Repair manual
BMW Z4 E89 facelift Repair Manual
Step-by-step repair and maintenance instructions for the BMW Z4 E89 facelift (2013–2017): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
- 41 0 0 Contents of Body, General
- 1.0 Recommended tools and equipment
- Setting blind rivets
- 41 00... Bonding on painted surfaces
- 1.0 Equipment
- 2.0 Expiry date of consumables
- 3.1 Preparation of surface on vehicle
- 3.2 Preparation of surface on new part
- 5.0 Hardening times
- 6.0 Subsequent treatment
- 7.0 Disposing of adhesive
- 41 00... Bonding steel on steel
- 2.0 Surface preparation
- 4.0 Hardening times
- 5.0 Subsequent treatment of bonding surfaces
- 41 00 505 Checking front body structure
- 41 00 510 Checking rear body structure
- 41 00... Corrosion protection
- 1.1 Removing sealing materials
- 1.2 Applying sealing materials
- 2.0 Cavity preservation of sheet-metal parts
- 2.1 Cavity preservation of steel parts
- 2.2 Cavity preservation of aluminum parts
- 41 00... EMC screws
- 1. Purpose
- 2. Procedure, aluminum front end
- 3. Procedure, steel body
- 41 00... Gap dimensions, body
- 99 00... General instructions on painting
- 5114... General notes for labelling with adhesive films
- 2.0 Grinding outer shell and structure
- 1.0 Scope of delivery
- 2.0 Start-up
- 5.0 Safety instructions
- 1.0 Airbags and restraint systems
- 1.0 Battery
- 2.0 Control units
- 41 00... Information/warning labels
- 1.0 Aluminum
- 41 00... Information on metal filler
- Storage
- Shelf life
- Surface pre-treatment
- Processing
- Applying filler
- Hardening time
- Post-processing
- Paintwork
- Metal filler disposal
- Situation
- Procedure
- 64 00 000 Information on using cleaning agent/paints (personal protection equipment)
- 41 00... Information on vehicle protection
- 41 00... Installing a cavity acoustic baffle (expanded)
- 41 00... Installing a cavity acoustic baffle (not expanded)
- 1.2 Material influences
- 1.3 Machining properties
- 1.4 Mounting
- 41 00... Notes on adhesive K1
- Required cartridge gun
- Preparing the glue cartridge
- Disposal of adhesive
- 41 00... Notes on adhesive K2
- 41 00... Notes on adhesive K3
- Adhesive disposal
- 41 00... Notes on adhesive K4
- 41 00... Notes on adhesive K5
- 41 00... Notes on cleaning agent R1
- 41 00... Notes on repairing threads
- 1. Opening spot-weld bonds
- 2. Opening adhesive bonds
- 3. Opening adhesive bonds on aluminum roofs
- 4. Opening adhesive bonds on carbon-fibre-reinforced plastic parts
- 41 00... Opening brazed joints
- 41 00... Opening riveted joints
- 1.1 Opening blind rivets (N1 and N2)
- 1.2 Opening blind rivets (N3 and N6)
- 2.1 Opening punch rivets by extraction
- 2.2 Opening punch rivets by drilling out
- 1. Opening weld spots (resistance pressure spot welding)
- 2. Opening MAG weld seams and MIG brazing seams
- 3. Opening laser weld seams
- 41 00... Position of shaped parts for cavity acoustic baffle
- 41 00... Procedure for folding hardtop after an accident
- 41 00... Punch rivets
- 41 00... Quality standard
- 41 00... Reinforcement plate (bonded)
- 41 00... Reinforcement plate with stud bolt (bonded)
- 41 00... Repair solution for straight shank/hexagon rivet nut
- 41 0 Repair techniques, repair stage 1
- 41 0 Repair techniques, repair stage 2
- 41 0 Repair techniques, repair stage 3
- 2.0 Shaping plastic parts
- 3.0 Bonding plastic parts
- 41 00... Safety at work
- 00 Safety information for working on vehicles with automatic engine start-stop function (MSA)
- 41 00... Separating cut determination with a template
- 41 00... Setting blind rivet nuts and bolts
- 41 00... Soldering steel components
- 2. Work materials
- 3. Preparation
- 4. Implementation
- 5. Subsequent treatment of brazed joints
- 6. Notes on melting/tinning
- 41 00... Spot-weld bonding steel parts
- 41 00... Straightening aluminum components in structure
- 41 00... Straightening aluminum parts on outer skin
- 41 00... Straightening steel components in the structure
- 41 00... Straightening steel parts on outer skin
- 41 00... Use of materials in outer skin
- 41 00... Welding in reinforcement plate (steel plate)
- 41 00... Welding steel components
- 3. Preparations for MAG and spot-welding
- 4. Welding
- 5. Subsequent treatment of weld joints
- 41 00... Working with 2-component PU cavity foam
- 41 00... Workshop equipment
- 41 21 512 Replacing door pillar inner section (door pillar removed)
- 41 11 015 Replacing front left or right engine bracket with wheel arch
- 41 11 733 Replacing front luggage compartment floor cross-member (luggage compartment floor completely removed)
- 41 12 535 Replacing complete rear luggage compartment floor (tail panel removed)
- 41 12 653 Replacing luggage compartment floor, left section (tail panel and side panel removed)
- 41 12 557 Replacing luggage compartment floor, middle section (tail panel removed)
- 41 12 548 Replacing rear cross-member on luggage compartment floor (tail panel removed)
- 41 14 511 Replacing complete rear left wheel arch (rear left side panel removed)
- 41 14 020 Replacing front left or right wheel arch
- 41 21 518 Replacing left B-pillar (rear left side panel removed)
- 41 14 502 Replacing rear left outer wheel arch section (rear left side panel removed)
- 41 21 540 Replacing front left or right door pillar (front side panel removed)
- 41 33 040 Replacing front wall
- 41 33 051 Replacing left front panel
- 41 33 052 Replacing right front panel
- 41 33 040 Replacing front left or right side wall holder
- 41 34 041 Replacing tail panel
- 41 34 121 Replacing complete tail panel and luggage compartment floor
- 41 35 000 Removing and installing/replacing front side panel, left or right
- 41 35 101 Replacing rear left side panel
- 41 35 111 Replacing rear right side panel
- 41 51 004 Adjusting left or right front door
- 41 5.... Removing and installing door
- 41 61 014 Adjusting engine bonnet/hood
- 41 61 014 Adjusting engine compartment lid (for vehicles with active pedestrian protection AFGS)
- 41 61 ... Checking hinge for engine compartment lid (for vehicles with active pedestrian protection system)
- 41 61 000 Removing and installing hood/bonnet
- 41 61 571 Removing and installing/replacing left hinge for engine compartment lid, (for vehicles with active pedestrian protection AFGS)
- 41 62 014 Adjusting tailgate
- 41 62 519 Removing and installing/replacing left or right hinge for rear lid
- 41 62 000 Removing and installing rear lid
- 41 63 000 Removing and installing flap for fuel filler neck
- 41 63 060 Removing and installing soft top compartment lid
- 51 71 360 Removing and installing/replacing seal for rear lid
- 41 63 002 Replacing cover bowl
- 34 00 050 Bleeding brake system with DSC
- Fully rinse the brake system
- Bleeding rear axle brake circuit
- Bleeding front axle brake circuit
- 34 00 EMF Additional brake bleeding procedure
- Necessary preliminary tasks
- Checking thickness of brake pad
- General
- Wheel brakes
- Brake lines, brake hoses
- Traction control system
- 34 00 012 Parking brake function check
- 00 Safety information for working on vehicles with automatic engine start-stop function (MSA)
- Observe safety precautions when working on MSA vehicles
- 34 11 667 Precision-turning both front brake discs on both sides
- Stationary brake disc lathe
- Mobile brake disc lathe
- Necessary preliminary work
- 34 11 020 Removing and installing/replacing left or right front brake caliper
- 34 21 947 Precision-turning both rear brake discs on both sides
- Replacing Brake Pads
- 34 32 861 Replacing all brake pipes
- 34 32 881 Replacing front left or right brake hose
- 34 32 951 Replacing rear left or right brake hose
- 34 33 051 Removing and installing/replacing non-return valve for brake booster
- 34 33 071 Replacing vacuum hose for brake booster (N52K)
- 34 33 071 Replacing vacuum hose for brake booster (N54)
- 34 35 001 Replacing a brake pad sensor (front)
- 34 35 001 Replacing a brake pad sensor (rear)
- 34 41 295 Removing and installing control unit for parking brake
- When replacing hydraulic unit
- When replacing control unit
- 34 52 550 Removing and installing/replacing DSC sensor
- 34 52 516 Removing and installing/replacing DSC control unit
- 34 52 535 Replacing a rear pulse generator
- 34 52 525 Replacing one front pulse generator
- 17 00 009 Checking cooling system for leaks (N54, N52K)
- 17 00 515 Checking function of radiator and heating system
- 17 00... Instructions for working on cooling system
- 00 Safety information for working on vehicles with automatic engine start-stop function (MSA)
- 17 00 039 Venting and filling cooling system with vacuum filling unit
- 17 00 039 Venting cooling system and checking for water leaks (N54)
- 17 11 052 Removing and installing left module carrier (N52K, N54)
- 17 11 000 Removing and installing radiator (N52K, N54)
- 17 11 054 Removing and installing right module carrier (N52K, N54)
- 17 11 100 Removing and installing/replacing coolant expansion tank (N54, N52K)
- 17 12 010 Removing and installing/replacing coolant pipe on front axle (N54)
- 17 11 150 Removing and installing/replacing engine oil cooler (N54)
- 17 11 035 Removing and installing/replacing fan cowl with electric fan (N52K, N54)
- 17 22 030 Removing and installing/replacing oil line for engine oil cooler (N54)
- 17 21 020 Removing and installing/replacing transmission oil cooler (DKG) (N54)
- 17 21 500 Rinse gearbox oil cooler and lines of twin clutch gearbox
- 17 51 000 Removing and installing/replacing intercooler (N54)
- 28 00... Checking/topping up oil level in twin-clutch gearbox (GS7D36SG)
- 00..... Instructions for performing service functions on the twin-clutch gearbox (GS7D36SG)
- 28 02 020 Removing and installing or replacing transmission oil sump (GS7D36SG)
- 28 00 001 Removing and installing twin-clutch gearbox (GS7D36SG) N54
- 28 00 060 Replacing output flange radial shaft seal (GS7D36SG)
- 64 00 000 Information on using cleaning agent/paints (personal protection equipment)
- 28 10 020 Removing and installing or replacing combination sensor (GS7D36SG)
- 28 10 010 Removing and installing or replacing pump unit (GS7D36SG)
- 28 10 000 Replacing suction filter (GS7D36SG)
- 28 40 000 Removing and installing or replacing clutch cover (GS7D36SG)
- 28 40 020 Removing and installing or replacing clutch support (GS7D36SG)
- 28 40 050 Replacing shaft seal for clutch cover (GS7D36SG)
- 28 40 010 Removing and installing or replacing twin clutch (GS7D36SG)
- 28 60... Notes on mechatronics (GS7D36SG)
- 28 60 010 Removing and installing mechatronics (GS7D36SG)
- 28 60 030 Removing and installing/replacing the hydraulic cap (GS7D36SG)
- 28 60 514 Replacing mechatronics (GS7D36SG)
- 28 60 000 Replacing pressure filter (GS7D36SG)
- Adapter MW
- Adapter Minimum set: Mechanical tools MW
- SI number
- Angle MW
- Bush Minimum set: Mechanical tools MW
- Bush MW
- Cap Minimum set: Mechanical tools MW
- MW
- Connection Minimum set: Mechanical tools MW
- Counter support Minimum set: Mechanical tools MW
- Device MW
- Device Minimum set: Mechanical tools MW
- Fixture MW
- Gauge MW
- Handle MW
- Handle Minimum set: Mechanical tools MW
- Holder MW
- Holder Minimum set: Mechanical tools MW
- Holding sleeve Minimum set: Mechanical tools MW
- Key Minimum set: Mechanical tools MW
- Lever MW
- Mandrel Minimum set: Mechanical tools MW
- Mandrel MW
- Open-end wrench MW
- Pin MW
- Pin wrench Minimum set: Mechanical tools MW
- Puller Minimum set: Mechanical tools MW
- Puller MW
- Release tool MW
- Ring Minimum set: Mechanical tools MW
- Sleeve Minimum set: Mechanical tools MW
- Sleeve MW
- Socket Minimum set: Mechanical tools MW
- Socket wrench MW
- Support MW
- Tool MW
- Tool Minimum set: Mechanical tools MW
- Wedge MW
- Wrench socket Minimum set: Mechanical tools MW
- 61 13... Butt connector for repairing a plug connection
- 12 00... Instructions for working on the ignition system
- 12 13 Notes on checking ignition system
- 12 00... Notes/information on removing and installing control units
- 12 00... Notes/information on start assistance (jump starting)
- 00 Safety information for working on vehicles with automatic engine start-stop function (MSA)
- 12 12 011 Replacing all spark plugs (N54)
- 12 13 Carrying out engine cleaning (N54, N53, N43)
- 12 13 511 Replacing ignition coils (N54)
- 12 14 700 Coding control module (DME/DDE)
- 12 14 705 Programming control unit (DME/DDE)
- 12 14 600 Removing/replacing knock sensors (N54)
- 12 14 550 Replacing control unit (DME) (N54)
- 12 14 521 Replacing crankshaft pulse generator (N54)
- 12 14 524 Replacing pulse generator on exhaust camshaft (N54)
- 12 14 523 Replacing pulse generator on inlet camshaft (N54)
- 12 14 651 Replacing suction pressure sensor on charge-air duct (N54)
- 12 14 650 Replacing suction pressure sensor on intake air manifold (N54)
- 12 31 020 Removing and installing or replacing alternator (N54)
- 12 31... Replacing alternator belt pulley
- 12 31... Replacing alternator belt pulley (with overrunning clutch)
- 12 32 501 Replacing voltage regulator
- 12 41 020 Removing and installing/replacing starter motor (N54)
- 12 41 041 Replacing solenoid switch
- 12 42 500 Replacing battery positive lead between starter, alternator and battery positive terminal (N54)
- 12 42 540 Replacing safety battery terminal (SBK)
- 12 61 285 Removing and installing/replacing oil level sensor for engine oil (N54)
- 12 61 280 Removing and installing/replacing oil pressure sensor (N54)
- Engine Performance Diagnostic Routine Outline - General Information
- Engine Performance Safety Precautions
- Parasitic Load Explanation & Test Procedures - General Information
- Waveforms - Injector Pattern Tutorial - General Information
- Electrostatic Discharge Warning - General Information
- State Emission Standards - Diesel
- 11 00 039 Checking compression in all cylinders (N43/N53/N54)
- 00 Danger of poisoning if oil is ingested/absorbed through the skin
- 11 00... Engine oil service (N54, N54T)
- 11 00 590 Exchange engine (N54, N54T)
- 11..... Removing and installing/replacing acoustic cover (N54, N54T)
- 11 00 050 Removing and installing engine (N54, N54T)
- 00 Risk of injury if oil comes into contact with eyes and skin
- 00 Safety information for working on vehicles with automatic engine start-stop function (MSA)
- 00 Safety instructions for handling oil
- 11 12 729 Checking cylinder head for watertightness (N54, N54T)
- 11 12 719 Milling cylinder head sealing surface (N54, N54T)
- 11 12 100 Removing and installing cylinder head (N54, N54T)
- 11 12 000 Removing and installing/sealing cylinder head cover (N54, N54T)
- 11 12 101 Replacing cylinder head gasket (N54, N54T)
- 11 13 000 Removing and installing, sealing or replacing oil sump (N54, N54T)
- 11 14 151 Replacing crankshaft radial seal (N54, N54T) up to 12.31.08
- 11 14 151 Replacing radial crankshaft seal on transmission side (N54N54T) from 01.01.09
- 11 14 005 Replacing front crankshaft seal (N54, N54T)
- 11 14 010 Replacing sealing cap for vacuum pump (N54, N54T)
- 11 22 500 Removing and installing/replacing flywheel (N54, N54T)
- 11 21 531 Replacing all crankshaft main bearings (N54, N54T)
- 11 21 500 Replacing crankshaft (N54, N54T)
- 11 21 505 Sealing crankcase lower section (N54, N54T)
- 11 22 513 Replacing roller bearing for dual-mass flywheel
- 11 24 571 Replacing all connecting rod bearings (N54, N54T)
- 11 25 530 Removing and installing or replacing all pistons (N16)
- 11 25 530 Removing and installing/replacing all pistons (N54, N54T)
- 11 25 671 Replacing piston rings on all pistons (N54, N54T)
- 11 28 010 Replacing drive belt for alternator (N54, N54T)
- 11 28 020 Replacing tensioning device for alternator drive belt (N54, N54T)
- 11 31 505 Adjusting camshaft timing (N54, N54T)
- 11 31 005 Checking camshaft timing (N54, N54T)
- 11 31 090 Installing and removing/replacing chain tensioner piston (N54, N54T)
- 11 31 028 Removing and installing/replacing exhaust camshaft (N54/N54T)
- 11 31 025 Removing and installing/replacing intake camshaft (N54/N54T)
- 11 31 051 Replacing timing chain (N54, N54T)
- 11 33 050 Removing and installing or replacing all rocker arms (N54, N54T)
- 11 34 552 Removing and installing or replacing all valves (N54, N54T)
- 11 34 715 Replacing all valve springs (N54, N54T)
- 11 34 560 Replacing all valve stem seals (N54, N54T)
- 11 36 655 Removing and installing/replacing both solenoid valves (N54, N54T)
- 11 36 046 Removing and installing/replacing intake and exhaust camshaft adjusters (N54, N54T)
- 11 40 000 Checking engine oil pressure (N54, N54T)
- 11 41 000 Removing and installing oil pump (N54, N54T)
- 11 66 000 Removing and installing or replacing vacuum/oil pump (N47 D20 O1)
- 11 41 010 Removing and installing/replacing chain module for oil pump/vacuum pump (N54, N54T)
- 11 42 198 Removing and installing oil feed line for exhaust turbocharger (N54)
- 11 42 250 Removing and installing oil return line for exhaust turbocharger (N54)
- 11 42 248 Removing and installing/renewing the oil return line for exhaust turbocharger cyl. 1-3 (N54)
- 11 42 020 Removing and installing/replacing full-flow oil filter (N54, N54T)
- 11 42 035 Removing and installing/replacing thermostat housing (N54, N54T)
- 11 44 000 Removing and installing/replacing oil-to-water heat exchanger (N54, N54T)
- 11 51 000 Removing and installing/renewing coolant pump (N54, N54T)
- 11 53 000 Removing and installing/replacing coolant thermostat (N54, N54T)
- 11 53 740 Removing and installing/replacing feed line (N54, N54T)
- 11 61 365 Removing and installing/replacing left charge air duct (N54, N54T)
- 11 61 362 Removing and installing/replacing right charge air duct (N54, N54T)
- 11 61 050 Removing and installing intake plenum (N54, N54T)
- 11 65 580 Replacing vacuum unit (wastegate valve) (N54, N54T)
- 11 66 000 Removing and installing/replacing vacuum pump (N54, N54T)
- 11 78 513 Replacing both oxygen control sensors (N54, N54T)
- 11 78 545 Replacing both oxygen monitoring sensors (N54, N54T)
- Adapter Minimum set: Mechanical tools MW
- SI number
- Adapter MW
- Bush Minimum set: Mechanical tools MW
- Clip MW
- Compression tester Minimum set: Mechanical tools MW
- Compression tester MW
- Device MW
- Device Minimum set: Mechanical tools MW
- Extension Minimum set: Mechanical tools MW
- Extractor Minimum set: Mechanical tools MW
- Fitting aid MW
- Gauge Minimum set: Mechanical tools MW
- Gauge MW
- Holder Minimum set: Mechanical tools MW
- Holder MW
- Lifting gear Minimum set: Mechanical tools MW
- Mandrel MW
- Mandrel Minimum set: Mechanical tools MW
- Oddments tray Minimum set: Mechanical tools MW
- Oil filter wrench Minimum set: Mechanical tools MW
- Pin Minimum set: Mechanical tools MW
- Plate MW
- Pliers MW
- Pliers Minimum set: Mechanical tools MW
- Plug Minimum set: Mechanical tools MW
- Screwdriver insert Minimum set: Mechanical tools MW
- Sleeve Minimum set: Mechanical tools MW
- Sleeve MW
- Socket wrench Minimum set: Mechanical tools MW
- Socket wrench MW
- Socket wrench insert Minimum set: Mechanical tools MW
- Spacer Minimum set: Mechanical tools MW
- Tool Minimum set: Mechanical tools MW
- Tool MW
- Tool set MW
- Torx Minimum set: Mechanical tools MW
- Washer Minimum set: Mechanical tools MW
- Wrench socket Minimum set: Mechanical tools MW
- 00 Danger of poisoning if oil is ingested/absorbed through the skin
- Protective measures/rules of conduct
- First aid measures
- Situation
- Effect
- Procedure
- 64 00 000 Information on using cleaning agent/paints (personal protection equipment)
- Recycling
- 31 00 Mobile table lift
- 31 00... Notes (aluminum chassis components)
- 31 00... Notes on repairing threads
- 00...... Raising vehicle with trolley jack
- 51 75 515 Removing and installing/replacing lower pedestrian protection
- 00 Risk of injury if oil comes into contact with eyes and skin
- 00 Safety information for working on vehicles with automatic engine start-stop function (MSA)
- Observe safety precautions when working on MSA vehicles
- 00 Safety instructions for handling oil
- Measures if oil is unintentionally released
- 51 47 490 Removing and installing/replacing front underbody protection
- 31 11 506 Lowering/raising front axle support
- 51 61 011 Removing and installing/replacing V-strut, front axle carrier, left or right
- 31 11 001 Replacing front axle support
- 31 12 080 Removing and installing/replacing both tension struts
- 31 12 000 Removing and installing/replacing left or right control arm
- 31 12 050 Removing and installing/replacing left or right trailing link
- 31 12 138 Replacing rubber mounts on both tension struts
- 31 12 134 Replacing rubber mount in left or right trailing link
- 31 21 180 Removing and installing/replacing bearing for front wheel
- 31 21 090 Removing and installing/replacing left or right swivel bearing
- 31 31 000 Removing and installing complete left or right spring strut shock absorber
- 51 71 371 Removing and installing/replacing tension strut on left or right spring strut dome
- 31 31 031 Replacing front left or right spring strut shock absorber
- 31 33 001 (Removing and installing) replacing front left or right spring strut support bearing
- 31 33 095 Measure vehicle ride height, front axle
- 31 33 100 Removing and installing/replacing coil spring for left or right front spring strut
- 31 35 000 Removing and installing/replacing front stabilizer
- 31 35 005 Removing and installing/replacing push rod (stabilizer link) for left/right stabilizer
- 31 35 040 Replacing rubber mount for stabilizer on body on left or right
- 00 Safety information for working on vehicles with automatic engine start-stop function (MSA)
- 13 31 029 Checking fuel delivery pressure (N54, N54T)
- 13 31 032 Check fuel pressure
- 13 31... Notes on fuel pressure check (reference pressure: environment)
- 13 53 192 Removing and installing/replacing a pressure line (N54)
- 13 53 332 Removing and installing/replacing feed line (N54)
- 13 51 017 Removing and installing/replacing high-pressure fuel pump (N54)
- 13 53 158 Removing and installing/replacing high-pressure rail (N54)
- 13 53 596 Replacing high-pressure fuel sensor (N54)
- 13 53 310 Removing and installing/replacing an injector (N54)
- 11 61 365 Removing and installing/replacing left charge air duct (N54, N54T)
- 11 61 362 Removing and installing/replacing right charge air duct (N54, N54T)
- 13 62 531 Replacing coolant temperature sensor (N54)
- 13 71 170 Removing and installing/replacing rear air duct (N54)
- 13 71 160 Removing and installing/replacing front air duct (N54)
- 13 71 000 Removing and installing/replacing intake filter housing (N54)
- 13 90 500 Replacing tank vent valve (N54)
- 61 00... Instructions for disconnecting and connecting battery
- Before disconnecting battery
- General notes on disconnecting battery
- After connecting battery
- 61 13... Instructions for opening contacts and locks of different plug contact systems
- 61 00... Notes on handling optical fibres
- 12 00... Notes/information on start assistance (jump starting)
- 61 00... Repairing airbag cables
- 00 Safety information for working on vehicles with automatic engine start-stop function (MSA)
- 61 00... Safety instructions for handling vehicle battery
- 61 13... Treating cables and fibre-optic cables
- 61 11... Installing the repair cable for the positive battery cable of the power distribution box
- 61 12 013 Replacing battery negative lead
- 61 12 002 Replacing battery positive lead
- 61 12 004 Replacing battery positive lead (from luggage compartment connector to engine bulkhead connector)
- 61 13... Butt connector for repairing a plug connection
- 61 13... Circular connector, 7-pin, 8-pin, system D2.5
- 61 13... Crimping Micro Power Quadlock contacts (MPQ)
- 61 13... Crimping Micro Quadlock System contacts (MQS)
- 61 13... Crimping optical fibres
- 61 13... Crimping stop parts
- 61 13... Cutting off, stripping insulation and cutting optical fibres to length
- 61 13... Cutting to length and stripping insulation from cables
- 61 13... Installing fan connector for retrofitting/repairs
- 61 13... Removing and installing/replacing OBD-II socket
- 61 13 050 Removing and installing/replacing fuse box in passenger compartment
- 6113... Unlocking and disconnecting different plug connections
- 61 14 010 Removing and installing/replacing distribution box
- 61 14... Removing and installing/replacing engine compartment B+ terminal
- 61 20... AGM battery
- 61 20... Battery charge
- 61 20 900 Disconnecting and connecting battery negative lead
- 61 20 503 Vehicle battery - closed-circuit current monitoring
- 61 21 028 Charge battery
- 61 21 010 Removing and installing or replacing battery
- 61 31 038 Removing and installing (replacing) switch for passenger airbag deactivation
- 61 31 052 Removing and installing center console control panel
- 61 31 133 Removing and installing/replacing AV connection socket
- 61 31 243 Removing and installing/replacing Hall switch
- 61 31 023 Removing and installing/replacing Start/Stop switch
- 61 31 134 Removing and installing/replacing USB/audio interface connection socket
- 61 31 113 Removing and installing/replacing both shift paddles for automatic transmission
- 61 31 229 Removing and installing/replacing both switches on sport steering wheel
- 61 31 062 Removing and installing/replacing button for steering wheel heating
- 61 31 299 Removing and installing/replacing clutch switch module
- 61 31 195 Removing and installing/replacing controller
- 61 31 287 Removing and installing/replacing driving dynamics switch
- 61 31 342 Removing and installing/replacing gear selector switch (twin-clutch gearbox)
- 61 31 037 Removing and installing/replacing light control unit
- 61 31 117 Removing and installing/replacing power window switch (driver's side)
- 61 31 043 Removing and installing/replacing roof switch cluster
- 61 31 008 Removing and installing/replacing steering-column switch cluster
- 61 31 172 Removing and installing/replacing switch for electromechanical parking brake
- 61 31 208 Removing and installing/replacing switch for front lumbar support
- 61 31 079 Removing and installing/replacing switch for hazard warning flashers/central locking
- 61 31 083 Removing and installing/replacing switch for unlocking rear lid
- 61 31 011 Removing and installing/replacing volute spring cassette
- 61 31 310 Replacing brake light switch
- 61 31 382 Replacing coolant level switch
- 61 31 118 Replacing front passenger power window switch
- 61 31 492 Replacing level switch for windscreen washer system
- 61 31 270 Replacing switch for reversing light
- 61 33 040 Removing and installing/replacing a fanfare horn
- 61 33 060 Removing and installing/replacing both fanfare horns
- 61 34... Removing and installing/replacing 12-V socket in the front storage compartment
- 61 34... Removing and installing/replacing 12V socket in center armrest storage compartment
- 61 35 679 Initializing rain/light (solar) sensor
- 61 35... Notes on ESD protection (Electro Static Discharge)
- 61 35 015 Removing and installing (replacing) control unit for Car Access System
- 61 35 177 Removing and installing (replacing) rain/light sensor
- 61 35 107 Removing and installing or replacing junction box electronics
- 61 35 146 Removing and installing/replacing Convertible top module
- 61 35 975 Removing and installing/replacing bumper aerial for comfort access system
- 61 35 095 Removing and installing/replacing control unit/module for seat heating
- 61 35 115 Removing and installing/replacing footwell module
- 61 35 953 Removing and installing/replacing interior aerial for comfort access system (version 1)
- 61 35 954 Removing and installing/replacing interior aerial for comfort access system (version 2)
- 61 35 970 Removing and installing/replacing luggage compartment aerial for comfort access system
- 64 11 970 Replacing fogging sensor
- Vehicle programming and encoding
- 61 61... Adjusting left or right windscreen wiper
- 61 61 010 Checking/adjusting approach angle of windscreen wiper arms on front windscreen
- 61 61 270 Removing and installing or replacing bracket for windscreen wiper system complete with motor
- 61 61 100 Removing and installing/replacing both windscreen wiper arms
- 61 61 041 Replacing both windscreen wiper blades
- 61 61 021 Replacing left or right windscreen wiper blade
- 61 67 040 Adjusting spray nozzles for headlight washer system
- 61 67 088 Removing and installing/replacing left or right high-pressure nozzle of headlight washer system
- 61 67 083 Removing and installing/replacing left or right high-pressure nozzle of headlight washer system
- 61 67 010 Removing and installing/replacing washer pump of headlight washer system
- 61 71 015 Removing and installing/replacing a jet nozzle in windscreen washer system
- 61 71 030 Removing and installing/replacing all spray nozzles of windscreen washer system
- 61 71 100 Removing and installing/replacing windscreen washer pump
- SI number
- Adapter cable MP
- Additions to repair kit I
- Additions to repair kit II
- Additions to repair kit III
- Case MP
- Crimping tool Minimum set: Mechanical tools MW
- 61 9 045 Female die
- 61 0 021 Fuse link FF 3.15 A/500 V
- 0492743 611410 Gauge tip MP
- 0495677 610327 Insertion aid MP
- 0495678 610328 Insertion aid MP
- 0495328 610220 Matrix MP
- 0495477 610230 Matrix MP
- 0495327 610210 Matrix MP
- 0495346 616100 Measuring device Minimum set: Mechanical tools MW
- 0494156 611190 Pliers MP
- 0492703 611110 Pressing-off tool MP
- 0492716 611142 Release tool MP
- 0496344 611104 Release tool MP
- 0495400 610318 Release tool MP
- 0495391 610309 Release tool MP
- 0495385 610303 Release tool MP
- 0495394 610312 Release tool MP
- 0492718 611144 Release tool MP
- 0495404 610322 Release tool MP
- 0492719 611145 Release tool MP
- 0495389 610307 Release tool MP
- 0495398 610316 Release tool MP
- 0495396 610314 Release tool MP
- 0496588 610250 Release tool Minimum set: Mechanical tools MW
- 0492717 611143 Release tool MP
- 0495399 610317 Release tool MP
- 0496333 610333 Release tool MP
- 0495383 610301 Release tool MP
- 0495397 610315 Release tool MP
- 0495578 610325 Release tool MP
- 0496342 611102 Release tool MP
- 0492723 611153 Release tool MP
- 0495406 610324 Release tool MP
- 0495405 610323 Release tool MP
- 0496345 611105 Release tool MP
- 0495676 610326 Release tool MP
- 0496332 610332 Release tool MP
- 0495401 610319 Release tool MP
- 0495403 610321 Release tool MP
- 0495395 610313 Release tool MP
- 0496343 611103 Release tool MP
- 0495680 610331 Release tool MP
- 0495387 610305 Release tool MP
- 0492715 611141 Release tool MP
- 0494218 613330 Socket MP
- 64 00 000 Information on using cleaning agent/paints (personal protection equipment)
- 00 Safety information for working on vehicles with automatic engine start-stop function (MSA)
- Observe safety precautions when working on MSA vehicles
- 64 11... Installing servodrive
- 64 11 377 Removing and installing (replacing) control panel for heating and air conditioning system
- 64 11 992 Removing and installing or replacing solar sensor
- 64 11 872 Removing and installing/replacing actuator drive for blending flap (left, automatic air conditioning)
- 64 11 875 Removing and installing/replacing actuator drive for defrosting flap (automatic A/C)
- 64 11 806 Removing and installing/replacing actuator drive for fresh-/recirculated air flap
- 64 11 869 Removing and installing/replacing actuator drive for ventilation/stratification flap (automatic air conditioning)
- 64 11 909 Removing and installing/replacing footwell temperature sensor
- 64 11 213 Removing and installing/replacing heater/air conditioner fan
- 64 11 205 Removing and installing/replacing heating unit (N52K)
- 64 11 205 Removing and installing/replacing heating unit (N54)
- 64 11 991 Removing and installing/replacing sensor for automatic recirculated air control (AUC sensor)
- 64 11 871 Removing and installing/replacing servodrive for blending flap (right, automatic air conditioning)
- 64 11 839 Removing and installing/replacing servodrive for footwell flap (automatic air conditioning)
- 64 11 829 Removing and installing/replacing servodrive for ventilation flaps (automatic air conditioning)
- 64 11 906 Removing and installing/replacing ventilation temperature sensor (middle fresh-air grille)
- 64 11 225 Replacing controller for heating and A/C system fan
- 64 11 943 Replacing evaporator temperature sensor
- 64 11 970 Replacing fogging sensor
- 64 11 208 Replacing heater core
- 64 22 137 Removing and installing or replacing left fresh-air grille
- 64 22 165 Removing and installing or replacing middle fresh-air grille
- 64 22 139 Removing and installing/replacing right fresh-air grille
- 64 31 010 Replacing microfilter for interior ventilation
- Air-conditioning efficiency measurement
- 64 50 010 Drawing off, evacuating and filling heating and air conditioning system (R 134a)
- Loss of R134a refrigerant
- 64 50... Instructions for handling refrigerant R 134a
- 64 52... Instructions for opening and replacing parts in refrigerant circuit
- 64 50... Safety instructions for handling refrigerant R134a
- Protective measures/rules of conduct
- First aid measures
- 64 50... Safety instructions for handling refrigerant oil
- Recycling
- 64 51 591 Removing and installing/renewing evaporator
- 64 51 525 Removing and installing/replacing expansion valve (N52K)
- 64 51 525 Removing and installing/replacing expansion valve (N54)
- 64 52 521 Replacing A/C system compressor (N52k)
- 64 52 521 Replacing air conditioning compressor (N54)
- 64 53 551 Removing and installing or replacing capacitor for heating and air conditioning system
- 64 53 517 Removing and installing/replacing desiccant insert for heating and air conditioning system
- 64 53 521 Replacing safety pressure switch
- 63 10 004 Adjusting headlights
- 63 99... Notes for replacing the protective cap of the headlight
- 63 12 015 Removing and installing/replacing left headlight (adaptive headlight)
- 63 12 010 Removing and installing/replacing left headlight (xenon headlight)
- 67 16 011 Removing and installing/replacing left headlight vertical aim adjuster
- 63 12 017 Removing and installing/replacing right headlight (adaptive headlight)
- 63 12 012 Removing and installing/replacing right headlight (xenon headlight)
- 67 16 016 Removing and installing/replacing right headlight vertical aim adjuster
- 63 12 860 Replacing control unit for left xenon headlight
- 63 12 861 Replacing control unit for right xenon headlight
- 63 12 895 Replacing drive/electronics box for left adaptive headlight
- 63 12 896 Replacing drive/electronics box for right adaptive headlight
- 63 12 870 Replacing ignition unit for left xenon headlight (with xenon bulb)
- 63 12 871 Replacing ignition unit for right xenon headlight (with xenon bulb)
- 63 13 200 Removing and installing/replacing front left or right auxiliary direction indicator (early version)
- 63 13 200 Removing and installing/replacing front left or right side repeaters (late version)
- 63 14 060 Removing and installing/replacing front left or right side marker
- 63 14 120 Removing and installing/replacing rear reflector (on rear bumper)
- 63 21 170 Removing and installing/replacing left or right tail light
- 63 21 055 Replacing a socket housing for left or right rear light
- 63 21 101 Replacing sealing frame for left or right rear light
- 63 25 000 Removing and installing/replacing auxiliary brake light
- 63 26 000 Removing and installing/replacing left or right number/license plate light
- 63 31 000 Removing and installing/replacing complete ceiling light
- 63 31 020 Removing and installing/replacing footwell light
- 63 31 020 Removing and installing/replacing footwell light (door)
- 63 31 150 Removing and installing/replacing glove box light
- 63 31 080 Removing and installing/replacing luggage compartment light
- 63 31 180 Replacing LED for front door trim panel light (left or right)
- 63 31 185 Replacing LED for side trim panel light
- 63 99... Instructions for handling light bulbs (exterior lights)
- 63 99... Instructions for replacing light bulbs (interior lights)
- 63 99 431 Replacing bulb for front ceiling light
- 63 99 145 Replacing bulb for front left (or right) side lights (xenon headlight)
- 63 99 275 Replacing bulb for front right direction indicator
- 63 99 461 Replacing bulb for glovebox light
- 63 99 273 Replacing bulb for left (or right) front turn indicator
- 63 99 076 Replacing bulb for left (or right) xenon headlight
- 63 99 077 Replacing bulb for right xenon headlight
- 63 99 437 Replacing light bulb for footwell light
- 63 99 452 Replacing light bulb for luggage compartment lighting
- 63 99 315 Replacing light bulb(s) for left or right rear light
- Bush MW
- SI number
- Bush Minimum set: Mechanical tools MW
- Cartridge gun MW
- Clamp MW
- Claw MW
- Device MW
- Consisting of
- Extractor MW
- Fixture MW
- Holder Minimum set: Mechanical tools MW
- Holder MW
- Holding sleeve MW
- Key MW
- Mandrel Minimum set: Mechanical tools MW
- Mandrel MW
- 0491496
- Plate MW
- Pliers MW
- Puller Minimum set: Mechanical tools MW
- Puller MW
- Ring MW
- Ring Minimum set: Mechanical tools MW
- Set of tools Minimum set: Mechanical tools
- Shaped element MW
- Sleeve MW
- Socket Minimum set: Mechanical tools MW
- Socket wrench insert MW
- Socket wrench insert Minimum set: Mechanical tools MW
- Spindle MW
- Tool Minimum set: Mechanical tools MW
- Tool MW
- 00 Danger of poisoning if oil is ingested/absorbed through the skin
- Protective measures/rules of conduct
- First aid measures
- Situation
- Effect
- Procedure
- 64 00 000 Information on using cleaning agent/paints (personal protection equipment)
- Recycling
- Protection measures!
- Hexagon/straight shank rivet nut (up to thread 8) with hand rivet gun ZS308
- Hexagon/straight shank rivet nut (up to thread M12) with hand rivet gun MB512
- 33 00... Instructions (chassis components made of aluminum)
- 33 00... Notes on repairing threads
- 00...... Raising vehicle with trolley jack
- 51 47 491 Removing and installing/replacing rear underbody protection
- Hexagon/straight shank rivet nut (up to thread M8) with hand rivet gun ZS308
- 00 Risk of injury if oil comes into contact with eyes and skin
- 00 Safety instructions for handling oil
- Measures if oil is unintentionally released
- 00 11... Checking/topping up oil level in rear differential
- 00 11 259 Oil change in rear differential incl. used oil disposal
- 33 10... Rear differential: Assignment to model series
- 33 10 010 Removing and installing/replacing rear differential
- 33 11 080 Replacing left drive flange on rear differential
- 33 11 021 Replacing radial shaft seal for drive flange on rear differential
- 33 11 271 Replacing rear cover gasket on rear differential
- 33 11... Replacing rear cover gasket on rear differential (188L)
- 33 11... Replacing rear cover gasket on rear differential (215 with lock)
- 33 11... Replacing rear cover gasket on rear differential (215L)
- 33 11 085 Replacing right drive flange on rear differential
- 33 11 140 Replacing shaft seal for left drive flange
- 33 11 145 Replacing shaft seal for right drive flange
- 33 17 004 Replacing all rubber mounts for rear axle differential mounting at front
- 33 17... Replacing rubber mount for rear differential mounting at rear
- 33 21... Pressing output shaft out of drive flange and drawing in (output shaft removed from rear axle final drive)
- 33 21 001 Removing and installing or replacing left output shaft
- 33 21 002 Removing and installing/replacing right output shaft
- 33 21 071 Replacing both gaiters on left and right of output shaft
- 33 21... Ribbed teeth
- 33 31 503 Lowering/raising rear axle carrier
- 33 31 000 Removing and installing complete rear axle carrier
- 51 71 390 Removing and installing/replacing reinforcement plate on rear axle
- 33 31 011 Replacing rear axle carrier
- 33 32 077 Removing and installing/replacing top right control arm
- 33 32 086 Removing and installing/replacing bottom left control arm
- 33 32 087 Removing and installing/replacing bottom right control arm
- 33 32 160 Removing and installing/replacing compression strut for rear axle carrier
- 51 71 482 Removing and installing/replacing left or right tension strut
- 33 32 076 Removing and installing/replacing top left control arm
- 33 32 024 Replacing a ball joint in trailing arm
- 33 32 042 Replacing a rubber mount in trailing arm, front
- 33 32... Replacing bearing support for front trailing arm
- 33 32 021 Replacing left or right trailing arm
- 33 32 681 Replacing one rubber mount in lower control arm (control arm removed)
- 33 32 671 Replacing one rubber mount in the upper control arm (control arm removed)
- 33 32 044 Replacing one rubber mount in trailing arm for lower control arm
- 33 53... Measuring ride height of vehicle (rear axle)
- 33 33 101 Replacing two rubber mounts (rear) for rear axle carrier
- 33 33 101 Replacing two rubber mounts for rear axle carrier (rubber mounts, front)
- 33 41... Detaching inner wheel bearing race from drive flange
- 33 41 005 Replacing left drive flange on rear axle shaft
- 33 41 153 Replacing left wheel bearing on rear axle shaft
- 33 41 007 Replacing right drive flange on rear axle shaft
- 33 41 155 Replacing right wheel bearing on rear axle shaft
- 33 52 000 Removing and installing/replacing rear left or right shock absorber
- Necessary preliminary tasks
- 33 52 161 Replacing rear left or right thrust bearing for spring strut/shock absorber
- 33 53 000 Removing and installing/replacing rear left or right coil spring
- 33 55 000 Removing and installing/replacing rear anti-roll bar
- 33 55 040 Replacing anti-roll bar links for stabilizer bar
- 33 55 021 Replacing both rubber mounts for stabilizer mounting
- 52 14... Performing function check with adapter cable (for seat repairs)
- 52 13 021 Removing and installing/replacing flexmat on left or right front seat
- 52 13... Removing and installing Isofix holder
- 52 13 000 Removing and installing left or right front seat (normal/manual)
- 52 13 390 Removing and installing or replacing front left or right head restraint
- 52 13 198 Removing and installing or replacing rear panel on left or right front seat backrest
- 52 13 030 Removing and installing/replacing backrest frame on left or right front seat
- 52 13 025 Removing and installing/replacing left or right seat mechanism (normal/manual)
- 52 13 055 Removing and installing/replacing lumbar support on front seat
- 52 13 059 Removing and installing/replacing lumbar support pump with valve housing for lumbar support
- 52 13 040 Removing and installing/replacing outer cover on left or right front seat backrest (normal/manual)
- 52 13 405 Replacing backrest cover for left or right front seat
- 52 13 455 Replacing heating elements for left or right front seat (basic)
- 52 13 415 Replacing left or right support for front seat (normal/manual)
- 52 13 420 Replacing left or right support for front seat backrest (normal/manual)
- 52 13 400 Replacing seat cover on left or right front seat (normal/manual)
- 65 77 604 Replacing sensor mat (CIS mat) for front passenger seat occupancy detection detector
- 52 14... Removing and installing carrier for outer cover on left or right front seat (electric)
- 52 14 040 Removing and installing/replacing outer cover on front left or right seat (normal/electric)
- 52 15 403 Removing and installing/replacing thigh support cover on front seat (sport/manual)
- 52 15 050 Removing and installing/replacing thigh support on left or right front seat (sport/manual)
- 52 15 451 Replacing backrest heating element for left or right sports seat
- 52 15 450 Replacing cushion heating element for left or right front seat
- 52 15 452 Replacing heating element for left or right front seat (thigh support)
- 52 15 455 Replacing heating elements for left or right front seat (Sport)
- 52 15 415 Replacing padding for left or right front seat (sport/manual)
- 52 15 420 Replacing padding for left or right front seat backrest (sport/manual)
- 52 15 417 Replacing padding for left or right thigh support (sport/manual)
- 52 15 400 Replacing seat cover for left or right front seat (sport/manual)
- 52 16 050 Replacing lumbar cushion on left or right front seat
- 2. Damage pattern and repair
- 3. Checking rubber seal
- 54 34 001 Checking function of electro-hydraulic convertible top
- 54 34... Removing and installing/replacing gas pressurized prop on left or right main mount
- 54 37 185 Removing and installing/replacing hydraulic unit (drive) for retractable hardtop
- 54 34 503 Removing and installing/replacing hydraulic valve (solenoid valve)
- 1. Definitions of terms
- 2. When working on hydraulic system, observe the following
- 4. Check oil level
- 6. Bleeding hydraulic system
- 54 37... Adjusting roof shells
- 54 37... Removing and installing/replacing hydraulic valve (solenoid valve)
- 54 37 125 Checking the control rods
- 54 37 625 Replacing the left or right control rod
- 54 37 295 Emergency closing hardtop
- 54 37 290 Hardtop emergency opening
- 54 37... Installing/replacing main bearing consoles
- 41 00... Procedure for folding hardtop after an accident
- 54 37 130 Removing and installing roof module
- 54 37 166 Removing and installing/replacing both kinematics boxes
- 54 37 162 Removing and installing/replacing left kinematics box
- 54 37 164 Removing and installing/replacing right kinematics box
- 54 37 100 Removing and installing roof shell fastener motor (drive)
- 54 37 188 Removing and installing/replacing hydraulic cylinder for kinematics box on left
- 54 37 187 Removing and installing/replacing hydraulic cylinder for kinematics box on right
- 54 37 190 Removing and installing/replacing hydraulic cylinder for left roof shell
- 54 37 195 Removing and installing/replacing hydraulic cylinder for roof shell on right
- 54 37 220 Removing and installing/replacing left Convertible top compartment lid hydraulic cylinder
- 54 37 090 Removing and installing/replacing left or right Convertible lock
- 51 31 200 Removing and installing/replacing rear window
- 54 37 225 Removing and installing/replacing right Convertible top compartment lid hydraulic cylinder
- 54 37 070 Removing and installing/replacing roof shell at front
- 54 37 080 Removing and installing/replacing roof shell at rear
- 54 37 035 Removing and installing/replacing roofliner for roof shell at front
- 54 37 045 Removing and installing/replacing roofliner for roof shell at rear
- 54 37 160 Removing rear module
- 54 37 005 Replacing front roof shell seal
- 54 37 024 Replacing rear roof shell seal