How to Overhaul & Installation the Engine Controls - Removal BMW X5 E53

INTRODUCTION

Removal, overhaul and installation procedures are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.

Note. Removal and installation procedures are supplied for those models and/or engines with available information.

COMPUTERIZED ENGINE CONTROLS

POWERTRAIN CONTROL MODULE (PCM) FOR DIGITAL MOTOR ELECTRONICS (DME) SYSTEM

Note. Disconnect battery before removing Digital Motor Electronics (DME) module (PCM). Disconnecting battery will clear PCM Diagnostic Trouble Codes (DTCs). Retrieve DTCs before disconnecting battery. PCM stores certain basic driveability values. PCM also receives different input values, depending on engine condition, which are compared with stored values. PCM adaptive system compares input values with stored values. PCM replacement could cause poor engine performance before all values are adapted to engine condition. Before exchanging PCM, ensure engine is at normal operating temperature. Remove old PCM, install new PCM and operate vehicle at different RPMs.

Removal & Installation (3-Series - Z3)

PCM is located in box in right rear of engine compartment. Remove PCM box cover. Disconnect electrical connector. Remove PCM. (Scheme 1) To install, reverse removal procedure.

Scheme 1

Removal & Installation (3-Series - E46)

PCM is located in box in left rear corner of engine compartment. (Scheme 2) Remove 4 cover screws. Disconnect PCM connector. Remove PCM. (Scheme 3) To install, reverse removal procedure. Ensure wiring harness and cover are correctly installed to prevent water entry.

Scheme 2

Scheme 3

Removal & Installation (5-Series & 7-Series)

PCM is located in box in right rear corner of engine compartment. 7-Series V12 equipped vehicles use 2 PCMs. Open locking bracket on PCM/control unit box. Open filter housing cover. Unhook filter housing from hinges. Unhook retaining clip and pull filter housing upward. Remove filter housing. Remove 4 PCM/control unit cover bolts. For V12 illustration (Scheme 4)and (Scheme 5). Disconnect PCM electrical connector. Remove PCM. To install, reverse removal procedure.

Scheme 4

Scheme 5

Removal & Installation (6-Cylinder)

On E46, open cable duct on lower section of microfilter housing and feed out cables. Remove screws and lower section of microfilter housing. (Scheme 6) On all models, remove engine cover. (Scheme 34) Mark oxygen sensor connectors for reassembly reference. (Scheme 7) Unclip cable from retainer. Disconnect connector. Unclip cable on rear side of engine from cable guide. Remove oxygen sensor from cylinders No. 1-3 and No. 4-6 with Special Tool (11 7 030). Remove oxygen sensor. To install, reverse removal procedure. Coat threads with anti-seize compound and install. Tighten oxygen sensor to 41 ft. lbs. (55 N.m).

Scheme 6

Scheme 7

Removal & Installation (V8 & V12)

Turn ignition off. Unclip oxygen sensor cable from retainer. Disconnect connector. Remove oxygen sensor with Special Tool (11 7 030). (Scheme 8) To install, reverse removal procedure. Threads of new oxygen sensors are already coated with anti-sieze compound. If an oxygen sensor is reused, apply a thin coat of anti-sieze compound. Do not clean oxygen sensor section which protrudes into the exhaust line and ensure that it avoids all contact with lubricants. Note cable routing of oxygen sensor. Interrogate fault memory of control unit on Digital Engine Electronics (DME), check fault messages in memory, rectify faults and cancel fault memory. Information is not available from manufacturer.

Scheme 8

Removal & Installation

Turn ignition off. Remove nuts in cover. Disconnect electrical connector. Remove monitor. (Scheme 9) To install, reverse removal procedure.

Scheme 9

1. To remove exhaust camshaft sensor, go to next step. To remove intake camshaft sensor, remove intake air filter housing. Remove VANOS adjustment solenoid valve located next to oil filter housing. See «11 36 570 REPLACING SOLENOID VALVE FOR INLET SIDE ON VANOS ADJUSTMENT UNIT»(ref-215207-S17788565972006011000000). Disconnect sensor electrical connector. Remove sensor screw. Remove sensor from cylinder head. (Scheme 10) To install, reverse removal procedure. Replace sealing ring as necessary.
2. Disconnect exhaust camshaft sensor connector on front of cylinder head. Remove sensor screw. Remove sensor from cylinder head. (Scheme 11) To install, reverse removal procedure. Replace sealing ring as necessary.

Scheme 10

Scheme 11

Removal & Installation (V8)

Remove engine cover. (Scheme 34) Locate sensor on front of right cylinder head. Remove sensor. (Scheme 12) Disconnect connector located on top of engine at harness conduit. To install, reverse removal procedure.

Scheme 12

Removal & Installation (V12)

Turn ignition off. Remove distributor cap with left ignition wiring harness. Remove sensor bolt. Remove sensor. (Scheme 13) To install, reverse removal procedure. Check seal for damage. (Scheme 14) Replace seal as necessary.

Scheme 13

Scheme 14

Coolant temperature sensor is located under intake air manifold in cylinder head on cylinder No. 6. (Scheme 15) Disconnect intake manifold. Disconnect electrical connector and unscrew temperature sensor. (Scheme 16) Remove coolant temperature sensor. To install, reverse removal procedure. Check coolant level and top up coolant if necessary. Read out fault memory of DME control module, check stored fault messages, rectify faults, and cancel fault memory.

Scheme 15

Scheme 16

1. Turn ignition off. On vehicles with idle speed control valve, disconnect electrical connection. (Scheme 17) On vehicles without idle speed control valve, sensor is fitted on water pipe at front. Disconnect vacuum lines. Detach plug from sensor. (Scheme 18) On all vehicles, unscrew sensor. (Scheme 19) To install, reverse removal procedure.
2. Replace sealing ring. After completing work, fill and vent cooling system and check for leaks. Interrogate fault memory of DME control unit.

Scheme 17

Scheme 18

Scheme 19

Coolant temperature sensor is located under front cable duct on water pump housing. Turn ignition off. Remove non-return valve on cylinders No. 1-6. See NON-RETURN VALVE. Disconnect sensor electrical connector. Remove temperature sensor. (Scheme 20) To install, reverse removal procedure.

Scheme 20

Crankshaft position sensor is located below starter. Remove cover under engine. Disconnect crankshaft position sensor connector. Remove crankshaft position sensor screw. Remove crankshaft position sensor. To install, reverse removal procedure. Replace sealing ring as necessary.

Identifying Crankshaft Sensor (6-Cylinder). Scheme 21

Sensor is located on transmission housing, bottom right.

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

1. Turn ignition off. Remove rear splash guard. Disconnect plug connection on crankshaft sensor for DME No. 1 (cylinders No. 1-6) or DME No. 2 (cylinders No. 7-12). (Scheme 23)and (Scheme 24). Remove crankshaft sensor screw. (Scheme 25) Remove crankshaft sensor. NOTE: If replacing transmission, flywheel or crankshaft position sensor, check whether one or more shims are installed between transmission housing and crankshaft sensor. If one or more shims are installed, distance between crankshaft sensor and pulse teeth must be measured.
2. To install, reverse removal procedure. Turn engine on front central bolt so a full crankshaft position sensor pulse tooth can be seen through opening of removed sensor. Ensure pulse tooth is exactly centered in hole. (Scheme 26) Measure depth to pulse teeth of flywheel, then measure depth of pulse sensor. (Scheme 27)and (Scheme 28). Subtract depth of pulse sensor from depth of flywheel to achieve gap measurement. Using shims, adjust gap to.021" (.55 mm).

DIRECT IGNITION SYSTEM (DIS)

1. Ensure ignition is turned off before working on the ignition system. The engine will not start without a connected secondary circuit. When checking compression, remove Digital Motor Electronics (DME) Electronic Control Unit (PCM) relay. See «DME & FUEL PUMP RELAY LOCATION»(/bmw/x5/e53-1999-2003/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal) table under FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEM.
2. Shielded capacitors may not be connected to terminal No. 1 of the ignition coil. Terminal No. 1 of the ignition coil may not be connected to ground or battery positive terminal, as this will damage ignition stages in DME control unit.
3. DO NOT connect DVOM or test light to terminal No. 1 of ignition coil while engine is running. High tension (350 volts) is present at coil terminal No. 4, secondary ignition leads, spark plugs and ignition coil terminal No. 1 to DME Powertrain Control Module (PCM).

Note. For location of DME master and fuel pump relays, see DME & FUEL PUMP RELAY LOCATION table under FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEMS .

Removal & Installation (Left Cap)

Turn ignition off. Remove fan. Unfasten clips on air filter box. Unfasten hose clip from auxiliary hose for air pump. Disconnect electrical connection. Remove upper section of suction filter housing with mass airflow sensor. Unfasten cable connectors. (Scheme 29) Unclip and remove left distributor cap cover. (Scheme 30) Pull off shielded connectors. Remove screws and distributor cap. (Scheme 31) To install, reverse removal procedure.

Scheme 29

Scheme 30

Scheme 31

Removal & Installation (Right Cap)

Turn ignition off. Remove fan. Remove non-return valve for cylinders No. 1-6. Disconnect electrical connection. Remove upper section of right intake filter housing with mass airflow sensor. Loosen retainers. Loosen hose clip on intake hose for air pump. Disconnect electrical connector. Unfasten hose clip. Unclip and remove right distributor cap cover. (Scheme 32) Pull off shielded connectors. Remove screws and distributor cap. (Scheme 31) To install, reverse removal procedure.

Scheme 32

Remove distributor. See DISTRIBUTOR CAP (V12). Remove 3 rotor bolts. (Scheme 33) Remove rotor. To install, reverse removal procedure.

Scheme 33

1. Remove engine cover. (Scheme 34) Disconnect ignition coil connector. Remove ignition coil nuts. Remove ignition coil(s). (Scheme 35)
2. To install, reverse removal procedure. Install ground strap. (Scheme 36) Ensure ignition coil common ground lead is attached to front of cylinder head, near engine lift bracket.

Scheme 34

Scheme 35

Scheme 36

Remove engine cover. (Scheme 34) Disconnect wiring connectors from coil. Remove ignition coil nuts. Remove ignition coil(s). (Scheme 35) To install, reverse removal procedure.

Disconnect electrical connections at left and right ignition coils. Remove sealing cap. Remove nuts. To install, reverse removal procedure.

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

1. Turn ignition off. Open clips on air filter housing. Unfasten hose clip. Disconnect electrical connector at mass airflow sensor. Remove upper section of suction filter housing with mass airflow sensor. Mark plug connectors No. 1 and 2 and remove. Remove plug connector, hose clip and air hose. Remove mass airflow sensor with upper section of intake filter. Unclip air hoses from bracket. Disconnect plug connector from solenoid valve.
2. If necessary, release cable ties and disconnect plug connector from alternator. Unfasten cable connector. Disconnect plug connector and pull solenoid valve out of bracket. Lay solenoid valve and air hose below engine. Unfasten screw connection of ignition wiring harness on manifold. Disconnect spark plug connectors. Unfasten cable connector on protective cap of distributor cap. Unfasten 3 clips and remove protective cap for distributor cap. (Scheme 37)- (Scheme 47). Remove ignition wires as necessary. To install, reverse removal procedure.

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

1. Turn ignition off. Press interlock and remove connector. (Scheme 48) Open clips on air filter housing. Unfasten hose clip from auxiliary hose for air pump. Pull off hose. Disconnect plug-in connection. Release hose clamp and withdraw hose. Remove upper section of suction filter housing style with mass airflow sensor. (Scheme 37) Pull air hose off air intake hose.
2. Unclip air hoses from bracket. Unclip diagnosis connector from bracket. Unfasten screw connection for ignition wiring harness from manifold. Remove spark plug connectors. Unfasten cable tie on protective cap for distributor cap. Unfasten 3 clips and remove protective cap for distributor cap. (Scheme 49)- (Scheme 52). Remove ignition wires as necessary. To install, reverse removal procedure.

Remove air intake ducting. Disconnect electrical connection from retainer at cable duct. (Scheme 53) Remove bolt from knock sensor for cylinders No. 1-3, and bolt from knock sensor for cylinders No. 4-6. (Scheme 54)and (Scheme 55). Remove knock sensors, located on side of engine block. To install, reverse removal procedure. Clean knock sensor contact surface. When tightening knock sensors, ensure sensor and wiring do not interfere or chafe on brackets or other components. See TORQUE SPECIFICATIONS.

Scheme 53

Scheme 54

Scheme 55

1. Remove engine cover. (Scheme 34) Disconnect vacuum hoses to intake manifold and throttle body. Drain radiator and remove coolant expansion tank. Remove coolant manifold from rear of cylinder heads.
2. Disconnect fuel feed and fuel return lines at engine. Disconnect fuel lines and fuel tank vent line at engine carrier. Disconnect fuel line and wiring from top of fuel vapor canister.
3. Loosen hose clamps on idle speed controller and throttle body. Disconnect airflow sensor connector. Remove air cleaner housing/airflow sensor assembly. Raise and support vehicle. Disconnect oil level sensor connector. Disconnect and remove ignition coils.
4. Disconnect crankshaft position sensor and both knock sensor connectors. Disconnect intake air temperature sensor, idle speed potentiometer and idle speed controller connectors. Remove BMW engine diagnostic connector socket from bracket. Disconnect connector next to BMW diagnostic connector socket.
5. Remove bolt securing ignition coil ground wire (near engine lift bracket). Disconnect temperature gauge and temperature sensor connectors for DME (Black connector and White connector near engine lift bracket).
6. Completely disconnect throttle cable from engine. Remove intake manifold. Mark knock sensor connectors for reassembly reference. Remove knock sensor(s). (Scheme 56) To install, reverse removal procedure. Ensure knock sensors are connected to proper connectors. See «TORQUE SPECIFICATIONS»(/bmw/x5/e53-1999-2003/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal__torque-specifications).

Scheme 56

Turn ignition off. Remove appropriate intake manifold to access knock sensor. To remove knock sensor, remove bolt in center of sensor. (Scheme 57)and (Scheme 58). To install, reverse removal procedure. See TORQUE SPECIFICATIONS.

Scheme 57

Scheme 58

1. Switch ignition off. If engine acoustic cover is screwed down, remove seal caps and unfasten nuts. Remove acoustic cover. If acoustic cover has press-stud fasteners, open press-studs, one at a time, at the same time lifting the acoustic cover slightly. Once all 4 press-studs have been opened, remove acoustic cover. Remove sealing caps and unfasten nuts. Remove cover from ignition coils.
2. On all models, unfasten coil plug connection. Unfasten screws on ignition coils. Unscrew and remove spark plugs. To install, reverse removal procedure. Ground straps of cylinder head cover must be secured on ignition coils for cylinders No. 3 and 6. Position acoustic cover and install nuts or press downward until press-studs click into place.

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

1. Turn ignition off. For cylinder bank 1-6, press interlock and remove connector on air filter box. (Scheme 48) Open clips on air filter box. Unfasten hose clip from auxiliary hose for air pump. Disconnect electrical connector. Unfasten hose clip. Remove upper section of suction filter housing with mass airflow sensor. On cylinder bank 7-12, open clips on air filter box. Unfasten hose clip. Disconnect electrical connector. Remove upper section of suction filter housing with mass airflow sensor.
2. Disconnect plug connections No. 1 and 2 from heating valve. Pull heating valves out of rubber mounts and lay below engine. Release cable ties and lay air hose below engine. (Scheme 59)- (Scheme 63). Using Extension (12 7 131), remove spark plugs. To install, reverse removal procedure.

FUEL SYSTEMS

FUEL SYSTEM PRESSURE RELEASE

Fuel system pressure release procedure not available from manufacturer. It may be possible to remove fuel pump relay, start engine, and run engine until fuel pressure drops (engine stalls). See DME & FUEL PUMP RELAY LOCATION table.

DME & FUEL PUMP RELAY LOCATION (1)

ACCELERATOR SENSOR (V12)

Note. When accelerator sensor is disconnected, basic adaptation of accelerator sensor is required. Connect DIS and select diagnosis on EPC-III control unit. Follow procedure set out in DIS instructions.

1. Turn ignition off. Remove lower trim from instrument panel. Press accelerator pedal by hand to avoid bending pedal tip and falsifying measured values. Accelerator sensor is installed on pedal block. (Scheme 64) Unscrew and remove control unit from bracket. (Scheme 65) Remove bracket. Remove retaining ring and unhook lever. (Scheme 66) Disconnect electrical connector. Remove screws. (Scheme 67)
2. To install, note position of pedal travel sensor and lever position. Lever No. 1 is factory-set and must not be released. (Scheme 68) If lever is released, entire sensor must be replaced. Install bracket with weld-in nuts. (Scheme 69) Check adjustment of kickdown switch.

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Unfasten screws and nuts. Remove right rear wheel trim. Unfasten hose clips and remove hose. Remove 2 nuts. Press back of expansion tank upward and remove. Release hose clamps and remove hoses. To install, reverse removal procedure. (Scheme 70)- (Scheme 72)

Scheme 70

Scheme 71

Scheme 72

Remove right rear wheel and right rear wheel arch. Unfasten plastic nut. Unfasten hose clip and remove hose. Tilt expansion tank forward at bottom. (Scheme 73) Release hose clip and disconnect hose. Release hose clip and disconnect hose. Remove expansion tank. (Scheme 74) To install, reverse removal procedure.

Scheme 73

Scheme 74

Removal & Installation (5-Series)

Remove right rear wheel. Remove right rear wheel trim. (Scheme 75) Unfasten hose clips and remove hose. (Scheme 76) Remove 2 expansion tank bolts. (Scheme 77) Unclip lines in front of tank. (Scheme 78) Loosen lines to activated carbon filter at expansion tank. Remove expansion tank.

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Removal & Installation (7-Series)

Remove left rear wheel. Remove left rear wheel trim. Remove return line. (Scheme 79) Unscrew and lower expansion tank. (Scheme 80) Disconnect connections No. 1 and 2. (Scheme 81) Unclip lines in front of tank. (Scheme 78) Loosen lines to activated carbon filter at expansion tank. Remove expansion tank.

Scheme 79

Scheme 80

Scheme 81

3-Series (Z3)

Filter on firewall of vehicle: Remove cover from fuel filter. Disconnect fuel delivery line with special tool 13 3 010 before and after the fuel filter. Unfasten hose clips and remove fuel line from fuel filter.

Scheme 82

Unfasten screw and remove filter from bracket. Filter on underbody of vehicle: Unfasten screws and remove cover from fuel filter. Disconnect fuel inlet line at points (1) and (2) with special tool 13 3 010.

Scheme 83

Unfasten hose clips and remove fuel line from fuel filter. Fuel filter with quick release coupling. Push lock toward filter while pulling off fuel hose. Unfasten screw and remove filter from bracket.

Scheme 84

Installation: Check direction of flow (arrow). Arrow must point towards the injection valve strip.

Scheme 85

3-Series (E46)

Turn off ignition. If installed: Remove engine underguard (1 and 2). Disconnect fuel feed line at points (1) with special tool 13 3 010.

Scheme 86

Release hose clips and disconnect fuel lines from fuel filter.

During installation, always replace hose clips and fuel hoses. Release screw (2) and remove filter from retainer.

Scheme 87

Observe flow direction (arrow). Arrow must point in direction of fuel injector block.

M52, M60, M62 & M73

Switch off ignition. Unfasten screws on lower trim (1).

Scheme 88

Fold lower trim to one side.

Scheme 89

Disconnect fuel lines with special tool 13 3 010. Catch and dispose of escaping fuel.

Scheme 90

Illustrated here without lower trim: Unfasten hose clips. Replace hose clips.

Scheme 91

Unfasten screws. Remove fuel filter. Replace fuel filter.

Scheme 92

Installation: Note installation direction of fuel filter. Direction of flow is marked with an arrow on the fuel filter. The arrow points towards the injector strip.

Scheme 93

The embossed designation "OUT " on outlet of fuel filter must be mounted facing the injector strip.

Scheme 94

On versions with hose clips, remove hoses No. 1 and 2. On versions with compressed air connection, blow fuel back into tank with a short blast of air at compressed air connection. On fuel hoses without integrated unlocking facility, unlock fuel hoses with Special Tool (16 1 050) and detach hoses. On fuel hoses with integrated unlocking facility, press fuel hose downward and keep pressed. Press unlocking ring upward, keep pressed and detach fuel hose. On fuel hoses with quick-release fittings, seal off fuel hoses with Special Tool (13 5 281 and 13 5 282). To install, reverse removal procedure. On versions with hose clips, replace clips. On versions with and without integrated unlocking facility and quick release fittings, check "O" ring in fuel hose and sealing services for damage and replace as necessary. Coat "O" ring with anti-friction agent.

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Removal (6-Cylinder)

1. Fuel pump is integral with right fuel level sensor. Siphon out as much fuel as possible from fuel tank. Remove passenger seat cushion (Z3) or rear seat cushion (all others). Remove or cut insulation mat along perforated line and fold open.
2. Remove fuel pump access cover (if equipped). Press Green unlocking ring and detach fuel delivery hose (M3), or mark fuel hoses for installation reference and disconnect hoses (all others). Disconnect electrical connectors. (Scheme 100) Loosen screw cap with Special Tool (161020). Remove screw cap and sealing ring. (Scheme 101) Remove fuel pump assembly.

Ensure height sensor is pressed onto inside face of fuel baffle. Rotate screen and float into fuel tank. Ensure marker rib on fuel pump unit aligns with mark on fuel tank. (Scheme 102)and (Scheme 103). Install new sealing ring. Tighten screw cap. To complete installation, reverse removal procedure.

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Removal (V8 & V12)

1. Siphon out as much fuel as possible from fuel tank. Remove rear seat. Remove or cut insulation mat along perforated line and fold open. Remove rubber grommet. (Scheme 104) Remove fuel pump/sending unit cover. Disconnect electrical connector.
2. Disconnect fuel line. (Scheme 105) Remove 8 lid nuts. Lift up lid as far as possible and swing it upward. Compress retaining hook on fuel pump Black housing. Remove fuel pump from fuel baffle White housing. Remove fuel pump and sender. (Scheme 106) Remove fuel pump from sender. Remove hose clamp and carefully remove spiral hose. Remove fuel pump.

1. To prevent torsional stress, align connector hose and cable between lid and fuel pump. (Scheme 107) Install unit in fuel tank, ensuring both retaining hooks are aligned.
2. Ensure "O" ring is correctly aligned on intake neck. Install lid and tighten 8 screws in a crosswise pattern. To complete installation, reverse removal procedure.

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Note. Fuel pressure regulator for 6-cylinder vehicles may be installed on fuel rail (type 1) or under vehicle (type 2).

Fuel pressure regulator is located on fuel rail. Open wire conduit on lower section of microfilter housing on cowl. Carefully feed wiring out of conduit. Remove 4 screws from microfilter housing. Remove lower section of microfilter housing. (Scheme 108) Remove engine cover. Disconnect vacuum hose from fuel pressure regulator. Note position of vacuum connector on fuel pressure regulator. Remove circlip. Remove fuel pressure regulator. To install, reverse removal procedure. Ensure lug on circlip engages in slot on injector fuel rail.

Scheme 108

1. Fuel pressure regulator is located at rear of intake manifold. Remove engine cover. (Scheme 34) Remove coolant expansion tank and BMW diagnostic connector (if necessary). Disconnect vacuum hose from pressure regulator. Remove circlip and pull pressure regulator out of fuel rail.
2. To install, reverse removal procedure. Replace "O" rings on regulator and lubricate with petroleum jelly. Install regulator in fuel rail. Compress circlip and engage tabs of circlip into fuel rail.

Release screws and clips on cover on underbody on passenger side. (Scheme 109) Remove cover. Catch and dispose of escaping fuel. Pull off vacuum hose. Pull out locking bracket. Remove fuel pressure regulator. (Scheme 110) To install, reverse removal procedure.

Scheme 109

Scheme 110

1. Remove engine cover. (Scheme 34) Loosen hose clamp and disconnect fuel supply hose from fuel rail. Remove 2 bolts and pull connector plate off fuel injectors. (Scheme 112) Remove 4 bolts and disconnect fuel rail. Pull up on fuel rail and injectors.
2. Remove retainer from top of fuel injector. Remove fuel injector(s). To install, reverse removal procedure. Coat injector "O" rings with petroleum jelly.

1. Open wire conduit on lower section of microfilter housing on cowl. Carefully feed wiring out of conduit. Remove 4 screws from microfilter housing. (Scheme 108) Remove lower section of microfilter housing. Remove engine cover. Disconnect low pressure hose from fuel pressure regulator valve. Disconnect intake air temperature sensor connector. Disconnect fuel injector terminal strip. NOTE: Mark HO2S connectors and fuel lines for reassembly reference.
2. Unclip HO2S connectors from retainers. Disconnect HO2S connectors. Remove electrical plug retainers from injection block. Release fuel system pressure See «FUEL SYSTEM PRESSURE RELEASE»(/bmw/x5/e53-1999-2003/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal__fuel-system-pressure-release). Disconnect fuel lines at rear of cylinder head. Remove injection pipe screws. Remove injection pipe with fuel injectors.
3. Remove tab washer at fuel injector. Remove fuel injectors from injection pipe. To install, reverse removal procedure. Coat injector "O" rings with petroleum jelly.

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/bmw/x5/e53-1999-2003/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal__fuel-system-pressure-release). Remove engine cover. (Scheme 34) Disconnect throttle cable at throttle body. Disconnect ignition coils and fuel injectors.
2. Disconnect fuel lines from fuel rail. Remove fuel rail mounting screws and pull off fuel rail with injectors. Remove retainer from top of fuel injector. Remove fuel injector(s). To install, reverse removal procedure. Coat injector "O" rings with petroleum jelly.

Scheme 111

Scheme 112

Turn ignition off. Remove wiring harness on engine. Lift harness upward and secure to hood. Pull supply air hoses for air-contained injection valves off injection valve strips. Loosen hose clips and pull off injection valve strips. Carefully pull off fuel hoses to release pressure. Catch escaping fuel in a container. Remove screws and injection valve strip with injection valves. Unclip and remove circlip. (Scheme 113)- (Scheme 117). Remove injector valves. To install, reverse removal procedure. Check injector seals and replace as necessary. Coat seals with acid-free grease

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Remove fuel from fuel tank. On right tank section, disconnect fuel pump connection for fuel pump and fuel level sensor. On left tank section, disconnect fuel level sensor connection. Disconnect fuel return hose and tank compensating hose. Disconnect fuel hoses with special tool (13 3 010) and remove supply and return lines. Remove heat baffle plate screws. Remove heat baffle plate. Remove complete propeller shaft. Unfasten cable on handbrake lever. Press cable out of clips and pull through retaining brackets. Release hose clamp and remove fuel filler hose. Remove tank mounting screws, lower and remove tank. Disconnect tank vent pipe. Unclip vent pipe to carbon canister. Disconnect tank vent pipe. Disconnect filler vent pipe. Remove fuel tank. To install, reverse removal procedure. Replace all hose clamps. Install washers between retaining strap at right outside and crossmember (rear take-up) at front. (Scheme 118)- (Scheme 129).

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

Scheme 134

1. Remove fuel from fuel tank. Remove complete rear axle. See DIFFERENTIALS & AXLE SHAFTS article. Remove carbon canister. See «CARBON FILTER»(/bmw/x5/e53-1999-2003/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal). Unfasten ground strap. Using Special Tool (161040), unlock and remove connecting nipple from tank ventilation line. Disconnect fuel hose with Special Tool (133010) and remove supply line. (Scheme 121)
2. Disconnect fuel hose with Special Tool (133010) and remove return line. Remove bolts on clamping straps. Support fuel tank. Remove bolt at center of tank. Disconnect plug connection. Pull fuel tank down to remove. (Scheme 130)- (Scheme 134) To install, reverse removal procedure.

1. Remove fuel from fuel tank. Unfasten Bowden cable on handbrake lever. Remove exhaust system. Remove propeller shaft. Remove under-car tank trim on left side of vehicle. (Scheme 135)
2. Remove lip behind wheel on left side of vehicle. (Scheme 136) Remove tank trim on right. (Scheme 137) Remove lip on right. (Scheme 138) Remove handbrake cables from guide tubes. (Scheme 139)
3. Release hose clips and detach fuel feed and return lines. (Scheme 140) Release hose clip and detach fuel filler pipe/fuel tank connecting hose from fuel tank. (Scheme 141) Support tank over a wide area with lifting equipment. Unfasten hex nut. (Scheme 142) Release nut and remove retaining strap on both sides. (Scheme 143)
4. Lower fuel tank and disconnect electrical connections. Release hose clip and detach vent line. (Scheme 144) Remove fuel tank toward bottom. To install, reverse removal procedure. Note position of guide on lip during installation. Replace hose clips.

Scheme 135

Scheme 136

Scheme 137

Scheme 138

Scheme 139

Scheme 140

Scheme 141

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

Scheme 152

1. Fill fuel tank with at least 1.2 gallons (5 L) of fuel. Draw fuel out of fuel tank. With Special Tool (34 1 030), unfasten lock nuts. Twist lock nuts and adjustment nuts completely out of handbrake cables and pull Bowden cables downward out of their guide tubes. Remove right rear wheel. Remove right rear wheel arch trim. Unfasten hose clip and remove hose from tank. (Scheme 145) Remove propeller shaft completely. Remove heat shield from tank. (Scheme 146) Remove handbrake Bowden cables from guide tubes.
2. Unfasten screw and remove cover from rear axle bearing. (Scheme 147) Unfasten hose clips, mark fuel lines and remove hoses. Open hose clip with pliers and remove hose (park heating only). (Scheme 148) On all models, unfasten screws and remove clamping straps. (Scheme 149)
3. Support fuel tank. Unfasten bolts for left and right tank mounting, then lower tank until hose connections and plug connections are accessible. (Scheme 150) On left half of tank, disconnect connector from fuel level sensor, unfasten hose clips and remove tank vent lines. (Scheme 151)
4. On right half of tank, disconnect connector on fuel delivery unit. Unfasten hose clip and remove tank vent line. (Scheme 152) Lower fuel tank and remove downwards. To install, reverse removal procedure. Note location of rubber mount and washers on left and right tank. After the installation of the fuel tank and prior to first engine start-up, check the electrical resistance between ground lug (tank filling pipe) and wheel hub. Measured value should be approximately.6 ohms.

Removal & Installation (7-Series V8)

1. Fill fuel tank with at least 1.2 gallons (5 L) of fuel. Draw fuel out of fuel tank. With Special Tool (34 1 030), unfasten lock nuts. Twist lock nuts and adjustment nuts completely out of hand brake cables and pull Bowden cables downward out of their guide tubes. Remove right rear wheel. Remove right rear wheel arch trim. Unfasten hose clip and remove hose from tank. Remove propeller shaft. Remove heat shield from tank. Remove hand brake Bowden cables from guide tubes.
2. Unfasten screw and remove cover from rear axle bearing. Unfasten hose clips (one return line, 2 inlet lines), mark fuel lines and remove hoses. Open hose clip with pliers and remove hose. Unfasten screws and remove clamping straps.
3. Support fuel tank. Unfasten screws for left and right tank mounting, then lower tank until hose connections and plug connections are accessible. Disconnect connector from fuel level sensor, unfasten hose clips and remove tank vent lines.
4. On right half of tank, disconnect connector on fuel delivery unit. Disconnect hose clip and remove tank vent line. Lower the fuel tank and remove downward. After installation of fuel tank, and prior to first engine start-up, check electrical resistance between ground lug (tank filling pipe) and wheel hub. Measured value should be approximately.6 ohms.

Scheme 153

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Scheme 160

Scheme 161

1. Fill fuel tank with at least 1.2 gallons (5 L) of fuel. Draw fuel out of fuel tank. Disconnect fuel pipe with Special Tool (13 3 010) and open hose clamp. Disconnect left and right fuel level sensor connectors. (Scheme 153)
2. Remove propeller shaft completely. Disconnect cable. (Scheme 154) Unscrew and remove dipstick tube. Remove left and right stone chip guards. (Scheme 155) Remove hydraulic lines. (Scheme 156) Replace fuel lines and hose clips. Remove filler hose clip and filler hose. (Scheme 157) Unscrew and remove clamping straps. (Scheme 149)
3. Support fuel tank. Unfasten left and right bolts. (Scheme 158) Slightly lower fuel tank and tilt it forward until lines can reach upper side of fuel tank. Loosen lines at upper left side of fuel tank. (Scheme 159) Loosen ventilation line at upper side of the fuel tank. (Scheme 160) Lower the fuel tank and remove downward.
4. To install, reverse removal procedure. Note location of rubber mount with spacer bushing. Wide collar on spacer bushing faces toward screw head. Note rubber supports at the back of fuel tank. (Scheme 161) Note locating wedges with rubber cover on floor assembly. After installation of fuel tank and prior to first engine start-up, check electrical resistance between ground lug (tank filling pipe) and wheel hub. Measured value should be approximately.6 ohms.

Removal & Installation (6-Cylinder - E36)

Remove air filter housing. Remove throttle valve extension. Disconnect dip stick guide tube. Disconnect idle speed control valve electrical connector. Remove 2 bolts. Remove idle speed control valve. (Scheme 162) Remove gasket and rubber clip. To install, reverse removal procedure.

Scheme 162

Idle speed control valve is located under intake air manifold, above throttle body. Remove air filter housing. Remove Mass Airflow (MAF) sensor. Pull throttle cable upward out of retainer and unhook. Loosen hose clamps and detach intake hose ducting from throttle assembly and idle speed control valve. Disconnect resonance flap and idle speed control valve connectors. Loosen retaining screw on cable duct mounting. Loosen 2 idle speed control valve retaining screws. Remove idle speed control valve and retainer from intake air manifold. (Scheme 163) To install, reverse removal procedure. Replace idle speed control valve seal. Coat inside of seal with antiseize compound.

Scheme 163

Remove engine cover. (Scheme 34) Disconnect idle speed control valve electrical connector. Remove top of air cleaner. Remove idle speed control valve mounting strap. Pull actuator from throttle body. To install, reverse removal procedure.

Disconnect temperature sensor electrical connector. (Scheme 164) Press locking button and unclip temperature sensor. To install, reverse removal procedure.

Open wiring conduit on lower section of microfilter housing on cowl. Feed out wiring from conduit. Remove 4 microfilter housing screws on cowl. Remove lower section of microfilter housing. (Scheme 108) Remove engine cover. Disconnect temperature sensor electrical connector. Press locking tab on side of temperature sensor. Remove temperature sensor from intake manifold. To install reverse removal procedure. To install, reverse removal procedure.

Remove throttle body. See THROTTLE BODY . Disconnect intake air temperature sensor electrical connector. Press locking tab on side of temperature sensor. Remove temperature sensor from intake manifold. To install, reverse removal procedure.

Scheme 164

Turn ignition off. Press down retaining ring. Disconnect electrical connector. Unclip and remove temperature sensor. (Scheme 165) To install, reverse removal procedure.

Scheme 165

Using scan tool, interrogate fault memory of DME control unit. Turn ignition off. Disconnect mass airflow sensor connector. Disconnect vacuum line from intake hose. Disconnect intake air hose clip. Disconnect clamps on intake filter housing. Remove intake hose with MAF sensor. (Scheme 166) To install, reverse removal procedure. Check gasket between MAF sensor and upper section of air filter housing for damage. Replace as necessary. Using scan tool, interrogate fault memory of DME control unit. Check for stored fault codes. Repair faults as necessary. Clear memory.

Scheme 166

Using scan tool, interrogate fault memory of DME control unit. Turn ignition off. Loosen hose clamp and pull off air intake hose. Unclip and remove upper portion of air cleaner housing. Remove mass airflow sensor mounting bolts. To install, reverse removal procedure. Using scan tool, interrogate fault memory of DME control unit. Check for stored fault codes. Repair faults as necessary. Clear memory.

Scheme 167

Using scan tool, interrogate fault memory of DME control unit. Turn ignition off. Disconnect mass airflow sensor connector. Loosen hose clip. (Scheme 168) Remove intake hose from mass airflow sensor. Remove clips and detach mass airflow sensor from air cleaner upper section. (Scheme 169) To install, reverse removal procedure. Check seal between mass airflow sensor and air cleaner upper section for damage. (Scheme 170) Replace as necessary. To ease assembly, coat seal with acid-free grease. Using scan tool, interrogate fault memory of DME control unit. Check for stored fault codes. Repair faults as necessary. Clear memory.

Scheme 168

Scheme 169

Scheme 170

Unfasten hexagon nut and plastic nut. Tank off cover for activated carbon canister. Release plug connector and pull off activated carbon canister non-return valve. Press detent to side and pull activated carbon canister non-return valve out of activated carbon canister. To install, reverse removal procedure. Ensure position marks are aligned. Check sealing ring for damage and proper sealing. (Scheme 171)- (Scheme 173).

Scheme 171

Scheme 172

Scheme 173

Removal & Installation (M Roadster)

Unfasten plug connection and disconnect connector. Release screw and remove activated carbon filter non-return shut-off valve from carbon filter. (Scheme 174) To install, reverse removal procedure. Ensure connector is locked in place. Check sealing rings.

Scheme 174

Removal & Installation (V12 - Cylinders 1-6)

Open clips. Unfasten hose clip from inlet hose for air pump. Remove hose. Disconnect plug connection. Unfasten hose clip. Remove complete top right section of intake filter housing. Remove fan coupling with fan. Unclip and remove oil drip tray. Unfasten hose clip to non-return valve for cylinder bank 7-12 and remove pressure hose. Unfasten hose clip on non-return valve for cylinder bank 1-6 and remove pressure hose. Unclip bracket for coolant vent hose. Unfasten screws in non-return valve for cylinders 1-6 to pressure pipe. Remove non-return valve. Unfasten hose clip on pressure pipe for air pump. Remove hose. Unfasten pressure pipe from brackets and remove. To install, reverse removal procedure. Replace gaskets. Ensure spacer disc is fitted under bracket to water pump to prevent pressure pipe from being subjected to tension.

Removal & Installation (V12 - Cylinders 7-12)

Compress retainer and pull off electrical connector. Open clips. Unfasten hose clip on intake hose for air pump. Remove hose. Disconnect plug connection. Unfasten hose clip. Remove complete upper section of intake filter housing. Unclip and remove oil drip tray. Unfasten hose clip to non-return valve for cylinder bank 7-12 and remove pressure hose. Unfasten hose clip on non-return valve for cylinder bank 1-6 and remove pressure hose. Unfasten hose clip on pressure pipe for air pump. Remove hose. Unfasten screws in non-return valve for cylinders 7-12 on pressure pipe, then remove non-return valve. To install, reverse removal procedure. Replace gaskets. Ensure spacer disc is fitted under bracket to water pump to prevent pressure pipe from being subjected to tension.

Scheme 175

1. Remove air filter housing. Remove mass airflow sensor. See «MASS AIRFLOW SENSOR»(/bmw/x5/e53-1999-2003/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal). Disconnect oil pressure and oil temperature switch connectors located next to oil filter housing. Remove wiring conduit mount screws. Unclip fuel lines and oil level sensor wire from retainer on oil dipstick tube. Disconnect oil return line from oil dipstick tube. Loosen screw and remove oil dipstick tube.
2. Move wiring conduit aside and disconnect electrical connector on throttle. Remove 4 bolts, throttle body and gasket. (Scheme 175) To install, reverse removal procedure. Replace oil dipstick tube and throttle body "O" rings.

1. Remove engine cover. (Scheme 34) Disconnect mass airflow sensor, idle speed control actuator and throttle position sensor connectors. (Scheme 176) Remove top of air cleaner housing.
2. Disconnect throttle cable, hoses and idle speed control actuator from throttle body. (Scheme 177) Remove 6 throttle body bolts. (Scheme 178) Remove throttle body. To install, reverse removal procedure.

Scheme 176

Scheme 177

Scheme 178

Turn ignition off. Disconnect batteries. Remove engine cover. To remove throttle body for cylinders 7-12, remove suction hose from throttle body. Disconnect electrical connector. Remove bolts. Remove bracket with positive battery terminal. Remove hose clamp and withdraw hose. Remove hose. If installed, remove faulty air valve. To remove throttle body on cylinders 1-6, remove suction hose on throttle body. Disconnect electrical connector. Remove bolts. Remove hose clip and remove hose. (Scheme 179)- (Scheme 182). Remove air relief valve. To install, reverse removal procedure. Replace gasket, fuel hose to tank vent valve, and hose clips.

Scheme 179

Scheme 180

Scheme 181

Scheme 182

THROTTLE POSITION SENSOR

Note. For throttle position sensor information, go to THROTTLE BODY .

1. Remove bolts and cover under vehicle. Clamp fuel lines with Clamp (13 3 010).
2. Interrogate fault memory of DME control unit. Turn ignition off. On 3-Series, remove underbody cover. (Scheme 183) On 5-Series, remove front underbody cover on left side. (Scheme 184) On 7-Series, remove front underbody cover on right side. Release screws and clips. Remove cover. (Scheme 109)
3. On all models, seal off all fuel hoses using Clamp (13 3 010). (Scheme 185) Disconnect vacuum hose from pressure regulator. Remove hose clips No. 2-5 and remove fuel hoses. Catch escaping fuel. Disconnect electrical connector. Remove nuts and 3/2 way valve. (Scheme 186) To install, reverse removal procedure. On 3-Series, ensure seal is correctly located. (Scheme 187) Replace fuel lines and hose clips.

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Pull up cover. Remove filter insert. To install, reverse removal procedure. Clean outside air tray and clean air tray before installation of new air filter element. To install, reverse removal procedure.

Open clips on air filter housing. (Scheme 188) Disconnect plug connection on temperature sensor for intake air. Remove air filter insert. To install, reverse removal procedure.

Scheme 188

Turn ignition off. For cylinder bank 1-6, press down interlock and disconnect plug connection. (Scheme 48) Open clips, release hose clamp and withdraw hose. Disconnect electrical connection. Lift off upper section of air filter housing and remove. (Scheme 59) For cylinder bank 7-12, open clips, release hose clamp and withdraw hose. Disconnect electrical connection. Lift off upper section of air filter housing and remove. (Scheme 60) Remove air filter insert. To install, reverse removal procedure.

Remove right intake filter housing. See RIGHT INTAKE FILTER HOUSING . Unfasten hose clip and remove hose. Unfasten hose clip on engine support. Unfasten screw. Remove bolts. Remove cover. Remove right foglights. Disconnect plugs. Unfasten hose clips and remove hoses. From top of vehicle, remove screws, pump and bracket by pulling downward. To install, reverse removal procedure.

Release connection nipple with Special Tool (16 1 040) and pull off tank venting valve. Pull hose off carbon canister. Unclip filter vent. Release screws and remove activated carbon canister. (Scheme 189)- (Scheme 192). To install, reverse removal procedure.

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Open hose clip and pull off evaporation line. Unfasten plug connection and disconnect connector. Unfasten plastic nut. Unfasten hexagon bolt and take off clamping strap. Carefully lower activated carbon canister. Actuate unlocking fixture and pull off vent line. Unclip tank vent line and vent line on front side of activated carbon canister. Press together ring to release detent. Pull off tank vent line. Remove activated carbon canister. (Scheme 193)- (Scheme 198). To install, reverse removal procedure. Replace hose clips. Ensure electrical connector is locked into place. Ensure vent lines are clipped in correct position.

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Removal & Installation (3-Series - E46 - With Leak Diagnosis Pump)

Remove screws and expansion rivet. Remove under-car cover. (Scheme 199) Disconnect vacuum line, scavenging air line, intake line for dust filter and line to expansion tank. (Scheme 200) Disconnect electrical connector. Remove bolts and remove carbon canister with leakage diagnosis pump toward bottom. (Scheme 201) To install, reverse removal procedure.

Scheme 199

Scheme 200

Scheme 201

Removal & Installation (3-Series - E46 - Without Leak Diagnosis Pump)

Remove screws and expansion rivet. Remove panel. (Scheme 202) Release locks on fuel lines. Disconnect lines. Remove bolt. Remove carbon canister. (Scheme 203) To install, reverse removal procedure.

Scheme 202

Scheme 203

Removal & Installation (V8 & V12 - Without Leak Diagnosis Pump)

Remove left rear wheel Remove left rear wheel housing trim. Loosen activated carbon filter. (Scheme 204) Release connections for intake pipe and tank ventilation before pulling off with Special Tool (16 1 050). (Scheme 205) Disconnect ventilation hose, suction tube-to-engine hose and tank venting hose. (Scheme 206) To install, reverse removal procedure.

Scheme 204

Scheme 205

Scheme 206

Removal & Installation (V12 - With Leak Diagnosis Pump)

Remove left rear wheel. Remove left rear wheel housing trim. Pull plug connection and disconnect vacuum hose from leak diagnosis pump. (Scheme 207) Detach vent line and scavenging air line and disconnect it from activated carbon filter. (Scheme 208) Withdraw activated carbon filter from retaining bracket and remove toward front. (Scheme 209) To install, reverse removal procedure.

Scheme 207

Scheme 208

Scheme 209

1. Turn ignition off. Remove nut and bolt. Remove cover. Disconnect plugs from retainer. Disconnect plug connections of positive leads for electronic catalytic converter. Remove nut on negative lead on body. Remove nut on negative lead on catalytic converter. Remove negative lead.
2. Cut through exhaust pipe between catalytic converter center muffler down welded seam with a grinder and deburr. Grind off remaining welded bead on center muffler.
3. To install, reverse removal procedure. Install new catalytic converter to center muffler with clamp. Ensure nuts point downward. Align exhaust system and clamping sleeve with sufficient distance from adjacent components.

Turn ignition off. Disconnect batteries. Remove front right inner entrance cover strip. Remove "A" pillar finisher. Lift floor carpet at front and rear and lay aside. Lift out expansion rivet and lift air duct slightly. Disconnect control unit connector. Remove screws. Remove control unit. (Scheme 210) To install, reverse removal procedure.

Scheme 210

Scheme 211

Scheme 212

1. Turn ignition off. On some models, tank venting valve is fitted in front left wheel arch. (Scheme 211) Disconnect plug connection. Release hose clamp and detach fuel hose. Open fastener and detach hose. (Scheme 212)
2. On some other models, disconnect plug connection. Release hose clamp and detach hose. Remove tank venting valve from bracket. Open fastener and detach fuel hose. On all models, to install, reverse removal procedure. Always replace clip and fuel hose.

Turn ignition off. Remove both throttle bodies. See THROTTLE BODY. Mark plug connection on tank vent valve and disconnect. (Scheme 213) Open fast release connections on tank vent valve, press down interlock, and remove hose. (Scheme 214) Remove tank vent valves for cylinder banks No. 1-6 and 7-12 from bracket. (Scheme 215) Unfasten hose clips and remove hoses. To install, reverse removal procedure.

Scheme 213

Scheme 214

Scheme 215

Turn ignition off. Press interlock and cut through plug connection. Loosen retainers. Unfasten hose clip. Disconnect electrical connection. Unfasten hose clip and remove hose. Remove upper section of intake filter housing. Unfasten screw. Remove lower section of suction filter housing. To install, reverse removal procedure. Ensure screw head does not twist away when attaching air intake hose clip. It must be tight against stop. Fit hose with hose clip on wheel arch. Slide lower section of intake filter housing onto hose. Tighten hose clip.

Turn ignition off. Unfasten hose clip. Disconnect electrical connection. Unfasten hose clip and remove hose. Remove upper section of intake filter housing. Unfasten screw. Remove lower section of suction filter housing. To install, reverse removal procedure. Ensure screw head does not twist away when attaching air intake hose clip. It must be tight against stop. Fit hose with hose clip on wheel arch. Slide lower section of intake filter housing onto hose. Tighten hose clip.

Removal & Installation (Cylinders 1-6)

Remove non-return valve for cylinders 1-6. Remove guide tube for dipstick. Remove right distributor cap. Remove spark plug connector for cylinders No. 1-6. Unfasten nut and remove ignition wiring harness. Unfasten screw connection for heat baffle plate on exhaust manifold of cylinders 1-3. Unfasten flanges. To install, reverse removal procedure. Ensure gasket residue is cleaned off flanges. Replace gaskets. Install flange and gasket to exhaust manifold. Install gasket to flange.

Removal & Installation (Cylinders 7-12)

Remove non-return valve for cylinders 7-12. Remove left distributor cap. Remove spark plug connector for cylinders No. 7-12. Unfasten nuts and remove ignition wiring harness. Unfasten screw connection for heat baffle plate on exhaust manifold of cylinders 7-9. Unfasten flanges. To install, reverse removal procedure. Ensure gasket residue is cleaned off flanges. Replace gaskets. Install flange and gasket to exhaust manifold. Install gasket to flange.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• RELAYS
• NON-RETURN VALVE
• FUEL SYSTEMS
• TORQUE SPECIFICATIONS
• FUEL SYSTEM PRESSURE RELEASE