t / right, maximum 30') -12' ±30' -30' ± 30' -12' ±30' -05' ± 30' -20' ± 30'

Adjustment camber * -12' ±25' -30' ± 25' -12' ± 2 5 ' -05' ± 25' -20' ± 25'

Toe angle difference with 20° lock on inside wheel 1°41'±30 ' 1°47'±30 ' 1 ° 43' ± 30' 1 ° 42' ± 30' 1°53'±30 '
(difference betwee n lef t / right, maximum 30')
Front caster (difference between left / right maximum 30')
Front wheel displacemen t 0°± 15 ' 0°± 15' 0°±15 ' 0°± 15' 0°± 15'

Maximum whee l loc k

Inside wheel (approx.) 43° 22' 43° 0 1 ' 43° 58' 43° 22' 39° 42'

Outside whee l (approx.) 34° 00' 33° 38' 34° 22' 34° 06' 31° 38'

Rear axle
Total to e 0° 18' ± 12 ' 0° 18' ± 12 ' 0° 18'± 12 ' 0° 18' ± 12 ' 0° 18' ± 12 '

Adjustment total toe * 0° 18' ±4 ' 0° 18' ±4' 0° 18' ±4' 0° 18' ±4' 0° 18' ±4 '

Camber (differenc e between lef t / right maximum 30' ) -2° 00' ± 25' -2° 00' ± 25' -2° 00' ± 25' -2° 00' ± 25' -2° 00' ± 25'

Adjustment camber * -2° 00' ± 5' -2° 00' ± 5' -2° 00' ± 5 ' -2° 00' ± 5 ' -2° 00 ' ± 5'

Geometrical axis deviatio n 0°±12 ' 0°± 12 ' 0°±12 ' 0°±12 ' 0°± 12 '

* To minimize inaccuracy, us e a narrower tolerance

** Fron t axle toe difference = criterion for steering wheel inclinatio n
320-38 Steerin g and Wheel Alignmen t
Alignment specifications

Table e. A/ignment specifications, Sport s Wago n (E61 )

Specifications

Piarameter Standard suspension Sport suspension xDrive

Front axle
Total to e 0° 12'± 10 ' 0° 12' ± 10' 0° 12'± 12'
Adjustment tota l toe* 0° 12 ' ± 4' 0°12'±4 ' 0°12'±4 '

Toe difference between righ t an d left* * max 12 ' max 12 ' max 12 '
Camber (differenc e between left / right , maximum 30' ) -12' ±30 ' -30' ± 30' -20' ± 30'
Adjustment camber * -12' ±25' -30' ± 25' -20' ± 25'
Toe angle differenc e with 20° loc k o n inside whee l 1°41'±30 ' 1 ° 47' ± 30' 1 ° 53' ± 30'
(difference between lef t / right , maximu m 30' )
Front caster (difference between left / right maximum 30')
Front wheel displacemen t 0°±15 ' 0°±15 ' 0°±15 '
Maximum wheel lock
Inside wheel (approx.) 43° 22' 43° 01' 39° 42'
Outside whee l (approx. ) 34° 00' 33° 38' 31° 38'
Rear axle
Total toe 0° 18'± 12 ' 0° 18 ' ± 12' 0° 18'± 12'
Adjustment total toe* 0°18'±4 ' 0° 18' ± 4 ' 0° 18 ' ± 4 '
Camber (differenc e between lef t / right maximum 30' ) -2° 00' ± 25' -2° 00' ± 25' -2° 00' ± 25'
Adjustment camber* -2° 00' ± 5' -2° 00' ± 5' 1 -2° 00' ± 5'
Geometrical axis deviatio n 0°± 12 ' 0°±12 ' 0°±12 '
* To minimize inaccuracy, us e a narrower tolerance
** Fron t axle toe difference = criterion for steering wheel inclinatio n
 330-1

330 Rea r Suspensio n

GENERAL 330- 1 REAR SUSPENSIO N ARMS ,

Rear suspension descriptio n 330- 2 SUBFRAME AN D BUSHINGS 330-1 6
Sedan rea r suspension component s 330- 3 Rear suspension ar m components 330-1 6
Sports Wagon rea r suspension component s . . 330- 3 Upper contro l arm, removin g and installing . . 330-1 7
Warnings an d Cautions 330- 4 Guide ar m (traction strut) ,
removing an d installing 330-1 8
ELECTRONIC HEIGH T CONTRO L (EHC) . . . 330- 4
Swing arm, removin g and installing 330-1 9
EHC description 330- 4
Integral link , removin g and installing 330-2 1
EHC power supply 330- 5
Swing ar m ball joint, removing and installing . 330-2 2
EHC control electronic s 330- 6
Rear subframe, removing an d installing 330-2 3
EHC, disabling , deflating , refilling 330- 6
Rear subframe bushings ,
EHC faults 330- 7 removing and installing 330-2 5
REAR STRU T ASSEMBL Y (SEDAN ) 330-8 REAR WHEEL BEARING S 330-2 6
Rear strut assembly, removin g and installin g Rear wheel bearing component s 330-2 6
(Sedan) 330- 8 Rear wheel bearing carrier ,
Rear strut assembly component s (Sedan) . . . . 330- 9 removing and installing 330-2 7
Rear strut assembly , disassemblin g Rear wheel hub , removin g and installing . . . . 330-2 9
and assembling (Sedan) 330-1 0
Rear wheel bearing, replacin g 330-3 0
REAR SHOC K ABSORBER S AND AIR SPRING S REAR STABILIZE R BA R 330-3 2
(SPORTS WAGON) 330-1 2 Active stabilizer bar (dynamic drive ) 330-3 2
Rear shock absorber components Rear stabilizer ba r component s
(Sports Wagon) 330-1 2 (mechanical stabilizer) 330-3 3
Rear shock absorber , removing and installing Rear stabilizer bar , removing and installin g
(Sports Wagon) 330-1 2 (mechanical stabilizer) 330-3 3
Air spring components (Sport s Wagon) 330-1 3
Rear stabilizer bar , removin g and installin g
Air spring , removin g and installing (active stabilizer bar) 330-3 4
(Sports Wagon ) 330-1 4 Stabilizer ba r link , removing and installin g . . . 330-3 6

GENERAL
This repair grou p cover s removal and replacemen t o f rea r
suspension components .

See also:
• 300 Suspension, Steerin g an d Brakes-General fo r a genera l
description o f the 5 Series suspension .
• 310 Front Suspension fo r front suspension componen t
replacement and active stabilizer system.
• 320 Steering and Wheel Alignmen t for ride height and alignment
specifications.
• 331 Rea r Axle Differentia l fo r rear drive axle and differential
repairs.
330-2 Rea r Suspensio n
Rear suspension description

Special service tools are required for some of the work described in
this repair group . Mos t o f these tools are specialized press jigs and
pullers that may be replaced b y standard puller s of various sizes.
Read the procedures through befor e beginnin g an y job.

Rear suspension descriptio n

The rear suspension uses a subframe as a rigid mounting platfor m
for the differential (als o called final drive) an d rea r suspensio n
components. The differential i s mounted t o the subframe and the
subframe is bolted t o the body throug h rubbe r bushings whic h hel p
isolate drivetrain noise and vibration.

. I n the 5 Series multi-link rear suspension, fou r control arms (or links)
12 45 on each side locat e the rea r wheels. The lowe r control arm. called
the swing arm, is attached to the wheel bearing carrier via a ball joint
at rear and an articulating integral lin k a t front.
1. Rea r drive axle
2. Guid e arm (traction strut)
3. Contro l arm
4. Whee l bearin g carrie r
5. Whee l hub
6. Swin g arm
7. Integra l lin k
8. Bal l joint

BentleyPublfshers Shock absorber an d spring applications diffe r on Sedan and Sports

Wagon models :
• Sedan (E60) rea r springs and struts are combined in a
conventional MacPherson strut assembly .
• Sports Wagon (E61) gains larger and flatter cargo space and better
load capacity by being equipped with separate air springs and
shock absorbers . Ai r spring height s ar e determined b y the
electronic heigh t control (EHC) system .
 Rear Suspension 330- 3
Sedan rear suspension component

Sedan rea r suspension componen t

1. Contro l arm
23
2. Stru t and coil spring assembl y
3. Stabilize r bar link
4. Rearsubfram e
5. Rea r drive axle
6. Rea r differentia l
7. Differentia l rear mount bushing
8. Whee l hub
9. Whee l bearing carrier
10. Integral link
11. Guide arm (traction strut)
12. Swing arm
13. Thrust rod
14. Differential fron t mount bushings
15. Differential input flange
Bent
89 1 01 1 12 14 1 5 1 4 12 1 1 1 01 3
B510330003

Sports Wago n rear suspension component s

1. Contro l arm
12 3 4 5 6 7 58 2 3 19
2. Shoc k absorber
3. Ai r spring
4. Rearsubfram e
5. Rea r drive axle
6. Rea r differential
7. Differentia l rear mount bushin g
8. Stabilize r bar link
9. Whee l hub
10. Wheel bearing carrie r
11. Swing arm
12. Integral link
13. Guide ar m (traction strut)
14. Thrust rod
15. Differential front mount bushing s
16. Differential inpu t flange
91 01 11 21 31 4 15 1 6 1 5 13 1412
B510330003
330-4 Rea r Suspension
Warnings and Cautions

Warnings and Caution s

WARNING—
• Do not reuse self-locking fasteners.
• Wear protective gloves and eye wear when working with
hydraulic fluid.
• Drain the EHC (self-leveling suspension) system before
carrying out any work on the air supply compressor, air pipes or
air springs. Se e EHC, disabling, deflating , refillin g in this
repair group.

CAUTION—
• Due to the chemical and corrosion characteristics of aluminum,
follow these precautions when working with aluminum
components:
—Do not bring into contact with battery acid.
—Do not use wire brushes with brass o r iron bristles.
—Do not expose t o flying sparks.
—Do not subject t o steel welding splashes.
—Do not expose t o temperatures over 80°C (176° F), even for
short periods. Paint shop temperatures are not a problem.
• When filling or bleeding active stabilizer bar hydraulic system,
do not allow contamination of fluid or reservoir.
• Do not allow the vehicle to stand on its wheels when the EHC
system is disabled or drained. Damage to air springs may
result.
• When disconnecting and connecting EHC air lines, do not allow
contamination to enter the lines.

ELECTRONIC HEIGHT CONTROL (EHC )

EHC description
Sports Wagon (E61 ) rea r suspension i s equipped with air springs.
Electronic control of air spring height allows the rear of the wagon to
remain at a relatively stable height, thereb y maintaining constant
suspension geometry and handling stability. The electronic heigh t
control (EHC) system i s also referred to as self-leveling suspension.

Air spring s and shock absorbers ar e supported independently on

the floor pan of the vehicle, allowing for flatter floor and larger cargo
space.

The EH C air supply system i s underneath th e rear of the vehicle

between the spare wheel well and batter y box.
 Rear Suspension 330- 5
EHC power supply

EHC compressor filtered air intak e is at right rear of vehicle behin d

cargo compartment paneling.

EHC power suppl y

The EHC power suppl y fuse is in the rear fuse panel at right side of
cargo compartment behin d trim.

F79, 7. 5 A (to 09 / 2005 )

B510330011

F81, 7. 5 A (from 09/2005)

330-6 Rea r Suspensio n
EHC control electronics

EHC control electronic s

EHC power relay and control module ar e in the cargo compartment,
underneath th e spare tire.

. A118 a EH C contro l modul e

K126 EH C relay

EHC, disabling , deflating , refillin g

Switch ignition OFF and remov e key.

Raise vehicle and support safely.

WARNING —
• Make sure the vehicle is stable and well supported at a/I times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Remove EHC power supply fuse in rear fuse panel. See EHC power
supply in this repair group.

Working underneath righ t rea r of vehicle, remov e plastic cover to

gain access to air compressor and valv e body.
• Label ai r lines (arrows), then loosen union nuts until hiss of
escaping air can b e heard.
• Full y releas e lines once sound o f escaping air stops.

CAUTION—
• Plug open air lines and ports.
• Do not lower vehicle on its wheels while air springs are
depressurized.

When installing:
• Check union nuts for contamination. Clean i f necessary.
• Start union nut by hand carefully to avoid damaging plastic threads
on valve body.

Tightening torque
EHC airline to valve body (4 mm line ) 2 N m (1 8 in-lb),

Reinstall EH C power supply fuse.

Connect BM W scan tool.

Switch ignition ON. Use scan tool "control unit functions" men u to
activate EHC and inflate rear air springs.
 Rear Suspensio n 330- 7
EHC faults

EHC faults
The driver i s alerted to EHC system faults by a warning icon and a
Check Contro l warning triangle in instrument cluster.

Check Contro l i n center dashboar d (iDrive ) displays a self-leveling

(EHC) malfunctio n message .

Stop and check the vehicle. If it is considerably lower at the rear than
at the front, or on one side, g o to the nearest BMW cente r o r other
qualified repai r shop. Driv e with appropriate cautio n i n the
meantime. Th e vehicle has reduced ground clearance an d drivin g
comfort ma y be noticeably reduced .

Even if the position of the vehicle i s normal, mak e sur e the vehicl e is
checked b y a qualified repai r shop .
330-8 Rea r Suspension
Rear strut assembly, removing and installing (Sedan)

REAR STRU T ASSEMBLY (SEDAN )

Sedan rea r shock absorbers ar e MacPherso n struts . The strut is a
major component o f the suspension an d supports th e spring. Most
strut assembly component s ar e available a s replacemen t parts.

If a shock absorber o r strut is defective o n one side of the vehicle,

replace both shock absorbers o n that axle. If a coil spring i s broken
due to corrosion, replace both coil springs on the axle.

Rear strut, upper strut mount or coil spring replacement is a two-step

procedure:
• Remova l of strut assembly fro m vehicle.
• Disassembl y an d replacement o f components o n work bench.

Special tool s ar e necessary fo r compressing th e coil spring safely.

Be sure to read the complete procedur e befor e starting work.

Rear strut assembly, removing and installing

(Sedan)
— Rais e car and remov e rear wheel .

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

Detach stabilizer lin k from swing arm .

Support rea r wheel bearin g carrie r with suitable jack.

Remove strut assembly lowe r mountin g bol t (arrow) an d detach

strut bas e from wheel bearing carrier . Tie strut up with stiff wir e to
prevent it from falling out.

. Workin g in trunk:
• Pee l back trunk side trim covering whee l well.
• Remov e sound absorbin g material s t o gain access to strut top
mount nut s (arrows).
• Remov e nuts.

Working in wheel arc h opening underneath vehicle :

• Pus h wheel bearin g carrier down
• Guide stru t assembly dow n between guide arm and control arm
and lif t out of wheel housing .

If replacing strut, coil spring o r upper stru t mount, disassembl e an d

reassemble stru t assembly o n bench. Se e Rea r strut assembly ,
disassembling and assembling in this repair group.
 Rear Suspension 330- 9
Rear strut assembly components (Sedan)

Installation i s reverse of removal . Note the following :

• Replac e uppe r strut mount nut s and lower strut moun t bol t with
new.
• Mak e sure that strut lowe r bushing mate s squarely with bor e i n
wheel bearin g housin g befor e installin g lowe r bolt. Do not use bolt
to force strut bushing int o alignment.

Tightening torques
Road wheel to hub 120 ± 1 0 Nm
(89 ± 7 ft-lb)
Strut lower mount to wheel bearing carrier 165Nm (122 ft-lb)
(replace M1 4 x 105 mm ZNS3 bol t with
new)
Strut upper moun t to chassis (replace M8 28 N m (2 1 ft-lb )
ZNS3 self-locking nuts with new )

Rear stru t assembly component s (Sedan )

1. M1 2 x 1. 5 self-locking nut
• Replac e with new
• Tighten to 27 Nm (20 ft-lb)
2. Washe r plat e
3. M 8 ZNS3 self-lockin g nut
1— £5

2 —& • Replac e with new

• Tighten t o 28 Nm (21 ft-lb)
3
Ah
4— t 10 4. Uppe r strut moun t
5. Uppe r spring pa d
6. Suppor t
7. Coi l spring
o 9
11
8. Rubbe r stop
9. Lowe r spring pad
10. Stru t with lower spring sea t
11. M14x105mmbol t
• Replac e with new
• Tighten to 165 Nm (122 ft-lb)
330-10 Rea r Suspensio n
Rear strut assembly, disassembling and assembling (Sedan)

Rear strut assembly , disassemblin g

and assembling (Sedan )
If replacin g strut, uppe r strut moun t o r coil spring, firs t remov e the
strut assembly from the vehicle. See Rea r strut assembly ,
removing and installin g (Sedan ) in this repai r group.

BMW recommends the use of BMW spring compressor (specia l tool

31 3 340). A number o f different spring compressor tools are
available. Photo s i n this section illustrat e the function of one such
tool i n use.

WARNING —
• Do not attempt to disassemble the strut assembly without a
spring compressor designed specifically for this job.
• Prior to each use, check special tool for functionality.
• Do not use a damaged tool.
• Do not make any modifications to tool.
• Use correct size spring retainers when compressing coil spring.
• When assembling BMW spring compressor (special tool
31 3 340), make sure spring retainer plates are felt and heard
snapping into place. Check seating of spring retainers carefully.

— Clam p sprin g compressor i n shop vise.

^C Clea n coil spring to remove coarse dirt , then position between

compressor spring retainers (arrows) a s shown. Compres s spring.

WARNING —
• Make sure that when tensioned, the spring coil rests completely
in the spring holder recess.
• Do not tighten or loosen spring compressor with an impact tool.
• Tighten down the coil spring until stress on the upper strut
mount is relieved.
• Only loosen upper strut nut if spring coils are completely
inserted in the spring holder grooves. If necessary, loosen
compressor, reposition and recompress.

^ Counterhol d strut piston shaft with small wrench and remov e uppe r
strut nu t (arrow).

— Remov e upper strut mount an d sprin g pad .

— I f a new coil spring i s being installed, relieve tension

compressor and remove coil spring .

— Chec k rubbe r stop and spring pads. Replac e as necessary .

— Replac e strut, upper strut mount or spring, a s needed. I f one spring

is corroded or damaged, replac e both spring s a s a matched pair .

BentleyPublfshers
 Rear Suspension 330-1 1
Rear strut assembly, disassembling and assembling (Sedan)

Assemble strut with coil spring an d tighten down uppe r moun t usin g
new nut.
• Uppe r moun t alignment : On e stud on upper moun t line s u p with
short en d of strut bushing .

Tightening torque

Strut shaft to strut top bearin g 27 N m (2 0 ft-lb )

(replace self-lockin g M12 x 1. 5 nut with new)

Be sure coil spring end s lin e u p correctly before releasing sprin g

compressor. Se e following illustrations.

: - : : • • ['vPunuf
B510330039]

Upper coi l spring end : Plac e spring end in spring pa d stop (inset) .

Lower coil sprin g end: Plac e spring en d against sprin g pa d sto p

(inset).

— Releas e spring compresso r carefull y and evenly, allowing sprin g t o

expand slowly.

— Reinstal l strut assembly i n vehicle.

330-12 Rea r Suspension
Rear shock absorber components (Sports Wagon)

REAR SHOC K ABSORBER S AND AIR SPRINGS

(SPORTS WAGON )
Sports Wagon models are equipped wit h rear air springs installed
separately from the shock absorbers. Se e Sports Wagon rear
suspension component s i n this repai r group.

If a shock absorber is defective on one sid e o f the vehicle, replace

both shock absorbers on that axle.

Rear shock absorber components

(Sports Wagon)
1 ft^ 1. M1 2 x 1.5 self-locking nut
2- —C~S > • Replace with new
3 CS 3 •Tighten to 27 Nm (20 ft-lb)
2. Suppor t washer
4 0
3. Suppor t bushin g
3
4. Space r sleeve
2(
5. Rubbe r bump sto p and dust sleeve
Pi) 6. Shoc k absorber
7. M 1 4 x 1 0 5 m m b o l t
• Replace with new
• Tighten to 165 Nm (122 ft-lb)
:'
B51033004.)

Rear shock absorber, removin g an d installin g

(Sports Wagon)
— Rais e vehicle and suppor t safely .

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

Disable and deflate EHC system. See EHC , disabling, deflating,

refilling i n this repair group.

. Remov e shock absorber lower mounting bol t (arrow). Detach shock

absorber from swing arm an d ti e securel y to prevent i t from falling
out.
 Rear Suspension 330-1 3
Air spring components (Sports Wagon)

"X. Workin g in cargo compartment:

• Remov e floo r covering an d side plasti c rails to gain access to
Air spring shock absorber uppe r mountings.
upper retainer
• Unscre w uppe r shoc k absorber nut (arrow) an d lif t off upper
support washer .

— Remov e shoc k absorbe r from belo w vehicle .

— Inspec t rubbe r bum p stop , dust sleeve and support bushing s for
wear and damage. Replac e as necessary.

— Transfe r used and ne w part s to ne w shock absorber. Installation i s

reverse of removal. Not e the following:
• Replace uppe r stru t mount nut and lower strut mount bolt with new.
• Mak e sure that shock absorber lower bushing mates squarel y with
bore in swing arm befor e installing lowe r bolt. D o not use bol t to
force shoc k absorbe r bushin g into alignment.

Tightening torques
Road wheel t o hub 120 ± 1 0 Nm
(89 ± 7 ft-lb)
Shock absorbe r lowe r bolt to swing arm 165 M m (122ft-lb )
(replace M^4x^05'mm ZNS3 bolt wit h
new)
Shock absorber upper mount to frame rail 27 N m (20 ft-lb)
(replace M8 ZNS3 self-locking nu t with
new)

Reactivate an d fill EH C system. See EHC, disabling, deflating,

refilling in this repai r group .

Air spring components (Sports Wagon )

1. Airlin e
2. Protectiv e boot
3. Unio n nut
• Plastic ai r line connectio n
• Tighten to 2 Nm (18in-lb)
4. Ai r spring
5. Plasti c retaine r
330-14 Rea r Suspension
Air spring, removing and installing (Sports Wagon)

Air spring, removing and installing

(Sports Wagon)
— Rais e vehicle an d remov e rear wheel .

~|
WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

- Disabl e and deflat e EHC system . See EHC, disabling , deflating,

refilling in this repair group.

^ Workin g at base of air spring above whee l bearing carrier:

• Tilt lower section of air spring (arrow ) by hand toward front. Rotate
counterclockwise 25° against resistance of lower plastic retainer to
detach.
• Not e that broke n off upper plasti c retaine r o n air spring i s not a
problem.

Squeeze air spring (arrows) and tilt top outward.

CAUTION—
-I*- If- • Do not kink, twist or crush air line.

BentleyF^ljishers
« B51033004 6

Detach air line from air spring at union .

• Moiste n air spring upper protectiv e boot (arrow) with soapy
solution, then remove air line, air line union and boot from spring.
Air line • Plu g or tape up open air ports immediately.
union
• Not e that union nut stays on air line.
• Lif t out air spring.
"V 1
| teg,-,
' mm Before reinstalling, check airline, union nuts and lowe r retaine r for
damage. Replace as necessary.

V^<
Behtlel
.coin
 Rear Suspension 330-1 5
Air spring, removing and installing (Sports Wagon)

To reinstall, plac e air spring at its location and place protective boot
over it. Clean air line union carefully, then screw in by hand to avoid
damaging plasti c threads .

Tightening torqu e
Air lin e to air spring (4 mm line) 2 M m (18in-lb )

Tip air spring into place and fit upper retainer in frame rail slot .
Rotate spring approx. 25° to lock in place. This ensures alignmen t
of ai r spring to lower retainer.
• Note that broken off upper plastic retaine r on air spring i s not a
problem.
• To make sure air line does not slip out of protective boot groove,
pull air line downward during installation.

CAUTION—
• Do not kink, twist or crush air line.

Align air spring to lower retainer and press down until retainer snaps
into place. I t is not necessary to replace retainer.

BentleyRu wishers Tightening torque

Road wheel to hub 120±10N m
(89 ± 7 ft-lb)

Reactivate and fill EHC system. See EHC, disabling, deflating ,

refilling in this repai r group.
330-16 Rea r Suspension
Rear suspension arm components

REAR SUSPENSION ARMS,

SUBFRAME AN D BUSHINGS
Rear suspension arm component s
The diagram belo w illustrates Seda n rea r control arms. Sport s
Wagon i s similar.

1. Self-lockin g M10 nut (replace)

12 1011 1 2 13
• Tighten wit h suspension loade d
•Tighten to65 Mm (48ft-lb)
2. Eccentri c washer
3. Eccentri c M1 O x 66 mm ZNS3 bolt
• Adjusts rear toe
4. Guid e ar m (traction strut)
5. M121.5x92mmZNS3bol t
6. Self-lockin g M10 nut (replace)
• Tighten to 65 Nm (48 ft-lb)
7. Self-lockin g M14x 1.5 nut (replace)
• Tighten t o 175 Nm (129 ft-lb)
8. Self-lockin g M12x 1.5 nut (replace )
• Tighten with suspension loaded
• Tighten to 100 Nm (74 ft-lb)
9. Uppe r control arm
10. Wheel bearin g carrier
11. Swing arm ball joint
12. Circlip
4om
1415 1 6 1819 20 2 1 2 2 13. M16 x 275 mm ZNS3 bolt
B510330020
14. M12 x 1.5 x 67 mm ZNS3 bolt
15. Self-locking M16x 1.5 nut (replace)
• Tighten wit h suspension loaded
• Tighten to 240 Nm (177 ft-lb)
16. Integral link
17. Self-locking M12 x 1.5 nut (replace )
• Tighten with suspension loade d
• Tighten t o 100 Nm (74 ft-lb)
18. M12 x 1.5 x 98 mm ZNS3 bolt
19. Eccentric M14 x 100 mm ZNS3 bolt
• Adjusts rear camber
20. Swing arm
21. Eccentric washe r
22. Self-locking M14 x 1.5 ZNS3 nut
(replace)
• Tighten with suspension loaded
• Tighten to 165 Nm (122 ft-lb)
 Rear Suspension 330-1 7
Upper control arm, removing and installing

Upper contro l arm , removin g an d installing

— Sport s Wagon: Disabl e and deflate EHC system. Se e EHC ,
disabling, deflating, refilling in this repai r group .

— Rais e car an d remov e wheel.

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

Release wheel speed sensor and brake pad sensor wires from
brackets. Note that brake pa d sensor is only on right side .

f 4^ 7V I
Remove contro l arm ball joint nut (arrow) at wheel bearin g carrier.
Separate control arm from wheel bearing carrier. (Brake backin g
l*"U£< X plate and disc cu t away for purpose o f illustration.)

\ N
•~-y

entleyPubllshers \B5103

, ....,.- « Remove contro l ar m mounting nut (arrow) at subframe. Slid e

]L_, f
mounting bolt out and remove control arm.

r~

«:•' " - S^Tt-jlr

If installing ne w control arm, b e sure to match shap e o f whee l

bearing carrier seat for ball joint.

B510330023]
330-18 Rea r Suspension
Guide arm (traction strut), removing and installing

Installation i s reverse of removal. Remember to:

• Keep control arm ball joint shaf t and wheel bearin g carrie r bore
clean and grease-free.
• Replace self-locking fasteners.
• Head of control arm to subframe bol t faces forward.
• Tighten control arm to subframe fastene r to final torque only after
vehicle i s lowered and suspension has settled.
• Sports Wagon: Reactivate an d fill EHC system. Se e EHC,
disabling, deflating , refilling i n this repai r group.

Tightening torques
Control arm to subframe (replace M12 x 1 .5 100Nm(74ft-lb)
self-locking nu t with new)
Control arm to wheel bearing carrier (replac e 175Nm (129ft-lb)
M14 x 1.5 self-locking nut with new)
Road wheel to hub 120+ 10 Nm
(89 ± 7 ft-lb)

— Hav e car professionally aligne d when job i s complete.

Guide arm (traction strut),

removing and installing
— Rais e car and remov e wheel.

WARNING—
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

^C Remov e guide arm ball joint nu t (arrow) at wheel bearing carrier .

Separate guide arm from wheel bearing carrier. (Brake backing
plate and disc cut away for purpose of illustration.)

Working at guide ar m to subframe bolt :

• Mar k position of eccentric bolt (rear toe adjustment bolt) (A) .
• Remove mounting nut (B).
• Remove eccentric washe r (C) and slide out bolt.

BentleyPubiishers
.com
 Rear Suspension 330-1 9
Swing arm, removing and installing

Installation i s reverse of removal . Remembe r to :

• Keep guid e ar m bal l joint shaft and wheel bearing carrier bor e
clean and grease-free.
• Replac e self-locking fasteners.
• Hea d of guide arm to subframe eccentric (toe-adjusting) bolt faces
backward.
• Refi t eccentric washer on eccentric bolt and match mark s mad e
previously.
• Tighten guid e ar m to subframe fastener to final torque onl y after
vehicle is lowered and suspension ha s settled.

Tightening torques
Guide arm to subframe (replace M10 self- 65 N m (4 8 ft-lb)
locking nut with new )
Guide arm to wheel bearing carrier (replace 65 N m (4 8 ft-lb )
M10 self-locking nut with new )
Road wheel to hub 120 ± 10Nm
(89 ± 7 ft-lb)

— Hav e ca r professionall y aligne d whe n job i s complete .

Swing arm, removing an d installin g

— Sport s Wagon: Disabl e an d deflate EHC system. Se e EHC,
disabling, deflating , refilling i n this repair group.

— Sport s Wagon: Detac h driv e axle at differential output flange . Se e

331 Rea r Axle Differential .

— Rais e car an d remov e wheel.

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

— Suppor t rea r wheel bearin g carrier with suitable jack.

^. Working underneath swin g arm:

• Disconnec t contro l ro d for suspension level sensor .
• Remov e stabilizer lin k nut (A) at swing arm and detach stabilize r
link. See Stabilizer ba r link, removin g an d installin g i n this
repair group .
• Sports Wagon: Remov e shock absorber fastener (B) at swing arm
and detach shoc k absorber. See Rear shock absorber ,
removing an d installing (Sport s Wagon ) in this repai r group .
330-20 Rea r Suspensio n
Swing arm, removing and installing

^C. Mar k (arrows) position of rear inboard swin g arm bolt (rear camber
adjusting bolt) , then remov e nut . Remove eccentric washer and
slide ou t bolt.

— Remov e front inboar d swin g arm fasteners .

Working at integral link, remove swin g arm mountin g nu t (arrow).

Drive outboard mountin g bol t toward rea r and pull swing arm
downward.

Note orientation of swing arm bol t heads :

• Eccentri c (cambe r adjusting) bol t hea d point s forward.
• Fron t inboard bolt hea d points backward .
• Outboar d (integra l link) bolt head point s backward .

Installation is reverse of removal. Remember to:

• Replac e self-locking fasteners.
• Refi t eccentric washer on camber bol t and match marks mad e
previously.
• Tighten swin g arm and shock absorbe r fasteners to final torque
only after vehicle is lowered and suspension ha s settled.
• Sports Wagon: Reactivat e and fill EH C system. See EHC,
disabling, deflating , refilling i n this repai r group.

Tightening torques
Drive axl e to differential output flange 80 Nm (59 ft-lb)
(replace M10 x 43 mm ZNS3 Torx bolts with
new)
Integral link to swing arm (M1 6 x 275 m m 240Nm(177ft-lb)
ZNS3 bolt, replac e nut with new)
Road wheel to hub 120± 10N m
(89 ± 7 ft-lb)
Shock absorber to swing arm (replac e M1 4 x 1 65 N m (12 2 ft-lb)
1 .5 x 1 05 m m ZNS bolt s with new)
Stabilizer link to swing arm (replac e M12 x 1 00 Nm (74 ft-lb)
1 .5 ZNS self-locking nut with new)
Swing arm t o subframe (M12 x 1 .5 x 98 m m 100Nm (7 4 ft-lb)
ZNS3 bolt , replace nut with new)
Swing arm to subframe (M1 4 x 100 mm 165Nm(122ft-/b)
eccentric camber adjusting bolt, replace nu t
with new)

— Hav e car professionally aligned when job i s complete .

 Rear Suspension 330-2 1
Integral link, removing and installing

Integral link, removing and installing

- Sport s Wagon: Disable and deflate EHC system. See EHC,
disabling, deflating, refillin g in this repair group .

— Sport s Wagon: Detac h driv e axle at differential output flange . Se e

331 Rear Axle Differential.

— Rais e car and remov e wheel.

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

— Suppor t rea r wheel bearing carrie r with suitable jack.

^. Working underneath swing arm:

• Disconnec t contro l rod for suspension leve l sensor.
• Remov e stabilizer link nut (A) at swing arm and detach stabilizer
link. Se e Stabilizer ba r link, removing and installing in this
repair group.
• Sports Wagon: Remove shock absorber fastener (B) at swing arm
and detach shock absorber. Se e Rear shock absorber ,
removing an d installing (Sports Wagon) in this repair group .

Working at integral link:

• Remove swing arm mounting nu t (A). Drive lower bolt out toward
rear and pull swing arm downward.
• Remove integral lin k mounting bolt (B) and remove link.

Installation i s reverse of removal. Remembe r to:

• Replace self-locking fasteners .
«Tighten swing arm and shock absorber fasteners to final torque
only after vehicle is lowered and suspension has settled.
• Sports Wagon: Reactivat e an d fill EHC system. See EHC ,
disabling, deflating , refilling i n this repai r group.

Tightening torques
Drive axle to differential outpu t flang e 80 Nm (59 ft-lb)
(replace M1 0 x 43 mm ZNS3 Torx bolts with
new)
Integral link to swing arm (M16 x 275 mm 240 Nm (177 ft-lb)
ZNS3 bolt, replac e nut with new)
Integral lin k to wheel bearing carrier 100Nm (74 ft-lb)
(M1 2 x 1 .5 x 67 mm ZNS3 bolt )
Road wheel to hub 120± 10Nm
(89 ± 7 ft-lb)
Shock absorber to swing arm (replace M14 x 165Nm (122 ft-lb)
1 .5 x 1 05 mm ZNS bolt s with new)
Stabilizer lin k to swing arm (replac e M12 x 100Nm (74 ft-lb)
1 .5 ZNS self-locking nu t with new)

— Hav e car professionally aligne d when job i s complete .

330-22 Rea r Suspension
Swing arm ball joint, removing and installing

Swing arm ball joint, removin g and installin g

Replace ball joints in pairs.

— Sports Wagon: Disable an d deflate EHC system. See EHC,

disabling, deflating , refillin g i n this repai r group .

— Sport s Wagon: Detach drive axle at differential outpu t flange. See

331 Rear Axle Differential.

— Rais e car and remov e wheel.

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

Remove integral link. See Integral link, removing and installing in

this repair group.

Modify BMW press too 33 4 191 as illustrated. Cut area highlighte d

in grey and deburr edges.
_B510330026]

Working at swing arm ball joint:

• Remove circlip.
• Use press tools to force ball joint out of wheel bearing carrier.
Orient newl y cut slot in special tool to point up toward wheel
bearing.
• Reinstall usin g similar tools .
• Install ne w circlip.

Installation i s reverse of removal. Remember to:

• Replac e self-locking fasteners.
• Tighten swing arm and shock absorber fasteners to final torqu e
only after vehicle is lowered and suspension ha s settled.
• Sports Wagon: Reactivate and fill EHC system. See EHC,
disabling, deflating, refillin g in this repai r group.
B510330027
Tightening torque s
Drive axle to differential output flang e 80 Nm (59 ft-lb)
(replace M10 x 43 mm ZNS3 Tor x bolts with
new)
Integral link t o swing arm (M16 x 275 m m 240Nm(177ft-lb)
ZNS3 bolt, replace nut with new)
Integral link to wheel bearing carrier 100 Nm (74 ft-lb)
(M12 x 1.5 x 67 mm ZNS3 bolt )
Road wheel to hub 120 ± 10 Nm
(89 ± 7 ft-lb)
Shock absorber to swing arm (replace M14x 165Nm (122 ft-lb)
1.5 x 105 mm ZNS bolt s with new)
Stabilizer link to swing arm (replac e M12 x 100 Nm (74 ft-lb)
1.5 ZNS self-locking nut with new)

— Hav e car professionally aligned when job i s complete.

 Rear Suspension 330-2 3
Rear subframe, removing and installing

Rear subframe, removin g an d installing

— Sport s Wagon: Disabl e an d deflate EHC system. See EHC ,
disabling, deflating , refillin g i n this repair group .

— Rais e vehicle and suppor t safely.

WARNING —
• Be sure the vehicle is stable and well supported. Removal of
the rear subframe may upset the balance of the vehicle. Use tall
jack stands to support the vehicle at all four corners.
• Alternatively, place 100 kg (220 Ibs) in trunk or cargo
compartment before starting work.
• Once it is raised up, make sure that the vehicle cannot be
raised or lowered and that it does not move off the lift locating
plates.

— Remov e both rea r wheels.

— Remov e rear brake calipers and tie aside securely with stiff wire. Do
not separate brake lines. Do not hang using brake hose . Se e
340 Brakes.

— Remov e both rear brake rotors . See 340 Brakes .

— Remov e bot h rear whee l speed sensors and unclip wiring

harnesses from control arms and subframe. Se e 340 Brakes.

— Sport s Wagon: Remov e X-brac e underneath rear suspension .

— Remov e complet e exhaust system. Se e 180 Exhaust System .

— Detac h rear driveshaft an d tie aside. See 260 Driveshafts.

— Sedan : Remov e both rea r strut assembly lower bolts and detac h
assembly fro m wheel bearing carriers. See Rear strut assembly ,
removing and installin g (Sedan) i n this repai r group.

— Sport s Wagon: Detach bottom of air springs from subframe. See Air
spring, removing and installing (Sport s Wagon) i n this repair
group.

— Sport s Wagon: Detac h bot h rear shock absorbers from swing arms.

— Disconnec t ride-heigh t senso r electrical connector and uncli p

harness from subframe.

— Disengag e both parking brake cable s from brake backing plates.

See 340 Brakes .

^. Working underneat h rear of vehicle, remove fasteners (arrows) and

remove splash shields underneath front subframe mountin g bolts .
330-24 Rea r Suspension
Rear subframe, removing and installing

Vehicle with active stabilizer system :

• Remove hydraulic lin e anchor mounting bol t (arrow) at right thrust
rod.
• Separat e hydraulic lines at junctions. B e prepared to catch
dripping hydraulic fluid and dispose i n a safe manner.

CAUTION—
• Do not allow dirt to enter hydraulic lines. Plug fluid line
openings.

BentlelPubiishers
•/ I .co m

While supportin g subframe wit h transmission jack or other suitabl e

device:
• Remov e thrust rod mounting bolt s (A ) and remove both thrust
rods.
• Remov e subframe rear mounting bolt s (B) and carefully lower
subframe, checking to make sure n o lines, hose s or harnesses
become snagged .

To install, jack subframe int o position. Install thrust rods i n their

original position s and tighten subframe mountin g bolts.

Rear subframe to body (M14x 1. 5 x 138 mm) 165 M m (122ft-lb )

Thrust ro d to body (M10 x 1. 5 10.9 grade) 48 Nm (35 ft-lb)

Remainder of installation is reverse of removal, noting the following.

• Tighten shoc k absorber fastener to final torque only after vehicle is
lowered an d suspension has settled.
• Vehicle with active stabilizers: Make sur e hydraulic lines are
correctly isolated and free of tension. Fil l and bleed hydraulic
system. Check for leaks once engine i s running. See 310 Front
Suspension.
• Sports Wagon : Reactivat e an d fill EHC system. Se e EHC,
disabling, deflating, refillin g in this repair group.
• Bleed entir e brak e syste m befor e drivin g car. Se e 340 Brakes .
• Adjust parking brake.

Tightening torques
Brake caliper to wheel bearing carrier 110Nm (81 ft-lb)
(M12x 1.5x43mmZNS3bolts )
Brake roto r to wheel hu b (M8 x 14 mm bolt) 16Nm (12 ft-lb )
Hydraulic line junction union nuts 30 Nm (22 ft-lb)
Road wheel t o hub 120± 10Nm
(89 ± 7 ft-lb)
Shock absorber to swing arm (replace M1 4 x 1 65 N m (12 2 ft-lb)
1.5 x 105 mm ZNS bolts wit h new)
 Rear Suspension 330-2 5
Rear subframe bushings, removing and installing

Tightening torques
Strut to wheel bearing carrier (replace M14 x 165 Nm (122ft-lb)
1 .5 x 1 05 m m ZNS3 bolt with new )
Wheel speed sensor to wheel bearing carrier 8 Nm (6 ft-lb)
X-brace to chassis
• M 10 bolts 59 N m (4 4 ft-lb)
• M10 nut 41 N m (30 ft-lb)

— Hav e car professionall y aligned when job i s complete.

Rear subframe bushings ,

removing and installin g
^k Th e aluminum subframe bolts to the vehicle chassis via 4 large
rubber bushing s (arrows) .

— Lowe r rear subframe. Se e Rear subframe, removing an d

installing in this repai r group.

.com B510330014J

Working a t subframe bushin g boss (arrow):

• Assemble press tools for bushing removal as illustrated.
• Us e hot air blower to heat subframe boss at maximum 600°C
(1100°F) for approx. 2 minutes.
• Rotat e press tool nut to remove bushing .

WARNING —
• Do point hot air jet at fuel tank.

BentleyPubiishers
.corn
1
330-26 Rea r Suspension
Rear wheel bearing components

When installing:
• Orient bushing so that inner sleeve (arrows) point to front and rear
as illustrated. Maximum deviation allowed from this orientation is
7°.
• Coat bushing with Circolight® antifriction agent.
• Press bushing in using special tools.

REAR WHEEL BEARING S

The rear wheel bearing i s bolted to the rear wheel bearin g carrier .
The wheel bearing can be replaced withou t removing the rear wheel
bearing carrier. The rea r wheel hub i s pressed into the rear wheel
bearing. Removin g the hub destroys the wheel bearing . To service
the wheel bearing, remov e the wheel hu b and replace the wheel
bearing.

Rear wheel bearing components

1. Driv e axle
2. M10 x 1 x 34 mm Torx bolt
• Replace with new
• Tighten i n 2 stages:
30 Nm (22 ft-lb)
additional 110°
3. Whee l bearing carrier
4. Gaske t
5. Backin g plat e
6. Reinforcemen t
7. M6 x 14 mm 8.8 grade bolt
8. Whee l bearing
9. Whee l hub
10. Brake rotor
11. M8x 1 4 Allen bolt
• Tighten to 16 Nm (12 ft-lb)
12. M27 collar nut
• Replace with new
• Tighten to 420 Nm
• Stake to axle end
.com 8510330050!
 Rear Suspension 330-2 7
Rear wheel bearing carrier, removing and installing

Rear wheel bearing carrier,

removing and installin g
— Rais e vehicle and remov e rear wheel.

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

Using a suitable punch , straighten staked sides o f wheel hu b collar

nut (arrows) .

With an assistant holding down brak e pedal, remov e collar nut and
discard.

CAUTION—
• The drive axle collar nut is tightened to a high torque. If
necessary, reinstall road wheel and place vehicle on floor
before breaking collar nut free.

Sports Wagon : Disabl e and deflate EH C system. Se e EHC ,

disabling, deflating, refilling in this repair group .

Sports Wagon: Remov e ai r spring. Se e Air spring, removin g and

installing (Sport s Wagon) i n this repai r group.

Remove brake caliper and brake rotor. Hang brake caliper aside with
stiff wire . Do not disconnect brak e fluid hoses. See 340 Brakes .
B510310010J

Disconnect parkin g brake cable fro m brake shoe expander . Se e

340 Brakes.

If replacing wheel bearing carrier with new: Remove rear wheel hub.
See Rear wheel hub, removin g and installing i n this repair group.

Remove ABS wheel speed sensor from wheel bearing carrier . See
340 Brakes.

Detach rea r stabilizer lin k from stabilizer bar. See Stabilizer bar
link, removing and installing i n this repair group.

Sedan: Detac h strut from wheel bearing carrier . See Rear strut
assembly, removin g an d installing (Sedan ) i n this repair group .

Remove integral link. See Integral link, removing and installing in

this repair group.

Use BMW special tools 3 3 2 200 or equivalent to press drive axle

out of wheel bearing hub .

CAUTION—
• In order to avoid damaging drive axle threads, do not drive out
stub axle using impact tool.
330-28 Rea r Suspension
Rear wheel bearing carrier, removing and installing

— Detac h guide ar m from wheel bearing carrier. See Guide ar m

(traction strut), removing and installin g in this repair group.

— Detac h upper control arm fro m wheel bearing carrier. See Uppe r
control arm, removing and installin g i n this repair group.

— Remov e wheel bearin g carrier .

^V I f installing new wheel bearin g carrier , b e sure to match shape of

upper contro l arm ball joint.

— Installatio n i s reverse of removal . Remember to :

• Replac e self-locking fasteners.
• Tighten swin g arm and shock absorbe r fasteners to final torque
only after vehicle is lowered and suspension ha s settled.
• Tighten drive axle collar nut with wheel on the ground. Stake nut to
axle end .
• Sports Wagon: Reactivate and fill EHC system. Se e EHC,
disabling, deflating , refillin g i n this repai r group.
• Adjust parkin g brake .

Tightening torque s
Brake caliper t o wheel bearin g carrie r 110 Mm (81 ft-lb)
(M12x 1.5x4 1 mm ZNS3 bolts )
Brake rotor to hub (M8 x 1 4 mm Allen bolt ) 16Nm(12ft-lb)
Control arm to wheel bearing carrier 175 N m (12 9 ft-lb)
(replace M14 x 1.5 self-locking nut with new)
Drive axle collar nu t to wheel hub 420 Nm (310 ft-lb)
(replace M27 collar nut with new, lightly oil
contact face, stake nut to axle end)
Guide arm to wheel bearing carrier 65 N m (4 8 ft-lb)
(replace M10 self-locking nut with new)
Integral link t o swing arm (M16 x 275 m m 240 Nm (177 ft-lb)
ZNS3 bolt , replace nut with new)
Integral lin k to wheel bearing earner 100Nm (74 ft-lb)
(M12x 1.5x67mmZNS3bolt )
Road wheel to hub 120± 10N m
(89 ± 7 ft-lb)
Shock absorber to swing arm (replace M1 4 x 165Nm (122 ft-lb)
1.5 x 105 mm ZNS bolt s with new )
Stabilizer ba r lin k to stabilizer bar 65 N m (4 8 ft-lb)
(M10x 1.5xZNS3nut )
Wheel speed sensor to wheel bearing carrier 8 Nm (6 ft-lb )

— Hav e car professionally aligne d when job i s complete .

 Rear Suspension 330-2 9
Rear wheel hub, removing and installing

Rear wheel hub , removin g and installing

— Rais e car an d remov e wheel.

WARNING —
• Make sure the vehicle is stable and well supported at all times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor jack is not adequate support.

Using a suitable punch, straighten staked side s of wheel hub collar

nut (arrows) .

With an assistant holding dow n brake pedal, remov e collar nu t and

discard.

CAUTION—
• The drive axle collar nut is tightened to a high torque. If
necessary, reinstall road wheel and place vehicle on floor
before breaking collar nut free.

— Detac h fron t brake calipe r fro m steering knuckl e and suspend aside
using stiff wire. D o not detach brake fluid hose . Se e 340 Brakes .

— Remov e brak e rotor . Se e 34 0 Brakes .

Attach slide hammer hub puller t o wheel hu b using 5 wheel bolts .

Drive hu b off wheel bearing .
• Not e that wheel bearing inne r rac e is removed with hub , thu s
destroying bearing . Separate race from hub and discard race. Do
not damage hub .

Replace wheel bearing . Se e Rear wheel bearing, replacin g i n this

repair group .

B510310034J
330-30 Rea r Suspension
Rear wheel bearing, replacing

To install wheel hub:

• Oil hub (arrow ) lightly and plac e ove r splines o f output shaft.
• Us e BMW special tools or equivalent t o draw hu b into wheel
bearing.

— Remainde r of installation is reverse of removal . Remember to:

• Tighten drive axle collar nut with wheel on the ground. Stake nut to
axle end.
• Adjust parkin g brak e whe n job is complete.

Tightening torques
Brake caliper to wheel bearing carrier 110Nm (8 1 ft-lb)
(M12x 1 . 5 x 4 1 mm ZNS3 bolts )
Brake roto r to hub (M8 x 1 4 mm Allen bolt ) 16Nm(12ft-lb)
Drive axle collar nu t to wheel hu b 420 N m (310 ft-lb)
(replace M2 7 collar nu t with new, lightl y oil
contact face, stake nut to axle end)
Road wheel to hub 120 ± 10 Nm
(89 ± 7 ft-lb)

Rear wheel bearing, replacing

Remove rear wheel hub (drive flange). See Rear wheel hub,
removing and installing i n this repai r group.

CAUTION—
• The wheel bearing is destroyed when the drive flange is
removed. Replace wheel bearing.

— Pres s wheel bearin g inne r rac e of f wheel hub shaft.

^ Workin g at back of wheel bearin g carrier, remov e wheel bearing

fasteners an d remove bearing .
 Rear Suspension 330-3 1
Rear wheel bearing, replacing

^V T o install, make sure threads (A ) and contact surfac e of whee l

bearing and wheel bearin g (B) carrier ar e clean and free of oil and
grease. I f necessary, rethread bearing bolt hole s (A).

— Instal l new wheel bearing .

Tightening torque
Wheel bearing to wheel bearing carrier
(replace M1 0 x 1 x 34 m m Tor x bolt s with
new):
• Stage 1 30 Nm (22 ft-lb)
• Stage 2 additional 110 °

— Remainde r of installation i s reverse of removal. Remember to :

• Tighten drive axle collar nut with wheel on the ground. Stake nut to
axle end.
• Adjust parkin g brak e whe n job is complete .

Tightening torques
Brake caliper to wheel bearing carrier 110Nm(81 ft-lb)
(M12x 1 . 5 x 4 1 mm ZNS3 bolts)
Brake roto r to hu b (M 8 x 1 4 mm Allen bolt) 16Nm(12ft-lb)
Drive axl e colla r nu t to wheel hu b 420 Nm (310 ft-lb)
(replace M2 7 collar nu t with new, lightly oil
contact face, stake nut to axle end)
Road wheel to hub 120 ± 1 0 Nm
(89 ± 7 ft-lb)
330-32 Rea r Suspensio n
Active stabilizer bar (dynamic drive)

REAR STABILIZER BA R
The rear stabilizer bar is mounted to the rear subframe and attached
to the swing arms with stabilizer bar links.

Active stabilize r bar (dynamic drive)

5 Series vehicles may be equipped with the optional active stabilize r
system (acronym ARS). The syste m i s also referre d to as dynamic
drive.

With this system, front and rea r stabilizer bars are split in half, with
the halves connecte d to each other via hydraulic oscillating motors .
An electronic control module operate s through a valve body to
control the coupling o f the two stabilizer ba r halves .

For additional details, including active stabilizer troubleshooting and

commissioning, see 300 Suspension, Steering and Brakes-
General. Hydrauli c bleeding o f active stabilizer system is in
310 Front Suspension .

Active stabilizer components, rea r

1. Rea r ride height sensor
2. Stabilize r bar link
3. Stabilize r bar
4. Stabilize r ba r mount
5. Rea r oscillating moto r
6. Oscillatin g motor pressur e line s

B510330054
 Rear Suspension 330-3 3
Rear stabilizer bar components (mechanical stabilizer)

r Rear stabilizer ba r components

(mechanical stabilizer )
1. Stabilize r bar
2. Stabilize r bar mounting bushin g
3. M 8 x 30 mm 10.9 grade bolt
4. Stabilize r bar mount
5. M 8 ZNS3 self-locking nu t
• Replac e with new
• Tighten to 28 Nm (21 ft-lb)
6. M1 0 ZNS3 self-locking nut
• Replace with new
• Tighten to 65 Nm (48 ft-lb)
7. Stabilize r bar link
iBemtevPubHshers
i .com 8. M12x1. 5 ZNS3 self-locking nut
• Replac e with new
• Tighten to 100 Nm (74 ft-lb)

Rear stabilizer bar , removing and installing

(mechanical stabilizer )
The rear stabilizer i s attached to the rear subframe.

— Rais e vehicle and safely support.

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

Detach stabilizer links from both ends of stabilizer bar . See

Stabilizer bar link, removing and installing i n this repai r group.

If necessary, remove vibration dampe r from right stabilizer ba r

mount.

Remove mounting nut s (arrows) at both stabilizer ba r mounts .

Slide stabilizer bar sideways to remove.

Check rubber mounting bushings . Replac e if necessary.

Installation is reverse of removal. Remember to replace self-locking

fasteners.

Tightening torques
Stabilizer bar mount to subframe (replace M8 28 N m (2 1 ft-lb)
ZNS3 self-locking nuts with new)
Stabilizer ba r link to stabilizer bar (replace 65 N m (48 ft-lb)
M10 x 1 .5 x ZNS3 self-locking nut with new)

' UMllXklHB.-l-- 1
330-34 Rea r Suspension
Hear stabilizer bar, removing and installing (active stabilizer bar)

Rear stabilizer bar, removing an d installin g

(active stabilize r bar )
The rear stabilizer is attached t o the rear subframe .

Use BMW scan tool to read and prin t fault codes.

Raise rea r of vehicle and support safely .

WARNING —
• Make sure the vehicle is stable and we/1 supported at a/1 times.
Use a professional automotive lift or jack stands designed for
the purpose. A floor Jack is not adequate support.

Sports Wagon : Remov e X-brace underneath rea r suspension.

Remove pressure lin e bracket screw s (arrows).

Sports Wagon : If necessary, remov e vibratio n damper from right

stabilizer ba r mount .

Remove mounting nut s (arrows) at both stabilizer bar mounts.

SH
1
 Rear Suspension 330-3 5
Rear stabilizer bar, removing and installing (active stabilizer bar)

Lower stabilizer ba r and note carefully installation position s o f fluid

pressure lines and brackets at oscillating motor. The n detach
pressure line union s (arrows) from motor. Be prepared to catc h
dripping hydrauli c fluid and dispose in a safe manner.

CAUTION—
-v'L
u • Do not allow dirt to enter hydraulic lines. Plug fluid line
openings.

To avoid confusion when installing, pressure lines are different

dimensions and the unions have different threads.

— Detac h stabilize r link s from both ends of stabilizer bar. Se e

Stabilizer ba r link, removin g an d installing in this repai r group .

— Slid e stabilizer ba r sideways to remove.

B510330058

Separate stabilize r ba r mount bracket s and rubber mount s fro m

roller bearings.
• Check roller bearings for free movement. Slight discharge of
grease from bearing i s acceptable. Replac e stabilizer ba r i f a
bearing binds or is otherwise damaged .
• Replac e rubbe r mount s if damaged. Keep rubbe r grease-free.

When reinstalling , first attach stabilizer bar to stabilizer links .

• Use new self-locking nuts.
• Us e Torx tool (T30) to counterhold shaft o f stabilizer ba r link bal l
joint while tightening nut .

Tightening torque
Stabilizer ba r link to stabilizer bar (replace 65 N m (48 ft-lb )
EiemteyPubfmliers M10 x 1. 5 x ZNS3 self-lockin g nuts with new)
corr _B510330061J

— Attac h pressur e lin e unions to oscillating motor finger-tight .

^. Place specia l tool 33 0 170 over lines and tighten win g nut. Thi s
forces pressure lines into correct alignment with motor. Tighten flui d
lines. Mak e sure line s do not contact stabilize r bar. Minimu m
distance = 5 mm (!4 in) .

Tightening torque
Fluid pressure line to oscillating motor 30 N m (22 ft-lb)
(union nut )

Reinstall stabilizer ba r to subframe, noting the following.

• To prevent stabilizer bar distortion, instal l left mount bracke t first
(without elongated holes) . Then instal l righ t mount bracke t (with
elongated holes) .
• Replac e self-lockin g fasteners .

Tightening torque
Stabilizer bar mount to subframe (replace M8 28 N m (21 ft-lb)
ZNS3 self-lockin g nuts with new)
330-36 Rea r Suspension
Stabilizer bar link, removing and installing

— Alig n pressur e line s to subframe and tighte n bracke t screws.

Tightening torqu e
Pressure lines to subframe 8 N m (6 ft-lb)]

— Remainde r of installatio n is reverse o f removal .

Tightening torque
X-brace to chassis
•M10 bolts 59 Nm (44 ft-lb)
• M10 nut 41 N m (30 ft-lb)

Fill hydraulic fluid reservoir (same as power steering fluid reservoir).

Active stabilizer system fluid

Hydraulic flui d for tandem pump system Pentosin CHF 11S

Use BMW scan tool to bleed ai r out of active stabilizer system. See
Hydraulic system, bleedin g in this repair group. Check line s and
connections for leaks.

Carry out commissioning procedure . Se e Active stabilizer ,

BenileyPubfe commissioning in 300 Suspension, Steering and Brakes-
B51031004S General.

Stabilizer ba r link, removing and installing

Raise vehicl e an d safely support.

WARNING—
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

Remove stabilize r link mounting nut (A) at stabilizer bar . Use Torx
tool (T30) to counterhold shaft of stabilizer ba r link ball joint while
loosening nut.

Remove stabilizer link mounting fastener (B) at swing arm.

Press out stabilizer lin k bal l joint an d remov e stabilizer link.

Installation is reverse of removal.

Tightening torques
Stabilizer bar link to subframe (replace M12 x 100 Nm (7 4 ft-lb)
1 .5 ZN3 self-lockin g nut with new )
Stabilizer ba r link to stabilizer bar (replac e 65 N m (4 8 ft-lb)
M10 x 1. 5 xZNSS self-locking nut with new )
 331-1

331 Rea r Axle Differential

GENERAL 331- 1 Differential output shaft seal, replacing 331-7

Rear differential and rea r drive axles 331- 1 Differential mounts , replacin g 331- 9
Warnings an d Cautions 331- 2 REAR DRIV E AXLES 331-1 0
REAR DIFFERENTIA L 331- 2 Rear drive axle assembl y 33 1 -10
Rear differential applications 331- 1 Rear drive axle, removing and installing . . . . 331-1 1
Differential oil, draining and filling 331- 2 CV joint boots 33 1 -12
Differential oil level, checking 331- 3 TABLE
Differential, removin g and installing 331- 3
a. Rear differential applications . . .. .331-2
Differential inpu t shaft seal, replacing 331- 4

GENERAL
This repai r group cover s remova l an d repair information for the rea r
differential (fina l drive), axl e shafts, CV joints, C V joint boots , an d
differential seal replacement .

Internal repair s of the differentia l assembly ar e no t covered i n this

manual.

Rear differential and rea r drive axles

1. Oute r CV joint
12 3
2. Oute r CV joint boot
3. Driv e axle
4. Inne r CV joint boot
5. Inne r CV joint
6. Differentia l outpu t flange
7. Differentia l
8. Differentia l input flang e

B510331001
331 -2 Rea r Axle Differential
Warnings and Cautions

Warnings and Cautions

WARNING —
• Do not reuse self-locking fasteners.

CAUTION—
• Due to the chemical and corrosion characteristics of aluminum,
follow these precautions when working with aluminum
components:
—Do not bring into contact with battery acid.
—Do not us e wire brushes with brass o r iron bristles,
—Do not expose t o flying sparks.
—Do not subject t o steel welding splashes.
—Do not expose t o temperatures over 80 °C (176°F), even for
short periods. Paint shop temperatures are not a problem.
• Do not allow the vehicle to stand on its wheels when the EHC
system is disabled or drained. Damage to air springs may
result.
• When disconnecting and connecting EHC air lines, do not allow
contamination to enter the lines.

REAR DIFFERENTIA L
Rear differential applications
Application information and oil fill capacities for rear differentials is in
Table a.

Table a. Rear differential applications

Engine Transmission Rear differentia l Capacity
M54, N5 2 Manual, automatic 188L/188LW 1.0ltr(1.05USqt)
N54 Automatic 188LW 1.0ltr(1.05 USqt )
N54 Manual 215LW 1.2ltr(1.27USqt)
N62, N6 2 TU Automatic 188L/188LW 1.0 Itr (1.05 USqt)
N62, N6 2 TU Manual 215K 1.4ltr(1.48USqt)

Differential oil, draining and filling

The 5 Series rear differential is filled with lifetime oil that ordinarily
does no t need to be changed. BM W recommend s using only a
specially formulated synthetic gear oi l (SAF-XO ) that is available
through an authorized BMW dealer part s department. For additional
information on this lubricant and an y other lubricants that ma y be
compatible, contact an authorized BM W dealer service department.

— Driv e vehicle to warm differential oil.

^C Remov e differential Drain plug and drain oil into suitable container.

Drain S'
 Rear Axle Differential 33 1 -3
Differential oil level, checking

Reinstall Drain plug .

• Plu g with sealing O-ring: Replace O-ring.
• Plu g without sealing O-ring: Replace plug.

Tightening torque
Drain plug to rear differential housing :
• Plug with sealing O-ring (replac e O-ring ) 65 Nm (48 ft-lb)
• Plug without sealing O-ring (replace plug) 60 Nm (44 ft-lb )

Remove Fil l plug and add rear differential oil and check level. See
Differential oi l level , checkin g i n this repair group.

Reinstall Fil l plug .

• Plu g with sealing O-ring : Replac e O-ring.
• Plug without sealin g O-ring: Replac e plug .

Tightening torque
Fill plug to rear differential housing:
• Plu g with sealing O-ring (replace O-ring ) 65 Nm (48 ft-lb)
• Plu g without sealin g O-ring (replac e plug ) 60 Nm (44 ft-lb)

Differential oi l level, checkin g

Check lubrican t leve l with vehicle o n a level surface :
• Remov e differential Fill plug.
• Leve l is correct when fluid just reaches edge of plug hole .
• I f necessary, top u p fluid.
• Plug with sealing O-ring: Replac e O-ring .
• Plu g without sealin g O-ring: Replac e plug .
• Instal l an d tighten oil Fill plug when oil level is correct.

Tightening torque
Fill / drain plug to rea r differential housing:
• Plu g with sealing O-ring (replace O-ring) 65 Nm (4 8 ft-lb)
• Plu g without sealing O-rin g (replace plug) 60 N m (4 4 ft-lb)

Differential, removing and installing

Raise ca r and support safely .

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

— Disconnec t rear driveshaft from differential. See 26 0 Driveshaft.

^. Remove drive axle CV joint bolt s (arrows) at left and right sides.
Suspend drive axles from body using stiff wire.
331 -4 Rea r Axle Differential
Differential input shaft seal, replacing

Support differential with special support or suitable transmission

jack. Mak e sure jack doe s no t damage outpu t flange dust covers:
• Remov e differential front mounting bolts .
• Remov e differential rea r mounting bolt.
• Remove vent line from differential .
• Carefully lower differential unit.

To install, lif t differential into place :

• Instal l mounting bolts finger tight.
• Remove differential support.
• Tighten bot h front mounting bolts .
• Tighten rear mounting bolt.
B309331003
Tightening torques
Differential to subframe
• Fron t mounting bolt s (M12) 100Nm(74ft-lb)
• Rea r mounting bolt (M14) 165 Mm (122ft-lb)

Remainder of installation is reverse of removal. Remember to check

differential oil. See Differential oi l level , checking in this repair
group.

Tightening torque s
Drive axle to differential output flange 80 N m (5 9 ft-lb)
(replace M10 x 43 mm ZNS3 Torx bolt s with
new)
Rear driveshaft CV joint to differential input
(replace M10 x 52 mm ZNS bolts with new)
• Stage 1 20Nm(15ft-lb)
• Stage 2 additional 90°

Differential inpu t shaft seal , replacin g

Remove exhaust system. See 180 Exhaust System.

Remove drive shaft. See 260 Driveshaft .

Lift out differential inpu t flange collar nu t locking plate.

Mark position of collar nu t (A) on input flange with a center punc h

(arrows).
 Rear Axle Differential 33 1 -5
Differential input shaft seal, replacing

Using BM W special tool 23 0 020 or equivalent, counterhold inpu t

flange and remove collar nut . Fo r clarity, illustration shows
differential removed.

188L/ 188LW rear differential: Using BMW special tool 33 1 150 or

equivalent puller , remov e differential inpu t flange .

215K / 215L / 215LW rear differential: Usin g BM W special tools

31 2101, 31 2 102,31 2 103 and 31 2 104 or equivalent puller ,
remove differential inpu t flange.
331 -6 Rea r Axle Differential
Differential input shaft seal, replacing

Using BMW special too l 00 5 010 or equivalent, remov e seal from

differential housing .

005010

8309331008

Using BMW special tools 00 5 500 and 33 3 470 or equivalent, drive

new seal into place unti l fully seated.

Coat drive flange sealing are a and seal lip with differential oil:
• Install drive flange on pinion shaft.
• Using BM W special tools 23 1 300, 33 1 341 and 23 1 302, pres s
drive flange on pinion shaft just far enough to allow collar nut to be
installed.
 Rear Axle Differential 33 1 -7
Differential output shaft seal, replacing

Tighten colla r nut (A) only until previously marked points are aligned
(arrow).

CAUTION-
DO not under any circumstances tighten collar nut beyond the
marked points. Otherwise clamping sleeve inside differential
housing may be damaged.

— Usin g a suitable drift pin punch, instal l ne w collar nu t locking plate .

Stake plate in place.

— Remainde r ot installation i s revers e of removal.

— Chec k differential oil level. Se e Differential oil level, checking i n

this repai r group.

Tightening torque
Rear driveshaft CV joint to differential input
(replace M10 x 52 mm ZNS bolts with new)
• Stage 1 20Nm(15ft-lb)
• Stage 2 additional 90°

Differential outpu t shaft seal, replacin g

Remove exhaust system (if necessary). See 180 Exhaust System .

Remove drive axle CV joint bolts (arrows). Suspend drive axle from
body using stiff wire.

^V Us e soft-faced hammer to drive output flange out of differentia l

(arrow).

— I f necessary, pry of f dus t cover.

331 -8 Rea r Axle Differentia l
Differential output shaft seal, replacing

Remove seal using BMW special tools 00 5 010 and 32 1 060 /

33 1 308 or equivalent.

^ Coa t seal with differential oil and drive into place using BMW special
tools 00 5 500 and 33 4 240 / 33 4 250 or equivalent .

00 5 500 Tool dimensions :

• 188 L /188LW differential: 3 3 4 240 (90 x 44 x 10 mm)
• 215k / 215L /215LW differential: 3 3 4 250 (100 x 50 x 10 mm)

— Replac e output flange dust cover (if applicable) .

B309331013

Replace snap ring (arrow) on differential outpu t flange shaft:

• Coat output flange shaf t with differential oil where it contacts shaf t
seal.
• Push output flange into differential unti l flange splines engag e
splines of differential gear and snap ring can be heard to snap into
place.

Remainder of installation i s reverse o f removal. Remember to:

• Check differential oil level. See Differential oil level, checking in
this repair group .

Tightening torque
Drive axle to differential outpu t flang e 80 Nm (59 ft-lb)
(replace M1 0 x 43 mm ZNS3 Tor x bolts wit h
new)

B309331014
 Rear Axle Differential 33 1 -9
Differential mounts, replacing

Differential mounts, replacing

Remove differential. See Differential, removin g and installing in
this repair group.

Rear differential mounts

Remove differential rear rubber mount using suitable puller.

Coat new mount with Circolight® anti-friction agent and draw moun t
in firmly using suitable press.

Front differential mounts

Using BMW special tools 33 3 312, 33 4 161, 33 4 162, 33 4 465 and
33 4 466, remove differential front mount.

Position slot s (A) horizontally in rear subframe.

Coat bearing sleeve in rear subtrame and rubber mount wit h

Circolight® anti-friction agent :
• Slide rubber mount from side with large diameter into BMW special
tool 33 4 311.
• Slot A must line up with mark B.

334311
331-10 Rea r Axle Differentia l
Rear drive axle assembly

*> Usin g BMW special tools 33 4 166, 33 4 311, 33 4 312, 33 4 465 and
33 4 466, install front differential moun t as far as it will go.

— Remainde r of installation is reverse of removal.

33 4 466 \ 6 33431 1

B309331021

REAR DRIVE AXLES

Drive axles use constant-velocity (CV ) joints on both ends. For
replacement parts, only CV joint boots or complete axles are offered
by BMW.

Rear drive axle assembly

1. Driv e axle
2. Inne r CV joint
3. Oute r CV joint
4. Reinforcemen t
5. Tor x bolt
36 . Colla r nut
7. Oute r CV boot kit
8. Inne r CV boot kit
 Rear Axle Differential 33 1 -11
Rear drive axle, removing an d installing

Rear drive axle, removing and installing

Raise vehicle an d remove rear wheel.

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands underneath structural
chassis points, not underneath suspension parts.

Using a suitable punch, straighten staked sides of wheel hub collar

nut (arrows).

With an assistant holding down brake pedal, remove collar nut and
discard.

CAUTION—
• The drive axle collar nut is tightened to a high torque. If
necessary, reinstall road wheel and place vehicle on floor
before breaking collar nut free.

Remove drive axle mounting bolts (arrows ) from differential flange .

Support rear wheel bearin g carrie r with a suitable jack.

Using jack, lift wheel bearing carrier so that inboard side of drive axle
clears differential .
331-12 Rea r Axle Differentia l
CVjoint boots

Press drive axle out of wheel hub. Remove drive axle towards center
of vehicle.

Installation is reverse of removal. Remembe r to :

• Replace CV joint bolts an d axle colla r nut.
• Tighten drive axle collar nu t with wheel on the ground. Stake nut to
axle end.

Tightening torques
Drive axle collar nut to wheel hub 420Nrn(310ft-lb)
(replace M2 7 collar nut with new, lightl y oil
contact face, stake nut to axle end)
332111 Drive axle to differential output flange 80 Nm (59 ft-lb)
332117 (replace M1 0 x 43 mm ZNS3 Tor x bolts wit h
B309331324 new)
Road wheel to hub 120+ 1 0 Nm
(89 ± 7 ft-lb)

CV joint boot s
When replacing C V boots, use a complete boo t repair kit. The kit
includes new boots, clamping bands , special lubricant and a new CV
joint shaft circlip.

The outer CV joint cannot be removed from the axle shaft. In order
to replace the outer CV boot, it is necessary to remove the inner joint
and boot first.

If the CV joints are worn or defective, a complete rebuilt axle shaft is

available fro m an authorized BM W dealer parts department.

— Remov e drive axle. See Rear drive axle, removing and installin g
in this repair group .

^ Workin g with axle shaft on bench, cut off old boot clamps and
remove boot (A) from inner joint (B ) with suitable tool. Clean old
grease off joint and shaft.

— Remov e dust cover from inner CV joint.

Mark CV joint component position s in relation to each other. Thi s

aids i n reassembly i f CV joint comes apart.
•Ball hub
• Ball cage
•CV joint
 Rear Axle Differential 33 1 -13
CV joint boots

Remove circlip (A).

Support inne r hub with BMW special tool 26 1 110 and pres s axl e
shaft ou t of joint using BMW special tool 2 1 2 120 .

— Clea n all old lubricant off shaft splines and inner joint splines.

CAUTION—
• If the CV joint must be disassembled for cleaning and
inspection, be sure to matchmark inner and outer race and
intermediate ball cage. This allows reassembly of parts in their
original positions.

To inspect a CV joint, clean away the grease an d look for galling,

pitting, and other signs of wear or physical damage .
• Polishe d surfaces or visible bal l tracks alone are not necessarily
cause fo r replacement .
B309331028
• Discoloratio n due to overheating indicates lack of lubrication .
Replace CV joint.

CAUTION—
• Do not let the ball hub pivot too far in the outer ring of the joint.
The balls may fall out.

Working at outer C V joint boot , cu t off old boot clamps (A) an d

remove boot (B) from outer CV joint. Clean ol d grease of f CV joint.

Slide new outer CV joint boot on axle shaft. Fill boot and joint with
CV grease, then slid e big end of boot over joint. Instal l big clamp.
331-14 Rea r Axle Differential
CV joint boots

k Befor e installing small boo t clamp:

• Fle x C V joint as far over as it will go.
• Inser t small screw-driver between boot and axle-shaft to "burp" air
from boot .
• Instal l new small clamp .

— Slid e inner CV joint boo t o n axle shaft .

While supportin g axl e shaft with BM W specia l too l 33 2 100 , press

inner hub of CV joint onto shaft. Instal l a new circlip.

— Attac h boo t to CV joint and install ne w boot clamps. B e sure to "burp"

air from boot.

— Us e sealing gel to seal dust cover to CV joint prior to reinstal/ation.

332100 — Installatio n i s reverse o f removal. Se e Rea r drive axle, removing

and installing in this repair group.
 340-1

340 Brake s

GENERAL 340- 1 PARKING BRAK E 340-19

Brake system 340- 2 Parking brake components 340-19
Electronic brakin g an d stability control 340- 2 Parking brake , adjustin g 340-19
Troubleshooting 340- 2 Parking brake shoes, removing and installin g 340-20
Warnings an d Cautions 340- 4 Parking brake cable, replacin g 340-22
BLEEDING BRAKE S 340- 5 ANTILOCK BRAK E AND
Brake calipers , bleeding 340- 6 STABILITY CONTRO L 340-24
Brake system, bleeding 340- 7 Antilock brake system (ABS) 340-24
Dynamic stabilit y control (DSC) 340-24
BRAKE PADS , CALIPERS AN D ROTORS . . . 340- 9
Braking system component s 340- 9 DSC COMPONENT S AND REPAIRS 340-26
Brake pads, checkin g and replacing 340- 9 DSC faults 340-26
Brake caliper an d pad carrier, DSC power supply 340-27
removing and installing 340-1 3 DSC controls 340-28
Brake roto r specifications 340-1 4 DSC control module ,
Brake rotor , removing an d installing 340-1 5 removing an d installing 340-29
Wheel speed sensor, replacing 340-30
BRAKE MASTE R CYLINDE R 340-1 6
ABS impulse wheel 340-32
Brake maste r cylinder, removin g and installing 340-1 6
DSC acceleration sensor,
Auxiliary brake booster vacuum pum p 340-1 8 removing an d installing 340-32
Steering angle sensor 340-32

GENERAL
This repai r group covers service for the brake system an d for
electronic brakin g an d stability control (traction control) systems .

See also:
• 020 Maintenance fo r basic brak e system checks
• 300 Suspension, Steering and Brakes-General
• 612 Switches fo r brake ligh t switch and steering angle senso r
• ECL Electrical Component Locations fo r fuse an d component
access
• EL E Electrical Wiring Diagram s
340-2 Brake s
Brake system

Brake syste m
, 5 Series models ar e equipped wit h vacuum power-assiste d four -
wheel disc brake s wit h integral antilock brakin g system (ABS).
Single-piston calipers act on vented front and rear rotors. Two-stage
brake pad wear sensors work alon g wit h condition base d service
(CBS) syste m to indicate whe n brak e pad s nee d replacement . The
first stage is activated when brak e pa d linings reac h a thickness of
6 mm (% in), the second is activated at a thickness of 4 mm (1/s in).
The dual drum-type parking brake system is integrated with the rear
brake rotors .

Electronic braking and stability control

5 Series models are equipped with dynamic stability control (DSC) .
DSC is a computer controlled traction control syste m that use s the
ABS system i n conjunction with engine management controls to
control wheel spin during acceleration and maintain vehicle stability
while braking .

Troubleshooting
Brake performance is mainly affecte d by three factors:
• Leve l and condition of brake fluid
• Ability o f brake syste m t o create and maintain pressure
• Conditio n of friction component s

Air i n brake fluid makes the brake peda l feel spongy during brakin g
or increases th e brake peda l force require d to stop. Flui d
contaminated b y moisture or dirt corrodes the system. Inspect th e
brake fluid inside the reservoir . I f it is dirty or murky, or is more than
two years old, replac e fluid. See Brak e system, bleeding i n this
repair group.

To check the function of the brak e maste r cylinder, hold the brak e
pedal down hard with the engine running . I f the pedal slowly falls to
the floor, either the maste r cylinde r i s leaking internally or fluid is
leaking externally.

Inspect the brake rotors for glazing, discoloration an d scoring.

Steering wheel vibration while braking at speed is often caused by
warped rotors , bu t can also be caused by worn suspension
components.

When troubleshooting, keep i n mind that tire inflation , wear and

temperature can all have an affect on braking. See
300 Suspension, Steerin g an d Brakes-Genera l fo r additional
suspension and brake system troubleshooting .
 Brakes 340- 3
Troubleshooting

Table a lists symptoms of brake problems, probabl e causes, and

suggested corrective actions . Unless note d otherwise , relevan t
repairs are described late r in this repair group.

Table a. Brake syste m troubleshooting

Symptom Probable cause Repairs

Brake squea l Brake pad carriers dirty or corroded or Remove brake pads an d clean calipers. Use origina l
pads loose (poor fit) in pad carrie r equipment pads for proper fit and use BMW anti-squeal
compound during installation.
Brake pads heat-glazed or oil-soake d Replace brake pads. Clean rotors. Replace leaking calipers
as required.
Wheel bearings worn (nois e mos t Replace wor n bearings. See 310 Front Suspension or
pronounced when turning) 330 Rear Suspension.
Incorrectly installe d brake pads , Check componen t installation . Check anti-rattle springs.
parking brake shoes , o r brake parts Replace a s necessary .

Pedal goe s to floor whe n Brake fluid loss du e to system leak s Check flui d leve l and inspect for signs o f leakage.
braking Replace master cylinder. Diagnose traction control system
Master cylinder or traction control
system faulty using scan tool.

Low pedal after system bleeding Master cylinder faulty Replace master cylinder.

Pedal spongy or brakes work Air i n brake fluid Bleed syste m using scan tool.
only when pedal is pumpe d
Master cylinde r o r traction contro l Replace maste r cylinder . Diagnos e tractio n contro l system
system faulty using scan tool .

Excessive braking effort Brake pad s we t Use light peda l pressure to dry pads while driving .
Brake pads heat-glazed or fluid-soaked Replace brake pads and rotors. Replace leaking calipers .
Vacuum pump, vacuum booster , o r Inspect vacuum lines. Test vacuum booste r an d replace as
vacuum hose connections to booster required. Test brake booster check valve for one-way flow.
faulty
Brakes pulsate, chatter o r gra b Warped brake rotor s Resurface or replace rotors .
Brake pads worn Replace brak e pads .
Brake pads heat-glazed or fluid-soaked Clean rotors. Replace leaking calipers.

Uneven braking, car pulls to one Incorrect tire pressures or worn tires Inspect tire condition. Chec k and correct tire pressures .
side, rear brakes lock Replace brak e pads . Clea n rotors . Replace leaking
Brake pads o n one side of car heat-
glazed o r fluid-soake d calipers.
Brake caliper or brake pad s binding Clean and recondition brakes .
Worn suspension components Inspect for worn or damaged suspension components. See
310 Front Suspension or 330 Rear Suspension.
Brakes drag, bind o r overheat Brake caliper or brake pads bindin g Clean o r replace caliper .
Master cylinder o r traction contro l Replace maste r cylinder . Diagnos e tractio n control syste m
system fault y using scan tool.
340-4 Brake s
Warnings and Cautions

Warnings and Caution s

WARNING —
• Make sure that the brake system is bled using a BMW scan tool
or equivalent. Se e Bleeding Brakes i n this repair group.
• Semi-metallic and metallic brake friction materials in brake pads
or shoes produce dangerous dust. Treat all brake dust as a
hazardous material. Do not create dust by grinding, sanding, or
cleaning brake friction surfaces with compressed air.
• Brake fluid is poisonous, corrosive and dangerous to the
environment. Wear safety glasses and rubber gloves when
working with brake fluid. Do not siphon brake fluid with your
mouth. Dispose of brake fluid properly.
• Do not reuse self-locking nuts, bolts or fasteners. They are
designed to be used only once and may fail if reused. Replace
them with new self-locking fasteners.
• A car with electronic stability control is still subject to normal
physical laws. Avoid excessive speeds for the road conditions
encountered.

CAUTION—
• Brake fluid damages paint. Immediately clean brake fluid spilled
on painted surfaces and wash with water.
• Use new brake fluid from a fresh, unopened container. Brake
fluid absorbs moisture from the air. This can lead to corrosion
problems in the braking system and a/so lowers the fluid boiling
point.
• When working on brake fluid lines:
-Do not mix up fluid lines at the master cylinder or hydraulic unit.
Label unions before disconnecting.
-Do not kink brake lines.
-Plug open lines and brake fluid ports to prevent contamination.
• Tighten brake hoses on front wheels with wheels in straight
ahead position.
• If carrying out electric we/ding work, be sure to disconnect
electrical harness connector from electronic control module.
• Do not expose electronic control modules to high sustained
heat. Maximum heat exposure:
-95°C (203°F) for short periods of time
-85°C (185°F) for long periods of time (approx. 2 hours)
• Replace brake pad sensor with new if sensor is removed. Loss
of spring tension in the sensor may cause it to fall off the pads.
 Brakes 340- 5
Warnings and Cautions

BLEEDING BRAKES
WARNING —
• The BMW traction control system uses electronic controls and
a sophisticated hydraulic unit in the brake system. Once air
enters the hydraulic unit, it is very difficult to remove using
traditional methods. For this reason, use BMW scan tool or
equivalent to pressure bleed brakes.
• When flushing brake fluid from the system, use extreme care to
not let the brake fluid reservoir run dry. If air enters the hydraulic
unit, use the BMW scan tool to bleed the brake system before
the vehicle is driven.
I
Brake bleeding i s usually don e for one of two reasons :
• To replace old brake fluid as part of routine maintenance
• To expel trapped air in the system that resulted from opening the
brake hydrauli c syste m during repairs .

BMW recommends completel y replacing the brake fluid in the entire

brake system, including th e brake fluid reservoir, at least once every
two years. Whe n replacin g brake flui d or bleeding brakes, us e the
correct specification brake fluid .

Brake fluid application

I•
BMW preferred fluid Low viscosity DOT 4 brake flui d
Low viscosity DOT 4 brake fluid may be used in all 5 Series
vehicles. DOT 4 and low viscosity DOT 4 brake fluid can be mixed.

When adding or replacing brake fluid, add new brake fluid from an
unopened container . I t is important t o bleed the entire system when
any part of the hydrauli c syste m is opened.

If you are certain n o air was introduced int o the maste r cylinde r or
DSC hydraulic unit, bleed the brakes at the calipers using a pressure
bleeder. Se e Brake calipers , bleedin g in this repair group .

However, if air enters the DSC hydraulic unit, bubbles may adhere to
the edges an d internal valves o f the unit and these cannot be
removed via conventional flushing. I n that cas e it is necessary to
bleed brakes usin g a BMW scan tool or equivalent. The special too l
creates pulsations or vibrations which loosen an d flush the bubbles.

Therefore, if you are in any doubt about introduced air into the brake
system, use BMW scan tool to bleed the system or have the brake s
bled by a BMW workshop. See Brake system, bleeding in this
repair group .

When bleedin g th e brakes, start at the wheel farthest from the

master cylinde r and progress i n the following order:
• righ t rea r brake
• left rea r brak e
• right front brak e
• lef t front brake
340-6 Brake s
Brake calipers, bleeding

Brake calipers, bleeding

Remove lef t side cabin microfilter housing (at left rear engine
compartment) t o access brake fluid reservoir. See
020 Maintenance.

Top off brake fluid to MAX marked on reservoir .

Connect pressur e bleeder to reservoir. Pressuriz e system to

approximately 2 bar (29 psi).

CAUTION—
• Do not exceed a pressure of 2 bar (29 psi) when pressure
bleeding the brake system. Excessive pressure damages the
brake fluid reservoir.

Connect bleeder hose and bottle to right rear caliper bleeder screw
(arrow). Hav e a helper hold brake pedal down .

Open bleede r screw (arrow). Have helpe r slowl y pump brakes

about 10 times with bleeder screw open, holding pedal down on last
pump. Whe n escapin g fluid is free o f air bubbles, close bleede r
screw. (Photo illustrate s fron t brake caliper . Rea r caliper is similar. )

CAUTION—
• Make sure bleeder hose remains submersed in clean brake
fluid whenever the bleeder valve is open.

Close bleede r screw and release brake pedal. Refill brake flui d
reservoir and proceed t o lef t rea r wheel .

Continue bleeding remainin g wheel s i n the following order:

• lef t rear
• right fron t
• left front

Tightening torques
Bleeder to caliper:
• 9 mm screw 7- 1 1 Nm (5 - 8 ft-lb)
• 1 1 mm screw 12- 1 6 Nm (9- 12ft-lb)
 Brakes 340- 7
Brake system, bleeding

Brake system, bleeding

The procedure below require s the use of BMW scan tool .

Remove left side cabi n microfilter housin g (a t left rea r engine

compartment) t o access brak e flui d reservoir . See
020 Maintenance .

Top off brake flui d to MA X marked o n reservoir .

Connect pressur e bleede r to reservoir . Pressurize system to

approximately 2 bar (2 9 psi).

CAUTION—
• Do not exceed a pressure of 2 bar (29 psi) when pressure
bleeding the brake system. Excessive pressure damages the
_.ccr" W _. _B510340001] brake fluid reservoir.

Connect BMW scan too l or equivalent to OBD II plug on left doo r

post.

Set tool to service function Bleedin g AB S / DSC .

Connect bleeder hos e and bottle to right rea r caliper bleeder screw
(arrow). Hav e a helper hol d brake pedal down.
340-8 Brake s
Brake system, bleeding

Open bleede r screw (arrow). Carry out bleeding procedure using

BMW scan tool on-screen instructions until clear, bubble-free fluid
flows. (Phot o illustrates front brake caliper. Rear caliper is similar.)

After BM W scan tool bleeding routin e has finished, press brake

pedal to floor 5 times until clear, bubble-fre e fluid flows. Clos e
bleeder.

CAUTION—
• Make sure bleeder hose remains submersed in clean brake
fluid whenever the bleeder valve is open.

Repeat procedur e a t left rea r brake .

Repeat procedure at right front brake .

SSIf _ BS1034002 6 Repeat procedure at left front brake.

Remove brak e bleedin g apparatus and disconnect BMW scan tool .

Top off brake fluid. Check to make sure brake fluid reservoir cap seal
is intact.

Tightening torque s
Bleeder to caliper:
• 9 mm screw 7 - 11 Nm (5-8ft-lb)
• 1 1 mm screw 12- 1 6 Nm (9- 12ft-lb )
 Brakes 340- 9
Braking system components

BRAKE PADS, CALIPER S AND ROTORS

Braking system components
1. Brak e pad s
• Wear limit: 3 mm (0.12 in).
• Follo w directional marking when
installing.
2. Brak e calipe r
3. Brak e caliper guide bolt
4. Calipe r carrier
5. Brak e pad wear sensor
• On left front, right rear inner pad .
• Replace with new pads.
• Replac e if brake pad wear warnin g
light illuminated.
6. Fron t brake backing plate
7. Fron t brake roto r
• See Table c for brake rotor
specifications.
• Clean off preservative before installing
new rotor.
8. Rea r brake backing plate
9. Parkin g brake shoes with hardware
10. Rear brake rotor
• See Table c for brake roto r
specifications.
• Clean off preservative before installing
new rotor.

Brake pads , checking and replacing

Brake pads can be replaced without disconnecting the brake fluid
hose from the caliper or having to bleed the brakes. The rotor s can
be replaced without disassembling whee l hub and bearing. Fron t
and rear brake pad replacement procedures are similar.

Replace pads i n axle sets.

Raise car and support safely. Remov e wheels .

WARNING —
• Make sure the car is stable and we/I supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.
340-10 Brake s
Brake pads, checking and replacing

To measure brak e pad lining thickness, inser t BMW special tool

34 1 260 at either righ t front or lef t rea r wheel.
• Mov e wheel unti l notch for brake wear indicator can be seen
through wheel opening .
• Inser t tip of tool into notch s o that bod y o f tool rests on brake pad
backing plat e (A) , and tip touches brak e roto r (B) .
• Replac e pads i f at minimum thickness . Se e Table b .

Table b. Brake pad lining minimum thickness

Minimum pad thickness, front o r rea r 3 mm (0 12 in)

Pry off brake caliper anti-rattle sprin g (arrow) .

8510340027

Left front or right rear : Pull pad wear senso r off inner brake pad .
 Brakes 340-1 1
Brake pads, checking and replacing

Remove plasti c caps (arrows) fro m caliper guide bolts.

Using 7 mm Allen wrench, remov e caliper guide bolts . Remov e

caliper from pad carrier.
• I f there is a ridge on brake rotor edge, press caliper piston s bac k
into caliper before removing caliper.

CAUTION—
• Before pressing in caliper pistons, siphon some fluid out of
brake fluid reservoir in order to avoid paint-damaging spillover.
• Do not let the brake caliper assembly hang from the brake hose.
Support caliper from chassis with strong wire.

— Remov e brake pads from caliper.

— Chec k brak e roto r thickness. Inspec t for rus t or damage. If

necessary replace or machine brak e rotors . See Brake rotor
specifications and Brake rotor , removin g an d installing in this
repair group .

^V Compres s caliper piston usin g BM W special tool 34 1 050 or

equivalent.

CAUTION—
• Before pressing in caliper pistons, siphon some fluid out of
brake fluid reservoir in order to avoid paint-damaging spillover.
i
Check caliper dust boots for damage an d replac e if necessary.

Clean contact surfaces between caliper an d caliper carrier.

510340035
340-12 Brake s
Brake pads, checking and replacing

Apply thin coating of BMW anti-squeal compoun d to caliper contact

face (arrows).

CAUTION—
• Do not let caliper rubber dust sleeve come in contact with anti-
squeal compound. The compound causes rubber to swell and
deteriorate.
• Do not apply grease to brake pad backing plate.

Apply thin coating of BMW anti-squeal compound to brake pad rests

(arrows) on pad carrier.

CAUTION—
• In order to preserve brake caliper surface coating use brake
cleaner only to clean.

If installing directional pads, be sure to install them as indicated by

manufacturer.

Where applicable, inser t brake pad wear sensor into cutout in new
pad. Pus h sensor into pad cutout unti l it locks into place.

CAUTION—
• If brake pad wear sensor light illuminated prior to brake pad
replacement, rep/ace wear sensor and reset CBS data.
• Brake pad sensor can only be installed once, then needs
replacing. See 020 Maintenance .
• Brake pad wear sensor is fragile. Be careful not to damage
during installation.

— Rout e pad wear sensor wirin g through caliper openin g an d unde r

bleeder dust cap .

— Remainde r o f installation is reverse o f removal .

• Clean brake caliper guide bolts ( 7 mm Allen). Replace ones which
are not in perfect condition. D o no t grease.
• Befor e driving car, pump brak e pedal severa l times so that brake
pads contact brake rotors.
• Check tha t brake fluid level is correct. To p off to MAX marking.
• Hold ignition key for at least 3 0 seconds in accessory positio n
without startin g engine . Thi s clear s fault code s i n memory an d
turns brake pad warning light OFF. I f light remains ON , reset
condition base d service (CBS) system . Se e 020 Maintenance.

Tightening torques
Brake caliper to pad carrier ( 7 mm Allen) 30 ± 2 Nm (22 ± 1 ft-lb)
Road wheel to hub 120±10Nm(89±7ft-lb )
 Brakes 340-1 3
Brake caliper and pad carrier, removing and installing

Brake caliper and pad carrier,

removing and installing
^, Insert peda l pro p and depress brak e peda l slightly. Thi s prevent s
brake fluid from escaping when brake lines are detached .

— Rais e ca r and support safely . Remov e wheels.

WARNING —
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Left front wheel: Working in junction box in wheel housing, separat e

brake pad warning sensor electrical harness (arrow).

i, , :' • •
If -9,. i , 1

Right rea r wheel: Remove right rea r wheel housing liner. Se e

410 Fenders, Engine Hood.

Working in junction box in wheel housing, separate brake pa d

warning senso r electrica l harness (arrow) .
340-14 Brake s
Brake rotor specifications

Working at brake caliper:

• Loosen brake hose fitting at caliper. Use shop towel to catch
dripping brake fluid.
• Remove pad carrier and caliper mounting bolts (arrows) from
steering knuckle (front caliper) or from wheel bearing carrier (rear
caliper).

Lift off caliper and spin assembly off hose. Plug open fluid lines and
ports.

Inspect brake caliper for signs of leakage. Check that caliper piston
slides smoothly into caliper. Replac e caliper i f any faults are found.

Installation is reverse of removal. Keep in mind the following:

• Tighten front caliper hose s with front wheel pointing dead ahead,
• Make sure brake hoses are not twisted or tensioned in any way.
• Make sure brake pad warning sensor harness does not chafe on
wheel or other moving parts.
• Bleed entire brake system before driving car. See Brake calipers,
bleeding in this repair group.

Tightening torques
Brake caliper to pad carrier (7 mm Allen) 30 ± 2 Nm
(22 ± 1 ft-lb)
Brake fluid hose to caliper 24Nm(18ft-lb)
Brake fluid hose to steel line 16Nm (12 ft-lb)
Front brake caliper to steering knuckl e 110Nm(81 ft-lb)
(replace M12x 1.5x43 mm ZNS3 bolts with
new)
Rear brake caliper to wheel bearing carrier 110Nm(81 ft-lb)
(M12 x 1.5x41 mm ZNS3 bolts )
Road wheel to hub 120 ± 1 0 Nm
(89 ± 7 ft-lb)

Brake rotor specifications

When inspecting brake rotors and pads, replac e pads only if brake
rotor thickness is greater than or equal to minimum thickness (MIN
TH) stamped on edge of brake rotor. This thickness is nominal
thickness (when new) minus 1.6 mm (0.06 in). Otherwise, replace
brake pads and rotors together.

Brake rotor dimensions vary based on model, engine size and drive
configuration (rear-wheel drive or xDrive). When replacing rotors,
match new parts to old parts on vehicle. If in doubt, check with BMW
parts department.

Table c. Brake rotor specifications

Model Parameter Front: mm (in) Rear: mm (in)
525i Diameter 310(12.2) 320(12.6)
525xi
MINTH 22.4 (0.88) 18.4(0.72)
 Brakes 340-1 5
Brake rotor, removing and installing

Table c. Brake rotor specifications

Model Parameter Front: mm (in ) Rear: m m (in )
528i Diameter 324(12.8) 320(12.6)
528xi
MINTH 28.4(1.11) 18.4(0.72)
530i
530xi
535xi
535i Sedan Diameter 348(13.7) 345(13.6)
545i
MINTH 28.4(1.11) 22.4 (0.88)
550i
Max. machine limi t per
0.8 (0.03 )
friction rin g sid e

Brake rotor, removing and installing

Machine o r replace brake rotor s in pairs per axle.

Raise car and support safely. Remove wheels.

WARNING —
• Make sure the car is stable and well supported at all times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Remove brake caliper carrier bolts (arrows). Suspen d brak e caliper

from chassis usin g stif f wire . Do not detach brake hydraulic line .

Remove brake rotor mounting screw (arrow) an d remov e rotor.

Inspect roto r for cracks, signs of overheating and scoring.

Minimum allowable thickness (MIN TH) is stamped on roto r hub.

Measure rotor braking surface with a micrometer at eight to ten
different points an d use the smallest measurement . Compare t o
specifications in Table c.

If roto r does not pas s minimu m thicknes s requirements or is

damaged, replace rotor .
340-16 Brake s
Brake master cylinder, removing and installing

Vented brake rotor s are equipped with an integrated balance weight

(arrow). D o not remov e o r repositio n weight .

— Clea n roto r with brake cleaner befor e installing.

— I f new rea r brake rotor s are installed , adjus t parkin g brake . Se e

Parking brake , adjusting i n this repai r group .

Tightening torques
Brake roto r to wheel hu b (replac e M 8 x 14 16 M m (12ft-lb )
mm Allen bol t wit h new )
Front brake caliper to steering knuckle 110Nm(81 ft-lb)
(replace M1 2 x 1 .5 x 43 m m ZNS3 bolts wit h
new)
Rear brak e caliper t o wheel bearin g carrie r 110 Mm (81 ft-lb )
B510340013
(M12x 1 . 5 x 4 1 mm ZNS3 bolts )
Road wheel to hub 1 20 ± 10 Mm
(89 ± 7 ft-lb)

BRAKE MASTE R CYLINDE R

The brake master cylinder i s mounted t o the front of the vacuu m
booster on the driver side bulkhead .
1. Brak e vacuum booste r
2. Brak e fluid reservoi r
3. Brak e fluid level senso r
4. Vacuu m lin e check valv e
5. Brak e master cylinder
6. Vacuu m lin e from intake manifold o r auxiliary vacuum pum p

.com
Brake maste r cylinder , removin g an d installing

CAUTION—
• Brake fluid is highly corrosive and dangerous to the
environment. Dispose of it properly.

— Remov e lef t side cabin microfilte r housings. Se e 020 Maintenance .

— Remov e lef t lower dashboard trim . See 513 Interio r Trim .

^. Working at brake fluid reservoi r at left rear of engine compartment :

• Detach brake flui d level sensor connector (arrow) .
• Remov e reservoi r cap.
• Usin g a clean syringe, empt y brak e fluid reservoir.

— Remov e brake fluid reservoir by tilting sideways ou t o f grommets.

 Brakes 340-1 7
Brake master cylinder, removing and installing

Working in passenger compartment underneath lef t side dashboard :

• Remov e brake booster mountin g fasteners (A).
• Remov e brake booster push ro d pin clip (inset) and detac h
booster pushrod from brake pedal .

, Disconnec t maste r cylinde r brak e line s (A).

• Plu g open brak e line s to prevent contamination.
• Remov e master cylinder mountin g nuts (B) and remove maste r
cylinder.

During reinstallation , make sur e fluid couplings, thread bore s an d

mating surface s ar e clean.

Mount maste r cylinde r to brake booste r usin g new sealing O-ring

and new self-locking nuts.

CAUTION—
• Be sure to align master cylinder pushrod and booster pushrod.
• Do not over-torque master cylinder mounting nuts. This could
damage the brake booster and prevent proper vacuum build-up.
• After 30 minutes, retighten master cylinder mounting nuts.

Tightening torque
Brake master cylinder to brake booster 26 Nm (19 ft-lb)

— Connec t brak e fluid lines to master cylinder .

Tightening torques
Brake fluid lin e to maste r cylinder
• M10 x 1 union nut 14 Nm (1 0 ft-lb)
• M12 x 1 union nut 17Nm(13ft-lb)

Reinstall fluid reservoir usin g new sealing grommets .

Fasten brake booster. After 30 minutes, retighten .

Tightening torque
Brake booster to bod y panel (M8 nuts) 21 Nm (15 ft-lb)

Remainder of installatio n i s reverse of removal . Remember to :

• Top up with fresh brake fluid.
• Bleed entire brake system. Se e Brake system, bleeding in this
repair group.
340-18 Brake s
Auxiliary brake booster vacuum pump

Auxiliary brake booster vacuum pump

5 Series models with N52, N54 or V8 engine use an auxiliary pump
to supply vacuum to the brake booster, rather than using traditional
manifold vacuum.

IM52 engine: Vacuum pump, in front lower left of engine, is driven by

oil pump chain.

N54 engine: Vacuum pump operates i n tandem with high-pressure

fuel pump, both driven by oil pump chain in front lower left of engine

V8 engine: Vacuum pump at right front of engine i s driven by right

exhaust camshaft.
 Brakes 340-1 9
Parking brake components

PARKING BRAK E
Parking brake components
Bracket
Grommet
Parking brake Bowden cable
Bracket
Gasket
Support
Backing plate
Reinforcement
Bolt
Brake shoe expander
Return spring
Parking brak e shoe
Brake shoe adjuster
Hold-down spring
Hold-down pi n

Parking brake, adjustin g

The parking brake i s a brake drum system integrated into the rea r
brake rotors . Adjust with rear of car raised off the ground an d th e
wheels installed . Mak e sure parkin g brake Bowden cables mov e
freely.

Adjust parking brake under the following circumstances:

• After replacing parking brake shoe s
• Afte r replacin g rear brake rotors
• Excessiv e stroke o f parking brak e handle required for actuatio n
(more then 1 0 clicks)
• After replacement of brake shoe adjuster or parking brake cable(s )

— Disengag e parkin g brake handle boot from center console .

^k Reliev e parking brake cable tension: Using a screwdriver, lock

parking brak e handle adjuste r b y pressing spring back to engag e
hook. Inset shows hook engaged .

— Rais e rear of car.

WARNING—
• Make sure that the car is firmly supported on jack stands
designed for the purpose. Place jack stands beneath structural
chassis points. Do not place Jack stands under suspension
parts.
340-20 Brake s
Parking brake shoes, removing and installing

^V Remov e one rear wheel lug bolt and rotate wheel until parking brake
adjuster i s visible through lu g bolt hole .
• Us e flat-bladed screwdriver to reach int o brake drum through bol t
hole and turn brake adjuster.
• Lef t rear wheel: Turn adjuster in direction A to spread brake shoes.
• Righ t rea r wheel: Turn adjuster i n direction B to spread brake
shoes.

— Tur n adjuster until wheel no longer turns. Back adjuster off 8 teeth.

Parking brak e adjusting (initial )

Back off adjuster through whee l lug bolt hole 8 teeth

— Workin g at parking brak e handle in center console, us e screwdriver

to release hook at brake cable spring.

— Se t parking brake several time s to seat brakes .

— Releas e leve r an d make sure rea r wheel s turn freely. I f any bindin g
is noticed, bac k off adjuster(s) one toot h a t a time.

— Switc h ignition ON. Pul l u p parking brak e leve r 1 notch and mak e
sure that parkin g brake warning ligh t switches ON. I f not, adjust
parking brak e warning light contact switch .

— Instal l parking brake leve r boot . Install road wheel lug bolt.

Tightening torque
Road wheel t o hub 120± 10 Mm
(89 ± 7 ft-lb)

Parking brake shoes, removin g an d installin g

— Disengag e parking brake handl e boot from center console .

^ Reliev e parkin g brak e cabl e tension: Using a screwdriver, lock

parking brak e handle adjuste r b y pressing sprin g back to engag e
hook. Inse t show s hook engaged .

— Rais e rear o f car an d remov e wheels.

WARNING —
• Make sure that the car is firmly supported on jack stands
designed for the purpose. Place jack stands beneath structural
chassis points. Do not place jack stands under suspension
parts.

Remove brak e caliper s and brake discs. Hang brake calipers aside
with stiff wire. Do not disconnect brake fluid hoses. See Brake rotor,
removing an d installing in this repai r group .
 Brakes 340-2 1
Parking brake shoes, removing and installing

Unhook retur n springs (arrows ) from brake shoes.

Remove brak e sho e hold-dow n pin s using BMW special tool

34 4 000 or 6 mm Allen wrench.
• Rotat e hold-dow n pin % turn to release.

34 4 000 • Spread shoes apart and lift out.

_502340758

Note positio n o f brake sho e adjuste r (arrow) . Righ t sid e is

illustrated. Lef t i s mirror image o f this.

Installation is reverse o f removal. Kee p in mind the following :

• Apply thin coat of grease to sliding parts and pins befor e
reassembly.
• B e sure to adjust parking brake . See Parking brake, adjustin g i n
this repai r group .

Tightening torques
Brake caliper to wheel bearing carrie r 110 Nm (81 ft-lb)
(M12 x 1 .5 x 41 mm ZNS3 bolts)
Brake roto r to hu b (M 8 x 14 mm Allen bolt) 16Nm (1 2 ft-lb)
Road wheel to hub 120± 10Nm
(89 ± 7 ft-lb)
340-22 Brake s
Parking brake cable, replacing

Parking brake cable, replacing

The parkin g brake is actuated by two separat e Bowden cables.
Each cable can be replaced separately.

— Rais e vehicle and remov e rear wheel.

WARNING —
• Make sure the car is firmly supported on jack stands designed
for the purpose. Place jack stands beneath structural chassis
points. Do not place jack stands under suspension parts.

Remove brake calipers and brake discs. Hang brake calipers aside
with stiff wire. Do riot disconnect brake fluid hoses. See Brake rotor,
removing and installin g i n this repair group.

Remove exhaust system and hea t shield. Se e 180 Exhaust

System.

Working inside car , gain access to base o f parking brake handle by

removing cente r console . Se e 513 Interior Trim.

Relieve parking brake cable tension: Using a screwdriver, loc k

parking brak e handle adjuster b y pressing spring back to engag e
hook. Inse t shows hoo k engaged .

Use screwdriver t o pry plastic clip off parking brak e balance ba r

(arrow).
 Brakes 340-2 3
Parking brake cable, replacing

Slide Bowde n cable bal l en d toward center of balance ba r (arrow)

and out toward rear of vehicle.

Remove parking brak e shoes . Se e Parking brak e shoes ,

removing an d installing in this repair group.

Pull shoe expander (A) forward and disconnect parking brak e cable
(B).

502340760

Working at wheel bearing carrier , remove fastener and cable hol d

down (arrow) .

Working underneat h vehicle, detach cable from brackets. Pull cable

out of brake backing plate and out of tube guide underneath vehicle.

Installation is reverse of removal. Adjust parking brake . See Parkin g

brake, adjustin g in this repai r group.

Tightening torques
Brake cable bracket to wheel bearing carrier 8 Nm (6 ft-lb)
(M6 bolt)
Brake calipe r to wheel bearing carrier 110 Nm (81 ft-lb)
(M1 2 x 1 .5 x 41 mm ZNS3 bolts)
Brake roto r to hu b (M 8 x 1 4 mm Allen bolt) 16Nm (12 ft-lb)
Road wheel t o hub 120± 10N m
(89 ± 7 ft-lb)
340-24 Brake s
Antilock brake system (ABS)

ANTILOCK BRAK E AND

STABILITY CONTROL
5 Serie s vehicles are equipped with antilock brakes (ABS) with
dynamic stability control (DSC). This manual refers to these systems
as ABS. DSC is specified when necessary.

Antilock brake system (ABS)

The electronically controlled antilock brake system (ABS) maintains
vehicle stability and control during emergency braking b y preventing
wheel lock-up. ABS provides optimu m deceleratio n an d stability
during adverse conditions. I t automatically adjust s brak e system
hydraulic pressur e at each wheel to prevent wheel lock-up .

Dynamic stability contro l (DSC )

DSC works in conjunction wit h ABS and the engine managemen t
system to enhance vehicle control. Th e main DSC function i s to
maintain contact between the tires and the road surface under all
driving conditions. This is achieved through exact application and
management of braking and drivetrain forces.

DSC is active throughout the drivin g range, helping to stabilize the

vehicle in cornering and avoidance maneuvers by adjusting engine
controls such as throttle, ignition, fuel injection and the application of
brake pressure individually to the wheels.

The DSC control module use s various input s t o determine vehicl e

instability during braking , cornering , o r reduced traction situations .
Based upon these inputs the ABS / DSC control module sends
outputs to the engine contro l modul e an d the ABS / DSC hydraulic
unit to activate torque reduction protocol s an d braking intervention.

The ABS / DSC control module, operating through the hydraulic unit,
modulates braking force at the wheels. In addition, DSC overrides
throttle opening to reduce engine torque and maintain vehicle
traction. Because throttle i s controlled electronically, the driver
cannot increase engine power output during DSC intervention
regardless of how far the accelerato r pedal is pushed.

Traction control also comes into operation durin g deceleration .

Decelerating on snowy or icy road surfaces can lead to rear wheel
slip. I f a rear wheel starts to drag o r lock up , DSC can limit the
problem by adjusting throttle , fue l injection an d ignition timing .

DSC can be toggled ON and OFF by a switch labeled DSC or DTC

in the center console switching center. Turning DSC OFF does not
disable ABS functions.
 Brakes 340-2 5
Dynamic stability control (DSC)

Bus systems and traction control

Serial bus systems connect the engine control module (ECM),
transmission contro l modul e (TCM), AB S / DSC control module,
active steering control module, active stabilizer (dynamic drive)
control module, longitudina l management system (LDM ) and active
cruise control (ACC) . Bus systems allow control modules to shar e
sensor informatio n and other electroni c data. Se e 600 Electrica l
System-General for additional details .

DSC acceleration sensor

The DSC acceleration sensor utilizes two yaw rate sensor element s
to detect yaw (rotation about the vertical axis) rat e an d lateral
acceleration (G-force) rate.

For rotational acceleration (yaw), the sensor produces a reference

signal and a linear voltage signal . The sensor also produces a linear
voltage signal for lateral acceleration. The DSC control module use s
this inpu t to determine rotationa l and side forces acting on the
vehicle.

Steering angle senso r

, Th e steering angle sensor is located in the steering column switc h

cluster (SZL) . I t optically measure s the angle of rotation of th e
steering whee l to determine steerin g angl e an d rate of steering.

After repairs to the steering or suspension system, use a BMW scan

tool or equivalent to calibrate the sensor. Once calibration is
complete, the sensor sends a n identification number over the CAN-
bus to the DS C control module . The I D confirms that the senso r i s
calibrated correctly.

DSC control module logi c checks the plausibility of the steerin g

angle sensor signa l against other input s such as wheel speed s and
acceleration inputs .

If batter y voltage i s interrupted, steering wheel angle o f rotatio n i s

Steering recalculated by the DS C control module evaluating wheel speeds. If
column
switch replacing steering angl e sensor, remembe r t o recalibrate sensor .
cluster

Wheel speed sensor s

A wheel speed senso r (A) is mounted at each wheel along wit h a
ring of magnets (B) used to measure directio n of wheel rotatio n and
speed. The electrical resistance of the wheel speed sensor changes
under th e influence of the magnetic field. Eac h increment generate s

; rm 2 pulses in the wheel speed sensor (96 pulses / revolution of wheel).

When the vehicle i s stationary th e sensor sends one pulse every
0.75 second.

SN SN
340-26 Brake s
DSC faults

DSC and xDrive

xDrive (all-whee l drive system) use s informatio n from the DSC
system to control a multi-plate clutch i n the transfer case. The multi -
plate clutch varies torque spli t between front and rear wheels .

xDrive calculates the necessary torque split from information

supplied b y DSC :
• Accelerator pedal positio n
• Engin e torque
• Dynami c stat e of vehicle (driv e dynamic state )

DSC COMPONENT S AN D REPAIRS

CAUTION—
• If the tires on the car are of different makes, the DSC system
may overreact. Only fit tires of the same make and tread
pattern.
• In adverse conditions, such as trying to rock the car out of deep
snow or other soft surface, or when snow chains are fitted,
switch traction control OFF and allow the car driveline to
operate conventionally.

DSC faults
DSC systems are self-diagnosing an d store fault codes (diagnosti c
trouble codes o r DTCs) i n the DS C control module. Fo r information
on how to access DTCs , see 020 Maintenance .

ABS / DSC components are coded to each other and to the vehicl e
using BMW sca n tool. I f you do no t hav e access to a scan tool, be
sure to have newly installed ABS / DS C components coded a t a
qualified BMW workshop wit h th e correct equipment .

The driver is alerted to DS C faults by a warning icon and a Check

Control warnin g triangl e in instrument cluster. A gong als o sounds .
 Brakes 340-2 7
DSC power supply

DSC power suppl y

See EC L Electrical Component Location s for fuse panel acces s
information.

Fusible link s i n back o f rear fuse panel, righ t rea r trunk o r cargo
compartment:
• F9 0 200A: Supplies powe r to fuses F1 - F33

Rear fuse panel, right rear trunk or cargo compartment, t o 09 / 2005:

• F66 5A: DSC control modul e

Rear fuse panel, right rear trunk or cargo compartment,

from 09 / 2005:
• F76 10A: Active stabilize r (dynamic drive)
• F7 8 5A: DSC control module , transfer case
340-28 Brake s
DSC controls

Front fuse panel, behin d glove compartment:

• F1 50A: DSC control modul e
• F13 30A: Transfer case
• F25 30A: DSC control module
• F28 20A: Steerin g column switch cluster (SZL )
• F32 10A: Active stabilizer (dynamic drive )
• F39 5A: Steering column switch cluster (SZL )

Pu m

DSC control s
Lower center dashboard abov e center console:
• DS C (dynamic stabilit y control) switc h
• DTC (dynamic traction control) switch
 Brakes 340-2 9
DSC control module, removing and installing

Right front engine compartment:

• A65 ABS / DSC control module

Above brake pedal, underneat h lef t side dashboard (arrow):

• S29 Brake light switch

DSC control module, removing and installing

DSC electronic contro l module and DSC hydraulic unit are
combined i n one assembly i n right front engine compartment .

— Us e BMW scan tool to read out and record DSC control module fault
memory.

— Usin g a syringe, remove brake fluid from master cylinder reservoir.

^ Inser t pedal prop and depres s brake pedal slightly. This prevent s
brake flui d from escaping when brake line s are detached.

B309340037]
340-30 Brake s
Wheel speed sensor, replacing

Working a t DSC module :

• Mar k brake line positions (arrows) at hydraulic unit . Detach brake
lines. Be prepared to catch drippin g fluid. Plug ope n port s and
lines.
• Disconnec t electroni c modul e electrica l connecto r (A) .
• Remov e control module bracket mountin g bol t (B) . Lif t module out
of engine compartment.

CAUTION—
• Do not bend brake lines.

— Installatio n i s revers e of removal .

Tightening torques
Brake fluid line to master cylinder (M1 0 x 1 or 17Nm (13ft-lb )
M12 x 1 union nut )

Bleed brak e system . See Brake system , bleedin g in this repair

group.

Use BMW scan tool to:

• Code DS C module.
• Adjust steering angl e sensor .
• Adjust brake pressure sensor.
• Adjust acceleration sensors .

Wheel speed sensor, replacin g

Raise car and support safely .

WARNING —
• Make sure the car is stable and well supported at a/I times. Use
a professional automotive lift or jack stands designed for the
purpose. A floor jack is not adequate support.

Front wheel speed sensor

Working i n junction bo x in wheel housing , separat e wheel speed
sensor electrical harness (arrow). (Left front junction box illustrated.
Right front contains singl e harnes s connector. )
 Brakes 340-3 1
Wheel speed sensor, replacing

Unscrew senso r mountin g bol t (arrow) a t steering knuckl e an d

remove sensor .

Installation is reverse of removal. Apply thin coat of Staburags®NBU

12/K or equivalent grease to speed sensor and housing .

Tightening torque
ABS wheel speed sensor to steering knuckle 8 Nm (6 ft-lb)

Rear wheel speed senso r

Remove rear wheel well housing liner . See 410 Fenders , Engin e
Hood.

Working in junction bo x in wheel housing , separate whee l spee d

sensor electrical harness (arrow).

Unscrew sensor mounting bol t (arrow) i n rear wheel bearing carrier.

Installation is reverse of removal. Apply thin coat of Staburags®NB U

12/K o r equivalent greas e t o speed sensor and housing .

Tightening torque
ABS wheel spee d sensor t o rear wheel 8 N m (6 ft-lb)
bearing carrie r
340-32 Brake s
ABS impulse wheel

ABS impuls e wheel

The front and rear ABS impuls e wheel s are integra l with the inner
wheel bearing sea l and not available a s separate parts . See
310 Fron t Suspension o r 330 Rea r Suspension fo r wheel bearing
replacement procedures .

DSC acceleration sensor,

removing and installin g
— Remov e right front seat. See 52 0 Seats .

— Remov e right door sill trim. See 51 3 Interio r Trim.

— Fol d right fron t carpet , la y aside and remov e carpe t underlay .

^V. Workin g at sensor:

ft . • Detac h electrica l sensor.
Harness * _
connectors ,- r • Remov e mountin g screws (arrows ) and lift out sensor.

— Installatio n i s revers e of removal .

CAUTION—
• Be sure to tighten the DSC acceleration sensor to specified
torques. The sensor is vibration sensitive and causes DSC
malfunctions if installed improperly.

Tightening torque
DSC acceleration sensor to body 8Nm (6 ft-lb)

B510340039 Program usin g BMW scan tool .

Steering angle sensor

The steering angle sensor is integral with the steering column switc h
cluster (SZL) . For more information , including removal and
installation of the SZL , see 61 2 Switches.

To reset steerin g angl e sensor, connect vehicle t o BMW scan tool

and carry out steering angl e senso r adjustmen t system function.
1 400-1

400 Body-Genera l

GENERAL 400- 1 Door handle s 400- 4

Central lockin g 400- 4
BODY ASSEMBL Y 400- 2
Dimensions 400- 2 INTERIOR FEATURE S 400- 5
Body 400- 2 Instruments, iDriv e 400- 5
Seats 400- 6
SAFETY AN D SECURITY 400- 3
Passenger safet y 400- 3 BODY ELECTRONIC S 400- 6
Restraint system 400- 4

GENERAL
This chapter covers system descriptions and general information for
the repai r groups i n partitions 4 Body and 5 Body Equipment .

The 5 Series chassis was introduced in the North America market as

a Sedan (E60) i n fall 2003 an d Sports Wagon (E61 ) in spring 2005 .
Both rear-whee l drive and all-wheel drive (xDrive) versions were
offered.

::
400-2 Body-Genera l
Dimensions

\n (E60) 80.5 / 2046 BODY ASSEMBL Y

4 0 8 / 1 0 3 6' 39.8/1010 .
Dimensions
In the accompanying illustration, dimensions for 2004 - 2010 Sedan
models ar e given in inches / mm .

Body dimensions have been increased from the previous generatio n

61.3 I 1558 (E39) t o improve knee room in the rea r seat area b y 5 cm (2 in) and
to increase the luggage compartmen t capacity , which at 520 L
(18.36 ft3) ha s the largest capacit y of all current BMW vehicle s
including the E65.

113.7/2888
190.6/4841

Body
In order to make the Sedan (E60) an d Sports Wagon (E61)
significantly lighter than the previou s generatio n 5 Series (E39).
BMW designed a reduced-weight aluminu m fron t end (GRAV) . The
front end consists almost entirel y of aluminum while the transition t o
steel occurs in the front bulkhead area . Aluminum component s are
shown i n darker shaded (fron t clip) section.

B510400003
 Body-General 400- 3
Passenger safety

The bodies of the Sedan and Sports Wagon are identical in structure
and design from the front bumper to the B-pillar. The rear doors, rea r
floor pans, inne r halves of the rea r wheel arches, rea r side frame s
and pillars, rear roof frame and roof outer skin have been redesigne d
for th e Sports Wagon. The rea r hatch was designed simila r t o the
E39 Sports Wagon with a separately opening rea r window. To
increase the bod y rigidity , a V-shaped tension strut is fitted on th e
underbody o n vehicles equipped wit h the panoramic glas s sunroof .

,«.•••

The Sport s Wagon luggage compartmen t is flat with the rea r seat
backrests folded down. 4 lashing eyes are fitted as standard on the
floor of the luggage compartment. The vehicle tool kit is located i n a
utility box on the left-hand frame side member. The lockable luggag e
compartment floor can be raised and with the aid of gas spring struts
(similar to the hood) an d remains in position until it is pressed dow n
again. A storage are a i s provided under the luggag e compartmen t
floor. Belo w this i s the spare wheel or a further storage are a
(35 liters) if the vehicle i s equipped with run-on flat tires.

SAFETY AND SECURITY

Passenger safet y
BMW passive safety is based o n the principle of protecting th e
passenger compartment wit h dynamic deformatio n zones. On e of
the first considerations i n designing a safe vehicle is the bod y an d
chassis design . It is vital to protect the passenge r i n the event o f an
impact. This i s accomplished b y maintaining th e integrit y of th e
1 •,-.:
"passenger cell" during an accident. Th e main consideration during
an impact i s to avoid transferring crash energy to the vehicl e
occupants. By adding energ y absorbin g crash elements to the
vehicle, this energy transfer is reduced considerably.
400-4 Body-Genera l
Restraint system

Restraint syste m
The passive restrain t system consists o f seat belts with pyrotechnic
(explosive) tensioners and a minimum of 6 airbags .
1. Drive r airbag
f« 4 3 2. Passenge r airbag
3. Curtai n sid e airba g
4. Sid e airba g (rea r optional )

For additional restrain t system information , see:

• 720 Seat belt s
• 721 Airbag System (SRS )

Door handle s
In vehicle equipped wit h comfort access, th e front door handl e
contains the components of the electronic outer door handle module
(TAGE).

If a vehicle remote key is in the vicinity of the vehicle, a hand inserted

between the door handle and the door automatically unlocks the car.

See 515 Central Lockin g an d Anti-theft.

Central lockin g
All doors locks as well as trunk lid lock, tailgate lock and fuel filler flap
lock are integrated into central locking an d can be operated via the
following:
• Remote key
• Driver' s door lock barrel (door lock )
• Central locking butto n
• Electroni c outer door handle modul e (TAGE ) (comfor t access
vehicle)

There are two different central locking system s in 5 Series models

dependant o n production date. See 515 Central Locking and
Anti-theft for more information .

Antitheft alarm (DWA)

When armed , the antitheft system monitors doo r loc k contact s and
trunk and engine hood lock s and sound s a n alarm i f it detects
tampering. Include d i n the enhanced syste m i s a tilt sensor t o
protect against the vehicle being towed away, and an interior motio n
sensor.

For more information, see 515 Central Lockin g and Anti-theft.

 Body-General 400- 5
Instruments, iDrive

INTERIOR FEATURE S
Instruments, iDriv e
The instrument cluste r and dashboard layou t is similar to other BMW
models with all of the control s i n easy reac h o f the driver .

The dashboard i s equipped wit h the iDrive central information

display (CID) or car information compute r (CIC). The display screen
Central informatio n
display (CID)
is used for a variety of vehicle control and diagnostic task s and i s
also capable o f displaying navigatio n information.

Navigation, climat e control , sound system and other function s ar e

controlled vi a iDrive controller.

J
Functions an d controls essentia l to the driver are logically groupe d
and easy to reach. Instrument s and controls are fully integrated int o
the overal l design o f the vehicle .
• Tilt-telescopic steerin g whee l ha s 30 mm (1.2 in ) of vertical an d
longitudinal adjustment .
• Multifunctio n steering whee l contain s two key pads containin g
controls for the sound system , telephone an d cruise control .
400-6 Body-Genera l
Seats

Seats
Economically engineered seats are constructed from polyurethane
foam containing area s or zones o f different firmness . They offer
superior lateral support without constricting th e occupant.

In cars equipped wit h seat positio n memory , two differen t seat

configurations can b e memorized b y the seat control module. Sea t
memory coordinate s wit h outside mirro r memory . These function s
are controlled by the seat memory module .

For additional information , see 52 0 Seats.

BODY ELECTRONIC S
5 Serie s vehicles are equipped wit h an integrated comple x of
electronic module s connecte d vi a the bu s system. An overview of
the bus system is in 600 Electrica l System-General. For details of
electrical functions, see:
• 121 Battery, Starter, Alternator
•512 Doo r Window s
• 515 Central Lockin g an d Anti-theft
• 520 Seats
• 611 Wipers and Washer s
• 620 Instrument s
• 630 Lights
 410-1

410 Fenders , Engine Hood

GENERAL 410-1 ENGINE HOO D 410- 3

Special tools 410-1 Engine hoo d latch component s 410- 3
Engine hood , aligning 410- 3
FRONT FENDER S 410-1
Engine hood , raisin g to service position 410- 5
Front wheel housin g liner ,
Engine hood , removin g an d installing 410- 5
removing an d installing 410-1
Front fender, removin g and installing 410-2

GENERAL
This repair group covers replacemen t of the front fenders an d
removal and installatio n of the engin e hood.

CAUTION—
• The body is painted at the factory after assembly. Realignment
of body panels may expose unpainted metal. Paint all exposed
metal once the work is complete.

Special tools
Most body repair s can be performed using regular automotiv e
service tools. Special BMW tools are required to set engine hoo d
into service position.

FRONT FENDER S
Front wheel housing liner,
removing and installing
— Rais e front of vehicle and remov e wheel.

WARNING —
• Make sure that the car is firmly supported on jack stands
designed for the purpose. Place jack stands beneath structural
chassis points. Do not place jack stands under suspension
parts.

Remove clips (A ) from fender edge b y driving center out with a

suitable sized punch, then prying out clip with suitable plastic pryin g
tool.

NOTE—
• The clips are not reusable. Replace with new.
410-2 Fenders , Engin e Hoo d
Front fender, removing and installing

^V Remov e fasteners (arrows ) from wheel housin g liner .

— Remov e liner.

— Installatio n is reverse o f removal .

Front fender, removin g an d installin g

Raise hoo d to service position. Se e Engin e hood , raisin g to
service position i n this repair group .

Remove front wheel housing liner . See Front wheel housing liner,
removing an d installing i n this repai r group .

Fastener location s shown for Sedan and Sports Wago n models .

Apply sprayable sealing wax Terostat 9320 or equivalent to

underside of fender in area A .

B510410009
 Fenders, Engin e Hoo d 410- 3
Engine hood latch components

ENGINE HOO D
Engine hoo d latc h component s
1. Hoo d latch
2. Hoo d latch end support
3. Twis t protection
4. Safet y bracket
5. Hoo d lock
6. Hoo d release cable, rear
7. Ga s support strut
8. Hoo d release cable, front
9. Wate r gutter cover
10. Left hood hinge
11. Spacer
12. Left hood seal
13. Hood release lever
14. Combination bracket
8510410003
15. Side hood seal
16. Center hood seal
17. Hood

Engine hood , alignin g

When installin g hood , align hinge s a s close to original painte d
surface as possible. Movemen t of hood on its attaching hardwar e
may require touch u p paint.

"X. Loose n lef t uppe r and lower hinge mounting bolts (arrows) . Mak e
sure hood can mov e relativ e to hinge.

— Repea t on right .

B510410005
410-4 Fenders , Engine Hood
Engine hood, aligning

Align hood s o gap (arrows ) to fender i s as even as possible.

Tightening torque
Hood to hood hing e (M8 x 2 4 mm, 8 8 grade) 18 5 Mm (13 5 ft-lb)

B510410004

If front height adjustment is off, adjust safety brackets:

• Releas e screw (A).
• Remov e cover (B).
• Adjust height by turning latch (C).

If heigh t adjustmen t o f engine hoo d lid to front fenders is off, tur n

front buffer stops (arrow ) on lef t and right .

CAUTION—
• To avoid excessive wind noise, make sure hood does not
protrude beyond front fenders.
 Fenders, Engine Hood 410- 5
Engine hood, raising to service position

Engine hood, raising to service position

^ Ope n hood. With hel p of an assistant, support hood and remove
retaining clips (arrow ) on uppe r end of left gas support strut .

— Slid e BMW special tool 51 2 170 (inset) over housing o f gas sprin g
strut then clip ball socke t of special tool on ball stud on hood .

— Repea t on right .

UBiieillUlfil

Engine hood, removing and installing

WARNING —
• The hood is heavy. Before removing the hood supports, be sure
to have an assistant help support the hood.

— Mar k position o f hood hinge mountin g plates.

^. Loosen upper hinge mountin g bolts (A) and remove lower bolts (B).
Lift hood of f carefully.

— Installatio n is reverse of removal . Note the following:

• Repai r any paint damag e an d paint any exposed metal .
• Check hoo d alignment. Se e Engine hood , aligning i n this repair
group.

Tightening torque
Hood to hoo d hinge (M 8 x 24 mm, 8.13 grade) 18.5 N m (13.5ft-lb )

B510410008
 411-1

411 Door s

GENERAL 411-1 Door, adjusting 411- 3

Warnings and cautions 411-1 Door, removing and installing 411- 4

DOORS 411-2 DOOR PANEL S 41 1 -6

Door check, replacing 411-2 Door trim panel, removing and installing 411- 6
Door hinge assembly, front. 411-3

GENERAL
This repai r group covers front and rear door repair informatio n an d
includes doo r trim panel service.

CAUTION—
• The body is painted at the factory after assembly. Realignment
of body panels may expose unpainted metal. Paint exposed
metal once work is complete.

For additional information , see:

• 512 Door Window s for power doo r window s an d door glas s
replacement
• 515 Central Lockin g an d Anti-theft for power door lock s
• 721 Airbag system (SRS) for side airbags

Warnings and caution s

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given i n 001 Warnings and Cautions .
• To avoid damaging plastic interior trim, use a plastic prying tool
or a screwdriver with the tip wrapped with masking tape.

WARNING —
• EGO and E61 cars are fitted with side-impact airbags in the front
doors and optional side impact airbags in the rear doors. When
servicing doors, a/ways disconnect the negative (-) battery
terminal. Se e 721 Airbag System (SRS) for cautions an d
procedures relating to the airbag system.
411-2 Door s
Door check, replacing

DOORS
Door check, replacing
— Clos e door window completely.

— Disconnec t negativ e (- ) battery cable .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given i n 001 Warnings an d Cautions,

— Remov e interio r door panel . See Doo r tri m panel , removin g and
installing i n this repai r group.

'X. Remov e door check sea l (C).

— Releas e doo r check screws (A an d B) .

Working inside door , remove door chec k assembly (A).

Installation is reverse of removal .

Tightening torques
Door check to bod y 21 Nm(15ft-lb)
Door check to door 10Nm(7ft-lb)

10411009
 Doors 411- 3
Door hinge assembly, front

Door hing e assembly , fron t

1. Doo r check seal
2. Doo r check
3. Uppe r door hinge
4. Lowe r door hinge
5. Doo r
6. Plu g
7. Reflecto r

B510411001

Door, adjustin g
Front and rear door adjustmen t procedure s are similar .

If installe d doo r i s uneven o r out o f parallel, loosen nut s a t doo r

hinges (arrows ) to adjust at top and bottom.

If mor e adjustment i s necessary, spacers (or shims) ca n b e used to

correct door alignment . Spacer s ar e placed behind hinges .
411-4 Door s
Door, removing and installing

Check that adjoining body parts are flush in terms of height

(dotted line ) and correct if necessary. Afte r adjustment, tighte n
hinge nut s and screws.

Loosen screws (A) to adjust loc k striker.

NOTE—
• When door is closed, lock striker must not touch or brush against
door lock. Avoid scratching door.

Tightening torques
Door to door hing e (M8 x 28 mm ) 20 N m (15ft-lb )
Lock striker to body 21 Nm(15ft-lb )

Door, removing and installin g

Front an d rea r door remova l and installatio n ar e similar.

Disconnect negativ e (- ) battery cable .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnect/on cautions given i n 001 Warnings and Cautions .

Remove harness connector mountin g bol t (arrow ) at door pillar .

 Doors 411- 5
Door, removing and installing

Pull plug connectio n fro m door pillar by lifting it up and out .

Detach plu g connectio n (arrows).

Remove doo r check mountin g bol t (A).

With door fully open, unscrew door hinge pin bolts (arrows) from top
and bottom hinges .
411-6 Door s
Door trim panel, removing and installing

Remove doo r b y pulling out sideways.

Installation i s reverse of removal. Not e the following:

• Mount an d align rea r doors firs t (if applicable), followe d b y front
doors.
• Align door so that panel gaps are equal on either side. If necessary,
adjust door hinges . Se e Door, adjustin g i n this repair group.
• Adjust lock striker so that trailing edg e o f front door is slightly
higher tha n leading edge of rear door .
• Repai r paint damage an d paint expose d metal .

Tightening torques
Door check to bod y 21 Nm(15ft-lb)
Door electrical harness to body (M5 x 1 6 mm) 3 N m (2 7 in-lb)
Door hinge pi n bolts 27 N m (20 ft-lb)

DOOR PANEL S
Sedan lef t front door pane l i s illustrated. Othe r doo r panel s are
similar.

Door trim panel, removin g an d installin g

WARNING—
• E60 and E61 cars are fitted with side-impact airbags in the front
doors and optional side impact airbags in the rear doors. When
servicing doors, always disconnect the negative (-) battery
terminal. Se e 721 Airbag Syste m (SRS) fo r cautions an d
procedures relating to the airbag system.

NOTE—
• Vehicle through 03 / 2007 shown, later vehicles similar

— Disconnec t negativ e (- ) battery cable .

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given i n 001 Warnings and Cautions.

Pry out footwell light (arrow ) using plasti c pryin g tool, disconnect
from harnes s connector and remove .
 Doors 411- 7
Door trim panel, removing and installing

^V Pr y out airbag emble m (A ) on doortrim pane l usin g plasti c pryin g

tool and release scre w underneath .

— Remov e cap (B ) an d scre w underneath .

Unclip door trim panel starting at bottom. Unclip doortrim panel clip s
(arrows) usin g plastic prying tool.

Carefully uncli p doortri m panel fro m retainers (arrows) by pullin g

straight out. Pul l door trim panel up out of central mounting clip and
release button (A) .
411-8 Door s
Door trim panel, removing and installing

'X Unhoo k Bowde n cable (A) from inner door opener by unlatching tab
(B).

— Disconnec t side airbag harness connector .

— Disconnec t wiring harness for window switch panel and remove

door trim panel.

If necessary , replace an y broken clip s (A an d B) . Instal l clips in

correct position. Clips A are gray and clips B are white.

Attach central mounting clip to door trim panel. Remainde r of

installation i s reverse of removal. Chec k doo r loc k mechanism an d
window for ease of movement and prope r function.

Tightening torque
Door trim panel to door 8 N m (71 in-lib )
(screw under airbag emblem )
Door trim panel to door 0.8 N m (7 in-lb)
(screw unde r cap)
 412-1

412 Trun k lid, Tailgate

GENERAL 412- 1 AUTOMATIC TAILGATE 412- 8

Tailgate hydrauli c cylinder ,
TRUNK LI D (SEDAN) 412- 1
removing and installing 412- 8
Emergency releas e 412- 1
Tailgate hydrauli c unit, removing and installing 412- 8
Trunk lid, removin g and installing 412- 2
Tailgate hydraulic fluid ,
Trunk lid , aligning 412- 2 checking and correcting level 412- 9
TAILGATE (SPORTS WAGON) 412- 5 Tailgate hydrauli c unit , setting readiness . . . . 412-1 0
Tailgate service position 412- 5 TABLE
Tailgate, removin g and installing 412- 5
a.Trunk li d gap specifications (Sedan ) 412- 4
Tailgate ga s strut, removin g and installing . . . . 412- 5
b.Tailgate gap specifications (Sport s Wagon) 412- 6
Tailgate, aligning 412- 6
REAR SPOILE R (SPORT S WAGON) 412- 7
Rear spoiler, removing and installing 412- 7

GENERAL
This repai r grou p cover s trunk li d and tailgate remova l an d
installation. Replacemen t procedur e for gas-charged suppor t strut s
that hol d tailgat e i n open positio n i s also covered .

CAUTION—
• The body is painted at the factory after assembly. Realignment
of body panels may expose unpainted metal. Paint exposed
metal once work is complete.

TRUNK LI D (SEDAN)
Emergency releas e
In case o f emergency, pul l handl e (arrow ) t o open trunk li d from
inside luggag e compartment .
412-2 Trun k lid , Tailgat e
7 runk lid, removing and installing

Trunk lid , removing an d installin g

Raise and support trun k lid.

Remove trunk li d trim panel. Se e 513 Interior Trim .

Mark hing e an d hinge fastener locations fo r reinstallation.

Unscrew lef t side hing e fasteners (arrows) . Repea t on right an d

remove trunk li d with help o f assistant .

Installation is reverse of removal. I f necessary, align trunk lid to body.

See Trunk lid , aligning i n this repai r group .

Tightening torque
Trunk lid to hing e (M 8 x 19.5 mm, 8. £3 grade ) 18.5Nm(13.5ft-lb)
11 f t

Trunk lid , aligning

Raise and support trunk lid.

Remove trunk li d trim panel. Se e 513 Interio r Trim .

Loosen lef t and right hing e fasteners (arrows ) so that trunk lid can
be moved t o set correct gap. Tighten bolts .

Remove trunk lowe r trim pane l an d lef t side tri m panel. Se e 513
Interior Trim.

B510412005

Disconnect electrica l connector (A).

Release fasteners (B) and remov e taillight .

 Trunk lid, Tailgate 412- 3
Trunk lid, aligning

Using BMW special tool 51 3 290 (inset) or equivalent, pull trunk lid
tension spring (A ) toward rear to release from side panel .

CAUTION—
• Support trunk lid in open position.

Unhook tension spring (A) from trunk li d hinge (B) .

Remove cap (A) from opening.

412-4 Trun k lid , Tailgate
Trunk lid, aligning

Loosen fastener (A) unti l trunk lid hinge (B ) can be moved.

NOTE—
• Rear parcel shelf is shown removed for purpose of clarity.

Sedan: Se t gap measurements as liste d below.

Table a. Trunk li d gap specifications (Sedan)

• Dimensio n A 6. 0 ± 0.5 mm (0.24 ± 0.02 in)
• Dimensio n B 4. 0 ± 0.8 mm (0.16 ± 0.03 in)
• Dimensio n C 1. 0 ± 1.0 mm (0.04 ± 0.04 in)
• Dimensio n D 5. 0 ± 0.8 mm (0.20 ± 0.03 in)
• Dimensio n E 0. 0 ± 1.0 mm (0.00 ± 0.04 in)

CAUTION—
• Before closing trunk lid, be sure that trunk lid and body do not
scrape.

— Adjus t trunk lock striker. See 51 5 Centra l Lockin g and Anti-Theft.

— Unscre w trunk lid detent buffers until left and right sides of lid rest on
buffers with trunk lid closed.

NOTE—
B510412014
• Be sure top surface of trunk lid is even with top surfaces offenders.

^C Installatio n is reverse of removal. Tighten tailligh t fasteners in the

following sequence: (A, B , C, D).

Tightening torques
Taillight to body 2.5 N m (2 2 in-lb)
Trunk hinge to body (M8) 20 Nm (15ft-lb )
Trunk lid to hinge (M8 x 19.5 mm) 18.5Nm (13.5ft-lb)
Trunk striker to body 10Nm (7ft-lb )
 Trunk lid, Tailgate 412- 5
Tailgate sen/ice position

TAILGATE (SPORTS WAGON)

Tailgate service position
Raise and support tailgate.

Remove tailgate ga s strut or hydraulic cylinder. See Tailgate ga s

strut, removing and installin g o r Tailgate hydrauli c cylinder,
removing an d installing in this repai r group.

Replace with BMW special tool 51 0 050 or equivalent .

Tailgate, removing and installing

Open rea r window .

Unclip and remove tailgat e upper rear window fram e trim panel.

Unplug electrical connectors.

Unhook tailgate ga s strut from tailgate. See Tailgate gas strut,

removing an d installing in this repair group .

Remove fasteners (A) and remove tailgate with help from assistant.

CAUTION—
• The tailgate is very heavy. Use assistance to support both sides
prior to removal of hinge bolts.

Installation is reverse of removal. To align, see Tailgate, aligning i n

this repai r group.

Tightening torque

1 B51041201 9
Tailgate to tailgate hinge (M10 ) 38 N m (2 8 ft-lb )

Tailgate gas strut,

removing and installing
Open and support tailgate. Remove retaining clip (arrows) on upper
end of gas strut.

CAUTION—
• The tailgate is very heavy and will close without both
pressurized struts installed. Properly support tailgate prior to
removal of a strut.

Pull gas strut off tailgate .

Remove retainin g cli p from lower end of gas strut.

Remove gas strut.

.v
\0
Installation i s reverse of removal. Replace retaining clips if damaged
during removal .
412-6 Trun k lid, Tailgate
Tailgate, aligning

Tailgate, aligning
^V Usin g plastic pryin g tool, remove upper rea r window frame trim (A)
by releasing from tri m clips (B) .

^V Loose n tailgate-to-hinge fasteners (A) so tailgate ca n move relative

to hinge .

— Loose n hinge-to-bod y fasteners (B ) so hing e ca n mov e relative to

side panel .

B510412042]

Set gap measurements a s listed belo w for Sports Wagon.

Table b. Tailgate gap specifications (Sports Wagon)

• Dimensio n A 4. 0 ± 0.8 mm (0.16 ± 0.03 in)
• Dimensio n B 1. 0 ± 0.5 mm (0.04 ± 0.02 in)
• Dimensio n C 6. 0 ± 1.0 mm (0.24 ± 0.04 in)
• Dimensio n D 1. 0 ± 1.0 mm (0.04 ± 0.04 in)
• Dimensio n E 5. 0 ± 0.8 mm (0.20 ± 0.03 in)

Tightening torques
Tailgate hinge to body (M8 ) 20Nm(15ft-lb)
Tailgate to tailgate hinge (M10 nut ) 38 Nm (28 ft-lb)

CAUTION—
• Before closing truck lid, be sure that trunk lid and body do not
scrape.

— Adjus t tailgate striker assembly. Se e 515 Centra l Lockin g and

Anti-Theft.
 Trunk lid, Tailgate 412- 7
Rear spoiler, removing and installing

^ I f necessary, loosen fasteners (A) so that uppe r section of tailgate

lock (B ) can b e adjusted.

— Chec k loc k adjustment. Repeat if necessary.

8510412036

REAR SPOILE R (SPORT S WAGON)

Rear spoiler, removing an d installing
Removing
Open and raise tailgate.

Pry out plugs (A) an d remove screws underneath (B) .

B510412037]

Raise rear spoiler slightly.

Disconnect electrica l connector (A) and hose (B).

Pull up and remov e antenna amplifier cover (C).

Disconnect electrica l connector (D).

Remove rear spoiler from tailgate an d set down on clean surface.

Installation i s reverse of removal .

Tightening torque
Rear spoiler to tailgate 8 N m (71 in-lb)
412-8 Trun k lid , Tailgat e
Tailgate hydraulic cylinder, removing and installing

AUTOMATIC TAILGATE
Tailgate hydrauli c cylinder ,
removing and installing
Removal of tailgate hydraulic cylinde r an d hydrauli c line s require s
disconnecting hydraulic line s a t hydrauli c unit , and removin g
headliner and lef t rear speaker. Afte r replacemen t o f hydraulic
cylinder, check fluid level in hydraulic uni t (se e Tailgate hydrauli c
fluid, checking an d correcting leve l i n this repai r group) an d set
readiness (se e Tailgate hydrauli c unit , settin g readines s i n this
repair group).

1. Hydrauli c cylinde r
2. Hydrauli c line s
3. Hydrauli c unit

Tailgate hydraulic unit , removing an d installing

— Rais e tailgate an d pu t int o service position . SeeTailgat e servic e
position i n this repair group .

— Remov e rea r left side tri m panel and soun d insulation.

NOTE—
• Have a cloth ready to catch any spilled hydraulic fluid.

^. Release fasteners (arrows) securing hydrauli c unit bracket to side

panel.
 Trunk lid, Tailgate 412- 9
Tailgate hydraulic fluid, checking and correcting level

Unclip hydraulic line s (A) from bracket (B ) and remove hydrauli c

unit.

Disconnect hose coupling (B) from hydraulic uni t by sliding retainer

wire (A) to right, pressing downward , and pulling hose coupling u p
off hydrauli c unit. B e sure to catch any escaping hydraulic fluid.
Dispose of safely.

Installation is reverse of removal. Chec k and correct fluid level if

necessary. See Tailgate hydraulic fluid, checking and correcting
level in this repair group .

Set readiness . Se e Tailgate hydrauli c unit, setting readiness in

this repai r group.

B510412024,

Tailgate hydrauli c fluid,

checking an d correcting level
— Ope n and close tailgate via automatic functio n t o bleed hydrauli c
system.

— Ope n tailgate agai n vi a automati c function.

— Remov e tailgate hydraulic unit . Se e Tailgate hydraulic unit ,

removing an d installing i n this repai r group.

Checking fluid level

^ Set hydraulic uni t dow n on a horizontal surfac e at angle of
installation i n vehicle. Fluid leve l (A) mus t match marking B .
412-10 Trun k lid, Tailgate
Tailgate hydraulic unit, setting readiness

Correcting fluid level

Remove fasteners (A) and separate hydrauli c uni t from bracket (B).

8510412027

Set tailgate hydraulic unit down on level surface with fluid tank (A)
facing up.

Open oi l filler plug (B ) and add hydrauli c fluid as necessary.

Installation i s reverse of removal .

Tightening torques
Oil filler plug to fluid tank 1 N m ( 9 in-lb)
Tailgate hydraulic uni t to bracket 2Nm(18in-lb)

B510412028

Tailgate hydrauli c unit , setting readines s

When a new hydraulic cylinder is installed, make sure system
detects "rear li d open" deactivation point .

— Disconnec t and reconnec t battery.

— Pres s button on tailgate. Tailgate hydraulic unit runs for 1 3 seconds

in "open" direction. Readiness is set.
 510-1

510 Exterio r Trim , Bumper s

GENERAL 510- 1 Rear bumpe r assembl y 510- 5

Rear bumper cover, removin g and installing . . . 510- 5
OUTSIDE REA R VIE W MIRRO R 510- 2 Rear bumpe r impac t absorber , replacing 510- 7
Outside mirror glass , removing and installing . . 510- 2
Outside mirro r housing, removin g and installing 510- 2 EXTERIOR TRIM 510- 8
BMW emblem, removin g and installing 510- 8
BUMPERS 510- 3 Radiator grill , removin g and installing 510- 8
Front bumpe r assembl y 510- 3
Front bumpe r cover , removing and installin g . . 510- 3

GENERAL
This repai r group include s repai r informatio n for the outsid e rea r
view mirrors , front and rea r bumper an d the easily removabl e
exterior trim parts.

The photo s i n this group illustrate a 2004 545i. Other model s ma y

vary.

See also:
• 411 Door s for door panel s
• 513 Interior Trim

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given i n 001 Warnings and Cautions .
• T o prevent marring th e trim, work with a plastic prying tool or
wrap a screwdriver tip with masking tape before prying out trim
panels, switches or electrical accessories.
510-2 Exterio r Trim, Bumpers
Outside mirror glass, removing and installing

OUTSIDE REA R VIE W MIRRO R

Outside mirror glass, removing and installing
To avoid breaking, move mirror glass carefully and slowly. For added
protection, cover glass completely with masking tape or wear hand
protection when removing.

CAUTION—
• Make sure mirror glass is at or above room temperature before
removing. Otherwise, small plastic parts or glass may break.

— Til t mirror housing out.

— Wit h mirror glass squarely positioned in housing frame, push bottom

of glass fully into housing .

^ Inser t plastic wedg e unde r corne r of glass and gently pry glass up
until glass disengage s fro m retaining clips.

— Lif t glass out and stor e mirror glass safely.

— Whe n installing:
• Positio n mirror glass i n housing while aligning plasti c retainers.
• Carefully lever top center o f glass dow n to engage retainin g clips.
• Chec k that mirror moves freely in all directions.

Outside mirror housing,

removing and installing
— Remov e interior door trim panel. Se e 41 1 Doors.

— Remov e door window frame cover.

'H, Disconnec t electrical connectors (A) . Vehicle equipped with door

module shown, others are similar .

Support mirro r from outside an d remov e fasteners (arrows).

Installation is reverse of removal .

NOTE—
• Check mirror function before reinstalling door panel trim.

Tightening torque s
Outside mirro r to door
• Previousl y installed mirror 6 N m (4.5 ft-lb)
• New mirro r 8 N m ( 6 ft-lb)
 Exterior Trim, Bumper s 510- 3
Front bumper assembly

BUMPERS
Front bumper assembl y
1. Fron t bumper cover
2. Fron t bumper support

/^~~\ 3. Bracke t
4. Towin g eye cover
... . -t r
»* \
i
V| 5. Licens e plate holder

^\
1 ) :,
6. Radiato r gril l

w
vv
— r^ _._..,,.:•_. - - •--•-'• ":—p! ' 7. Lowe r grill
8. Ai r duct trim
9. Fogligh t

1 .. .. =
•. f
v^M/t ~-. i._
/ /
/^^"i,

[-)V)©
r^ m -.. . JjSJyS: • V^

®© ( V —<• ^ '
©
B510510006

Front bumpe r cover , removing and installing

/X" \
N." 1 ' * fi
^. Release lowe r grill catches (B ) and remove grill (A).

L 0 x.

Release air duct grill catches i n direction of arrow an d remov e

grill (A).
510-4 Exterio r Trim, Bumper s
Front bumper cover, removing and installing

Working in left front wheel well, remove wheel housing trim fasteners
(A). Repea t procedure for right side of vehicle.

Remove bumper fasteners (arrows).

Lift of f trim strip with seal

Remove bumper cover fasteners (A).

B510510022
 Exterior Trim, Bumper s 510- 5
Rear bumper assembly

Detach bumper cover at sides in direction of arrows.

Slide bumpe r cover forward just enough to detach connections fo r

headlight washers, foglight s an d parktronic sensor s (i f equipped).

Remove bumpe r cover forward with help from an assistant.

Installation is reverse of removal.

Tightening torques
Bumper cove r to front en d 5 N m (3.6 ft-lb )

Rear bumpe r assembl y

1. Impac t absorber
2. Bumpe r support
3. Sid e holder
4. Rea r reflector
5. Botto m guid e
6. Bumpe r cove r
7. To p guide

Rear bumper cover , removin g and installing

Working in trunk, remove lef t and right side trim panel (A). Lef t side
shown, right side is similar.
510-6 Exterio r Trim, Bumper s
Hear bumper cover, removing and installing

Working at left taillight assembly :

• Disconnec t electrica l connecto r (A) .
• Remov e taillight fasteners (arrows) .
• Remov e taillight assembl y fro m bod y panel .
• Remov e bumper cove r fasteners (B )
• Repea t procedure for right side of vehicle.

Working in left rear wheel well :

• Remov e fasteners (A).
• Pul l rear bumper cove r out of mounting bracke t i n direction or
arrows.
• Repea t procedure fo r right side o f vehicle.

Working unde r rea r bumper, Remov e expansio n rivets (inset).

Release bumpe r trim fasteners (arrows).
 Exterior Trim, Bumper s 510- 7
Rear bumper impact absorber, replacing

Using a screwdriver, pry out bumper retainin g tabs (arrows).

^C Pul l left and right side upper edge s out in direction of arrows. Then
remove bumpe r cover b y pulling back and up.

— Disconnec t electrica l connectors for parktronic sensors, if equipped .

— Remov e bumper cover with help from an assistant. B e careful not to

damage bumper catches.

— Installatio n i s revers e of removal .

Rear bumpe r impact absorber, replacin g

Remove rear bumper cover . See Rear bumper cover , removin g
and installing in this repair group.

Remove fasteners (arrows) and remove impact absorbe r (A).

Installation i s reverse of removal. Remembe r to replac e defectiv e

panel nuts .

Tightening torques
Impact absorber to bod y
•M10 36 Nm (26.5ft-lb)
510-8 Exterio r Trim, Bumper s
BMW emblem, removing and installing

EXTERIOR TRIM
Exterior trim is attached to the bod y wit h plastic clips and fasteners
that ma y be damaged durin g removal . B e sure to have necessar y
fasteners o n hand when reinstalling exterior tri m pieces.

BMW emblem, removin g an d installing

The procedure given belo w applies to both front and rear emblems.

Wrap end of a screwdriver with tape .

CAUTION—
• Protect hood paint by covering area around emblem with tape.

Pry up emblem carefull y on either side (arrows) .

Installation i s reverse of removal .

• Replac e plastic insert s i n body i f damaged .
• I f emblem fits loosely, use a small amoun t o f body molding tape or
adhesive on rear of emblem before installing.

Radiator grill , removing and installing

— Remov e front bumper cover . Se e Fron t bumpe r cover , removing
and installing in this repai r group .

'X. Releas e catches (inset ) and remove radiato r grill in direction of

arrow.

— Onc e grill is removed, pry remaining tabs to separate inner grill from
chrome trim ring.

— Befor e installation, assembl e chrom e tri m ring and grill insert

securely. Replac e components i f tabs o r catches are broken or
missing.

— Instal l grill and trim ring in appropriate locatio n in hood. Press on trim
ring until grill snaps int o place .

— Assembl e front bumper cover.

 512-1

512 Doo r Windows

GENERAL 512-1 Panic mod e 512- 6

Power windo w features 512-1 Warnings and Cautions 512- 6
Power window control modules WINDOW SERVICE 512- 7
to 09 / 2005 512-2
Front door window, removing and installin g . . . 512- 7
Power window control modules
Front door window, adjusting 512- 9
from 09 / 2005 512-3
Window switche s 512-4 WINDOW REGULATO R SERVICE 512-1 2
Power windo w motor s 512-5 Front window regulator ,
Convenience opening / closing 512-5 removing and installing 512-1 2
Window anti-trap protection . . . 512-5 INITIALIZING WINDOWS 512-1 3

GENERAL
This repai r group covers door glass and window regulator repair
information. Th e windshield, rear window and fixed rear door glass
are bonded using special adhesives and tools. For bonded glas s
replacement, see an authorized BMW service facility or an
automotive glas s installer.

See also:
• 411 Door s for door trim panel
• 515 Central Locking and Anti-theft
• 612 Switches for electric window switch replacement
• 721 Airbag System (SRS ) for side-impact airba g informatio n

Power window features

• To 09 / 2005: Front doo r windo w moto r activated by door module .
• From 09 / 2005: Fron t doo r window motor s activated by body
gateway module (KGM).
• Rea r door window motors activated by body base module (KBM).
• Convenienc e operations controlled by car access system (CAS).
• One-touch operation in both directions on all four windows.
• Cable-typ e window regulato r used for all door windows.
• Anti-trap protectio n monitors windo w moto r torque.
• Convenience openin g / closing from driver's lock cylinder and from
remote key.
• Window operation customized by owner with Car Memory function.
See 515 Central Locking an d Anti-theft.
• After ignitio n i s switched OFF, electric windows can be operated
until a door i s opened, or until 1 6 minutes ha s elapsed.
512-2 Doo r Windows
Power window control modules to 09/2005

Power windo w control module s t o 09 / 200 5

1. Lef t front door module (TMFA)
a * 2. Safet y gateway module (SGM)
3. Righ t front door module (TMBF )
4. Righ t front window switch
5. Lef t front window maste r switch
TMFA SGM TMB F
6. Lef t front door latc h
7. Righ t front door latc h
8. Lef t front window moto r
9. Righ t front window motor
10. Car access system (CAS)
11. Basic bod y module (KBM )
12. Left rear window switc h
K-CAN 13. Right rear window switch
14. Left rear door latc h
15. Right rear door latch
10 16. Left rear window motor
11
17. Right rear window motor
12
13

KBM
14
15

c 17

B510512001

Car access system (CAS) is the master control module for lowering
and raising the windows .

Door module s (TMFA , TMBF ) contai n separat e modules for door

electronics an d advanced safety electronic s (ASE).

Door modules ar e the interface between:

• Lef t front window master switc h
• Right fron t window switc h
• Power-windo w motor
• Door contacts

Safety gateway modul e (SGM) convert s an d forwards message s

to and from the byteflight and K-CAN.

Basic bod y modul e (KBM ) receive s signal from the rear doo r
window switches vi a CAN bus through SG M and provides powe r
and ground to the rear window motors.
 Door Windows 512- 3
Power window control modules from 09 / 2005

Power windo w contro l module s fro m 09 / 2005

1. Lef t front window master switch
2. Bod y gateway module (KGM )

b
•
3. Righ t front window switch
4. Lef t front door latch
5. Righ t front door latch
KGM
6. Lef t front window motor
7. Righ t front window motor
8. Ca r access system (CAS)
9. Basi c body module (KBM )
10. Left rear window switch
11. Right rear window switch
12. Left rear door latch
K-CAN 13. Right rear door latch
14. Left rear window motor
15. Right rear window motor

10 11

KBM
13

14 15

BS10512020

Car access system (CAS) is the master control module for lowering
and raising the windows.

Body gatewa y modul e (KGM ) receive s signal from the front door
window switches and provides power and ground to the rear window
motors.

Basic body modul e (KBM ) receive s signal from the rea r doo r
window switches via CAN bus through SG M and provides powe r
and ground t o the rea r window motors.
512-4 Doo r Window s
Window switches

Window switche s

Front window switche s

To 09 / 2005: When the power windo w switc h for the window i n the
driver door or front passenger doo r i s operated the driver window
switch cluster sends a signal via the LIN-bus to left front door module
(TMFA). TMFA then actuates the corresponding powe r window
motor.

From 09 / 2005: When the power window switch for the window in
the driver's door or front passenger's door is operated, the driver
window switch cluster sends a signal via the LIN-bus to KGM. KGM
then actuates the corresponding window motor .

To 09 / 2005: When the power window switc h for the window in a

rear door i s operated, the driver window switc h cluste r sends a
signal via LIN-bus to TMFA. TMFA send s the signal via byteflight to
the SGM. SGM converts the signal and sends i t on K-CAN to CAS.
CAS evaluates the signal and sends a command to SGM on K-CAN.
SGM forwards the command signa l vi a the byteflight to right front
door modul e (TMBF) . TMBF receive s the command fo r window
movement, and the window moto r i s then moved.

From 09 / 2005: When the power window switch for the window in a
rear door is operated, the driver window switc h cluster sends a
signal via LIN-bus to KGM . KGM then sends a signal to KBM and
KBM actuates the corresponding window motor.

Rear window switches

When the power window switches i n the rea r doors are operated a
signal i s sent to KBM and KB M then actuates the corresponding
window motor.

Window switch positions:

1. Of f
2. Ope n
3. On e touch open
4. Clos e
5. On e touch close

The window toggle switch provides th e corresponding control

module wit h a coded ground signal. Holdin g a switch at the first
detent provide s a single ground signal on one wire requesting the
module to open the window. When released , the ground signal is
removed and the window motor stops .

Momentarily pushing the switch to the second deten t and releasing

provides an additional groun d signal o n the second wire requesting
one touch mode. The corresponding modul e lowers the window
automatically until it reaches the en d position .
 Door Windows 512- 5
Rear window child lockout switch

Rear window chil d lockou t switc h

. Th e rea r window chil d lockou t switc h (arrow) i s incorporated i n th e
driver's window switc h block.

To 09 / 2005: Whe n activated , loc k out switch provides a signal via

LIN-bus to TMFA. TMFA send s the signal via byteflight t o the SGM .
SGM converts the signal an d sends it on K-CAN to CAS. CA S
prevents windows from being operated from the rea r door switches.

From 09 / 2005: When activated, loc k out switch provides a signal

via LIN-bus to the KGM . KG M sends th e signal via K-CAN t o CAS .
CAS prevents windows from being operated from the rea r door
switches.

The lockou t switch signal i s overridden if a multiple restraint system

(MRS) cras h signal is received .

Power window motor s

The window motors are mounted o n cable regulators . The windo w
motor control circuit consists of two wires for operating the moto r in
both directions .

To 09/2005: The motors ar e activated by relays in the TMFA, TMBF

and KBM. The relays provid e either power or ground dependin g o n
the direction of window travel . TMFA , TMBF and KBM controls th e
polarity based on a request to run the window from a window switch
or a convenience opening / closing signal.

From 09 / 2005: The motor s are activated by relays in the KGM . h e

relays provid e either power o r ground depending on the direction of
window travel. KGM controls the polarity based on a request to run
the window from a window switch or a convenience opening / closing
signal.

Convenience openin g / closin g

The CAS module provide s the convenience open / close feature,
providing control o f the power window s (an d sunroof ) fro m outsid e
the vehicle using the key in the driver's door lock, or with the remot e
key.

Anti-trap protection is active during convenience closing from the

driver's door lock .

If the CAS module receives a request t o operate convenience

closing or opening for more than 110 seconds, the function is
deactivated and a fault code i s stored.

Window anti-trap protectio n

Anti-trapping function does no t prevent an object being trapped bu t
rather limits the trapping force to maximum 80 Nm. The powe r
window moto r is reversed when this force is exceeded.

Anti-trapping function is based on the evaluation of power windo w

motor Hall sensor pulses. During initialization, the speed of Hal l
sensor pulse s i s learned. Spee d fluctuations within a certain rang e
triggers the anti-trapping function .
512-6 Doo r Window s
Panic mode

If window i s not initialized o r a faulty hall sensor is detected the

window will only mov e in small increments .

Panic mod e
Panic mod e can be used to close a window i n the event of an
emergency. It is triggered by overpulling - releasing - overpulling
(overpulling means pulling the switch beyond its limit stop) the power
window switch. I t is necessary to releas e and overpul l the switch
again i n order to deactivate the anti-trappin g protection function,
which is still active the first time the switch is overpulled.

Overpulling th e power window switc h the second time withi n 4

seconds closes the window with maximum force .

Anti-trapping function is not active durin g pani c mode. The window

closes at the maximum closing force and does not reverse.

Warnings and Caution s

WARNING—
• 5 Series models are fitted with side-impact airbags in the front
door trim panel. When servicing the door windows on cars with
side-impact airbags, disconnect the negative (-) battery cable.
See 721 Airbag System (SRS ) fo r cautions an d procedures
relating to the airbag system.
• Wear hand and eye protection when working with broken glass.
• If a window is broken, vacuum all of the glass bits out of the door
cavity. Use a blunt screwdriver to clean out any remaining glass
pieces from the window guide rails.
• When servicing the door windows, the harness connector to the
window regulator should always be disconnected to prevent
pinching fingers in the moving window mechanism.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given i n 001 Warnings and Cautions.
 Door Windows 512- 7
Front door window, removing and installing

WINDOW SERVIC E
Front door window, removing and installing
— Remov e door panel . Se e 41 1 Doors.

— Usin g BM W sca n tool, prin t o r note Car and Ke y Memory settings .

^ Lowe r window to 205 mm (8 in.).

To 09 / 2005: Detac h doo r modul e electrica l connectors (arrows),

remove fasteners (A) and remov e door module fro m door.

CAUTION—
• Do not remove center door module fasteners (B). Doing so will
damage door module.

Detach wire mount bracket s (arrows). Disconnec t doo r latc h

electrical connector (A ) and lay wire harness aside.
512-8 Doo r Windows
Front door window, removing and installing

Using a sharp plastic scraper, leve r sealing bead (A ) off vapor

barrier (B).

CAUTION—
• Use care when peeling back vapor barrier. Replace a damaged
vapor barrier to prevent possible water leaks and insure proper
operation of side impact airbags.

Loosen window glass mount fasteners (inset) .

Tilt and lif t glass ou t of door i n direction o f arrow.

Installation i s reverse of removal, notin g the following:

• Adjust door window i f necessary. Se e Fron t door window,
adjusting, i n this repai r group .
• Initializ e power window. See Initializing window s in this repair
group.

Tightening torques
Door window glass moun t 8 N m (5.9 ft-lb)
 Door Windows 512- 9
Front door window, adjusting

Front doo r window , adjustin g

Using BM W scan tool , prin t or note Car and Ke y Memory settings .

Fully close door window to be adjusted.

Remove front door panel. Se e 411 Doors .

To 09/2005: Detach doo r modul e electrica l connectors (arrows) ,

remove fasteners (A) and remov e door module fro m door.

CAUTIOM—
• Do not remove center door module fasteners (B). Doing s o will
damage door module.

Detach wir e mount bracket s (arrows). Disconnect door latc h

electrical connector (A ) and la y wire harness aside .

Using a sharp plasti c scraper, lever sealing bead (A ) of f vapo r

barrier (B) .

CAUTION—
• Use care when peeling back vapor barrier. Replace damaged
vapor barrier to prevent possible water leaks and insure proper
operation of side impact airbags.
512-10 Doo r Windows
Front door window, adjusting

Loosen window regulato r fasteners (arrows) . Do not remove

window motor mount (A) . Disconnect powe r window motor electrical
connector.

CAUTION—
• Do not loosen fasteners at top of window regulator.

Connect fuse d jumper lead s to power window moto r terminals

(arrows). Open window approximately 10 0 mm (4 in) by connecting
jumper lead s to an external 12 volts powe r source .

CAUTION—
• Do not activate power window motor in excess of 0.5 seconds
once limit position is reached.

NOTE—
• Reversing polarity of jumper leads reverses direction of power
window motor.

Loosen window glas s fasteners (A).

Close window and tighten windo w glas s fasteners (inset).

Tightening torques
Door window glas s moun t 8 N m (5. 9 ft-lb)
 Door Windows 512-1 1
Front door window, adjusting

Open window approximately 4 0 mm (1.5 in. then tighten windo w

regulator fasteners (A).

Tightening torque s
Regulator to doo r 8 N m (5.9 ft-lb)

^V, Clos e doo r window until fastener (A) i s accessible and tighte n
fastener (A).

— Clos e door window completel y an d check adjustment .

— Onc e adjustmen t i s complete :

• Usin g BMW scan tool, check Car and Key Memory settings against
previously mad e notes .
• Initializ e powe r window . Se e Initializing window s i n this repai r
group.

Tightening torque s
Door window glas s moun t 8 Nm (5.9 ft-lb)
Window moto r moun t 8 Nm (5.9 ft-lb)
Regulator to door 8 N m (5.9 ft-lb)
512-12 Doo r Window s
Front window regulator, removing and installing

WINDOW REGULATO R SERVIC E

The electronically-controlled window moto r doe s no t have
mechanical end positions. For this reason the motor can be removed
and installed wit h the window i n any position .

Front windo w regulator ,

removing an d installin g
Remove window regulato r and moto r as one unit . I f necessary,
separate the two on the bench.

There are two window rail s in each front window regulator , only one
in the rear window regulator. Otherwise th e front and rear regulators
are similar.

— Remov e front door panel . Se e 41 1 Doors.

— Remov e window glass . Se e Fron t doo r window , removin g and

installing i n this repai r group .

^ Loose n window moto r mount fastener (A) and remove mount (B)
from window motor .

Disconnect window motor electrica l connector (A) and cut wire tie
(B). Loosen windo w regulato r fasteners (arrows) and remove
window regulato r fastener s (C).
 Door Window s 512-1 3
Front window regulator, removing and Installing

Lift rea r window regulato r rea r rail (A) ou t of door the n front rai l (B )

Installation i s reverse of removal , noting the following:

• Rout e wiring harnesses t o keep them away from moving windo w
mechanism. Us e new wire ties as necessary.
• Initializ e powe r window. See Initializing window s i n this repai r
group.

Tightening torques
Door windo w glas s moun t 8 M m (5.9ft-lb )
Window moto r mount to redulato r 8 N m (5. 9 ft-lb )
Window regulato r to door 8 N m (5. 9 ft-lb)
Window moto r to regulato r 4 N m (4. 4 ft-lb )

INITIALIZING WINDOWS
Window contro l module learn s two parameters during initialization :
• Uppe r end stop (normalization of the power windows) .
• Powe r characteristic curv e for opening and closing (learnin g th e
characteristic curve) .

Initialization can be carried out using the control switch in each doo r
or the power-windo w switc h bloc k in the driver's door.

Initialization prerequisite s
• Vehicle stationary.
• Adequate batter y voltag e presen t (12. 4 volts), connec t vehicl e
power suppl y i f necessary .
•Terminal R (radio readiness ) o r terminal 1 5 switched O N (ignitio n
ON) See 020 Maintenanc e fo r vehicle key states.
• All doors closed .

Performing initializatio n
— Full y close windo w b y pulling the switc h so that to p en d sto p i s
reached (normalization) .

— Ope n window completely so that lower en d stop is reached.

— Pul l control switch into one touch operation mode, then pull to clos e
(one touch operation , close ) positio n an d hold it there unti l the
window ha s reached th e top end stop (learning the characteristic
curve).

Initialization i s successful if the windo w can be opened an d close d

without faults in one touch operatio n mode.

Window move s i n small increment s if not initialized.

 513-1

513 Interio r Trim

GENERAL 513- 1 GLOVE COMPARTMEN T 513-1 0

Trim clips 513- 2 Glove compartment, removin g and installin g . 513-1 0
Warnings an d Cautions 513- 2
COVERS AN D TRIM PANELS 513-1 2
DASHBOARD 513- 3 Steering colum n fron t trim,
Right dashboard tri m strip, removing an d installing 513-1 2
removing and installing 513- 3 Steering colum n uppe r trim,
Left dashboard trim strip, removing an d installing 513-1 3
removing an d installing 513- 3 Steering colum n lowe r trim,
Center dashboard tri m panel , removing an d installing 513-1 4
removing and installing 513- 4 Door sill trim, removin g 513-1 5
Right lower dashboard trim , A-pillar trim, removin g and installing 513-1 5
removing an d installing 513- 4 B-pillar trim, removin g and installing 513-1 6
Left lowe r dashboard trim , C-pillar trim, removing and installing 513-1 8
removing an d installing 513- 5 Trunk li d trim panel, removin g and installing . 513-1 8
CENTER CONSOL E 513- 6 Trunk lower trim panel,
Center console , removin g and installing 513- 6 removing and installing 513-1 9
Trunk side trim panel, removin g and installing 513-1 9
Tailgate trim panel, removin g and installin g . . 513-2 0

GENERAL
This repair group cover s interio r trim removal and installation.

See also:
• 411 Door s for interior door trim panel remova l
• 520 Seats for rear side bolste r removal
•612 Switches
• 620 Instruments
• 640 Heating and Air-conditioning
• 650 Radio
• 721 Airbag Syste m (SRS) fo r passenger airba g
513-2 Interio r Trim
Trim clips

Trim clips
Interior trim and finish panels are clipped or screwed into place.
When removing trim that is held in place with clips, be sure to have
spare clips (also known as plastic rivets ) on hand before beginning
the job.

Many trim clips ma y be reused if removed correctly:

• Carefully pr y out center lockin g pin .
• Lever out clip using removal tool.

Other trim retaining clips ar e designed to be used only once:

• Us e thin pin punch to drive in headless pi n (inset) i n center of clip.
• Leve r out clip using removal tool.

=65105130011

Warnings and Caution s

WARNING —
• Serious injury may result if airbag system service is attempted
by persons unfamiliar with the BMW SRS and its approved
service procedures.
• Before performing any work involving airbags, disconnect the
negative (- ) battery cable. See 721 Airbag Syste m (SRS) .
• BMW airbags are equipped with a back-up power supply inside
the airbag control module. Observe a 5 second waiting period
after disconnecting the battery cable to allow the reserve power
supply to discharge.

CAUTION—
• When working on electrical switches o r lights, disconnect the
negative (-) battery cable and insulate the cable end to prevent
accidental reconnect/on.
• Prior to disconnecting the battery, read the battery
disconnection cautions given in 001 Warnings an d Cautions.
• To prevent marring the trim, work with a plastic prying tool or
wrap a screwdriver tip with masking tape before prying out trim
panels, switches or electrical accessories.
 Interior Trim 513- 3
Right dashboard trim strip, removing and installing

DASHBOARD
Right dashboard tri m strip,
removing and installing
^C Usin g a plastic pryin g tool, releas e hazard warning switch retainin g
tabs (A ) and pull switch out of dashboard. Disconnec t electrica l
connector (B ) and remov e switch.

— Remov e trim strip fastener (arrow ) if equipped.

Starting at outside of trim strip, pry in areas (A) using a plastic pryin g
tool and remov e in direction o f arrow.

CAUTION—
• Do not twist prying tool during removal of trim panel.

Installation is reverse of removal. Replace missing or damaged tri m

panel clips.

Left dashboard trim strip,

removing and installing
— Remov e headlight switch . See 61 2 Switches.

^{ Remov e trim strip fasteners (A). Using plastic prying tool, unclip trim
strip in area B and remov e in direction of arrow.

— Installatio n i s reverse of removal. Replace missing o r damaged tri m

panel clips.
513-4 Interio r Trim
Center dashboard trim panel, removing and installing

Center dashboard trim panel,

removing and installing
Remove right dashboard trim strip. See Right dashboard trim
strip, removing and installin g i n this repair group.

Remove trim panel fasteners (arrows).

Insert 180 mm (7 in) flat blade screwdriver (inset) behind trim panel
and release clips in area A.

— Usin g a plastic prying tool, release clips in area B and pull back trim
panel.

— Disconnec t electrical connectors an d remov e trim panel.

— Installatio n is reverse of removal. Replac e missing or damaged trim

panel clips.

Right lowe r dashboard trim,

removing and installin g
— Mov e passenger seat all the wa y back .

^ Usin g plastic pryin g tool (A), slide trim panel (B) towards rear of
vehicle (arrow) and unclip.
 Interior Trim 513- 5
Left lower dashboard trim, removing and installing

Remove trim panel fasteners (A) and lower trim panel in direction of
arrow.

Disconnect footwell light electrical connector if equipped .

Remove trim panel .

Installation i s reverse of removal .

Left lowe r dashboard trim,

removing an d installin g
— Mov e driver seat all the way back .

^ Usin g plasti c pryin g tool (A), slide trim panel (B) towards rea r
(arrow) of vehicle and unclip.

B510513003 |

Remove tri m panel fasteners (A) . Usin g plastic prying too l

disconnect clips in area (B) and partially lower trim panel i n direction
of arrow .

Lower trim panel an d disconnect fiber optic programming connecto r

(if equipped ) an d footwell light electrica l connector.

Remove trim panel .

Installation is reverse o f removal.

513-6 Interio r Trim
Center console, removing and installing

CENTER CONSOL E
Center console, removing and installing
Remove iDrive control knob. See 612 Switches.

Manual transmission: Pul l gearshift knob straight u p (arrow) to

remove. It may require up to 90 Ibs. of force to do this. Remove shift
boot by grasping boot material (A ) and pulling up to release tabs. Be
careful not to break retainin g tabs.

Automatic transmission: Pull gearshift knob straight u p (arrow) to

remove. I t may require up to 90 Ibs . of force to do this.

CAUTION—
• Automatic transmissions for 2008 - 2009 models (starting with
03 /2007 production) are equipped with gear selector switch
(GWS) instead of a shift lever. The procedure given here for
gearshift knob removal does not apply.
• Some versions of shift boot and knob are one piece. Release
boot from console before removing knob.
• To prevent damage to shift knob locating tabs, do not twist while
removing.

Automatic transmission: Using a plastic pryin g tool, lever and lift out
shift boot. Be careful not to break retainin g tabs (A).
 Interior Trim 513- 7
Center console, removing and installing

Automatic transmission: Gras p and pull out trim piece (A) .

Disconnect electrical connectors and remove in direction o f arrow.

Using a plastic pryin g tool uncli p and remove rea r center consol e
insert (A) i n direction of arrows. Disconnect electrical connectors, if
equipped.

Using a flat blade screwdriver, detach clip s (A) . Unclip and remov e
vent (B ) i n direction of arrow. I f equipped, disconnec t electrica l
connectors.
513-8 Interio r Trim
Center console, removing and installing

Using plastic prying tool, slide trim panel (A) towards rear (arrow) of
vehicle and unclip . Lef t side shown; righ t side is similar.

Working at rear of center console, remov e fasteners (arrows).

Working at front of center console :

• Remov e fasteners (arrows).
• Remov e ashtray insert.
• Usin g a plastic prying tool, lever trim (B ) in areas A up enough to
disconnect iDrive menu button electrica l connector.
• Remov e trim (B).
 Interior Trim 513- 9
Center console, removing and installing

Working at side of center console, remove fastener (arrow) . Repeat

procedure fo r right side.

B510513058

Working a t front of center console, remov e fasteners (arrows) if

equipped.

Pull parking brake handle boo t (arrow ) over handle.

''f

B51051301
513-10 Interio r Trim
Glove compartment, removing and installing

Raise center console (A ) a t rear in direction of arrow while feeding

parking brak e leve r boot (B) through opening. Disconnect electrica l
connectors and remove center console (A) .

Installation i s reverse of removal . Remembe r to :

• Connect electrical connectors .
• Connect air ducts.
• Replac e any damaged pane l clips .

GLOVE COMPARTMEN T
Glove compartment , removin g an d installin g
— Remov e door sill trim. See Doo r sil l trim, removin g i n this repair
group.

'X. Uncli p righ t side kic k panel tri m (A ) from retaining points (B) in
direction of arrow and remove.

— Remov e right lower dashboard trim . See Righ t lower dashboar d

trim, removing and installin g i n this repai r group .

— Ope n glove compartment.

Working on righ t side of glove compartment, remov e pin (A) for

retaining strap (B ) and disconnect .
 Interior Trim 513-1 1
Glove compartment, removing and installing

Working on left side of glove compartment, remove pin (A) for shock
absorber (B ) an d disconnect . '

Working below glove compartment, remove fastener s (inset).

Remove fasteners (arrows ) and pull glove compartment ou t slightly.

513-12 Interio r Trim
Steering column front trim, removing and installing

Disconnect electrical connectors (A) , remov e harness from clips

(arrows). Remov e glove compartment .

Installation is reverse of removal. Remembe r to :

• Connect electrica l connectors.
• Replac e any damaged pane l clips .

COVERS AND TRIM PANELS

Steering colum n front trim, removin g an d
installing
Adjust steering column to fully extende d an d raised position .

Remove steering wheel. See 320 Steering an d Wheel Alignment.

Remove front trim by pulling towar d rea r o f vehicle (arrows).

Installation is reverse of removal. Chec k that panel clips (arrows)

engage properly.
 Interior Trim 513-1 3
Steering column upper trim, removing and installing

Steering column upper trim,

removing and installing
— Remov e steering column lowe r trim. See Steering column lowe r
trim, removing and installin g i n this repair group.

— Adjus t steering column t o fully extended and lowered position .

^ Usin g a plastic pryin g tool, uncli p steering column cover trim (A)
from upper cover (B).

Remove upper trim fasteners (inset).

. Remov e by bending side s of upper trim out (curve d arrow) an d

lifting u p (arrow).

— Installatio n is revers e of removal.

513-14 Interio r Trim
Steering column lower trim, removing and installing

Steering colum n lowe r trim ,

removing an d installing
— Remov e steerin g colum n fron t trim. See Steering column lower
trim, removin g an d installing i n this repai r group .

X Remov e trim fastener (arrow) . Unclip an d lower trim in direction of

curved arrow .

X, Tilt steering colum n tri m (A) down an d unclip (arrows) from cover
(B).

— Remov e lower trim.

Installation i s reverse of removal . Chec k tha t panel clips (arrows)

engage properly .

B510513032
 Interior Trim 513-1 5
Door sill trim, removing

Door sil l trim, removin g

Using a plastic pryin g tool (A ) unclip door sill trim clips (arrows)
starting at rear.

^V, Remov e panel clip s (arrows ) left i n floor panel (B ) afte r trim panel
removal if necessary .

— Installatio n is reverse of removal. Replace any damaged pane l clips.

A-pillar trim, removin g and installin g

Using plasti c trim tool remov e cover (arrow) then remov e fastener
beneath it .

10513035 !
513-16 Interio r Trim
B-pillar trim, removing and installing

^V Releas e doo r seal from A-pillar trim.

— Uncli p trim from A-pillar in area A and remov e out of dashboard in

direction of arrow.

— Installatio n i s reverse of removal. Replac e any damaged panel clips

B-pillar trim, removin g and installing

— Remov e driver door sill trim. See Doo r sil l trim, removin g an d
installing i n this repai r group .

Lower B-pillar trim

^ Sna p trim out of trim clips in area A and slide trim panel out of rear
door sill trim (B ) and door seal .

— Carefull y guide trim panel out o f uppe r trim panel (C) .

Upper B-pillar trim

Remove lower B-pillar trim

Using a plastic pryin g tool, releas e retainin g tabs (arrows) for for
seat trim (A). Lift seat trim u p to releas e tab B and remove.
 Interior Tri m 513-1 7
B-pillar trim, removing and installing

Remove sea t bel t fastener (arrow ) and discard. Disconnec t sea t

belt an d lay aside.

Disconnect uppe r B-pilla r tri m panel trim clips (arrows).

Remove trim panel i n direction of arrow.

Installation i s reverse of removal. Remembe r to :

• Replac e any damaged pane l clips.
• Replac e fastener for seat belt.

Tightening torque
Seatbelt to front sea t (Replace fastener) 36 N m (2 6 5 ft-lb)
... . . .
513-18 Interio r Trim
C-pillar trim, removing and installing

C-pillartrim, removing and installing

Remove cap (A) and fastener underneath .

Disconnect clip s in area C and remov e trim panel (B) in direction of

arrow.

Installation is reverse of removal. Replace any damaged pane l clips.

Tightening torque
Panel to C-pillar 3.5 M m (2.5 ft-lb )

Trunk lid trim panel, removin g and installin g

Remove emergency trun k releas e handle by pushing lever an d
releasing cable (inset).

Remove trim panel clips (inset) and remove trunk lid trim panel.

Installation is reverse o f removal. Remembe r to replace damaged

trim panel clips.
 Interior Trim 513-1 9
Trunk lower trim panel, removing and installing

Trunk lower trim panel, removin g and installin g

Remove trunk floor trim panel in direction of arrow.

B510513044

X Remov e plastic cover and fasteners (A). Lift out and remove trunk
rear trim panel (B).

- Installatio n i s reverse of removal. Remember to replace damaqe d

trim panel clips. '

Trunk side trim panel, removin g and installin g

Remove trunk floor trim panel in direction o f arrow.
513-20 Interio r Trim
Tailgate trim panel, removing and installing

Right side shown, lef t is similar.

Remove pane l fastener (A) by rotating 90 ° with flat blad e

screwdriver and remove panel .

Installation i s reverse of removal. Remembe r to replace damage d

trim panel clips.

Tailgate tri m panel, removin g an d installin g

, Workin g at left side of tailgate: Lever tailgate light (A) out at recesses
(arrows). Disconnect electrical connector and remove light. Repeat
procedure for righ t side ligh t i f equipped .

Models with auto tailgate: Using plastic prying tool, lever out tailgate
switch (A). Disconnect electrical connector and remov e switch.
 Interior Trim 513-2 1
Tailgate trim panel, removing and installing

Rotate retainer in direction of arrows and open panel.

Remove panel (A ) by squeezing retaining tabs (inset) in direction of

arrows and unclipping .

Using a plastic prying tool, remove tailgate center trim pane l (A).
513-22 Interio r Tri m
Tailgate trim panel, removing and installing

Using a plastic pryingl tool, remove tailgate righ t side trim pane! (A)
in direction o f arrows. Repea t procedure for left side.

Remove tailgate trim panel fastener s (arrows).

X. Carefull y remove trim panel i n direction of arrows.

— Installatio n i s reverse of removal . Remembe r t o replace damage d

trim panel clips .
 515-1

515 Centra l Locking and Anti-theft

GENERAL 515- 1 Trunk loc k striker, removin g an d installing . . . 515-1 8

Fuel filler flap emergency opening 515- 2 Trunk lock striker, adjusting 515-1 8
Tailgate loc k 515-2 0
CENTRAL LOCKING 515- 3 Rear window loc k assembl y 515-2 2
Central lockin g features 515- 5
Rear window lock, adjusting 515-2 2
Car memor y / key memory (personalization) . . 515- 8
Comfort access (CA) 515- 9 ELECTRONIC IMMOBILIZE R (EWS) 515-2 3
Comfort access features 515-1 0 ANTI-THEFT SYSTEM (DWA) 515-2 3
DOOR HANDLE S AN D LOCKS 515-1 1 DWA components 515-2 3
Door loc k cylinder, removing and installing . . 515-1 1 DWA operation 515-2 3
Door handle , removin g and installing 515-1 2 DWA LED display 515-2 4
Door handle trim, removin g an d installing . . . 515-1 3 DWA alarm siren 515-2 4
Door latch , removin g and installing 515-1 4 Tilt sensor 515-2 4
Interior protectio n 515-2 5
TRUNK AN D TAILGATE LOCK S 515-1 6 Panic mod e 515-2 5
Trunk lock cylinder 515-1 6 Emergency disarmin g 515-2 5
Trunk loc k assembly 515-1 7

GENERAL
This section covers repair information for door, trunk and tailgate
locks, central locking, electronic immobilization (EWS) an d anti-theft
alarm (DWA).

5 Series vehicles are equipped with sophisticated self-diagnostic

electrical systems. When experiencing malfunctions relating to
central locking or anti-theft systems, using a BMW scan tool can
usually pinpoint electrical faults quickly and safely.

See also:
• 411 Doors for inner door trim removal
• 513 Interior Trim for tailgate trim removal
• 600 Electrical System-General
• ECL Electrical Component Locations
• ELE Electrical Wiring Diagrams
515-2 Centra l Lockin g an d Anti-theft
Fuel filler flap emergency opening

Fuel filler flap emergency openin g

The fuel filler flap can be unlocked manually in the event of an
electrical defect. The emergency release i s located i n the luggage
compartment on the right behind luggage compartmen t trim.

Remove trunk floor trim panel i n direction of arrow.

B510513044

Remove panel fastener (A ) by rotating 90° with flat blade

screwdriver and remove panel.

K ;.,.'; " corn

IP • - : •

Pull green knob (inset) with fuel pump symbol to release fuel fille r
flap.
 Central Locking and Anti-theft 515- 3
Fuel filler flap emergency opening

CENTRAL LOCKIN G
Central lockin g in 5 Series vehicles controls the door locks, trunk lid
lock and fuel filler flap lock.

Central locking is distributed over several control modules. Thi s

offers the advantage tha t sensors and actuators are connecte d
directly to a control module i n the vicinity of their installe d location ,
resulting in shorter cable connections. By interlinking the control
modules, i t is possible to exchange sensor data betwee n them .

There ar e two different central locking systems in 5 Series model s

dependant on production date.

To 09 / 2005: The primary control modules for central locking in the

b Series are:

1. Drive r door module (TMFA)

2. Ca r access system (CAS)
3. Passenge r door module (TMBF)
4. Basi c bod y module (KBM)
5. Safet y gateway module (SGM)

IT/—
45
B510515001

From 09 / 2005: The primary control modules for central lockin g in

the 5 Series are:

1. Ca r access system (CAS)

2. Basi c body module (KBM)
3. Bod y gateway module (KGM)

II
23
515-4 Centra l Locking and Anti-theft
Fuel filler flap emergency opening

Central lockin g can be operated via the following components:

• Remot e control / remote key.
• Drive r door loc k barrel (doo r lock) .
• Center-lock button .
• Electroni c outer door handle modul e (TAGE ) in connection with
comfort access .

Car access system (CAS )

Car access system (CAS ) is the maste r control modul e fo r central
locking, i t issues the enable signal t o activate a lock / unlock
function. When CAS receives a lock / unlock signal from the remote
control receiver , it checks whether th e remot e key is valid and
belongs t o the vehicle. I f the check / authentication i s successful
CAS will forward the request to activate centra l locking via body bus
system (K-CAN) to:
• to 9 / 2005: SGM and KBM.
• from 9 / 2005: KGM and KBM

NOTE—
• For summary o f CAS functions Se e 600 Electrical System-
General.
B510515002

To 9 / 2005: Front door modul e (TMFA, TMBF )

TMFA (A ) is responsible fo r locking an d unlockin g driver front door.
It contains relay s which drive the respectiv e loc k / unlock motors.

TMBF is responsible for locking and unlocking passenger front door .

It contains relay s which drive the respectiv e loc k / unlock motors.

To 9 / 2005: Safety gateway modul e (SGM )

SGM converts and forwards messages t o and from byteflight and
K-CAN.
Central Lockin g an d Anti-theft 515- 5
Central locking features

From 9 / 2005: Bod y gateway module (KGM)

KGM is responsible for locking an d unlocking the front doors. It
contains relay s which drive respective lock / unlock motors.

Basic body module (KBM)

KBM is responsible for locking and unlocking passenger doors an d
trunk or tailgate o f vehicle. I t contains relays which drive the
respective lock / unloc k motors.

Central locking features

Central locking can be activated when driver doo r i s closed.

Vehicle lockin g / unlocking is initiated by the following components :

• Remote control / remote key.
• Centra l locking button on center dashboard.
• Mechanical key / spare key.

Driver identificatio n is incorporated withi n the remote key and is also

used for the optional comfort access (CA ) system. C A module
activates the identification transmitter in the remote ke y by way of a
radio signal . This makes i t possible to unlock the vehicle withou t
actively usin g the remot e key.

The central locking syste m activate s the following system

components:
• Drive r and front passenger doo r locks.
• Rear door locks .
• Fue l filler flap lock .
• Trunk lid or tailgate.
515-6 Centra l Locking and Anti-theft
Central locking features

Unlocking/locking
When the remote key unlock button is pressed, the signal is
received b y the rear window antenna and forwarded to the remote
control receiver . The remote control receive r forward s the signal to
CAS.

The signal from the remote key is verified in CAS. If signal is valid:
• To 9 / 2005 SG M and KBM are authorized t o unlock vehicle.
• From 9 / 2005 KG M and KBM are authorized t o unlock vehicle .

To 9 / 2005: Remote key signal pat h

|1 . Remot e key
2. Rea r window antenna
3. Remot e key receiver

T
IPS
4. Ca r access system (CAS)
5. Safet y gateway module (SGM)
6. Drive r door module (TMFA )
7. Passenge r door module (TMBF)
8. Bod y basic module (KBM)
9. Loc k actuator, trunk or tailgate
10. Lock actuator, passenger door, rear
doors and fuel filler flap
11. Lock actuator, front passenger door
12. Lock actuator, drive r door

8510515014

From 9 / 2005: Remote key signal path

1. Remot e key
2. Rea r window antenna
3. Remot e key receiver

TI») T
I i / I P
4. Ca r access system (CAS)
5. Bod y gateway module (KGM)
6. Loc k actuator, front passenger door
7. Loc k actuator, driver door
8. Bod y basic modul e (KBM)
9. Loc k actuator, trunk / tailgat e
10. Lock actuator, passenger door, rear
KBM
doors and fuel filler flap

fir
10
BS10515013
 Central Lockin g an d Anti-theft 515- 7
Central locking features

Mechanical ke y locking / unlocking

The vehicle can be locked / unlocked using a mechanical ke y in the
driver door lock . Driver door modul e (TMFA ) monitors the loc k
cylinder Hal l sensor signal. When the lock is turned, a change i n the
Hall sensor state initiates locking / unlocking .

, Doo r key positions for electrical / manual locking and unlocking are :
1. Tur n once: Unlock s driver door
Turn twice: Unlocks remainin g doors, trunk, tailgate, fue l filler
Turn and hold (door closed): Opens windows, sunroo f
2. Tur n once: Lock s all doors, tailgate, fuel filler
Turn and hold (door closed): Closes windows, sunroof

Selective unlockin g
When unlockin g with the remot e key, the first unlock reques t onl y
unlocks the driver's door. A second unlock reques t unlock s
remaining doors, tailgate and fuel flap.

Central lockin g butto n

'X, Central locking butto n (arrow ) is in the center of dashboard .
• Central lockin g button lock s doors and tailgate. The fuel filler flap
remains unlocked for refueling purposes.
• I f a door i s opened fro m inside while centrally locked, th e
remaining door s remain locked.

The open door can be relocked, when closed, by manually locking or

pressing the central locking button twice. This synchronizes the door
locks.

Single loc k and double lock function

Each door loc k actuator incorporate s two lock positions .

Single lock controls the mechanical loc k mechanism whe n th e

central lock switch is pressed. The lock mechanism is fully locked at
this point but can still be opened from interior by pulling interio r door
handle twice or by pressing central lock switch again. When singl e
lock function is activated, the fuel filler flap is not locked.

Double lock, also know n as central arrest, is activated only when

vehicle is locked from the outside a t the driver's door lock with a key
or when CAS receive s a lock reques t from the remot e key. In this
case the double loc k moto r i s activated, mechanically offsetting an
internal rod in the lock actuator. This disables the actuator from
unlocking the vehicle from the interior and prevents the doors from
being unlocked b y any means othe r than an unlock reques t a t the
driver's door o r via the remot e key.
515-8 Centra l Locking an d Anti-theft
Car memory / key memory (personalization)

Vehicle accident unlockin g

During a vehicle accident the airbag contro l modul e sends a signal
to CAS to unlock the vehicle. Th e remot e key and central locking
button are disabled unti l ignition statu s (terminal R) is changed from
ON to OFF back t o ON.

Car memory / key memory (personalization)

A numbe r of features and functions can b e customized to the
driver(s) preference. The identity of the vehicle user i s provided by a
signal fro m the remot e key.

Car memory and key memory are two separate functions, although
they are marketed a s a combined feature .

Car memory
Prior to new vehicle delivery, the BM W factory scan tool is used to
code driver preferences int o the appropriate contro l modules .
Thereafter thes e choices cannot be changed without receding using
a BMW factory scan tool or equivalent. Only one car memory setting
setting per vehicle is possible .

The functions tha t can b e set using ca r memor y include :

• Audible confirmation (siren chirp) and visual confirmation (via turn
signal lights) when alar m i s armed. Siren chirp can be deactivated
with BMW factory scan tool o r equivalent .
• Daytim e running lights ON or OFF.
• Pathwa y lighting allows use of the dimmer switc h to turn on the
headlights an d interior lights fo r 40 seconds .
• Automatic locking of central locking syste m once vehicle reaches
10 mph.
• Selective unlocking. Unlock s only driver s door on first actuation of
unlock button on remote key. Unlocks all doors, trunk and fuel filler
door after second actuatio n o f button o n remot e key.

Key memory
When a remote key (identification transmitter) is used to lock or
unlock the car, the use r is identified b y CAS. Multiple keys can be
programmed with the personalizatio n feature . The use of a
personalized key then triggers car memor y functions such as
"\y 4 \ heating
y 1 signa l ^ j and
< air-conditioning settings o r memory seat position
adjustment.

JlfUJU' J Most key memory options can b e programed using the iDrive menu.
Some programmin g require s the us e of BMW factory scan tool or
equivalent.

Available ke y memory function s vary based on vehicle equipment .

The functions that can be set include :
• Audio tone settings and radio presets .
• Language of displays and voice functions.
• Climate control temperature .
• Seat / mirror memory settings.
Seat memor y modul e • Lightin g preferences.
SM
 Central Locking and Anti-theft 515- 9
Comfort access (CA)

Comfort acces s (CA )

Comfort acces s (CA) , optional in 5 Series models , is a passiv e
access system which allows the vehicle to be unlocked by grasping
the outer door handle , provide d the remote key is located withi n a
radius of no more than approx . 0.5 -1. 5 m (1 1/2 - 4Vz ft ) from th e
vehicle. With CA it is sufficient for the driver to carry the remot e key
on his or her person i n order to open o r start the vehicle.

Modules an d other components whic h control and operate CA:

1. Ca r access system (CAS)

2. Basi c body module (KBM)
3. Bod y gateway module (KGM )

I/—
23
B510515010

When a remote key comes into range of the CA antennas, the signal
is sent to CAS t o be verified. If seen as valid the loc k / unloc k
function i s granted .

Comfort access antennas

• Driver door handle
• Passenger door handle
•Rear bumper
• Luggage compartment
• Interior fron t
•Interior center
515-10 Centra l Lockin g an d Anti-theft
Comfort access features

Comfort access feature s

Passive entry
Passive entry enables acces s t o vehicle withou t operating the
remote key . The vehicle recognizes the presence of a valid remote
key and access i s granted b y grasping th e outer door handle .

Unlocking
A capacitive sensor i n door handl e modul e (TAGE ) recognize s that
the handle has been grasped and activates the transmit antenna .
The transmit antenna send s a signal t o the remot e key . In turn, the
identification transmitter send s a 315 MHz high frequency signal to
the remote contro l receiver, whic h contains the authentication
request. CAS checks the remote ke y authentication code . Following
successful authentication , CAS issue s a n enable signa l to unlock
vehicle and initiates vehicl e unlocking . KG M and KBM executes the
unlocking procedure. Th e electronic steering lock (ELV ) i s not yet
unlocked (i f equipped) .

1. Doo r handle module (TAGE)

2. Remot e key

I
3. Rea r window antenn a
4. Remot e key receive r
5. Ca r access system (CAS )

® 6. Electroni c steering lock (ELV )

7. Comfor t access (CA ) module
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B510515019

Trunk lid /tailgate unlocking

An authentication check take s place when a remote ke y is located
within the rear area of the vehicle. Afte r successful authentication,
the trunk lid or tailgate can b e unlocked an d opened with the outer
trunk lid or tailgate button.

Passive go

When a valid remot e ke y is located withi n the vehicle interior , the

passive go function makes it possible t o start the vehicle withou t the
remote ke y inserted in the key slot.

When a door is opened, after 3 seconds CA S checks to see whether

a valid remote ke y is in the vehicle. The remote replies with data for
the electronic vehicle immobilizer . CA S enables engine star t by
sending a signal to the ECM . I f equipped, th e electri c steering lock
(ELV) i s unlocked.
 Central Locking and Anti-theft 515-1 1
Door lock cylinder, removing and installing

Passive exit
Passive exi t makes i t possible to lock the vehicle withou t using a
remote key. After a door is closed, the locking procedure i s started
by touching the recognition area on the outer door handle. The door
handle module (TAGE) sends the request to CAS to lock the vehicle.

If a valid remote ke y is detected i n the interior o f the vehicle durin g

locking with another vali d remote key from the exterior, the key left in
the vehicle is deactivated unti l the vehicle i n unlocked again .

DOOR HANDLE S AN D LOCKS

In the procedures tha t follow, doo r handl e removal , doo r loc k
cylinder remova l and door latc h remova l are covered for left fron t
door. Other doors are similar although simpler, due to the lack of lock
cylinder.

Inner door panel remova l is covered in 411 Doors .

Door lock cylinder, removing and installing

Remove doo r latch . See Door latch , removin g an d installing in
this repai r group.

Remove door handle. See Door handle , removing and installin g

in this repai r group.

Loosen carrie r fastene r (A) , bu t do not remove. Releas e carrie r

catches (arrows in inset) while pressing lock cylinder int o door .

Working inside door, disconnect comfort access connector, if

equipped.

^ Workin g inside door, pull carrier in direction of arrow while sliding

fastener out of slot (inset).

— Remov e carrier fro m door .

— Installatio n i s reverse of removal.

• Replac e door handle gasket s if damaged.
• Rese t comfort access (CA) usin g BM W scan tool.
See 600 Electrical System-General .

Bentley
 515-12 Centra l Locking and Anti-theft
Door handle, removing and installing

Door handle, removing and installing

Remove rubber plug (arrow) .

. Pul l outside handle up until fastener (inset) i s accessible and hol d

in place.

Turn fastener (inset ) counterclockwis e to secure handl e an d lock

actuator in position. If lock actuator i s not properly secure d in
position, lock actuator leve r ma y return int o latch and door pane l
removal will be required to reset.

Pull outside handle out of rea r lock actuator in direction of arrow.

Pull outside handl e downwar d (curve d arrow ) from front of lock

actuator.

h: • ' "
 Central Locking and Anti-theft 515-1 3
Door handle trim, removing and installing

Installation i s reverse of removal .

• Check that stop pad (arrow) is in place.
• Inser t outside handl e bor e (A) correctly in mounting (B) .
• Engage outsid e handl e (C) correctly in lock actuato r (D).
• Replac e door handle gasket s if damaged.
• Reset comfor t acces s (CA) module using BM W scan tool.
See 600 Electrica l System-General .

Tightening torque
Handle t o lock actuator 3 Nm (26.5 in-lb )

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Door handl e trim, removin g an d installing

— Remov e doo r handle . Se e Doo r handle , removing and installin g
in this repair group .

"X. Remov e rubbe r plu g (arrow) .

Remove trim fastener (arrow).

:
E Is ! • '-
515-14 Centra l Locking an d Anti-theft
Door latch, removing and installing

Remove doo r handl e sto p pad b y pulling of f in direction of arrow.

Remove fastener (arrow). Press handl e moun t (A ) into door.

Slide trim out, towards rea r of vehicle an d remov e in direction of

arrow.

Installation i s reverse of removal .

• Replac e door handle gaskets if damaged.
• Rese t comfort access (CA ) using BM W scan tool.
See 600 Electrical System-General .

Tightening torque
Cover to handle mount 2.5 N m (22.1 in-lb )
Handle t o lock actuator 3 Nm (26.5 in-lb)

Door latch , removin g an d installin g

CAUTION—
• Do not use silicone lubricant on door latch. Latch faults have
been traced to silicone contamination.

— Remov e door trim panel. Se e 41 1 Doors .

"x. Working at corner of door a t door latc h assembly:

• Detac h electrical connector (A ) from latch assembly.
• Detac h door loc k rod (B) from latch assembly.
• Pul l Bowden cabl e (C ) down (arrow ) to detach from latch
assembly.
Central Locking and Anti-theft 515-1 5
Door latch, removing and installing

Using a sharp plastic scraper, lever sealin g bead (A) off vapor
barrier (B) .

CAUTION—
Use care when pee/ing back vapor barrier. A damaged vapor
barrier should be replaced to prevent possible airbag
malfunction and water leaks.

Partially remov e window regulator to gain acces s to door latch. See

512 Door Windows .

Remove door lock cylinder. Se e Door lock cylinder, removin g an d

installing in this repair group.

Working inside door, disconnec t Bowden cabl e (A) from latch (B) .

, Remov e latc h fasteners (arrows) .

— Remov e latch assembl y fro m inside door.

515-16 Centra l Locking and Anti-theft
Trunk lock cylinder

Installation is reverse of removal, keeping in mind the following:

• D o not bend door loc k button metal rod when inserting through
door skin opening.
• Hand tighten fasteners to properly seat door latch seal (arrows)
before tightening.
• Replace latch mounting screws and use threadlock compound.
• Make sure seal on latch is not damaged.
• Make sure inner door cavity vapor barrier is installed intact and
leak-proof.

Tightening torque
Latch assembly to door (replace screws) 9.5 M m (7 ft-lb)

B510515008I

TRUNK AND TAILGATE LOCKS

Trunk lock cylinder
— Remov e trunk lid trim panel. See 513 Interior Trim.

^C Disconnec t electrical connector (arrow) . Uncli p bowden cable (A)

from holder and remove from lock cylinder usin g a small pick.

e'sio

Remove lock cylinder fasteners (arrows).

BentleyPMbiishers
 Central Locking and Anti-theft 515-1 7
Trunk lock assembly

Rotate lock cylinde r until tabs (arrows ) are visible through slot s in
trunk li d and remove loc k cylinder fro m trunk lid.

Installation is reverse of removal. Remember t o inspect and replace

lock cylinder seal i f necessary .

BentleyPublisters
.com B510515032

Trunk loc k assembl y

— Remov e trunk lid trim panel. Se e 513 Interior Trim.

^k Disconnec t electrical connector (arrow ) from trunk loc k assembly .

— Remov e fasteners (A) an d pull latch assembly out of trunk lid.

^V Leve r out locking pin (inset) i n direction o f arrow and remov e

bowden cable from lock assembly .

— Installatio n is reverse of removal .

Tightening torque
Lock assembly to trunk li d 10 Nm (7.3ft-lb)
 515-18 Centra l Lockin g an d Anti-theft
Trunk lock striker, removing and installing

Trunk loc k striker , removin g an d installin g

— Remov e lower trunk trim panel. Se e 51 3 Interior.

'X. Remov e trunk lock striker fasteners (arrows ) then remove striker.

— Installatio n i s reverse of removal . Adjus t striker if necessary. See

Trunk lock striker, adjusting i n this repair group .

Tightening torque
Trunk loc k striker to body 10 Nm (7 3 ft-lb)

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Trunk loc k striker, adjustin g

Completely screw i n trunk detent buffers (arrows) .

Remove trunk loc k striker fastene r access covers (arrows) .

B51051S037!
 Central Locking and Anti-theft 515-1 9
Trunk lock striker, adjusting

Inspect fulcrum pads (arrows) for wear of damage, replac e if

necessary. Interio r trim panel removed for clarity.

^V Loose n trunk lock striker fasteners (A) slightly, just enough s o it is

able to move and center itself.

— Clos e trunk lid. This allows for the trunk lock striker to adjust itself.

— Ope n trunk and tighten fasteners. Check adjustment and repeat

procedure i f necessary.

Tightening torque
Trunk lock striker to body 10 Mm (7.3ft-lb )

— Reassembl e trunk interio r trim .

Unscrew trunk lid detent buffers (arrows) until closed rea r trunk lid
left and right detent buffers make contact with body panels. Trunk lid
should b e even with rear body panels .
515-20 Centra l Locking and Anti-theft
Tailgate lock

Tailgate lock
To gain access to tailgate lockin g mechanism, remov e tailgate trim.
See 513 Interior Trim.

Tailgate lock assembly, removing and installing

— Ope n upper tailgate and remove trim. Se e 513 Interior Trim .

^C Remov e emergency releas e cable from latch (A) .

— Disconnec t lock actuator (B ) electrical connector (E) .

— Remov e tailgate lock fasteners (D) and remov e lock (C) from
tailgate.

— Installatio n is reverse of removal .

Tightening torque
Lock to tailgate lid 10Nm(7.3ft-lb)

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Tailgate striker assembly, removin g and installing

Snap out cover (A) i n direction o f arrow and remove.

Remove fasteners (A ) and remove striker (B) .

Installation is reverse o f removal .

Tightening torque
Lock to tailgate li d 10Nm(7.3ft-lb)
 Central Locking and Anti-theft 515-2 1
Tailgate lock

Tailgate striker assembly, adjusting

Fully screw in left and right side bump stops (A). See 41 2 Trunk Lid,
Tailgate.

B510515043

Snap ou t covers (A ) and remove. Loose n fasteners beneath covers

slightly, just enough so striker it is able to move an d center itself .

CAUTION—
• Check that tailgate fasteners do not strike tailgate during
adjustment.

Close rear lid . Tailgate will center itself .

Open lid and tighten tailgate striker fastener s (A).

Tightening torque
Striker to bod y 10Nm(7.3ft-lb)

— Instal l strike r trim panel .

^ Unscre w and adjus t bum p stops (A ) until tailgate is flush wit h side
body panel .
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— Chec k for proper adjustmen t an d tailgate operation . Repea t
adjustment i f necessary .

B510515043
515-22 Centra l Locking and Anti-theft
Rear window lock assembly

Rear window lock assembly

The rea r window (tailgat e glass ) loc k assembl y i s part of the rear
wiper motor . Fo r removing and installin g se e 611 Wipers and
Washers.

Rear window lock, adjusting

— Chec k tha t tailgate i s adjusted properly .

^ Remov e plasti c cover s (A). Be careful not to break catches (B) .

Remove fasteners (A ) then trim pane l (B) .

B510515047

^ Loose n nut (A). Adjust striker by turning in or out (B)

— Tighte n nu t and rechec k adjustment .

— Instal l tailgate tri m panels .

 Central Lockin g an d Anti-theft 515-2 3
DWA components

ELECTRONIC IMMOBILIZE R (EWS )

EWS is a shared syste m betwee n car access system (CAS ) an d
digital moto r electronic s (DME). I f an authorized key is recognize d
by CAS a start signal i s authorized an d sent to the DME .
Troubleshooting i s performed with a BMW factory scan tool or
equivalent.

ANTI-THEFT SYSTEM (DWA)

DWA components
1. Ultr a sonic sensor (USIS)
2. DW A LED
34
3. Ca r access system (CAS )
4. Ligh t module (LM)
5. Til t sensor/alarm siren (SINE)
6. Hoo d switch

DWA operatio n
When the anti-theft system (DWA ) is armed:
• The doors, hood, window s and trunk lid are monitored agains t
forcible entry.
• A tilt sensor protects the vehicle from being jacked up or towed
away.
• Movement inside the vehicle is monitored.
• Batter y voltage i s monitored.

The system responds to unauthorized vehicle entry or attempte d

theft by activating the following:
• Alarm siren sounds fo r 30 seconds.
• Hazar d warning lights and high beams flash for approx. 5 minutes.

The system i s armed o r disarmed from the driver door lock o r the
remote transmitter when the vehicle i s locked or unlocked. Th e
interior compartment monito r is activated approx. 30 seconds after
the vehicle is locked .

The system indicates that it is armed by flashing the hazard warning

lights once and emitting a brief chir p from the siren .

If the alarm is activated, the tailgate may still be opened using button
3 on the remot e key . The alarm reset s when the tailgate i s closed.
515-24 Centra l Locking an d Anti-theft
DWA LED display

Following th e triggering of an alarm, th e syste m resets and can

trigger again i f further tampering t o the vehicl e i s detected .

The interior protection ultrasoni c senso r (USIS ) i s in the DWA main

control module. I t monitors the passenge r compartmen t an d
receives input s fro m corresponding module s fo r alarm activation,
deactivation an d triggering.

DWA LED display

. Th e DW A status LED (arrow) is below th e interio r rear view mirror.
LED displays ar e listed i n Table a.

Table a. DWA LED status

DWA status LED signal
Disarmed OFF
Armed Continual slo w flash.
Armed with tailgate o r door Rapid flas h for 1 0 second, the n
not fully closed continual slo w flash. Interior motion
sensor no t activated.
Alarm activate d Rapid flash for 5 minutes, then
continual slo w flash.
Disarmed after activated Blinks for 5 minutes then goes OFF, or
alarm goes OF F when remote ke y in
inserted.

DWA alarm sire n

. Th e DW A alarm sire n is at the righ t side rea r inner bumper, behind
the plastic inne r fenderwell.
Alarm * B44a
siren X18038 The sire n is powered b y a separate rechargeabl e battery. This
battery i s recharged by the vehicl e electrica l system when DWA is
not armed.

B510515049

Tilt sensor
The tilt sensor i s integrated int o the alar m siren. It registers the
vehicle res t position when armed an d detects changes i n position,
for exampl e jacking o f the vehicle .

When flat-bed transporting the vehicle, lock the vehicle twice within
10 seconds t o switch tilt sensor OFF.
 Central Lockin g an d Anti-theft 515-2 5
In terior protection

Interior protectio n
The interio r motion ultrasoni c sensor (USIS) i s in the cente r o f the
headliner. Du e to the design o f the vehicle interior, install senso r i n
the correct direction to ensure prope r operation of the system. Th e
arrow on sensor point s toward front of vehicle

As with the tilt sensor, when flat-bed transporting the vehicle, loc k
the vehicle twice within 1 0 seconds to switch interior motion senso r
OFF.

The USI S system use s ultrasoun d to sense motio n insid e its

detection cone. Ever y time DW A is armed, the USI S senso r adapt s
to whatever objects are stationary i n the interior. USI S als o check s
for backgroun d his s (wind nois e through a partially open window )
and adapts fo r this.
• I f detected echoes an d sounds ar e consistent, no movement i s
detected.
• I f the echoes are altered (inconsistent), USIS determines motio n in
the interior compartment.
• I f motion i s detected, the USI S changes from a pulsed signa l t o a
constant signa l and the echo i s compared again .
• I f the inconsistency is still present USI S triggers th e alarm.

Panic mod e
If the tailgate button (arrow) is pressed and held for more than 2
seconds, USI S activates the sire n in panic mode . This functio n is
available with either an armed o r disarmed DWA.

B510515050

Emergency disarmin g
Emergency disarming occur s automatically when a recognized key
is inserted int o the ignitio n loc k or a remote key is inserted int o th e
key slot. If the ke y is accepted b y CAS, the doors ar e unlocke d an d
the alarm deactivated .
 520-1

520 Seat s

GENERAL 520-1 Passenger seat occupanc y sensor 520- 5

Seat memor y 520-1 Front sea t backres t rea r panel ,
Seat memor y position , setting 520-2 removing and installing 520- 8

FRONT SEAT S 520-2 REAR SEAT S 520- 8

Front seat , removin g an d installin g . 520-3 Rear seat, removin g and installin g (Sedan ) . . . 520- 8
Front seat control switch, Rear seat headrest , removin g and installin g
removing and installing 520-5 (Sedan) 520-1 0

GENERAL
This repai r group covers remova l and installation of the front and
rear seats.

See also:
• ECL Electrical Componen t Location s
• EL E Electrical Wiring Diagram s

Seat memor y
Seat and outside rear-vie w mirror positions can b e memorized an d
stored i n the seat control module for two different users . The sea t
control module i s mounted t o the botto m of the sea t (inset).
520-2 Seats
Seat memory position, setting

Seat memory position, setting

With transmission rang e selector i n P, switch ignition ON and adjust
seat an d mirrors to desired position .

Press M on memory switch and pres s on e of the two memory

switches (E).
• The current position of the mirrors , seat an d steering colum n is
now stored in memory.

Power seat controls.

• A — Thigh suppor t
• B — Lumbar suppor t
• C — Backrest width adjustmen t
• D — Seat adjustmen t
• E — Memory buttons

FRONT SEAT S
Seat repair and component replacemen t i s possible once the seat is
removed from the vehicle. Before servicing front seats read safety
regulations on handling pyrotechnic seat belt tensioners. See 720
Seat Belts an d 721 Airbag Syste m (SRS) .

WARNING —
• The front seats are equipped with pyrotechnic seat belt
tensioners. These tensioners are powerful devices. Handle with
extreme care. Incorrect handling can trigger off the airbag or
tensioner and cause injury.
• BMW recommends that repair or replacement work on airbag
and pyrotechnic devices be carried out by a qualified BMW
technician.
• Be sure to disconnect the battery and wait 30 seconds before
attempting to work on pyrotechnic devices.
• During body straightening and welding with an electric arc
welder, disconnect the battery and the connection to the
pyrotechnic gas generators.
 Seats 520- 3
Front seat, removing and installing

Front seat , removing an d installin g

Using a plastic pryin g tool, releas e retaining tabs (arrows ) for for
seat trim (A). Lift seat trim up to release tab B and remove .

^k Remov e fastener (arrow) for seat belt and discard. Disconnect sea t
belt from tab and lay aside.

— Mov e seat a s far forward as possible .

H. Remov e rear seat trim covers (A) and mounting bolt s (arrows) .
Discard mounting bolts .

— Mov e sea t as far back as possible.

520-4 Seat s
Front seat, removing and installing

Remove front seat rai l trim covers (arrows).

w
B510520018

Remove front seat mountin g bolt s (arrows ) and discard.

Tilt seat back and remov e front trim cover.

Disconnect electrical connectors (arrows ) and unclip harness (A )

from seat bottom .

Cover door sill with protective covers an d remov e front seat from
car.

CAUTION—
• Use a blanket to protect the seat upholstery from damage if
placing the seat upside down for repairs.

Installation is reverse of removal. Us e wire ties or equivalent means

to keep seat harnes s wirin g from fraying.

Tightening torques

Front seat to floor (replace bolts ) 44 N m (32. 4 ft-lb)

Seatbelt to front seat (replac e bolt ) 36 N m (26. 5 ft-lb)
 Seats 520- 5
Front seat control switch, removing and installing

Front seat control switch,

removing an d installing
— Mov e seat a s far forward as possible an d to fully raise d position .

^C Usin g a plastic pryin g tool releas e retainin g tabs (arrows ) for for
seat trim (A). Lift seat trim up to release tab B and remove .

Remove seat control switch fasteners (arrows).

Disconnect seat switch electrical connector an d remove sea t switch .

Installation is reverse o f removal .

Passenger seat occupancy sensor

Vehicles covered by this manual ar e equipped wit h a passenge r
seat occupancy senso r i n the passenger sea t cushion. This devic e
is part of the two-stage deployment airba g system. Access t o th e
seat occupancy sensor i s described below. 5 Series models us e an
OC3 mat which i s integrated in the seat cushion . Th e sea t cushion
and occupancy mat are replaced as a unit.

Using BMW scan tool, disable occupancy detectio n mat from

restraint control module .

Remove passenger seat. See Front seat, removing an d installin g

in this repai r group .

Remove front seat backres t rea r panel. See Front seat backres t
rear panel , removing and installing in this repair group.

Remove seat control switches. See Front seat contro l switches ,

removing an d installin g i n this repair group.
520-6 Seat s
Passenger seat occupancy sensor

Remove fastener (A ) and remove trim panel in direction of arrow.

Remove seat front trim (A) b y pressing sid e ou t (curved arrows)

and pulling forward (arrow).

Unhook sea t cover from retainin g point s (A).

 Seats 520- 7
Passenger seat occupancy sensor

Unhook sea t cover (A ) i n area B . Disconnect electrica l connector s

(C) and remov e seat cover with cushion.

X. Detac h all retainers (inset ) i n side area from longitudinal wires (A).
Carefully fold back seat cover and release retainers from cross-
wires (B) .

— Remov e seat cover from cushion.

Using BMW special tool 52 0 050, ben d new clip (B) closed.
• A - Paddin g
• B - Clip s
• C - Tri m wire in seat cover
• D - Tri m wire in cushion
• E - Sea t cover

Remainder o f installation i s reverse of removal. Remembe r to

enable occupancy ma t with BMW scan tool.
520-8 Seat s
Front seat backrest rear panel, removing and installing

Front sea t backres t rea r panel ,

removing an d installing
The bac k of the front seat i s accessible b y removing the rigi d
backrest panel .

Left side seat is shown. When servicing righ t seat, transpose the pull
and striking sides accordingly.

^ Gri p between rea r panel and backrest cover (A) on door side until
clip can be felt. Do not pull on panel .

— A t same time, firmly push towards middle o f seat on inner side (B)
at top. Uppe r retainers release out of seat guide.

— Pul l rear panel u p (arrow) out o f lowe r guides.

— Installatio n is reverse of removal . Remembe r to replac e damage d

panel clips .

B510520003

REAR SEAT S
Rear seat, removin g and installin g (Sedan )
Pull seat cushion up and away (arrows) from pedestal and feed seat
belt buckles (A) through opening i n seat. Lif t out rear seat.
 Seats 520- 9
Rear seat, removing and installing (Sedan)

Working in trunk, locate backrest locks (inset).

Using a screwdriver, release backres t lock (inset) i n direction of

arrow.

Remove seat belt buckl e fasteners (arrows) and discard. Remove

seat bel t buckles.

i.BentleyPubiishers
8510320021
520-10 Seats
Rear seat headrest, removing and installing (Sedan)

Working at center of rear seat, remov e backres t fasteners (inset).

Tilt backrest forward while lifting guides (inset ) out of body panel .

Lift backres t while feeding out seat belts and remove backrest .

Installation i s reverse of removal .

Tightening torque
Seat bel t buckle to body (replace fastener ) 36 N m (26. 5 ft-lb)
Rear seat bel t to bod y 31 Nm (22.8 ft-lb)

Rear seat headrest , removin g and installing

(Sedan)
Remove rear seat backrest . See Rea r seat, removing and
installing (Sedan) i n this repai r group .

Slide headres t a s far up as possible .

Press lock (B) and pull headrest (A) upwar d t o remove .

Installation is reverse of removal .

 540-1

540 Sunroo f

GENERAL 540-1 SUNROOF ADJUSTMENT S 540- 3

Functional overvie w 540-1 Sunroof, initializing 540- 3
Sunroof, emergency closin g 540-2 Sunroof, adjusting 540- 4
Sunroof, emergency operation mode 540-2
SUNROOF MOTO R 540- 7
Sunroof motor , replacing 540- 7

GENERAL
This repair grou p cover s the slide-tilt sunroof assembly . There are
two types o f sunroofs available: one-piec e standard sunroof an d
two-piece panorama sunroof . Service procedures are different for
each type .

Replacement of the cable assembl y or frame require that the

headliner be removed. Removal an d repair of the sunroof assembl y
and other components insid e the roo f cavity is beyond the scope of
this manual .

Functional overview
Vent position: When th e sunroof i s set to the vent position (rear of
panel up), the inside headliner pane l automatically moves rearward.
This provide s cabin ventilatio n with less wind noise.

Anti-trap: This feature uses a Hall sensor to detect obstruction s

while the sunroof is closing i n the automatic clos e function. The anti -
trap feature is shut down prior to full closing ( 4 mm from full closed)
to allow the sunroof to seat into the seal.

CAUTION—
• The anti-trap feature is not functional when the switch is held in
the manual close position.

Unloading: Th e sunroof i s deactivated durin g engine start . This

function is to provide maximum starting power to the engine starter
motor. Th e sunroof contro l module receives the consumer cut off
signal via K-CAN.

A water channe l is incorporated into the sunroof assembly. It

automatically rise s when the sunroof panel is in the vent positio n
and prevents water from entering th e interior during braking .
540-2 Sunroo f
Sunroof, emergency closing

Sunroof, emergency closin g

Standard sunroof shown in illustrations .

Using a plastic prying tool, carefully pry interior light out of headliner
at arrows, disconnect electrical connectors and remove.

Using a plastic prying tool, carefully pry switch panel (A) out of
headliner, disconnect electrical connector s and remove.

Insert 4 mm Allen into drive in sunroof motor (arrow). Turn Allen to

manually close sunroof .

Bentley Pulps

Sunroof, emergency operation mod e

When an electrical faul t is detected the sunroof operates i n
emergency operation mode, moving for 750 milliseconds at a time.
Emergency function is available when CA S sends an emergency
mode enabled signal via K-CAN to sunroof contro l module.
 Sunroof 540- 3
Sunroof, initializing

SUNROOF ADJUSTMENTS
Sunroof, initializing
Initialization allows the sunroof control module to learn the en d
positions o f the motor travel. Hall sensors send motor rotation
pulses to the control module, which count s the pulses to determine
panel position.

The sunroof initializatio n process consist s o f two steps:

• Normalizatio n
• Setting characteristic curve

Initialize sunroof i n the following situations :

• Malfunctions such a s lack of one-touch function , lac k of comfort
opening / closing o r lack of safety (anti-trapping ) features .
• I f sunroof motor is removed and reinstalled.
• If power supply to the sunroof i s interrupted .
• I f repairs have been performed on the slide / tilt mechanism .

WARNING —
• There is no anti-trapping protection during initialization.

Sunroof normalizatio n
During normalization the mechanical en d positions of sunroof
movement are detected and stored by the control module.

"^V. Pres s and hold sunroof switch in raised (vent) position .

• After reaching end position (A), keep switch presse d for
approximately 2 0 seconds longer .

— Normalizatio n i s complete when sunroof in raised positio n (A )

moves briefly u p (B) .

— Releas e sunroof switch.

Setting characteristic curve

Models wit h standard sunroof : Characteristi c curv e is learne d

manually i n the following steps:
• Release switc h within 5 seconds of normalization completion.
• Press and hold switch in sunroof i n raised (vent ) positio n until
sunroof ha s returned to closed position after a complete opening
operation.
• Characteristic curve learning i s complete. Release sunroof switch.
540-4 Sunroo f
Sunroof, adjusting

— Model s with panorama sunroof: Characteristic curv e is learned

manually i n the following steps :
• After completion of normalization process , press and hold switch
in raised (vent) position . Hold during procedure describe d below .
• The panorama glass roof stops for 5 seconds in the final raised
position after normalization .
• Sunroof headline r panel close s completel y an d then ope n
completely.
• The panorama glass then moves into closed position.
• The panorama glas s will then moves to open positio n and
immediately back to the closed position .
• Sunroof headline r panel close s completely .
• Characteristic curve learning is complete. Release sunroof switch.

— Al l models: Check sunroof operation, includin g anti-trap protection.

Sunroof, adjusting
The sunroof is controlled by a set of cables that move the sunroof
panel along guide rails when the motor is operated. The sunroof can
be adjusted withou t removin g i t from the car.

NOTE—
• Be sure to check drains in front corners of sunroof carrier if water
is entering car through headliner.

— Adjus t sunroof panel unde r th e following circumstances :

• Sunroof misaligned with roof.
• Sunroof doe s no t close squarely .
• Wind noise at high speeds (sunroo f closed).
• Sunroof ha s been remove d an d installed.

— Fo r correct sunroof alignment :

• Sunroof mus t be fully closed .
• Gap must be even all around edges of sunroof.
• Fron t of sunroof mus t be flush to 1 mm (0.04 in ) below surface of
roof.
• Rea r of sunroof must be flush to 1 mm (0.04 in) above surface of
roof.

'X. Use credit card to measure gap. Card should insert through gap with
equal resistanc e al l around perimeter .
 I

Sunroof 540- 5
Sunroof, adjusting

Standard sunroof

Slide sunroof headline r pane l bac k int o roof cavit y until approx. 6 0
mm (2.36 in ) i s exposed.

. Rais e glass sunroof panel to vent position to expose pleate d rubbe r

panel (arrow).

Starting at rear section of pleated rubber panel, carefully pull pleate d

rubber pane l of f slotted moun t o n sunroof glass panel. Unlci p
pleated rubber pane l at front and slide forward to remove .

CAUTION—
• The pleated rubber panels tear easily.

Sunroof pane l is retained by three fasteners (arrows) on each side .

To adjust sunroof height :
• Loose n fasteners until sunroo f can be moved.
• Pus h sunroof panel u p or down unti l correct height i s achieved .
• Reinstal l sunroof pleated rubbe r panels .

Sunroof heigh t adjustment specification s

Rear Flush / 1 mm (0.04 in) higher than roof top
Front Flush / 1 m m (0.04 in ) lower than roo f to p

Tightening torque
Glass panel to sunroof frame 4 N m (3 5 in-lb )
540-6 Sunroo f
Sunroof, adjusting

Panorama sunroof
— Clos e glas s sunroo f panel t o expose rubbe r pleated panel .

^V Gras p and remove pleated rubbe r pane l from guide in directions of

arrows.

Pleated rubbe r panels cannot b e removed without damaging them.

Replace with new every time removed .

Loosen mounting fasteners (A) on lef t and right sides until sunroof
can be moved.

X Adjus t panorama sunroof glass panel s for consistent front and rear
gaps (A).
• Special tool 00 9 341 is used to check ga p spacing.
• A = 5.8 ± 0.3 mm (0.23 ± 0.012 in)

— Tighte n mountin g screw s for glass panels .

Tightening torque
Glass panel to sunroof frame 4 Nm (35 in-lb)
(replace fasteners)

— Instal l new rubber pleate d rubber panels .

 Sunroof 540- 7
Sunroof motor, replacing

SUNROOF MOTOR
Sunroof motor , replacing
The procedure shown below applies t o models with standar d
sunroof. I t also applies to the front sunroof motor for models wit h
panorama sunroof.

Using a plastic prying tool, carefully pry interior light out of headliner
at arrows, disconnect electrica l connectors and remove.

Using a plastic prying tool, carefully pry switch panel (A) ou t of

headliner, disconnec t electrica l connector s and remove.

Remove sunroof motor mounting fasteners (arrows) and disconnect

electrical connector (A). Remove motor .

Installation i s reverse of removal.

• Be sure to properly engage sunroof motor drive gear sprocket into
sunroof drive gear.
• Perfor m coding an d programming if motor was replaced .
See 600 Electrical System General.
• Perfor m initialization procedure . See Sunroof, initializing in this
repair group.

Tightening torque
Sunroof moto r to sunroof carrier 3.5 M m (30 in-lb)
 600-1

600 Electrica l System-General

GENERAL 600- 1 VEHICLE ELECTRICAL SYSTE M

Electrical overview 600- 1 (2008-2010) 600-1 1
Bus basics 600- 2 Electrical system (2008 - 2010) 600-1 1
Electrical test equipment 600- 2 POWER MANAGEMEN T 500-1 2
Static damage prevention 600- 3
Power management basics 600-1 2
Warnings and Cautions 600- 3
CODING, PROGRAMMING, ADAPTATIO N . . eoo-1 3
VEHICLE ELECTRICA L SYSTEM Scan tool basics 600-1 3
(2004 - 2005) 600- 5 Coding 600-1 3
Power supply (2004 - 2005) 600- 5
Programming 600-1 3
Bus systems (2004 - 2006) 600- 6
Adaptation 600-1 4
Bus functions and types (2004 - 2005) 600- 7
Coding and programming procedure 600-1 4
VEHICLE ELECTRICAL SYSTE M ELECTRICAL TROUBLESHOOTIN G 500-1 5
(2006 - 2007) eoo- 9 Voltage and voltage drop 600-1 5
System overview (2006 - 2007) 600- 9 Continuity, checkin g 600-1 7
Bus system (2006 - 2007) 600- 9 Short circuits, testing 600-1 7

TABLES

a. Bus system parameter s 600- 8

GENERAL
This section describes the principal parts o f the electrical system.
Also covered here are basic electrical system troubleshooting tips .

See also:
• 12 1 Battery, Starter, Alternator
• EC L Electrical Componen t Location s for common BM W
acronyms as well as component location informatio n
• ELE Electrical Wiring Diagram s
• OBD On-Board Diagnostics

Electrical overview
The vehicle operate s on a 12-volt direct current (DC) negative-
ground system. Power is supplied by a lead-acid battery in right side
of the trunk or cargo compartment .

A voltage regulator controls system voltage a t approximately 12

volts. All circuits are grounded by direct or indirect connection to the
negative (- ) termina l o f the battery.

A number of ground connections throughout the vehicle connect the

wiring harness to chassis ground. Thes e circuit s are completed by
the battery cable o r ground strap between the body and the batter y
negative (- ) terminal .
600-2 Electrica l System-Genera l
Bus basics

Due to the extensive use of aluminum i n 5 Series front end

components, grounding leads are used to electrically bridge body
components to each other.

Fuses are color code d to indicate current capacities.

Electrical components connec t usin g one of the following:

• Heavy cables with lug-type connector s (battery, starter, alternator) .
• Electrica l harnesse s with keyed, push-on connectors that loc k int o
place.
• Buse s with modular connectors.

Relays and control modules ar e mounte d i n various places

throughout the vehicle. See ECL Electrical Componen t
Locations.

Bus basics
To handle electrica l complexity, 5 Series vehicles are equipped
extensively wit h bus systems. Signal s are shared digitall y amon g
electrical components o n a bus, eliminatin g th e need for separate
connections for each pai r of components. Th e us e of bus
communication for controls an d accessories reduces wiring
complexity an d improves system respons e time.

Data transfer ove r a bus is similar to a telephone conference. A

component on the bus transmits a stream o f data (dat a telegrams)
which other components receive at the same time. Each component
is then free to use or ignore this telegram.

The benefit s of the bu s method of data transfer are as follows:

• As data and programs are modified an d extended, only software
modifications are necessary .
• Continuou s verification of transmitted dat a leads to low error rate.
• Sensors and signal wires can be simplified or eliminated due to the
transmittal of multiplexed digita l data .
• Control module s transfer dat a at a high rate .
• Control modul e sizes an d connector sizes ar e smaller.
• Bus architecture conforms to international standards. This
facilitates data interchange between components of different
manufacture.

Electrical test equipmen t

Many electrical tests described i n this manual call for measuring
voltage, current or resistance using a digital multimeter . A digital
meter i s preferred for precise measurements an d for electronics
work because i t is generally mor e accurate than an analog meter
(swing-needle). An analog mete r ma y draw enough current to
damage sensitiv e electronic components .

An LE D test light is a safe, inexpensive tool that can be used to

perform man y simpl e electrical tests that would otherwise requir e a
digital multimeter . The LE D indicate s when voltage is present
between any two test-points in a circuit.

The integrated safety, comfort, security and handlin g systems on

5 Series vehicles are designed with self-diagnostic capabilities . Th e
 Electrical System-General 600- 3
Static damage prevention

quickest way to diagnose many problems is to start with a scan too l

read-out of diagnostic trouble codes (DTCs). See Scan tool basic s
in this repair group.

12
Static damag e preventio n
Electronic circuits can be easily damaged by static electricity held by
the human body and vehicle electrical components. To avoid static
electricity damage, take precautions to ground the static electricity
before touching any internal components of a circuit.

Wearing an electrostatic discharge (ESD) wrist strap or working on

an anti-static mat prevents stati c electricit y damage .
1. ES D mat
2. Groundin g lead
3. ES D wrist strap

Warnings and Caution s

WARNING —
• Airbags and pyrotechnic seat belt tensioners utilize explosive
devices. Handle with extreme care. See warnings and
cautions i n 721 Airbag System (SRS).
• The ignition system operates at lethal voltages. If you have a
weak heart or wear a pacemaker, do not expose yourself to
ignition system electric currents. Take extra precautions when
working on the ignition system or when servicing the engine
while it is running or the key is ON. See 120 Ignition Syste m fo r
additional ignition system warnings and cautions.
• Keep hands, clothing and other objects clear of the electric
engine cooling fan when working on a warm engine. The fan may
start at any time, even when the ignition is switched OFF.
600-4 Electrica l System-General
Warnings and Cautions

CAUTION—
• Do not disconnect the battery with the engine running.
• Prior to disconnecting the battery, read the battery
disconnection cautions given in 001 Warnings and Cautions.
• Switch the ignition OFF and remove the negative battery cable
before removing any electrical components. Connect and
disconnect electrical connectors and ignition test equipment
leads only while the ignition is switched OFF.
• Relay and fuse positions are subject to change and may vary
from vehicle to vehicle. If questions arise, an authorized BMW
dealer is the best source for the most accurate and up-to-date
information.
• Use a digital multimeter for electrical tests. Switch the multimeter
to the appropriate function and range before making test
connections.
• Many control modules are static sensitive. Static discharge
damages them permanently. Handle the modules using static
prevention equipment an d techniques. Se e Static damag e
prevention in this repair group.
• To avoid damaging harness connectors or relay panel sockets,
use jumper wires with flat-blade connectors that are the same
size as the connector or relay terminals.
• Do not try to start the engine of a vehicle which has been heated
above 176°F (80°C) (for example, in a paint drying booth). Allow
it to cool to normal temperature.
• Disconnect the battery before doing any electric welding on the
vehicle.
• Do not wash the engine while it is running, or any time the
ignition is ON.
• Choose test equipment carefully. Use a digital multimeter with at
least 10 MQ. input impedance or an LED test light. An analog
meter (swing-needle) or a test light with a normal incandescent
bulb may draw enough current to damage sensitive electronic
components.
• Do not use an ohmmeter to measure resistance on solid state
components such as control modules.
• Disconnect the battery before making resistance (ohm)
measurements on a circuit.
 Electrical System-General 600- 5
Power supply (2004 - 2005)

VEHICLE ELECTRICAL SYSTE M (2004 - 2005)

Power supply (2004 - 2005)
1. Intelligen t battery sensor (IBS )
• Monitors battery state of charge, state
3 of health.
d' r . n r b • See 121 Battery, Starter, Alternato r
for additional information.
2. Battery .
3. Starter .
4. Rear power distribution and fuse panel
(A46).
• Houses terminal 30g relay for electric
load cut-off function.
• See ECL Electrical Componen t
Locations for fuse and relay
positions.
5. Micro-powe r module (MPM).
• In trunk, underneath spare tire.
• House s bistable (latching) relay for
electric load cut-off function.
• Switches power supply to audio and
communications equipment .
6. Ignitio n and starter switch (ZAS).
.com B510600002 7. Engin e control module (ECM) .
8. Alternator .
9. Fron t fuse and relay panel (A41).
• See ECL Electrical Component
Locations for fuse and relay
positions.
10. Car access system (CAS), version 1.
• Underneath left side dashboard .
• See 121 Battery, Starter, Alternato r
for replacement procedure .
600-6 Electrica l System-General
Bus systems (2004 - 2006)

D-Bus
I

SMC

CiD CCC BBS! DME

M-ASK -IPS
SH .VPM TV!FA TMBF

DSC

SZN KOW3I SF2 S2L

ACC
PDC SHD SOARS ' HU D
£GS

ARS
3WA CON I EL TOP-HiFi
AHL

SMFB

LM IHKA

K-CAN MOST byteflight PT-CAN B510600005

Bus systems (2004 - 2006 ) EGS Automatic transmission control SOARS Satellite radio
module
ACC Active cruise control SFZ Center satellite crash sensor
EKP Fuel pump control module
AFS Active steering SGM Safety and gateway module
FS MOST direct access
AHL Adaptiv e headlights SH Seat heate r
IHKA Automatic climate control
AHM Hazard warnin g SHD Sunroof modul e
KBM Body basi c modul e
ARS Acceleration senso r SMBF Passenger sea t modul e
KOMBI Instrument cluste r
CAS Car access syste m SMG Sequential manual gearbo x
LM Light modul e
CCC Car communications compute r SMFA Drive r seat module
M-ASK Multi-audi o system controller
CDC CD changer SZL Steering column switch cluster
MPM Micro-power module
CID Central information display SZM Center console switch center
PDC Par k distance control
CON iDrive controller TMBF Passenger doo r modul e
RLS Rain and light sensor
DME Engine control module (ECM ) TMFA Drive r doo r modul e
SBSL B-pillar satellite crash sensor ,
DSC Dynamic stability control modul e left TEL Telematics contro l modul e

DWA anti-theft alar m SBSR B-pilla r satellit e cras h sensor , TOP-HIFI Amplifier
right
 Electrical System-General 600- 7
Bus functions and types (2004 - 2005)

Bus functions an d types (2004 - 2005)

Main buses
Main bus systems exchange data between control modules
throughout the vehicle.

D-bus (diagnostic -bus) connects SGM to diagnostic plug (OBD

plug).

K-CAN (body CAN) connects the instrument cluster, central

information display (CID ) and iDrive controller.

MOST (media oriented systems transport fiber optic bus ) connect s

satellite radio, telephone and top HiFi system.

byteflight (fibe r optic bus) connects satellite crash sensors, door

modules and driver airbag to SGM (primary airbag module).

PT-CAN (powertrain CAN) links fuel injection, powertrain and

traction control modules. The change from CAN-bus (twisted pair of
wires) is that PT-CAN has three wires, with the third wire used as the
wake-up line for associated modules .

Sub-buses
Sub-bus systems exchange relatively small quantities of data within
one system.

LIN-bus (local interconnect network), a bidirectional single-wire bus

system, includes a main controller and several server units. The 5
Series LIN-bus connects control modules with blower motor, tire
pressure monitoring wheel housing antenna s and door modules .

F-CAN (chassis CAN) enables fast data transfer among

components in DSC and active steering.
1. DS C acceleration senso r 1
2. DS C acceleration senso r 2
DSC 3. Activ e steering actuato r
4. Steerin g column switch center (SZL)
F-CAN 5. DS C control module

H
6. Activ e steering control module

^iri 3

5tf 4 AFS
BentleyPublisttfers^
.com B510600006
600-8 Electrica l System-General
Bus functions and types (2004 - 2005)

BSD (bit-seria l dat a interface) connect s intelligen t batter y sensor

(IBS) wit h alternator an d engine contro l module (ECM) .
1. Alternato r
2. Intelligen t battery sensor (IBS )
BSD 3. Engin e control module (ECM )
Table a summarizes bus structure and data speeds.

Table a. Bus system parameters

Bus system Data rate Structure
BSD 9.6 kBd Linear, single wire
byteflight 10MBd Star, fiber optic
D-bus 10.5 -115 kBd Linear, single wire
.com B510600007 DWA-bus 9.6 kBd Linear, single wire
F-CAN 1 00 kB d Linear, 2-wire
K-bus seats 9.6 kBd Linear, single wir e
K-CAN 100 kBd Linear, 2-wir e
LIN-bus adaptive headlights 19.2 kBd Linear, singl e wire
LIN-bus doors 19.2 kBd Linear, single wir e
LIN-bus IHK A 9.6 kBd Linear, singl e wire
LIN-bus tire pressur e monito r 9.6 kBd Linear, singl e wire
MOST 22.5 Mb d Ring, fiber optic
PT-CAN 500 kBd Linear, 2-wire
 Electrical System-General 600- 9
System overview (2006 - 2007)

VEHICLE ELECTRICAL SYSTEM (2006 - 2007)

System overview (2006 - 2007)
Beginning with 09 / 2005 production (2006 model year), 5 Series
electrical system was modified as follows:

System network:
• byteflight bus eliminated.
• Body-gateway module (KGM) mounted in front fuse and relay
panel behind glove compartment.
• Door module functions transferred to KGM.

Energy management: Micro-powe r module (MPM) eliminated.

MPM function, including bistable relay, integrated in KGM.

Comfort access (optional):

• Keyless access.
• Electronic outer door handle module s (TAGE)

Car access system (CAS), version 2:

• Start / stop button .
• Key slot.
• Electric steering column lock (ELV).

Expanded diagnostic functions:

• Monitoring of control modules to detect authorized bus system
wake-up.
• Monitoring of control modules to detect sleep mode preventer
(control unit that prevents bus system from switching to sleep
mode).

Steering column switch cluster (SZL): New connection to

PT-CAN.

Passive safety: Airbag control system changed from advanced

safety electronics (ASE) to advanced crash and safety management
(ACSM).

Audio systems: MP3 function in radio module.

Bus system (2006 - 2007)

The 2004 - 2005 bus system is modified as follows:

Body-gateway module (KGM) perform s the gateway interconnec t

function for the following buses:
• Diagnostic-bus (D-bus)
• PT-CAN (powertrain CAN)
• K-CAN (body CAN)
• LIN-bus (local interconnect network)

Data transmission rate s and data telegram structure vary among

different buses. KGM is responsible for buffering data telegrams and
forwarding them according to priority.
KGM
Body-gateway module
(A16760)
600-10 Electrica l System-Genera l
Bus system (2006 - 2007)

KGM is the interface to the diagnostic-bus fo r the purpose of

diagnosing or programming control units connected to the bus
system.

The KGM additionally features a link to UN-bus for the purpose of

reading informatio n from the driver's door switch cluster.

Main airbag control module function s are transferred to the

advanced crash and safety management (ACSM ) control module ,
above center tunnel, connected to sensors and airbags vi a K-CAN.

Comfort access components, including the control module, door

handle module s (TAGE ) and electric steerin g column lock (ELV)
interconnect vi a K-CAN.
 Electrical System-General 600-1 1
Vehicle Electrical System (2008 -2010)

VEHICLE ELECTRICAL SYSTE M (2008 - 2010)

Electrical syste m (2008 - 2010)
Beginning wit h 03 / 2007 production (2008 model year) new
electrical features are either standard or optional on 5 Series:

S-CAN (sensor CAN), a new bus system based on PT-CAN,

transmits data at the same speed as PT-CAN and uses PT-CAN
protocol.

D-CAN (diagnostics-CAN), also a new bus, is connected to KGM.

Car access system (CAS), version 3 with electronic immobilizer 3

or 4 (EWS 3 or EWS 4), depending on the engine. With EW S 4,
engine electronics are connected to CAS by an additional data
connection. The data connection is redundant to PT-CAN and uses
K-bus protocol.

Rain / light sensor connected by LIN-bus to wiper and lights

systems.

Welcome light .

Daytime driving light with corona rings.

Adaptive headlights with turn-off light.

Turn signal LED and additional rea r side-marker lights standard.

Diagnostics-CAN o n body-gateway module (KGM).

Lane departure warning (TLC) generate s a vibration warnin g in

the steering wheel when the driver accidentally change s lane ,
prompting the driver to counter-steer.

Active cruise control with stop and go function makes it easier to

drive in heavy traffic. The system supports repeated pulling away
and braking i n slow traffic queues.

Longitudinal dynamics management (LDM) is used, among other

things, for active cruise control stop and go function.

Long and short range radar are for active cruise control with stop
and go function.

> Gea r selector switc h (GWS) control module replace s automati c

transmission mechanical gear shift .

. Cente r console switc h cluster (SZM ) consists of two column s of

buttons on two sides of center dashboard ashtray.

Gear selector
switch (GWS)

Center consol e
switch center (SZM) •
600-12 Electrica l System-General
Power management basics

POWER MANAGEMEN T
Power management basic s
Power management strategies in 5 Series vehicles are designed to
monitor battery power, minimize powe r loss (dead battery) and
diagnose battery state of charge problems. Intelligent battery sensor
(IBS) data is continuously monitore d an d evaluated for this purpose.

During vehicle operation, engine mechanical energy is converted by

the alternator into electrical energ y and made available t o electric
loads i n the vehicle. Mos t electric load s receiv e power primarily via
switched terminal 30g and terminal 30g_f relays . Certain electric
loads are supplied unswitche d battery power directly by terminal 30
or terminal R . Example: Anti-theft alarm system is active when the
vehicle is parked and engine is shut OFF. Therefore anti-theft power
is from an unswiiched terminal.

The power management portion of the engine control module (ECM)

operating program is able to:
• Regulat e idle speed and charging voltag e while the engine is
running.
• Regulat e power consumption of electric loads with relativel y high
power demands, o r switch OFF those loads if power is needed
elsewhere.
• Switch OFF electric loads when engine is stationary either as a
timed function (via CAS and terminal 30 g relay) or in response to
electrical faults (via ECM and terminal 30g_f relay).
• Generate and store fault codes to help with vehicle or battery
diagnosis.

Additional information on IBS is in 121 Battery, Starter, Alternator.

 Electrical System-General 600-1 3
Scan tool basics

CODING, PROGRAMMING , ADAPTATIO N

Scan tool basics
The scan tool , shown her e connected to the OBD 2 plug, i s an
electronic devic e use d for the following:
• Displayin g vehicle data such a s engine, engine managemen t an d
transmission versions
• Viewing and clearing fault codes (diagnosti c trouble codes or
DTCs)
• Coding an d programming ne w control modules an d other
electronic equipmen t
• Clearing and resetting adaptation s

Coding
The procedur e of assigning one labele d group o f data t o the
operating progra m of a control module o r component i s referred to
as coding. A codable control module has a basic operating program
already installed along with several variations of operating data. Th e
coding process allows a specific set of operating data to be assigne d
to the basic operatin g progra m o f that modul e o r component t o
match a specific application .

Here are some type s o f operating requirements:

• Nomina l value s of device input signals (0.2 5 - 2.5 volts, 5 - 25
watts, etc.)
• Type of device inpu t signa l (PWM , square wave, analog )
• Operational parameters (device activation or deactivation time)
• Marke t specific operations (oxyge n sensors, fuel type, emissio n
standards)
• Countr y specifi c regulations (USA , Canada, Japan , UK , EU)
• Powertrai n configurations (manua l transmission, automati c
transmission, TLEV, ULEV , SULEV , Diesel )

Programming
BEFORE PROGRAMMIN G
. Programmin g load s applicatio n an d system-specific operatin g
I BASIC I instructions (program) int o a coded module. Programming is also a
means o f updating data an d operating instruction s previousl y
No specific operationa l (
installed in a control module .
program installed.
600-14 Electrica l System-Genera l
Adaptation

Adaptation
The engine contro l model (ECM) , automati c transmission control
module (EGS) , dynamic stabilit y contro l (DSC ) modul e and other
modules and components i n the vehicle are adaptive. The software
in each modul e learn s from use and become s adapte d t o other
accompanying modules .

When installin g a new module or component, b e sure to use the

scan tool to clear old adaptations i n order to allow the components to
readapt.

Coding an d programming procedur e

. Befor e starting the codin g an d programmin g procedure , us e a
vehicle power supply to maintain correct voltage throughou t the
electrical system. See 121 Battery, Starter , Alternator.

For the most up-to-dat e data an d progra m information , make sure

the scan tool ha s the current versio n o f CIP (coding ,
individualization an d programming) installed .

Connect BM W scan tool or equivalent t o OBD I I plug under

dashboard. See Scan tool basic s i n this repair group. In addition to
BMW scan tools, there are a number o f aftermarket tools available.
See Tools i n 020 Maintenance.
 Electrical System-General 600-1 5
Voltage and voltage drop

ELECTRICAL TROUBLESHOOTIN G
Four thing s are require d for current to flow in any electrical circuit :
• Voltage source.
• Wires or connections to transport voltage.
• Loa d o r device that use s electricity.
• Connection to ground.

Most problems ca n be found usin g a digital multimeter (vol t / ohm /

ammeter) to check the following:
• Voltage supply.
• Break s in the wiring (infinite resistance / no continuity).
• A path to ground that complete s the circuit.

Electric current is logical i n its flow, always moving from the voltag e
source toward ground. Electrica l faults can usually be locate d
through a process of elimination. When troubleshooting a complex
circuit, separate the circuit into smaller parts . General tests outlined
below may be helpful in finding electrical problems. The informatio n
is most helpfu l when used with wiring diagrams.

Be sure to analyze the problem . Use wiring diagrams t o determine

the most likely cause. Get an understanding of how the circuit works
by following the circuit from ground back to the powe r source .

When making test connections at connectors and components, us e

care to avoid spreading or damaging th e connectors or terminals .
Some tests may require jumper wires to bypass components or
connections in the wiring harness. When connecting jumper wires,
use blade connectors at the wire ends that match the siz e of the
terminal being tested. The small interna l contacts are easily sprea d
apart, and this can cause intermittent or faulty connections that can
lead to more problems.

Voltage and voltage drop

Wires, connectors, and switches that carry current ar e designe d
with very low resistance so that current flows with a minimum loss of
voltage. A voltage drop i s caused by higher than norma l resistanc e
in a circuit. This additiona l resistanc e actually decreases o r stops
the flow of current. Excessive voltage dro p can b e noticed by
problems ranging from dim headlights to sluggish wipers. Som e
common sources of voltage drops are corroded or dirty switches ,
dirty or corroded connections o r contacts, and loose or corroded
ground wires and ground connections.

A voltage drop test is a good test to perform if current is flowing

through the circuit but the circuit is not operating correctly. A voltage
drop test helps pinpoint a corroded ground strap or a faulty switch.
Normally, there should be less than 1 volt drop across most wires or
closed switches. Voltage drop across a connector or short cable
varies but should not exceed 0.3 volt.

A voltage dro p test i s generally more accurate than a simple

resistance check because the resistances involved are often to o
small to measure with mos t ohmmeters. For example, a resistanc e
as small as 0.02 Q results in a 3 volt drop in atypical 150 amp starter
circuit. (150 amps x 0.02 Q. = 3 volts).
600-16 Electrica l System-General
Voltage and voltage drop

Keep in mind that voltage with ignition key ON and voltage wit h
engine running are not the same. With ignition ON and engine OFF,
fully charged battery voltage i s approximately 12.6 volts. With
engine runnin g (chargin g voltage), norma l voltage is approximately
14.0 volts. Measure voltage at battery with ignition ON and then with
engine runnin g to get exact measurements .

Voltage, measuring
from Batter y Connect digital multimeter negative lea d to a reliable ground point
on vehicle.

NOTE—
• The negative (-) battery terminal is always a good ground point.
Battery voltag e
Connect digital multimeter positive lead to point in circuit you wish to
measure.

Check that voltage readin g does no t deviate mor e than 1 volt from
voltage at battery. If voltage drop i s more than this, check for a
No voltage
corroded connector or loose ground wire.

Load

Voltage drop, testing

Check voltage drop only when there is a load on the circuit, such as
when operating the starter motor or turning on the headlights. Use a
digital multimeter to ensure accurate readings .

Connect digital multimete r positiv e lea d to positive (+) battery

terminal or a positive power supply clos e to battery source.

Connect digital multimeter negative lea d to other end of cable or

switch being tested.

With power switched ON and circuit working, meter shows voltage

drop (difference between two points). This value should not exceed
1 volt.

Maximum voltage drop in an automotive circuit, as recommended by

the Society of Automotive Engineers (SAE) , is as follows:
• 0 volt for small wire connections
• 0.1 volt for high current connection s
• 0.2 volt for high current cables
• 0.3 volt for switch o r solenoid contacts

On longer wires or cables, the dro p may be slightly higher. In any

case, a voltage drop of more than 1.0 volt usually indicate s a
problem.
 Electrical System-General 600-1 7
Continuity, checking

Continuity, checkin g
Brake pedal in rest position
Use continuity test to check a circuit or switch. Because mos t
automotive circuit s are designed t o have little or no resistance, a
circuit or part of a circuit can be easily checked for faults using an
ohmmeter. An open circuit or a circuit with high resistanc e doe s no t
allow current to flow. A circuit with little or no resistance allow s
current to flow easily.

When checking continuity , switch ignition OFF. On circuits that ar e

powered at all times, disconnec t battery . Using the appropriat e
wiring diagram, test circuit for faulty connections, wires, switches ,
relays and engine sensor s b y checking for continuity.

Example: Tes t brake ligh t switch for continuity:

• With brak e pedal i n rest position (switc h open) ther e is no
continuity (infinit e D).
• Wit h pedal depressed (switch closed ) ther e is continuity
(0 il).

Short circuits , testin g

Short circuits are exactly what the name implies . Curren t i n the
circuit take s a shorter path than i t was designed to take. The mos t
common short that causes problem s is a short to ground wher e the
insulation o n a positive (+) wire wears away and the meta l wire is
exposed. When the wire rubs against a metal par t of the vehicle or
other ground source, the circuit is shorted to ground. I f the expose d
wire is live (positive battery voltage), a fuse blows or the circuit may
be damaged .

Short circuits vary in nature and are often difficult to locate. They can
be found using a logical approac h based o n knowledge of the
current path.

Use a digital multimeter to locate short circuits .

CAUTION—
• In circuits protected with high rating fuses (25 amp and
from Battery
greater), wires or circuit components maybe damaged before
the fuse blows. Check for wiring damage before replacing
fuses of this rating. Also, check for correct fuse rating.
Fuse box

Short-circuit
Testing with ohmmete r
—(• t o earth
— Remov e blown fuse from circuit and disconnect cables from battery.
Switch Disconnect harnes s connecto r from circuit load or consumer.

"^V Usin g a n ohmmeter, connect on e test lead to load side o f fuse

terminal (termina l leadin g t o circuit) and other test lea d to ground .

— I f there is continuity to ground , ther e is a short to ground .

600-18 Electrica l System-Genera l
Short circuits, testing

If there i s no continuity, wor k from wire harness neares t to fuse and

relay panel and move or wiggle wire s whil e observing meter.
Continue t o move down harness until meter displays a reading. This
is the location of the short to ground .

Visually inspect wire harness at this point for any faults. If no faults
are visible, carefully slice open harnes s cover or wire insulation for
further inspection. Repai r any faults found.

Testing wit h voltmete r

Remove blow n fuse from circuit. Disconnect harness connecto r

from circuit loa d or consumer .

NOTE—
• Most fuses power more than one consumer. Be sure all consumers
are disconnected when checking for a short circuit.

^. Using a digital multimeter, connect test leads across fuse terminals.

Make sure power is present in circuit. If necessary switch ignition
ON.

— I f voltage is present a t voltmeter, ther e is a short to ground .

— I f voltage i s not present, wor k from wire harness neares t to fuse and
relay panel an d move or wiggle wires whil e observing meter .
Continue to move down harness until meter displays a reading. This
is the locatio n of the short to ground .

Visually inspect wire harness at this poin t for any faults. I f no faults
are visible, carefully slice open harnes s cover or wire insulation for
further inspection. Repai r any faults found.
 611-1

611 Wiper s and Washers

GENERAL 611- 1 WIPER ASSEMBLIE S 61 1 -1 o

Wiper and washer syste m operatio n 611- 1 Windshield wipe r assembly ,
Wiper and washer system component s removing and installing 611-1 0
(Sedan) 611- 2 Rear wiper assembly 611-1 3
Wiper and washer system component s Rear wiper motor , removin g and installing . . . 611-1 3
(Sports Wagon) 611- 2 Rear window wiper pivot,
Wiper an d washer switch operation 611- 3 removing and installing 611-1 4

WIPER BLADE S AN D ARMS en- s WASHER SYSTE M 611-1 5

Wiper blad e cleanin g problems 611- 3 Windshield washe r jet,
removing and installing 611-1 6
Windshield wipe r blade, replacin g 611- 4
Headlight washer jet, removing and installing 611-1 6
Windshield wiper arms,
removing and installing 611- 4 Rear window washer jet,
removing and installing 611-1 7
Windshield wipe r blades and arms,
adjusting position 611- 6 Washer fluid reservoir components service . . 611-1 8
Rear wiper blade, replacing 611- 8 TABLES
Rear wiper arm, removing and installing 611- 9
a. Wiper blad e position in PARK 611- 6
b. Wiper blade contac t angle 611- 7

GENERAL
This repai r group cover s repair information for windshield, headligh t
and rear window wiper and washer systems.

See also :
• 020 Maintenance fo r cabin microfilte r housing remova l
• 612 Switches fo r steering colum n switc h cluster replacemen t
• EC L Electrical Componen t Location s fo r wiper an d washe r
system fuse and relay locations an d application s
• ELE Electrical Wiring Diagrams

Wiper and washer system operation

. Drive r input t o wiper and washe r syste m is via multi-functio n stalk
switch t o right of steering column . Wipe r and washer syste m
functions ar e capable of activation onc e ignition i s switched ON .
611 -2 Wiper s and Washers
Wiper and washer system components (Sedan)

Body base module (KBM) is the control hub for wiper an d washe r
operation. Base d o n driver input, rai n and light sensor signals and
vehicle speed, KB M activates the following components :
• Windshield wipe r motor dual rela y in E-box.
• Rea r window wipe r rela y in spare tire well .
• Headligh t washer relay.
• Washer pumps in washer reservoir behind lef t front wheel housing
liner.

Windshield washe r nozzle heating i s activated b y IHKA.

Wiper an d washer syste m components

(Sedan)
1. Wipe r blade s
2. Wipe r arms
3. Heate d windshield washer jet s
4. Wipe r motor assembly
5. Headligh t washer jets
6. Washe r fluid reservoir

Wiper an d washer syste m component s

(Sports Wagon )
1. Windshiel d wipe r blades
2. Windshiel d wipe r arms
3. Heate d windshiel d washer jets
4. Windshiel d wiper motor assembly
5. Rea r wiper blade
6. Rea r wiper motor assembly
7. Headligh t washe r jets
8. Washe r fluid reservoir
9. Washe r reservoi r filler neck

B510611002
 Wipers and Washers 61 1 -3
Wiper and washer switch operation

Wiper an d washer switch operation

1. Switc h wipers ON.
• Flick UP once for slow speed.
Intermittent when vehicle stops.
• Flick UP twice or push past detent for fast speed.
Slows when vehicle stops .
2. Flic k DOW N to switch wipers OFF or for single wipe.
3. Pus h IN to activate or deactivate rain sensor.
Wiper operation controlled automatically by rain intensity .
4. PUL L toward driver to activate windshield an d headlight
washers.
5. Sensitivit y adjustmen t thumb wheel for interval control.
6. PUS H away from driver to activate rear wiper in intermitten t
mode.
Continuous operatio n when in reverse gear.
7. PUS H past detent to activate rear window washer.

WIPER BLADES AND ARMS

Wiper blade cleaning problems
Common problems with the wipers include streaking o r sheeting ,
water drops after wiping and blade chatter.

Streaking is usually caused when wiper blades are coated with road
film or car wash wax.

— Clea n blades using soapy water. If cleaning does not cure problem,
replace blades.

BMW recommends replacing the wiper blades twice a year, before

and after the cold season.

Drops that remain behind after wiping are usually cause d by oil,
road film or diesel exhaust residue on the glass.

— Us e an alcohol or ammonia solution o r other non-abrasive cleaner

to clean glass.

Chatter may be caused by dirty or worn blades or by incorrect wiper

blade contact angle.

— Clea n blades and glass as described above.

— Chec k and adjust wiper arm twist. See Windshield wiper blade s
and arms, adjusting positio n in this repair group.

— I f problems persist, replace wiper blades and arms. See Windshield

wiper blade, replacin g and Windshield wipe r arms, removing
and installing, i n this repair group.
611-4 Wiper s and Washers
Windshield wiper blade, replacing

Windshield wiper blade , replacing

Pivot wiper arm off windshield. Note that arm only pivots approx.
45°.

Working at wiper blade pivot:

• Press on locking clip to release wipe r blade .
• Slide wiper blade forward (arrow) to detach from arm.

CAUTION—
• Do not allow wiper arm to snap back against windshield when
wiper blade is off.

— Installatio n i s reverse of removal .

Windshield wiper arms,

removing and installin g
Open engine hood .

Left wiper arm

Spread retaining tab s (arrows) and lift off wiper pivot nut plastic
cover (curved arrow).

CAUTION—
• Do not shear off or otherwise damage retaining tabs.

BentfeyPublishers
-con±

Remove wiper arm pivot nut (arrow). Lift arm off pivot.

Note that tightening torqu e is stamped o n wiper arm.

 Wipers and Washers 61 1 -5
Windshield wiper arms, removing and installing

Right wiper arm

Pry off wiper pivo t nu t plastic cap s (arrows).

Note that tightenin g torqu e is stamped on wiper arm link . (Plasti c

cover remove d for illustration. )

Remove wiper arm pivo t nut s (arrows) . Lift linkage off pivots .

If necessary , use pulle r t o remov e wiper arm fro m pivot .

CAUTION—
• Do not bend wiper arm while removing

— Befor e installing wipe r arms , mak e sur e wipers ar e i n PARK

position:
• Switch ignitio n ON.
• Switc h wipers O N and allow two cycles to complete .
• Switch wipers OFF. Wait for wiper moto r to come t o rest , then
switch ignition OFF.
611 -6 Wiper s and Washers
Windshield wiper blades and arms, adjusting position

Attach wiper arms and tighten pivot nuts .

• Left wiper arm: Temporarily tighten pivot nut, then check and adjust
wiper blade position. Se e Windshield wipe r blades and arms,
adjusting position in this repair group.
• Right wiper arm: Fully tighten pivo t nuts.
• If applicable, tighten pivot nuts to torques stamped on wiper arms.
• After approximately 50 minutes settling time, rechec k torques.

Tightening torqu e
Front wiper arm to wiper pivo t
• M8 nut 17-20Nm(13- 15ft-lb )
• M10 nut 30 - 35 Nm (22 - 26 ft-lb)

Right wiper arm: Check and adjust wiper blade position. See
Windshield wipe r blade s and arms, adjusting positio n in this
repair group.

Windshield wiper blades and arms,

adjusting position
Wiper blade position is set in relation to top of cowl cover at base of
windshield.
• Make sure wipers are in PARK position .
• Measure from bottom edge of wiper blade to base of windshield.
See Table a.

Table a. Wiper blade position in PARK

Left side (A) |69±3mrn(2.7 + 0.1 in)
Right side (B) 87 ±3 mm (3.4 + 0.1 in)

.corri ___B5iQ6nqi o

Wiping action is improved by correctly setting contact angle of wiper

blade (A to plane of windshield. Bot h wiper arms are designed with
a tilt adjustment for setting wiper blade contac t angle.

Plane o f
windshield

8510611013
 Wipers and Washers 61 1 -7
Windshield wiper blades and arms, adjusting position

r BMW special tool 61 6 100 or equivalent protracto r may be used to

measure wiper blade contact angle. Correct wiper blade contact
angle is in Table b

Table b. Wiper blade contact angle

Wiper blade angl e to windshiel d 86° ±1 °
(left or right)

61 6100

B510611014

Left wiper arm, adjusting

Left wiper arm attachment components :
1. Pivo t nut, M1 0
• Tighten t o 30 - 35 Nm (22 - 26 ft-lb)
2. Eccentri c washer
3. Wipe r arm
• Slide on slotted hole to adjust wiper blade angle
4. Wipe r pivot
5. Dome d adjusting disc
• Use puller to remove from pivot

Curved bottom of wiper arm contact surface and domed adjustin g

disc allow wiper blade angle adjustment.

With pivot nut finger tight, slide wiper arm up or down (arrow ) unti l
blade position and angle are correct. See Table a and Table b.

Tighten pivo t nut and recheck wiper blade position .

• I f applicable, tighten pivo t nut to torque stamped on wiper arm.
• After approximately 5 0 minutes settling time, recheck torque .

Tightening torque
Front wiper arm to wiper pivo t 30 - 35 N m (2 2 - 26 ft-lb)
(MIOnut)
611 -8 Wiper s and Washers
Rear wiper blade, replacing

Right wiper arm, adjusting

^C Wit h right wiper arm pivot nuts fully tightened :
• Remov e right wiper arm plastic trim.
• Loosen adjuster nut.
• With adjuster nut finger tight, slide wiper arm up or down (arrow)
until blade position and angle are correct. See Table a and
Table b.

— Tighte n adjuste r nu t and recheck wiper blade position .

Tightening torque
Right wiper arm adjusting nut 20Nm(15ft-lb)

Rear wiper blade, replacin g

Pivot wiper arm off rear window.

Pull wiper blade off wiper arm (arrows) .

BentleyPubiishers
B510611020

When installing, make sure wiper blade mounting tab clips firmly in
wiper arm slot (arrow).

BontloyPublishers
 Wipers and Washers 61 1 -9
Rear wiper arm, removing and installing

Rear wipe r arm, removin g and installing

Spread wiper pivo t plasti c ca p catches (curved arrows) and
remove cap (flared arrow).

S"l
^ Pivo t wiper arm off rear window, then remove mounting nut (arrow).

— Remov e wiper arm off pivot. If necessary, use puller to remove wiper
arm from pivot .

— Befor e installing wipe r arm, mak e sure wiper assembly i s in PAR K

position:
• Switch ignition ON.
• Switc h rear wiper ON and allow two cycles to complete .
• Switc h wiper OFF. Wait for wiper motor to come to rest, then switch
ignition OFF.

Attach wiper arm and tighten dow n mountin g nu t temporarily, the n

check and adjust wiper blad e position.

Rear wiper blade position

Measurement A (distance between bottom of 30mm (1.2 in)
wiper arm and rea r window lowe r edg e

— Tighte n ar m t o final torque.

Tightening torque
Rear wiper arm to wiper pivo t (M8 ) 13 M m (10ft-lb )
611-10 Wiper s and Washers
Windshield wiper assembly, removing and installing

WIPER ASSEMBLIES
Windshield wiper assembly ,
removing an d installing

CAUTION—
• Make sure wipers are parked (stalk switch in OFF position) and
the ignition is also OFF.
• Use fender cover to protect windshield.
• To avoid damaging the wiper arms and pivots, do not manually
slide or force the wiper arms across the windshield.

— Remov e wiper arms. See Windshield wipe r arms, removin g and

installing in this repair group.

— Remov e cabin microfilter housing s on left and right . See 020

Maintenance.

— Remov e front strut tower brace. Se e 310 Front Suspension .

^k Us e suitable pulle r to remove dome d adjustin g disc fro m left wiper

pivot.

Remove cowl cover panel:

• Pry out plastic rivet s (lower inset) .
• Use 5 mm Allen wrench to rotate plastic retainer s 90° (upper
inset), thus detaching panel fro m base o f windshield.
• Remov e plastic fasteners (arrows) at corners of panel.
• Lift panel off base o f windshield.
 Wipers and Washers 611-1 1
Windshield wiper assembly, removing and installing

Working at front air duct:

• Remov e 4 side duct mounting screw s (arrows).
• Rotat e center quick-release plasti c fastener (A) approx. 90° .
• Remov e Torx screw (B) at strut tower brace center anchor .
• Pus h air duct forward to expose strut tower brace mountin g
bracket bolts.

Remove strut tower brace mounting bracket bolts (arrows) and lift
out bracket .

Working at wiper motor assembly:

• Detach wiper motor electrical connector
• Loosen and remove Torx screws in order 1 - 5.
• Lift wiper motor out of cowl opening.

When installing:
• Install mounting screws hand tight at first.
• Tighten screw s in order 5 -1.
• I f wiper linkage interferes with installation of screw 4, attac h
electrical connector, switch ignition ON, then switch wipers ON
long enough to move linkage to right. Switch ignitio n OFF midwa y
through wipe cycle.

Tightening torque
Wiper moto r assembl y t o bod y 10Nm(7ft-lb)
(M6 Torx bolts )
611-12 Wiper s and Washers
Windshield wiper assembly, removing and installing

Remainder of installation is reverse of removal. Before installing

wiper arms, make sure wipers are in PARK position :
• Switch ignition ON.
• Switch wipers ON and allow tw o cycles to complete.
• Switch wipers OFF. Wait for wiper motor to come to rest, then
switch ignition OFF.
• Left wiper arm: Install domed adjustin g dis c and wiper arm.
Temporarily tighten pivot nut, then check and adjust wiper blade
position. See Windshield wipe r blades and arms, adjusting
position in this repair group .
• Right wiper arm: Install wiper arm and fully tighten pivot nuts.
• If applicable, tighte n pivo t nuts to torques stamped on wiper arms .
• When reinstalling microfilter housings, to avoid water leaks into
cabin, chec k that seals are intact an d seat correctly.
• After approximately 5 0 minutes settlin g time, rechec k wiper arm
torques.

Tightening torque
Air duct to side mounting s 4.5 N m (40 in-lb)
(M6 bolts)
Air duct to strut tower brace 3.5 Nm (31 in-lb)
center anchor (Tor x screw)
Brace to strut tower or bulkhead 30.5 N m (22 ft-lb)
bracket (use new M8 Torx bolts )
Front wiper arm to wiper pivot
• M8 nut 17-20Nm(13- 1 5 ft-lb)
• M10 nut 30 - 35 Nm (22 - 26 ft-lb)
Strut tower brace mounting 24 Nm (18 ft-lb)
bracket to bulkhead (Tor x bolts )
 Wipers an d Washers 611-1 3
Rear wiper assembly

Rear wipe r assembl y

1. Wipe r arm nut (M8)
•Tighten to 10Nm (7ft-lb)
2. Wav e washe r
3. Wipe r arm
4. Wipe r blade
5. Tor x bolt (M6 x 9 mm)
•Tighten to 10 Mm (7 ft-lb)
6. Wipe r pivot nut (M6)
•Tighten to8 Nm (6ft-lb)
7. Gaske t
8. Cove r
9. Loc k nut
10. Rear window lock release button
11. Gasket
12. Wiper pivot assembly
13. Wiper motor assembly
5—
14 14. Torx bolt (M6x 22 mm)
• Tighten to 10Nm (7 ft-lb)
B309611024

Rear wipe r motor, removing and installing

The rea r wiper motor is bolted to the Sports Wagon tailgate . The
wiper arm and blade are mounted to the rear window which is
hinged at the top. The motor drive s th e rear wiper arm via a pivot
assembly mounte d on the rea r window. For the window t o clos e
correctly and rea r wiper to operate, align the pivo t assembly o n the
glass with the drive o n the wiper moto r using BMW special too l
61 1 330.

The rea r window loc k is bolted to the rear wiper motor assembly.

— Remov e tailgat e inner trim panel. See 513 Interior Trim.

^C Workin g at rear wiper motor:

• Detac h electrica l connectors (A).
• Remov e mounting screw s (B).
• Lif t off wiper motor .

— I f replacing motor: Separate rear window loc k from rear wiper moto r
assembly and bolt to new unit .

— Reinstal l wiper moto r bu t tighten mounting bolt s finger tigh t at first.

— Attac h wiper motor electrical harness. Switch ignition ON. Cycle rear
wiper twice to mak e sure wiper motor is in PARK position . Switch
ignition OFF.
611-14 Wiper s and Washers
Rear window wiper pivot, removing and installing

Align assembly using BMW special tool 61 1 330: Position special

tool so that pin (A) on tool inserts into slot (B) in wiper motor drive.

^ Wit h rea r wiper arm vertical to glass, close rear window and allo w
journal of wiper pivot assembly to snap into bore (arrow) . Close
window completely.

— Tighte n rea r wiper motor mounting bolts .

Tightening torque
Rear wipe r motor t o tailgate 10 Nm (7 ft-lb)

Open windo w an d remove special tool.

Reinstall tailgate trim.

Rear window wipe r pivot,

removing an d installing
Remove rear wiper arm. See Rear wiper arm, removing and
installing in this repair group.

Use duct tape to hold window lock releas e button in place.

Remove nut (arrow) securin g pivo t t o window loc k release button .

 Wipers and Washers 611-1 5
Rear window wiper pivot, removing and installing

With window open:

• Carefully pry out wiper pivot assembl y trim covers.
• Remov e trim cover mountin g nut s (arrows) and pull off cover.

B309611031

k Wit h window open :

• Detac h window lock releas e button electrical connector.
• Remov e pivot assembly mountin g nut (arrow) and remove pivo t
(flared arrow).

— Installatio n i s revers e of removal .

Tightening torques
Window loc k release button to glas s 10Nm(7ft-lb)
Wiper pivot to glass (M6 ) 8 N m (6 ft-lb)

Synchronize wiper pivot and wiper motor drive. See Rear wiper
motor, removing an d installin g i n this repair group.

B309611029

WASHER SYSTE M
The windshield washer system include s electrically heated spray
jets under the engine hood, the washer fluid pump, and washer fluid
reservoir i n front of the lef t front wheel housing.

The headlight washe r system (optional ) consists o f front washer

fluid reservoir (share d with windshield washer system) , a separate
washer pump , an d washer jets in the front bumper.

The rear window washer consists of the fluid reservoir (shared wit h
windshield washer system), a separate washer pump, and a washer
jet at the top of the rea r window.
611 -16 Wiper s and Washers
Windshield washer jet, removing and installing

I Windshield washe r jet, removing an d installing

Open engine hood.

Working on underside of hood:

• Pinc h off washer hose, then detach washer fluid hose (A) from jet.
• Pres s on lock clip (B) and separate washer jet electrical connector.
• Pres s on washer jet locking clip (arrow ) and push jet u p through
hood to remove.

When installing, check that washer jet snaps in place firmly. Route
washer hose without kinks.

Check windshield washer function. Washer jet nozzl e aim is set at

factory and cannot be adjusted.

Headlight washe r jet, removing an d installing

Remove front bumper cover. See 51 0 Exterio r Trim, Bumpers.

To avoid washer fluid spillage, pinch of f washer hose with hos e

pinch tool 1 3 3 010 or equivalent.

Working at headlight washer jet:

• Detac h high pressure hose connector.
High pressur e
hose connecto r • Remov e washer jet mounting screws (arrow). Lift washer jet out of
bumper opening.

Installation is reverse of removal. Check headligh t washer function.

Nozzle aim is set at factory and canno t b e adjusted.

BentleyPubfjshers
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 Wipers an d Washers 611-1 7
Rear window washer jet, removing and installing

Rear windo w washer jet ,

removing and installing
— Remov e rea r spoiler. Se e 412 Trunk Lid , Tailgate.

^ Remov e center brake ligh t screws (arrows) and pull brake ligh t uni t
and rea r window washe r nozzl e awa y (curved arrow) from spoiler.

B510611032

Unhook washe r hos e fro m catch and pull nozzl e away fro m center
brake light assembly (arrow) .

Installation i s reverse of removal. Rout e washer hose a s before ,

making sur e i t is not kinked .
611 -18 Wiper s and Washers
Washer fluid reservoir components service

Washer fluid reservoi r component s servic e

— Washe r fluid reservoir is behind left front wheel housing liner . See
410 Fenders, Engin e Hoo d for wheel housin g line r removal.

'A. Dependin g o n model, washer reservoi r components ar e as follows:

1. Headligh t washer pum p
2. Rea r window washer pump (Sport s Wagon )
3. Windshiel d washe r pum p
4. Washe r fluid level switc h

— T o replace any component :

• Detac h electrica l connector.
• Separat e high pressure fluid hose , i f applicable .
• Rotat e component clockwise and pry out of reservoir. Be prepared
to catch dripping fluid.

— Installatio n i s reverse of removal , notin g the following:

• Replac e strainers on washer pumps.
• Coat grommet at base of pump or sensor with anti-friction agent.
• Use new hose clamps, if applicable.
• Afte r installation , check that fluid hoses ar e not kinked.

— Fil l reservoir and chec k for leaks .

 612-1

612 Switche s

GENERAL 612- 1 DASHBOARD SWITCHES 612- 8

Warnings and Cautions 612- 2 Light switch, removing and installing 612- 8
START STOP switch, removing and installing . 612- 8
STEERING WHEEL SWITCHE S 512- 2
Hazard warning, central locking switch assembly,
Multifunction steerin g wheel switches 612- 2 removing and installing 612- 8
Sport steering wheel switches 612- 3
Steering wheel switches, OTHER SWITCHE S 612- 9
removing an d installing 612- 3 Back-up light switch 612- 9
Brake light switch, removing and installin g . . . 612- 9
STEERING COLUMN SWITC H CLUSTE R
Trunk li d or tailgate release button, replacing 612-1 0
(SZL) 612- 5
iDrive controller, removing and installing . . . . 612-1 0
Steering column switch cluster (SZL) basics . . 612-5
Driver door switch, removing and installing . . 612-1 0
Steering column switch cluster (SZL) ,
removing and installing 612- 6
Airbag and horn contact spring, steering angle sensor,
removing and installing 612- 7

GENERAL
This repai r group covers replacement of electrical switches a t the
steering wheel, steerin g column, dashboard, pedal cluster, center
console and door panels.

See also the following sections:

• 210 Clutch fo r clutch switc h
• 230 Manual Transmissio n fo r manual transmission back-u p ligh t
switch
• 240 Automatic Transmission fo r automatic transmission back-u p
light switch functio n
• 250 Gearshift Linkage for automatic shiftloc k
• 320 Steering an d Wheel Alignment fo r steering whee l an d
steering colum n component s
• 520 Seats for seat position control switche s
• ECL Electrical Componen t Locations
• ELE Electrical Wirin g Diagram s
612-2 Switche s
Warnings and Cautions

Warnings an d Cautions

CAUTION—
• When working on electrical switches or lights, disconnect the
negative (-) cable from the battery and insulate the cable end
to prevent accidental reconnect/on.
• Prior to disconnecting the battery, read the battery
disconnection cautions given i n 001 Warning an d Cautions.
• To prevent marring interior trim, work with plastic prying tools or
wrap the tips of screwdrivers and pliers with tape before prying
out switches or trim.

WARNING —
• The steering wheel mounted airbag is an explosive device.
Treat with extreme caution. Follow the airbag removal
procedure in 721 Airbag Syste m (SRS) .
• Airbag removal may set SRS fault codes. The SRS indicator
light remains ON until problems are corrected and fault memory
cleared.

STEERING WHEEL SWITCHES

The steering wheel of vehicles covere d by this manual ar e equipped
with the following:
• SRS airbag and horn button
• Horn contac t
• Cellular telephone controls
• Radi o controls

To replace the steering wheel switches and buttons, remov e the

airbag first. The hor n button i s integrated wit h the airbag an d is not
replaceable separately.

Multifunction steerin g wheel switche s

1. Multifunctio n steering wheel
2. Multifunctio n switches
3. Steerin g wheel trim
4. Airba g unit and horn button
5. Mountin g bol t (M12)
• Tighten to 62.5 Mm (46 ft-lb)
6. Multifunctio n switch mounting plate

.com
B510612001
 Switches 612- 3
Sport steering wheel switches

Sport steering wheel switches

1. Spor t steering wheel
2. Mountin g bolt (M12)
• Tighten to 62.5 Nm (46 ft-lb)
3. Multifunctio n switches
4. Steerin g wheel trim
5. Multifunctio n switch mounting plate
6. Airba g unit and horn button

.com

Steering wheel switches,

removing and installing
Disconnect negativ e (-) battery cable and cover battery terminal to
keep cable from accidentally contactin g terminal.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given in 001 Warnings and Cautions .

Remove driver airbag in steering wheel. See 721 Airbag System

(SRS).

WARNING —
• The steering wheel mounted airbag i s an explosive device.
Treat with extreme caution. Follow the airbag removal
procedure in 721 Airbag System (SRS).
• Airbag removal may set SRS fault codes. The SRS indicator
light remains ON until problems are corrected and fault memory
cleared.

Multifunction steering wheel

Remove multifunction switc h mounting bracket fasteners (arrows).

Bentley
612-4 Switche s
Steering wheel switches, removing and installing

Disconnect electrical connectors (arrows).

Remove multifunction switc h fasteners (arrows). Unclip

multifunction switch in area A an d remove from bracket.

B5106120121

'A, Uncli p (A) multifunctio n switch from steering wheel trim and remove
in direction of arrow.

— Installatio n i s reverse of removal .

Tightening torques
Mounting plate to steering wheel 6 Nm (4.4 ft-lb)

.com £510612005J
 Switches 612- 5
Steering column switch cluster (SZL) basics

Sport steering wheel

^V Remov e multifunction switch mounting plate fasteners (A).

— Remov e mounting plat e (B), multifunctio n switche s and trim panel

(D) from mounts (C ) in direction of arrow.

— Disconnec t electrical connector s and remove from steering wheel.

— Remov e multifunction switc h fasteners and separate switches from

mounting plate .

— Installatio n is reverse of removal.

Tightening torques
Mounting plat e to steering wheel 6 Nm (4.4 ft-lb)

STEERING COLUM N SWITCH CLUSTER (SZL)

Steering column switch cluster (SZL) basic s
The steering column switch cluster (SZL) integrates the following
functions:
Airbag and horn • Wiper and washer switc h
contact spring,
steering angle • Headlight bea m switch
sensor
• Turn signal switc h
• Cruise contro l
• Airbag and horn contact spring, steering angle sensor with stop pin
(A)
• On-board computer (BC ) switch

SZL switches are optical devices.

Steering
column
switch
cluster

BS106120131

Steering column switch cluster (SZL),

removing and installing
Disconnect negativ e (- ) battery cable and cover battery terminal to
keep cable from accidentally contacting terminal.

CAUTION—
• Prior to disconnecting the battery, read the battery
disconnection cautions given in 001 Warnings and Cautions .
612-6 Switche s
Steering column switch cluster (SZL), removing and installing

Remove driver airbag in steering wheel. See 721 Airbag System

(SRS).

WARNING —
• The steering wheel mounted airbag is an explosive device.
Treat with extreme caution. Follow the airbag removal
procedure in 721 Airbag System (SRS).
• Airbag removal may set SRS fault codes. The SRS indicator
light remains ON until problems are corrected and fault memory
cleared.

Extend steering column as far back and as low as possible.

Remove steering wheel. See 320 Steering an d Wheel Alignment.

CAUTION—
• Do not move front wheels from straight-ahead position while
steering wheel is off.
• While steering wheel is off, do not turn or twist the airbag and
horn contact spring.

Remove steering column trim. See 513 Interior Trim.

Remove SZL mounting fasteners (arrows) and pull cluster back.

Detach electrical connector s and remove SZL.

If replacing SZ L remember to:

• Remove turn signal, cruise control and windshield wiper stalk
fasteners (arrows) and swap stalks to new part.
• Remove airbag and horn contact spring. See Airbag and horn
contact spring, steering angle sensor, removing and installing
in this repair group.

Installation i s reverse of removal. Use BMW scan tool to code,

program and carry out steering angle sensor adjustment.

B510612014
 Switches 612- 7
Airbag and horn contact spring, steering angle sensor, removing and installing

Airbag and horn contact spring, steering angl e

sensor, removing an d installing
— Remov e SZL. Se e Steering column switc h cluster (SZL),
removing and installing in this repair group .

^V. Workin g a t contact sprin g module :

• Unlock catches A in direction of arrows.
• Lif t contact spring of f SZL.

CAUTION—
• Do not rotate inner ring of contact spring. If necessary, secure
ring using adhesive tape.

When installing contac t spring, mak e sure electrical connectors

(arrows) are properly aligned.

.com

DASHBOARD SWITCHE S
Light switch , removin g and installing
^C Us e plastic prying tool to lever ou t light switch beze l wit h switch.
• Note that switch bezel snaps into dashboard using lug in areas A.
• Unclip switch electrica l connector .

— Detac h switch from bezel and replace.

— Installatio n is reverse of removal .

612-8 Switche s
START STOP switch, removing and installing

START STOP switch , removin g an d installing

^k Usin g a plastic prying tool, lever STAR T STOP switch out of
dashboard i n direction of arrow.

— Disconnec t electrical connector an d remove.

— Installatio n i s reverse o f removal .

Hazard warning, centra l locking switch

assembly, removin g an d installing
^ Usin g a plastic pryin g tool, release hazard warning switch retaining
tabs (A) and pull switch out of dashboard. Disconnec t electrical
connector (B) and remove switch.

— Installatio n i s reverse o f removal .

OTHER SWITCHE S
Back-up ligh t switc h
For manual transmission back-up ligh t switch replacement, see
230 Manual Transmission.

Automatic transmission electronic s combines th e following

functions:
• Neutra l safety switch.
• Back-up light switch.
 Switches 612- 9
Brake light switch, removing and installing

Brake light switch, removin g and installing

Remove left lower dashboard trim (above pedals). See
513 Interior Trim.

Working at pedal cluster, disconnect electrical connector (arrow)

from brake light switch .

H, Pull brake light switch (A) from bracket mounting in direction of

arrow.

— T o install, depress brake pedal and hold down with brake pedal prop
tool.

— Slid e brake light switch as far as it will go into brake light switch
holder.

— Attac h harness connector.

— Gri p brake light switch holder, slowly return brake pedal to rest
position and pull switch back to stop.

— Chec k function of brake light switc h with assistant.

Trunk lid or tailgate release button , replacin g

. Workin g at lef t door jamb:
• Open OBD II plug cover (A).
• Reach through opening and push out trunk lid or tailgate switch
(B).
• Detach electrical connector.

Installation i s reverse of removal.

8510612018]
612-10 Switche s
/Drive controller, removing and installing

iDrive controller, removing an d installing

— Remov e center console. See 513 Interio r Trim .

^, Remove iDrive controller fasteners (arrows) and remove from

center console.

— I f installing new controller use BMW scan tool to code and program
new unit.

Driver door switch, removing and installing

The maste r front and rea r window switches are ganged with child
safety switch and outside mirror control switch on the driver door
arm rest .

— Remov e door trim panel. See 51 3 Interior Trim.

^. Remove fasteners (black arrows). Unlock retaining clips

(white arrows) and remove switch from door panel.

— Installatio n i s reverse of removal.

 620-1

620 Instrument s

GENERAL 620-1 INSTRUMENT CLUSTE R SERVIC E 620- 2

Instrument cluste r replacemen t 620- 2
INSTRUMENT CLUSTE R . 620-1
Instrument cluster , removing and installing . . . 620- 2
Instrument cluster layout. 620-1

GENERAL
This repai r group covers removal and installation o f the instrument
cluster. The cluster does not contain any replaceable components. If
necessary, replace the entire unit.

See 020 Maintenance for an explanation of condition based service

(CBS) and Check Control, bot h of which use instrument cluster
displays.

INSTRUMENT CLUSTER
Instrument cluste r layou t
1. Speedomete r
2. Indicato r and warning light s
3. Tachomete r
4. Tri p odometer reset button
5. Fue l gauge
6. Cloc k
Outside temperature
Check Control
Indicator and warning lights
7. Automati c transmission gear selected
On-board computer (BC)
Next scheduled service
Odometer
Trip odometer
Flat tire monitor (FTM) initialization
Engine oil level
Settings and information
8. Fue l mileage gauge
620-2 Instrument s
Instrument cluster replacement

INSTRUMENT CLUSTER SERVICE

Instrument cluster replacement
If replacing th e instrument cluster , kee p in mind that vehicle
odometer reading and other data is redundantly stored in the
instrument cluster , light module (LM) and car access system (CAS)
module.

If LM, CAS and the instrument cluster are replaced simultaneously,

the odometer reading ma y be lost as a result.

Instrument cluster, removing and installing

Extend steering column as far back and down as it will go.

Remove instrument cluster fasteners (arrows). Tilt cluster backward

(curved arrow ) out of dashboard .

Unlock an d disconnect harnes s connector s fro m back of cluster.

Slide cluster sideways to clear steering wheel.

Installation is reverse of removal, noting the following:

• Make sure instrument cluster harnes s connector lockin g levers are
in fully unlocke d positio n befor e installing connector.
• Code replacement cluste r usin g BM W scan tool.

Instrument cluster to dashboard 1.5Nm(8.5in-lb)

 630-1

630 Light s

GENERAL . 630-1 Daytime runnin g ligh t bulb, replacin g

Bulb applications . 630-2 from 3 / 2007 630 - 16
Exterior lights overview . 630-3 Headlight assembly , removing and installing . 630-1 6
Exterior lighting functions . 630-3 Front turn signal bulb, replacing 630-1 8
Xenon headlights . 630-5 Side turn signal bulb, replacing 630-1 9
Adaptive headlight control . 630-5 Front parking ligh t bulb , replacing 630-1 9
Exterior light troubleshooting . 630-6 Front foglight bulb, replacing 630-2 0
Interior lights-overview . 630-7 Front foglight, adjustin g 630-2 0
Interior lighting modules and functions . 630-7 TAILLIGHTS 530-2 1
Warnings and Cautions . 630-8 Taillight assembly (Sedan) 630-2 1
HEADLIGHTS . 630-9 Taillight assembl y (Sports Wagon) 630-2 1
Halogen headlight component s . 630-9 Taillights service 630-2 2
Xenon headlight components Center brake light service 630-2 4
(to 03 / 2007) . 630- 9 License plat e ligh t bulb, replacin g 630-2 5
Xenon headlight components INTERIOR LIGHT S 530-2 5
(from 03 / 2007) 630-10
Interior ligh t bulb replacement 630-2 5
Headlight aim, adjusting 630-10
Headlight bulb , replacin g TABLES
(halogen headlight assembly) 630-11 Bulb applications: Sedan, Sport s Wago n 630- 2
Headlight bulb , replacin g
(xenon headlight assembly ) . 630-13

GENERAL
This repai r group covers interior and exterior lights.

See also:
• 600 Electrical System-Genera l for bus system basic s
• 611 Wipers and Washers for headlight washer syste m
• 612 Switches for light switch replacement
• 620 Instruments fo r instrument cluster removal
• ECL Electrical Component Location s
• ELE Electrical Wirin g Diagram s
630-2 Light s
Bulb applications

Bulb application s
Bulb applications for Sedan an d Sports Wagon models

Table a. Bulb applications: Sedan, Sports Wagon

Location Type and wattag e
Headlights
• Low beam (halogen) H755 w
• Low beam (xenon )
6 cylinde r D1S
V8 to 9 / 2005 D2S
V8 from 9 / 200 5 D1S
• Hig h beam H755 w
• Daytime runnin g
from 03 72007 (xenon only ) H8
Back-up lights 921

Brake lights
• Sides 7506 21 w
• Cente r LEDs
Licence plate lights 6418 5 w
Rearfoglight 7506 21 w
Taillights 750621 w
Parking lights
to 03 / 2007 2825
from 03 / 2007 3457
Turn signals
• Front
to 03 / 2007 750721 w
from 03 / 2007 345721 w
• Rear
to 03 / 2007 7507 21 w
from 03 / 200 7 7506 21 w
• Side
to 03 / 2007 2827
from 03 / 2007 LED
Interior lights
• Cargo area light (D-pillar) 6411
• Dom e and map lights, front or rear
to 03 / 2007 6486
from 03 / 2007 2886
• Door courtesy lights
to 03 / 200 7 6411,6418, 6486
from 03 / 2007 6411, 6418, 2886X
• Footwell light s Festoon C10 w
• Glove compartment 6418
• Trunk light Festoon C1 0 w
• Vanity mirro r Festoon C10 w
 Lights 630- 3
Exterior lights overview

Exterior light s overview

The exterior lighting syste m consists of:
• Headlight s wit h low beams, hig h beam s and parking light s
• Turn signal light s
• Brak e lights including center brak e light
• Sid e turn signals
• Taillights
• Back-up light s
• Fron t an d rear foglights
• Rai n and light sensor with automatic driving light contro l
• Ligh t modul e (LM )

The optional bi-xeno n headlight s ar e available i n conjunction wit h

adaptive headlights .

Light module

Light modul e (LM ) control s and monitors exterior lights as well as

adaptive headligh t function . It also controls instrument pane l
dimming an d include s emergenc y function s in case o f a fault.

Exterior lighting functions

Automatic headlight control is activated by turning the light switch
to the AUTO headlight position . Drivin g lights are switched O N
together with the side light s by the automatic drivin g lights contro l
system. Light s activation i s based on input from the rai n and ligh t
sensor (RLS), depending o n ambient lightin g conditions (tunnel ,
twilight, rain or snow).

In case of RLS malfunction, light module (LM ) illuminates th e

headlights.

WARNING —
• The automatic headlight control cannot serve as a substitute for
personal judgement in determining when to switch the lights
ON. For example: The system cannot detect fog.

On vehicles equipped wit h iDrive, the sensitivity of the lightin g

activation point ca n be adjusted by the driver. Refer to the owner' s
manual.

Foglights ar e activated b y pressing the foglight button; switch

parking light s or low beam headlight s ON first.

Turn signal s are activated via the turn signal stalk on the steering
column switch cluster (SZL) , an optical switch. A defective bulb i n
the front or rear turn signals results in the remaining lights flashing at
double th e normal rate .

The one- touch function flashes th e turn signals three times. Th e

function can be modified using car / key memory (persona l profile).
See 515 Central Locking and Anti-theft .

Hazard light s ar e activated by depressing the hazar d ligh t switch

ganged wit h the central locking switch and locate d in the cente r of
the dashboard .
630-4 Light s
Exterior lighting functions

Turn signals have priority if the hazar d flashers are activated first.
Hazard flashers have priority if the turn signal is activated first .

Vehicle with alarm system: Hazar d lights flash for up to 6 minutes if

alarm i s triggered an d not switched off. LM receives the flasher
request directly from hazard switch.

When central locking is activated, car access system (CAS)

supplies a signal to LM via K-CAN to flash the hazard lights
indicating that the vehicle i s locked. This visual feedback ca n be
deactivated usin g car/ key memory (persona l profile). Se e 515
Central Locking and Anti-theft .

Taillights. In case of a taillight bulb failure or other malfunction, the

brake light bulbs are used as a substitute. The bulbs are dimmed by
a pulsed signal to provide substitute taillights .

Brake lights, brake force display. Brak e lights illuminate in two

stages, depending o n how sharply th e brakes are applied :
• Normal braking: Outboar d an d center brake lights illuminate
• Sharp braking: additional brake light bulb illuminates. Note that this
bulb also functions as the rearfoglight. Foglights ON overrides the
brake force display .

Brake force display, standard on 5 Series vehicles, is activated at

speeds abov e 5 kph (3 mph). The threshold for triggering brake
force display is deceleration abov e 5 m / s 2 (0.003 mach).

The brake light switch is powered by CAS with terminal R ON.

Back-up lights. Automatic transmission signal for activating back-

up lights i s communicated fro m automatic transmissio n control
(EGS) module vi a K-CAN to LM.

Manual transmission back-up light signa l i s communicated by

reverse gear switch to LM.

Bulb monitoring. L M monitors the exterior lighting system with the

lights switche d ON or OFF i f terminal 15 is active (ignitio n ON).

Cold monitoring with lights OFF: Brie f current pulses, so short that
bulbs are not illuminated, ar e used for measurement purposes. L M
evaluates individual bul b outputs to establish whether there is a line
break or a bulb i s defective.

The number of current pulses is large during the first 4 seconds after
terminal 1 5 ON to check whether bulbs are in working order before
setting off. This function is referred to as the predrive check. The
number of pulses is then reduced after the predrive check Pulse d
power is then applied to the bulb s ever y 1. 5 minutes.

The center brake light is not included in the cold monitoring system
because LEDs react too fast to the current pulse an d would
consequently light up. The bi-xenon headlight i s also not included in
the cold monitoring because of legal restrictions.

Hot monitoring with lights ON is based on measuring the current of

individual bulbs, used to detect an overload or interruption (break).

Pathway / follow me home light i s activated by the headligh t

flasher positio n o n the SZL stalk.
 Xenon headlights
To 3 / 2007: Vehicles equipped wit h the optional xenon headlight s
(also known as high intensit y discharge or HID headlights) utiliz e a
special hig h voltage bulb and control unit for the lo w beam
headlights. High beam bulbs are conventional halogens.

Bi-xenon headlights

From 3 / 2007: The optional bi-xenon headlight is equipped wit h an

34
electrically activated shutter which directs the low beam cone of light
in the same direction as the high beam.
1. Xeno n bulb
2. Bul b for side light and daytime running light
3. Bul b for cornering ligh t
4. Mirro r for cornering light

Adaptive headlight contro l

Bi-xenon headlight s are equipped with an adaptive headlight control
system.

Adaptive headlight s rotate slightl y as the front wheels (3 ) turn,

providing an enhanced lighting path as the vehicle travels through a
turn. The light / dark transition point (2 ) is designed to be to the righ t
of the anticipated curve of the vehicle (1 ) in order to reduce the ris k
of glare to oncoming traffic.

Headlights ar e rotated via a stepper motor in each headligh t

assembly. LM controls the amount of headlight rotation based on the
following information:
• Steering angle (fro m steering angl e sensor )
• Roa d speed (from vehicle speed sensors)
• Yaw rate (from DSC acceleration sensor)
630-6 Light s
Exterior light troubleshooting

Exterior ligh t troubleshootin g

The following table use d i n conjuction with a BMW scan tool and a
digital volt/ohm meter (DVOM) can speed diagnosis of exterior light
faults.

Table b . Exterior light troubleshooting

Possible fault or light failure Faulty, missing signal to light module (LM) Signal transmitting control module
No permanent high beam, Steering_columnjever_operation Steering column switch center (SZL )
emergency function while lever
remains pressed .
Turn signal i s not automaticall y Steering wheel angle (physical angle ) Steering colum n switc h center (SZL)
canceled.
Turn signal i s not automaticall y Steering_wheeLangle_fault (steerin g angl e Steering colum n switc h center (SZL)
canceled. sensor (SAS))
Restricted monitoring o f back u p Trailer_status Trailer modul e (AHM )
lights.
Flashing frequency not doubled . Trailerjndicator _fault_statu s Trainler modul e (AHM )
Lights permanentl y ON. Headlamp_status Rain an d light sensor (AIC )
No back u p lights. Transmission_gear_status Electronic transmissio n contro l (EGS )
No headlight flasher, brake lights , Terminal_FLstatus Car access syste m (CAS )
turn signals a t Terminal R .
Position light remains ON . Key_Jn_ignition_status Car access syste m (CAS )
No brake lights via active cruise Brake_Jight_control Dynamic stabilit y contro l (DSC )
control (ACC) .
No stop position for turn signals, Steering_column_lever_operation Steering column switc h center (SZL)
emergency function while leve r
remains pressed.
No hazard warning lights wit h Anti-theft_alarm_control Anti-theft alarm (DWA )
antitheft alarm.
No alarm acknowledgment active . Alarm_acknowledgment_control Anti-theft alarm (DWA)
 Lights 630- 7
Interior lights overview

Interior lights overview

Interior lights consis t of:
• Fron t dome lights with switches
• Rea r dome light s with switches
• Readin g light s with switches
•Trunk light (Sedan)
• Cargo compartment ligh t (Sport s Wagon)
• D-pilla r light s (Sport s Wagon)
• Vanity mirror lights, driver and passenger
• Footwel l lights, driver and passenger
• Doo r courtesy lights
• Doo r handle courtes y lights

Interior lightin g module s and functions

Interior lightin g function is distributed over several contro l module
that communicate wit h each other via K-CAN.

Basic body module (KBM )

The basic body module (KBM) control s interior an d rear door
lighting. Fron t door lightin g i s controlled by:
• to 09 / 2005 Fron t door modules (TMFA, TMBF).
• from 09 / 2005 Bod y gatewa y modul e (KGM) .

The interior lights are pulse-width modulate d (PWM) and controlle d

by various inputs. PWM adjusts brightness in relation to vehicle
battery voltage . Above 12. 8 volts PW M is adjusted to provide a
power output of 100%. Below 12. 8 volts the interio r lights di m
accordingly.

Electric loa d shutdow n

Some interior lights suc h as map, glovebox and trunk ca n b e
switched on when the vehicle is OFF. To prevent battery drain ,
interior lighting i s switched of f after 16 minutes.

Instrument light s
Instrument lighting via terminal 58 g and K-CAN is pulse-widt h
modulated an d features two brightness levels :
• Brightnes s level for instrument lighting is toggled via switch on turn
signal lever (light s ON) .
• Brightness level for function lighting is not dimmed and is switched
on at full brightness .
630-8 Light s
Warnings and Cautions

Warnings an d Cautions

WARNING —
• There is high pressure inside a halogen bulb. Bulb temperature
may exceed 700° Celsius. Wear safety glasses and gloves
when removing and installing a halogen bulb.
• Do not look directly at an operating xenon bulb. The UV
emissions are approximately 2.5 times that of a comparable
halogen bulb.
• When working on electrical systems, remove the fuse protecting
the circuit under repair. See ECL Electrical Componen t
Locations fo r fuse locations.

CAUTION—
• Xenon bulbs and igniter modules are electrically sensitive. Use
an antistatic ma t and work with caution. Se e 600 Electrical
System-General.
• Do not operate the xenon control module unless a bulb is
connected.
• Before servicing th e headlight system, switch electrical
consumers OFF. Switch ignition OFF and remove ignition key.
• Do not handle bulb glass with bare fingers. Dirt and skin oils
cause a bulb to fail prematurely. If necessary, wipe bulb using a
clean cloth dampened with rubbing alcohol.
• Use only original equipment replacement bulbs. Non-original
bulbs may cause false failure readings in Check Control.
• To avoid marring car paint or trim, work with plastic prying tools
or wrap the tips of tools with tape.
 Lights 630- 9
Halogen headlight components

HEADLIGHTS
Halogen headligh t component s
1. Parkin g light bulb
• 2825 5 w
2. Parkin g light bulb socket
1 2
3. Hig h and low beam bulb
•H755w
4. Bul b retaining spring
5. Hig h beam bulb cover
6. Lo w beam bulb cover
7. Tur n signal bulb
•750721 w (amber )
8. Tur n signal socket

.com

Xenon headligh t component s (t o 03 / 2007)

1. Parkin g light socket with bulb
2. Haloge n high beam bul b
• H7 55 w
3. Bul b retaining spring
4. Hig h beam bulb cover
5. Xeno n bulb igniter
6. Tur n signal bulb
•750721 w
7. Tur n signal socket
8. Xeno n bulb cover
9. Cove r
10. Xenon low beam bulb
• 6 cylinder: D1 S
•V8to9/2005:D2S
11. Adaptive headlight control module
12. Xenon bulb ignition unit
13. Headlight vertica l aim stepper motor
630-10 Light s
Xenon headlight components (from 03/2007)

Xenon headlight components (from 03 / 2007)

1. Parkin g light bulb

1 2 3 4 5 6
•H355w
2. Daytim e runnin g light bulb
• H8 35 w
3. Hig h bea m bulb cover
4. Cove r
5. Cove r
6. Xeno n bulb retainer
7. Xeno n low beam bulb
•D1S
8. Tur n signal bulb
•345721 w
9. Tur n signal socket
10. Xenon bulb cover
11. Adaptive headlight control module
12. Headlight vertical aim stepper motor
13. Xenon bulb ignition unit

Headlight aim, adjusting

Adjust headlight ai m with correct tire pressures, fuel tank full, and
weight of one person (approximately 7 5 kg or 16 5 Ib) i n driver seat.

When adjusting xenon headlights, switc h lights ON, then wait 80

seconds before proceeding with adjustment. Do not move or vibrate
vehicle during that time.

Working above and i n rear of headlight housing , us e screws to

adjust headlight aim :
• A: Primarily vertical aim adjustment
• B: Primarily lateral aim adjustmen t

Note that turning eac h adjuster affects both planes of adjustment.

 Lights 630-1 1
Headlight bulb, replacing (halogen headlight assembly)

Headlight bulb, replacin g

(halogen headlight assembly )
Switch lights OFF.

Left headlight: Remov e air filter housing. See 020 Maintenance .

Low beam bul b

To 03 / 2007: Working in engine compartmen t behind headlight ,
rotate cap (A) approx. 30° counterclockwise and remove from
headlight.

From 03 / 2007: Unclip cover cap (A) and remove from headlight (B )
towards rea r o f vehicle.

Rotate bulb socke t (A) counterclockwise and remove from

headlight.
630-12 Light s
Headlight bulb, replacing (halogen headlight assembly)

X. Remov e bulb from socket in direction of arrow.

— Replac e bulb. D o not touch bul b surfac e with bare finger. Oil from
skin can cause bul b to fail prematurely.

— Installatio n i s reverse of removal . Mak e sure cover i s firmly seated

on headlight .

.com
B510630014

High beam bulb

Working in engine compartment behin d headlight, rotat e cap (A)

approx. 30° counterclockwise and remov e from headlight.

Rotate bulb socket (A) counterclockwise an d remove from

headlight.
 Lights 630-1 3
Headlight bulb, replacing (xenon headlight assembly)

Remove bulb from socket i n direction of arrow.

Replace bulb. D o not touch bul b surface with bare finger. Oil from
skin can cause bulb to fail prematurely.

Installation is reverse of removal. Mak e sur e cover is firmly seate d

on headlight.

BentleyPyWlshers
.com B510630014

Headlight bulb, replacing

(xenon headlight assembly)
To 3 / 2007: Vehicle s equipped with the optional xeno n headlight s
(also know n as high intensit y discharge o r HID headlights) utiliz e a
special high voltage bulb and control unit for the low bea m
headlights. Hig h bea m bulb s are conventional halogens .

From 3 / 2007: Th e optional bi-xeno n headlights ca n be switche d

over from low-beam to high-beam. When the low beams are ON, the
lower part of the light beam is blocked by a shutter directly in front of
the reflector. When high beams are switched ON, an electro-magnet
is energized by light modul e (LM) . The electro-magnet flips the
shutter open, allowing th e entire beam of light generated b y the
xenon bulb to be the high-beam. Th e halogen hig h bea m bul b in
earlier model s i s now used for daytime runnin g lights .

Remove headlight fuse(s). See ECL Electrical Componen t

Locations.

WARNING —
• High voltage in xenon headlights is hazardous. Disconnect
xenon headlight components from power supply before
removing.
• The physical and mechanical properties of xenon bulb and
igniter module are very sensitive. Use an antistatic mat and
work with caution.

Remove headligh t assembly. See Headlight assembly, removing

and installing in this repair group .

Xenon low beam bulb, replacing

Unlock headlight bul b cove r retaining clip s (small arrows ) and
remove cover (arrow).
630-14 Light s
Headlight bulb, replacing (xenon headlight assembly)

To 02/2005: Remove retaining spring (A). Rotate igniter (B)approx.

30° counterclockwise an d remove . Electrica l connector (C) is
automatically released .

To 02 / 2005: Unloc k retainin g rin g (A) and remove bulb from

headlight assembly .

X, Fro m 02/2005: Disconnect electrica l connecto r (A). Press tab

(arrow) and rotate igniter (B ) approx. 30° counterclockwise and
remove.

— Replac e bulb. D o not touch bul b surface with bare finger. Oil from
skin can cause bulb to fail prematurely .

— Installatio n i s reverse of removal . Make sur e cover is firmly seate d

on headlight .
 Headlight bulb, replacing (xenon headlight assembly)

High beam bulb : to 3 / 2007

Working i n engine compartmen t behin d headlight , rotat e cap (A )
approx. 30° counterclockwise an d remove from headlight .

Rotate bulb socke t (A ) counterclockwise and remov e from

headlight.

^V Remov e bulb from socket i n direction of arrow.

— Replac e bulb . D o not touch bul b surface with bare finger. Oi l from
skin can cause bul b t o fail prematurely.

— Installatio n is reverse of removal. Mak e sure cover is firmly seate d

on headlight.
630-16 Light s
Daytime running light bulb, replacing from 3/2007

Daytime running light bulb, replacing

from 3 / 2007
Working in engine compartment behind headlight , rotat e cap (A)
approx. 30° counterclockwise an d remove from headlight.

. Disconnec t electrica l connecto r (A) . Rotat e bulb (B)

counterclockwise an d remove from headlight (C).

Replace bulb. Do not touch bul b surface wit h bar e finger. Oil from
skin can cause bulb to fail prematurely .

Installation is reverse of removal. Make sure cover is firmly seated

on headlight.

Headlight assembly, removing and installing

Xenon headlight: Remove headlight fuse(s). See ECL Electrica l
Component Locations .

WARNING—
• High voltage in xenon headlights is hazardous. Disconnect
xenon headlight components from power supply before
removing.
• The physical and mechanical properties of xenon bulb and
igniter module are very sensitive. Use an antistatic mat and
work with caution.

Lift off trim strip with seal (A).

 Lights 630-1 7
Headlight assembly, removing and installing

Remove bumpe r cove r fasteners (A).

Working i n engine compartmen t behin d headlight , rotat e cap (A)

approx. 30 ° counterclockwise an d remove from headlight .

Working above headlight:

• Remov e upper headligh t assembly fastener s (A) .
• Loosen headligh t assembl y fastener s (inset) just enough t o
remove headlight .
630-18 Light s
Front turn signal bulb, replacing

Pull bumper cover (A) forward then pull out headlight slightl y and
disconnect electrical connector in back. Remove headlight in
direction o f arrow.

When installing, se t gaps from top (below fender) and bottom (above
bumper cover) according to specifications.

Headlight installation gaps

Dimension A (belo w fender edge) 4.0 ± 1 0 mm (0.16 ± 0.04 in)
Dimension B (above bumper cover) 3.0 ± 1 3 mm (0.12 ±0.05 in)

Adjust headligh t aim when done. Se e Headlight aim, adjusting in

this repair group.

Front turn signal bulb , replacing

^, Twist turn signal bulb socket (A) to remove.

— Replac e bulb. Do not touch bul b surface with bare finger. Oil from
skin can cause bul b to fail prematurely .

— Installatio n is reverse of removal.

 Lights 630-1 9
Side turn signal bulb, replacing

Side turn signal bulb, replacing

^ Us e plasti c pryin g tool or finger to push sid e turn signal housin g
forward (white arrow) . Pivot housing awa y from fender (curve d
arrow) and remove .

— Rotat e bulb socket an d remove . Replac e bulb. D o not touch bul b

surface with bare finger. Oil from skin can cause bul b to fail
prematurely.

— Installatio n i s revers e of removal .

Front parking light bulb, replacing

— Remov e headligh t hig h beam bulb . See Headlight bul b replacing ,
for you r model 5 Series i n this repai r group.

^{ Rotat e socket (A) approx. 30° counterclockwise and remove fro m

headlight assembly . Disconnec t electrica l connector an d remov e
socket from vehicle .

— Replac e bulb . D o not touch bulb surfac e with bare finger . Oi l from
skin can cause bul b t o fail prematurely.

— Installatio n i s reverse of removal .

630-20 Light s
Front foglight bulb, replacing

Front foglight bulb , replacin g

— Remov e engin e lower covers . Se e 020 Maintenance.

^, Remov e fasteners (arrows ) and remove foglight splas h shield (A).

V, Workin g behin d end of front bumper cover:

• Detach foglight harness connector (A) .
• Twist foglight socket (B) to remove.

— Replac e bulb. D o not touch bul b surfac e with bare finger. Oil from
skin can cause bul b to fail prematurely.

— Installatio n i s reverse o f removal.

— Adjus t foglight ai m through slo t i n front bumper cover . See Front

foglight adjusting in this repair group.

Front foglight, adjusting

Adjust foglight aim with correct tire pressures, fuel tank full, and
weight of one person (approximately 75 kg or 165 Ib) in driver seat.

Working above an d on inside o f foglight, us e screw (A) to adjust

foglight aim .

B510630011
 Lights 630-2 1
Taillight assembly (Sedan)

TAILLIGHTS
Taillight assembly (Sedan)
1. Tailligh t socket
2. Sealin g gasket
3. Brak e light bulb
•7506
4. Tur n signal bul b
•to 0372007:7507
•from 03/2007: 7506
5. Tailligh t and parking light bulb
•7506
6. Back-u p light bulb
•921
7. Rea r foglight, brake force display light
•7506
8. Tailligh t lens

Taillight assembly (Sports Wagon)

1. Tailligh t sealing gasket, outboard
2. Tailligh t and parking light bulb
•7506
3. Tur n signal bulb
•7507
4. Brak e light bulb
•7506
5. Tailligh t sealing gasket, inboard
6. Tailligh t socket, inboard
7. Rea r foglight, brake force display ligh t
•921
8. Back-u p light bulb
•921
9. Tailligh t lens, inboar d
BentleyPublisher 10. Mounting clip
11. Taillight lens, outboard
 Electrical Component Locations ECL-5 9
Passenger compartment components

Fig 73 Lef t bank front pipe and catalytic converter

(N62 engine)

Left ban k catalytic converter:

• B62201 Pre-catalys t oxygen sensor, left ban k
X62202 • B6220 2 Post-catalys t oxygen sensor, left ban k
• X62202 Oxyge n senso r connecto r
B62201

B62202
!

Fig 74 Righ t bank front pipe and catalytic converter

(N62 engine)

Right bank catalytic converter :

• B6210 1 Pre-catalys t oxygen sensor, right ban k
• B62102 Post-catalyst oxygen sensor , righ t ban k
• X62102 Oxygen sensor connector

Fig 75 fron t pipes and catalytic converters

(N62TU engine)

Left bank catalytic converter :

• B62102 Post-catalyst oxygen sensor, righ t ban k
• B6220 1 Pre-catalys t oxygen sensor, left ban k
• X62102 Oxygen sensor connector
• X62201 Oxyge n sensor connecto r
• X62202 Oxyge n sensor connecto r

Passenger compartment components

Fig 76 To p of windshield

In headliner:
• B57b Rai n an d light senso r
• B400 Microphon e
• B429 a Hands-fre e microphon e
B429a S38 a B40 0 • H23 Passenger airba g deactivate d warnin g ligh t
• S38a Sunroo f switc h
• S253a Emergenc y cal l button
ECL-64 Electrica l Componen t Location s
Seat components

Fig 93 Drive r door

Behind trim:
• B78a Airba g crash sensor
• E88 Door courtesy light
•G14b Sideairbag
• H59a Tweeter
• M21 Window regulato r motor
• M408 Soft-close lock motor
• S246 Doo r lock motor
• X257 Driver door electronics harness connector

Fig 94 Lef t rear door

M20a Behind trim:

X1260
• E90a Doo r courtesy ligh t
gBB| • G20a Rea r side airba g
S255a

G20a
X1781
E90a
X10140
"\3 • H78a Midrange speake r
• M20 a Window regulato r motor
• S255a Doo r lock motor
• X273 Left rea r door electronic s harness connector
'
•X1260 Connector
•X1781 Connector
•X10140 Connector

Seat component s
Fig 95 Drive r seat

t> .. - 3 ' 3 M50 a Seat control motors, underneath seat :

/ •• ,~ •'.'/', -i. X14016 • M50a Sea t angle adjustment motor
• M52 a Seat height adjustment moto r
• M55a Lumba r suppor t adjustment moto r
• M191 Seat depth adjustment motor
• X14010 Connector
•X14012 Connector
• X14016 Connector

Fig 96 Drive r seat

. Sea t control motor, underneath seat :

• M51 a Seat fore-aft control moto r
M51a • X14014 Connector
X14014
X14305 • X14305 Connector
 Electrical Component Location s ECL-6 5
Seat components

Fig 97 Drive r seat

Seat control motor, underneat h seat :

• M55c Lumba r suppor t driv e uni t
• X729 Connector
• X1503 Connector
• Y193 Vaive block, lumba r suppor t

Fig 98 Drive r sea t

Underneath seat :
• A853 Backres t width adjustment (activ e backrest) modul e
•X11550 Connector
•X11548 Connecto r
•X11549 Connector

X11549 „ .
B510ocl106

Fig 99 Drive r seat backrest

Seat rear panel removed:

• M53 a Backres t angle adjustmen t motor
• X729 Connector
•X1503 Connecto r
• Y193 Valve block, lumbar support

Fig 100 Driver seat backrest

Seat rea r panel removed :

• M106 Upper backres t angle adjustment moto r
•X18307 Connector
 Electrical Wiring Diagrams ELE- 2
Schematic convention s
The schematics (wiring diagrams ) divide the vehicle electrica l syste m int o individual
Incomplete component Complete circuits. Interactin g electrical components ar e shown on one schematic.
(dashed outline) component
(solid outline )
Electrical components are represented in such a way that their genera l layou t an d
HIT l F 2 « function are self-explanatory. The y are usually arranged in the diagrams s o that th e
1 |f j1 5 A
11 current path can be followed from positive at the top to negative a t the bottom .
1 l l1

16 Y X1001 6
• If a schematic span s several pages , this fact is clearly indicate d at the top of each
page.
X18820 X1882 2 X110 1 XI882 5 X1882 8 • A component (o r connector) which is completely represented in the schematic i s
shown as a solid box.
Wire size (in mm 2) • A component (o r connector) which ha s other connectors in addition t o the one s
! STAR T
shown i n the schematic i s shown with a dashed line .
07
0.75 5 0.3 5 0.3 5 05 0.3 5
GN/SW SW.G E SW-V I BR'R T SW V I | G E BR • Switches and relays are always show n i n rest position (generally OFF) .
26 6 1 02 23 3 40 X6020 4
_». 1_ » A602 0
f| Engin e control
I) modul e (ECM)
t f3
for-, t
1 1 fop- , |W« | H-
t ,1 | >-| for- i module 4
131 1 T3 1 i T 31 1 31 iTa i i
31 ^~- _3 6„ 37~ Y X6020 4 5 X6020J
^Ox / I
Pins in connecto r
0.350. 50 5 1.5
BR.'GN GES W GE'B R BR

X18827 X1882 6
4 |
X154 4 * * >
[" ~ 1 K11 8
Wire color
11
11
(German abbreviation )
11

Connector continue s L

in another diagra m

Component Groun d
code

B701ele001
 Symbols
Fuse Resistor Bulb LED
The schematics utilize simplified electrical symbols.

Ignition
coil
Variable
resistor ! Connector
(removable)
jj, Groun d

1
Heater Control Wire
element module connection Switch

<§> Motor /- Relay Shielded

wire
4, Ligh t
-¥• sensitiv e
Jf diod e
B701ele002

Wire insulation colors i n this section are given with German colo r abbreviations.

Wire sizes follow the DI N (European) convention.

Example: 0.5 wire i s 1 /2 mm2 in cross-section area. This corresponds to approx. SA E

16 gauge wire .

BMW identifies many electrical circuits with unique designations which follow the DI N
standard. Also, BMW designates electrica l components, junction s and grounds wit h a
unique alphanumeric designation , most of which also follow the DI N standard.

B701eie003

Electrical Wirin g Diagram s ELE- 3

Wiring Diagrams Inde x Electrical Wirin g Diagram s ELE- 4
Component Page Component Pag e
Alternator, battery, intelligent batter y sensor (IBS ) Central locking , tailgate (Wagon from 09 / 2005) ELE-39 6
Alternator, battery, intelligent batter y sensor (IBS ) (M54 engine) ELE-14 4 Central locking , trunk li d (Sedan) ELE-39 3
Alternator, battery, intelligent battery sensor (IBS) Comfort access module , powe r supply ELE-39 1
(N52 engine u p to 03 / 2007) ELE-14 4 Driver's door module , powe r suppl y ELE-38 2
Alternator, battery, intelligent batter y sensor (IBS ) Passenger's doo r module , powe r suppl y ELE-38 2
(N52 engine or N54 engine as of 03 / 2007) ELE-14 5 Clutch
Alternator, battery , intelligent batter y sensor (IBS) Clutch switch module (N5 4 engine) ELE-18 5
(N62 engine or N62 TU engine up to 03 / 2007) ELE-14 3 Clutch switc h module (except N54 engine) ELE-18 7
Alternator, battery, intelligen t battery sensor (IBS ) Dynamic Stabilit y Contro l (DSC )
(N62TU engine as of 03/2007) ELE-14 3 DSC control module , powe r supply (u p to 03 / 2007) ELE-26 3
Battery se e Alternator, battery, intelligent batter y sensor (IBS) DSC control module, powe r supply (a s of 03 / 2007) ELE-26 4
Bit serial data interfac e (BSD) DSC, sensor s (u p to 09 / 2005) ELE-26 7
Bit serial data interfac e (N5 2 engine u p to 03 / 2007) ELE-20 0 DSC, sensor s (a s of 09 / 2005) ELE-26 9
Bit serial data interface (N52 engine a s o f 03 / 2007) ELE-20 0 DSC, sensor s (DSC Dynamni c Stabilit y Control Premium) ELE-27 1
Brakes DSC switch functions (up to 03 / 2007) ELE-26 5
Brake ligh t switch (M54, N6 2 and N62 TU engines) ELE-13 5 DSC switch functions (as of 03 / 2007) ELE-26 5
Brake light switc h (N52 engine with Dynamic Stabilit y Contro l PLUS ) . . . . ELE-186 DSC switch functions (DSC Dynamni c Stabilit y Contro l Premium ) ELE-26 6
Brake ligh t switch (N52 engine with Dynami c Stabilit y Control Premium) . . ELE-186 Engine managemen t (fue l injection, ignition , turbocharger )
Brake ligh t switch (N54 engine) ELE-18 5 Accelerator pedal modul e (M5 4 engine ) ELE-13 5
Brake vent flaps (N52 engine or N54 engine ) ELE-27 3 Accelerator peda l modul e (N5 2 engine ) ELE-18 7
Brake vent flaps (N62 TU engine) ELE-27 3 Accelerator peda l module (N6 2 engin e o r N62 TU engine) ELE-15 3
Car access system (CAS) Accelerator pedal modul e (N5 4 engine ) ELE-18 5
Car acces s system, powe r supply (u p to 03 / 2005) ELE-25 9 Air suppl y (N5 2 engine ) ELE-19 3
Car access system , power supply (a s of 03 / 2005) ELE-25 9 Air suppl y (N5 4 engine) ELE-19 4
Car access system, terminal control (N6 2 engine u p to 09 / 2005) ELE-25 4 Boost pressur e control (M54 engine) ELE-16 7
Car access system, terminal control (N6 2 T U engin e a s of 09 / 2005). . . . ELE-25 7 Camshaft positio n (M5 4 engine) ELE-14 0
Car access system , terminal control (withou t N6 2 engine u p to 09 / 2005) ELE-25 6 Camshaft positio n (N6 2 engine or N62 TU engin e u p to 09 / 2005) ELE-17 2
Car access system, terminal control Camshaft positio n (N6 2 engine o r N62 TU engin e as of 09 / 2005) ELE-17 3
(without N6 2 TU engine as of 09 / 2005) ELE-25 8 Crankshaft positio n senso r (M5 4 engine ) ELE-13 8
Crankshaft positio n senso r (N6 2 engin e or N62 TU engine) ELE-15 0
Car information computer (CIC )
Crankshaft senso r (N5 4 engine) ELE-18 4
CIC Car information computer ELE-28 9
Diagnostic module , fue l tank leakag e (M5 4 engine ) ELE-14 8
CIC Car information computer, power supply ELE-28 8
Diagnostic modul e fo r fuel tank leakag e (N5 2 an d N5 4 engines) ELE-21 0
Center consol e switch center Diagnostic module , fue l tank leakage (N6 2 engine o r N62 TU engine). . . .ELE-160
Center console switch center, power suppl y (u p to 09 / 2005) ELE-28 1 DISA changeover valv e (M5 4 engine) ELE-13 7
Center console switch center, powe r suppl y DME control module , powe r supply (M5 4 engine) ELE-14 7
(as of 09/2005 up to 03/2007) ELE-28 2 DME control module , powe r supply (N5 2 engine ) ELE-20 8
Center consol e switc h center, power supply (a s of 03 / 2007) ELE-28 3 DME control module , powe r supply (N5 4 engine) ELE-20 9
Central lockin g system DME control module , power supply (N6 2 engine o r N62 TU engine) ELE-17 1
Central locking, driver's door ELE-38 0 DME inteface signals (N5 4 engine) ELE-19 9
Central locking, fron t ELE-39 2 DME main rela y (M5 4 engine ) ELE-14 6
Central locking, passenger's door ELE-38 0 E-box fan (M54 engine ) ELE-13 2
Central locking, rea r doors and fuel filler flap ELE-38 1 E-box fan (N52 an d N5 4 engines) ELE-18 4
Central locking , tailgate (Wagon to 03 / 2005) ELE-39 4 E-box fa n (N62 engin e o r N62 TU engine) ELE-15 1
Central locking, tailgate (Wagon from 03 / 2005 t o 09 / 2005) ELE-39 5 Exhaust fla p (N52 and N5 4 engines) ELE-18 0
Wiring Diagram s Index Electrical Wirin g Diagrams ELE- 5
Component Page Component Page
Exhaust flap (N62 engine or N62 TU engine) ELE-15 0 Throttle valv e (N5 2 engin e a s of 09 / 2005) ELE-19 1
Fuel injector s (M54 engine) ELE-13 3 Throttle valve (N62 engin e o r N62 TU engine ) ELE-16 5
Fuel injector s (N62 engine or N6 2 TU engine) ELE-15 1 Valve gear (N5 2 engine ) ELE-18 2
Fuel injector s (N52 engine ) ELE-18 9 Valve gear (N5 4 engine ) ELE-21 1
Fuel injector s (N54 engine) ELE-19 0 VANOS solenoi d valve s 1 and 2 (N62 engine o r N6 2 TU engine ) ELE-17 4
Fuel pum p (M54 engine) ELE-13 4 VANOS valves (M5 4 engine ) ELE-14 1
Fuel pum p (N52 engine a s of 03 / 2004 up to 09 / 2005) ELE-19 1 Variable intak e system (N6 2 engine ) ELE-16 6
Fuel pump (N62 engin e or N62 TU engine up to 09 / 2005) ELE-15 9 Variable intak e syste m (N6 2 T U engine) ELE-16 6
Fuel pum p (N6 2 engine o r N62 TU engin e as of 09 / 2005) ELE-15 9 Variable valv e timing gea r 1 (N62 engine o r N62 TU engine ) ELE-17 5
Fuel tank vent valve (M5 4 engine) ELE-14 8 Variable valve timing gea r 2 (N62 engin e o r N62 TU engine) ELE-17 6
Fuel tank vent valve (N52 an d N54 engines) ELE-21 0 Vehicle speed contro l (M5 4 engine ) ELE-13 4
Fuel tank vent valve (N62 engine or N62 TU engin e u p to 0 9 / 2005 ). . . . ELE-160 Vehicle spee d contro l (N5 2 engin e u p to 09 / 2005) ELE-20 3
High pressur e fuel system (N52 and N54 engines) ELE-18 8 Vehicle spee d contro l (N52 engine a s of 09 / 2005) ELE-20 3
Idle speed control valve (M5 4 engine) ELE-13 7 Vehicle spee d signal ELE-14 1
Ignition coils (M5 4 engine) ELE-14 9 Engine cooling system
Ignition coils (N5 2 engine ) ELE-21 2 Engine cooling system (M54 engine) ELE-13 9
Ignition coils (N54 engine) ELE-21 4 Engine coolin g system (N5 2 engin e up to 03 / 2007) ELE-19 5
Ignition coils 1 (N62 engine or N62 TU engine) ELE-17 7 Engine coolin g syste m (N5 2 engine as of 03 / 2007) ELE-19 6
Ignition coils 2 (N62 engine or N62 TU engine) ELE-17 8 Engine coolin g system (N5 4 engine) ELE-19 7
Knock control (N6 2 engine or N6 2 TU engine) ELE-15 4 Engine coolin g system (N6 2 engine o r N6 2 TU engine , u p to 03 / 2007) . .ELE-168
Knock sensors (M54 engine) ELE-13 6 Engine cooling system (N6 2 engin e or N62 TU engine, as of 03 / 2007 ). . ELE-169
Knock sensors (N52 and N5 4 engines) ELE-18 8
Engine oil supply
Local CAN-bus (N62 engine or N62 TU engine) ELE-17 0
Oil supply (M5 4 engine ) ELE-14 0
Low pressure fuel system (N5 4 engine) ELE-19 2
Oil supply (N52 engine ) ELE-19 8
Mass air flow sensor, hot-fil m (M54 engine) ELE-13 8
Oil supply (N54 engine ) ELE-19 9
Mass ai r flow sensor, intak e pip e pressur e senso r
Oil supply (N6 2 engine o r N6 2 TU engine , up to 0 9 / 2005) ELE-17 9
(N62 engine o r N62 TU engin e u p to 09 / 2005 ) ELE-16 4
Oil supply (N62 engine o r N62 TU engine , a s of 09 / 2005 ) ELE-17 9
Mass ai r flow sensor and intak e pipe pressure sensor
(N62 engineer N6 2 TU engin e as of 09 /2005) ELE-16 4 Fuses ELE-9 - 116
Oxygen sensors after catalytic converter (N6 2 engine) ELE-16 3 Ground connections
Oxygen sensor s afte r catalyti c converte r (N6 2 T U engine) ELE-16 3 Ground connection X6 (M54 engine ) ELE-26 0
Oxygen sensors before catalytic converter (N6 2 engine ) ELE-16 1 Ground connectio n X6 (N52 engine ) ELE-26 1
Oxygen sensors befor e catalytic converter (N62 TU engine) ELE-16 2 Ground connectio n X751 7 (N62 engine ) ELE-26 2
Oxygen sensors befor e catalytic converter (M54 engine ) ELE-13 1 Heating and air-conditioning
Oxygen sensor, lambda contro l (N52 and N54 engines) ELE-18 1 Blower / independent ventilatio n ELE-38 3
Power train CAN-bu s (M5 4 engine ) ELE-14 2 Heating an d air conditioning contro l unit , power supply (IHK A Basic ) ELE-38 4
Power train CAN-bus (N52 and N54 engines u p to 03 / 2005) ELE-20 4 Heating an d air conditioning contro l unit , power suppl y
Power train CAN-bus (N52 and N54 engines as of 03 / 2005 (IHKA Hig h u p to 09 / 2005) ELE-38 5
with DS C Dynamic Stabilit y Contro l PLUS) ELE-20 5 Heating an d air conditioning contro l unit , power suppl y
Power train CAN-bus (N5 2 and N5 4 engines (IHKA Hig h a s of 09 / 2005) ELE-38 6
with DS C Dynamic Stabilit y Control Premium ) ELE-20 6 Horn
Secondary air injection pum p (N6 2 engine or N6 2 TU engine) ELE-17 1 Horn ELE-40 1
Secondary air system (M54 engine) ELE-14 5
Secondary ai r system (N5 2 and N5 4 engines) ELE-20 7
Ignition switc h se e Starter
Throttle valve (M54 engine ) ELE-13 6
Wiring Diagram s Inde x Electrical Wiring Diagrams ELE- 6
Component Page Component Page
Instrument cluste r Light switch uni t (S8) ELE-37 3
Instrument cluster, power supply ELE-28 7 Low beam / high bea m (with Xenon lights u p to 03 / 2005) ELE-32 2
Instrument gauges / indicators (N62 engine or N6 2 TU engine) ELE-17 0 Low beam / high bea m (wit h Xenon lights as of 03 / 2005 u p to 09 / 2005) ELE-32 3
Warning and indicator lights ELE-28 7 Low beam / high bea m (wit h Xenon lights a s of 09 / 2005 u p to 03 / 2007) ELE-32 4
Integrated supply module (IVM) Low beam / high bea m (wit h Xenon lights a s of 03 / 2007) ELE-32 5
Integrated supply modul e (IVM) Low beam / high bea m (withou t Xenon lights u p to 03 / 2005) ELE-31 8
(N62 engine or N62TU engine up to 09/2005) ELE-11 7 Low beam / high bea m (w/ o Xenon lights as of 03 / 2005 u p to 09 / 2005). ELE-319
Integrated supply module (IVM) Low beam / high bea m (w/ o Xenon lights a s of 09 / 2005 u p to 03 / 2007). ELE-320
(N62 engine or N62 TU engine as of 09 / 2005) ELE-12 0 Low bea m / high bea m (withou t Xenon light s a s of 03 / 2007) ELE-32 1
Low beam / rain sensor (RL S Rain / light senso r u p to 03 / 2005 ) ELE-37 4
Intelligent batter y sensor (IBS ) se e Alternator, battery,
Low beam / rai n sensor (RLS Rain / light sensor 0 3 / 2005 t o 09 / 2005) . ELE-37 4
intelligent batter y sensor (IBS)
Low beam / rain sensor (RLS Rai n / light sensor from 09 / 2005) ELE-37 5
Lighting Low beam / rai n sensor (RL S Rain / light solar sensor ) ELE-37 5
Backup lights (automatic transmission) ELE-37 1 Side light, parking light , brake light (up to 03 / 2005) ELE-35 0
Backup lights (automatic transmission a s of 03 / 2007) ELE-37 1 Side light, parking light , brake light (from 03/2005 up to 09/2005) ELE-35 2
Backup lights (M54 engine with manual transmission ) ELE-36 8 Side light, parking light, brake ligh t (from 09 / 2005 u p to 03 / 2007) ELE-35 4
Backup lights (N52 engine up to 09 / 2007) ELE-37 0 Side light, parkin g light, brake light
Backup lights (N52 engin e a s of 09 / 2007) ELE-37 0 (Sedan with Xenon light s up to 03/2005) ELE-33 2
Backup lights (Sedan with N62 engine with manual transmission) ELE-36 8 Side light, parking light , brake light
Backup lights (Wagon with N62 engine with manual transmission) ELE-36 9 (Sedan with Xenon lights as of 03 / 2005 up to 09 / 2005) ELE-33 4
Basic body module, power supply ELE-38 3 Side light, parking light, brake light
Direction indicator lights (Sedan up to 03 / 2005) ELE-36 0 (Sedan with Xenon lights a s of 09 / 2005 u p to 03 / 2007) ELE-33 6
Direction indicator lights (Sedan as of 03 / 2005 u p to 09 / 2005 ELE-36 1 Side light, parking light, brake ligh t
Direction indicator lights (Sedan as of 09 / 2005 u p to 03 / 2007) ELE-36 2 (Sedan without Xenon light s up to 03 / 2005) ELE-32 6
Direction indicator lights (Sedan as of 03 / 2007) ELE-36 3 Side light, parking light, brake ligh t
Direction indicator lights (Wagon up to 03 / 2005) ELE-36 4 (Sedan withou t Xenon lights as of 03 / 2005 u p to 09 / 2005) ELE-32 8
Direction indicator lights (Wagon as of 03 / 2005 u p to 09 / 2005) ELE-36 5 Side light, parking light, brake light
Direction indicator lights (Wagon as of 09 / 2005 u p to 03 / 2007) ELE-36 6 (Sedan withou t Xenon light s as of 09 / 2005 u p to 03 / 2007) ELE-33 0
Direction indicator lights (Wago n as of 03 / 2007) ELE-36 7 Side light, parkin g light, brake light
Fog lights (up to 03 / 2005) ELE-37 2 (Wagon with Xenon lights up to 03 / 2005) ELE-34 4
Fog lights (from 03 / 2005 u p to 09 / 2007) ELE-37 2 Side light, parking light, brake light
Fog lights (as of 09 / 2007) ELE-37 3 (Wagon with Xenon lights as of 03 / 2005 u p to 09 / 2005) ELE-34 6
Interior lights (Sedan or Wagon with SHD Slide/til t sunroof 2) ELE-37 8 Side light, parking light, brake light
Interior lights (Wago n with SHD Slide/tilt sunroof 2) ELE-37 9 (Wagon wit h Xenon light s as of 09 / 2005 up to 03 / 2007) ELE-34 8
Light module (Sedan with Xenon lights up to 03 / 2005) ELE-29 0 Side light , parking light , brake light
Light module (Seda n with Xenon lights as of 03 / 2005 u p to 0 3 / 2007) . . ELE-301 (Wagon without Xenon lights up to 03 / 2005) ELE-33 8
Light module (Seda n with Xenon lights as of 03 / 2007) ELE-31 3 Side light, parking light, brake light
Light module (Seda n without Xenon lights up to 03 / 2005) ELE-29 3 (Wagon without Xenon lights as of 03 / 2005 up to 09 / 2005) ELE-34 0
Light modul e (Sedan w/o Xeno n lights as of 03 / 2005 u p to 0 3 / 2007) . . ELE-304 Side light, parking light, brake light
Light modul e (Seda n without Xenon lights as of 03 / 2007) ELE-31 6 (Wagon without Xenon lights as of 09 / 2005 u p to 03 / 2007) ELE-34 2
Light module (Wagon with Xenon lights u p to 03 / 2005) ELE-29 6 Side light, parking light , brake light (Sedan a s of 03 / 2007) ELE-35 6
Light module (Wagon with Xenon lights as of 03 / 2005) ELE-30 7 Side light, parking light , brake ligh t (Wagon as of 03 / 2007) ELE-35 8
Light module (Wago n without Xenon lights up to 03 / 2005) ELE-29 8
Light module (Wagon without Xenon lights as of 03 / 2005) ELE-31 0
Light module, power supply (SMG transmission control up to 03 / 2005). . ELE-229
Light module, powe r supply (SMG transmission control as of 03 / 2005). . ELE-230
Wiring Diagrams Inde x Electrical Wiring Diagram s ELE- 7
Component Page Component Page

Mirror Starter
Electric outside mirror, driver's side ELE-37 7 Convenient star t (M54 engine ) ELE-24 8
Electrochromic mirro r (Sedan an d Wagon) ELE-37 6 Convenient star t (N52 engin e u p to 09 / 2005) ELE-20 1
Electrochromic mirro r (Coupe an d Convertible) ELE-37 6 Convenient star t
MOST networ k (N52 engin e wit h Dynamnic Stabilit y Contro l PLU S a s of 09 / 2005) . . . .ELE-25 0
Audio system controller, power suppl y ELE-28 8 Convenient start
MOST-bus network (up to 09 / 2006) ELE-40 7 (N52 o r N54 engine wit h Dynamni c Stabilit y Contro l Premium ) ELE-25 2
MOST-bus network Convenient start (N62 engin e o r N62 TU engine u p to 09 / 2005) ELE-15 5
(without CIC Car Informatio n Computer a s of 09 / 2006) ELE-40 8 Convenient star t (N62 engin e o r N62 TU engine a s of 09 / 2005) ELE-15 7
MOST-bus network (with CIC Car Information Computer) ELE-40 9 Steering
On-board diagnostic s (OBDII ) Active steering (up to 09 / 2005) ELE-27 4
OBDII socket (M54 engine o r N62 engine) ELE-12 3 Active steering (a s of 09 / 2005) ELE-27 5
OBDII socke t (N52 engine u p to 09/2005) ELE-12 4 Active steering, powe r suppl y (A L active steerin g up to 09 / 2005) ELE-27 6
OBDII socke t (N5 2 engine as of 09/2005 u p to 03/2007) ELE-12 5 Active steering, power suppl y (A L active steering as of 09 / 2005) ELE-27 6
OBDII socket (N52 engine a s of 03 / 2007 u p to 09 / 2008) ELE-12 6 Body gatewa y modul e powe r supply ELE-28 6
OBDII socke t (N52 engine o r N5 4 engine as of 09 / 2008) ELE-12 7 Closed circuit current infringemen t shutdow n ELE-28 4
OBDII socket (N62 TU engine up to 03 / 2007) ELE-12 8 Controller ELE-28 5
OBDII socket (N62 TU engin e as of 03 / 2007 u p to 0 9 / 2008) ELE-12 9 Micro-power modul e (vehicle s without Bod y Gatewa y Module ) ELE-28 5
OBDII socke t (N62 TU engine a s of 09 / 2008) ELE-13 0 Safety and gateway module, powe r suppl y ELE-27 7
Power sunroo f Servotronic (u p to 09 / 2005) ELE-27 8
Servotronic (a s of 09 / 2005) ELE-27 8
Electric sunroo f (Seda n t o 09 / 2005) ELE-39 7
Steering colum n switch center, powe r supply (u p to 03 / 2005) ELE-23 6
Electric sunroo f (Sedan from 09 / 2005) ELE-39 8
Steering column switch center, powe r suppl y
Electric sunroof (Wagon to 09 / 2005) ELE-39 9
(as of 03 / 2005 u p to 09 / 2005) ELE-23 8
Electric sunroof (Wagon from 09 / 2005) ELE-40 0
Steering column switch center, power suppl y
Power window s (as of 09 / 2005 u p to 03 / 2007) ELE-24 0
Heated windshield washe r jets ELE-38 6 Steering column switch center, power suppl y
Power window, driver's door (wit h KGM body gatewa y module) ELE-38 9 (as of 03 / 2007 u p to 09 / 2007) ELE-24 2
Power window, driver's door (without KGM bod y gateway module ) ELE-38 8 Steering column switch center, powe r supply (a s of 09 / 2007) ELE-24 4
Power window, passenger's door (wit h KGM bod y gateway module ) ELE-38 9
Tire pressure contro l
Power window, passenger's doo r (without KG M bod y gatewa y module ) . . ELE-38 8
Tire pressur e contro l (RDS) ELE-27 9
Power window, rear left door ELE-39 0
Tire pressure control system, powe r suppl y ELE-28 0
Power window, rear right door ELE-39 0
Rear window defogger ELE-38 7
Seats
Driver's seat heating (with SMFA Seat module u p to 03 / 2007) ELE-40 2
Driver's seat heating (wit h SMFA Seat module a s of 03 / 2007) ELE-40 3
Driver's seat module, power supply ELE-40 6
Passenger's seat heating (with SMBF Seat modul e u p to 03 / 2007) ELE-40 4
Passenger's seat heating (with SMBF Seat module as of 03 / 2007) ELE-40 5
Passenger's seat module, powe r supply ELE-40 6
Wiring Diagrams Inde x Electrical Wiring Diagram s ELE- 8
Component Page Component Page
Transmission
EGS Gear selector switch (EGS transmission contro l 6HPTU) ELE-24 7
EGS Mechatronics, power supply (M5 4 engine) ELE-22 1
EGS Shift loc k ELE-22 1
EGS Steptronic switch (up to 03 / 2005) ELE-21 6
EGS Steptronic switch (as of 03 / 2005 up to 09 / 2005
without N6 2 or N62 TU engine) ELE-21 7
EGS Steptronic switch
(as of 09/2005 without N6 2 TU engine ) ELE-21 8
EGS Steptronic switch
(as of 03 / 2005 u p to 09 / 2005 wit h N62 engine) ELE-21 9
EGS Steptronic switch (N62 TU engine) ELE-22 0
EGS Transmission control, power supply (N52 engine u p to 09 / 2005). . . ELE-22 3
EGS Transmission control, power supply (N5 2 engine a s of 09 / 2005). . . ELE-22 3
EGS Transmission control, powe r suppl y (N6 2 engine ) ELE-22 2
EGS Transmission control, power supply (N62 TU engine ) ELE-22 2
SMG control module, power supply (M5 4 engine) ELE-22 4
SMG control module, power supply (N6 2 engine) ELE-22 5
SMG control module, powe r supply (N5 2 engine u p to 09 / 2005) ELE-22 6
SMG control module, power supply (N5 2 engin e as of 09 / 2005) ELE-22 7
SMG control module, power supply (N62 TU engine a s of 09 / 2005) . . . . ELE-22 8
SMG Hydraulic system (M54 engine) ELE-23 2
SMG Hydraulic syste m (N52 engine) ELE-23 4
SMG Hydraulic syste m (N62 engine ) ELE-23 3
SMG Selector lever and gear indicator lighting ELE-23 5
SMG Sensor system (M54, N62, N52 engines) ELE-23 1
VTG transmission control (up to 09 / 2005) ELE-24 5
VTG transmission control (as of 09 / 2005) ELE-24 6
Windshield wiper/washer system
Wiper / washer system (up to 03 / 2005) ELE-41 0
Wiper / washer system (as of 03 / 2005 u p to 09 / 2005) ELE-41 1
Wiper / washer system (as of 09 /2005) ELE-41 2
Fuse F00 1
N62 engin e

1 A41 a
"3 ,_ , p g Fus e holder ,
front
60A j

3' X11002

6.0
RT/WS
1 X13844
_£b
"• A600 9
Integrated
I
ifc \ ^" ^ '
'
I3 ) DM E relay 1

I ^
-*• —^

[ 30A

-j - j
22 X60094 3 ' '~ " 8 ' X6009 3 7 ' X6009 2

0.5 2 5 0,75 1. 5
BR RT/WS RT/W S RT/B L

23 X60002 1J[X60212 s | X60001

-*. ~ n A600 0 T A6021 0 ~" A600 0
[©] DM E control module 1 B Variabl e valve timing S^ l DM E contro l modul e
^32J gea r contro l modul e ^ <
IOf —i
fail
X6820 X682 0 X682 0 X682 0 X682 0

0 75 0 75 0.7 5 0.7 5 0.7 5

RT/WS RT/W S RT/W S RT/W S RT/W S
3'
center of engine)
075 07 5 0.7 5 0.7 5
RT R TR TR T
1 X6105 1 X610 6 1 X610 7 1 X610 8 21 J X7001 4
Y6105 ^ ' n Y610 6 " 1 Y6107 " Y610 8i " ]A7001 0
Fuel injector. Fue l injector, j Fuelinjector , Fue l injector , j |jjg | j Sequentia l
cylinders cylinder si cylinde r 7 cylinder si i manual
(SMG)

B510ele20333

Electrical Wiring Diagram s ELE- 9

 Electrical Wiring Diagrams ELE-1 0

Fuse F001 Fus e F002

M54 engine with SMG Sequential Manual Transmission N6 2 engine

1' 41a
I p use
30 1 p8 older,
^ A41 a A | ? ont

r~~a 0 1- ,C Q
8
Fus e holder , front | 60 A

60A L j
j 3 X1100 2

3 " ' X 1 1 0 0 2 RT/W S

6.0
RT/WS 1 |
X1384 4
1 A600 9
X18326 : integrate d suppl y
i
I Z\1
I _» I B + potentia l distnbu- I LZ3 ~ " \
I tor * — f_] _I
I
2* X64101 i_ ^ L
4.0
~ F00 2

I X8681 |J20 A

A8681

electronics 2 2 T X6009 4 1 2 ' X6009 3

( 30A
0.5 2.5
RT/SW

2v X8681 2 3 1 X60002
X6821 X682 1 X682 1 X682 1 X682 1
r "t-» . " " A600 0

RT/GE O H DM E , 0.5 0. 5 0. 5 0. 50 5
T contro l RT/SW RT/S W RT/S W RT/S W RT/S W

E
8 X6318 ^ ] modu e
1 X6224 2
~| | K631 8 L j
, JB6224 2
_ _ -rTn M I Hydrauli c pum p relay,
^y j SM G ' ' Exhaust
; camshaf t
j | sensor 2
2 Y X631 8
1 X6224 11 X628 4
4.0 r '"1B6224 1 [ ^--]Y628 4
RT Intake j | VANOS
(camshaft i , solenrad
2 | X6975 I1 sensor 2 1 ( valve 2
i_, i i_ . i exhaust
[•-"J 1 Y697 5 ! X6120 1 X628 3
1I Hydrauli c pump ' ~~JY6120 I " '"1Y628 3
1<
j \™** '< ^n°o? d
] vent valve , ] valve 2,
1_« —•j i 1 intake
B510ele21848 B510ele20334
Fuse F00 2
N62 TU engine

A41a
Fuse holder, front

60A

X11002
60
RTAA/S

X13844
n A600 9
Integrated supply
module (IVM)
3) DM E rela y 1

F002

12 T X6009 3

05 25
BR OR

23 X60002 X6821 X6821

A6000
DME contro l 05 05
05 05 05
module OR OR OR OR OR

3 X6224 2

1 Exhaus t camshaf t
1 ' senso r 2

X62241 1 X628 4
1B62241 I Y628 4
'Intake camshaft 1 VANO S solenoi d
[sensor 2 valve 2 . exhaust
1 X612 0 1 X628 3
"'Y6120
1 Fuel tank ven t VANOS solenoi d
valve valve 2, intak e
l

B510ele24299

Electrical Wiring Diagram s ELE-1 1

 Electrical Wiring Diagrams ELE-1 2

Fuse F003
N62 engine

15 A149 an A41 a
Car access system , , ,_ „ Fus e holder , fron t

BOA

7 Y X1031 8

3 Y X1100 2

0.5 6. 0
GN/WS RT/W S

6 X600 91 X1384 4
"" A600 9
Integrated supply
module IV M
1) Ignitio n coi l un-
loader rela y

F003
;*( 20 A

X13701 2 Y X6009 1

31L
6.0 2. 5
BR G N

X6831 X683 1

1.0 1. 0 iC 1.0
GN G N GN GN
3 X615 1 3 |
X615 2
1 T615 1 * ~ ~ T615 2 T6153 T6154
j Ignitio n coil. Ignitio n coil, Ignition coil, Ignition coil,
, cylinde r 1 cylinde r2 cylinder 3 cylinder 4

B510ele20335
Fuse F004
N62 engine

15 "" A149 a A41a

Car access system Fuse holder , front
F8
f3 0 1
I
60A I

7 T X1031 8

X11002

0.5 6.0
GN/WS RT/WS

X6009
A6009
Integrated suppl y
module IVM
1) Ignitio n coil un -
toader rela y

6.0 2.5
BR GN
X6832

1.0 1.0 1.0

GN GN GN

T6155 T6156 T6157 ~~j T615 8

Ignition coil, Ignition coil , Ignition coil . * Ignitio n coii,
cylinder 5 cylinder 6 I cylinde r 7 I cylinde r 8

B510ele20336

Electrical Wiring Diagrams ELE-1 3

 Electrical Wiring Diagrams ELE-1 4

Fuse F005
N62 engine

"" A41 a
Fuse holder , front
["30 1 F8

60A

X11002

Rt/WS

X 13844
A6009
Integrated supply
module IV M
4) DM E rela y 2

F005

1
22 Y X6009 4

0.5 1.5
BR RT/GE

X6822 X6822 X6822

A6000
DME control module
0.5 0.5 0.5 0.5 0.5 0.5 0.5
GE RT/GE RT/GE RT/GE RT/GE RT/GE RT/GE
31 J

X62141 2
X6279 1 X6282
,. ,_., Y627g
,662141 f '~" j Y6282
! Intake X62142 ' jCharactensti c | | VANOS solenoid
X6203 camshaft i ! [ma p,
XRPR1
X6281 valve , exhaust
~j B6203 ~] B620 7 ~"JB62142 L 1 thermostat [ ' "JY6281 L J
] Crankshaft I Hot-film | Exhaust 1 IVANO S solenoi d
! senso r ! air mas s camshaft va |ve intak e
JI meter _ J sensor I J

B510ele20337
Fuse F005
N62 TU engine

r3
I]
• „— _ . _ Fus e holdsr fron t
0 | F8

60A 1
1

3' X11002

60
RT/WS

1 X13844

i —^ ~" A600 9
lnt^grat0^ «i_ippl y

yj:
— x modul e (IVM )
fl J D \4 ) DME rela y 2
T

.—*
— 1 F00 5
r
30A
1

22 ' X6009 4 13 ' ' X6009 3

05 15
BR OR

23 X60002 X6822 X682 2 X682 2 X682 2 X682 2 X682 2 X682 2

-f n A600 0
[Q| DM E contro l
05 0 5 0 5 0 5 0 5 0 5 0 5
\a
^ modul
Or"!
e
GE O RO RO RO RO RO R
I 31 i

3 1x6214 1 2^X627 9 jJ_ X f 82

•— •*-- -BB7141 r "i Y6279 r i
r

Y6282
| I I Characteristic 1 j VANOS solenoid
j Ic-amS i1 ] ma p j j valve, exhaus t
1 X6203 1 'senso r ' J thermostat i J
,1x6207 ^ ~ " 3JX6214 2 r jJ_ X f 81
, r — ^---0,5707 i " 1B6214 2 | ] Y628 1
I86203 I j ' 'Exhaus t ' ' VANOS solenoid
j Crankshaft [ , ™t-; mm 1 camshaf t valv e intak e
l^nsor ] _J ^tef " ^ sensof • - J
1

B510ele24300

Electrical Wiring Diagrams ELE-1 5

 Electrical Wiring Diagram s ELE-1 6

Fuse F006
N62 engine

1 A41 a
I Fus e holder fron t
[ 3 0 1 F8 I
1 ffl 1 I
1I j 60 A 1 I
1 + 1 |

t. - J J I
s
I

A6009
—- fr.

4) DM E rela y 2
15
1 r \
b

t>

F006

L J 20 A

22 ' X60094 1 4 ' ' X6009 3

0.5 1.5
BR RT/BL

X6823 X6S2 3 X682 3 X682 3

X60002
23 ,
-» " j A600 0 0.75 0.7 5 07 5 07 5
RT/BL RT/B L RT/B L RT/B L
ISzl 1 DM E contro l
3T~1 | modul e 3 • 5 7 9 X605 3
center o f engine,
0.75 0.7 5 0.7 50 75 6-pin, round)
RT R TR TR T

p __ _
X6101 1 1X610 2 1 X610 31 X610 4
I Y610 1 I Y610 2 Y6103 j Y610 4
I Fue l injector, j Fue l injector, Fuel injector, J Fue l injector,
cylinder 1 ] cylinde r 2 cylinder 3 cylinder 4

B510eie20338
Fuse F00 7
N62 engine

A41a
Fuse holder , front
F8
I
60A I

6.0
RT/WS

Integrated supply
F007
module IV M

13 T X6009 4

2.5 0.75
RT RT

X6410
| A600 0
[(Q)| ' DM E control modul e

1.0
RT

7 X7001 1
I A7001 0
' Sequentia l manual
transmission (SMG )

B510ele20339

Electrical Wiring Diagrams ELE-1 7

 Electrical Wiring Diagram s ELE-1 8

Fuse F008
N62 engine

A41a
Fuse holder , front
30 I F8
I jT iI
I {! ! 60 A I

6.0
RT/WS

A6009
Integrated supply
module IV M
5) DM E relay 3

19 21 T X6009 4 X60093

0.5 0.5 0.5 0.5 0.5 0.5

BR 6N GN GN GN RT/WS

X62201 X62102

23 X60002 X62540
rt A6000
DME control
B62202
| Oxyge n senso r 2
B62101 j
Oxygen sensor '
j B6220 1 |
j Oxyge n sensor 2 '
"j B6210 2
I Oxyge n senso r
B62540
Oil quality
module I behin d catalytic before catalytic j j befor e catalytic j behind catalytic
b^ • -1 converte r converter « - j converte r •_ .

B510e!e20340
Fuse F009
(up to 03 / 2007)

A41a
Fuse holder, front

60A

60
RT/WS

1— —
-----gj.
"" A600 9

(E C
°\) DME relay 3
\

i —e>
— F009
i
i
10A

22 ' ' X6009 4 1 3 '' X600 9

05 075
BR RT/WS

23 X60002
i— ». " ] A600 0
1 DM E contro l
1 modul e
9-1
i 3 1- « ;
!
X11212 X1121 2 X11212 X11212 X1121 2 X11212

0 75 0 75 075 075 0.7 5 075

RT/WS RT/W S RT/WS RT/WS RT/W S RT/WS

8 X1015 62 X1337 3 2 J [ X1386 4 2 X6506 4 J X171 4 X6304

|" " j K9 6 [ " ] Y19 8 j" ~ j Y1386 4 r n M650 6 f 1 M119 a

! ' Fue l pump ! ' Exhaus t |' Solenoid , E-boxfan : j Diagnosti c ! Secondar y ai r
radiator • modul e j pum p refa y
!j rela y ] j fla p
L. j shutte r , _ 1 j fo r fuel tank
leakage

B510ele2034i

Electrical Wiring Diagrams ELE-1 9

 Electrical Wirin g Diagram s ELE-2 0

Fuse F00 9
(as of 03 / 2007)

1 A41a

i1 'r f3
J Fuse holder fron t
o" IF8
ii 60A 1
1

ii u - 1

60
RT/WS

- A6009
i —B*
Integrated supply
module (IVM )
0c
A
D- ^ 5} DM E relay 3

1 —^ L
P 5

MJ 39

[j 10 A

22' X60094 13' ' X600 9

0.5 075
BR RT/WS
23 X60002
t* ' A600 0
fj |© | DM E contro l
lL modul e
131 1

X11212 X1121 2 X11212 X11212 X11212 X1121 2 X1121 2 X11212 X1121 2

0 75 0 75 0.75 075 0.75 07 50 5 0 5 07 5

RT/WS RT/W S RT/WS RT/WS RT/WS RT/W S RT/W S RT/WS RT/W S

X10156 2 X1337 33 X16663 2 X6506 4 X171 48 X630 41 X10684 1 X10S8 5 1 X321 1

~~JK96 \ 8[ "' ~"JM1997 ' '"~"]M650 6 [ '~lM119 a f ' |K630 4 [ " ^~"JI0122 5| " i ~"jl01224 , r~^ JB41 4
'Fuel pump ' 'Exhaus t ' 1 Radiator 1 E-box fa n I1 Diagnostic | ] Secondary ' j Brake air flap 1 'Brak e air flap ' |O l ' AUC
[relay j [fla p| I shutter 1
1 !SeUank f0r ' | ^^ pump j (sensor , lef t | [sensor , righ t | M ] sensor
[drive uni t , _ J ' ' " 1 relay i 1 i . — ii i

B510ele25707
Fuse F01 0

N62 engine an d N62/TU engin e N52 engine

A46 A41a
Fuse holder, rear Fuse holder, front
F8

60A i

X13802 (N62 engine)

X11014 (N62/TU engine ) 6.0
RT/WS

X18326
A2076
B+ potential distributor

I A6009 1.5
RT

p
I Integrated supply
| module IV M
\ X60551 (E-box , right rear
3 6) Rela y 1, valve
timing gear engine compartment )
• i
I
1.5
RT
I
F010

j°
I n A868 5
[4A I
I F010
Fuse carrier , engine
electronics
I
I mIf 5 A
4 ' X6009 3 1 X60095

2s X8685
0.5 40
BR/WS RT/WS
1.5
RT
3 1 X60211
A60210 6 X6539
Variable valve timing K6539
gear control modul e Engine breathe r
heating rela y

20342 2336 0 21601

B510ele20342

Electrical Wiring Diagrams ELE-2 1

 Electrical Wiring Diagram s ELE-22

FuseFOII
N62 engine and N6 2 TU engine

A46
Fuse holder, rea r

X13802 (N6 2 engine)

X11014 (N62/T U engine)

GO
RT

X10681
A6009
ntegrated supply
module iV M
7) Rela y 2, valve
_ timing gea r

F011

[j 40A

5 ' X6009 3 2 ' X60095

0.5 4.0
BR/WS RT/WS

8 5 X60211

m
I A6021 0
[ Variabl e valv e timing
gear contro l modul e

20343, 23361

B510ele20343
Fuse F0 1
M54 engine

v £__. K630 0

,:
fjp j | j DM E relay

5 X6300
TJ j
4.0
RT/WS

1 X8680

'
A8680

electronics
'
| 30 A

2 X8680

2.5
RT/WS

1 X60541 (E-box . right rear

engine compartment)
2.5
RT/WS

X6969 X696 9 X696 9 X696 9 X696 9 X696 9 (Welde d splice .

^ • • • F-hn x righ t rear
engine compartment)

10 1 0 1. 0 1. 0 1- 01 '°
RT/WS RT/W S RT/W S RT/W S RT/W S RT/W S

3 X6151 3 X615 23 J X615 3 3 ^ X615 4 3 ^ X615 5 3 J [ X615 6

~~JT6151 | |T615 2[ ~ ~ """"JT615 3 | ~ ~ (T615 4 f "JT615 5j " "JT615 6

1 Ignition coil ' ' Ignition coil. ' 1 Ignition coil, ' Ignition coil . ; [ Ignition coil. ] Ignition coil.
I 1 cylinder! 1 cylinder 2 'cylinder s, 1 cylinder 4 [ cylinder s^ cylinder s
I
__ iL ', i 1 i 1 > > ' '

B510elel9305

Electrical Wiring Diagrams ELE-2 3

 Electrical Wiring Diagrams ELE-2 4

Fuse F01
N52 engine

i
ii
r^ 0

J 60 A

3 ' ' X1100 2

6.0
1

1
1

1
"j A41 a
I Fus e holder fron t

I
I

1 X18326

1 1 A2076
1 1 B+ potential dis-
E -»
J tributor
1 ' X6410 1
40

X6300
"j K630 0
I DM E relay

40
OR
X8680
A8680
F01
I Fuse carrier,
j 30 A I engine electronics

25
OR

X605S2 (E-box, righ t rea r

engine compartment}
2.5
OR
X6963 X6963 X6963 X6963 X6963

10 10 1.0 1.0 1.0 1.0 10

OR OR OR OR OR OR RT/WS

X6153
X6151 X6154
" X6155 X6156
"JT6151 [ " (T6152 |T6153 "|T6154 [ " ~]T61S5 T ~~JT6156 1101046
' Ignition coil [ J Ignition coil. j Ignition coil Ignition coi f j j Ignition coil. • Ignition c j Interference
cylinder 1 [cylinder 2 I cylinder 3 I cylinder 4 I cylinder 5 [cylinder 6 suppression
j capacitor for
ignition coifs

B510ele21594
Fuse F02
M54 engine

-Li3
K6300
0
1 DM E rela y

' X630 0

40
RT/WS

X8680
3^
n A868 0
— &•
Fuse carrier,
HJ2 engine electronic s

[ j 30 A

J
A ' X868 0
4.0
RT/WS/GE
X6961 X6961 X696 1

15
RT/WS/GE
25 15
RT/WS/GE RT/WS/GE 7 IX601 1
0.75
RT/WS
2 ' X6053 1 X11212 X1121 2 X1121 2 X1121 2 X1121 2
(E-box. righ t rear
engine compartme •") I 07 5 j 07 5 j 0.7 5 I 0.7 5 I 07 5
1 RT/W S RT/W SI RT/W S RT/W S1 RT/W S
3 X6000 1 8 1X1015 6 2 |
X1386 4 4 J[ X171 4 2 J[ X620 7 8 J[ X630 4

'-* JA600 01 '""JK9 6] ' |Y1386 4 | '~"JM119 aj ' ~~ " j B6207 ] '~"JK6304 a
I |0] I DME contro l ' | Fuel pump j j Solenoid ] ' Selo'? i j Hot-film air j j Secondary air
I ™ ™dul e ! j relay J j ^.ator j | SefJ^T ! ] mass mete r j j pump relay
I
L— i i 1 i 1 i 1 leakage ' J ' '

X6964 X6964 X696 4 X696 4 X696 4 X696 4

I
05 I 05 I 05 I 0. 5 I 1 0 I 05
RT/WS/GE RT/W S RT/WS/G E RT/WS/G E RT/WS/G E RT/WS/G E

1 X6275 1 1 X627 6 2 J X616 7 1 \0 2 |

X613 0 2 \3
t
r
""JY6275 j"~~'~"]Y627 6[ " '~]Y616 7 f '""JY612 0 , r ~^~"]Y6130 r~"""]Y616 3
VANOS solenoid '
1 ' VANOS solenoid \ Valve individua l | ] Fuel tank ] ] Idle actuato r j j Secondary ai r
valve intak e !
1 ' valve, exhaust 1 control intake ven t valv e pum p valv e
i _J 1 J 1 . Jsyste m| _ J j _ J [ J

B510ele19306

Electrical Wiring Diagrams ELE-2 5

 Electrical Wiring Diagrams ELE-2 6

Fuse F02
N52 engine

r~~~ • A41a
0~ ~ J F8 1
! '5 60A •
1 Fus e holder fron t
'! I 1
i u- 1
1

3 ' ' X1100 2

60
RT/WS
1 X18326
1 A2076
1 *"*• I B+ potential
1 1 distributor
— i i .*
1 ' X6410 1
40
RT
6 X6300
~] K630 0
| DM E relay
U T3 '
f 1

40
OR
3 X8680
A8680

1-02 engin e electronic s

[ 30A

4 ' ' X868 0

25
OR

2 ' ' X6055 2 (E-box , right rear

~ , - engin e compartment)
OR
X6964 X696 4 X696 4 X696 4 X696 4 X6964

05 1 05 1 0.5 1 05 1 05 JOS
OR 1 OR J OR I O R1 O R 1 OR
X603S 1 I X627 9 3 1 X621 4 3 1 X622 4 1 I X627 5 1 1 X6276
-. *. - V* ? JT 1_ V
]M6035 [ ^ ^B627 9J ^ ]B6214 aj "" j B6224a | "" " " " ] Y6275 '' " j Y6276
1
[Ql 1 Electric 1 1 Thermostat 1 1 Intake 1 1 Exhaust 1 1 VANOS I VANOS
B63 coolan t1 1 characteristic 1 1 camshaft 1 'camshaf t ' , solenoid 11 solenoid
jP ump L j ma p cooling 1 J sensor j _J se nsor L J tT 1J valv e
exhaust
B510ele21595
Fuse F03
M54 engine

§
1 K630 0
n
1 / [ DM E rela y

^: i
2 X6300
4.0
RT/WS

5 X8680
f
s
A8680
" i —-e>

F03
electronics

( 20A

1 j
V
6 X8680

3 X60531 (E-box, righ t rea r

engine compartment)

RT/WS

X6965 X696 5 X696 5 X696 5 X696 5

0.5 0. 50 50 5 0. 5
RT/WS RT/W S RT/W S RT/W S RT/W S
1 X622 4
31 X620 3 , X621 4 A
3 X6207 1 1 X627 9A
t S •7 1 i
1' 1i ' 1 i ' 1 i ' 1 i ' 1
| B620 7 | | B6203 | | Y6279 | |B621 4 | | B622 4
1

!1 € ?) '
/_ I
Hot-film '
air mass I
| meter |
I
|
Crankshaft '
sensor |
|
I
|
Characteristi c '
map I
thermostat |
I
|
Camshaft '
sensor I '
|
I
|
Camshaf t
sensor II

II I1 II

3510ele193o?

Electrical Wiring Diagrams ELE-2 7

 Electrical Wiring Diagrams ELE-2 8

Fuse F03
N52 engine

n A41a
r— so , r o Fus
I
1
e holder, fron t

i 60A 1 1

3 ' ' X11002

50
RT/WS

r
} X 18326
'""] A207 S
». j B-* - potentia l dss -
nbutor

X64101

40

y
RT
X6300
"" K630 0
i 1 ;•" • ' r D M E r e ay

? X6300

40
OR
5 X8680
"" A868 0

huj engin e electronic s

20A

6 X8680

si
X6965 X696 5

, ,I 10
to1 np
OR I
2 1X6000 3
3 X60551 (E-box . rght rea r i A600 0
engine [S I] DM E control
1.5 compartment ) , EE I | module

X6960 X696 0 X696 0 X696 0 X696 0 X696 0

OR U Is as a& is i
3 X62540 3JX654 0 3JX654 1 1 | X612 0 1 | X6^0 3 3 I X6207
1 "" B62S40 a ] Y654 0 f " j Y654 1 [ " — j Y612 0 | " "" j B6203 a [ " ] B620 7
1 PI Oi l condition j DIS A j DIS A j Fue l tan k ( Crankshaf t 1 1 Hot-fil m
I
1 ! controlle r 1 ] controlle r 2 | | ven > «ai"e | senso r i ] ai r mass
'' ' ' ' ' " i 1 ' .j mete r
B510ele21596
Fuse F0 4
M54 engine

~C_ ~ j K630 0
! rh i
Cp . DME relay

X6300

4.0
RT/WS

X8680
] A868 0
I Fus e carrier, engine
\s

1.5
RT/WS

X6962 X6962

0.5 0.5 0.5 0.5 0.75

RT;WS RT/WS RT W S RT/WS RT/WS

1 Y X6210 2 (Lef t side o f engine, front, cylinder head )

B62102
QGO 1m

Oxygen senso r
behind catalytic
converter

I B6220 1 I A7001 0
' Oxyge n sensor 2 ' Sequentia l manua l
' befor e catalytic transmission (SMG )
4 Y X6210 1 i converter 1 Y X6220 2

I B6210 1 B62202
' Oxyge n senso r Oxygen sensor 2
before catalytic behind catalytic
converter converter

B5IOele19309

Electrical Wirin g Diagram s ELE-2 9

 Electrical Wiring Diagrams ELE-3 0

Fuse F04
N52 engine

1
A41a
6" 1 F8

111 L
Fuse holder, front
"i i
60A 1
J 1

X18326
I A207 6
-e. ] 8 + potential
distributor
L_. !
' X6410 1

A8680
F04I
Fuse carrier, engine
I electronic s

X6966

1.5 I 0.75
OR I OR
21 J X70014

X60551 (E-box . righ t rea r II A70010

engine compartment) Sequential manual
1.5 transmission {SMG }
OR
X6961 X6961 X6961 X6961
"" To~ 5
0.5 1 00.5
OR OR I 0.5 I 0.5
OR OR OR
X62101 4 |
X6220 1 1 |
X62102
11
rj—-i
1
X622°2
B62101 I B6220 2 E65390
Oxygen senso r j Oxyge n senso r 2 1 Oxyge n senso r | Oxyge n senso r 2
before catalytic Crankshaft
before catalyti c 1 behin d catalytic behind catalytic breather
converter J converte r heating 1
B510ele21597
Fuse F05
M54 engine or N52 engine

A4ia
Fuse holder , front
I3 0|
1 IT !'
| 60 A I

60
RT/WS

B-t- potentia l
distributor

X64102

2.5
RT

Fuse carrier engin e

F05 electronics

10 T X868 0

6 X632 7
I K6327
j Relay , fuel injectors

B510('l!-?!59H

Electrical Wiring Diagrams ELE-3 1

 Electrical Wiring Diagrams ELE-3 2

Fuse F06
N52 engine up to 03 / 2007

I A41a

! 1—3 0 — iF S I Fus e holder, front

11 ft p
11 I 60 A 1
I1 V 1
1
3 Y X11002

I
|—[ 1
RT/WS
X18326
A2076
] 8 + potentia l dis-
j tnbuto r

4.0
RT

Fuse carrier

Ij
engine electronic s
j 10 A

2 ' ' X868 1

075
OR

X6011 (E-box , right rear

0 75 engin e compartment)
RT/WS

X11212 X11212 X11212 X11212

075 0.75 0.75 075

RT/WS RT/WS RT/WS 0R-75
TTM/S RT/WS T/WS
2 |X650 6 X6206
—._ — -__ — _ ,
I M65Q6 j M119 a I B620 6
I Solenoi d radialo r Secondary ai r j Exhaus t flap ' E-bo x fan
I shutte r pump rela y j Diagnosti c 1 Secondar y air -
I module for fuel I hot-fil m air-mas s
J tan k leakag e ! mete r

B510ele21599
Fuse FO G
as of 03 / 2007

A41a
Fuse holder, front
f"30 1 F8
BOA!

— -
xTf002

"I A207 6
j B + potential distributo r

J
40
RT
X6300
~; — f=-f~ KBisui j
O] - / DM E relay

17
1 OR
l| X8681
I
i engine
ill 10 A electronics

2 X8681
075
OR
11 X6011 (E-box right rear
engine compartment)
0.75
RT/WS
X11212 X11212 X1121 2 X1121 2 X1121 2 X1121 2 X1121 2 X1121 2 X1121 2 X1121 2

075 I 075 07 5 I 075 0 75 I 0.5 0 5 I 0 75 I 0.7 5 1 0 7 5

RT/WS 1 RT/WS RT/W S1 RT/WS RT/W S1 RT/WS RTAA/ S1 RT/WS 1 RT/WS 1 RT/WS
81
X6304 21x650 6 llx!068 4 llx671 0 4JX171 4 2J[x620 6
~ 1 K6304 f ~ " — M650 6 f — '~\ 5 f~ "" J 10121 4 f — ' M119 af ~ 1 B6206
! i Secondar y ' E-bo x fan i j Brak e air flap sensor, j g5 j j Nitroge n oxide j Diagnosti c modul e for i j Secondar y air
i ai r pum p ! i i lef t i i module i fue l tank leakag e i i hot-film
3
X 16663 ' rela y 2 X 1 3 3 7 3 ^1 X321 1 " 1 X1068 5 ' ' " " J a,r-mas s meter
d.41997 1 Y198 f " ~~i B41 4 r "1 101224
Radia or ' Exhaus t flap i g | j AD C senso r t j Brak e air flap sensor.
shutter drive ! i J L J rlaht
unit

B510ele25705

Electrical Wiring Diagrams ELE-3 3

 Electrical Wirin g Diagram s ELE-3 4

Fuse F07 Fuse F0 8

N52 engine N52 engine with SMG Sequential Manua l Transmission

A41a
A41a
Fuse holder, front
Fuse holder , front f 3 0 - ] F 8
30~ ] F8
60A
IN 60 A !

6.0
RT/WS

6.0
RT/WS

8+ potential
distributor
l-J
A2076 2Y X6410 1
3+ potential
4.0
RT

X8683
A8683
4.0 Fuse carrier , engin e
RT FOB electronics

,-„_ I Fus e carrier, engine ' X868 3

hu/ I electronic s
4.0
RT/GE

X6318

X8682 T~~F?r [ <e318

Hydraulic pum p relay .

4.0 X6318
RT
4.0
RT

K6319
VVT rela y Y6975
Hydraulic pum p

B510ele21600 B510ele21849
Fuse F1 Fuse F2

A46
I A4 6
Fuse holder , rear
I3 0| I Fus e holder, rear
1I HT ' 30 1 F9 °
I ?OO A I*! I
200A ]

25.0
RT
250
RT

A41a
Fuse holde r fron t
A41a
Fuse holder, fron t

5 f X1100 1

4 T X1100 1
40
RT/GE
4.0
RT/WS

2 | ^ X630 4

j(O)| ' Dynami c stability K6304a

13=4 I contro l (DSC ) Secondary ai r pump
relay

B510ele19811 B510ele19812

Electrical Wirin g Diagrams ELE-3 5

 Electrical Wiring Diagrams ELE-3 6

Fuse F3 Fuse F4
up to 09 / 2005

A46 | A4 6

I Fus e holder, rea r r ,i Fus e holder, rear

F90
I 30 F9 °I

!!
1 A ai
1
200A 200A 1
j

X 13507

25,0 25.0
RT RT

X 13766

—> I M1 a

j
[
F3 F4 ,

40A I
J i

XI1001 2 X11001

4.0 4.0
RT/BL RT/BR

2 X1372 8 1 X13718

N2 A467
Biower output stage Active steerin g

B510ele19813 B510ele19814
Fuse F4 Fuse F5
as of 09 / 2005

A46 A46

Fuse holder, rear Fuse holder, rea r

F90 F90

X13507

25.0 25.0
RT RT

1
A41a A41a

Fuse holder , front I Fus e holder , front

F4
I

20A

X11001 1 X1100 1

4,0
4.0
RT/BL
RT/6N

| K9 3

Power-saving Light modul e

relay, electronic
! dampe r control

B510elei B510eie19815

Electrical Wiring Diagram s ELE-3 7

 Electrical Wiring Diagrams ELE-3 8

Fuse F6 Fuse F7

j A4 6
I Fus e holder , rea r
F90 A46
I Fus e holder rea r
1 ' I 200 A I
| :L:

ffl 200A

25.0
RT 25.0
RT

X13766

A41a A41a
-*•
I Fuse holder, front I Fus e holder , fron t
F6
fL
50A

1 X11002

4.0
RT/GE

47 X12 I A149 a

A3 Car access system

<> Light modul e

IMJ

B510ele19816 B510ele19817
Fuse F8 Fuse F8
M54 engine N52 engine

|" n A4 6
~" A4 6
| | " 3 0 F9 ° 5- - i F9 0 e holder. rear

!(
Fus

i |T i 1
1 200 A 200AI
1H J

!i_ i^— -J .-_,

rXl"3507

X13507

25.0 25.0
RT RT

X 13766
i —*•
X13766
i. r~< n A41 a
A41a a Fus e holder , fron t
"j F

f
h8
j 60 A 1
|t
[ j 60 A

3 ' ' X 1 1002

_J
6.0
q
X11002 RT/WS

1 i X1832 6
6.0
RT/WS A2076

1 X 18326 distributor

A2076
2'' ' X64101 P """ I' X6410 2 1 Y X6410 8

1
1.5
RT
V RT
distributor 2.5 4. 0
1 X60003
, X6300 RT R T
1 A6000 1.5 ]K6300
1 '2 Y X6410 1 2 Y " f^ T X6410 2
[©] 1 control
RT ior
I U ' T_/t IDM E 1 |
X868 2
J module relay T r 'F07" j A868 2
1.5 4. 0 4. 0 2. 5 1 I , -1 | j Fus e carrie
RT R TR TR T 5 ' X6055 1 (E-box, right rea r
1 1 j J40 A 1 1 engine
1 5 engin e
4.0 ! i . J1 , electronics
1 X868 1 9 I X868 0 RT compartment )
RT
X60001 r~,I-i — ~— ~pgg.|1 A8681 6 ,, X630 0 P^t^. " ^~I A868 0 i X8685 1 X8683 9 X8680

Ik
| A6000 i j M, i . Fuse carrier, j | F _ jK630 0 j j A t | Fuse carrier, T'r^ iFOs]*8683 [ r - , FOS1 A8680
SI IDM E I I soA lI 6"9'"6 . ' V--cb f l |DME ' ' 30A l l e " 9!ne ! Fuse carrier' | |ft j JFus e earner, j f .j j Fuse carr er,
4 'contr a | 1 W 1 | electronics | V M ^ t j l re|ay | 1 W1 | electronics 5A 1 1 engine ! j [ 30A' 1 engine i \ ! 'electronic
30A 1 1 s1
engine j
i Jrnodue^ J | _ J_ f ^ J[_• - ' J Jj electronics j |_ J 'electronic s
J
r —_ j L 1 -- 1 J

B510ele19818 B510ele21602

Electrical Wiring Diagrams ELE-3 9

 Electrical Wirin g Diagram s ELE-4 0

Fuse F8 Fuse F 8
N62 engine without SMG Sequential Manua l Transmission N62 engine wit h SMG Sequential Manua l Transmissio n

"~j A4 6
A46 I Fus e holder , rear
F90
Fuse holder , rear ! 200 A I

ffl
25.0
RT

] A41 a
I Fus e holder , front

25.0
RT

I
3 Y X1100 2
I A41 a
6.0
! Fus e holder , front RT/WS
F8
X18326 (E-box , right rear
engine compartment )
; 60 A

A8683
3 X1100 2 Fuse carrier , engine
F01 electronics

6.0
RT/WS

RT

Integrated supply 8 X631 8

moduie IV M
' Hydrauli c pum p rela y
SMG

B510ele20332
Fuse F 9 Fuse F10
up to 09 / 2005

r
| | A4 6 Fuse holder , rea r
1 r __ 1 Fus e holder, rear
!i 3 D| F9 0 |
11 r lh 1 1
|1 j 200 A! 1
11
iJ
1 L --
1

25.0
X 13507 RT

250 A41a
RT
Fuse holder , front

X 13766

— *. I M1 a

!i f
F9 ,

) 60 A

I!
4.0
RT/VI

^|_ j
4 X11002

X257 (Driver' s door

harness, door hinge )
6.0
RT/BL 40
RT.'GE
2 X1797

i Ml 35
I' Electri c fan
II
>1 ' Driver' s door modul e
II
i

B5H!Hr1<>8!9

Electrical Wirin g Diagram s ELE-4 1

 Electrical Wiring Diagram s ELE-4 2

Fuse F1 0 Fuse F1 1
as of 09 / 2005

i i A4 S | A4 6
-- -- , pg o j Fuseho,der, rear _ _ .I Fus e holder, rea r

1i '! f 1 I 200A 1
I r 3 0 F9 °|
" I ?\
ii 1 1 200A
j
i •-- - 11 1

i 1|
I _. J
< y X13507
( X 13507

250 25.0
RT RT

X13766

— *i A4i a r
X13766
. ( *.________.,d ^_
1 — ». I A41 a
1 I Fus e holder fron t
F10 j F11 ,

i[ r1 ' 1 30 A1 1
' f *! i
5A I

ii
1| I
1|

i
I
1| I

1 X11003 2
-J L .
' X11003

2.5 0.5
RTA/I RT/SW

33 X 16759 3 X 13254
1'
~j A1676 0 A1a
I (C^ Body-gatewa y
(C) Basi c body module
' modui e

B510ele23293 B510ele19821
FuseF12 FuseF12
up to 09 / 2005 as of 09 / 2005

A46
Fuse holder, rear A46
30
I Fuse holder , rea r
F90
200A I
I

25.0
X13507
RT

250
A41a
RT
Fuse holder , front
F12

A41a

Fuse holder fron t

30A

4.0
RT/GE

3 X1100 3

X256 (Passenger door

harness, door hinge )
25
RT/GE
4.0
RT/GE

A16760
Body-gateway
[fO] ' Passenger' s doo r moduie
LSi^l I modul e

B510eJe!!.!»Xi B510ele23S94

Electrical Wiring Diagrams ELE-4 3

 Electrical Wirin g Diagram s ELE-4 4

Fuse F13 FuseF13

up to 09 / 2005 VTG Transfer case as of 09 / 200 5

A46 A46
Fuse holder , rear Fuse holder , rear
30 F90
30

!I
L. — ,—
200A

X13507
c
X13507

25.0 25.0
RT RT

X 13766
c
A4ta A41a
i o
Fuse holder, front I Fus e holder , front
F13
I
JI
30A

I 4 X1100 3 4 X11003

0.5 2.5
RT/BL RT/GR

1 X10594

A70006
Instrument cluste r Control module ,
control module transfer bo x

B510ele19823
Fuse F1 4 FuseF15

| A46

A46 I Fus e holder, rea r

Fuse holder , rea r 30 I
"30" F90
ffl
: 200 A
200A I
I I
.j , i
X13507

25.0
RT

n A41a
Fuse holder, front 25 '•]
RT
:i 30 A

X13766
' X1100 3
A41a

40 Fuse holder, front

RT.'BR F15

without sems-electn c semi-electric

basic sea t basic seat

X275 (Unde r driver' s

seal. 25-pin)

X13285
0.35
25 RT/GN
RT/BR

X13989 X603
S50 "] S52 34 X1031 8
| ig j| Driver' s sea t Switch, driver' s sea t 1 Driver' s lumbar
i modul e adjustment i suppor t switc h

Car acces s system

B510ele19824 B510ele19826

Electrical Wiring Diagrams ELE-4 5

 Electrical Wiring Diagrams ELE-4 6

FuseF16 FuseF17
as of 09 / 2005 up to 09 / 200 7

r n

i I Fus e holder, rea r

r. 0^ F9 0 | A46
f Fl ' 1 F9 0
Fuse holder , rea r
200A 1 30
'1 I 9.

1
1

X13507
X13507

25.0
RT

X 13766

A41a A41a
• >
Fuse holder , fron t Fuse holder, fron t
F16

f
i 30A

X11003
7 X11003

0.35
4.0 RT/BL
RT/WS
10 X188 0
2 X1242
Steering colum n
switch cluster
Windshield wiper
relay

B510ele 1982
7 B510ele23298
FuseF17 FuseF18
as of 09 / 2007 up to 09 / 200 5

| A4 6

I Fus e holder, rea r

] F9 0 I
I i 30

Fuse holder, rear i' ] [j

iT 1
j 200 A
r ~~3(

( J200A

25.0
250 RT
RT

i A41a
• —>• Fuse holder , front
Fuse holder , front
F18

f J20A

8'
1I X1100 4

25
RT/BL

6 X63

Power-savi
damper co r
K6
Relay, headlight
washer

B510ele51171 BSIOele 19828

Electrical Wiring Diagrams ELE-4 7

 Electrical Wiring Diagrams ELE-4 8

Fuse F18 Fuse F19

as of 09 / 2005

i A46 : . | A4 6

,I Fus e holder, rear : I .1 Fus e holder, rear

n! ' fl
! r 3 0 F9 °i | | 3 0 F9 ° I
If "ii '200
II
II
200A : I I A1
L J j I | I L I:
I' ~1
J1
i
I I 1
l_ J i L

X 13507 | X 13507 j

250 25.0
RT : RT i

X13766 X13766
_C i- n i f )

I >-* I M1 a • I | — «. I M1 a

;I .! Fn<5 p hnlrif»r frnn t i |

;i F18 | ; ! F19 |

:!
! I ! SO A ;
I!
: i
: I L
|5 A• I
I!
I 1' 1
I
i,
\ X11004 | : 2 X11004 I

2.5 ; : 0.5 :
RT/SW j RT/BL

2 X16759 ' 3 X1193

I'
1 |A 16760 r E82 ;
j(CI^ Body-gatewa y Gear indicato r lighting
' —^ modul e
p;

B510ele23299 B510ele 19829

Fuse F20 Fuse F2 0
SHZH Independen t / auxiliary heater EDC Electronic Dampe r Contro l

r
1 | A4 6 A46
| I Fus e holder , rea r Fuse holder , rear
0 F9 0
13 30

!i • f
fe.

200A I
_j

i I
I

X 13507

25.0 25.0
RT RT

X 13766
r
>- — A41 a A4ia
1
I FuCQ holde r fro n Fuse holder fron t
F20
1
ii 1 1I
1i
1L
1 20
J
A1
L
1
I
!
i 1

3 X11004 3 X1100 4

25 25
RT/BL RT/BL

1 X642
r
i A14a K93
i
i :^~>) Independen
heater
t auxiliary 1 Power-savin g
' relay , electronic
damper control

B510ole19830

Electrical Wiring Diagrams ELE-4 9

 Electrical Wirin g Diagram s ELE-5 0

Fuse F2 1 Fuse F22

A46
Fuse holder, rea r A46
30 F90
• Fuse holder, rea r
F90

200A

25.0
RT

X13766
25.0
A41a RT
Fuse holder , front
F21
X13766
A41a
Fuse holder, fron t
f X1100 4

4.0
RT/GN

semi-electric not semi-electri c X11004

basic sea t basic seat

4.0
X279 (Unde r passenge r RT/GE
seat, 25-pin)

R'T/GN
X18092 X18092

2.5 0.75
4 X 1325
5
RT/GN RT/GN
A1a
X13990 n X60 4 4 X659 Basic body module
I A18 6 "1 S56 |" ~1 S5 5
I25| i Passenger' s ] Switch , | Passenger' s
| sea t i passenger' s ] , lumba r
i modul e J sea t adjustment ' - J suppor t switc h

B510ele19831 B510ele 1983

3
Fuse F24 Fuse F25

A46 A46
Fuse holder , rea r Fuse holder , rear

200A
IL -f

X13507

25.0 25.0
RT RT

A41a
A41a
I Fus e holder , front
Fuse holder, fron t F25 I
s \A

X11004
7 T XI100 4

25
40 RT/GR
RT/BR

25 X174 6
Ala
Basic bod y module j(O)l | Dynami c stability
I bi u I controll (DSC
f-nrltfn /PlQP )^

B510ele19834 B510ele1983S

Electrical Wiring Diagrams ELE-5 1

 Electrical Wiring Diagrams ELE-5 2

Fuse F26 Fus e F26

IHKA Basic up to 09/2005 a s of 09 72005

r
i | A4 6 | A4 6

i1 3 0t
11
F9 ° |
Fus e holder, rear 1
r
1
3 0 ] F9 °
Fus e holder rea r

f1' 200A 1 1!
11
ffl
200 ' A' 1'
1
1 U -- 1I " J 1
1
1

X 13507 X13507

25.0
RT 250
RT

X 13766 X13766
i- C )_

I _> I A41 a E_» . 1 A41 a

!ii [ ]
F26 | , F2 6|

1i i |T i'
7-5A j 20 A

1I
1i

1 X11005 1 X11005

0.75 25
RT/SW RT/GE

10 X 18793 6 X1110

"j A11 a | "

|(CS ' Heating/ai r I \' conditionin
- — r/ ±7i" i "
gI
n Load-sheddin g
relay, terminal 15
J syste m I

B510ele19836 B510ele233302
Fuse F27 Fuse F28
up to 09 / 2005

A46 | A4 6

r3
r
Fuse holder, rea r 11 Fus e holder, rear
n F9 0

^1 1

_ _•
200A 1
L 11

1
•f J" c
X13507 X 13507

250 250
RT RT

X 13766 X13766
( r
/~ i
I A41 a
-»
I Fus e holde r fron t I FHS & holder fr^n t
F27 F28 |
I
f *l I
30A
L 20A I
I
I
I
i
2 X11005 3 X11005

2.5 1.5
RT/VI RT/BL

2 X 13253 2 X1880
r'
I A1 a i A72
i
Basic body module
i (C~7) Steerin g column

i '' switc
I
1
h cluster

B510ele19837 BStOele 19838

Electrical Wiring Diagrams ELE-5 3

 Electrical Wiring Diagrams ELE-5 4

Fuse F28 Fuse F29

as of 09 / 2005 up to 09 / 2005

1 —"~ — ~"" — i
A46
i j A4 6

i r __
13
__ _
0 F9
_I
°I
Fus e holder, rea r
I I" 30 | re° |
Fuse holder , rea r

II ft I I
1'
*] ' ' II M | 200 A! I
200A i I
i -J I 1!I
i 1,
1 1
I: I
1 1
i J
XI 3507

250
250 RT
RT

X13766
A41a
r
| A41 a Fuse holde r fron t
|
F29
j I PLI^ O finfrjpf fron t
F28 |

ii
i j

20A I
L J !

I
i i 4 X1100 5
^
3 X11005

15
0.75
RT/BL
RT/WS

1 X1880 40 X1358 1 16 X19527

i'
~j A7 2 A220
(Q) Steerin g column Safety an d gateway
^— ^— 'switc h cluster module

B510ele23303
B510ele19839
Fuse F2 9 Fuse F3 0
as of 09 / 2005 IHKA Hig h u p to 09 / 2005

1
A46 A46
Fuse holder , rea r

i
ou F90

200A '

c
X13507

250
RT L'5 0
RT

X13766
_* A41 a
X13766

A41a

[
F29 j
Fuse holder , iron!
}j 10 A

4 X11005

\5

RT/WS

1 X1376 5
38 X16760 1 6
i I Ali a
A167BO
' Heating/ai r
[O)j Body-gatewa y OBD "
conditioning system

B510ele23304 B510ele19840

Electrical Wiring Diagram s ELE-5 5

 Electrical Wiring Diagrams ELE-5 6

Fuse F30 Fus e F31

as of 09 / 2005 SMF A Seat module, drive r

I A46
I . _„ „ Fus e holder , rear
:I 0 r-y u
" A4 6 | j t
}I

=ri f 0 F9 0| | I
| 200 A !

;I
iiL
•i
200A i
I
I

' X 13507

' X1350 7
25.0
RT

25.0 ;
RT X13766
c
1 & A41 a
X 13766 ! t *

>-* " A41 a i

30A

( i 20 A: I
I

:6 ' X1100 5

5 ' ' X1100 5 j i

2.5
RT/SW
25
RT/GR

6 X10156
"j K9 6 i
' Fue l pump rela y \ X 13989

I A187
fjC^j Driver' s seat modul e
N62 engine i I
I

B510ele23305 B510ele19917
Fuse F32 Fuse F32
up to 09 / 2005 as of 09 / 2005

|" A46

1 I A4 6 3 Q i-a o

~_ „I Fus e holder , rea r •i

j 200 A
3 3 F9 0

I1 rL i
II
200A i .
I X13507

I 250
RT
X13507
X13766
A41a
Fus^ h^ld^r fr^n t

RT f
10A

X 13766
j

i [L >i A41 a
' X1100 5

F32 | 075
RT/BL/GE

ftin! 1 °A X6419 X641 9

ii
I 17 ' ' X25 7 1 7 T X25 6
l_ | — J
V
7 X11005
075
RT/BL/GE

1.5 1 ( X62 4
RT.'GE
X6418 X641 8' ] A1 "

] outsid e minor .
' passenger' s sid
33 X1877 0.75 07 5
i ~~ RT/BL/GE RT/BL/G E
A148a
X623 1 X1072 5
[©) Dynami c dnv e , ^
, A i gg , - , S12(.

' Electrochromi c i;O) |' Switc h block,

L- — i' outsid e mirror driver' s doo r
1 driver s sid e

B510eie19841 B510ele23306

Electrical Wiring Diagrams ELE-5 7

 Electrical Wiring Diagram s ELE-5 8

Fuse F3 3 Fuse F3 4
SMFA Seat module , driver up to 09 / 200 5

A46
Fuse holder , rear
"] F5 7
I
20A '
I

A46
F90
Fuse holder , rear
X11013
| 200 A
i. J
40
RT/GN

25.0
RT A16021
X13766 Micro-power module
A41a
1 F3 3 Fuse holder, front

' X1100 5

2.5
RT/BR A41a
Fuse holder, front

7 X1399 0
A186
Passenger's
seal
module

CCC/M-ASK

B510ele 1984
2
B510ele19843
Fuse F3 4 Fuse F3 4
without CIC Car Information Computer with CIC Car Information Compute r
as of 09 / 2005

A41a A41a
Fuse holder , fron t Fuse holder , front
30" - ~ j F1 8 30
I
30A I

X11004

25 25
RT/SW RT/SW

X16759
"] A1676 0 A16760
' Body-gatewa y modul e Body-gateway modul e

X16759 X16759

25 25
RT/GE RT/GE

X11008
A41a I A41 a
Fuse holder , front I Fus e holder, front
F34 I

2.5 25
RT/BR RT/BR

X13812 15 X1381 2

CCC/M-ASK 1 Ca r Informatio n
1) CHAMP 1 Compute r CI C

B510ele27137
B510e!e23307

Electrical Wiring Diagrams ELE-5 9

 Electrical Wiring Diagrams ELE-6 0

Fuse F35
as of 09 / 2005

"
A41a
Fuse holder , front

(I
co 1 F1S

1
1 30 A !

2.5
RT/SW

X16759
I A1676 0
|(Ojl | Body-gatewa y
I32I I mnrlnl o

X16759

25
RT'GE

X11008
A41a
Fuse holder , front

X11006

05
RT/BL

10 X13I 2

B510ele23308
Fuse F36
as of 09 / 200 5

Fuse holder fron t

"35- ] Fie
\fi i
80A I

2.5
RT/SW

X16759
'""] A1676 0
Q] I Body-gatewa y

X16759

RT/GE

X H008
' —* A41a

7.5A

05
RT/GN

X13930 X13930

05 0.5 05 05 05
RT/GN RT/GN RT/GN RT/GN RT/GN

4 ' X257 4 ' X256 27 ' 1 X27 3 27 ' X274

05 05 05
RT/GN RT/GN RT/GN RT/GN
14 X 13354 4 X10712 4 X10713 4 X10714 4 X10715
l 1 A21 5 T ~] S26 3 T 1 S26 4 1 S265 a f ~] S266 a
E5jl ! Comfor t access KSI i Oute r doo r handl e }/f5] ' Oute r doo r handl e j(O| ' Electroni c oute r fO J Electroni c oute r
i control module £5-1 I electroni c modul e S2J t electroni c modul e ^<=4 1 doo r handl e l^tii ' doo r handl e
' J driver' s side ' passenger' s sid e 1 modul e rea r lef t J modul e rea r righ t

B510ele23309

Electrical Wiring Diagrams ELE-6 1

 Electrical Wirin g Diagrams ELE-6 2

Fuse F37
up to 09 / 2005

i A46
PC- Fus e holder , rear
\

11 40 A

1
L.
2 ' ' X1101 3

40
RT/GN

1 ' X996 9 (I n spare tire well)

!8 X16021
;p . !-____- ,
A16021
Micro-power module

i1 5 ' X16021

40
RT/GE
!1 X11008
n A41 a
( ^
_ Fus e holder, front

_j ] 10 A

L J
i4 ' ' X1100 6

05
RT/GE
X1228 X1228 X122 8

TCU
0.5
RT/GE

I 05 0
RT/GE RT/G

ULF
5
E

[" |
TT
17 1 1
A- —
8 1 X69 5
^?
U400 b I"
L T5
18^X695
j U400 C J ""
V X454 5

] A117 a
;i [@ ]j TC U | [@ j ] UL F I [Q j I Ejec t box

L- J I I I I

B510ele21845
Fuse F37
as of 09 / 2005 up to 03 / 2007

q1
A41a
.-,„ Fus e holder fron t
o~ j r1o

30A
1

' X1100 4
25
RT/SW
2 X16759

I A 16760
I
I M Body-gateway modul e

1r
I

1] X16759
25
RT/GE
1 J
X11008
A41a

[ 5A

I
I
|

4 X1I006
075
RT/BL/GE
X1228 X1228 X122 8

0 75 0 75 0 75
RT/BL/GE RT/BL/GE RT/BL/G E

TCU ULF

•Y "| -5 X454 5 fi n center console )

17 I 1 8 | X695
17 A .1 8 A X69 5

[" " | U400 b |" " | U400 C J "1 A117a

n-r-') , UL F * [s.™- ^ Eiec l bo x
I L_iii J I j j VJxl |

I I I t I I
| ) i_ _ 1 u j

B510ele23310

Electrical Wiring Diagrams ELE-6 3

 Electrical Wiring Diagrams ELE-6 4

Fuse F37
as of 03 / 2007

I A41 a
r! F1 8 I Fus e holder fron t

30A I

25
RT/SW
X16759
j~ ' " " 1 A1676 0
j(£^}| { Body-gatewa y modul e
I

A41a
Fuse holde r fro m

0.75
RT/Bl./GE

0.75 075 075

RT/BL/GE RT/BL/GE RT/BL/GE
5 V X454 5

T~ 1 A87 3 A117a
] |Q [j US B hub Eject box
I I

TCU ULF-SBX interfac e ULF-SBX-H interfac e

box box Hig h

1 7 X69 5 17 X69 5
"1 U400 e
ii im : TCU I ULF-SB X j ULF-SBX- H

B510ele25709
Fuse F38 Fuse F38
up to 09 / 2005 as of 09 / 2005

A46 A41a
Fuse holder , rea r !- use holder , front

I( J 20 A ] 30A I

2 T X1101 3

40 2.5
R r/GN RT/SW

8 XI602 1
I A1602 1 |I A1676 0
|O| ' Micro-powe r module ] [(p) j' Body-gatewa y
I BE !I modul e
II

15 T X1602 1

4.0
RT/GE

A41a A41a
Fuse holder, front Fuse holder , front
F38

5 T X1100 6

0.75
RT'VI

N22
CD changer

B510ele19918 B510ele233n

Electrical Wiring Diagrams ELE-6 5

 Electrical Wiring Diagram s ELE-6 6

Fuse F3 9 Fuse F40

up to 09 72005

Fuse holder , front A46

Fuse holde r rea r

_ ^ 20 !J

2.5
RT/SW 4.0
RT/GN

Ai6760
Body-gateway modul e A16021
|{D)| ' Micro-powe r module
LVL-^I I

15 T X1602 1

2.5
RT/GE 4.0
RT.'GE

rt
»,-! 1
Fuse holder , front
I A41 a
±±. I Fus e holder , front

7 T X1100 6
0.35
RT/GE
0.75
RT/WS

Steering column switch cluste r 20 X 10389

N39a
DVD change r

B510ele51172 B5100le19845
Fuse F40 Fuse F41
as of 09 / 2005 as of 09 / 2005

A41a A41a
Fuse holder, front Fuse holder, front

30A

25 ?5
RT/SW RT/SW

2 X1675 9 2 X1675 9
A16760
|C3 ' Body-gatewa y Body-gateway
I IS& JI modul e module
II
1 T X1675 9

A41a A41a
Fuse holder, front Fuse holder, front

0.75
RT/VVS

20 X1038 9 9 X1 6
I N39 a II A2 a
[Oil ' DV D changer ](O)| ' Instrumen t cluster
' contro l modul e

B510ele23312 B510ele233l3

Electrical Wiring Diagram s ELE-6 7

 Electrical Wiring Diagrams ELE-6 8

Fuse F50 Fuse F50

without S85 engine up to 09 / 2005

G1 Gl
Battery Batlery

X13769 X13769

500 50.0
RT RT

X13768
A46 A46
Fuse holder , rear Fuse holder, rea r
F50 F50

250 2 50
RT/WS RT/WS

M54 engine M54 engine

N62 engine N52 engin e N62 engine N52 engine

6 X1015 6 2 XI366 3 6 X1015 6 1 X1366 3

| K96 I_ I A13663
1 Fue l pump relay Fuel pum p control ' Fue l pump relay ' i(G> ]' Fue l pump control
(EKPS) I t±*4 I (EKPS )

B510ele19919 B510ele23314
Fuse F5 0
as of 09 / 200 5

G1
Battery

I _ .

X13769

500
RT

X13768

| A46

I Fus e holde r rea r

1 F5 0

6
- — r /i
1/.J

X11010

25
SW/BR

|M 7
' Headligh t washe r
pump

B510ele23315

Electrical Wiring Diagrams ELE-6 9

 Electrical Wiring Diagrams ELE-7 0

Fuse F51

Ratio™

^ X13769
J

50.0
RT

X13768

A46

[u
^
F51

6 (up to 09 / 2005) 5 X11012 (u p to 0 9 / 2 0 0 51

12 (as o f 09 / 2005) 7 X11015 (a s of 0 9 / 2005 )

05 0.5
RT/SW RT/SW
X16009 X1600 9

0.5 0 5
RT/SW RT/S W

Sedan Tourin g

I
I
3 X372 8

|fC~^[ Sire
H1b j

n and tilt alarm I

~]

|(C3 Electrochromi
A? 9 r

c '
~
II
fc~>)
1__, <*
X1582 1

| I
" A121 a r
Antitheft alarm t
system with I
~
I
f(Q)
1 | X1431 2 (Tailgate , in D-pillar )

I X158 2
>

l '
> A121 a
Antitheft alar m
s V stem Wlth
I |M>! senso rf L-==^™J interio r rea r ' L_3iZ J I ultrasonic interio r I L^kl jI ultrasonic interio r
I ' vie w mirror ' ' sensor I I sensor
Jt - F1 J ! _J
19846, 23316

B510ele19846
Fuse F5 1

G1
Battery

; X1376 9

50.0
RT

A46
-»
Fuse holder , rea r
F51

! 5A

_
6 5 X11012 (u p to 0 9 / 2 0 0 5)
12 (as o f 09 / 2005) X11015 (as of 09 ; 2005 )
0.5 0.5
RT/SW RT/SW
X 16009 X 16009 X 16009 X 16009 X 16009

0.5
RT/SW 8f;SW frfVsw
22' 53 1 X25 6 (Passenge r doo r
harness, door hinge)
0.5 0.5
RT/SW RT/SW

2 X14147 8 X 18246 1 2 X14144 1 X14145 1 X14146

t A14147 " " " A2 2 " 1 B1414 4 , j 81414 5 ] B1414 6
Siren wit h tilt Kg ] Electrochromi c j@ lj Microwav e j |Q |j Microwav e j [0 ]] Microwav e
1 alarm sensor j interio r rea r I sensor , i sensor. i sensor , rea r
••- J vie w mirro r " " ' passenger s • •• " rea r left " - ~ J righ t

door 20330.2331 7

B510ele20330

Electrical Wiring Diagrams ELE-7 1

 Electrical Wiring Diagram s ELE-7 2

Fuse F5 2 Fuse F5 2
up to 09 / 200 5 as of 09 / 200 5

G1
Batlery

50.0
RT

X13768
A46
Fuse holder rea r
F52
A46

I Fus e holder, rear

I

40
RT/BL

6 X1027 4
0.75 K126
RT'BL/GE Relay, compresso r
air suspension

| A1602 1

Micro—power module

BS10ele19847 B510eie23318
Fuse F53
up to 09 / 2004

B510ele19848

Electrical Wiring Diagram s ELE-7 3

 Electrical Wiring Diagrams ELE-7 4

Fuse F53
as of 09 / 2004 up to 09 / 2005

r ~T 1 GI
Battery

-1C—
" X13769

500
RT

• —»> n A46

i ' 7.5 A

075
RT/GE

X13930 X13930 X13930 X13930

075 05 05 05 05
RT/GE RT/GE RT/GE RT/GE RT/GE

A X257 (Driver' s door harness. 4 X256 (Passenge r door 27 ' ' X27 3 (Rea r door. 27 ' ' X27 4 (Rea r door,
door hinge) harness, door hinge) driver's, door hinge ) passenger, doo r hinge )

05 05 05 0.5
RT/GE RT/GE RT/GE RT/GE
14 X13354 4 X10712 4 X10713 4 X10714 4 X10715
1 "i A21 5 [ 1 S26 3 | " 1 S26 4 C "] S265 a | " "] S266 a
1 j/Qil ' Comfor t acces s t IS1 1 Oute r door handl e 1 IjOJj ' Oute r door handl e ](Q\ ' Electroni c outer I {(Si ' Electroni c outer
1 I^>| 1 contro l module ' electroni c module . electronic modul e 1 doo r handl e CS3 1 doo r handl e
1 J driver' s sid e J passenger' s side J modul e rea r left J module , rear right

B510ele21847
Fuse F53 Fuse F54
as of 09 / 2005 up to 09 / 2005

G1
Battery }G 1

',0 0
RT
-___J
X 13769
XI3768
A46
Fuse hoider . rea r 50.0
RT

X 13768
c
—B, i A4 6

F54
f>
20A

2.5
RT/BR

5 X11010
13 X279 (Under passenge r seat )

25 2.5
RT/BR RT/GE

A854
s X1110
1 Activ e backres t
1 width adjustment ,
1 passenge r K9
Load-shedding relay ,
terminal 1 5

B':. Uh'li:23319 B510elel9849

Electrical Wiring Diagrams ELE-7 5

 Electrical Wiring Diagrams ELE-7 6

Fuse F54 Fuse F55

as of 09 / 2005 up to 09 72005

G1
Battery 'T G1
Battery

' X1376 9

500
RT

50.0
X13768 RT
A46
Fuse holder , rea r X13768
F54

•10 A
Fuse holder , rear
101068

40
RT/WS

101101
Wave trap 1 0.5
RT/GR

1 T X0105 8

B57b
E9
Rain/headlight senso r
Rear window defroste r

B510ele23320 B510ele198GO
Fuse F55 Fuse F56
as of 09 / 2005 as of 09 / 2005

A46 A46
Fuse holde r rea r Fuse holder , rea r

15 X177 1
I A20<t a
1 Trun k li d lift Rain/headlight
sensor

B510ele23321 B510ele23322

Electrical Wiring Diagrams ELE-7 7

 Electrical Wirin g Diagrams ELE-7 8

Fuse F57 Fuse F5 7

up to 09 / 2005 IHKA Basi c as of 0 9 72005

IG t G1

1 Batter y Battery
H_ 1
|
-; 1

i —( J
X 13769

500
RT
50.0
RT
[ X1376 8

A46
X 1 3768 Fuse holder, rear
f 101068

1*. ! A4 6

F57 j
[ t "J
^]
j 20 A j
F57

I
|
l L

5A

2 X11013

12 ^ X1101 2

40
RT/GN
075
RI

8 X 16021
10 ^ X1879 3
A16021
A11a
I i(O>: Micro-power module
Heating/air
' conditioning system

B510ele 19851 B510ele23323

Fuse F5 8 Fuse F5 8
up to 09 / 200 5 as of 09 / 200 5

G1 G1
Battery
Battery

50.0 X13769
RT

A46 50.0
RT
Fuse holder , rear
F58

X12768

A46

Fuse holder, rea r

40 5 T X1101 1
RT/WS

1 X37 9
25
101101
RTA/I
Wave tra p 1

2 X1305 6
1 [ X0105 8
K91

Rear wiper rela y

II ,
r9
dr ' Rea r window
C^1. ! defroste r

B510<:u*3
B510ele19852

Electrical Wiring Diagrams ELE-7 9

 Electrical Wirin g Diagram s ELE-8 0

Fuse F59 Fuse F59

as of 09 / 200 5

IG 1
I Batter y
G1
Battery

X13769
500
RT
50.0
RT
I A4 6
I Fus e holder, rea r
FS9
A46
Fuse holder , rear

X11012 05
RT

05
RT/WS

X1406S (Rea r body doo r

Sedan Touring bulkhead, 3-pin )

6 X1391 1

' Antenn a tuner with Antenna tuner with

! remot e controi remote control
' receive r
Antenna tune r with
remote contro l
receiver

B510eie23325 B5IOele26107
Fuse F6 0 Fuse F61
as of 09 / 200 5 up to 09 / 2005

61
G1 Battery
Battery

^1
X13769

500
RT
A46
Fuse holder, rea r
101069
j A4 6

! Fus e holder , rear

F61

: 20 A

18 X1101 2
i- —L
9 X1101 0

075
RT/BUGE 2.5
GN/'WS

X13044
1 XI049 3

Rollover protectio n Chargin g socket ,

1 Fron t cigar 1
controller 1 lighte r glovebox

B510ole23326 B510ele19854

Electrical Wiring Diagram s ELE-8 1

 Electrical Wiring Diagram s ELE-8 2

Fuse F61 Fuse F62

as of 09 / 2005 up to 09 / 2005

I~ I Batter y
I I

50.0
RT

A46 A46
I Fus e holder, rear Fuse holder, rear
101069

0.75
GE

X14068 (Rea r bod y floor 13

bulkhead, 3-pin)

0.75 035
GE GN/VI

1 X42Z 2

A445
Cooler box T Load-shedding relay,
terminal 15

B510ele23327 B510ele19855
Fuse F62 Fuse F63
as of 09 / 2005 up to 09 / 2005

81
Battery Battery

X13769

500
RT 50.0
RT

X1376

A46 X13768

Fuse holder , rea r A46

Fuse holder, rea r
101069

=63

25
RT/GN 5A

16 | X1101 2

1 X60 9 0,5
GN/BL

Trailer module
3 X1824 6

m
A22 A81a
Electrochromic interio r Park distanc e control
rear vie w mirror (PDC)

B510ele23328 B510ele19856

Electrical Wirin g Diagram s ELE-8 3

 Electrical Wirin g Diagram s ELE-8 4

Fuse F6 3 Fuse F64

as of 09 / 2005 up to 09 / 2005

i S 1
_r__ Batter y
—
G1
i- Battery
— i—
1 —
Y X 13769
50.0
RT
XI 3768
X13769 r)
r~ ,^ ~
Fuse holder,
i | 10106 8
50.0 rear
RT
£n] j
^[ tr 3J "
u
X13768 i

A46
Fuse holder , rear F64
"I 10106 8

flM 10 A

L ... - J
_ ^V- ,
F63 29 30 J 3 1 X11012

1 L

20A
1 T X 13702 behin d dash ,
1t o right o f steerin g
1 X1161 6 colum n

101119
Interference

1
10 ' X1101 1 suppression
coil 1
O
j X1161 5
2.5
RT/BL

0.75 07 5 0.75
1 X642
RT/WS RT/V I RT'GE
A14a 1 X13821 1 X1382 21 X 10387
Independent I' 1 r —i , , 1
auxiliary heater | A821 | |A165 a | |A167a

E )] j
-J I
Rear I IjOi j I Central I
compar men t Ui
[ display l ^J
l I information '
d|Spiay ^
f( C "y)l 'Contro l er
L' >
I
1

B510ele23330
B510ele 19920
Fuse F6 4 Fuse F65
IHKA High as of 09/2005 up to 09 / 2005

G1 " X nG 1
Battery
Battery

50.0
RT
500
RT
X13768
A46
Fuse holder , rea r
A46
Fuse holder , rear

F65

10A

11 X1101 2

0.75 0.75 0.75

HT/GN RT/SW RT/GN

1.5
RT/GN
X14068 {Rea r body floo r
bulkhead. 3-pin)
1 X1376 5
X10385 X13819
I A1l a A503
| Heating/ai r Oji ' Headse t connectio n Head-up display
' conditionin g ' modul e
j syste m

B510ele23331 BSIOelo 10857

Electrical Wiring Diagrams ELE-8 5

 Electrical Wirin g Diagram s ELE-8 6

Fuse F6 5 Fuse F66

as of 09 / 2005 without VT G Transfer cas e u p to 09 / 2005

S1
~T G1
Battery
Battery

500 500
RT RT

X13768
X13768

A46
f us e holder rea r
Fuse holder, rear
101068

F66

25
RT/SW i

X1276

0.35
RT/SW
25
RT/VI

Dynamic stability
control (DSC)

B510ele23332 B510ele 19858

Fuse F66 Fuse F66
VTG Transfer case up to 09 / 2005 Sedan as of 09 / 2005

"Y G1
Batter/

A46 A46
Fuse holder , rea r Fuse holder, rea r
101068

5A

8; X1101 2 8 X1101 1

035 25
RT/SVV RT/GN/GE RT/GR

X9I6
A33a

Dynamic stabilit y Control module . Sunroof

control (DSC) I

B510ele23333

Electrical Wiring Diagrams ELE-8 7

 Electrical Wirin g Diagram s ELE-8 8

Fuse F66 Fuse F67

except Sedan as of 09 / 2005 up to 03 / 2006

G1
Battery

Battery

X13769
50.0
RT

50.0
RT
A46
X13768 Fuse holder, rear
"! 10106 8
A46 I j
'"
Fuse holder, rear
3!
V

F67

F66 fj 10 A

! : 20A
7 23 ' X1101 2

0.75 075
RT/BL RT/BL
25
RT/'GR

3 10 X 14068
bulkhead, 3-pin)

1 X14102 0.75 075

RT/BL RT/BL

|(O)J ' Panoram a 11 X 18803 1 X 14062

LWJ | )as s roof
A197 j N4 7
Video module ' Satellit e receiver
!

B510eltv:i."i;i.|
B510ele19921
Fuse F6 7 Fuse F68
as of 03 / 2006 up to 03 / 2006

G1
j. v j•
Battery
- Batter y

"° X13769 i— "" X1376 9

50.0
RT 50.0
RT
X13768
"" A4 6 X 13768
Fuse holder, rea r "" A4 6
1 10106 8 —^
Fuse holder, re
r~ • " 10106 8

\1 'p j
— --E
1
I

F67
' —*
F68

5A

_
__ _ _
15 20 19 ' X1101 2
RT/GN
30G<68 30G<68
035 0.5 0.5
X5991 X5991 RT.'VI RT/BR RT/WS
30G<67
15 1.5
RT/GN RT/GN

311 X274
1 X 14057 3 X275 (Unde r driver' s 3 X279 (Unde r passenge r
15 15 JA169 seat, 25-pin) seat. 25-pin
RT/GN RT/GN , q I Center consol e
r —
bb switc h center p X603 2 X604
2 X10758 1
/ ~ "]S5 6
] M411
f , !
"] M409 i-Qj Jswitch ,
I Automati c softclos e
] drive , passenger's
l Automati c softclos e
! drive, rear right
ii liOl! '
133 1
Switch, driver's '
seat [ jseat
j adjustmen t 1 __ ladiustrnent
- J doo r

B510ele24301 B510ele19922

Electrical Wiring Diagram s ELE-8 9

 Electrical Wiring Diagrams ELE-9 0

Fuse F68 Fuse F69

as of 03 / 2006 up to 09 / 2005

n G1
Battery
G1
Battery

500
RT
X13769
1 A4 6
101068 Fuse holder , rear
50.0
RT

F68

A46
Fuse holder, rea r

\2
1.5
RT/BR
X14068 (Rear bod y floo r
bulkhead, 3-pm)
F69
15
RT/BR

1.5 15
RT/BR RT/BR

X257 (Driver' s doo r harness . X273 (I n B-pillar pillar,

door hinge ) lower)
15 1 5
RT/BR RT/BR

2 X1075 7 2 X1075 9
M408 ~~"J M41 0
X300
Automatic softclose j Automati c softcfos e
drive, driver's door i drive , rear lef t | A81 a
Park distanc e contro i
(PDC)

B510ele24302 B510ele19923
Fuse F69 Fuse F70
as of 09 / 2005 up to 09 / 2005

G1
Batter/
A46
3 0 - - - F9 0I Fuse holder , rea r
I —— . I
! —i — I III 200 A

X13769

25.0
50.0 RT
RT
X13766
1 A4l a
Fuse holder , front
A46
Fuse holder , rear
"I 10106 8

r X1100 3
4.0
RT/BR

F69 without semi-electric semi-electric

f
basic sea t basic sea t

5A
L
13 X275 (Unde r driver's
seat, 25-pin)
2.5
FIT/BR
13 X11015
XI3285

2.5 0.75
035 RT/BR RT/BR
RT/GN
X13989 X652
] S50 S52
1 X300 1 Switch , driver's sea t Driver's lumba r
i adjustmen t support switc h
A81a

Park distance
control (PDC )

B5 If. .-1023335 B510ele19824

Electrical Wiring Diagrams ELE-9 1

 Electrical Wirin g Diagram s ELE-9 2

Fuse F70 Fuse F7 0

as of 09 / 2005 u p to 03 / 2007 as of 03 / 200 7

i=- —

500
RT
X13768
A46
r;--] 10106 8 Fuse holder, rea r

A46
F70
Fuse holder , rear

101

0.75 0.75
RT/SW RT/WS
X10847

0 75
RT/WS RT/WS

8 X1084 6
.__-• , B155

jjQj | Far-range 075

f senso r RT/WS
X10848
X1783
A144a
Active cruise 075
RT/WS RT/WS
control
X10845
" ""] B154 B153
jo] \ e Close-range
I sensor , righ t sensor lef t

B510c!e2rti:>.r. B5lOele25703
Fuse F71 Fuse F71
up to 09 / 2005 as of 09 / 2005

r -~ -i G1
II G 1
Battery
Battery
1 |
1 |
1 |
—I
X13769

XI 3769

50.0
RT

A46
X 13768 Fuse holde r rea r
f 101068
A46

Ip . [CD hnlrto f roq f

F71
A L

( 20A

15 X11015

RT/VI
25
RT;WS

6 X 13056
I' 2 X1405 8
IL^ 1 K9 1
Q( 1T r-t- .

L/~l Rea r w'Per relaV

Center consol e
switch center

B510ele 19925 B5tOc!(v'H:«7

Electrical Wiring Diagrams ELE-9 3

 Electrical Wiring Diagrams ELE-9 4

Fuse F72 Fuse F72

up to 09 / 2005 (Wagon) as of 09 / 2005

Battery

G1
Battery

500 A46
RT
Fuse holder , rea r

A46
Fuse holder
F72

40
RT/BL 2 50
RT/WS

N62 engine N52 engine

6 X1027 4

Relay.
'compressor
Jair suspensio n

6 X1015 6 1 X1366 3
K96
1 Fue l pump rela y ' Fue ! pump control
I (EKPS )

B510ele19859 B510Ble23338
Fuse F73 Fuse F73
except Convertible up to 09 / 2005 Convertible up to 09 / 2005

G1
G1
Battery Battery

j
L i
X13769
X 1376
9

500 50.0
RT RT

XI3768
XI 376
8

A46
A46
— e-
Fuse holder , rea r
Fuse holder, rear F73

fL s ffl
F73

30A

7 X1101 0 X11011

25 25
2.5
RT/WS RT/GN
RT/GN

Relay for lowering Relay for raising

Trailer module
rear windo w rear windo w

B510ele23339
B510ele19860

Electrical Wiring Diagrams ELE-9 5

 Electrical Wirin g Diagram s ELE-9 6

Fuse F73 Fuse F73

as of 09 / 2005 up to 09 / 2007 as of 09 / 2007

Battery

X13769 XI3769

50.0 50.0
RT RT

X13768 X13768
A46 A46
Fuse holder, rea r Fuse holder , rea r
101068

F73 F73

2 Y X1101 0

40 40
RT/GN RT/GN

X14068 (Rea r bod y tloo r X14068 (Rea r bod y floo r

bulkhead, 3-pin) bulkhead, 3-pin)

4.0 40
RT/GN RT/GN

Hifi Top Hifi Hlfr Top Hif i

10j_ X1877 3 10 X1877 3 10J X18773 10 X1877 3

'"" 1 N40a A18a N40a A18a
(O] I Hif i amplifie r Top-HiFi amplifier Hifi amplifier Top-HiFi amplifie r

B510ele23340 B510ele26535
Fuse F74 Fuse F74
up to 09 / 2005 as of 09 / 2005

G1

Battery

50.0
RT

"" A4 6
101068 Fuse holder, rear

F74

A46

Fuse holder, rear

341

035 0.5 05
RT/VI RT/BR RT/WS
iii 20 A |
J
(Under driver' s X27 E X279 (Unde r passenge r
seat. 25-pin) seat, 25-pi n
X11010
0.5 0.5
RT/GN RT.'GN
1 X1405 7
2.5 S56
If >l ' Cente r consol e Switch,
RTA/I switch cente r passenger's seat
adjustment

S50
' Switch , driver's
; sea t adjustmen t

Trailer socke t

BSIOele 19861 B510(ile23341

Electrical Wiring Diagrams ELE-9 7

 Electrical Wiring Diagrams ELE-9 8

Fuse F74 Fuse F75

as of 09 / 2007 up to 09 / 200 5

IG 1

• Batter y

I _n _
—1 G1
i Batter y

X13769

50.0
RT
50.0
A46 RT
101068 Fuse holder , rear

X 1376
8

e> A4 6

F75
27
J11
035
RT/VI
0.5
RT/BR
0.5
RT/WS i- | 30A

(Under driver' s X275 3 X279 (Unde r passenge r

seat. 25-pin) seat, 25-pi n X11010
05 05
RT/GN RT/GN
X14057 X604
1 A16 9
ii| ] Centre consol e jg || Switch . 2.5
J switc h centre _ j passenger' s sea t RT/GR
X603 adjustmen t
-~l S5 0
^i | Switch , driver's
j sea t adjustment X10594

Control module,
transfer bo x

B510ele19853 B510ele19862
Fuse F7 5 Fuse F76
as of 09 / 200 5 up to 09 / 2005

r , G1

_ I Batter y
:I
G1 I
Battery
—I

u_ ^
X 13769
500
RT

XI3768 50.0
A46 RT
101068 Fuse
holder
rear
X 13768

F7S I A4 6

I FIIC: ^ hn|rfof |-»a r

F76 j
-1L i I

1 2' 3 X11012 i 40A '

I
0.75 0.75 0.75 I
RT/BL RT/BR RT/VI
I
4 2 3 X14068 (Rea r body floor i
bulkhead. 3-pin)
10 X11010
0.75 0.75
RT/BL RT/BR

1 X14130 1 1 X 18803
N48 1 A19 7 4.0
©| ; Digita l Ki i Vide o RT/BR
tuner US module

1 X14062
15 X1771
1 N47
1 Satellit e
, receive r

B510ek'19863
B510ele23342

Electrical Wiring Diagrams ELE-9 9

 Electrical Wiring Diagrams ELE-10 0

Fuse F76 Fuse F77

as of 09 / 2005 up to 09 / 2005

G1 G1
Battery Battery

50.0
RT
500
RT
X13768
A46
I Fus e holder , rea r
A46
Fuse holder , rear

0.5
RT-WS

Sedan Touring

33 X187 7 6 X13911 1 X1391 1

|{Cj! ' Dynami c drive Antenna tune r wit h K5I ' Antenn a tune r with
remote contro l | remot e control

B510ele23343 B510e!e19864
Fuse F77 Fuse F77
as of 09 / 2005 up to 03 / 2007 as of 03 / 2007

I ^ ,1
r™
i -J G 1
_ i E attery - —~ Batter y

I
I
-j_

T +
' X I 3769

50.0
RT 500
RT
X1376 3
"1 A4 B Jj._ _

i1
-M - ^ g

— 1 Fus e holder, rear ; t—* Fus e

~ 1 10106 8
~ •"1 — ~ — r~ ~ ' 10106 8 holder ,
I ]1 • rea r
i ! H
c a[ I
—*

i A
1 -- -- — _ i \ Ty
F77
[
1
10A
i i 10 A
I
>
9s 1 1^ 10 X11012 K __ ___ J' _ i
9 ' 11 ^ ^ X1101 2

r .75 0.75 0.75

F*T/SW RT/BL RT/GN
0,75 0.7 5 0.7 5
RT.'SW RT/B L RT/G N
12 X 14068
(Driver side of spar e
tire well, on fioor )

075 I •
RT/GN ; i 5 6 X1381 91 X913 7
-- - - - - A5Q 3 r - ' K913 7
5 6 X13819 1 X10385 i
Head-up Cut-ou t relay
1 A50 3 | " \a . • display electri c fan

l<c ' Head-u p display ' O] '

.MZf I
Headse t '
connectio n
i
11 j modul e

65100102334.1 B510eie51173

Electrical Wiring Diagram s ELE-10 1

 Electrical Wiring Diagram s ELE-10 2

Fuse F78 Fuse F7 9

as of 09 / 2005 up to 09 / 2005

G1
Battery
—I G1
I Batter y

X13769

50.0
RT

X13768
A46
Fuse
101068
holder, A46
rear
Fuse holder , rear
101068

5A

14'I X11012
7.5A
0.35 0.35
RT/SW RT/GN/GF

3 X1101 1

075
RT/SW
7 X174 6 8 X1059 4

22 X144 8
Dynamic stabilit y Control module,
control (DSC ) transfer box

Electronic rid e heigh t

control

B510ele23345 B510ele19865
Fuse F79 Fuse F80
as of 09 / 2005 up to 09 / 2005

I Batter y ' 01
Battery

50.0 50.0
RT RT

X13768 X13768
A46
Jp* A46
101068
Fuse holder , rear

\r
^ 10106 8
holder

>1
|
! I
— ~~] I

»••• &

10A

X11011

40
RT/GN
0.75 0.75
RT/VI RT/GE X14068 (Drive r side of spare
tire well, on floor)
40
RT/GN

Sedan Coupe Hlfi Top Hifi

Touring Cabriolet

X10387 10 X1877 3
A165a A167a A167a N40a A18a
Central Controller Controller Hifi amplifier Top-HiFi amplifie r
information
display

B510ele19926
B510ele23346

Electrical Wiring Diagrams ELE-10 3

 Electrical Wiring Diagrams ELE-10 4

Fuse F80 Fuse F81

as of 09 / 2005 as of 09 / 2005

A46
Fuse holder, rear

A46

Fuse holder, rear

0.75 0.75 0.75

RT/GE RT RT/GN

X14252 (Righ t side of

shift lever) I A85 9
! Electroni c nigh t vision
075 0.75 module
RT/GE RT/GE
33 X1101 2

~~j M80 1
| Fan . spare wheel wel l
0.75
X13412
RT/SW
I E82
[ Gea r indicato r lighting
22 X144 8

X13726 | A118 a
] A13 4 Electronic rid e
! Selecto r lever ' heigh t contro l

B510ele23347 B510ele23348
Fuse F8 2 Fuse F82
up to 09 / 200 5 as of 09 / 200 5

I Batter y
I
G1
Battery

X13769

X13769

M0
50.0 RT
RT

X13768 X13768
A46
Fuse holder, rear A46
101069
Fuse holder , rear

I—*•

9' " 8" " ' X1101 1 I 7.5A

25 2.5
GN/WS GN/WS

X14174 X14174 (Transmissio n tunnel

41 X1101 2
behind shif t lever )

2.5 2.5
GN/WS GN/WS
05
1_ X14112 1 X1247 RT/GN
1A14112 I " "]I A83 8 A839
| Luggag e ' |I Rea r Socket
j cigarette outlet, 15 X1803 4
j compartmen t j I
j SOC ket outlet ^ J lighte r rear

Tire pressure
control (RDC)

B510ele23349
B5106101 9927

Electrical Wiring Diagrams ELE-10 5

 Electrical Wirin g Diagram s ELE-10 6

Fuse F83 Fuse F83

up to 09 / 2005 as of 09 / 2005

G1
Battery

G1
.attery

X13769 50.0
RT
50.0
RT

A46
n A46 Fuse holder , rear
Fuse holder , rear 101068

1 T X1101 5

25
RT/SW
Sedan
Touring Coupe
X275 (under driver' s seat)

X916 1 j X1410 2 1 X1157 8

""i A33 a ' " ] A33 b A853
| Sunroo f \(5j | Panoram a Active backrest
i glas s root width adjustment,
driver

B510ele 19866 B510ele23350

Fuse F84 Fuse F84
up to 09 / 2005 N62 TU engine
as of 09 / 2005

G1
Battery
G1
Battery

50.0
50.0 RT
RT

A46
| A4 6
Fuse holde r rea r
I Fus e holder , rea r
101068

1 10 A

6 Y X1101 5

0.75 075
RT'WS RT 3 W 15
RT/GE

7 X603 1 (In E-Box )

Sedan Coupe
louring Cabriolet X6410

25
8 X178 3 RT
•I .,J X1783 A144a I A144 a
14 X850 0
1 Activ e 1 Activ e

cruise i cruis e I A7000 a

control -1 contro l ' Transmisst c

B5 10,-1019867 B510elo23351

Electrical Wiring Diagrams ELE-10 7

 Electrical Wiring Diagrams ELE-10 8

Fuse F84 Fuse F85

without N6 2 TU engine as of 09 / 2005
as of 09 / 2005

...
~ G1 G1
Battery Battery

XI3769

50.0
RT
SO.O
RT

A46
X13768
Fuse holder , rea r
A46
Fuse holder, rear

7.5A
X11011

1.5
RT.GE
37 ' ' X1101 2
X6021 (in E-box)
075
GN/BL

automatic transmissio n SMG transmissio n

Nfi2

X6410
X6021 (i n E-bOx )

2.5 2.5
RT RT
7 X7001 1
14 X850 0 A70010 A70010
""] A7000 a A70010 Sequential manua l
Sequential manua l
I Transmissio n Sequential manua l transmission transmission
1 contro l transmission (SMG) (SMG)
(SMG)

B510ele23352 B510ele23555
Fuse F8 6 Fuse F86
without N6 2 TU engine N62 engine
up to 09 / 2005 up to 09 / 2005

^G 1 G1
Battery
Battery

50.0
RT
50.0
RT

1 A4 6
X13768
Fuse holder , rear
101068
A46
Fuse holder, rea r

F86

1.5
RT'GE

X6021(ln E-Box)

15
RT/GE
automatic SMG transmission
transmission X6031 (In E-Box )

X6410

X6410
2.5
RT
2.5 2.5
RT RT
14 X850 0
X8500
I A7000 a
A7000a ' Transmissio n control
Transmission control Sequential manual
PS transmission (SMG )

B510ele 19928 B510e!(v'()445

Electrical Wiring Diagram s ELE-10 9

 Electrical Wiring Diagrams ELE-11 0

Fuse F86 Fuse F87

as of 09 / 2005 as of 09 / 2005

G1 G1
Battery Battery

j
X13769

50.0 50.0
RT RT

X13768 X13768

A46 A46

Fuse holder , rea r Fuse holder, rear

F87

iti
j 20 A

2 X1101 5 24 X1101 2

4.0 25 2.5
RT/BR GN/WS GN/WS

1 X1371 8 X531 1 X1049 3

A467 E28 101007

| Activ e steerin g Front ciga r lighter Charging socket,
glovebox

B510ele23353 B510ele23556
Fuse F88 Fuse F88
up to 09 / 2005 as of 0 9 / 2005

G1
Battery

Battery

50.0 50.0
RT RT

X13768
A46
A46 Fuse
101069
holder,
Fuse holder , rear rear
101068

F88

F88

25 2.5
GN/WS GNAWS

X11011 X14174 (Transmission tunnel

behind shift lever )

2.5 25
2.5 GN/WS
GN/WS
RT.'WS
1 X1411 2 1 X124 7 1 X38 7
I A1411 2 A838 A839
1 Luggag e com- Rear Socket
1 partmen t socke t cigarette outlet.
1 outle t
lighter
Center consol e switc h
center

B510ele19929 B510ele23354

Electrical Wiring Diagram s ELE-11 1

 Electrical Wiring Diagrams ELE-11 2

Fuse F89
up to 09 / 2005

r~~r G1
Battery

~* X1376 9

500
RT

A46
Fuse holder , rea r

tr J

10A

_— I
H f •1 0 • f JYX11015
(Transmission tunne l
0.75 ^ —-~~~ be h nd shif t lever )
RT/GN
X 14252 " ~ X 14252 X 14252
a X14068 RT/BL X1228 X1228 X1228 (Spare tir e well)
3X 1 1 1 23
RT/GN RT/GE RT/G E RT/G E
j Fan , spar e
't whee l wel l
4 X13412 4 J X 1 3 7 2 6 2|xi60 05 X14068 (Drive r sid e o f spar e
tire well, on floor)
I "] E8 2 " j A13 4 ] E82
I |Q| 1 Gea r |Q |j Selecto r j Gea r 0.75 075
I
I I indicato r " i leve r i indicato r RT/BR
RT/BR J235
lighting J lightin g ^ JJ
X4545 (Cell phon e cradle)
ULF
1 X14313

LJ
"] M30 4 •"J A117a
I Fa n MM C ] Ejec t bo x

X695 X695
U400b U400c
TCU ULF

B510ele 19930
Fuse F89
as of 09 / 2005

G1
Battery

XI3769

50.0
RT

X13768

A46
Fuse holder , rear

8 X111 0

I A2 2 K9
' Electrochromi c Load-shedding
' interio r rea r view relay, terminal 1 5
' mirro r

B510ele23355

Electrical Wiring Diagrams ELE-11 3

 Electrical Wiring Diagrams ELE-11 4

Fuse F90
up to 09 / 200 5

•• G 1
Battery

50.0
RT

A46
Fuse holder , rea r

X13507

250
RT

j A41 a
I Fus e
j I
hoider.

i•i i
1 F2 r i F4 l " 1 r r - 1 F1 1 front
11 i
D
1 A

1 it ] 1 1f
Fj

f f \
ji U 50 A 1 1
[J 60 A j 111 40 A [ j 40 A 11 |L PL 50 A
\
j 50 A
1 "
} 30 A j 60 A | L
] 60 A | J 30 A ' ffl 5 A I

|— |
1 F1 2 ... , "l '
1 F13 F14 '— -
__
F15 r — I' Fie r- - F17{— F18 r —
rV l
-] F1 9 -j F2 0 r- , F21
,1] — -
, F22
m i
[ uJ 20
[' \A 1r 1t f •i fTi !
HI 30 A
iti
1 H I 3 °A
1 ft l
1 f

L
"l 1
jU J 30 A j j 7.5 A 1 1
1* -
15A
!DJ 30 A Lj 5 Aj A1 , j 30 A 1 UJ 30 A ]

r~J-
|

, F2 3r- -] F2 4 r _ J
J
, F25 r 1 F26 f
[ , F29 -i F3 0 -,
1
1 • > F27 -
r F28 [ • — .——
— F3 1
'" r~ 1" > F3 3
1 it l1 h I I1 •l 1
1y j 20 A 1 ij 30 A 1 UJ 25 A f i 7 5A 1 j] ) 30 A
i f J 2 «A i 1
] 10A ] 1 5A i j 30 A 1 I
j 10 A 1 |1] 30 A !

B510ele 19931
Fuse F90
as of 09 / 200 5

r -~L "" G1
Battery

i
X13769

500
RT

n A4 6
Fuse holder, rea r

X13507

25.0
RT

X13766
A41a

•
ri f M F2 \ J...., , 4 H — — 1 F5 |-
— ,F6 r , F7 1 F8 ,._ , , r "~j F9 , H- , F1 0 , ^_-„,
Fuse
holder,
front

i
1L
'l '
UI
50A 1
I
1
|
"]
UJ1
I I
50A 1
I
1
1 L
1
^ 1' 40A 1
U ffi
40
LI J |' A1
1 ffi
1| 40
1
11 1 |
A1
M
|
I
1i
ILu | 40A 1
i
1| 30A
m |
m i
1
i
1|
r1 i
LU | 60A 1 1|
i m i
1 U60A
J |
1
i
1|
m i
30A
UJ |
1 1|
i f »1
L
15 A1

T
| 11 J
i F13 r
1
•j F1 2 [• - -] F1 4 - ] - j F 15 ri H F1 6 j-1
\i i F1 8 ~! F1 9 [ " | " j F2 0 T J ~ " ] F2 1 [" ^

"i ' ! f
1

\ I f }1 |T |1 I iT i i i fI ' ' ff i ' I I *'i ' ! ff i i i m ' ( f

[i 30 A 1 1 30A i 1L 7.5A 1 1| 111 130 i A 1 1| J |5A I I| I i |20 A I I| 30 | A I| I 30A I
u | | UJ | 30A 1 1| LU | J5| A 1 1I 30
U J |A1 1| JU | U H UJ l

1
, i1

i F3° n] ri ~ i r "
1J
--, F2 3 ,- _ -• F33
1 F2 41 ,
~ 1 F25 ["- j 1 F
26 [ " ~ " I F2 7 r ~ - -• ] F2 8 ["j — j F2 9 j ~
F31 F3 2
1 '
30A 1 1
' f"i ' ' r *i ' 30A 1 1
' it i '
20
1A 1 1 r 1 ' 20A 1 ' iT i ' ' ( "l !
20A 1
'
1|
ff
30
i '
A1
'ff
1|
i '
10 AI
1
1|
f
f
U1 1 UJ |
30A 1 1, LU | | U J |A1 1I U
30, | A1 M | U |
U
1| 10 U J |A 1 1| LJ | U J | UJ | L] 30 A 1
jt 1 t- ~

B510ele23356

Electrical Wiring Diagrams ELE-11 5

 Electrical Wiring Diagrams ELE-11 6

Fuse F91 Fuse F92

N62 engine and N62 TU engine

Battery
G1
Battery
X13769

50.0
RT

X13768
X 13769
"• A4 6
F91 Fuse holder, rear

500
RT

X13802(N62 engine )
X11014 (N62/T U engine )
X 1 3768
10.0
RT j A4 6
X13915 X13915 I Fus e holder, rear
F92

6.0 6.0
RT RT

M3
~1 moflul e IV M
3
i6 ' •n 7 6
' timin
) Relay 1 . valve
g gear
7) Rela y 2, valve X14273 (u p to 09 /2005)
X1 1013 (a s of 0 9 / 2005)
F010 FOI1
.
( I 40 A I 40A 10.0
RT

4 X6009C 1 X6009.c 5 ' X6009 3 2 X60095

1 X1405 2
0.5 4.0 0.5 4.0
BR/WS RT/WS BR/WS RTjWS | 10106 2

3 1 8 5 X60211 l^/)! Electri c auxiliary

m
1 A6021 0
Variable valve timing
gear contro l module
19868, 2335 9
20331. 23358

B510ele20331 B510ele19868
Integrated suppl y module (IVM)
N62 engine or N62 TU engine up to 09 / 2005
(page 1 of 3)

1 ^.A149a r ~" ] A41 a

1f ?51 ' Ca ' Fuse carrier.
1I S£:• 1 access [ "~ 0 " jF 8 fron t
I [system | 1
7 ' ~X10318 j I j 60 A '
.._- J

3'1 xiiuu 2

05 6.0
GN/WS RT/WS

6 X6009 1 X13844

| |

Jtz---
j
o. IA
i

Iq
/ 1 ~\ fl riv
I ! G ~f 3

J
7 O3" 1
\] F00 5

I I
r _ _
F003 j "~ "j F00 4 ~" j F00 1 F002 j '
i rt "l 1 fl 11 | , 1f "| (
!i j 20 A
!1 1 20 A | D 30A I l
I 20A 1 [ j 30 A |

. . _
r
H

1 YX1370 1 5 ' X60092 1 1 5 X60094 2 ' X60091 2 2 ' X60094 7 X60092 8 ' 12'

6.0 1.0 1.0 C 0.5 25 2.5 15 .5 2.5 15

BR BR BR \,1 WS/VI GN GN RT/BL &?&s i^T/WS RT/SVV RT/GE

(6866 X6831 X6832 >(6820 X6821 X6822

> i ^MPW^^

X6 1 6 13 3 >(8500 3 X60003 23 X60002 8 X60001 1 X60212

J. - - 4
[Transmission | (Engine (Variable valve
I control I I control I timing gea r
II | module . jcontrol module

B510ole21243a

Electrical Wiring Diagrams ELE-11 7

 Electrical Wiring Diagram s ELE-11 8

Integrated suppl y module (IVM)

N62 engine or N62 TU engine up to 09 / 2005
(page 2 of 3)

1 A149a
i Ca r
I acces s
j syste m

0.35 4.0
BR.'RT SW

15 X6009

F006 F008 F009 F007

I
I
20A I 30A 40A I

X60093 19 2i"YX60094 13 ' X60092 X60095

0.5 0.5 0.5 0.5 075 2.5 4.0

R'f/BL RT/WS GN GN GN RT/WS RT SW.'GE RT/WS

X6823 X6410(ln E-Box )

1.0
RT

X62540 X8500
"JB62101 --]B62201 B62102 •|ly16510a
f~\\\ I Oil I Oxygen || Oxygen : |Oxyge n j Oxygen i Transmissio n I Starter
II quality I sensor 2 II sensor II sensor 2 I sensor I
nsor | behind [j before |J before J behind I
catalytic catalytic catalytic catalytic
converter converter converter converter

B510ele2l243b
Integrated supply module (IVM)
N62 engine or N62 TU engine up to 09 / 2005
(page 3 of 3)

-- A4 6 [• 1 B623 1 [ •~ ] B895 [ 1A65 af -~!A149 ar ~ ] A3

1
1- Fuse I1 Oil 1 B J1 Battery i [S 3 ' Dynamic i
lol i Car i IS 3 ' L'9ht
0 holder, 11 pressure 1 tSii j senso r YirwMQ vmRA B ' ™ ! stability I (W j I access I ISE l I module
!jj 1 LJ switch L j X10549 X1054 8 | ! control (DSC ) ! ! svslem ! !
!1 100A I 1 ' ' X623 1 37 24' X1703 4 1 X1031 8 13 ' X1 2

1' X 13895 [Righ t sid e ot trunk

X 13802 BL/SW GR/V f

, "* - •* -, ,
10.0
RT ^C
au omatic manual
transmission transm ssson,

— fc-

60 0.5 0.5 0.35 0.35 0.35 0.35 0.35

RT RT BR/GN GR RT,GN RT BL/RT BUR l RT

l 2 X10681 9 X60093 2 9 8 10 11 5 X6009

"" A600 9
Intearated suoofv

— -^H 1
|JD A 6 1) Ignitio n coi l un-
loader rela y

j rela y
i - T F01 0 |3 , DM E rela y 1
4) DM E rela y 2
5) DME relays
40A 61 Relay 1 . valve
i
""'
7) Rela y 2 valv e

5' 4 ' X6009 3 1 ' 'X60095 4 X6009 17 ' 'X60093 10 ' 7 8 17 24 12' ' X6009 4 " 9

automatic manua transmissio n

0.5 0.5 4.0 0.35 0.5 0.5 0.5 0.5 0.5 R-§ transmissio n SMG
BR/WS BR/WS RT'WS VI GR GN GE SW SW

X6038 X6835 X8090 X8090

TT
X8091 X8091
' " u. 5 u. a
VI G R

8 3 1 X60211 2 5 X60004 1 9 X60003 10 X850 0 1 X852 4

' - _ _ - -JA6021 0 r - ' -JA600 0 f ~'~]A7000 a [- J— JS8511
[7=55 I Variable
= i 17 5 1 i En9' 1e I fiOi l (Transmissio n j , Backup
iWI Ivalv p1 IW I1 control 1 ISZ l Icontro l 1 1 light
11 !_ J switc h
.Jtimi nq [ _J module

B510ele2ta43c

Electrical Wiring Diagrams ELE-11 9

 Electrical Wiring Diagrams ELE-12 0

Integrated supply module (IVM)

N62 engine or N62 TU engine as of 09 / 2005
(page 1 of 3)

f— !A149a r~ ~"[A4la
| rg- , jCa r j Fuse carrier,
01 ^ 8j fron t
j_ J system i r
7^ X1031 8 | | 60A |

,_
3' X11002

05 6.0
GN/WS RT/WS

6 J|x600 9 1 t X 1 3844

] \ I f '•
I]

y_ f~
Ir 1] 1

p* jf. ^T i " C-^ -^ TT

ii
ii
"] F00 3 | " 1 1 F004 ! 1 1 F001 I ] F00 2 I ~ 1 F00 5
rTi i r f j i i r t i ) i r i i i f i i
Jl 20 A ! ] il l 20 A ! ! 11 ! 30 A | ! I I 20 A ! j [ ] 3° A [
i i
!- - •1 1 "* "
115 X6009 4 !1 X6009 1 2 2 X6009 4 7 ' X6009 2 8 ' 3~ " 12 "1 3

0.5 0. 5 2.5 2. 5 0. 5 1. 5 0.7 5 2 52 5 1 5

WS WSA/ I GN G NB R RT.'B L RT'W S RT/W S RT/S W R'T/G E

X6866 X6831 X683 2 X682 0 X682 1 X682 2

3 |
X850 0 3 \
3 23 X6000 2 8 X6000 1 1 X6021 2
[" "]A7000 a[ "- 1
""" ' JA600 0 | "' """JA6021 0
1 r 0j (Transmissio n | \f-\\e | r^ i (Variabl e valve
1 ^' 1 Icontr o 1 L^-J (contro lI i^ 1-'! ttiiT)tnggea r
11 1
. jmodul c L _- j contro! module

B510ele23378a
Integrated suppl y modul e (IVM)
N62 engine o r N62 TU engine as of 09 / 2005
(page 2 of 3)

13 ! acces s
1 | [ syste m
22 Y X1031 8

JX18740

JL
i*

0.35 4.0
BR/RT sw
15 14 X6009

^
5
~\ 30 A tyr /
2 /
i ^
^

:006 F009 I "' 1 F00 7 "j F01 1

" ~ ] 1 F 0 38
!i f )
1
1
L
J 20 A | ( i( ] 10 A 20A i
i I
40A I

_]
__,
19 ' X6009 3 15 ' 19 20 21 X60094 1 3 'X6009 8 ' X60092 15 ' 'X60093 2 ' X60095

05 0.5 0.5 0.5 0.5 0.75 2.5 25 40

RT/BL RT/WS GN GN GN GN RT/WS RT SW/GE RT/WS

X6823 X11212 X6410 (Transmission nea r driveshaft)

1.0
1 X62202 3 X62101 3 X62201 1 X62102 RT

3 X62540 14 X8500 X6510 5 f

i ' -•JB62540 |" Jp -]B62 2 32 r"~ •JB62101 j ' - 1662201 I " -;B62102 r -|A7000a •JM65103 [~ ~
1 1
] Oxygen | Oxygen j Oxygen | ^ 5T-i | Transmission
1 [Oil I |ox V g an 1 (Starter
1 (quality 1 1 senser 2 1 1 sensor (sensor 2 I I sensor | | V21 1 control 1l
1 J sensor [ _ Jbehi nd 1 ! before 'before ! ' behind 11
catal>tie catalytic catalyti c catalyti c
corw€ rter converter converte r converte r

B510ele23378b

Electrical Wirin g Diagram s ELE-12 1

 Electrical Wiring Diagrams ELE-12 2

Integrated supply module (IVM)

N62 engine or N62 TU engine as of 09 / 2005
(page 3 of 3)

r~ ~ --> A4 6 r^ B623 1 r - j B89 5 r ~^A65 a• •— ]A149a r - | A3

if
Fuse II Oil i |Q ii Battery = | r r- || Dynamic I |o| ! Car 1 S5 3 1 Li9ht
o1 >-9 i holder, II pressure I 132 II sensor
X 10549
1 Isz l1 stability i I32 l 1 access 1 132 1 1 modul e
rear L - , J switch [ j A1u-j^M ! ! control (DSC)! Uvste m! !
1 100 A I ' X623 1 37 24 X1703 4 1 X1031 8 13t X12

1
1 ' ' X 13895
(Right side o trunk 0.35 0.35
X11014 near groun d ng point ) BL/SW GR/VI

10.0
RT
automatic manua
transmission transmission,
X 10547
SMG

6.0 6.0 0.5 0.5 0.35 0.35 0.35 0.35

B'L/RT
1
RT RT BR/GN GR RT/GN RT BL/RT RT

2 X10681 9 X60093 2 1 9 8 10 11 5 X6009

] A600 9
Integrated supol y

3)
module IVM
7
0c 3_ \
N,
6 1) Ignition coif un -
loader rela y

relay
"] F010 3) DM E rela y 1
1 4) DME rela y 2
5) DM E rela y 3
40A
i I I 6) Rela y 1 , valve
timing gear
7) Rela y 2, valve
5 4 X60093 1 ' 'X6009 5 4 ' X6009 17 ' 'X60093 1 0 7' 3 17 24 12 X60094 M y

automatic manual transmission ,

0.5 0.5 4.0 0.35 0.5 0.5 0.5 0.5 0.5 Q| trans m ssio n SMG
BR/WS BR/WS RT/W. V GR GN GE sw SW

X6038 X68 35 X8090 X8090

—*
• X8091 X8091
0.5
vf GR
8 3 1 X6021 1 2 5 X60004 1 9 X60003 10 X850 0 1 X852 4
— |A60 210 r - 1 -]A600 0 [•-- J -jA7000a I"- 1 'S851 1

m |Var able j
I valve 1
jtimi nq !
175.
IxP
J
1j
IJ
En g n e
contro l
module
1 [o ] i Transmission { [Backu
1 [Vr/ J 1 control 1
L1 L
(ligh
|
t
switch
p

gear

B510ele23378c
OBDII socket
M54 engine o r N62 engine

~ ~> A4i a n A7000a [ "~ " ] A6000

Fuse carrier . Transmission i |Q ^I i Engin e contro l
r3 0 F2 & fron t KE J Control | i^ SI module (DME )

9y
1 il l| •10 -- „ g T ...
IN A etxasoo ?e ''3 7 r~ 36 'f1 7 X6000 4
" "*A/00 10

mi
r

4 ' ' X I 1005 ji

1^X70011377 ~36f x 70014 9 X70003

0 35 0 5 0.5 0 35 0 5 0 5 0 35 0 35
RT/GN R T BL'RT RT.'GN R T Bu ;RT SW S W

X10545 X10545 X 10545 X243 X24 3

X 10546 X10546 X 10546

X105 47 X10547 X 10547

X15008 X15007

05 0.5 0.35 0.5 05

GE SW RT/GN RT BL/RT

36 35 30 34 32 X13581
A149a J - •] A22 0
| HQJ Ca r access i rQi i Safet y and
|
^J syste mj ^Eij I gatewa y modul e
I

13' X10318 29 ' X13581

XI S3

0.75 0.5 0.35 0.35

RT/WS GN/RT WS/BL SW

16 1 7 9 X 19527

XI9527

3'R/SW
0.5
BR X18751
X13789

B510ele19905

Electrical Wiring Diagram s ELE-12 3

 Electrical Wiring Diagrams ELE-12 4

OBDII socket
N52 engine up to 09 / 2005

- - -1 A41 a - • "]A7000 a
I A6000
0 ] F2 9 fron
Fuse carrier. i
t taz
tQ if
l i
Transmission
control
ISI
Iffil
1i Engin e Control
i Module (DME )
If •i I
!L J 10 A 1 9 T '2 Y ~ ~ 6^X850 0 1 '' X 60002 1 ' 14 21 Y X6000 1

I A70010

4 ' ' X1100 5 iifea

I £cS

1 Y X 7 0 0 1 1 37? " 36^X7001 49 X 70003

035 0. 5 0. 5 0.350. 5 0. 5 035 03 5

RT/GN G ES W RT/GN G ES W SW S W

X 10545 X10545 X1054 5 X243 X24 3

X 10546 X 10546 X 10546

X10547 X10547 X10547

X 15008 X 15007

0.5 I 0. 5 0.35 05
GE 1 SW RT/GN °RT5 BL/RT

36 3 5 1^ 3 0 34 32 X13581
[• ~ A149 a| - - - 1 ~] A22 0
I rQ i Ca r access i ro n i S a ety and
j W syste m1 M ' gatewa y modul e

13]' X1031 8 29 ? X1358 1

X183

0.
0.75 5 03 5 0.35
RT/WS GN/R T WS/B L SW

16 17 9 X19527

X19527

B'R/SW

X18751

X13789

B510ele22244
OBDII socke t
N52 engine as of 09 / 2005 up to 03 / 2007

r~ j A7000 3 J " ' ~ ] A6 0

r-^rn i Transmissio n • Engine control
| Eng
I |W
I1
| I
1
contro l | L©l
CrTi
1 mo d
1
9 f~ 2 T" 6 1 X8SO O 1 X60002 i 14 21 Y X6000 1
~] A7001 0
1
I Sequentia l
1
1
lio?
IWI j manua l
1 1 transmissio n
' (SMG )
1 1r X/001 1 3 /1 3 6 I X7001 4 9 * | X / 0003
11
11
0.35 0. 51 05 035 1 0. 5 I 0.5 0.35 0.3 5
RT'GN G E I SW RT/GN j G Ej SW SW S W
' X 10545 X 10545 ' j X1054 5 X243 X24 3

X10546 XI 0546 [ X 10546

X 10547 X 10547 XI 0547

n A41 a
Fuse carrier, X1500 8 X150Q 7
front j ^ , ^

i f i 1 °A i
0" | F2 S

I 0. 5 I 0. 5 0.35 0.5 0.5

1 GE I S W RT/GN RT BL/'RT
1L
1
8 1 9 12 7
L 30 JI- X 16760
1
-«•

4 *\ I"6 X I 1005
r
1 fT^S I
M J
I
A16760
| Body-gateway
M
^ A149 a lii ^J
1 I
; I Ca r access •
1 \&\ syste m 1 8 V X 16759
1
J | X18 3
13 ' X1031 8 J K >
075 0.5 I 0.3 5 0.35
RT/WS GN/RT I WS/B L SW

1 9 X 19527
d

4 i] X19527

05 0.5
BR/VI BR'SW

X 18726 XI 8751

B510eie23385

Electrical Wirin g Diagram s ELE-12 5

 Electrical Wiring Diagram s ELE-12 6

DBDII socke t
M52 engine as of 03 / 2007 up to 09 / 2008

"j A7000 a r ~~ ~ "" ~ ~ ~ 1 A800 0

1
I Transmissio n | TT^I i Engin e contro l
I contro l I ISEa 1 modul e (DME )
1 11
9 IT 2 IT 6 V X850 0 1 X60002 1 14 21 X6000 1
r— — — — — — j A7001 0
I rrs ^ i Sequentia l
I ivi^ i1 manu a
[_ | transmissio n
l"?X7C011 37 ? 36"Tx700149 ' X70003 (SMG )

0.35 0. 5 0. 5 0.35 0. 5 0. 5 0.35 0.3 5

HT/GN G ES W RT/GN G ES W SW S W

XI 0545 X10E45 X1054 5 X243 X24 3

X 10546 X10S46 X 10546

X 10547 X 10547 X10547

;i * 4 ' a X1500
f-usecarrer. , t
8 XI500
D
7

i[ " "3 0 ] FZ 9 fron t1

1f
1|
t!
| 10 A j
1
1
°-5
GE
0.5 0.3
SW RT/G
5
N
O- 5 0.5
BL/RT

u8 JL__
i i 1 1
X 16760
~ " 1 A1676 0
4 ' ' X I 1005 |
1
1
m 1 Body-gatewa y
1 modul e
1
(r A149 a ""le" "~ ~ 17 Y X 16760
1 [Q^ I Ca r acces s
1 LiE d syste m
1 X859 8 X8597

13 IX1031 8
0.5 I 0. 5 0.3 5 0.35 035
RT/WS 1 GN/R T WS/B L WS/GE SW
16 1 J^ 1 4 6 9 X 19527

' 5 J X I 9527

0.5 1 0.5

1
BR/VI 1 BR/S W
X18726 I X1875 1

B51Cele25739
OBDII socket
N52 engine or N54 engine as of 09 / 200 8

Transmission ; j Engin e control

control ! 1 module (DME. )
i j
9'f- 2 -!T- 6 V X8500 1 X60002 1 1 14 ' "- 21 ' X6000 1

j Seque n ia i
! manua l

1*X7001137Y ' 36 y X7001 4 9 X70003 i.SMG )

0.35 0. 5 0. 5 0 35 0.3 5
RT/GN G ES W RT/GN G ES W SW S W

X 10545 X 10545 X 10545 X243 X24 3

X10546 XI 0546 XI 0546
X10547 X10547 X 10547

X 15008 X 15007

P Fus e earner.
f" "I 0 fron t
| 10 A

0.5 0. 5 0.35 0.5 0.5

GE S W RT/GN RT BL/RT
i X I 1005
8 9J [2 7 30 29 , X16760
N38b
I Ca r acc e ss ! Body-gatewa y Car informatio n
i syste m ' modul e computer CI C
13] X1031 8 16t 17YX1676 0 1| 3 |4 | "" • 9 | 10TX1381 3

X8598 X859 7

05 0. 5 0.35 0 35 0 3 5 0.3 5 0.3 50 35 0.3 5 0.3 5

RT/WS GN/R T WS-'BL WS/G E SW BL/G EG N OR/G NR T BL/R T

16 1 4 69 21 2 13 ^3 |1 1^X1952 7

4Y 5 r X19527

0.5 0. 5
BR/VI 6R/S W

X 18726 X1875 1

B510ele51336

Electrical Wirin g Diagram s ELE-12 7

 Electrical Wiring Diagrams ELE-12 8

OBDII socket
N62 TU engine up to 03 / 2007

f^ A7000 a r ^ A600 0
, r-p^- j | Transmissio n . rr=r-i i Engin e control
I L3Z i1 con 'r0' I l^rJI | modul e (DIME)
11 1 1
l_ _ p T _ J U t

91 2 16 Y X850 0 1 Y X6000 2 1' 1 42 1 X6000 1

r ~ j A7001 0
rp=r | Sequentia l
I j^xy ;| manua l
II transmissiot 1

1 Y X7001 1 3 7Y 3 6 Y X7001 4 9 X70003

11 1
11 1

i
035 0. 5 I 0. 5 O.35 1 0. 5 1 0. 5 0.35 03 5
RT/GN G Ej SW RT/GN 1 GE1 SW SW S W
j X'054 5 ,>,Uo,-. t j j X 10545 X243 X24 3

X10546 X10546 ' J X1054 6

X 10547 X 10547 ' X 10547

r~ " A4! a
| Fus e carrier. X1500 gX 15007 1

ii " I
-> foa tron t .. . f.
u| J I P P 1
II 1 0. 5 0. 5 0.3 5 0.5 1 0. 5

8L A !2 u3
j 10 A I 1 GE S W RT/G N RT | BL/R T
'I l
012 9 1 X16760
. _/*i_ A
"~ " j A1676 0
1 Body-gatewa y
' X1100 5 l IJQJ 1 j modul e
!" ~ ~ j A!49 a j ^
1
•i j i Ca r access (
| !W jj syste m 1 8 V X i6759

L_ , _ J I X183
13 Y X10318 j t
0.75 0. 51 0 35 0.35
RT/WS GN/R T1 WS'B L SW

: 1 6
1 , 7 1 9 X 19527

4 5 Y X1952 7

0.5 0. 5
BR/VI BR/S W

X18726 X1875 1

B510ete23385
OBDII socket
N62 TU engine as of 03 / 2007 up to 09 / 2008

r - -- , A7000 a r ^ A600 0
I r^s i( Trans m ssion | r^-i j Engin e control
I ISl2 l I contr o I [321 1 modul e (DME )
11 1 I
9^ 2" T 6~ Y X850 Q 26 ' 37 Y 3 6 Y 17 " X6000 4
A70010
j~ | Sequential
1 foj j1 manua l
| 132 1j transmissio n
L_ , ^ r- J iSMG )
1 Y X7001 1 3 7 Y 3 6 Y X 7 0 0 1 4 ;) ' X70003

035 0. 5 0. 5 035 0. 5 0. 5 0 35 0.3 5

RT/GN R T BL/R T RT/GN R T BL/R T SW S W

X 10545 X 10545 X 10545 X243 X24 3

X 10546 X 10546 X 10546

XI 0550 X1 0 550 X1055 0

n A41 a X1b00 8 X1500 7

r?
Fuse carrier . •^^•-^ ^• fr .
] F2 9 fron t1
11 05 0 51 0.3 5 1 05 \
i 1 10 |1
A
GE S W RT / 3N I R T L^/R T

-* '8 1 9
A.. - _A
2
_. —f^-
71
~ ^
30J^ 2
"
9 J[ X 16760
] A 16760
4 Y X1103 5 1 Body-gatewa y
1 modul e
1 1

rpsi | Ca r access ^^ ^ X 16760

i^l I syste m
1 X853 8 X859 7
13Y X1C31 8

0.5 I 0 5 0.3 5 0.3 5 0.35

RT.'WS 1 GN/R T WS/B L WS/G E SW
16 1 A1 46 9 | X1952 7

4| " • 5~Y X 19527

0.5 0.5
1 BR/V I BR/SW

I X1872 6 X18751

B510ele25741

Electrical Wiring Diagrams ELE-12 9

 Electrical Wiring Diagrams ELE-13 0

OBDII socke t
N62 TU engine a s of 09 / 200 8

. „ po o Fus e carrier, ! Transmission ; i Engin e control

r~"3
'1 0 F29 fron t control ! ! rnodu e {DME}
j 2' 6 y X850 0 26 ' 37 36 V/Y X6000 4

_ Sequential
4' X11005 manual
1Y X70011 37Y 3 6 X70014 9 X70003 (SMG )

0.35 0.5 0 5 0
0.35 5 0. 5 0.35 0 35
RT/GN RT BL/R T HT/GN R T BL/R T SW S W

X10545 X 10545 X 10545 X243 X24 3

X 10546 X 10546 X 10546 *
X1055 3 X 10550 X 10550

X 1 5008 XI 5007

0.5 05 0.35 05 05
GE SW RT/GN RT BL/RT

8| 9 27, 30 k 29 , X 1 6760
' " ~ ~ ~• ~ ~ ~ ~ N38 b
i Ca r access ! Body-gateway Car information
! syste mj module computer CI C
13YX10318 16 Y 17 ' ' X 16760 1T 3 4'f "9 Y1 0 X1381 3
X8598 X8597

0.5 0. 5 0.3 5 0.35 035 0.3 5 0.3 5 0.3 5 0.3 5 0.3 5

RT/WS GN/R T WS/B L WS/GE SW BL/G EG N OR/G NR T BL/R T
16 11 46 9 21 21 33 1 1 X1952 7

" 5} X1952 7

0.5 0. 5
BR/VI BR/S W

X 18726 X1875 1

B510ele51337
Oxygen sensor s before catalyti c converte r
M54 engine

I
1 —- -
A8680

| F0 4 electronic s

1 30 A ]

•1
1

J
X8680

05 05
RT/WS RT/WS

4 X62101 (On intak e manifold 4 X62201

' nea r cylinde r head )

|— B62101 [ ^ r 86220 1

/j^\n sensor d /i\n

\~r) befor e catalyti c Q Vry befor ec
converter "~> convert e

3 6 2 1 5 X6210 1 3 6 1 2 1 i f 5 1 X6220 1

0.5 0 5 0 5 0. 5 0 5 0.5 0 5 0. 5 0. 5 0. 5
BR G ES WO RB L BR G ES WO RB L

iD r r
1 20 7 I 1 91 32 22 9 2 1I S X6000 2

^ 1_ » |U ~ |i > U -fe f- »4 —B. f- > jp* -" I A600 0

[I I DM E
I UI contro l
0- Dp -3 , iQ - K _ H Qr- fy - for - br -] mod *
I 31 A T 31 1 13 1A T 31 * T 31 i T 31 1 I 31 A I 31 A
i

B510ele19343

Electrical Wirin g Diagram s ELE-13 1

 Electrical Wiring Diagrams ELE-13 2

E-box fa n
M54 engine

Fuse carrier, engine

electronics

A6000

DME control modul e

| X6506(l n E-Box)

M6506
E--box fan

BSIOele 19366
Fuel injector s
M54 engin e

A149a n A868 0

I -ft ac
Car
:ess
« r~~3o—i Fuse carrier ,
engine
]u 1 syst , ! |30 A ! electronics
L_.if \ L

1 ~X10318
X6011
| X683 0
X8680

0.5 2.5
GNAWS RT

i UV J J30 K6327
H'--""]
Relay, fuel injectors

X60531(ln E-Box)

05 2.5
BR RT/GE
X6970 X6970 (On fuel rail)

o.s 0.5 05 0.5 0.5 0.5

RT/GE RT/GE RT/GE RT/GE RT/GE RT/GE
X6102 1 X6103 1 I X6104 1 | X610 5 1 1 X610 6
Y6102 Y6103 Y6IQ4 Y6105
Fuel injector , Fue! inj < Fuel injector , Fue! injector ,
cylinder 2 cylinder cylinder 4 cylinder 5
X6102 X6104 X6105 X6106

0.75 075 075 0.75 0.75 075

BR/WS BR/RT BR/GE BR/BL BR/GN BR/VI

X60003

T"
i—». A6000
U DME contro l modul e

B510ele 19340

Electrical Wiring Diagrams ELE-13 3

 Electrical Wiring Diagrams ELE-13 4

Fuel pump Vehicle speed control

M54 engine M54 engine

=use holder, rear I , _ -

f - ....
. _ , Fuse carrier , engin e
I3 0I electronics
i• *I
I 20 Ai 30A
'
! A7 2
[<V/:! ; Steerin g colum n ' Rea r right wheel
6' X11010 4 X8680 ' switc h cluster ' spee d sensor
8) Steerin g colum n
"' X1033 4 switch , cruis e
control

X377(Right whee l well)

2.5 0.75 0.5 0.5

RT 'WS RT/WS GN BL/GN

6 8 X10156

h
31 19 I X174 6
1. K9 6 A220 *• 1 5" ] A65 a
-- - . . .{•'•/• ] I Fue l pu Safety and I ! Dynami c stabilit y
? gateway '\ I contro l (DSC)
!, IQ} f • • 12Z I I
"Q
2' 4 XI 01 56 34 3 2 ^ ' X1358 1 ; 3 1 i

X10546 XI 0545 3 X1746

2.5 035
WS/BL SW.VI

4 X638 1 0 X60004 0.5 05

RT BU'RT 0.35
101070 rf * •n A600 0 GE/GN
Fuellank
DME control module
37 36 22 X60004

T3i i
1f i DME contro l
'> I
f3ii |
2.5
BR

X13792

B510ele19345 B510ele20366
Brake light switc h Accelerator peda l modul e
M54 engin e

15 15 | A600 0
T- I DM E

T* 3
15 |1 5 I contro l
? I modul e
"• A149 a f~» l2±i !
^ ^ " ^
15 §3 ^ ar Access syste m
TT
z X60004
XI 031 8

035
VI/SW
0.5 0.5 0.5 0.5
GE/BL WS/BL WS/GN GE.'GN
1 X78
— S2 9
t Brake
\f
light
3 4 2 X78 s "lk-h B10
035 035 0 35 -- 1 0 : o,., , « ^1 Accelerator
BR/GR BL/RT BR/SW
' ... . - .i J pedal
X1179 X1179 X181 X181 X181 module

X 13787 0.5 0.5

,I

BR/BL BR/GN
39X10318 24 X60004 5 1 X12 3 0 X1746
TV " ^ A149 a -. "L » A600 0 "~ A 3 '~~ _/ > 65a
n DM E ' S Ligh t [ I g j C ynamic stabilit y
t>— ,acces
T311 syste
s
m
> —i H2 ] r*.
311 T3l
—contro
i modul e
l
?a modul e %i i c ontrol (DSC)
.tr* A6000

DME
control
module

31 « ^31

B51 Dele 1945

7 B510ele19355

Electrical Wiring Diagrams ELE-13 5

 Electrical Wiring Diagrams ELE-13 6

Knock sensor s Throttle valv e

M54 engine M54 engine

| A6000
' DM E control module

5 X60003

05

30 3 0 A6000

i.j . Tr~r
~^ DME control module s
0
X6390

» —»• , I
* ^iu
i...:-i'. j
i, * * Y6390

-© v1 o -A—
~4" Electric
: e — -/
J throttle
T3 i 31 valve
j( O
46 33 47 34 1 X60003

0
i, i

y| — <k>— ]
0.5 0.5 0.5 0.5
GE SW GN BH '"
6 4 i 3 5" 'X6390
1 2 3~ 4 X62400 (Belo w throttl e
housing) 0.5 0.5 0.5 0.75 0.75

B62400 |
ll i j
I
| || :
Double knoc k sensor ^ 5_ 32 [ 31 42 j
43 X60003
1) Cylinder 1-- 3 r — '- ~ b- —s ( 1
LJ 1 f —B> » -»• *-I - t - A600 0
2) Cylinder 4-6 *'"*' 1 " ^ i L

I:
MM DME
UV ( 7
51 V '^ H! control
&n
T oA
L'
3
E! O j 1
vjv I
13 0A '
t
v
>1
u Vj.-
30A i
( iC>^-- 1
y
30 *
module

L 1

B510ele 19242 BSIOele 19246

DISA changeover valve Idle speed control valve
M54 engine M54 engine

A8680 I A868 0
Fuse carrier, engine I Fus e carrier, engin e
F02 87 F02 I electronic s
electronics

30A 30A

4 | X868 0

0.5 1.0
RT/WS/GE RT/WS/GE

X6167 2 X613 0
Y6130
Valve, individual Idle actuator
control intake system

1 X616 7 3 T X613 0

0.5 0.5
0.5 WS/GN WS/GE
BR.'BL

40 X60003 22 23 X60003

o
f—*• I A600 0 A6000
M !(v) jI DM E control module DME control module
V-, !
31 31 «

B510ele19357 051 Oelel 9348

Electrical Wiring Diagram s ELE-13 7

 Electrical Wiring Diagrams ELE-13 8

Hot-film mas s air flow sensor Crankshaft positio n sensor

M54 engine M54 engine

I A868 0

I Fus e carrier, engine

| A8680 5V , A600 0 I electronic s
—f- i
|j! DME
87 I! F0
i 3
engin e [(£51 U ' control i 20 A
[T I I electronic s !^! ,,-?--* • | module
'! 20 A I I --

J—' ! X60003
6 X868 0

61 X8680

05
RTAWS
X6203

B6207
B6203
| Hot-film
air mass Crankshaft sensor
meter

1 X620 7
X6203 (Lef t rea r
engine block)
0.5 05 05
GE/BL SW GE
0.5 0.5
GE BR

I A600 0 37 X6000 3
i DM E

e
I contro l
A600°
iV>/ I modul e DME control module
31

B510ele 19347
B510ele 19349
Engine cooling system
M54 engine

"JA41a [ AGOOO A8080

t n

DME
5 15 " F03
M
30 1 F9 1 holder, 1 4 controi 87 ~ 8' 1 engin e
j fc
1
fl 1 !
Lj 60 A 1
fron t 1 module
i |
D
30A
' electronic s

JL •—* <-* j . j
39 1 X60004 28 1 X60003 |
_ K ~ J
4 ' XI 1002 6 4 'X8B80

60 0 35 05 0.5 076
RT/BL SW/GR BR/RT RT.'WS RT.'WS

r
2 X1797 2 X13380 1 Xb236 1 X6279 2 X 13864

B604 B6236a Y6279 Y13864

r
I h M13 5I J
Engine r— -}-j7 Solenoid ,
]Oj (V ) Electri cj Temperature j ^f Characteristic
coolant
L_ sensor a t map radiator
J
— .L jJ T fa n l ^ temperature
i 4 X179 71 'X13380 2 ' 'X6236 sensor 2 ' 'XK279 1 ' X 13864

60 0. 5 0 35 05 0.5 0.5
BR GE/R T BL'GR GR/BR GR/BR BRAVS

X60004 12 X60003 X60004

rf
4 j^ 3 8 35 21
r ~l — >- , ^ -+ —> ~» - j A6000
I1
i |1 DME

ta
Ui ir Pi] d- r contro l
M~- |L &f t
T 31 i
modul e
T 31 i
X13797 3 1

B510ele19361

Electrical Wiring Diagrams ELE-13 9

 Electrical Wiring Diagrams ELE-14 0

Oil supply Camshaft position

M54 engine M54 engine

n A868 0
I, , Fus e carrier ,
II 8 7 F° 3 engin e
IT l electronic s
j 20 A

'' , [Relay , : L _ . [ _,
!\'
'' j!n^ctor s i 6 T X 8680
X6327
15 A600 0 m Bb23 1
I©: T DM
U contro
E
l
„¥ Oi
U_, pressur
l
e
0.5 : . . UK ,;
QN/WS " ^
,_f^~* modul e „-- | switc h
X6830
44 X6000 3 1 X623 1 0.5 0. 5
1 X60531 (in E-Box) ; . RT/W S RT/W S

0.5 0.5
RT/BL GN.'WS 1 X621 41 X622 4
1 X623 8 1 X6254

[ ST -
B6238 B62543
Oil Oil
:1 ^ temperat u
sensor llensar I B621 4 B622 4

2 X623 8 3Y 2 ' X6254 I - | - - Camshaf t, .- Camshaf t

:• senso rI ' ' senso rH
0.5 0.5 0. 5 ns:
GR/BR BR/GR GR/B L BR ;
4 X60531 !
3Y 2 Y X621 4 3 * 2 Y X622 4
0r- (Fron t of cylinder head ) (Fron t o f cylinder head )
45 16 5o { X6000 3 BR
t-» I « • " "A600 0 X6458 0. 5 0. 5 0. 50 5
P" iDM E ** B RG EB RG E
31, Br > - r > —[contro l
r"3li V'3i , [modul e
36 I 2 9 I 4 9J[ 3 0 J X6000 3 ;

• — >4 e > p-» - t o n A600 0

!: i | !I DM E
1 ••• '- r HO ,v 1 T 1 contro l ' .
31 • Or -I
ViX Vi
M3 1 A br-. Vj
.m °ocluie :
I 31 i : 31 i|

B510ele19809 B510ele19350
VANOS valves Vehicle speed signa l
M54 engine

A8680
Rear righ t whee l
, Fus e carrier .
speed sensor

!i °
F engin e
| electronic s

i 30A I

1 X37 7 (Right wheel well)

4 X8680
0.5 0.5
BL/GN GN

19 31 X174 6
0.5 0, 5 15 *--» • | A65 a
RT-'WS/GE RT/W S
I Dynami c stabilit y
I contro l (DSC)
1 X6275 1 J X627 6
~ Y627 5 Y627 6 31
VANOS VANO S
solenoid A — : solenoi d
^ valve. valve ,

2 X6275 2 ' X627 6

05 0 5
GN/BL GN'V I
035
GE-GN
10 9 X6000 3
22 X6000 4
>— e. • —»• A600 0
DME
control DME contro l
j(G) modul e module
Q— 1LvL d pr— H
Vj_/ v^ ,
31 » ; 3 1«
J

B510ele19351 B51()olo 19359

Electrical Wiring Diagram s ELE-14 1

 Electrical Wirin g Diagram s ELE-14 2

Power train CAN-bus

M54 engine

] A220

M ! Safel y and gateway

module

34 32 'X13581
0.5 0.5
RT BL/RT
(Bottom of right A-pillar
X10545 X1054 5 behin d instrument panel) x '0545
(Bottom ol right A-pilla r
behind instrumen t panel) X10546 X 10546 X 10546

0.5 O.S 0. 5 0. 5 0. 50 5
RT BL/RT R T BL'R TR T BL/R T
37 3 6 I X6000 4 1 4 13J[xi051 3
|" 1A600 0[ " ^A21 4
[©] DM E r OI Adaptive
I control | headlight

(Behind instrument panel ,

X10548 X1054 8 righ t side ) X1054 8

{Behind instrument panel, X10549 X10549 X1054 9

0.5 0. 5 0. 5 0, 5
RT BL'R TR T BL/R T

2 1 X6021 9 [8 |X13718 2 84 3 X187 7

\ A467 , r" 1 A148a
Oj Active [Q j! Dynamic
0.5 0.5 i steerin g driv e
GE
X8090 X809 0 (Transmissio n nea r driveshaft ) X809 0

(Transmission near driveshaft) X8091 X8091 X809 1

I 0.5 0. 5 0. 50 5
GE S WG ES W
37^ 36JX7001 4 2\ X850 0
4* 3 ' X6021 ~]A7001 0I "" ] A7000 a
j Sequentia l [ O| ] Transmissio n
i manua l \ l

(SMG)
X10554 X 1 0554 (Nea r right foglight )

(Near right foglight) X 10555 X 10555

0.5 0,5 0. 5 0. 5
RT BL/RT R T BL/R T
24 37 X1746 4 2JX178 3
I A65 a J "" ] A144a
I©! j Dynami c stabilit y j^ lI Active
I contro l (DSC) , j cruj se control

B510ele19744
Alternator, battery, intelligent batter y sensor (IBS) Alternator, battery, intelligent battery sensor (IBS)
N62 engine o r N6 2 TU engine N62 TU engine
up to 03 / 2007 as of 03 / 2007

X10556
&>.

035 X6402
RT/GN
X13895

, A6000 I B895 G1
ipp ' DME control Battery senso r Battery
A6000 B895 ! module
DME contro l module Battery s
•:
1TX138951 X9230 (Nea r battery) X13769
I X2403
1.5 X2219(Near battery)
(Near battery ) i ' X923 C (Nea r battery ) RT
0.5 0.5
VI GR
X2219 (Nea r battery)
X6009
A6009
Integrated suppl y W9110 1
module (IVM )
X6430
1 Integrate d supply
module IV M
! Jum p start
I terminal
J. poin t
X6038 X6038

Jump star! terrr

point
0.5 0.5 250
VI VI RT
X62540
1 B62540
;Tr>! jOi! quality
i sensor

I M6510 a 25.0
l y ^ t jj Starte r RT
M6510a
G6524 1 X652 4 X6509
Starter
G6524
Alternator

B510ele20367
B510ele26576

Electrical Wiring Diagrams ELE-14 3

 Electrical Wiring Diagrams ELE-14 4

ernator, battery, intelligent battery sensor (IBS) Alternator , battery, intelligent batter y sensor (IBS)
4 engine N5 2 engine
up to 03 / 2007

X 10547

X10547
°RT%N X6402
0.35
RT/GN X6402

',tjl '
] A600 0 i J- -L ^ ^
DM E control Batter
B89 5
y
X6406 3
"1 G 1
Battery ' B89
£|j Batter
5
y
I_
X6406
U
- Batter
1
y
i modul e j senso r
sensor
19 X60003
,L J ±+
(Near battery ) 1 t X I 3895 1 f X923 0 X 13769 ' X 1 3895 (Nea r battery) 1 Y X923 0 YX13769
0-5 (Nea r battery) /
a[ xeo n f 05 1
GR R
5
T

_ J
I J X 2 2 I 9 (Nea r battery)
w X2219 (Nea r battery)
,. ,
X60001
, A600 0 W9110.1
0,5
GR W9110.1 j JQ |i DM E contro l
i mod u e
: W9H0. 1
3 T X6053 1 35 ' X6000 5
W9110 1 X6430
0.5
VI i< 3 0 1 G6430
&8 X6430 j| j Jum p start
X6038 X603 8 t termina l poin t
30 ] G643 0
X6038 X603 8 " X64C M
! Jum p start
i termina l poin t 05 250
V! RT
X6404
05 1 1X6254 0 J X651 2
BL
05 t 1 B62540 a 2 5 rj '-^ 1 M6510a
R5t° VI H ! Oil conditio n R T C) cStarte r
] senso r
250 \ 4j X650 9
X6512 1 X6524 j X650 9
I MS510 a GB524
1
Alterna tor

mi T
*) 12 ! Starte r
G6524 \ 1

|31I

B510ele 19364 B510ele26573

Alternator, battery, intelligent battery sensor (IBS) Secondary air system
N52 engine or N54 engine M54 engine
as of 03 / 2007

X10556
>
0.35

n
RT/GN
X13895
X6406
B895 A8680

rI [jsr"i
Battery Ba«ery Fuse carrier ,
sensor F02
engine
1 30A ; electronics
IT X13895 (Near battery ) 1 X13769
! X240
3 4T X868 0
1.5
RT X2219 (Near battery )
05
GR 0.75
RT/WS
"\0 ^£?5?_ B6206
] DM E contro l ~~n = H K6304 a
Secondary ai r
i modul e 87i "'87 aI pump relay
X60Q05 X6304
X6206
,5^1 G643 0
i Jum p star t 0 5 0.35 4.0 0.35
i termina l point SW/GE BR/BL SVV/RT/GE BR/RT
X6038 X603 8 "X6404
A6000
250 DME control | Secondary
RT 3« B air pum p X18740
module i
X1124
X6512
~[ M6510 a 4.0
X62540
i r' Starte r BR
1 B62540 a
05 pv ' Oi l condition 250
X13782
VI RT
i senso r
X6509
G6524
Alternator

B510cle26575 B510olc193S4

Electrical Wiring Diagrams ELE-14 5

 Electrical Wirin g Diagram s ELE-14 6

DME main relay

M54 engine

A41a
Fuse holder ,
JO ] F8
front
U 60A i

rX11002

6.0
RT/WS
X18326
; : A207 6
.» B + potentia l
i distributo r
•~X64i02

4.0
HT
X6300

r
K6300
DME
(p
IL
f°

8£ 87 87
4' 5' -2 ' X630C

0.5 4.0 4.0

BR/WS RT/WS RT/W

23 X60002 1 5 X868C
-» ^ A600 0 ~" A868 0
1 g | DM E -,F01 -- > -jF0 2^ — F03|---| ^F0 4 ^^ gr
i -j —, contro l i• •> it ii i (
T31, modul e i30A !i|30 A] i | J20A
1'r ' electronic s
" 1 '
i _ J

B510ele 19344
DME control module
power supply
M54 engine

A8680 [ " A41a

r8
i "T
?
i
F02 carrer
Fuse 1
. |
engine |
_

|
[
_
3
rt
0 1
i I
F 8
Fuse
holder.
front
i 30A elecronics | I 60 A1
i -^ 11 T 1
u__| , i u_ _

i1 I !

4 X8680 3 X11002
60
RT/WS
1 X 18326
f3 0~ j A207 6 X 10547 X I 0546 X I 0545 X24 3
^ ! . —&. ! B+ potential * *
1 ' d'Slributo r
1 I
1

1 'X64101
i.S 0.35 0. 5 0. 5 0.3 5
RT/WS/GE 1.5 RT.'GN H T BL/R TS W
RT

8 7 X60001 26 3 73 61 7 X6000 4

F* r"*
A6000

Vi T
DME

FT ^
— r
-U
u ty~\ 1
control
rh L — ,

f
module
IT 31 .J
13 1A
31 A 31 * 31 A j
5 X60005 4 5 6 X60001

2.5 1.5 1.5 1.5

BR BR/OR BR BR
In E-box) 2 X60541

/ X64542 2 X64541 X6458 X6458

r~
ii ,_. ». '
| 10105 3
Termina l 31
j support . E-bo x

i 'X2350
i

6.0
BR
X6

B510elel9339

Electrical Wirin g Diagram s ELE-14 7

 Electrical Wiring Diagram s ELE-14 8

Fuel tank vent valve Diagnostic module, fuel tank leakage

M54 engine M54 engin e

| A8680 A8680
I Fus e carrier, engine Fuse carrier, engine

i
| 8 7 "I F0 2 I electronic s II 87 electronics

II
30A
II 30A

X8680 4 [ X868 0

0,5 0.75
RT/WS/GE RT/WS

1 X612 0 4 X1714
Y6120 M119a

i
Fuel tan k ven t valv e \-L
A' s
Diagnostic modul e for
^ fuel tank leakag e
_.:

X6120 3 ' 1 > ^

2 X1714

0,5 0.75 0.75 0.75

BR BR/BL SW/GN SW'RT

21 X6000 3 30 ( ,2 X60004
L. 2 0
1
f - - >, A600 0
n n?[§xi'v I A6000
: DM E contro l modul e
DME control module

BSIOelo 19360 B510ele19358

Ignition coils
M54 engine

A8680
Fuse carrier, engine
["87 T F0 1
I |T i I
electronics
| I 30AJ

2.5
RT/WS

lio 1.0 1.0 1.0 1.0 10

I RT/W S RT/WS RT/WS RT/WS RT/WS RT/WS

3JX6151 3 X6152 3 X6153 3 X6154 3 X6155 T _3 . X6156

T6"=1 T6152 T6153 T6i ^4 T6156

IL
1 Ignition coil. Ignition coil . , I ignitio n coil . Ignition coil ,
H
[ !gnition coil. Ignition coil . I
cylinder 1 cylinder 2 cylinder 3 cylinder 4 I 1 ^ 4 cylinde r 5 T4cylinder 6
*4 |!1 , + 4 L^»4 _ 4} Spar k plu g
4) Spar k plug 4) Spar k plu g 4) Spar k plug 4) Spar k plu g
12 X615 connection 2 X6152 connection 1 2 X615C connection 1 2 X615-: connection 1 21X6155 'connectio n 1 2 X6156 connection

15 10 1.5 10 15 1.0 1.5 1.0 1.5 I 1. 0 1.5 1.0

SW/WS BR SW/RT BR SW/GE BR SW/BL BR SW/GN 1 BR SW.'V BR
X6176 X6176 X6176 X6177 |x6177 X6177

r rfei
6 7 4 8 1 9 X60005
-u. —-
g
fe
" T- »- T- » A600 0
00
Ea
DM E

fel ^i b-i
1311 V
T3i nl con
modul 'ro1e

B510e!e19352

Electrical Wiring Diagrams ELE-14 9

 Electrical Wiring Diagrams ELE-15 0

Exhaust flap Crankshaf t position senso r

N62 engine or N62 TU engine N6 2 engine or N6 2 TU engine

up to 09 / 2005 a s of 09 / 2005

A.6009 ^ A600 9
| A600 9

I, , I Integrate d supply J ~< 7| h005 modul e IV M ( J7 IFOO S saEtoMM "

I8 7 | huu y | modul e IVM I j I ' s1
! lt | U l. .!
10 A ! ! l
30A ] 30A |

!L . j ! l _ j
II rj " X60093 1 3 ' X6009 3

13 j X600 9

I—* 0.5 0.5

GE OR

075 - j X6203 1 X6203

RTA/VS '

B6203 B620 3
2X 13373
-|~^Q- Crankshaf t -px~} - Crankshaf t
Y198 [ senso rr senso r
p/n-Y Exhaus t flap

I 3 Y X620 3 (Left rea r 3 v 2Y X620 3 (Left rea r

1 Y X1337 3 engine block) engine block )

0.5 0. 5 0.5 0. 5
SW B R GE/WS SW/W S
05
BR/GR
X6450 X6450

18 1 X6000 4

1 ft - r , A600 02 7 37 | X6000 3 2 7 37 j [ X6000 3

'/** n\ i DM E control module '
•— »• ~f — >" ] A600 0 >-»T ~ ~ "f^tJ | A6000
I DME IDME
O| [JO] V ! control r liOl lT ' control
T31 1 Or-n Ml bp- 1 1 module Qj ; ISa fc> — 1 ! module
T 31 1 T 31 1 131 t T 31 1

15584 2430 7

B510ele20353 B510el e 15584

E-box fa n Fuel injectors, cylinder s 1 through 4
N62 engine or N62 TU engine N62 engine or N62 TU engine

Integrated supply
F009
module IV M
II A6009
10A i>7 ; F00 6
§20A !

14 X60093

X6009 1.5
RT/BL
X6823 X6823 X6823 X6823I

0.75 0.75 0.75 0.75

RT/BL RT/BL RT/BL RT/BL
A6000
3 5 7 9 X6053
DME
control 0.75 0.75 0.75 0.75
module RT RT RT RT
1 X6101 1 X6 1 02 1 X6103 1 X6104
r- 1 Y610 1 | ' 1 Y610 2 I ' Y6103 '
,, ^
' Y610 4
^] Fue l injector, j yi Fue i injector j - ^ Fue l injector , ^ '"'• i F

| cylinde r 1 i I cylinde r 2 i cylinder 3 ic

2 X6101 2 X6102 2 X6103 2 X6104

0.75 0.75 0.75 0.75

GR BR GN BL
0.75 U.5
1 4 6 8 X6053
RT/WS GE ntake manifold)

075 0.75 0.75 0.75

BR.AA/S BR/GE BR/GN BR/BL
13 24 26 6 X60003
'* ":. "n /A6000
j[ DME
M6506 o- • -Tr - '& control
T3-U Y31i tS-li T3ll r module
E--box fa n

B510ele20970 BSIOele 15575

Electrical Wirin g Diagram s ELE-15 1

 Electrical Wiring Diagrams ELE-15 2

Fuel injectors, cylinders 5 through 8 Brake light switch, DSC Dynamic Stability Control Premium
N62 engine or N62 TU engine N62 engine or N62 TU engine

A149a
Car
15 ^ J

1T
access
•• A600 9 system
r- , crtrt H Intearate d upply
rf
i, F " modul e IV X1 LJbi.-.,
30A| 2 f X1031 8

3 X60093
035
VI/SW
2.5
RT/WS
X6820 X682 0 X6820 X6820

0.75 0.75 0.75 075

RT/WS RT/WS RT/WS RT/WS Brake
light
9' "T 5' 3' 1 X605 4 switch
3 4 2 X78
0.75 075 0.75 0.75
RT RT RT RT
(Bottonn of lef t side
1 X8105 1 X6106 1 X6107 1 X6108 035 035
A-pilla behind instrum ant 0 35 (Be h n d front fue l panel)
• -| Y610 5 Y610 6 ~] Y610 7 11 Y610 8 BR/GR BL/RT BR/SW
^ Fue l injector . ±^ Fue l injector , ^ ^ Fue l injector , L ^ Fue l injector, pane!)
_| cylinde r 5 cylinde r6 j cylinde r 7 | cylinde r 8
X1179 X1179 X181 X18 1 X18 1
2 'X6105 2 ' X6106 2 ' X6107 2 X6108

0.75 0.75 0.75 0.75

GR BR GN BL
8 6 4 1 X6054

0.75 0.75 0.75 075

OR BR/GR BR/RT BR/VI

7 8 11 25 X60003
U. "- » "' i-» " "~F » A600 0
32 X10318 28 24 X60004 5 1 X12 3 7 X10821

rl
If ij l DM E
'•QI—I pr ^ H t» — ,h — contro l —* ~JA149 a r ~T-» .-» IAGOO O r ^r— IAS <--
El ILiqht I
T3ll Tai l Wt l *W . modul e
El I Car | j IDME j l^j I Dynamic
access x_ ^ IS ] U, 'contro l h
^|modu,e ) CV-, i stablNty
h?n syste m M I ^ lf> 1 [module :x> I ] control
1 3 1 i [ T3 1 1 i 31 A , 131 ^ |(DSC ) X13787

B510elc15576 B510ele25800
Accelerator peda l module Knock control
N62 engine or N62 TU engine N62 engine o r N62 TU engine

15

- 30" " ' ' A600 0

X60004

r
7T Pi i DM E
jT P i "coiitro l
-£T* ~y 3J 3U
!- ; moaul e

46 33 47 34 48 35 49' 36 X60003

0.5 0.5 0.5 05 05 0.5 0.5 0.5

GE'SW GE/BR GE/SW GE/BR GE/SW GE/BR GE/SW GE/BR

! B1 0
Accelerator
pedal
J modul e
X11400

0.5 0.5 0.5

BR/GN WS/GN WS/BL

1 2 3 4 X6257 1 2 3 4 X6258
X60004 I B625 7 B6258
ip| iU
: '' ! Knoc k Ipt (Pi Knock
A6000
I
LJ< '
sensor 'J' 'u! sensor 2
DME

W
b, - control
module
i 31 i 31 A

B510ele15577 B510ele15578

Electrical Wiring Diagram s ELE-15 3

 Electrical Wirin g Diagram s ELE-15 4

Knock control
N62 engine or N62 TU engine

- -3 0 - • - gg- -3 0 " " A600 0

nr s
DME

46' 33
T 47 34
3ii
48
-^*

35
n~
31-
49
J*
T~* contro l
ij modul

' X6000 3
e

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

GE/SW GE/BR GE/SW GE/BR GE/SW GE/BR GE'SW GE/BR

1 2 3 4 X6257 1 2 3 4 X6258
B6257 - - • • - B625 8
r,
-•'il- "fl- '
Knock — fr Knock
: sensor sensor 2

B510ele15578
Convenient start (up to 09 / 2005)
N62 engine or N62 TU engine
page 1 of 2

A4la | i j ] S2 9 r " j A65 a

-_ - Fus e1 \ 1 Brak e feyl ' Dynami c
0 I h8 1 3 0 1 f holde r | 9 ^ 1 ligh t --f- stabilit y
___ X640 2
1 ' ' ff l' fon t <- 4 4 H contro l
j 60 A | j [I ) 30 A 1 - , ' --— 3 - X7 8
j ,(DSC )
X6406 i 1 .
15 Y X174 6

-£- 3 ' 2 Y X1100 2

035
BR/RT

' X1376 9 X1179 X1101

X2219
40 0 35 0 35 0 35
RT/GN VI/S W BR/G R BR/RT
: W9110 1
21 2 3 2 31 X1031 8
: wgiio i r ~\-f. s o- j t *r > .
O n^
rt ~T li !i

31 * i-
J
>
^y Oi
— <~~T, 13
r\y
_ - -^
—
i 1 -i13 1^
a t
31 i¥-» •
261 35" T
60 1 2. G
RT/WS I SW
1 X13844 1 4 J X600 9 035 05 0 5 0 5
GE/BR SW/VI G ES W
f1 . ~ " A600 9
X6430 n p \ Integrate d suppl y 36 L35 J X I 358!
<1 rRAlr, V , o 6 „ muuui e (ivivi ) " • A22 0
1 „„ G643 0T : —f 1 4 ^ c ,_,_ ,„*;,,,, „,„„ r

1 Jump star t Safety an d

terminal point — £- [£^ j gatewa y

J4- — p—^ j
u _ -, 1i ' modul e
' X640 4

22' ' X6009 4 1 5 Y X600 9 1 5 Y X6009 3 30 3 43 2 X1358 1

05
BR X10547 X1054 6 X1054 5
23 X60002 03 5 2 5
035 0 5 0. 5
250 , RT/GN R T BL/R T
RT I ' DME X1R74 0
JI control ^~ 4 0 33 26 3 73 6 X6000 4
31 J |^X7| [modul e '
-»• T- » *- »" " A600 0
L JH
iI f] 1 DM E
X6512 I X651 0 L
Q,— ,3 1 I3 1 I I© ! contra l
cp modul e
r 31 1
^
V 1 1 Starttnq motor i
12 ) Solenoi d switc h
^M) 1 3 ) Holding windin g
i^f 4 ) Pull-in w nding
I

B510ele19446a

Electrical Wiring Diagrams ELE-15 5

 Electrical Wiring Diagrams ELE-15 6

Convenient start (up to 09 / 2005)

N62 engine or N62 TU engine
page 2 of 2

L1
EWS
toroidal

3 Y X0115 1

S2
JO Ignitio n
switch
1' 2 4 D 6/ 8 9 T O1 11 2 13 "1 4 X1402 6

012 0 12 0 12 0 12 012 01 2 01 2 01 2 01 2 01 2 01 2 01 2 01 2 01 2
RT GR GR GR GR G RG RG RG RG RG RG RG RG R
I 2 3 4 5 67 8 9 1 01 11 21 31 4 X1402 7
A149a

y
Car
access
system
j 31."
41 6"* X10318

automatic transmissio n SMG transmission manua l transm ssio n

5 I X600 9
A6009
Integrated
I supply
module (IVMt 035 035
12 Y X6009 4 BL/SW SW/BL
035 035
BL/SW 12 I X7000 3 BL/SW
10 I X850 0 ,_,____.
A70010
A7000a Sequential
Transmission manual j S805 a
control transmission Clutch
fcl switch
l (SMG)

B510ele19446b
Convenient star t (as of 09 / 2005)
N62 engine o r N62 TU engin e
page 1 of 2

^A41a | | ]S29 r ]* B5a

\ Brak e .. I© ! i Dynamic
X6402 • ; o - i » - r ,, i ^ ;i, ght Jj ? ' stabilit y
I 60A l m 30 A lron t 1 3 ' 'X 7
X640S ] I

1
3 i ' ;»i (DSC )
: r 1' 36 X174 6
Battery ^
2 rX11002
-.
- , j
~
'X137G9

X1179
X2219

. W911 0 1 4 0 03 5
RT/GN VI/S W BR/GR BL/R T
W9110 1
21 2 3 2 31 1 X10318
T. . »5 0 £ - » , _ » . .-i .
:" "^ rL r n
i 3 1 '» t_ » 'i h, 3 1 131 *

22 • - ' - - — -'
23 24 30 "
6.0 2. 5
RT/WS S W
075 07 5 03 5
1 XI 3844 1 4 [X6009 SW/GN SW/G EW S
r ; i A600 9
X6430 . 1 — _ _ i Integrate d suppiv
30 < G643 ° r T iI ] modul e (IVM )
1 Jump start y c
1 termina! point — | | 44 ) DME relay 2
I— >I
X6404 XI 01 34
flTL i
1 '^--±L
;\
J L2
4 15* 1 X600 9 1 5 ' X6009 3 2 43 X1032 0
22 | M137 a
0.5 0 35 2 5 ^..^^ Electri c
250 BR BR/R TW S
RT ?* steerin g
23 X60002
"t-» A600 0 AIO/J4 U 1 ' X10230
| DM E
31 tr Oi! contro l*
X6512 . . ^ m °dUie X651 0 BR/Vi
, r~- | |M6510 a X 18726
4-- " "' ^'2 -i - : 3 Starte r
(*\} Solenoid switch
W3 ) Holding winding .

B510ele23454a

Electrical Wirin g Diagram s ELE-15 7

 Electrical Wirin g Diagram s ELE-15 8

Convenient start (as of 09 / 2005)

N62 engine or N62 TU engine
page 2 of 2

]S2a
START-STOP
button

| ; | JS1402 8
I Slide-i n
!; i I compartmen t

012 01 2 01 2 0.1 2 01 2 0.1 2 01 2 01 2 01 2 01 2 01 2 01 2 01 2 01 2

RT G RG RG RG RG RG RG RG RG RG RG RG RG R

l| 2 [ 3 J 4J ^ 5j [ 6 J 7 8 J Q [ 1o |1 1 12 J 1 31 4 [X1402 7
"] A149a
^c I Car
' T~ *' D l^ v• f ~~* i *"^ * l

U0
(T T TVl® ii M
( i1' access
system
31 1 V * l3l l j_31 ii
HI - 2 3 261' 3 5T 4 1Y 6 ^ X1031 8

I
035 05 0. 5 0 5
GE/BR SWA/I G ES W

8^9 ] X1676 0
"" A16760
Body-gateway automati c transmission SM G transmission manua l transmissio n
£- |5 ^ modul e

^ T" *
271 301 '2 9 T X1676 0 5 X600 9
r - - i- , A6009
,_x105g>7 X105 ^6 . X105^5 | j ! Integrated
!I ] supply
.- ] j modul e fIVM)
12 X6009 4

0 35 0 5 0 5
RT/GN R T BL/R T0 35 0 35 0.35
BL/SW BL/S W SW/B L BL/SW
• 4 0 33 26 3 73 6 X6000 4 1 0 X850 0 3 1 2 X7000 3 4 X121
•[ " ,-« . f.. » \-.r A600 0 Jr* W "A7000 a r ~t- » "l » 1A7001 0" ^ ] SSOSa
•I [ 1f lP DM E1 . !W | Trans m ssion | l [' ! Sequentia l IS ] j Clutc h
1 | V-> — 31 13 1 1M contro j Kv— T contro ' for -3 1 1' [5 2 manua l ^ I switc h
• I %., { modul e vfl ^ j (^ | - transmissio n " J module
1_ j L . , (SMG )

1 B510ele23454 b
Fuel pump Fuel pum p
up to 09 / 2005 as of 09 / 2005
N62 engine o r N62 TU engine N62 engine o r N62 TU engin e

[" "i A4 6 ; ^ A600 9 | i A41 a i A600 9

-, 1 PFu-e.^.er.rea
f Q h --(Ha cj ar: . _ , ., j ciiin !\ 1
30 7 '] F °09 modul e !V M ! ( 30 I F3 ° i fron t I 8 7i F00 9 ! mod u
,4t. i
i1 11 I I I *i
1 ! ' f
•l !' ' f
1!
!! I
i 20 A 1i [ ! 1 ! ! 20 A ! 10 A I I
J 10 A !
!
l
1> 1! i i 'I I

\ i i

X1101 D 1 3 X6009 -j X1100 5 1 3' X6009

25 0 75 25 075
RT/WE RT.-WS RT/GR RT/WS

8 X10156 8 X10156
.] K9 6

1N
_ -. l
IV AN
yi Fue l Dump relay
M> _J
' - j
'
2 4 X10156 ; 2 4 ' X1015 6

.5 0.35 5 035
\VS/BL SW/V! \VS/BL SWA/I

4 (638 10 X60004 i 4 (638 10 X60004

101070 | — «" ^ A600 0 : f ] 10107 0 I " —»• " I A600 0

! ^^ ' DM E contro l module ! ..^ ! Fue l tan k I [©] DM E
f~ M2 | JI M2 |

:>
r contro l
j f* g- I Oj ; i •*,
1
I Oj ] modul e
,-
X i

Tail ; | I 31 i

i— ^ I
\
!1

1 >638 1 >(638

.5 5
EiR tiR

>v 13792 >,13792

B510ele20354 B510ele23390

Electrical Wiring Diagrams ELE-15 9

 Electrical Wiring Diagram s ELE-16 0

Diagnostic module , fuel tank leakag e Fuel tank ven t valv e

N62 engine o r N62 TU engin e up to 09 / 2005
N62 engine or N62 TU engine

j A600 9 i Mouu y
! Integrate d suppl y i Integrate d suppl y
h i modul e (IVM ) i | F module IVM
I

X6009 12 X6009 3

075 0.5
RT/WS RT'SW (u p t o 09 / ' 2005)

X1714
OR (a s of 0 9 / 2005 )

X6120
Diagnostic modul e
for fuel tank leakage Y6120

Fuel lank vent valve

0.5
BR/GN

21 X6000 3

A6000
I DM E contro l DME control module
module |

15598.24311

B510ele20364 B510ele15598
Oxygen sensors before catalytic converter
N62 engin e

A6009
Integrated supply
87 n FO O
B modul e IV M

] 3C A

>E C

j
19 20 X60094

05 0.5
GN GN

3 X62101 (Top of intake manifold near cylinder head) 3 X62201

B62101
Oxygen C B62201
sensor =l
C Oxygen sensor 2
before Z] before catalytic
C
p
f"
£> catalytic converter
converter

4 1 5 6 2 X62101 1 5 6 2 X62201

0.5 0.5 05 05 0.5 0.5 0.5 0.5 0.5 0.5

BR SW GE WS BL BR SW GE WS BL

20 7 19 13 2 22 9 21 15 X60002
A6000
DME
control
module

B510ele1557

Electrical Wiring Diagram s ELE-1 6

 Electrical Wiring Diagram s ELE-16 2

Oxygen sensors before catalytic converte r

N62TU engine

r
| A600 9
:|

I I 8 j7 | uu o | modul e IV M
I I I

! I
I
!i L J 30 A
I I
I I
j

I
i . _ ^ I
II
1
I

:I
!_._
1
jI 1
J
J

19 20 X60094

0.5 05
OR OR

4 X62101 (Top of intak e manifol d near cyl nder head ) 4 X62201 :

c B62101 TJ . j , | B6220 1

c- f^"^ Oxygen senso r I /^-^ i• Oxyge n sensor 2

c^-j Vj^ x
before catalytic 1 , \_~TJ befor e catalytic
converter converter

*~ 6 Y~ 2 ^ 1 5 3
3 X62101 6 Y 2 Y 1 Y 5~ Y X6220 1

05 0 5 05 05 05 05 0 5 0 5 0 5 0 5
WS/BL G E SW/BL GE/WS WS WS/R1 G E SW/W SG EW S

1
^_ 22 JL 9 JL_ 2 1A 1 5 J X6o °°2

[r
20 7 19 13 2

:-* -
S A.. . _ >
> Jt--* ~J — *• "^-* - P-B - f^s . ~ " A600 0

fr*
I ' k~
^n $
I.
n3
I
13
!
1 L CD r 0 u DM E
&-} g
jU v y y contro l
5| i — Or— |3 1 1 &"~ 1 fe^ n OP" 1 modul e
131 1 ! 31A 13 11 ' 31 i ' 31 i T 31 t i 31 iT 31 A
1

B510ele22523
Oxygen sensors after catalytic converter Oxygen sensors after catalytic converter
N62 engine N62 TU engine

n A600 9 I r --
Integrated suppl y 87
F008
87 module !VM T
30A

1 X60094
21 15 X6009 4

0.5 0.5 05
GN OR OR
X62102(Side of transmission) X62202 (Side ol transmission) X62102fSide of transmission) X62202 (Side of transmission)

I B6210 2 I B6220 2 B62102 B62202

-,, \ n senso r --- ! Oxyge n senso r
Oxygen sensor Oxygen senso r 2
: behin d catalyti c | 2 behind catalytic behind catalytic I behin d catalytic
__L__J converte r J converte r

3' 4 ' X62102 2 3 4 X62202 T

0.5 0.5 0.5 0.5 0.5 0.5
BR GE SW BR GE SW 05 05 0.5 0.5
GE SW/RT WS/GR SW/GN
10 16 12 8 14 X60002
»-» - » j — »I A600 0 X60002
[| ' "; ;i DME A6000
Qy-i 3 U fc> - i@i Tb — ,3 1 1Tb,-~ |! contro i
DME
Tail Ya i T3li '31. 1[ modul e 31.
control
module
31J '31.

B510ole15580 B510ele22522

Electrical Wiring Diagrams ELE-16 G

 Electrical Wiring Diagrams ELE-16 4

Hot film air mass meter, intake pipe pressure senso r Hot film air mass meter, intake pipe pressure sensor
up to 09 / 2005 as of 09 / 2005
N62 engine or N62 TU engine N62 engine o r N62 TU engin e

1" A600 S[ " "5V 5V n A600 0

T DM E
JL s
A6009 "5V" A6000 r- > cnn< ; Integrate d i
F005 Integrated DME ! | 7 i suppl y U ^ contro l

-9
,7 supply control i[ n 3QA ' modul e IV M i f"^^ modul e
30A module module
IVM
' X6000 3
'. 44 ' 4 X6000 3
1 3 X6009 3

X8035

0.5 0.5 0.5 0.5 05 0.5

RT/GE RT/GN RT/GN OR BL BL

4 I X6207 14 X6207 3 X623 9

B6207 B6239 B620/ ! B623 9
Hot-film Intake pipe I' 1 Hot-film -£T^ ^ Intak e pipe
air mass pressure sensor air mass pressure senso r
V- meter
X6239 {Ks | Y • meter 2 '' 1 ]X623 9
5 X620 7 3 ^ - - 2" 5 " X6207

0.5 0.5 0.5 0.5 0.5 05 0 5 0.5 O f 05

GE/BL BR GE BR GE/GN GE/RT B R GE B F GE
X6460 X6460
X6460 X6 460
— f-

X60003

rk- AGOOO 3i 1 4 5 2 X6000 3

r yr
u i* rp' P
DME £-»- " • A600 0
M control ,t j
I] DM E
rai module fa—, contro l
T3ll modul e

B510ele15581 B510ele22515
Throttle valve
N62 engine or N62 TU engine

A6000
DME control module

O.S
BR

Y6390
Electric
throttle
valve

5 X639 0

05 0.5 0.75 0.75

BL BR/RT WS RT

31 X60003

A6000
DME
control
I31 module

B510ele15582

Electrical Wiring Diagram s ELE-16 5

 Electrical Wiring Diagrams ELE-16 6

Variable intake system Variabl e intake system

N62 engine N6 2 TU engine

15 | A600 0
|5 V~ | A600 0
7j\ I DM E
I DM E ' contro l
I :(Ql ' contro l -T "* ' modul e
I [VP j V » | modul e
¥! 1
TO ! 40 ' X6000 3
, _J j
4 X6000 3

I X803 5 0.75
WS/GE

X6987 X698 7 (To p of intak e manifold)

0.5
RT/GN
0.75 0 75
3 | X616 7
WS/GE WS/G E
Y6167

/~ Y Valve ,2 J X6540 1 1X554 1

Y6540 Y654 1
A^X, contro l
M— H^-l intak e ~ - _ v DIS A 1 DIS A
system j(O| (? ) ) controlle r JO) ] controlle r
= : 4 ;_ VX 1 Y '2
4 5 I 1 1 2 T X616 7

1 ' X654 0 2 Y X654 1

0.5 0. 5 0.7 5 0.7 5

0.75 07 5
GR/GE B R GR/B L GN/B L
WS/SW WS/S W

X6460 X6988 X698 8 (To p of intake manifold )

45 1 4 J4 04 1 X6000 3 0.75
WS/SW
*-—&• f — *• » -« • * — >A600 0

D
X60003
nh 4 1
DME r --

(or-, i^ - ^ • o - fe n; modui e i ,
— »• " " A600 0
fO^ contro l
|©| DM E
^ contro l
31 A 3 1 * I 31 1T 31 i vj modul e
I 31 I

B510ele15583 B510ele22534
Boost pressure control
M54 engine

15/5V "JA600 0
)j T IDM E
M' control
— • j ^ 1 modul e
-& \ 3

X8035

05
RT/GN

j{QJ] Boos t| -ri^ S Exhaust J^p O Exhaus t

' pressur ev temperature V temperatur e
..__. sensor I sensor I c;Rnsn r9
X62306 lY ~ 2YX6230 1 lY 2YX6230 2
05 05 0 5 0 5 05 0 5
IBR GE/BL G NB R GE B R
| X6460

"iT""* 3 )
Lm ^r
X60003 1 11 7 24 5 X6000 2
P-B. t- »~ ] A600 0
r T — 87— -1 F00 5 1 AS009 " ir -
| * ] integrate d
il I I '

" *
DME

sn ^ e~t
•j^ U contro l
LJ4J 30 A j «VM > 31 * Mj 3 1 * modul e
I3 1A ' •3 1A 131 *

1 3 TX60093 1 0* 34 X60004

0.75 0.75
GE/SW BL/GE

1 ^~~ ~r X6011 (In E-box)

075 05 05
RT/GE GE/SW BL/GE

2 3 4 X2235

Y2235
,I

~^, I pressur e
' liffi P
— -^^JB— controlle r

L^
I
0.75
BR
X6461

B510ele2471C

Electrical Wiring Diagrams ELE-16 7

 Electrical Wiring Diagram s ELE-16 8

Engine cooling system

up to 03 / 2007
N62 engine or N62 TU engine

A41a A6009

r1 e' -- _ , .-r,,, ^ Integrate d

I
7— " • F00 9 £
I holder , r
7 1 ro °5 suppl y
front D modul e (IVM )
j 60 A j I 10 A
1 30A

.
4 ' ' X1100 2 13' ' X600 9 13 ' ' X6009 3

30 15 ~ " A600 0
DME
control
—,ci * " modul e

J
39 ' ' X6000 4 2 8 ' ' X6000 3 0 5 (u p to 09 / 2005 )
RT/GE
60 075 0.35 0 75 0 5 (a s of 07 / 2003)
RT/BL RT/WS SW/GR GE/GN OR

X1797 2

r
X13864 2 X 13380 1 X6236 2

F
2 | X627 9
~" Y 13864 B604

mj 5 )
. M135 B62363 Y6279
Electric £ .-jjw Solenoi d Temperature
V' Engin e coolant I Characteristic map
fan ~^ radiato r" 1 sensor at 1 thermostat
temperature
radiator outle t
1' 4 X1797 1 ' X1386 4 1 ' ' X1338 0 2 ' ' X623 6 1 ' ' X627 9

60 OS 05 035 075 05
BR GE/RT BR/WS BL/GR BR BR/WS

X6460

1r
4 21 38 X60004 1 4 12 X60003

r* " 1— ^
r" " " — «• ~ " A600 0

.m [
[ DME
][ „ contro l
X13797 (up to 09 / 2005 ) r> —i3 1J 31 .
9r-
<F i module
X 13782 (a s of 09 / 2005) 31 i T31i T3ll
j 1

20357.22742.24310

B510ele20357
Engine coolin g syste m
as of 03 / 2007
N62 engine o r N62 TU engin e

i
r" * A4 6 ~" A600 9
F ^p> -. i-™ r Integrate d
I 30 G 1 F7 7 T 3 0n F 92 ^,ri Pr f8 7" I F00 9 87 ] F00 5 SUD olv
1' i iT |i f
1
1
10A | [ ] 100 A 1 [[ J 10 A | J 3OA
0 (IVM )

t 1 J

10 ' X11EJ1 2 1 Y X1101 3 1 3 Y X6U0 9 J

XbOOSS

RT/GE R T j " 3 0 15 ~ " A600 0

~n~ DM E
™
1 X9137 X179 8 3 1 X1666 3 U
*• - I *
;- 4i K913 7 r u_ ^ M199 7| CV 9

4L_1 ? b rela y |' ' J i f / shutte r drive 3 9 '' X6000 4 28' X60003
o' X9137 Y X179 9 11 2"!r 4 X1666 3
035 0 75 05
2 |
X1157 3 SW/GR GE/GN OR

2 X13380 1 X6236 2_ X6279

0 5 10 0 05 05 0 5 B504 I B6236 a Y6279
BR R T BR/WS BR GE/W S pp . Temperature j^ Engin e coolan t yf Characteristi c
X13792 2 |
Xi79 7 1 |X 13864 sensor a t temperature ~ ma p thermostat
Y13864 , ' X 13380 ^ ' X623 6 1
i—1 - n -a . M13 S X62/9
[JGl (V ) Electri c r^>V Solenoid ,
| iw l ^ fa n radiator
i
if 4 Y X1797 2 Y X1386 4

100 0. 5 05 035 075 05

BR GE/R T BR BL/GR BR BRAA/S

1 Y X1157 3

X942 X94 2 X6460

4 31 38 X60004 14 12 X60003

1 » ~ t* ~ " F -" 1> P» " " A600 0

nu
r

i0 M
v_
H DM
T_^ contro
E
l
©1 M?1 i ^l? 1 modul e
X14054 ! 31
T 31 A I 31 1

B510ele25745

Electrical Wirin g Diagram s ELE-16 9

 Electrical Wiring Diagram s ELE-17 0

Instrument gauge s / indicator s Local CAN-bu s

N62 engine or N62 TU engine N62 engine or N62 TU engine

DME control module

„ J

38 X60003

"15 1S" 15 A2 a
T If ^- ]
^T Instrumen t cluster
y_^ contro l module
ng
rJ-
y
^• 4 -
"f
3 ' X16

SW/RT/GE SW/VI 85RT

5 46 X638 2 X770
101070 I B21a

sensor 0.5 0.5

b< 3 *n 1 ' X770 GE/SW GE/BR

>n : -J
2' 1~^ 3 ' ' X63 8

05
BH/SW/GE BR/SW/WS B'L/BR

16_ 15 5 X16
r --^ -» A2 a
Instrument cluster
-. , contro l modul e
i

19 X6021 2

A60210

Variable valv e timin g

gear control module

B510ele 19454 B510e!e15594

Secondary air injection pump DME control modul e
N62 engine or N62 TU engine power supply
N62 engine o r N62 TU engin e

A6009
Integrated
! F007
supply
module IV M
30A

v— -,™» X10547 (up 1009/2005)

13 X60094 XI0550 (as of 09/2005)
(>
X10546 X1054 5

1.5 0.75 0.5

RT/BL RT BL/RT

X60001 36 J [ X6000 4
'"" A6000

r; 3 1« r
L J ~3 1 i
31 i 31 • 31 *
5 X60005 4 ' 6 ' X6000 1

2.5 1.5 15
BR BR BR
A6000 I M6 3
DME Seconaary 1
(i). airpumo X6454 2 r 1 X60092
{In E-box) i < V- -------- ^ , Agoo g

I e- ' Inogiate d
I i suppl y
\ < X1370 1

60 6.0
BR BR

X6 X6

20363, 2338
9

B510ele20362 B510ele20363

Electrical Wiring Diagrams ELE-17 1

 Electrical Wiring Diagrams ELE-17 2

Camshaft position
up to 09 / 2005
N62 engine or N62 TU engine

r_

ii .
A6009 A6009
Integrated

!i (
1 ' °05 suppl y supply
module IV M module IV M
J 30 A | II f'

13 ' X60093

1.5 25
RT/GE RT/SW

X6822 X6821

0.5 0.5 0.5 0.5

RT/GE RT/GE RT/SW RT/SW

1 X62141 1
B62141 B62142 B62241 B62242

£xj Intake
camshaft •c$> Exhaust
camshaft
-C$3- Intake
camshaft
-CxT Exhaust
camshaft
sensor sensor sensor 2 c^ncnr 9

3 2 X62141 3 2 X62142 3 2 X62241 3 2 X62242

0.5 0.5 0.5 05 05 0.5 05 0.5

BR/OR GE BR/OR ws BR/OR GR BR/OR OR

(Right side o f intak e mani old) X6450 X6450 X6450 X6450

r
JI J 16 30 17 X60003
A6000
DME
control
-i &-[ module
1 i T 31 1 31 31 i

B510ele15587
Camshaft position
as of 09 / 2005
N62 engine or N62 TU engine

A6009 A6009

re
ii
7 | huu s modul e (IVM ) | 8 I h00 -- modul e (IVM)
1 ' I f
J 30 A ! J20A j

13 ' X60093 1 2 ' ' X6009 3

15 2.5
OR OR

X6822 X582 2 X6821 X682 1

KL87
05 0 5 05 0 5
OR O R OR O R

3^ X62141 3 J [ X6214 2 3 ^ X6224 1 3 J [ X6224 2

B62141 B6214 2 B62241 B6224 2

-j > ^|_ Intak e camshaft J x \- Exhaus t camshaft J > <~L Intak e camshaft J x L - Exhaus t camshaf t
sensor V — senso r sensor 2 — ~r—' senso r2

2 1~Y X6214 1 2 "p 1~ Y X6214 2 2 ' "~ 1 Y X5224 1 2 Y 1 Y X6224 2

05 05 0 5 0 5 0. 5 05 0 5 0 5
SW/WS GE SW/WS GE/B L SW/W S GE/RT SW/W S GE/W S

X6450 (Right side of intake manitold ) X645 0 X645 0 X6450

37 29 1 6 30 j ^ 1 7 X6000 3

jt» J — »" " A600 0

J* DME
V^^ contro l
0 0 — modul e
far" V
b-
131 1 I 31 i I 31H
A I 31 i 1 31 A

B510ele24308

Electrical Wiring Diagrams ELE-17 3

 Electrical Wiring Diagrams ELE-17 4

VANOS solenoid valve s 1 and 2

N62 engine or N6 2 TU engine

I" " " A600 9 | A600 9

I
ply !
Ie 7 F00 5 modul e IVM 87 | modul e IVM

:! [ ^!
i
' I
3CA
I J20A ^ ]
— — ~— _ -l
I L

I I I

13 X60093 12 X60093

1.5 2 5 :

RT/GE RT/SW ;

X6822 (Righ t side of intake manifold) X6822 X6821 (Righ t side of intake manifold) X682 1

0 5 (u p to 09 / 2005) 0.5 (u p to 09 / 2005) 0.5 (u p to 09 / 2005) 0. 5 (u p to 09/2005)

RT/GE RT/GE RT/SW RT/S W

0 5 (a s o f 09 / 2005) 0.5 (a s o f 09 / 2005) 0.5 (a s of 09 / 2005) 0. 5 (a s ot 09 .' 2005) ;

OR OR OR O R

i1 t X6281 1j X6282 1 X6283 1 X628 4

Y6281 Y6282 1 Y628 3i Y628 4

'j VANO S solenoid h VANOS solenoid 'X'-Hn VANO S solenoid X~Ci j VANO S solenoid

- 5 valve, intake A""-^ valve, exhaust ^' \ e 2, intake vaiv e 2, exhaust

1 ?
2 X6281 X6282 2 X6283 2 Y X628 4

0.5 05 0.5 0 5
GN/BL GN/GR GN/GE GN/S W

10

r ^__
20 9 23 X6000 3

1r f —&• »

0• D
—6- A600 0

\H !31* - Vi
i3 1A
®
V^ V
Oj 1
H7 !
(Q
W
I 31 A T
DM
contro
j1 modul
31 i
E l
e

15588, 2430 9

B510ele1558H
Variable valve timing gear 1
N62 engine or N62 TU engin e

r" * A4 6 ; • "i A600 0

-> m« Fus e holder, rea r ! Ion
f" 3 0 F9 1 ! luj
i
t |j j 100 A I 3 8• • 51 18' X60003

" X1380 2 (u p to 09/2005)

1 X1101 4 aso f 09/2005)

6.0
RT
2 |X1068 1
r | — —~~-— — __ — ____ _ _^ ^~ * A600 9
rh f a ! s I n eqrated supply

ipnni P — 4? 6 ' Refay 1 , valve

R7 .rUU !j s fimin n np^r
1
30AJ [ if , 1 F01°
i j [ j 4QA

8 Y ~~<T( X6009 3 1 Y X6009 5

I 0.7 5 0. 5 4. 0 05 0.5 0.5
RT/WS BR/W S RT/W S GE/SW GE BR BL/SW

(rfenfb t °f
1 J [ X6021 2 3 1 X602 1 17 19 13 X60212

30 30 A6021 0

r<n j Variable valv e timing

n _< ^ fe n@
gear control module
1
1 3 1 i T3 1 1 pi p I 31 1
j -•A >

-^ :1

2 4"fx60211 2 Y" 1 5 Y X6021 2 6' 7~Y X6021 1

0 35 i
GE : W60213. 7
4.0 4 0 4.0 4.0
BR B R W60213.7:' - W60213. 7 RT BR
*

6f 4 \
3
1 ,2 I X6053 B6021 3 2 1 I X635 1
~" - (I n E-bo x Eccentri c
s^ 5 Y 1 T 3 Y 7 Y 9 Y syx6021 3 shaf t senso r . ..... . Vaivetroni c actuator
-*V>
0 35 0.3 50 35 0.3 5 0.3 5 0.3 5 -.
motor
SW B LT RB RW SG N
: . W60213.7 . W60213.7 : W60213. 7 W60213.7 , ; W60213.7 . W60213. 7
'0358, 2339 1
16 3 4 1 71 85 X6021 2
BR r * - >• 1- » t » t * *- »( i;-*- ^ A6021 0
RH M j ]' i I! Variabl e valv e timing
TT .T ;O ]T _ t i L9 ear control module
(Q —lM r — iM —I W —] O —i w —i
X6 13 1 i 13 1 1T 31 t I 31 i ""3 1* i 31 »
t . . ._ _ _ _ i

B510ele20358

Electrical Wiring Diagrams ELE-17 5

 Electrical Wiring Diagram s ELE-17 6

Variable valve timing gear 2

N62 engine or N62 TU engine

r
r n A46 I 1AA6000
1DDM E control module
M
I
0| 1
| ; F9 1 I
I 1
i j *!J 100
'
AI 38' 51 ' 18' ' X6000 3

' X1380 2 (u p to 09 / 2005 )

1 X11014 (a s of 09/2005)

6.0
RT
2 X10681

ri :___ j
,
~~4 7 Integrate d suppl y
!fj7
iU• °[ 7 ) Rela y 2, valve

i(
I" 1 f--|F001 !

J30AJ '"I ,— -j F01 1

I
iL J 40A |
-»
"~1
8 ' X6009 3 2 ' ' X6009 5
0.75 0.5 4.0 0.5 0.5 0.5
RT/WS BR/WS RT/WS GE/SW GE/BR BL/SW

r rtei
ifei
1 X60212 a ,v .__ _ . _ _ _ _ _ _ 5 ,
X60211 7 19 13 X60212
z— 30 30
f
ji f
LL
t It
^-S *C
?p I
p ,s
31 1
r?s,n
h f:
fi h
y
i i Variabl
gea
e valve timin g
r control modul e

2' 4~ X60211 9 ' 20Y X6021 2 10T" 9 Y X6021 1

035 !
GE : W60213. 7
4.0 4. 0
4.0 4.0 RT B R
BR BR : ; W60213. 7 :^; W60213. 7

6, 4 J[ X6022 3
1 2 X6453 B60223 2 I1 I X635 2
(In E-box) Eccentric i &— —v , .„-.,
—. i M635 2
S 5 ' 1Y 3 Y 7' Y 9 Y8 Y X60 2 33 shaf t sensor
I g^ M J! Valvetroni c actuator
0.35 0.3 5 0.3 5 0.3 5 0.35 0.3 5 ^~-^ moto r
SW B RW SB LT RG N
: W60213. 7 W60213.7 : ; W60213 7 ; W60213.7 : : W60213.7 ; : W6 0213.7
20359. 23392
21
^2 ?JL 2: LL 10 A 11 _JL 1 2 xeo 2
IS ^ ^ - ..- p -_- - A602 1 0
Variable valve timin g
gear contro l module
©! S ^I © I ^ ^ 3| © —iO 5" —^
T 31 i 1 3 1 -1 13 1 1I 31 i i 31 1 1 31 i
X6 _j

B510ele20359
Ignition coils 1
N62 engine or N62 TU engine

1 A6009
1
1 15" ~" 1 F00 3 supply
1 module IV M
1 ffl '
IpOA I
1
1
1

X6831 (Right sid e cylinder head) X6831 X6831

1.0 1.0 1.0 1.0

GN GN GN GN

3 X6151 3_ X6152 3 ^ X615 3 3 X6154

|| ' 4
T6151
Ignition coil .
cylinder 1
r^ i T6152
ignition coil.
cylinder 2
i \ '"
4
T6153
ignition coil.
cylinder 3
•
'4 1
T6154
Ignition coil.
cylinder 4
_I
!
, ^
4) Spar k plu g 4) Spar k plug
2 1 X6151 connection 1 r 2 ^ ' X615 2 connection 2 1 X6153 connection 1 X6154 connectio n
^

10
1.0 1.0 10 10 1.0 1.0 1.0
BR BR RT GE BR BR BL

X64S61 X64561 X64562 X64562

3 7 1 2 X60005
— *• 1* > —^ -»• n A600 0
i
I 1 DM E

br-n
f1 I|
f El
j

ri
I, ^ contro !
1
V9 I M1 modul e
Y! I 31 A T 31 i
j

B510e!e15600

Electrical Wiring Diagrams ELE-17 7

 Electrical Wiring Diagrams ELE-17 8

gnition coils 2
M62 engine or N6 2 TU engine

A6009
integrated
r 1 51 FO C supply

f 20A |
module IV M

1 X60091

2.5
GN

X6832 X6832 XC832 X6832

1.0 1.0 1.0 1.0

GN GN GN GN

3 X6155 3( X61S6 3 X6157 3 X6158

T6155 T6156 T6157

' : ti
T6158

! if "| i
^4 Ignitson coil, J Ignition coil, *4 Ignitio n coil. I Ignition coil,
J cylinder 5 cylinder 6 cylinder 7 cylinde' 8
4) Spar k plug 4) Spar k plu g 4) Spar k ping
1 X6155 connection 1 2 X6156 connection 2 1 ^f X615 7 connectio n 1 X6158 connectio n

1.0 1.0 1.0 10 1.0 1. 0 1.0 1.0

WS BR BR RT GE 8 R BR BL

X64563 X64563 X64564 X64564

. . .

9 8 4 6 X60005
— * t-> i-* " " A600 0
1
m
DME

3r- <SH
T 3 1 .* .
T* contro
M I modul
l
e
T 31 * l 31 i T 31 1

B510ele 15601
Oil supply Oil supply
up to 09 / 2005 as of 09 / 200 5
N62 engine or N62 TU engine N62 engine or N62 TU engine

1 A600 9
Integrated
supply
A6009 module (IVM)

F008 Integrated
supply
U 30A module IV M X6009 1

05 0.5 035 60
X60093 X6009 1 } ' X1370 1 BR OR VI BR

0.5 0.5 0.5 6.0 X6461

RT/WS BR BR/GN BR

X6231
"] B6254 0 1 1 B623 1 3 X6254 0 X6
; Oi l qualit y /°....:~ \ l pressur e B62540 B6231
I senso r | | switc h Oil qualit y Oil pressure
sensor switch

0.5
GR
05
X6038 GE

05
GR
25 X60004 0.5
A6000 GR
DME X60003 X60004
control
*• " ! A600 0
"31. module
i DM E
[ contro l
31 j[ modul e

B510ele20356 B51Qele24312

Electrical Wiring Diagrams ELE-17 9

 Electrical Wirin g Diagrams ELE-18 0

Exhaust flap
N52 and N54 engine s

| A868 1

i 37
! Fus e carrier , engin e
"! F0 6
t electronic s
ii t

2 X868 1

0.75
RT/WS

1 X1337 3

0.5
BR/GR

S X60001

II | |M> J I DME contro l module

IU I

B510ele21645
Lambda contro l
N52 and N54 engine s

"" A868 0

'[ engin e electronic s

j i J 30 A |
8' X8680

6 1 X60561

05 05 05 05
OR OR OR OR

4 X62101 4 X62201 1 X62102 1 X62202

=C D
d
before catalyti c c 5 before catalyti c 3- E E~ behin d catalytic c :5 -i j behin d catalyti c

^ ^
3 21 5 6 X62101 3 p
1 5 6 X62201 4 2 X62102 2 34 X6220 2

05 0 5 0 5 05 05 05 0.5 05 05 05 \ E \ 05 05 r/ 05 0. 5 0. 5
WS/BL SW/B L GE/W S WS GE WS/BL sw/ws GE/WS WS SW/RT GE /i/S/GR WS/GR SW/G NG E

f
12 10 6 1 8 8 13 11 7 5 9 23 20 2W
C-— =™.-»--S! 24 1 9 X6000 2

311
rsn fel 3li

(On intake manifold near cylinde r head )

Electrical Wiring Diagrams ELE-18 1

 Electrical Wiring Diagrams ELE-18 2

Valve gear
N52 engine
(page 1 of 2)

~" A868 0

r
r -Q—~- I
"• carrier .
1 "n a engin e
{ j 20 A I
' ° electronic s

6' 4 ' X868 0

05 05 05 05 0.5
OR OR OR OR OR

1 X6203

3 X6214 3 X6224 1 X6275 1 X6276

B6203a B62243
_p^i Intak e Exhaust l ^ VANOS I VANO S
Crankshaft
-[*} — ^ camshaf t & camshaft solenoid H21^ solenoi d
sensor sensor ! valve ; valv e
1 ' X622 4 intake 2 ' 1 X627 6 exhaus t
2l
2' 1 X621 4 ^ ' X6275
" " ~ " 2"" 1
3' ' X620 3 ( ^Jear throttl e housing}

05 0.5 05 0 5 05 05 05 05
GE BR SW/BL G E SW/WS GE/BL WS/BL WS/RT

rp
30 _ X6000 5

r r lr
29 24 11 25 12 5 18

L- 1 ( ( |"

3O I
fcl 3
31 !l
©|
1 T 31 1 T31i T I

B510216503
Valve gear
N52 engine
(page 2 of 2)

r n A600 0 r n A868 2
<£§ DM Fuse
15 E r o n" • FO
con Iroi 1 ^~ i ca r ler.
H modul e
!1 ilm 40 A ! electronic
l i e "gine s
21 Y X6000 7
L. L J

2 X8682
; W9110 7
4.0
RT

0 35
TR 6 X6319
[ K6319
WT v"Jv_ Actuator .
6 X60253 relay I §j jI variabl e valve
f ™i tirmn n nsar
B60213
4 " ](~ ' o " 1 X6319 r 2 YX6353
X! -
IH Eccentric
shaft
sensor 40 40 4 0
9' 7 1 3 8" 4 Y X6025 3 OR RT B R

; W9110. 7 : : WS110 7 : • VV9110 7 : ; W9110 7 : ; W9110 7 : ; W9110 7 ;" ; W911 0 7 X6358 XS358 XS35 6 X6356 X635 7 X635 7

I"
1 O R 1I "
035 035 035 0 35 035 0 35 •' • VV911 0 05 25 25 2 5 2 5
WS BR SW GN GE BL '•' VMS OR RT RT B RB R

A tl
r rfarfa
9 8 20 22 7 6 10j[ 23 X60007 1 6 35 X6000 4
„,,
~ '£ H>. - i—* ~ "L * r f i~ f fl». f % "V* ." * A600 0

D I f
fa fai
] DU u DM E
31 ¥ ] 31 I
j^r~| ^T~ 1 Qr- ^ modS e
fa

B510ele21650b

Electrical Wiring Diagrams ELE-18 3

 Electrical Wiring Diagram s ELE-18 6

Brake light switch brake ligh t switch

N52 engine with DSC Dynamic Stability Control PLU S N52 engine wit h DSC Dynamic Stabilit y Control Premiu m

A149a j A149 a
Car access system I Ca r access system

2 ' ' X1031 8

035 035
VI/SW VI/SW

1. i X7 8
S29 S29
Brake Brake

N
a i i o
•
V [x> — \* light light
1^-^ switch
4 ' X7 8 3' 4" 2 I1 X7 8
035 0.35
035 035 BR/SW 035 BR/SW
0 35
BR/GR BL/RT X13787 BR/GR BL/RT X13787
.L

X1179 X1179 X181 X18 1 X18 1

y
32 |
X1031 8 16 4 X60001 5 1 1 X 1 23 0 1 X1746 32J X10318 37 ^ X10821
r & ]A149 a r f * f e JA600 0r "~t» JA 3 I""? * ]A65 a j" t » " ] A149a "JA6000 T^ "]A65 a
3 'Car 0Q IDM E [ j B ILl9ht ' 0 ©j ' Dynamic I j ] [@|lCa r IDME I 'Light N [Q l I Dynamic
| access J-v |2 ! rj- ^I control u — [modul ej for- — I s ability jaccess [control j module ]L—^ j stability
I system T3li T31 il moc|ule 131 1' ' i3l l 1 control (D | I syste m I module ^T3il I control (DSC )
1 1

B510ele21843 B510ele25802

•V^- • '
Clutch switch modul e Accelerator pedal module
except N5 4 engine N52 engine

11 51 5 A600 0
J,
f M DM E
I f(Ol M contro l
&. 1_5Z J ^ fe - modul e

[_L !

rn A600 0 r R 1 5 " ] A149 a I" . , 1 5" ] A7001 0 11 24^ X60001

"if" [ V l Ca r I I© ~7 i I Sequentia l
15 ^^ ' . ,
~r~ contro l |j g |U | acces s ] U j manua l
fl modul e '-<J no T I syste m | r-£ 3i transmissio n
ITT I I T i (SMG)
18' ' X60001 3' 41 Y X1031 8 3 Y X7000 3
GE/GN GE/BL

0.35 0.35 0.35 035

BL/BR Vi/GE BL/S W BL/SW
5 3 X11400
„

-r. B10
USA SMG transmission
- >< j - - ^X r - Accelerato r
r, | peda l module
2 3 1 }X12 1
•'
S805a 1 4 6 2 X1I400
<& Clutch
switch
module
1 X121

05 0.5 05 0.5
0.35 BR/GN WS/GN WS/BL BR/BL
BR/SW

X18 751

10 v
20 23 X60001

7
s \^
i-O t> t~^ f t > A600 0
i j DM E
V U'^ lV Y contro l
1 O 1 Lii^ i O j 1 O 1 modul e
I3 1 AI 31A 3 1A I 31 *
J

B510ele21641 B510ele21618

Electrical Wiring Diagrams ELE-18 /

 Electrical Wiring Diagrams ELE-18 8

Knock sensor s High pressure fue l syste m

N52 and N54 engines N52 and N54 engines

A6000
i Fus e DME
i carrier . 15 control
! engin e module
I i I electronic s
30 A6000
'
DME

t* control 10 T X60007

'•-••-•dr^ n LS5L J *-•* . r1 module ! I *

¥ u' —^"^ 6 X8680

31 I | T 31 i

' ?9 ^ 42 20 X60005
^

0.5 0.5
OR BL

0.5 0.5 0.5 0.5 1 X6538 3 X6328

GE SW/Vi GE sw/ ~F '* <"i

I Y2381 B2261

Jj
CO-? Volum
A I contro l
e
QD Rail
pressure
IJ valv e sensor
2 3 4 X62400 (Near throttle housing) ^
X6538 1 2 X6328

05
B62400 WS GE/RT SW/GN
Double knock sensor
1) Cylinder 1-3
12 X60005 9 8 X60007
2) Cylinde r 4-6 ^
A6000
DME
control
module

1i

B510ele21643 B510ele24640
Fuel injectors
N52 engine

1— A149a ~* A868 0
1 [^| Ca r 130 ] F0 5 carrier ,
-1- acces s !

\ 1 X1031 8
system j [j 30 A ! electronic s

X6011 ' OY X868 0

0.5 2,5
GN RT

8| oj[ X632 7
86 J 3 0 rv632 /
f] I V Relay .
Mi 85 8 7 " ^ fu e

4' ~~~^ ,_ s _^ X632 ?

1 ' ' X60552

05
BR on

I
X6462 X6970 X697 0 X697 0 X6970 X697 0 X697 0

0.5 I 0. 5 1 0. 5 0.5 0. 5 I 0. 5
OR I OR O R OR O R1 OR

1 X6101 1 |
X610 2 1 |X6103 X6104 1 X610 5 1 I X610 6
A
Y6101 I Y610 2 Y610 3 Y6104 Y610 5 Y610 6
3-Y Fue l injector , i^r^. Fue l injector , i>7 \ue^ Nector- rc>V Fue l injector , rrr-S Z Fue l injector , dh ^ Fue l injector
cylinder 1 | cylinde r2 j cylinde r3 cylinder 4 cylinder s cylinder s

2 ' ' X610 1 2 X610 22 Y X610 3 2YX6104 2YX610 5 2YX610 6

075 0.7 5 0.7 5 0 75 0.7 5 0.7 5

WS WS/G N WS/G E WS/BR WS.-'V I WS/S W

, 23 14 1 51 6 X6000 7

IL I L "-. .a
Jp» t — f— »~ " A600 0

0r>—
I* i !!
-~>— i 'rv
" DM- contro E l
^fQ T 3u y 3il modul e
!

I3li I3l l i'31« .

B510ele21640

Electrical Wiring Diagrams ELE-18 9

 Electrical Wirin g Diagrams ELE-19 0

Fuel injector s
N54 engin e

15 A600 0
DME
control
module

A6000
DME
control
module

B510ele24342
Fuel pum p Throttle valve
N52 engine as of 03 / 2004 up to 09 / 2005 N52 engine as of 09 / 2005

Fuse holder , rea r

i
11 ' A868 21 rDiaita ,, l
i " 8 7 ] F °1 ! Fus e i j© | diese l
] carner - 1 1 electronic s

0 2 °A i
j
i en 9!ne ^ - ,— J contro l
6 X11010 X10547 X10552 X10551 ! electronic s 9 4 Y X241 1 mo(Ju| e

8 ^* i I
I

2 v ' X858 2
25 0.35 05 05
RT/WS RT/GN RT BL/RT

1 13 16 9 X13663

iu » 0 75 0 75
15 ^ A1366 3 RT/WS WS/B R
1

L, rr $
f] i Fue l

~T
3^ 2 X957 5

i
| pum p
I contro l [p* M957 5
vjy i 1 (EKPS) Throttle
T 30 i Y ~9
31 A 31 « - 17 l^-^ l valv e

31 1
2 X13663 2 4 X 18203
4* X9575

25 2.5 25 0.75
BR BR RT/WS BR/V!

6 ' X6011
1 4 X638
;~ i 10107 0
0.75
'r — _ _ _ _ _ ^ I Fue l BR
I| •a ^2 | tan k
II O) I] ! X6
II a
_J
I
!~
I
X 13792
jt

B510cleZ1258 B510ele26583

Electrical Wiring Diagrams ELE-19 1

 Electrical Wiring Diagrams ELE-19 2

Low pressure fuel system

N54 engine

A46 30 | A600 0

Fuse holder, rear MI DME

| 30 G | F72 I contro l
I modul e

I
X60005

X11015 X10547 X10552 X10551

05
BL/GE

.5 0.35 0.5 05
X60558
TAWS RT/GN RT BL/RT

13 16 X63280

B6125a

Low pressur e
pump fuel sensor
control

4T X1820 3 X60558
(Near throttle housing )

2.5 25 25 05 05
BR BR RT/WS GE/RT SW/RT

X60005
I
A6000
Fuel DME
tank control
module

X13792

B510ele25755
Air supply
N52 engine

^ "" A868 0

r~8T~ — -i F0 3 Fuse carrier.

enaine ele •tror ICS
i] ||it ii 20
' A| r ~5 y ~~ ~ " •" '' A600 0
i._J 1
!T u 1S ™
^- |{^J!
1
J ~r
5 DM
- contr
E
o
— i
I j modul e
5 ' X8680 1 -^ If~» Jfc » j

I
25' 31 14 X6000 5

0.5
OR
U HR< 3
05
OR
I..'
I OR
05
BL
05 0
BL/GE B
5
L

3L ?
„
X6540 X6541 X6207 3 X6042 2 |
X639 0

m ™<S>) DISA
PTn^) DISA Air mass
_pi"n lntake P'P e /
pressure ) c£>
,
^^^
Electri c

3^Ly~~
mrot(| e
controller ', flow sensor
controller 2 h
1 T X6540 2 ' X654 1 1 2' 1'
Jspensor J - ~$ —- 9 valv e
!n f , j^ k actuato r
.p
5' 4' 1 X620 7 T j '
W£ BR °Bri WS/RT 6 Y 4-j 1 1' V 3" YS Y X639 0

X6460 X6460
05
GE/RT SWAA/S GE SW/GE GEA/VS SWA/ iG E GE/B L WS/G N WS/G E

40 18 28 27 26 32 33 38 3eJ [3 7 15J ^ ie j X6000 5

j--».
u
ir^ i—*
r* t * "L-» l- » T- » T- » t- » ^ A600 0
f| 1
0D 0 U l i DM
j

E
JQI—
Ysi i
o
y
Vji
Oj —i3
T3tl
1J for— I® ! 3 11 bn 3^.
i 3 1 1 T30
L~ n
1 I30
L- , t>-
i T30
i ^-
i TSO
i contro
i moaui
[
e

B510elo21644

Electrical Wiring Diagrams ELE-19 3

 Electrical Wiring Diagrams ELE-19 4

Air supply
N54 engine

30 A6000
Fuse carrier, DME
15
engine electronics control
module
30A I

X60005

05 05 05 05 0.5
OR BL/GE GE/RT BL/GE BL

X6583 X6390

J
Y6039 Y6723

\'
B6583 B6239 Y63900
Wastegate Wastegate \B Intake temperature ntake pipe
t
Electric
*%

"~f
^
valve valve 2 boost pressur e sensor pressure sensor throttle
valve
2 ' ' X672 2 ' X672 3 1 ' X658 3 X6584 actuator

X6390

05 05 05 05 0.5 0.5 05 05 0.5 05 05

WS/GR WS GE SW/GE SW/RT GE SWA/I GE GE/BL WS/GN WS/GE

7 14 X60007 10 9 36 15 16 X6000 5
— »

L
A6000
"
[ DME

b— i fe n
control

I 31.
Q —i ~> 1 l© l 31 i
3U Tsoi tei tei module

B510ele24345
Engine cooling system
N52 engine up to 03 / 2007

I r A868 1 A6000 f "• A868 0 r" * A41 a

A41a n

Fuse pQg Fus e carrier DME F02

;0 F9 15
H
Fus e
holder 87 engine control 87 earner iu | holde r
^ 60A front iTi
LJ] 60 A electronics
I I module j 30A engine
electronic s
? 20A ! fron t

4i
[J
- -
i 19] X60001 X60007

1
X11002 9 1 X8681 X8680 X11004
41 4l

X6011

6 J [ X6055 2

6.0 0 75 035
SW/GR G!/RT 81 TT
OR RT5
1
RT/BL RT/WS
X 13380 X6236 1 X6279 LJ X6035

r
2 X1797 2 X 13864 2 2J
M135 B62363 Y6279
Solenoid, Temperature "JO ^ ~ VJ \c
|
Electro Engine coolan t Charac eristic
<fi> radtator sensor at
— — cz: fan temperature sensor
f map thermostat L^-J J ^ coola n

1' 4" X1797 1 X13864 1 ' X 13380 2 ' X6236 2 ' X6279 3' <r X6035 " • "

60 05
GE/RT gR/WS
5 035
BL/GR §W/VI
5 05
ws
0.5
VI
25
BR

8 9 6 X60001 17 19 26 X60007 X645S

r
i - -L » ~" A600 0
r |j
m
DME
rv— , t, 31 con rol
Vn Oi—
(to 03 / 2005) X 13797 ^ T3U . 31 4 31 i

(from 03 / 2005 X 13782

to 03 / 2007)
21648. 22744

B510ele21648

Electrical Wiring Diagrams ELE-19 5

 Electrical Wiring Diagrams ELE-19 6

Engine cooling system

N52 engine as of 03 / 2007

A8681 A46
Fuse Fuse
30G 0- j F9 2
carrier holder.
engine 10A 100AI
electronics

10' A6000
DME
control
075 100 module
RT/GE RT 1
-q K9137
M199? \9 Cut-out rela y
Radiator electric fan
shutter 2 X9137
drive unit ^
05 100
BR RT 0.5
GE/RT
X13792 2 X1797 X6236
05 05
BR BR/WS B6236a
Engine coolant
temperature
sensor
X6236

100 0.5 05
BR GE/RT SWA/I

X942

B510elc25749
Engine cooling system
N54 engine

n A868 1 "• A41 a [ "• A600 0 [ ~ n A868 0 r A41 a

DM E I r __, ^ F(J 2 Fus e P ___ , F2 3 Fus e
Fuse 1
"
5
r~B7 1 F06 Fus e "36~ 1 F9 15
4- contro lI ° 71 carrier .j ^ 0j holde r
i. i carrier , holder j ~!
®
H 60 A i engin e J60A j l
front i H modul e i ff l 30 A I engin e i I | 20 A fron t
[_ V J e ectronics 1 JjL» I H 11 electronic s1 ^
19' X60001 4 ' X60007 j

2 X8681 4 ' X11002 4 Y X868 0 6 ' X1100 4

8 X601 1
— +•
6 I X6055 2
6.0 ^
RT/BL
075 035 05 0 5 0. 5 2 5
RT/WS 2 | X1797 SW/GR GE/RT O RO RR T

2 M135 1 X6236 1 X627 9 1 3 X603 5

XI 6663 2 X 13380
! ! |Cj! ! —r^
r
Electric _. . . r- S — ,, — fr -' 1 M6035
B604
Col I ^ ^ Radiato r
1 r= L j J^ fan
j!k En g ne coolan t Vf Characteristi c | '^ ( ^ Electri c
_ „, Temperature sensor
11
iSK) L_y V shutte r X1797 k at radiato r outlet V temperatur e senso r \ p tnermostat I L-S *
K r num p
r1 Y X1666 3 1 \ X13380 2 ) X6236 2 X627 9 2 ' 4~ Y X603 5
41
60 0.5 oe
BR GE/RT
2^ X1 1573 RB
05
BR/WS X1 3782
8 35
L/GR
0 5 0.
SWA/I W
5 0.
S V
51
! |
BR
X645 5
05 19J^ 26^X6000 7
GE/WS 9 8 X60001 1 7

ry -* ^j_> f* . i A600 0
1 X 13864
r t\*
r7=^
jjM 1 DM E

d>X
Solenoid,
radiator
o —i\ o —i
T3ll
31 1T
i;92l
31 i I 31 1 |

2 ' X 13864

05 05
BR BR

1 ' X11573

fir
BR

X942 X942

B510ele25758

Electrical Wiring Diagrams ELE-19 7

 Electrical Wiring Diagram s ELE-19 8

Oil supply
N52 engine

A8685
Fuse
30 F010
carrier
engine
electronics
1 X6231

2 X868
, A868 0
RT

i \ ¥!F0
T F0 4
3 ' 1' : carrie r 6 X653
i 2Q A 30A I engin e
t -' •<, nfl

7,"""" " "

\

6 8 X8680 X653
—4" ^

OR 0.5
WS
X65399
05 05 075
GE/WS OR OR X6989 X6989 X6989
3J X62540 1 X65390
B62540a E65390
H Oii condition N
sensor
k 9 Crank s laft
breather
075
OR
0,75
OR
075
OR

1 heating 1
£ ' X6254 0 c 1 ' X65393 1 ' X65394 1 ' X65395
2 X65390 075 0.75 075
OR OR OR
05 0 75
VI BR BR d E65393 J E65394 [ J E65395
c^ Engin e c _ Engin ec :^ Engin e
c:-, breathe r ^ breather c breatner
neater i neater J neater 4

2 X65393 2 _ X65394 2 { X65395

075 075 075

BR BR BR
X6469 X6469 X6469

2 1 X65399
10
BR

X6038 X6460 X6460 X6460

X60007 3 5 12 X600
AGOOO
DME
control
module

8510ele21647
Oil supply DME inteface signals
N54 engine N54 engine

86231 A868 0
Fl ' n

oT Oil r- - . „,. . Fus e earner

i 87 ! F0 3
>°^ 1 51 5" " A149 a [" " j M603 5
il l
r
|I
11 20 ! A1 I i 30 A I ' |{Oj j ' Electri c
1 1L p1 1 - J1 H u acces s j coolan t
•*• 1 * l X6231 ni i, 1 pum p
1
i naT* pQ " " syste m 2 X6035
6 1' ~ ~ " ( X868 0 i j_ l |_ Li
20 28 X10318

[" JB89 5 j" JG652 4

fc B»
| {©] 'Batter y I [© ] I Alternator
sensor I I
05 05 0 75 0 75
3E/BL OR OR O R u « 1 u "^ — '

3 X62540 1 X65391 1 X6539 2

X13895 |" ~ ] B62540 a
B62540a I! E65390 I E653 9
KS j j Oil condition
El
1
H^l § Crankshaf t ^ P g . Crankshaf t
^~~* Oi
conditiol
j | senso r
n ^' breathe rV breathe r
r heatin g1 r heatin g2 X10134 X 18828 X2403 X243 1 tX6254 0
X10186 X10545 X10546
2
' X6254 0

^^
2 * ' X6539 1 2 Y X6539 2 VI V I

X6038 X603 8
05 05 0.75 07 5
VI BR BR B R
035 05 0.5 0.35 0.5 05 035 0.5 05
GE/GN BL/RT RT WS GE/BR GR SW VI VI
X6038 X6460 X6460 X646 0
17 J 15 2 3 21 X60007 3 5 X60005
I1
r- i —».
*L tj X60001 2 6
.*. A6000
nn
i— **i^* -

13 X60007 3 5 X600Q5 1
DME

n
•---Ir; !-». " " A600 0 lU. T- , ? ~2\\l
DME
ST-I module
T 31 i I 31 i I 31 A

(C
j(Q) V ^ contro l
&"^, modul e
3ll 131 i
1 1

B510ele25757
B510ele24348

Electrical Wiring Diagrams ELE-19 9

 Electrical Wiring Diagrams ELE-20 0

Bit serial data interfac e Bit serial data interface

N52 engine up to 03 / 2007 N52 engine as of 03 / 2007

"| B89 5 r ~ ~^ A65 a

\ 1 B895
| senso r ..-«•- - stabilit y j^l i Batter y
-_. —- contro l
J
i senso r
'?U, < DSC ) ""] "

i ' X1389 5 3 v ' X174 6 1 X13895

X10186
v?4m
0.5 0.35
GR GE/GN
05 035
3fI 1 7 X60001 GR GE/GN
f--*. ^ A600 0
3J 17 X60001
f DM E
- - - - - jp » A600 0

Ml ky— contra
^p- j modul
r 31 i
l
e r^ D
Isa fc >—
DM |contro E l
^'
26 " "f X6000 7 3 5 Y XRnnn s
26 X60007 35 ' X60005

05 05 05 0.5
VI VI VI VI
X6038 X6038
X6038 X6038

0.5
Vi
l oVIs
VI
05 0.5
VI VI 3 j X6035 1 X6524 1 J _ X6254 0
ycoc^n I M603b ; "^juwt- G652 4r [ ] B62540 3
3 s X603 5 1 X6524 1
Tj M603 5 , r ] G652 4 " "
^ Ab^s4 u jg
] B62540 a "
| Electri
coolan
ci
ti
B j Alternato r
!H '
i i
Oi l
conditio n
j j@
i —
| |
I
Electri c I
coolan t !
[Gj
"
|j
'|
Alternato r I
|
I©1
'——' |
! Oi l pum
conditio n
p
sensor

1> Dum p ^ j i -

B510ele21649
B510ele;'[jf>l3
Convenient start
N52 engine up to 09 / 2005
(page 1 of 2)

A41a -J, | S29 A65a

Fuse \ Brak e Dynamic
30 I ligh t stability
* -J. 1 switc h control
30A
! 3 X78
„,„, ,„,_! mmr J
(DSC)

1 X1746

02

X1179

40 0.35 035 0.35

N
RT/GN VI/SW BR/GR BR/RT

t
2 32 3 X10318

50

¥ 1
31 1
T 31 i
31
26 y
25 0.35 0.5 0.5 0.5
X6404 SW GE/BR SWA/I GE SW

X6011 (i n E-box ) X1S828 X13459 3 6 |3 5 |X13581

A220
[1 5 rT^l
I I Safet y and
25.0
RT X60551 (i n E-box) gateway
I module
X13581
2.5
WS
X10546 X10545

I 03 5 0.5 0.5
j RT/G N RT BL/RT
M6510a 15 X60001 1 I X6000 2 1 X60001
Starter A6000
1) Starting moto r
2) Solenoid switch DME
3} Holding winding control
4) Pull-in windin g module

B510ele21842£

Electrical Wiring Diagrams ELE-2 0

 Electrical Wiring Diagram s ELE-20 2

Convenient start
N52 engine up to 09 / 2005
(page 2 of 2)

L1
EWS
toroidal
coil
1 [ 3~ Y X0115 1

1 J[ s j X01150
S2
Ignition
switch

6^ 7 8 9^ 10 11 12 13 14 X 14026

0 12 0.12 0 12 0.12 0.12 0 12 0.12 0.12 0,12 0.12 0.12

RT GR GR GR GR GR GR GR GR GR GR

6 7 8 9 10 11 12 13 14 X14027
A149a
Car
access
system

X10318

SMG transmission automatic transmission manual transmissio n

035
BL'SW

X6031

035 035 0.5 0.35

BL/SW SW/BL BL/SW BL/SW

12 X7000 3 4 X12 1
A70010 A7000a j "" j S805 a

m 31 i
Sequential
manual
transmission
(SMG)
Transmission ! i£ 3! Clutch
I switch
module

B510ele21842b
Vehicle speed contro l Vehicle speed control
N52 engine up to 09 / 2005 N52 engine as of 09 / 2005

63

B3 ••to: Rear right

wheel spee d
Rear righ t sens.)
wheel spee d
sensor
,_ - ,
1 X377 ( m
wheelhousing
wh
X377 (i n rear passenger
pa side )
wheeihousing
passenger side ) 05 05
GN BL/GN

31 19 X1746
S A7 2 A65a
^j ' Steerin g colum n
=-J ' switc h cluster
j 8 ) Steering column
i — switc h cruis e AJl (DSC)
9 1 X1880 control
I
X10545 3 ' X174 6

0.5 05
RT BL/RT 035
GE/GN

17 X60001
A6000
DME
control
module
31

B510ele21875 B510ele23395

Electrical Wiring Diagrams ELE-20 3

 Electrical Wirin g Diagram s ELE-20 4

Power train CAN-bus

N52 and N54 engines
up to 03 / 2005

"j A22 0
I Safet y and gateway
i module
32 ^ ' X1358 1
05 05
RT BL/RT
X10545 X1054 5 X10545

XI 0546 X 10546 X 10546

(
05 05 I 05 0 5 5 0 5
RT BL/RT 1 R T BL/R T T BL/R T
X10551 X1055 11
_. 1 1 1 4 1 X6000 1 13 X1051 3
zi?

i
. " ' I | | Afinnn r " ] A214
o 5 I 0 5| [T> S j DM E j^P)| j Adaptiv e
RT BL/R T V^J contro l ^^ ] headlight
9 1 X1366 3 L J modul e
— jj i L. — — T....I . ...... I .,„- , ,„,- „ a ,J

T ~~"r? = sn ~ ~] A13663
I |(*^9 |j Fue l pump contro l

X10548

X10549 X10549 X10549

05
1 X6021 (i n E-box) 1
9 18
I 05 0
R T BL/R

A S\
X1371
5

W !
T
8
""^"Ir : steer,
( 05 0
RT BL/R
43 X187
5
T
7

GE l" [© ] 1 A14
£

X8090 L . j C 'Ve S eenn9 X809 0 X8090 L j DyK

X8091 X8091 X8091

3 ' X602 1 (in E-box ) [75

I 05 0
GE S
6 X850

1 ]
5
W
03

A7000 3 j
7J

"
05 0
GE S

^ ~ A
36 X7001

r7=^| "
l^yj j
5
W

j A7001 0
4

Sequenti a manua l
X10554 ' • Transmissio n contro l ! j transmission (SMG ) X1055 4

X 10555 X10555 I

0 5 Seda n 1 05 I 05 Coupe
BL/RT Tourin g J R T J BL/R T Cabriolet
*** ^ -
I"
X1746 " L 2J[X17 83 3 I 2 1 X178
*) A65a
t*\~- ./* *

1 Dynami c stabilit y contro l I DSC) , Active cruise control Active cruise control

B510ele21606
Power train CAN-bus
N52 and N54 engines
as of 03 / 2005 with DSC Dynamic Stability Control PLUS
] A220
y and gatewa y

05
BL/RT
X10545 X10545 X10545

without active backres t 05 05 W ith active backrest | o s 10. 5

width adjustment RT BL/RT widt h adjustment I RT I BL/RT
iej J§X27 9 (unde r passenger seat )
16T 15jrX27 5
(under driver's seat)—
0.5 00 05 05
el elxns s
.rol module ,—*"•*---= * • •j, A85 4
RT BL/RT RT BL/RT
ra j Activ e backrest widt h
X13826 j . j adjustment , passenge r
X13827 X13827 j
with active backrest
(under driver' s seat'^ gV I 05 1 0 5 width adjustment
I RT I BL/RT
without activ e backrest T | wit h active backrest 4 81X1154 8
r , , f
width adjustmen t [ '. widt h adjustment . A85 3
i Active backrest width
without adaptiv e headlight 1 1 wit h adaptive neadlic i adjustment , drive r
X10557
X10558

0.5 05 05
BL/RT RT BL/RT

_X 10606 I X1060 6 I 1 A3
j Ligh t modul e
I I 9' i 16 l
......._._. J p _ Jt———i.=--Sp.
i A7 2
without adaptiv e headlight with adaptive headlight
! Steerin g colum n
_J switc h cluster
X10551
X1055:
X10548
X10549

0.5 0.5
RT BL/RT
X6021 (in E-box)
X8090 X8090
X8091

0.5 0.5
GE SW
X6021 ( in E-box ) X8500
XI0554 A7000a
Transmission
control

05 0.5 A70006
RT BL/RT Control module, transfe r box

A70010
! Sequentia l manua l
_J transmissio n (SMG )
|A65a A144a
S j Dynamic stability ! & ! Actlv i Activ e cruise
LJ control (DSC ) J "ujf. J contro l
B510ele22725

Electrical Wiring Diagrams ELE-20 5

 Electrical Wiring Diagrams ELE-20 6

Power train CAN-bus

N52 and N5 4 engines
with DSC Dynamic Stability Control Premium

"} A1676 0
' Body-gatewa y modul e

'29? X16760
without activ e backrest I pj BL/RT w !'^ actiye backrest
width adjustment J , widlh adjustment

18 17 X27 5 (unde r passenger seat)

X13826 X1382 6
X13827 X1382 7j

I 05 I 0.5
16 151X27 5 (unde r passenge r seat) 1 RT 1 BL/RT
61 8|xi154 8
1 I AUbJ
ckrest with active backrest ' e g i Act ve backrest wdth
width adjustmentt width adjustment | adju s ment. drive r
X10545 X1054 5 X10S4 5 X10545 X1054 5
X1054S X10546 X1054 6 X10546 X1054 6

05 0 5 0 5 0. 5 05 0 5 0 5 0. 5
X10557 X1055 7R T BL/R TR T BL/R T RT BL/R TR T BL/R T
X 10558 X10558 1 1 81 7 X27 9

X 10605 X 10605 I RT I Blf/R T ft f BT^/R T

X10606 X10606 72| _ 71JX1 21 1 4 X6000 1 6 8 X1155 1 34 X51 1 6 5 X178 3
. . - -_, A3 , _ '"JA600 0r '-JA85 4| ~ -\S227a f — iA144 a
10.5 0 5 flE Sj Light S3 ] IDM E K 3| Ac ive backrest width I I Sj Gear EX ] [Activ e
X10551 X1055 11 RT BL/R T imodul e i I control I , adjustment, passenger , 'selecto r ' ' 'cruis e
X 10552 X10552 j 9J ^ ie|xi88 0 modul e switch contro l

05 05 1 £-5 I SMR T I55 I 'Steerin g column

RT
BL/RT 1 6[R
91x1366 3 L _ _ _ _ - _ _ j-' * duster
f j ~ ^~JA1366 3
1 r a "Fue l pum p
M Icontro l
X10548 ' '(EKPS ) X1054 8 X10S48 X1054 8
X10549 X 10549 X10549 X1054 9

8 7 X6021 (i n E-box) 0 5 0 5 0.5 0. 5 I 0.5 0 5

RT BL/R T RT BL/R T1 RT BL/R T
X8090 X809 0 X809 0
X8091 X8091 j X809 1 28J_ 4 3 X187 7
[•- — ~ "~JA148 a
6' 5 X6021 (i n E-box ) I 05 I 0.5 I 0.5 0. 5 H (Dynami c
g° 1 GE 1 SW/BL I G E SW/B L _J drive
05
RT BL/RT | eJxSSO O 37j L3 6 X7001 4 7 6 X1059 4 98 X1371 8
X 10555 X10554 f -\ af ~~\ 0 f —— '~"JA70006 [ "JA46 7
05 H j Transmissio n j g | | Sequential manua iz a i Control module. K S 'Activ e
05
RT BL/RT L i control [ ^ i transmission (SMG) | {transfe r box 'steerin g

25 40 X10821

r^i j Dynami c stability

[, • MJ control (DSC )
B510ele25719
Secondary ai r system
N52 and N5 4 engines

t' " ["

1 A8681 A41a
1 | r
11 87 ~ | F0 6 electronics I I 3 0
11 Jf I 11 ff< 1
11 I I 10 A I
I
11 1 I 60A 1
11 4 , | L J |

1u -
1 L|

1
' X868 1 4 X 11001

0.75 0.75 4.0

RT/WS RTAWS RT/WS

2 , X6206 2 X6304
1_ • — | B6206 86 30 ! K6304 a

K r ai r h t fil m fl r A>
kd |
a r-mass mete r 'iLJ 85 _,/ relay
87 i 87a
—
1 3 X6206 4 6 5 X6304

0.75 0.75 035 4.0 0.35

BR SW/RT BR/BL SW/RT/GE BR/RT

25 13 X60001 2 X1124

r
1
i —&• | A600 0 M63

j^
1
1L I DM E contro l module (M) I D Secondary ai r pump
V'
[Oil
hp-i i T
y^y

%!
M\
T3i 1 j 1 X1124
i
X942 X 18740
|» 4.0
^-
BR

X 13782

B510ele21653

Electrical Wiring Diagrams ELE-20 7

 Electrical Wiring Diagrams ELE-20 8

DME control module

power supply
N52 engine

1 A41a

LI
o" jF B Fuse holder, front
1 i
J 60 A I
I

3 ' X1100 2

6.0
HT/WS

1 X 18326

r
i I B + potential distributo r

1 X64101 2

, 6
[
<
X64102
X6300
K6300
T-] \ E rela y
| t_ - . _ - : - _ _ _ _ . 1
1.5 4 0.5 2 4. 05 X630 0
RT WS O R

1T. _. 3f.. 5 L _7l X868 ° r.-^ 1— -; Foe'i^ 681

/ \/ / 1 \
1

"I A868 0 l u' 1 Fuse carrier, engine

] F0 1 ! - ' ] F0 2 ; ' ] F0 3 ' ' ~] F0 4 ; | etectron.c s
A iT i r" i; ' i" i I Fus e carrier , engine , I 10 A '
| I j j 30 A I f p 30 A : I Q 20 A ; I [ ] 30 A I , eectromc s J L^ _ _ J

I - I • ; j I ; I

L 1 1 . J '
6 [ X868 0 X 10547 X 10546 X 10545 X24 3

I 1. 0 I I 0. 5 I 0. 5 I 0.35
4 X60551 1 OR | 1 R T1 BL'R T j SW
1 X60003 1 3 _ X6000 5 2 \31 ^ X6000 2 1 1 1 4I 2 1 1 X6000 1

i! i ^ 1 •— »• 1U » A *" " A600 °

n~ Tm ¥ n V i :~ T r r T
I, J DM E control module

1 9n
131 '- 1 131 ! 131 - 13 11 ; U y U
L 31 * I 31 A3 1 i3 1 1 J
4 3 y~ 5 Y~ 6^ ' X6000 3
2- 5 1 2. 5 2. 5 2. 5
:~ ' 1 B RB RB R
X6454 | X645 4 X645 4 X645 4

B510e!e21639
DME control modul e
power supply
N54 engin e

r n A41 a
er fron t
j0 i K
S1
i 60A 1

X11002
60
RT/WS

i X 18326
A2076
B+ potential distributor

1' 2 X64101
40
RT
6 X6300
Kfiann
n \ E re ay
| ; ±2 - - - - - - -
4' 2'5 ' X630 0
15 05 4 0
RT WS/GR O R
10

/ / ^ / ^
13 5 7 1 X868 0 : X868 1
n A868 0 n A868 1
rH ~" F0 1 "" — -- i po 2 r~ ~~ F0 3 r ~ 1 F04 , r • " F0 6
1 i * 1 carrie r, , carrier .
N 30 A ! 30 A1 ^ 20 A i f 30 Ai en 9'ne 1 | ID A en 9lne
1 I I\ l -1 electronic s1 electronic s

, _ 1_ _ 1 _ _ __ I , , _ ,
4 J X 8 6 8 0 X1054 7 X1054 6 X1054 5 X24 3

1
4'
1.0 I 1 0 I 035 I 05 I 05 I 0.3 5
OR 1 OR 1 RT/G N 1 RT 1 BL/RT 1 SW
i X60003 1 3 3j[ X6000 3 1 | X6000 2 1 J ^ 14J ^ 21_J [ X6000 '
-» "}- » f- » 7- » T- »" " A600 0
DME contro l module
T [/r> ji — ^— f~* i —t"* i v
sn
Tail fe
Tai nl M
3i
fe ]jl Tai ln^
n ^ te lnTai
Tai <9 nl
4 5 6 X6000 3
25 2 5 2 5
BR B RB R
X6454 X645 4 X645 4

B510ele25751

Electrical Wirin g Diagrams ELE-20 9

 Electrical Wiring Diagram s ELE-21 0

Fuel tank vent valve Diagnostic modul e fo r fuel tank leakag e

N52 and N5 4 engines N52 and N54 engine s

A8680
Fuse carrier,
Fuse carrier' engin e engine electronics
87 F03 87
electronics
IDA

0.75
RT/WS

Diagnostic
module
for fuel tan k
X6120 leakage
Y6120
Fuel tank ven t valve

0.75 0.75 075

BR/BL SW/GN SW/RT
2 X612 0

(in E-box)
0.5
WS/BL

0.75 075 075

23 I X6000 5 WS/BR WS/VI ws/sw

16
I A6000
I DM E control modul e
I DME
control

fen
tnodule
I31A
31-1 131!

B510ele21651 B510ele21654
Valve gear
N54 engine

- — - - ---- - — - — - - - —- — — - — -— - . ._.. . ... . _ . - _ -- - - - - - -- — -

A8680
| Fus e carrier,
*" 8 7 F02 j engin e electronic s
I
30A I

I
!

V"
4 T X868 0

05 05 05 0.5
CR OR OR OR

3X 6214 3 X6224

i X6275 1 X6276

B6214a B6224a Y6275 Y6276

X I - Intak
— i—' senso
e camshaf t
r -D-D- Exhaust camshaf t
sensor
G2>X VANOS solenoid
valve, intak e
G 2]47 VANO S solenoid
valve, exhaust

2 ' X627 5 2 ' X6276

2 V/ ~
1 Y X621 4 2 1 X6224

05 0.5 05 0.5 05 0.5

SW/BL GE sw/ws GE/BL WS/BL WS/RT

24 11 25 12 5 18 X60007

f-fr
[j I
«-».
I |
> —•»
;r
1 "
f— »• A600
DME
0

M
I f

fo~~i
. T contro l
| 3 1 i 0 —i 31 3 t I r- 1 QZ5y i modul e
i \p r
31 A I 31 i T 31 i
I
1

B510ele24347

Electrical Wiring Diagrams ELE-21 1

 Electrical Wiring Diagrams ELE-21 2

Ignition coils
N52 engine
(page 1 of 2)

1 1 A868 0
t ! Fus e
1 !a 7 ] F0 1 ' carrier .
1
1
1
11 "l 1
j 30 A !
engine
) electronic s
1 1
1 1
_
X8680

X60552 (i n E-box)

2.5
OR

,„
OR
10
OR
10
OR
10
OR

u
3 J X6151 3 X6152 3 X6153 3 X6154

M
Ignition coil, Ignition coil, Ignition coil, j |Ignitio n coil
'1
cylinder 1
A) Spark plug
i, cylinder 2
4) Spark plug 1. cylinder 3
4) Spark plug
i j I
1 ———
i
.4
cylinde r 4
) spar k plug
1 2 ' X615 1 connection 1' 2" ' X615 2 connection 1' 2^ ' X615 3 connection 1' 2 X615 4 connectio n

1.0 1.0 10 1.0 10 10 10 1 0

ws BR WS/BL BR WS/GR BR WS B R

X6176 X6176 X6176 X6177

,. . . j . j.

1 2 3 4
1 —> • •> •
... i. m i i , ™ -i i _ •" —— — — .— — ,.__„_

T31 1
•i
SH
T3li
i9-|
131 1
© 1
^1

B510eie21646a
Ignition coils
N52 engine
(page 2 of 2)

0 10 10
OR OR RT/WS
3 X6155 3 X6156

1'
ii.1 L2' X6155
ignition coil
cylinder 5
4) Spark piug
connection 1'
Li - 2" ' X615 6
ignition coil
cylinder 6
4) Spar k plug
connection
Interference
suppression
capacitor for
ignition coils

10 1.0 0 1.0 10
WS/BL BR WS/GR BR BR

X6177 X6177 X6176

.L .. ,.

5 6 X60006
T-» A600 0
DME
rc;
1 R— co
W I moaul
n
e
. _. A 131 i

B510ele21646b

Electrical Wiring Diagram s ELE-21 3

 Electrical Wiring Diagrams ELE-21 4

Ignition coils
N54 engine
(page 1 of 2)

A8680

X8680

X605S3

25
OR

10 10 10 1.0
OR OR OR OR
3 X6151 3 X6152 3 X6153 3 X6154

I
T6151 T6152 1 T615 3
T6154
Ignition coil ; ;. < Ignitio n coil ^ ignitio n coil, ;3 Ignitio n coil.
1 I , cylinder 6 "! L T 4 cylinde r 2 ' | T 4 cylinder s ' 'T T 4 cylinde r 4

1 2 X615 1 connection • } 2 X615 2 connectio n1 2 X615 3 connectio n• ) 2 XG15 4 connectio n

1.0 1 0 10 1 0 1.0 1. 0 1.0 1. 0

WS B R WS/BL B R WS/GR B R WS B R
X6170 X6170 X6171 X6171
X. JL

1 2 3 4

j
• —»• •••-»> *.._^
|

?n SH n
0f
&~\1 A Tail H
1311 I 31 i

B510e!e24343a
Ignition coil s
N54 engin e
(page 2 of 2)

1
IOR
0 10
OR
10
RT/WS

3 j _ X6 1 55 3 X6156
[n-jrvi^

i
T6155 T6156
Interference
Ignition coil Ignition coil, suppression
fi T 4 cylinder 5
4) Spark plu g
ll_ i . cylinder 6
4} Spar k plu g
=
capacitor fo r
ignition coils
2 X6155 connection 1 2 X615 6 connection

0 1.0 10 1 0 1.0
WS/BL BR WS/GR B R BR

X6172 X6172 X6171

.L .A. , .

5 6 X60004
t-». T- * | A6000
j ]1 1 DM E control modul e

B510ele24343b

Electrical Wirin g Diagrams ELE-21 5

 Electrical Wiring Diagrams ELE-21 6

EGS transmission control

Steptronic switch
up to 03 / 2005

.
15 ~ * A7000 a

T
15
Transmission
control

L. ^
, 'r
4 5 ' X850 0

M54 N62
~" A4 6 r ""A 3 r "" A41 a
J
_™ ^ .r Fus e
^ - r 3 -, ~ - , n ^ Fus e rr . ^T^ i Ligh t module r c
r ^ h8 9 holder . -4 ?r aT 3 ° l" S holder .
0.5
ws I sw L
iU ID A — 0 ^i L j 5 A1 Iron t

43Y X1 2

„•>' 2 ]f X1101 5 2 1 X11004

M54 N62

ai 05
GR X1019 RT/BL

4 3 2 X6031 (i n E-box)
30G<89
0 35 0 75 0 35
WS/BL RT/GE GR/R T

rTs71 r^ 3 rt
3 2 X1600 1 |3 X1193
15 1 51 51 5 E82
[ Gear
¥ I I I r- r i indicato r

ITT ^ rT ™^ nI P
T 3v 11
[J lightin
31 A
g

1 ' ' X160 0 2 f" 3~ Y 4Y ~5 "Y~ " ~1~¥ X 1 599 2 ' X1193

035 0.35 035 035 03 5 0.3 5Q 15 0 3 5 035

BL/GE BL/GR WS/GN WS/SW SW/G E WS/V I SVWG N BR/W S BR

2, 3 4 X1561
S224
\_ Steptronic
\
\- ' \.
-4- switch Tf _ _| _J L selecto
1 | ever
r
1 Y X1561
position

035
BR

X 13784 XI 3784

B510ole19377
EGS transmission contro l
Steptronic switc h
as of 03 / 2005 u p to 09 / 2005 without N6 2 or N62 TU engin e

ir is "~ ~ ~ 15 - - ~'A7000 a
^T Transrmsso n

i i JiU. |© j contro l r - j A149 a A41a

^P T ~¥^ !
_' _ _, jj
I©
acces
] Ca
s
r
r : ] holde r

! I
0 MM
4' 5 ^ 1 X8500 ' 3 ,J syste m
11 Y X1031 8 5A 1 fron !
05 05 0.5
GE GR GE/BL GR [?^\
RR Iw l ' Ligh t
4' 3 2" ' X603 1 -? ?] modul e
[" ~ " A4 6 (in E-box ) y |
2 ' ' X1100 4

-30G— 1F89 ^ eer

43f X12 0.5

P 10 A t rea r 1 RT/BL
V1 X1427 6
L~ j • i > J X101 9
2 Y X1101 5

0 3 5 0.7 50 5 05 03 5 0.3 5
WS/BL RT/G E SWA/ I SW SWA/ I GR/R T

2 X160 01 2 3 X1427 51 3 X1193

l-«. 1 51 5J ^1 5 E82
___« Gea r
I--.. U U L M i A ,1, indicato r

T3il r
KI> j ^-T~*
v
T |r
^ ^~
v
T n
I
J * • —T~
y TrQ
T
* ^-T~
3g
*M
1A 31 i
H lightin g

X1600 2| ~ 3 ' 4~Y" 5 Y1 Y X I 599 4 X14275 2 " X1193

0.35 035 0 35 0 35 0 35 0 35 n 3 5n 35 05 035

BL/GE BL/GR WS/GN WS/S W SW/GE WS/V I SW/G N BR/W S BR/RT BR

2 3 4 X1561
I 0i S22 4 „ „ S22 7
T swc hT t\ Switc
0 a 0 6 6 Q 0

\c \ 1 t h
] | 1 selecto r

1 |X1561 potio n

0.35
BR

X 18740 X18740 X18740

Electrical Wiring Diagrams ELE-21 7

 Electrical Wiring Diagrams ELE-21 8

EGS transmission control

Steptronic switch
as of 09 / 2005 without N62 TU engine

15 15 OS ^ A7000 a
Transmission
M contro
£ i
4 5 15 X8500
r*
05 05
GE GR
11 X10318

05
GE/BL

A "" ~3 2 7 X6031
(in E-box r ~ ~ " • A41 a

! w%58 1^1 'f^h9 tt ! 5

i ° holder
A fron t
-
i Tf | | holder , -r* modul e i u
•' ' " " 1 A7 2 j |J j 10 A j rea r
gl | Stee r ng •• —I• >
i colum n 43VX12 2YX1100 4
L
r XH01 5
2]
13 X1880 swltc n 1
cluste r 1 0. 5
X14276 J X101 9 RT/B L
0.35 035 ^
BL/GE BL/GR
0.35 0.75 05 05 0 35 0 35
WS/BL RT/GE SW/Vi sw SW/VI GR/R T

X 10808 X 10808 3 2 X1600 1 2 3 X14275 1 3 X119 3

—•>• 15 1 61 5I S' ' E8 2

X 10809 X 10809
TT TT Gea r
[ r> —i !L. J UJ LJ U 'H T? ) indicato r
Tsli ~^f2 rt ? r^ ? rtj j3 ^ 31 M lightin g
1' XI 600 2 3 4T ST ' fYX159 9 4 ' X 1 4275 21X119 3

0.35 035 0.35 0.35 0 35 0 35 n 35 0 35 ° ° 35

ws/sw
5
BL/GE BL/GR WS/GN SW/GE WS/V i SW/G N BR/W S BR/R TB R

2 3 4 X1561
. i . i . i
Steptronic \
\ \ \ .
switch i[ I selecto r
1 X1561 lever
position
0.35
BR

X18740 X18740 X1874 0

B510ele23412
EGS transmission contro l
Steptronic switc h
as of 03 / 2005 u p to 09 / 2005 with N6 2 engine

I
A7000a
Transmission
ontroi

4 5 1' 15 X8500

' A41 a
GE GR sw
H acces s 5 8 M Ll 9ht
j5 °! holde r
._„ J system f modut e
4' '" ~3 ~ ? i X6031 11YX10318 v ft lS AI fron t
(in b-box) _
43Y X1 2
I ,
j 3 $G holde r 2 XI 1004
] £ 10 A rea r
i . 05
X14276 X1019 RT/BL
2 ' X11015

035 0.75 05 05 035 0 35

WS/BL RT/GE SWA/I SW SWA/I GR/RT

r
3 2 X1600 2 3 X14275 1 3 X1193
15 1 5 15 E82

QD T Gear
\
-^* ^ L i r « ..

^ indicato r
-T^r
hr-,
fel "V*
J IU
311
lightin g

X1600 2 3 4 5 1 X1599 4 ' X14275 2 X1193

035 0.35 0.35 0.35 0.35 0 35 0 35 0.5 0 35

BL/GE BL/GR WS/GN WS/SW SW/GE WSA/I SW/GN BR/WS BR/RT BR

2 3 A X1561

V? I \
S224 S227
Steptronic Sw ten.
.... \ \ I \5
t switch selector
1 X1561 lever
position

035
BR
X 18740 X 18740 X18740

B510ele22752

Electrical Wirin g Diagram s ELE-21 9

 Electrical Wiring Diagrams ELE-22 0

EGS transmission contro l

Steptronic switch
N62 TU engine

-p ^ __ ?_ A7000a
Transmission
control
rtT rt?
4 1 15 X8500

05 05 A 3' "' ' A41a

GE GR SW BR j -- j « r

if modui e[ F
Fuse
tt acces s syste m holder,
__ ._ T
4 3 2 _ A4 g X6031 1 1 X1031 8 front
43? X12 1
,._,_...„ —T pg g Fus e *.— — — — U- -
1 A7 2 2>
] Steerin g i ff l ! holder .
9 !i 10A I rea r
i colum n C
13) "x~1880 switch X14276 X1019 F RT/BL
cluster 2 X1101 5 *

0.35 0.35 0 35 0.7 5 0. 5 0 5 03 5 0.35

BL/GE BL/GR WS/BL RT/G E SWA/ I SW SWA/ I GR/RT
3 2 X160 0 1 2 3 X1427 5 1 3X
X10808 X10808 11
r^ L 0"

L
1D!

L
Di

L
D E82

nr
T T T T __, Gear
indicator
X10809
1
]T
X1600 2 '3
T
"
j
4" 5
T T
- -I
3I
X1599 4 X14275 2
|3|
X1193
lighting

035 035 0 35 0 35 0 35 0 35 o 35 035 05 0.35

BL/GE BL/GR WS/GN WS/S W SW/GE WSA/ I SW/G N BRA/VS BR/RT BR

2 3 4 X1561
S22/
\ I V Steptroni c \ switr h > Switch.
1 I I
selector
X1561 lever
position
035
BR
X 18740 X 18740 X1874C

3510ele23413
EGS transmission control EGS transmission control
Shift lock Mechatronics, power supply
M54 engin e

(up to 03 / 2005) (a s O f 03 / 2005 )

. 4 § 1 A7000a 1 5 A7000a

Li
Transmission j^> | ~"T r
Transmission
control ^- l!
p^ ' control A46 T 15 A149 a

-a Fuse I
holder, [
[ SIf Car
u acces s
""/"'"xasob T rear ,

^r syste
1 . |
| [ J 15 A |
7" X8500
m
"L 41 '' X1031 8

0.5 I" | A600 0

RT 6 Y X1101 1
M54 N62 i ( ^ | DM E
X 10547 X8091 X8090 jj contro l

1
^ 5 ' X6031 (in E-box)
BL/SW 3 '' X6000 1
^-
0.5 0. 5 X14276
VI/SW R T X6021 1 X6031
8^
—^
M54 N62 1.0 0.5 0.5 0.5 0.35 0.5
RT RT/SN GE SW BL/SW WS/VI
05
SWA/I
5 ' ' X603 1 in E-box) 2 6 10 3 X8500
1 4 JL 9 .
1 ] A7000 a
0.5 X13396
SW/VI i Transmission

1, X13396 | C
Y19
Shift loc k
<~ n la a control
'-^L^
Y19 selector
31 I
Shift loc k L __ iever loc k
13" ' 16 ' ' X850 0
l^X selector 3 ' X 13396
3' l X13396 l e u e r l o c K
0.5 1.0 1.0
BRA/ 1 BR BR
05
BR/VI 6 X6031 (in E-box)
6 ' 7 ' X602 1 (i n E-box)
6 X6031 (m E-box )
0.5
VI
0.5 1.5 05
11 X85QO BR/RT BR/SW
VI

r
i1 1
11 X8500 A7000a
X18740 X 18750
f~» A7000a M Transmission
h control
Transmission 3 1 A .. .
3-ti control K> J

L. J

22750

B510ele19378 B510e!e19376

Electrical Wiring Diagrams ELE-22 1

 Electrical Wiring Diagrams ELE-22 2

EGS transmission control EGS transmission contro l

Transmission control , powe r suppl y Transmission control, powe r suppl y
N62 engine N62 TU engin e

'] A46 J6 A149 aI n A600 0

5? TCa r I P DM E
\W~~^ F8 6 holder , U ^ acces s i J contro l
i || j 15 A i rea r ~^5 syste m3 >' X60001 moauie
41 t X1031 8
i- l __ j
6 X 10547 A46 r " 1 5 • ; A149 a \ A600 0
1» j -~- pg^ j Fus e (S I n ' Ca r > i@ | j Divt t
{ s P holder . ^ U ,; access i ^j contro l moduf e
0.5 0.35
RT/GN BL/SW vvs/vi ! If 15 A rea r I T syste ms | xeoooi
7 5 X6009 5 X60094 j 41TX1031 8
i
(in E~box ) , r
i i Integrate d *•
i '\ y 0. 5 0.3 50 5
10' 12' 11'
X60094 7 } X6031 1 }5 J X6009 s[ X6009 4
X8091 X8090 (in E-box ) , '" ]r " ~" ~ 1 A6009
gs- • ^ £> j' integrate d supply
ii modul e (IVM)
1.0 0.5 0. 5 05 0.5 w| 1 0 •"- • 12'"" ' 11YX6009 4
RT GN I GE SW VI
14 9 A_ „ .... . 10 3 X8500 , . ,_X8°g 1 . X8°9°

ir
: f c rr
A7000a 1 5 0 5 0. 5 0. 5 0 5 0 5
_, Transmissio n RT/G EG NG ES WV IW S
fj ^ C0ntr0 ' 14 X &[ 2( 6 J 10 | 31X850 0
' (_3 H 31« 31 'r ~i-r' ~ ~"~ ~ " " l «~ "~ ~ •" " A7000 a
131I 16 1 X8500
n: | Tidnsniissiu n
Q-, -. : A M l |Q — ,contro l
T311 :., v i,, d T31 1
•311 !31 i
BR BR 1ST 16TX850 0
6 5 X60092 1.0 1. 0
{ ] A600 9
— 1-«. | Integrate d supply X646 1 X646 1
i 1 modul e IVM ... .* .
! i
1 ' 1 X13701 •

6.0
BR

X6

B510e!e20370 B510ele23411
EGS transmission control EGS transmission contro l
Transmission control , power suppl y Transmission control , powe r suppl y
N52 engine u p to 09 / 2005 N52 engine as of 09 / 200 5

X10547
A4G " 15~ 1 A149 a
/\ U .J** f

r. , pg g Fus e §2 h i Car 1 A46 15 A149 a

j 3$G | holde r JL» i acces s r 3 nQ ; i-n^
ro- » ,i Fuse holder rea r j & J Ca r
' [ j 15 A i rea r i ^ . acces s
L1 j_ I _J]¥ ] SySte m i § 1S A | i | r$f 3 syste m
41T X1031 8 L ' • !
1
L sTxiToi i
"iiylKIOSIS
0.5 0 35 4 Fxnon
RT/GN BL/S W 0 5 03 5
RT/GN BUS W
8, X6021 X809 1 X809 0 1|X603 1 (i n E-box)
8 X6021 X809 1 X809 01 ( X603 1 (i n E-box)
(in E-box ) ' " " •
(in E-box) ~ ^ ^
10 05 0 5 0 5 0 5
R'T GE G E SW/B LG E 15 05 0. 5 0 5 0 5
RT/GE GE G E SW/B LG E
14 9 26 1 0 X850 0
r „-H^-- - " - -— ----- —-^- ; 1 -. •"£ . ---: — --^ Aypn n ^ 9 26 1 0 X850 0
ii j Transmissio n( U. " " " " " ". A7000 a

; L- i T V f TS contro l i !_
p. —: : ' T" ' ^ "
Transmissio
^ contro l
n

'; 31I J3l i! <3li ^V ^^

13 iOT XbDU U ^ _
13" 16Y X850 0
1 0 1. 0
BR B R 1 0 1. 0
BR B R
61 T'X6021 ( n E-box )
6' 7" X602 1 (i n E-box)
15 0 5
BR BR/S W 1.5 0 5
BR BR/S W
X18750
X18750

X18139
X18139

B510ele22749 B510ele23410

Electrical Wiring Diagram s ELE-22 3

 Electrica! Wiring Diagrams ELE-224

SMG control module, power supply

M54 engine

i A46 r A8680
Fuse Fuse
I _

'
I1 poc holder , I r — -i F0 4 carrier ,

r
1 30 G | F86 rea r I I °1 enain e
i <* i I electronic s
I I J 30 A J
i ] -A J
1
I I
1

6 X11011 X10547
L.

8
, — —

X8680
— -
j
J

gs^
4k ^^^^••••lft'~

i1 55 0 A149 a
~T 7 T Ca r
035 15 i 1 acces s
RT/GN RT/WS U ( MU syste m
I* — £• L3Z J f — *•
1i —O
l i —<~i
1 M M
X8091 X809 0 1 ~Y 1 X24 3 X18 1
5 8 X6021 (in E-box)
p"
41 |6 T X01318
1.5 0.5 0.35 0.35 0 75 0.3 5 0.3 5 0.3 5 0.3 5
RT/GE RT/GN GE SW RT/WS BL/S W SW/B LS W BL/R T

7 1 X70011 3 7 21 X70014 3 1 29 1 5 X7000 3

,_ 36 , > O —- - - — » ~ O — ™ _/"\™. . _ _ __ _ — S~\

rU ^ IT* ~f—& i~* "~ | A7001 0

i1 i1 M MM i Sequentia l

IT
yu j , manua l
^^ M
n br - ter-n
p% TU & n fer ^ 1. i n ' <™ s'°n
[3 1^
©

ii 31 1
T U T '!
^ / ^ X70011 1 7
31 -* -
.^ ^,
5 32 X70014
1.5 0.5 0.5
BR BR WS/VI
3 X60001
X6458 X6458 _/J 1
I •WB^^^HMH^^^ | A6000
[/oil DME
IMI
|

|
control
module
I

L.

B510ele19367
SMG control module, power suppl y
N62 engine

r
-i r
"1 A600 0 r 15
A48 50 " " A149 a
if
n A41a

^m
PI icp ! i,O! 1 DM E 7T Ca r
5 1 F63 &^ 1 I
!*
~^r
holder, 0 " 1 H2 holder . X10547 1 contro l U acces s
\ i3
!I j 5 A | 1
1'
i 20 A 1 fron t 3 X60001J m °du!e
J 1
41' 6 ' X1031 8
0.35 0.5
16' ' X1101 2 ' X1100 7 RT'GN WS/VI

1 X6009 5 X60094
0 75
GN/BL
1.5 r
RT/GE
~ * "j A600 9
j integrate d
6 7 X6031 (i n E-bo x I suppl y
10 11 X60094 X809 1 X809 0 X243 X18 1

0.75
GN/BL Rt5 °RT3/5GN
05 I
WS/VI 1
0.5 I
GE 1
0. 5
SW B'L/SW
I
0.35
SW/BL 1
I
0.3 5
SW 1
0.35
BL/R T

21 X70014 7 1 X70011 3 2 3?J^ 36^X7001 43 12 9 1 15 1 X7000 3

r- (-»
]
H*.
ii
" > —IP

I ltl
-» — #• ~ " A7001 0
|
r Sequential

fel
T~* ^__ manua l
9n
l
1
c^S
Tail T 31 i
^FV, i transmissio n
3j| 31 1 T3U J (SMG )
4 * 'X70011 17 ' X70014

1.6 0.5
BR BR

X6458 X6458

B510ele20368

Electrical Wiring Diagrams ELE-22 5

 Electrical Wirin g Diagram s ELE-22 6

SMG control module, powe r suppl y

N52 engine u p to 09 / 200 5

A46 A8680
Fuse holder,
I r- Fuse
30G F86 F04 carrier,
I I
I I I i engine 15 A149a
electronics
I I I I 30A Car
I I access
I '-• system
I

X8680
X10318
0.35 1.5
RT/GN RT/WS
X243 X181
X6021
{in E-box)

1.5 0.5 0.35 035 0.75 0.35 0.35 0.35 0.35

RT GE/GN GE SW RT/WS BL/SW SW/BL SW BL/RT

1 X7001 13 7 36 21 X7001 4 15 X7000 3

+-> A70010

Sequential
manual
transmission
(SMG)

1.5 0.5
BR BR

X6462

B510eie19368
SMG control module, power supply
N52 engine as of 09 / 2005

1 1
A46
i— 1 A868 0

Fi \<zc>
r
— Jnm n ..:..... . .-:-:: : .yy.y.yy. y yyyyy.y . .m^ u _ 1 FUS E

| holde r | 8 7 | | carrier ,
11 5
F0 4

I rear ^ i i engin e
if] 1 fl
1 i
j, , electronic s
Ii 15A I 1 J 30 A1 1
iLL T H ,
|L
i' 1 1 55 0 A149 a
I -r - -r-
1
X10547
—I i • «^
\n n Ca r
i_ [
i_ i i : _ |_ J I I I fZ^ l I i acces s
V ^ S2 J t ^ systen n
37 X11012 8 X8680

I
075 035 -15 \ S4 _ 1| 1V _ I_
GN/BL RT/GN 6i X1031 8

5 8 X6021 (i n E-box ) X8091 X8090 X243 X18 1

I > — I*>
1 — —
^ ^ *

0.5 0.35 035 075 035 0.3 5 03 5 0.3 5

RT GE/GN GE SW RT/WS BL/SW SW/B LS W BUR T

F
1 X70011 3 7 36 21 X70014 3 12 9 1 5 X7000 3
>i r

1 ni
*• t*. T-*- P-& -~ " A7001 0
'1 IT p n
!| Sequenti a

1 -- «S L J
(V)
I y V manua l

0
^— ^
| 3 1 * xl/
! f
T 31 1 1 3 1 1 Ta t i T 31 i.
I 31 i 31 - *

5 X70011 1 7 X70014

15 0.5
BR BR

X6462 X6462
. „ —— i t •^^•m— -nf"^-

B510ele19374

Electrical Wiring Diagrams ELE-22 7

 Electrical Wiring Diagrams ELE-22 8

SMG control module, power supply

N62 TU engine as of 09 / 2005

"] A4 6 [" " j A600 0

IP i ica

T1 5
1i n
F85 I holder . X10547 L — J co n roj
11 rea r *,.,, . , moduf e
I I 75 A I I 3 X60001 15 5 0 A149 a
1 I f1 1 ——
t — T—
t__j j .
nn Ca r
l_ [ _
i U |O | U
Jf-*- Si ) I-*
a«es
- syste
s
m
035 05
37 Y X 1 012
RT/GN WS/Vi
, J^ ? J -^

1 X6009 5 X60094 41 g
' X1031 8

I "j A600 9
I Integrate d
j

|T 3 0 ] F00 7 ! suppl y
i i iT i i i modul e
0.7 5 1 1 20A I I IV M
GN /BL | | L
1 i ^J I
1X 6 351 | I

8 ' X6009 2 1 0 11 X60094 X8091 X8090 X243 X18 1

t

0 75 2.5 035 05 0.5 05 0.35 0 35 0 35 0 35

GN/BL RT RT/GN WS/VI GE SW BL/SW SW/BL S W BL/R T

21 X 7 )014 7 1 X70011 3 2 37 36 X70014 3 12 9 1 5 I X7000 3

cr
\— *• t

0
1*- ~\-*- t — *• ~ " A7001 0
' t^
1 u Sequential

n1 ny
T
© !i V ^r manua l

b
t>-— ,A i ^1
M i M
•4- ^Y
'1 ^} | ^O ) i transmissio n
T31 i 3 1 1 13 1 1 T 31 I I 31 i (SMG )
L_ 31 A I 31 1

4 Y X7001 1 1 7 Y X7001 4

1.5 0 5
BR B R

X6458 X645 8

B510ele23405
SMG transmission contro l
Light module
power supply, up to 03 / 2005

A41a I "j A149 a

X 15002 X15001
ri f3 0 « f 3 0 | holder .
1
I
f/Ol I
iW I
Car
. acces s fr

ii
F8
!| l! i fron t j syste m
50A 1 J 50 A 1
iL 14 X10318
1 l
1* - ~ l i

! 1

1 X11001 ' X1100 2

4.0 4.0 0.5 0.5 05

RT/GN RT/GE GN/SW GE SW

g 47 31 32 14 X12
r _». -^ A3

'i L^
Ugr-
1*
n P
moc

^
f,ll U '< 3 1 i
31
Ui
31 i i
56 57 X12

0.5 0.5
BR/RT BR/SW

X 18726

X 13787

B510e!e 19456

Electrical Wiring Diagrams ELE-22 9

 Eiectrica! Wiring Diagrams ELE-23 0

SMG transmission contro l

Light modul e
power supply, as of 03 / 2005

with adaptiv e
headlight

" A41 a i HTA !! ^ 149a X1500 2 X1500 1 X1055 8 X1055 7

(
F5 r ;
0 1 F6 holde r jI acces s
i
1 -! , ' syste m
j 50 A
!I ] 50 A fr °nt 14 Y X1031 8

1' ' X1100 1 1 ' ' X1100 2

40 4,0 05 0 5 0 5 0 5 0, 5
RT/GN RT/GE GN/SW G ES WR T BL/R T

9 47 31 3 21 47 27 1 X1 2
• —^ i —> |A3
I Light

TT"
yi S i
] }
\n moduie
^1
56'
T'
31 I ^1 31 i J
57 ' X1 2

05 0,5
BR/RT BR/SW

X18726

X 13787

B510ele22930
Steering colum n switc h center
power suppl y (a s of 03 / 2005 up to 09 / 2005)
(page 2 of 2 )

028
Ste rjtron c

1
^ 3" X01064
pu; hbutton,
fro t lef t
2 101032
Sw tch bloc k
I©! multifunction
ste ering wheel .
3' left
T 1 X01068
101030
-j x ^ Steptroni c
' pushbutton ,
1 2 3 X01066 ' u

H
32 1 X0106 9

0.5 0.5 0.5 0.5 0.5 0.5 05 0. 50 50 5

RT/WS GE GR BR/WS BL/WS RT/WS RT/WS GE GR BR/S W BL/S W RT/S W

11 12 13 20 19 18 1 2 3 10 9 8 X0100 9
101004
Electronic
steering wheol
module

Electrical Wiring Diagr a

 Electrical Wiring Diagran

Steering column switch center

power supply (as of 09 / 2005 up to 03 / 2007)
(page 1 of 2)

A41a A7000a
I o] F2 8 T :01 F1 < Fuse | Transmissio n

!i j 20 A j 1 [
) ^ i
holder,
front
control

3 ' ' X1100 5 8 ' ' X1100 3

X6031 (i n E-box )
X10808

X10547 X 10606 X106 X14221

— c™™™.

15 035 0,35 05 0.5 I 05 035 035 035

RT/BL RT/BL RT/GN RT BL/R" | BL/W S GR/RT BL/GE BL/GR
I
I
1_ 10 7 9 16

\-pj CT y
T 31 A T 31 A
_| 31 I 31 I
2 11 2 5 1

05
RT/WS

X01227 X0122 7

05 05 I 0. 5
15 05 BR/WS RT/WS 1 RT/W S
BR BR/SW
3 X01068 2 13
JL S £\ — — - _ — — _* *
101032

X18751
H Switch block |O]
multifunction
|

' ]' X0106 8 left 1 Y X0106 9

X13785 05 05
jL . RT/SW RT/SW
X01236 X01236

3 I X0100 1

I I I 10108 6 | A7 2
; i1 ' j Steerin g colum n
X01239 j switc h cluster
Steering colum n switc h cente r
power suppl y (a s of 09 / 2005 u p to 03 / 2007)
(page 2 of 2)

"" A7 2

"" 1 X01001
n 10108 6 ai »en"9
column
switch
j cluste r

0.5 05
BL/WS BL/SW
X01238 X0123 8

X01237 X01237

0.5 05 I 0. 5 0. 5
BL/WS BL/SW 1 BL/W S BL/S W
1 2 X01054 1
V A
1 2. X0106
A
6
101091 10109 2
Rocker T~^f~l _
switch, "^
^ |pft rl .
3 ' X01 064 3 V X0106 6

05 0.5
RT/SW 1 RT/S W
X01236 I X0123 6
,

SMG transmission

B510e!e23422b

Electrical Wiring Diagrams ELE-24 1

 Eiectrica! Wiring Diagram s ELE-242

Steering column switch center

power suppl y (as of 03 / 2007 up to 09 / 2007)
(page 1 of 2)

A41a [" " ] A7000 a

ip 7 Fus e holder, 1 jJQj jj Transmissio n

1(
~- J F2 8 ["- - 0 I iS aj CO ntrol

I
| 20A j j | I 5 " 45 X850 0
i

3 X11005 8 X11003 10 1 1 X6031(i n E-box )

X 10547 X 10606 X 10605 X14221 X1422 0 X80 6

1.5 0.35 1 0.35 1 0.5 1 0. 5 | 0.5 1 0.5 1 0.35 0.3 5 0.3 5

RT/BL RT/BL 1 RT/GN 1 RT 1 BL'RT 1 WS 1 BL/WS 1 GR/RT BL'G E BL/G R
10
7JL d L 16 JL

u
>— *•
]
SH <
131 A 13 1 i
nr r
31 I|
"
2 11 £. 5
0.5
RT/WS

1.5
BR X01227

0.5 0. 5
BR/WS RT/W S
05
BR/SW 3 2 X0106 8
101032
IQI Switc h bloc k
X 1 3785 multifunction
j.
— •*• r X01068 lef t
0.5
RT/SW
X01236
^.

3 X01001
r--|—
~l 10108 6 "" A7 2
IS Bering colum n
1
!s w ch cluster
L__

' X01839

B510e!e27177a
Steering colum n switc h center
power suppl y (as of 09 / 2005 up to 03 / 2007 )
(page 2 of 2)

ji |Q|
"j A27 3 [
j Lan e departur e j
j warnin g j
"
|O| j
] A3
Ligh t module

10 X10930 28 X12

07 0.35
BL WS/GE

14 5 X1880
~" A7 2

1 switc h cluste r

r 6 4~^ X01001
05 0.5
BL/WS BL/SW
X01238 X0123 8

X01227 X01237 X01237

0.5 0.5 0.5 0.5 1 0.5 0. 5

RT/WS BR/SW BL/WS BL/SW 1 BL/WS BL/S W
2 3 XC1069 1 2 X01064 1 j^ 2 X0106 6

m
101033 101091 10109 2
Switch block -p*"}- Rocke r switch , "T*~t ' Rocke r switch ,

1•
multifunction ' le u' righ t

X01069 right 3 tX0106 4 3 ¥ X0106 6

0.5 1 0. 5 0 5
RT/SW 1 RT/S W RT/S W
X01236 1 X0123 6 X0123 6

^J

SMG transmissio n

B510ele27l77b

Electrical Wiring Diagrams ELE-24 3

 Eiectrica! Wiring Diagrams ELE-24 4

Steering column switch center

power supply (as of 09 / 2007)

1— 30-— j F2 8 j — 30— - F39 Fus e holder, I Transmission ! Lan e departur e ] Light modul e
front 1 control ! warnin gj
!; 4 5 X850 0 1 0 X 10930 28 1 X12

3 X 11005 6 X11006 10 11 X603 1 (i n E-box)

X 10547 X 10606 X 10605 X1422 1 X1422 0 X80 6

1.5 035 0.5 0.5 0. 5 0. 5 10.3 5

Si75
0.35 0.35 0.3 5 0.35
RT/BL RT/GE RT/GN RT BL/RT W S BL/W S !GR/R T BL/GE BL/G R WS/GE
10 7 9 16 8A 15A 6; 12 13 1 4 5 X1880 .
' » > 101086 Steerin g colum n
•• •- ;! switc h cluster
: 31 31 3i
3^
2 11 2 5 1 6 4 X0100 1
0.5 0.5 0.5 0.5 0.5 0. 5
BR/SW BR/WS RT/WS BR/WS BL/WS BL/S W
X01238 X0123 8

BR X01227 X0122 7 X01237 X0123 7

X 13785 X18751
05 0. 5 0. 5 0. 5
RT/WS RT/W S BL/WS BL/S W BL/W S BL/S W
3 2 X01068 3) 2 X01069 1 2JX01064 l) [2 X0106 6

Switch block Switc h bloc k Rocke r switch, Rocke r switch ,

multifunction multifunctio n lef t riah t
1- X01068 steerin g wheel, 1fX0106 9 steerin g wheel , 3|X0106 43 X0106 6
left righ t
0.5 0.5 0. 5 Q. 5
RT/SW RT/S W1 RT/SW RT/S W
X01236 X0123 6I X01236 X0123 6

3 X01001 v

01086 Steerin g colum n

i switch cluster
" X01239

B510ele51175
VTG transmission contro l
up to 09 / 2005

11
"i pv e r A46
0| h 'b | 3 0 F66

'] I I ff Fuse
holder
] 30 * j j \A i rear
jL
y ^ ,

4 X11010 8 X11012
X10550 X10548
i I.

2.5 05 035
RT/GR RT/GN/GE RT/GN

1 8 3

30 30 30

X10594

25 25 0.5 0.5 0.5 05

RT/WS BR RT/WS BL SW BR

X13788 X8597

X8540

M8533

VTG actuator
Classification
resistor

B510ele22753

Electrical Wirin g Diagram s ELE-24 5

 Electrical Wiring Diagrams ELE-24 6

VTG transmission control

as of 09 / 2005

I A41 a A46

I Fus e Fuse
holder, I I 30G holder.
front I I rear
I I
I I
i1

X11012

X10550 X1054 9 X1054 8

2D 035 035 0.5 05

RT/GR RT/GN/GE RT/GN RT BL/RT

30

&-\ rr
1Y 31
I module
'ransfer

X80003

25 2.5 2b 05 0.5 05 05 0.5

BR RT/WS BR RT/WS BL VI sw BR

2 1 X854 0

<?> i Classification
H resistor

B510ele23414
EGS transmission control 6HPTU
Gear selector switch

n A4 6 I A7000 a I A7000 a
Fuse ' Transmissio n ' Transmissio n
-365 " 1 re o holder,
rear
X8500 8 Y X850 0

X10547 X1054 5 X1054 6

05 0.5
X11012 VI WS

not N6 2 engin e T NJ62 engin e

9 Y X603 1

075 035 035 0 35 05

RT/GE GN/RT BL/RT RT WS

X511
S227a
Gear
selector
switch
31 1

X511

075
BR

X18740

B510e 1625759

Electrical Wiring Diagrams ELE-24 7

 Electrical Wiring Diagrams ELE-24 8

Convenient start
M54 engine
(page 1 of 2)

r ' "-- I M1 a r 1" ] S2 9 " " A65 a

\ Brak e . _ [@ | Dynami c
Q

XS402 ^ 0• holder .| 1 * j ligh t -23 - stabilit y

A ' fron t i _| j switc h l i contro l
J 3C A I , - X78 (DSC )
t_Jb— j
X6406 | 1 3

i G1 15 T X174 6

' X1100 2
035
BR/RT
~n~ +

X 13769 X1179 X110 1

X2219

: w9no i 40 035 0 35 0.3 5

RT/GN VI/SW BR/GR BR/R T
; W9110 1

JTLr - r* H
21 2 32 31 X1031 8

X6430
50 "t- » t* .
" F~ ^
-4
J
15
r 3 0 1 G643° V -
Jump start \ l 87 |
(— »13 1 i
i- - I j poin t L ._ J 1t±
X6404 2 2 '' 28 ' 20~1T 26^ Y 35~Y "
035 0 5 10 5 10 5
GE/BR SW/V Ij GE j SW
25
SW 36 j^_ 35 ^ X1358 1

3 X601 1 (i n E-box) I"j ~I1 5~ r

|qy
^| "I ! Safet
^ y and
I | gatewa y
Ir ^ I modul e
!_ _|~ ^T - J
7 Y X6053 1 i n E-box) 30 Y~~ ^ 3 4 Y " 32~ Y X 13581
X10547 X1054 6 X1054 5
250 2 5
RT S W
0 35 0 5 0. 5
RT/GN R T BL/R T

r
X6512 X651 0
iQ 40 33 2 63 73 6 X6000 4

v A -cEr ~ "5 i
V4~ : _z r2
i "*" t_ » n A600 0
Starter
1 } Starting moto r DME

t: ,
2) Solenoid switc h U ff^i C0 ntrol
tf, 3 1 IM modu |e
3) Holdin g winding

_
4) Pull-in winding 131 i

B510elo19447a
Convenient start
M54 engin e
(page 2 of 2)

L1
EWS
toroidal
coil

S2

M Ignition
switch
__,
1 " 2~* 3
"V sT e"1 8~^ 9 14 I X1402 6

012 0 12 012 012 012 0 .12 012 0 12 0 12 012 0 12 0 12 012

RT GR GR GR GR GR GR GR GR GR GR GR GR

1 2 3 4 5 6 7 8 9 11 14 X1402 7
, ^ , ^
A149a
Car
access
system

SMG transmission automatic transmissio n manual transmission

035
BL/SW

X6031 (i n E-box)

035 035 0.5 035

BUSW SW/BL BL/SW BL/SW

3 I 12j [ X7000 : X121

"~f+ p » A 7 0 0 1 0 A7000a S805a
Sequential Transmission
0 r^ U manual control
n transmission
31 i (SMG)

B510ele19447b

Electrical Wiring Diagrams ELE-24 9

 Electrical Wiring Diagrams ELE-25 0

Convenient start
N52 engine with DSC Dynamnic Stability Control PLUS
as of 09 / 2005 (page 1 of 2)

11 A41 ai -j S2 9 | Abb a

I _ Fus p1 \ Brak e I i s S 3 Dynami c

1 X6402 j ' 01 h/ holder . i TV | l,ght j - ^ stabilit y
-j J c^.t^ H i I I contro l
j 30 A 1 tron tT 3 X78 , 1, 1 (DSC )
iJ — "- 1
36 tX174 6
X6406 | '
1. G 1 2 * ' X1100 2
z__ Batter y

'—

X1179

X1 3769 (at battery positive cable)

40 0 35 0 35 0 35
X2219 a t battery positive cable) RT/GN VI/SW BR/GR BL/R T

21 2 32 31 X1031 8

-£
50 1
; W911 0 1
\0 8 7 J
T 31 1

30 1 0 6430 22 1 23" 24 ' 3< T

Jump start
1 termina l
I . 25
SW 075 0 7 5 0,3 5
SW/GN SW/G EW S
3 | X6011 < in E-box)

X10134

2 43 ^ X1032 0
250 M13/a
RT 8 ' X6055 1 (i n E-box)
V^ Electri c
H steerin g
25
WS 1 ' ' X1023 0

X6512 X6510
M6510a 05

V -nK- i -J BRA/I
4 n~ ^2 3 Starte r
1 ) Startin g moto r X 18726
2) Solenoid switch
&, 3) Holdin g winding
4) Pull-i n winding
\ L

B510ele23455a
Convenient start
N52 engine with DSC Dynamnic Stability Control PLUS
as of 09 / 2005 (page 2 of 2)

S2a
START-STOP
button

S 14028
Slide-in
compartment

0 12 0 12 0 12 I 0 12 0 12 0 12 0 12 012 012 0 1 2 01 20 12 0 12 0 12
RT G RG RI GRG RG R GR GR GR G RG RG RG RG R

12 3 4J [5 6 7 8 9 10 1 11 21 31 4 X1402 7
^ A149 a
Car
IT — *I T~ *

[J 1 m
f| (\ s
|j I I ) syste m
J31* I 31 1I
28' 20' 26Y • " 3 5 Y" 41^ 6 ' X1031 8

035 05 0 5 0 5
GE/BR SWA/I G ES W

XI 8828 XI 3459 8 1 9J ^ XI 6760

[~ * ~ " ~" • A1676 0
1 Body-gatewa y SMG transmission automati c trans m s s on manua l transmissio n
' ~l r 0 modul e
iy

27 Y~" " 3(TT " 29 Y X1676 0

11 035
BL/SW
X10547 | X1054 6 J X10545

1 X603 1 (in E-box)

0 35 0 5 0 5 035 03 5 0 5 03 5
RT/GN R T BL/R T BL/SW SW/B L BL/S W BL/S W

2 15 X60001 1 ^ X6000 2 1 |
14 ^ X6000 1 3 12j[ X7000 3 1 0 X850 04 X121
h* tV ~ ~T U ~ " A600 0 — » "V *" " A7001 0 "f- »" " A7000 a [ "' " | S805 a
y Sequenti aM \Q}\ n I O l I Clutch
1 Df l r~ i ° ME
(>_, 3 1 i
3 1 1 S CORtro 1
r> |Q | jt > manua l K> — contro l ! ' | switch
vp | ' modul e
'Ol* iol * rr,nr^\ A
SMG)

B510ele23455b

Electrical Wiring Diagrams ELE-25 1

 Electrical Wirin g Diagrams ELE-25 2

Convenient start
N52 engine or N5 4 eng ine
with DSC Dynamnic SI ability Control Premium (page 1 of 2)

"• A41 a I =I ^- j~ ] S2 9 I " | A65 a

\ Brak e 1 . , (© j 1 Dynami c
I X640 2 j " 30 ~1 F7 'olde r ! T * " i ligh t I 4 2 | stabilit y
I IP ' frnn t <- -
Hi 3Q A 1 tron t , '
I 3 X7 8 1 ^ 1 (DSC )
--) J
X6406 4 t X1028 1
j_ j
1_ G 1 2 t X1100 2
:_ Batter y

X1179

X 13769 (a t battery positiv e cable )

40
X2219 (at battery positive cable ) RT/G N VI/SW BR/G R BR/R T

JT r r1 r
21 2 32 3 1 X1031 8
50 t- »L » t *
: W9110. 1

.— --Th*fcT3 ^3 1 1
X6430 8 7
• r~—- ^
:1 30 1 G643 ° 2 2 23 2 4 3( T
1 J Jum p start
1
1 1 termina l point
2.5
' X640 4 SVV 0 75 0.7 50 35
SW/GN SW/G EW S
3 X6011 (i n E-box )

X10134

2 4 3 X1032 0
25.0
RT 8 ' X6055 1 (in E-box) M137a
•(D1 Electri c
H steerin g
25
WS 1 t X1023 0

0.5
X6512 X6510 BR/VI

~T1 ._j =
; —: M6510a X 18726

\ 4 ^ 2 " ^
3 3 Starte r

Ai
1) Startin g moto r

f1
2) Solenoid switc h
3) Holdin g winding

I 4} Pull-i n winding

B510ele26599a
Convenient star t
N52 engine o r N54 engine
with DSC Dynamnic Stability Control Premiu m (pag e 2 of 2)

S2a
START-STOP
button
1' 2^ 3^ 4"1 5^ lT 7"" 8"1 9~^ 1<T X3650

0.12 0.12 0 12 0.12 0.12 0 12 0.12 0 12 0.12 0.12

GR GR GR GR GR GR GR GR GR GR

1 2 3 4 5 6 7 8 9 10 11 12 13
. ...f V. -
14,„./ X10770
. .

S14028
Slide-in
compartment

0.12 0.12 0.12 0.12 0 12 0.12 0.12 0.12 0 12 0.12 0.12 0.12 0.12 0 12
RT GR GR GR GR GR GR GR GR GR GR GR GR GR

1 2 3 4 5 6 7 8 9 10 11 12 13 14 X14027
"" A149 a

T
Car
access
system
3 1*

035 05
GE/BR GE SW

X18828 X16760

I Body-gatewa y SMG transmission automatic transmission manua l transmissio n

15 j modul e

Li
27T "30T
I I
" " 291X16760
t

0.35
BL/SW
X10547 ' X1054 6 ' X10545

X6031 (i n E-box)

0.35 035 0.5 0.35 035 0 35

WS RT/GN RT BL/SW SW/BL BL/SW

1 I X6000 2 1 X3500
^-^A
t- A6000 A70010 I S805 a
DME Sequential Transmission j Clutc h
control manual control I switc h
module transmission -1 modul e
131 i
(SMG)

B510ele26599b

Electrical Wiring Diagram s ELE-25 3

 Electrical Wiring Diagram s ELE-25 4

Car access system

terminal control, N6 2 engine up to 09 / 2005
(page 1 of 2)

3OG 1 51 51 51 5

1} *-*• T- I
* t t*r I *- —
1 8 9 14 13

0.35 0.35 0.5 0.5 0.5

RT/BL GN/GR GN/GE GN/SW GN/RT

31 X12
i :
"j A 3
1 Ligh t
' modui e

M\
17 1 X11012 7 X1880
T" " A4 6 r "!- » ] A7 2
X19527
] 10106 8 | J r~ " I 10106 9 J^j ^ y j Ujj^" 9
OBDII socket
3 [j ! i \
M ! rsa r3 1 ^ l© l i swic h
.— i
| | f L J , | cluste r

J ,
i
11 X11015

0.35
BR

X 13790

B510ele20372a
Car access syste m
terminal control, N62 engine up to 09 / 200 5
(page 2 of 2)

n A149 a
15 R R R Ca
B
r
r— — < access

Ll tS j syste m
1 [r»
7 2 r 3 4 X10318

05 0.35 0.35 0.35

GN/WS VI/SW V!;GE VI/WS

6 X6009 17 X279 (under passenger seat)

~* A600 9
integrated
supply
' rT ^ i
-7 i module IV M
M c
! ^
1
7| 1) Ignitio n coil

0-35
VI.'WS

i
F003 j " "I F00 4 2 J [ X1601 4 (unde r passenge r seat )

-»
] 20 A | [ j 20 A ! 3
|" *l A222 a
1 1 S805 a j
JQJ Passenger' s
1 [SI ' Clutc h 1
1 X13701 ! ' occupanc y
detection
1 X78

BR I" ] S2 9
ii | Brak e
X6 i 1 ligh t

B510ele20372b

Electrical Wiring Diagram s ELE-25 5

 Electrical Wiring Diagrams ELE-25 6

Car access system

terminal control
without N62 engine up to 09 / 2005

"j A149 a
I Car
30G 1 51 51 51 =
5 17 5 31 5 RR

4-— LI__.---X___.._L_ H_JL _JLJL_J

i j acces s
system

E-* i
8 9 14 13 7 2 3 4 X10318

035 035 0.5 05 0.5 0.35 0.35 0.35

RT/BL GN/GR GN/GE GN/SW GN/RT VI/SW VI/GE VI/WS

31 X12 17 X279 (unde r

' passenger
f~-» A 3 seat)
f] Ligh t
., ' modul e

M GN/WS

M 1 X11012 7 X1880 6 X6011

T n A4 6 ~1 — ». ~ " fi.7 2
1 X 19527 X6830 X6830

T J'~ f ] I0106 B T T~ t ] l0106 9 holde rV column 9

OBDII socket
i V 1— cp—
1T
0J |! i| V
?
—I
ca 0—!T | rea
'
r " 1 '© Icluste
switc h
r 0.5 0.5 3 X121
GN/WS GN/WS
[" ]S805 a 0.35
VI/WS
' X1101 5 1 ' X6053 1 j' ' j switch 2 X16014
"

0.35
8 X6327 1 X6254 1 X78
BR [ '"\KB327 \ ~"JB6254a j '~~ J S2 9 [ " "~"JA222 a

X 13790
I! Relay> 1 S tit^ leve
' Oil I
|(Q | | Brake ]
l
IM = il ligh t li±d
[O j ] Passenger's
j j seat occupanc y

"1 injectors i -Jsensor L J switc h | j detection

B510ele19974
Car access system
terminal contro l
N62 TU engine as of 09 / 2005

"1 A149 a
30G 1 51 51 51 51 5 r?=ji R R R R i

I 11 T j^
Ca r

•T 7 •— — •—— *—

L 1K-
'
— - -i . L 8 9
_ J- I
14- 13
-- 7~"
i_ - @l
2' 3"" 5 4 X10318

0 35 035 05 05 05 05 035 035 0 75 035

RT/BL GN/GR GN/GE GN/SW GN/RT GN/WS VI/SW VI/GE VI/GN Vl/WS

31 X12 6 X6009 20 X18069

X8103
r\ ' j •i-^^^^i
r L ^ ~[ /\
""' A600 9 1
|j I Ligh t 1 Integrate d ! Ej| [ ' Cras h
o-i imodul e supplv
i —-•-• modul
safet y

31 " i S li
1 iQ?--/!
L^t L j 1
module
IVM
e

"I L _
r
1 } Ignitio n
8 4 X11015 7 X1880 coil
t A4 6 r ^ A72 1 unloader 17 X279
X 19527 (under passenger seat)
^•
*-?, o
" 10106 8 r ~
i
[~
T
i 1
— ?, holde
101069 L _ujsf [
r 3 1 i
Steering
column O P Di! socket r i
—Fi 003 r ]F004 rela y 3
X121
j \ CtllJ i | V Cp U ] rear ~ |^ | swrtc h r - - — jS805a
i 20A I1 J20AI
L ] H jL J ET J_ , L 3J L J I

uJ r — r» custe r L 1 ijQj i i Clutch

1! 1 ISZ i 1 switch 0 35
t LL " u j module
9 X11015 1 ' ' X1370 1 2^ X16014
1
X78
035 6.0 r1 -i A222 a
BR [— - - |S29
BR
I 17= 5 ] I Brake l I7= % i i Passenger' s
] M | light 1 62 1 1 sea t
A
X137QO
^ X6 !1 switch [J occupanc y
detection

B510ele19973

Electrical Wiring Diagrams ELE-25 7

 Electrical Wiring Diagrams ELE-25 8

Car access system

terminal control
without N62 TU engine as of 09 / 2005

A149a

: it '
30G 1 51 51 51 Co ? 5R RR R Ca r
5 1 -— -
j --^ - acces s
f 1 7 f " J[ I[ J syste m

u 3* _ 1 * _ „ „ 3 t» ^ 2
f-» t * __r *
8 9 14 13 7 3 5" 4 X10318
1

035 035 05 0.5 05 035 035 0 75 0.35

RT/BL GN/GR GN/GE GN/SW GN/RT VI/SW VI/GE VI/GN Vl/WS

31 X12 X8103
r } ^• > A3 f-
I inh t
O.,T modul e f" j S805 a
0.5 17 X279
S3 GN/WS t S~> | 1 Clutch
j — | switch
(under passenger seat)

8_ 4 X11015 7 X1880 5 X6011 (m E-box ) 1 X78

n A46 r 1 -* n A7 2 1
X6830 X683 0I , _
]S29
X 19527
Steering S 1 Brake
f~ [ ! IU1UO B ; • | - ~ " ~ ! IUlUb 9 -, " |
\ fr * \
| Y-.-tt] | |JJ
i?
VC
i holdeD I I ! rea
r 3 1r l(M!
i i sw
column
i ch
1
1 'switc
i light
)}
h
^y 1 j _J f •— r1 " " cluste i 05 0 5
GN/WS GN/W S
1 035

9 ' ' X1101 5 1 V X6053 1 (i n E-box) 2 X16014

(under passenge r seat )
8 X6327 1 J[ X625 4 2 0 X18069
035
BR f "JK632 7[ "" ] B6254 a [ " ~]A12 a! " l^T" "
j- . [Passenger s

X13790
I ! fuel ! ! level I ' safet y I '' i occupancy
1 'injector s '• 'senso r ' 'modul e ' 'detectio n

B510ele19775
Car access system Car access syste m
power suppl y power suppl y
up to 03 / 2005 as of 03 / 200 5

1 A4ia
1r -- , Fuse holdor .
I | 3 0 | "- ' | 3 0 | F1 - front
[ 3 0 | | 3 0 | fron t
i i if i i i iT i i
F 7 F1 5
X1500? X 15001
! j f! ! I N! X1500 2 X1500 1 II I 30 AI I I j5 AI F^

L J J L 4 J
~F
30A I | M l5 A j ^ ,
I I 1
u_-
—J L -j—- J ii '
i
2 ' ' X1100 2 6 X11003
2 ' X1100 2 6 " ' X1100 3
X10547
X 10547 • III !-fr.

4.0 0.5 0.35 0.5 0.5

4.0 035 0.5 0.5 RT/GN RT/GN RT/GN GE SW
RT/GN RT/GN GE SW
035
RT/GN

ro
34 19 26 35 X10318
21 34 19 26 35 X10318
r 1_ - ^_ _
_^_-^r-_r~_^^-^r ^— — ^--^~-_riS _ r t- f 1 —, | A149 a
| A149 a I X" * f ^
1 Ca r acces s
I Ca r access | y y
IT^ [JO !' s ystem | 3 1 I3 1 A FT
[I M
n~"^ 1 syste m

u
31 i
3 1 i ^
II
|
31 1 _ j
31 A 31 * ' ^___.J
25 X10318
12 25 X10318 1 2

05 0.5
0.5 0.5 BR/SW BR/RT
BR/SW BR

X18726

X13787 X13785
. *"
jL J

X 13787

B510e!el9444 B510ele22771

Electrical Wiring Diagrams ELE-25 9

 Electrical Wiring Diagrams ELE-26 0

Ground connection X6
M54 engine

B6254a - ] A600 0 r" " " j S8;>11

; _ ,j Sequentia I Reversin g
[HI lOi l! Ipj l I DME
IsKI 1 level ' Isz lj contro l [gr3j I manual | light
' transmission LJ switc h
2 X6254 S ' 6 X60001 5 ' 'X70011 17 ' X70014 (SMG ) X8511
; W851 6
|
0.5 , i Reiay, I 1 Hydraulic
BR Hue ! 1 1 pump relay ,
_J SMG
'
(in E-box ) 4 _ X60531 4 X6327 4 ' ' X631 8

0.5 0.5 1.5 15 0.5 1.5 0.5 0.5

BR BR BR BR BR BR BR BR BR

X6458 X6458 X6458 X6458 X6458 X6458 X6458 X6458 X6458

r - A6000 r -• — - i Y6561 r — — — -i Y6562 p

I CQ 3 IDM E | j Solenoid i i Solenoid f I So enotd t I Solenoid
: M I control valve 1 , i J valve 2 , ' • 1 valve, ' ' valve,
J brake s L J clutc h
4 X60001 5 X60005 2 ' ' X656 1 2 ; X6562 2 ' X656 3 2' X6564

0.75 0.75 0 75 0.75

BR BR BR BR

X6461 X6461 X6461 X6461

2 X60541 (i n E-box)
8 9 X60532 (underside o f transmis sion)

1.0 1.0
BR BR

X6460 X6460

4,0 1.5 2.5 2.5

BR BR/OR BR BR

1 2 X64541 1 2 X64542
101053

support. E-box
X2350

6.0
BR

X6

B510ele19310
Ground connection X 6
N52 engine

1 A6000 r ! Y6561 [ -• • Y656 2 j "- --JY656 3 <• ' Y6564

i->-^ri f DME i i Solenoid t I Solenoid i i Solenoid i i Solenoid
Szl j control I j valve 1, j j valve 2, j j valve, I 'valve ,
j module L j aear L j aear L j brakes L J clutch
5" "~ 6 X60003 2 ' X6561 2 ' X656 2 2 X656 3 2 ' X656 4
1 "j E653 9
I1 0.75 07 5 07 5 ' 1 Crankshaft
t1 Control valve BR B RB RB R1 ' breathe r
J | refrigeran t •---I i heating 2
i, " compresso r X646I X646 1 X646 1 X646 1
2 Y X809 9 ' X6539 9

2.5 2.5 2.5 0 75

BR BR BR B Ra " 9 X6055 9 I1 Y6540
]j DISA
1 i controller
1.0 1. 0 [ " i B62540 3 | " ---jCKwa u 2 Y X654 0
BR B RI O 1 Oi l condition 1 1 Crankshaft
X6464 X646 4| !_ ISE
j I senso r
s e so ^breathe j ^^ r 1 I Y6541
5 X6055 2 (i n E-bOX) 1
-- - • 2 • X62540 2 1 | DISA
X6539 0 I controller 2
1
0.75 2.5 2 Y X654 1
BR BR
•• • ; K6327 05 0 75 1.0 0. 5 0. 5
X.6454 X6454 X6454 X6454 X645 4 X6454 | ! Relay. BR B R BR B RB R
|1 uel X6460 X646 0 X6460 X646 0 X646 0
«- - , - » injector s
61Q 4 Y X6327
| _ ,\ lj ] Hy
1 i^r/ l i manual l 1 , r
p^ mp relay, 1S851 1 25
' BR
1J transmission [ _J 5^<Q 1 Reversing
5 X70011 1 7 X70014 (SMG ) 4 ' X631 8 ! light switc h X60551(in E-box)
1 Y X851 1
1.5 05 0. 5 0.5 I 05 1.5
BR BR B R BR 1 BR BR

X6462 X6462 X6462 X646 2 X6462 1 X646 2 X6462

2.5
BR
1 X64541
I01053
1erminat 31
upport, E-bo x

6.0
BR

X6

B510ele21855

Electrical Wiring Diagrams ELE-26 1

 Electrical Wiring Diagram s ELE-26 2

Ground connection X7517

N62 engine

A60210
1 A7001 0
1
m
n
I
. bequentia l
> Vanabi e valve I DME ' manua l
| timin g gear | contro l I I transmission
1 contro l module • modul e
1
1 _ ^
| (SMG )
1
>v
X60211 X6000 1 4 X7001 1 1 7 X 700 14

r
I
I 1 Hydrauli c
I | pum p
i relay , SMG
I
_____ 1

X6313

W8516

4.0 4.0 1.5 1.5 0.5 0.5

BR BR BR BR BR BR

X6458 X6458 X6458 X6458 X6458

a

1.5
BR

X7517 X7517

B510ele20344
DSC control module, power suppl y
DSC Dynamic stabilit y control
up to 03 / 2007

r n A41 a r A4 6
I , 1 , , Fus e , , Fus e
| | 3 0 | Fl j 3 0 j F2 5 hoWe r ^ 3Q G - i F6 6 hoide r

1 if )1 1* 11 fron t1 [T ] 1 rea r
MU 50 A I N 30 A 1 1 Ij j S A 1
j !t _ _ _ J L _ j _ _ _ _ J L4- —J

5 ' X1100 1 8 Y X1100 4 2 4 Y X 1 101 2 (t o 09/2005) X1054 7 X1055 5 X105S 4 X1422 1 X1422 0

i i i i
4.0 2 5 03 5 0.3 51 051 051 0. 5 1 0. 5
RT/GE RT/G R RT/S W RT/G N | RT | BL/R T | W S | BL/W S
i l l !
1 25 7 3 52 41 3 71 1 41 2 61 X174 6

<—&•

— ~r « L i ,. .1 5 I
f
I i
-> I—

i L
n
5-

J Dynai
~ " A65 a

J
J JT^ -• "T B 3 T- ^ stabili t
11 3
U
1 1
fl f
U h
l 3
13
1 i IW l Igp- n contr

1 I (DSC )
o

31 i 31 A f- »

13 38 ^ 32 ^ X174 6

40 2.5 0.3 5
BR BR GN/G E 19397,19398,2341 7

X13796

4 j ^ X165 3

F ' 1 B75

' E3 i' DS C
X13782 X 13782 I l I senso r
j J 1, „ I

B510ele19397

Electrical Wiring Diagram s ELE-26 3

 Electrica! Wiring Diagram s ELE-26 4

DSC control module, power suppl y

DSC Dynamic stability control
as of 03 / 200 7

"J A41 a A46

r ,
o1 PI T : 0 ] I holde r OG ~ ] F7 8 holder,

\l
F2 5
11 1 f }1 ' fron t
j 3
rear
j 50 A | j 1 j 25 A I 1 1j i5 A j
jL

1 .-»

5 ' ' X1100 1 8 ' ' X1100 4 14 v ' X1101 2 X10547 X1055 5 X1055 4 X1372 5 X1372 4
i

40 2.5 05 035 0 5 0 5 0 5 0 5
RT/GE RT/GR RT/SW RT/GN R T BL/R TW S BL/W S

r
1 32 45 14
. .. . 25 A 40 JL 23 JL 38 Jk X1082 1

"" A65 a
Dynamic
'T ^U ^T SV 1 . stabilit y
11 3 1 i n3 1 1 l^ aM —i 7
31 i
yV
31 A J
3i i! —+• j
control
(DSC)

16 v 47^ 21 ' ' X1082 1

40 2.5 0 35
BR BR/GE GN/GE

4 X1653

1 "] B7 5
1 j(Ql I DS C sensor
X 13782 X13782 | 11
j L i

B510ele25762
DSC switch functions DSC switch functions
DSC Dynamic stability control DSC Dynamic stability control
up to 03 / 2007 as of 03 / 2007

r ~ S83 9 T > S2 9
r" ~ " A4 6 I I Centr e I I
Fuse holder, rear I I consol e | | Brak e
| switc h i 1 liorit
j" 30 G| F6 8 1 (up to 09/2005) I i cluste r . s w ch
1 [T
15
|1
A1 1
F7 4 1 (as o f 0 9 / 2005 up to 03 / 2007) i _ _ J dnve r L ^ V_ _ _ J
1L p1 3 ^ X17 257 4 X78
c1
1
X10812 X181
21 Y X1101 2 (u p to 09 / 2005 ) B^-
26 X1101 2 (a s of 09 / 2005 up to 03 / 2007)

035 X90 8
RT/Vt \ 5
WS/GE
I GR/R T B18a
1 4 I X1405 7 1
1 X16919
" " S c Brak e fluid ieve i switch
"] A169 [ ~ ~ j S2 9 1 B 1 8a i " " ' ri , 1 ) Insufficien t
, A1G 9
| I I renter I Brake ~,~,**, ,,^^ .^..^ . , Centr e -s/ 2 ) Sufficient
I! f l consol e light 2 console f
/L ) switc hj __ | switc h cf 1) Insufficien t j vly I switc h
2) Sufficien t | | centr e
I / ' Cenle f 4 ^ X78
I L. — , J
j
^^
| I X18 1 2 X111 1 4 X16919 21 X11 1
LJ J fe-

3Y~2 Y X1405 7

0 35 0.35 0.3 5 0.3 5

0.35 0.3 5 0.35 BL/VI BL/RT BR/GN/G E BR/S W
0.35 0.35
BL/VI BR/S W BL/RT
BR/GN/GE BR/SW

X 13787 X 13787 X 13787

.L a.

A 30 5 X174 6
/\ 1 /N /* \ ^ 1 ^ A65 a
4 I 3 0 , 5 X1746
i1 f—4-i ». f-s _ - T^ 1 A65 a r t h h
I1 Dynami c
I I Ij 1 1 Dynami c
[-Qn U U s ability
=
1U r? 5 | y M 1 stabilit y T
I 31 I m Op- ! ^r n | ^01 3 1 i LS4 O 1 O j C Dsc01
I
T 31 i t •}• < 4 (Uou
1
j
TI 311A I T 3 1i A <DSC >

1 l
19400, 2576 5

B510e!e19400 BS10ele25766

Electrical Wiring Diagrams ELE-26 5

 Electrical Wiring Diagrams ELE-26 6

DSC switch functions

DSC Dynamnic Stability Control Premiu m

I S839
I Centre consol e switch
cluster, drive r

3 T X1725 7

035
WSGE

| A16 9 | | S2 9 B18a
o
' Centr e console ' ' Brak e Brake fluid level switch
£> ' switc h center 1 • ligh t

r
2 1) Insufficien t

I
' I 1 switc h
1_ ,
2) Sufficien t

14 X16919 4 X78

<
X181 2 1 X111

0.35 0 35 0.35 035

BL/VI BL/RT BR/GN/GE BR/SW

X13787
JL

31 3? 5 X10821
r
-»• f"> f% -~ " A65 a

Dynamic
fO V V stabilit y
ISlI O 1 O 1 contro l
^T [ M ^ (DSC )
I 3 1 A 13 1A

B510ete25763
DSC, sensors to 09 / 2005
DSC Dynamic stability control
(page 1 of 2)

"j A65 a
I Dynami c
j stabilit y
t contro l
J (DSC )
X1746

035
GE/RT

I
035
N/GE GE/RT GE/RT

X1653 X14033 X14047

817a

DSC
sensoi
sensor. sensor j, , j wear sensor. r Brake pad
wear sensor ,
front axie rear axie front left rear right
X 14033 1' 2 X1404/-

1 1 2\5X18145(in fron t
wheeihousing
7 * /-- X18146
(in rea r
X14220 driver's side) wheeihousing
passenger
0,35 035 0.35 o.; 5 side)
BR/WS BRA/VS GE BR/WS BF
BR/WS
0.35
0.35 05 05 X186 X186 X186 XI GE/BR
BR/SW ws BL/WS

XI 3786
035
GR °Bfi °Gi5 05
BR/WS

12 23 29 10

L
fa 3 ^ "
~* n
ai
r?^

B510ele 19399a

Electrical Wiring Diagrams ELE-26 7

 Electrical Wiring Diagrams ELE-26 8

DSC, sensors to 09 / 2005

DSC Dynamic stability contro l
(page 2 of 2)

B2 B4 B3
Front lef t Rear ief t Rear righ t
wheei spee d wheel spee d wheel spee d
sensor sensoi sensor

1 Y 2~ Y X 1 1 4 (in front 1 ' 1 X11 3 (i n fron t 1 '

wheeihousing wheeihousing wheeihousing wheeihousin g
driver's side) passenger side ) driver's side) passenge r sid e
0,5 0 5 05 0^ 05 0 5 0 5
RT BL/R T GE I3L/GE vvs B'L/WS G N Bl/G N

f i r t '
22 1^ 21 ^6 18 20 33 31 1 9 X174 6
15 ~ U t i - 1 5 ~ - 1— *. "£- >1 5 £- * —» 1 5 t *H » ^ A65 a

CT F s-i
"?T M [ 1 Dynami c

jijT fe l fe l j-*j T ^1 % rf * f a' fisl J-r f» %

fe n ©-
1 Tis ni st-'*lllt-f
2~8 2 7 15' 3" X174 6

0 35 0 35 0 35 0 35
GE/RT GE/W S BR/RT GE/G N

X10183 X1018 4 X1101

M54 engine
24 2 5 X69 5 31 X10318 N6 2 engine J _ N5 2 engine

TT " "
I " " 1 " " " - - - - j U400 b _» _, A149 a

ig § i TCU
[ J
-, acces s 22 1X60004 1 7 XS000 1
\ X37 6 (i n rear 1 Y 2" Y X37 7 (in rear
T31 isyste m
r "Jr * lot" 1 A6°°° r "!-* ' cr 5?"l1DM
A6 °°°
i_ J
M M DM E Ee E
^-> , contro ll L contro l
withou navigatio n MK ^ —i

B510ele19399b
DSC, sensors from 09 / 2005
DSC Dynamic stability control
(page 1 of 2)

^ A65 a
P/C\ Dynami c stabilit y

.1 E
^l - W co n ro! (DSC)

32' 9
L X1746

X 13796
0 35
GE/RT

i
X1 4049 XI 4049

o35
GN/GE WKT IGE/RT
4 X1653 3,
| X 14033 3 J X14047
U» B/5 B112a B114a
ft ____„ -, Brak e pad
Brake pressure

TH
DSC Brake pressure
d sensor sensor, front axl e sensor, rea r axl e I wea r sensor ,

T3li 2 1 X 14033 1' X1404

1' 2'Y 3^X165 3 1' ^ 1 X 1 81 45 (in fron t

wheelhousing
X14221 X I 4220 driver's side)
»> » • 0.35
BR/WS BR/WS ai5 035
BR/WS

0 35 0 5 0 5 X186 XI 86 X186
BR/SW W S BL/W S
DGR 2
035 05 035 05
X13786 GR BR GE BR/WS
12 10 23 29 10
14 X 26 JL
fl»-

L 3l 5 M
>3 1- *
^ I

B510e!e23882a

Electrical Wiring Diagrams ELE-26 9

 Eiectricai Wiring Diagrams ELE-27 0

DSC, sensors from 09 / 2005

DSC Dynamic stability contro l
(page 2 of 2)

Bi/a B1
,1 Brak e pa d &&\t lef t ,^!£h Fron t right Rear lef t ,4fir& Rea r right
&
*v5

?, .. . _,_ ,
•r X18146 (i n rear X114 ( n front 2 1 X113(i n front 1 ' X3/-6 (i n rea r 1 ' ' X37 7 (i n rear
wheeihousing wheeihousing wheeihousing wheeihousing wheeihousing
passenger side driver's side) passenger side) driver's aide) passenger side)
035
BRAA/S
0.35
GE/BR
05
RT
05
BL/RT °Gi 0.5
BL/GE
0.5
WS B'L/WS &§ BL/GN

X186

8 21 6 18 20 33 31 19 XI 746
- T V "15 — ' "- -^ -» ~5 - -; _ - p ~is ~' "15 ~ t* P » 1 A65 a

1 I
h,^ i U L^ L L
Tr>— i H —, i UI l fel k~> — iJr > —) L i-^... W
y Dynami
j stabilit y
c

-r-—d 28' - ~2 7 "" is " -- - 36 ' 3 ' X174 6

^

a 35 035 035 035 035

GE/RT GE/WS BR/RT BR/RT GE/GN

X10183 X10184 X1101

M54 engine
24 25 X695 3 1 X10318 N6 2 engine J N52 engine

f" " " " 1 U400b r ~J- » rj-s" 1 A149 a ' T "~ "" ~ " ' "^
1 |Q | j TC U I ! IM l Ca r f |
!1 l-^ _ acces s 22 1 X6000 4 1 7 I X6000 1
T3li s ystem r TVr ?= 5l'n A600 0 T IT " Bl A600 °

without navtgatio n bp- i contro lj T>_ ^ contro l

T31 imodul e I YS I 1modul e
L. J 1 - J

B510ele23882b
DSC, sensors
DSC Dynamnic Stabilit y Control Premiu m
(page 1 of 2)

A65a
uQtt Dynami c
. stabilit y
n contro l
U (DSC )
___f^ — j
21 T X1082 1

X13796

035 1 B17 3 B2
GN/GE
~1 Brake pad
4cx"

C
wear sensor .
front lef t rear riqht sensor
B75
DSC
2 X18145 in rear 2 1 X18146 ( n rear 1 2 X114 (i n front
— iI rTn ts
* \f?)\ r 1
3 wheelhousing wheeihousing
passenger side )
wheelhousing
jriver's side ) driver's s de)
I 31 i V
31 1

1Y ~ 2~T~ 3 ~T x1653
035 0.35 035 0.35
GE BR/WS BR/WS GE/BR RT BL/RT

X13725 X1372 4 X186 X186

BR/SW

0.5 0. 5 0.5
X13786 W S BL/W S BR/WS
M.

t r
23 3 82 0 7 33 27 43
1"
>— *•1 5 — g» i5
\a
]T
L [ ) r ,t

.. 1
1= ' tl r^ * T 31 i ^ J
M-' i<r
Msl P M
H -
22
8 1
I 0.3 5 0 35
1 GE/R T GE/WS

I X1018 3 X10184

24 I 25 J [ X69 5

1 1C U
I

—Y—

without navigatio n

B510ele25764a

Electrical Wiring Diagram s ELE-27 1

 Electrical Wiring Diagrams ELE-272

DSC, sensor s
DSC Dynamic stabilit y contro l premium
(page 2 of 2)

B1 B4 B3
/J-Sh Fron t righ t /Jgj\^ Rear left Rear right
$%*
£v-» whee l spee d wheel spee d 2^fS wheel spee d
sensor sensor sensor

' X113(i n ron t 1 '

__, ' X 3 7 6 (inrear
1 2 1 2 ' X377( in r"ear
wheeihousing wheeihousing wne?e!housing
passenger side ) drivers side) passenger
pas side)
0.5 0.5 0.5 0.5 0.5 0.5
GE BL/GE WS BL/WS GN BL/GN

26 11 13 29 28 44 X1746
A65a
Dynamic
stability
control
(DSC!

24 I X1746
0.35
GE/GN
0.35
BR/RT
M54 engin e X10186 (unde r dashboard passenger side )
N62 engin e N52 engine

22 I X6000 4
A6000
f DM E
control
|j modul e
31 1 j ]
B510ele25764b
Brake vent flaps Brake vent flap s
N52 engine or N54 engine N62 TU engine

A6009
A8681 Integrated
Fuse carrier , supply
"~87~ engine electronics module
*
(IVM)

0 75
RT/WS

05
RT/WS X10685
-] 10122 4
X10684 X10685 Brake ai r
101224 flap sensor .
-— j—- Brakftap sensor
e air
.
. Brake air
flap senso r 1 Y XI068 4 X10685
J right

1 ' X 10684 1 ' X106K

05 05
WS/SW BR/GE
05 0.5
WS/SW BR/GE
X10821
-i A65a
36 2 XI 082
i Dynami c
A65a
I stability
Dynamic stabilit y
1 control
control (DSC) 17 Y XI0821 (DSC)
f X1082 1

3N/RT
GN/RT

X10962 B142
B142 Pressure
Pressure accumulator
accumuiator —i vaiv e
valve
X10962

05
BR

X18132

B510ele25767 B510elc2:V(>a

Electrical Wiring Diagrams ELE-27 3

 Eiectricai Wiring Diagrams ELE-274

Active steering
up to 09 / 2005

r A72
i — T1 g § j Steering column X 13796
|
U ! switch c tjster "
i 31 1 J 0.35
GN/GE
2 1~Y X 10334
0.5 I 10 4 J X1372 1
BL/RT 1 GE
f-> B10 5
26 X13581 1 |
X1358 3
j DS C
P? "1A22 0
15/31 15/3 1 1 5 I© ! 1 , (Safet y ar d
-j-. -j- -£- 1W ) r > —, gatewa y
31 I3 1
U U O T3l i modul e
1' 2~1T 3~ Y X1372 1
Jh* f * b* i
8' 4 9 30 "3 4¥ 3 2 T X1358 1 0.35 ' 0.5 1 0. 5
BR/SW 1 WS 1 BLW S
11
X10547 J X1054 9 J X1054 8
X13786 [ X1372 5 J XI372 4
.

0.75 0.75 0.3 5 0.5 I 0. 5 0.5 I 0. 5

GE/BR GE RT/G N RT I BL/R T 1 WS I BL'W S

3 19 _ 8 1 _ 6 JL 5 J, X13718

—15
»« ~]A46
i 7
n I Active

! i
3
rt O iL . I rT ~ j steer n g

L5 31 V1PL T
¥ 3V 1 1iJ
3 21 X13719 23 ' 27" " ~ 24~ l 26lT ~2 5 21 2 21 1 X1371 8

X 14040 4.0 4. 0 4.0 0.35 0.3 5 0.3 5 0.3 S 0.35 03 5 0.3 5 0.3 5
SW B L BR BL/WS WS/G N BL'R T WS/R T BL/GE SW/W S SW/R T VI/G N

LHJ—
Y 14040a
W9110.3 ; ; W9110. 3 ; ; W9110. 3 :.: W9110. 3
ECO valve
1' 2" 3 ' 4 j" X1403 7 5 ' 1 3 2 4 11 1 21 0 X1403 6 (i n fron t
I \ 5' '' \ R \ ' W9110. 3 : f: W9110. 3 noe n oc wheeihousin g
SW/WS SW/R T passenge r side)
2.5 2. 5 0.35 03 5 0.3 5 0.3 5
SW B L BL/WS WS/G N BL'R T WS/R T BL/GE 1 i2 1X1403 5 WG N
\ 4 5 1 6 I Y 14035
W9110.3 : : W9110. 3 : Lp ]! Electri c
lock
1 23 4j X 13720 1 ___-

I r - - _ L 1 M179
I Steering
I |jG)j gear
I
!
11
^J^[^^= \ f X1377 3
\ 0.3 5
\ BR/S W
(in front 7 1 X 14036
wheelhousinq T
passenger side) (t o 03 / 2005) 'J^(0 3 / 2005 to 09 / 2005)

x 18753

19772,22754 B510ele19772
Center consol e switch center, power suppl y
as of 03 / 2007

1 A4 6

~3c 75 - j F7 1 J-g c~ F7 4 Fus e holder,

f J rea r
11 t
i 30A j j | 10A MS

5 ' X11010 26 ' X11012

X908

2.5 0.35 0 3 5 0.3 5 0.35

RT/WS RT/VI RT/VI RTA/ I GR/RT

1 X17257 1 X1725 9 4 | X 13938

3839 S84 0 1
O| Centr e console [Oi | Centr e console j
switch cluster, switc h cluster,
2 1 )f 3^X1725 * II I
7 dHVB I 3 r ' W5<i725 9 fr °nt PaSSen9e'
I I
2 r5 '3
0.35 0,3 50 35 0.3 5
BR.'SW WS/G E WS/G E BR/S W

X 15006 X 15005 X4066 X1081 2 X1081 2 X406 6

0.5 0. 5 0.35 0.35 0.3 5 0.3 5

GE S W WS/GE BR/GE SW/G E Bb'G E

11JL 1 °
.

12 19 82 77
r— ~

m
1
1
1
1
X16919
' 0.75
BR/SW
12 9 X 16920
"] A86 2
1
m i Centr e console
{ switc h c us er ,
1 X 16920

X4066
2.5
8R

X13784

Electrical Wiring Diac

 Electrical Wiring Diagra

Closed circuit current infringement shutdow n

KGM body gateway modul e

—i A41a

Fuse holder,
1" 3 01 F1 8 front
I [? j I
I 30 A I
L j J
] j

2.5
RT/SW

X16759

Body-gateway
module

2.5
RT/GE

i
_j f _I
1" i F3 4 r 1 " i F3 s r 1 i F36 j " 1 "j F3 7
i F3s r ~ "I F3 9
ir "• " ~j ~" j F40 r
I
i
| 20 A j j 1 5A j I |
7.5 A
1{
j 15 A1
i1
il
j 10 A1 1l J D-i i
i 1 - ii
1
1
rl>,

j
j
IJ -; 1 1 L
Micro-power modul e Controller
vehicles withou t KG M body gateway modul e

A46
i F6 4 (up to 09/2005} I
F79 (as Of 09/2005) I Fuse holder'
'. , I rear
30G j |

i 10A I

X11012 (up to 09/20055

X11012 (a s of 09/2005)
[" " • A4 6 0.35
' r --3D— -!F57 r ;30--F52 - 15 —1F60 Beholder , 3R/RT
l i* i I ff i it . ea r
S14099
I i uIj ;l 20
,[ i
A • '-i •1 10 A ' ! : 7.5 A 1
-t
Push-button,
X150U center consol e
- -y X11013 9 control center
' 2' X11012
3 1 X1409 9
4.0 0.75 0.75 0.5
RT/GN RT/BL/GE GN/SW GE s'w
035
8_ 7 14 3, X16021
A16021
30
Micro-power A
5_y"w 4A
C1 3—'
module
T311 •31i

4.0
RT/GE

19515-23423
F36 ,__| —F3 8 ,._- j —
A41a
r _jj —F3 4 _ J — ,F35 |---j F40
Fuse holder ,

fi > iT i ii tI
I \j 10 A i | P 10 A
111 30 A : I E5 A 1 [i ; 7.5 A l
0.5
X13790 BR
X943

B510eJe19776

Electrical Wiring Diagrams ELE-28 5

 Eiectricai Wiring Diagrams ELE-28 6

Body gateway module power supply

it
A41a

0 1 0 1
F18 f - ; F10 r - 0 " I F1 2 r - 0 ] F29
from
D l I f I> i f1 1 I f |1
30A | [ | I 30 A J I I j 30 A j | 1

;
1 1° A |
X15008 X1500 7 X1054 7

1
»- > > •

XI 1004 1 3 X11003 4 X11005

X10546 X1054 5

11
2.5 25 2.5 0.75 0.5 0. 5 0.3 5 1 0. 5 1 0. 5
RT/SW RT/V] RT/GE RT/WS GE S W RT/G N | RT r BL/R T

2 33 X 16759 3 3 38 89 2 7 30J ^ 29j^X1676 0

- ~ , -». 1 —> 1» .
"" A 16760

I¥H
I

Sa
(

ri
Body-gateway

»L. _
ri iO ^ rtiodul e
Tail Si '
T3ll Tail

34 X 16759 3 4 3 7X 16760

4.0 4. 0 0.7 5
BR B R BR/S W

X 13782 X 13788 X 13786

B510ele23427
Instrument cluste r Warning and indicator light s
power supply

r F1 3 (up to 09/2005) 1 A41a

! F4 1 (as of 09/2005) ! Fus e holder<
ij fron t

X15004

4 Y X1100 3 (up to 09/2005)

S63b S136 S31
8 X11006(a s of 09/2005) Coolant ievelswitc h Wash wate r Parking brak e
1) Insufficien t level switc h switch
2} Sufficien t 1) Insufficient
0.5 [ 2 ) Sufficien t
GE
2' r X112 '" " "T X 10046 1 X423

r 0.35
BR/WS
0.35
BR
X 13783
0.35
BR/GN
0.35
BR
X 13783
0.75
BL/BR/GE

11 12 13 X16
~* -» 1 A2 a
' X1 6 "
| Instrum e
i• m

B510ele19453 B510ele19455

Electrical Wiring Diagrams ELE-28 7

 Electrical Wiring Diagrams ELE-28 8

Audio system controller CIC Car information computer

power supply power supply

"" A 3 |" 1 101555

"1 A41 a f • • A 3 [ l A41a
! 17^1 I Fuse holder. Q Ligh t module j j Component(s )
F34 , f ^«"°raer, 58 G [t^ j Ligmmoaur ej 3 Q
I 3 0 hj I front S i— i t according to

! it i !
1 20
1T 1
A1 1 j
T
f =
1f? rs
„ |
i n U
|01555 i
O Component(s )[ __
i D TJ
20A
i
1 ;
1 vehicl e
equipment level 1

ij 1 | i 4—" -1 l —1 accordin g to
j4 3 T X1 2 , t _ j vehic e equipmen t 43 T X1 2
i 1
1 10155 5
1 txnooe X90 8 1 ' X1100 6
. r7
= r i i
^ j(O ) Component(s )
T1 101555 j ^^ ] according to
X15004 X 15003
X 15004 X I 5003^ j Q j Component(s) ». c. , i ventcle
' equipmen t level
J* & P j j according to ^
i. 1 vehicte equipment
0.5 0. 5 03 51 0 ^ i 2.5 0.5 0.5 0.35 1.0 1.0
GE SV V GR/R TG N1 1. 0 e RT/BR GE sw GR/RT GN GN
GN
11 1 4 X1381 2 1 2 1 X1381 5 1 5 9 11 14 X13612 1 2 X13815
I i~ ~* ' f —— ^ '' 1 t~ ~ ~ _^
£-> 4 — »• N38 a1 f- * | N38 b

„!
0 CCC/M-AS KI *~4j I Ca r information
j
bn-i
Qy
l1^ 3,
t ^>
1 |©
l * Lbkl
| 1
Jf
) CHAMP V
fLJ t
_ [(Ojj 1 Compute r CI C

1 31 i LI i YI I i J 1
31 i_ , L 31 i 1

12 X13812 1 2 X13812

31
2.5 25
BR BR

X 13793 X13793

510ele19501 B510ele27141
CIC Car information compute r

101012

r — iM fl P 1 ^ ear win- ow
U L J U aeria l
1
j \ \/ \ \/ I "
13393 I~ |

antenna N8 a j
J Centra l information
_ ._ jf^Jv) ! Antenn a tune r | j displa y
l™*^-1 w t h remot e j

t X14065 X1676
, ~
7 I
J
X1382 4 J
v- 4
3 2 1 X17428
I IW9110. 4 ; ; W91104; ; W9110.4 ,' ; W9H0.4 ; ; W91 10.4

;W9110.1 .'W9iio.i : ~ ; w 9 i i o . i : 'wgno i : ;wgno. i

0 14 014 0.14 0.14
ANT_GPS ANT .DAB j ANT..DAB 3 ANT.DI V :.;W911C 4 BR GN OR BL

r.j.
X13392 X16766 1 X I 3387 X1742 4 1 1 2 4 X17427

ii
__£! £* Q « ^ f

~j N38b

ii j Ca r information
j compute r C! C

3 49 1 0 X1381 3 1 3Y1 2 34 5 6 8 X13812 | 4 3 2 1 X1742 5

0.35 0.35 0.3 5 03 5 0.3 5 1 0.3 5 ; ; W 9 1 1 0 4 ; ; w 9 n o ; ;w9ncu ; ; wgno.4 ; ;vvgiio. 4

BL/GE GN OR/G NR T BL'R T 1 WS/V i
1 07 5 0.7 5 0.7 5 0.7 5 0.75 0.75
BR/OR BR/OR BR/OR BRWR r'WSHO.
BH/UH •. • B 4 O- 1 4 0.1
R G
4 0.1
N Q R g 4 0.1 L
4
2 12 13 3 1 1 X1952 71 X1388 7 BL;S W BL/R T GE/R T GE/S W

i i i 11 2 3 4 X1743 4
OBDii socket 8 9 3 83 71 6 17 30 29 X10266 ' ' ' ' '

"j N40 a
1
' Hif i amplifier

1 i

B510ele27152

Electrical Wiring Diagrams ELE-28 9

 Electrical Wiring Diagrams ELE-29 Q

Light module
Sedan with Xenon lights up to 03 / 2005
(page 1 of 3 )

1 ~"| A41 a
' Fus e carrer ,

I 30 | F * r 3 0 1 F6 j '"-" "
u, i 1f
Ij ' I
j 50 AJ
ii f — ~ _ —. -1
J SO A | X1500 2 X1500 1I
L -
1 ' ^- j 493 vA/ — - -— —T' I — __.(. — — _ __.»,- _ _ _ _ _ ! , ___!, „ _ ( l r _ __ „ _„ _ __ v i r ___

i, , , , ' Ca r access , - , ^ 9 7 3 10 51 11 2
v
1 X11001 1 'X11002 I M I 578'6"1 | ,_ I Steering column
II (C^ ) switc h cente r
i, p 1 lb± d 1
14 X10318 ' J X80 6
4.0 4.0 0.5 0. 5? / • _ fe. 0.35 0.35 0.35 0.35 0.35 0.3 5 0.3 5 0.3 5
RT/GN RT/GE 0.5 Q ES W6 T X188 0 I WS WS/BR GE/VI GE SW G N BR/S W GE/G N
GN/SW 0.3 50 75

9 47 31 32 1 4 28 JLWS/GE 4 3 IGH/R T 6 0 33 34 35 36 69 I 7 0 I 7 3

m
I
I
I
I
|

56 57 38 59 21 76 Y ~ 68^1 ^ 25 ~T" 53 ^T~ 12 ^T 4 8 | 2

24 40 15 5 0
0.5 0,5 0.5 0. 5 0.7 5 0. 5 2. 5 1. 5I 0.5 0.5 0.75 0.5 2. 5 1. 5
0.5 0.5 GE/RT GE/BR BL/RT BL/B R BL'G N GR/G N GE/G N WS/G N I BL GE/SW BL/BR GR/BL GE/B L WS/B L
BR/RT BR/SW
| X1363 7 X 13502 X 13502

X18726
^ V_ i ^

J
X1378/7
^. USA ^ -y ,
j.
1 2 3 X13420 8 j 6 4 23 X1342 1
_ _ . _ ^ , — _j j ^

Headlight,
left

without adaptiv e
headlight
B510elel9966a
Light modul e
Sedan wit h Xenon lights up to 03 / 2005
(page 2 of 3)

SMG transmissio n without adaptiv e

manual transmis s on headlight

-A. . ^
1
r

— ion r ~~ ! S851 1 I" 1 A6009 B42 B6 9

1 L°ht switch ] ' Back-u p I | Integrate d supply Front right Rea r righ t
1 " , ligh t switch modul e (IVM) level sensor leve l sense
1
1r -- , I I I '
,- X1 ,,,q i Brak e light , V X851 1 5 Y X60o g 1 4 5^ X18032 1 Y4 ^1^ 5 T X145 1
8 X13339 switc n1 1

[_ 2 Y X60 1 1 (in E-box) I

4 | X7 8
-C 4,

0.35 | X181 M54 T N62 0.5 0.5 0.5 0. 5 0. 5 0. 5

GR/SW » & 1 n,. GR/WS GR/GN GR/BR SW/W S SW/G N SW/B R
I 0.3 5 I GR/V I
74 51 J^BL/R T 1 3J^2 7 54 66 75 54 6

i1
37 58 44 ^6 ^ ^ 22~ ^ 39 4 64 4 22 34 1
f2 °1
0.5 0.5 0.5 0.5 OS
GE/SW GE/BR BLSW BL/BR
SW/VI
1.5 1.5 0.5 0.75 0.7 5 0.7 5 0.7 5 0.7 5
GE.'RT GE/BR Bb'GE f BL/BR/GE SW/R T GR/G N GE/S W WS/G E
r ~" . H8a
I Direct on indicator
I . light repeater ,
front right
{

1 2 3 * J X1035 1 X768 1 X769 2 X389 t ~ 15

:
6 A 4 A 2 A. 3 A X31 9
E27 E16
II t/i;
II Right fog II Direction indicator
right II II II left (Saloon)
II light
II light repeater ,
II
U. 1
II front lef t

without adaptive
headlight

B510ele19966b

Electrical Wiring Diagrams ELE-29 1

 Eiectrica! Wiring Diagrams ELE-29 2

Light module
Sedan with Xenon lights up to 03 / 2005
(page 3 of 3)

"1 S1 8
1 Hazard
1 warning/centra!
1 locking switch
1
j J r I Aj g
4 5
X516 ! . . | Electrochromi c
NVx) interio r rear-view
:' mirro r

1 T X1824 6
0.35 0.35 0.3 5
BL'BR BR/BL BL'WS/G E

45 52 65 I X1 2
V_^__.^ __ _ . „ „ __ _-£j' »

A3

Light module

3 29 49 10 30 6 72 6X I2
0.5 0.5
0.75 0.75 0.7 5 0.7 5 0.7 5
GR/BR SW/GE
BL'BR SW/BR WS/B R GE/R T GE/W S
X11218 0.5
GR/SW 5
6 4I 2 3 X31 8
2 X709 ^

'1 E43 a .r In E1 7
. Licens e plat e Tail light.
light, left right (Saloon )

12 X710 ' _ j

i ^ ^
License plat e
light, lef t

11
iJ

BS10ele19966c
Light module
Sedan without Xenon lights up to 03 / 2005
(page 1 of 3)

1 ~] A41 a
1 Fuse carrier,

Ir 3 5 I F 6 'ran t

i1i 'i' L
0" JF S i 3
}1 1 "l I
50A 1 1
J j 50A I
ii * J1 1 L

J" ~ ! A149 a
j J I ' ^
1
- , =rp r ^1 ^ ar aCCGSS

X11001 1 X11002 l^jM j S y-stem X 15002 X 15001

i i
14 Y X1031 B
4.0 40 0 5 0. 5 0. 5
RT/GN RT/GE GN/S WG ES W

9 47 31 3 21 4

I
1
1
1

56 '
0.5
57
0.5
3iT
r 59 i 21 76 68
r ~ 25~i 62 53 12 ' 2

BR/RT BR/SW
0.5 0.5 0.5 0.5 0.75 05 0.5 2.5 1.5 0.5 0.75
X18726 GE/RT GE/BR BL/RT BL'BR BL/GN GR/GN WS/RT GE/GN WS/GN GE/SW BL/BR
9- X 13787
X 13502 X13502

j. L
J

USA
1
1 3 4 X1034 6 4 5 2 3 X 13420 8 86
I2 ^ Sr
E7
Headlight.

B510ele19896a

Electrical Wiring Diagrams ELE-29 3

 Electrical Wiring Diagram s ELE-29 4

Light module
Sedan without Xenon lights u p to 03 / 2005
(page 2 of 3)

,y y
1 Light switch
, uni t
1
1 1
. , |

,^ v^ ^^ — J^ '
~j A7 2 6
1
1 r-^-i i Steerin g column
1 j^g^j | switc h cente r
1 1
1 j
6 X1880
X806

0.35 I 0.7 5 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0,35 0.35
WS/GE 1 GR/R T RT WS/'BR GE/VI GE SW GN BR/SW GE/'GN GR/SW

28 33 34 35 36 69 70 73 74
43Jl 1 9 S

40 5 37 ~~
15 50 58 20 75 44 |6 |~ 22 ^ 39
1.5
1 GE/R T 1 GE/B R
0.5 0.5 2.5 1.5 0.5 0.5 0.5 0.5 0.5
GR/BL ws/sw GE/B WS/BL GE/SW GE/BR BLSW BL5/BR ' I X76 8 1 \769 BL/GE SW/VI
"! E2 6 - ; E2 7
1 Lef t fo g j j Righ t fo g
i iigh t [ | igh t
1 I I1
2 X390
"I H8 a
1
I • Directio n indicato r
1 1 iigh t repeater .
4 5 2 3 X13421 1 2 3 4 X1035 1 1 fron t right

I Headiight . "j H9 a
I righ t I Directio n indicator
I ligh t repeater .
| fron t left

B5loelel9896b
Light modul e
Sedan without Xenon lights up to 03 / 2005
(page 3 of 3)

manual transm ssion

SMG transmissio n
(

(" " i S8511 ~j A600 9

11
| | Back-up j i Integrate d supply
I1 light switch j I modul e (IVM )
11 I I
L. . __ , J[ • ] S1 8
S29 2"|X851 1 5 ' X600 9 | | Hazar d
11 1j warning/centr a
Brake light J , jI lockin g switch
11 E-box)
11 switch 2 1X6°1 1 (in i_ _ ^ j
11 4 5 X516 I 1
1 CrS l1 Eiectrochromi c
4 |X7 8 V
j 1 Ssiy lj interio r rear-view
| | mirro r
| X18 1
M54 N62
I
1X 18246
1 0.35 0.35 0.35 0.35 0.3 5
1 BL'R T GR/VI BL/BR BR/BL BL/WS/G E

13 45 52 65 X1 2
«1
\3
' Ligh t modul e

4 r 64 T 42 T 23 1 41 3

0.5
29

0.5
49

0.5
61

0.75
10

0.75
30 ^ 67
0.75
^ ^ 26" * X12

0.75
0.75 | 0.7 5 1 0.7 5 0.75 0.75 0.75
BL/BR/GE 1 SW/R T 1 GR/G N GE/SW WS/GE GR/BR SW/GE GR/SW BL/BR SW/BR WS'BR GE/RT GE/WS
C
el4 1 2 3 X319 5 6 4 2 3 X318

"| E1 6
| Tai l light, X11218 I 1] TaiE1 7l light,
I lef t (Saloon) *" ^ I I righ t (Saloon)
I2 J X709 2 [ X71 0 | I
j" " I E43 a | "" j E44 a
, , Licens e plate . • Licens e plat e
I| light , lef t | | light , right
I I I I

B510ele19896c

Electrical Wiring Diagram s ELE-29 5

 Electrical Wiring Diagrams ELE-29 6

Light module
Wagon with Xenon lights up to 03 / 2005
(page 1 of 2)

~] A41a , " - ' - ' - , S8

Fuse carrier, 1| Light
r!o~ ~" n F5 I 3 0 1 F6 fron t
1 | switch
11 unit
i [f i
r 11" "r" 1 2
1f |1

L _ __ ,L
! j 50 A 1 [
j r-^%
•~
1
] A7 2
I Steering colum n
4Y~9 Y" 7 IT 3^ r1
1 0 1f~ 5 ~^| Y" 8~YX1333 9

I A149 a i'^Iy l | switch center

, J I lOi l I Caraccess X1500 2 X15H0 1 I
1 ' X1100 1 1 ?X11002 I IM I | system — —fr.
^6 Y X188 0 X806
i , _ i *"™™^^
14 X1031 8

4.0 4.0 0. 5 0. 5 0.5 0.3 5 0.75 0.3 5 0.3 5 0.35 0.35 0.35 0.35 0.35 0.35 0.3 5
RT/GN RT/GE GN/S WG E SW WS/G E GR/RT W S WS/B R GE/V I GE SW GN BR/SW GE/GN GR/S W

9 47 31 3 21 4 28 43 36 69 70 73 74
60JL 33 JL 34 Jl 3 5

m
56 57 38 1 59~Y ^ 2 1 Y~ 76 ~Y~ 6 e Y" 25 ~y~ 53 ~Y~ 1 2% 48~Y~ ~ 2 ' 24 Y ^ 40^Y " 15 ~1^ 50 ~^ 37 "" 58 ^ 20~"
0.5 0. 5 0. 5 0. 5 0.7 5 0. 5 2. 5 1.5 0. 5 0.5 0.75 0. 5 2. 5 1.5 0.5 0.5 0.5 0. 5
GE/RT GE/B R BL/R T BL'B R BL/G N GR/G N GE/G N WS/GN B L GE SW BL/B R GR/B L GE/B L WS/BL GE/SW GE/BR BLSW BL/B R
0.5 0-5
BR/RT BR/SW
X 13637 X 13502 X 13502

X18726
L
X13787 L I
USA T
,- 1 2 3 4 X103 4 6 4 2 3
. . 1X1342 0 8
( J^ 6j ^ 4J ^ 2j ^ 3
X13421 1 2 3 4_JSX1035

1
I Headlight, | | Headlight,
I left | | right
i
1
1 1
!_ |

^ ;
\ ^/
Y
without adap t ve
witfiout
adaptive headlight
headlight

B510eieZ1240a
Light module
Wagon with Xenon lights up to 03 / 2005
(page 2 of 2)

without adaptive
SMG transmissio n headligh t
manual trans m ssion ^
\9

•j Rea r right
!' j S85 1 1 ! j A600 9 I j level sensor
|- Back-u p i j integrate d supply I (
Ij light switch j j module (IVM) u ^^r-_-t_rr-~,Tr.,-ri— — — - — ' | if/ 8
4 5 X1451
I. ,, _ I L . ,-.. , 1 j [warning/centra l
1 liockin swi ch
, coo 2 j X851 1 5 Y X600 9
)
. bi9 1
1
|
Brake i ght I B4 2 4 5 X51 6 r ,
ii switc h v L, Fron t right
]1 2 1X601 1 (m E-box) leve l sensor , r~^~ i j ESectrochromi c
1 |^iy | ( interio r rear-view
| I mirror
i- _, 1
X181 M5 4 ' Y N6 21 T 4" T 5^X1803 2 1 I X1824 6
0.35 0. 5 0. 5 0. 5 0.5 0.5 0.5 0.35 0.3 5 0.3 5
0 35 GR/V I GR/W S GR/G N GR/B R SW/WS SW/GN SW/BR BUBR BR'B L BL/WS/G E
BL/RT
51 13 2 71 5 41 6 61 7 55 46 45 52 I 6 5
v_

1 Light
i module
1

44 ~| ~6 "~ 2 23 9 4^ j 64 | 42 |2 34 13 2 9 49 61 10 30 67 r26 nr xi 2
15 15 0 5 0 5 I 0 - 75 I 0-75 I °- 75 0.75 1 0.7 5
IGE/RT G'E/BR BL/G E sw/v i BL/BR/G E SW/R T GR/G N 1 GE/R T 1 GEW S
1 1X76 8 2l 4 13 1 X31 9 0.7 5 0.7 5 0. 5 0.5 0.5 0.75 0.75 0.75 1 1 3 1 X32 8
r^-—^-^---r^^--r-^r=^L.^ GE/S W WS/G E GR/B R SW/GE GR/SW BUBR SW/BR WS/BR r -_iti-^^T^^? .
1 ' " ] E2 6 T1 E46
Left ]j Rea r 1j Tai l light.
i1 tOQ i i light. j| inne r righ t
1 l light L, Jnnlo r 3 1 X32 9
11
1 , X769 2 X11218
X39 0 Tai l to- 3 1 2 X318
!" '~!E27 r^-lHS a i i '««• r ^-•—^--^ rj!l;-_j:-_i =A_, E47

1 ,6 a ' Directio n indicator I 1 I

I inner j Rea r light,
I
I °9ht I | light repeater , lef t2 X70 g j oute r right
I
I i" a'" i i front right _£ > | 1

2 X38 9 i | Licens e plate

r.-i>_-,Hga 1 | light , lef t 2 f I X710

• Dire c ion indicator [ ^j j ( E44a

| | ligh t repeater, 1 | License plate
i j front left 1 | light, right
11

B510ele21240b

Electrical Wiring Diagrams ELE-29 7

 Electrical Wiring Diagrams ELE-29 8

Light module
Wagon without Xenon lights up to 03 / 2005
(page 1 of 3)

n
1
A41a
Fuse carrier,
front
0 ] F 8

L±J
11
1 F5 r
i 1f

j SO A j j

1 X11001 1 ' X1100 2

I" j A149 a X1500 2 X1500 1

! rp^r i1 Ca r acces • ^ • [£ s
! IM J| syste m
11
40 4.0 14 |XHB1 8 O. | 0 ^
RT/GN RT/GE
I GN/S W
9 47
31 JL 3 21 4

-— — — — - - — , _ __
57 38 59 21 76 68 25 62 53 12 2

0.5 0.5
BR/RT BR/SW
0.5 0.5 0.5 0.5 0.75 0.5 0.5 2.5 1.5 0.5
GE/RT GE/BR BL/RT BL'BR BL/GN GR/GN WS/RT GE/GN WS/GN GE/SW

X 13787 X13502 X13502

.1
J
v
LI
j
1 2 3 4 X1034 6 4 5 2 3 X13420 8 J

IE 7 I
j Headligh t j
I lef t |
:I

B5lOele21239a
Light module
Wagon without Xenon lights up to 03 / 2005
(page 2 of 3)

i1 Ligh t switch
1| uni t
!1
, , A? 2
6 9 7 3 10 5 11 12 8 X 13339
sring columri
iI [igy
IS ]j |i st e
sw i ch center
11
6 ' ' X188 0 X806

0.35 0.75 0.35 0.35 0.35 035 0.35 035 0.35 0.35 0.35
WS/GE GR/RT RT WS/BR GE/VI GE SW GN BR/SW GE/GN GR/SW

28 43 19 34 35 36 69 70 73 74 ,
,

24 "" 40 ^ 5 15 50 37 58 20 75 44 6 22 39

0.75 0.5 0.5 25 1.5 0.5 0.5 0.5 0.5 1.5 1.5 0.5 0.5
BL/BR GR/BL WS/SW GE/BL WS/BL GE/SW GE/BR BLSW BL/BR GE/RT GE/BR BL/GE SWA/I

1 X768
r' ' ~™ J [= 2 6
'] Lef t fog
I I lig M
I I

6 4 5 2 3 X13421 1 2 3 4 X1035 1 X769 X390

•- ^ - - - - - iE 8 r - i E2 7 "j H8 a
I
j Headlight . | Righ t fog I Directio n indicator
| r ght j j ligh t I j ligh t repeater ,
11 1 I I fron t right

2 X389
|" " j H9 a
j | Directio n indicato r
1| ligh t repeater ,
| | fron t left
B510ele21239b

Electrical Wiring Diagrams ELE-29 9

 Electrical Wirin g Diagram s ELE-30 0

Light modul e
Wagon without Xenon lights u p to 03 / 200 5
(page 3 of 3)

SMG transmissio n
manual transmissio n

"j S18 "j S8511 A6009 ! A2 2

I Hazar d I Back-u p ,| Integrate d suppl y i Electrochromi c
I warning/centra l I ligh t switch jj modul e (IVM) | interio r rear-view
| lockin g switch tI I mirro r

5 4 X516 2 J X851 1 5 ' X6009 1 X18246

•j S2 9
I 1 Brak e ligh t
I 2 T X60 1 1 (i n E-box )
I j switc h
I 1
1,
X78
M54 l\532
X18^ (unde r dashboar d ^
^ passenge r side )
0.35 0.35 035 0.35
BL/RT BR/BL BL/BR GR/VI BL/WS/GE

51 ^ 52 45 13 65 X12
A3
Light modul e

4 64 42 23 41 3 29 49 61 10 30 67 26 X12

0.75 0.75 0.75 0.75 0.75 0.5 0.5 0.5 0.75 0.75 0.75 0.75 0.75
BL'BR/GE SW/RT GR.'GN GE/SW WS/GE GR/BR SW/GE GR/SW BL/BR SW/BR WS/BR GE/RT GE/WS
X11218 3 1 2 X318
2 4 3 X3iy _ Ji\^-^_-^_— ^_^{t~™r_^r_^r™ ^fu

r i
• VM^^^^B^^

Sr (in dash, driver' s !1

1 |
E4e
Rea r light.
2 y^gg side , nea r A~pil!ar ) 1 |
1j
Rea r light.
oute r righ t
ji oute r lef t fj E43 a 11
Ij ligh t lef t
Ii o X710 1 X328
if 3

r i
1j
E44a r
Licens e plat e .
j ] E8 1
, Tai l light.
X329 | | light , right | I inne r righ t
~j E8 0
I Tai l fight ,
j inne r tett

B510ele21239c
Light modul e
Sedan with Xenon lights as of 03 / 2005 u p to 03 / 200 7
(page 1 of 3)

I1 1
r A41 a Steerin g column
! Fus e carrier, j l^rty] switc h cente r
I , , =
, , fron t 1^ 4
| | 3 0 | K | 3 0 I ™ 1 1 1 _
1 i . 1 i ,
r^- — ~
11 [t l1 I f X1880 4 7
!1 1 1 50 A I 1 }\ 50A 1 i
11 L H1 1 L 1 |
, i i 1 I {in dash, driver's
1 side, near A-pii!ar)
A149a
I X806
)1 ,, , . Ca r access
7' ( O ' svste m
1 X1 1001 1 X1 1002 I iSZ i! y
11 Ji n dash, driver's
i, 1 side , near A-pil!ar)
14 Y X1031 8 X15UU 2 X1500 1
4.0 40 0 5« fc >« t- 0.35 0.75 035 0.35 035
RT/GN RT/GE GN/S W1 .5 1
0 0. 5 WS/GE GR/RT WS WS/BR GE/VI
1G E1 SW
9 47
31 3 2 J^ 14 _JL 2 8
43 60 33 34

_ _ _ _ „. __ . „_ _ Q^.... _ _ _ , 1_ _ _ — . -.
57 76 I 3 8 j 5 9 21 68^ 25 53 12 48
with adaptive headlight j I v/ithou t adaptive headligh t 0.5 0.5 0.75 0.5 2.5 1.5 0.5
0.5
GE/BR BL/RT BU'GN GR/GN GE/GN WS/GN BL
BR/RT BR/SW 4 ,- 1
>
f
X 18726 *• p- r X 13637
' t*f
'in dash, driver' s 1 (in dash, driver' s
side, nea r A-pillar ' I side , near A-ptllar)
0.5 0.5 0.5 0.5
SW/BL SW/GN BL/BR GE/RT
L
X 1 3787 3 2 X 10608 4 1 2 3 X1034 6 4 2 3 51

without adaptiv e headligh t

B5tOe!e22733a

Electrical Wiring Diagrams ELE-30 1

 Electrical Wiring Diagrams ELE-30 2

Light modul e
Sedan wit h Xenon light s as of 03 / 2005 u p to 03 / 200 7
(page 2 of 3)

SMG transmissio n
S3 manual transmissio n
Light switch

-I | | *°= '
•j _ _ : Back-u p
10 5 11 12 8 X13339 ; ] S2 9 I l,gh t switch ; rnodui e (IVM)
Brake light I I '
: switc hI I I I
t |
I ! 1 , _ _

2 T X851 1
J
~z>
5 I X600 9

4 | X78 A
2 IX60 1 1 (in E-box )
j x-|g- | (unde r dashboard \^ •-L
'* a ^ passenge r side) ^ j
0.35 0.35 0.35 0.35 0.35 0.35 0.3 5 M5 4 0.35 N6 2
GE SW GN BR/SW GE/GN GR/SW BL/R T GR/VI

35 36 69 70 73 74 51 1 3

1 24 40 15 50 58 20
0.5 0.75 0.5 2.5 1.5 0.5
GE/SW BL/BR GR/BL GE/BL WS/BL GE/BR with adaptive headlight
1.5
f GE/RT
v-tn^no (i n dash, driver's v-iocn
XU5U2 sid e nearA-piiiar ) *13bU
o
2
„
r l r1 -

14 ,
j 0.5 0.5 0.5 0.5
BL/BR GE/SW WS/BL WS/GN
T US A >
8j^ X1342 0 8 1 6 4 2 3 X13421 2 3 4 1 X1035 3 2 X 10609
E7 E8
Headlight, Headlight.
left right X768
E26
Left fog
light
I i
without adaptiv e headligh t
I I
j_ M _ __ ]

B510ele22733b
Light module
Sedan with Xenon lights as of 03 / 2005 up to 03 / 2007
(page 3 of 3)

B42
Front righ t with adaptiv e headligh t
level senso r

Rear right
4~*
j— —- --— - • — v ! leve l sensor side, near A-pillar )
1 5 X 18032
I! "" ! S1 8
"- | - - . > ' 1 H-nr H •^ * • ~— •"""""•"•
1 4 5 X1451 warning/centra l
locking switch

j A2 2
4 5 X516 I , Electrochromi c
I HV?) interio r rear-view
j
'' ! mirro r
I I
i, 1
1 X 13246 05 0.5
RT BLYRT
0.5 0.5 0.5 0.5 0.5 0.5 0.35 0.35 0.35
GR/WS GR/GN GR/BR SW/WS SW/GN SW/GR BL/BR BR/BL BL/WS/GE
27 54 66 7 55 46 45 52 65 72 71 X12
v_ s_ , ~ r
A3
Light module

r~ 22~ ^ """ 67 ^
39 4 | 6 4 42 23 41 3 29 49 61 ^ 10~ ^ 30 ^2 6 ^ X12
0.5 0.5 1 0.7 5 0.75 0.75 0.75 0.75
BUGS SWA/I 1 BL/BR/G E SW/RT GR/GN GE/SW WS/GE 0.75 0.75 0.75 0.75 0.75
BL/BR SW'BR WS/BR GE/RT GE/WS
1.5 A 2 3 X319 0.5 0.5 0.5
5J^
GE/BR I' ' GR/BR SW/GE GR/SW
"I £1 6
1 Tail light , 5 6 4 2 3 X318
X769 X11218
1 left (Saloon) *r - -^r >>
1 I
I E2 7 (in dash, driver's | | Tail light,
1 I
Right fog 1 1 side, near A-pillar) right (Saloon )
light
1 I I
2 X390
| i i
r~ i H8Direction
a indie s tor 2

P1
/s X710
E44 a
light repeater.
front right L cense plat e
11 j| light , righ t
11
2 X3S9 t_ __ i
2 X709
H9a
E43a
Direction indicato r
License pia e
light repeater ,
light, lef t
front lef t

B510ele22733c

Electrical Wiring Diagrams ELE-30 3

 Electrical Wiring Diagrams ELE-30 4

Light module
Sedan without Xenon lights as of 03 / 2005 u p to 03 / 200 7
(page 1 of 3)

(in dash, driver's

side, near A-pillar )
A41a X15002 X1500 1
Fuse carrier, ^p <
,f fron t
i i r-r - f
(G) switc h cente r '
[ 3 0 | F 5 | 3 0 | F 6 I
!f Ii ' m !50A I '
I I ^ A149 a
II > - — - ^r — ~J=-.

i [ J 50 L n dash, driver' s
A
I ! 6 X1880 * ! de, near A-pillar )
J' ro H Ca r access
I ^ s vstem X806

JL ' P>

1 X11001 1 X11002 1 4 * X10318 0.5 0.5 0.35 0.75 0.35

4.0 4.0 0.5 Gt SW WS/GE GR/RT RT
RTVGN RT/GE GN/SW
9 47 31 32 14 28 43 19 ^__
^^_^™ ^:r-_^-^r™ ™ i
I
I
I
I

r "2H
„ -
56 57 38 76 *" 68 ^ 25^ "~ 62 ^ r^ 53 ] r 12 ^ 1| T2 4
0.5 0.5 0.5 0.5 0.5 0.75 0.5 0.5 2.5 1.5 1 0. 5 0.75
BR/SW GE/RT GE/BR BL/RT BL/BR BL'GN GR/GN WS/RT GE/GN WS/GN 1 GE/S W BL/BR

0.5 1 X1350 2 side , near A-pillar) X1350 2

X 13787
BR/RT j
IX
L

s(in
dash, driver's ^J

J
X1872%de, near A-pillar )

*• USA T
1 2 3 4 X1034 6 4 5 2 3 X13420 8 I 6
S/ *

| | Headlight , j
left

I I I
L- J l _ .

B510ele22732a
Light module
Sedan with Xenon lights as of 03 / 200 7
(page 1 of 3)

P —, , (i n dash, drivers
|_ . side , near A-piilar)
Fuse carrier, Y 1 Rnn9 r - i A7 2

i ^ ' | , ! Steerin g colum n

I | 3 0) | 3 0j

ii r '
F 5 Ff e
(Q) j switc h center
iI r l
*1 1 f ' f ! I

50A 1 1 50 A1
! 1 J j | LL Jj r n A149 a .j
11 L (in dash, driver's s
side, near A-pillar ) ^ X1880 |
j 1
I1 n^r i i
11 !© i1
ua r access
X15001
|
syste m (in dash, driver's t
71 1 9 7
1 X11001 1 X11002 ' n ' X806
14 X10318 ». [ >
0.5 0.5 0.5 0.35 I 0,35 035 0.
GN/SW GE SW WS/GE 1 0.7 5 WS WS/BR G
40 4.0 1 GR/R T
RT/GN RT/GE
<3 47 31 32 14 28 43 I 6 0 33 34
,
l>- ^_-_^- -^r^^^-^^r-- = T

, j— - iLr- - ^- - - - ^ .— ^^ . ._
56 57 76 J 3 8 I5 9 21 68 25 53
with adaptive headlight j I withou t adaptive headlight 0.5 0.5 0.75 05 2.5
0.5 0.5 *- . ' GE/BR BL/'RT BL'GN GR/GN GE/GN WS/GN

1
BR/RT BR'SW ^ ^

(in dash, driver's 0.5 0. 5 0. 5 0. 5

side, nea r A-piliar ) X 18726
SW/BL 1 SW/G N 1 BL/B R 1 GE/R T
9 1 1 1 1 8 19 10 12 4 3
_y*v - A ^ ~^ ^/
X 13787 |

without adaptiv e headlight

Electrical Wiring Diagrar

 Electrical Wiring Diagram s

Light modul e
Sedan with Xenon lights as of 03 / 2007
(page 2 of 3)

SMG transmission
Brake light
switch A ,
f \
l' 1 S851 1 ' " I A600 9

"41 xisi ^ ;
'N ™i [ Back-u p ! J Integrate d supply
: ligh t switc h modul e (IVM )
; [ ; i 4 5 X18032
tch
(under dashboard 2 T X851 1 5 J X600 9
passenger side ) j

12 Y X601 1 (i n E-box ) j
X13339 'T-. '~\

~\
Y
035 0.5 0.5 0.5
BR/SW GE/GN GR/SW Bum notN K I N6 2 GR/WS GR/GN GR/BR
1 0.3 5
| GR/V I
51
13 L 27 54 66

- —o
24 11 15 50 58 20 75 T 3 7T
44 T 0,7 5
0.75 0.75 0.5 2.5 1.5 0.75 0 75 withou t adaptive headiight * 1 wit h adaptive headlight I GE/R T
BL/BR BL/BR GR/BL GE/BL WS/BL GE/BR BL/SW A
f . . . 1 I X76 8
0.75
~Y " v "t- GE/BR
I I
I 07 5 1 0.7 5 1 0.5 0.5 ; I Lef t fog
1 BL/B R 1 GE/S W 1 WS/B L /GN ligh t
12 ,4 3 6 9 10 11 I 8 1 1 01 9 9 | X13 5
si —_ . — Q— - — (7> — . A — l I
1
E8 ' J X769
I
Headlight,
right
R
lig

without adaptive headlight

Light modul e
Sedan wit h Xenon light s as of 03 / 2007
(page 3 of 3)
I
Rear righ t
level senso r

1 4 5 X1451 Hazar d
; warning/centra l
! lockin g switch w t h adaptive headligh t

4 5 X516 A2 2 (— -^
I. fciectrochromic
(Q) interio r rear-vie w X1055 8 X1055 7
mirror * g^.
^> *
,_ j , . , (in dash, driver's (in dash, driver's
,. Bb/ a side, nea r A-piiiar) side, near A-pi!lar )
1 X18246 . Rain/ligh t
(O) sola r senso r
[Vixl
II
0.5 0.5 0.5 0.5 0.5
2 Y X1315 1
sw/ws SW/GN SW/GR RT BL'RT
0.35 0.35 0.35 I 0.3 5
Bb'BR BR/BL BLAVS/GE I BL'G E
7 55 46 45
k 5Z .-.s
65J
l_ 1 6 X _7 2J 71 J I X1 2

22 39 4 64 42 62 23 41 3 29 4 9 61 1 03 05 6 72 6 X1 2
0.75 0.75 0.75 0.5 075 0.75 Q50.7 5 0.7 5 0.7 5 0. 5 0.7 5 0.7 5
0.5 0. 5
BUBB/GE SW/RT GR.'GN WS/RT GE/SW WS/GE GR/SW BL'B R SW/B R WS/B R WS/S W GE/R T GEAV S
GR/BR SW/G E
0.5 0.5
BL/GE SWA/I 3 4 6 7 2 1 X338 l [ 2J I 7 I 6J | 3 J 4 | X33 9
,_, 1 ?
~]E16
Tail light, X11218 ' Tai lI
1 left (Saloon) right
1 <
(in dash, driver's^
side, near A-piliar ) I I
2 X390 i _ — i
2 X710
I1 , £44 a
Direction indicator
light repeater , : Licens e plate
front right light, righ t
2 X389 ' ,
I I
"j H9 a 2 X709 i j
Direction indicatoi
1 ' ' E43 a
light repeater ,
! Licens e plat e
rant lef t
j light , lef t
11

B510ele26117c

Electrical Wiring Diagrams ELE-31 5

 Electrical Wiring Diagrams ELE-31 6

Light module
Sedan without Xenon lights as of 03 / 2007
(page 1 of 2)

(in dash, driver's

side, near A-pillar)
A41a X15002
Fuse carrier,
front I
I
^^
I ' ' f (in dash, driver s j I steerin g column 6 9 7 3^ 10 5
A149a s^near™ , g | j ^ ^
IJ 50 A j I [ j 50A |
Car access
system
i, _1 X80 6
X1880 • 6 ?
^ (in dash, driver's
1 X11001 1 X11002 side, near A-piliar)
0.5 05 0.35 0.75 0.35 0.35 0.35 0.35 0.35 0.35
4.0 4.0 0.5 GE SW WS/GE GR/HT RT WS/BR GEM GE SW GN
RT/GN RT/GE GN/SW
9 47 32 14 28 43 19 33 34 35 36 69
—— — —— — — S— — i

56 ' 57 38 59 21 r~76~l ^~ 6 8 25 53 12 2 1 Y ~ 24^T "1 I~Y~ 1 5T 5 0 Y~ 3 7 Y^ 5 8 ^f 2 0 Y~ ~ 7 5 Y^ 44

f
^

05 0.5 0.5 0.5 0.5 0.5 0.75 0.5 2.5 15 0.5 0.7 5 0.7 5 0. 5 2. 5 1. 5 0. 5 0. 5 0. 5 0. 5
BR/RT BR/SW GE/RT GE/BR BL/RT BL'BR BL/GN GR/GN GE/GN WS/GN BL'GN BL'B R BL'B R GR/B L GE/B L WS/B L GE/S W GE/B R BLS W BL'B R
0.75
X 8726
7 I 1 2 J l | s i e l 8 I9J I 1 0 | 1 1 I X13 5 GE/RT
If-

| | Headlight.
X13787 right
.L
I I

..
8 9 10 11 12 4 3 6 7 X130

i i E 7 1 X768
(in dash, driver's ! ! Headlight , _£
side, near A-pillar} ' ' lef t r ~~! E2 6
I] | i Left fog
LJ w

B5tOele26116a
Light module
Sedan without Xenon lights as of 03 / 2007
(page 2 of 2)

manual transmission
SMG transmission
,
l S1 8
1 Hazard
1 ^1 warning/central
1 locking switch
~! S 8 |

Light switch ; | b851 1 ; "1 A600 9 | r

unit : Back-u p: integrated supply . ^ "I A2 2

5 X516 ;
I' \ t switch module (IVM ) . Electrochromi c
I I
—1 i 1 QQ Q 1 I 1 1 my ! ' n*enor rear-view
I '' mirro r
/ i l b ^9 i -' •~ 1

11 12 8 X13339 ' Brak e light " ^ ^ I

jj switc h 2 T X851 1 5
X6009 i
1 X18246 I " ! B57 a
1 i i
,] i 1 2 T X60 1 1 (in E-box) Rain/light
: \(*TJ)\ 'ar senso r
I ' (unde r dashboard . I I
<—,—>
0.35 0.35 2 T X1315 1
GR/SW I~~~ ^n °'N62 I N62
BR/SW GE/GN 0.35 0.35 0.35 1 0.35
°-35 I 0.3 5 BL/BR BR/BL BL/WS/GE 1 BL/G E
BL/RT GR/V I
70 73 74 51 I 1 3 1 45 52 65 16 I X1 2
SA .

1 Light modul e
ioil

22 39 46 44 26 22 34 13 29 49 "~ 61 ^ 10 Y 3 0 Y 5 I 6 7 ¥2 6 T X12
0.5 0.7 5 07 5 0.7 S 0. 5 0.7 5 0.7 5 0.75 0.7 5 0.7 5 0. 5 0.7 5 0.7 5
05 05 05
SW/Vl BL/BR/G E SW/R T GR/G N WS/R T GE/S W WS/G E BL/BR SW/B R WS/B R WS/S W GE/R T GE/W S
GR/BR SW/GE GR/SW
0.75 0.5
GE/BR BL/GE 3 A 4 A 6 A 7 A 2 A 1 A X33 8
1 2 7 6 3 4 X33 9

X769
j--1 - " " - - - | E16
Tail light. r ~i E17
Tail fight ,
left (Saloon ) right (Saloon)
— JE27 X11218
I I | |
Right too | J •p i
light (in dash, driver's L -
1 side, near A-pillar)
1 2 X390 2 X710
|

r - 1~ ! H8 a j" E44 a
'j Directio n indicator License plate
' ligh t repeater, light, right
' fron t righ t
1
LJ 2 X709 i 1

X389
License plate
H9a light, lef t
Direction indicator
light repeater,
front left

B510ele26116b

Electrical Wiring Diagrams ELE-31 7

 Electrical Wiring Diagrams ELE-31 8

i Low beam / high beam

without Xenon lights
up to 03 / 2005

n A3 r ~ A72
Jgjj)| Ligh t module „ Steerin g colum n

_L_,
_ switc h cluster
]3 ) Direction
J indicator/lo w
H _____j ^ bea m switc h
69 Y X12 1 ' X 10334 6 X1880

5V
0.35 1.0 0.35
GN GE WS/GE

5X 13339 1 X 13583
r i n Q B r "j A22 0
I 1 !I ! Ligh t switc h unt i ITS ] J Safet y and gatewa y
I-- \ ) Ligh t switch tZ U module
Is 0 8 ) Lighting f o r I g ht [ _
switch u n t 3 6 1' -3* P
i- - -I f j 1
11 1 21 03 X1333 91
0.35 0.3 5 0.3 5 0.3 5 /•_,.__, •, 1 viwin o
BR/SW GE/G NS WG E (i n dash, drivers 1 X150 02 X1500.l (i n dash, driver's
side, near A-piHar) • F ^ side , nea r A-pillar)

I 0. 5 0.5
GE SW
70 7 33 63 5 32 JL 1 2fL
4 X12

-*• ~ " A3
Light modul e
U5 6U 5 61 10 5 65 =6 rf j i

Ty T3V 1 i1 T
y T v 3i i i73
V 1ii ut uT s ?~1
T 31 i
•- r * t *t *t *
53 Y ~ 12^ Y1 5 Y"" 5 0 Y X1 2

2.5 1. 5 2. 5 1. 5
GE/GN WS/G N GE/B L WS/B L

2J ^ 3 X1342 02 3 X1342 1
| ~] ~\ j E 7[ " " 11 " jE 8
! (X ) 4 (X ) 5 Lef t headligh t ] f<> ) 4 f\? \1 Righ t headligh t
Xjv y.y 4 ) Low beam VI V VL V1 4 ) Low beam
[_ j 1 J headligh t ' \ —*• ' headligh t
7 Y X 1 3 4 2 0 5)H h?adlST 7 Y X 1 3 4 2 15 ) High beam
headlight headligh t
2.5 2. 5
BR BR/G E

X18132 (i n dash, driver's X1813 9 (unde r dashboar d

tt side , near A-pillar) £ - Passenger side)

B510e!e19468
Low beam / high bea m
without Xenon light s
as of 03 / 2005 u p to 09 / 2005

~" A7 2
r" i A3
rj=ri 1 Ligh t module c switch cluster
_3 ) Direction indicator/lo w
30 ^ | |v2 J~ ?1 bea m switc h

T i _ J jH*
1 .. . 1 V v
L__4I7! 1 1 T X1033 4 6 X1880
69 T X1 2 1 Q
0.35
I 0.3 5 G E WS'GE
I G N
I1 X1358 3
5 1 X1333 9 A
_ _f ?_ , r n A22 0
Ii *, [ I 1 , kbyhlawitdiuni
i • i ,, i i t HT]
r ——
ni modu|
I Safet v and
e
aatewav
16 1 6 1 1 ) Main ligh t I l^lsl I
I -- ' \ h I I
rh 8 8 ) Ligh t switc h unit ^I / ^
I 1 ljgh!i yng 3 6 I3 5 TX1358 1

11 T 1 21 03 X1333 9 side , near A-pillar)* F • P

0.35 0.3 5 0.3 5 0.3 5 I 0. 5 I 0.5
BR/SW GE/G NS WG E1 GE1 SW

X12

~u - u p u ~ - - -
70 7 33 6 J^ 3 5 J^ 32 _JL 1 4 JL_ 2 8

r "~ -
T '
| A 3
Ligh t modul e

in I
U5 6U 5 6U U 5 65 =6 17 ^ 1

T 9~i T T I ¥
UT
i_» 1-*
31 A L I T
. i-
3i A T 1T T
3i A I )U
» f- >
31 A
i
53 ' 1 21 5 ~j 5 0 X1 2
2.5 1. 5 I 2. 5 1. 5
GB'GN WS/G NI GE/B L WS/B L
23 X1342 02 I 3 X1342 1

I J- . J- ^ Leftheadlgh t ' ,- L J- ^j Righ t headligh t

1 (> O 4 (X )5 4 ) Low beam ] (V ) 4 fX )5 4 ) Low beam
1 Vi y V^ y headligh t ^- ^ ^O 'j headligh t
|_ _ | ^ j 5 ) High beam i __ |_ J a ) Hign beam
7 Y X1342 0 headligh t7 V X1342 1 headligh t

2.5 2. 5
BR B R

X 13783 X 13782

B510ele22784

Electrical Wiring Diagram s ELE-31 9

 Electrical Wiring Diagrams ELE-32 0

Low beam / high beam

without Xenon lights
as of 09 / 2005 up to 03 / 2007

-> A 3
I Ligh t modul e A72
Steering column
30 switch cluster
3) Direction indicator/low

[_£*___- ~ i
beam switc h

16 5 X1880
69 X12 0.5 0.5
RT BL/RT
Q[^ {unde r dash near (under dash nea r
steering column) X 10606 X 10605 steerin g column)
»p
I
a ^ n ,Mw 3 0 I 2 9 1 X16760
"1 " { S 8 r-- ^
1 "] A 16760
1? Ligh t switch unit -. ' Body-gatewa y
\ \ 1 ) Light switch ! |(O) j f modul e
1 "i f' \ ) Lighting for light ; SZ J
1 rI 8 1
u ' switc h unit i
1
1 j
18 Y ~ 9~ T X1676 0

~*
i— _ _ ,
X 15002
11 ' To - 3 X13339 side , near A-pillar) |™™\side, near A-pillar )
0.35
0.35 0.35 0.35
WS/GE
BR/SW GE/GN SW rf °' 5I °'5

L J
GE I G E S W
=
70
73 S/
36
*
35
I 32 JL 14 J 28 _^
X12

B510ele23466
Low beam / high beam
without Xenon lights
as of 03 / 2007

A72
l1 Steering colum n

E!
A 3

fT^ri ' Ligh t module switch cluste r

\Q)\ i 3} Direction indicator/low
30 ' ' | 1 beam switch
n^ / V N
i 16 T 5 X1880

0.5 I 0. 5
mI Bum
69 \ (under dash near X10606 I X1060 5 (unde r das h nea r
1 „ 0,- steerin g column) ^1 ^ steenn q column)

1G N 1
29 1 X 16760
5 1 X1333 9 3 0 , SA
A, 1

}
I
1 i" l S8 ht- itc h ni t ' Body-gateway
1 1 1 i - ) I 1 ) Ligh t switc h | U"^ modul e
1 '' \ 8 ) Lightin g for light | I
1
1 8 I I 8 1 9 I X1676 0
1 1
\1 1J (i n dash driver' s X15002 | X1500 1 l lirioano;>rdAVnMlar^

L
12 Y 1Q~Y 3^ X1333 9 side , near A-pillar )
0.35
0.35 0.3 5 03 5 0.3 5
WS/GE
BR/'SW GE/G NS WG E GE 1 SW
70 73 3 63 53 2 14 1 2 8 X12
J\A < "
11 |
l A3
Light modul e

X135
2.5
BR
X13782

B510ele25815

Electrical Wiring Diagrams ELE-32 1

 Electrical Wiring Diagrams ELE-32 2

Low beam / high beam

with Xenon light s
up to 03 / 2005

"•A3 r n A7 2
Light module Steerin g colum n
?° ||Q |^ ° switc h cluster
nQT] ISCl lp |3 ) Direction
IMvi J I indicator/lo w
T t i i-e » bea m switc h
69 Y X1 2 1 Y X1033 4 6 Y X188 0

0.35 1. 0 0.35
GN 1 GE WS/GE
1 J ^ X1358 3
5 1 X1333 9 r _____„_ _ ^

. . ~ I - ~ " S 81 IT^S l1 Safet y an d gateway

' ( -, I ! Ligh t switch unit ! ^ ^ J modul e
f \ ) Light switc h L ._ ,_ , j
A S 8 ) Lightin g for light 3 6 |
35~ Y X 13581
1 1 switc h uni t 1
•1 • , — ^ /i « H^t- ^ ^-;,,^r' o 1 X1500 ? X15n m ti n Hn^ h d r ver's
11 12 1 03 X1333 9 side , nea r A-pillar) i
» » side, near '/> -pillar)

0.35 0.3 5 0.3 5 03 51

BR/SW GE/G NS WG EI °- 5 a 6
IG E S W
70 73 3 63 5 32 JL 1 4 28 X1 2

•— »• ~i~ * i^ 1* A * Jr~ *~ "A 3

1 56 f l5 60 0 5 6 ^ 5 65 6M Ligh t modul e

T
J 13 ¥ H
1 A MTTai
¥ Hl Ta¥ l T f T ¥ 1!
31 - i
1 tA U U m U 131
f* I . t * t * >- *
12 53 4 8T 1 55 0 ' X12
I 0. 5
1.5 2. 5 1 BL 2. 5 1.5
WS/GN GE/G N (i n dash driver s GE/B L WS/BL
X 13637 | X 13637 side , near A-pillar) X 13637

7± t"" 1-t headligh "~1 r

3( 2I 5 I X1342 0 5 j 2 3 X13421
OV ^~ — A_ _ r

Lr j Lef
r t>• "• E 8
Right headligh t

P5 m T !S?II hL. r S
/\ 5 } High bea m
$
B 6 6 m a V headligh t
6) Solenoid bi-xenoh
; headligh t! headlight
8) Xenon headlight
/O\n device /<~ X ignition devce
V;y a 9 ) Bulb for xenon V_ y 9) Bul b for xenon
^ _T 1 headligh t , ^ . headligh t
1

7 1 Y X1342 0 1 ' •" • 7 ~^ ' X1342 1

2.5 I 2. 5 2 5 2.5
BR j B R BR/G E
BR/GE
X18132 I X1813 2 X1813 9 X18139

!' • . , «.
B510ele19469
Low beam / high beam
with Xenon lights
as of 03 / 2005 up to 09 / 2005

r~ " A 3 r ~[ A7 2

1 1m i H I
I3 01 Ligh t modul e c Steerin g column

L-r— ' . i
L switc h cluster
] 3 ) Direction indicator/Sow
' bea m switch
J
69 T X1 2 ~7j _ _ j
0.35 1 T X1033 4 6
X1880
1 G N 1. 0 0.35
S I X1333 9 G E WS/GE

1 i1 ^
1 i 1 A 1 I 1 ) Main light ' ' Safet y and gateway
1 -/' \ switc h I S~A J I modul e
1 ' '8 ? 9 ° I 8 ) Light switch ' i3Zi I
1 ] I uni t lighting ' J
1 LJ I
_{ J
~3
3
< ^
6T 3 5 I f X1358 1
11 "~ 1 2 l ~ 10~Y ~ 3~ Y X1333 9 (i n dash, driver's I X1500 2 X15001< in dash >
*!vel;',s .
0.35 0.3 5 0.3 5 0.3 5 side , near A-pillar) J ^ J |de , near A-pllar)
BR/SW I GE/G N S WG E1 0. 5 1 0.5
70 73 1 3 63 53 21 GE1 4I S W2 8 X12

rli h
\\

^_^. "I—* -1 — »• I — »> -* ] A3

n n r h* Ligh t modul e

I 31

12 53 «~Y 05 50 X12

1.5 2.5 B L 2.5 1.5

WS/GN GE/GN X1363 7 | X13637;.j de nea r VpT,Sar)X1 3637
; GE/BL WS/BL

3 2 5 I X 13420 2 3 X13421
"I
t" ~ |" • F 7 r • - |n E 8

I| I I Lef t headlight ' I x-Lv Ri 9ht headligh t

/<TX
(/\ 5 (Q) 8 r/ 1 6 '5 ) High beam ' i6 |(O| 8 rX j5 5 } High beam
vV Q=!klJ 1 1 1 ' headligh t 1
I ''
^-ry headligh t
6j Solenoid bi-xe n
j

/o\V
[^ | headligh t | j_^ headlight
/\~X | 8 ) Xeno n headligh t | 8) Xenon headligh011
\^\J ® | ignitio n device j ignition device
i 9 ) Bulb tor xenon i ^. 9 ) Bulb for xenon l 5
J headligh t [ _ _! headligh t

7
'
1 X13420 1 7 X13421

2.5 2.5 2.5 2.5

BR BR BR BR
X13783 X13789 X 13782 X 13782
JL jL J tL
B510ele22785

Electrical Wiring Diagrams ELE-32 3

 Electrical Wiring Diagrams ELE-32 4

Low beam / high beam

with Xenon lights
as of 09 / 2005 up to 03 / 2007

] A72
A3 . Steerin g colum n
30 Light module ! switc h cluster
3) Direction indicator/low
ISH I ^ "
U' T °-5
beam switc h

^± j
9
R T
16— |0. 5
I BL/R T
5 X1880

69 X12 (unde r das h nea r 1 10606 (under dash near

X | X 10605 steering column)
steering column) 1 ^
0.35
GN 29^ X1676 0
30 J ^
I X 13339
i "j A1676 0

I
I 1
I " Ligh
S8
t switc h unit i
i
i(„. ,, , ,
m Body-gateway
module

i- V H. 1 1 ) Light switc h I

_ y i ny 810
, f

I switc h unit 8 r~ 9~~Y X 16760

(in dash, driver's
! (i n dash, driver's 1 X 1 5002 I X1500 1 side, nea r A-pillar)

2 - 3 X13339 1
i —'
tf
0.35
WS/GE
0.35 I 0.3 5 0.35 0.5
0.35 °- 5
BR/SW I GE/G N 1S W
SW GE G
I 32 JL 14J
E
70 73JI 3 6 35 28 X12
A3
Light module
56
I31

TiT
I 31 i
U
-t±
12 53 X12
T 0. 5
1.5 BL 2.5 1.5
WS/GN WS/BL
^/GN X1363 7 X 13637
Ka^Nlr) J X13637

3 2 51 X1342 0 3 X 13421
i1
V _j" >
E7 •J====s-_i
Left headligh t Right headlight
5) High beam 5) High beam
headlight headlight
1 6) Solenoid bi-xenon
I 6) Solenoi d bi-xeno n

6
headlight I headlight
8) Xeno n headlight 8) Xeno n headlight
9 9
ignition device ignition devic e
— »

' F""i
t
6*
- $1
9) Bulb for xenon
headlight
9) Bulb for xenon

7 1— 1* X13420 X 13421
2.5 2. 5 2.5
BR B R I B R BR
X13783 1 X1378 9 1 X 1378
2 X 13782

B510ele23467
Low beam / high beam
with Xenon lights
as of 03 / 2007

1
ri s, o " ' i ALighS it module '
A72

H Steering column
switch cluster
3) Direction indicator/lo w
16~| 0. 5 5 X1880
beam switch
! ^L ' . J
1 (unde
9 p
r das h nea r 1 X1060 6
1 BL/R T
(under das h nea r
69 T X1 2 steerin g column) } | steering column)

29 1 X1676 0
I G N 30 _J, _ y^ i
5 I X1333 9 ! " ~j A1676 0
JT j Body-gatewa y
r_ _[ _ „ I module
PI
i 1 i • )1 ) Light switch 1 i
* \ ) Lightin g for light " ~ IV - "
T? T switc h unit 8 T 9 1 X 16760
(in dash, driver's S_FL
0 (i n dash , driver's | X1500 2 I X1500 1 side, nea r A-pillar)
0.35
u I _ j j j j side , near A-pillar)« | > • 1 s-
11 |0.3 5 1 2 |T 0.3 5 10.~1rO.3 5 3~ Y X1333 9 I
1 0. 5
I BR/S W 1 GE/G N 1 SW1 0.3 5 1 "• =
14 Jsw 28 X12
70 1 7 3 | 3 61 3 5 1 GE 3 21 Gt
A_ . _ _A _ A _ _A __ £
A3
Light module

.
53 1 f~ 1 2 I 48 50 15 X12
0.75
2.5 0.75 BL 0.75 2.5
GE/GN BUGE GE/BL
BL/GN vile-a y (i n dash, driver' s X13637 X 13637
A I J D J / side , near A-pillar)

3 6 5 I X13 0 5 6 3 X135

r E8

mi m• i
T
I 1 1
E?
Lef t headligh t Right headlight
i
a ' 6 ) Solenoid bi-xeno n 6) Solenoid bi-xenon

/\y\ " 1 8
r-4-i „ 1
) Xenon headlight
headligh t
!/n 6 S ~~^ , headlight
8} Xenon headlight
(Vl r — I
1 '
VV 1 1
/o\^ g j ignition devic e
\\ 1 1 inniti^ n Hov/i^ Q

1 7I 9 ) Bulb for xenon 17 Qxf )9 I 9) Bulb for xenon

I headligh t r I headlight
17) Turning lights

2 X130 2 ' X13 5

2.5 2.5
BR BR

X 13789 X 13782

B510ele25817

Electrical Wiring Diagrams ELE-32 5

 Electrical Wiring Diagrams ELE-32 6

Side light, parking light, brake light

Sedan without Xenon lights up to 03 / 2005
(page 1 of 2)

A3
Light modul e

S29
Brake ligh t
switch
69 X12

3 Y~0.3 5 X78 0.35

BR/GR
I BR/ G 0.35 GN
(in dash, driver's I X11 7 BH/SW
5 X13339
side, nearr A-pillar)
A-pillar)' I_
S8
32 I X1031 8 Light switch unit
f
1) Light switch
8) Lighting fo r ligh t
switch uni t

(under dashboar d
assenger side )
X13339
3.35 I 0.3 5 0.35 0.35
;
3R/SW I GE/G N SW GE
73 35

X13502 (i n dash, drivers

Side, near A-pillar}

E8
Right headligh t

11) Side marker 's

! y_y Wd
' 3 ) Side ligh t
I 11 ) Side marker
light

7 X13421
2.5
BR/GE
X18139

B510ele194643
Side light, parking light, brake light
Sedan without Xenon lights up to 03 / 2005
(page 2 of 2)

~" A7 2
' Steerin g column

m-
I switc h cluster

}L ' 3 ) Directio n indicator/low

I bea m switc h
I
.__]
1 X 10334 6 X1880
1.0
GE
1 X 13583
~" A22 0

ii m
Safety an d
gateway modul e

I
u— r- — i j
36 Y ~ 35~ ^ X13581
(in dash, driver's J X1500 2 X15001 (i n dash, driver's
side, near A-pillar) • ^ < s^side. near A-pillar) 0.35
WS/GE

'I A 3
I Ligh t module

29 | 0.5 30 ^ 10 3 1 4 9J X1 2
I SW/G E 0.75 0.7 5 0. 5 0. 5
I X1121 8 (i n dash, driver's WS/BR SW/B R1 GR/B R I GR/S W
« K sirJP nea r A-pil!ar} ^
6 X31 8 2 I X70 9 2 I X71 0
V- A A ^
11 X1391 3 '
n b1 7 E43 a' " r E44a
1^ Tai l light, righ t /cS \e plate x ? \) 3 6< ) 7 3 License piate) Brak e ligh t (X )

y^~i TU
Noise suppressor I X T light, right
58 [7=jn i r — «i r —« filter I ( >
l©l h i1! i v :.V Xi y7 ) Tail light | ^J ^

u u i
i VV
^T 1 t-
31 31 I 31 I 1

1 hi—
I SW/G E
2 X13914 2
0.5
X13913 1 ' X 8 °'
1.5
5

1.5 BR X1127 3 X1127 3

1 |X13 8 BR
H34a BR
X13792 " ^
Auxiliary brak e .
I'
a v KIS S
light X13791
A •" •
B510ele1P4f

Electrical Wiring Diagrams ELE-32 7

i
Electrical Wiring Diagrams ELE-32 8

Side light, parking light, brake ligh t

Sedan without Xeno n lights a s of 03 / 2005 up to 09 / 2005
(page 1 of 2)

n A149 a
—•— *r I Ca r access
I syste m
I

LJb—J
2 T X1X10318
i
I 0.
0.35 3
I VI,'
VI/SW:
1 A X7X78 ;
S29
Brake light

3Y 2 X78 69 I X1 2
1 0.3 5
1 0.3 5 0.35 0.35
1 BR/G R BL/RT BR/SW
5 I X1333 9
(in dash, driver'ss | X117 9 X181 _V
*»
side, near A-pillar) S8
1
32 1 X1031 8 passenger side) Light switch uni t

1 V
I 1) Ligh t switch
1 1
__p. n A149 a X 13787 I

fI
8) Lighting fo r light
n Ca r access jL I \ X 13339 switch unit
M syste m I

I
I
1
&~\ J J, ,
I 31 A j 11 10 T 3
14 Y X1031 8 135 1 0.3 5 0.35
0.5 3E/GN 1 SW GE
51 70 36 1 3 5
31 JLpWSy L _
— v— '

25 62 1 J X1350 2 (in dash, driver's X 13502 5 40 64 42

side, near A-pillar)
0.75 0.75
0.5 0.5 I 0. 5 0.5 SW/RT GR/GN
05 0.5
GR/GN WS/RT I GE/S W GE/SW WS/SW GR/BL 6 4 X319
4 5 8 I X1342 0
• JL^ j J 4 X13421 -l E1 6

?»• ! i.« c>

E7 r — I Tai l light, left

d
s * E8
1 Left headlight ! Right headlight ~X I 3 ) Brake light
1
),, 6
y3I 7 ) Tail light
J. ( J 1
3) Side light : 3) Side ligh t
?>' < 5
1
1 1 ) Side marker '
light : ,;
5' 11) Side marker
light I
1 * I
1 1 > —• — ~- $ 3 ^ . —o
_ j
1 X319
7 X 13420 7 X13421 1.5
2.5 2.5 BR
BR BR
X 13795
X13783 X 13782

B510ele22780a
Side light, parkin g light, brak e ligh t
Sedan without Xenon lights as of 03 / 2005 u p to 09 / 2005
(page 2 of 2)

i_ —_ ~" A7 2
Steering column

m- j
switch cluster
_3 ) Direction indicator/low
1 bea m switch

i —1»
L -3 , " d
1 T X1033 4 6 X1880
1.0
GE
1 1 X I 3583
(^
~! A22 0
1
1 r-p^-. Safet y and
1 ^rf) , gatewa y module
11 1
1

36 Y 35 I X1358 1
(in dash, drivers [ X1500 2 I X1500 1 ^ n dash, driver's
i ^sid e nea r A-pi!lar) 0.35
side, near A-ptllar) • f c
WS/GE
05 las
GE 1s w
_32JL 14 1 2
/V ^
8 X12
[~ f r i A 3
-i 1 Ligh t module
54
= (7 ;

29 I 0.5
SW/GEE
I SW/G
I X11211 ^8 (i n dash, driver's
^ side , near A-pillar )
1 A , X1391 3
Z13
Noise suppresso r

B510ele22780b

Electrical Wiring Diagrams ELE-32 9

 Electrical Wiring Diagram s ELE-33 0

Side light , parking light, brake ligh t

Sedan withou t Xenon lights a s of 09 / 2005 u p to 03 / 200 7
(page 1 of 2)

A149a
Car access
system
~" A 3
rp=Tl Ligh t modul e
2 Y X1031 8
1 0.3 5 30 ^^© ^

._!?—,
1 VI/S W
1 ^ X7 8
S29
f
MC * Brake ligh t

3 y~b-3 5 4 "^ ""0.35 2 y X7 8

035
1 BR/G R BL/RT 0.3 5 GN
(in dash, driver's 1 X117 9 X181 1 BR/S W 5 I X1333 9
side, nea r A-pillar ) ,^ , ^. 1 X1378 7
~" S 8
32 A X1031 8 "
T" L-f. 1 A149 a (under dashboar d
| Ca r access passenger side) \) Lighting for light
J5 r^- i | syste m
rt B T \4 1 1
switc ) Light switch
h uni t

I
| m k~ i _J j
,. 4-* - J
T T 11 1
*l *-/ ^

14 Y X1031 B ).35 0.3 5 0.3 5

0.5 3E/GN S WG E
31 1 GN/S W 5 1 70 36 3 5
A_ , • yj j j

I 5-8
31
58

_ - ._. -

25 1 |T ~ (i n dash, driver's 40 64 42
I X13502 side, near A-pillar ) X13502 0.75 0.75

J
0.5 0.5 0.5
0.5
GR/GN GR/BL 6 , 4 X319
GE/SW GE/SW
41 X 13420
,L_ 4
8 J X13421 r ~J E1 6
i —
u

E7
Left headlight
~" E Right
8 /
headligh t f
r
>
7\) Brake ligh t

93
3) Sid e light s /\) Sid e lights ^ C V3 7 ) Tail light
1 1) Side marke r y 3 11 ) Side marke r
i ( ^ I" light

^
1 |
K <- - 1 j
1

^ \
L. _ J 1 |

7 X13421 1.5
7 ' X 13420 X31 9
BH
2.5 2.5
BR BR X 13795
JL
X13783 X 13782

B510ele23464a
Side light, parkin g light, brak e ligh t
Sedan without Xenon lights as of 09 / 2005 u p to 03 / 200 7
(page 2 of 2)

A72
Steering colum n
switch cluster
3) Direction indicator/low
beam switch
X1880
0.5
BL/RT
(under dash near I X1060 6 X10605 (unde r dash near
steering column) > ^ glaring column)
29 I X 16760
1 "j A1676 0
1 , ^, - Body-gatewa y
1
1 \Q)\e
1 1
i
9~Y X 16760
1 X 15002 ' X1500 1
i ,^ . (i n dash , driver's
(in dash, driver's ™""^™^"^ ^ side, near A-pillar) 0.35
side, near A-pillar) WS/GE
0.5 0.5
GE SW
32 14 2 8 X12
' 1 A 3
Light modul e

11
29 J 0. 5 30 3T 4 9 T X1 2
1 SW/G E 0.75 10 1
1 X1121 8 ( n dash, driver's WS/BR
| ^. s de, near A-pillar ) SW/BR I GR/B R I GR/S W

1 ^ X1391 3
r-'
1 -' JI X318 2
1 E1 7 o
I X70 9 2
*
I X71 0
213 i E44a

11 1 T
T
Noise suppresso r | ^
«
Tail light, right 1 I
License plat e
f7
U - H
T L© l
tiller | (\ ^
£>. $ i >3
V7 7
) Brak e ligh t /O
) Tail light V
v LhTS
V "
, (V
9hUe" W
^
light, right

bn D
I 31 i t —^ 11 1 |
1
, it .v
*1
V
T X70 9 1 T X71 0
kL s 0.5 0. 5
1 T 0. 5 2 X13914 2 X13913
1 X318
1 SW/G E 15 BR B R
0.5 1.5
1 ^ X13 8 BR | X1127 3 | X1127 3
BR BR
X13791 j ' d
^ Auxiliar y brake X 13792
JL
2 y X13 8 " gm

B510ele23464b

Electrical Wiring Diagrams ELE-33 1

 Electrical Wiring Diagrams ELE-33 2

Side light , parkin g light , brak e ligh t

Sedan with Xenon lights up to 03 / 2005
(page 1 of 2)

A149a
Car acces s
system I1
A,
IjOl Light module
Li
so '-32 '

L
3 ^p3.3 £
0.35
m nn
0.35 X78
S29
Brake ligh t
switch
0.35
GN
BR/GR
I BR/ ' BL/RT 0.35 X13339

r
(in dash ,,, driver's | X1 X1179
1 . X1B1 BR/SW S8

F
side, near A-pillar)
I Ligh t switch uni t

V
i
V\ !
32 1 X1031 8

_--T_--j
1) Ligh t switc h
i A149 a i 8) Lighting fo r tight
I Ca r access X 13787 I 0C I switc h unit
I syste m LI I
I
w-i 1 (un jer dashbo a L_, J
-»• Ts
pas senger side
n 12 | ~ 1 0 3 X 13339
X10318 0.35 I 0.3 5 0.35 0.35
0.5 BR/SW 1 GE/G N SW GE
GN/SW 5 1 70 73 I 3 6 35
•> A ,j *

58

.t± _. —, 1
25 64 42
2 I X1350 2 fin dash, driver's X13502
side, nea r A-pillar) 075 0.75
05 I 0. 5 1 0. 5 SW/RT GR/GN
0.5
GR/GN GE/S W GE/SW GR/BL 6 4 X319
4 8 I X1342 0 8 4 X13421
,L _ 4J

R
i" i 1 i E81
I Lef t headligh t 1 ^ Tai l light, left
-^ 1 Righ t headligh t 1 x ^

$> I'
I 3 ) Side light
I 11 ) Side marker
1
1 6 <J 3 ' s
•* 1
i Side light 1
11 ) Side marker I
( /
<>' Q (Q 3 3
-V 7
) Brake light
) Tail light
I f>
I ligh t 1* I ligh t I
I I 1
,
X 13420
2.5 2.5 1 X319
BR BR/GE 1.5
X18132 X18139 BR
» — ^
— ^
— *"_:.

^
X 13795

B510ele19465a
Side light, parking light, brake light
Sedan with Xenon lights as of 09 / 2005 u p to 03 / 200 7
(page 2 of 2)

~> A7 2
, Steerin g colum n

M . switc h cluster
1 3 ) Directio n indicator/lo w
_3 bea m switch
-rp ^
9I f 1 6 I 5 ' X188 0
0.5 1 0. 5
1R T1 BUm
(under das h earl X1060 6 I X1060 5 (unde r das h near
steering coturnn) i » steering column)
30 X1676°
i A1676 0
' Body-gatewa y
I modul e

9 I X16760
X15001
(in dash, driver's (in dash, driver' s 0.35
side, near A-pillar) side, nea r A-pillar) WS/GE

"' A 3
Light modul e

r " i°i ? 1 /^ V
29"t 0.5 30 3T 49 T X1 2
0.75 0-75 0. 5 0.5
v'fi'So ( m dash, driver's WS/BR SW/BR GR/B R 1 GR/S W
L6 J
| A I i<ntj sid e nea r A-pillar )
4 , X318 2 I X70 9 2 I X71 0
N O V
^ t1 / £43 a E44a

5 -< ? /o \)
Z13 Tail light, right J~ ,L icen, License plate
e plate

T
Noise suppressor >\ rV / e light (V
7\) Brak j light ,I light, righ t
fl 5 8
y7 7 ) Tail light ^y

vl

r
1 1 X71 0
TsTl |H . 31 * 1 | o. S 0.5
2 X13914 2 X13913 1 X318 IB R 1B R
I X1127 3 1 X1127 3
3W/GE 1.5
K138 0.5 BR
BR
H34a BR I
Auxiliary brake X13791 X13792 ^
t light j J
L
2 y X13 8

B510ele23465b

Electrical Wiring Diagrams ELE-33 7

 Electrical Wiring Diagram s ELEE-33 8

Side light, parking light, brake light

Wagon without Xenon lights up to 03 / 2005
(page 1 of 2)

A3
Light module

S29 69 X12
Brake light 035
switch GN
3 | 0.35
0.3 E 0.35 X78 5 X 13339
I BR /
BR/GR BL/'RT 0.35 r
(in dash, driver's I Y1 1 S8
X18.1 BR/SW
— ^
ciHo noa r A-nillar l I A l '
T" • I I Ligh t switch uni t

V
1
^^HII—

32 A X1031 8 1 (
& I 1 ) Light switc h

V!
If r 1 A149 a 8) Lightin g tor light
X 13787
r^| ' Ca r access j J
1 b1 switch unit

M Y !
15 8'
1
L syste m (und =r dashboa r
pass enger side) •\ 1

Vl !
J
11 10 3 X 13339
—+ I 31A _ |
).35 0.35 035
14 X10318
0.5 3E/GN SW GE
31
: GN/SW 5 1
70 36 35

58

25 62 | X13502 (i n dash, driver' s 40 64 42

2 X 13502 5
n ^f side , near A-pillar ) 0.75 0.75
05 05 05
SW/RT GR/GN
GR/GN WS/RT 1 o. 5 I 05 WS/SW GR/BL
I GE/S W GE/SW

L^
4 X319
4 5 sj X 13420 8 4 X13421 , '. 1 E4 6
1 -1 E 7 r 1 E 81 Taillight, outer lef t
n' Lef t headligh t 1 Righ t headlight 1 .<- • ^X 4 ) Taillight
^\ 3 ) Side light ^X 1 3 ) Side ligh t 1 ( / §. ( <O 5 5 ) Brake ligh t
$ J. < < \3 f 1 1 '

-f ]
11 ) Sid e marker

1
«gh « In ^ v) 3 1 11 ) Sid e marke r 1
1 ligh t |
1
^

1
^ ^ 1 X319
7 ' X 13420 7 X13421 1.5
2.5 25 BR
BR BR/GE X13795
X18132 X18139 j.

I
B510ele20893a
Side light, parkin g light, brake light
Wagon without Xenon lights up to 03 / 2005
(page 2 of 2)

A72
Steering colum n
switch cluster
56
3) Direction indicator/lo w
beam switch

1 I X1033 4
1.0
GE
I X1358 3
A220
Safety an d
gateway modul e

I I

36 r ~
(in dash, driver's ' X1500 2
35 I X1358 1
I X1500 1 (' n dash, driver's
side, near A-pil!ar) ^m 1 fajide , nea r A-piiiar) 0.35
WS/GE
I 05 I 05
QE I sw
2 1 . 4JL
-| A 3
1 Ligh t module

29 I 0. 5
31
I
I SW/G E 075 0,75
I X1121 8 (i n dash, driver's WS/BR SW/BR
f*.side, near A-pillar,
1 I X31 8
X13913 -i E4 7
T Z13
I Taiilight . oute r
i Nois e suppresso r
I righ t
I filte r
U5=8 [7 n I 4 ) Taiilight
I

ViT
I 5 ) Brake light

T 31 i y m
I
I
I

t± 31 1 3
v
TX13914 2 T X1391 3
1 A

1 lfo. 5 2 "
I SW/G E 1.5
0.5 I 0. 5
BR
1 J ^ X13 8 BR I BR
,, H34 a
| X 13794
"^ Auxiliar y brake
2Y X13 8 ''9 ht

510ele20893b

Electrical Wiring Diagrams ELE-33 9

 Electrical Wiring Diagrams ELE-34 0

Side light, parking light, brake light

Wagon without Xenon lights as of 03 / 2005 up to 09 / 2005
(page 1 of 2)

-/~ri A149 a
15 (p) I ! Ca r access
VLX
I syste m

B8
Light switch unit
1) Light switch
8} Lighting for light
switch unit
'
| ..
12 | " 10~ * f 3^ X 13339
0.35 I 0.3 5 0.35 0.35
SR/SW j GE/G N SW GE
70 73 1 3 6 35

62 40 64 42
1 I X1350 2 X1350 2 5
0.75
.5 0.5 1 0. 5 f 0. 5 0.5 0.5 SW/RT GR/GN
3R/GN WS/RT 1 QE/S W GE/S W WS/SW GR/BL 4 3 X319
5 8 1 X1342 0 8 I 5 4 X13421 _ i
-"==H - J E 7 r — f=
- 1 E 8 | Tailiight. outer left
^
,'i 1 Lef t headlight i
3) Sid e light
A | Righ t headligh t |
3) Side ligh t
s-
7\ /\ 5
^X 4 ) Taiilight
5) Brake light
1 11 ) Side marker
I ligh t
, vr y v2 y 11) Sid e marke r
light
/f

II fr

X319
X13420 7 X13421
31
2.5 2.5
BR 0.75
BR
BR
X13783 X 13782
X13795

B510ele22790a
Side light, parkin g light, brake light
Wagon without Xenon lights as of 03 / 2005 up to 09 / 2005
(page 2 of 2)

-1 A7 2
1 Steering colum n
1

L _.®__ j
switch cluster
_3 } Direction indicator/low
-i bea m switch

*—+
1 j X1033 4 6 X1880
10
GE
11 X1358 3
A
"] A22 0
Safety an d
(CM gatewa y modul e
u^J i
I

36 Y ~ 35~ Y X1358 1
' YiRnn p ' Y 1 snm
0.35
WS/GE

A3
Light modul e

58

y
f*
i3
^ 1A L

~&~Y~0*~~ 30 ^ I 10"T~
*3 ^ | X12
I SW/G E 0.75 0.7 5 I 0. 5
^
0.5
| X1121 8 WS/BR SW/B R1 GR/B R GR/SW
> 2 ,
1 X31 82 1 X70 9 X710
1 A X1391 3 ^ _/* \»
. | ,
1 Z1 3 r

v c
I I* " Taillight, outer J- . Lice n se plate J _ License piate
' Nois e suppressor
58 S, X^ N r,gh t (V ) light . eft Ay A light, righ t

Y
T~* I filte r (\ i

ii Or t— i T M
S^ X_ V4 ) Taillight ^O 7

i* I ' T' ^5 ) Brak e light I

iY I 31 i 31 I I 4e > 1
V
1 ^7n Q 1 Y ^ 710
u' 31 A j 10 S
t 0. 5 2 X13914 2 X13913 s ( 1X318 X112? BR
1BR
3
1 SW/G E 0.5 0.5 4 1 X1127 3
A X13 8 BR BR 31 1
1 H34 a 0.75 1
--x Auxiliar y brake X 13794
JL BR M.
Y X13 8 ° X 13792

B510ele2a790b

Electrical Wiring Diagrams ELE-34 1

 Electrical Wiring Diagrams ELE-34 2

Side light, parking light, brake light

Wagon without Xenon lights as of 09 / 2005 up to 03 / 2007
(page 1 of 2)

-I A149 a
I Ca r access
I syste m
A3
Light modui e

1
X10318 30
0.35
VI/SW
X78
„ S29 L* — *• J
LJlJ Brake I grit
switch
3 | 0.35 4 |0.3 5 2 X78 0.35
1 BR/G R 1 BL/R T 0.35 GN
1 X117 9 | X18 1 BR/SW 5 X 13339
""" S 8
32 A X1031 8 , fr |
T * Lig h switc h unit
Light
r
P

i
!_(.> 1 A149a X 13787
41 A . 1 ! i)L i 1} Light switc h

]• !
M1 Ca r acces s -* \ Rll i 8} Lighting for light
I1 I/r ^ I] | syste m o b c
i -TT m
S 0 ' swit c

I 1

J
M I |
fT t T 31 iI i, J ' _ _ _ _ _ _ — . __ — _ —_ _„ _,^
11 12 3 X13339
14 Y X1031 8 0.35 0.35 0.35
I 0.5 BR/SW SW GE
51 70 35

r
31 A GN/S W ,, 1 3J f

i f-> 4 —e» » — •> f — >f —>

rn n n
ii
r ir3 1* r i 1¥ i T V i H
f
8| J5 85 8 j 85 3M U 58 II 54 1 1 r^r,

\5 ] ,_ ™^_
^ I
_. ,
T
__rn_ . .
\
_ _ . „ _ „ „
—
H
31 A L t S* i-~
i —9-
JI
— *- J-H
.—
^ i-~

.
^ 31 A L JI

— ..^ L ^
> |_#
31 A J I
.
31 A

62 1 [ X1350 2 X 13502 5
40 64 T 4 2T
1 0.7 5 I 075
0.5 0. 51 0. 5 0.5 0.5 0.5 I SW/R T I GR/G N
GR/GN WS/R TJ GE/S W GE/SW WS/SW GR/BL 4 1 3 I X31 9
AA
[^ 5 _A_ A X1342 ° 5 4 |^ X1342 1 " " | " " E4 6

M
8 8

i JV
I• >E 7r - j
I[ 1 Lef t headlight ^ ' Righ t headlight (V ) 4 (V )5 4 ) Ta" '*'
/^ - /X? N3 ) Side lights >, 3 ) Sid e lights VC V W 5 j 5 ) Brake light
93 Q y3 I 1 1 IDSidemarke r| ]J1 1 " $3 ( J
V 3 11 ) Side marker |
[ -* • ' ligh t , ;
i 1 I I
, nyi n f • p |
i r— - , ... * - . f t | ^L
I —>• | T
.— 1J
,
J L j 1 IX31 9
1 0.7 5
7 X 13420 7 X13421
1BR
2.5 2.5
BR BR 1 X 13795
A
X13783 X 13782

B510ele2347ia
Side light, parking light, brake light
Wagon without Xenon lights as of 09 / 2005 u p to 03 / 200 7
(page 2 of 2)

' Steerin g colum n

(C^ switc h cluste r
3) Direction indicator/lo w
J bea m switch

9 |1 61 5 X1880
10 51 0. 5
1R T1 Bu m
\6 I X1060 5

30 1 2 91 X1676 0
AA
- — -- - -- - - I A1676 0
I1 . Body-gatewa y
\<Qn modul e
I
. |

8 1 9 I X1676 0
] X1500 2 ] X1500 1

J
0.35
WS/GE
0.5 I 0. 5
GE S W
X12
14Jl_ 2 8
"""" " ^ ' A 3
Light modul e
54 5 45 85 85 8

1
i* i 1 1 16 " t~~ ^ r^ 6" t
1
* "'
29 | 0 5 30~"T ~1 0 ~| 3 |4 9 ^ X 1 2
SW/GE ° °
75 7 5 0. 5 0. 5
X11218 WS/B R SW/B R GR/B R GR/S W
• ^ 2 j^ ij ^ X31 8 2 J[ X70 9 2 J [ X71 0

| I" * I Noi ,p „,„„,„„„, ' ! Tai l lighl. outer right x~ X Licens e piate /O \e P'ate

,u j p n J i ! •»«•«*• x Y
| 58 ^ -.- « -»- « | No^suppre . ^^ ^ A A ^ ^ Q A ^ ^

I T 3 1 I 3 1 I I I—a . t I X7n q ' ' x/1 "

1_ I 31 A t T j I I
' 1AT ^0.5
Y 2 xnQl 4
^2V T X1391
! h 1 °R5 0.5
I XU»1 3 I T BJ 1B R
SW/GE 0. 5 0. 5 X11 2 73 | X1127 3
1 A X13 8 B R | B R 07 5 ]
1" ' HL(4 aB RJ
T* Auxiliar y brak e _| _ X 13794 x^yq p i
2 V X13 8 ligh t j .

B510ele23471b

Electrical Wiring Diagram s ELE-34 3

 Electrical Wiring Diagrams ELE-34 4

Side light, parking light, brake light

Wagon with Xenon lights up to 03 / 2005
(page 1 of 2)

'r — T1 A149 a
1.5
\Q)\ Ca r access
n' ' I syste m

I I/ — N| ' Ligh t module

.2.i-J
V X1031 8
1 0.3 5 ! -T - !
I VI/S W
1 ^ X78
H
MC H2 Brak e ligh t 6
switch
9 Y X 12

3 | 0.35 4~ ^ 0.35 2 X7 8Q N
1 BR/G R BL/RT 0.3 5 5 I X1333 9
1 X117 9 ^
• ^ -
9
r 1 ^ n A149 a
1 rh ' Ca r access X13787 I J ^ ' \ 8 } Lightin g for light
=
11 5 lT x l I syste m •*• I I g . o b o b | switc h unit

!<- U-4 !
i I
L 14JhV X1031
» 8
Vn i 31 J 11 I 1
-j-^ =i J-
2 T1 0 T3
^^ ^
T X1333 9
"
I 0.3 5 I 0.3 5 0.3 5 0.3 5
0.5 I BR/SW GE/G NS WG E
51 70 1 7 31 3 63 5
31 I
GN/S W ^_ A _ A A A

58

r2 T1 X 13502 X 13502
40 64 42
0.75 0.75
05 GR/GN
SW/RT
GR/GN I 0 5 GR/BL
0.5 4 3 X319
I GE/S W GE/SW
"l E4 6
8 I X1342 0 8 X13421 |
•s . A^ 1 Taillight . outer lef t
I- lE 7 r 1E 8' / C ~X i 4 ) Taillight
-^ j ]' Lef t headlight 1 _^ 1 Righ t headligh t 1 (J > C) 5 Is ) Brak e ligh t
/) 3 L J n1 3 ) Sid e ligh t 1 A3 1 3 ) Side ligh t 1 -
)« d
Y
y 1 1 11 ) Sid e marke r I V1 11 ) Sid e marke r I
I ligh t I
\ *1
1
.i — ». j ,

X13420 7 X13421 1 X319

2.5 1.5
2.5
BR
BR BR/GE
X18132 X18139 X 13795
.L

B510ele20894a
Side light, parking light, brake light
Wagon with Xenon lights up to 03 / 2005
(page 2 of 2)

,
A72
1 II Steerin g column
1
mj
i switch cluster
1 3) Direction indicator/low
1 beam switch
1 [j .
1 ' i
1
J 1 — ^J

1
1 X10334 6 X1880
1.0
GE
1 X13583
'~ i A22 0

ra
I Safet y and
I gatewa y module

--i A 3
I Ligh t module

58 58

T
—— 1
49^ X12
0.5 0.5
SW/BR GR/SW

2 X710

T ~> E4 7
I Taillight , outer
I righ t
I 4 ) Taillight
1 5 ) Brake light

Yl
I 3 1 A U0
U I
I
31 1 31 I
t±
1 fb.5 !T | X13914 2 X13913
1 SW/G E 0.5 0.5
1 A X13 8 BR BR
,, " H34 a
^^- Auxiliar y brake X 13794 X13792
2 y X13 8 ligh t J.
B510ele20894b

Electrical Wiring Diagrams ELE-34 5

 Electrical Wiring Diagrams ELE-34 6

Side light, parking light, brake ligh t

Wagon with Xenon lights as of 03 / 2005 up to 09 / 2005
(page 1 of 2)

..p.

!t T y i i
system

2 V X1031 8
035
f
1 AA X7
VI/SW
: 8
S29
Brake ligh t

H| 0.3 5
I BL-'R T 0.35
I X18 1 BR/SW

32 X1031 8 S8
Light switc h unit
A149a
I—I X13787 j 1) Ligh t switch
n Ca r access * \ 8) Lighting for light
' syste m

M D8 '
switch uni t
I J £ i
lb~- 1 i |
M7 ! | , -., -T —1 J
->
\1

12 J 1 0T 3
14 X10318 0.35 I 0.3 5 j 0.3 5
0.5 BR/SW 1 GE/G N 1 SW
31 GN/SW 51 70 73 1 3 61 3 5
r

las
I GE/S W
8 I X1342 0 E46

E7
Left headlight
3) Sid e light
n E8
Right headlight
3) Side light I
TaiHight, outer lef t
4) TaiHight
5) Brake light
T
11) Side marker ' 3 11 ) Side marker I
light ' light

1 X319
0.75
X13421
BR
2.5
BR X13795
X 13782

B510ele22791a
Side light, parking light, brak e ligh t
Wagon with Xenon lights as of 03 / 2005 u p to 09 / 2005
(page 2 of 2)

A72
Steering colum n
switch cluster
3) Directio n indicator/lo w
beam switch

A3
Light module

B510ele22791b

Electrical Wiring Diagrams ELE-34 7

 Electrical Wiring Diagrams ELE-34 8

Side light, parking light, brake light

Wagon with Xenon lights as of 09 / 2005 up to 03 / 2007
(page 1 of 2)

,c
-T-
-
system

2 Y X1031 8 i3 0
1 0.3 5
1 VI/S W
1 4 > X7 8
S29
Brake light
switch 69 X12
| 0 35 4 I 0.3 5 2 I X7 8 0.35
I BR/G R I BL/R T J 035 GN
I X117 9 I X18 1 I BR/S W 5 X 13339
S8
32 I X1031 8 ,__- .... ..jjg.
Light switch uni t

I
/*\ j ^ T A149 a

1" "
1) Light switch

-m 8
I
rT ' Ca r access 8) Lightin g fo r light
I
- \ switch uni t

— B. JJ
I

V] !
T 31 ij
=f
, p , ^J ,
X13339
X10318 0.35 1
1 103 5 1 0.3 5 0.35
0.5 BR/SW 1 GE/G N 1 SW GE
GN/SW 51 70 73 1 3 6J 35
x— — -- ~. . yyv— . . .. _ _ _ __/*\_

Tl
I 3 1 -i

Tail light, outer left

5) Brak e ligh t

X1379S

B510ele23472a
Side light , parkin g light, brak e ligh t
Wagon with Xenon lights as of 09 / 2005 up to 03 / 2007
(page 2 of 2)

1 A7 2
• Steerin g column
, switc h cluster
. 3 } Direction indicator/low
_j bea m switch
- .....
T 5 X188 0
1 0.
0.55 0.5
I RRTT BL/RT
I XX10606
1 X10605

1 2 9
n A1676 0

iI §
— ,. Body-gatewa y
4^?) , modul e
J^\
I

8f
1

9^Y X1676 0
| X 15002 ] X1500 1 0.35

JT~^
WS/GE
I 0. 5
GE IS W
32 1
/N__ 14_JL_ 2 8 X12
A3
Light modul e
54 54 58

29 T °- 5 30 1 10 | X12
SW/GE 0.75 0. 5
X11218 WS/BR SW/B R
21 1 I X318
1 A X1391 3 E47
,
Z13 Tail tight, outer right
No.se suppressor |

X13792

B510ele23472b

Electrical Wirin g Diagram s ELE-34 9

 Electrical Wiring Diagrams ELE-35 0

Side light, parking light, brake ligh t

up to 03 72005
(page 1 of 2)

A149a "I A3
I Light module

30 1

L__b>—
2 V X1031 8
J
1 0.3 5
1 GN/S W
1 A X7 8 69 Y X1 2

2 cz :
S29
0.35
Brake light
1 switch GN
3 [ 0 . 3 5 4~ ^ 0.35 2 X78 5 X1333 9
I BR/G R BL/RT
1 X I 179 X181
f
BR/SW |
32 A X 1031 8 I ,
^ " I A149 a I ,, \

L
r
1r S* Ca r acces s i
i i l l r
1 syste m
' [

- 1r iz i
X13787
j. 1
1T 1 I T.J

JL . J
L 14_hV X1031
>J 8
0.5 BR/SW GE/GN 1 SW
31 J ^ GN/S W 5 1
73 -— 36 -i - - :

31
r
_trt. — &*
40 64 42 j " 6 2^
| X1350 2 X 13502 0.75 I 0.7 5 0.35
SW/RT 1 GR/G N WS/RT
.5 I 0.5 0.5
^ X319
3R/GN j GE/S W I GE/S W GR/BL f
^" > E46
(14135 1 I X1412 1 1 I X1412 2 1 X14136 I „ Taillight, outer left
1 ---- i H7a H4a
—-1—1 E8 4) Taillight
r-a
f
1^ 1 Direction indicator Direction indicator Right headlight 5) Brake light
fight, front lef t
1? Side marker
light, fron t right
1) Side marke r
3) Side ligh t
n
i

X14136
0.5
BR
0.75 0.5
X923 BR
BR
X 13795 X13795

B510ele19466a
Side light, parking light , brake light
up to 037 2005
(page 2 of 2)
A72
Steering coiumn
switch cluster
3) Directio n indicator/So w
beam switc h

1 X1033 46 X1880
1.0
GE
1 X1358 3
r ~ J n A22 0
i S 8 Safet y and
— t— ^1 Ligh t switch unit ; 4_ M gatewa y module
i , 1 1 ) Ligh t switch ; i-^- l;
\ 8 ) Lightin g for light [ _
|3 6T 3 5 T X1358 1

j ' X1500 2 ' X1500 1

X13339 f ^ j ^ 0.35
WS/GE
0.35 0. 5 0. 5
GE G ES W
32 I 1 4 I2 8 X12
\. /* \1
iA3
' Ligh t modul e
58

T31 1
1
•i center console )
Z13 E47
Noise suppresso r ! Taillight , outer
right
4! 4 ) Tailligh !
I 5 } Brake light

31 i

B510ele19466b

Electrical Wiring Diagram s ELE-35 1

 Electrical Wiring Diagrams ELE-35 2

Side light, parking light, brake light

from 03 / 2005 up to 09 / 2005
(page 1 of 2)

A149a
Car access
system

2 V X1031 8
1 0.3 5
1 GN/S W
1 | X7 8
V*
a^a

M ra Brake light
switch
3 Y~0.3S 4 ^ H3.3S 2 ^ X7 8
1 BR/G R BL/RT I 0.3 5
| X117 9 X181 I BR/S W

J ^ ^ | X1378 7 j "
32 1 X1031 8
7
1 | f r 1 A149a
15 n I Ca r access
— ?—(O )l s ysfem
jD
L 4 ^ T
fen ' 31 i J
,_ -^_-__ - __-_ ^

14 V X1031 8 1 0.3 5 1 0.3 5

0.5 1 BR/S W 1 GE/G N
31 1 GN/S W 6 1 70 1 7 31

X13502
).75

0.5 0.5
;3R/GN
GE/SW GR/BL
X14122 X14136 E46
H7a Taillight, outer left
H4a
Direction indicato r 4} Tailiight
Direction indicato r Right headligh t t
light, front lef t 5) Brak e light
light, front righ t 3) Side ligh t i
1) Sid e marke r 1) Sid e marker
light

2 X14122 2 Y X14136
0.5 0.5 0.75
BR I B R BR
X923 | X92 3
. „ •P >

B510ele22782a
Side light, parking light, brake light
from 03 / 2005 u p to 09 / 2005
(page 2 of 2)

1 A7 2
r~ i A 3 1 Steerin g colum n
r?-\ Ligh t module ! switc h cluster

| ] Lj
_1 3 ) Direction indicator/low

H s
-] | bea m switc h

j„
' i' 1 f X1033 4 6 X1880
69 T X1 2 , 0
0.35 G E

GN 1 I X1358 3
5 X1333 9A
Ar — - i A22 0
"1 1 S 8 1 ^ 1 Safet y an d
T ^ Ligh t switch unit ' (V^ ) gatewaymodui e
41 \ 1 ) Light switch ' I-5E- 1 '
\) Lighting lor light j _ _ j
1' ' switc h unit " ^^ v
|3 6T 3 5 T X1358 1
I ' X1500 2 ' X1500 1

10~Y S^ f X1333 9 1 1
0.35 0.3 51 0- 5 0. 5 0.35
SW G EG ES W
WS/GE
36-JL 35 _J^ 32 JL 14 Jl 2 8 X12

t* t » " ~ l A3
hn r 11 Ligh t module
54

31

1135
WS/SW

r--f-
Z13
Noise suppressor

0.75
BR

X13792

B510ele22782b

Electrical Wirin g Diagram s ELE-35 3

 Electrical Wiring Diagrams ELE-35 4

Side light, parking light, brake light

from 09 / 2005 u p to 03 / 2007
(page 1 of 2)

A149a
Car acces s
system

ij i
2 Y X1031 8
1 0.3 5
1 GN'S W

m s
1 A X7 8
S29
Brake ligh t

3 f 0.35 - 4- 1 0.35 2 X78

1 BR/G R BL'RT 0.35
1 X117 9 ^ X181 ^ BR/SW

11 r
X10318
r ' 1
.
A149 a
X13787 "
i 1 Ca r acces s j . U-
11 51 7 j syste m

14 Y X1031 8
1 0. 5
11
( 0.35
~*T~"1 0.35
-
BR/SW 1 GE/G N
31 I GN/S W
51 70
A . . V_ - - I ______
73.....S™^.

31 A

25
,— ^- ~Y ^ 62 |~0.3 5
1 1 X1350 2 X 13502 4 0 I 0.7 5 I 07 5 I WS/R T
4_A X31 9
1 0.
1 n 5= 1 0.
1 n5 r 0,5 r — t •+ - f~ " ^ E4 6
GR/GN 1 GE'S W
n
1 GE/S W GR/BL I _ LI ] Tai l light, outer lef t
1
1 X1413 5 1 | X14121 1 I X1412 2 1 X14136 I 6 0 f lG ' 4 ) Tail light
ji E 7
|H4 a r ~ ] ' E 8 1
y4 M U5 5) Brak e ligh t

\»
1
II 1 H? a
X^x Lef t headligh t 1 /<C/\ Directio n indicator • /\ \ Directio n indicator /C> \t headligh t t |
(A ) 3 3 ) Side light s ( X i 1 light , front lef t rv
1
I- pi 1 ) Sid e marke r light 1 ^r y | 1 ) Side marker ligh t ] V- ' j , _ j
ij 1 •-- -\• L.--1 - .6 ] X319
2 Y X1413 5 2 Y X1412 1 2 T X1412 2 2 Y X1413 6 0.75
0.5 1 0. 5 0.5 I 0. 5 BR
1B R 1B R BR 1 BR
1 X913 I X92 3 | X92 3 X 1 3795
| X91 3
»^™™^-™^^ • . _j*~
L . .

B510ele23475a
Side light , parking light, brake light
from 09 / 2005 up to 03 / 2007
(page 2 of 2)

A3 1 A7 2
Light modul e • Steerin g column
. switc h cluster
• 3 ) Direction indicator/lo w
beam switch

,_K__j To , 16 T
1" 3 ^
5 X1880
0.5
KQ I X1 P I RT I BURT
69 X1 2 X1060 6 X10605
035 1 ^ i
*•
X 16760
5 lxiN3339 3 ° A i 9J

~i A1676 0
I , » " !S 8 I r- n • Body-gatewa y
t I 9 S W ""' ' <)) ] . modul e
4 1 \ 1 ) Ligh t switch I lS5 j
\) Lightin g for light I I
? swltc h uni1 " "" ^ ^v "
1 8 1 9 1 X 16760
11 J X1500 2 ] X15001
is. 0.35
lO^f 3 Y X1333 9 1 1 WS/GE
0.35 0.3 5 0. 5 0.5
1S WG E1 G E1 SW
36 1 3 53 21 1 41 28 X12
— A— . — A- . . . A —A

Light modul e
58

29 | 0.5 30 I 5 I1 0
I SW/GE
sw; 0.75 I 0.3 5 1 0. 5
X13913
1 Jl , X13 ! WS/BR I WS/S W I SW/B R
—»
! 213 5 1 4 I 3 I X31 8
Noise suppressor i X14256 (in center console)
E47
filter
54 Tail light, outer right
J, rr
11 t I ~5r— iVI7 ^
i 4) Tail ligh t

v
T7 1 i 5) Brake light
T
U
f-*
1 31 1
31 1 31 1

2 Y X1391 3 2 X13914
1 A X13 8
H34a X318
BR
Auxiliary brake 0.75
X13795 2 V X13 8 light BR
0.5
^ BR X13792

B510elo23475b

Electrical Wiring Diagram s ELE-35 5

 Electrical Wiring Diagrams ELE-35 6

Side light, parking light, brak e light

Sedan as of 03/2007
(page 1 of 2)

A149a
Car access
system
r
1M j -> A 3
\fC~\\ Ligh t modul e
2 V X I 03 18 1^1
30

T
1 0.3 5
1 VI/S W 1

m
1 A X7 8 1
S29 i _
E3 Brake light ' $S~
*___J
X12
j switc hb aT
3 Y~0.3 5 4~ ^ '"o.SS 2^ X78 1 0.35
1 BR/G R BL'RT 0.35 1 GN
| X117 9 X181 BR/SW 5 _ _ _ _ 1 X 13339
r _ _ _ _ *
•> S 8
32 A X1031 8 1 . . f 1

r l ^- 1 A149 a

i f m 0 !"" ™
14 1 1 ) Light switc h
' n Ca r access
i1 ' I " ^
; " °
\) Lightin g for light
switc h uni t

i I
% i i
,__p ?!__
14 T X1031 8
, jL
X13787 ,
V~
_ J -
" ^
I'
T
~ ^
3~Y X 13339
l

I 0.3 5 I 0.3 5 0. 35 0.3 5

0.5
1 BR/SW 1 GE/G N S W GE
31 GN/S W5 1 70 I 7 31 3 6 35
^1 _ . _ , . . . , AA A

7T b mT
yT 3i 1 I I
.i± -t^ -
'„ -
_t_^ _ _-_ _, .

63 2T 64 42 62
0.5 0.5 1 0.5 0.75 0.75 0.5
GR/GN 1 BL/G N BL/BR GE/GN SW/RT Gfl/GN WS/RT
1 7 1 X13 0 , X13 5 4
A 6 7 X338
"" E 8 i :

U
"" E 7
nE1 6
H ' Lef t headlight i Righ t headlight
Tail light, lef t

£>• < ?<)= ^

M 11 ) Sid e marke r ligh t JA 11 ) Sid e marke r light s
<) 1 6 /\) Brak e ligh t
I 11 16 ) Side lights/daytim e y 1 6 16 ) Side lights/daytime Q >

[• 1
T^ drivin g light V3 7 ) Tail light
driving ligh t ^
I
I l>
„1
4 X130 4 X135
8 X338
2.5 2.5
BR 1.5
BR
BR
X 13783 X 13782
X13791

B510ele25810a
Direction indicator lights
Wagon as of 03 / 2005 up to 09 / 2005

A72
Steering column
switch cluster
3) Directio n indicator/lo w
beam switc h

X1880
0.35 S18
WS/GE
Hazard warning/centra l
locking switc h
A220
Safety and
gateway module

28

A3
Light modul e

075
BL'BR
H9a H8a
Direction indicator Direction indicato r r E47
light repeater. E46 E8 light repeater, I Taillight, oute r
front lef t Taillight. outer left Right headlight front right I right
3) Directio n 12) Directio n I
3) Directio n
indicator ligh t indicator ligh t I
indicator light

B510ele22775

Electrical Wiring Diagrams ELE-36 5

 Electrical Wirin g Diagrams ELE-36 6

Direction indicator lights

Wagon as of 09 / 2005 up to 03 / 2007

A149a
Car access
system
A72
Steering column

Lei switch cluster

3) Direction indicator-low

"16 T" 5 ] ' X188 0

beam, switch
0.35
<=a A i U J !O
0.35
3.5 I 0. 5 GR/RT GE/ RT
TT I BL/R T X51
2 JI 1 J

T;
K 10606 1 X 10605 S18
J Hazard warning/central
1
LA X1676 ° locking switch

rit*
K
"^-~~---' 1 A1676 0 1 \ p
r-z- -, . Body-gatewa y I
iv^y-y i modul e
i 1 r'~1'
, i 3 4 X516
"IT" 91 X 16760 0.35
BR
X15002 j X1500 1
jj: [ ^ - 0.35 X943 0.35 0.35
WS/GE i BR/BL BL'BR
3.5 I 0. 5
3E I S W
^
j 1.

14J^ 2f L. 52 45 X12
A3
Light module

H9a
Direction indicato r E46 E47
light repeater. Tail light, outer lef t Taii light, outer righ t
front lef t 3) Direction 3) Directio n
indicator lam p indicator lam p

B510ele23468
Direction indicator light s
Wagon as of 03 / 2007

i- i A149 a
[<C5ii ^ ar access
-,(- [vl2 J syste m

iii, m.
~i. A7 2'
Steerin g colum n |
"^T j
"
, switc h cluster * U
I 3 ) Direction indicator/tow X90 8 ^ [ _ T"* 1
_i bea m switch ? P " i
9 r1 6 r5
^ „ ~ — w— — ™ i ./ 1 2 9 X1031 8
X1880 o.3 5 0.3 5
0.5 0. 5 I GR/R T GE/R T
I R T BL/R T 2I 1 X51 6

| S1 8
hT | ^ Hazar d warning/centra l
30 J ^ 2 9 ^ X1676 0 "S lockin g switch
V S ^ I
[" ~ " " j A1676 0

r ' I
I i^^ l- Body-gatewa y

11
v^— ~ — i^ j• — ~V *
3T 5 4 X51 6
8 1 9™ Y X1676 0 1 03 5
| X1500 2 | X1500 1 1B R
0.35 1 03 5 03 5
WS/GE | X94 3 ^ BR/B L BL/B R
I 0. 5 I 0. 5

32 J L .i 4J^ _ 28 J
GE S W
A5 2I 4 5 X1 2

1
n-
h "* —
Ligh 1 M
t module

E7 H9a HSa
Direction indicator E46 Direction indicato r E47
Left headligh t
light repeater , Tail light, ouler lef t light repeater , Tail light, outer righ t
12) Directio n
front Sef t 3) Direction front righ t 3) Directio n
I indicato r light
indicator lamp indicator lam p

X319
0.75
BR
X13795

B510ele25806

Electrical Wiring Diagram s ELE-36 7

 Electrical Wiring Diagrams ELE-36 8

Backup lights Backup lights

M54 engine with manual transmission Sedan with N62 engine with manual transmission

S8511
Reversing light

V
switch SHM1
Reversing ligh t
switch
X8511
05 I
05 BR 1 "~ 2J X851 1
GR/Vi X6458
0.5 I 0.5
GR I B R
X6011 (i n E-box )
12 X60094 I X646 0
0.35
GR/VI 1 AB00 9 & "
X12 • Integrate d supply
j modul e (IVM )
A3
1
Light modul e
5 ' X600 9
0.35
GR
not used
V J
X12 Y
0.75 0.75

Sedan
WS/GE
"1 GE/WS
Sports Wagon
•>*
SMG transmission I
automatic transmission 1
manua

13 I X1 2
O
l transmission

j i^ | Ligh t module

if J m f
|E16
6 | Tail light, lef t
16) Reversin g light
|E80
| Taillight, inner lef t
1 11 ) Reversing light
n -H
L Jr* "j
I I
41 Y 26 ^f X1 2
0.75 1 0.75
WS/GE 1 GE/W S
3 X31 93 I X318
A. i* \I i gi g I I i E1 7
X13795 X318
|E81 ! x~ x Tai l light, left j x^> . Tai l light, right
|E17 | Taillight, inner right 1 (/ O 6 i 6 ) Reversing OK )6 1 6 ' Reversing
[Tail light , right 1 11 ) Reversin g light
1 i_f c1 '' 9ht i_- k1 Ii9h t
6 |6 ) Reversin g ligh t I
I
1 Y X31 9 1 Y X31 8
15 1 5
1B R1 B R

B510ele19471 B510ele20380
Backup light s
Wagon with N62 engine with manual transmission

Reversing light
switch

,1 1
1 2 T X851 1
0.5 I 0.5
OR 1 BR
12 X60094 1 X64 60
' A600 9 * -*•
Integrated supply
module IV M
1
j ±.
5 X6009
035
6R
not used

manual transmission

X12
A3
Light module

E80 r H - j E8 1

I Taillight , inne r left . X~ X | Taillight , inner righ t

I 1 ) Reversin g light | \/\) 1 | 1 ) Reversin g ligh t
I TLf rI I T-* .I

B510ele20381

Electrical Wiring Diagram s ELE-36 9

 •••••••I

Electrical Wiring Diagrams ELE-37 0

Backup lights Backup lights

N52 engine up to 09 / 2007 N52 engine as of 09 / 2007

S8511
S8511
Reversing ligh t
Reversing light
switch

X8511
0.5 0.5 X8511
GE BR 0.5 0.5
GE BR
X6011(in E-box )
X6011 (in E-box)

0.35 I
not used J:
GR/VI not use d 0.35
GR/VI

automatic transmission manual transmission

SMG transmissio n automatic transmissio n manual transmissio n
SMG transmissio n

13 X1 2
A3
Light modul e A3

IJ 5 15
Light modul e

41 26

X14256 (i n center console)

1 23 X14256 (i n center console)
0.75 0.75
WS/GE GE/WS
3 X329 3 X328

i E8 ° r
E81
I E8 ° I E81
i Taillight , inner lef t • • Taillight , inner right
' Reversin g light . i 1 ) Reversin g light i Tai ! light, inner lef t . I Tai l light, inne r right
i 1 ) Reversin g light i 1 i 1 ) Reversing iight
I I

B5IOele21885 B510e!e2S850
Backup lights Backup lights
automatic transmission automatic transmission as of 03 / 2007

0.5 0.5
GE SW

0.5 0.5
32 SW
GE
A3
Light modul e
A3
Light modul e

0.75 0.75
X12
WS/GE GE/WS
0.75 075
WS/GE GE/WS
Saloon Touring
Saloon . Touring

1
/xr~x
X319 3

| Tail light, left |

I
r\ i i"
JE17
16 I

• Tai l light, righ t .

X329

JTaillight,
JX32
E81
I Taillight .
JE16 f E17 f
I I
• Tail light, inner lef t t
-I
E81
Taillight,
i 6} Reversing • inner lef t ., i inner right I Tail light , lef t i Tail light, right .
i O v 6 I 6' Reversing | inner right
j1) Reversin g • , 1 ) Reversing 16) Reversin g iight i i 6) Reversing light . 1) Reversin g ligh t ,
1 I 1) Reversin g
I J_+ l light | _
_4zt.J«flM I I I I I
I^t- J light
1T X319
X328
075
BR
BR
I X1379 5
X11273

B510ele19472 B510e!e25824

Electrical Wiring Diagrams ELE-37 1

 Electrical Wirin g Diagram s ELE-37 2

Fog lights Fog light s

up to 03 / 2005 from 03 / 2005 u p to 09 / 200 7

A3
A3
Light modul e
Light module

69 X12
0.35
GN
5 X 13339
S8
S8
Light switch unit
Light switc h unit
2) Fo g light switch ]
2) Fo g light switc h
3) Rea r fog ligh t switch
3) Rear fog light switc h

A3
A3
Light modul e
Light modul e

v v s
44 I 6 T 23 67 X12
15 1. 5 0.75 0.75
44 "T~ | 5 6 T 1 5 23 67 ' X12
1 GE/R T 1 GE/R T GE/SW GE/RT I GE/R T I GE/R T 0.75 0.75
1 I X76 8 1 I X76 9 GE/SW GE/RT
1 1 X76 8 1 I X76 9 >
9
TV 2 ] f 24 ~1 ' X14P5 R ^ n cen'er
I E2 6 f „,.„. - (in center

c
1 E2 6 E2 7 1 2 1 24
X14256 console )
0.75 0.75 /Ov Lef t tog X~X Righ t fog 0.75 0.75
-S, Lef t fog x^> . Righ t fog
GE/SW GE/RT

T2 J
0<J 'iOn t (X) Ij 8ht GE/SW GE/RT
K) Ii9h t (X ) ''9" '
X329 2 X328 X329 2 X328

V
Ji
2 T X76 8 2
v
T X76 9 -
i
1
-k , i E8 ° r
Tai l light , , x ^~X |
i Tai l light,
I
2 T X76 8 2 T X76 9 I
I1
S. i
E8 0 r
Tai l light. .
- 1
^ ~X Tai
"I E8 1
l light.

I v,C>
<J 2 i inne r lef t (
r^ 2
><f) 2 | inne r right
) Rear fog N -^ , 2 ) Rear tog
1.5
1B R
<J 2 inne
r-^' 2
r lef t ( ><J 2 , inne r righ t
) Rear fog N -^ ] 2 ) Rear fog
| X1813 2 | X94 2 i 1?Lj ligh t j "Z*Lj ligh t I X 13783
X942 [ _ ~^_j ligh t | 'Z'Lj |j ght
,_» j- ^ , X329 1 X328 A ^ 1 X329 1 X328
0.75 0.75 A 0.75 0.75
BR BR * BR BR
X18510 X18510 X18510 X18510
— i fa

B510ele20379 B510ele22787
Fog lights S8 Light switch unit
as of 09 / 200 7

A3
Light modul e

1 A50 3
r-=-, | Head-u p
iMl i if dis Plav
S8 i- —,
J_ 7

V-
Light switc h unit 1 X1381 9
2) Fo g light switch
\
3) Rea r fo g light
0D ( switch
0.35 0.3 5
1 BL/BR BL/G E

X 13339
).3S 0.35
1 2X 13339
3E/VI WS/BR
33 X12
f Light switch
A3 unit
Light module
55 55
10 3 79 8 1 25 1 16 4 X1333 9

r .9
~~ —

375

<768 2
5

3E/RT I

E26

(\?\t foa f\A

(X) »9
— —

M (X
—

0 T
y

0.7

GE/R T
I X76 9

)
5

E27
Right fog
light
23
0.75
GE/SW

075
GE/SW
67 X12
0.75
GE/RT

f X14256f' ncenler
0 75
GE/RT
console)
36
0.35
SW

35
0.35 0.3
GE GEA/

" "
34 3
"
5 0.3
I WS/B

37
-
5 0.3

.
47
.
5 03
R GR/S

-
36
-
5 03
W GE/G

-
NG

97
- -
5 0.3

01
N BR-'SV

___^ Ligh
5 03
VR
5 03

96
_ _ —, --
TW
5

0 X1
S

2
,A3
t modu l

TT
V ^
2

r i n E8° r
X329 2 X328

ii es i
l©J
1 T X76 8 1 T X7B 9
xr> jTaiHiant . x-> ,| Tai l light.
1 0.7 5 1 0.7 5 ( X ) 2 inne r lef t ( X ) 2 inne r righ t
1B R 1 BR V7 2 ) Hea r fog ^ 2 ) Rea r fog without xeno n headligh t wit h xenon headligh t
| X1378 3 I x94 2 L_4I*lJ light I Jl?l j lifl W

i
i
1 [ X32 9 1 |X328
I 0 75 I
•*•
0.75
BR 1 BR
I X1851 0 1 X1851 0

B510ele26604 B510elel9893

Electrical Wiring Diagrams ELE-37 3

 Electrical Wiring Diagrams ELE-37 4

Low beam / rain sensor Low beam / rai n sensor

up to 03 / 2005 from 03 / 2005 to 09 / 2005
RLS Rain / light sensor RLS Rain / light senso r

A46
"• A4 6 Fuse holder,
Fuse holder , rear
F55
| 3 0G | F5 5

]5 A !
i

pp pp
1
28 X1101 2
28 X11012
X15012 X15011 X15006 X15005
XI 5012 X1501 1 X1500 6X 15005

t
• —• • L^J • •' *~ »"t^ » --="•™«wi L., •^

i I I I
0.5 not Convertible Cabriolet
RT/GR
0.5 no t Convertible Cabriole t
0.5 0.5
RT/GR

r
GE SW
0.5 0. 5
GE S W 3 X1308 4
1 43 X1308 4 B57b
Rain/headiight
"1 B57b
Rain/headlight sensor
sensor
—r* [ a
J
J
2 Y X1308 4
2 X1308 4

0.75
0.75 BR
BR X1816
X 13790

B510ele19450 B510ele22773
Low beam / rain sensor Low beam / rain senso r
from 09 / 2005 RLS Rain / light sola r sensor
RLS Rain / light sensor

r
i ~* A4 6
' Fus e holder .
r ^ A4 6 I , . , I rea r
it | 11 i 30 Gi i li "bb 1
Fuse holder,
i
iii i
I1 1
i1 p(- R rea r
(
j1—
5 Ai
30G |
i
F5 6 5A 1 1
*i
L

i i
J1 1
i i 1
1
i L ii 1
i i i

ii_
,

8 X11012
j j

, rr r
j/ r ""A 3
28 X11012
i. , Ligh t module
X15012 X1501 1 X1500 8 X 15007 fOi '
p
ISEJ 1

16 Y X1 2
P
0 35 0.35 0.3 5
Cabriolet RT/GR BU'G E
RT/GR n0 t Convertible
0.5 0.5
GE SW
1 43 X 13084 1 2 I X1315 1

T=
j —' '
B57b f-> B57 a
Rain/headltght p Rain/ligh t
._«
31 1 M rr "
sensor solar sensor

31 A n J
O

31 I

2 T X1308 4 3 | X1315 1

0.75
BR 0.35
BR
X18I6

i X 18063

8510ele23459 Bb10ele26131

Electrical Wiring Diagrams ELE-37 5

 Electrical Wiring Diagrams ELE-37 6

Electrochromic mirror Electrochromic mirror

Sedan and Wagon Coupe and Convertible

r i A4 6
' Fus e holder,
1 , , rea r
| | 1 5 | F8 9

11 f "l 1 __-_ ^
5A 1 f
11 ' [ L J1 ' — ?—Ligh t mod u e
J1 [7 = >] f ]'
1
i L s4 I
1
t_ i JH> '
r-0 I
with high beam assistan t

28 X11012 |
I,
TI r '
,' X1501 2 X1501 1
65 X12 . fc~. ,-.-. - ^

0.35
0 35 1 1 0. 5
I G E
ITs
i
3 GN/GE 1 X18246 2 I 1 I X1428 4
s /^i —— - j*\

A22
Eieclrochromic
i »— «N 15/3 1=
r^ ^ 15/3 1I
An K
o ~r~
—H \Q)\ iIA K o
I isi —i
view mirror

31 I|-» - j U

0.35 5
4 X 18246
Eiectrochromic
BR 0.35 interior rea r vie w
X 13792 WS/GE
L
44 45 X16759
I A1676 0
, Body-gatewa y ,
5

I
, modul e X 18246
0.35
BR 0.35 0.35
WS/GE WS/BL
X 13792
X16759 14 T X1676 0 X1662 X1662

X1663 X1663
(in front
035 (in front i
WS/BL °35
WS/BL driver's v __ 1
passenger
side door )
21 X62 4 side door) 2 7 X257 2 7Y 26 X256
-f
0.35 035 1 0.35 0.35
WS/GE WS/BL 1 WS/GE WS/BL
r - - --"i Y 5 -- --- (in driver's 3 1 1 X1520 ( in passenge r
X1519 3 I

.riir-j,
' Outsid e mirror, Outside mirror. side mirror ) t I / side mirror)
j driver' s sd e Passengers side ^ ^
A198 A199
Electrochromic Electrochromic
outside mirror, outside mirror,
driver's side passenger's sid e

B510ele23560 B510ele23605
Electric outside mirror, driver' s side

A23a

A23a
Driver's
15 door

uI T\ o -wi (
module
13 1A j J
fU
^^
eY~ :i~ l i —s-
1^ 2 'X01172 4 ' 5 6 'x01050

I
i Outside mirror , driver's side
i J .—
LL,O 7a A
1) Positio n
4 <!
s> 2 ^
n5 J potentiometer, vertical

^
2) Actuator motor ,
Kf '// c
, ^
s vertical
_1_. , T' n 3) Actuato r motor,
horizontal
|I 4) Positio n
i potentiometer, horizonta
5) Heatin g
6} Fold—i n motor
X01050 1 X01172

A23a
Driver's
door
module

B510e!e19777

Electrical Wiring Diagrams ELE-37 7

 Electrical Wirin g Diagram s ELE-37 8

Interior lights
Sedan or Wagon with SHD Slide/tilt sunroof 2

light package

30 30

f-*:... _. . _
yy
|- * .. . . fc * .... . __ ._ .. _ _ .... .. . .. . _ . . . . . . . . . — *•
2 < X 13254 5 4
'
52 X 13252 1

1 Ligh t light packag e RT/WS

X18121
58 j(O ) | r ' ""> &
X18122 X18122 X1812 2 X18122
11
L X10148 X10148 3 X541
E42a
Glove compartment
light

0,5
RT/BL 6
E34 E108a
Interior light , front Rear compartment S37a
0)OFF interior light Glove compartment
1)ON 0) OFF light switch
2) Map-readin g light 1) O N 1) Glov e
3) Interior ligh t 2} Map reading compartment open
4) Top light lights X540 2 ) Glove
3) Interio r Hght compartment closed
4) Top-light 0.5 BR
RT/GE X943
1 X38 4 X712
0.5 E32 E33 -« .
RT/GE Luggage Luggage X667
0.75 X381 compartment compartment light ,
BR £61
E35 E36 light trunk !id/£aiigat e Footwell light ,
Make-up Make-up front lef t
mirror light. mirror Sight , X384
front lef t tont righ t

X381
0.35
GR/SW
X401
S77 S78 M17b
Make-up Make—up Trunk lid central
mirror switch , mirror switch, iocking drive with
front left front right trunk lid contact switch
0)OFF 0)OFF 0) Trunk lid closed
X401 1)ON 1)ON 1) Trunk lid open
0.35
BR
X13791 X13791

B510ele19477
Interior light s
Wagon with SHD Slide/tilt sunroof 2

light package

~>A1a
I Basic
I body
I module
I

1
52 X13252 1 54 53 X1

r1 A3

T
58 (O ILight 0.5
LVL4. module BL/RT BL
f
1
UH-*— J X18122 X18122 X 1
43 1 X1 2 3 X6
[ X90 8 X10148 X10148 X10148

1 0.3 5 0.5 0.7 5 0.5 0.5 J0. 50 .

1 GR/R T RT/BL RT/G E RT/BL RT/GE 1 RT/BL R 1
,..4JL_ _J L S -
6 X33
A
6
|E34
1 13
(*\
X C
t ' X6

^
1ol Interior light,
fron
oP r 1
01OFF

i
/ /
1)ON A <!
AP- X
(X) (X )
x^-X
A, r\
I I 2) Map-reading Tient
/N o light ch
\ 3 v^ y v2 v
(V^ \ {^C^
• 4 6 t '
i V 3) interio r light
ii i i 4) Top light
2 Y X36 4 nent
^iq. 31
7 8 T X33 6
05 Tient
0.5 0.5
BR
RT/GE 1 RT/G E
X13792
2 1 X38 1 1 X38 2
0.75 •f ••*• 3 X 367
BR I E3 5 t36 1 I 3 X357
E61
j E39 a Footweli
rXj mirro r light . PxQ mirro r light. /° Interio r light,
YY fron t lef t X-^ fron t light y rea r lef (5 5 front let!
i /r
1 I X381
0.35
1 T X38 2 Q
0.35 S
>?)
y (X)
jr
1 t X66 7
I 05 O.E
I GR/S W 1 GR/S W BR BP
1 1 X40 1 1 X4°2 2 1' X35 7 I X1813 2 X1
•">
! b/ / S78 0.5
11 0 Make-u p 61 ° Make-u p BR
/ mirro r switch . / mirro r switch. X13791
</ fron t lef t </ fron t righ t - *.
]m npc IC ) ^F F
3 tx40 1 DO N 3 YX40 2 1)O N light packag e
10.35 I 0.35
IBR 1 BR
X13791 1X13791 1x13791

B510eiel94/6

Electrical Wiring Diagrams ELE-37 9

 Electrical Wirin g Diagram s ELE-38 0

Central locking Central lockin g

Driver's door Passenger's doo r

.
~] A24 a
— «.— i

J 3Gt31 30/3 1 _ 30/3 1 Q d Poaosrmno9deu7e

L? P
A23a
...-«—. — ~-f~- pA L3? J• - 4- >I
Driver's : M
| „-£ -i

LJ door J .F T
^ ^- 4 " "^
Y
r^l r if 1 Lvi-J *-- * module *E > f ^ ^ j ' 1
^ ^
vL
1 12 10 ^ 4 ' X 10668
. __ ^
1 "~ 1 0^ 13^ 4 X 10667

0.75 0.75 0.35 0.35 0.35 0.35

WS/BR BL/GE SW/GE WS/GN BL/RT GE/BL
0.75 0.75 0.35 0.35
WS/BR BL/GE SW/GE GE/BL

6 7 8 5 4 2 X10489
6 ,7 8_ _ 2 X 10693
S246 S254

e- n
I
j System : System
£xT lock, J~L lock ,
driver's ^.r-7^ ^s
HH ^^^t
door
aE passenger's
door
v./

3 ' X 10693
0.5
BR
0.5
BR
16 X 10667

16 X10668
| i Driver's
31
31 *1IWMll I doo r e
modul
r }Z ^" ! A24a
I II P Passenger' s
iV liC")i i I door module
31

B510ele19413 B510ele19414
Central locking
Rear doors and fuel filler flap

A1a
Basic
30/31 30/3 1 30/3 13 CG 30/31 r7
= r i 30/3 1 30/3 1 30 G 30/31 30/3 1h ,H

u 4i
> r* T • i I1
— »_ — •— bod y
nf ] modul e

?-* II
jr*1 t * t* "i
_r *1 h* _ -H -
s' 7 4 X13253 1 2 X 13252 13 11 9 X13253 2 8 X 13252 5 12 ' X 13253

0.75 0.75 0.75 0.35 0.75 0.75 0.75 0.35 0.75 0.75
WS/BL BL/BR SW/BL GE'SW WS/VI BL/WS SW/VI GE/BR BL WS

23' 24 -5 22 ' X273 (in rear 23 * 24 25 22

right door)
left door)

0.75 0.75 075 0.35 0.75 0.75 0.75 0.35

WS/BL BL/BR SW/BL GE/SW WS/VI BL/WS SW/VI GE/BR

6 7 8 2 X10694 6 7 8 2 X 10477 1 2 X312

1 " ^—^ 1 M1 6
S2553 I S256 3
^v System [O! - T x l - Syste m ^^ ' Centra l
^>
L> lock, rea r ISZl ' —i—' lock , rea r m lockin g drive ,
HH left doo r HH I righ t door n fue l filler flap
3 X 10694 3 X 10477

0.5 0.5
BR BR

X834 X835

B510ele19415

Electrical Wirin g Diagram s ELE-38 1

 Electrical Wiring Diagrams ELE-38 2

Driver's door module Passenger's door module

power supply power supply

A41a I A4l a X 15008 X 15007

Fuse F1P ' Fus e
holder. /P 2 ! holder,
front [ j 30 A i fron t
I
I, j
1 ' X1100 3 3 X11003

0.5 0.5 0.5 0.5

GE sw GE sw
35 X13581 36 35 X13581
A220 1 A22 0
Safety an d 1 Safet y an d
3O JO E5
gateway ' -& a| | gatewa y
module module
I.
5 X1358 12 1 X1358 3
i
13
f-»
X13581 3 V X 13583

40 0.5 1.0 4.0 0.5 10

RT/VI WS/GN GE RT/GE WS/GR GE

X257 ('n 'ron* driver' s 9 ^ ~ 1 8 11 X256 ( m front passenger

side door ) side door )
4.0 05 1.0 4.0 0.5 1.0
RT/GE WS/GN GE RT/GE WS/GR GE

X1128 t X1130 2 1 X1131

i '-
A23a A24a
V
T T&
Driver's

T
Passenger's

fa J ta
door door
ta module fa
31jf
module
2 5" ' X112 9 2 3 X1130

25 1.5 2.5 1.5

BR BR BR BR
(in Iront driver's 1 0 X257 X849 X256 X891
n! passenger 1^
side door )
oor)
4.0 4.0
BR BR
. .

X I 3789 X 13788

B510ele19411
B510ele1941£
Basic body module Blower / independent ventilatio n
power supply

r" 1 A41 a r - . A11 a r - i A 11a

Fuse holder , j Heating/ai r. . Heating/ai r

I| 3 0I | 3 0| I li± 4 syste m' ' syste m

i' Ii ' —,1 i —,1
!! il l • j 30 A | | • L
| 1 1 T X1879 3 1 T X152 7

M
30A

lt

I — '\ [
s
5 ' 7 X11004 ' ' A41 a ^ ,
'I Fus e holder , [HK A Basic IHK A H gh
Ir —1 c o ' fron t
13 0 | F 3 |
—
1
1
~"A41a i iT i i i
Fuse holder . 11 40 A1 i

1| 3 0
en 1
R1 |3 0 |
,„ J
r"
ront
Ii ' ' T' !
i

!!1, 1ii —U LJ
11 f I f
I I 30A | Jr BL'R T
tL

i .J 1 ^ I
X15008 X1500 74
3 X1100
-°
1

1
,^ - . ^ » 2 ^RT.'B L 1 ^X1372 8
I

2 { X1100 3 2 1 X11005 4.0 4.0 I j U. ' U .N *

0.5 2.5 RT/GE RT/BR I 0 5 I 0 5 f |f ) Blowe r output
RT/SW RT/Vl GE s wy | —1-« FO I3 0| —,-• g stas e
3 X13254 2 X13253 4 , 1
l x1325539 i^^l 8 4 X13252 3 1 1I 1, fe^- T\ r^
r— , —&. :_». '^ ' V» ~ ~~ ~ " |A1a S M M U T 3i 1
r
! L
V
J | T^ 1 T
[| [

|(O) jf '
j1 Basic bod y 3

3
1 1 —

T X1372 8 4.
s> J

0 4.
31 A

0
1 (Qr~~ ~ M^ f] O 1 E2 1 pj 1 I 4. 0R TB R
H7
i3 1- . TaTl y I 31 i T 31 1 1 B H M3 °
31 1 j | X 13788 ^^ Blowe r moto r

X 13253 ^^-"
1
40 H
BR
X 13782

B510ele19417 B510ele19490

Electrical Wiring Diagrams ELE-38 3

 Electrical Wirin g Diagram s ELE-38 4

Heating and air conditioning control unit Heating an d air conditioning control unit
power supply power supply
IHKA Basic up to 09 72005 IHKA Basi c as of 09 / 2005

A41a
Fuse holder,
front
i A41 a
I Fus e holder,
I fron t
F26
I3 ?
I ]I
11 L JJ
j

1 ' X 11005

X
Mm

0.75 0. 0.5
RT/SW G SW

10 7
A11a
Heating/air
conditioning
system

0.75
BR

B510ele19488 B510ele23480
Heating and air conditioning control unit Heating and air conditioning contro l unit
power supply power suppl y
IHKA High up to 03/2005 IHKA High as of 03 / 2005 up to 09 / 2005

~> A41 a
Fuse holder,

i(
' fron t
A41a I
Fuse holder .
front I I* * |
i

15A I

5 X11005

5 ' X1100 5

X1
X1 X15005
——

1.5 0.5 0.5 1.5 0.5

RT/GN GE SW RT/GN GE

1 X 13765 7 1 X13765 7
A11a
Heating/air Alia
conditioning Heating/air
system conditioning
system

X13765 2 5 T X152 7

X13765 2 5
1.5 0.5
BR BR
1.5 0.5
BR BR

B510eie19489 B510ele22795

Electrical Wiring Diagrams ELE-38 5

 Electrical Wiring Diagrams ELE-38 6

Heating and air conditioning control unit Heated windshield washer jets
power supply
IHKA High as of 09/200 5

r n A4 6
' Fus e holder ,
CQn Heating/ a r ro H I Healing/ai r
| | 30 G | r° 4 ^c I^E7 i conditionin g, c i^^ i conditionin c

TJ
11 r — *— syste m ™f — syste m
11
I - j
L_ — i
-4* - "i - -4 *- i
1 15 T X1879 3 2 0 T X152 7
1 t
1 X11011
^1
{

IHKA Basi c IHKA High

X 15006 X 15005 0.5

GN/SW

X1301 X1301

1.5 0. 50 5
RT/GN G ES W 0.5 0.5
GN/SW GN/SW

1 X13765 7 6 X152 7 1 X105 (unde r engine hood ) 1 X106 (unde r engine hood )
S A_ .A
f ~f- »" I Ali a
rS '
11 ^ 1 Heating/ai r E51a " j bb2 a
C Heated washer |— — ] Heate d washer
i v I ^ ^ [^Gl l ' 1 ^ ' conditionin g cID
—j nozzle, lef t ^ 1 nozzle , righ t
I31A| p ISZ I n I syste m
c
p

|_ \ 3 l l 3 1 I j
2 | X13765 2 5 |
X1527 ^
2' XI 05 (unde r engine hood ) 2 X106 (unde r engin e hood )

1.0 0. 5 0.5 0.5

BR B R BR BR

X1598 X1598
X875

X 13784 | j.

B510ele23481 B510ele19451
Rear window defogger Rear window defogger
up to 09 / 2005 as of 09 / 2005

J5_ j A11 a | _ , 15 A11a A11a

(©] f]
uI Heating/ai r I [© j 7 l '
[j |
Heating/ a
conditionin g
IS T
y
Heating/air
conditioning
12 ~?J^
yT
Heating/air
conditioning
system

FT
system
rtT system

14 T X1879 3 ) Y X152 7 14 Y X1879 3

IHKAHigh
IHKA Basic 035 IHKAHig h
035 GR/SW
GR/SW
9 X1101 5
A46
A46
Fuse
Fuse F54
F58 holder.
holder,
rear
rear
|N 40 A -
t-___|________™j

101061

21 X11012

4.0 40
RT/WS RT/WS
Sports Wagon Sports Wagon
Sedan

1 ! X1415 0
101101 1 Z1 t Z1
Wave f7~^ i Lockou t circui t | Lockou t circuit for
trap 1 •^=^ ! fo r rear-window rear-window defroste r
\r (positive) - - ^ (positive )
1 Y X0105 8 X14151 1 f X1415 1
E9
Rear
window
defroster
1 Y X37 9 (in top ot tailgate) X379 (i n top o f tailgate)

101102
Wave
1Rear
E9
E9
Rear
trap 2 window window
—I defroste r defroster
1 |
X38 0 (in top of tailgate) 1 I X38 0 (in top of tailgate)
4.0 40 40
BR BR BR
X13793 X13793
X13793 X13793

B510ele19441 B510ele23448

Electrical Wiring Diagrams ELE-38 7

 Electrical Wiring Diagrams ELE-38 8

Power window Power window

without KG M body gateway modul e without KG M body gateway module
Driver's door Passenger's door

. i- , e __ j
j A23 a A ^4a
Driver's : 5 8 CC S Passenger' s
2 doo r -£- doo r module

module
— ^^ ... - ...tri^L
1Y 8 ''X13807 8 X1380 8

0.35 R'l?Q-r 0.3 5

RT/GE GR/RT GR/R T

14 X10725 3 A X317
f-» window switch,
Swi'ch i jX / / / pass e nger's doo r
r^ Wock ,{ / < / „ , /" , , 7 o „ 0)O FF
^T— ]driver' s" i0 [ 12 0 1 | 20 1 34 0 3 1 4 1)O p 9H
I 31 1 M 31 floo
l rt I I 2 ) Co ivenient open
31 i
; Y' l r t T Q R O v /Pt " i~ Y voi 7/ 3 ) Close
2Y3 ^ Aiu/ ' ::a 4
2 4 1 Aol
) Convenient clos e

0.35 0 q" s 0 5 0.3 5 0.3 5

BR WS/BL B R GR/G N GR/W S

X13807 2 1 5 |
4 [ X13R0 8
2I 3 ,
£-» 3 03 0 " * A23 a '~ » tj- > jf- * .3 0 _3 0 A24a
Passenger's

0 *?
»-» 3
3u 0 (
1 A f~
I ~ Jv
» 3
ny
1 i I
* ^~^
|
9'
I [
modul
,
e 31 * 0 TaY
_ t- *i
Iy T
31 A j
' 0
— »3
% i r&* n ¥
1 * J I j
4 Y 5~YX112 9 15 Y 3"Y " 1 7Y ' " 18YX1066 7 4 T 5YX113 0 15 Y 3 Y 1 7 Y" 18YX1066 8

25 ? 5 03 5 03 5 03 5 03 5 2. 5 2. 5 0,3 5 0.3 5 0.3 5 0.3 5

RT/BL SW/B L RT/W S BRAA/ SW S GE/W S RT/B L SW/B L RT/W S BR/W SW S GE/W S

5 6 2 1 4 3 X74 95 j[ 6 J^ 2_J ^1 J[_ 4 J^ sj ^ X74 4

M23

U
| | I i MP 1 i I i

e
Driver's ; Passenger's
window
motor

a^V ^ ^ -fe^ ^ o f A / ^ -£]J —

^Y ^ ^ L r^^ : j X Y ^ 7 V j

^. .. i . |

B510ele19422 B510ele19423
Electric sunroo f
Sedan to 09 / 2005

r
"• A4 6 A33a
Fuse holder, rear 58 H Sunroo f
30G F8 3

i 20A
[i —*•
8' ' X91 6
7 '"X11011
0.35
BR/BL
X15012 X1501 1 2f X643
S38a
[ i tI I I i Slide/til t
£ ! \ : -^ X \ \ f
*; i t ^ j o • » , _, s « o ^ o v switc h
': I I

6 3T 4~ T5 7 X64 3

2.5 0.5 0.5 0.35 0.3 5 0.3 5 0.3 5

RT/GR GE SW BR/GE GE/W S GR/S W GE/G N
1 13 12 4 7 6 5 X91 6
»-* \-r- ^- » i- » A33 a

31 F T "— ^ —®— '

[] I II I Sunroo f
3U b — iV
T3li T
nli &-
3 T31
1
I
311 H
2' ' X91 6

2.5
BR

X 13792

Electrical Wiring Diagram s ELE- 3

 Electrical Wiring Diagram s ELE-3 £

Electric sunroof
Sedan from 09 / 2005

i Fus e Sunroof
| holder , rea r 58

1 _ ,

035

X11011 BR/BL

Slide/tilt
sunroof
switch

2.5 0.5 0.5 0.35 0.35 035

RT/GR GE SW BR/GE GR/SW GE/GN

A33a

Sunroof

31 -* -
Electric sunroof
Wagon to 09 / 2005

A46 r" " A33 b

Fuse |@| Panoram a
|~30G ~" I F8 3
holder. —}— glas s roo f
1 |T l 1 rear
1 l | 20 A1
i4j 1
' -J~ *
16 ' ( X1410 2
\
X11011
0.35
BR/BL
X15008 X 15007

2 X643

u
M \
.
I 6
N. \
i sunroof
Slide/tilt

\aswitch
|_ J ° f ? J f
T
34 5 X643

2.5 0.5 0.5 0.35 0.35 0.3 5 035

RT, GR GE SW BR/GE GE/WS GR/S W GE'GN

.i* ff
4 3 12 15 1 4 13 X 1 4 1 02
15 15 i- f i- » I-* . 15 \-+ 15 A33 b
~n~ Panoram a

r^r ^ 31 i T wt t a
15/31 1 5 31 r-T- 1 ES 0 ^/3 1 f,5/3 1 F

rJ-
T U glas s roo f
r~CT*
?& T
^~~} 31 1
31 1 T | — k^—B
i 1 ' —fr - T
r^3
2 X 141 02 1 2 5 6Y3 ' 49 8 10 X1410
7

2.5 2.5 25 035 0 35 0.3 5 2.5 2. 5 0.35 0.35 0.3 5

BR SW GE SW/BR SW/GE SW/G N SW/BL GE/B L BL/BR BL/GE BL/G N

XI 3792 1 _ 2 3 4 5 X1410 51 23 4 5X 1 4 1 04
M14105 i m M14104
-Vi^E |ij5| Glas s ^trv I \£2)\r
V / l^-*} rnn f l^^l m^trt r
~*~*'
^ - ^

__ _ t-pn(n r

B510ele2o377

Electrical Wiring Diagrams ELE-39 9

 Electrical Wiring Diagrams ELE-40 0

Electric sunroof
Wagon from 09 / 2005

A46 A33b
Fuse Panorama
I | 30 G holder, glass roof
I rear
I
il 16 X1410 2

8 Y X1101 1
0 35
BR/BL
X15004 X1500 3

S38a
Slide/tilt
sunroof
switch

X643

25 05 0.5 035 035 0.35 035

RT/GR GE SW BR/GE GE/WS GR/SW GE/GN

X14102

15 15 15 15

15/31
31

31 A
X14102 1 10 X14103

25 25 25 035 035 25 2.5 035 035 035

BR SW GE SW/BR SW/GE SW/BL GE/BL BL/BR BL/GE BL/GN

X13792 1 5 X1410 5

L L
M14105 M14104
Glass Visor
roof motor
motor

B510ele23442
Horn Horn
up to 09 / 2005 as of 09 / 200 5

11 11 r~3
f p'
)Q A

Fuse \ n
holder, switc h

1 1 [ j |„. __j Horn

! :rr3'
switch
l Y 2~YX0100 5

'X11005
0.5 0. 5
VI G N X01005 (inside steerin g wheel)

56 X0100 3 0.5 0.5

VI GN
[" ~ j A149 a """"I"* ' "J- * I010 M

1 [ S ' Car Electroni c

IWJ 1 access U U fo ] steerin g
L j syste m M j 3 1 A whee l A72
91X10318 T 31 A m °dUie Steering
column
1 y" iY " JTl ^ 4 ^ sTt ^ eYxoioo 2 switch
X010334 cluster
1.5 0.5 0. 5 0. 5 0- 50 5 0. 5 0. 5
RT/BL GN/GE W SS WR TG RG NB R
X1880

2 7 X188 0 1 2 3 4 56 X0100 1
0.75 0.75
, —B> "1— »- i- > " | A72 VI/GR VI/BL
t Steerin g
45- (S I J 5 U colum n
Cp
7T ^ T 3 1 J ^i' *
131 1 _.l j duster H2 H3

311 _ 4 ^. _ f -* J Fanfare
(horn), lef t
Fanfare
(horn), righ t
1 3Y~ 4^X188 0
^ (low-pitched) (high-pitched)
2.5 I 0.75 0.7 5
BR I VI/GR VI/B L
2 I X13 2 2 X13 3
I
JLx, H 2 i . H 3 0 75 0.75
BR/GE BR/GE
Fanfare , : Fanfar e
LJj (hor n , left "-r-k j (horn) , righ t
(low-ptched) i fhiah-Ditched )
O V
1 T X13 2 1 1X133 X942 X942
I 0.7 5 0.7 5
1 BR B R
1 X942 X94 2
i , nt -

B510ele19443 B510ele23451

Electrical Wiring Diagrams ELE-40 1

 Electrical Wiring Diagrams ELE-40 2

Driver's seat heating

with SMFA Seat module, driver
up to 03 / 200 7

• switc h
t cente r

JL-
A187

I Driver's
I seat
I module
I
I

5 I X1398 7

0.35 1.0 1.0 4-circuit sea t heating 0.35 1.0 0.35 1.0
BL/GE SW/BR SW/VI BL/GN SW/VI BL/GE SW/BR

X732 X733
E56a E57a
Driver's Driver's
seat seat
backrest cushion
heating heating
X733

1.5
BR/SW

X13985

A187

Driver's
seat
module

B510ele19437
Driver's seat heating
with SMFA Seat module, driver
as of 03 / 2007

"I A169
Center console
J switc h center

X13989

A187
Driver's
15 15
seat
module

3 4 2~Y~ 5 |X13987
2l 5 T 4 ' X 13985

TT Y T T
L
035 1.0 I 03 5 1 1.0 4-circui t seat heating | 0.3 5 | 1. 0 0.35 1.0
BL/GE SW/BR I BL/G N 1 SW/V I BL/GN 1 SWA/ I BL/GE SW/BR
2 3 5 11 1 X73 2 3 X733
V_ — . --*> -- A 1 '—I
1 1
.*. .2
™»
^
_1

I r- 1 I [- 1 E56 a H H

r_ ^ f
Lr'c^ 1 -f T 9 ^ Driver' s sea t |V9 r ^ rt^ 9 r ^ Driver' s
"Y C ^" YC ~ backres t heatin g

I I
>• — ^cushio n
X732 , YX733
w<healln 9
4 4
1.5 1.5

r
BR/SW BR/SW
X13987 X 13985
' J 0

i; h " "
1 ~ "
~j A18 7

i[ 3
J
I Driver' s sea t module
1 3 1 J [I ^
^ 2 3
1 1J I
J

B510ele25787

Electrical Wiring Diagrams ELE-40 3

 Electrical Wirin g Diagram s ELE-40 4

Passenger's seat heating

with SMBF Seat module, passenge r
up to 03 72007

Center console
switch cente r

X15005

i
I 05
| S W
I
6 1 X1399 0

A186
I Passenger' s
I sea t module
I

T
5 I X1398 8 X13986

0.35 10 0.35 1.0 4-cirouit sea t heatin g

0.35 1.0 0.35 1.0
BL'GE SW/BR BL/GN SW/VI BL/GN SW/VI BL/GE SW/BR

X740

ESE.i
Passenger's Passenger's
seat backrest seat cushion
heating heating

4 X741 4 X740

1.5 1.5
BR/SW BR/SW

1 X 13988 1 X 13986

I Passenger' s
I sea t modul e
I 31

B510ele19438
Passenger's seat heating
with SMBF Seat module, passenger
as of 03 / 2007

I S840
I Centr e console
' switc h cluster ,
' fron t passenger
X17529

1X10812

0.35
WS/GE

1 I X1691 9
"\9
' Cente r console
' switc h center
X16919
0.5
SW
X15005

0.5
SW

X13990
___ 6 J,

Passenger's
15 15 15 seat module

4
2 J[ 5T X13986

1.0 0.35 1 .0 4-circuit seat heatin g 0.35 10 0.35 1.0

SW/BR BL/GN SWA/I BL/GN SVV/VI BL/GE SW/BR
3 5 X741

E59a E58a
Passenger's Passenger's
seat backres t seat cushio n
heating heating
4 T X74 0
1.5 15
BR/SW BR/SW
1 I X1398 8

I Passenger' s
I sea t module
31

B5lOele25?89

Electrical Wiring Diagrams ELE-40 5

 Electrical Wirin g Diagrams ELE-40 6

Driver's seat module, Passenger's sea t modul e

power suppl y power suppl y

_ _ _ „- ,
A41a

Fuse Fuse

r'"*
holder holder,
'"I F3 1 front r--37' F1 4

i(
front
i« A41a
Fuse
30A 1
!l I 30A "38' holder,
front

'~
*
-— —

X11005
6 X11005 5 X11003

2.5 2.5 2.5 2.5

RT/BR RT/GN
RT/SW RT/BR

1= J
semi-electric basi c seat not semi-electric basin seat semi-electric basic seat not semi-electric basi c seat
XI5002
m BOi IBBWtr -* i

0.5 X15010 X1500 9

SW

-j^ r\ 1X13989
A187 0.5 0.5
GE SW
Driver's
seat
module X13990
A186
Passenger's
seat module
31

X13989 31
X13990

2.5 2.5 0.35

BR BR
BR
X13784 X13784

X13789

B510ele 1942
9 851 Oelel 943
0
MOST-bus networ k
up to 09 / 2006

X15003

05 0.5
GE SW

9 11 X138 2

1 "J N38 a 1 "j N2 2 1 ~\3

1 i ^ 1 CCC/M-AS K I |(C~>i i 1L 1 |6~>| * Head-u p
I IW J 1 '-' 1
— '] display
I 1 1 1 1

1 2 X1381S 1 2 ' X1063 9 1 ' 2 X13835

10 10 10 1.0 10
GN GN GN GN GN
1.0 10
2 GN GN
1 X13836

dashboard
passenger
side)

114255
MOST-bus
connector

10 10 10 1.0 1.0 1.0 10 10 1.0 10 10 10 10 10

GN GN GN GN GN GN GN GN GN GN GN GN GN GN

1 2 X10633 1 2 X10642 1 2 X10637 1 2 X10635 1 2 X 14063 1 2 X 10638

m
~~j A18 a j " ~JA197 [ ~\a r ~JA112a \ Navigatio n~~]' N4 7 [ " ~~j N42 a
TCU ULF j

~~ " TT ^ L S3 M 83
1Top-HlF i 1 ] Video | I Satellit e ' lojl ' Headset
[©] ' DVD
j amplifie r I module j change r I syste m j j receive r j connection
ji _ i' ji _ „ ._ i module
XI0634 X10634
~jU400b "1 U400
C
ITCU !ULF

B510ele19774

Electrical Wiring Diagrams ELE-40 7

 Electrical Wiring Diagram s ELE-40 8

MOST-bus network
as of 09 / 2006 without CIC Car Information Computer

X15004 X15003

05
SW
11 I X13812
i 1 N38 a |
1 CCC/M - 1
1 N22
CD ch 1
1 A50 3
1 li-v l
Oil '
1 132 1 11
1 11 1 1 displa y
1' 2 " X13815 1 2 ' X1063 9
1' T ' X 13835

10 10 1.0 10 10
GN GN GN GN GN
10 10
1 2 X1383 6 GN GN
(under
dashboard
side)
114255
MOST-bus
connector

10 10 10 10 10 10 10 1.0 10 10 10 10 10
GN GN GN GN GN GN GN GN GN GN GN GN GN GN

2 X10633 1 2 X10642 1 2 X 10637 1 2 X10635 1 2 X14063 1 2 X 10638

ULF-SBX ULF-SBX- H1
TCU nterface box i n efface bo x High j "j A18 a [ " "JA197 [ " 1 N39a f ~JA112a I " "j N4 7 [ " ~ ~ ] N42 a
I \^\\ 1 Top-HiF i ' \fC~X\ 0 1 Video 1 j s~ -.I
1 DV D 1 l/C"~x! l<""Si

JLJ
1 amplifie r {
[ — ii —
1 module |
— iL —
1 changer ,
_ ji —
1 system |
— ii — . — j receive r (
— ii
1 connection
' modul e
X10B34 lj[ _ 2j [ X10634 X 10634

i I.Q J U400b C
I TCU I
" '~jU400 d
|@ | j ULF-SB X 1
fI
liQ I 1
U400e
ULF-SBX-H
i 11 11

B510ele26129
MOST-bus networ k
with CIC Car Information Compute r

/v X15003
• •Hill

J!
05
SW

11 I X1381 2
"j N38 b N22 j A50 3
' Ca r Information CD ' Head-u p
1 E69 ' Compute r CIC changer I displa y
1
1
f
X1381 X10639 X13835

10 10 10 10 1.0
GN GN GN GN GN
10 10
o GN GN
1 X 13836
(under
dashboard
side)
114255
MOST-bus
connector

10 1.0 10 10 10 10 10 10 10 10 10 10 10 10
GN GN GN GN GN GN GN GN GN GN GN GN GN GN

2 X10633 1 2 X 10642 1 2 X10637 1 2 X 10635 1 2 X14063 1 2 X10638

ULF-SBX ULF-SBX-H
TCU interface bo x interface box High I A197 ]N39a ,A112a JN47 N42a
I Top-HiF i I | H j Video JDVD ] Navigation ] Satellite j Headset
j amplifier I j module ichanger | system I receiver j connection
- J modul e
1I [ X10634
J ^ 2j I 2 I X1063
106344 1 I2 1 X10634
- -£- _£^.-^.^j _
""1 ' -"] U400 b j U400 d 1 U400e
i TC U ! ULF-SBX j ULF-SBX-H
I I

B510ele27138

Electrical Wirin g Diagram s ELE-40 9

 Electrical Wiring Diagrams ELE-41 0

Wiper / washer system

up to 03 / 2005

1 B57 b
j Rain/headligh t
j senso r
>. J 1 i Wiper switch
X10334 31 XI3084

"TS" 5 ~ " A1 a

f Basse
body
module

035 3.75
A46 3L/WS VI/RT SW
Fuse
i 30 holder, X13058
rear M95
Rear window
washer pum p
X11015
X13058
25
K'T V I

X61 K91

0— ~V
K6 Rear
X18132
Relay wiper
headlight relay
4~Y X1305 6
2~ washer
4' ' X6 1 J5 0.35
5W/GN BR
035 25 1
BR SW/BR
2 X1011 M94
Wiper
drive, rea r

X1011 pum p

X137B2 X13/88 I X1378 3

B510ele19448
Wiper / washer syste m
as of 03 / 2005 u p to 09 / 2005

TA72 lB57b
j Rain/headlight
I sensor
3t XI308 4

F18 -jA41a
!I Fuse
j holder.
( | 30A J I front
Hd
L
1 ' X11004
25
RT/SW
8 6 X61

y
r-—

Relay
headlight
washer

035
BR

BR
X13785 X13788 X13783

B510ele22772

Electrical Wiring Diagrams ELE-41 1

 Electrical Wiring Diagram s ELE-41 2

Wiper / washer syste m

as of 09 / 2005

A41a JA72 'lB57b

Fuse I Steerin g colum n j Rain/headlight
;o F16 holder, j switc h cluster
front 1) Wiper switc h
i30A 'ft X1308 4

X 10605

30^ _ 29^X 1 6760

,. :--~--^ , A1676 0
fO j Body-gatewa y
I modul e
U ~~ " i 6760

X15008

M95
Rear window
washer purn p

B510ele23456
 OBD-1

OBD On-Board Diagnostic s

GENERAL . OBD- I Drive cycle OBD- 5

Readiness codes OBD- 5
ON-BOARD DIAGNOSTIC S (OBD II) .OBD-1
Diagnostic trouble codes (DTCs) OBD- 7
Malfunction indicato r ligh t (MIL ) .OBD-2
Scan tool and sca n tool display .OBD-3 TABLE
Diagnostic monitor s .OBD-3 a.Diagnostic trouble codes (DTCs) . OBD-8

GENERAL
This chapte r outlines the fundamentals and equipmen t
requirements of On-Board Diagnostics II (OBD II) standards as they
apply to BMW vehicles. Also covered her e i s a listing of BMW and
OBD I I diagnostic trouble codes (DTCs).

ON-BOARD DIAGNOSTIC S (OB D II)

OBD I I standards were developed by the SA E (Societ y o f
Automotive Engineers) and CARB (California Air Resources Board).
OBD I I is the second generation of on-board self-diagnosti c
equipment requirements . These standard s wer e originall y
mandated for California vehicles. Since 199 6 they have bee n
applied to all passenger vehicle s sold in the United States .

On-board diagnostic capabilities are incorporated into the hardware

and software of the engine control module (ECM) to monitor virtually
every component that can affec t vehicle emissions. Th e OB D I I
system works to ensure that emissions remain as clean as possible
over the lif e of the vehicle .

Each emission-influencing componen t i s checked b y a diagnosti c

routine (called a monitor) to verify that it is functioning properly. If a
problem or malfunction i s detected, the diagnostic executiv e built
into the OBD I I system illuminates a malfunction indicator ligh t (MIL)
on the instrument panel.

The OBD II system also stores diagnostic troubl e codes (DTCs )

about the detected malfunction in the ECM so that a repair
technician can accurately fin d and fix the problem. Specialize d
OBD I I scan tool equipment i s needed to access the fault memor y
and OBD I I data.
OE3D-2 On-Boar d Diagnostic s
Malfunction indicator light (MIL)

The extra hardware needed t o operate th e OBD II system consists

mainly of the following:
• Additional oxygen sensors downstrea m o f the catalytic converter s
• Fue l tan k pressur e senso r and device t o pressurize fuel storag e
system
• Several engin e an d performance monitorin g devices
• Standardized 16-pi n OBD II connector under the dashboar d
• Upgraded components for the federally required reliability mandate

Malfunction indicato r ligh t (MIL )

OBD I I software cause the malfunctio n indicato r ligh t (MIL ) to
illuminate when emission level s excee d 1. 5 times Federa l
standards.

For 5 Series vehicles covered by this manual , tw o MI L symbols are

used.

MIL illuminates unde r the followin g conditions :

• Engin e managemen t syste m faul t detected for two consecutiv e
OBD I I drive cycles. Se e Driv e cycl e in this repai r group.
• Catalyst damaging fault detected.
• Component malfunctio n causes emission s t o exceed 1.5 times
OBD I I standards.
• Manufacturer-define d specifications exceeded .
• Implausibl e inpu t signal .
• Misfir e faults.
• Lea k in evaporative system.
• Oxyge n sensors observe n o purge flo w from purge valve /
evaporative system.
• EC M fails to enter closed-loop operation withi n specified time .
• EC M or automatic transmission contro l modul e (TCM) i n "limp
home" mode .
• Ignitio n key ON before cranking (bulb check function) .

OBD I I fault memor y (includin g th e MIL ) ca n onl y b e reset using a

special scan tool. Removin g the connector from the ECM or
disconnecting the batter y does no t erase the fault memory.

Additional MIL information:

• A fault code is stored within the ECM upo n th e first occurrence o f
a fault i n the system bein g checked.
• Two complete consecutiv e driv e cycles with the fault present
illuminate the MIL . The exception to the two-fault requiremen t is a
catalyst-damaging fault, which illuminate s the MIL immediately.
• I f the second driv e cycle was not complete an d the fault was not
checked, the ECM counts the third drive cycle a s the next
consecutive drive cycle. The MI L illuminate s i f the syste m is
checked and the fault is still present.
• Once the MIL is illuminated, i t remains illuminated unti l the vehicle
completes three consecutive drive cycles without detecting a fault.
• An existing fault code i s cleared from memory automaticall y whe n
the vehicle completes 40 consecutive drive cycles without the fault
being detected .
 On-Board Diagnostic s QBD- 3
Scan tool and scan tool display

In order to automatically clear a catalyst-damaging faul t from

memory, the condition unde r which the fault occurred mus t b e
evaluated for 80 consecutive drive cycles without the fault
reoccurring.

A generi c scan tool connected to the OBD I I plug can displa y

diagnostic trouble codes (DTCs), along with the condition s
associated with the illumination of the MIL. Usin g a more advance d
or BMW-dedicate d sca n tool, additional proprietary information is
normally available .

Scan tool and scan tool display

, Th e complexit y of the OB D I I system requires that al l diagnostics
begin by connecting a scan tool to the 16-pi n OBD I I plug insid e the
vehicle.

OBD I I standards requir e that the 16-pi n OBD I I plug b e locate d

within three (3) feet of the driver and not require any tools to access.

Professional diagnostic sca n tools available a t the time of this

printing include the BM W factory tools (GT1, ISTA ) and a small
number o f aftermarket BMW-specific tools. Se e
020 Maintenance.

In addition to the professional line of scan tools, inexpensive generi c

OBD II scan tool software programs an d handheld units are readily
available. Though limited , they are nonetheless powerful diagnostic
tools. These tools read live data streams and freeze frame data a s
well as a host of other valuable diagnosti c data .

Diagnostic monitors
Diagnostic monitor s run tests and checks on specific emissio n
control systems, components, an d functions.

A complete drive cycle is required for the tests to be valid. See Drive
cycle in this repair group. The diagnostic monitor signals the ECM of
the loss or impairment o f the signal or component an d determines if
a signal or sensor i s faulty based on 3 conditions:
• Signal or component shorte d to ground
• Signa l or component shorte d to B+
• Signal or component missin g (open circuit)

The OBD II system monitors all emission control systems tha t are
installed. Emissio n control systems vary by vehicle mode l an d year.
For example, a vehicle ma y not be equipped wit h secondary ai r
injection, so no secondary ai r readines s code woul d b e present .

OBD I I software monitors th e following:

• Oxygen sensors
• Catalysts
• Engin e misfire
• Fue l tank evaporativ e control system
• Secondary ai r injectio n
• Fue l syste m
OBD-4 On-Boar d Diagnostic s
Diagnostic monitors

Oxygen senso r monitoring . Whe n driving conditions allow,

response rate and switching time of each oxyge n sensor is
monitored. The oxygen sensor heater function is also monitored .
The OB D I I system differentiates between precatalys t and post -
catalyst oxygen sensors and reads each one individually. In order for
the oxygen sensor to be effectively monitored, the system must be in
closed loop operation .

Catalyst monitoring. This strategy monitors the two heated oxygen

sensors per bank of cylinders. It compares the oxygen content going
into the catalytic converter t o the oxygen leavin g the converter .

The diagnostic executive knows that mos t of the oxygen should be

used u p during the oxidatio n phase. I f it sees highe r than
programmed values, a fault i s set and the MIL illuminates.

Misfire detection. Thi s strateg y monitors crankshaf t speed

fluctuations and determines i f an engine misfir e occurs by
monitoring variation s i n speed between each crankshaft senso r
trigger point. This strategy is so finely tuned that it can determine the
severity of the misfire.

The system determine s if a misfire i s occurring, as well as other

pertinent misfir e information such as:
• Specifi c cylinder(s)
• Severit y of the misfire event
• Emission s relevant or catalyst damagin g

Misfire detection is an on-going monitorin g proces s tha t is only

disabled under certain limited conditions.

Secondary ai r injection monitoring . Secondar y air injection is

used to reduce H C and CO emissions durin g engine war m up.
Immediateiy following a cold engine start (-10° to 40°C), fresh air
(and therefore oxygen) is pumped directly into the exhaust manifold.
By injecting additional oxygen into the exhaus t manifold , catalyst
warm-up time is reduced .

Secondary air system components are :

• Electri c air injection pump
• Electri c pump rela y
• Non-retur n valve
• Vacuum / vent valve
• Min i air mass meter

The secondar y air system is monitored vi a the us e of the pre-

catalyst oxygen sensors and a mini ai r mass meter . Th e oxyge n
sensors monitor exhaust gas for a lean condition onc e the air pump
is active and air is injected into the system.If the oxygen servsov
signal does not change, a fault i s set and the faulty bank(s )
identified. I f after completing the nex t cold start a fault is again
present, the MIL illuminates. The mini air mas s mete r monitor s th e
air supplied by the secondary air pump when commanded on. If the
mini air mass meter detects n o air mass o r insufficient air mass, a
fault is stored in the EC M and the malfunction indicator ligh t (MIL) is
activated.
 On-Board Diagnostic s OBD- 5
Drive cycle

Fuel syste m monitoring . This monitor look s at the fuel delivery

needed (long / short term fuel trim) for proper engine operatio n
based on programmed data, i f too much or not enough fue l is
delivered over a predetermined time, a DTC is set and the MI L is
turned on.

Fuel trim refers to adjustments to base fuel schedule. Long-ter m fue l

trim refers to gradual adjustments to the fuel calibration adjustmen t
as compared to short term fuel trim. Long term fuel trim adjustments
compensate for gradual changes that occur over time.

Fuel system monitoring monitors the calculated injection time (ti ) in

relation to engine speed, load , and precatalytic converter oxyge n
sensor(s) signals.

Using this data, the system optimizes fuel delivery for all engine
operating conditions .

Evaporative system monitoring . This monito r checks th e fuel

storage system an d relate d fuel lines for leaks. I t can detec t very
small leaks anywhere in the system .

A leak detection unit (DMTL) is used to pressurize the EVA P system

on a continuous basis (a s the drive cycle allows) an d to chec k
system integrity.

Drive cycle
The OB D I I drive cycle i s an importan t concept i n understandin g
OBD I I requirements. The purpos e of the driv e cycle i s to ru n al l of
the emission-relate d on-board diagnostics over a broad range of
driving conditions .

A drive cycle is considered complet e when all of the diagnosti c

monitors hav e run their tests without interruption. For a drive cycle to
be initiated, th e vehicle must be started cold and brough t u p to
160°F and at least 40°F abov e its original starting temperature.

Readiness code s
Inspection/maintenance (I/M) readines s codes ar e mandate d a s
part of OBD II . The readines s code is stored after complete
diagnostic monitorin g of specified components an d system s is
carried out. The readiness cod e function was designed to prevent
manipulating an I/M emission test procedur e by clearing faults
codes or disconnecting the EC M or battery.

Readiness codes indicat e whether th e OBD II system i s actually

ready to monitor the various emissio n control systems on the
vehicle. The vehicle must complet e a drive cycle to set readines s
codes. The code i s binary:
• 0 for ready
• 1 for not ready
OEBD-6 On-Boar d Diagnostics
Readiness codes

^ iThe parameters which are monitored for readiness are:

1. Catalyst efficienc y
2. Catalyst heatin g
3. Fuel tank evaporative contro l
I/M readiness codes
4. Secondary air injection
/^ /2 £3/J / 5 / 6 /7 / 8 5. A/C refrigerant
6. Oxygen sensors
0 0 0 0 0 0 0 0 7. Oxygen sensor heater s
8. Exhaust gas recirculatio n

When
W all zeros are displayed, the system has established readiness.
Readiness
R( codes can be displayed usin g BM W and aftermarket
B701obd001
scan tools.

Readiness codes are set to 1 (not ready ) i n the following cases:

• The battery or ECM is disconnected .
• DTC s are erased afte r completion of repairs and a drive cycle is
not completed.
 On-Board Diagnostics OBD- 7
Diagnostic trouble codes (DTCs)

Diagnostic trouble codes (DTCs)

SAE standard J2012 mandate s a 5-digit diagnostic troubl e cod e
(DTC) standard. Eac h digit represent s a specific value. Emissio n
related DTCs star t with the lette r P for power train. When th e MI L
illuminates it indicates that a DTC has been stored :
• DTC s are stored as soon as they occur, whether or not the MIL
illuminates.
• DTC s stor e and display a time stamp.
• DTC s recor d the current fault status: Present, no t currently
present, or intermittent.

DTC digit interpretation

1st digit
P powertrain
B body
C chassis
2nd digit
0 SAE
1 BMW
3rd digit
0 total syste m
1 air /fuel inductio n
2 fuel injectio n
3 ignition system o r misfire
4 auxiliary emission contro l
5 vehicle speed & idle control
6 EClvl inputs / output s
7 transmission
4th - 5th digits individual circuit s or component s

DTC example: P 0 3 0 6
• P: A powertrain problem
• 0: SAE sanctioned ('generic' )
• 3: Relate d to an ignition syste m / misfire
• 06 Misfire detected at cylinder #6

DTCs provide a freeze frame or snap-shot of a vehicle performanc e

or emission s fault at the momen t tha t the fault first occurs. Thi s
information i s accessible through generic scan tools.

Freeze frame data contains, bu t isn't limite d to, the followin g

information:
• Engin e loa d (calculated)
• Engin e rpm
• Shor t and long-term fuel trim
• Vehicle speed
• Coolant temperatur e
• Intak e manifold pressur e
• Open / closed loop operatio n
• Fue l pressur e (if available)
OBD-8 On-Boar d Diagnostics
Diagnostic trouble codes (DTCs)

Diagnostic trouble code s (DTCs)

Table a. Diagnostic trouble code s (DTCs)

P-code BMWFC Definition
POOB2 2EEC Radiator Coolan t Temperatur e Sensor Circuit Range / Performance
POOB3 2EEA Radiator Coolan t Temperature Sensor Circuit Low
POOB4 2EEA Radiator Coolan t Temperature Sensor Circuit High
PO0 10 2A80 'A' Camshaft Positio n Actuator Circuit Open (Ban k 1 )
P0011 'A' Camshaft Positio n Timing Over-Advanced o r System Performance (Bank 1 )
PO0 12 2A82 'A' Camshaft Positio n Timing Over-Retarded (Bank 1 )
PO0 13 2A85 'B1 Camshaft Positio n Actuator Circuit Open (Ban k 1 )
PO0 14 'B' Camshaft Positio n Timing Over-Advance d or System Performanc e (Ban k 1 )
P001 5 2A87 'B1 Camshaft Positio n Timing Over-Retarded (Bank 1 )
PO0 16 2AA4 Camshaft Positio n Sensor Correlation (Bank 1 Sensor 'A' )
P0017 2AA5 Camshaft Positio n Sensor Correlation (Bank 1 Sensor 'B' )
PO0 18 2A8F Camshaft / Crankshaft Position Sensor Correlation (Bank 2 Sensor 'A' )
PO0 19 2A91 Camshaft / Crankshaft Position Sensor Correlation (Bank 2 Sensor 'B' )
P0020 VANOS Camshaf t Timing Inle t Rationality
P0021 VANOS Inle t Camshaft Rang e Rationality Check
P0022 VANOS Differenc e Betwee n Actual and Target
P0023 VANOS Outle t Circuit
P0024 VANOS Outle t Rationalit y Check
P0025 VANOS Outle t Rationalit y Check
P0030 2C9C HO2S Heater Control Circuit (Ban k 1 Sensor 1)
P0031 2C9C HO2S Heater Control Circuit Low (Ban k 1 Sensor 1 )
P0032 2C9C HO2S Heate r Control Circuit High (Ban k 1 Sensor 1)
P0036 2C9E HO2S Heate r Control Circuit (Bank 1 Sensor 2)
P0037 2C9E HO2S Heater Control Circuit Low (Bank 1 Sensor 2)
P0038 2C9E HO2S Heater Contro l Circuit High (Ban k 1 Sensor 2)
P0040 2C24 HO2S Signals Swappe d Ban k 1 Sensor 1 / Bank 2 Sensor 1
P0041 2C64 HO2S Signals Swappe d Ban k 1 Sensor 21 Bank 2 Sensor 2
P0050 2C9D HO2S Heate r Control Circuit (Bank 2 Sensor 1 )
P0051 2C9D HO2S Heater Control Circuit Low (Bank 2 Sensor 1 )
P0052 2C9D HO2S Heate r Control Circuit High (Ban k 2 Sensor 1 )
P0053 2CA6 HO2S Heater Resistanc e (Ban k 1 Sensor 1 )
P0056 2C9F HO2S Heate r Control Circuit (Ban k 2 Sensor 2)
P0057 2C9F HO2S Heate r Contro l Circuit Lo w (Bank 2 Sensor 2)
P0058 2C9F HO2S Heate r Control Circuit Hig h (Bank 2 Sensor 2)
P0059 2CA7 HO2S Heater Resistance (Bank 2 Sensor 1 )
P0070 2F9A Ambient Ai r Temperature Senso r Circuit
 On-Board Diagnostics OBD- 9
Diagnostic trouble codes (DTCs)

Table a . Diagnostic trouble codes (DTCs) (continued)

P-code BMWFC Definition
P0071 2F99 Ambient Air Temperature Sensor Circuit Range / Performance

P0072 2F9A Ambient Air Temperature Sensor Circuit Low

P0073 2F9A Ambient Air Temperature Sensor Circuit Hig h

P0090 2FBC Fuel Pressure Regulator 1 Control Circuit Open

p0091 2FBC Fuel Pressure Regulator 1 Control Circuit Low

P0092 2FBC Fuel Pressure Regulator 1 Control Circuit Hig h

POA14 2FAB Engine Mount 'A' Control Circuit Open

POA15 2FAB Engine Mount 'A' Control Circuit Low

POA16 2FAB Engine Mount 'A ' Control Circuit High
POA3B 2E97 Generator Over Temperature
POA3B 2ECF Generator Over Temperature

P0100 2D16 Mass Air Flow or Volume 'A' Circui t

P0101 2D15 Mass or Volume Air Flo w Circuit Range/Performance
P0102 Mass or Volume Air Flow Circuit Lo w Input

P0103 Mass or Volume Air Flow Circuit High Inpu t

P0107 Manifold Absolute Pressure/Barometric Pressur e Circuit Low Input
P0108 Manifold Absolut e Pressure/Barometri c Pressur e Circuit Hig h Inpu t

P0111 2F09 Intake Temperature Senso r Ban k 1 Temperature Rang e / Performanc e

P0112 2F08 Intake Air Temperature Sensor 1 Circuit Low

P0113 2F08 Intake Air Temperature Sensor 1 Circuit High
P0116 Coolant Temperature Sensor rationalit y Chec k
P0117 2EEO Engine Coolant Temperature Circuit Low
P0118 2EEO Engine Coolant Temperature Circuit Hig h
P0120 General Code Used In Conjuction With Other TPS Faul t Code
P0121 2CF6 Throttle/Pedal Position Sensor/Switch 'A' Circuit Range/Performance
P0122 2CF9 Throttle/Pedal Position Sensor/Switc h 'A ' Circuit Low
P0123 2CF9 Throttle/Pedal Position Sensor/Switch 'A ' Circuit High
P0125 Insufficient Coolant Temperature for Closed Loop Fuel Control
P0128 2EF4 Coolant Thermosta t (Coolan t Temperatur e Below Thermostat Regulatin g Temperature)
P0131 2C3F O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
P0132 2C3F O2 Sensor Circuit Hig h Voltage (Bank 1 Sensor 1 )
P0133 2C39 O2 Sensor Circuit Slo w Response (Ban k 1 Sensor 1 )
P0134 O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)
P0135 2CA6 O2 Sensor Heater Circuit (Bank 1 Sensor 1 )
P0137 2C75 O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2)
P0138 2C73 O2 Sensor Circuit High Voltage (Bank 1 Sensor 2)
P0139 2C7B O2 Sensor Circuit Slow Response (Bank 1 Sensor 2)
OBD-10 On-Boar d Diagnostics
Diagnostic trouble codes (DTCs)

Table a. Diagnostic trouble codes (DTCs) (continued)

P-code BMWFC Definition
P0139 O2 Senso r Circuit Slow Response (Bank 1 Sensor 2)
P0140 2C77 O2 Sensor Circuit No Activity Detected (Ban k 1 Sensor 2)
P0141 2CA8 O2 Sensor Heate r Circui t (Bank 1 Sensor 2)
P0151 2C40 O2 Sensor Circui t Lo w Voltage (Ban k 2 Sensor 1 )
P0152 2C40 O2 Senso r Circuit High Voltage (Bank 2 Sensor 1)
P0153 2C3A O2 Sensor Circuit Slow Response (Bank 2 Sensor 1 )
P0154 O2 Sensor Circui t N o Activity Detecte d (Ban k 2 Sensor 1 )
P0155 2CA7 O2 Sensor Heate r Circui t (Bank 2 Sensor 1 )
P0156 2CA7 O2 Sensor Heater Function (Ban k 2 Sensor 1)
P0157 2C76 O2 Sensor Circuit Lo w Voltage (Bank 2 Sensor 2)
PCM 58 2C74 O2 Sensor Circui t Hig h Voltage (Bank 2 Sensor 2)
P0159 2C7E O2 Sensor Circui t Slo w Response (Ban k 2 Sensor 2)
P0159 2C7C O2 Sensor Circuit Slow Response (Bank 2 Sensor 2)
P0160 2C78 O2 Senso r Circuit No Activity Detected (Bank 2 Sensor 2)
P0161 2CA9 O2 Sensor Heater Circuit (Bank 2 Sensor 2)
P0171 29EO System Too Lean (Bank 1)
P0171 2A2B System To o Lean (Ban k 1)
P0172 29EO System Too Rich (Bank 1)
P0172 2A2B System Too Rich (Bank 1)
P0174 29E1 System Too Lean (Bank 2)
P0174 2A2C System To o Lean (Ban k 2)

P0175 29E1 System Too Rich (Bank 2)

P01 75 2A2C System Too Rich (Bank 2)
P0190 29E2 Fuel Rail Pressur e Senso r 'A ' Circui t
P01 92 29E2 Fuel Rai l Pressur e Senso r 'A ' Circuit Low
P0197 Engine Oi l Temperature Sensor Low
P01 98 Engine Oil Temperature Sensor High
P02AA 3074 Cylinder 5 Fuel Trim at Maximum Limi t
P02AB 3074 Cylinder 5 Fuel Trim at Minimum Limi t
P02AE 3075 Cylinder 6 Fuel Trim at Maximum Limi t
P02AF 3075 Cylinder 6 Fuel Trim at Minimum Limi t
P02A2 3072 Cylinder 3 Fuel Trim at Maximum Limi t
P02A3 3072 Cylinder 3 Fuel Trim at Minimum Limit
P02A6 3073 Cylinder 4 Fuel Trim at Maximum Limi t
P02A7 3073 Cylinder 4 Fuel Trim at Minimum Limi t
P0201 2E30 Injector Circuit/Ope n - Cylinder 1
P0202 2E31 Injector Circuit/Ope n - Cylinder 2
 On-Board Diagnostic s OBD-1 1
Diagnostic trouble codes (DTCs)

Table a. Diagnostic trouble codes (DTCs) (continued )

P-code BMWFC Definition
P0203 2E32 Injector Circuit/Open - Cylinder 3
P0204 2E33 Injector Circuit/Open - Cylinder 4

P0205 2E34 Injector Circuit/Open - Cylinder 5

P0206 2E35 Injector Circuit/Open - Cylinder 6

P0207 2E36 Injector Circuit/Open - Cylinder 7

P0208 2E37 Injector Circuit/Ope n - Cylinder 8

P0221 2CF7 Throttle/Pedal Position Sensor/Switc h 'B' Circuit Range/Performanc e
P0222 2CFA Throttle/Pedal Positio n Sensor/Switch 'B' Circuit Low

P0223 2CFA Throttle/Pedal Positio n Sensor/Switc h 'B' Circuit Hig h

P0234 30FE Turbocharger 'A ' Overboost Conditio n
P0236 2ABD Turbocharger Boost Sensor 'A ' Circuit Range / Performanc e
P0237 2ABC Turbocharger Boost Senso r 'A ' Circuit Low
P0238 2ABD Turbocharger Boos t Senso r 'A ' Circuit Hig h
P0243 30CF Turbocharger Wastegat e Solenoid 'A'
P0245 30CF Turbocharger Wastegate Solenoi d 'A ' Low
P0246 30CF Turbocharger Wastegate Solenoi d 'A ' Hig h
P0247 30DO Turbocharger Wastegate Solenoi d 'B '
P0249 30DO Turbocharger Wastegate Solenoid 'B' Low
P0250 30DO Turbocharger Wastegate Solenoi d 'B ' Hig h
P0261 2E30 Cylinder 1 Injector Circuit Low
P0262 2E30 Cylinder 1 Injector Circuit Hig h
P0264 2E31 Cylinder 2 Injector Circuit Low
P0265 2E31 Cylinder 2 Injector Circuit High
P0266 2E32 Cylinder 3 Injector Circuit High
P0267 2E32 Cylinder 3 Injector Circui t Low
P0268 2E32 Cylinder 3 Injector Circuit Hig h
P0269 Injector Circuit Low / Hig h
P0270 2E33 Cylinder 4 Injector Circuit Low
P0271 2E33 Cylinder 4 Injector Circuit High
P0273 2E34 Cylinder 5 Injector Circuit Lo w
P0274 2E34 Cylinder 5 Injector Circuit High
P0276 2E35 Cylinder 6 Injector Circuit Lo w
P0277 2E35 Cylinder 6 Injector Circuit Hig h
P0278 Cylinder 7 Injector Circuit Low
P0279 Cylinder 7 Injector Circuit Hig h
P0280 Cylinder 8 Injector Circui t Lo w
P0281 Cylinder 8 Injector Circuit Hig h
OBD-12 On-Boar d Diagnostics
Diagnostic trouble codes (DTCs)

Table a. Diagnostic trouble codes (DTCs) (continued)

P-code BMWFC Definition
P0282 Injector Circuit Lo w / Hig h
P0283 Injector Circuit Lo w / Hig h
P029A 3070 Cylinder 1 Fuel Trim at Maximum Limi t
P029B 3070 Cylinder 1 Fuel Trim at Minimum Limi t
P029E 3071 Cylinder 2 Fue l Trim at Maximum Limi t
P029F 3071 Cylinder 2 Fuel Trim at Minimum Limi t
P0298 12055 Engine Oi l Over Temperature

P0299 30FF Turbocharger 'B ' Overboost Condition

P0300 29CC Cylinder Misfire , Several Cylinders
P0301 29CD Cylinder 1 Misfire Detecte d

P0302 29CE Cylinder 2 Misfire Detected

P0303 29CF Cylinder 3 Misfire Detected

P0304 29DO Cylinder 4 Misfire Detected

P0305 29D1 Cylinder 5 Misfire Detected

P0306 29D2 Cylinder 6 Misfire Detecte d

P0307 29D3 Cylinder 7 Misfire Detected

P0308 29D4 Cylinder 8 Misfire Detecte d

P0313 29D9 Misfire Detecte d with Low Fuel

P0326 2E68 Knock Senso r 1 Circuit Range / Performance (Bank 1 or Single Sensor )

P0326 2CA6 Knock Senso r 1 Circuit Range / Performanc e (Bank 1 or Single Sensor)

P0327 2E68 Knock Senso r 1 Circuit Lo w (Bank 1 or Single Sensor )

P0328 2E68 Knock Senso r 1 Circuit Hig h (Ban k 1 or Single Sensor)

P0332 Knock Senso r 2 Circuit Low (Bank 2)

P0335 2A94 Crankshaft Positio n Sensor 'A 1 Circuit

P0336 2B5C Crankshaft Positio n Senso r 'A' Rang e

P0339 Crankshaft Positio n Senso r 'A ' Circuit Intermitten t

P0340 2AAO Camshaft Positio n Senso r 'A ' Circuit (Ban k 1 or Single Sensor )

P0341 2A9A Camshaft Positio n Sensor 'A' Performanc e (Bank 1 )

P0342 2B62 Camshaft Position Sensor 'A' Circuit Lo w (Bank 1 )

P0343 2B62 Camshaft Positio n Sensor 'A ' Circui t High (Ban k 1 )
P0344 2A9E Camshaft Position Sensor 'A' Circuit Intermittent (Bank 1 or Single Sensor)
P0345 Camshaft Positio n Senso r Rationalit y Check Inle t

P0346 Camshaft Positio n Sensor Performance Inle t

P0347 Camshaft Positio n Sensor Short to Ground Inle t
P0348 Camshaft Position Sensor Short t o Battery Inlet

P0351 2E24 Ignition Coi l 'A ' Primar y / Secondary Circui t

P0352 2E25 Ignition Coil 'B' Primar y / Secondary Circuit
 On-Board Diagnostic s OBD-1 3
Diagnostic trouble codes (DTCs)

Table a. Diagnostic trouble codes (DTCs) (continued)

P-code BMWFC Definition
P0353 2E26 Ignition Coil 'C' Primar y / Secondary Circuit
P0354 2E27 Ignition Coil 'D' Primary / Secondary Circui t
P0355 2E28 Ignition Coil 'E' Primar y / Secondary Circuit

P0356 2E29 Ignition Coil 'F' Primar y / Secondary Circuit

P0357 Ignition Coil 'G' Primary / Secondary Circui t
P0358 Ignition Coil 'H' Primar y / Secondary Circuit
P0365 2AA1 Camshaft Positio n Sensor 'B' Circuit (Bank 1 )
P0366 2A9B Camshaft Positio n Sensor 'B' Performance (Bank 1 )
P0367 Camshaft Positio n Sensor Short to Ground Outle t
P0367 2B63 Camshaft Positio n Sensor 'B ' Circuit Lo w (Bank 1 )

P0368 2B63 Camshaft Positio n Sensor 'B ' Circuit High (Ban k 1 )

P0369 2A9F Camshaft Positio n Sensor 'B 1 Circuit Intermittent (Bank 1 )

P0370 29DB Smooth Running Segmen t Timin g

P0370 2A96 Timing Referenc e High Signal 'A' Resolution

P0370 2A97 Timing Reference High Signal 'A ' Resolutio n

P0372 2B5D Timing Referenc e High Signa l 'A ' Resolutio n Erratic Too Few Pulses

P0373 2A95 Timing Referenc e Hig h Signal 'A' Resolution Errati c

P0390 Camshaft Positio n Sensor Inlet Outlet Rationality Check

P0391 Camshaft Positio n Sensor Signal Outle t

P0392 Camshaft Positio n Senso r Shor t to Ground Outlet
P0393 Camshaft Positio n Sensor Short t o battery Outle t
P0411 Secondary Air Injection System Low Flow
P0412 Secondary Ai r Injection System Valve Circuit (Continuity)

P0413 Secondary Air Injectio n System Switching Valve A Circuit Open

P0414 Secondary Air Injection System Switching Valve A Circuit Shorte d

P0418 10755 Secondary Ai r Injection Syste m Contro l A Circui t

P0420 29 F4 Catalyst System Efficienc y Below Threshold (Bank 1 )

P0420 29F6 Catalyst System Efficienc y Below Threshold (Bank 1 )
P0430 29F5 Catalyst Syste m Efficienc y Below Threshold (Bank 2 ) ~ l
P0440 2A1A Evaporative Emission System Incorrect Flow
P0441 2A1A Evaporative Emissio n System Incorrect Purge Flow
P0442 2A15 Evaporative Emission Syste m Lea k Detecte d (small leak )
P0443 Evaporative Emission Syste m Purg e Control Valve Circui t
P0444 2A19 Evaporative Emission Syste m Purg e Control Valv e Circuit Ope n
2A1A Fuel Tank Venting Function Faul t
P0445 Evaporative Emission Syste m Purge Control Valve Circuit Shorte d
P0455 Evaporative Emission Syste m Lea k Detecte d (larg e leak )
OBD-14 On-Boar d Diagnostic s
Diagnostic trouble codes (DTCs)

Table a. Diagnostic trouble codes (DTCs) (continued)

P-code BMWFC Definition
P0456 2A16 Evaporative Emissio n System Lea k Detecte d (ver y small leak )
P0457 2A1B Evaporative Emissio n System Leak Detecte d (Fuel Fille r Ca p Loose )
P0458 2A19 Evaporative Emissio n Syste m Purg e Control Valv e Circuit Lo w
P0459 2A19 Evaporative Emissio n Syste m Purg e Control Valve Circuit Hig h
P0460 2A1E Fuel Level Senso r 'A ' Circuit
P0461 2A1C Fuel Leve l Sensor A Performance
P0462 2DE2 Fuel Leve l Senso r 'A ' Circuit Low
P0463 2DE2 Fuel Level Sensor 'A' Circuit High
P0475 2F6C Exhaust Pressur e Control Valve
P0476 2F6C Exhaust Pressur e Contro l Valve Low
P0477 2F6C Exhaust Pressure Contro l Valv e Low
P0478 2F6C Exhaust Pressur e Control Valve High
P0479 Exhaust Pressur e Control Valve Intermittent
P0480 2EFE Fan 1 Control Circui t
P0491 2AOO Secondary Ai r Injectio n System Insufficien t Flow (Bank 1 )
P0492 2AOO Secondary Ai r Injectio n Syste m Insufficien t Flo w (Ban k 2)
P0500 2F4E Vehicle Speed Senso r 'A '
P0503 2F4F Vehicle Speed Senso r 'A ' Intermittent / Errati c
P0505 Idle Air Control Syste m
P0506 2ADF Idle Air Control Syste m Lower Than Expecte d
P0507 2ADF Idle Air Control Syste m Higher Than Expecte d
P0512 2F58 Starter Reques t Circui t
P0520 2F7B Engine Oi l Pressure Switch Circui t
P0521 30C6 Engine Oi l Pressur e Switch Range / Performanc e
P0522 30C3 Engine Oi l Pressur e Switch Ope n
P0523 30C3 Engine Oi l Pressure Switch Hig h
P0524 30C5 Engine Oi l Pressure Too Low
P053A 2AE4 Positive Crankcas e Ventilation Heater Circui t Ope n
P053B 2AE4 Positive Crankcas e Ventilatio n Heater Circui t Lo w
P053C 2AE$ Positive Crankcase Ventilation Heate r Circuit High
P0530 2F12 A/C Pressure Senso r 'A ' Circui t
P0532 2F12 A/C Pressure Sensor 'A ' Circuit Low
P0533 2F12 A/C Pressure Senso r 'A ' Circuit Hig h
P0545 2C87 Exhaust Ga s Temperature Sensor Circuit Low (Bankl Senso r 1 )
P0546 2C87 Exhaust Gas Temperature Sensor Circuit High (Bank l Senso r 1 )
P0560 System Voltage
P0561 System Voltage Unstabl e
P1300 2AA2 Camshaft Positio n Sensor 'A ' Segment Timin g Erro r (Bank 1 )

P1301 2E18 Ignition Monitorin g Cylinde r 1 Spark Duratio n To o Short

P1302 2E19 Ignition Monitoring Cylinde r 2 Spark Duratio n To o Short

P1303 2E1A Ignition Monitorin g Cylinde r 3 Spark Duratio n To o Short

P1304 2E1B Ignition Monitoring Cylinder 3 Spark Duratio n Too Short

P1305 2E1C Ignition Monitorin g Cylinder 5 Spark Duration Too Short

P1306 2E1D Ignition Monitorin g Cylinde r 6 Spark Duratio n To o Short

P1314 Fuel Mixtur e Deviation Detecte d with Lo w Fue l

P1315 Camshaft Positio n Sensor Rationalit y Check (Inle t - Outlet)

P1316 Camshaft Positio n Senso r Rationalit y Check (Inle t - Outlet)

P1318 Camshaft Positio n Senso r Rationalit y Check (Inle t - Outlet)

P1319 Camshaft Positio n Sensor Rationality Check (Inlet - Outlet)

P1327 2E69 Knock Sensor 2 Circuit Lo w (Bank 1 or Single Sensor )

P1328 2E69 Knock Sensor 2 Circuit Range / Performance (Bank 1 or Single Sensor )

P1329 Knock Senso r Rang e Check Minimu m

P1329 Knock Sensor 3 Circuit Low

P1330 Knock Senso r 3 Circuit High

P1330 Knock Senso r Rang e Minimu m

P1332 Knock Senso r Rang e Minimu m

P1333 Knock Senso r Range Maximu m

P1338 Camshaft Positio n Sensor Rationalit y Chec k (Inle t - Outlet )

P1339 Camshaft Positio n Sensor Rationalit y Check (Inle t - Outlet)

P1342 Misfire Durin g Start Cylinder 1

P1343 Misfire Cylinder 1 with Fue l Cut-Of f

P1344 Misfire Durin g Star t Cylinder 2
P1345 Misfire Cylinder 2 with Fue l Cut-Off

P1346 Misfire Durin g Start Cylinde r 3

P1347 Misfire Cylinder 3 with Fue l Cut-Off
P1348 Misfire Durin g Start Cylinder 4
P1349 Misfire Cylinder 4 with Fuel Cut-Off
P135B 2E69 Knock Senso r 2 Circuit Range / Performanc e (Ban k 1 or Single Sensor)

P1350 Misfire during Star t Cylinder 5

P1351 Misfire Cylinder 5 with Fue l Cut-Off
 '
P1379 Knock Senso r Modul e System Error

P1380 Knock Senso r Modul e Syste m Erro r

P1381 Knock Senso r Modul e Syste m Erro r

P1382 Knock Senso r Modul e Syste m Erro r

P1383 2E77 Ignition Monitorin g Malfunctio n

P1384 Knock Senso r 3 Circuit

P1386 Knock Senso r Modul e Syste m Error

P1396 29DA Crankshaft Positio n Senso r Segmen t Timing Plausibilit y

P140A 2AOO Secondary Ai r Injectio n System Flo w Ban k 1 and Ban k 2

P140B Secondary Ai r Injectio n Syste m Lo w Flow

P140C Secondary Ai r Injectio n Syste m Low Flow

P140E 29DC Cylinder Injectio n Cut Off , Fuel Level Too Low

P14CO 2EFF Fan Mechanical Hardwar e Defect

P14C1 2FOF Radiator Shutter Mechanica l hardwar e Defec t

P14C2 2AAB DISA (Differentiate d Intake Manifold) Actuato r 1 Fault

P14C3 2AAC DISA (Differentiate d Intake Manifold) Actuator 2 Fault

P14C4 2F11 Upper Radiato r Shutter Mechanical fault

P14C5 2F11 Upper Radiato r Shutter Electrica l fault

P14C6 2F10 Lower Radiato r Shutter Electrica l fault

P140E 29DC Cylinder Injectio n Cut Off, Fuel Leve l Too Low

P1407 2DE2 Fuel Leve l Signal 1

P1408 2DE1 Fuel Leve l Signal 2

P1411 Secondary Ai r Injectio n System Pump No t Active

P1412 Secondary Ai r Injectio n Syste m Ma x Limi t o f Leakage Betwee n Air Pum p and Valve

P1413 2A03 Secondary Air Injection Pump Relay Contro l Circuit Signa l Low

P1414 2A03 Secondary Ai r Injectio n Pump Rela y Contro l Circuit Signal Hig h
P1415 2D06 Mass or Volume Air Flo w To o Low
P1417 2D06 Throttle Control Incorrect Air Suppl y
P1417 2D09 Throttle Contro l Incorrec t Air Suppl y
P1418 Secondary Ai r Injectio n System Valve or Tube Blocke d
P142A 2AE4 Crankcase Ventilatio n Heater Rela y Circuit Input Hig h
P142B 2AE4 Crankcase Ventilation Heate r Rela y Circui t Inpu t Low
P142C 2AE4 Crankcase Ventilatio n Heate r Rela y Circuit Input Open
 On-Board Diagnostics OBD-2 5
Diagnostic trouble codes (DTCs)

Table a. Diagnostic trouble codes (DTCs) (continued )

P-code BMWFC Definition
P142E 29DC Cylinder Injectio n Cut Off, Pressure Too Low (High Pressur e Fuel System)
P142F 29DC Cylinder Injectio n Cut Off, Pressure Too Low (Low Pressur e Fue l System )
P1424 2D06 Mass or Volume Air Flo w To o High
P1429 2A18 DMTL Heater
P143B 2AD9 Direct Ozone Reduction Catalyst Temperature Sensor Wrong Cod e
P143C 2AD8 Direct Ozone Reduction Catalyst Temperature / Radiato r Temperature Correlation
P1429 DMTL Heater Circuit Ope n
P143E 2AD8 Direct Ozone Reductio n Catalys t Temperature Senso r Gradient Too Low
P1429 2A18 DMTL Heater Activation
P1430 2A18 DMTL Heater Circuit Low
P1431 2A18 DMTL Heater Circuit High
P1434 2A17 DMTL Tank Leakage
P1444 Diagnostic Modul e Tank Leakag e (DMTL ) Pump Contro l Open Circuit
P1445 Diagnostic Modul e Tan k Leakage (DMTL ) Pum p Control Circuit Signal Low
P1446 Diagnostic Module Tan k Leakage (DMTL ) Pum p Contro l Circuit Signa l Hig h
P1447 2A17 Diagnostic Module Tank Leakage (DMTL) Pum p Curren t Too High durin g Switching Solenoid Tes t
P1448 2A17 Diagnostic Module Tank Leakage (DMTL) Pum p Current Too Low
P1449 2A17 Diagnostic Modul e Tank Leakag e (DMTL) Pum p Current To o High
P1451 Diagnostic Modul e Tank Leakage (DMTL ) Switching Solenoi d Control Circui t Signa l Low
P1452 Diagnostic Module Tan k Leakage (DMTL ) Switching Solenoi d Contro l Circuit Signal Hig h
P1453 2A03 Secondary Air Injectio n Pump Relay Control Circuit Fault
P15AA 30FC Turbocharger Lea k i n System
P15A1 30C4 Engine Oi l Pressure Mechanica l Valv e Stuck in De-energized Positio n
P15A2 30C4 Engine Oi l Pressure Mechanica l Valve Stuck i n Fully Energize d Positio n

P15A3 30C5 Engine Oil Pressure Too High

P15A6 30C6 Engine Oil Pressure Too High Befor e Start
P15A7 30C6 Engine Oil Pressure Too Low Before Start
P15A9 2FC7 Energy Saving Mode - Transportation Mode
P15BO 2DC3 Terminal 15 Sense Circui t Input High
P15B1 2DC3 Terminal 1 5 Sense Circui t Inpu t Lo w
P15B2 2DC3 Terminal 15 Sense Circuit CAS Error
P15B3 2DC3 Terminal 1 5 Sense Circuit Range / Performance
P150A 2E8B Battery Sensor Extended Communication Circuit
P150B 2E8B Battery Sensor Serial Data Interface
P150C 2E8B Battery Senso r Firmwar e Implausibl e
P150D 2E8B Battery Sensor Temperature Erro r
P150E 2E8C Battery Senso r Voltage Erro r
OEJD-26 On-Boar d Diagnostics
Diagnostic trouble codes (DTCs)

Table a. Diagnostic trouble codes (DTCs) (continued)

P-code BMWFC Definition
P150F 28EC Battery Sensor Current Error
P1500 Idle-Speed Contro l Valve Stuck Open
P1501 Idle-Speed Control Valve Stuck Closed
P1502 Idle-Speed Control Valve Closing Solenoid Control Circuit Signal High
P1503 Idle-Speed Contro l Valve Closing Solenoi d Contro l Circui t Signa l Low
P1504 Idle-Speed Control Valve Closing Solenoi d Contro l Open Circui t
P1506 Idle-Speed Contro l Valve Opening Solenoi d Control Circuit Signal Hig h
P1507 Idle-Speed Contro l Valve Opening Solenoi d Control Circuit Signal Low
P1508 Idle-Speed Control Valve Opening Solenoid Control Open Circui t
P151A 2E8D Battery Sensor Terminal 1 5 / 30 Wakeup Circui t
P151B 2E8D Battery Senso r Wakeup Circuit
P151C 2E8D Battery Sensor System Error
P1511 2AA8 DISA (Differentiated Intak e Manifold) Contro l Circui t
P1511 2AA9 DISA (Differentiated Intake Manifold ) Control Circuit
2AAA Variable Intak e System Plausibilit y
P1512 2AA8 DISA (Differentiate d Intak e Manifold) Control Circuit Signal Low
P1512 ^2AA9~~ DISA (Differentiate d Intake Manifold) Contro l Circuit Signal Low
P1513 2AA8 DISA (Differentiate d Intak e Manifold) Contro l Circui t Signa l High
P1513 2AA9 DISA (Differentiate d Intake Manifold ) Control Circui t Signal High
P1515 2F80 Engine OF F Timer Plausibilit y
P1517 29DD Poor Roa d Surface - No Wheel Speed Signa l
P1518 29DD Poor Roa d Surface - Wheel Speed To o High
P1519 2EAO Engine Oil Quality Senso r Temperatur e
P152A 2F4F Vehicle Spee d Sensor Too Low Under Load Compared to Reference Unde r Load
P152B 2F4F Vehicle Speed Sensor Too Low During Coas t Down Compared to Referenc e Under Load
P1520 2EAO Engine Oil Quality Sensor Temperature
P1521 2EAO Engine Oi l Quality Sensor Temperature Communication Error
P1521 2E9F Engine Oil Quality Senso r Temperatur e Communicatio n Erro r
P1522 2EAO Engine Oi l Quality Senso r Temperature
P1523 'A' Camshaft Position Actuator Signal Lo w (Bank 1)
PI 524 'A 1 Camshaft Positio n Actuator Control Circuit Signal High (Bank 1 )
P1525 'A' Camshaft Positio n Actuator Control Open Circui t (Bank 1 )
P1529 'B' Camshaft Positio n Actuator Contro l Circui t Signa l Low (Bank 1 )
P1530 'B' Camshaft Positio n Actuator Control Circuit Signa l Hig h (Bank 1 )
P1531 'B' Camshaft Position Actuator Control Open Circuit (Bank 1 )
P1535 2B71 DISA Coil Temperature Limit Exceeded
P1536 2B71 DISA Contro l Deviation
 On-Board Diagnostics OBD-2 7
Diagnostic trouble codes (DTCs)

Table a. Diagnostic trouble codes (DTCs) (continued )

P-code BMWFC Definition
P1537 2B71 DISA Potentiomete r Volatge in Lower Diagnosis Rang e

P1538 2B71 DISA Potentiomete r Volatge in Upper Diagnosi s Rang e

P1539 2B72 DISA Coil Temperature Threshold Exceede d
P1540 2AC6 Driving Dynamic s Switch Input High
P1541 2AC6 Driving Dynamics Switch Input Low
P155A 2DB7 Multifunction Steering Wheel Toggle-Bit Faul t
P1551 2F80 Engine OFF Timer Time-out
P1553 2A99 Engine Position System 'B ' Performanc e (Bank 1 )
P1554 2A98 Engine Position System 'A' Performance (Ban k 1)
P1561 2AEO Cold Start Idle RP M Lower Than Expecte d
P1562 2AEO Cold Start Idle RP M Higher Tha n Expecte d
P1563 2DB6 Multifunction Steering Wheel Rocker Switch Defective
P1565 2DB5 Multifunction Steerin g Wheel Rocke r Switch + / - Pressed Simultaneously
P1567 2DB7 Multifunction Steering Wheel Toggle Bit Error
2DBE Adaptive Cruise Control Blocked fo r Driving Cycle
2DCO No Message From LD M
2DC3 Monitoring Terminal 15
P1576 2DB5 Multifunction Steering Wheel Interfac e Error
P1577 2F50 Speed Indication Instrument Pack
P1578 2F50 Speed Indicatio n Instrumen t Pac k / ASC Signal Correlatio n
P1582 30C2 Oil Pump Circuit High
P1583 30C2 Oil Pump Circuit Low
P1584 30C2 Oil Pump Circuit Open
P1586 2E9F Engine Oil Quality Senso r Temperature Measuremen t
P1587 2E9F Engine Oil Quality Senso r Temperature Level Measuremen t
P1588 2E9F Engine Oil Quality Senso r Temperature Permeability Measuremen t
P16AO 2AB3 Internal Contro l Module Checksum Faul t
P16A1 2AB3 Internal Control Module Application Software Checksum Faul t
P16A2 2AB3 Internal Control Module Checksu m Faul t i n Data
P16A3 2AB4 Internal Control Module Checksum Faul t in Non-Volatile Memor y
P16A4 2AB5 Time-out Control Modul e Knoc k Sensor SPI-Bus
P16A5 2AB6 Time-out Control Module Multipl e Outpu t Stage SPI-Bu s
P16A6 2D50 Control Module Self test / Cruise Contro l Monitorin g
P16A7 2D51 Control Module Self Test Hot Film Air Mass Mete r Monitoring
P16A8 2D51 Control Modul e Sel f Test Throttle Positio n Monitorin g
P16A9 2D52 Control Module Sel f Test Speed Monitorin g Reset
P16BO 2D55 ECM Internal Fault Accelerator Pedal Modul e
OBD-28 On-Boar d Diagnostic s
Diagnostic trouble codes (DTCs)

Table a. Diagnostic trouble codes (DTCs) (continued)

P-code BMWFC Definition
P16B1 2D56 Control Modul e Sel f Test Idle Air Control System Plausibility
P16B2 2D56 Control Module Sel f Test Idle Air Control Syste m Component Plausibilit y
P16B3 2D57 Control Modul e Sel f Test Engine Dra g Torque
P16B4 2D50 Control Module Self Tes t Dynamic Cruise Control Monitoring
P16B5 2D57 Control Modul e Sel f Test Automatic Manual Transmissio n
P16B6 2D57 Control Modul e Self Test ETC Monitoring
P16B7 2D58 Control Modul e Sel f Test Clutch Torque Monitoring Maximum valu e Plausibilit y
P16B8 2D58 Control Modul e Self Test Clutch Torque Monitoring
P16B9 2D58 Control Modul e Sel f Test Torque Loss Monitorin g
P16CO 2D58 Control Module Sel f Test Driving Dynamics Control Switch Monitorin g
2D5A Monitoring Engine Torqu e Limiting
P16C1 2D59 Control Modul e Sel f Test Torque Monitoring Current Indicated valu e Plausibilit y
P16C2 2D53 Control Modul e Sel f Test Speed Limitation Monitorin g
P16C3 2D54 Control Modul e Sel f Test Speed Limitatio n Rese t
P16C5 2AAC DME Mai n Rela y Switching Delay
P16C6 2E7C CAN Time-out Bi t Serial Data Interface
P16C8 2DEO Serial Communicatio n Lin k EK P (Electronic Fuel Pump)
P164C 2D1D Pedal Positio n Sensor Potentiomete r Supply Channel 1 Electrical
P16BO 2D55 Control Module Sel f Test Pedal Positio n Monitorin g
P160A 2DEC Powermanagement Exhaustiv e Discharge
P160B 2DEC Powermanagement Defective
P160C 2DEB Powermanagement Overvoltag e
P160D 2DEB Powermanagement Undervolatge
P160E 2DEB Powermanagement Operatio n Without Battery
P16CF 2DED Powermanagement N o Load Current Erro r
P165F 2CA6 Internal Contro l Module Measuremen t Erro r O2 Sensor Heating (Ban k 1 Sensor 1 )
P1602 Control Modul e Self-Test , Control Module Defective
P1603 Control Module Self-Test , Torque Monitoring
P1604 Control Modul e Self-Test , Speed Monitoring
P1611 2DC8 Serial Communication Lin k TCM
P1612 2DDO Serial Communication Link Instrumen t Panel
P1613 2DCC Serial Communicatio n Lin k ASC
P1613 2DCD Serial Communication Lin k ASC
P1613 2DCE Serial Communication Lin k ASC
P1614 11711 Serial Communication ACC
P1618 2D5C Control Module Sel f Test AD-Converter Monitoring
P1619 Map Cooling Thermostat Control Circuit Signal Low
 On-Board Diagnostic s OBD-2 9
Diagnostic trouble codes (DTCs)

Table a. Diagnostic trouble codes (DTCs) (continued)

P-code BMWFC Definition
P1620 Map Cooling Thermostat Contro l Circui t Signal Hig h
P1624 2D1D Pedal Positio n Sensor Potentiomete r Suppl y Channe l 1 Electrical (M52 : Coolant Thermostat (Coolan t
Temperature Below Thermostat Regulatin g Temperature))
P1625 2D1E Pedal Position Senso r Potentiomete r Suppl y Channe l 2 Electrica l
P1628 Throttle Valve Sprin g Doe s No t Ope n
P1629 Throttle Valve Spring Doe s No t Ope n
P163C 2B9D Voltage Monitoring Contro l Modul e Overloa d
P163D 2B9D Voltage Monitoring Contro l Module Cut-OFF Detecte d
P163E 2B9D Voltage Monitoring Contro l Module Communicatio n Erro r
P1631 Throttle Valve Actuator Spring Test
P1632 2CFB Throttle Valv e Adaptation Condition s No t Met
P1633 2CFB Throttle Valve Adaptation Limp-Hom e Positio n Unknow n
P1634 Throttle Valv e Adaptation Sprin g Tes t Faile d
P1634 2CFC Throttle Valve Adaptation Spring Test Failed
P1635 2CFE Throttle Valve Adaptation Lowe r Mechanica l Sto p no t Adapte d
P1636 2CEF Throttle Valve Control Circuit
P1637 2CEE Throttle Valve Position Control , Control Deviatio n
P1638 2CEC Throttle Valve Position Contro l Throttle Stuck Temporaril y
P1639 2CED Throttle Valve Position Contro l Throttle Stuc k Permanentl y
P164E 2DOC Throttle Deicin g Stuck i n Closed Directio n
P164F 2DOC Throttle Deicing Stuck in Open Directio n
p1641 2D03 Throttle Valve Adaptation Stop Du e to Environmenta l Condition s
P1642 2D03 Throttle Valve Adaptation Sto p Du e to Environmental Value s
P1643 2CFF Throttle Actuator Start Test Amplifier Balancing Fault y
P1644 2CFB Throttle Valve Adaptation Relearnin g Lowe r Mechanica l Sto p
P1645 2B99 Internal Contro l MOdule Faul t - RAM Readin g Erro r
P1649 2B99 Internal Control MOdul e Faul t - RAM Writing Erro r
P1650 Automatic Start While Engin e Runnin g
P166A 2D50 Control Module Sel f Test, Hot Fil m Air Mas s Mete r Monitorin g
P166B 2DCO Longitudinal Dynamic s Modul e Torqu e Reques t Inspit e o f Brake Signal
P166C 2DCO Longitudinal Dynamics Module Request Implausible
P166F 2CA7 Internal Control Modul e Measuremen t Erro r O2 Sensor Heatin g (Ban k 2 Sensor 1 )
P166F 2CAB Internal Contro l Module Measuremen t Erro r O2 Sensor Heatin g (Bank 2 Sensor 1 )
P1660 2F4A EWS Telegram Error
P1661 2F4A Time-out EW S Telegra m
P165A 2F4A EWS Interfac e to EC M Error
P165B 2F4A EWS Interface to ECM Checksum Erro r
OBD-30 On-Boar d Diagnostics
Diagnostic trouble codes (DTCs)

Table a. Diagnostic trouble codes (DTCs) (continued)

P-code BMWFC Definition
P165C 2F4B EWS Data , N o Available Storage Possibl e
P165D 2F4B EWS Data , Fault y Releas e Cod e
P165E 2F4B EWS Dat a Checksum Error
P1655 2F46 EWS Rollin g COd e Fault y Storag e in EEPROM
P1660 2F45 EWS Telegram Error
P1661 2F45 EWS Telegram Time-out
P1662 2F45 EWS Telegram Parit y Error
P1663 2F46 EWS Rollin g Code Fault y Storag e in EEPRO M
P1664 2F46 EWS Rollin g Code Fault y Writing in EEPROM
P1665 2F46 EWS Rollin g Code Tamperin g
P1666 EWS Tampering vi a KWP2000 / Start VAlue Not Accepted
P1667 2F49 EWS Star t Value not yet Programme d
P1668 2F4B EWS Start Valu e Destroye d
P167C 2D08 Throttle Heatin g Rela y Circuit Input Lo w
P167D 2D08 Throttle Heatin g Rela y Circuit
P1675 2CFD Throttle Valv e Actuator Start Test Re-Adaptatio n Require d
P1676 2DBF ACC Signal Plausibilit y
P1677 2DBF ACC N o Activity Detected
P1678 2DBF ACC N o Respons e To Cut-OFF
P1680 2D70 Throttle Valv e Control Monitor Level 2/3 ADC Processo r fault
P1681 2D75 Throttle Valve Contro l Monitor Level 2/3 Engine Speed Erro r
P1686 2D76 Throttle Valve Control Monitor Leve l 2/3 Peda l Positio n Sensor Erro r
P1694 2CFB Throttle Valve Adaptation Value
P169A 2CFC Throttle Valv e Actuator Start Test Faile d Lim p Hom e Positio n
P17EA Ratio Upshift 5 - 6
P17EB Ratio Downshif t 6 - 5
P17EC Ratio Downshif t 5 - 4
P17ED Ratio Downshif t 4 - 3
P17EE Ratio Downshif t 3 - 2
P17EF Ratio Downshif t 2 - 1
P17E1 Ratio in Gear 1 - Clutch A
P17E2 Ratio in Gear 3 Clutch B
P17E3 Ratio i n Gear 2 Clutch A
P17E4 Ratio i n Gear 1 - Clutch D
P17E5 Ratio i n Gear 4 Clutch E
P17E6 Ratio Upshift 1 - 2
P17E7 Ratio Upshif t 2 - 3
 On-Board Diagnostic s OBD-3 1
Diagnostic trouble codes (DTCs)

Table a. Diagnostic trouble codes (DTCs) (continued )

P-code BMWFC Definition
P17E8 Ratio Upshif t 3 - 4
P17E9 Ratio Upshif t 4 - 5
P17FO Ratio in Gear 1 - Clutch A or B
P17F1 Ratio i n Gear 2 - Clutch A or B
P17F2 Ratio in Gear 3 - Clutch A or B
P17F3 Ratio i n Gear 4 - Clutch A or E
P17F4 Ratio in Gear 5 - Clutch B or E
P17F5 Ratio in Gear 6 - Clutch C or E
P17F6 Ratio in Gear R Clutch B or D
P1694 2CFB Throttle Valve Actuator Start Test Spring Test and Limp-Hom e Positio n Failed
P1700 Automatic Transmission 5HP1 9 Output Speed , Whee l Speed , Doubl e Faul t
P1701 Range Position Switch Plausibility
P171A Watchdog Check
P171B Watchdog Chec k
P171C Watchdog Check
P171D Watchdog Check
P171E Watchdog Check
P1702 Colliding Function or Not Allowed Actuating of valves
P1704 ATF Temperature Sensor Rang e
P1711 ATF Temperature Sensor Rationality
P1712 Level 2 Calculation Check
P1713 Level 2 Calculation Chec k
P1714 Level 2 Calculation Check
P1718 ATF Temperature Sensor Rationalit y
P1719 TCM BUS Check
P1720 TCM BU S Check
P1721 CAN Time-out ASC / DSC
P1722 MC Components
P1723 MC Components
P1724 MC Components
P1725 MC Components
P1727 Engine Speed Signal Plausibility
P1728 Engine Overspeed Plausibilit y
P1729 CAN Version Plausibility
P1730 Impossible Combinatio n o f Substitute Function s or Not Allowed Actuating Valves
P1731 Automatic Transmission 5HP1 9 Gear Rati o Rationality
P1732 Automatic Transmission 5HP19 4th Gear Rati o Rationality
OBD-32 On-Boar d Diagnostic s
Diagnostic trouble codes (DTCs)

Table a. Diagnostic trouble codes (DTCs) (continued)

P-code BMWFC Definition
P1736 Automatic Transmission 6th Gear Ratio Plausibility
P1747 TCM BU S Check
P1760 Desired Engin e Torqu e Message o n CAN
P1761 Shift Loc k Rationality
P1762 Shift Loc k Shor t to Power
P1763 Shift Loc k Short to Ground
P1764 Shift Loc k Circuit Disconnection
P1765 TCM Rationality
P1766 Engine Spee d Plausibility
P1767 CAN Speed Rea r Wheels Plausibilit y
P1771 CAN Generate d Engine Torque Plausibility
P1780 TCM Rationality
P1782 CAN Brake Signal Plausibility
P1790 TCM Rationality
P1791 TCM Sel f Chec k
P1792 TCM Rationalit y Micr o controller
P1793 TCM Ho t Disablin g
P1794 2DD3 TCM Checksum Erro r
P1796 Power Latc h Relay s Plausibility
P1798 EPROM Plausibilit y
P1810 Turbine Inpu t Spee d Senso r (NTU ) Uppe r Threshol d
P1811 Turbine Inpu t Spee d Senso r (NTU) Lowe r Threshold
P1812 Output Spee d Senso r Uppe r Threshol d
P1813 Output Spee d Sensor Lower Threshold
P1814 Output Spee d Senso r Plausibilit y
P1817 Gear Leve r Analog Lines 0 Upper Threshold
P1818 Gear Leve r Analog Lines 0 Lower Threshold
P1819 Gear Leve r Analog Line s 0 Plausibilit y
P1820 Gear Leve r Analog Lines 1 Upper Threshold
P1821 Gear Leve r Analog Lines 1 Lower Threshold
PT822 Gear Leve r Analog Lines 1 Plausibility
P1823 Gear Leve r Digita l Lin e N o Signal
P1850 Shift Positio n Sensor Upper Threshol d
P1851 Shift Positio n Senso r Lowe r Threshol d
P1852 Shift Positio n Sensor Plausibilit y
P1859 Gear Lever Halls Sensor s No Signa l
P1860 Clutch Speed Plausibility
 On-Board Diagnostic s OBD-3 3
Diagnostic trouble codes (DTCs)

Table a. Diagnostic trouble codes (DTCs) (continued)

P-code BMWFC Definition

P1861 2-1 Shif t General

P1862 3-2 Shift Genera l

P1863 4-3 Shift Genera l

P1864 5-4 Shift Genera l

P1865 6-5 Shift General

P1866 Gear Lever Analog Lines 2 Upper Threshol d

P1867 Gear Lever Analog Lines 2 Lower Threshol d

P1868 Gear Lever Analog Line s 2 Upper Plausibilit y

P1869 Gear Leve r Analog Line s 3 Upper Threshol d

P1870 Gear Lever Analog Lines 3 Lower Threshold

P1876 Gear Lever Analog Lines 3 Plausibility

P1881 Range Shift Monitoring A 1- 2 Upper Threshol d

P1882 2-3 Shif t Rationality , N o Change

P1883 3-4 Shift Rationalit y Too Big
P1884 4-5 Shift Uppe r Threshol d

P1885 5-6 Shift Uppe r Threshol d

P1887 Hydraulic Pum p Failur e

P1889 System Voltage Rationality

P1890 Power Supply Genera l

P1891 Power Supply Rationality

P1892 System Voltage Low Inpu t
P1893 Control Solenoid / Shift Solenoid Shor t to Powe r
P1894 Control Solenoid / Shif t Solenoi d Short to Ground
P1895 Control Solenoid / Shift Solenoi d Circuit Disconnectio n
P1896 Valve Voltage Supply Plausibilit y
P1897 Sensor Voltage Supply Uppe r Threshold

P1898 Sensor Voltage Supply Lowe r Threshold

P2065 Fuel Level Sensor 'B' Circuit

P2067 2DE1 Fuel Leve l Senso r 'B ' Circuit Low
P2068 2DE1 Fuel Level Senso r 'B' Circuit High
P2088 2A80 'A' Camshaft Position Actuator Control Circuit Low (Bank 1 )
P2089 2A80 'A' Camshaft Position Actuator Control Circuit High (Ban k 1 )
P2090 2A85 'B' Camshaft Positio n Actuato r Control Circui t Low (Bank 1 )
P2091 2A85 'B' Camshaft Positio n Actuator Control Circuit High (Bank 1 )
P2092 VANOS Inle t Camshaft Rang e Minimu m
P2093 VANOS Inlet Camshaft Range Maximu m
P2094 VANOS Range Limit Minimu m
™
OBD-34 On-Boar d Diagnostic s
Diagnostic trouble codes (DTCs)

Table a. Diagnostic trouble codes (DTCs) (continued)

P-code BMWFC Definition
P2095 VANOS Rang e Limi t Maximu m
P2096 2C31 Post Catalyst Fue l Trim System Too Lean (Ban k 1 )
P2097 2C31 Post Catalys t Fue l Tri m System Too Rich (Bank 1 )
P2098 2C32 Post Catalyst Fuel Trim Syste m Too Lean (Bank 2)
P2099 2C32 Post Catalys t Fue l Tri m System To o Rich (Ban k 2 )
P2100 2CEF Throttle Actuato r 'A' Control Motor Circuit Ope n
P2102 2CEF Throttle Actuator 'A ' Control Motor Circuit Low
P2103 2CEF Throttle Actuato r 'A' Control Moto r Circui t Hig h
P213F 2AAD Fuel Pump Syste m Faul t Engin e Shu t Dow n
P2120 2D1F Throttle / Pedal Position Sensor 'D' Circuit
P2122 2D1B Throttle Peda l Positio n Sensor 'D ' Circuit Low

P2123 2D1B Throttle Peda l Positio n Sensor 'D ' Circuit Hig h
P2127 2D1C Throttle Peda l Positio n Senso r '£' Circuit Low

P2128 2D1C Throttle Peda l Positio n Senso r 'E ' Circuit Hig h
P213F 2AAD Fuel Pum p Emergenc y Cu t Off
P2138 2D20 Throttle / Peda l Positio n Sensor 'D ' 'E ' Voltage Correlatio n
P2177 Fuel Trim Limi t Exceede d Syste m Too Lean
P2178 Fuel Trim Limit Exceeded System Too Rich
P2179 Fuel Tri m Limi t Exceede d Syste m Too Lean

P2180 Fuel Tri m Limi t Exceede d System Too Rich

P2183 2EEC Engine Coolant Temperature Senso r 2 Circuit Range / Performance

P2184 2EEA Engine Coolant Temperate Sensor 2 Circuit Low

P2185 2EEA Engine Coolan t Temperate Senso r 2 Circuit Hig h
P2187 29EO System Too Lean at Idle (Bank 1 )

P2188 29EO System Too Rich at Idl e (Ban k 1 )

P2189 29E1 System Too Lean a t Idl e (Ban k 2)
P2190 29E1 System To o Rich at Idl e (Ban k 2 )

P2191 29E5 System To o Lean, Highe r Loa d (Ban k 1 )

P2192 29E5 System To o Rich, Higher Loa d (Ban k 1 )

P2193 2E96 System To o Lean, Highe r Loa d (Ban k 2)

P2194 2E96 System To o Rich, Higher Load (Bank 2)
P2195 2C27 O2 Sensor Signal Stuck Lea n (Bank 1 Sensor 1)
P2196 2C27 O2 Sensor Signa l Stuc k Ric h (Bank 1 Sensor 1 )
P2196 2C2B O2 Senso r Signal Stuc k Ric h (Bank 1 Sensor 1 )
P2196 2C2C O2 Sensor Signal Stuck Rich (Bank 1 Sensor 1 )
P2197 2C28 O2 Senso r Signal Stuc k Lea n (Ban k 2 Sensor 1 )
P2198 2C2C O2 Senso r Signa l Stuck Rich (Bank 2 Sensor 1 )
 On-Board Diagnostic s OBD-3 5
Diagnostic trouble codes (DTCs)

Table a. Diagnostic trouble codes (DTCs) (continued )

P-code BMWFC Definition
P2200 2AF4 NOx Senso r Circuit (Bank 1 )
P2205 2AFO NOx Sensor Heater Contro l Circui t Ope n (Ban k 1 )
P2227 ECM Integrated Barometric Pressur e Sensor Rationalit y Check
P2228 2F76 Barometric Pressur e Circuit Low
P2228 ECM Emigrated Barometric Pressure Sensor Circuit
P2229 2F76 Barometric Pressur e Circuit Hig h
P2229 ECM Emigrated Barometric Pressure Sensor Circuit
P2231 O2 Sensor Signal Shorted To Heater (Ban k 1 Sensor 1)
P2234 O2 Sensor Signal Shorte d To Heater (Bank 2 Sensor 1 )
P2237 O2 Sensor Reference Circuit Continuity (Bank 1 Sensor 1 )
P2240 O2 Sensor Reference Circuit Continuity (Bank 2 Sensor 1 )

P2243 2C3D O2 Sensor Reference Voltage Circuit Open (Ban k 1 Sensor 1 )

P2247 2C3E O2 Sensor Reference Voltage Circuit Open (Ban k 2 Sensor 1 )
P2251 O2 Sensor Reference Circuit Continuity (Bank 1 Sensor 1 )
P2254 O2 Sensor Reference Circuit Continuity (Bank 2 Sensor 1 )
P2270 2C6B O2 Sensor Signal Stuc k Lean (Ban k 1 Sensor 2)
P2271 2C6B O2 Sensor Signal Stuck Lean (Ban k 1 Sensor 2)
P2272 2C6C O2 Sensor Signal Stuc k Lean (Ban k 2 Sensor 2)
P2273 2C6C O2 Sensor Signal Stuck Lea n (Ban k 2 Sensor 2)
P2297 2C2D O2 Sensor Signal Ou t O f Rang e During Decel (Ban k 1 Sensor 1 )
P2298 2C2E O2 Sensor Signal Ou t Of Range Durin g Dece l (Bank 2 Sensor 1 )
P2299 2F8F Brake Pedal Positio n / Accelerator Pedal Position Incompatibl e
P2301 30AO Ignition Coil Primar y 'A' Circuit Hig h
P2304 30A1 Ignition Coi l Primary 'B ' Circuit High
P2307 30A2 Ignition Coil Primary 'C ' Circuit High
P2310 30A3 Ignition Coil Primary 'D' Circuit High
P2313 30A4 Ignition Coil Primar y 'E' Circuit High
P2316 30A5 Ignition Coil Primary 'F' Circuit High
P2332 2ED1 Generator Mechanica l
P232D 2D78 Air Mas s Balancing Contro l Rang e
P240A 2A18 DMTL Pum p Heater Circuit Ope n
P240B 2A18 DMTL Pump Heate r Circui t Low
P240C 2A18 DMTL Pum p Heater Circuit Hig h
P2400 2A13 DMTL Activation Control Circuit Ope n
P2401 2A13 DMTL Activation Control Circuit Low
P2402 2A13 DMTL Activation Control Circuit High
P2414 2C3B O2 Sensor Oxygen Sample Erro r (Bank 1 Sensor 1 )
OBD-36 On-Boar d Diagnostics
Diagnostic trouble codes (DTCs)

Table a. Diagnostic trouble code s (DTCs) (continued)

P-code BMWFC Definition
P2415 2C3C O2 Senso r Oxyge n Sampl e Erro r (Bank 2 Sensor 1 )
P2418 2A12 DMTL Solenoid Contro l Circuit Ope n
P2419 2A12 DMTL Solenoid Contro l Circuit Low
P2420 2A12 Evaporative Emissio n System Switching Valve Control Circui t Hig h
P2430 Secondary Ai r Injectio n System Mass Ai r Flow Sensor Rationalit y (Disconnected o r Stuck)
P2440 Secondary Air Injection System Air Valve Jammed Ope n
P2450 Evaporative Emissio n Syste m Switchin g Valve Short to Powe r
P250A 2F9E Engine Oil Level Sensor Circui t
P250B 2F9E Engine Oi l Level Senso r Rang e / Performance
P250F 2F9E Engine Oil Leve l Too Low
P252A 2EA1 Engine Oil Quality Sensor Circuit
P2420 2A12 DMTL Solenoi d Contro l Circuit High
P2541 29F3 Low Pressur e Fuel System Sensor Circuit Low
P2542 29F3 Low Pressur e Fuel Syste m Sensor Circui t Hig h
P2568 2ADA Direct Ozon e Reductio n Catalys t Temperature Sensor Performanc e
P2569 2ADA Direct Ozon e Reductio n Catalyst Temperature Sensor Circui t Low
P2570 2ADA Direct Ozone Reductio n Catalys t Temperature Sensor Circui t High
P2610 Engine OF F Timer Plausibilit y Comparison With CAN Timer
P2626 2C3D O2 Senso r Pumpin g Curren t Circuit Open (Ban k 1 Sensor 1 )
P2629 2C3E O2 Senso r Pumpin g Curren t Circuit Open (Ban k 2 Sensor 1 )
P2713 Pressure Control Valv e 4 Plausibilit y
P2716 Pressure Contro l Valve 4 No Signal
P2720 Pressure Regulato r Valv e 4 Lower Threshol d
P2721 Pressure Regulato r Valve 4 Upper Threshol d
P2722 Pressure Regulato r Valve 5 Plausibilit y
P2725 Pressure Regulato r Valv e 5 No Signa l
P2729 Pressure Contro l Valve 5 Lower Threshold
P2730 Pressure Control Valve 5 Upper Threshol d
P2759 Pressure Control Valve Circuit
P2761 Pressure Control Valve 4 Rationalit y
P2763 Pressure Contro l Valve 4 Short to Power
P2764 Pressure Control Valve 4 Short to Ground
P300A 2FOD Controlled Air Guiding Circui t Hig h
P300B 2FOD Controlled Air Guiding Circuit Low
P300C 2FOD Controlled Air Guiding Circuit
P3003 29F2 Fuel Rai l Pressure Flow Rate Controlled, Pressur e Too High
P3004 29F2 Fuel Rai l Pressure Flow Rat e Controlled, Maximum Pressur e Exceede d
 On-Board Diagnostics OBD-3 7
Diagnostic trouble codes (DTCs)

Table a. Diagnostic trouble codes (DTCs) (continued)

P-code BMWFC Definition
P3008 O2 Sensor Low Engin e Cold (Ban k 1 Sensor 1 )

P3009 O2 Sensor Low Engin e Cold (Ban k 1 Sensor 1 )

P3010 O2 Sensor Range Check Cold Senso r (Bank 1 Sensor 2)

P3011 O2 Sensor Range Chec k Cold Sensor (Ban k 2 Sensor 2 )
P3012 Adaptation value Too High (Ban k 1 Sensor 1 )
P3013 Adaptation valu e Too High (Bank 2 Sensor 1 )
P3014 O2 Senso r 1 C Suppl y Voltag e Too Lo w (Ban k 1 Sensor 1 )
P3015 O2 Senso r 1 C Suppl y Voltag e Too Low (Ban k 2 Sensor 1 )
P3016 O2 Sensor Ceramic Interna l Resistance Adjusted Value Plausibility (Bank 1 Sensor 1 )
P3017 02 Senso r Ceramic Interna l Resistanc e Adjusted Value Plausibility (Bank 2 Sensor 1 )
P3018 O2 Sensor Lambda Controller Value Above Threshold Due to Open Pumping Circuit (Bank 1 Sensor 1)
P3019 O2 Sensor Lambda Controlle r Value Above Threshold Du e to Open Pumpin g Circui t (Bank 2 Sensor 1 )
P3020 O2 Sensor Signa l Too Low During Coast Down Fuel Cut-OFF (Bank 1 Sensor 1 )
P3021 O2 Sensor Signal Too Low During Coas t Dow n Fue l Cut-OF F (Ban k 2 Sensor 1 )
P3022 2C41 O2 Sensor Disturbed SP I WRAF-IC (Bank 1 Sensor 1 )
P3023 2C42 O2 Sensor Disturbed SPI WRAF-IC (Bank 2 Sensor 1 )
P3024 2C41 02 Senso r Initialization Erro r WRAF-IC (Bank 1 Sensor 1 )
P3025 2C42 O2 Sensor Initialization Erro r WRAF-IC (Bank 1 Sensor 1)
P3026 2CAA O2 Sensor Operating Temperatur e No t Reached (Ban k 1 Sensor 1 )
P3027 2CAA O2 Sensor Operatin g Temperature No t Reached (Bank 2 Sensor 1 )
P3028 2CAO O2 Sensor Heate r Control N o Activity Detected (Ban k 1 Sensorl)
P3029 2CA1 O2 Sensor Heater Control No Activity Detected (Bank 2 Sensorl)
P3030 O2 Sensor Heater Internal Resistance (Ban k 1 Sensor 1 )
P3031 O2 Sensor Heater Interna l Resistance (Bank 2 Sensor 1)
P3041 O2 Sensor Lean an d Ric h Voltage Thresholds no t Reached (Ban k 2 Sensor 2)
P3090 29F2 Fuel Rai l Pressure Flow Rat e Controlled, Fallen Belo w Minimum Pressur e
P3094 2A2D Fuel Low Pressure System Pressur e To o High
P3095 2A2D Fuel Lo w Pressure System Pressur e Maximum Pressur e Exceeded
P3096 2A2D Fuel Low Pressure System Pressur e Minimum Pressur e Fallen Belo w
P310B 2E30 Cylinder 1 High Pressur e Injecto r Low Side / Hig h Sid e Electrica l
P310E 2E31 Cylinder 2 High Pressur e Injecto r Low Side / Hig h Sid e Electrica l
P3101 30AC Cylinder 1 High Pressur e Injector Lo w Side Circui t Lo w
P3102 30AC Cylinder 1 High Pressure Injector Low Side Circuit High
P3105 30AD Cylinder 2 High Pressure Injector Lo w Side Circuit Low
P3106 30AD Cylinder 2 High Pressur e Injecto r Low Side Circui t high
P3109 30AE Cylinder 3 High Pressur e Injector Low Side Circui t Low
P311B 2E32 Cylinder 3 High Pressur e Injector Lo w Side / High Sid e Electrica l
OBD-38 On-Boar d Diagnostic s
Diagnostic trouble codes (DTCs)

Table a. Diagnostic trouble codes (DTCs) (continued)

P-code BMWFC Definition
P311E 2E33 Cylinder 4 High Pressur e Injector Low Side / High Sid e Electrical
P3110 30AE Cylinder 3 High Pressur e Injector Low Side Circuit High
P3113 30AF Cylinder 4 High Pressur e Injector Low Side Circuit Low
P3114 30 A F Cylinder 4 High Pressure Injecto r Lo w Side Circuit High
P3117 30BO Cylinder 5 High Pressur e Injector Low Side Circuit Low
P3118 30BO Cylinder 5 High Pressur e Injector Low Side Circuit Hig h
P312B 2E34 Cylinder 5 High Pressur e Injector Lo w Side / Hig h Side Electrica l
P312E 2E35 Cylinder 6 High Pressure Injector Low Side / High Side Electrical
P3121 30B1 Cylinder 6 High Pressur e Injector Low Side Circuit Low
P3122 30B1 Cylinder 6 High Pressur e Injector Low Side Circuit High
P3149 30AC Cylinder 1 High Pressur e Injector High Sid e Circuit Low
P3150 30AC Cylinder 1 High Pressure Injecto r High Side Circui t Hig h
P3152 30AC Cylinder 2 High Pressur e Injector High Sid e Circuit Low
P3153 30AD Cylinder 2 High Pressur e Injector High Sid e Circuit Hig h
P3155 30AD Cylinder 3 High Pressur e Injector High Side Circuit Low
P3156 30AE Cylinder 3 High Pressure Injecto r Hig h Side Circuit High
P3158 30AF Cylinder 4 High Pressur e Injector High Sid e Circuit Low
P3159 30AF Cylinder 4 High Pressur e Injector Hig h Sid e Circuit High
P316A 2EE6 Engine Coolan t Temperatur e Signal Stuc k High

P3161 30BO Cylinder 5 High Pressure Injecto r Hig h Side Circuit Low
P3162 30BO Cylinder 5 High Pressure Injecto r Hig h Side Circui t Hig h
P3164 30B1 Cylinder 6 High Pressur e Injector High Sid e Circuit Low
P3165 30B1 Cylinder 6 High Pressur e Injector Hig h Sid e Circuit High
2FBF Fuel Suppl y Pressur e Low During Releas e of Injectio n
2FCO Fuel Rai l Pressure Management Rang e
P319A 2FBD Fuel Pressur e Control Minimum Characteristic Curve Operation 1 Out of Rang e
P3194 2FBD Fuel Pressur e Control Basic Characteristic Curve Operation 1 Out of Rang e
P3196 2EEC Radiator Coolan t Temperature Sensor Hig h
P3197 2EEB Radiator Coolan t Temperature Gradient Too High
P3198 2EE3 Engine Coolan t Temperature Gradient Too High
P230D ECM BUS Check
P3199 2EE2 Engine Coolan t Temperatur e Signal Stuc k
P3200 CAN Interna l Powertrain Chi p
P3201 BUS Check CAN Powertrain Chi p
P3202 CD87 Powertrain CAN Chip Cut-Of f
P3203 BUS Check Local CA N
P3204 BUS Check Loca l CAN
 On-Board Diagnostic s OBD-3 9
Diagnostic trouble codes (DTCs)

Table a. Diagnostic trouble codes (DTCs) (continued )

P-code BMWFC Definition

P3205 CD8B Local CAN Chip Cut-Off

P3206 11737 CAN Time-out AR S

P3207 11737 CAN Messag e Monitorin g ARS, No Signa l

P3208 2DD( CAN Message AR S

P3209 11735 CAN Message ASC / DSC

P321E 2F77 Ambient Pressur e Sensor Maximum Pressur e Implausibl e

P321F 2F77 Ambient Pressur e Sensor Minimu m Pressur e Implausibl e

P3210 11735 CAN Monitorin g ASC / DSC

P3211 2DDA CAN Message CA S

P3212 2DDA CAN Message CAS

P3213 2DD3 CAN Messag e Monitorin g ETC Alive Check

P3214 ECM BIS Check

P3215 2DDC CAN Message SZL

P3216 11727 CAN Time-out Instrumen t Pac k

P3217 11727 CAN Messag e Instrumen t Pac k

P3219 2DDC CAN Messag e SZL Alive Check

P322A Ambient Pressur e Senso r Continuit y

P3220 2DDC CAN Messag e SZ L No Signal

P3221 2DDC CAN Messag e SZ L

P3223 2E97 Generator Mechanica l

P3225 11927 Generator Communication Erro r

P3231 2D70 Control Module Monitorin g Error Response

P3233 2D70 Control Module Monitorin g Relative Charge Plausibilit y

P3226 27F1 E-box Control Fa n High Inpu t

P3227 27F1 E-box Contro l Fan Low Input

P3228 27F1 E-box Control Fan Open Circuit

P323F 2D60 Control Modul e Monitoring Fuel Volume, Ai r Mass Injected Fuel Volume Correlation

P3231 Control Module Interna l Fault , Throttle Actuator Control MOnito r 2 /3 ADC Processor Faul t
P3232 Control Module Interna l Fault, Monitorin g of Engine Function s
P3234 2D71 Control Module Monitorin g Throttle Actuator Stop Test
P3235 2FA4 Control Module Monitorin g Versio n Coding Plausibilit y
P3236 2D71 Control Module Monitorin g Injectio n Time Relativ e Fuel Quantit y Plausibility
P3237 2D71 Control Module Monitorin g Fue l Correction Error
P3238 Control Module Monitorin g TPU Chi p Defective
P3239 2 FAS Control Module - No Coding
P324A 2E97 Generator Type Implausible
P324A 2ED3 Generator Type Implausibl e
 OBD-40 On-Boar d Diagnostic s
Diagnostic trouble codes (DTCs)

liable a. Diagnostic trouble codes (DTCs) (continued)

P-code BMWFC Definition
P324C 2EDO Generator Ove r Temperature Calculated
P324E 2ED2 Generator Regulator Type Implausible
P3247 2B98 Control Modul e Faul t - RAM BAckup
P325A 2ECE Generator Electrica l Error Calculated
P3255 2E96 Generator Voltage I n Starting Above Threshold
P3256 2DD2 CAN Time-out Steerin g Angle Sensor
P3258 Control Modul e Interna l Fault , Hardware
P3259 2D60 Control Modul e Monitorin g Fuel Volume, Lambda Implausible t o Operating Mod e
P3283 29F1 Fuel Pressur e Control Adaptive Fuel Volume Out of Rang e (Ban k 1 )
P3284 29F1 Fuel Pressur e Control Adaptive Fuel Volume Implausible (Ban k 1 )
P3300 2E24 Ignition Coil Cylinder 1 High Inpu t
P3301 2E24 Ignition Coil Cylinder 1 High Resistance
P3302 2E24 Ignition Coil Cylinder 1 Cut OFF Du e to Hig h Temperature
P3303 2E28 Ignition Coil Cylinder 5 High Inpu t
P3304 2E28 Ignition Coi l Cylinde r 5 High Resistance
P3305 2E28 Ignition Coil Cylinder 5 Cut OFF Du e to High Temperature
P3306 2E27 Ignition Coi l Cylinder 4 High Inpu t
P3307 2E27 Ignition Coi l Cylinder 4 High Resistanc e
P3308 2E27 Ignition Coi l Cylinde r 4 Cut OFF Du e to High Temperature
P3309 2E2B Ignition Coil Cylinder 8 High Inpu t
P3310 2E2B Ignition Coil Cylinder 8 High Resistanc e
P3311 2E2B Ignition Coil Cylinder 8 Cut OFF Due to High Temperature
P3312 2E29 Ignition Coil Cylinder 6 High Input
P3313 2E29 Ignition Coil Cylinder 6 High Resistanc e
P3314 2E29 Ignition Coil Cylinder 6 Cut OFF Due to High Temperature
P3315 Ignition Coi l Cylinder 3 High Input
P3316 Ignition Coi l Cylinde r 3 High Resistance
P3317 11814 Ignition Coi l Cylinde r 3 Cut OFF Due to High Temperatur e
P3318 2E2A Ignition Coil Cylinder 7 High Inpu t
P3319 2E2A Ignition Coil Cylinder 7 High Resistance
P3320 2E2A Ignition Coil Cylinder 7 Cut OFF Due to High Temperature
P3321 11813 Ignition Coi l Cylinder 2 High Inpu t
P3322 11813 Ignition Coi l Cylinder 2 High Resistanc e
P3323 11813 Ignition Coil Cylinder 2 Cut OFF Due to Hig h Temperature
P3325 2E26 Ignition Coil Cylinder 3 High Input
P3326 2E26 Ignition Coil Cylinder 3 High Resistance
P3327 2E26 Ignition Coi l Cylinder 3 Cut OFF Due to Hig h Temperature
 On-Board Diagnostic s OBD-4 1
Diagnostic trouble codes (DTCs)

Table a . Diagnostic trouble codes (DTCs) (continued )

P-code BMWFC Definition
P3321 2E25 Ignition Coil Cylinder 2 High Input
P3322 2E25 Ignition Coil Cylinder 2 High Resistance

P3323 2E25 Ignition Coil Cylinder 2 Cut OFF Due to High Temperature
P3400 Cylinder Deactivation System (Bank 1 )

P3497 Cylinder Deactivatio n System (Ban k 2 0

 INDEX 1

Advanced crash and safety Antifreeze (engine coolant )

WARNING management (ASCM ) 020-30, 170- 7
720-1,721-11
Your common sense, good judgement Antilock brake system
and general alertness are crucial to Advanced safety electronics (ASE) see ABS (antilock brak e system )
safe and successful service work. 720-1, 721- 3
Anti-theft alarm (DWA )
Before attempting any work on your Air-conditioning 400-4, 515-23
BMW. b e sure t o read 001 Warnings see IHKA emergency disarming 515-25
and Cautions and th e copyright page see a/so Heating interior protectio n 515-25
at the front of the manual. Review
Air distributio n control servo motor s Anti-trap protection
these warnings and cautions each time
(stepper motors ) sunroof 540-1, 540- 3
you prepare to work on your car. window 512-5
640-5, 640-19
Please also read any warnings and
cautions that accompany the Air ducts, turbo A-pillar trim
procedures in the manual. seeTurbocharger 513-15
Air filter Arm, contro l
element 020-2 4 300-2. 300- 3
housing see a/so Front suspension
M54 130-13 see also Rear suspensio n
N52 131-11 ARS (active stabilizer )
ABS (antilock brake system ) N54 132-11
300-11.340-2, 340-2 4 V8 133-18 see Active stabilizer (ARS )
impulse whee l 340-3 2 ASCM (advanced crash an d safety
wheel speed senso r 340-25 , 340-30 Air flow sensor
see also Brake s see Mass air flow sensor management)
see also DSC (dynamic stability 720-1, 721-11
Air qualit y (AUC) sensor
control) ASE (Advanced safety electronics )
640-4
A/C (air-conditioning ) 720-1,721-3
Air sprin g
fluid 640-1 ATF (automatic transmission fluid )
seea/solHKA 330-13
see a/so Electronic height contro l 020-48, 200-6, 240-12, 240-1 4
see a/so Heater capacity 240-1 4
(EHC)
ACC (active cruise control ) see a/so Rear suspension cooler 170-3 , 170-1 6
340-25 Airbag system AUC (air quality) senso r
Acceleration sensor 010-28, 400-4, 720-1 , 721- 1 640-4
active stabilizer 300- 6 contact spring 612-6, 721-13 Automatic shiftlock
DSC 340-25, 340-3 2 control module 72 1 -3, 721 -11 250-8
crash sensor 721-4 , 721-12
Accelerator peda l modul e (PWG ) curtain (head protection) 721-3, Automatic tailgat e
132-19 721-11 412-9
Accessory bel t driver 320-9 . 721-5 , 721-20
locations 721-3, 721-11 Automatic transmissio n
020-32 010-19. 240-4
passenger 721-6, 721-13, 721-21
Acronyms, commonly use d seat occupancy senso r 520-5, 721-6, applications 200-3, 240- 2
ECL-2 721-14 control module (TCM ) 240-3 , 340-2 5
status light 721-6 , 721-14 cooler 170-3 , 170-1 9
Activated carbo n canister thorax (side ) 721-3 , 721-7 , 721-11 , fluid leaks 240-10
160-30 721-22 gearshift 250- 7
troubleshooting 720-2 mechatronics 240-3, 240-1 0
Active cruise control (ACC ) neutral safety switch function 121-1 4
warning light 721-4. 721-12
340-25 250-1
Alarm removing / installing 240-17
Active stabilizer (ARS)
010-22, 300- 4
400-4,515-24 service 020-48, 240-12
shiftlock 250- 8
bleeding 310-3 0 Alignment troubleshooting 240-9, 250- 2
commissioning 300-8 020-49. 300-12 , 320-3 2
front 310-32 valve body 240- 3
specifications 320-3 7 see a/so ATF (automatic transmission
IPO diagram 300- 5
troubleshooting 300- 8 Alternator (generator) fluid)
121-18 see also Torque converter
Active steerin g bit-serial data (BSD ) interface 121-18 Axle joint
see Steering troubleshooting 121-2 , 121-1 9 311-1, 331-10
Adaptation Aluminum suspension components
600-14 300-2 B
Adaptive headlight s Amplifier Back-up light s
630-5 650-4 630-4
Adaptive transmission control (ACS) function
Antenna
automatic transmissio n 612-10
240-5 515-6, 515-9, 650-5, 650- 6 SMG231-8
ECL-39 switch manua l transmission 230- 4
2 INDE X

Ball joint Brake ligh t Camshaft

front tension strut 310-19 center 630-2 4 adjustment
swing arm 330-22 force display 630- 4 see VANOS (variable camshaft
switch 340-29, 612- 9 timing)
Battery sensor 120-7 , 12016
020-25. 121-4 , 600-1 Brakes service M5 4 117-35
charging 121-10 010-23, 300-1, 300-11 , 340-2
checking 020-26 bleeding 340- 5 Camshaft timing chain
reconnection note s 121-1 2 booster M54 117- 6
registration 121-1 2 vacuum pum p 100-13 , 100-15 , N52 113-17 , 117-5 1
replacing 121-10 100-16, 133-26, 300-11, 340-18 N54 113-31 , 117-5 1
safety terminal 121-4 , 721-9, 721-1 6 caliper 340-6, 340-1 3 tensioner
sensor 121- 5 components 340- 9 N52, N5 4 117-64
testing 121-7 fluid 020-26, 340- 5 V8 117-8 4
troubleshooting 121-2 light switch 612-9 V8 113-42 , 117-6 9
master cylinder 340-16 see a/so VANOS (variable camshaft
BC (on-board computer ) pads, calipers , rotors 340-9 timing)
612-5, 620-1 pad / rotor wear 020-27, 340- 9
CAN
Bearing pedestal parking brak e 020-28, 340-1 9
rotor 340-14 130-8, 130-27, 131-8, 132- 8
311-1, 311-14 see a/so Bus
troubleshooting 340- 2
Bearing, wheel vacuum pump 100-13 , 100-15 , 100- Capacities, flui d
front 310-22 16, 133-26, 300-11, 340-18 A/C system 640- 2
rear 330-2 6 see a/so ABS (antilock brak e system) ATE 240-14
see a/so DSC (dynamic stabilit y differential
Belt control)
020-32 front 311-9
BSD (bit-serial data ) interface rear 331-2
Bit-serial data (BSD) interfac e 121-18, 600- 8 coolant 170- 8
121-18,600-8 fuel 160-2
BST (battery safet y terminal) manual transmissio n 230-4
Blade, wiper 121-4, 721-9, 721-1 6 oil 020-41, 020-43, 119-3
020-51,611-4,611-8 SMG 231-13
Bulb
Blower transfer case 270-5
applications 630- 2
640-6, 640-11 monitoring 630-6 Car access syste m (CAS)
Bluetooth see CAS (car access system)
Bumper
650-2 front 510-3 Car information computer (CIC)
antenna 650-2 rear 510-5 020-7
BMW acronyms Bus Car communications computer (CCC )
ECL-2 130-8, 130-27 , 131-8 , 132-8 , 240-2, 650-9
BMW 240-4, 340-2 5
basics 600-2, 600-7 , 600-9 , 600-11 Car memory
Assist 650-9 515-8
emblem (Roundel) 510- 8 parameters 600- 8
Online 650-9 Bushing CARB (California Air Resource s
TeleServices 650- 9 front tension strut 310-1 Board)
Body subframe 330-2 5 OBD-1
assembly 010-25, 400- 2 byteflight Carbon canister , activated
design 010-25, 400- 3 600-7 160-30
dimensions 010-4, 400-2
grounds ECL-3 4 CAS (car access system)
maintenance 020-49 010-28, 010-29 , 121-13, 121-14,
technical data 010-3 CA (comfort access) 512-1, 512-2, 512-3, 515-4, 600-5,
630-4
Body basic module (KBM ) 515-9
see KBM (body basic module ) Caster
Cabin microfilte r
320-36
Body gateway module (KGM ) 020-28, 640- 7
see KGM (body gateway module ) Catalytic converter
California Air Resource s Board
120-9, 180-2 9
Bonnet (CARB) monitoring OBD-4
see Engine hoo d OBD-1
Cautions
Boot Caliper 001-2
see Trunk 300-1,340-6,340-13
CBS (condition based service)
B-pillar trim Camber 020-3
513-16 front 320-35
rear 320-3 6 CCC (car communications computer )
Brake flui d 650-9
020-26, 340-5
Center bearing , rea r driveshaft
260-1, 260-5, 260-10
 INDEX 3

Coil sprin g C-pillartrim

WARNING front 300-1, 310-2, 310-3, 310-1 0 513-18
rear 300-1 , 330-2, 330-8, 330-12
Your common sense, good judgement Crankcase
and general alertness are crucial to Combustion chambe r lea k tes t 100-4, 100- 8
safe and successful service work. 170-6 breather 100-15 , 130-24 , 131-2 0
Before attempting any work on your Comfort access (CA) 132-37
BMW, b e sure t o read 001 Warnings 515-9 Crankshaft
and Cautions an d th e copyright page antenna 515- 9 100-4
at the front of the manual. Review Compass front seal
these warnings and cautions each time M54 119-11
121-13
you prepare to work on your car. N52, N5 4 119-1 4
Please also read any warnings and Component location s V8 119-21
cautions that accompany the see Electrical component s rear main sea l
M54 119-1 2
procedures in the manual. Compressor N52, N5 4 119-17
640-6, 640-14 V8 119-2 4
Condition base d servic e (CBS ) sensor 120-6 , 120-1 4
vibration damper 117- 3
Center brake light 020-2, 020- 3
630-24 Crash sensor
Connecting ro d
721-4
Center consol e 100-4
Cruise contro l
513-6 Constant velocit y joint
switch cluster (SZM ) 640-2, 640- 3 130-8, 131-8 , 132- 8
see CV (constant velocity ) joint
active (ACC) 340-2 5
Central informatio n displa y (CID ) Consumer cutof f clutch switch 210- 6
020-4, 650-1 0 630-7 switch 612-5
Central locking Continuity CV (constant velocity) join t
400-4, 515- 3 600-17 300-3, 311-1 , 311-9
button 515-7 , 612-8 boot 020-46, 311-6 , 311-6, 331-1 2
Control ar m driveshaft 260-1, 260-5, 260-1 1
Charge air duct s 300-1, 300-2, 300-3 , 310-2 , 310-3,
seeTurbocharger 310-13, 330-2, 3301 7 Cylinder hea d
see also Fron t suspension cover
Charging syste m M54 113- 4
troubleshooting 121-1 9 see a/so Rear suspensio n
N52, N54 113-14
Check Contro l Control module s V8 113-3 9
020-52, 620-1 010-28 M54 100-4 , 113- 5
Convenience openin g / closin g N52 100-10, 113-1 7
CIC (car information computer ) N54 113-3 1
020-7 windows 512-4 V8 113-4 2
CID (central informatio n display) Coolant (antifreeze )
see Cooling system
020-4, 650-10
see also Engin e coolan t temperatur e
Classification resistor (ECT) senso r Dashboard
270-4 010-31, 513- 3
Coolant pum p switches 612- 8
Cleaning 170-2, 170-16,640- 6
exterior 020-4 9 Defogger
Cooling syste m 640-2, 640-6
Climate contro l 100-7
see Heate r ATF cooler 170-3 , 170-1 9 Diagnostic executiv e
see also IHKA coolant (antifreeze ) OBD--
bleeding 170-9 Diagnostic monitor s
Clock capacities 170- 8
121-12 OBD-3
level 020-3 0
Clutch draining /fillin g 170-7 Diagnostic troubl e cod e (DTC )
200-3, 210- 1 expansion tank 020-33, 170-2 , 170-1 3 see DTC (diagnostic troubl e code )
fluids 200- 5 fan 170-3 , 170-1 2
hoses 020-3 1 Differential
hydraulics 210- 2 300-1,300-3,311-1, 331-1
mechanical 210- 7 intercooler 170-2 1
power steering cooling loo p 170-2 0 applications 331- 2
switch 121-14 , 210-6