2007-2013 BMW M3, E90, E92, E93 PDF

2007-2013 BMW M3
E90, E92, E93
SERVICE AND REPAIR MANUAL

2010 BMW M3
GENERAL INFORMATION Commonly Used Abbreviations
GENERAL INFORMATION
Commonly Used Abbreviations
* PLEASE READ THIS FIRST *
NOTE: This article is intended for general information purposes only. This information
may not apply to all makes and models. Not all abbreviations are covered as
manufacturers add new ones every day.
"A"
A
Amperes
ABS
Anti-Lock Brakes
ABRS
Air Bag Restraint System
AC
Alternating Current
A/C
Air Conditioning
ACCS
A/C Cycling Switch
ACCUM
Accumulator
ACCY
Accessory
ACT
2010 BMW M3
Air Charge Temperature Sensor
ADJ
Adjust or Adjustable
ADV
Advance
AFS
Airflow Sensor
AI
Air Injection
AIR or A.I.R.
Air Injection Reactor
AIS
Air Injection System
Alt.
Alternator or Altitude
Amp./amp/amps
Ampere
ASCS
Air Suction Control Solenoid
ASD
Auto Shutdown
ASDM
Air Bag System Diagnostic Module

2010 BMW M3
ASV
Air Suction Valve
A/T
Automatic Transmission/Transaxle
ATC
Automatic Temperature Control
ATDC
After Top Dead Center
ATF
Automatic Transmission Fluid
ATS
Air Temperature Sensor
Aux.
Auxiliary
Avg.
Average
AXOD
Automatic Transaxle Overdrive (Ford Models Only)
"B"
BAC
By-Pass Air Control
BAP
Barometric Absolute Pressure Sensor

2010 BMW M3
BARO
Barometric
Batt.
Battery
Bbl.
Barrel (Example: 4-Bbl.)
BCM
Body Control Module
BHP
Brake Horsepower
BMAP
Barometric and Manifold Absolute Pressure Sensor
BOO
Brake On-Off Switch
B/P
Backpressure
BPS
Barometric Pressure Sensor
BPT
Backpressure Transducer
BTDC
Before Top Dead Center
BTSI
2010 BMW M3
Brake Transmission Shift Interlock
BTU
British Thermal Unit
BVSV
Bimetallic Vacuum Switching Valve
"C"
C
Celsius (Degrees)
Calif.
California
CANP
Canister Purge
CARB
California Air Resources Board
CAT
Catalytic Converter
CB
Circuit Breaker
CBD
Closed Bowl Distributor
cc
cubic centimeter
CCC
2010 BMW M3
Close Coupled Catalyst
CCC
Computer Command Control
CCD
Computer Controlled Dwell
CCOT
Cycling Clutch Orifice Tube
CCW
Counterclockwise
CDI
Capacitor Discharge Ignition
CEC
Computerized Engine Control
CID
Cubic Inch Displacement
cm
Centimeter
CMP
Camshaft Position Sensor
CO
Carbon Monoxide
CO2
Carbon Dioxide
2010 BMW M3
Cont.
Continued
CONV
Convertible
CP
Canister Purge
CKP
Crankshaft Position Sensor
CTS
Coolant Temperature Sensor
Cu. In.
Cubic Inch
CVC
Constant Vacuum Control
CV
Check Valve or Constant Velocity
CW
Clockwise
CYL or Cyl.
Cylinder
C3 I
Computer Controlled Coil Ignition
C4
2010 BMW M3
Computer Controlled Catalytic Converter
"D"
"D"
Drive
DC
Direct Current Or Discharge
DDD
Dual Diaphragm Distributor
Def.
Defrost
Defog.
Defogger
DERM
Diagnostic Energy Reserve Module
DFI
Digital Fuel Injection
Diag.
Diagnostic
DTC
Diagnostic Trouble Code
DIC
Driver Information Center
DIS
2010 BMW M3
Distributorless Ignition System
DIST
Distribution
DLC
Data Link Connector
DOC
Diesel Oxidation Catalyst
DOHC
Double Overhead Cam
DOT
Department of Transportation
DPF
Diesel Particulate Filter
DRB-II
Diagnostic Readout Box
DVOM
Digital Volt-Ohmmeter
"E"
EACV
Electric Air Control Valve
EATX
Electronic Automatic Transaxle
EBCM
2010 BMW M3
Electronic Brake Control Module
EBL
Electronic Back Light
ECM
Engine Control Module
ECT
Engine Coolant Temperature Sensor
EDIS
Electronic Distributorless Ignition System
EEC
Electronic Engine Control
EECS
Evaporative Emission Control System
EEPROM
Electronically Erasable PROM
EFE
Early Fuel Evaporation
EGO
Exhaust Gas Oxygen Sensor
EGR
Exhaust Gas Recirculation
EOT
Engine Oil Temperature

2010 BMW M3
ESA
Electronic Spark Advance
ESC
Electronic Spark Control
EST
Electronic Spark Timing
EVAP
Fuel Evaporative System
EVIC
Electronic Vehicle Information Center
EVP
EGR Valve Position Sensor
EWMA
Exponentially Weighted Moving Average (MODE 6)
Exc.
Except
"F"
F
Fahrenheit (Degrees)
F/B
Fuse Block
Fed.
Federal
2010 BMW M3
FI
Fuel Injection
FICU
Fuel Injection Control Unit
FIPL
Fuel Injector Pump Lever
FLI
Fuel Level Indicator
FPR-VSV
Fuel Pressure Regulator Vacuum Switching Valve
Ft. Lbs.
Foot Pounds
FWD
Front Wheel Drive
"G"
g
grams
Gals.
gallons
GND or GRND
Ground
"H"
HAC
2010 BMW M3
High Altitude Compensation
HC
Hydrocarbons
H/D
Heavy Duty
HO2S
Heated Exhaust Gas Oxygen Sensor
Hg
Mercury
Hgt.
Height
HLDT
Headlight
HO
High Output
HO2S
Heated Oxygen Sensor
HP
High Performance
HSC
High Swirl Combustion
HSO
High Specific Output

2010 BMW M3
HTR
Heater
Hz
Hertz (Cycles Per Second)
"I"
IAC
Idle Air Control
IACV
Idle Air Control Valve
IAT
Intake Air Temperature
IC
Integrated Circuit
ID
Identification
I.D.
Inside Diameter
IFS
Independant Front Suspension
IFS
Inertia Fuel Shutoff (Ford)
Ign.
Ignition
2010 BMW M3
IMRC
Intake Manifold Runner Control
In.
Inches
INCH Lbs.
Inch Pounds
in. Hg
Inches of Mercury
Inj.
Injector
IP
Instrument Panel
IRS
Independant Rear Suspension
ISC
Idle Speed Control
IVD
Interactive Vehicle Dynamics (Ford)
IVSV
Idle Vacuum Switching Valve
"J"
J/B
Junction Block
2010 BMW M3
"K"
KAPWR
Keep Alive Power
k/ohms
kilo-ohms (1000 ohms)
kg
Kilograms (weight)
kg/cm2
Kilograms Per Square Centimeter
KM/H
Kilometers Per Hour
KOEO
Key On, Engine Off
KOER
Key On, Engine Running
KS
Knock Sensor
kW
Kilowatt
kV
Kilovolt
"L"
L
2010 BMW M3
Liter
lbs. (Lbs. when used in table)
Pounds
LCD
Liquid Crystal Display
L/D
Light Duty
LDP
Leak Detection Pump (Part of EVAP system.)
LED
Light Emitting Diode
LH
Left Hand
"M"
mA
Milliamps
MA or MAF
Mass Airflow
MAFS
Mass Airflow Sensor
MAP
Manifold Absolute Pressure
MAT
2010 BMW M3
Manifold Air Temperature
Mem.
Memory
MEM-CAL
Memory Calibration Chip
mfd.
Microfarads
MFI
Multiport Fuel Injection
MICU
Multiplex Integrated Control Unit (Acura/Honda)
MIL
Malfunction Indicator Light
MPI
Multi-Point (Fuel) Injection
mm
Millimeters
MPH
Miles Per Hour
mV
Millivolts
"N"
NA
2010 BMW M3
Not Available
NAC
NOx Adsorber Catalyst
NCA
No Color Available (Wiring Diagrams)
NGS
New Generation Star
N.m
Newton Meter
No.
Number
Nos.
Numbers
NOx
Oxides of Nitrogen
"O"
O2
Oxygen
OBD
On-Board Diagnostics
OC
Oxidation Catalyst
OD
2010 BMW M3
Overdrive
O.D.
Outside Diameter
OHC
Overhead Camshaft
OSS
Output Speed Sensor
O/S
Oversize
oz.
Ounce
ozs.
Ounces
"P"
"P"
Park
P/C
Printed Circuit
PCM
Powertrain Control Module
PCS
Purge Control Solenoid
PC-SOL
2010 BMW M3
Purge Control Solenoid
PCV
Positive Crankcase Ventilation
PFI
Port Fuel Injection
PGM-FI
Programmed Fuel Injection
PID
Parameter Identification
PIP
Profile Ignition Pick-up
PNP
Park Neutral Position Switch
P/N
Park/Neutral
PRNDL
Park Reverse Neutral Drive Low
PROM
Programmable Read-Only Memory
psi
Pounds Per Square Inch
P/S
Power Steering
2010 BMW M3
PSPS
Power Steering Pressure Switch
PTC
Positive Temperature Coefficient
PTO
Power Take-Off
Pts.
Pints
Pwr.
Power
"Q"
Qts.
Quarts
"R"
RABS
Rear Anti-Lock Brake System
RECIRC
Recirculation
RH
Right Hand
RPM
Revolutions Per Minute
RWAL
2010 BMW M3
Rear Wheel Anti-Lock Brake
RWD
Rear Wheel Drive
"S"
SAS
Steering Angle Sensor
SBC
Single Bed Converter
SBEC
Single Board Engine Controller
SDARS
Satellite Digital Audio Radio Service
SES
Service Engine Soon
SFI
Sequential (Port) Fuel Injection
SIL
Shift Indicator Light
SIR
Supplemental Inflatable Restraint
SOHC
Single Overhead Cam
SOL or Sol.
2010 BMW M3
Solenoid
SPFI
Sequential Port Fuel Injection
SPK
Spark Control
SPOUT
Spark Output
SRI
Service Reminder Indicator
SRS
Supplemental Restraint System (Air Bag)
STAR
Self-Test Automatic Readout
STO
Self-Test Output
SUB-O2
Sub Oxygen Sensor
Sw.
Switch
Sys.
System
"T"
TAB
2010 BMW M3
Thermactor Air By-Pass
TAC
Throttle Actuator Module
TAD
Thermactor Air Diverter
TBC
Body Control Module (General Motors)
TBI
Throttle Body Injection
TCC
Torque Converter Clutch
TDC
Top Dead Center
Temp.
Temperature
TFI
Thick Film Ignition
THERMAC
Thermostatic Air Cleaner
TPM
Tire Pressure Monitor
TPMS
Tire Pressure Monitor System

2010 BMW M3
TPS
Throttle Position Sensor/Switch
TS
Temperature Sensor
TV
Thermovalve
TWC
Three-Way Catalyst
"V"
V
Valve
Vac.
Vacuum
VAF
Vane Airflow
VAPS
Variable Assist Power Steering
VCC
Viscous Converter Clutch
VCRM
Variable Control Relay Module
VIN
Vehicle Identification Number

2010 BMW M3
VM
Vacuum Modulator
Volt.
Voltage
VOM
Volt-Ohmmeter (Analog)
VRV
Vacuum Regulator Valve
VSS
Vehicle Speed Sensor
VSV
Vacuum Switching Valve
"W"
W/
With
W/O
Without
WAC
Wide Open Throttle A/C Switch
WOT
Wide Open Throttle

2010 BMW M3
GENERAL INFORMATION Emission Control Abbreviations
GENERAL INFORMATION
Emission Control Abbreviations
"A"
A/C
Air Conditioning
A/C-ISUS
A/C Idle Speed-Up Solenoid
AAI
Air Assist Injector
ACL
Air Cleaner (Thermostatic Air Cleaner)
ACL-AD
ACL Air Diverter
ACL-BMS
ACL Bimetallic Sensor
ACL-CKV
ACL Check Valve
ACL-DV
ACL Delay Valve
ACL-PVS
ACL Ported Vacuum Switch
ACL-RDV
ACL Reverse Delay Valve

2010 BMW M3
ACL-RDVS
ACL Reverse Delay Valve (Single)
ACL-TCV
ACL Thermal Control Valve
ACL-TS
ACL Temperature Sensor
ACL-TSOV
ACL Temperature Sensor Override Valve
ACL-TVS
ACL Thermal Vacuum Switch
ACL-TVV
ACL Thermal Vacuum Valve
ACL-VCDV
ACL Vacuum Control Delay Valve
ACL-VCV
ACL Vacuum Control Valve
ACL-VM
ACL Vacuum Motor
ACL-WP
ACL Wax Pellet Type Motor
ADS
Anti-Dieseling Solenoid
AFS
2010 BMW M3
Air/Fuel Ratio Sensor
AIH
Air Intake Heaters
AIH-TS
AIH Temperature Sensor
AIS
AIS-ACV
AIS Air Control Valve
AIS-AMV
AIS Air Management Valve
AIS-ASS
AIS Air Switching Solenoid
AIS-ASV
AIS Air Switching Valve
AIS-BPV
AIS By-Pass Valve
AIS-CKV
AIS Check Valve
AIS-CV
AIS Combination Valve
AIS-DV
AIS Diverter Valve

2010 BMW M3
AIS-PAF
AIS Pulse Air Feeder
AIS-PM
AIS Pump Motor
AIS-PV
AIS Pneumatic Valve
AIS-RV
AIS Relief Valve
AIS-SOL
AIS Solenoid
AIS-SV
AIS Solenoid Valve
AIS-VCV
AIS Vacuum Control Valve
AIS-VSV
AIS Vacuum Switching Valve
AIS-VT
AIS Vacuum Tank
AIS-VCV
AIS Vacuum Control Valve
AIS-VSV
AIS Vacuum Switching Valve
ALVW
2010 BMW M3
Adjusted Loaded Vehicle Weight
AP
Air Pump Injection System
AP-ACV
AP Air Control Valve
AP-AMV
AP Air Management Valve
AP-ASRV
AP Air Switching Relief Valve
AP-ASS
AP Air Switching Solenoid
AP-ASV
AP Air Switching Valve
AP-BPV
AP By-Pass Valve
AP-CKV
AP Check Valve
AP-CS
AP Control Solenoid
AP-DCTO
AP Dual Coolant Temperature Override
AP-DLY
AP Delay Valve
2010 BMW M3
AP-DV
AP Diverter Valve
AP-EADV
AP Electric Air Control Diverter Valve
AP-EAMR
AP Electric Air Management Relay
AP-EAMS
AP Electric Air Management Solenoid
AP-EAP
AP Electric Air Pump
AP-EC
AP Electromagnetic Clutch
AP-ERLY
AP Electric Air Pump Relay
AP-RDV
AP Reed Valve
AP-RV
AP Relief Valve
AP-SOV
AP Shut-Off Valve
AP-SV
AP Solenoid Valve
AP-SWV
2010 BMW M3
AP Switchover Valve
AP-TV
AP Transmitting Valve
AP-VCS
AP Vacuum Control Solenoid
AP-VCV
AP Vacuum Control Valve
AP-VSV
AP Vacuum Switching Valve
A/T
Automatic Transmission
ATCV
Air Temperature Control Valve
"B"
BP/EGR
Backpressure EGR System
BP/EGR-BPS
BP/EGR Backpressure Sensor
BP/EGR-BPT
BP/EGR Backpressure Transducer
BP/EGR-BPV
BP/EGR Backpressure Valve
BP/EGR-BS
2010 BMW M3
BP/EGR Bleed Solenoid
BP/EGR-BVSV
BP/EGR Bimetallic Vacuum Switching Valve
BP/EGR-C
BP/EGR Controller
BP/EGR-CLR
BP/EGR Cooler
BP/EGR-CS
BP/EGR Control Solenoid
BP/EGR-CTO
BP/EGR Coolant Temperature Override
BP/EGR-CV
BP/EGR Control Valve
BP/EGR-DCTO
BP/EGR Dual Coolant Temperature Override
BP/EGR-DS
BP/EGR Diagnostic Solenoid
BP/EGR-DSOL
BP/EGR Duty Solenoid
BP/EGR-DTVSW
BP/EGR Distributor Thermal Vacuum Switch
BP/EGR-DV
BP/EGR Delay Valve

2010 BMW M3
BP/EGR-EET
BP/EGR Electric Transducer
BP/EGR-EPV
BP/EGR External Pressure Valve
BP/EGR-FDV
BP/EGR Forward Delay Valve
BP/EGR-LC
BP/EGR Load Control Valve
BP/EGR-PS
BP/EGR Position Sensor
BP/EGR-PVS
BP/EGR Ported Vacuum Switch
BP/EGR-RES
BP/EGR Reservoir
BP/EGR-RST
BP/EGR Restrictor
BP/EGR-SOL
BP/EGR Solenoid
BP/EGR-TCTVS
BP/EGR Torque Converter Thermal Vacuum Switch
BP/EGR-TCV
BP/EGR Thermal Control Valve
BP/EGR-TCVLV
2010 BMW M3
BP/EGR Temperature Control Valve
BP/EGR-TS
BP/EGR Temperature Sensor
BP/EGR-TVS
BP/EGR Thermal Vacuum Switch
BP/EGR-TVV
BP/EGR Thermal Vacuum Valve
BP/EGR-VCV
BP/EGR Vacuum Control Valve
BP/EGR-VM
BP/EGR Vacuum Modulator
BP/EGR-VRV
BP/EGR Vacuum Regulator Valve
BP/EGR-VS
BP/EGR Vacuum Switch
BP/EGR-VSOL
BP/EGR Vent Solenoid
BP/EGR-VSV
BP/EGR Vacuum Switching Valve
"C"
C-4
Computer Controlled Catalytic Converter
CAC
2010 BMW M3
Charge Air Cooler
CAS
Clean Air System
CB
Crankcase Breather
CBPS
Coasting By-Pass System
CBVC
Crankcase Breather Vapor Canister
CCIEV
Coolant Controlled Idle Enrichment Valve
CCS
Controlled Combustion System
CCV
Closed Crankcase Ventilation
CD-REGVLV
Crankcase Depression Regulator Valve
CDRV
Crankcase Depression Relief Valve
CEAB
Cold Engine Air Bleed
CEAB-TVS
CEAB Thermal Vacuum Switch

2010 BMW M3
CEAB-TVV
CEAB Thermal Vacuum Valve
CEC
Computerized Engine Controls
CESS
Cold Engine Sensor Switch
CETS
Cold Engine Temperature Switch
CFI
Continuous Fuel Injection
CMH
Cold Mixture Heater
CNG
Compressed Natural Gas
CO
Carbon Monoxide
CO2
Carbon Dioxide
CPI
Central Port Injection
CRV
Coasting Richer Valve
CSI
2010 BMW M3
Central Sequential Injection
CTAVS
Cold Temperature Activated Vacuum System
CTOX
Continous Trap Oxidizer
"D"
DCLV
Deceleration Valve
DCS
Deceleration Control System
DDI
Direct Diesel Injection
DFI
Direct Diesel Injection
DI
Direct Injection
DKV
Deceleration Kick Valve
DMCV
Deceleration Mixture Control Valve
DMS
Dual Manifold System
DOHC
2010 BMW M3
Dual Overhead Cam
DPF
Diesel Particulate Filter
DPFE
Differential Pressure Feedback EGR Valve
DPFEGR
Differential Pressure Feedback EGR Valve
DTM
Deceleration Throttle Modulator
"E"
EAIR
Electric Air Injection System
EAIR-DV
EAIR Diverter Valve
ECM
Electronic Control Module
ECU
Electronic Control Unit
EDC
Electronic Diesel Control
EDS
Electronic Diesel System
EEC
2010 BMW M3
Electronic Engine Control
EFE
Early Fuel Evaporation
EFE-CKV
EFE Check Valve
EFE-CV
EFE Control Valve
EFE-DTVS
EFE Delay Thermal Vacuum Switch
EFE-HTR
EFE Heater
EFE-HCV
EFE Heat Control Valve
EFE-OTS
EFE Oil Temperature Switch
EFE-PTC
EFE Positive Temperature Coefficient (Intake Heater Grid)
EFE-PVS
EFE Ported Vacuum Switch
EFE-SOL
EFE Solenoid
EFE-TVS
EFE Thermal Vacuum Switch

2010 BMW M3
EFE-TVV
EFE Thermal Vacuum Valve
EFE-VSV
EFE Vacuum Switching Valve
EFI
Electronic Fuel Injection
EFI-MA
EFI Mass Airflow Sensor
EFI-MAF
EFI Mass Airflow Sensor
EGR
Exhaust Gas Recirculation System
EGR-BCS
EGR Boost Check Solenoid
EGR-BPBV
EGR By-Pass Backpressure Valve
EGR-BPT
EGR Backpressure Transducer
EGR-BPV
EGR By-Pass Valve
EGR-BS
EGR Bleed Solenoid
EGR-BSSV
2010 BMW M3
EGR Boost Sensor Solenoid Valve
EGR-BVSV
EGR Bimetallic Vacuum Switching Valve
EGR-C
EGR Controller
EGR-CC
EGR Coolant Controlled
EGR-CLR
EGR Cooler
EGR-VSOL
EGR Vacuum Solenoid
EGR-CKV
EGR Check Valve
EGR-CS
EGR Control Solenoid
EGR-CSOL
EGR Cut-Off Solenoid
EGR-CSV
EGR-CTO
EGR Coolant Temperature Override
EGR-CTS
EGR Charge Temperature Sensor

2010 BMW M3
EGR-CTSW
EGR Charge Temperature Switch
EGR-CTTS
EGR Coolant Temperature Thermoswitch
EGR-CV
EGR Control Valve
EGR-CVCV
EGR Constant Vacuum Control Valve
EGR-CVS
EGR Control Vent Solenoid
EGR-DC
EGR Digital Control
EGR-DCTO
EGR Dual Coolant Temperature Override
EGR-DPFE
Differential Pressure Feedback EGR Sensor
EGR-DPFS
EGR Differential Pressure Feedback Sensor
EGR-DS
EGR Diagnostic Solenoid
EGR-DSOL
EGR Duty Solenoid
EGR-DTVS
2010 BMW M3
EGR Delay Thermal Vacuum Switch
EGR-DTVSW
EGR Distributor Thermal Vacuum Switch
EGR-DV
EGR Delay Valve
EGR-EPRS
EGR Exhaust Pressure Regulator Solenoid
EGR-EPRV
EGR Exhaust Pressure Regulator Valve
EGR-EPV
EGR External Pressure Valve
EGR/EVAP-CSV
EGR/EVAP Control Solenoid Valve
EGR-EVR
EGR Vacuum Regulator
EGR-EVRV
EGR Electronic Vacuum Regulator Valve
EGR-FDV
EGR Forward Delay Valve
EGR-FJS
EGR Floor Jet System
EGR-FPS
EGR Feedback Pressure Sensor

2010 BMW M3
EGR-LCV
EGR Load Control Valve
EGR-MAP
EGR Manifold Absolute Pressure Sensor
EGR-PFE
EGR-PFE Sensor
EGR-PS
EGR Position Sensor
EGR-PSW
EGR Pulse Switch
EGR-PVS
EGR Ported Vacuum Switch
EGR-REG
EGR Regulator
EGR-RES
EGR Reservoir
EGR-RST
EGR Restrictor
EGR-SC
EGR Signal Converter
EGR-SEC
EGR, Secondary
EGR-SEN
2010 BMW M3
EGR Sensor
EGR-SOL
EGR Solenoid
EGR-SU
EGR Switchover Valve
EGR-SUB
Sub-EGR Valve
EGR-T
EGR Temperature Sensor
EGR-TC
EGR Transmission Controlled
EGR-TCTVS
EGR Torque Converter Thermal Vacuum Switch
EGR-TCV
EGR Thermal Control Valve
EGR-TCVLV
EGR Temperature Control Valve
EGR-TRANS
EGR Transducer
EGR-TS
EGR Temperature Sensor
EGR-TSW
EGR Temperature Switch

2010 BMW M3
EGR-TVD
EGR Throttle Valve Diaphragm
EGR-TVS
EGR Thermal Vacuum Switch
EGR-TVSOL
EGR Throttle Valve Solenoid
EGR-TVV
EGR Thermal Vacuum Valve
EGR-VA
EGR Vacuum Amplifier
EGR-VCV
EGR Vacuum Control Valve
EGR-VM
EGR Vacuum Modulator
EGR-VR
EGR Vacuum Regulator
EGR-VRS
EGR Vacuum Regulator Solenoid
EGR-VRSV
EGR Vacuum Regulator Solenoid Valve
EGR-VRV
EGR Vacuum Regulator Valve
EGR-VS
2010 BMW M3
EGR Vacuum Switch
EGR-VSDV
EGR Vacuum Switch Dump Valve
EGR-VSEN
EGR Vacuum Sensor
EGR-VSOL
EGR Vent Solenoid
EGR-VSS
EGR Vacuum Switching Solenoid
EGR-VSV
EGR Vacuum Switching Valve
EGR-VVCS
EGR Venturi Vacuum Control System
EGRC
EGRC-BPT
EGR Control Backpressure Transducer
EGRC-SV
EGR Control Solenoid Valve
EHOC
Electronically Heated Oxidation Catalyst
EHTWC
Electronically Heated Three-Way Catalyst

2010 BMW M3
EI
Electronic Ignition System
EIS
Electronic Ignition System
ELB
Electronic Lean Burn
EPR
Exhaust Pressure Regulator
EPR-SOL
EPR Solenoid
ESA
Electronic Spark Advance
EVAP
EVAP-AAC
EVAP Auxiliary Air Control
EVAP-BPSV
EVAP By-Pass Solenoid Valve
EVAP-BVSV
EVAP Bimetallic Vacuum Switching Valve
EVAP-CAV
EVAP Canister Air Valve
EVAP-CCV
2010 BMW M3
EVAP Control Canister Close Valve
EVAP-CCVSV
EVAP Control Canister Vent Shut Valve
EVAP-CCVVSV
EVAP Closed Canister Valve Vacuum Switching Valve
EVAP-CDCV
EVAP Canister Drain Cut Valve
EVAP-CKV
EVAP Check Valve
EVAP-CPCS
EVAP Canister Purge Control Solenoid
EVAP-CPCV
EVAP Canister Purge Control Valve
EVAP-CPRV
EVAP Canister Purge Regulator Valve
EVAP-CPSV
EVAP Canister Vent Shut Valve
EVAP-CPT
EVAP Canister Purge Timer
EVAP-CPTVS
EVAP Canister Purge Thermal Vacuum Switch
EVAP-CPV
EVAP Canister Vent Valve

2010 BMW M3
EVAP-CPVCSV
EVAP Canister Purge Volume Control
EVAP-CPVDV
EVAP Canister Purge Vacuum Delay Valve
EVAP-CS
EVAP Control Solenoid
EVAP-CSPS
EVAP Control System Pressure Sensor
EVAP-CST
EVAP Canister Surge Tank
EVAP-CVCS
EVAP Canister Vent Control Solenoid
EVAP-CVCV
EVAP Canister Vent Control Valve
EVAP-CVS
EVAP Canister Vent Solenoid
EVAP-CVSV
EVAP Carburetor Vent Switching Valve
EVAP-CVV
EVAP Canister Vent Valve
EVAP-DCTO
EVAP Dual Coolant Temperature Override
EVAP-DPS
2010 BMW M3
EVAP Differential Pressure Sensor
EVAP-EV
EVAP Emission Valve
EVAP-FBVV
EVAP Fuel Bowl Vent Valve
EVAP-FBVS
EVAP Fuel Bowl Vent Solenoid
EVAP-FLS
EVAP Fuel Level Sensor
EVAP-FOLV
EVAP Fuel Overflow Limiter Valve
EVAP-FS
EVAP Flow Switch
EVAP-FSV
EVAP Flow Switchover Valve<
EVAP-FTPCSV
EVAP Fuel Tank Pressure Control Solenoid Valve
EVAP-FTPS
EVAP Fuel Tank Pressure Sensor
EVAP-FTS
EVAP Fuel Temperature Sensor
EVAP-FVCV
EVAP Fuel Vapor Control Valve

2010 BMW M3
EVAP-FVS
EVAP Fuel Vapor Separator
EVAP-FVV
EVAP Fuel Vent Valve
EVAP-IVS
EVAP Inner Vent Solenoid
EVAP-LDP
EVAP Leak Detection Pump
EVAP-LDPAF
EVAP Leak Detection Pump Air Filter
EVAP-LDPF
EVAP Leak Detection Pump Filter
EVAP-LDPVV
EVAP Leak Detection Pump Vent Valve
EVAP-LSEP
EVAP Liquid Separator
EVAP-NVLD
EVAP Natural Vacuum Leak Detection
EVAP-ORVR
Evaporative On-Board Refueling Vapor Recovery System
EVAP-ORVRFTVRV
EVAP-ORVR Fuel Tank Vapor Recirculation
EVAP-OVCV
2010 BMW M3
EVAP Outer Vent Control Valve
EVAP-OWV
EVAP One-Way Valve
EVAP-PCSV
EVAP Purge Cut-Off Solenoid Valve
EVAP-PFS
EVAP Purge Flow Sensor
EVAP-PFSVVSV
EVAP Purge Flow Switching Valve Vacuum Switching Valve
EVAP-PRRV
EVAP Pressure Relief Rollover Valve
EVAP-PSVVSV
EVAP Pressure Switching Valve Vacuum Switching Valve
EVAP-PSOL
EVAP Purge Solenoid
EVAP-PSSV
EVAP Pressure Switching Solenoid
EVAP-PSVVSV
EVAP Pressure Switching Valve Vacuum Switching Valve
EVAP-PV
EVAP Purge (Frequency) Valve
EVAP-PVS
EVAP Ported Vacuum Switch

2010 BMW M3
EVAP-RV
EVAP Rollover Valve
EVAP-RV/FTPS
EVAP Rollover Valve/Fuel Tank
EVAP-RVSV
EVAP Rollover Vapor Separator Valve
EVAP-SNR
EVAP Canister Sensor
EVAP-SOV
EVAP Shutoff Valve
EVAP-SSV
EVAP Shut-Off Solenoid Valve
EVAP-SV
EVAP Solenoid Valve
EVAP-TS
EVAP Temperature Switch
EVAP-TPBPV
EVAP Tank Pressure By-Pass Valve
EVAP-TPCS
EVAP Tank Pressure Control Solenoid
EVAP-TPCV
EVAP Tank Pressure Control Valve
EVAP-TRWV
2010 BMW M3
EVAP Tree-Way Valve
EVAP-TV
EVAP Thermal Valve
EVAP-TVS
EVAP Thermal Vacuum Switch
EVAP-TWV
EVAP Two-Way Valve
EVAP-VC
EVAP Vapor Canister
EVAP-VCAT
EVAP Vapor Canister Air Tank
EVAP-VCF
EVAP Vapor Canister Filter
EVAP-VCTV
EVAP Vacuum Control Valve
EVAP-VCV
EVAP Vacuum Canister Valve
EVAP-VCVS
EVAP Vapor Canister Vent Solenoid
EVAP-VM
EVAP Vacuum Motor
EVAP-VPS
EVAP Vapor Pressure Sensor

2010 BMW M3
EVAP-VPSVSV
EVAP Vapor Pressure Sensor Vacuum Switching Valve
EVAP-VS
EVAP Vacuum Sensor
EVAP-VSOL
EVAP Ventilation Solenoid
EVAP-VSOL/LDP
EVAP Ventilation Solenoid/Leak Detection Pump
EVAP-VST
EVAP Vacuum Surge Tank
EVAP-VSV
EVAP Vacuum Switching Valve
EVAP-VV
EVAP Ventilation Valve
EVRS
EGR Vacuum Regulator Solenoid
"F"
FBC
Feedback Carburetor
FCOV
Fuel Change Over Valve
FF
Flex Fuel
2010 BMW M3
FF-CKV
Fuel Fill Check Valve
FF-FCV
Fuel Tank Fuel Cut-Off Valve
FF-FLVV
Fuel Tank Fill Limit Vent Valve
FGOV
Fuel Gravity/Overflow Valve
FGVV
Fuel Gravity Vent Valve
FI
Fuel Injected
FICD
Fast Idle Control Device
FISR
Fast Idle Solenoid Relay
FLV
Fill Limit Valve
FLVV
Fill Limiting Vent Valve
FP-CKV
Fill Pipe Check Valve
FP-RV
2010 BMW M3
Fill Pipe Rollover Valve
FR
Fill Pipe Restrictor
FT-FLVV
Fuel Tank Fill Limit Vent Valve
FT-GVV
Fuel Tank Grade Vent Valve
FT-OPRV
Fuel Tank Over Pressure Vent Valve
FT-PCV
Fuel Tank Pressure Control Valve
FT-VCV
Fuel Tank Vapor Control Valve
FT-VRV
Fuel Tank Vapor Recirculation Valve
FTCV
Fuel Tank Check Valve
FTDPS
Fuel Tank Differential Pressure Sensor
FTEV
Fuel Tank EVAP Valve
FTPS
Fuel Tank Pressure Sensor

2010 BMW M3
FTT
Fuel Tank Temperature Sensor
FTTS
Fuel Tank Temperature Sensor
FTVPRV
Fuel Tank Ventilation Pressure Retention Valve
FTVV
Fuel Tank Vent Valve
FVV
Fuel Vapor Valve
"G"
GVWR
Gross Vehicle Weight Rating
"H"
HAC
High Altitude Compensator
HAFS
Heated Air Fuel Ratio Sensor
HAI
Hot Air Intake
HAS
High Altitude System
HC
2010 BMW M3
Hydrocarbons
HCAC-VSV
Hydrocarbon Absorber Catalyst Vacuum Switching Valve
HDC
Heavy Duty Cooling
HDC-CTO
HDC Coolant Temperature Override
HFM-SFI
Hot Film Engine Management SFI
HIC
Hot Idle Compensator
HIM
Heated Intake Manifold
HO
High Output
HO2S
HP
High Performance
HP
Horsepower
HPCA
Housing Pressure Cold Advance

2010 BMW M3
HSC
High Swirl Combustion
"I"
IAC
Idle Air Control Valve
IACV-SW
IACV Switch
ICOM
Idle Compensator
IDI
Indirect Diesel Injection
IES
Idle Enrichment System
IMCO
Improved Combustion System
"K"
KS
Knock Sensor
"L"
LH-SFI
Hot Wire Sequential Multiport Fuel Injection
LVFD
Liquid/Vapor Fuel Discriminator

2010 BMW M3
LVW
Loaded Vehicle Weight
"M"
MD-TICS
Timing & Injection rate Control System
ME-SFI
Motor Electronics Sequential Fuel Injection
MFI
Multiport Fuel Injection
MFI-MAF
MFI Mass Airflow Sensor
MFLS
Main Fuel Level Sensor
MI
Mechanical Fuel Injection
MIL
M/T
Manual Transmission
"N"
NAC
Nitrogen Oxides (NOx) Adsorbing Catalyst
NLV
2010 BMW M3
Non-Linear Valve
NOS
NOx Sensor
NOx
NOx Emission Control
NOxC
Nitrogen Oxide Catalyst
NOxS
Nitrogen Oxide Sensor
NSC
Nitrogen Oxides (NOx) Storage Catalyst
"O"
OBD
On-Board Diagnostic System
PBD (F)/(P)
Full/Partial On-Board Diagnostic
OC
Oxidation Catalytic Converter
OHC
Overhead Cam
ORVR
On-Board Refueling Vapor Recovery
ORVR-COV
2010 BMW M3
ORVR Cut-Off Valve
ORVR-CV
ORVR Control Valve
ORVR-FMV
ORVR Flow Management Valve
ORVR-FTVCV
ORVR Fuel Tank Vapor Control Valve
ORVR-FTVRV
ORVR Fuel Tank Vapor Recirculation Valve
ORVR-LV
ORVR Leveling Valve
ORVR-OCKV
ORVR Overfill Check Valve
ORVR-RCV
ORVR Refueling Control Valve
ORVR-VCV
ORVR Vapor Cut Valve
ORVR-VRV
ORVR Vapor Recirculating Valve
ORVR-VSV
ORVR Vent Shut Valve
ORVR-VV
ORVR Vent Valve

2010 BMW M3
OVCV
Outer Vent Control Valve
O2S
Oxygen Sensor
"P"
PAIR
Pulsed Secondary Air Injection
PAIR-ABV
PAIR Anti-Backfire Valve
PAIR-ACOV
PAIR Air Cut-Off Valve
PAIR-ACS
PAIR Air Control Solenoid
PAIR-ACV
PAIR Air Control Valve
PAIR-AIV
PAIR Air Injection Valve
PAIR-ASCS
PAIR Air Suction Control Solenoid
PAIR-ASOV
PAIR Air Shutoff Valve
PAIR-ASS
PAIR Air Switching Solenoid

2010 BMW M3
PAIR-ASV
PAIR Air Switching Valve
PAIR-ASVL
PAIR Air Suction Valve
PAIR-AVCS
PAIR Air Valve Control Solenoid
PAIR-CSV
PAIR Control Solenoid Valve
PAIR-CKV
PAIR Check Valve
PAIR-DV
PAIR Diverter Valve
PAIR-PAF
PAIR Pulse Air Feeder
PAIR-PAV
PAIR Pulse Air Valve
PAIR-RES
PAIR Resonator
PAIR-RV
PAIR Reed Valve
PAIR-SCSV
PAIR Swirl Control Solenoid Valve
PAIR-SCV
2010 BMW M3
PAIR Swirl Control Valve
PAIR-SOL
PAIR Solenoid
PAIR-VSV
PAIR Vacuum Switching Valve
PCM
Powertrain Control Module
PCV
PCV-DOV
PCV Dual Orifice Valve
PCV-HCB
PCV Heated Crankcase Breather
PCV-HE
PCV Heating Element
PCV-PRV
PCV Pressure Regulator Valve
PCV-SOL
PCV Solenoid
PEVR
Power Enrichment Vacuum Regulator
PPM
Parts Per Million

2010 BMW M3
PTOX
Periodic Trap Oxidizer
PURCV
Purge Crankcase Ventilation
PVCS
Ported Valve Control System
PVCS-A
PVCS Actuator
PVCS-CS
PVCS Control Solenoid
PVLCS
Power Valve Control System
"R"
ROV
Rollover Valve
"S"
SAI-SV
Secondary Air Injection Shutoff Valve
SC
Supercharged or Super Charger
SC MFI
Supercharged Multiport Fuel Injection
SCR
2010 BMW M3
Selective Catalytic Reduction
SCSV
Swirl Control Solenoid Valve
SCV
Swirl Control Valve
SCV-A
SCV Actuator
SFI
Sequential Multiport Fuel Injection
SFI-MAF
SFI Mass Airflow Sensor
SFLS
Sub-Fuel Level Sensor
SOHC
Single Overhead Cam
SPK
Spark Controls
SPK-AVM
SPK Advance Vacuum Modulator
SPK-BVSV
SPK Bimetal Vacuum Switching Valve
SPK-CC
SPK Computer Controlled

2010 BMW M3
SPK-CKV
SPK Check Valve
SPK-CSSA
SPK Cold Start Spark Advance System
SPK-CSSH
SPK Cold Start Spark Hold System
SPK-CTO
SPK Coolant Temperature Override
SPK-DAVS
SPK Distributor Vacuum Advance Solenoid
SPK-DCKV
SPK Distributor Check Valve
SPK-DCTO
SPK Dual Coolant Temperature Override
SPK-DDD
SPK Dual Diaphragm Distributor
SPK-DMV
SPK Distributor Modulator Valve
SPK-DPD
SPK Dual Point Distributor
SPK-DPVS
SPK Distributor Ported Vacuum Switch
SPK-DRCV
2010 BMW M3
SPK Distributor Retard Control Valve
SPK-DRS
SPK Distributor Retard Solenoid
SPK-DSVMV
SPK Distributor Spark Vacuum Modulator Valve
SPK-DTVS
SPK Distributor Thermal Vacuum Switch
SPK-DTVV
SPK Distributor Thermal Vacuum Valve
SPK-DV
SPK Delay Valve
SPK-DVA
SPK Distributor Vacuum Advance
SPK-DVAS
SPK Distributor Vacuum Advance Solenoid
SPK-DVCS
SPK Distributor Vacuum Control Solenoid
SPK-DVCSW
SPK Distributor Vacuum Controlled Switch
SPK-DVCV
SPK Distributor Vacuum Control Valve
SPK-DVDV
SPK Distributor Vacuum Delay Valve

2010 BMW M3
SPK-DVRS
SPK Distributor Vacuum Retard Switch
SPK-DVRV
SPK Distributor Vacuum Regulating Valve
SPK-DVVV
SPK Distributor Vacuum Vent Valve
SPK-EAVS
SPK Electronically Actuated Vacuum Switch
SPK-EDM
SPK Electronic Distributor Modulator
SPK-EI
SPK Electronic Ignition
SPK-ESA
SPK Electronic Spark Advance
SPK-ESC
SPK Electronic Spark Control (Retard)
SPK-ESS
SPK Electronic Spark Selection
SPK-EST
SPK Electronic Spark Timing
SPK-FDV
SPK Forward Delay Valve
SPK-HPCA
2010 BMW M3
SPK Housing Pressure Cold Advance
SPK-ITCS
SPK Ignition Timing Control System
SPK-ITVS
SPK Ignition Timing Vacuum Switch
SPK-NLVR
SPK Non-Linear Vacuum Regulator
SPK-OSAC
SPK Orifice Spark Advance Control
SPK-PVA
SPK Ported Vacuum Advance
SPK-PVS
SPK Ported Vacuum Switch
SPK-RDO
SPK Retard Delay Orifice
SPK-RDV
SPK Reverse Delay Valve
SPK-RDVD
SPK Reverse Delay Valve (Dual)
SPK-RDVLV
SPK Retard Delay Valve
SPK-RDVS
SPK Reverse Delay Valve (Single)

2010 BMW M3
SPK-RETS
SPK Retard Switch
SPK-SC
SPK Speed Controlled
SPK-SOL
SPK Solenoid
SPK-SRRV
SPK Spark Relay Regulator Valve
SPK-TAVIA
SPK Temperature Activated Vacuum Ignition Advance
SPK-TCS
SPK Transmission Controlled Spark
SPK-TCSYS
SPK Timing Control System
SPK-TIDC
SPK Thermostatic Ignition Distributor Control
SPK-TV
SPK Thermal Valve
SPK-TVS
SPK Thermal Vacuum Switch
SPK-VACTO
SPK Vacuum Advance Coolant Temperature Override
SPK-VAS
2010 BMW M3
SPK Vacuum Advance Solenoid
SPK-VAV
SPK Vacuum Advance Valve
SPK-VR
SPK Vacuum Retard
SPK-VRSW
SPK Vacuum Retard Switch
SPK-VSV
SPK Vacuum Switching Valve
SPK-VTCS
SPK Vacuum Timing Control System
SPL
Smoke Puff Limiter
SRI
Service Reminder Indicator
SSCA
Stepped Speed Control Actuator
SSCS
Stepped Speed Control Solenoid
STS
Service Throttle Soon Light
STVS
Secondary Throttle Valve System

2010 BMW M3
SUB-O2S
Sub-Oxygen Sensor
SUB-TWC
Sub Three-Way Catalytic Converter
"T"
TAA
Turbo Air-To-Air
TAA
Throttle Actuator Assembly
TAB
Thermactor Air By-Pass
TAD
Thermactor Air Diverter
TBI
Throttle Body Injection
TBPCS
Throttle By-Pass Control System
TC
Turbo Charger
TCC
Torque Converter Clutch
TCCL
Torque Converter Control

2010 BMW M3
TCD
Throttle Closing Dashpot
TC-DV
TC Delay Valve
TC-TVC
TC Thermal Vacuum Switch
TC-VS
TC Vacuum Switch
TD
Thermactor Diverter
TFT
Tank Fuel Temperature Sensor
TICV
Thermal Ignition Control Valve
TIV
Thermal Idle Valve
TK
Throttle Kicker
TLUC
Transmission Lock-Up Converter
TLUC-TVS
TLUC Thermal Vacuum Switch
TLUC-VS
2010 BMW M3
TLUC Vacuum Switch
TM
Throttle Modulator
TOS
Throttle Opener System
TP
Throttle Positioner
TPI
Tuned Port Fuel Injection
TPV
Throttle Poppet Valve
TR
Thermal Reactor
TRC
Throttle Return Control
TRCS
Throttle Return Control Solenoid
TRCTL
Throttle Return Control Throttle Lever Actuator
TRSCV
Throttle Return Solenoid Control Valve
TRTVV
Temperature Regulator Thermal Vacuum Valve

2010 BMW M3
TRVV
Transmission Vacuum Valve
TSOL
Throttle Solenoid
TVISD
Throttle Vacuum Idle Speed Diaphragm
TVM
Transmission Vacuum Modulator
TWC
Three-Way Catalytic Converter
TWC+OC
Three-Way + Oxidation Catalytic Converter
"V"
VA
Vacuum Advance Unit
VAC-AMP
Vacuum Amplifier
VA-CTO
VA Coolant Temperature Override
VCV
Vacuum Cut Valve
VCV-BV
VCV By-Pass Valve

2010 BMW M3
VLFR
Vent Line Flow Restrictor/Anti-Trickle Fill Valve
"W"
WU
Warm-Up Catalyst
WU-OC
Warm-Up Oxidation Converter
WU-TWC
Warm-Up Three-Way Catalytic Converter

2010 BMW M3
ACCESSORIES AND BODY, CAB Audio, Navigation and Anti-Theft - Repair
ACCESSORIES AND BODY, CAB
Audio, Navigation and Anti-Theft - Repair
MONO RADIO
65 11... INSTRUCTIONS ON SETTING THE INSTALLATION LOCATION ON THE CD CHANGER
NOTE: To ensure trouble-free CD changer operation, ensure both suspension springs

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

removed from the CD changer.
E36:
Observe Notes on handling CD changers
E60, E61, E63, E64:
Remove CD changer magazine
E83:
Ejection via self-diagnosis
E87, E90, E91:
CD changer must be sent in
Remove cover cap (1) from CD changer (2).

2010 BMW M3
Fig. 1: Identifying Cover Cap And CD Changer

Courtesy of BMW OF NORTH AMERICA, INC.
Arrange installation location of CD changer (2) with a suitable tool by sliding suspension spring (1) into
required position.
Fig. 2: Sliding Suspension Spring

65 11 070 REMOVING AND INSTALLING/REPLACING CD CHANGER
IMPORTANT: Read and comply with notes on PROTECTION AGAINST ELECTROSTATIC

DAMAGE (ESD PROTECTION) .
Necessary preliminary tasks:
Disconnect BATTERY NEGATIVE LEAD

Remove LUGGAGE COMPARTMENT trim on left.
If necessary, remove video module for on-board monitor
2010 BMW M3
NOTE: Follow instructions for HANDLING OPTICAL FIBRES .
Release screws (1).
Pull CD changer (2) forward and unlock and disconnect plug connections.
Remove CD changer (2) complete with holder.
Fig. 3: Identifying CD Changer With Screws

Replacement:
Release screws (1) and remove holder (3) from CD changer (2).
Fig. 4: Identifying Screws, Holder And CD Changer

65 12 230 REMOVING AND INSTALLING/REPLACING DAB TUNER

2010 BMW M3
NOTE: FOLLOW INSTRUCTIONS FOR HANDLING OPTICAL FIBRES .
Necessary preliminary tasks

Remove LUGGAGE COMPARTMENT FLOOR TRIM
E93:
Remove panel for luggage compartment partition
Release screws (1).
Disconnect plug connections (2) and remove bracket with DAB tuner (3).
Installation:
DAB tuner bracket (3) must be inserted in guides.
Fig. 5: Identifying DAB Tuner With Screws And Plug Connections

Replacement
Release screws (1) and remove DAB tuner (2).

2010 BMW M3
Fig. 6: Identifying DAB Tuner With Screws

65 11 080 REMOVING AND INSTALLING/REPLACING RADIO RECEIVER

DISCHARGE (ESD PROTECTION).

Remove CONTROL PANEL FOR HEATING AND A/C SYSTEM
NOTE: Comply with notes and instructions on HANDLING OPTICAL FIBRES .
Release screws (1).
Pull back radio receiver (2) slightly.
Disconnect associated plug connections and remove radio receiver (2).
Installation:
Make sure the rear guide pin of the radio receiver (2) is correctly seated in the associated mounting.
2010 BMW M3
Fig. 7: Pulling Radio Receiver

For US version only:
If there is a violet antenna connection (1) present in addition to the black antenna connection (2), additional
work is required when replacing the radio receiver!
Refer to REPLACING SATELLITE TUNER!
Fig. 8: Identifying Violet And Black Antenna Connections

Replacement
Carry out vehicle programming and encoding.
65 11... REMOVING AND INSTALLING/REPLACING SATELLITE TUNER (US VERSION ONLY)

2010 BMW M3
Necessary preliminary work
Remove RADIO
NOTE: Satellite tuner can be recognized by the violet aerial connection (1) which is
also located next to the black aerial connection (2).
Additional work is required when the satellite tuner is replaced!
Fig. 9: Identifying Violet And Black Antenna Connections

Replacement
Record SID number (1) of the removed device.
NOTE: The SID number (1) can be found on the label of the housing.
Record SID number (1) of the new device.

2010 BMW M3
Fig. 10: Identifying SID Number On Label Of Housing

Replacement
Carry out vehicle programming and encoding .
Replacement
Contact Sirius. Use the SID number to cancel current device and register new one.
STEREO RADIO, AMPLIFIER

65 00... OVERVIEW OF AUDIO COMPONENTS (HIFI SYSTEM)
2010 BMW M3
Fig. 11: Overview Of Audio Components (HiFi System)

65 00... OVERVIEW OF AUDIO COMPONENTS (TOP HIFI SYSTEM)

2010 BMW M3
Fig. 12: Overview Of Audio Components (Top HiFi System)

65 00... OVERVIEW OF AUDIO COMPONENTS (STEREO SYSTEM)

2010 BMW M3
Fig. 13: Overview Of Audio Components (Stereo System)

65 12 072 REMOVING AND INSTALLING (REPLACING) AMPLIFIER (TOP HIFI SYSTEM)

Necessary preliminary work:

2010 BMW M3
Disconnect BATTERY EARTH LEAD

Vehicles with CD changer or video module only:
Remove LUGGAGE COMPARTMENT TRIM on left.
Remove video module for on-board monitor
Remove CD CHANGER
Vehicles without CD changer or video module only:
Unclip cover (1) in direction of arrow from luggage compartment trim panel (2).
Fig. 14: Removing Cover From Luggage Compartment Trim Panel

Shown with luggage compartment trim panel removed:
Unlock plug connections (2) and disconnect.
Pull out retaining plates (3) in direction of arrow.
Remove amplifier (1) from holder (4).
Fig. 15: Pulling Retaining Plates

2010 BMW M3
NOTE: Until 09/2009 a Top HiFi amplifier with a different pin assignment is installed!
Install cable jumper consisting of socket (1) (BMW Parts Service 6901844) and wire jumper (2) in connector
(3).
Create wire jumper (2) from wire (cross-section 0.75 mm2 ) and two stops (BMW Parts Department 1393724).
Then connect pins 1 and 2 in the socket (1) with wire jumper (2).
NOTE: Connector chamber (4) is not included in current version and remains unused
in new replacement Top HiFi amplifier!
Fig. 16: Identifying Cable Jumper Socket With Wire Jumper, Connector And Connector Chamber
Replacement:
65 12 200 REMOVING AND INSTALLING (REPLACING) AUDIO SYSTEM CONTROLLER


Remove OPERATOR UNIT FOR HEATER/AIR CONDITIONER (with CCC/ASK)
2010 BMW M3
Remove CENTRE CONSOLE SWITCH CLUSTER (with CCC/ASK)
NOTE: Comply with notes and instructions on HANDLING OPTICAL WAVEGUIDES .
Release screws (1).
Pull back audio system controller (2) slightly.
Unlock associated plug connections and disconnect.
Remove audio system controller (2).
Fig. 17: Pulling Audio System Controller

Replacement:

NOTE: FOLLOW INSTRUCTIONS FOR HANDLING OPTICAL FIBRES .

E93:
2010 BMW M3
Remove panel for luggage compartment partition
Release screws (1).
Installation:
Fig. 18: Identifying DAB Tuner With Screws And Plug Connections
Replacement
Fig. 19: Identifying DAB Tuner With Screws

65 12 070 REMOVING AND INSTALLING/REPLACING AMPLIFIER

2010 BMW M3

DISCHARGE (ESD PROTECTION) .

Remove LUGGAGE COMPARTMENT TRIM ON LEFT .
If necessary, remove
If necessary, remove CD CHANGER
Unfasten plug connection (2) and disconnect.
Release screws (1).
Remove amplifier (3) complete with holder (4).
Fig. 20: Identifying Amplifier With Plug Connection, Screws And Holder
Replacement
Release screw (2).
Unscrew nuts (4).

2010 BMW M3
Fig. 21: Identifying Amplifier With Nuts, Screw And Holder

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

SPEAKER (UNDER FRONT SEAT)
Remove FRONT SEAT

If necessary, remove PANEL FOR DOOR PILLAR (BOTTOM)
Release screws (1).
Remove central bass speaker trim (2) from floor trim (3).
Fold back floor panel (3) in direction of arrow.
Fig. 22: Identifying Screws, Central Bass Speaker Trim And Floor Trim
NOTE: Floor panel shown removed for purposes of clarity.

2010 BMW M3
Unscrew nuts (2).
Feed out central bass speaker (3) in direction of arrow and remove.
Fig. 23: Removing Central Bass Speaker

Installation:
Make sure seal (3) and rubber damper (4) are correctly seated on central bass speaker (1).
Insert central bass speaker (1) with guides (2) exactly in frame side member.
Fig. 24: Identifying Central Bass Speaker, Guides, Seal And Rubber Damper
65 12 220 REMOVING AND INSTALLING/REPLACING SATELLITE RADIO (US VERSION ONLY

UNTIL 09/2009)
2010 BMW M3

NOTE: FOLLOW INSTRUCTIONS FOR HANDLING OPTICAL FIBRES.

Remove LUGGAGE COMPARTMENT FLOOR PANEL
Disconnect plug connection (1).
Release screws (2) and feed out satellite tuner (3).
Installation:
Unlock plug connections correctly.

Bracket (4) must be inserted in guides on floor pan.
Fig. 25: Identifying Satellite Tuner With Plug Connection, Screws And Bracket
Replacement
Release screws (1) and remove
bracket (2) from satellite tuner (3).

2010 BMW M3
Fig. 26: Identifying Satellite Tuner With Screws And Bracket

When replacing, please observe
Record ID number (2) of the removed device.
NOTE: The ID number (2) can be found on the label of the housing. Above the barcode
the text reads "Sirius ID" (1) and next to it is the company's logo "Sirius
Satellite Radio" (3).
Record ID number (2) of the new device.
Fig. 27: Identifying Sirius ID, ID Number And Sirius Satellite Radio Logos
Replacement
2010 BMW M3
Carry out vehicle
programming/encoding.
NOTE: Please contact Sirius. Use the ID number to cancel current device and register
new one.
65 12 220 REMOVING AND INSTALLING/REPLACING SATELLITE TUNER (ONLY FOR US

MODELS STARTING AT 09/2009)
Remove CAR INFOTAINMENT COMPUTER
NOTE: The SID number (1) can be found on the label of the housing. Location may be
different, depending on the equipment manufacturer.

Input enabling code from the Aftersales Assistance Portal, ASAP.
Replacement:
2010 BMW M3
Perform vehicle programming and encoding .
NOTE: Please contact Sirius. Use the SID number to cancel current device and register
new one.
61 35... NOTES ON ESD PROTECTION (ELECTRO STATIC DISCHARGE)
NOTE: Electrical components which are particularly sensitive to electrostatic

discharge (electronic control units, sensors, etc.) are marked with the ESD
warning symbol.
E-Electro
S-Static
D-Discharge
Statically charged persons can discharge themselves when they touch electrical components.
NOTE: Humans can only detect a discharge starting from a level of approx. 3000 V.
The danger threshold for electrical components already starts from a level of
approx. 100 V.
Fig. 29: Discharging Charged Person By Touching Electrical Components

Example:
Mechatronic control unit.

2010 BMW M3
Fig. 30: Identifying Mechatronic Control Unit

Fig. 31: Caution For Not Touching Pins And Multi-Pin Connectors Directly
IMPORTANT: Do not touch pins and multi-pin connectors directly!

Touch electrical components by their housings only.
2010 BMW M3
IMPORTANT: To avoid damaging or destroying electrical components as a result of

electrostatic discharge, it is absolutely essential to observe the following
instructions:
When replacing electrical components, leave the replacement

components in their original packaging until immediately before they are
to be installed
If necessary, always return a removed component in its original
packaging (always pack the component away immediately)
Personal protective equipment:
Electrically conducting clothing (high wool content, antistatic shoes required).
These can primarily be identified by the logo on the side.
Fig. 32: Identifying Antistatic Shoes

65 12 220 REMOVING AND INSTALLING/REPLACING SATELLITE TUNER (ONLY FOR US

MODELS STARTING AT 09/2009)
Remove CAR INFOTAINMENT COMPUTER
NOTE: The SID number (1) can be found on the label of the housing. Location may be
different, depending on the equipment manufacturer.
2010 BMW M3

Input enabling code from the Aftersales Assistance Portal, ASAP.
Replacement:
Perform vehicle programming and encoding .
NOTE: Please contact Sirius. Use the SID number to cancel current device and register
new one.
SPEAKER AND COVER

65 13 400 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT FREQUENCY GATE
Remove FRONT DOOR TRIM PANEL
Release screws (2) and remove frequency gate.

2010 BMW M3
Fig. 34: Identifying Plug Connection And Frequency Gate Screws

65 13 188 REMOVING AND INSTALLING/REPLACING REAR MID-RANGE SPEAKER (IN REAR

SHELF)
Lever speaker cover (1) with special tool 00 9 340 out of rear shelf (2).
Fig. 35: Removing Speaker Cover Out Of Rear Shelf Using Special Tool (00 9 340)
Installation:
Lugs (1) and locks (2) of speaker cover (3) must not be damaged.
2010 BMW M3
Fig. 36: Identifying Lugs, Locks Of Speaker Cover

Release screws (1).
Remove mid-range speaker (2) upwards from rear shelf (3).
Disconnect associated plug connections and remove mid-range speaker (2).
Fig. 37: Identifying Mid-Range Speaker, Rear Shelf With Screws

65 13 195 REMOVING AND INSTALLING/REPLACING REAR TREBLE SPEAKER (IN REAR

SHELF)
Remove REAR MID-RANGE SPEAKER

2010 BMW M3
Release screws (2).
Remove rear treble speaker (3) from rear shelf (4).
Fig. 38: Removing Rear Treble Speaker From Rear Shelf

65 13 070 REMOVING AND INSTALLING/REPLACING SPEAKER (MIDRANGE SPEAKER IN

DOOR TRIM PANEL AT FRONT)
Remove front DOOR TRIM
NOTE: Secure speaker against falling out.
Release nuts (1) and remove speaker (2) in direction of arrow from door trim (3).
Tightening torque 65 13 1AZ .
NOTE: The studs for the speaker screw connection are microencapsulated.
2010 BMW M3
Fig. 39: Removing Speaker From Door Trim

NOTE: A. Previous version with adapter lead and external capacitor

B. New version with integrated capacitor
Adapter lead with capacitor on speaker omitted.
Remove adapter lead completely in each case when replacing.
Fig. 40: Identifying Speaker With External And Integrated Capacitor (Build Date E90/E91)
Build date E87 from CW 44/2005:


2010 BMW M3
Fig. 41: Identifying Speaker With External And Integrated Capacitor (Build Date E87)
65 13 090 REMOVING AND INSTALLING/REPLACING SPEAKER (MIDRANGE SPEAKER, DOOR

AT REAR)
Remove REAR DOOR TRIM PANEL .
Unscrew nuts (1).
Remove speaker (2) upwards out of rear door trim panel (3).
Fig. 42: Identifying Speaker With Nuts And Rear Door Trim Panel
2010 BMW M3
65 13 060 REMOVING AND INSTALLING/REPLACING SPEAKER (MIDRANGE SPEAKER, IN

INSTRUMENT PANEL)
Unclip trim for speaker cover (1) at fastening points (2) and (3) and remove
Fig. 43: Identifying Speaker Cover With Fastening Points

Release screws (1).
Remove speaker (2).
Disconnect associated plug connection and remove speaker (2) towards top.
Fig. 44: Identifying Speaker With Screws

65 13 050 REMOVING AND INSTALLING/REPLACING SPEAKER (TREBLE SPEAKER IN

QUARTERLIGHT MIRROR)
Detach COVER ON DOOR WINDOW FRAME in front area.

2010 BMW M3
NOTE: For purposes of clarity, cover on door window frame is removed.
Remove foam wedge (1) in direction of arrow from door window frame (2).
Installation:
Fit foam wedge (1) exactly over guide (3).
Fig. 45: Removing Foam Wedge From Door Window Frame

Unlock catches (1) and remove speaker (2) from cover on door window frame (3).
Disconnect plug connection and remove speaker.
Fig. 46: Removing Speaker From Cover On Door Window Frame

65 13 080 REMOVING AND INSTALLING/REPLACING SPEAKER (TWEETER IN REAR DOOR)

2010 BMW M3
Remove REAR DOOR TRIM
Disconnect plug connection (1) and remove cable (2) from mounting.
Release plastic nut (3) in counterclockwise direction and feed out speaker (4).
Installation:
Do not place plastic nut (3) on thread at a skewed angle.
Fig. 47: Releasing Plastic Nut

AERIAL/ANTENNA
65 20 090 REMOVING AND INSTALLING OR REPLACING ANTENNA AMPLIFIER
Remove TRIM FOR AUXILIARY BRAKE LIGHT
Release screws (3).
Unlock plug connections (2) and (4) and disconnect.
Remove antenna amplifier (1).

2010 BMW M3
Fig. 48: Identifying Antenna Amplifier With Plug Connections And Screws
65 20 150 REMOVING AND INSTALLING/REPLACING BACK-UP ANTENNA
Remove PANEL FOR PARCEL SHELF
Unscrew nuts (2).
Remove back-up antenna (3) from rear window shelf (4).
Fig. 49: Removing Back-Up Antenna From Rear Window Shelf

65 20 030 REMOVING AND INSTALLING/REPLACING EMPTY HOUSING FOR ROOF-

MOUNTED AERIAL
2010 BMW M3
NOTE: Clean roof.
Tape off roof surface (2) around aerial cover (3) with yellow adhesive tape (1). To do so, slide adhesive tape
slightly under roof aerial.
If necessary, carefully heat vehicle roof in aerial area with a hot air blower (max. 50C).
Fig. 50: Identifying Aerial Cover With Roof Surface And Yellow Adhesive Tape
IMPORTANT: Risk of damage!

Handle special tool correctly and make sure you are standing safely with a firm
foothold next to vehicle.
In order to prevent dents in the roof outer skin, do not exert any pressure on
the roof.

Make sure your arms do not cross over (1) when holding special tool 65 2 010
KNIFE .
Pull handle must always be ahead of the guiding hand (2).
2010 BMW M3
Fig. 51: Caution For Holding Special Tool (65 2 010)

Cut through adhesive bead all round with special tool 65 2 010 KNIFE . Pull on handle (1) and align blade on
handle (2).
NOTE: Use sharp blades only. If necessary, sharpen blade.
Fig. 52: Pulling Handle

Remove cover of multiband telephone aerial (3).
Installation
The cover of the multiband telephone aerial is secured with window adhesive.
All preparatory operations correspond to the WINDOW CEMENTING INSTRUCTIONS .

2010 BMW M3
NOTE: The aerial cover must be replaced if its centering pins (1) are damaged.
Bonding surface (2) must be clean and free from grease.
Fig. 53: Identifying Aerial Cover Centering Pins With Bonding Surface
Position two spacers (1) on cleaned aerial cover.
Dimensions:
A. 10 mm
B. 14 mm
Position spacer (2) centrally and flush with shoulder of adhesive flange.
IMPORTANT: Spacers must be used without fail!
Fig. 54: Identifying Spacer Position Dimensions On Aerial Cover

2010 BMW M3
Apply trace of adhesive bead all round outer contour as follows.
Distance between adhesive bead and edge of aerial cover:
A. 6.5 mm 1 mm
Start and end of bead trace must have an overlap length of max. 10 mm.
IMPORTANT: To prevent the adhesive from escaping, the adhesive bead diameter must not
exceed 3 mm 1 mm.
Fig. 55: Identifying Distance Between Adhesive Bead And Edge Of Aerial Cover
NOTE: Attach the aerial cover coated with adhesive by hand. To spread the adhesive
better, move the cover back and forth horizontally slightly when pressing down.
If necessary, secure aerial cover with adhesive tape and do not press down on one side of the aerial more firmly
than the other.
After bonding, leave vehicle to stand for at least 3 hours at room temperature.
To guarantee a permanent bond:
Only use washing installations after a period of 24 hours has passed.
65 20 035 REMOVING AND INSTALLING/REPLACING ROOF-MOUNTED AERIAL/ANTENNA
Detach EMPTY HOUSING for roof-mounted aerial/antenna
Release screw (1) and feed out roof aerial/antenna (2) towards top.
2010 BMW M3
Fig. 56: Identifying Roof Aerial/Antenna With Screws

Disconnect plug connections (1) and remove aerial/antenna (2).
Installation:
Do not mix up aerial/antenna connections (1).
Fig. 57: Identifying Plug Connections And Aerial/Antenna

65 20 350 REMOVING AND INSTALLING/REPLACING SUPPRESSION FILTER
Remove PANEL FOR ROOF PILLAR AT REAR LEFT .
Disconnect plug connections (1).
Release screw (2).

2010 BMW M3
Remove suppression filter (3) from C-pillar (4).
Fig. 58: Removing Suppression Filter From C-Pillar

Installation:
Fit suppression filter (1) so that screw (2) engages thread (3) and locating pin (4) engages bore (5).
Fig. 59: Identifying Suppression Filter, Locating Pin And Engages Bore With Screws
REAR WINDOW AERIAL/ANTENNA

65 24 020 REMOVING AND INSTALLING OR REPLACING BLOCKING CIRCUIT
Remove PANEL FOR ROOF PILLAR ON REAR LEFT .

2010 BMW M3
Release screw (2).
Remove blocking circuit (3) from C-pillar (4).
Fig. 60: Removing Blocking Circuit From C-Pillar

Installation:
Fit blocking circuit (1) so that screw (2) engages thread (3) and locating pin (4) engages bore (5).
Fig. 61: Identifying Blocking Circuit, Screw, Engages Thread, Locating Pin And Engages Bore
VIDEO AND TV EQUIPMENT

65 50 011 REMOVING AND INSTALLING (REPLACING) VIDEO MODULE FOR ONBOARD
MONITOR
2010 BMW M3

Disconnect BATTERY NEGATIVE LEAD .

Remove LUGGAGE COMPARTMENT TRIM ON LEFT .
NOTE: Follow instructions for HANDLING OPTICAL FIBRES .
Unfasten screws (2) and nuts (3).
Pull back video module for on-board monitor (1) and disconnect plug connections.
Remove video module for on-board monitor (1) complete with holder.
Fig. 62: Identifying On-Board Monitor With Screws And Nuts

Replacement:
Release screws (3) and remove holder (2) from video module for onboard monitor (1).
2010 BMW M3
Fig. 63: Identifying On-Board Monitor With Screws And Holder

Replacement:
ANTI-THEFT ALARM SYSTEM

65 75 071 REMOVING AND INSTALLING (REPLACING) MODULE FOR INTERIOR MOVEMENT
DETECTOR
IMPORTANT: Read and comply with NOTES on protection against electrostatic damage (ESD
protection).
Remove CEILING LIGHT (REAR)
Open retaining shook (1), and detach and remove module for passenger compartment sensor (2) from trim (3) in
direction of arrow.
Installation:
Retaining hooks (1) must not be damaged.
Fig. 64: Removing Module For Passenger Compartment Sensor From Trim
Replacement:
65 75 055 REMOVING AND INSTALLING/REPLACING EMERGENCY POWER SIREN WITH

2010 BMW M3
TILT SENSOR
Remove REAR LEFT WHEEL ARCH COVER
Release screws (1) and lower complete mounting plate (2).
Unlock and disconnect associated plug connection, remove complete mounting plate (2).
Fig. 65: Identifying Mounting Plate With Screws

Release nut (1) and remove emergency power siren with tilt sensor (2) from mounting plate (3).
Fig. 66: Identifying Tilt Sensor And Mounting Plate With Nut
Replacement:
AIRBAG TRIGGERING UNIT, DIAGNOSIS UNIT

2010 BMW M3
65 77... NOTES ON SCRAPPING BMW VEHICLES WITH GAS GENERATORS (CENTRAL

AIRBAG CONTROL UNIT, AIRBAG SYSTEM)
The gas generator is a pyrotechnic component of:
Airbag module
Driver's/passenger airbag
Side airbags
Head airbag
Knee airbag
Seat belt tensioner

Belt buckle tensioner
Battery safety terminal
1 Series: E81, E82, E87, E88
3 Series: E46, E90, E91, E92, E93
5 Series: E60, E61 from build date 09/2005
X3: E83
X5: E53, E70
Z4: E85, E86
Gas generators that have not fired constitute a hazard (also to the environment)!
In accordance with accident prevention regulations and specific national regulations, gas generators must be
rendered unusable before they are scrapped. This is necessary because pyrotechnical objects can cause injury if
improperly activated (e.g. scrapping with flame cutters).
For vehicles mentioned above that are scheduled for scrapping, it is always essential prior to draining and
further disassembly work to ensure that all the gas generators in the vehicle are fired. The fired gas generators
can then be scrapped together with the vehicle.
Firing failure
If correct triggering is not possible, the relevant components must (while observing the safety regulations for
handling airbag system components) be removed and disposed of by special disposal companies!
If a triggering operation has failed:

2010 BMW M3
Disconnect the triggering device from the battery and

approach the vehicle only after a few minutes
The components of an airbag system must always be disposed of. Such components must not be sold on as used
parts.
Ignition
Triggering of the gas generators may only be carried out by expert personnel and under the supervision of a
responsible person. Other standard accident prevention regulations (safety goggles, ear defenders etc.) must also
be observed.
The gas generators must be fired from the outside in the vehicle scheduled for scrapping with the doors closed
but with the tailgate, door windows and sunroof open. To fire the gas generators, use the BMW-developed
triggering device with the corresponding cables.
WARNING: Once gas generators have been fired, observe a ventilation period of 10
minutes with the doors opened. Only then is it permitted to continue work
inside the vehicle.
Wear protective goggles and protective gloves when handling a fired gas
generator!
The burning of solid fuel will heat up airbag unit - danger of burning
hands!
Wash skin with water after contact with fired gas generators!
1. Vehicles with central airbag control unit (all airbags, seat belt tensioners, battery safety terminal)
1.1 Expose AIRBAG CONTROL UNIT.

1.2 Connect "Airbagmaster".
72 12... OVERVIEW OF AIRBAG MODULES, AIRBAG CONTROL UNIT, BELT TENSIONERS

2010 BMW M3
Fig. 67: Overview Of Airbag Modules, Airbag Control Unit, Belt Tensioners
65 77... OVERVIEW OF SENSORS FOR AIRBAG SYSTEM

2010 BMW M3
Fig. 68: Overview Of Sensors For Airbag System

65 77 720 REMOVING AND INSTALLING (REPLACING) LEFT B-PILLAR SENSOR

WARNING: NOTE AIRBAG SAFETY INSTRUCTIONS!

Incorrect handling can activate airbag and cause injury.
2010 BMW M3
DISCONNECT BATTERY NEGATIVE LEAD and cover

Remove TRIM PANEL FOR DOOR PILLAR (BOTTOM)
Release screw (1).
Loosen screw (2).
Installation:
If necessary, remove B-pillar sound insulation (5).
Raise B-pillar sensor (3) slightly through opening in B-pillar and feed out towards rear.
Fig. 69: Identifying B-Pillar Sensor With Insulation, Plug Connection And Screws
Remove B-pillar sensor (3) from B-pillar.
Installation:
Establish correct positioning of B-pillar sensor (1) by means of guide pin (2) and screw (3).
2010 BMW M3
Fig. 70: Identifying B-Pillar Sensor With Guide Pin And Screw
65 77 740 REMOVING AND INSTALLING (REPLACING) LEFT FRONT DOOR SENSOR

WARNING: NOTE AIRBAG SAFETY INSTRUCTIONS !

Detach SOUND INSULATION in work area
Release screw (2).
Remove sensor with pin (3) from door panel fit (4) towards rear.
Installation:
Make sure fit (3) is correctly seated.

2010 BMW M3
Fig. 71: Identifying Plug Connection, Screw, Sensor Pin And Door Panel Fit
65 77 745 REMOVING AND INSTALLING/RENEWING RIGHT FRONT DOOR SENSOR
This operation is described in:
REMOVING AND INSTALLING (REPLACING) LEFT FRONT DOOR SENSOR
65 77 016 REMOVING AND INSTALLING/REPLACING AIRBAG CONTROL UNIT

WARNING: NOTE AIRBAG SAFETY INSTRUCTIONS !


Remove STORAGE COMPARTMENT
If necessary, remove foam cover from airbag control unit.
Release screw (2) and nuts (3).
Installation:
Before screwing down airbag control unit (4), make sure negative lead (5) is resting on associated threaded pin.
2010 BMW M3
Fig. 72: Removing Airbag Control Unit

Remove airbag control unit (4) in direction of arrow.
Replacement:
65 77 541 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT

ACCELERATION SENSOR
NOTE: Acceleration sensor only fitted in US version!
Unlock plastic fasteners (1) by turning counterclockwise through 180.
Feed flap (2) in direction of arrow out of front wheel arch cover (3) and remove.
Fig. 73: Removing Flap Out Of Front Wheel Arch Cover

2010 BMW M3
Release screws (1) and remove acceleration sensor (2).
Installation:
Replace screws (1).
Fig. 74: Identifying Acceleration Sensor With Plug Connection And Screws
65 77 725 REMOVING AND INSTALLING/REPLACING RIGHT B-PILLAR SENSOR
Operation is identical to:
REMOVING AND INSTALLING LEFT B-PILLAR SENSOR
65 77 604 REPLACING SENSOR MAT (OC3 MAT) FOR PASSENGER SEAT OCCUPANCY
DETECTOR
WARNING: Note AIRBAG SAFETY INSTRUCTIONS !

WARNING: US/CDN front passenger seat (with OC3 mat) only:

The OC3 mat can only be removed in conjunction with the padding from
the seat cover.
If OC3 mat or padding is defective, both parts may only be replaced
together.
After fitting seat cover, enable OC3 mat with BMW diagnosis system.
2010 BMW M3
Operation for replacing the OC3 mat in conjunction with padding and seat cover is described in:
Remove padding for front seat . See REPLACING SEAT COVER FOR LEFT OR RIGHT FRONT
SEAT (M3 SPORT SEAT) or REPLACING SEAT COVER FOR LEFT OR RIGHT FRONT
SEAT (SPORT/MANUAL)
Enabling seat occupancy detector (OC3 mat):
Connect vehicle programming and encoding scan tool.

Code airbag control unit
Clear fault memory if necessary
65 77 601 REPLACING SENSOR MAT FOR FRONT PASSENGER SEAT OCCUPANCY DETECTOR
(SPORT SEAT)
Operation is described in:
Replacing sensor mat for front passenger seat occupancy detector.
ON-BOARD COMPUTER
65 81 060 REMOVING AND INSTALLING/REPLACING OUTSIDE TEMPERATURE SENSOR (M3)
Release screws (1 and 2).
Remove tip of engine compartment shield (3) on left/right.
Installation:
Make sure tip of engine compartment shield (3) is installed in correct position.
Fig. 75: Identifying Engine Compartment Shield With Screws

2010 BMW M3
Unclip outside temperature sensor (2) in direction of arrow and remove.
Installation:
Outside temperature sensor (2) must audibly snap into place.
Ensure correct seating in air duct (3).
Fig. 76: Removing Outside Temperature Sensor

CENTRAL DISPLAY AND OPERATING UNIT

65 82 050 REMOVING AND INSTALLING (REPLACING) ON-BOARD MONITOR

IMPORTANT: Proceed with care so as to avoid damaging the on-board monitor and adjoining
trims.
Release screws (1).
Fold out on-board monitor (2) in direction of arrow.

2010 BMW M3
Fig. 77: Folding On-Board Monitor

Installation:
Ensure correct cable routing.
Remove on-board monitor (2).
Fig. 78: Identifying On-Board Monitor With Plug Connections

Replacement:
65 82... REPLACING FRONT TRIM PANEL OF CENTRAL INFORMATION DISPLAY (CID),

(09/2009 ON)
2010 BMW M3
NOTE: Front trim panel can only be replaced on versions without glass cover from
09/2009 on.
REMOVE CENTRAL INFORMATION DISPLAY
Release screws (1) and remove front trim panel (2).
Fig. 79: Identifying Front Trim Panel With Screws

CAR COMMUNICATION COMPUTER (CCC)

65 83 020 REMOVING AND INSTALLING (REPLACING) CAR INFORMATION COMPUTER (CIC)
A hard disk is installed in the Car Information Computer (CIC).
Carry out mechanical work on the CIC and adjacent components with care.
Avoid subjecting the CIC to vibration/shocks.
IMPORTANT: Read and comply with notes on protection against electrostatic damage (ESD
PROTECTION) .

2010 BMW M3

Remove CENTRE CONSOLE SWITCH CLUSTER
Release screws (1).
Pull back Car Infotainment Computer (2) slightly.
Remove Car Infotainment Computer (2).
Fig. 80: Pulling Car Communication Computer

Only for US models with satellite tuner:
When replacing the CIC unit, additional work is required!
Heed document REPLACE SATELLITE TUNER FROM 09/2009 .
Replacement:
65 83 570 REMOVING AND INSTALLING/REPLACING CD DRIVE FOR CAR COMMUNICATION

COMPUTER

DAMAGE (ESD PROTECTION) !

2010 BMW M3
Remove FRONT TRIM FOR CAR COMMUNICATION COMPUTER
If necessary, cut through warranty seal.
Raise cover (1) with special tool 64 1 020 HOOK all round and remove from Car Communication Computer
(2).
Fig. 81: Raising Cover Using Special Tool (64 1 020)

Release bolts (1).
Feed CD drive for Car Communication Computer (2) in direction of arrow out of Car Communication
Computer (3) and set down.
Installation:
Ensure correct routing of cables.
Fig. 82: Removing CD Drive Out Of Car Communication Computer

2010 BMW M3
Release bolts (1).
Remove CD drive trim (2) in direction of arrow from CD drive for Car Communication Computer (3).
Installation:
Fig. 83: Removing CD Drive Trim From CD Drive

Cut through warranty seal (1) at marked point.
Release screw (2).
Lift side cover out of mounting (3) and carefully place to one side.
Fig. 84: Identifying Warranty Seal With Mounting And Screw

Disconnect plug connection (1) and remove CD drive.

2010 BMW M3
Installation:
Fig. 85: Identifying Plug Connection

65 83 010 REMOVING AND INSTALLING/REPLACING CAR COMMUNICATION COMPUTER

Clamp off BATTERY NEGATIVE LEAD

Remove CENTER CONSOLE SWITCH CENTER
Release bolts (1).
Pull back Car Communication Computer (2) slightly.
Remove Car Communication Computer (2).

2010 BMW M3
Fig. 86: Pulling Car Communication Computer

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

COMMUNICATION COMPUTER

Risk of damage!
Place Car Communication Computer on special tool 12 7 192 (antistatic mat)
and connect to earth/ground.
Remove FRONT TRIM PANEL FOR CAR COMMUNICATION COMPUTER
Raise lid (1) with special tool 64 1 020 HOOK all round and remove from Car Communication Computer (2).
2010 BMW M3
Fig. 87: Raising Lid Using Special Tool (64 1 020)

Release screws (1).
Feed out bridge (2).
Installation note:
Use special tool 00 9 450 TORQUE WRENCH to tighten down screws.
Fig. 88: Identifying Bridge With Screws

Cut through labels at marked points (1).
Release screws (2) and remove cover (3).
Installation note:
2010 BMW M3
Use special tool 00 9 450 TORQUE WRENCH to tighten down screws.
Fig. 89: Identifying Cover, Screws And Labels

Release screws (1) with magnetic screwdriver.
Installation note:
Tab (2) of DVD drive must be above tab (3) of Car Communication Computer.
Fig. 90: Identifying DVD Drive Tab And Car Communication Computer Tab With Screws
Turn Car Communication Computer through 180 and carefully feed out DVD drive.
Carefully disconnect plug connections (1, 2).
Remove DVD drive (3).

2010 BMW M3
Installation note:
Fig. 91: Identifying DVD Drive With Plug Connections

NOTE: There are two versions of the plug connection (2):

Previous version (1): ribbon cable is connected horizontally
Current version (2): ribbon cable is connected vertically
Fig. 92: Identifying Ribbon Cable Connection Horizontally And Vertically

After installation
65 83 550 REMOVING AND INSTALLING/REPLACING FAN FOR CAR COMMUNICATION

COMPUTER
2010 BMW M3

Remove CAR COMMUNICATION COMPUTER
Raise retaining hook (1) and turn fan for Car Communication Computer (2) in direction of arrow.
Remove fan for Car Communication Computer (2) from Car Communication Computer (3).
Fig. 93: Turning Fan For Car Communication Computer

65 83 560 REMOVING AND INSTALLING/REPLACING FRONT TRIM FOR CAR


Release screws (1).
Fold down front panel for Car Communication Computer (2) and set down.
Installation:
Make sure retaining lugs (3) of front panel for Car Communication Computer (2) are correctly seated.
2010 BMW M3
Fig. 94: Removing Car Communication Computer

NOTE: "LIF" stands for Low Insertion Force.
Open catch of LIF plug (2) in direction of arrow and feed out LIF cable (1).
Remove front trim for Car Communication Computer (4) from Car Communication Computer (3).
Fig. 95: Opening Catch Of LIF Plug

65 83 590 REMOVING AND INSTALLING/REPLACING GYRO SENSOR DRIVE FOR CAR



2010 BMW M3
Release bolts (1).
Remove floor pan (2) towards bottom and set down.
IMPORTANT: Contact spring strip (3) on floor pan (2) must not be bent: otherwise risk of
short-circuiting!
When reinstalling floor pan (2), make sure individual springs of contact spring
strip (3) are correctly seated.
Fig. 96: Identifying Bolts Of Floor Pan And Spring Strip

Release bolt (1).
Detach gyro sensor for Car Communication Computer (2) in direction of arrow from plug-in contact (3).
Fig. 97: Removing Gyro Sensor From Plug-In Contact

2010 BMW M3
65 83 600 REPLACING HIP MODULE FOR CAR COMMUNICATION COMPUTER

Release screws (1).
Remove cover (2) towards top.
short-circuiting!
Fig. 98: Identifying Bolts Of Floor Pan And Spring Strip

Press catches (1) and feed out HIP module (2) in direction of arrow.
Installation:
Make sure front guides (3) of HIP module (2) are correctly seated.
2010 BMW M3
Fig. 99: Removing HIP Module

Disconnect plug connection (1) in direction of arrow and remove HIP module (2).
Fig. 100: Disconnecting Plug Connection

After installation
Cars with out-of-date software status at time of repair:
After replacing the HIP module, program the Car Communication Computer. Then take the car for an
initialization drive.
Cars with current software status at time of repair:
After replacing the HIP module, take the car for an initialization drive.
Initialization drive:
2010 BMW M3
Drive for 15-20 minutes at 50 km/h and with good GPS reception until correct vehicle position is achieved in
the navigation display.
NOTE: During this time, the position pointer of the navigation system can be
motionless or move across country.
2010 BMW M3
ACCESSORIES AND BODY, CAB Audio, Navigation and Anti-Theft - Repair Instructions - M3
Audio, Navigation and Anti-Theft - Repair Instructions - M3
RADIO
65 11 070 REMOVING AND INSTALLING/REPLACING CD CHANGER
protection) . See .61 35 ... NOTES ON ESD PROTECTION (ELECTRO STATIC
DISCHARGE) .
Disconnect battery negative lead . See 61 20 900 DISCONNECTING AND CONNECTING

BATTERY NEGATIVE LEAD .
Remove luggage compartment trim on left. See 51 47 210 REMOVING AND
INSTALLING/REPLACING TRUNK TRIM PANEL ON LEFT SIDE PANEL .
If necessary, remove video module for on-board monitor
NOTE: Follow instructions for handling optical fibres . See 61 00 ... NOTES ON
HANDLING OPTICAL FIBERS .
Release screws (1).
Pull CD changer (2) forward and unlock and disconnect plug connections.
Remove CD changer (2) complete with holder.
Fig. 1: Identifying CD Changer

2010 BMW M3
Release screws (1) and remove holder (3) from CD changer (2).
Fig. 2: Identifying Holder And Screw

65 11 080 REMOVING AND INSTALLING/REPLACING RADIO RECEIVER
protection) . See61 35 ... NOTES ON ESD PROTECTION (ELECTRO STATIC
DISCHARGE) .

Remove operator unit for heater/air conditioner . See 64 11 377 REMOVING AND
INSTALLING/REPLACING HEATER/AIR CONDITIONER OPERATOR UNIT (VERSION
WITHOUT CCC/ASK) .
NOTE: Comply with notes and instructions on handling optical waveguides . See 61
00 ... NOTES ON HANDLING OPTICAL FIBERS .
Release screws (1).
Pull back radio receiver (2) slightly.
Disconnect associated plug connections and remove radio receiver (2).
Installation:
Make sure the rear guide pin of the radio receiver (2) is correctly seated in the associated mounting.
2010 BMW M3
Fig. 3: Pulling Back Radio Receiver

Replacement:
Carry out programming/coding .
STEREO RADIO, AMPLIFIER

65 12 050 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT CENTRAL BASS
SPEAKER (UNDER FRONT SEAT)
NOTE: Procedure is for Sedan. Other models are similar.
Remove front seat . See SEATS - REPAIR (SEDAN) or SEATS - REPAIR INSTRUCTIONS
(CONVERTIBLE/COUPE) .
If necessary, remove panel for door pillar (bottom)
Release screws (1).
Remove central bass speaker trim (2) from floor trim (3).
Fold back floor panel (3) in direction of arrow.

2010 BMW M3
Fig. 4: Identifying Central Bass Speaker Trim And Floor Trim

NOTE: Floor panel shown removed for purposes of clarity.
Unscrew nuts (2).
Feed out central bass speaker (3) in direction of arrow and remove.
Fig. 5: Identifying Central Bass Speaker

Installation:
Make sure seal (3) and rubber damper (4) are correctly seated on central bass speaker (1).
Insert central bass speaker (1) with guides (2) exactly in frame side member.
2010 BMW M3
Fig. 6: Identifying Central Bass Speaker And Guides

65 12 070 REMOVING AND INSTALLING/REPLACING AMPLIFIER
IMPORTANT: Read and comply with notes on protection against electrostatic discharge (ESD
DISCHARGE) .

Remove luggage compartment trim on left . See 51 47 210 REMOVING AND
If necessary, remove video module
If necessary, remove CD changer
Release screws (1).
Remove amplifier (3) complete with holder (4).

2010 BMW M3
Fig. 7: Identifying Plug Connection And Screws

Replacement:
Release screw (2).
Unscrew nuts (4).
Fig. 8: Identifying Amplifier, Holder And Nuts

65 12 072 REMOVING AND INSTALLING (REPLACING) AMPLIFIER (TOP HI-FI SYSTEM)
DISCHARGE) .
2010 BMW M3
Disconnect negative battery cable . See 61 20 900 DISCONNECTING AND CONNECTING

Vehicles with CD changer or video module only:
Remove luggage compartment trim on left. See 51 47 210 REMOVING AND
Remove video module
Remove CD changer
Vehicles without CD changer or video module only:
Unclip cover (1) in direction of arrow from luggage compartment trim panel (2).
Fig. 9: Identifying Luggage Compartment Trim Panel And Unclip Cover

Shown with luggage compartment trim panel removed:
Pull out retaining plates (3) in direction of arrow.

2010 BMW M3
Fig. 10: Removing Amplifier From Holder

Replacement:
65 12 200 REMOVING AND INSTALLING (REPLACING) AUDIO SYSTEM CONTROLLER
DISCHARGE) .

Remove operator unit for heater/air conditioner (with CCC/ASK). See 64 11 377 REMOVING AND
WITHOUT CCC/ASK) .
Remove center console switch cluster (with CCC/ASK). See 61 31 054 REMOVING AND
INSTALLING/REPLACING CENTRE CONSOLE SWITCH CLUSTER (WITH CCC/ASK) .
Release screws (1).
Pull back audio system controller (2) slightly.
Remove audio system controller (2).

2010 BMW M3
Fig. 11: Identifying Audio System Controller And Screws

Replacement:
65 12 220 REMOVING AND INSTALLING/REPLACING SATELLITE RADIO (US VERSION ONLY)
DISCHARGE) .
NOTE: Follow instructions for handling optical fibres .

Remove luggage compartment floor panel . See 51 47 101 REMOVING AND
INSTALLING/REPLACING LUGGAGE COMPARTMENT FLOOR TRIM PANEL .
Release screws (2) and feed out satellite tuner (3).
Installation:
Unlock plug connections correctly.

Bracket (4) must be inserted in guides on floor pan.
2010 BMW M3
Fig. 12: Removing Satellite Tuner, Bracket And Screws

Replacement:
Release screws (1) and remove bracket (2) from satellite tuner (3).
Fig. 13: Remove Bracket From Satellite Tuner

DISCHARGE) .
NOTE: Follow instructions for handling optical fibres .

2010 BMW M3

Remove luggage compartment floor trim . See 51 47 101 REMOVING AND
E93:
Remove panel for luggage compartment partition . See 51 47 140 REMOVING AND
INSTALLING/REPLACING PANEL FOR LUGGAGE COMPARTMENT PARTITION .
Release screws (1).
Installation:
Fig. 14: Disconnect Plug Connections And Remove Bracket With DAB Tuner
Replacement:

2010 BMW M3
Fig. 15: Identifying DAB Tuner And Screws

SPEAKERS
65 13 050 REMOVING AND INSTALLING/REPLACING SPEAKER (TREBLE SPEAKER IN
QUARTERLIGHT MIRROR)
Detach cover on door window frame in front area (sedan) or front door trim panel (convertible).
NOTE: For purposes of clarity, cover on door window frame is removed.
Remove foam wedge (1) in direction of arrow from door window frame (2).
Installation:
Fit foam wedge (1) exactly over guide (3).

2010 BMW M3
Fig. 16: Identifying Door Window Frame And Foam Wedge

Unlock catches (1) and remove speaker (2) from cover on door window frame (3).
Disconnect plug connection and remove speaker.
Fig. 17: Identifying Speaker On Door Window Frame

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

INSTRUMENT PANEL)
Unclip trim for speaker cover (1) at fastening points (2) and (3) and remove
Fig. 18: Identifying Speaker Cover And Fastening Points

Release screws (1).
Remove speaker (2).

2010 BMW M3
Disconnect associated plug connection and remove speaker (2) towards top.
Fig. 19: Identifying Speaker And Screws

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

DOOR TRIM PANEL AT FRONT)
Remove front door trim . See 51 41 000 REMOVING AND INSTALLING LEFT OR RIGHT
FRONT DOOR TRIM PANEL .
NOTE: Secure speaker against falling out.
Release nuts (1) and remove speaker (2) in direction of arrow from door trim (3).
Tightening torque 65 13 1AZ , see 65 13 SPEAKERS .
NOTE: The studs for the speaker screw connection are microencapsulated.
Fig. 20: Removing Speaker And Nuts

2010 BMW M3
Build date E90 / E91 from CW 44/2005:

Fig. 21: Identifying External Capacitor And Integrated Capacitor (Build Date E90 / E91 From CW
44/2005)
Build date E87 from CW 44/2005:


2010 BMW M3
Fig. 22: Identifying External Capacitor And Integrated Capacitor (Build Date E87 From CW 44/2005)
65 13 080 REMOVING AND INSTALLING/REPLACING SPEAKER (TWEETER IN REAR DOOR)
Remove rear door trim . See 51 43 034 REMOVING AND INSTALLING/REPLACING REAR
LEFT OR RIGHT LOWER SIDE TRIM SECTION .
Disconnect plug connection (1) and remove cable (2) from mounting.
Release plastic nut (3) in counterclockwise direction and feed out speaker (4).
Installation:
Do not place plastic nut (3) on thread at a skewed angle.
Fig. 23: Release Plastic Nut, Feed Out Speaker And Plug Connection
2010 BMW M3
65 13 090 REMOVING AND INSTALLING/REPLACING SPEAKER (MID-RANGE SPEAKER,

DOOR AT REAR)
Remove rear door trim panel . See 51 43 034 REMOVING AND INSTALLING/REPLACING
REAR LEFT OR RIGHT LOWER SIDE TRIM SECTION .
Unscrew nuts (1).
Remove speaker (2) upwards out of rear door trim panel (3).
Tightening torque 65 13 1AZ , see 65 13 SPEAKERS .
Fig. 24: Identifying Rear Door Trim Panel, Speaker And Nuts
65 13 188 REMOVING AND INSTALLING/REPLACING REAR MID-RANGE SPEAKER (IN REAR

SHELF)
Special tools required:
00 9 340
See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .
Lever speaker cover (1) with special tool 00 9 340 out of rear shelf (2).
2010 BMW M3
Fig. 25: Identifying Rear Shelf And Lever Speaker Cover

Installation:
Lugs (1) and locks (2) of speaker cover (3) must not be damaged.
Fig. 26: Identifying Lugs, Locks And Speaker Cover

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

2010 BMW M3
Fig. 27: Identifying Mid-Range Speaker And Rear Shelf

65 13 195 REMOVING AND INSTALLING/REPLACING REAR TREBLE SPEAKER (IN REAR

SHELF)
Remove rear mid-range speaker
Release screws (2).
Remove rear treble speaker (3) from rear shelf (4).
Fig. 28: Identifying Rear Treble Speaker And Rear Shelf

65 13 400 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT FREQUENCY GATE

2010 BMW M3
Remove front door trim panel . See 51 41 000 REMOVING AND INSTALLING LEFT OR RIGHT
FRONT DOOR TRIM PANEL .
Release screws (2) and remove frequency gate.

AERIAL ANTENNA
MOUNTED AERIAL
65 2 010
See AUDIO, NAVIGATION AND ANTI-THEFT - SPECIAL TOOLS .
See .
NOTE: Clean roof.
2010 BMW M3
Fig. 30: Identifying Roof Surface


the roof.

Make sure your arms do not cross over (1) when holding special tool 65 2 010.

Cut through adhesive bead all round with special tool 65 2 010 .
Pull on handle (1) and align blade on handle (2).

2010 BMW M3
Fig. 32: Removing Cover Of Multiband Telephone Aerial

Installation:
Fig. 33: Identifying Centering Pins And Bounding Surface


2010 BMW M3
Dimensions:
A. 10 mm
B. 14 mm
Fig. 34: Positioning Spacer On Cleaned Aerial Cover

A. 6.5 mm 1 mm
exceed 3 mm 1 mm.
2010 BMW M3
Fig. 35: Identifying Adhesive Bead Diameter

If necessary, secure aerial cover with adhesive tape and do not press down on
one side of the aerial more firmly than the other.
65 20 035 REMOVING AND INSTALLING/REPLACING ROOF MOUNTED AERIAL/ANTENNA
Detach empty housing for roof-mounted aerial/antenna
Release screw (1) and feed out roof aerial/antenna (2) towards top.
Fig. 36: Identifying Roof Aerial And Screw

2010 BMW M3
Disconnect plug connections (1) and remove aerial/antenna (2).
Installation:
Do not mix up aerial/antenna connections (1).
Fig. 37: Identifying Plug Connections And Antenna

65 20 090 REMOVING AND INSTALLING OR REPLACING ANTENNA AMPLIFIER
Remove trim for auxiliary brake light . See 63 25 000 REMOVING AND
INSTALLING/REPLACING AUXILIARY BRAKE LIGHT .
Release screws (3).
Unlock plug connections (2) and (4) and disconnect.
Remove antenna amplifier (1).

2010 BMW M3
Fig. 38: Removing Antenna Amplifier

65 20 090 REMOVING AND INSTALLING OR REPLACING AERIAL AMPLIFIER

(CONVERTIBLE)
Necessary preliminary tasks: Remove luggage compartment trim on side panel. See 51 47 210 REMOVING
AND INSTALLING/REPLACING TRUNK TRIM PANEL ON LEFT SIDE PANEL .
Release screw (1). Disconnect plug connections (2) and remove antenna amplifier.
Fig. 39: Disconnect Plug Connections (2) And Remove Antenna Amplifier
65 20 130 REMOVING AND INSTALLING/REPLACING LEFT ANTENNA AMPLIFIER
Necessary preliminary tasks: Remove upper section of side trim panel. See 51 43 012 REMOVING AND
INSTALLING/REPLACING REAR LEFT OR RIGHT UPPER SIDE TRIM SECTION .
Disconnect plug connections (1) and feed out cable. Release screw (2). Remove antenna amplifier (3).
2010 BMW M3
Fig. 40: Disconnect Plug Connections (1) And Feed Out Cable
65 20 132 REMOVING AND INSTALLING/REPLACING RIGHT ANTENNA AMPLIFIER
Operation is identical to: Removing and installing/replacing left antenna amplifier.
65 20 140 REMOVING AND INSTALLING/REPLACING LEFT ANTENNA (AM/FM)
Necessary preliminary tasks: Remove upper section of side trim panel. See 51 43 012 REMOVING AND
Release retaining rings (1) and remove sound insulation (2).
Fig. 41: Release Retaining Rings (1) And Remove Sound Insulation (2).
Important! Antenna (1) must not be kinked. Remove antenna (1).

2010 BMW M3
Fig. 42: Remove Antenna (1)

65 20 142 REMOVING AND INSTALLING/REPLACING RIGHT ANTENNA (AM/FM)
Operation is identical to: Removing and installing/replacing left antenna.
65 20 150 REMOVING AND INSTALLING/REPLACING BACKUP ANTENNA
Remove panel for parcel shelf . See 51 46 001 REMOVING AND INSTALLING PANEL FOR
REAR WINDOW SHELF (PARCEL SHELF) .
Unscrew nuts (2).
Remove back-up antenna (3) from rear window shelf (4).
Fig. 43: Remove Back-Up Antenna From Rear Window Shelf

2010 BMW M3
65 20 220 REMOVING AND INSTALLING/REPLACING REAR WINDOW ANTENNA AMPLIFIER
Move lowerable hardtop into position shown.
Fig. 44: Move Lowerable Hardtop Into Position

Release screw (1) and disconnect plug connections (2).
Fig. 45: Release Screw (1) And Disconnect Plug Connections (2)
65 20 240 REMOVING AND INSTALLING/REPLACING TELEPHONE ANTENNA
Necessary preliminary tasks: Remove front wheel arch trim
Disconnect plug connection (1). Release nut (2), turn telephone antenna (3) and feed out.
2010 BMW M3
Fig. 46: Release Nut (2), Turn Telephone Antenna (3) And Feed Out
65 20 250 REMOVING AND INSTALLING/REPLACING REAR TELEPHONE ANTENNA
Necessary preliminary tasks: Remove rear bumper trim. Remove luggage compartment trim on left side panel.
See 51 47 210 REMOVING AND INSTALLING/REPLACING TRUNK TRIM PANEL ON LEFT SIDE
PANEL .
For purposes of clarity, the bumper bracket is shown removed. Release screw (1). Turn telephone antenna (2)
and feed out. Feed out lead (3) and disconnect associated plug connection.
Installation: Make sure grommet is correctly seated so as to avoid water ingress.
Fig. 47: Feed Out Lead (3) And Disconnect Associated Plug Connection
65 20 300 REMOVING AND INSTALLING/REPLACING BUMPER ANTENNA
Necessary preliminary tasks: Remove luggage compartment wheel arch trim on left. See 51 47 210
2010 BMW M3
REMOVING AND INSTALLING/REPLACING TRUNK TRIM PANEL ON LEFT SIDE PANEL .

Remove rear bumper trim.
Unclip cable fasteners (1).
Fig. 48: Unclip Cable Fasteners (1)

Pull out grommet (1). Installation: Make sure grommet (1) is correctly seated so as to avoid water ingress.
Fig. 49: Make Sure Grommet (1) Is Correctly Seated So As To Avoid Water Ingress
Disconnect plug connection (1) and feed out antenna lead.

2010 BMW M3
Fig. 50: Disconnect Plug Connection (1) And Feed Out Antenna Lead
65 20 350 REMOVING AND INSTALLING/REPLACING SUPPRESSION FILTER
Remove panel for roof pillar at rear left . See 51 43 251 REMOVING AND
INSTALLING/REPLACING TRIM PANEL FOR LEFT OR RIGHT REAR ROOF PILLAR (C-
PILLAR) .
Release screw (2).
Remove suppression filter (3) from C-pillar (4).
Fig. 51: Identifying Suppression Filter, C-Pillar And Screw

2010 BMW M3
Installation:
Fit suppression filter (1) so that screw (2) engages thread (3) and locating pin (4) engages bore (5).
Fig. 52: Identifying Suppression Filter, Locating Pin And Screws

65 20 780 REMOVING AND INSTALLING/REPLACING AERIAL OF GLOBAL POSITIONING

SYSTEM (GPS)
protection).
Necessary preliminary tasks: Remove roof switch cluster. See 61 31 043 REMOVING AND INSTALLING
OR REPLACING ROOF SWITCH CENTRE .
Disconnect plug connection (1). Unclip cable holder (2) from aerial holder for Global Positioning System (3).
Release screws (4). Remove aerial of Global Positioning System (3) from cowl panel (5).
Fig. 53: Removing Aerial Of Global Positioning System (3) From Cowl Panel (5)
2010 BMW M3
REAR WINDOW AERIAL ANTENNA

65 24 020 REMOVING AND INSTALLING OR REPLACING BLOCKING CIRCUIT
Remove panel for roof pillar on rear left .
Release screw (2).
Remove blocking circuit (3) from C-pillar (4).
Fig. 54: Removing Blocking Circuit From C-Pillar

Installation:
Fit blocking circuit (1) so that screw (2) engages thread (3) and locating pin (4) engages bore (5).
2010 BMW M3
Fig. 55: Installing Blocking Circuit

65 24 020 REMOVING AND INSTALLING/REPLACING BLOCKING CIRCUIT (LEFT OR RIGHT)
Move lowerable hardtop into position shown.
Fig. 56: Move Lowerable Hardtop Into Position Shown

Release screw (1) and disconnect plug connections (2).

2010 BMW M3
Fig. 57: Release Screw (1) And Disconnect Plug Connections (2)
Installation: Fit blocking circuit (1) so that screw (2) engages thread (3) and locating pin (4) engages bore (5).
Fig. 58: Fit Blocking Circuit (1) So Screw (2) Engages Thread (3) And Locating Pin (4) Engages Bore (5)
VIDEO AND TV EQUIPMENT

65 50 011 REMOVING AND INSTALLING (REPLACING) VIDEO MODULE FOR ON-BOARD
MONITOR
DISCHARGE) .

2010 BMW M3

Remove luggage compartment trim on left . See 51 47 101 REMOVING AND
NOTE: Follow instructions for handling optical fibres . See 61 00 ... NOTES ON
HANDLING OPTICAL FIBERS .
Unfasten screws (2) and nuts (3).
Pull back video module for on-board monitor (1) and disconnect plug connections.
Remove video module for on-board monitor (1) complete with holder.
Fig. 59: Identifying On-Board Monitor And Screw

Replacement:
Release screws (3) and remove holder (2) from video module for on-board monitor (1).
Fig. 60: Identifying Holder, On-Board Monitor And Screw

2010 BMW M3
Replacement:
ANTI-THEFT ALARM SYSTEM

65 75 055 REMOVING AND INSTALLING/REPLACING EMERGENCY POWER SIREN WITH
TILT SENSOR
Remove rear left wheel arch cover . See 51 71 041 REMOVING AND INSTALLING/REPLACING
REAR LEFT OR RIGHT WHEEL ARCH COVER .
Release screws (1) and lower complete mounting plate (2).
Unlock and disconnect associated plug connection, remove complete mounting plate (2).
Fig. 61: Lower Complete Mounting Plate

Release nut (1) and remove emergency power siren with tilt sensor (2) from mounting plate (3).
2010 BMW M3
Fig. 62: Removing Emergency Power Siren

65 75 071 REMOVING AND INSTALLING (REPLACING) MODULE FOR PASSENGER

COMPARTMENT SENSOR
DISCHARGE) .
Remove complete ceiling light (rear) . See 63 31 004 REMOVING AND INSTALLING OR
REPLACING COMPLETE CEILING LIGHT (REAR, WITH MODULE FOR PASSENGER
COMPARTMENT PROTECTION) .
Open retaining hooks (1) and feed module for passenger compartment sensor (2) in direction of arrow out of
trim (3) and remove.
Installation:
Retaining hooks (1) must not be damaged.

2010 BMW M3
Fig. 63: Identifying Passenger Compartment Sensor And Trim

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

MODULE IN LEFT OR RIGHT B-PILLAR
protection).
Remove lower section of side trim
Release screw (1). Detach interior movement detection module (2) in direction of arrow from side trim.
Fig. 64: Detach Interior Movement Detection Module

AIRBAG TRIGGERING UNIT

65 77 ... NOTES ON SCRAPPING BMW VEHICLES WITH GAS GENERATORS (CENTRAL
AIRBAG CONTROL UNIT, AIRBAG SYSTEM)
The gas generator is a pyrotechnic component of:
Airbag module
Side airbags
2010 BMW M3
Head airbag
Knee airbag
Belt pretensioner
Safety battery terminal
1 Series: E81, E82, E87, E88

3 Series: E46, E90, E91, E92, E93
X3: E83
X5: E53, E70
Z4: E85, E86
With above-mentioned vehicles which are scheduled for scrapping, it is always essential prior to draining and
further stripping work to ensure that all the gas generators in the vehicle are fired. The fired gas generators can
then be scrapped together with the vehicle.
Triggering failure
If correct triggering is not possible, the relevant components must (while observing the safety regulations for
handling airbag system components) be removed and disposed of by special disposal companies!
If a triggering operation has failed:
Disconnect the triggering device from the battery and

only approach the vehicle after a few minutes have elapsed
The components of an airbag system must always be disposed of. Such components must not be sold on as
used parts .
Triggering
Triggering of the gas generators may only be carried out by expert personnel and under the supervision of a
be observed.
The gas generators must be fired from the outside in the vehicle scheduled for scrapping with the doors closed
2010 BMW M3
but with the tailgate, door windows and sunroof open. To fire the gas generators, use the BMW-developed
triggering device with the corresponding cables.
inside the vehicle.
generator!
The burning of solid fuel will heat up airbag unit - danger of burning
hands!
1. Vehicles with central airbag control unit (all airbags, seat belt pretensioners, safety battery
terminal)
1. Expose airbag control unit .
2. Connect "Airbagmaster".
65 77 ... OVERVIEW OF SENSORS FOR AIRBAG SYSTEM

2010 BMW M3
Fig. 65: Identifying Airbag System Locations

65 77 016 REMOVING AND INSTALLING/REPLACING AIRBAG CONTROL UNIT
DISCHARGE) .
WARNING: Note airbag safety instructions!

Disconnect battery negative lead and cover. See 61 20 900 DISCONNECTING AND
2010 BMW M3
CONNECTING BATTERY NEGATIVE LEAD .

Remove storage compartment . See 51 16 200 REMOVING AND INSTALLING STORAGE
COMPARTMENT .
If necessary, remove foam cover from airbag control unit.
Release screw (2) and nuts (3).
Tightening torque 65 77 1AZ , see 65 77 AIRBAG TRIGGERING CONTROL .
Installation:
Before screwing down airbag control unit (4), make sure negative lead (5) is resting on associated threaded pin.
Remove airbag control unit (4) in direction of arrow.
Fig. 66: Removing Airbag Control Unit

Replacement:

ACCELERATION SENSOR
Unlock plastic fasteners (1) by turning counterclockwise through 180.
Feed flap (2) in direction of arrow out of front wheel arch cover (3) and remove.
2010 BMW M3
Fig. 67: Identifying Front Wheel Arch Cover And Flap

Release screws (1) and remove acceleration sensor (2).
Installation:
Replace screws (1).
Fig. 68: Identifying Acceleration Sensor And Plug


ACCELERATION SENSOR (CONVERTIBLE)

2010 BMW M3
Remove front wheel arch trim. .
Disconnect plug connection (1). Release screws (2) and remove sensor (3).
Fig. 69: Identifying Plug Connection, Screws And Sensor
Installation: Replace screws. Tightening torque 65 77 9AZ, see 65 77 AIRBAG TRIGGERING CONTROL .
65 77 601 REPLACING SENSOR MAT FOR FRONT PASSENGER SEAT OCCUPANCY DETECTOR
(SPORT SEAT)
Replacing sensor mat for front passenger seat occupancy detector .

(CONVERTIBLE)
DISCHARGE) .

Remove rear side trim panel . See 51 43 034 REMOVING AND INSTALLING/REPLACING
2010 BMW M3
Release screw (2) and disconnect plug connection (2). Tightening torque 65 77 5AZ, see 65 77 AIRBAG
TRIGGERING CONTROL .
Fig. 70: Release Screw (2) And Disconnect Plug Connection (2)
Installation: Establish correct positioning of B-pillar sensor (1) by means of guide pin (2) and screw (3).
Fig. 71: Establish Correct Positioning Of B-Pillar Sensor (1) By Means Of Guide Pin (2) And Screw (3)
DISCHARGE) .

2010 BMW M3
Remove trim panel for door pillar (bottom)
Release screw (1).
Loosen screw (2).
Installation:
If necessary, remove B-pillar sound insulation (5).
Raise B-pillar sensor (3) slightly through opening in B-pillar and feed out towards rear.
Remove B-pillar sensor (3) from B-pillar.
Fig. 72: Identifying B-Pillar Sensor And B-pillar Sound Insulation

Installation:
Establish correct positioning of B-pillar sensor (1) by means of guide pin (2) and screw (3).
2010 BMW M3
Fig. 73: Identifying B-Pillar Sensor And Screw

65 77 725 REMOVING AND INSTALLING/REPLACING RIGHT B-PILLAR SENSOR
Removing and installing left B-pillar sensor or 65 77 720 Removing and installing (replacing) left B-pillar
sensor (Convertible).
65 77 740 REMOVING AND INSTALLING (REPLACING) LEFT FRONT DOOR SENSOR
DISCHARGE) .

Incorrect handling can activate airbag and cause injury. See 72 00 ...
SAFETY REGULATIONS FOR HANDLING COMPONENTS WITH GAS
GENERATORS .
Detach sound insulation in work area. See 51 48 060 REMOVING AND

INSTALLING/REPLACING SOUND INSULATION IN LEFT OR RIGHT FRONT DOOR .
Release screw (2).
Remove sensor with pin (3) from door panel fit (4) towards rear.
2010 BMW M3
Installation:
Make sure fit (3) is correctly seated.
Fig. 74: Remove Sensor With Pin From Door Panel

65 77 745 REMOVING AND INSTALLING/REPLACING RIGHT FRONT DOOR SENSOR
Removing and installing (replacing) left front door sensor
65 77 770 REMOVING AND INSTALLING (REPLACING) ROLLOVER CONTROLLER
Important! Read and comply with notes on protection against electrostatic damage (ESD protection).
Necessary preliminary tasks: Remove panel for passenger compartment partition. See 51 47 143 REMOVING
AND INSTALLING/REPLACING PANEL FOR PASSENGER COMPARTMENT PARTITION .
Release expansion rivets (1). Fold back insulating mat (2).

2010 BMW M3
Fig. 75: Release Expansion Rivets And Fold Back Insulating Mat
Disconnect plug connection (1). Release screws (2). Remove rollover controller.
Fig. 76: Disconnect Plug Connection (1), Release Screws (2) And Remove Rollover Controller
Function check with BMW diagnosis system: Trigger/retract rollover protection system.
72 12 ... OVERVIEW OF AIRBAG MODULES, AIRBAG CONTROL UNIT, BELT TENSIONERS

2010 BMW M3
Fig. 77: Identifying Airbag Modules, Airbag Control Unit And Belt Tensioners
ON-BOARD COMPUTER
65 81 060 REMOVING AND INSTALLING/REPLACING OUTSIDE TEMPERATURE SENSOR (M3)
Installation:
2010 BMW M3
Fig. 78: Identifying Engine Compartment Shield And Screws

Unclip outside temperature sensor (2) in direction of arrow and remove.
Installation:
Outside temperature sensor (2) must audibly snap into place.
Ensure correct seating in air duct (3).
Fig. 79: Identifying Outside Temperature Sensor And Air Duct

CENTRAL DISPLAY
65 82 050 REMOVING AND INSTALLING (REPLACING) ONBOARD MONITOR
2010 BMW M3
DISCHARGE) .
IMPORTANT: Proceed with care so as to avoid damaging the on-board monitor and adjoining
trims.
Release screws (1).
Fold out on-board monitor (2) in direction of arrow.
Fig. 80: Identifying On-Board Monitor And Screws

Installation:
Remove on-board monitor (2).

2010 BMW M3
Fig. 81: Identifying On-Board Monitor And Plug Connections

Replacement:
CAR COMMUNICATION COMPUTER

65 83 010 REMOVING AND INSTALLING/REPLACING CAR COMMUNICATION COMPUTER
DISCHARGE) .
Clamp off battery negative lead . See 61 20 900 DISCONNECTING AND CONNECTING
Remove center console switch center . See 61 31 054 REMOVING AND
Release bolts (1).
Pull back Car Communication Computer (2) slightly.
Remove Car Communication Computer (2).

2010 BMW M3
Fig. 82: Identifying Car Communication Computer

Replacement:
65 83 020 REMOVING AND INSTALLING/REPLACING CAR INFOTAINMENT COMPUTER
DISCHARGE) .
Remove center console switch cluster . See 61 31 054 REMOVING AND
Release bolts (1).
Pull back Car Infotainment Computer (2) slightly.
Remove Car Infotainment Computer (2).

2010 BMW M3
Fig. 83: Identifying Car Infotainment Computer

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

COMPUTER
DISCHARGE) .
Remove Car Communication Computer
Raise retaining hook (1) and turn fan for Car Communication Computer (2) in direction of arrow.
Remove fan for Car Communication Computer (2) from Car Communication Computer (3).
2010 BMW M3
Fig. 84: Identifying Retaining Hook And Car Communication Computer

65 83 560 REMOVING AND INSTALLING/REPLACING FRONT TRIM FOR CAR

DISCHARGE) .
Release screws (1).
Fold down front panel for Car Communication Computer (2) and set down.
Installation:
Make sure retaining lugs (3) of front panel for Car Communication Computer (2) are correctly seated.
2010 BMW M3
Fig. 85: Identifying Car Communication Computer And Retaining Lugs

NOTE: "LIF" stands for Low Insertion Force.
Open catch of LIF plug (2) in direction of arrow and feed out LIF cable (1).
Remove front trim for Car Communication Computer (4) from Car Communication Computer (3).
Fig. 86: Removing Front Trim For Car Communication Computer

65 83 570 REMOVING AND INSTALLING/REPLACING CD DRIVE FOR CAR COMMUNICATION

COMPUTER
64 1 020
See HEATING AND AIR CONDITIONING - SPECIAL TOOLS .

2010 BMW M3
protection)! . See61 35 ... NOTES ON ESD PROTECTION (ELECTRO STATIC
DISCHARGE) .
Remove front trim for Car Communication Computer
Raise cover (1) with special tool 64 1 020 all round and remove from Car Communication Computer (2).

Release bolts (1).
Feed CD drive for Car Communication Computer (2) in direction of arrow out of Car Communication
Computer (3) and set down.
Installation:

2010 BMW M3
Fig. 88: Identifying Car Communication Computer

Release bolts (1).
Remove CD drive trim (2) in direction of arrow from CD drive for Car Communication Computer (3).
Installation:
Fig. 89: Identifying CD Drive Trim And Car Communication Computer

Cut through warranty seal (1) at marked point.
Release screw (2).
Lift side cover out of mounting (3) and carefully place to one side.
2010 BMW M3
Fig. 90: Lifting Side Cover Of Mounting

Disconnect plug connection (1) and remove CD drive.
Installation:
Fig. 91: Identifying Plug Connection And CD Drive

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

00 9 450
12 7 192
64 1 020
2010 BMW M3
See ENGINE ELECTRICAL SYSTEM - SPECIAL TOOLS .
DISCHARGE) .
Risk of damage!
Place Car Communication Computer on special tool 12 7 192 (antistatic mat)
and earth/ground.
Remove front trim for Car Communication Computer
Raise cover (1) with special tool 64 1 020 all round and remove from Car Communication Computer (2).

Release bolts (1).
Feed out bridge (2).
Installation:
Use special tool 00 9 450 to tighten down screws.

2010 BMW M3
Fig. 93: Identifying Bridge And Bolts

Cut through stickers at marked points (1).
Release screws (2) and remove trim (3).
Installation:
Use special tool 00 9 450 to tighten down screws.
Fig. 94: Identifying Trim And Screws

Release screws (1) with magnetic screwdriver.
Installation:
Lug (2) of DVD drive must be above lug (3) of Car Communication Computer.
2010 BMW M3
Fig. 95: Identifying Lug Of Car Communication Computer

Turn Car Communication Computer through 180 and carefully feed out DVD drive.
Carefully disconnect plug connections (1, 2).
Remove DVD drive (3).
Installation:
Fig. 96: Identifying Plug Connections And DVD Drive

After installation:
On cars before March 2006 it is essential after replacing the DVD drive to carry out a measures plan or a
software update as per SSS/Progman/CIP .
2010 BMW M3
65 83 590 REMOVING AND INSTALLING/REPLACING GYRO SENSOR DRIVE FOR CAR

DISCHARGE) .
Release bolts (1).
Remove floor pan (2) towards bottom and set down.
short-circuiting!
Fig. 97: Identifying Floor Pan, Spring Strip And Bolt

Release bolt (1).
Detach gyro sensor for Car Communication Computer (2) in direction of arrow from plug-in contact (3).
2010 BMW M3
Fig. 98: Detaching Gyro Sensor For Car Communication Computer

65 83 600 REPLACING HIP MODULE FOR CAR COMMUNICATION COMPUTER
DISCHARGE) .
Release screws (1).
Remove cover (2) towards top.
short-circuiting!
2010 BMW M3
Fig. 99: Identifying Spring Strip, Floor Pan And Screw

Press catches (1) and feed out HIP module (2) in direction of arrow.
Installation:
Make sure front guides (3) of HIP module (2) are correctly seated.
Fig. 100: Pressing Catches And HIP Module

Disconnect plug connection (1) in direction of arrow and remove HIP module (2).
2010 BMW M3
Fig. 101: Disconnecting Plug Connection Of HIP Module

After installation:
Cars with out-of-date software status at time of repair:
After replacing the HIP module, program the Car Communication Computer. Then take the car for an
initialization drive.
Cars with current software status at time of repair:
After replacing the HIP module, take the car for an initialization drive.
Initialization drive:
Drive for 15-20 minutes at 50 km/h and with good GPS reception until correct vehicle position is achieved in
the navigation display.
NOTE: During this time, the position pointer of the navigation system can be
motionless or move across country.
2010 BMW M3
GENERAL INFORMATION Trouble Shooting - Basic Procedures
GENERAL INFORMATION
Trouble Shooting - Basic Procedures
NOTE: This is GENERAL information. This article is not intended to be specific to any
unique situation or individual vehicle configuration. The purpose of this Trouble
Shooting information is to provide a list of common causes to problem
symptoms. For model-specific Trouble Shooting, refer to SUBJECT,
DIAGNOSTIC, or TESTING articles available in the section(s) you are accessing.
ACCESSORIES & ELECTRICAL

CHARGING SYSTEM TROUBLE SHOOTING
BASIC CHARGING SYSTEM TROUBLE SHOOTING CHART

CONDITION & POSSIBLE CAUSE CORRECTION
Vehicle Will Not Start
Dead battery Check battery cells, alternator
belt tension and alternator
output
Loose or corroded battery connections Check all charging system
connections
Ignition circuit or switch malfunction Check and replace as necessary
Alternator Light Stays On With Engine Running
Loose or worn alternator drive belt Check alternator drive tension
and condition, See Belt
Adjustment in TUNE-UP
article in the TUNE-UP section
Loose alternator wiring connections Check all charging system
connections
2010 BMW M3
Short in alternator light wiring See Indicator Warning Lights in

STANDARD INSTRUMENTS
in the ACCESSORIES &
EQUIPMENT section
Defective alternator stator or diodes See Bench Tests in
ALTERNATOR article
Defective regulator See Regulator Check in
ALTERNATOR article
Alternator Light Stays Off With Ignition Switch ON
Blown fuse See WIRING DIAGRAMS
Defective alternator See Testing in ALTERNATOR
article
Defective indicator light bulb or socket See Indicator Warning Lights in
STANDARD INSTRUMENTS
in the ACCESSORIES &
EQUIPMENT section
Alternator Light Stays OFF With Ignition Switch ON
Short in alternator wiring See On-Vehicle Tests in
ALTERNATOR article
Defective rectifier bridge See Bench Tests in
ALTERNATOR article
Lights or Fuses Burn Out Frequently
Defective alternator wiring See On-Vehicle Tests in
ALTERNATOR article
Defective regulator See Regulator Check in
ALTERNATOR article
Defective battery Check and replace as necessary
Ammeter Gauge Shows Discharge
Loose or worn drive belt Check alternator drive belt
tension and condition. See Belt
Adjustment in TUNE-UP
article in the TUNE-UP section
Defective wiring Check all wires and wire
connections
Defective alternator or regulator See Bench Tests and On-
Vehicle Tests in
ALTERNATOR article
Defective ammeter, or improper ammeter wiring connection See Testing in STANDARD
INSTRUMENTS in the
ACCESSORIES &
EQUIPMENT section
Noisy Alternator
Loose drive pulley Tighten drive pulley attaching
nut
2010 BMW M3
Loose mounting bolts Tighten all alternator mounting

bolts
Worn or dirty bearings See Bearing Replacement
ALTERNATOR article
Defective diodes or stator See Bench Test in
ALTERNATOR article
Battery Does Stay Charged
Loose or worn drive belt Check alternator drive belt
tension and condition. See Belt
Adjustment in appropriate
TUNE-UP article in the TUNE-
UP section
Loose or corroded battery connections Check all charging system
connections
Loose alternator connections Check all charging system
connections
Defective alternator or battery See On-Vehicle Tests and
Bench Tests in ALTERNATOR
article
Add-on electrical accessories exceeding alternator capacity Install larger alternator
Battery Overcharged-Uses Too Much Water
Defective battery Check alternator output and
repair as necessary
Defective alternator See On-Vehicle Test and Bench
Tests in ALTERNATOR article
Excessive alternator voltage Check alternator output and
repair as necessary
IGNITION SYSTEM TROUBLE SHOOTING
2010 BMW M3
Fig. 1: Ignition Secondary Trouble Shooting Chart

2010 BMW M3
2010 BMW M3
Fig. 2: Ignition Primary Trouble Shooting Chart
STARTER TROUBLE SHOOTING
BASIC STARTER TROUBLE SHOOTING CHART

Starter Fails to Operate
Dead battery or bad connections between starter and battery Check battery charge and all
wires and connections to
starter
Ignition switch faulty or misadjusted Adjust or replace ignition
switch
Open circuit between starter switch ignition terminal on starter Check and repair wires and
relay connections as necessary
Starter relay or starter defective See Testing in STARTER
article
Open solenoid pull-in wire Testing in STARTER article
Starter Does Not Operate and Headlights Dim
Weak battery or dead cell Charge or replace battery as
necessary
Loose or corroded battery connections Check that battery connections
are clean and tight
Internal ground in starter windings See Testing in STARTER
article
Grounded starter fields See Testing in STARTERS
Armature rubbing on pole See STARTER article shoes
Starter Turns but Engine Does Not Rotate
Starter clutch slipping See STARTER article
Broken clutch housing See STARTER article
Pinion shaft rusted or dry See STARTER article
Engine basic timing incorrect See Ignition Timing in TUNE-
UP article
Broken teeth on engine flywheel Replace flywheel and check
for starter pinion gear damage
Starter Will Not Crank Engine
Faulty overrunning clutch See STARTER article
2010 BMW M3
Broken flywheel teeth Replace flywheel and check

for starter pinion gear damage
Armature shaft sheared or reduction gear teeth stripped See STARTER article
Weak battery Charge or replace battery as
necessary
Faulty solenoid See On-Vehicle Tests in
STARTER article
Poor grounds Check all ground connections
for tight and clean connections
switch as necessary
Starter Cranks Engine Slowly
Battery weak or defective Charge or replace battery as
necessary
Engine overheated See ENGINE COOLING
SYSTEM article
Engine oil too heavy Check that proper viscosity oil
is used
Poor battery-to-starter connections Check that all between battery
and starter are clean and tight
Current draw too low or too high See Bench Tests in STARTER
article
Bent armature, loose pole shoes screws or worn bearing See STARTER article
Burned solenoid contacts Replace solenoid
Faulty starter Replace starter
Starter Engages Engine Only Momentarily
Engine timing too far advanced See Ignition Timing in TUNE-
UP article
Overrunning clutch not engaging properly Replace overrunning clutch.
See STARTER article
Broken starter clutch See STARTER article
starter pinion gear for damage
Weak drive assembly thrust spring See STARTER article
Weak hold-in coil See Bench Tests in STARTER
article
Starter Drive Will Not Engage
Defective point assembly See Testing in STARTER
article
Poor point assembly ground See Testing in STARTER
article
Defective pull-in coil Replace starter solenoid
Starter Relay Does Not Close
2010 BMW M3
Dead battery Charge or replace battery as

necessary
Faulty wiring Check all wiring and
connections leading to relay
Neutral safety switch faulty Replace neutral safety switch
Starter relay faulty Replace starter relay
Starter Drive Will Not Disengage
Starter motor loose on mountings Tighten starter attach bolts
Worn drive end bushing See STARTER article
Damaged engine flywheel teeth Replace flywheel and starter
pinion gear for damage
Drive yolk return spring broken or missing Replace return spring
Faulty ignition switch Replace ignition switch
Insufficient clearance between winding leads to solenoid terminal Replace starter solenoid
and main contact in solenoid
Starter clutch not disengaging Replace starter clutch
Ignition starter switch Replace ignition switch
contacts sticking
Starter Relay Operates but Solenoid Does Not
Faulty solenoid switch, switch connections or relay Check all wiring between relay
and solenoid or replace relay
or solenoid as necessary
Broken lead or loose soldered connections Repair wire or wire
connections as necessary
Solenoid Plunger Vibrates When Switch is Engaged
necessary
Solenoid contacts corroded Clean contacts or replace
solenoid
Faulty wiring Check all wiring leading to
solenoid
Broken connections inside switch cover Repair connections or replace
solenoid
Open hold-in wire solenoid
Low Current Draw
Worn brushes or weak brush springs Replace brushes or brush
springs as necessary
High Pitched Whine During Cranking Before Engine Fires but Engine Fires and Cranks Normally
Distance too great between starter pinion and flywheel Align starter or check that
correct starter and flywheel are
being used
High Pitched Whine After Engine Fires With Key released. Engine Fires and Cranks Normally
Distance too small between starter pinion and flywheel Flywheel runout contributes to
2010 BMW M3
the intermittent nature
AIR CONDITIONING & HEAT

AIR CONDITIONING TROUBLE SHOOTING
WARNING: This is GENERAL information. This article is not intended to be specific to

any unique situation or individual vehicle configuration. The purpose of
this Trouble Shooting information is to provide a list of common causes
to problem symptoms. For model-specific Trouble Shooting, refer to
SUBJECT, DIAGNOSTIC, or TESTING articles available in the section(s)
you are accessing.
BASIC AIR CONDITIONING TROUBLE SHOOTING CHART

CONDITION POSSIBLE CAUSE
Compressor Not Working Compressor clutch circuit open.
..... Compressor clutch coil inoperative.
..... Poor clutch ground connection.
..... Fan belts loose.
..... Thermostatic switch inoperative.
..... Thermostatic switch not adjusted.
..... Ambient temperature switch open.
..... Superheat fuse blown.
Excessive Noise or Vibration Missing or loose mounting bolts.
..... Bad idler pulley bearings.
..... Fan belts not tightened correctly.
..... Compressor clutch contacting body.
..... Excessive system pressure.
..... Compressor oil level low.
..... Damaged clutch bearings.
..... Damaged reed valves.
..... Damaged compressor.
Insufficient or No Cooling; Expansion valve inoperative.
Compressor Working
..... Heater control valve stuck open.
..... Low system pressure.
..... Blocked condenser fins.
..... Blocked evaporator fins.
..... Vacuum system leak.
..... Vacuum motors inoperative.
..... Control cables improperly adjusted.
..... Restricted air inlet.
2010 BMW M3
..... Mode doors binding.

..... Blower motor inoperative.
..... Temperature above system capacity.
HEATER SYSTEM TROUBLE SHOOTING
symptoms. For model-specific Trouble Shooting, refer to DIAGNOSTIC, or
TESTING articles available in the section(s) you are accessing.
BASIC HEATER SYSTEM TROUBLE SHOOTING CHART

Insufficient, Erratic, or No Heat Low Coolant Level
..... Incorrect thermostat.
..... Restricted coolant flow through core.
..... Heater hoses plugged.
..... Misadjusted control cable.
..... Sticking heater control valve.
..... Vacuum hose leaking.
..... Vacuum hose blocked.
..... Vacuum motors inoperative.
..... Blocked air inlet.
..... Inoperative heater blower motor.
..... Oil residue on heater core fins.
..... Dirt on heater core fins.
Too Much Heat Improperly adjusted cables.
..... Sticking heater control valve.
..... No vacuum to heater control valve.
..... Temperature door stuck open.
Air Flow Changes During Vacuum system leak.
Acceleration
..... Bad check valve or reservoir.
Air From Defroster At All Times Vacuum system leak.
..... Improperly adjusted control cables.
..... Inoperative vacuum motor.
Blower Does Not Operate Correctly Blown fuse.
..... Blower motor windings open.
..... Resistors burned out.
..... Motor ground connection loose.
..... Wiring harness connections loose.
2010 BMW M3
..... Blower motor switch inoperative.

..... Blower relay inoperative.
..... Fan binding or foreign object in housing.
..... Fan blades broken or bent.
BRAKES
BRAKE SYSTEM TROUBLE SHOOTING
BRAKE SYSTEM TROUBLE SHOOTING CHART

Brakes Pull Left or Right
Incorrect tire pressure Inflate tires to proper pressure
Front end out of alignment See WHEEL ALIGNMENT
Mismatched tires Check tires sizes
Restricted brake lines or hoses Check hose routing
Loose or malfunctioning caliper See DISC BRAKES or
BRAKE SYSTEM
Bent shoe or oily linings See DRUM BRAKES or
BRAKE SYSTEM
Malfunctioning rear brakes See DRUM, DISC BRAKES
or BRAKE SYSTEM
Loose suspension parts See SUSPENSION
Noises Without Brakes Applied
Front linings worn out Replace linings
Dust or oil on drums or rotors See DRUM, DISC BRAKES
or BRAKE SYSTEM
Noises With Brakes Applied
Insulator on outboard shoe damaged See DISC BRAKES or
BRAKE SYSTEM
Incorrect pads or linings Replace pads or linings
Brake Rough, Chatters or Pulsates
Excessive lateral runout Check rotor runout
Parallelism not to specifications Reface or replace rotor
Wheel bearings not adjusted See SUSPENSION
Rear drums out-of-round Reface or replace drums
2010 BMW M3
Disc pad reversed, steel against rotor Remove and reinstall pad
Excessive Pedal Effort
Malfunctioning power unit See POWER BRAKES or
BRAKE SYSTEM
Partial system failure Check fluid and pipes
Worn disc pad or lining Replace pad or lining
Caliper piston stuck or sluggish See DISC BRAKES or
BRAKE SYSTEM
Master cylinder piston stuck See MASTER CYLINDERS
or BRAKE SYSTEM
Brake fade due to incorrect pads for linings Replace pads or linings
Linings or pads glazed Replace pads or linings
Worn drums Reface or replace drums
Excessive Pedal Travel
Partial brake system failure Check fluid and pipes
Insufficient fluid in master cylinder See MASTER CYLINDERS
or BRAKE SYSTEM
Air trapped in system See BRAKE BLEEDING or
BRAKE SYSTEM
Rear brakes not adjusted See Adjustments in DRUM
BRAKES or BRAKE
SYSTEM
Bent shoe or lining See DRUM BRAKES or
BRAKE SYSTEM
Plugged master cylinder cap See MASTER CYLINDERS
or BRAKE SYSTEM
Improper brake fluid Replace brake fluid
Pedal Travel Decreasing
Compensating port plugged See MASTER CYLINDERS
or BRAKE SYSTEM
Swollen cup in master cylinder See MASTER CYLINDERS
or BRAKE SYSTEM
Master cylinder piston not returning See MASTER CYLINDERS
or BRAKE SYSTEM
Weak shoe retracting springs See DRUM BRAKES
BRAKE SYSTEM
Wheel cylinder piston sticking See DRUM BRAKES or
BRAKE SYSTEM
Dragging Brakes
Master cylinder pistons not returning See MASTER CYLINDERS
BRAKE SYSTEM
Restricted brake lines or hoses Check line routing
Incorrect parking brake adjustment See DRUM BRAKES
2010 BMW M3
BRAKE SYSTEM
Parking Brake cables frozen See DRUM BRAKES
BRAKE SYSTEM
Incorrect installation of inboard disc pad Remove and replace correctly
Power booster output rod too long See POWER BRAKE UNITS
BRAKE SYSTEM
Brake pedal not returning freely See DISC, DRUM BRAKES
BRAKE SYSTEM
Brakes Grab or Uneven Braking Action
Malfunction of combination valve See CONTROL VALVE or
BRAKE SYSTEM
Malfunction of power brake unit See POWER BRAKE UNITS
or BRAKE SYSTEM
Binding brake pedal See DISC, DRUM BRAKES
or BRAKE SYSTEM
Pulsation or Roughness
Uneven pad wear caused by caliper See DISC BRAKES or
BRAKE SYSTEM
Uneven rotor wear See DISC BRAKES or
BRAKE SYSTEM
Drums out-of-round Reface or replace drums
ENGINE MECHANICAL
COOLING SYSTEM TROUBLE SHOOTING
COOLING SYSTEM TROUBLE SHOOTING

Overheating
Coolant Leak Fill/Pressure Test System
A/C Condenser Fins Clogged Remove/Clean Condenser
Radiator Fins Clogged Remove/Clean Radiator
Thermostat Stuck Closed Replace Thermostat
Clogged Cooling System Passages Clean/Flush Cooling System
Water Pump Malfunction Replace Water Pump
Fan Clutch Malfunction Replace Fan Clutch
Retarded Ignition Timing Reset Ignition Timing
2010 BMW M3
Cooling Fan Malfunction Test Cooling Fan/Circuit

Cooling Fan Motor Malfunction Test Fan Motor
Cooling Fan Relay Malfunction Test Fan Relay
Faulty Radiator Cap Replace Radiator Cap
Broken/Slipping Fan Belt Replace Fan Belt
Restricted Exhaust Repair Exhaust System
Corrosion
Impurities In Coolant Clean/Flush System
Coolant Leakage
Damaged hose Replace Hose
Leaky Water Pump Replace Water Pump
Damaged Radiator Seam Replace/Repair Radiator
Leaky Thermostat Cover Replace Thermostat Cover
Cylinder Head Problem Check Head/Head Gasket
Leaky Freeze Plugs Replace Freeze Plugs
Recovery System Inoperative
Loose and/or Defective Radiator Cap Replace Radiator Cap
Overflow Tube Clogged and/or Leaking Repair Tube
Recovery Bottle Vent Restricted Clean Vent
No Heater Core Flow
Collapsed Heater Hose Replace Heater Hose
Plugged Heater Core Clean/Replace Heater Core
Faulty Heater Valve Replace Heater Valve
GASOLINE ENGINE - MECHANICAL TROUBLE SHOOTING
BASIC GASOLINE ENGINE - MECHANICAL TROUBLE SHOOTING CHART

Engine Lopes At Idle
Intake manifold-to-head leaks Replace manifold gasket, See
ENGINES
Blown head gasket Replace head gasket, See
ENGINES
Worn timing gears, chain or sprocket Replace gears, chain or
sprocket
Worn camshaft lobes Replace camshaft, See
2010 BMW M3
ENGINES
Overheated engine Check cooling system, See
COOLING
Blocked crankcase vent valve Remove restriction
Leaking EGR valve Repair leak and/or replace
valve
Faulty fuel pump Replace fuel pump
Engine Has Low Power
Leaking fuel pump Repair leak and/or replace
fuel pump
Excessive piston-to-bore clearance Install larger pistons, See
ENGINES
Sticking valves or weak valve springs Check valve train
components, See ENGINES
Incorrect valve timing Reset valve timing, See
ENGINES
ENGINES
Blown head gasket Replace head gasket. See
ENGINES.
Clutch slipping Adjust pedal and/or replace
components, See ENGINES
Engine overheating Check cooling system, See
COOLING
Auto. Trans. pressure regulator valve faulty Replace pressure regulator
valve
Auto. Trans. fluid level too low Add fluid as necessary
Improper vacuum diverter valve operation Replace vacuum diverter
valve
Vacuum leaks Inspect vacuum system and
repair as required
Leaking piston rings Replace piston rings, See
ENGINES
Faulty High Speed Operation
Low fuel pump volume Replace fuel pump
Leaking valves or worn Replace valves and/or springs,
See ENGINES
Incorrect valve timing Reset valve timing,See
ENGINES
Intake manifold restricted Remove restriction
Worn distributor shaft Replace distributor
Faulty Acceleration
Improper fuel pump stroke Remove pump and reset pump
2010 BMW M3
stroke
Incorrect ignition timing Reset ignition timing, See
TUNE-UP
Leaking valves Replace valves, See
ENGINES
Worn fuel pump diaphragm or piston Replace diaphragm or piston
Intake Backfire
Improper ignition timing Reset ignition timing, See
TUNE-UP
Faulty accelerator pump discharge Replace accelerator pump
Improper choke operation Check choke and adjust as
required
Defective EGR valve Replace EGR valve
Fuel mixture too lean Reset air/fuel mixture, See
TUNE-UP
Choke valve initial clearance too large Reset choke valve initial
clearance
Exhaust Backfire
Vacuum leak Inspect and repair vacuum
system
Faulty vacuum diverter valve Replace vacuum diverter
valve
Faulty choke operation Check choke and adjust as
required
Exhaust system leak repair exhaust system leak
Engine Detonation
Ignition timing too far advanced Reset ignition timing, See
TUNE-UP
Faulty ignition system Check ignition timing, See
TUNE-UP
Spark plugs loose or faulty Retighten or replace plugs
Fuel delivery system clogged Inspect lines, pump and filter
for clog
EGR valve inoperative Replace EGR valve
PCV system inoperative Inspect and/or replace hoses
or valve
Vacuum leaks Check vacuum system and
repair leaks
Excessive combustion chamber deposits Remove built-up deposits
Leaking, sticking or broken valves Inspect and/or replace valves
External Oil Leakage
Fuel pump improperly seated or worn gasket Remove pump, replace gasket
and seat properly
2010 BMW M3
Oil pan gasket broken or pan bent Straighten pan and replace
gasket
Timing chain cover gasket broken Replace timing chain cover
gasket
Rear main oil seal worn Replace rear main oil seal
Oil pan drain plug not seated properly Remove and reinstall drain
plug
Camshaft bearing drain hole blocked Remove restriction
Oil pressure sending switch leaking Remove and reinstall sending
switch
Excessive Oil Consumption
Worn valve stems or guides Replace stems or guides, See
ENGINES
Valve "O" ring seals damaged Replace "O" ring seals, See
ENGINES
Plugged oil drain back holes Remove restrictions
Improper PCV valve operation Replace PCV valve
Engine oil level too high Remove excess oil
Engine oil too thin Replace thicker oil
Valve stem oil deflectors damaged Replace oil deflectors
Incorrect piston rings Replace piston rings, See
ENGINES
Piston ring gaps not staggered Reinstall piston rings, See
ENGINES
Insufficient piston ring tension Replace rings, See ENGINES
Piston ring grooves or oil return slots clogged Replace piston
rings, See ENGINES
Piston rings sticking in grooves Replace piston rings, See
ENGINES
Piston ring grooves excessively worn Replace piston and rings, See
ENGINES
Compression rings installed upside down Replace compression rings
correctly, See ENGINES
Worn or scored cylinder walls Rebore cylinders or replace
block
Mismatched oil ring expander and rail Replace oil ring expander and
rail, See ENGINES
Intake gasket dowels too long Replace intake gasket dowels
Excessive main or connecting rod bearing clearance Replace main or connecting
rod bearings, See ENGINES
No Oil Pressure
Low oil level Add oil to proper level
Oil pressure sender or gauge broken Replace sender or gauge
2010 BMW M3
Oil pump malfunction Remove and overhaul oil

pump, See ENGINES
Oil pressure relief valve sticking Remove and reinstall valve
Oil pump passages blocked Overhaul oil pump, See
ENGINES
Oil pickup screen or tube blocked Remove restriction
Loose oil inlet tube Tighten oil inlet tube
Loose camshaft bearings Replace camshaft bearings,
See ENGINES
Internal leakage at oil passages Replace block or cylinder
head
Low Oil Pressure
Low engine oil level Add oil to proper level
Engine oil too thin Remove and replace with
thicker oil
Excessive oil pump clearance Reduce oil pump clearance,
See ENGINES
Oil pickup tube or screen blocked Remove restrictions
Main, rod or cam bearing clearance excessive Replace bearing to reduce
clearance, See ENGINES
High Oil Pressure
Improper grade of oil Replace with proper oil
Oil pressure relief valve stuck closed Eliminate binding
Oil pressure sender or gauge faulty Replace sender or gauge
Noisy Main Bearings
Inadequate oil supply Check oil delivery to main
bearings
Excessive main bearing clearance Replace main bearings, See
ENGINES
Excessive crankshaft end play Replace crankshaft, See
ENGINES
Loose flywheel or torque converter Tighten attaching bolts
Loose or damaged vibration damper Tighten or replace vibration
damper
Crankshaft journals out-of-round Re-grind crankshaft journals
Excessive belt tension Loosen belt tension
Noisy Connecting Rods
Excessive bearing clearance or missing bearing Replace bearing, See
ENGINES
Crankshaft rod journal out-of-round Re-grind crankshaft journal
Misaligned connecting rod or cap Remove rod or cap and
realign
2010 BMW M3
Incorrectly tightened rod bolts Remove and re-tighten rod

bolts
Noisy Pistons and Rings
Excessive piston-to-bore clearance Install larger pistons, See
ENGINES
Bore tapered or out-of-round Rebore block
Piston ring broken Replace piston rings, See
ENGINES
Piston pin loose or seized Replace piston pin, See
ENGINES
Connecting rods misaligned Realign connecting rods
Ring side clearance too loose or tight Replace with larger or smaller
rings
Carbon build-up on piston Remove carbon
Noisy Valve Train
Worn or bent push rods Replace push rods, See
ENGINES
Worn rocker arms or bridged pivots Replace push rods, See
ENGINES
Dirt or chips in valve lifters Remove lifters and remove
dirt/chips
Excessive valve lifter leak-down Replace valve lifters, See
ENGINES
Valve lifter face worn Replace valve lifters, See
ENGINES
Broken or cocked valve springs Replace or reposition springs
Too much valve stem-to-guide clearance Replace valve guides, See
ENGINES
Valve bent Replace valve, See ENGINES
Loose rocker arms Retighten rocker arms, See
ENGINES
Excessive valve seat run-out Reface valve seats, See
ENGINES
Missing valve lock Install new valve lock
Excessively worn camshaft lobes Replace camshaft, See
ENGINES
Plugged valve lifter oil holes Eliminate restriction or
replace lifter
Faulty valve lifter check ball Replace lifter check ball, See
ENGINES
Rocker arm nut installed upside down Remove and reinstall correctly
Valve lifter incorrect for engine Remove and replace valve
lifters
2010 BMW M3
Faulty push rod seat or lifter plunger Replace plunger or push rod
Noisy Valves
Improper valve lash Re-adjust valve lash, See
ENGINES
Worn or dirty valve lifters Clean and/or replace lifters
Worn valve guides Replace valve guides, See
ENGINES
Excessive valve seat or face run-out Reface seats or valve face
ENGINES
Loose rocker arm studs Re-tighten rocker arm studs,
See ENGINES
Bent push rods Replace push rods, See
ENGINES
Broken valve springs Replace valve springs, See
ENGINES
Burned,Sticking or Broken Valves
Weak valve springs or warped valves Replace valves and/or springs,
See ENGINES
Improper lifter clearance Re-adjust clearance or replace
lifters
Worn guides or improper guide clearance Replace valve guides, See
ENGINES
Out-of-round valve seats or improper seat width Re-grind valve seats
Gum deposits on valve stems, seats or guide Remove deposits
Improper spark timing Re-adjust spark timing
Broken Pistons/Rings
Undersize pistons Replace with larger pistons,
See ENGINES
Wrong piston rings Replace with correct rings,
See ENGINES
Out-of-round cylinder bore Re-bore cylinder bore
Improper connecting rod alignment Remove and realign
connecting rods
Excessively worn ring grooves Replace pistons, See
ENGINES
Improperly assembled piston pins Re-assemble pin-to-piston,
See ENGINES
Insufficient ring gap clearance Install new rings, See
ENGINES
Engine overheating Check cooling system
Incorrect ignition timing Re-adjust ignition timing, See
TUNE-UP
2010 BMW M3
Excessive Exhaust Noise

Leaks at manifold to head, or to pipe Replace manifold or pipe
gasket
Exhaust manifold cracked or broken Replace exhaust manifold,
See ENGINES
ENGINE PERFORMANCE
CARBURETOR TROUBLE SHOOTING:
BASIC COLD START SYMPTOMS TROUBLE SHOOTING CHART

Engine Won't Start
Choke not closing Check choke operation, see
FUEL SYSTEMS
Choke linkage bent Check linkage, see FUEL
SYSTEM
Engine Starts, Then Dies
Choke vacuum kick setting too wide Check setting and adjust see,
FUEL SYSTEMS
Fast idle RPM too low Reset RPM to specification,
see TUNE-UP
Fast idle cam index incorrect Reset fast idle cam index, see
FUEL SYSTEMS
Vacuum leak Inspect vacuum system for
leaks
Low fuel pump outlet Repair or replace pump, see
FUEL SYSTEMS
Low carburetor fuel level Check float setting see FUEL
SYSTEM
Engine Quits Under Load
Choke vacuum kick setting incorrect Reset vacuum kick setting,see
FUEL SYSTEMS
FUEL SYSTEM
Incorrect hot fast idle speed RPM Reset fast idle RPM, see
TUNE-UP
2010 BMW M3
Engine Starts, Runs Up, Then Idles, Slowly With Black Smoke
Choke vacuum kick set too narrow Reset vacuum kick, see FUEL
SYSTEMS
FUEL SYSTEMS
Hot fast idle RPM too low Reset fast idle RPM, see
TUNE-UP
BASIC HOT START SYMPTOMS TROUBLE SHOOTING CHART

Engine Won't Start
Engine flooded Allow fuel to evaporate
BASIC COLD ENGINE DRIVEABILITY SYMPTOMS TROUBLE SHOOTING CHART

Engine Stalls in Gear
Choke vacuum kick setting incorrect Reset choke vacuum kick, see
FUEL SYSTEMS
Fast idle RPM incorrect Reset fast idle RPM, see
TUNE-UP
Fast idle cam index incorrect Reset fast idle cam see FUEL
SYSTEMS
Acceleration Sag or Stall
Defective choke control switch Replace choke control switch
Choke vacuum kick setting incorrect Reset choke vacuum kick see,
FUEL SYSTEMS
Float level incorrect (too low) Adjust float level, FUEL
SYSTEMS
Accelerator pump defective Repair or replace pump see
FUEL SYSTEMS
Secondary throttles not closed Inspect lockout adjustment,
see FUEL SYSTEMS
Sag or Stall After Warmup
Defective choke control switch Replace choke control switch,
see FUEL SYSTEMS
Defective accelerator pump Replace pump, see FUEL
SYSTEMS
Float level incorrect (too low) Adjust float level, see FUEL
SYSTEMS
Backfiring & Black Smoke
Plugged heat crossover system Remove restriction
BASIC WARM ENGINE DRIVEABILITY SYMPTOMS TROUBLE SHOOTING CHART

2010 BMW M3

Hesitation With Small Amount of Gas Pedal Movement
Vacuum leak Inspect vacuum lines
Accelerator pump weak or inoperable Replace pump, see FUEL
SYSTEMS
Float level setting too low Reset float level, see,FUEL
SYSTEMS
Metering rods sticking or binding Inspect and/or replace rods,
see FUEL SYSTEMS
Carburetor idle or transfer system plugged Inspect system and remove
restriction
Frozen or binding heated air inlet Inspect heated air door for
binding
Hesitation With Heavy Gas Pedal Movement
Defective accelerator pump Replace pump, see FUEL
SYSTEMS
Metering rod carrier sticking or binding Remove restriction
Large vacuum leak Inspect vacuum system and
repair leak
Float level setting too low Reset float level, see FUEL
SYSTEMS
Defective fuel pump, lines or filter Inspect pump, lines and filter
Air door setting incorrect Adjust air door setting, see
FUEL
DIESEL ENGINE TROUBLE SHOOTING
NOTE: Diesel engines mechanical diagnosis is the same as gasoline engines for items
such as noisy valves, bearings, pistons, etc. The following trouble shooting
covers only items pertaining to diesel engines.
BASIC DIESEL ENGINE TROUBLE SHOOTING CHART

Engine Won't Crank
Bad battery connections or dead batteries Check connections and/or
replace batteries
Bad starter connections or bad starter Check connections and/or
2010 BMW M3
replace starter
Engine Cranks Slowly, Won't Start
Bad battery connections or dead batteries Check connections and/or
replace batteries
Engine oil too heavy Replace engine oil
Engine Cranks Normally, But Will Not Start
Glow plugs not functioning Check glow plug system, see
FUEL SYSTEMS
Glow plug control not functioning Check controller, see FUEL
SYSTEMS
Fuel not injected into cylinders Check fuel injectors, see
FUEL SYSTEMS
No fuel to injection pump Check fuel delivery system
Fuel filter blocked Replace fuel filter
Fuel tank filter blocked Replace fuel tank filter
Fuel pump not operating Check pump operation and/or
replace pump
Fuel return system blocked Inspect system and remove
restriction
No voltage to fuel solenoid Check solenoid and
connections
Incorrect or contaminated fuel Replace fuel
Incorrect injection pump timing Re-adjust pump timing, see
FUEL SYSTEMS
Low compression Check valves, pistons, rings,
see ENGINES
Injection pump malfunction Inspect and/or replace
injection pump
Engine Starts, Won't Idle
Incorrect slow idle adjustment Reset idle adjustment, see
TUNE-UP
Fast idle solenoid malfunctioning Check solenoid and
connections
Fuel return system blocked Check system and remove
restrictions
Glow plugs go off too soon See glow plug diagnosis in
FUEL SYSTEMS
Injection pump timing incorrect Reset pump timing, see FUEL
SYSTEMS
No fuel to injection pump Check fuel delivery system
Low compression Check valves, piston, rings,
see ENGINES
2010 BMW M3
Injection pump malfunction Replace injection pump, see

FUEL SYSTEMS
Fuel solenoid closes in RUN position Check solenoid and
connections
Engines Starts/Idles Rough W/out Smoke or Noise
Incorrect slow idle adjustment Reset slow idle, see TUNE-UP
Injection line fuel leaks Check lines and connections
Fuel return system blocked Check lines and connections
Air in fuel system Bleed air from system
Injector nozzle malfunction Check nozzles, see FUEL
SYSTEMS
Engines Starts and Idles Rough W/out Smoke or Noise, But Clears After Warm-Up
SYSTEMS
Engine not fully broken in Put more miles on engine
Air in system Bleed air from system
Injector nozzle malfunction Check nozzles, see FUEL
SYSTEMS
Engine Idles Correctly, Misfires Above Idle
Blocked fuel filter Replace fuel filter
SYSTEMS
Engine Won't Return To Idle
Fast idle adjustment incorrect Reset fast idle, see TUNE-UP
Internal injection pump malfunction Replace injection pump, see
FUEL SYSTEMS
External linkage binding Check linkage and remove
binding
Fuel Leaks On Ground
Loose or broken fuel line Check lines and connections
Internal injection pump seal leak Replace injection pump, see
FUEL SYSTEMS
Cylinder Knocking Noise
Injector nozzles sticking open Test injectors, see FUEL
SYSTEMS
Very low nozzle opening pressure Test injectors and/or replace
Loss of Engine Power
Restricted air intake Remove restriction
EGR valve malfunction Replace EGR valve
Blocked or damaged exhaust system Remove restriction and/or
2010 BMW M3
replace components
Blocked fuel tank filter Replace filter
Restricted fuel filter Remove restriction and/or
replace filter
Block vent in gas cap Remove restriction and/or
replace cap
Tank-to-injection pump fuel supply blocked Check fuel lines and
connections
Blocked fuel return system Remove restriction
Blocked injector nozzles Check nozzle for blockage, see
FUEL SYSTEMS
Low compression Check valves, rings, pistons,
see ENGINES
Loud Engine Noise With Black Smoke
Basic timing incorrect Reset timing, see FUEL
SYSTEMS
Internal injection pump malfunction Replace injection pump, see
FUEL SYSTEMS
Incorrect injector pump housing pressure Check pressure, see FUEL
SYSTEMS
Engine Overheating
Cooling system leaks Check cooling system and
repair leaks
Belt slipping or damaged Check tension and/or replace
belt
Thermostat stuck closed Remove and replace
thermostat, see ENGINE
COOLING
Head gasket leaking Replace head gasket
Oil Light on at Idle
Low oil pump pressure Check oil pump operation, see
ENGINES
Oil cooler or line restricted Remove restriction and/or
replace cooler
Engine Won't Shut Off
Injector pump fuel solenoid does not return fuel valve to OFF Remove and check solenoid
position and replace if needed
VACUUM PUMP DIAGNOSIS

Excessive Noise
2010 BMW M3
Loose pump-to-drive assembly screws Tighten screws

Loose tube on pump assembly Tighten tube
Valves not functioning properly Replace valves
Oil Leakage
Loose end plug Tighten end plug
Bad seal crimp Remove and re-crimp seal
FUEL INJECTION TROUBLE SHOOTING
BASIC FUEL INJECTION TROUBLE SHOOTING CHART

Engine Won't Start (Cranks Normally)
Cold start valve inoperative Test valve and circuit
Poor connection;vacuum or wiring Check vacuum and electrical
connections
Contaminated fuel Test fuel for water or alcohol
Defective fuel pump relay or circuit Test relay and wiring
Battery too low Charge and test battery
Low fuel pressure Test pressure regulator and
fuel pump, check for restricted
lines and filters
No distributor reference pulses Repair ignition system as
necessary
Open coolant temperature sensor circuit Test sensor and wiring
Shorted W.O.T. switch in T.P.S. Disconnect W.O.T. switch,
engine should start
Defective ECM Replace ECM
Fuel tank residual pressure valve leaks Test for fuel pressure drop
after shut down
Hard Starting
Disconnected hot air tube to air cleaner Reconnect tube and test
control valve
Defective Idle Air Control (IAC) valve Test valve operation and
circuit
Shorted, open or misadjusted T.P.S. Test and adjust or replace
T.P.S.
EGR valve open Test EGR valve and control
2010 BMW M3
circuit
Poor Oxygen sensor signal Test for shorted or circuit
Incorrect mixture from PCV system Test PCV for flow, check
sealing of oil filter cap
Poor High Speed Operation
Low fuel pump volume Faulty pump or restricted fuel
lines or filters
Poor MAP sensor signal Test MAP sensor, vacuum
hose and wiring
Poor Oxygen sensor signal Test for shorted or open
sensor or circuit
Open coolant temperature sensor circuit Test sensor and wiring
Faulty ignition operation Check wires for cracks or poor
connections, test secondary
voltage with oscilloscope
Contaminated fuel Test fuel for water or alcohol
Intermittent ECM ground Test ECM ground connection
for resistance
Restricted air cleaner Replace air cleaner
Restricted exhaust system Test for exhaust manifold
back pressure
Poor MAF sensor signal Check leakage between sensor
and manifold
Poor VSS signal If tester for ALCL hook-up is
available check that VSS
reading matches speedometer
Ping or Knock on Acceleration
Poor Knock sensor signal Test for shorted or open
sensor or circuit
Poor Baro sensor signal Test for shorted or open
sensor or circuit
Improper ignition timing See VEHICLE EMISSION
CONTROL LABEL (where
applicable)
Check for engine overheating problems Low coolant, loose belts or
electric cooling fan
inoperative
NOTE: For additional electronic fuel injection trouble shooting information, see the
appropriate article in the ENGINE PERFORMANCE section (not all vehicles have
Computer Engine Control articles). Information is provided there for diagnosing
fuel system problems on vehicles with electronic fuel injection.
IGNITION SYSTEM TROUBLE SHOOTING

2010 BMW M3
Fig. 3: Ignition Secondary Trouble Shooting Chart

2010 BMW M3
2010 BMW M3
Fig. 4: Ignition Primary Trouble Shooting Chart
STARTER TROUBLE SHOOTING
BASIC STARTER TROUBLE SHOOTING CHART

Starter Fails to Operate
Dead battery or bad connections between starter and battery Check battery charge and all
wires and connections to
starter
switch
Open circuit between starter switch ignition terminal on starter relay Check and repair wires and
Starter relay or starter defective See Testing in STARTER
article
Open solenoid pull-in wire See Testing in STARTER
article
Starter Does Not Operate and Headlights Dim
Weak battery or dead cell Charge or replace battery as
necessary
Loose or corroded battery connections Check that battery
connections are clean and
tight
Internal ground in starter windings See Testing in STARTER
article
Grounded starter fields See Testing in STARTERS
Armature rubbing on pole shoes See STARTER article
Starter Turns but Engine Does Not Rotate
Starter clutch slipping See STARTER article
Pinion shaft rusted or dry See STARTER article
Engine basic timing incorrect See Ignition Timing in
TUNE-UP article
for starter pinion gear
damage
Starter Will Not Crank Engine
2010 BMW M3
Faulty overrunning clutch See STARTER article

Broken flywheel teeth Replace flywheel and check
for starter pinion gear
damage
Armature shaft sheared or reduction gear teeth stripped See STARTER article
necessary
Faulty solenoid See On-Vehicle Tests in
STARTER article
Poor grounds Check all ground connections
for tight and clean
connections
switch as necessary
Starter Cranks Engine Slowly
Battery weak or defective Charge or replace battery as
necessary
Engine overheated See ENGINE COOLING
SYSTEM article
Engine oil too heavy Check that proper viscosity
oil is used
Poor battery-to-starter connections Check that all between
battery and starter are clean
and tight
Current draw too low or too high See Bench Tests in
STARTER article
Bent armature, loose pole shoes screws or worn bearings See STARTER article
Burned solenoid contacts Replace solenoid
Faulty starter Replace starter
Starter Engages Engine Only Momentarily
Engine timing too far advanced See Ignition Timing in
TUNE-UP article
Overrunning clutch not engaging properly Replace overrunning clutch.
See STARTER article
Broken starter clutch See STARTER article
starter pinion gear for
damage
Weak drive assembly thrust spring See STARTER article
Weak hold-in coil See Bench Tests in
STARTER article
Starter Drive Will Not Engage
2010 BMW M3
Defective point assembly See Testing in STARTER

article
Poor point assembly ground See Testing in STARTER
article
Defective pull-in coil Replace starter solenoid
Starter Relay Does Not Close
Dead battery Charge or replace battery as
necessary
Faulty wiring Check all wiring and
connections leading to relay
Neutral safety switch faulty Replace neutral safety switch
Starter relay faulty Replace starter relay
Starter Drive Will Not Disengage
Starter motor loose on mountings Tighten starter attach bolts
Worn drive end bushing See STARTER article
Damaged engine flywheel teeth Replace flywheel and starter
pinion gear for damage
Drive yolk return spring broken or missing Replace return spring
Faulty ignition switch Replace ignition switch
Insufficient clearance between winding leads to solenoid terminal Replace starter solenoid
and main contact in solenoid
Starter clutch not disengaging Replace starter clutch
Ignition starter switch contacts sticking Replace ignition switch
Starter Relay Operates but Solenoid Does Not
Faulty solenoid switch, switch connections or relay Check all wiring between
relay and solenoid or replace
relay or solenoid as necessary
Broken lead or loose soldered connections Repair wire or wire
Solenoid Plunger Vibrates When Switch is Engaged
necessary
Solenoid contacts corroded Clean contacts or replace
solenoid
Faulty wiring Check all wiring leading to
solenoid
Broken connections inside switch cover Repair connections or replace
solenoid
Open hold-in wire Replace solenoid
Low Current Draw
Worn brushes or weak Replace brushes or brush
springs as necessary
High Pitched Whine During Cranking Before Engine Fires but Engine Fires and Cranks Normally
2010 BMW M3
Distance too great between starter pinion and flywheel Align starter or check that
correct starter and flywheel
are being used
High Pitched Whine After Engine Fires With Key released. Engine Fires and Cranks Normally
Distance too small between starter pinion and flywheel Flywheel runout contributes
to the intermittent nature
TUNE-UP TROUBLE SHOOTING - GAS ENGINE VEHICLES
BASIC SPARK PLUG TROUBLE SHOOTING CHARTS

Normal Spark Plug Condition
Light Tan or Gray deposits No Action
Electrode not burned or fouled No Action
Gap tolerance not changed No Action
Cold Fouling or Carbon Deposits
Overrich air/fuel mixture Adjust air/fuel mixture, see
ENGINE PERFORMANCE
section
Faulty choke Replace choke assembly, see
ENGINE PERFORMANCE
section
Clogged air filter Clean and/or replace air filter
Incorrect idle speed or dirty carburetor Reset idle speed and/ or clean
carburetor
Faulty ignition wires Replace ignition wiring
Prolonged operation at idle Shut engine off during long
idle
Sticking valves or worn valve guide seals Check valve train
Wet Fouling or Oil Deposits
Worn rings and pistons Install new rings and pistons
Excessive cylinder wear Rebore or replace block
Excessive valve guide clearance Worn or loose bearing
Gap Bridged
Deposits in combustion chamber becoming fused to electrode Clean combustion chamber of
deposits
Blistered Electrode
2010 BMW M3
Engine overheating Check cooling system

Wrong type of fuel Replace with correct fuel
Loose spark plugs Retighten spark plugs
Over-advanced ignition timing Reset ignition timing see
ENGINE PERFORMANCE
Pre-Ignition or Melted Electrodes
Incorrect type of fuel Replace with correct fuel
Incorrect ignition timing Reset ignition timing see
ENGINE PERFORMANCE
Burned valves Replace valves
Engine Overheating Check cooling system
Wrong type of spark plug, too hot Replace with correct spark
plug, see ENGINE
PERFORMANCE
Chipped Insulators
Severe detonation Check for over-advanced
timing or combustion
Improper gapping procedure Re-gap spark plugs
Rust Colored Deposits
Additives in unleaded fuel Try different fuel brand
Water In Combustion Chamber
Blown head gasket or cracked head Repair or replace head or head
gasket
NOTE: Before diagnosing an electronic ignition system, ensure that all wiring is
connected properly between distributor, wiring connector and spark plugs.
Ignition problem will show up either as: Engine Will Not Start or Engine Runs
Rough.
BASIC ELECTRONIC IGNITION TROUBLE SHOOTING CHARTS

Engine Won't Start
Open circuit between distributor and bulkhead connector Repair circuit
Open circuit between bulkhead connector and ignition switch Repair circuit
Open circuit between ignition switch and starter solenoid Repair circuit
Engine Runs Rough
Fuel lines leaking or clogged Tighten fitting, remove
restriction
Initial timing incorrect Reset ignition timing see
ENGINE PERFORMANCE
Centrifugal advance malfunction Repair distributor advance
Defective spark plugs or wiring Replace plugs or plug wiring
2010 BMW M3
Component Failure
Spark arc-over on cap, rotor or coil Replace cap, rotor or or coil
Defective pick-up coil Replace pick-up coil
Defective ignition coil Replace ignition coil
Defective vacuum unit Replace vacuum unit
Defective control module Replace control module
BASIC ELECTRONIC IGNITION TROUBLE SHOOTING CHARTS - USING OSCILLOSCOPE

PATTERNS
Firing Voltage Lines are the Same, but Abnormally High
Retarded ignition timing Reset ignition timing, see
ENGINE PERFORMANCE
section
Fuel mixture too lean Readjust carburetor, see
ENGINE PERFORMANCE
High resistance in coil wire Replace coil wire
Corrosion in coil tower terminal Clean and/or replace coil
Corrosion in distributor coil terminal Clean and/or replace
distributor cap
Firing Voltage Lines are the Same but Abnormally Low
Fuel mixture too rich Readjust carburetor, see
ENGINE PERFORMANCE
Breaks in coil wire causing arcing Replace coil wire
Cracked coil tower causing arcing Replace coil
Low coil output Replace coil
Low engine compression Determine cause and repair
One or More, But Not All Firing Voltage Lines are Higher Than Others
Carburetor idle mixture not balanced Readjust carburetor, see
ENGINE PERFORMANCE
EGR valve stuck open Clean and/or replace valve
High resistance in spark plug wires Replace spark plug wires
Cracked or broken spark plug insulator Replace spark plugs
Intake vacuum leak Repair leak
Defective spark plugs Replace spark plugs
Corroded spark plug terminals Replace spark plugs
One or More, But Not All Firing Voltage Lines Are Lower Than Others
Curb idle mixture not balanced Readjust carburetor, see
ENGINE PERFORMANCE
Breaks in plug wires Replace plug wires causing
arcing
Cracked coil tower causing arcing Replace coil
2010 BMW M3
Low compression Determine cause and repair

Corroded spark plugs Replace spark plugs
Cylinders Not Firing
Cracked distributor cap terminals Replace distributor cap
Shorted spark plug wire Determine cause and repair
Mechanical problem in engine Determine cause and repair
Spark plugs fouled Replace spark plugs
BASIC DRIVEABILITY PROBLEMS TROUBLE SHOOTING

Hard Starting
Binding carburetor linkage Eliminate binding
Binding choke linkage Eliminate binding
Binding choke piston Eliminate binding
Restricted choke vacuum Check vacuum lines for
blockage
Worn or dirty needle valve and seat Clean carburetor, see
ENGINE PERFORMANCE
Float sticking Readjust or replace float see
the ENGINE
PERFORMANCE section
Incorrect choke adjustment Reset choke adjustment see
ENGINE PERFORMANCE
Defective coil Replace coil
Improper spark plug gap Regap spark plugs
ENGINE PERFORMANCE
Detonation
Over-advanced ignition timing Reset ignition timing see
ENGINE PERFORMANCE
Fuel lines clogged Clean fuel lines
EGR system malfunction Check and repair EGR system
PCV system malfunction Repair PCV system
Vacuum leaks Check and repair vacuum
system
Loose fan belts Tighten or replace fan belts,
see ENGINE
PERFORMANCE
Restricted airflow Remove restriction
2010 BMW M3
Vacuum advance malfunction Check distributor operation

Dieseling
Binding throttle linkage Eliminate blinding
Binding choke linkage or fast idle cam Eliminate binding
Defective idle solenoid Replace idle solenoid see
ENGINE PERFORMANCE
Improper base idle speed Reset idle speed, see see
ENGINE PERFORMANCE
ENGINE PERFORMANCE
Incorrect idle mixture setting Reset idle mixture, see
ENGINE PERFORMANCE
Faulty Acceleration
ENGINE PERFORMANCE
Engine cold and choke too lean Adjust choke and allow
engine to warm-up
Defective coil Replace coil
Faulty Low Speed Operation
Clogged idle transfer slots Clean idle transfer slots, see
FUEL
Restricted idle air bleeds and passages Disassemble and clean
carburetor, see FUEL
Clogged air cleaner Replace air filter
Defective ignition wires Replace ignition wire see
ENGINE PERFORMANCE
Defective distributor cap Replace distributor cap
Faulty High Speed Operation
ENGINE PERFORMANCE
Defective distributor centrifugal advance Replace advance mechanism
Defective distributor vacuum advance Replace advance unit
Incorrect spark plugs or plug gap Check gap and/or replace
spark plugs
Faulty choke operation Check choke and repair as
required
Clogged vacuum passages Remove restrictions
Improper size or clogged main jet Check jet size and clean, see
FUEL
2010 BMW M3
Restricted air cleaner Check filter and replace as

necessary
Defective distributor cap, rotor or coil Replace cap, rotor or coil
Misfire at All Speeds
Defective spark plug wires Replace spark plug wires
Defective distributor cap, rotor, or coil Replace cap, rotor, or coil
Cracked or broken vacuum hoses Replace vacuum hoses
Vacuum leaks Repair vacuum leaks
Fuel lines clogged Remove restriction
Hesitation
Cracked or broken vacuum Replace vacuum hoses hoses
Vacuum leaks Repair Vacuum leaks
Binding throttle linkage Eliminate binding
Binding choke linkage or fast idle cam Eliminate binding
Improper float setting Readjust float setting, see
FUEL
Cracked or broken ignition wires Replace ignition wires
Rough Idle, Missing or Stalling
Incorrect curb idle or fast idle speed Reset idle speed, see see
ENGINE PERFORMANCE
Incorrect basic timing Reset ignition timing see
ENGINE PERFORMANCE
Improper idle mixture adjustment Reset idle mixture, see
ENGINE PERFORMANCE
Improper feedback system operation Check feedback system see
ENGINE PERFORMANCE
Incorrect spark plug gap Reset spark plug gap, see
ENGINE PERFORMANCE
Moisture in ignition components Dry components
Loose or broken ignition wires Replace ignition wires
Damaged distributor cap or or rotor Replace distributor cap or
rotor
Faulty ignition coil Replace ignition coil
Fuel filter clogged or worn Replace fuel filter
Damaged idle mixture screw Replace idle mixture screw,
see FUEL
Improper fast idle cam adjustment Reset fast idle cam
adjustment, see TUNE- see
ENGINE PERFORMANCE
Improper EGR valve operation Replace EGR valve
2010 BMW M3
Faulty PCV valve air flow Replace PCV valve

Choke binding or improper choke setting Reset choke or eliminate
binding
Vacuum leak Repair vacuum leak
Improper float bowl fuel level Reset float adjustment, see
FUEL
Clogged air bleed or idle passages Clean carburetor passages, see
FUEL
Clogged or worn air cleaner filter Replace air filter
Faulty choke vacuum diaphragm Replace diaphragm, see
ENGINE PERFORMANCE
Exhaust manifold heat valve inoperative Replace heat valve
Improper distributor spark advance Check distributor operation
Leaking valves or valve components Check and repair valvetrain
Improper carburetor mounting Remove and remount
carburetor
Excessive play in distributor shaft Replace distributor
Loose or corroded wiring connections Repair or replace as required
Engine Surges
Improper PCV valve airflow Replace PCV valve
Clogged air bleeds Remove restriction
Restricted air cleaner filter Replace air filter
Cracked or broken vacuum hoses Replace vacuum hoses
Cracked or broken ignition wires Replace ignition wires
Vacuum advance malfunction Check unit and replace as
necessary
Defective or fouled spark plugs Replace spark plugs
Ping or Spark Knock
ENGINE PERFORMANCE
Distributor centrifugal or vacuum advance malfunction Check operation and replace
as necessary
Carburetor setting too lean Readjust mixture setting, see
ENGINE PERFORMANCE
Vacuum leak Eliminate vacuum leak
Poor Gasoline Mileage
Cracked or broken vacuum Replace vacuum hoses hoses
Defective ignition wires Replace wires
2010 BMW M3
Incorrect choke setting Readjust setting, see ENGINE

PERFORMANCE
Defective vacuum advance Replace vacuum advance
Binding carburetor power piston Eliminate binding
Dirt in carburetor jets Clean and/or replace jets
Incorrect float adjustment Readjust float setting, see
FUEL
Defective power valve Replace power valve, see
ENGINE PERFORMANCE
Incorrect idle speed Readjust idle speed
Engine Stalls
Improper float level Readjust float level
Leaking needle valve and seat Replace needle valve and seat
Vacuum leaks Eliminate vacuum leaks
VACUUM PUMP - DIESEL TROUBLE SHOOTING
NOTE: Diesel engines mechanical diagnosis is the same as gasoline engines for items
such as noisy valves, bearings, pistons, etc. The following trouble shooting
covers only items pertaining to diesel engines.
VACUUM PUMP (DIESEL) TROUBLE SHOOTING CHART

Excessive Noise
Loose pump-to-drive assembly screws Tighten screws
Loose tube on pump assembly Tighten tube
Valves not functioning properly Replace valves
Oil Leakage
Loose end plug Tighten end plug
Bad seal crimp Remove and re-crimp
seal
MANUAL TRANSMISSION
MANUAL TRANSMISSION TROUBLE SHOOTING
2010 BMW M3
MANUAL TRANSMISSION/TRANSAXLE TROUBLE SHOOTING

Condition Possible Cause
Noisy In Forward Gears Low gear oil level, Loose bell housing bolts, Worn
bearings or gears
Clunk On Deceleration (FWD Only) Loose engine mounts, Worn inboard CV joints,
Worn differential pinion shaft, Side gear hub
counterbore in case worn oversize
Gear Clash When Shifting Forward Gears Clutch Out Of Adjustment, Shift linkage damaged
or out of adjustment, Gears or synchronizers
damaged, Low gear oil level
Transmission Noisy When Moving (RWD Only) Worn rear outputshaft bearing
Quiet In Neutral With Clutch Engaged
Gear Rattle Worn bearings, Wrong gear oil, Low gear oil, Worn
gears
Steady Ticking At Idle (Increases With RPM) Broken tooth on gear
Gear Clash When Shifting Forward Gears Worn or broken synchronizers
Loud Whine In Reverse Normal condition (1)
Noise When Stepping On Clutch Bad release bearing, Worn pilot bearing
Ticking Or Screeching As Clutch Is Engaged Faulty release bearing, Uneven pressure plate
fingers
Click Or Snap When Clutch Is Engaged Worn clutch fork, Worn or broken front bearing
retainer
Transmission Shifts Hard Clutch not releasing, Shift mechanism binding,
Clutch installed backwards
Will Not Shift Into One Gear, Shifts Into All Others Bent shift fork, Worn detent balls
Locked Into Gear, Cannot Shift Clutch adjustment, Worn detent balls
Transmission Jumps Out Of Gear Pilot bearing worn, Bent shift fork, Worn gear teeth
or face, Excessive gear train end play, Worn
synchronizers, Missing detent ball spring, Shift
mechanism worn or out of adjustment, Engine or
transmission mount bolts loose or out of adjustment,
Transmission not aligned
Shift Lever Rattle Worn shift lever or detents, Worn shift forks, Worn
synchronizers sleeve
Shift Lever Hops Under Acceleration Worn engine or transmission mounts
(1) Most units use spur cut gears in reverse and are noisy
2010 BMW M3
POWERTRAIN
CLUTCH TROUBLE SHOOTING
BASIC CLUTCH TROUBLE SHOOTING CHART

Chattering or Grabbing
Incorrect clutch adjustment Adjust clutch
Oil, grease or glaze on facings Disassemble and clean or replace
Loose "U" joint flange See DRIVE AXLES article
Worn input shaft spline Replace input shaft
Binding pressure plate Replace pressure plate
Binding release lever See CLUTCH article
Binding clutch disc hub Replace clutch disc
Unequal pressure plate contact Replace worn/misaligned
components
Loose/bent clutch disc Replace clutch disc
Incorrect transmission alignment Realign transmission
Worn pressure plate, disc or flywheel Replace damaged components
Broken or weak pressure springs Replace pressure plate
Sticking clutch pedal Lubricate clutch pedal & linkage
Incorrect clutch disc facing Replace clutch disc
Engine loose in chassis Tighten all mounting bolts
Failure to Release
Oil or grease on clutch facings Clean or replace clutch clutch
disc
Incorrect release lever or pedal adjustment See CLUTCH article
Worn or broken clutch facings Replace clutch disc
Bent clutch disc or pressure plate Replace damaged components
Clutch disc hub binding on input shaft Clean or replace clutch disc
and/or input shaft
Binding pilot bearing Replace pilot bearing
Sticking release bearing sleeve Replace release bearing and/or
sleeve
Binding clutch cable See CLUTCH article
Defective clutch master Replace master cylinder
2010 BMW M3
Defective clutch slave Replace slave cylinder

Air in hydraulic system Bleed hydraulic system
Rattling
Weak or broken release lever spring Replace spring and check
alignment
Damaged pressure plate Replace pressure plate
Broken clutch return spring Replace return spring
Worn splines on clutch disc or input shaft Replace clutch disc and/or input
shaft
Worn clutch release bearing Replace release bearing
Dry or worn pilot bearing Lubricate or replace pilot bearing
Unequal release lever contact Align or replace release lever
Incorrect pedal free play Adjust free play
Warped or damaged clutch disc Replace damaged components
Slipping
Pressure springs worn or Release pressure plate
Oily, greasy or worn facings Clean or replace clutch disc
Incorrect clutch alignment Realign clutch assembly
Warped clutch disc or pressure plate Replace damaged components
Binding release levers or clutch pedal Lubricate and/or replace release
components
Squeaking
Worn or damaged release Replace release bearing
Dry or worn pilot or release bearing Lubricate or replace assembly
Pilot bearing turning in crankshaft Replace pilot bearing and/or
crankshaft
Worn input shaft bearing Replace bearing and seal
Incorrect transmission alignment Realign transmission
Dry release fork between pivot Lubricate release fork and pivot
Heavy and/or Stiff Pedal
Sticking release bearing sleeve Replace release bearing and/or
sleeve
Dry or binding clutch pedal hub Lubricate and align components
Floor mat interference with pedal Lay mat flat in proper area
Dry or binding ball/fork pivots Lubricate and align components
Faulty clutch cable Replace clutch cable
Noisy Clutch Pedal
Faulty interlock switch Replace interlock switch
Self-adjuster ratchet noise Lubricate or replace self-adjuster
Speed control interlock switch Lubricate or replace interlock
switch
2010 BMW M3
Clutch Pedal Sticks Down

Binding clutch cable See CLUTCH article
Springs weak in pressure plate Replace pressure plate
Binding in clutch linkage Lubricate and free linkage
Noisy
Dry release bearing Lubricate or replace release
bearing
Dry or worn pilot bearing Lubricate or replace bearing
Worn input shaft bearing Replace bearing
Transmission Click
Weak springs in pressure Replace pressure plate plate
Release fork loose on ball stud Replace release fork and/or
ball stud
Oil on clutch disc damper Replace clutch disc
Broken spring in slave cylinder Replace slave cylinder
DRIVE AXLE - NOISE DIAGNOSIS
Unrelated Noises
Some driveline trouble symptoms are also common to the engine, transmission, wheel bearings, tires, and other
parts of the vehicle. Ensure cause of trouble actually is in the drive axle before adjusting, repairing, or replacing
any of its parts.
Non-Drive Axle Noises
A few conditions can sound just like drive axle noise and have to be considered in pre-diagnosis. The 4 most
common noises are exhaust, tires, CV/universal joints and wheel trim rings.
In certain conditions, the pitch of the exhaust gases may e gear whine. At other times, it may be mistaken for a
wheel bearing rumble.
Tires, especially radial and snow, can have a high-pitched tread whine or roar, similar to gear noise. Also, some
non-standard tires with an unusual tread construction may emit a roar or whine.
Defective CV/universal joints may cause clicking noises or excessive driveline play that can be improperly
diagnosed as drive axle problems.
Trim and moldings also can cause a whistling or whining noise. Ensure none of these components are causing
the noise before disassembling the drive axle.
Gear Noise
A "howling" or "whining" noise from the ring and pinion gear can be caused by an improper gear pattern, gear
damage, or improper bearing preload. It can occur at various speeds and driving conditions, or it can be
2010 BMW M3
continuous.
Before disassembling axle to diagnose and correct gear ke sure that tires, exhaust, and vehicle trim have been
checked as possible causes.
Chuckle
This is a particular rattling noise that sounds like a stick against the spokes of a spinning bicycle wheel. It
occurs while decelerating from 40 MPH and usually can be heard until vehicle comes to a complete stop. The
frequency varies with the speed of the vehicle.
A chuckle that occurs on the driving phase is usually caused ive clearance due to differential gear wear, or by a
damaged tooth on the coast side of the pinion or ring gear. Even a very small tooth nick or a ridge on the edge
of a gear tooth is enough the cause the noise.
This condition can be corrected simply by cleaning the gear tooth nick or ridge with a small grinding wheel. If
either gear is damaged or scored badly, the gear set must be replaced. If metal has broken loose, the carrier and
housing must be cleaned to remove particles that could cause damage.
Knock
This is very similar to a chuckle, though it may be louder, and occur on acceleration or deceleration. Knock can
be caused by a gear tooth that is damaged on the drive side of the ring and pinion gears. Ring gear bolts that are
hitting the carrier casting can cause knock. Knock can also be due to excessive end play in the axle shafts.
Clunk
Clunk is a metallic noise heard when an automatic transmission is engaged in Reverse or Drive, or when throttle
is applied or released. It is caused by backlash somewhere in the driveline, but not necessarily in the axle. To
determine whether driveline clunk is caused by the axle, check the total axle backlash as follows:
1. Raise vehicle on a frame or twinpost hoist so that drive wheels are free. Clamp a bar between axle
companion flange and a part of the frame or body so that flange cannot move.
2. On conventional drive axles, lock the left wheel to keep it from turning. On all models, turn the right
wheel slowly until it is felt to be in Drive condition. Hold a chalk marker on side of tire about 12" from
center of wheel. Turn wheel in the opposite direction until it is again felt to be in Drive condition.
3. Measure the length of the chalk mark, which is the total axle backlash. If backlash is one inch or less,
drive axle is not the source of clunk noise.
Bearing Whine
Bearing whine is a high-pitched sound similar to a whistle. It is usually caused by malfunctioning pinion
bearings. Pinion bearings operate at drive shaft speed. Roller wheel bearings may whine in a similar manner if
they run completely dry of lubricant. Bearing noise will occur at all driving speeds. This distinguishes it from
gear whine, which usually comes and goes as speed changes.
Bearing Rumble
2010 BMW M3
Bearing rumble sounds like marbles being tumbled. It is usually caused by a malfunctioning wheel bearing. The
lower pitch is because the wheel bearing turns at only about 1/3 of drive shaft speed.
Chatter On Turns
This is a condition where the entire front or rear of vehicle vibrates when vehicle is moving. The vibration is
plainly felt as well as heard. Extra differential thrust washers installed during axle repair can cause a condition
of partial lock-up that creates this chatter.
Axle Shaft Noise
Axle shaft noise is similar to gear noise and pinion bearing whine. Axle shaft bearing noise will normally
distinguish itself from gear noise by occurring in all driving modes (Drive, cruise, coast and float), and will
persist with transmission in Neutral while vehicle is moving at problem speed.
If vehicle displays this noise condition, remove suspect parts, replace wheel seals and install a new set of
bearings. Re-evaluate vehicle for noise before removing any internal components.
Vibration
Vibration is a high-frequency trembling, shaking or grinding condition (felt or heard) that may be constant or
variable in level and can occur during the total operating speed range of the vehicle.
The types of vibrations that can be felt in the vehicle can d into 3 main groups:
Vibrations of various unbalanced rotating parts of the vehicle.

Resonance vibrations of the body and frame structures caused by rotating of unbalanced parts.
Tip-in moans of resonance vibrations from stressed engine or exhaust system mounts or driveline flexing
modes.
DRIVE AXLE - RWD TROUBLE SHOOTING
For definitions of listed noises or sounds, see DRIVE AXLE - NOISE DIAGNOSIS
under POWERTRAIN.
DRIVE AXLE (RWD) TROUBLE SHOOTING

Knocking or Clunking
Differential Side Gear Clearance Check Clearance
Worn Pinion Shaft Replace Pinion Shaft
2010 BMW M3
Axle Shaft End Play Check End Play

Missing Gear Teeth Check Differential/Replace
Gear
Wrong Axle Backlash Check Backlash
Misaligned Driveline Realign Driveline
Clinking During Engagement
Side Gear Clearance Check Clearance
Ring and Pinion Backlash Check Backlash
Worn/Loose Pinion Shaft Replace Shaft/Bearing
Bad "U" Joint Replace "U" Joint
Sticking Slip Yoke Lube Slip Yoke
Broken Rear Axle Mount Replace Mount
Loose Drive Shaft Flange Check Flange
Click/Chatter On Turns
Differential Side Gear Clearance Check Clearance
Wrong Turn On Plates (1) Replace Clutch Plates
Wrong Differential Lubricant (1) Change Lubricant
Knock Or Click
Flat Spot on Rear Wheel Bearing Replace Wheel Bearing
Low Vibration At All Speeds
Faulty Wheel Bearing Replace Wheel Bearing
Faulty "U" Joint Replace "U" Joint
Faulty Drive Shaft Balance Drive Shaft
Faulty Companion Flange Replace Flange
Faulty Slip Yoke Flange Replace Flange
(1) Limited slip differential only.
FWD AXLE SHAFTS & CV JOINTS TROUBLE SHOOTING
BASIC FWD AXLE SHAFTS & CV JOINTS TROUBLE SHOOTING CHART

Grease Leaks CV boot torn or cracked
Clicking Noise on Cornering Damaged outer CV
Clunk Noise on Acceleration Damaged inner CV
Vibration or Shudder on Acceleration Sticking, damaged or worn CV Misalignment or
2010 BMW M3
spring height
STEERING & SUSPENSION

MANUAL STEERING GEAR TROUBLE SHOOTING
BASIC MANUAL STEERING GEAR TROUBLE SHOOTING CHART

Rattle or Chucking Noise in Rack and Pinion
Rack and pinion mounting bracket loose Tighten all mounting bolts
Lack of/or incorrect lubricant Correct as necessary
Steering gear mounting bolts loose Tighten all mounting bolts
Excessive Play
Front wheel bearing improperly adjusted See FRONT SUSPENSION
article
Loose or worn steering linkage See STEERING LINKAGE
article
Loose or worn steering gear shift See MANUAL STEERING
GEAR article
Steering arm loose on gear shaft See MANUAL STEERING
GEAR article
Steering gear housing bolts loose Tighten all mounting bolts
Steering gear adjustment too loose See MANUAL STEERING
GEAR article
Steering arms loose on knuckles Tighten and check steering
linkage
Rack and pinion mounting loose Tighten all mounting bolts
Rack and pinion out of adjustment See adjustment in STEERING
article
Tie rod end loose Tighten and check steering
linkage
Excessive Pitman shaft-to-ball nut lash Repair as necessary
Poor Returnability
Lack of lubricant in ball joint or linkage Lubricate and service systems
Binding in linkage or ball joints See STEERING LINKAGE
and SUSPENSION article
Improper front end alignment See WHEEL ALIGNMENT
2010 BMW M3
article
Improper tire pressure Inflate to proper pressure
Tie rod binding Inflate to proper pressure
Shaft seal rubbing shaft See STEERING COLUMN
article
Excessive Vertical Motion
Tires, wheels or rotors out of balance Balance tires then check
wheels and rotors
Worn or faulty shock absorbers Check and replace if necessary
Loose tie rod ends or steering Tighten or replace if necessary
Loose or worn wheel bearings See SUSPENSION article
Steering Pulls to One Side
Front tires are different sizes Rotate or replace if necessary
Wheel bearings not adjusted properly See FRONT SUSPENSION
article
Bent or broken suspension components See FRONT SUSPENSION
article
Improper wheel alignment See WHEEL ALIGNMENT
article
Brakes dragging See BRAKES article
Instability
Low or uneven tire pressure Inflate to proper pressure
Loose or worn wheel bearings See FRONT SUSPENSION
article
Loose or worn idler arm bushing See FRONT SUSPENSION
article
Loose or worn strut bushings See FRONT SUSPENSION
article
Incorrect front wheel alignment See WHEEL ALIGNMENT
article
Steering gear not centered See MANUAL STEERING
GEARS article
Springs or shock Check and replace if necessary
Improper cross shaft See MANUAL STEERING
GEARS article
POWER STEERING TROUBLE SHOOTING
2010 BMW M3

BASIC POWER STEERING TROUBLE SHOOTING CHART

Rattle or Chucking Noise
Pressure hoses touching engine parts Adjust to proper clearance
Loose Pitman shaft Adjust or replace if necessary
Tie rods ends or Pitman arm loose Tighten and check system
Rack and pinion mounts loose Tighten all mounting bolts
Free play in worm gear See POWER STEERING
GEAR article
Loose sector shaft or thrust bearing adjustment See POWER STEERING
GEAR
Free play in pot coupling See STEERING COLUMN
article
Worn shaft serrations See STEERING COLUMN
article
Growl in Steering Pump
Excessive pressure in hoses Restricted hoses, see POWER
STEERING GEAR article
Scored pressure plates See POWER STEERING
GEAR article
Scored thrust plates or rotor See POWER STEERING
GEAR article
Extreme wear of cam ring See POWER STEERING
GEAR article
Rattle in Steering Pump
Vanes not installed See POWER STEERING
PUMP article
Vanes sticking in rotor See POWER STEERING
PUMP article
Swish noise in Pump
Defective flow control valve See POWER STEERING
PUMP article
Groan in Steering Pump
Air in fluid See POWER STEERING
PUMP article
Poor pressure hose connection Tighten and check, replace if
necessary
Squawk When Turning
Damper "O" ring on valve spool cut See POWER STEERING
PUMP article
2010 BMW M3
Moan or Whine in Pump

Pump shaft bearing scored Replace bearing and fluid
Air in fluid or fluid level low See POWER STEERING
PUMP article
Hose or column grounded Check and replace if
necessary
Cover "O" ring missing or damaged See POWER STEERING
PUMP article
Valve cover baffle missing or damaged See POWER STEERING
PUMP article
Interference of components in pump See POWER STEERING
PUMP article
Loose or poor bracket alignment Correct or replace if necessary
Hissing When Parking
Internal leakage in steering gear Check valved assembly first
Chirp in Steering Pump
Loose or worn power steering belt Adjust or replace if necessary
Buzzing When Not Steering
Noisy pump See POWER STEERING
PUMP article
Free play in steering shaft bearing See STEERING COLUMN
article
Bearing loose on shaft serrations See STEERING COLUMN
article
Clicking Noise in Pump
Pump slippers too long See POWER STEERING
PUMP article
Broken slipper springs See POWER STEERING
PUMP article
Excessive wear or nicked rotors See POWER STEERING
PUMP article
Damaged cam contour See POWER STEERING
PUMP article
Poor Return of Wheel
Wheel rubbing against turn signal See STEERING COLUMN
SWITCHES article
Flange rubbing steering gear adjuster See STEERING COLUMN
article
Tight or frozen steering shaft bearing See STEERING COLUMN
article
Steering gear out of adjustment See POWER STEERING
GEAR article
Sticking or plugged spool valve See POWER STEERING
2010 BMW M3
PUMP article
Improper front end alignment See WHEEL ALIGNMENT
article
Wheel bearings worn or loose See FRONT SUSPENSION
article
Ties rods or ball joints binding Check and replace if
necessary
Intermediate shaft joints binding See STEERING COLUMN
article
Kinked pressure hoses Correct or replace if necessary
Loose housing head spanner nut See POWER STEERING
GEAR article
Damaged valve lever See POWER STEERING
GEAR article
Sector shaft adjusted too tight See ADJUSTMENTS in
POWER STEERING GEAR
article
Worm thrust bearing adjusted too tight See ADJUSTMENTS in
POWER STEERING GEAR
article
Reaction ring sticking in cylinder See POWER STEERING
GEAR article
Reaction ring sticking in housing head See POWER STEERING
GEAR article
Steering pump internal leakage See POWER STEERING
PUMP article
Steering gear-to-column misalignment See STEERING COLUMN
article
Lack of lubrication in linkage Service front suspension
Lack of lubrication in ball joints Service front suspension
Increased Effort When Turning Wheel Fast Foaming, Milky Power Steering Fluid, Low Fluid Level or
Low Pressure
High internal pump leakage See POWER STEERING
PUMP article
Power steering pump belt slipping Adjust or replace if necessary
Low fluid level Check and fill to proper level
Engine idle speed to low Adjust to correct setting
Air in pump fluid system See POWER STEERING
PUMP article
Pump output low See POWER STEERING
PUMP article
Steering gear malfunctioning See POWER STEERING
GEAR article
2010 BMW M3
Wheel Surges or Jerks

Low fluid level Check and fill to proper level
Loose fan belt Adjust or replace if necessary
Insufficient pump pressure See POWER STEERING
PUMP article
Sticky flow control valve See POWER STEERING
PUMP article
Linkage hitting oil pan at full turn Replace bent components
Kick Back or Free Play
Air in pump fluid system See POWER STEERING
PUMP article
Worn poppet valve in steering gear See POWER STEERING
PUMP article
Excessive over center lash See POWER STEERING
GEAR article
Thrust bearing out of adjustment See POWER STEERING
GEAR article
Free play in pot coupling See POWER STEERING
PUMP article
Steering gear coupling loose on shaft See POWER STEERING
PUMP article
Steering disc mounting bolts loose Tighten or replace if
necessary
Coupling loose on worm shaft Tighten or replace if
necessary
Improper sector shaft adjustment See POWER STEERING
GEAR article
Excessive worm piston side play See POWER STEERING
GEAR article
Damaged valve lever See POWER STEERING
GEAR article
Universal joint loose Tighten or replace if
necessary
Defective rotary valve See POWER STEERING
GEAR article
No Power When Parking
Sticking flow control valve See POWER STEERING
PUMP article
Insufficient pump pressure output See POWER STEERING
PUMP article
Excessive internal pump leakage See POWER STEERING
PUMP article
Excessive internal gear leakage See POWER STEERING
2010 BMW M3
PUMP article
Flange rubs against gear adjust plug See STEERING COLUMN
article
Loose pump belt Adjust or replace if necessary
Low fluid level Check and add proper amount
of fluid
Engine idle too low Adjust to correct setting
Steering gear-to-column misaligned See STEERING COLUMN
article
No Power, Left Turn
Left turn reaction seal "O" ring worn See POWER STEERING
GEAR article
Left turn reaction seal damaged/missing See POWER STEERING
GEAR article
Cylinder head "O" ring damaged See POWER STEERING
PUMP article
No Power, Right Turns
Column pot coupling bottomed See STEERING COLUMN
article
Right turn reaction seal "O" ring worn See POWER STEERING
GEAR article
Right turn reaction seal damaged See POWER STEERING
GEAR article
Internal leakage through piston end plug See POWER STEERING
GEAR article
Internal leakage through side plugs See POWER STEERING
GEAR article
Lack of Effort in Turning
Left and/or right reaction seal sticking in cylinder head Replace, see POWER
STEERING GEAR article
Wanders to One Side
Front end alignment incorrect See WHEEL ALIGNMENT
article
Unbalanced steering gear valve See POWER STEERING
GEAR article
Low Pressure Due to Steering Pump
Flow control valve stuck or inoperative See POWER STEERING
PUMP article
Pressure plate not flat against cam ring See POWER STEERING
PUMP article
Extreme wear of cam ring Replace and check
adjustments
Scored plate, thrust plate or rotor See POWER STEERING
2010 BMW M3
PUMP article
Vanes not installed properly See POWER STEERING
PUMP article
Vanes sticking in rotor slots See POWER STEERING
PUMP article
Cracked/broken thrust or pressure plate See POWER STEERING
PUMP article
STEERING COLUMN TROUBLE SHOOTING
BASIC STEERING COLUMN TROUBLE SHOOTING CHART

Noise in Steering
Coupling pulled apart See STEERING COLUMNS
article
Column not correctly aligned See STEERING COLUMNS
article
Broken lower joint Replace joint
Horn contact ring not See STEERING COLUMN
article
Bearing not lubricated See STEERING COLUMN
article
Shaft snap ring not properly seated Reseat or replace snap ring
Plastic spherical joint not lubricated See STEERING COLUMN
article
Shroud or housing loose Tighten holding screws
Lock plate retaining ring not seated See STEERING COLUMN
article
Loose sight shield Tighten holding screws
High Steering Shaft Effort
Column assembly misaligned See STEERING COLUMN
article
Improperly installed dust shield Adjust or replace
Tight steering universal joint See STEERING COLUMN
article
High Shift Effort
Column is out of alignment See STEERING COLUMN
2010 BMW M3
article
Improperly installed dust shield Adjust or replace
Seals or bearings not lubricated See STEERING COLUMNS
article
Mounting bracket screws too long Replace with new shorter
screws
Burrs on shift tube Remove burrs or replace tube
Lower bowl bearing assembled wrong See STEERING COLUMN
article
Shift tube bent or broken Replace as necessary
Improper adjustment of shift levers See STEERING COLUMN
article
Improper Trans. Shifting
Sheared shift tube joint Replace as necessary
Sheared lower shaft lever Replace as necessary
Improper shift lever adjustment See STEERING COLUMN
article
Improper gate plate adjustment See STEERING COLUMN
article
Excess Play in Column
Instrument panel bracket bolts loose Tighten bolts and check
bracket
Broken weld nut on jacket See STEERING COLUMN
article
Instrument bracket capsule sheared See STEERING COLUMN
article
Column bracket/jacket bolts loose Tighten bolts and check
bracket
Steering Locks in Gear
Release lever mechanism See STEERING COLUMN
article
SUSPENSION TROUBLE SHOOTING
BASIC SUSPENSION TROUBLE SHOOTING CHART

Front End Noise
2010 BMW M3
Loose or worn wheel See Wheel Bearing

Adjustment in SUSPENSION
Worn shocks or shock mountings Replace struts or strut
mountings
Worn struts or strut mountings Replace struts or strut
mountings
Loose or worn lower control arm See SUSPENSION
Loose steering gear-to-frame bolts See STEERING
Worn control arm bushings See SUSPENSION
Ball joints not lubricated Lubricate ball joints & see
Ball Joint Checking in
SUSPENSION
Front Wheel Shake, Shimmy, or Vibration
Tires or wheels out of balance Check tire balance
Incorrect wheel alignment See WHEEL ALIGNMENT
Drive shaft unbalanced Check drive shaft balance
Loose or worn wheel bearings See WHEEL ALIGNMENT
Loose or worn tie rod ends See SUSPENSION
Worn upper ball joints See Ball Joint Checking in
SUSPENSION
Worn shock absorbers Replace shock absorbers
Worn strut bushings Replace strut bushings
Car Pulls to One Side
Mismatched or uneven tires Check tire condition
Broken or sagging springs See SUSPENSION
Loose or worn strut bushings See SUSPENSION
Improper wheel alignment See WHEEL ALIGNMENT
Improper rear axle alignment Check rear axle alignment
Power steering gear unbalanced See STEERING
Front brakes dragging See BRAKES
Abnormal Tire Wear
Unbalanced tires Check tire balance & rotation
Sagging or broken springs See SUSPENSION
Incorrect front end alignment See WHEEL ALIGNMENT
Faulty shock absorbers Replace chock absorbers
Scuffed Tires
Toe-In incorrect See WHEEL ALIGNMENT
Suspension arm bent or twisted See appropriate
SUSPENSION article
Springs Bottom or Sag
Bent or broken springs See SUSPENSION
Leaking or worn shock absorbers Replace shock absorbers
2010 BMW M3
Frame misalignment Check frame for damage

Spring Noises
Loose "U" Bolts See SUSPENSION
Loose or worn bushings See SUSPENSION
Worn or missing interliners See SUSPENSION
Shock Absorber Noise
Loose shock mountings Check & tighten mountings
Worn bushings Replace bushings
Air in system Bleed air from system
Undercoating on shocks Remove undercoating
Car Leans or Sways on Corners
Loose stabilizer bar See SUSPENSION
Faulty shocks or mountings Replace shocks or mountings
Broken or sagging springs See SUSPENSION
Shock Absorbers Leaking
Worn seals or reservoir tube crimped See SUSPENSION
Broken Springs
Loose "U" bolts See SUSPENSION
Inoperative shock absorbers Replace shock absorbers
WHEEL ALIGNMENT TROUBLE SHOOTING
BASIC WHEEL ALIGNMENT TROUBLE SHOOTING CHART

Premature Tire Wear
Improper tire inflation Check tire pressure
Front alignment out of tolerance See ALIGNMENT SPECS in
WHEEL ALIGNMENT
section
Suspension components worn See SUSPENSION section
Steering system components worn See STEERING section
Improper standing height See WHEEL ALIGNMENT
Uneven or sagging springs See SUSPENSION section
Bent wheel See WHEEL ALIGNMENT
Improper torsion bar adjustment See SUSPENSION section
Loose or worn wheel bearings See WHEEL BEARING ADJ.
2010 BMW M3
in SUSPENSION section
Worn or defective shock Replace shock absorbers
Tires out of balance Check tire balance
Pulls to One Side
Brake dragging See BRAKE section
Mismatched tires See WHEEL ALIGNMENT
Broken or sagging spring See SUSPENSION section
Broken torsion bar See SUSPENSION section
Power steering valve not centered See STEERING section
Front alignment out of tolerance See WHEEL ALIGNMENT
section
Defective wheel bearing See WHEEL BEARINGS in
SUSPENSION section
Uneven sway bar links See SUSPENSION section
Frame bent Check for frame damage
Steering system bushing worn See STEERING section
Hard Steering
Idler arm bushing too tight See STEERING LINKAGE in
STEERING section
Ball joint tight or seized See SUSPENSION section
Steering linkage too tight See STEERING LINKAGE in
STEERING section
Power steering fluid low Add proper amount of fluid
Power steering drive belt loose See STEERING section
Power steering pump defective See STEERING section
Steering gear out of adjustment See STEERING section
Incorrect wheel alignment See WHEEL ALIGNMENT
Damaged steering gear See STEERING section
Damaged suspension See SUSPENSION section
Bent steering knuckle or supports See SUSPENSION section
Vehicle "Wanders"
Strut rod or control arm bushing worn See SUSPENSION section
Loose or worn wheel bearings See WHEEL BEARINGS in
SUSPENSION section
Stabilizer bar missing or defective See SUSPENSION section
Wheel alignment out of tolerance See Adjustment in WHEEL
ALIGNMENT section
Broken spring See SUSPENSION section
Defective shock absorber Replace shock absorbers
2010 BMW M3
Worn steering & suspension components See SUSPENSION section

Front End Shimmy
Tire out of balance/round Check tire balance
Excessive wheel runout See WHEEL ALIGNMENT
Insufficient or improper caster See WHEEL ALIGNMENT
section
Worn suspension or steering components See SUSPENSION section
Defective shock absorbers Replace shock absorber
Wheel bearings worn or loose See WHEEL BEARING ADJ.
in SUSPENSION section
Power steering reaction Bracket loose See STEERING section
Steering gear box (rack) mounting loose See STEERING section
Steering gear adjustment loose See STEERING section
Worn spherical joints See SUSPENSION section
Toe-In Not Adjustable
Lower control arm bent See SUSPENSION section
Frame bent Check frame for damage
Camber Not Adjustable
Control arm bent See SUSPENSION section
Frame bent Check frame for damage
Hub & bearing not seated properly See SUSPENSION section
2010 BMW M3
GENERAL INFORMATION The Battery - Overview - All Models
GENERAL INFORMATION
The Battery - Overview - All Models
THE BATTERY
Model: All
Production Date: All
Fig. 1: View Of Electrical Components Connected To Battery

Purpose of the Automotive Battery:
The battery is the primary EMF source in the automobile. In addition the battery performs the following
functions:
Provides voltage and current for the starter motor.

Provides voltage and current for the ignition during cranking.
Supplies all electrical power when the charging system is not operating.
Supplies the extra power necessary when the vehicle's electrical load exceeds the supply from the
charging system.
2010 BMW M3
Acts as a voltage stabilizer in the electrical system. The battery evens out voltage spikes and prevents
them from damaging other components in the electrical system.
Provides power to KL30, KL15 and KLR.
The battery does not store electrical energy. It stores chemical energy that is converted to electrical energy as it
discharges.
BATTERY CONSTRUCTION
Modern automotive batteries are made of cases (usually plastic) containing alternating plates of Lead and Lead
Dioxide (or Lead Oxide) separated by insulators. These alternating plates are connected in series to produce a
voltage of 12.6 volts, or about 2.1 volts for each set of Lead and Lead Dioxide plates. The negative terminal is
connected to a Lead Dioxide plate and the positive terminal to a Lead plate.
2010 BMW M3
Fig. 2: Identifying Battery Plates

The plates are covered with electrolyte which is a solution of 35% Sulfuric acid and 65% Water.
2010 BMW M3
Fig. 3: Cross Sectional View Of Battery

1. Plastic container.
2. Positive and negative internal plates made of lead.
3. Plate separators made of porous synthetic material.
4. Electrolyte which is a dilute solution of Sulfuric acid and water better known as Battery Acid.
5. Lead terminals which are the connection point between the battery and whatever it powers.
Battery Case
Most battery cases and their covers are made of polypropylene. The case is divided into six sections or cells,
shaped similar to an ice-cube tray.
The case is designed to:
Withstand hot and cold temperature extremes.

Resist damage caused by mechanical shock in automotive applications.
2010 BMW M3
Resist acid absorption and chemical damage.
The Grids
The grids are the supporting framework for the active material of the plates. They also conduct current to and
from the active material plates.
Fig. 4: Identifying Battery Grids

2010 BMW M3
The Plates
Plates are grids covered with a paste mixture of Lead Oxide and Sulfuric Acid and water. An expander material
made of powdered sulfates is added to the paste to produce negative plates.
A forming charge is applied to the positive plates converting the Lead Oxide to Lead Dioxide, a highly porous
material which allows the electrolyte to freely penetrate the plate.
A forming charge is also applied to the negative plates converting the Lead Oxide to Sponge Lead. The Sponge
Lead allows the electrolyte to penetrate freely allowing the material beneath the plate surface to take part in the
chemical reaction.
The Separators
Separators are thin sheets of electrically insulating porous material used as spacers between the plates to prevent
short circuits within the cells.
Fine pores in the separators allow ionic current flow in the electrolyte between the positive and negative plates.
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Fig. 5: Identifying Battery Separators

Elements
In the most common method of construction, a stack of alternate positive and negative plates are formed with
separators between each positive and negative plate. The lugs of the negative plates are welded together as are
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those of the positive plates. The plate strap of each group of plates is used to connect them in series with the
plate group of the next cell, or with a battery terminal.
The assembly resulting from placing one positive plate group and one negative plate group together, with
separators is known as an element. There is one element per battery cell. More or larger plates per cell will
increase plate surface area and increase capacity of the battery but will not affect the voltage output.
Electrolyte
The electrolyte is a mixture of Sulfuric Acid and Water. Electrolyte consists of 35% sulfuric acid and 65%
water.
The electrolyte is the carrier for the electric current to move between the positive and negative plates through
the separators.
The Lead Terminals
BMW's use a tapered top terminal. This design uses tapered terminal posts built to industry standards so that all
cable clamps will fit any battery with these posts.
The positive terminal is slightly larger than the negative to minimize the danger of installing the battery in
reverse. The positive terminal is 17.5mm in diameter at the top. The negative terminal is 15.9mm at the top.
Fig. 6: Identifying Battery Terminals

BATTERY TYPES
There are at least three types of the Lead-acid batteries that are currently used in the Automotive Industry.
Lead-Acid Battery
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The three major contributors to battery chemistry are lead, lead dioxide and sulfuric acid. Pure lead is too soft to
withstand the physical abuse of mobile applications, so a strengthener is needed. About 6% antimony, a semi
metallic element produced as a by-product to copper and lead ore refining, is added to strengthen the lead.
The antimony added to the grids acts as a catalyst and makes the loss of hydrogen and oxygen through
outgassing worse. These batteries require frequent water replenishing.
Lead/Calcium Battery
Introduced in the 1970's Lead/Calcium batteries have Calcium added to the positive and negative grids to
reduce the outgassing. These batteries were first referred to as "maintenance free". The Lead/Calcium batteries
are not resistant to deep-cycling which occurs when a battery is drained to a very low voltage before being
recharged. Frequent deep-cycling renders these batteries unable to sustain a charge. Lead/Calcium batteries
need to be charged at higher voltage settings or they will not be recharged to full capacity.
Hybrid Battery
Hybrid batteries use a positive grid strengthened with antimony and a negative grid with calcium. The hybrid
battery is more resistant to deep cycling than the lead/calcium, but still not as good as the original Lead-acid
battery. Water usage is greatly reduced in the hybrid battery, although regular checking is advisable. Most cars
supplied with hybrid batteries have their voltage regulators set to 14.3 volts.
Hybrid batteries were first installed in the E30 convertible during the 1991 Model Year.
HOW THE BATTERY WORKS
Discharging
Batteries don't store electrical energy, they store chemical energy and convert it to electrical energy during the
discharging process.
Each cell of a battery contains positive and negative plates (grids). The positive plate is made of lead dioxide,
the negative plate of a spongy lead. The negative plate combines with the sulfuric acid to create lead sulfate and
one extra electron. The positive plate produces hydrogen ions and sulfuric acid ions (positive ions, atoms
missing one electron).
The extra electrons from the negative plate are passed from the negative battery terminal and through the
electrical consumer, back to the positive battery terminal. Once back at the battery, the free electrons combine
with the positive ions at the positive battery terminal producing lead sulfate and water.
It is important to remember that the system is closed. For every electron generated at the negative terminal,
there is an electron consumed at the positive terminal.
As the process continues, the active materials (lead and lead dioxide plates and the electrolyte) become depleted
and the reactions slow down until the battery is no longer capable of supplying electrons. At this point the
battery is discharged.
2010 BMW M3
The discharge process changes the ratio of sulfuric acid to water in the electrolyte, as more water is produced in
the discharge process. By measuring the volume of acid in the water, the state of charge of the battery is
discovered.
Fig. 7: Identifying Discharge Process

Charging
Applying voltage to the battery from an external source such as the generator or battery charger reverses the
chemical action in the battery.
Reversing the chemical action in the battery, forces the free electrons at the negative terminal of the battery
back into the electrolyte raising the sulfuric acid percentage. This chemical action removes the Lead sulfate that
had formed on the negative plates leaving pure active material.
The electrons that were forced into the electrolyte are able to react with the lead sulfate on the positive terminal
again raising the Sulfuric acid content and leaving pure active material on the positive plates.
This process enables the battery to be used over and over again.
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Fig. 8: Identifying Charging Process

COMMON BATTERY TERMS
Fig. 9: View Of Battery Label

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Ah - Amp Hour Capacity
This rating is derived from discharging a fully charged battery at a constant amp draw for 20 hours @ 80
F, without the voltage of the battery falling below 10.5 volts. The constant amp draw is multiplied by the
20 hours to come up with the Amp Hour Rating.
CCA - Cold Cranking Performance
Represents the amperage capacity a fully charged battery can deliver @ 0F for 30 seconds before the
voltage of the battery falls below 7.2 volts.
RC - Reserve Capacity
Reserve capacity is expressed in minutes and relates to the amount of time a fully charged battery can
maintain a constant draw of 25 amps @ 80F before the voltage falls below 10.2 volts.
W - Watts
The measurement of electrical power that the battery can deliver for a cold start. It is calculated by
multiplying the starter amperage draw @ 0F times 10 volts.
V - Volt
Unit of measure of potential difference (Electrical pressure).
A - Amp
The current flow in a circuit. Value is proportional to the number of electrons flowing past a point in one
second.
ohms - Ohm
The measurement of the resistance of a component or circuit to current flow.
Electrolyte
The mixture of sulfuric acid and water. 35% sulfuric acid, 65% water.
Specific Gravity
The measurement (by weight) of the volume of sulfuric acid in the electrolyte. A specific gravity of 1.275
(the specific gravity of a fully charged battery) means that the electrolyte is 1.275 times heavier than
water. The specific gravity of water is 1.000.
Sulfate
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Deposits formed on the plates of the battery as the electrolyte gives up its sulfuric acid. Excessive deep
cycling of a battery can cause a hardening of this deposit and make it impossible to return sulfate to the
electrolyte. A sulfated battery is one which has these hardened deposits on the plates and cannot be
recharged to full capacity.
OCV Open Circuit Voltage
The measurement of the voltage of a battery across the terminals.
Fig. 10: View Of Battery Information Label

BATTERY TESTING
There are four steps to follow in testing an automotive battery:
Inspection.
Removal of Surface Charge.
State-of-Charge Test.
Load Test.
Tools Needed
To test a battery following tools are needed:
DVOM Digital Volt Ohm Meter.

Battery Load Tester (i.e. Snap On VAT 60).
DISplus or MoDic.
Battery Draw Test Special Tool PN 61 2 300.
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Closed Circuit Measurement Adapter PN 90 88 6 612 310.

Temperature Compensating Hydrometer.
Fig. 11: Identifying Battery Load Tester

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Fig. 12: View Of Draw Test Tool

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Fig. 13: Identifying Temperature Compensating Hydrometer

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Fig. 14: View Of Closed Circuit Measurement Adapter

Inspection
Visual inspection is important for the detection of obvious problems:
Loose Generator Belt.

Low Electrolyte Level.
Corroded Cable or Terminal Clamps.
Loose Hold-Down Camps or Cable Terminals.
Damaged Battery Case.
NOTE: The proper electrolyte level is just covering the plates, not all the way to
the top of the battery inspection holes.
Removal of Surface Charge

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If the battery has just been recharged, or the car has been driven, eliminate any surface charge by one of the
following methods:
Allow the battery to sit for 2-3 hours.

Turn the headlights on high beam for 5 minutes and wait 5 minutes after turning off.
With battery load tester, apply a load of 1/2 the battery's CCA for 15 seconds, then wait 5 minutes.
State-of-Charge Test
OPEN CIRCUIT BATTERY VOLTAGE SPECIFICATIONS

Open Circuit Battery Voltage Approximate State Of Charge Average Cell SG
12.65 + 100% 1.265 +
12.45 75% 1.225
12.24 50% 1.190
12.06 25% 1.155
11.89 0% 1.120
Use the table to determine the battery's State-of-Charge.
Pay special attention if the DVOM measurement of OCV is equal to:
0 volts - Indicate an open cell.

10.45-10.65 volts - Indicates a shorted cell.
For non-sealed batteries, check both specific gravity (SG) in each cell with a temperature compensated
hydrometer and battery OCV, without the engine running.
For sealed batteries, measuring the battery's OCV (without the engine running) with an accurate DVOM is the
only way to determine the state-of-charge.
Batteries with a built-in hydrometer measure the state-of-charge in one cell only. If the indicator is clear or light
yellow, the battery has a low electrolyte level and should be refilled before proceeding or replaced.
A state-of-charge reading BELOW 75% using SG, voltage measurement or dark indicator in batteries with
built-in hydrometers, indicates the battery must be recharged before proceeding.
Replace the battery if one or more the following conditions are met:
More than 0.050 difference in the specific gravity readings between the highest and lowest cell (There is a
weak or dead cell).
The battery will not recharge to 75% or greater state-of-charge or the built in hydrometer does not
indicate good (green indicates 65% or better).
DVOM reading indicates 0 volts (Open cell).
DVOM reading indicates 10.45-10.65 volts (Shorted cell).
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Load Test
A battery which has a state-of-charge of 75% or greater or has a "good" built-in hydrometer indication may be
load tested.
With a battery load tester properly installed, load the battery for 15 seconds to one of the following:
One-half (1/2) the CCA (Cold Cranking Amps).

Three (3) times the AH Rating (Amp Hour Rating).
The voltage on a good battery will NOT drop below 9.7 volts during the battery load test. After the load is
removed, wait 5 minutes, the battery should bounce back to 50% or greater state-of-charge. If a battery drops
below 9.7 volts during the load test, does not bounce back or fails to start the engine, the battery should be
replaced. Batteries which pass this test should be recharged to restore peak performance.
Load Test Conditions
Tests assume electrolyte temperature of 80 F, 26.7 C.
If the electrolyte temperature is above 80 F add .1 volt for every 10 degrees up to 100.
If the temperature is below 80 F subtract .1 volt for every 10 degrees to 40.
BATTERY MAINTENANCE
Electrolyte Level
If battery electrolyte level is allowed to drop substantially, the gas volume inside the battery grows
proportionately resulting in an increased amount of flammable gas mixture. Any external or internal spark may
result in an oxyhydrogen explosion. Additionally the plates are no longer covered by the electrolyte and may
corrode.
The battery electrolyte level should be checked on every Inspection I and Inspection II.
Use only distilled water to top up the battery!
Tap water and electrolyte must never be used to refill or top off an automotive battery.
Workshop Hint:
Electrolyte levels may drop at a higher rate in the winter months, due to higher loads and increased utilization of
electrical systems.
Battery Cable Connections
The top of the battery should be clean. Check for and correct corrosion on the top of the battery and the cable
connections.
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Workshop Hint
Many battery problems are caused by loose or corroded connections. Insure that cables are free from corrosion
and tight before continuing diagnosis.
Battery Charging
The purpose of charging a battery is to put back the energy that has been removed. A battery that is not properly
charged will deliver sub-standard performance and display a shorter life span.
A battery should be charged only after performing a visual inspection on the battery case and the electrolyte
levels. Never attempt to charge a battery with a damaged case or low electrolyte levels.
A state-of-charge test should be performed before attempting to charge a battery.
Always connect the positive lead of the battery charger to the positive terminal of the battery and the negative
lead of the battery charger to the negative terminal of the battery.
Unplug the charger or turn it off BEFORE disconnecting the leads at the battery.
Batteries that are fully discharged should be charged according to the following table.
BATTERIES SPECIFICATIONS
Reserve Capacity Rating (RC) Slow Charge Fast Charge
80 minutes or less 15 hours @ 3 amps 2.5 hours @ 20 amps
80 to 125 minutes 21 hours @ 4 amps 3.75 hours @ 20 amps
125 to 170 minutes 22 hours @ amps 5 hour @ 20 amps
170 to 250 minutes 23.hours @ 6 amps 7.5 hours @ 10 amps
Above 250 minutes 24 hours @ 10 amps 6 hours @ 40 amps
The best charging method is to SLOWLY recharge the battery using the BMW approved battery charger.
A slow charging rate allows more time for the electrolyte to penetrate the plates.
Sulfated Batteries
Continuous discharging of the battery or low electrolyte levels cause crystals to form on the plates. These
crystals of lead sulphate occur when a battery is discharged. The deeper the discharge the more serious the
sulphation. The sulphur molecules that form the sulphate are then absent from the electrolyte, causing the
electrolyte to become inefficient.
A battery relies on clean plates and strong electrolyte to both receive charging current and offer strong current
discharge. A sulphated battery can do neither. Proper recharging of the battery will remove some but not all of
the sulphate. Eventually the battery plates are coated with enough sulphate that it is impossible to achieve an
efficient recharge.
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Testing A Battery for Sulphation
A battery which fails the load test should be tested for sulphation. To test a battery for sulphation, place it on a
battery charger for three minutes with the charger set on 40 amps. After three minutes check the OCV, if the
reading is greater than 15.0 volts the battery is sulphated. Batteries which indicate a sulphated condition should
be recharged slowly and retested before being discarded.
Battery Freezing
A fully charged battery can be stored at sub-freezing temperatures with no damage. The battery is protected
from freezing to a temperature of -75 F. A fully discharged battery however will freeze at +27 F.
Avoid freezing by keeping the battery fully charged.
Carefully inspect a battery which has frozen for a cracked case.
Battery Maintenance (Center Vehicles)
The battery charge is monitored while the vehicle is at the VPC and before it leaves on the transport. When the
vehicle is having the QC I performed at the center the check list requires that the battery voltage be checked and
maintained to 12.65V minimum.
In order to facilitate tracking vehicles in inventory, BMW has in place a Battery Maintenance Program. The
program uses:
Battery Log Forms.

Battery Log Binder.
Colored windshield stickers (red, green, yellow and white).
The Battery Maintenance Program has three possibilities:
Vehicle in storage, battery disconnect switch removed.

Vehicle in showroom or display.
Vehicle in storage, Battery disconnect switch left in the vehicle.
Vehicle In Storage, Battery Disconnect Switch Removed
A four week charging cycle has been established for these cases. All vehicles arrive with a color coded sticker
on the windshield. The color corresponds to the week that the battery must be charged. Also the vehicle will be
provided with a Battery Log Form.
The "A" portion (Vehicle Receipt) of the Log Form must be completed during the QC I Display check and then
has to be filed in the Battery Charge Log Book under the applicable color coded section. All the vehicles in that
color section will have to be charged that week.
Vehicle In Showroom or Display

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Because of the high consumer demand on vehicles that are being displayed and not driven, a four week
charging cycle is not enough. For vehicles in the showroom the battery has to be charged as frequently as
necessary to ensure that the battery never drops below 12.5V. Use the "C" portion of the log form (Display
Vehicle - Monitored Daily) to keep track of the charging and checking of the battery.
Vehicle In Storage, Battery Disconnect Switch Left In The Vehicle.
Since the battery disconnect switch is left installed and in the "OFF" position the 3 month charge cycle can be
used. Use the "D" section of the Battery Log Form to document when the battery is charged.
Upon the sale of the vehicle, the Battery Log Form should be removed from the binder and placed in the vehicle
file for future reference.
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Fig. 15: Battery Log Form (B Section)

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Fig. 16: Battery Log Form (D Section)

NOTE: If the battery voltage drops below 11.6v for three days or more the battery must
be replaced before delivery to the customer
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Battery Maintenance Flowchart
Fig. 17: Battery Maintenance Flow Chart

BATTERY REPLACEMENT
Batteries determined to be defective through testing procedures should be replaced using the following
guidelines.
2010 BMW M3
Reconfirm battery is actually defective and it does not need charging.

Insure that ignition switch is in "Off" position and engine is not running.
Disconnect negative battery terminal first.
Place negative battery cable in a position so that it can not come in contact with battery during removal
process.
Reinstall battery hold down clamp.
Install positive cable first.
Recheck output of vehicle generator and balance of electrical system for other problems.
Provide clear and concise description of the defect including cell readings, load test results and any other
pertinent information which led to the battery replacement.
Tag battery with VIN and repair order number.
Battery Failures
An analysis of batteries replaced under warranty shows that many claims could have been avoided had the
batteries been maintained in a full state of charge.
Batteries must be maintained at all times when vehicles are at a retailer whether they are new cars, used cars, in
storage (back lot), on display, or customer cars in for maintenance or repairs.
Batteries replaced due to lack of maintenance will not be covered by warranty.
Most Common Causes of Premature Battery Failures
Failure to maintain proper state of charge.

Loss of electrolyte due to overcharging or excessive heat.
Deep discharging (Leaving lights on or other parasitic draws).
Undercharging of battery.
Vibration (Loose battery hold down clamp).
Using tap water (instead of distilled water).
Corrosion.
Freezing.
Workshop Hints
Safety Tips
Proper Clothing:
Always wear a face shield or safety goggles.
Plastic gloves can prevent acid burns to hands.
Neutralizing Electrolyte:
2010 BMW M3
Any leakage or spillage of battery electrolyte should be neutralized as soon as possible to prevent damage to
paint, body or trunk linings. Depending on the amount of spillage dilute some baking soda in water and apply to
areas of the car that have been exposed to the battery electrolyte. The neutralizing action will create some
foaming in the area where the chemical action takes place. Flush with ample amounts of water once the
chemical reaction has subsided.
General Battery Hints
Add only distilled water NEVER TOP OFF WITH ACID.

Keep electrolyte level above plate separators.
Keep battery top clean and dry.
Keep open flame and metal objects away from battery top and terminals.
Keep vent caps tightly in place (if applicable).
Use proper charging equipment.
SPECIAL BATTERY SYSTEMS
Special battery systems are broken into two groups:
Vibration Compensating Battery Systems.

Dual Battery Systems.
Vibration Compensating Battery Systems
Vibration Compensating Battery Systems act as vibration absorbers, smoothing out road vibrations in the E36
and E46 convertibles.
E36:
The E36 convertible is not only an energy source. The battery is designed as a vibration dampener. Due to this
additional function the battery also has a special tray with an integrated vibration absorber.
NOTE: E36 convertible batteries are labeled "Vibration Proof". Replacement batteries
must be of the same type.
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Fig. 18: View Of Battery Identification Label

E46:
The E46 convertible uses the same battery as the E46 sedan, coupe and touring. The battery box is specially
designed to float on the vertical axis through three articulated rods.
This allows the battery to act as an inertia mass and dampen various vibrations while the vehicle is driven.
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Fig. 19: Identifying Dampening Rods

Dual Battery Systems
E31 (850i):
The dual battery system on the 850i was introduced to handle the higher level of electronic technology with
increased functions and safety features that were added to the vehicle, as well as the added diagnostic
information.
Design considerations were made to minimize electrical loads during Key Off and periods of driving with low
engine speeds while certain timed operations (e.g. Glove compartment light, courtesy lights and seat heating)
were active.
Special testing and charging procedures exist for the dual battery system on the 850i, refer to appropriate article
for specific information.
E38 750iL:
The dual battery system on the 750iL is necessary due to the addition of the E-CATs. If a single battery system
was used, the E-CATs would be provided power from the single battery just after cold engine start-up when the
battery is at its lowest capacity. This would increase engine loads due to charging of the single battery and cause
an increase in injector "On" time during the cold engine warm-up period, which result in unnecessary tail pipe
2010 BMW M3
emissions.
Providing separate battery systems for the starting circuit and the vehicle circuits also minimizes the possibility
of a discharged starter battery ensuring reliable engine starting.
Components of E38 Dual Battery System
Starter Battery: Located in the right rear trunk wheel, the starter battery is connected to the starter motor
and to the heating coils of the E-CATs (via the E-CAT module).
Vehicle Circuit Battery: Located above the starter battery on a swing out mount, the vehicle circuit
battery provides operating power for the balance of the vehicles electrical requirements and is directly
connected to the vehicle generator.
Battery Isolation Switch: Located on the swing out mount of the vehicle circuit battery the battery
isolation switch opens and closes the circuit between both batteries based on monitored conditions.
NOTE: The battery isolation switch is NOT used to boost a discharged starter battery
with the voltage of the vehicle circuit battery to start the engine. The battery
isolation switch can only withstand a maximum current flow of 60 amps.
Battery Isolation Switch
The Battery Isolation Switch provides the vehicle with separate battery systems for the vehicle circuits and the
starting circuit.
When the isolation switch is open, the vehicle circuit battery is the only power source connected to the power
distribution center.
When the isolation switch is closed the starter battery is charged and the vehicle circuit battery is boosted by the
starter battery.
Modes of the isolation switch:

2010 BMW M3
Fig. 20: Identifying Battery Isolation Switch

Starting Mode:
Normal Starting.
Safety Starting.
Driving Mode.
Charging Mode.
Sleep Mode.
Starting Mode
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When the isolation switch recognizes KL15 via the K Bus, it determines the voltage of the vehicle circuit
battery.
If the vehicle circuit battery IS sufficiently charged, it proceeds with Normal Starting.
If the vehicle circuit battery IS NOT sufficiently charged, it proceeds with Safety Starting.
Normal Starting
The isolation switch is open.

Within 0.5 seconds of engine start-up the E-CAT module energizes the E-CAT heating coils (program
dependent) and simultaneously signals the isolation switch that the ECATs are "On" via signal
"KATON" (low signal).
Upon completion of the heating period, the E-CAT module signals the isolation switch that the E-CATs
are off (High Signal).
Under normal conditions, the isolation switch is not closed before the heating procedure is finished.
Safety Starting:
In response to a discharged condition of the vehicle circuit battery, the isolation switch closes to
momentarily boost the vehicle circuit battery and supply all systems with starter battery voltage via the
power distribution center.
This operation lasts for a maximum of 30 seconds or until confirmation of engine start up is received.
(TD signal on the K Bus)
Receiving the TD signals causes the isolation switch to immediately open for the duration of the E-CAT
heating cycle.
If the engine is not started within the 30 seconds, the isolation switch opens and remains open until KL 15
is recognized on the next start-up cycle.
Driving Mode
The vehicle circuit battery is permanently connected in parallel to the generator and is charged when the engine
is running. When the isolation switch is closed, the generator simultaneously charges the starter battery.
As the vehicle is driven the isolation switch cycles between open and closed based on:
Voltage values of both batteries.

Current transfer between both batteries as monitored by the isolation switch.
Internal temperature of isolation switch.
Conditions Causing Switch To Open While Driving:
Sufficiently charged starter battery.

Current flow through switch exceeding 0.5 amps.
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The starter battery will supplement vehicle electrical needs during periods of high demand (e.g
continuous wiper operation combined with lights and blower).
The internal temperature of the isolation switch exceeds programmed maximum value.
Conditions Causing Switch To Close While Driving:
Monitored voltage of vehicle circuit battery exceeds that of starter battery by 0.7 volts.
The voltage of the vehicle circuit battery drops below 9 volts three times within one minute.
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2010 BMW M3
Fig. 21: Identifying Battery Charging System

Charging Mode (in the workshop)
The isolation switch monitors starter battery voltage during key off conditions and continues monitoring after
the vehicle and the isolation switch have entered sleep mode.
If starter battery voltage exceeds 13.8 volts during charging in the workshop, the isolation switch comes
out of sleep mode and closes.
This causes the starter battery voltage to bleed off to the vehicle circuit battery, charging the circuit
battery and protecting the starter battery from overcharging.
The isolation switch remains closed until the next key on cycle.
Fig. 22: Identifying Charging Mode (In Workshop)

Sleep Mode
The isolation switch goes into sleep mode as soon as the engine is switched off. The current draw of the
isolation switch drops below 1 mA. The isolation switch comes out of sleep mode if:
KL15 is recognized.
Starter battery voltage exceeds 13.8 volts (charging mode)
Failure of KATON signal:

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If the KATON signal is not received due to:
Open or short to B+ - isolation switch closes for 4 seconds after start-up, TD received.
Short to B- - isolation switch opens 60 seconds after receiving TD.
CLOSED CIRCUIT CURRENT DRAW TESTING
Increased closed-circuit currents may occur permanently or intermittently and cause the battery to discharge
prematurely. The increase in closed circuit current may be caused by a faulty control unit or by the installation
of a non-approved accessory.
In a situation where a vehicle has broken down due to a discharged battery, for diagnostic purposes it is
important not to disconnect the battery. The control unit may reset if the battery is disconnected. Following a
reset, a faulty control unit may start functioning correctly again, making accurate diagnosis impossible.
Tools Needed:
Closed Circuit Current Measurement Adapter.

MoDic Adapter.
DISplus, MoDic or DVOM.
To correctly measure closed-circuit current, measurement adapter 61 2 300 (P/N 90 88 6 612 300) should be
used. This tool provides a bridge to ground, before the negative battery terminal is disconnected, and this
prevents the control units from being reset.
The additional use of MoDiC adapter 61 2 310 (P/N 90 88 6 612 310) provides a method for current
measurements over an extended period of time.
The measuring device needed depends on the situation.
The DISplus may be used in situations of suspected high current draw.
The 1000 amp probe measures AC and DC current from 0 to 1000 amps. It is a self calibrating inductive pick-
up. (Use this pick-up with current draws over 10 amps) The DISplus, through MFK 1 is capable of measuring
up to 2 amps.
The MoDic is particularly suitable for extended measurements and provides a graphical readout of recorded
measurements over time. It is recommended for the situations where the use of a multimeter provided
insufficient information for problem diagnosis.
The DVOM may be used for measurements up to 10 amps either with the measurement adapter or alone.
NOTE: It is extremely important that the battery is NOT disconnected during the
installation of test equipment. Disconnection of battery may cause faulty
component to function normal.
2010 BMW M3
Performing Closed Current Draw Test
Select proper measuring device (DISplus, MoDic or DVOM)

Remember amperage draw in excess of 10A will damage DVOM.
Use inductive amp probe of DISplus when amperage draw is high.
When using DISplus inductive probe, clamp on negative battery cable with:
Arrow pointing away from battery. Switch off all consumers.
(It is not necessary to disconnect B- from body when using inductive probe).
Connect (-) test lead to negative battery terminal and (+) test lead to a known good ground.
Ensure all systems are OFF !
Be sure DVOM is on and set in proper mode.
Disconnect battery ground lead from body.
Observe meter reading, wait for vehicle to enter sleep mode.
Identify faulty circuit by disconnecting fuses, relays, control modules or connectors, observing meter
readings.
Defective circuit is found when current is below maximum closed current for vehicle being tested.
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Fig. 23: Identifying Performing Closed Current Draw Test

MAXIMUM CLOSED CURRENT BY VEHICLE

E31 50mA
E32 50mA
E34 40mA
E36 30mA
E38 50mA
E39 40mA
E46 40mA
E52 50mA
E53 40mA
Z3 30mA
NOTE: Refer to appropriate article for complete instructions to perform closed circuit
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current measurement using measurement adapter and MoDIc adapter.

2010 BMW M3
GENERAL INFORMATION BMW Universal Bluetooth - Overview - All Models
GENERAL INFORMATION
BMW Universal Bluetooth - Overview - All Models
BMW UNIVERSAL BLUETOOTH

INTRODUCTION
The BMW Universal Bluetooth HandsFree System (ULF) utilizes Bluetooth wireless technology to enable
a wireless connection to be established between a Bluetooth enabled mobile phone and the ULF Control
Module installed in the vehicle. The combination of these components results in a new generation of in-vehicle
phone system.
The ULF Control Module forms an interface that allows a mobile phone with the embedded Bluetooth
wireless technology feature to be wirelessly integrated into the vehicle. For the first time BMW is introducing a
new generation hands-free telephone system kit that provides the customer with the option of using various
Bluetooth enabled mobile phones (a list of recommended phones is available from your BMW Center).
Fig. 1: Identifying Oddment Tray Button

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WHAT IS BLUETOOTH
The name Bluetooth is derived from the Danish King Harald Bluetooth who lived in the 10th century. He was
well known for his ability to unify his kingdom and today lends his name to a wireless technology standard that
can connect/unify various electronic devices that are Bluetooth enabled and located within a short range
(approx. 10 m or 32.8 ft) of each other.
Bluetooth wireless technology is a short-range radio frequency technology standard that allows several
devices to communicate with each other simultaneously. The standard indicates that up to seven simultaneous
connections can be established and maintained at one time, as long as the connected devices are within a range
of 10 m (32.8 ft).
NOTE: The ULF system will allow four phones to be paired to the system at a time and
only allow one phone to be connected at a time.
Fig. 2: Bluetooth Network Area Description

2010 BMW M3
Communication/Security
The system uses the license-free, global Industrial Scientific Medical band (ISM) at 2.45 GHz. This frequency
range from 2.402 GHz to 2.480 GHz is subdivided into 79 channels with a 1 MHz bandwidth.
Signals transmitted through the airways can be scrambled and unscrambled to enhance communication security.
With Bluetooth technology, communication frequencies are changed 1600 times per second to reduce the risk
of interference or interception of the transmitted signal. The relatively small operating range of approx. 10 m
(32.8 ft) also enhances the security of this technology, since tampering with the transmitted data is only possible
when inside the 10 m (32.8 ft) wireless "network".
To further enhance the security of this short-range wireless network the ULF system requires a pairing
procedure to be carried out for each device that will be introduced into the network. As part of this procedure a
required passkey must be entered once (during the initial pairing procedure) to establish a secure connection
between the phone and the ULF Control Module.
Data and Voice
Bluetooth was developed for the transmission of both voice as well as data. A bandwidth of approx. 1 MB/s
is available for this purpose.
Bluetooth Enabled Phones
Ideally all phones that are Bluetooth enabled should work with the ULF system, however not all phones
utilize the same profiles and therefore may not be recognized by the ULF System. A list of recommended
Bluetooth enabled phones is available from your BMW Center.
ADVANTAGES OF THE ULF SYSTEM
Once a phone is paired to the system it will be able to automatically connect to the Bluetooth wireless
network of the vehicle, the next time it is introduced into the vehicle and the vehicle ignition is on.
Up to four different Bluetooth phones can be paired to the system at one time, although only one phone
can be wirelessly connected at any time.
The phone does not need to be inserted into a phone specific cradle in order to be integrated into the
vehicle.
The phone can remain in a briefcase, purse, glove box, etc.; as long as it is turned on and located within
the interior of the vehicle.
The MFL buttons on the steering wheel can be utilized to place or receive a call, to scroll the phone book
and select a number or activate voice recognition in order to dial a number via voice command.
A voice recognition system is integrated into the ULF control module and can be activated by depressing
the send/receive button.
The communications protocol of Bluetooth wireless technology is standardized irrespective of the
manufacturer, this therefore allows various mobile telephones that utilize Bluetooth wireless
technology and a recognized profile to be connected to the ULF System.
System Overview
2010 BMW M3
A ULF system consists of a control module, microphone, Bluetooth antenna, a standalone pairing
(send/receive) button, or eject box with a coin tray insert.
Fig. 3: ULF Control Module System Components

ULF Control Module
The ULF module forms the interface between the Bluetooth mobile phone and the electronic system in the
vehicle. The mobile phone with the embedded Bluetooth wireless technology is the transceiver, this requires
that the phone be activated, paired and present within the vehicle network in order to place or receive a call in
the vehicle.
Oddment Tray
The oddment tray, which is connected to the ULF control module via the vehicles wiring harness, serves the
purpose of:
Housing the send/receive or pairing button, which must be depressed to activate the pairing procedure
2010 BMW M3
between the phone and the control module.
Fig. 4: Identifying Oddment Tray Button

Pairing Button
A stand-alone send/receive or pairing button is supplied for the 3 Series in order to retain the cup holders.
The button provides the same function as the send/receive button on the steering wheel, plus is the button
that must be depressed to activate the pairing procedure between the phone and the control module.
2010 BMW M3
Fig. 5: Identifying Pairing Button

Bluetooth Antenna
The Bluetooth antenna operates on a frequency of 2.45 GHZ and is installed in the interior compartment of
the vehicle. This antenna provides the wireless interface between the Bluetooth enabled phone and the ULF
Control Module.
SYSTEM OPERATION
Initial Operation
Prior to using the system for the first time, the Bluetooth mobile phone that is to be used must be paired with
the ULF control module. This pairing procedure is necessary in order to assign the digital code of the mobile
phone to the ULF control module installed in the vehicle. The pairing procedure is only required when a new
phone is introduced to the ULF system for the very first time or the list of paired devices is cleared form the
memory of the ULF module, it does not need to be performed every time the phone is used with the system.
After pairing, the mobile phone is recognized automatically by the ULF control module within 45 seconds after
it is introduced into the vehicle and the ignition is turned on.
NOTE: Depending on the mobile phone manufacturer, particular care must be taken
prior to initial operation to ensure that no headset is coupled with the mobile
phone. Various devices may interpret the ULF control module as a headset and
2010 BMW M3
request deactivation of the headset. Please refer to the operating instructions of

the mobile phone for detailed information.
Pairing Procedure
The pairing procedure that must be initiated through the phone will differ corresponding to the different menu
configurations of the various Bluetooth mobile phones on the market. The user's manual of the phone
manufacturer should always be referenced for specific steps on how to activate the Bluetooth feature and to
pair/link devices.
The following steps are generalized steps that should help in activating the Bluetooth function of most
phones:
In Vehicle:
1. Depress the send /receive (pairing) button located in the center console, for at least 1 second prior to
switching on the ignition and continue to hold the button down for approximately 2-3 seconds after the
ignition is turned on.
2. Release the button.
NOTE: The send/receive (pairing) button in 5 Series and X5 SAV is located on the
oddment tray assembly in the center console.
2010 BMW M3
Fig. 6: Identifying Send /Receive (Pairing) Button Location (1 Of 2)

2010 BMW M3
Fig. 7: Identifying Send /Receive (Pairing) Button Location (2 Of 2)

3. Shortly after releasing the button on the Radio or Display Screen, the following message should be
displayed:
a. Display Screen:
"Bluetooth Pairing" displayed.
Green, Yellow and Red LEDs on the right side of the unit are flashing which indicates that the ULF
is waiting for a signal from the Bluetooth device to be paired.
2010 BMW M3
Fig. 8: Identifying Releasing Button On Radio

b. Radio Display (5 Series and X5 SAV):
"Bluetooth Pairing" Display Which Indicates That The Ulf Is Searching For Available Bluetooth
Devices. Green, Yellow And Red Leds On The Right Side Of The Unit Are Flashing Which
Indicates That The Ulf Is Waiting For A Signal From The Bluetooth Device To Be Paired.
2010 BMW M3
Fig. 9: Bluetooth Pairing Display

c. Radio Display (3 Series with CD or Cassette):
"BT Pairing" display which indicates that the ULF is searching for available Bluetooth devices.
2010 BMW M3
Fig. 10: BT Pairing Display

4. Activate the search function of the phone as indicated below.
ON PHONE:
1. Locate the connection/settings menu and select Bluetooth.

2. Select the response that will activate the Bluetooth feature of the phone.
3. Next select a menu option that will allow you to "Discover" or "Search" for active Bluetooth devices.
4. If the phone identifies/finds a device (named "BMW" followed by 5 digits) select it and follow the
indicated steps to complete the pairing process.
5. Once the phone is successfully paired to the device cycle the vehicle ignition switch off and back on and
the devices should wirelessly connect within 30 seconds. When the connection is established the phone
will display a connection symbol.
The following steps are an example of the pairing procedure that must be initiated to pair the Sony
Ericsson T68i phone to the ULF Control Module.
1. Press the menu button.

2. Select "Connect".
3. Select option 3: "Bluetooth".
4. Select option 4: "Options".
5. Select option 1: "Operation mode" and set to "On" or "Automatic".
2010 BMW M3
6. Go back one step by pressing the red phone button several times.
7. Select option 3: "Discover".
8. Mobile phone display shows 'Searching'
9. Select "BMW ......" in upcoming list.
10. Select option 1: "Add to paired".
11. Enter the password (= ULF passkey) located on ULF Control Module that is in the rear of the vehicle or
on the Passkey Reference Card.
Mobile phone display shows 'BMW ...... Pairing'
Mobile phone display shows 'Pairing Successful'
Display screen shows 'Pairing succeeded' for 3 seconds
12. Enter device name or accept the name that is automatically displayed.
13. Mobile phone display shows "Added to paired devices".
14. Exit menu by pressing the red phone/NO button.
15. Once the phone is successfully paired to the device cycle the ignition switch off and back on.
16. The devices should wirelessly connect within 30 seconds. The connection is established when the phone
displays the symbols indicated, on the right side of the screen.
NOTE: Shortly after turning on the ignition and the Bluetooth connection is
identified, the phone may display a message asking if the connection should be
established/accepted. The connection authorization request will always occur
unless the setting on the phone is modified to allow automatic connection every
time, please refer to the user's manual of the phone to determine how to change
this setting.
2010 BMW M3
Fig. 11: Locating Connection/Settings Menu On Phone

System Functions
The mobile phone must always be activated, paired and present within the Bluetooth network in order to
place or receive a call through the vehicle.
2010 BMW M3
Indicator Lamps
The indicator lamps show the following:
Fig. 12: Identifying Indicator Lamps

Active call (green light).
No mobile phone in range (steady red light).
No network (flashing red light).
Adopting Telephone Book
Depending on the type of Bluetooth mobile phone, the telephone book is either transferred automatically (ex.
Nokia 6310, Sony Ericsson T68i) or manually (depending on software version of phone) by the user to the ULF
control module. The address book is stored temporarily for the purpose of accessing/displaying stored
phonebook information using the steering wheel controls or telephone menu selections available on the display
screen or some radio displays.
If a manual transfer of the address book must be made, the ULF must be in setup mode for manual transfer. The
corresponding data can then be transferred. If phonebook data is modified while the phone is wirelessly
connected to the vehicle the changes will not be displayed in the vehicle if the phonebook is scrolled via the
steering wheel or display screen, changes will only be transferred the next time the ignition is cycled.
Placing a Call
A call can be placed in several different ways:
1. Using the keypad or address book of the mobile phone and depressing the send button on the phone.
NOTE: Some phones may ask if the call is to remain within the phone. Refer to the
users manual of the phone for specific instructions on disabling this
feature.
2. Depressing the R/T button on the steering wheel, then scrolling (using the or buttons) through the
address book of the phone that is linked to the ULF, until the desired number is displayed on the radio or
2010 BMW M3
place the call.

3. Depressing the button on the steering wheel until an audible "beep" is heard through the vehicle
speakers, at this point a call can be placed by using the following voice commands:
"Dial number" or "Dial phone":
After the system asks for a number say the number.
Example: "123 456 7890"; the system will repeat the number requested once you stop speaking
momentarily, the number may also be displayed depending on the vehicle and
equipment/accessories installed.
"Dial":
NOTE: Once the dial command is given the number will be displayed on the
dis play screen or radio; plus it will always be displayed on the
mobile phone after a call is placed.
4. Briefly depressing the button on the steering wheel will redial the last number dialed.
For more information on using voice commands refer to the " Owner's Manual for Voice Input System. The
Convenient Alternative to Manual Control" (P/N 84 11 027 942)
Receiving/Accepting a Call
The call ringer in the Bluetooth mobile phone is audible when an incoming call signal is received. At the
same time, the signal is sent via the Bluetooth interface in the mobile phone to the Bluetooth antenna in the
vehicle. The ULF receives the incoming ring/call signal via the Bluetooth antenna and mutes the radio. The
incoming ring/tone signal is then also transmitted to the vehicle speakers.
The following options are available for accepting a call:
3 Series without Display Screen:
Press send/receive button on MFL (Steering Wheel).

Press send/receive button in the center console.
Press send/receive key on mobile phone.
5 Series and X5 SAV without Display Screen:

Press send/receive key on radio.
Press send/receive button on the oddment tray (Center Console).
Vehicles with Display Screen:

2010 BMW M3

Select the green phone symbol on the Display Screen.
Conducting a Call
If the call is accepted by pressing the send/receive key on the Radio (5 series and X5 SAV), Display Screen,
steering wheel or center console, it will be conducted via the hands free microphone and vehicle speakers.
If a call is accepted by pressing the send/receive key on the mobile phone, the reaction will depend on the
type of handset. In the majority of cases, however, the question appears:
"Do you wish to use the mobile phone?"
Please refer to the operating instructions of the mobile phone for a detailed description of the operating
procedure of the phone.
The hands-free function is activated after pressing the send/receive key. The incoming call is encoded
(scrambled) via the Bluetooth interface in the mobile phone and sent to the Bluetooth antenna in the
vehicle. The call is received by the ULF control module and output via the radio to the audio speakers.
Fig. 13: Identifying Call Components (1 Of 2)

Since the ULF system provides a digital full-duplex hands-free operation, it is possible to simultaneously speak
and listen to calls. An echo cancellation function prevents feedback when speaking into the microphone. The
microphone audio signal is sent via a hardwire connection to the ULF control module. In the ULF module the
received audio signal is scrambled via the Bluetooth module and transferred via the Bluetooth antenna to
the mobile phone. The mobile phone then transmits the call via the phone antenna.
2010 BMW M3
Fig. 14: Identifying Call Components (2 Of 2)

Ending a Call
The following options are available for ending a call:
3 Series without Display Screen:

Press send/receive button in the center console.
5 Series and X5 SAV without Display Screen:

Press send/receive key on radio.
Vehicles with Display Screen:

Select the green phone symbol on the Display Screen.
Transfer Active Call From Phone to ULF
If a call is received or placed via the handset, it can be transferred into the vehicle once the phone is within the
active Bluetooth network of the vehicle.
Call transfer procedure:

2010 BMW M3
1. Ignition must be on.

2. Bluetooth connection must be established.
3. Briefly depress the send/receive button located in the center console.
NOTE: Some phones may automatically display a statement asking the user if the
active call should be transferred to the ULF system shortly after the Bluetooth
connection is established. If the request is acknowledged the call is
automatically transferred into the vehicle/ULF system without having to depress
the send/receive button.
Transfer Active Call from ULF to Phone
If you are currently in an active call and you need to leave the vehicle the call can be transferred into the
handset in several ways.
1. Ignition is turned off and you walk away from the vehicle. Once outside the 10 m (32.8 ft) range a
message may be displayed on the phone asking if the current call should be maintained or ended, by
maintaining the call it will be transferred to the handset.
2. Depending on the model of phone being used the call can be transferred to the handset by manually
disconnecting from the Bluetooth network via the connections menu or selecting a transfer function in
the settings menu of the phone (refer to the user's manual of the phone for more information).
Linking Several Bluetooth Mobile Phones
Up to four Bluetooth mobile phones can be paired one after the other to the ULF control module. The pairing
operation corresponds to the procedure described above.
The handset paired last has the highest priority. The telephone paired first will drop out of the list if a fifth
Bluetooth mobile phone is paired.
NOTE: For incoming and outgoing calls, only the user connected first to the system
can speak via the hands-free facility.
If two users enter the network or connection range simultaneously, only the user with the highest priority (the
user last paired during the initial pairing procedure) will be able to use the hands-free function for incoming &
outgoing calls. If the highest priority phone is turned off the phone with the next highest priority will be
connected.
Deleting Devices
The paired Bluetooth mobile phones can only be deleted as a single group from the ULF control module.
The pairing procedure must first be activated, and then the send/receive button on the installed eject-box or
the pairing button located at the rear of the center console must again be depressed for an additional 10 seconds
after the "Bluetooth Pairing" message is displayed on the radio in order to clear the list of paired devices from
the control module and the message "paired devices deleted" is displayed.
2010 BMW M3
TECHNICAL INFORMATION
Not only does the Universal Bluetooth Hands-Free System offer a means to wirelessly integrate a mobile
phone into the vehicle, it also can be diagnosed using the DISplus or GT1.
The control module should always be coded to the specific vehicle that it is installed into to ensure optimum
system performance. Coding of the module can be done using the DISplus or GT1 with CD33 or higher
installed.
The ULF control module contains several controllers that provide the following functions:
1. Bluetooth Control Circuit:
The Bluetooth control circuit is physically connected to the Bluetooth antenna. It establishes the
connection between the Bluetooth mobile phone and the vehicle, de-scrambles the incoming call/signal
from the phone, scrambles the outgoing signal from the microphone for transmission to the phone, plus
controls all communication to paired Bluetooth devices.
2. Hands-free Control Circuit:
The hands-free control circuit in the ULF controls the input/output of audio frequency signals in hands-
free mode. The hands-free mode is designed for full-duplex transmission. This means the user can listen
and speak simultaneously. Voice transmission takes place via a microphone located in the interior of the
vehicle.
Pressing and holding the send/receive button until an audible beep is heard will activate the integrated
voice recognition system and place the system into a hands-free mode.
3. Audio Output Control:
The incoming signal from the Bluetooth phone is processed, sent through the radio and to the speakers.
4. Audio Input Control:
The outgoing audio received from the vehicle microphone is processed and transmitted to the
Bluetooth phone.
5. I/K-Bus Interface:
The interface in the ULF control module for the I/K-bus controls the procedure for transmitting and
receiving data telegrams via the I/K-bus in connection with other components on the bus.
6. Power Module:
The power module in the ULF control module regulates the voltage supply and monitors system
shutdown in the event of an under voltage situation in the vehicle.
2010 BMW M3
SYSTEM OVERVIEW
Fig. 15: Identifying Power Module System Components

Voice Recognition
The voice recognition for the this system is integrated into the ULF Control Module and utilizes the same voice
commands as those used with the TEMIC Voice Recognition Module used with the CPT8000 phone system.
The "Owner's Manual for the Voice Input System" P/N 84 11 0 027 942 should be referenced for more detailed
information regarding voice command features.
Coding ULF Control Module to Vehicle
After installing the ULF Kit, the vehicle should be re-coded with DISPlus/GT1 SW 33 or higher, using the
"Retrofit" path to ensure that the system works properly with the systems currently installed in the vehicle. The
recoding is done automatically when using the following "retrofit" procedure:
Example for coding E46 with ULF installed:
Connect DIS or GT1 to vehicle (with SW 33 or higher installed).

Turn on ignition.
2010 BMW M3
Select "Coding ZCS".

Series: "E46 Series".
Path: "2 Retrofit".
System: "ULF Universal charging and Handsfree facility".
Follow the on screen requests to activate the coding procedure.
Function Test
Upon completion of the recoding, verify that the BMW Universal Bluetooth HandsFree System is working
correctly by going through the following action steps. After completing each step ensure that the desired result
is obtained:
FUNCTION TEST
Action Response
Pair phone to vehicle (refer to section for pairing Phone and or Radio/MID/Board Computer should
instructions). display statement indicating Pairing succeeded.
Turn on radio and initiate a call using voice Radio should mute and an audible beep is heard
recognition commands by depressing/holding the through vehicle speakers.
Voice recognition button on steering wheel until an
audible beep is heard.
Say "Dial number". System states "Please speak the number".
Say phone number to be dialed ex"1234567890". System states "1234567890".
If number is correct say "Dial" Call is placed and number being dialed is displayed
on phone as well as on Radio/MID/Board
Computer.
TROUBLESHOOTING
TROUBLESHOOTING
Situation Correction
No audio output through vehicle speakers. Check SES module jumper plug.
Radio does not mute after placing a call. Check connections at rear of radio for Tel On and
Tel Mute signal. Verify that connectors and pins are
properly seated.
Audio quality in vehicle may not sound very good. Recode ULF Control Module.
NOTE:
Audio quality in vehicle or at person being
contacted, is dependent on the quality and signal
strength of the wireless service provider in the
area traveled.
Customer complains that the person being contacted Intermittently a "Buzzing" noise is noticeable to the
hears a "Buzzing" noise, at times during their person being called from the vehicle. The "Buzzing"
conversation or on voice mail message that he/she noise is a result of the GSM signal being feedback
2010 BMW M3
has left. through the microphone, this usually occurs if the

GSM phone is located too close to the microphone.
The customer should change the location of where
the phone is placed/stored.
Driver is told that the person being contacted Audio volume in vehicle during a call may be a bit
complains that there is an echo/reverberation in the to loud, causing the other person to hear his/her
audio; person can hear his/her voice back through voice coming back through the phone.
the phone.
A second call is received while in a call, and call Use handset to expect second call and place
cannot be accepted using MFL controls. previous called on hold. Call waiting is functional
only via the handset.
The radio audio does not come back immediately if It takes approximately 15 seconds for the ULF
the "other" person hangs up first. system to recognize that the call was terminated
from outside the vehicle. If the call is terminated
from outside the vehicle first, the driver can depress
the button on the steering wheel to terminate the call
from the vehicle and un-mute the radio quicker.
Customer is not able to pair phone to system, not The "Bluetooth Passkey" is identified on the label
able to locate ULF passkey/password reference of the ULF Control Module located in the rear of
card. the vehicle. The "Bluetooth Passkey" for the
installed control module can be obtained by
connecting the DISPlus or GT1and accessing the
diagnostics for the ULF system:- select "Diagnostic
requests" - select "Bluetooth code".
Intermittently a popping noise is audible through the Vehicle and /or ULF Control Module are not
vehicles speaker and there is no Bluetooth correctly coded. Recode module and vehicle
wireless communication established between the (refer to CODING ULF CONTROL MODULE
ULF module and the phone. TO VEHICLE).
E46 Only: After installation of ULF system the Remove pin 7 & 8 from the 54-pin connector going
speedometer and odometer do not work. to the ULF Control Module. .
CONNECTOR PIN ASSIGNMENTS
The 54-pin connector of the ULF Control Module utilizes the following pins on X01185
PINS DESCRIPTION
PIN Description
1 Microphone +
11 Cradle On/Enable
15 I-Bus
17 KL 30
19 Microphone -
21 Microphone Shield
22 Hook
27 Programming
2010 BMW M3
28 Programming
32 Cradle Key +
33 Telephone On
34 Telephone On (pin 33)
35 KL R (Ignition)
36 KL 31 (Ground)
43 Programming
44 Programming
45 Programming
51 Telephone Mute
52 KL 58g (illumination)
The following pins on X4545 are utilized when the eject box is connected
PINS DESCRIPTION
PIN Description
1 Cradle Key +
2 KL 31
3 58G
5 KL 30
13 Cradle On/Enable
NOTE: The pairing button used on the E46 only utilizes pin 1, 2 & 3 of X4545
ULF Wiring Schematic for the E53 with Boardmonitor

2010 BMW M3
Fig. 16: ULF Wiring Schematic For E53 With Boardmonitor

ULF Wiring Schematic for the E53 with Multi Information Display
2010 BMW M3
Fig. 17: ULF Wiring Schematic For E53 With MULTI Information Display

2010 BMW M3

ULF Wiring Schematic for the E39 with Multi Information Display
2010 BMW M3
Fig. 19: ULF Wiring Schematic For E39 With Multi Information Display

2010 BMW M3

ULF Wiring Schematic for the E46 without the Boardmonitor

2010 BMW M3
Fig. 21: ULF Wiring Schematic For E46 Without Boardmonitor

2010 BMW M3
ACCESSORIES AND BODY, CAB Body - Repair
Body - Repair
BODY
41 0 0 CONTENTS OF BODY, GENERAL
General Information
QUALITY STANDARD
WORKSHOP EQUIPMENT
Safety regulations
SAFETY AT WORK
INFORMATION ON HAZARDS
Information on VEHICLE PROTECTION
Materials
MATERIALS SCIENCE
USE OF MATERIALS in outer skin
EXPENDABLE MATERIALS
Handling components after an accident
ELECTRICAL SYSTEM, electronics and optical fibre

Vehicles with Hybrid drive
Passive safety See 4100... HANDLING AIRBAGS AND RESTRAINT SYSTEMS or 7212...
PROCEDURE AFTER AIRBAG TRIGGERING AS RESULT OF AN ACCIDENT
CHASSIS, SUSPENSION AND STEERING

Folding roof
Body dimensions
FRAME DIMENSIONS
GAP DIMENSIONS
Cavity sealing
Installation of shaped parts See 4100... INSTALLING A CAVITY ACOUSTIC BAFFLE

2010 BMW M3
(EXPANDED); 4100... INSTALLING A CAVITY ACOUSTIC BAFFLE (NOT EXPANDED) or

4100... INSTALLING A CAVITY SEALING WITH 2-COMPONENT PU CAVITY FOAM
Position of shaped parts . See 4100... POSITION OF SHAPED PARTS FOR CAVITY
BULKHEAD
Vehicle identification number
VEHICLE IDENTIFICATION NUMBER, GENERAL

Stamping vehicle identification number See 4100... STAMPING VEHICLE IDENTIFICATION
NUMBER
Repair techniques
REPAIR STAGE 1: All repairs that only provide for replacement of screwed/bolted components and
planishing operations.
REPAIR STAGE 2: Repairs that are carried out by bonding and riveting without the use of a
straightening bench.
REPAIR STAGE 3: Repairs that are carried out by bonding and riveting with the use of a straightening
bench or welding.
Corrosion protection
GENERAL INFORMATION
INFORMATION/WARNING LABELS
41 00... BLIND RIVETS
1.0 Recommended tools and equipment
Blind riveting tongs

Rivet head extension
Setting blind rivets
Refer to repair instruction for rivet size.

Position bore holes for blind rivets as specified in repair instruction. If necessary, carry over the positions
of the rivets to the new component.
Drill holes (0.2 mm bigger than the outside diameter of the rivet. Example 4.2 mm dia. for 4 mm rivet and
6.7 mm dia. for 6.5 mm rivet).
Deburr holes.
APPLY ADHESIVE .
Insert blind rivet. If necessary, remove adhesive that has emerged.
2010 BMW M3
Position blind rivet tool vertically. Use rivet head extension if accessibility is poor.
Rivet blind rivet with blind rivet tool. In the meantime clean rivet head if fouled with adhesive. Risk of
damage to rivet head by penetrating adhesive.
Seal blind rivets with SEALANT D1 (risk of corrosion).
Seal cavities after painting vehicle with CAVITY SEALANT (risk of corrosion).
41 00... BONDING ON PAINTED SURFACES
IMPORTANT: Conform with safety regulations See 4100... SAFETY AT WORK or 4100...
INFORMATION ON HAZARDS!
Overview of topics:
1. Equipment
2. Expiry date of consumables
3. Preparation of surface
4. Bonding coat
5. Hardening times
6. Subsequent treatment
7. Disposing of adhesive
1.0 Equipment
CLEANERR1
Adhesive as specified in repair instructions
CARTRIDGE GUN
2.0 Expiry date of consumables
Glue cartridge is marked with a date.

Do not use adhesive after this date.
3.0 Preparation of surface
4.0 Adhesive application
Processing temperature of glue cartridge 18C - 30C.

Object temperature, vehicle and new parts, min. 15C.
Do not use any compressed-air-operated cartridge guns.
Insert glue cartridge in cartridge gun, remove cap and allow both adhesive components to emerge. Strip
adhesive components uniformly and attach mixing tube.
2010 BMW M3
Allow approx. 10 cm of mixed adhesive to emerge and then apply the mixed adhesive first on one side of
the bonding surface.
After applying the adhesive, check whether an adhesive component has emerged at the back of the
cartridge. If yes, break off the bonding procedure. Clean new part. Use new glue cartridge. Contact
national hotline.
Potlife of mixed adhesive approx. 2 hours. A change of mixer is only necessary if over a period of 30
minutes no material has flowed through the mixer.
Join components and secure in position.
Remove excess adhesive.
5.0 Hardening times
6.0 Subsequent treatment
Reseal areas which are cavity-sealed as standard.
Do not move the vehicle before the adhesive has hardened.
Check the degree of hardness of the adhesive with a fingernail.
If the adhesive cannot be pressed in any further with a fingernail, the vehicle may be moved (without
engine force) for further processing applications (e.g. painting).
Vehicle strength for driving applications is achieved after:
48 hours at min. 15C object temperature (corresponding to approx. 18C room temperature).
or 1 hour in the spray booth (spray booth temperature 80C/object temperature 60C).
When using radiant heaters, make sure that the object temperature does not exceed 85C. Excessively
high temperatures will destroy the adhesive.
Remove contamination caused by adhesive residue immediately.
Hardened adhesive can only be removed mechanically.
7.0 Disposing of adhesive
Hardened adhesive is disposed of as normal waste.

Empty glue cartridges are disposed of as normal waste.
Non-hardened adhesives and mixtures of adhesive and solvent and the like must be disposed of as
hazardous waste.
These regulations apply to the Federal Republic of Germany.
For other countries, comply with the (possibly differing) nationally applicable regulations.
2010 BMW M3
41 00... BONDING STEEL ON STEEL
IMPORTANT: Conform with safety regulations . See 4100... SAFETY AT WORK or 4100...
Overview of topics:
1. Equipment
2. Preparing the surface
3. Bonding coat
4. Hardening times
5. Subsequent treatment
1.0 Equipment
Sandpaper
CLEANING AGENT R1
ADHESIVE K1
CARTRIDGE GUN
2.0 Surface preparation
For better adhesion, remove oxide film and paint from the adhesive areas with a stainless steel wire brush
or special sandpaper.
Clean bonding surfaces with cleaning agent R1.
Allow cleaned surfaces to dry for approx. 5 minutes.
Bonding surfaces must be completely dry.
3.0 Adhesive application
Processing temperature of glue cartridge 18C - 30C.

Object temperature, vehicle and new parts, min. 15C.
After applying the adhesive, check whether an adhesive component has emerged at the back of the glue
cartridge. If yes, break off the bonding procedure. Clean new part. Use new glue cartridge. Contact
national hotline.
Join components and secure in position.
Remove excess adhesive. Do not use solvent cleaning agents.
4.0 Hardening times
5.0 Subsequent treatment of bonding surfaces

2010 BMW M3
Protect the repair area with cavity sealant.
41 00... CORROSION PROTECTION
NOTE: Following repairs, the corrosion protection work already begins with the correct
removal of the PVC undercoating, anti-drumming layer and seam seals.
The PRODUCTS RECOMMENDED by BMW are optimized with regard to
corrosion protection.
1.0 Removing and applying sealing materials
2.0 Cavity preservation of sheet-metal parts
Carry out cavity preservation after all body repairs.
Concluding cavity preservation is the most important part of all corrosion protection measures.
Use the cavity protection spray only for smaller-scale straightening work where the parts in question are easily
accessible. Use the Vaupel PRESSURE CUP GUN for all other repairs. Cavity protection agent is available in
different container sizes.
Use the relevant probes with tubes for the different cavity areas.
IMPORTANT: Incorrectly performed cavity protection can, especially in the case of

steel/aluminum joints, give rise to a non-calculable product liability and safety
risk.
The best repair is worth nothing if the subsequent cavity protection measures are not conscientiously carried
out.
41 00... EMC SCREWS
(EMC = Electro-Magnetic Compatibility)
1. Purpose
EMC SCREWS are used in the Bonding/Riveting repair method to re-establish bonding transition.
They assume the function of welded joints, which ensure transition to ground between the individual
components.
The punch or blind rivets used in the repair do not guarantee permanent bonding transition between the
individual components!
The EMC screws ensure the operational reliability and safety of the electrical/electronic components
following repairs!
2. Procedure, aluminum front end

2010 BMW M3
Each welded joint which is opened must be replaced by at least 2 EMC screws.
Position the 2 screws on the flange on which the weld seam has been separated. In the event of partial
replacement, position the screws in the area of the component overlap.
In the case of repairs using partial replacement, the number of EMC screws described in the repair
instructions must be fitted.
Drill holes to a diameter of 4.2 mm and insert screws.
Seal EMC screws with PU sealing material (risk of corrosion).
3. Procedure, steel body
Install the number of EMC screws described in the repair instructions.

Drill holes to a diameter of 4.2 mm and insert screws.
Seal EMC screws with PU sealing material (risk of corrosion).
41 00... FRAME ALIGNMENT CONTROL DIMENSIONS, BODY
Dimensions in mm.
Measurement tolerances:
< or = 1000 mm 1.5 mm

> or = 1000 mm 2.5 mm
The control points shown serve to check the body and the straightening attachment.
The specified dimensions/measurements always refer to the centerpoint of the bore/screw.
Underbody view 1
2010 BMW M3
Fig. 1: Underbody Measurements (View 1)

Underbody view 2
2010 BMW M3
Fig. 2: Underbody Measurements (View 2)

Top view, front end

2010 BMW M3
Fig. 3: Underbody Measurements (Top View, Front End)

The specified dimensions refer to removed assemblies.
View, B-pillar (Saloon and Touring only)

2010 BMW M3
Fig. 4: Identifying B-Pillar Measurements (Saloon And Touring Only)

Measurement a=1551 mm between screw-on points of door brakes.
View, B-pillar (Coupe only)

2010 BMW M3
Fig. 5: Identifying B-Pillar Measurements (Coupe Only)

Measurement a=1543 mm between screw-on points of lock strikers.
41 00... GAP DIMENSIONS, BODY
Dimensions in mm
2010 BMW M3
Fig. 6: Identifying Body Gap Dimensions (1 Of 2)

2010 BMW M3

41 00... GENERAL CEMENTING INSTRUCTIONS
IMPORTANT: Conform with safety precautions See 4100... SAFETY AT WORK or 4100...
2010 BMW M3
The bonding surfaces must be kept free of all types of dirt and contamination. Avoid leaving fingerprints.
Cleanliness is the golden rule for all bonds!
Cleaning agent: isohexane
Expiry date of adhesive
The adhesive cartridge is marked with a date.

Do not use the adhesive after this date.
2-component adhesive application
Insert adhesive cartridge in adhesive gun, remove cap and allow some adhesive to emerge. Strip adhesive
components uniformly and attach mixing tube.
Allow approx. 1 mixer length of mixed adhesive to emerge (there must be no smearing of colors). Only
then apply the mixed adhesive to one side of the bonding surface.
Adhesive disposal

Empty adhesive cartridges are disposed of as normal waste.
hazardous waste.
99 00... GENERAL INSTRUCTIONS ON PAINTWORK
Special procedure for matte paintwork:
Matte paintwork cannot be touched up since the painted surface cannot be polished.
For further information, see also the BMW painting handbook and the Aftersales Assistance Portal.
41 00... GRINDING ALUMINUM PARTS
Grinding on the outer shell:
To carry out grinding work by hand or machine, you must use the recommended tools and equipment.
2010 BMW M3
The work area can be cleaned with conventional extractor systems (low dust concentration).
Grinding work on the structure (except Z8):
To carry out grinding work by hand or machine, you must use the recommended tools and equipment.
The work area can be cleaned with conventional extractor systems (low dust concentration).
Z8 Spaceframe structure:
To carry out machine grinding on the structure, you must use the recommended device with grinding dust
extractor facility.
The work area must be cleaned with the recommended explosion-proof extractor system.
High dust concentration, explosion hazard!
2.0 Grinding outer shell and structure
Do not use any abrasives (grinding wheels, paper, etc.) which contain iron (risk of corrosion).
Always replace abrasives which have already been used to treat steel (risk of corrosion).
Use stainless steel wire brushes only (risk of corrosion).
Reduce speed of grinding machines. Excessive speeds cause a smearing effect.
Do not use coarse abrasive grains (only > or =. 80).
Do not grind notches into the material (risk of cracking).
Do not grind the material thin.
41 00... GRINDING STEEL PARTS
Tools are recommended for manual grinding work.

Machines/equipment are recommended for machine grinding work.
Always replace abrasives which have already been used to treat aluminum (risk of corrosion).

2010 BMW M3
41 00... GUN FOR CAVITY SEALING
Fig. 8: Identifying Gun For Cavity Sealing

1.0 Scope of delivery
Owner's Handbook
Pressure vessel gun (1) for cavity sealing
Spray set, consisting of spray hoses: angle nozzle (2) and round spray nozzle (3)
IMPORTANT: Before start-up, read Owner's Handbook and safety instructions.
2.0 Start-up
Open pressure vessel and introduce cavity sealant in form of a 1-litre can.
Close pressure vessel.
Connect spray hose to quick-connect coupling.

Connect apparatus to compressed air supply.
Working pressure 2-6 bar, max. 8 bar!

2010 BMW M3
3.0 Mode of operation
NOTE: Unlike previous apparatus, it is possible here to alter the spray pattern with the
air flow control screw (large knurled screw)!
Twisting the air flow control screw in decreases the air flow and thus reduces the material spray mist.
This facilitates optimum working when preserving open components/surfaces.
Twisting the air flow control screw out increases the air flow and thus the material spray mist (for closed
cavities).
The trigger lever has two stages.
Stage 1 - discharge of air only.
Stage 2 - discharge of air and material.
After finishing work, press the first stage to clean the spray hose with compressed air.
When storing, remember to twist the air flow control screw closed to prevent the material from drying
out.
Clean the gun prior to extended periods of non-use (approx. 2 weeks and upwards).
To ensure that the spray hoses function properly, do not store the hoses coiled up e.g. in the frame side
member area!
Store spray hoses stretched out.
4.0 Application examples
Use the matching spray hoses for the different cavities or surfaces.
Example - doors and lids:
Spray hose with angle nozzle. Reduce air flow to keep spray mist to a minimum.
Example - frame side member:
Long spray hose with round spray nozzle. Depending on the type, increase the air flow slightly.
Always keep the spray mist to a minimum so as to avoid fouling and bad smells.
5.0 Safety instructions
Do not inhale spray mist.

Use only in well ventilated rooms.
Working pressure max. 8 bar.
2010 BMW M3
41 00... HANDLING AIRBAGS AND RESTRAINT SYSTEMS
1.0 Airbags and restraint systems
In the case of vehicles with airbags and restraint systems observe the relevant SAFETY
INSTRUCTIONS .
When straightening work is carried out on the body there is a risk of airbags being accidentally activated
when the battery is connected.
Because of this risk the battery negative lead must be DISCONNECTED prior to all repair work on the
body.
41 00... HANDLING ELECTRICAL AND ELECTRONIC EQUIPMENT
1.0 Battery
Explosion hazard in the vicinity of the battery during welding and grinding work. The battery must be
REMOVED .
2.0 Control units
The following risks exist when the battery is connected:

Damage to control units resulting from welding work on the body or a line short circuit.
Accidental activation of airbags during straightening work on the body.
Because of these risks the battery negative lead must be DISCONNECTED prior to all repair work.
Control units are designed for a temperature of 65C. The temperatures in a spray booth do not pose any
problems. If a vehicle is in the spray booth at a displayed temperature of 80C, the actual temperature of
the vehicle is < or = 60C (object temperature).
Protect control units against effects of heat >65C (e.g. during welding and drying work with an infrared
radiator or hot air blower).
3.0 Electrical wires and wiring harnesses
Protect electrical wires and wiring harnesses against damage (e.g. during straightening and grinding
work).
Protect electrical wires and wiring harnesses against effects of heat >65C (e.g. during welding and
drying work with an infrared radiator or hot air blower).
Do not kink electrical wires.
4.0 Optical fibres
Follow instructions for handling optical fibres . See 6100... NOTES ON HANDLING OPTICAL
FIBRES or .
2010 BMW M3
41 00... INFORMATION/WARNING LABELS
Missing or damaged information/warning labels (e.g. tire inflation pressure) must be replaced.
--> Overview of INSTALLATION LOCATIONS
41 00... INFORMATION ON HAZARDS
1.0 Aluminum
HAZARDS AND REGULATIONS INFORMATION

Hazards/effects Measures/regulations
Repair stage 1:
When a vehicle outer skin is ground, aluminium
(replacement of bolted components, dent
removal) dust accumulates in small amounts. This dust
Repair stage 2: can be removed with conventional exhaust
(repairs with bonding and riveting) extraction unit.
Repair stage 3:
(repairs with welding)
Explosion hazard due to high concentration

of fine aluminium dust.
Avoid high concentration of fine aluminium
Arising e.g. during straight-through dust by means of continuous extraction.
grinding of coated components in the base Use explosion-proof exhaust extraction unit
material and large-surface grinding of Do not use compressed air when cleaning the
bright-finish components. workbay.
Avoid swirling up dust when cleaning the
Explosion hazard due to swirling up of fine
workbay.
aluminium dust in cavities.
Created by the necessary, thorough

cleaning of machining surfaces and tools
before and after machining aluminium.
Spontaneous combustion of fine aluminium
dust when ignition and fire sources are
drawn in. Do not operate ignition and fire sources in the
intake area of exhaust extraction unit.
E.g.: hot debris, grinding sparks, cigarettes,
etc.
41 00... INFORMATION ON METAL FILLER
IMPORTANT: Note the following information before starting to apply metal filler!
Country-specific safety and industrial safety regulations

2010 BMW M3
Material safety data sheet of manufacturer

Processing instructions on the packaging
Storage
Dry at 15C to 25C.
Shelf life
The packaging is marked with a date.
Do not use the metal filler after this date.
Surface pre-treatment
Grind surface to a metallic bright-finish. The surface must be clean, dry and free from grease.
Clean the surface with a cleaning agent R1 and let it vent for 2-3 minutes.
Processing
The working temperature of the metal filler must be at least 18C.
Fig. 9: Identifying Metal Filler And Hardener

A = Metal filler
B = Hardener
2010 BMW M3
NOTE: The mixture ratio refers to the volume.
Mix metal filler in mixture ratio of 5:2. Mix components thoroughly and free of pores.
IMPORTANT: Do not stir components. Danger of air pockets in metal filler!
Working life of the metal filler is approx. 45 minutes.
Applying filler
Apply pressure to apply a thin layer of metal filler. Carefully coat all edges in gaps with filler.
Then fill gap completely with filler. Apply filler with about 30% excess because the filler will significantly
shrink during hardening. A second application of metal filler is not possible due to poor adhesion.
IMPORTANT: Use a narrow spatula to fill the gaps. Apply the filler in one draw if possible.
Danger of formation of pores in gaps!
No restrictions related to the layer thickness.
Hardening time
The metal filler must be hardened using a short-wave infrared heater.
10 minutes at 50C - pre-hardening (avoid formation of bubbles/blisters and pores)

10 minutes at 75C - 1st stage hardening
10 minutes at 85C - 2nd stage hardening (avoid material shrinkage)
IMPORTANT: In the first 10 minutes, the temperature of 50C may not be exceeded. In
contrast, a temperature that is too low may be equalized by extending the time.
NOTE: When the heater is used for the first time, the distances that match the
temperature must be determined.
Switch the heater on and change the distance until the surface temperature of
the metal filler no longer changes for a period of 2 minutes. Measure the
temperature with a temperature gauge. When optical temperature gauges are
used (Epsilon value 0.92-0.95), the heater must be switched off briefly during
the measurement. Record the measurement
Post-processing
WARNING: When grinding, wear a fine dust mask with particulate filter P2-P3!
2010 BMW M3
After cooling, the metal filler can be machined.
Pores and faulty spots that become visible after grinding the surface must be closed with polyester filler (BMW
Color system).
Special procedure for pores:
Use a 4.2mm drill. Turn the drill by hand to expand the pores in v shape.
Fill cavities with polyester filler.
Paintwork
Perform paintwork according to the specifications in the painting handbook.
Metal filler disposal
Hardened metal filler is disposed of as normal waste.
Empty packaging is disposed of as normal waste.
Non-hardened metal filler and mixtures of metal filler with solvent and the like must be disposed of as
hazardous waste.
32 00... INFORMATION ON REPLACING STEERING GEAR AFTER ACCIDENT DAMAGE
Situation
In the event of accidents or driving conditions similar to accidents, shock-like loads can cause different types of
damage to steering gears. When a steering gear is externally undamaged, it is sometimes only possible to
identify damage with great difficulty and with great effort. However, damage of this nature poses an
unacceptable risk to the vehicle because it can result in failure of the steering system.
Because of the disproportionate amount of effort involved, it is generally not sensible to check thoroughly all
the individual components of the steering gear and as an alternative it is necessary to take into account other
components which can be checked more easily.
Procedure
The steering gear must be replaced if one or more of the following points apply:
A. Visible or noticeable damage to the steering gear

2010 BMW M3
Version with electric steering gear (EPS): Examine in particular the control unit with all plug
connections for damage and hairline cracks.
B. Unacceptable torque increase and jamming when the steering gear is turned from lock to lock (without
hydraulic/electrical assistance)
C. Permissible tolerances exceeded during axle/wheel alignment (include alignment record with
invoice/report if necessary)
D. Fire damage
E. Damage, permanent deformation or fractures to:
Wheel rims in the event of a negative result from the wheel/axle alignment check
Spring struts, steering knuckles, wheel carriers
Control arms
struts or diagonal members or stabilizers with this function
Body-side screwing/bolting points for wheel guide/control components
Front axle support
Pitman arms
Tie rods
Steering gear fixtures
Steering Column
64 00 000 INFORMATION ON USING CLEANING AGENT/PAINTS (PERSONAL PROTECTION

EQUIPMENT)
WARNING: Use of cleaning agents/paints not compliant with instructions can cause
serious injuries or burns!
Handling cleaning agents/paints can trigger allergic skin and respiratory
reactions!
IMPORTANT: Observe following instructions:
Store cleaning agents/paints only in a secure cabinet.

Keep cleaning agents/paints away from naked flames and other sources
of ignition.
Protect cleaning agents/paints from high temperatures and direct
sunlight.
Always keep an eye bath on hand, change the water regularly (once a
month).
IMPORTANT: Observe following instructions before use:
Manufacturer's instructions (on container/packaging)

2010 BMW M3
Hazard warnings (on container/packaging)

Manufacturer's instructions on package insert
Product information in EPC
National market regulations
IMPORTANT: Observe following instructions during use:
Do not eat, drink or smoke while working with these products.

Avoid direct contact with skin and eyes.
Wear personal protective clothing/equipment.
Ensure that all enclosed areas are well ventilated or extract fumes
directly.
Immediately change working clothes soiled with cleaning agent/paint.
After finishing work, wash your hands and apply protective skin cream.
IMPORTANT: Follow hazard warnings and wear personal protection equipment!
First Aid:
If product comes in contact with eyes, immediately flush with running water for about 10 - 15 minutes.
Seek the advice of eye specialist.
In the event of skin contact and where applicable an allergic skin reaction, clean the affected areas
immediately with soap and water and then apply silicone-free skin cream. Seek advice of physician.
If an adhesive product is swallowed, rinse mouth/parts of mouth thoroughly with running water. Drink 1-
2 glasses of water. Do not induce vomiting. Consult a doctor.
After inhaling vapors ensure ample supply of fresh air. Keep calm, keep respiratory tracks clear and call
doctor.
Recycling
Dispose of cleaning agents/paints in a professional manner!
Observe national/country-specific disposal regulations.
41 00... INFORMATION ON VEHICLE PROTECTION
Vehicle parts located in the repair zone or threatened by heat, sparks or dust, must be removed or covered.
IMPORTANT: Do not use flammable or dirty material for covering.
41 00... INSTALLATION SOLUTION FOR STRAIGHT SHANK/HEXAGON RIVET NUT

2010 BMW M3
Protection measures!
Wear safety goggles

Wear protective gloves
Hexagon/straight shank rivet nut (up to thread 8) with hand rivet gun ZS308

Failure to comply with these instructions may result in the drill bit slipping and
causing significant paintwork damage.
1. Mark position of bore and then punch-mark component
Fig. 10: Identifying Bore Position For Installing Hexagon/Straight Shank Rivet Nut
IMPORTANT: If the determined drill bit diameter is not observed:
the knurling on the straight shank rivet nut is rendered useless

the component will be damaged when the straight shank rivet nut is
inserted
Determining suitable drill bit:
Depending on the rivet nut shank diameter, the next drill bit diameter higher (5/10 step) can be used.
E.g. with a shank diameter of 10.1 mm, the 10.5 mm drill bit can be used. The 11.0 mm drill bit must not
be used.
2. Drill bore with determined drill bit and deburr, pilot-drill with a smaller drill bit if necessary
2010 BMW M3
Fig. 11: Drilling Bore For Installing Hexagon/Straight Shank Rivet Nut
3. Clean component, eliminate paintwork damage if necessary
Fig. 12: Identifying Cavity

IMPORTANT: To avoid corrosion, stop chips/debris by means of cavity sealing.

Follow INSTRUCTIONS ON CORROSION PROTECTION .
4. Preserving cavity
2010 BMW M3
Fig. 13: Preserving Cavity

IMPORTANT: Follow manufacturer's operating instructions.

Make sure straight shank rivet nut correctly contacts component.
5Set rivet nut with hand rivet gun
Fig. 14: Installing Rivet Nut Using Hand Rivet Gun

Hexagon/straight shank rivet nut (up to thread M12) with hand rivet gun MB512

Make sure hexagon rivet nut correctly contacts component.
Set rivet nut with hand rivet gun

2010 BMW M3
Fig. 15: Installing Rivet Nut With Hand Rivet Gun

41 00... INSTALLING A CAVITY ACOUSTIC BAFFLE (EXPANDED)
NOTE: Carry over schematic representation to the relevant vehicle type.
The following repair represents the procedure for an already expanded cavity bulkhead.
The cavity bulkhead remains on the body in this instance.
Before these work steps, prepare the new part so that it is ready to install (adapting, cutting to size, applying
welding primer etc.).
Clean contact surface (1) with cleaning agent R2.
Apply a bead (2) approx. 15 mm high of SEALANT D1 to contact surface (1).
In order to avoid run off of the sealant when bonding to a vertical surface, a thin coat of sealant on both sides of
the surface may be necessary.
Fit, secure and weld up new part.

2010 BMW M3
Fig. 16: Identifying Contact Surface And Bead

WARNING: Ensure adequate ventilation over entire processing period.
41 00... INSTALLING A CAVITY ACOUSTIC BAFFLE (NOT EXPANDED)
The following repair represents replacement of a cavity bulkhead.
Sand contact surface of cavity acoustic baffle (1) with coarse-grained sandpaper (grain 50-100).
Clean contact surface (1) with cleaning agent R2.
Apply a bead approx. 15 mm high of SEALANT D1 to contact surface (1).
If necessary apply sealant D1 somewhat thinner on each side, to prevent the sealant from running.
Attach cavity bulkhead in specified position (see old part).

2010 BMW M3
Fig. 17: Identifying Contact Surface And Bead

41 00... INSTALLING A CAVITY SEALING WITH 2-COMPONENT PU CAVITY FOAM
IMPORTANT: The cavity foam may only be use for cavity sealing at the points at which cavity
sealing is present as standard!
The following repair represents the replacement of a shaped part for the cavity sealing by the use of cavity
foam.
This type of cavity sealing is used at points at which shaped parts cannot be used for repairs.
This is the case when large amounts of heat occur (e.g. due to welding, soldering or tin-plating) in the direct
vicinity or at the point of the standard cavity sealing.
It is not possible here to install shaped parts for the cavity sealing because of the fire risk!
To replace shaped parts with cavity foam at further locations, adopt the procedure shown here and adapt it to the
relevant ratios.
It must be ensured that the cavity is completely sealed off.
NOTE: Check the accessibility for the spraying pipe of the cavity foam to the affected
cavity after removing the defective parts.
Properties of cavity foam:
2-component PU foam, solvent-free.

Excellent flow capacity, enabling complete sealing of cavities.
2010 BMW M3
Good strength, preventing slipping in cavities.

Low water absorption, preventing corrosion.
Ideal for use as insulating and sealing compound.
Information on dangers/hazards
Avoid eye and skin contact.
Wear eye protection, solvent-resistant protective gloves and protective clothing.
Do not inhale.
Apply in well ventilated rooms only.
WARNING: Application time after mixing: within 8 minutes!

Completely empty open can after use.
Residual amounts which are not used can cause the can to explode on account of a chemical reaction
(buildup of heat)!
Alternatively, cool the can containing the non-removed residual amount for several hours in cold water.

Keep heat and ignition sources well away.
Read the manufacturer's information on hazards/dangers (printed on the can) prior to application.
Processing instructions
Observe the expiry date on the cartridge.
Do not use the spray can after the expiry date on the can has expired. After the Use by date the properties
of the cavity foam will no longer meet the requirements of the BMW Group.
Cavity sealing of repair area possible after an air drying time of 1 hour.
Backing surface must be
clean and free from
dust,
grease,
2010 BMW M3
oil and stripping agent.
Application temperature at least 15C. Optimally 20C.

IMPORTANT: Foam expands many times over as it sets (change in volume).
Before applying to the vehicle, fill a clearly visible cavity of corresponding size with foam on a used part.
This enables an optimal dosage (i.e. spraying time) to be specified for filling the cavity on the vehicle
with foam.
Tape off open passages to visible areas with adhesive tape to prevent foam from escaping.
Setting takes approx. 30 minutes. Mechanical processing (e.g. drilling, cutting, etc.) is then possible.
Remove fresh, non-hardened PU foam with adhesive cleaner 208.
Hardened PU foam can only be removed by mechanical means (machine).
Excess, hardened PU foam can be disposed of as residual waste.
Cans which are not entirely empty and unused whose expiry date has expired are classed as hazardous
waste.
Observe country-specific waste disposal regulations.
Observe the manufacturer's processing instructions (printed on the can).
41 00... MATERIALS SCIENCE
1. Aluminum
4100... NOTES ON ADHESIVE K1
IMPORTANT: Note the following information before starting to apply adhesive!

Processing instructions on glue cartridge
Storage
Dry at 15- 25C.
Shelf life
2010 BMW M3
The glue cartridge is marked with a date.
The PRE-TREATMENT depends on the material to be bonded and its coating.
Required cartridge gun
Overview of glue cartridge guns
Do not use any compressed-air-operated cartridge guns
Preparing the glue cartridge
Opened glue cartridges may be used again before the expiry date as long as a new mixing tube is used.
The working temperature of glue cartridge must be at least 20C.
Insert glue cartridge into cartridge gun, remove cap and allow both adhesive components to emerge. Strip
adhesive components uniformly and attach mixing tube. Only use mixing tubes supplied with glue cartridge.
Approx. Allow approx. 10 cm of mixed adhesive to emerge and then apply the mixed adhesive first on one side
of the bonding surface.
Pot life of mixed adhesive approx. 2 hours. A change of mixer is only necessary if over a period of 1 hour no
material has flowed through the mixer.
Adhesive application
Read the vehicle-specific repair instructions to determine the thickness and positioning of the adhesive bead.
cartridge. If yes, break off the bonding procedure. Clean new part. Use new glue cartridge. Contact national
hotline.
Hardening time

2010 BMW M3
If the adhesive cannot be pressed in any further with a fingernail, the vehicle may be moved (without engine
force) for further processing applications (e.g. painting).
48 hours at min. 15C object temperature (corresponding to approx. 18C room temperature).
When using radiant heaters, make sure that the object temperature does not exceed 85C. Excessively high
temperatures will destroy the adhesive.
Disposal of adhesive
Non-hardened adhesives and mixtures of adhesive and solvent and the like must be disposed of as hazardous
waste.

Storage
Dry at 15-25C.
Shelf life
See vehicle-specific repair instructions

2010 BMW M3
CARTRIDGE GUN 81 43 2 159 881/883
Fig. 18: Identifying Cartridge Gun With Speed Control

IMPORTANT: Set speed control (1) to interval stage 3 to prevent overloading the cartridge
gun.
Working life of adhesive is approx. 20 minutes.
IMPORTANT: At working temperatures above 30C, the working life of the adhesive is
reduced to 10 minutes!
2010 BMW M3
Approx. Allow approx. 10 cm of mixed adhesive to emerge and then apply the mixed adhesive first on one side
of the bonding surface.
hotline.
Hardening time
waste.

Storage
Dry at 15- 25C.

2010 BMW M3
Shelf life
Do not prepare the glue cartridge until just before applying the adhesive.
Pot life of adhesive is approx. 10 minutes at 25C.
Before starting to apply adhesive, allow approx. 1 mixing tube length of mixed adhesive to emerge. Only then
apply the mixed adhesive to one side of the bonding surface.
Opened cartridges may be used again before the expiry date as long as a new mixing tube is used.
Hardening time
Adhesive disposal
waste.
2010 BMW M3

Storage
Dry at 15- 25C.
Shelf life
Do not prepare the glue cartridge until just before applying the adhesive.
Working life of adhesive is approx. 10 minutes.
Before starting to apply adhesive, allow approx. one half mixing tube length of mixed adhesive to emerge. Only
2010 BMW M3
Hardening time
The bonded connection will be resistant after 30 minutes.
waste.

Storage
Dry at 15- 32C.
Shelf life

2010 BMW M3
Before starting to apply adhesive, allow approx. 1 mixing tube length of mixed adhesive to emerge. Only then
apply the mixed adhesive to one side of the bonding surface.
Pot life of adhesive is approx. 60 minutes at 23C.
hotline.
Hardening time
If the adhesive cannot be pressed in any further with a fingernail, the vehicle may be moved (without engine
force) for further processing applications (e.g. painting).
The procedure may be accelerated by using a radiant heater. Let the adhesive harden for 30 minutes at 85C.
The component can then be processed in the joint areas.
24 hours at a minimum object temperature of 23C.
When using radiant heaters, make sure that the object temperature does not exceed 85C. Excessively high
temperatures will destroy the adhesive.
2010 BMW M3
waste.
41 00... NOTES ON CLEANING AGENT R1
Use only cleaning agent R1, as other cleaning agents cab be emollient/moistening or may start to dissolve the
cathodic dip paint primer.
41 00... NOTES ON REPAIRING THREADS
IMPORTANT: Install Helicoil thread inserts so that they are flush with the original thread.
NOTE: Damaged threads may be repaired with Helicoil thread inserts. Comply with the
PROCEDURE described in the example.
THREAD REPAIRING REFERENCE CHART

Bolting point Helicoil thread
Screw connection Vehicle
(s) insert
E46 All M12x1.5x18
E53 All M12x1.5x18
Front, middle See repair elements
E60, E61, E63, E64
Rear M12x1.5x18
E65, E66, E67 All M12x1.5x18
Front axle support to engine support E70, E71, E72 All M14x1.5x21
E83 All M12x1.5x18
E85, E84, E86, E89 All M12x1.5x18
E81, E82, E87, E88 All M12x1.5x18
E90, E91, E92, E93 All M12x1.5x18
E92 with S65 All M10x1.5x15
Bracket, wishbone, to engine support E46, E85, E86, E89 All M10x1.5x15
E46 All M12x1.5x18
E53 All M14x1.5x21
E60, E61 All M14x1.5x21
E63, E64 All M14x1.5x21
2010 BMW M3
E65, E66, E67 All M14x1.5x21

E70, E71, E72 All M14x1.5x21
E83 All M12x1.5x18
Rear axle support to side member
E84, E85, E86, E89 All M12x1.5x18
E81, E82, E87, E88 All M12x1.5x18
E90, E91, E92, E93 All M12x1.5x18
Bearing support, trailing arm to side E46, E83, E85, E86,
All M12x1.5x18
member E89
41 00... OPENING ADHESIVE BONDS
1. Opening spot-weld bonds
OPEN WELD SPOTS .
WARNING: Extract vapors and gases.

Use personal protective clothing/equipment.
Heat connecting flange with a hot-air blower. Heat components to max. 250C object temperature.
Release connection flange with chisel.
Remove adhesive residue from connecting flange.
2. Opening adhesive bonds
If necessary, open existing PUNCH OR BLIND RIVETS .
Roughly cut out damaged component.
WARNING: Extract vapors and gases.

Use personal protective clothing/equipment.
Heat adhesive flange with a hot-air blower. Heat components to max. 250C object temperature.
The component can be peeled with the aid of pliers. Do not damage adjacent components.
Remove adhesive residue from connecting flange.
3. Opening adhesive bonds on aluminum roofs
Procedure is described in detailed in the relevant repair instructions.
4. Opening adhesive bonds on carbon-fibre-reinforced plastic parts

2010 BMW M3
41 00... OPENING BRAZED JOINTS
The "Bonding and Riveting" repair method involves replacing the watertight brazed joint with adhesive.
This gives rise to a new procedure for opening brazed joints.
Grind brazed seam with a belt grinder. This keeps the influence of heat in the area around the brazed seam as
small as possible.
IMPORTANT: Never use a gas flame.
All traces of brazing solder do not have to be removed.
Do not grind body panels thin.
41 00... OPENING RIVETED JOINTS
Different rivet types are used on BMW vehicles.
1. Opening blind rivets
2. Opening punch rivets
41 00... OPENING WELDED CONNECTIONS
1. Opening weld spots (resistance pressure spot welding)
Sheet steel panels made from high- and super-high-strength materials make great demands on the tools used.
Only with special carbide milling cutters can weld spots be drilled out on these sheet panels.
Use BTR/BOR milling cutters only in conjunction with Vario Drill spot-weld remover
Shop Workshop Equipment

Procedure:
If necessary, surface-grind existing unevenness with a belt or angle grinder in the area around the
weld spot.
Set punch mark in center of weld spot. Set 8 mm dia. weld spot drill bit on punch mark and drill
through top metal sheet.
NOTE: Because the weld spots may have surface-hardened, grind them if
necessary with an angle grinder and paper grinding disk.
2010 BMW M3
Use a chisel to separate the sheet metal flange and remove the component.
Follow the special procedure for SPOT WELDS .
2. Opening MAG weld seams and MIG brazing seams
Procedure:
Grind off weld seams with a belt or angle grinder. Do not grind the base material thin.
Use a chisel to separate the sheet metal flange and remove the component.
3. Opening laser weld seams
Laser weld seams are used in the roof outer skin area.
Procedure:
Roughly cut roof outer skin in the roof channel to improve accessibility.
Place angle grinder with grinding disc on laser weld seam and grind through top metal sheet. Be careful
not to cut through and damage sheet metal underneath.
Remove sheet metal flange.
41 00... OVERVIEW OF ADHESIVE CARTRIDGE GUNS
Adhesive gun 83 19 2 149 522
Usable for adhesives K4, K5a.
Including insert 1:1 and 2:1.

2010 BMW M3
Fig. 19: Identifying Adhesive Gun (83 19 2 149 522)

Adhesive gun 81 49 0 443 166
Usable for adhesive K3.
Fig. 20: Identifying Adhesive Gun (81 49 0 443 166)

Adhesive cartridge gun 81 49 2 159 881/883
Usable for adhesives K1, K2, K5b, sealant D1 and window glass adhesive.
2010 BMW M3
Fig. 21: Identifying Adhesive Cartridge Gun (81 49 2 159 881/883)

Adhesive cartridge gun 83 30 0 494 836
Usable for structural foam HS2.
NOTE: Special tool number 41 3 010
Fig. 22: Identifying Adhesive Cartridge Gun (83 30 0 494 836)

41 00... OVERVIEW OF CONSUMABLES (ELECTRONIC PARTS CATALOGUE)
1.0 Adhesives
2010 BMW M3
ADHESIVES REFERENCE CHART

Designation, repair Designation, Electronic Parts Part number, Electronic Parts
Remarks
instructions Catalogue Catalogue
Adhesive K1 Body adhesive K1 83 19 0 413 015 195 ml
2 x 300
Adhesive K3 Body adhesive K3 83 19 0 417 144
ml
Adhesive K5a Body adhesive K5a 83 19 2 158 654 50 ml
Adhesive K5b Body adhesive K5b 83 19 2 157 298 195 ml
Adhesives K5a and K5b are the same adhesive in different package sizes.
1.1 Primer
PRIMER REFERENCE CHART

Remarks
Primer P1 Primer P1 83 19 0 302 556 50 ml
Primer P2 Primer P2/Gas cartridge 83 19 0 302 555 50 ml
1.2 Cleaning agent
CLEANING AGENT REFERENCE CHART

Remarks
Cleaning agent R1 Cleaning agent R1 83 19 2 157 286 125 ml
Cleaning agent R2 Cleaning agent R2 83 19 0 417 324 500 ml
Cavity sealing wax
Cavity sealing wax remover 83 12 0 390 086 500 ml
remover
1.3 Fillers
FILLERS REFERENCE CHART

Remarks
83 19 2 154 175
US version:
Metal filler 2C metal filler 83 19 2 163 602
Asian version:
83 19 2 163 603
2.1 Rivets
RIVETS REFERENCE CHART

2010 BMW M3
Designation, repair Designation, Electronic Part number, Electronic

Remarks
instructions Parts Catalogue Parts Catalogue
Blind rivet N1 dia. 6.5 mm; clamping
Blind rivet N1 83 19 0 301 414
Hemlock 813 range 2.8-4.8 mm
Blind rivet N2 dia. 6.5 mm; clamping
Blind rivet N2 83 19 0 301 419
Hemlock 815 range 4.8-6.8 mm
dia. 4 mm; clamping
Blind rivet N3 Blind rivet N3 83 19 0 301 421
range 1-3 mm
Punch rivet N4 Punch rivet N4 83 19 2 158 080 dia. 3 mm; length 4 mm
Punch rivet N5 Punch rivet N5 83 19 2 158 079 dia. 5 mm; length 5 mm
dia. 4 mm; clamping
Blind rivet N6 Blind rivet N6 83 19 2 158 655
range 3-5 mm
2.2 Plastic nuts
PLASTIC NUTS REFERENCE CHART

Remarks
Dia. 18
Cap nut Plastic nut 51 16 1 943 122
mm
Dia. 30
Cap nut Clip nut 07 14 7 139 081
mm
3.0 Primer
PRIMER REFERENCE CHART

Designation, repair Designation, Electronic Part number, Electronic
Remarks
instructions Parts Catalogue Parts Catalogue
HS-AK multibase filler 2K 200 ml; pot life 5
Primer 51 91 0 432 612
spray hours
200 ml; pot life 8
Primer EP base filler 2K spray 51 91 0 432 615
hours
Welding primer INOX spray welding primer 83 40 0 409 992 500 ml
4.0 Sealant
SEALANT REFERENCE CHART

Remarks
Sealant D1
Seam sealing 83 42 0 428 349 310 ml
Sprayable sealant
5.0 Cavity preservation

2010 BMW M3
CAVITY PRESERVATION REFERENCE CHART

Remarks
Cavity sealant Cavity sealant spray 83 42 0 428 190 400 ml
Cavity sealant Cavity preservation 83 42 0 428 348 1000 ml
6.0 Cavity foam
CAVITY FOAM REFERENCE CHART

Remarks
Cavity foam HS1 Cavity foam 83 42 9 410 694 400 ml
Structural foam HS2 Structural foam 83 19 0 007 361 420 ml
7.0 EMC screw (electromagnetic compatibility)
EMC SCREW REFERENCE CHART

Designation, repair Designation, Electronic Parts Part number, Electronic
Remarks
instructions Catalogue Parts Catalogue
SF Plus
EMC screw Screw 83 19 0 301 639
M5x15
8.0 Twist drill
TWIST DRILL REFERENCE CHART

Remarks
4.2 x 119
Drill bit Twist drill 83 19 2 166 461
mm
6.8 x 156
mm
4.2 x 55
mm
6.8 x 74
mm
41 00... POSITION OF SHAPED PARTS FOR CAVITY BULKHEAD
Cavity sealing is carried out in specific body areas in order to reduce internal noise and to reduce condensate.
To do this, shaped parts are inserted in the cavities. These shaped parts adapt themselves optimally due to
heating of the body to approx. 180C by expansion to the shape of the cavities.
Because it is not possible to heat the body to this extent for a body repair, a different procedure See 4100...
INSTALLING A CAVITY ACOUSTIC BAFFLE (EXPANDED); 4100... INSTALLING A CAVITY
2010 BMW M3
ACOUSTIC BAFFLE (NOT EXPANDED) or 4100... INSTALLING A CAVITY SEALING WITH 2-

COMPONENT PU CAVITY FOAM has been specified for this situation.
Fig. 23: Identifying Shaped Parts Position For Cavity Bulkhead

41 00... PUNCH RIVETS
The "Bonding and Riveting" repair method involves the use for the first time of punch rivets in the repair. This
requires new tools and procedures.
The punch rivets are matched in size to the material thickness and quality used at the respective connection
point.
Punch rivet tool (see Service Information 05 03 09 (535))
Setting punch rivets
Refer to the vehicle-specific repair instructions for the punch rivet size.
Mark the positions of the rivets on the vehicle. Set punch rivets at roughly equal spacings.
Punch rivets do not require a predrilled hole. They are pressed directly into the full material.
Insert punch rivet in riveting die. Position punch rivet tool on sheet metal parts to be riveted.
Riveting direction:
2010 BMW M3
Always from new part to used part.
Deviations are specified in the vehicle-specific repair instructions.
Rivet punch rivets with punch rivet tool. In the meantime clean riveting die and matrix if fouled with
adhesive.
Seal punch rivets in moist area (e.g. wheel arch or carrier support) on both sides with SEALANT D1
(risk of corrosion).
Seal cavities after painting vehicle with CAVITY SEALANT (risk of corrosion).
41 00... QUALITY STANDARD
The overall requirements relating to a vehicle can only be implemented by including "all" components.
This applies in particular to the body. With regard to an optimum crash result, it is necessary to maintain
the structural measures.
It is absolutely essential to observe the procedures set out in the repair instructions.
The use of non-approved repair steps or tools may have serious consequences for the structure of the
vehicle (e.g. in the event of a crash). In the end, this can result in safety and product liability risks which
cannot be calculated.
Corrosion protection measures during and after repairs are absolutely essential to maintain the value of
the vehicle.
Use only genuine BMW parts and approved auxiliary devices, materials and operating fluids when
carrying out repairs.
41 00... REINFORCEMENT PLATE (BONDED)
In the case of a partial replacement piece, a body component is cut at a point described in the repair instructions.
A reinforcement plate is bonded in to ensure sufficient strength.
Observe notes on REPAIR STAGE 2.
NOTE: The following graphics serve as general illustrations of reinforcement plate

repair work. They apply to sectional repairs to the structure.
Mark component in accordance with measurement a and cut.

2010 BMW M3
Fig. 24: Identifying Component Cutting Dimension

Preparation of new part
Cut new part (1) in accordance with cut on vehicle and if necessary adjust to fit with straightening attachment or
universal mount.
Fig. 25: Identifying Part Cut Position

Make reinforcement plate (1) from trim of new part (2).
Length of reinforcement plate is 80 mm.

2010 BMW M3
Fig. 26: Identifying Reinforcement Plate And Part Trim

Slide reinforcement plate (1) half-way into component on body and fasten with 2 self-tapping screws (2).
Fig. 27: Identifying Reinforcement Plate With Self-Tapping Screws

Adjust new part (1) to fit and set 4.3 mm dia. bore holes (2).
Remove new part again.
Release self-tapping screws (3).
Remove reinforcement plate.

2010 BMW M3
Drill out bore holes (3) for screws to 4.3 mm dia.
Deburr all bore holes.
Fig. 28: Drilling Out Bore Holes

IMPORTANT: Do not grind new part and body in area of bonding surfaces.
Installing reinforcement plate
Clean all bonding surfaces with cleaning agent R1.
Apply adhesive (1) to reinforcement plate bonding surface.
Carefully slide reinforcement plate half-way into body component (2).
IMPORTANT: When joining reinforcement plate, make sure there is sufficient adhesive on
bonding surfaces.
2010 BMW M3
Fig. 29: Identifying Adhesive And Body Component

Rivet reinforcement plate (1) up to half-way with blind rivets N3 (2).
Fig. 30: Identifying Reinforcement Plate With Rivets

Apply adhesive (1) to reinforcement plate bonding surface.

2010 BMW M3
Fig. 31: Identifying Adhesive And Rivets

Install new part (1) with straightening attachment or universal mount and rivet with blind rivets N3 (2).
After adhesive has hardened, flatten adhesive area and seal blind rivets.
Fig. 32: Identifying Blind Rivets

41 00... REINFORCEMENT PLATE WITH STUD BOLT (BONDED)

2010 BMW M3
Reinforcement plates are available as new parts and must also be used.

repair work. They are applicable to sectional repairs in the outer skin area.
Overview of reinforcement plates:
1. Reinforcement plate, sill

2. Reinforcement plate, C-pillar
3. Reinforcement plate, universal
4. Reinforcement plate, C- or D-pillar
5. Lock nuts (not pictured)
Plastic nut 18 mm, part number 1 943 122
Clip nut 30 mm, part number 7 139 081
Fig. 33: Identifying Reinforcement Plate (Sill, C-Pillar, Universal And C- Or D-Pillar)
Mark component in accordance with dimension a and cut.

2010 BMW M3

The reinforcement plates must if necessary be reworked and cut to size.
Adjust reinforcement plate (1) to fit in component (2) on vehicle.
Make recesses (3) for stud bolts (4) in a semicircular shape.
Diameter of recesses approx. 10 - 12 mm.
Fig. 35: Adjusting Reinforcement Plate On Components Of Vehicle

2010 BMW M3
Secure reinforcement plate by screwing on lock nuts (1).
Fit new part (2). Make recesses (3) in new part in a semicircular shape.
Remove reinforcement plate again.
NOTE: Width of joint between new part and component on vehicle approx. 3 - 8 mm (at
least 30 mm flange width per side).
Plastic nuts should be screwed on once before applying adhesive (no thread in
new plastic nut)!
Fig. 36: Fitting New Part

Round off cutting edges (1) on joint by grinding.
(2) Component on vehicle

(3) New part
2010 BMW M3
Fig. 37: Identifying Cutting Edges

Procedure for using universal reinforcement plate
The universal reinforcement plate needs to be adapted. The plate must be divided if the distance between the
pins is too great.
Dimension a is between 40 and 80 mm depending on the space available.
Secure plates with N4 punch rivets.
NOTE: Ensure the rivet is positioned correctly! Rivet head is on the adhesion side!
Rivet the plate to the inside of the flange!
2010 BMW M3
Fig. 38: Identifying Universal Reinforcement Plate Dimension

Clean all bonding surfaces.
Apply adhesive to reinforcement plate in area (1). Apply more adhesive in the radii to avoid air pockets.
Carefully slide reinforcement plate into component on vehicle and secure by screwing on nuts (2). Screw on
nuts a few turns only.
bonding surfaces.
Fig. 39: Sliding Reinforcement Plate Into Component On Vehicle

2010 BMW M3
Apply adhesive to reinforcement plate bonding surface (1). Apply more adhesive in the radii to avoid air
pockets.
Fit new part (2).
Align new part to adjoining component and secure with gripping pliers.
Tighten nuts.
Tightening torque 41 14 1AZ.
IMPORTANT: Check that the transition of the components is OK at the separation point.
Corrections can only be made before the adhesive has hardened. Straightening
at a later stage is not possible.

Concluding tasks at separation point:
After adhesive has hardened:
In area visible to customer:
Cut off stud bolts with bodywork saw.
Completely remove adhesive residue in joint (1).
Round off sharp edges by grinding.

2010 BMW M3
IMPORTANT: Avoid heating the separation point by excessive grinding.

Reworking by pressing not permitted!
Fig. 41: Identifying Joint

Only the BMW-approved METAL FILLER should be used on the joint.
METAL FILLER - INSTRUCTIONS FOR USE
Not in area visible to customer:
Examples: The joint is covered by sill trim panel, windows, seals, etc.
Grind off stud bolts and surplus adhesive flush. Do not use metal filler.
NOTE: After painting, the joint becomes visible as the adhesive shrinks. This has no
affect on the quality.
41 05 800 RELEASING BONDED FOLDED SEAM CONNECTIONS

2010 BMW M3
Fig. 42: Identifying Bead Edge Area, Heating Area And Sealing Areas
Remove area (1) of bead edge on wheel arch bend with a one-hand angle grinder and rough grinding
wheel.
Heat area (2) with hot air blower.
CAUTION: Extract vapors and gases.

Grind adhesive residue (4) off wheel arch connection flange.
CAUTION: Wear a grinding dust mask.
Remove remnants of sealing material in area (3).
41 00... REPAIR SOLUTION FOR STRAIGHT SHANK/HEXAGON RIVET NUT
Wear safety goggles

2010 BMW M3
IMPORTANT: To prevent the material from tapering, do not drill out the rivet head.
1. Carefully spot-drill rivet head with a larger drill bit/countersink
Fig. 43: Drilling Rivet Head Using Larger Drill Bit

IMPORTANT: Avoid paintwork damage
2. Knock rivet head away with a chisel
Fig. 44: Knocking Rivet Head Using Chisel

3. Drive through rivet shank into cavity, remove if necessary

2010 BMW M3
Fig. 45: Identifying Rivet Shank Cavity


If the rivet shank can be removed:
IMPORTANT: To avoid corrosion, stop chips/debris by means of cavity sealing.

2010 BMW M3

If the rivet shank cannot be removed:
WARNING: Risk of injury!

Observe NOTES ON CAVITY FOAM .
IMPORTANT: To avoid corrosion and rattling noises, stop chips/debris and rivet nut shank
with cavity foam.
Remove foam remnants with isohexane (benzine).

5. Stop rivet shank by means of specific foaming

6. Set rivet nut with hand rivet gun
NOTE: Fit rivet nut as quickly as possibly, ideally before the cavity foam hardens.
2010 BMW M3
Hexagon/straight shank rivet nut (up to thread M8) with hand rivet gun ZS308

Make sure rivet nut correctly contacts component.



41 0 REPAIR TECHNIQUES, REPAIR STAGE 1

2010 BMW M3
All work which provides only for replacement of screwed/bolted components and planishing operations.
Repair techniques
Straightening outer skin

Straightening aluminum parts See or 4100... STRAIGHTENING ALUMINUM PARTS ON
OUTER SKIN
Straightening steel parts See or 4100... STRAIGHTENING STEEL PARTS ON OUTER SKIN
METAL FILLER
Grinding
Grinding aluminum components See 4100... GRINDING ALUMINUM PARTS or
Grinding steel parts See or 4100... GRINDING STEEL PARTS
Repair elements
Steel thread repairs See ; 4100... REPAIR SOLUTION FOR STRAIGHT SHANK/HEXAGON
RIVET NUT or 4100... NOTES ON REPAIRING THREADS
Repairs that are carried out by bonding and riveting without the use of a straightening bench.
Repair techniques
Removing used part

OPENING WELDED CONNECTIONS
OPENING BRAZED CONNECTIONS
OPENING RIVETED CONNECTION
Opening bonded connection See 4100... OPENING ADHESIVE BONDS or 4105800 RELEASING
BONDED FOLDED SEAM CONNECTIONS
GRINDING ALUMINUM COMPONENTS
GRINDING STEEL COMPONENTS
Sectional repairs
Reinforcement plate (bonded) See 4100... REINFORCEMENT PLATE (BONDED) or 4100...
REINFORCEMENT PLATE WITH STUD BOLT (BONDED)
METAL FILLER
Installing new part

Notes on consumables See 4100... OVERVIEW OF CONSUMABLES (ELECTRONIC PARTS
CATALOGUE); 4100... NOTES ON CLEANING AGENT R1 or 4100... INFORMATION ON
METAL FILLER
BONDING ON PAINTED SURFACES
BLIND RIVETS
2010 BMW M3
PUNCH RIVETS
Cavity sealing See 4100... INSTALLING A CAVITY ACOUSTIC BAFFLE (EXPANDED); 4100...
INSTALLING A CAVITY ACOUSTIC BAFFLE (NOT EXPANDED) or 4100... INSTALLING A
CAVITY SEALING WITH 2-COMPONENT PU CAVITY FOAM
EMC SCREWS
Miscellaneous
REPAIRING PLASTIC PARTS
BONDING GLASS PANES
BLIND RIVET NUTS AND BOLTS
Repairs that are carried out by bonding and riveting with the use of a straightening bench or welding.
Repair techniques
Straightening structure
STRAIGHTENING ALUMINUM COMPONENTS ON THE STRUCTURE
STRAIGHTENING STEEL COMPONENTS ON THE STRUCTURE
Removing used part

OPENING WELD JOINTS
OPENING BRAZED CONNECTIONS
OPENING RIVETED CONNECTIONS
OPENING BONDED CONNECTIONS
GRINDING ALUMINUM COMPONENTS
GRINDING STEEL COMPONENTS
Sectional repairs
WELDING IN REINFORCEMENT PLATE (STEEL PLATE)
SECTIONAL REPAIR (STEEL) WITH REPAIR ELEMENT
Sectional repair (aluminum) with repair element
Installing new part

Welding aluminum components
WELDING STEEL COMPONENTS
SPOT-WELD BONDING STEEL COMPONENTS
SOLDERING STEEL COMPONENTS
Notes on consumables . See 4100... OVERVIEW OF CONSUMABLES (ELECTRONIC PARTS
2010 BMW M3
CATALOGUE) or 4100... NOTES ON CLEANING AGENT R1.

Bonding aluminum on steel
BONDING STEEL ON STEEL
BLIND RIVETS
PUNCH RIVETS
Cavity sealing . See 4100... INSTALLING A CAVITY ACOUSTIC BAFFLE (EXPANDED); 4100...
INSTALLING A CAVITY ACOUSTIC BAFFLE (NOT EXPANDED) or 4100... INSTALLING A
CAVITY SEALING WITH 2-COMPONENT PU CAVITY FOAM
EMC SCREWS
41 00... REPAIRING PLASTIC PARTS
1.0 General information
Economic efficiency must always be checked prior to repair.

- Only the following painted COMPONENTS IN THE OUTER SKIN AREA are approved for repair:
Bumper trims (exception: E52)
Sill trims
Front side panels
Hardtop/roof
Convertible top compartment lid
Rear lid
Prerequisite for professional repair:

Only minor deformations (without microcracks, usually visible in the paint)
Only minor damage, e.g. abrasions, cracks and holes up to 2.5 cm long
No damage (cracks) to the edge of the component!
CAUTION: The following are not approved for repair:
Fuel tanks, reservoirs for liquids/fluids (e.g. windscreen washer

unit, brake fluid, coolant expansion tank, etc.)

Headlight mountings (pedestrian protection)
2.0 Shaping plastic parts
Plastic parts can be reshaped using a hot-air blower.

Microcracks can occur in the plastic if plastic parts are deformed. After the component is reshaped and
then painted, the cracks may become visible again on the surface after a period of time.
The component must be replaced if microcracks can be identified in the area of deformation.
3.0 Bonding plastic parts

2010 BMW M3
IMPORTANT: Conform with safety precautions See 4100... SAFETY AT WORK or 4100...
A plastics repair box is offered for cost-effective and time-value-

compatible repairs.
The plastics repair box contains the step-by-step instructions for
repairing plastic parts.
41 00... RIVETING STEEL PARTS
Manual riveting tool for blind rivet nuts and bolts.
2.0 Setting blind rivet nuts and blind rivet bolts
Drill holes (0.2 mm larger than the outside diameter of the blind rivet nuts or blind rivet bolts).
Blind rivet nuts and bolts must have a special coating for corrosion reasons.
Use the blind rivet nuts and bolts supplied in the case of the manual riveting tool for steel only!
Insert blind rivet nuts or bolts and tighten down with the riveting tool.
41 00... SAFETY AT WORK
1.1 Working with aluminum dust
Wear a fine dust mask.

E52 only: Use an explosion-proof extractor system.
Note national regulations.
1.2 Removing sealant
Hydrochloric acid is created when PVC sealing material is heated to temperatures in excess of 180C.
Remove PVC sealant with a rotating wire brush only or heat material with a hot air blower to max. 180C
and remove with a spatula.
Ensure that all enclosed areas are well ventilated or are provided with direct extractor facilities.
1.3 Arc welding and brazing
IMPORTANT: The extremely bright arc during welding may cause serious injury to the eyes if
appropriate protective measures are not taken.
Use a special welding screen for the relevant welding method (MAG or MIG).
2010 BMW M3
Partition off the workbays with beam protection screens.

Use a welding-emissions extractor facility.
The welder must wear protective clothing and gloves which are suitable for welding (i.e. flame-proof).
A fire extinguisher must be located within reach of the welding area.
Do not carry out any welding work in the proximity of a fuel tank e.g. when it is installed.
1.4 Working with chemical products (adhesive, cleaning agents, fillers, etc.)
Heed the manufacturer's material safety data sheets.
IMPORTANT: Handling chemical products may result in allergic skin and breathing reactions.

Avoid direct contact with eyes and skin.
Wear safety goggles, protective gloves and if necessary an apron.
Ensure that all enclosed areas are well ventilated or extract fumes directly.
Use a breathing apparatus with a suitable filter type when ventilation is insufficient.
Wear impermeable protective clothing.
Immediately change contaminated work clothing.
After finishing work, wash your hands thoroughly and apply protective skin cream.
Always keep an eye douche on hand, change the water regularly (once a month).
Store bonding products in a secure cabinet only.
Keep bonding products away from naked flames and other ignition sources.
Protect bonding products against strong heat sources and direct sunlight.
First Aid:
If product comes in contact with eyes, immediately flush with running water for about 10 -15 minutes. Seek the
advice of eye specialist.
In the event of skin contact and where applicable an allergic skin reaction, clean the affected areas immediately
with soap and water and then apply silicone-free skin cream. If necessary, consult a doctor.
If an adhesive product is swallowed, rinse mouth/parts of mouth thoroughly with running water. Drink 1-2
glasses of water. Do not induce vomiting. Consult a doctor.
After inhaling adhesive vapors ensure ample supply of fresh air. Stay calm. Keep air passages open. Consult a
doctor.
00 SAFETY INFORMATION FOR WORKING ON VEHICLES WITH AUTOMATIC ENGINE

2010 BMW M3
START-STOP FUNCTION (MSA)
WARNING: If the engine hood/bonnet contact is pulled upwards (workshop mode),

the information "switch closed" is output. The automatic engine start-stop
function is active.
An automatic engine start is possible.
Observe safety precautions when working on MSA vehicles
Before carrying out practical work on the engine, always ensure that the MSA functionality is deactivated so as
to prevent automatic engine starting while work is being carried out in the engine compartment.
MSA function is deactivated by
Deactivate MSA by means of button (1) in passenger compartment

Open seat belt buckle and driver's door
Fig. 51: Identifying Automatic Engine Start/Stop Button

Open engine bonnet/hood and ensure that engine hood/bonnet contact is not in workshop mode
Workshop mode
A = 10 mm
Basic setting (engine hood/bonnet open)
B = 7 mm
2010 BMW M3
Fig. 52: Identifying Engine Hood/Bonnet Basic Setting And Workshop Mode
To make sure that the engine hood/bonnet contact is at the basic setting, if necessary press the
hood/bonnet contact up to the limit position before starting work and slowly release.
41 00... SEPARATING CUT DETERMINATION WITH A TEMPLATE
A template may be used for the exact position determination for the separating cut.
The template is made from the reinforcement plate and can be reused.
Carry over schematic diagram at the separation cut C-pillar to the relevant vehicle type.
Remove stud bolts (1).
Set bore holes 4 mm at the positions of the removed stud bolts.
If applicable, place additional bore holes in the area of the edges.

2010 BMW M3
Fig. 53: Identifying Stud Bolts

Insert the template (1) into the new part (in direction of arrow) until it is flush (without gap).
Carry over the positions of the holes (2) to the new part.
Fig. 54: Inserting Template Into New Part

Connect marks (positions of holes) to the separating cut line (1).

2010 BMW M3
Carry out the separating cut.
Tear and separate the separating cut on the vehicle according to the new part.
Fig. 55: Connecting Position Of Holes To Separating Cut Line

41 00... SETTING BLIND RIVET NUTS AND BOLTS
Studs welded as standard are always replaced by blind rivet bolts.

Blind rivet nuts and studs must have a special coating for anti-corrosion purposes.
It will no longer be possible to set a blind rivet nut if the drilled hole is too big. In this event, set a clip
nut. This nut tightens itself automatically when screwed to the component.
Insert blind rivet nuts or bolts and TIGHTEN DOWN WITH RIVET TOOL .
Seal blind rivet nuts and blind rivet bolts with SEALANTD1 (risk of corrosion).
41 00... SOLDERING STEEL COMPONENTS
IMPORTANT: Comply with the following topics from "Body, General":

Safety regulations See 4100... SAFETY AT WORK or 4100... INFORMATION ON
HAZARDS.
Handling electrical/electronic equipment, airbags and restraint systems See
4100... HANDLING AIRBAGS AND RESTRAINT SYSTEMS or 4100... HANDLING
ELECTRICAL AND ELECTRONIC EQUIPMENT.
2010 BMW M3
1. General information
For repair cases the following method will implemented:

Gas brazing
The MIG soldering procedure is not used in repairs for strength reasons. MIG soldered/brazed seams
used in series production are replaced in repairs by MAG weld seams.
Brazed areas from vehicle production are bonded with the same method.
2. Work materials
Tube pack and torch (gas torch)

Brazing solder
Gas bottles (oxygen and acetylene)
Welding goggles
3. Preparation
Remove the paint and zinc coating in an area of approx. 30 mm around the seam to be soldered.
4. Implementation
Execute brazed seam without overheating the solder and with low heat dissipation. If necessary, use heat
protecting paste.
5. Subsequent treatment of brazed joints
Remove burnt residual zinc completely. Align and grind visible connection faces.
Remove burnt paint with a stainless steel wire brush.
6. Notes on melting/tinning
Only applicable within the European Union!
European used-car regulations prohibit the use of tin containing lead in motor vehicles introduced after
01.07.2003!
Even out unevenness smaller than 2 mm with filler according to painting handbook
If an exceptional unevenness is larger than 2 mm, use METAL FILLER .
Only perform in visible areas of the outer skin and on the carrier support.
All areas which have covers on the vehicle are not to be processed.
41 00... SPOT-WELD BONDING STEEL PARTS

2010 BMW M3

Safety regulations . See 4100... SAFETY AT WORK or 4100... INFORMATION ON
HAZARDS.
Handling electrical/electronic equipment, airbags and restraint systems . See
WELDING STEEL PARTS .
The spot-weld bonding process is used starting from the E65 to increase vehicle rigidity. In partial
bodywork areas, a 1-component adhesive is applied to the spot flanges and this is followed by resistance
pressure spot welding. The adhesive is hardened only after the paint drying process (at approx. 180C).
In the case of repairs, adhesive is not applied to the spot flanges. The number of welding spots is doubled
as a substitute for the omitted adhesive.
The following processes are used as a substitute for spot-weld bonding:
MAG welding (M etal A ctive G as welding)
Resistance pressure spot welding (referred to in the following and in the repair instructions as spot
welding).
Adhesive is not applied between the spot flanges on new parts in the case of 2- or multi-sheet joints.
Areas which cannot be reached by the spot-welding tongs can be joined by MAG spot welding. The
number of welding spots is doubled as a substitute for the omitted adhesive.
Exceptions (e.g. E65) are described in the relevant repair instructions. Apply welding spots to existing
welding spots on new part. This is necessary because the adhesive between the spot flanges of the new
part acts as an insulator.
CAUTION: Extract smoke and fumes during welding work.

41 00... STAMPING VEHICLE IDENTIFICATION NUMBER
NOTE: If the stamped vehicle identification number is removed during repair work, it
must be stamped in again.
Read and comply with GENERAL INFORMATION .
Remove front right spring strut

Remove rubber base from guide plate 41 1 141
The set of special tools 411140 for stamping the vehicle identification number consists of:
Guide plate 41 1 141

2010 BMW M3
Counter-support plate 41 1 142
Fig. 56: Identifying Guide Plate And Counter-Support Plate

Position counter-support plate 41 1 142 at bottom on spring strut dome.
Position guide plate 41 1 141 at top on spring strut dome and tighten screws (1) by hand.
Fig. 57: Identifying Counter-Support Plate And Guide Plate With Screws
Tighten screw (1) until counter support 41 1 142 rests on spring strut dome.
2010 BMW M3
Fig. 58: Identifying Screw And Counter Support 41 1 142

Tighten down screws (1).
NOTE: The illustration is a schematic representation and is to be applied to the

relevant vehicle type.
Insert punch numbers 410000 (1) individually into guide plate (2) and stamp vehicle identification number.
2010 BMW M3
Fig. 60: Inserting Punch Number 41 0 000 Into Guide Plate

NOTE: In the event of component or body replacement by the workshops/garages,

clearly delimit the vehicle identification number at front and rear by stamping a
"+" in place of the BMW emblem.
41 00... STRAIGHTENING ALUMINUM COMPONENTS IN STRUCTURE
Reshaping or heating extruded sections and cast parts is not permitted!
Failure to comply with this requirement would have the following results:
In the case of reshaping, weld seams (E52) or glued connections (E60, E61, E63, E64) tear in the
surrounding area.
In the case of reshaping, the material loses up to 40 % of its original strength.
In the case of heating, the material loses up to 40 % of its original strength.
The adhesive is destroyed at temperatures > or = 120C (E60, E61, E63, E64).
Extruded sections and cast parts which show visible or measurable signs of deformation must be replaced.
Perform the check for deformation with the aid of the straightening system.
For optical testing, strip adjoining components in cases of doubt.
Extruded sections are used in the E52 as engine supports, door pillars, side members, etc.
Extruded sections are used in the E60, E61, E63, E64 as engine supports.
Cast parts are used in the E60, E61, E63, E64, E70, E71 as spring supports.
2010 BMW M3
Reshaping of extruded sections and cast parts may only be used to achieve optimum joining of connecting
faces (e.g. when bulkhead is damaged). Reshaped parts must be replaced.
Repairs which affect the mounting points of mechanical assemblies and chassis components must be
carried out on the straightening bench. Use the vehicle-specific straightening attachment set or vehicle-
specific data sheet.
Straightening attachment supports and data sheets are also available for the top section, e.g.: door pillars,
convertible top mounts, cowl, rear lid hinges, etc.
Check windshield and rear window apertures for curvature by inserting the original glass.
Take the gap dimensions for doors, engine hood and rear lid from the vehicle-specific gap dimension
diagram.
Exceptions on the E60, E61, E63, E64:
Carrier support and bulkhead may be straightened if they do not have any cracks, sharp-edged damage or
holes. After repair work, check parts again for cracks.
Examine adjoining adhesive flanges for peeling off. If necessary, seal and preserve with SEALING
COMPOUND .
Observe the frame alignment control dimensions for the carrier support.
Any repairs to the bulkhead if cracked outside the approved repair scopes are only permitted after
consultation with and approval by BMW. Should you have any questions, please contact the country-
specific Hotline.
41 00... STRAIGHTENING ALUMINUM PARTS ON OUTER SKIN
1.0 Recommended tools
Use only those tools specially intended for aluminum repairs.

Do not use any tools that have already been used for steel repairs (contact corrosion).
Do not use any sharp-edged tools (notch effect).
2.0 Straightening outer shell
"Cold" straightening: Press dents out from their center and smooth in an outwards direction with gentle
taps.
In the case of small, soft dents (hail and parking damage), this is also possible without damaging the
paintwork. This work requires a special tool.
"Hot" straightening: Heat dents in their central point only with a gas flame or hot air blower. Then quench
the material with a wet cloth. Heating can only be detected by warpage of the material. The color of the
paint does not change.
2010 BMW M3
In the case of damaged areas which are only accessible from one side, stud welding can be used. The
aluminum stud welded on in the center of the damaged area is beaten out with a hammer until the dent is
eliminated. The stud is then ground off.
Avoid notching and cracking.
Avoid hardening and overstretching.
Avoid heating and overheating the outer shell over large areas.
41 00... STRAIGHTENING STEEL COMPONENTS IN THE STRUCTURE
High-strength and super-high-strength steel plates as a rule cannot be reshaped. Reshaping only serves as
a preparatory measure to replacing the component in order to achieve optimal joining of the connection
points.
Bearing body components such as e.g. engine supports, door pillars, side members etc. with deformations
which can no longer be returned to their original shape by "cold straightening" must be replaced.
Heating bearing body components for better reshaping is not permitted!
Failure to comply with this requirement would result in a loss of original strength of up to 40 %.
The body must be anchored as follows for reshaping:
If using vehicle-specific/universal straightening attachment sets (Carbench/Celette/Car-O-Liner), it is

necessary to secure the body additionally with 4 retaining clips to the spot flange of the entrance or to the
4 jacking points. The spot flange (if available) is to be preferred.
If using universal electronic or mechanical straightening systems (Car-O-liner/Celette), it is necessary to

secure the body with 4 retaining clips to the spot flange of the entrance or to the 4 jacking points. The
spot flange (if available) is to be preferred. In addition anchor at least 2 points with the securing set.
Failure to comply with these instructions will result in damage to the body during reshaping in non-
damaged areas. Vehicle-specific straightening attachments and universal mounts may be damaged.
Repairs affecting the mounting points of assemblies and chassis/suspension components must be carried
out on the straightening bench with the matching straightening attachment set or specification sheet for
the vehicle.
Straightening attachments and specification sheets are also available for the top section, e.g.: door pillars,
diagram.
41 00... STRAIGHTENING STEEL PARTS

2010 BMW M3
Only use those tools designed for steel repairs.
"Cold" straightening: Press dents out from their center and smooth in an inwards direction with gentle
taps.
paintwork. This work requires a special tool and a trained worker.
"Hot" straightening: Heat dents in their central point only with a gas flame until bright red hot. Then
quench the material with a wet cloth.
Stud welding can be used in the case of damage where access is only possible from one side. Weld on the
stud in the middle of the damaged area. The steel pin or shim is driven out using a hammer until the
depression is removed. The stud, pin or shim is then ground or twisted off.
Avoid cracking.
If, after steel parts have been straightened, the surface shows no dents larger than 2 mm, these dents may
be touched up with knifing filler.
Dents larger than 2 mm must be treated with filling solder.
NOTE: Only applicable within the European Union!
01.07.2003!
For safety vehicles, follow the special notes and information in the repair instructions.
3.0 Straightening structure
the vehicle.
diagram.
Bearing body components such as e.g. engine carriers, door pillars, frame side members etc. with
2010 BMW M3
deformations which can no longer be returned to their original shape by "cold straightening" must be
replaced.
points.
If using vehicle-specific/universal straightening attachment sets (Carbench/Celette), it is necessary to

secure the body additionally with 4 retaining clips to the spot flange of entrance or to the 4 jacking
points. The spot flange (if available) is to be preferred.
If using universal electronic or mechanical straightening systems (Car-O-liner/Celette), it is necessary to

secure the body with 4 retaining clips to the spot flange of entrance or to the 4 jacking points. The
spot flange (if available) is to be preferred. In addition anchor at least 2 points with the securing set.
41 00... STRAIGHTENING STEEL PARTS ON OUTER SKIN
taps.
paintwork. This work requires a special tool and a trained worker.
Avoid cracking.
2010 BMW M3
01.07.2003!
41 00... USE OF MATERIALS IN OUTER SKIN
The following illustration is a schematic representation of all the body variants.
Apply this illustration to the relevant vehicle.
Fig. 61: Identifying Body Components

All components not listed in the table below are composed of established sheet steel qualities.
2010 BMW M3
BODY COMPONENTS MATERIAL DESCRIPTION CHART

Component Vehicle Material
(1) Side panel, front E52 (Z8) Aluminium
E60, E61 Aluminium
E63, E64 Plastic (thermoplastic)
E65, E66: Aluminium
E70, E71, E92, E93 Plastic (thermoplastic)
E89 (Z4) Aluminium
(2) Front door E36/C (M3) Aluminium or steel
E36/2 (M3) Aluminium or steel
E52 (Z8) Aluminium
E63, E64 Aluminium
(4) Side panel, rear E52 (Z8) Aluminium
(5) Engine compartment lid E38 (750i) Aluminium or steel
(5) Engine compartment lid E46/C (M3) Aluminium
E46/2 (M3) Aluminium
E52 (Z8) Aluminium
E60, E61, E63, E64 Aluminium
E65, E66, E70, E71 Aluminium
E85 (Z4) Aluminium
E92 (M3) Aluminium
E89 (Z4) Aluminium
(6) Hardtop/roof E36/C Aluminium
E36/7 (Z3) Plastic (glass fibre/epoxy resin)
E46/C Aluminium
E46/2 (M3 CSL) Plastic (CFK)
E52 (Z8) Plastic (PU)
E85 (Z4) Plastic (SMC)
E63 (M6) Plastic (CFK)
E89 (Z4) Aluminium
(7) Soft top compartment lid E46/C Magnesium
E64 Plastic (SMC)
(8) Rear lid E46/2 (M3 CSL) Plastic (SMC)
E52 (Z8) Aluminium
E63, E64 Plastic (SMC)
41 00... VEHICLE IDENTIFICATION NUMBER, GENERAL
In the event of repair 2 procedures are used, depending on the vehicle. Refer to the vehicle-specific repair
instructions for the correct procedure.
1. General notes for stamped vehicle identification numbers

2010 BMW M3
The vehicle identification number is stamped with a special tool. There are different special tool numbers and
stamping procedures for the various vehicles. Refer to the relevant repair instructions.
In repair work, the vehicle identification number is always stamped into a replacement vehicle identification
number surface. The replacement surface is usually situated under the original VIN surface.
The IGEF number (bodyshell number) is omitted when the wheel arch is replaced.
In the event of component or body replacement by the BMW garages/workshops, clearly delimit the vehicle
identification number at front and rear by stamping a + in place of the BMW badge.
If a VIN is stamped into the replacement surface in addition to the original VIN (e.g. if the original VIN has
been tampered with), the following applies: The original VIN must be crossed out. To do so, stamp the letter I
from the punch digits lengthways through the original VIN.
IMPORTANT: Do not use an angle grinder in conjunction with a cutting disk!
The protective film used as standard is omitted after the VIN has been manually stamped in. Paint area in
accordance with BMW Painting Handbook. Ensure that layer thicknesses are small.
Observe national/country-specific regulations.
2. General notes for embossed vehicle identification numbers
This procedure is used on all newly launching model series from model year 09/2008 (exception X1).
For the repair new parts with an embossed vehicle identification number can as a rule be ordered from the
BMW Parts Department. If this is not possible, observe country-specific regulations.
If a VIN is embossed into the replacement surface in addition to the original VIN (e.g. if the original VIN has
been tampered with), the following applies: The vehicle-specific repair instructions describe the procedure.
The protective film used as standard is omitted after the VIN has been embossed. Paint area in accordance with
BMW Painting Handbook. Ensure that layer thicknesses are small.
41 00... WELDING AND SOLDERING STEEL PARTS

HAZARDS.
2010 BMW M3
A. Welding steel parts
B. Soldering steel parts
41 00... WELDING IN REINFORCEMENT PLATE (SHEET STEEL)
A reinforcement plate is welded in to ensure sufficient strength.
Follow notes for WELDING STEEL PARTS .
NOTE: The following illustrations serve as general illustrations of reinforcement plate

repair work. They are applicable to all cutting repairs.
Mark component in accordance with distance A and cut.
Fig. 62: Identifying Component Cutting Distance

Cut new part (1) in accordance with cut and if necessary adjust to fit with straightening attachment or universal
mount.
Installation:
Adhere to a gap at severance cut of approx. one to max. two material thicknesses in order to ensure welding
with the reinforcement plate and to facilitate a more tolerant fit.
2010 BMW M3
Fig. 63: Identifying Part Cutting Position

Clean inner and outer sides of connecting areas (1) on new part and (2) on body.
Coat inner sides with welding primer.
Fig. 64: Identifying Connecting Areas And New Part

Drill holes (1) and (2) at distance of 25 mm to each other.
Hole diameter approx. 8 mm.

2010 BMW M3
Fig. 65: Identifying Drill Holes Position

Make reinforcement plate (1) from trim of new part.
If necessary, make further reinforcement plates.
Length of reinforcement plates is min. 40 mm.
Coat reinforcement plates (1) and (2) on both sides with welding primer.
Fig. 66: Identifying Reinforcement Plate

Push reinforcement plate (1) into component on body up to half way and plug-weld (3).
2010 BMW M3
Fig. 67: Identifying Reinforcement Plate And Plug-Weld

If necessary, adjust new part (1) to fit with straightening attachment or universal mount and plug-weld (2).
MAG weld joint (3).
Grind and clean weld seam and plug weld spots.
Only visible areas of the outer skin and worn areas on the support carrier must be tinned.
All areas which have covers on the vehicle are not to be tinned.
Fig. 68: Identifying Plug-Weld And MAG Weld Joint


European used-car regulations prohibit the use of tin containing lead in motor
vehicles introduced after 01.07.2003!
41 00... WELDING STEEL COMPONENTS

2010 BMW M3

HAZARDS.
The following procedures are used for repairs:

welding).
Take the number and location of weld spots and MAG weld seams from the separated part. Replace areas
inaccessible to spot-welding tongs with MAG plug/spot welds at the same distance. Diameter of bores for
plug/spot welds 8 mm.
In the case of emissions extraction, observe a minimum distance of 30 cm for MAG welding during the
welding process. Otherwise the inert gas would be drawn off.
Follow the equipment manufacturer's instructions for use.
2. Work materials
MAG welding:
Steel welding apparatus (see WORKSHOP EQUIPMENT ).
Steel welding wire - G3SI1 (SG2) or alternatively G4SI1 (SG3)
Welding mask
Gas bottle containing inert gas (82 % argon, 18 % CO 2)
Resistance pressure spot welding:

Spot-welding apparatus (see WORKSHOP EQUIPMENT ).
Protective goggles
3. Preparations for MAG and spot-welding
Remove the paint coating in an area of approx. 30 mm around the weld seam or spot.
The zinc coating underneath must be removed during the MAG welding operation.
It is not necessary to remove the zinc coating underneath during spot-welding.
Remove the paint coating on the reverse side of the weld seam or spot.
Contaminants will otherwise enter the weld pool via the root of the weld seam.
An insufficient electron flow prevents an optimum spot-weld joint.
Coat all metal overlaps and weld spot flanges with welding primer.
To determine the optimum electrode contact force for spot-welding, carry out spot-weld shear tests on
sample metal sheets.
2010 BMW M3
In order to keep the electron flow short during MAG welding on the body, you must if possible attach the
ground terminal directly to the component to be welded.
4. Welding
During MAG welding, the weld gap must be kept as small as possible. The larger the weld gap, the lower
will be the strength of the joint.
During spot-welding, the metal flanges to be joined must be placed as close together as possible without
gaps.
The larger the gap, the lower will be the strength of the joint.
Minimum gap between welding spots 25 mm.
5. Subsequent treatment of weld joints
When grinding a weld seam, do not grind thin the base material next to the seam.
After joining, clean all weld seams and spots with a stainless steel wire brush.
All weld joints sealed off with body sealing compound in original state must be primed and sealed off
again thoroughly after repairing. Replace damaged or removed anti-drumming layers.
41 00... WORKING WITH 2-COMPONENT PU CAVITY FOAM

Ideal for use as insulating and sealing compound
Information on dangers/hazards
Wear protective goggles, solvent-resistant protective gloves and protective clothing.
Do not inhale.

2010 BMW M3
Remaining amounts which are not used can cause the can to explode on account of a chemical reaction
(buildup of heat)!
Alternatively, cool the can containing the non-removed remaining amount for several hours in cold water.
Do not eat, drink or smoke during this operation.

Application instructions
Use by date on can.
Do not use the spray can after the Use by date on the can has expired. After the Use by date the properties
clean and free from
dust,
grease,

Cans which are not entirely empty and unused whose Use by date has expired are classed as hazardous
waste.
Observe country-specific waste-disposal regulations.
Observe the manufacturer's application instructions (printed on the can).

2010 BMW M3

41 00... WORKSHOP EQUIPMENT
Minimum workshop equipment requirements in order to ensure the correct and expert performance of body
repairs:
The tools listed below must be used.
All repair stages:
TOOLS REFERENCE CHART

Steel Aluminium
Tool)* Structure Outer skin Structure Outer skin
Vaupel pressure cup spray gun for cavity preservation x x x x
Repair stage 1:

Steel Aluminium
Body tool trolley x x x
Aluminium bodywork tool assortment x x
Repair stage 2:

Steel Aluminium
Body tool trolley x x
Bodywork saw x x
Belt sander x x x x
Single-handed x x x x
grinder
Welding spot x x
remover
Universal riveting x x x
tool
Punch riveting tool x x x
CARTRIDGE GUN x x x
2010 BMW M3
Repair stage 3:

Steel Aluminium
Tool) Structure Outer skin Structure Outer skin
Body tool trolley x x
Aluminium x x
bodywork tool
assortment
Bodywork saw x x
Belt sander x x x x
grinder
Welding spot x x
remover
Drill x x
MAG welding x x
apparatus
MIG welding x (E52 only)
apparatus
Spot welding x x
apparatus
Gas welder x
Straightening system x x
Stud welding x x
apparatus
Flame coating set x
Universal riveting x
tool
CARTRIDGE GUN x x x
adhesives
IMPORTANT: In vehicles from model year 2001, higher-tensile and high-tensile steels are
used in certain areas.
It is essential to check whether the spot-welding apparatus used conforms to
the technical requirements of the currently recommended welding sets. Should
you have any questions, please contact the country-specific Hotline.
The use of technically obsolete equipment may have serious consequences for
the structure of the vehicle (e.g. in the event of a crash). In the end, this can
result in safety and product liability risks which can not be calculated.
Use and restrictions:
Definition of recommendation:
2010 BMW M3
All currently recommended spot welding sets comply according to the latest information with the requirements
relating to reliable welding of today's and future BMW Group vehicles. A spot welding unit will loose its
recommendation as soon as tests with materials and material combinations designated for future use in BMW
Group vehicles return negative results (see Table Group 1). All previous application before the withdrawal of
the recommendation shall remain unaffected.
RECOMMENDED SPOT WELDING

Device designation Manufacturer
Group 1 CR500 Car-O-Liner
Devices currently no longer Spot9000 Tecna
recommended ATL 400V Wielander&Schill
Group 2 MIDIspot QSVM9000 Celette) (1)
Devices currently recommended MIDIspot QSVM9000
Elmatech) (1)
CR600 QSM Car-O-Liner) (1)
MIDIspot QSVM12000T Car-O-Liner
Multispot MI-100 Control Elektron
MIDIspot QSVM12000T Elmatech
(1) no longer produced
Application options and restrictions of above devices.
RESTRICTIONS OF SPECIAL TOOLS

Vehicle Group 1 Group 2
x
All convertibles from E64 x
Except A-pillar, B-pillar, sill
x
All model series from E70 x
Except B-pillar
NOTE: Status October 2009
All vehicles not mentioned can be repaired with the equipment of Group 1 and Group 2.
SUPPORT MEMBERS
41 14 511 REPLACING COMPLETE REAR LEFT WHEEL ARCH (REAR LEFT SIDE PANEL
REMOVED)
Read general service information under BODY, GENERAL.
Remove or cover those vehicle components in the repair area which are susceptible to heat or dust.
Spot-weld bonding is used on this vehicle. Observe specific PROCEDURE .

2010 BMW M3
Use only approved SPOT-WELDING APPARATUS for repairs!
Place vehicle on straightening bench.
Following new body parts are required:
(1) C-pillar reinforcement

(2) Wheel arch, outer, rear
(3) Support, wheel arch
(4) Wheel arch, rear, inner half
(5) Support, frame side member
(6) Shaped part, C-pillar, outer (not shown)
Fig. 69: Identifying Body Parts

(7) Rear entrance shaped part (not shown)
Secure door opening at spot-welding flanges with support strut (1).

2010 BMW M3
Fig. 70: Identifying Support Strut

Fig. 71: Identifying Cut Mark And Welding Areas On Wheel Arch
Mark severance cut (1) in accordance with measurement and cut.
IMPORTANT: Cut outer metal sheet only.

2010 BMW M3
Measurement a = approx. 140 mm from roof edge.

Open weld joints in areas (2).
Installation:
Weld in REINFORCEMENT PLATE at severance cut.
Apply window glass adhesive to CAVITY ACOUSTIC BAFFLES (3).
Fig. 72: Identifying Cut Mark, Welding Areas And Adhesive Applying Areas On Wheel Arch

Measurement a = approx. 30 mm from lock striker reinforcement.
Installation:
Apply window glass adhesive to CAVITY ACOUSTIC BAFFLE (3).

2010 BMW M3
Installation:
Weld new components in areas (2) additionally.
Fig. 73: Identifying Welding Areas On Wheel Arch

NOTE: Rear parcel shelf not shown.
Installation:
Fig. 74: Identifying Welding Areas On Parcel Shelf

2010 BMW M3
Open weld joints in area (1).
Installation:
Weld new components in area (2) additionally.

Mark new part in accordance with severance cut on vehicle + 20 mm extra material and cut (1).
Slide new part under weld spot flange in area (3).
Plug weld in areas (2) and (3).
Fig. 76: Identifying Welding And Cutting Areas

2010 BMW M3
41 11 300 REPLACING COVER FOR LONGITUDINAL MEMBER WITH LEFT DOOR PILLAR
(PARTIAL REPLACEMENT B-PILLAR)
Use only approved SPOT-WELDING APPARATUS for repairs.
Following new body parts are required :
(1) B-pillar with entrance

(2) Shaped part, B-pillar, inner (not shown)
Fig. 77: Identifying B-Pillar

2010 BMW M3
Fig. 78: Identifying Welding Areas And Measurements On Left Door Pillar
Mark severance cuts in accordance with specified measurements and cut.
IMPORTANT: Cut outer plate only for following severance cuts.
Measurement a = approx. 128 mm behind hole dia. 25 mm.
Measurement b = approx. 100 mm from roof edge.
Measurement c = approx. 80 mm below cut b.
Measurement d = approx. 190 mm from center point of hole dia. 20 mm.
Installation:
Cut out metal section (2) is needed again for sealing.
Weld in REINFORCING PANELS at all severance cuts.

2010 BMW M3
Mark severance cut in accordance with specified measurement and cut.
IMPORTANT: Cut outer metal plate only for following severance cut.
Measurement a = 140 mm from roof edge.
Installation:
Fig. 79: Identifying Measurement From Roof Edge

NOTE: View from inside
Fig. 80: Identifying Weld Joint Areas

2010 BMW M3
Open adhesive bonds in areas (1).
Fig. 81: Identifying Adhesive Applying Areas

NOTE: View from below
Open weld joint in area (1).
Fig. 82: Identifying Weld Joint Area

2010 BMW M3
Fig. 83: Identifying Adhesive Applying Areas And Cavity Acoustic Baffle
Installation information:
Mark new part in accordance with severance cuts on vehicle and cut.
Apply window glass adhesive See 4100... INSTALLING A CAVITY ACOUSTIC BAFFLE (EXPANDED)
or 4100... INSTALLING A CAVITY ACOUSTIC BAFFLE (NOT EXPANDED) to cavity acoustic baffle
(1).
Apply ADHESIVE in areas (2).
Adjust new part to fit with straightening attachment or universal mount.
41 11 516 REPLACING FRONT LEFT OR RIGHT CARRIER SUPPORT (PARTIAL

REPLACEMENT, FRONT SIDE PANEL REMOVED)
STRIP DOWN VEHICLE .

2010 BMW M3
NOTE: Observe new procedure for bonding and riveting (REPAIR STAGE 2) .
Carry over schematic representation to the relevant vehicle type.
(1) Carrier support, wheel arch, outer
Fig. 84: Identifying Wheel Arch Carrier Support

Following CONSUMABLES are required:
CONSUMABLES REFERENCE CHART

Material Quantity
Adhesive K5a 1
Blind rivets N1 2
Blind rivets N3 6
Punch rivets N5 12
CleanerR1 1
Cavity sealing wax remover 1
Sealing compoundD1
Removing carrier support
Mark severance cut (1) through 20 mm dia. hole and cut carrier support.

2010 BMW M3
Fig. 85: Identifying Severance Cut And Welding Areas

Remove carrier support section.
Fig. 86: Identifying Carrier Support Welding Areas

Make severance cut on new part in accordance with severance cut on vehicle.
Adjust new parts with add-on parts to fit and secure.
Set two 6.8 mm dia. holes for blind rivets N1 in area (1).
2010 BMW M3
Fig. 87: Identifying Hole Area For Blind Rivets

In area of REINFORCEMENT PLATE (1) set six 4.3 mm dia. holes for blind rivets N3.
Remove new part again and deburr holes.
Fig. 88: Identifying Reinforcement Plate Rivet Areas

Installing carrier support
Clean all bonding surfaces (1) on vehicle and on new part with cleaning agentR1!
Apply adhesive K5a to bonding surfaces.

2010 BMW M3
Fig. 89: Identifying Bonding Surfaces On Vehicle

Install new part with add-on parts and rivet.
IMPORTANT: Three-plate connection (1)!

In area (1) rivet new part on both sides offset with 4 punch rivets N5.
In area (2) rivet new part with 2 punch rivets N5.
Fig. 90: Identifying Reinforcement Rivet Areas

Use 6 punch rivets N5 in area (3).
In area of reinforcement plate (4) use 6 blind rivets N3.

2010 BMW M3
In area (1) rivet new part with 2 blind rivets N1.

41 14 021 REPLACING FRONT LEFT WHEEL ARCH
Procedure OBSERVE repair step 3!
Read general service information under BODY, GENERAL . STRIP DOWN VEHICLE .
(1) Wheel arch, front

(2) Support carrier, wheel arch, outer
Fig. 92: Identifying Front Wheel Arch And Outer Wheel Arch Support Carrier
2010 BMW M3

Material Quantity
Adhesive K1 1
Blind rivets N1 56
Punch rivets N5 39
EMC screws 4
CleanerR1 1
Sealant D1
Removing wheel arch
Mark severance cut (1) in front of holder (2) and cut (holder (2) remains on vehicle).
Open welded connections in area (3).
Installation:
Mark severance cut (1) in on new part and cut. Take off holder (2).
Apply sealant to cavity acoustic baffle See 4100... INSTALLING A CAVITY ACOUSTIC BAFFLE
(EXPANDED) or 4100... INSTALLING A CAVITY ACOUSTIC BAFFLE (NOT EXPANDED) (4).
Fig. 93: Identifying Severance Cut With Cavity Acoustic Baffle And Welding Areas
Open welded connections in areas (1).

2010 BMW M3
Fig. 94: Identifying Welding Areas


Installation:
If equipment compartment partition wall (2) is damaged, cut along line (3).
Mark new part in accordance with severance cut on vehicle + 20 mm extra material and cut.
Bond both parts overlapping and rivet.
Depending on accessibility, use punch rivets N4 and blind rivets N3.

2010 BMW M3
Fig. 96: Identifying Welding Areas On Compartment Partition Wall


Make severance cut on new carrier support part in accordance with severance cut on vehicle.

2010 BMW M3

In areas (1) cut open engine support from opposite side and open welded connections.
In area (2) open welded connections from inside.
Fig. 99: Identifying Engine Support Welding Areas

Adjust new parts to fit with alignment bracket or universal mount and secure.
In areas (1) to (3), set 6.8 mm dia. holes for blind rivets N1:
Area (1): 3 holes
Area (2): 8 holes
Area (3): 6 holes

2010 BMW M3
Installation:
After adhesive has hardened, install 2 EMC SCREWS in areas (1) and (2).
Fig. 100: Identifying EMC Screws Area

In areas (1) and (2), set 6.8 mm dia. holes for blind rivets N1:
Area (1): 3 holes
Area (2): 2 holes
Fig. 101: Identifying Rivet Areas

2010 BMW M3
Area (1): 1 hole
Area (2): 7 holes
Installation:
In area (3) 2 N5 punch rivets are used later.

In area (1) set seven 6.8 mm dia. holes for blind rivets N1.
Installation:
In area (2) 1 N5 punch rivet is used later.

2010 BMW M3

Area (1): 5 holes
Area (2): 2 holes
Area (3): 1 hole
Area (4): 9 holes
Installation:
After adhesive has hardened install 2 EMC screws in areas (1) and (4).
2010 BMW M3

Remove all new parts and deburr holes.

Installing wheel arch
IMPORTANT: Do not grind/sand new parts in area of bonding surfaces.
Clean bonding surfaces with adhesive cleaning agent R1.
Apply adhesive K1 to bonding surfaces.

2010 BMW M3
Install new parts and rivet with blind rivets.

Fig. 106: Identifying Rivet Areas On Wheel Arch

Installation:
Vehicles with spring strut dome plate insert:
Different plate inserts are fitted, depending on the model.
Version (A) riveted or glued

Version (B) screwed
IMPORTANT: Use only identical plate inserts on both sides of the vehicle.
Riveted version:
If damaged, the plate inserts must always be replaced with glued versions on both sides of the vehicle.
2010 BMW M3
Fig. 107: Identifying Spring Strut Dome Plate Insert (Glued And Screwed)
Glued version:
Adhesive/contact surfaces of plate insert must be free of sealant, final paint coat and underbody protection.
Do not grind off primer.
Use adhesive gun 41 3 102 in conjunction with adhesive K3.
Apply K3 adhesive in areas (1). Do not apply any adhesive in area (2).
Fig. 108: Identifying K3 Adhesive Applying Areas

Secure plate insert with 3 screws and nuts for 2 hours at min. 20C.
IMPORTANT: Operational strength is only achieved after 12 hours!
41 11 023 REPLACING FRONT SECTION OF ENGINE SUPPORT TO LEFT WHEEL ARCH

2010 BMW M3
Observe procedure for REPAIR STAGE 3 .

(2) Carrier support, outer wheel arch section

Material Quantity
Adhesive K1 1
Blind rivets N1 41
Punch rivets N5 39
EMC screws 2
Cleaning agent R1 1
Sealant D1
Installation note:
2010 BMW M3
Apply sealant to cavity sealing (4).
Mark severance cut (1) in accordance with dimension a and cut engine support.
IMPORTANT: Cut outer metal panel only.
Measurement a=130 mm from front edge of bush
Fig. 111: Identifying Severance Cut And Measurement From Front Edge Of Bush
Installation note:
2010 BMW M3
Weld in REINFORCEMENT PLATES at all severance cuts.


Installation note:
2010 BMW M3
Bond both parts overlapping and rivet. Depending on accessibility, use punch rivets N4 and blind rivets N3.


Mark new part in accordance with severance cut on vehicle and cut.
Open weld joints in areas (1) on both sides.

2010 BMW M3
Detach remainder of reinforcement from engine support.

Take off holder.

Installation note:
2010 BMW M3
Fig. 118: Identifying Alignment Bracket Or Universal Mount

In area (1) set ten 6.8 mm dia. holes for blind rivets N1.
Installation note:

In areas (1) and (2) set 6.8 mm dia. holes for blind rivets N1:
Area (1): 3 bore holes

2010 BMW M3

Installation note:

In areas (1) to (4) set 6.8 mm dia. holes for blind rivets N1:

2010 BMW M3

Area (3): 1 bore hole

Installation note:
After adhesive has hardened install 2 EMC SCREWS in areas (1) and (4).

2010 BMW M3
Installing wheel arch:


Installation note:
Version (A) riveted

Version (B) screwed
2010 BMW M3
Riveted version:
If damaged, the plate inserts must always be replaced with screwed versions on both sides of the vehicle.
Glued version:
Adhesive/contact surfaces of plate insert must be free of sealing compound, final paint coat and underseal.

2010 BMW M3
41 11 043 REPLACING FRONT SECTION OF LEFT ENGINE SUPPORT
Observe procedure for REPAIR STAGE 3.
Read general service information under BODY.
Following new body parts are required (refer to BMW Electronic Parts Catalogue):
(1) Engine carrier, front
Fig. 127: Identifying Front Engine Carrier

Mark severance cut (1) in accordance with measurement a and cut engine support.
Measurement a=130 mm from front edge of sleeve
Installation:

2010 BMW M3
Fig. 128: Identifying Severance Cut And Measurement From Bush Front Edge


2010 BMW M3

Mark new part in accordance with severance cut on car and cut.
Detach remainder of reinforcement from engine carrier.

Take off holder.

2010 BMW M3

Installation:
Fig. 133: Identifying Straightening Attachment Or Universal Mount

Weld new part in area (1) with additional MAG weld seams.
2010 BMW M3
Fig. 134: Identifying MAG Welding Areas

41 11 028 REPLACING LEFT ENGINE SUPPORT (PARTIAL REPLACEMENT BEFORE FRONT

AXLE)
(1) Partial section, engine support

(2) Repair element (not shown)
(3) Screw (not shown)

2010 BMW M3
Fig. 135: Identifying Partial Section Of Engine Support


Material Quantity
Adhesive K1 1
Blind rivets N2 8
CleanerR1 1
Sealant D1
Mark severance cut (1) in accordance with measurement a and cut.
Measurement a=125 mm
IMPORTANT: Clean engine support - measured min. 50 mm from cutting edge - thoroughly
with cavity sealing wax remover.
Fig. 136: Identifying Severance Cut

Take off holder.

2010 BMW M3

Mark severance cut (1) in accordance with vehicle and cut.
Fig. 138: Identifying Severance Cut

Open welded connections on holder (1) by grinding with a belt grinder from inside.
Take off holder (1).

2010 BMW M3
Fig. 139: Identifying Holder

NOTE: The inside surfaces of the engine support must be smooth. If necessary,
surface-grind existing raised areas.
Belt grinder
Adjust new part to fit with alignment bracket or universal mount.
Drill hole (1) at side.
Take hole position from repair element.
Hole diameter 12 mm
Remove new parts.

2010 BMW M3
Fig. 140: Identifying Drilling Hole

Installing engine support
NOTE: Schematic diagram without alignment bracket or universal mount.
Insert screw (2) in repair element (1).
Apply adhesive to repair element.

2010 BMW M3
Carefully slide repair element (1) into body engine support.
Make sure there is sufficient adhesive on the bonding surfaces.
Fig. 142: Identifying Repair Element

Push new part onto repair element and secure with alignment bracket or universal mount.
Expand repair element with screw until it rests on engine support and adhesive can be seen to emerge.
NOTE: Do not tighten bolt too tightly!
Make sure the bonding surfaces are correctly aligned, especially on the engine end.
2010 BMW M3
Fig. 143: Identifying Bolt

In area (1) install 6 blind rivets N2.

In area (1) install 2 blind rivets N2.

2010 BMW M3

NOTE: Remove screw after adhesive has hardened.

Seal separation point and hole with sealant.
41 35 101 REPLACING LEFT REAR SIDE PANEL M3
Read general service information under BODY, GENERAL. STRIP DOWN vehicle.
NOTE: Observe procedure for bonding and riveting (REPAIR STAGE 2) .
The following new body parts are required:
(1) Rear side wall

(2) Reinforcement plates (not pictured)
(3) Lock nuts (not pictured)

Material Quantity
Adhesive K5b 1
Adhesive K5a 1
Sealant D1
Blind rivets N3 17
Punch rivets N4 19
EMC screws 1
R1 cleaning agent 1
2010 BMW M3
Fig. 146: Identifying Rear Side Panel

Removing side wall:
Fig. 147: Identifying Weld Areas And Severance Cut Position

Mark severance cuts in accordance with specified dimensions and cut.

2010 BMW M3
IMPORTANT: Cut outer panel only.

Compare position of severance cuts with REINFORCEMENT PLATES .
Dimension a = approx. 110 mm from roof edge.
Dimensions b = approx. 250 mm from centerpoint of hole diameter 25 mm
Undo FOLD BONDED CONNECTION . in the area (2).
NOTE: In addition to the dimensions, the position of the separating cut can be
determined with a TEMPLATE (1).
Fig. 148: Identifying Template

Open brazed connections in areas (2).

2010 BMW M3
Fig. 149: Identifying Welded And Brazed Connection Areas

IMPORTANT: Release entrance section from new part.
Mark severance cuts on the new part according to vehicle and cut.
Prepare REINFORCEMENT PLATES at all severance cuts.
Adjust new part to fit and secure.
Set 4.2 mm diameter bore holes for blind rivets in areas (1) and (2).

2010 BMW M3

Set 4.2 mm diameter bore hole for blind rivets in bulkhead of jacking point in the area (1):
Fig. 151: Identifying Rivets Areas In Jacking Point Bulkhead

Remove new part and deburr bore holes.

2010 BMW M3

IMPORTANT: Do not grind/sand new part in area of bonding surfaces.
Installing side wall
Clean all bonding surfaces on vehicle, on the new part and on the reinforcement plate with cleaning agent R1.
Apply adhesive to reinforcement plates.
Install reinforcement plates.

2010 BMW M3
Fig. 153: Identifying Adhesive Applying Areas On Rear Side Panel

Apply adhesive in areas (1).
Adhesive must be applied to new part in area (2).
Apply sealant D1 to cavity sealing in areas (3).
Apply adhesive (1) to inside of side wall (2) at distance a.
Dimension a = approx. 10 mm
2010 BMW M3
Fig. 154: Identifying Side Wall Adhesive Applying Area

Fig. 155: Identifying Blind Rivets And N4 Rivets Areas

Install side wall with a second person helping.
NOTE: When installing side wall, make sure there is sufficient adhesive on bonding
surfaces.
2010 BMW M3
Secure side wall next to reinforcement plates with gripping pliers.
Rivet side wall with blind rivets in areas (1).
Use punch rivets N4 in areas (2) and (3):
RIVET AREAS REFERENCE CHART

Area Number
2 10
3 2
Side wall is glued and bordered in area (4).
Use punch rivets N4 in areas (2) and (3).
RIVET AREAS REFERENCE CHART

Area Number
2 3
3 4

Also apply adhesive (2) to outer wheel arch section (3).
1. Rear side wall.

2010 BMW M3
Fig. 157: Identifying Outer Wheel Arch Section Adhesive Applying Area
Installation note:
Flange edge of wheel arch (3) of side wall flush to outer wheel arch section.
Do not create sharp edges when flanging as otherwise the flange edge may begin to tear.
Dimension (A) = 5 mm.
1. Adhesive
2. Rear side wall
Also seal in area (3) according to standard.

2010 BMW M3
Fig. 158: Identifying Rear Side Wall Adhesive Applying Area

IMPORTANT: Flange edge must be completely filled with adhesive (1).
IMPORTANT: The wheel arch must be flanged immediately after riveting before the adhesive
hardens.
After adhesive has hardened in the lower sill area, install an EMC SCREW .
41 35 101 REPLACING LEFT REAR SIDE WALL
Read general service information under BODY, GENERAL. STRIP DOWN vehicle.
(1) Rear side wall


Material Quantity
Adhesive K5b 1
Adhesive K5a 1
Sealant D1
2010 BMW M3
Blind rivets N3 17
Punch rivets N4 26
EMC screws 1
R1 cleaning agent 1

Removing side wall

2010 BMW M3
Fig. 160: Identifying Welding Areas With Dimension On Left Rear Side Panel
Before loosening the wheel arch welding connections:
Straighten wheel arch edge similarly to new part.
Dimension b = approx. 250 mm to centerpoint of 25 mm diameter hole.
NOTE: In addition to the dimensions, a TEMPLATE (1) may be used to determine the
position of the separating cut.


2010 BMW M3


2010 BMW M3

Set 4.2 mm diameter bore hole for blind rivets in bulkhead of jacking point in the area (1).

In areas (1) and (2) set 4.2 mm diameter bore holes for blind rivets.
Remove new part again and deburr bore holes.

2010 BMW M3

Apply adhesive to reinforcement plates.
Install reinforcement plates.

2010 BMW M3


2010 BMW M3
Fig. 167: Identifying Rivet Areas On Left Rear Side Panel

surfaces.
RIVETS AREAS REFERENCE CHART

Area Number
2 10
3 6

2010 BMW M3

Area Number
2 5
3 5

hardens.
41 14 502 REPLACING REAR LEFT OUTER WHEEL ARCH SECTION (REAR LEFT SIDE PANEL
REMOVED)

2010 BMW M3
Fig. 169: Identifying Rear And Outer Wheel Arch With C-Pillar Reinforcement

2010 BMW M3
Installation:
Apply window glass adhesive to cavity acoustic baffles See 4100... INSTALLING A CAVITY ACOUSTIC
BAFFLE (EXPANDED) or 4100... INSTALLING A CAVITY ACOUSTIC BAFFLE (NOT EXPANDED)
(3).
Fig. 171: Identifying Severance Cut With Welding And Adhesive Applying Areas

2010 BMW M3
Installation:

41 11 021 STRIPPING OPERATIONS - REPLACING FRONT LEFT WHEEL ARCH
NOTE: Owing to the different engine variants and equipment specifications, not all the
components are taken into consideration.
The following list basically represents the removal sequence.
Disconnect battery negative lead (FR number: 6120900)

Remove bumper trim (FR flat rate number: 5111156)
Remove bumper carrier (FR number: 5111050)
Remove headlight (FR number: 6312010)
Remove front panel (FR number: 4133040)
Remove radiator (FR number: 1711000)
Remove A/C system condenser (FR number: 6453550)
If necessary, remove and install intercooler (FR number: 1751000)
Remove hydraulic steering cooling coil (FR number: 1711370)
2010 BMW M3
If necessary, remove intake silencer housing (FR number: 4135111)

If necessary, remove coolant expansion tank (FR number: 1711100)
Remove left wheel arch cover (front section) (FR number: 5171038)
Remove left wheel arch cover (rear section) (FR number: 5171039)
Remove left side panel (FR number: 4135010)
Remove left spring strut (FR number: 3131000)
Remove left wishbone (FR number: 3112000)
Remove brake booster (FR number: 3433000)
Remove sill strip (FR number: 5171447
Release left wiring harness
41 11 023 STRIPPING OPERATIONS - REPLACING FRONT SECTION OF ENGINE SUPPORT

WITH LEFT WHEEL ARCH

If necessary, remove intercooler (FR number: 1751000)
If necessary, remove air filter housing (FR number: 13)
Remove cowl panel cover (FR number: 5113116)
Remove engine (FR number: 1100050)
Remove and install complete front axle (FR number: 3110000)
Remove tandem brake master cylinder (job number: 6034000)
2010 BMW M3
41 11 516 STRIPPING OPERATIONS - REPLACING LEFT CARRIER SUPPORT

Remove bumper trim (FR flat rate number: 51 11 156)
Remove headlight (FR number: 63 12 010)
Remove support for bumper trim (FR flat rate number: 51 11 050)
Remove front panel (FR number: 41 33 040)
Remove radiator (FR number: 17 11 000)
Remove A/C system condenser (FR number: 64 53 550)
If necessary, remove intercooler (FR number: 17 51 000)
Remove hydraulic steering cooling coil (FR number: 17 11 370)
Remove left wheel arch cover (front section) (FR number: 51 71 038)
Remove left wheel arch cover (rear section) (FR number: 51 71 039)
If necessary, remove intake silencer housing (FR number: 41 35 111)
If necessary, remove coolant expansion tank (FR number: 17 11 100)
Partially release left wiring harness
41 11 028 STRIPPING OPERATIONS - REPLACING LEFT ENGINE SUPPORT (PARTIAL

REPLACEMENT BEFORE FRONT AXLE)
Clamp off battery lead from negative terminal

Remove and install intake filter housing (FR number: 1371000)
Remove and install left wheel arch cover (front section) (FR number: 5171038)
Remove and install A/C system condenser (FR number: 6453550)
Remove and install hydraulic steering cooling coil (FR number: 1711370)
LUGGAGE COMPARTMENT FLOOR

2010 BMW M3
41 12 651 REMOVAL REQUIREMENTS - REPLACING THE LEFT LUGGAGE COMPARTMENT

FLOOR (TAIL PANEL OR SIDE PANEL REMOVED)

Remove exhaust system (FR number: gasoline engine 1800020, diesel engine 1800018)
Remove heat shield
Remove luggage compartment floor storage tub.
Remove rear left wheel well cover (FR number: 5171041)
Remove left luggage compartment wheel arch trim (FR number: 5147151)
Remove audio amplifier
Partially detach wire harness place to one side and fasten
Partially release/remove sound insulation
51 71... REMOVING AND INSTALLING/REPLACING MULTIFUNCTION PAN
Remove luggage compartment trim panels See 5147161 REMOVING AND

INSTALLING/REPLACING RIGHT LUGGAGE COMPARTMENT WHEEL ARCH TRIM or
5147151 REMOVING AND INSTALLING/REPLACING LEFT LUGGAGE COMPARTMENT
WHEEL ARCH TRIM
Remove exhaust system .
Unclip vacuum line (1) from heat shield.
Unfasten screws (2).

2010 BMW M3
Fig. 173: Identifying Heat Shield Vacuum Line With Mounting Screws
Release screws (1).
Remove both heat shields.
Fig. 174: Identifying Heat Shield Mounting Screws

Unclip line (1).
Fig. 175: Identifying Vacuum Line With Screws

Release nuts (1) and remove multifunction pan.

2010 BMW M3
Fig. 176: Identifying Multifunction Pan Nuts

Installation:
Seals (1) on multifunction pan (2) must be replaced each time they are removed.
Fig. 177: Identifying Seals On Multifunction Pan

41 12 535 STRIPPING OPERATIONS - REPLACING COMPLETE REAR LUGGAGE

COMPARTMENT FLOOR (TAIL PANEL REMOVED)
Remove heat shield
2010 BMW M3
Remove carbon canister (FR number: 1612010)

Remove battery (FR number: 6121010)
Remove both backrests (FR number: 5226020)
Remove rear seat (FR number: 5224005)
Remove and install rear left and right wheel arch cover (FR number: 5171041)
Remove left luggage compartment wheel arch panel (FR number: 5147151)
Remove right luggage compartment wheel arch panel (FR number: 5147161)
Partially detach wiring harness and tie to one side
41 12 535 REPLACING COMPLETE REAR LUGGAGE COMPARTMENT FLOOR (TAIL PANEL

REMOVED)
STRIP DOWN vehicle.
Follow procedure for REPAIR STAGE 3 .
(1) Luggage compartment floor, left section

(2) Frame side member, left
(3) Frame side member, top left
(4) Frame, luggage compartment floor
(5) Frame side member, top right
(6) Frame side member, right
(7) Luggage compartment floor, right
(8) Mounting for left and right bumper
2010 BMW M3
Fig. 178: Identifying Frame Side Member And Luggage Compartment Floor
Following CONSUMPTION MATERIALS are required:

Material Quantity
Adhesive K5b 1
R1 cleaning agent 1
Blind rivets N3 14
Punch rivets N5 8
EMC screws 2
Sealant D1
Cavity wax remover
Removing luggage compartment floor:
Carry over the work steps shown symmetrically to the other side of the car.
Mark severance cuts (1) at edge of 20 mm diameter bore hole.
Cut frame side member (2).

2010 BMW M3
Fig. 179: Identifying Reinforcement Plate Severance Cuts

Mark severance cuts (1) and cut.
IMPORTANT: Cut only outer panels.
Open welded connections in areas (2) and remove luggage compartment floor (3).
Fig. 180: Identifying Luggage Compartment Floor Severance Cuts And Welding Areas
Saloon and Coupe only:

2010 BMW M3
Fig. 181: Identifying Adhesive Applying Areas (Saloon And Coupe Only)
Touring only:
Open weld joints in areas (1) and (2).
Fig. 182: Identifying Adhesive Applying Areas (Touring Only)

Installation note:
Adjust new parts to fit with alignment bracket or universal mounting.
Before welding in side member, also adjust tail panel, tailgate and rear lights to fit.
2010 BMW M3

Weld in REINFORCEMENT PLATES at severance cuts.
Cut side member (2).
Fig. 184: Identifying Reinforcement Plate Severance Cuts

Mark new luggage compartment floor part in accordance with severance cut on vehicle + 20 mm extra material
and cut.
Adjust new parts in combination with tail panel to fit and secure.
2010 BMW M3
In area (1) set seven 4.2 mm diameter bore holes for blind rivets.
Remove new parts and deburr bore holes.
Touring only:
In areas (1) and (2) set six 4.2 mm dia. holes for blind rivets.
Remove new parts and deburr bore holes.

Installation of luggage compartment floor
2010 BMW M3
IMPORTANT: Do not grind new parts and body in area of bonding surfaces.
Apply adhesive K5b.
Installing luggage compartment floor:
Replace along similar lines to LUGGAGE COMPARTMENT FLOOR, CENTRE .
Apply adhesive K5b in areas (1) and (2).

2010 BMW M3
In area (1) apply adhesive K5b and set 7 blind rivets N3.
Touring only:
In areas (1) and (2) apply adhesive K5b and set 6 blind rivets N3.

In areas (1) and (2) secure luggage compartment floor to side member.
2010 BMW M3

After adhesive has hardened, fit 2 EMC SCREWS in area of earth support points.
41 12 560 REPLACING LUGGAGE COMPARTMENT FLOOR (COMPLETE WITH BOTH INNER

WHEEL ARCH SECTIONS, TAIL PANEL REMOVED)
Spot-weld bonding is used on this vehicle.
Observe specific PROCEDURE .
(1) Luggage compartment floor, upper section

(2) Rear axle carrier
(3) Wheel arch, rear, inner half, left
(4) Wheel arch, rear, inner half, right
Touring only:
(5) Bracket, tension strut, rear (2 x) (not shown)
2010 BMW M3

Carry over the work step shown symmetrically to the other side of the vehicle.
Mark severance cut in accordance with measurement a and cut.
Measurement a=40 mm behind support, frame side member (1).
Installation:
Fig. 193: Identifying Measurement From Frame Side Member

Mark severance cut (1) and cut.

2010 BMW M3
Installation:
Fig. 194: Identifying Severance Cut With Welding Areas

Mark severance cut (1) in accordance with measurement a and cut rear axle carrier.
Measurement a=70 mm from rear axle bushing mounting.
Fig. 195: Identifying Measurement From Rear Axle Bushing Mounting

2010 BMW M3
Installation:

Installation:

2010 BMW M3
Fig. 197: Identifying Welding Areas (Saloon And Coupe Only)

Touring only:
Installation:

NOTE: Rear parcel shelf of Saloon and Coupe is shown removed for purposes of
clarity.
2010 BMW M3
Fig. 199: Identifying Rear Parcel Shelf Welding Areas

clarity.
Installation:
Weld new component in areas (2) additionally.

2010 BMW M3

Mark severance cuts (1) in accordance with measurement and cut.
Fig. 202: Identifying Severance Cuts With Measurements

2010 BMW M3
Measurement b = 110 mm
Installation:
Installation:
The parts separated by cutting are still needed.
Fig. 203: Identifying Severance Cuts With Welding Areas


2010 BMW M3


Installation:
The parts (2) separated by cutting are still needed.

2010 BMW M3


Installation:
Adjust new parts to fit with straightening attachment or universal mount.
Before welding in, also adjust tail panel, rear lid and rear lights to fit.
2010 BMW M3
Weld new components in following order:

Fig. 208: Identifying Welding Components

clarity.
Installation:
For reasons of accessibility, the repair joining sequence differs from the standard joining sequence.
Fit new component from above in area (1), adjust to fit and weld.
2010 BMW M3
Fig. 209: Identifying New Component Fitting Areas

Installation:
Touring only:
Adjust new parts (1) to fit with tension strut and weld.
Fig. 210: Identifying New Parts

41 12 590 REPLACING LUGGAGE COMPARTMENT FLOOR (COMPLETE WITH LEFT OR

RIGHT INNER WHEEL ARCH SECTION, TAIL PANEL REMOVED)

Touring only:
(4) Bracket, tension strut, rear (not illustrated)
2010 BMW M3

Installation:
Fig. 212: Identifying Measurement From Frame Side Member

Installation:

2010 BMW M3
Fig. 213: Identifying Severance Cut With Welding Areas

Installation:
Fig. 214: Identifying Measurement From Rear Axle Bushing Mounting


2010 BMW M3

Installation:
Fig. 216: Identifying Welding Areas (Saloon And Coupe Only)

Touring only:
Installation:
2010 BMW M3

clarity.
Fig. 218: Identifying Parcel Shelf Weld Join Areas

clarity.
2010 BMW M3
Installation:

clarity.
Mark severance cut (1) centrally and cut.
Cut floor pan and cross-member underneath.

2010 BMW M3
Installation:
Fig. 221: Identifying Severance Cuts With Measurements

Installation:
The cut part is not needed.

2010 BMW M3



2010 BMW M3

Installation:
The cut part (2) is not needed.


2010 BMW M3

Installation:

Fig. 227: Identifying Welding Components

clarity.
Installation:
2010 BMW M3
Fig. 228: Identifying New Component Fitting Areas

Installation:
Touring only:
Adjust new part (1) with tension strut to fit and weld.
Fig. 229: Identifying New Part

41 12 651 REPLACING LUGGAGE COMPARTMENT FLOOR, LEFT SECTION (TAIL PANEL OR

SIDE WALL REMOVED)

2010 BMW M3
(1) Luggage compartment floor, left

(2) Left tensioning strap C-pillar

Material Quantity
Adhesive K5a 1
Blind rivets N3 20
CleanerR1 1
Sealing compoundD1
Fig. 230: Identifying Left Luggage Compartment Floor And Left Tensioning Strap C-Pillar
Removal of luggage compartment floor

2010 BMW M3

With removed tail panel:
Mark severance cut (1) and disconnect tensioning strap (2).
Installation:
Mark severance cut on new part C-pillar reinforcement acc. to vehicle + 25 mm material extra and disconnect.
Bond tensioning strap in area of the overlap with 3 blind rivets N3 and rivet.
Fig. 232: Identifying Severance Cut And Tensioning Strap

2010 BMW M3
For removed side wall:
Release welded connection in area (1) and remove tensioning strap (2).
Installation:
Bond tensioning strap in area (1) with 3 blind rivets N3 and rivet.
Fig. 233: Identifying Welded Connection Area And Tensioning Strap

Mark severance cut (2) next to reinforcement (3) and disconnect.
Fig. 234: Identifying Welding Areas, Severance Cut And Reinforcement

2010 BMW M3
Remove the trunk floor.
NOTE: Tail panel and side wall hidden for better overview.
Fig. 235: Identifying Welding Areas On Luggage Compartment Floor

New part preparation
Mark severance cut on new part luggage compartment floor acc. to vehicle + 15 mm material extra and
disconnect.
Adjust new part in combination with tail panel and side wall to fit and secure.
Set 5 4.2 mm dia. bore holes for blind rivets in area (1). N3
2010 BMW M3

Set four 4.2 mm dia. bore holes for blind rivets N3 in area (2).
On vehicle clean the connection face for bonding with cavity sealing wax remover.

2010 BMW M3
Clean all bonding surfaces on new part and on vehicle with cleaning agent R1.
Apply adhesive K5a on all bonding and riveting surfaces.
Install new part and rivet with blind rivets N3.
When installing the new part, make sure that all bonding surfaces have sufficient adhesive.
41 12 557 STRIPPING OPERATIONS - REPLACING LUGGAGE COMPARTMENT FLOOR,

MIDDLE (TAIL PANEL REMOVED)

Partially detach wiring harness and tie to one side.
41 12 557 REPLACING LUGGAGE COMPARTMENT FLOOR, MIDDLE SECTION (TAIL PANEL

REMOVED)

Material Quantity
Adhesive K5a 1
Punch rivets N5 8
CleanerR1 1
Sealing compoundD1
2010 BMW M3
Fig. 238: Identifying Frame And Luggage Compartment Floor

IMPORTANT: Cut only outer plates.
Open weld joints in areas (2) and remove luggage compartment floor (3).

2010 BMW M3
Clean all bonding surfaces (1) on vehicle and on new part with cleaning agent R1.
Apply adhesive K5b to bonding surfaces (1).
Fig. 240: Identifying Bonding Surfaces For Applying Adhesive K5b

Adjust luggage compartment floor (1) to fit in conjunction with TAIL PANEL and secure.
Rivet luggage compartment floor with 6 punch rivets N5 in areas (2).

2010 BMW M3
Fig. 241: Identifying Luggage Compartment Floor And Rivet Areas

WHEEL WELLS
REMOVED)

2010 BMW M3


2010 BMW M3
Installation:

2010 BMW M3
Installation:
Installation:

2010 BMW M3

Installation:

Installation:
2010 BMW M3


41 11 516 REPLACING FRONT LEFT OR RIGHT CARRIER SUPPORT (PARTIAL

2010 BMW M3
Carry over schematic representation to the relevant vehicle type.
(1) Carrier support, wheel arch, outer

Material Quantity
Adhesive K5a 1
Blind rivets N1 2
Blind rivets N3 6
Punch rivets N5 12
CleanerR1 1
Sealing compoundD1
Fig. 250: Identifying Carrier Support

Mark severance cut (1) through 20 mm dia. hole and cut carrier support.

2010 BMW M3

Remove carrier support section.

Make severance cut on new part in accordance with severance cut on vehicle.
Adjust new parts with add-on parts to fit and secure.
2010 BMW M3

In area of REINFORCEMENT PLATE (1) set six 4.3 mm dia. holes for blind rivets N3.
Fig. 254: Identifying Reinforcement Plate Rivet Areas

Installing carrier support
Clean all bonding surfaces (1) on vehicle and on new part with cleaning agentR1!
Apply adhesive K5a to bonding surfaces.

2010 BMW M3
Fig. 255: Identifying Bonding Surfaces On Vehicle

Install new part with add-on parts and rivet.

In area (2) rivet new part with 2 punch rivets N5.
Fig. 256: Identifying Reinforcement Rivet Areas

In area of reinforcement plate (4) use 6 blind rivets N3.

2010 BMW M3
In area (1) rivet new part with 2 blind rivets N1.


2010 BMW M3

41 14 021 REPLACING FRONT LEFT WHEEL ARCH
Procedure OBSERVE repair step 3!
Read general service information under BODY, GENERAL .


Material Quantity
Adhesive K1 1
Blind rivets N1 56
Punch rivets N5 39
EMC screws 4
CleanerR1 1
Sealant D1
2010 BMW M3
Removing wheel arch
Installation:
Apply sealant to cavity acoustic baffle See 4100... INSTALLING A CAVITY ACOUSTIC BAFFLE
(EXPANDED); 4100... INSTALLING A CAVITY ACOUSTIC BAFFLE (NOT EXPANDED) or 4100...
WELDING IN REINFORCEMENT PLATE (STEEL PLATE) (4).

2010 BMW M3


Installation:
Bond both parts overlapping and rivet.
Depending on accessibility, use punch rivets N4 and blind rivets N3.

2010 BMW M3


In areas (1) cut open engine support from opposite side and open welded connections.
In area (2) open welded connections from inside.

2010 BMW M3
Fig. 265: Identifying Engine Support Welding Areas

Area (1): 3 holes
Area (2): 8 holes
Area (3): 6 holes
Installation:
After adhesive has hardened, install 2 EMC SCREWS in areas (1) and (2).
2010 BMW M3
Fig. 266: Identifying EMC Screws Area

Area (1): 3 holes
Area (2): 2 holes

Area (1): 1 hole

2010 BMW M3
Area (2): 7 holes
Installation:

Installation:

2010 BMW M3
Area (1): 5 holes
Area (2): 2 holes
Area (3): 1 hole
Area (4): 9 holes

Installation:
After adhesive has hardened install 2 EMC screws in areas (1) and (4).

2010 BMW M3



2010 BMW M3

Installation:
Version (A) riveted or glued

Version (B) screwed
Riveted version:
2010 BMW M3
If damaged, the plate inserts must always be replaced with glued versions on both sides of the vehicle.
Glued version:
Adhesive/contact surfaces of plate insert must be free of sealant, final paint coat and underbody protection.



2010 BMW M3


(2) Carrier support, outer wheel arch section

2010 BMW M3

Material Quantity
Adhesive K1 1
Blind rivets N1 41
Punch rivets N5 39
EMC screws 2
Cleaning agent R1 1
Sealant D1
Installation note:
Apply sealant to cavity sealing See 4100... INSTALLING A CAVITY ACOUSTIC BAFFLE
(EXPANDED) or 4100... INSTALLING A CAVITY ACOUSTIC BAFFLE (NOT EXPANDED) (4).
2010 BMW M3
Mark severance cut (1) in accordance with dimension a and cut engine support.
IMPORTANT: Cut outer metal panel only.
Measurement a=130 mm from front edge of bush
Installation note:
Weld in REINFORCEMENT PLATES at all severance cuts.
Fig. 277: Identifying Severance Cut And Measurement From Front Edge Of Bush

2010 BMW M3


Installation note:
Bond both parts overlapping and rivet. Depending on accessibility, use punch rivets N4 and blind rivets N3.
2010 BMW M3


Mark new part in accordance with severance cut on vehicle and cut.
Detach remainder of reinforcement from engine support.

2010 BMW M3

Take off holder.

Installation note:
2010 BMW M3
Fig. 284: Identifying Alignment Bracket Or Universal Mount

In area (1) set ten 6.8 mm dia. holes for blind rivets N1.
Installation note:

In areas (1) and (2) set 6.8 mm dia. holes for blind rivets N1:

2010 BMW M3

Installation note:

In areas (1) to (4) set 6.8 mm dia. holes for blind rivets N1:

2010 BMW M3


Installation note:
After adhesive has hardened install 2 EMC SCREWS in areas (1) and (4).

2010 BMW M3


Installation note:
Version (A) riveted

Version (B) screwed
2010 BMW M3
Riveted version:
Glued version:
Adhesive/contact surfaces of plate insert must be free of sealing compound, final paint coat and underseal.

2010 BMW M3

REMOVED)

2010 BMW M3
Installation:
(3).
2010 BMW M3
Installation:

2010 BMW M3

41 00... STAMPING VEHICLE IDENTIFICATION NUMBER
Remove front right spring strut

The set of special tools for stamping the vehicle identification number consists of:
Counter-support plate 41 1 142

2010 BMW M3
Fig. 297: Identifying Guide Plate And Counter-Support Plate

Position counter-support plate 41 1 142 at bottom on spring strut dome.
Position guide plate 41 1 141 at top on spring strut dome and tighten screws (1) by hand.
Tighten screw (1) until counter support 41 1 142 rests on spring strut dome.
Fig. 299: Identifying Screw And Counter Support 41 1 142


2010 BMW M3

Insert punch numbers 410000 (1) individually into guide plate (2) and stamp vehicle identification number.
Fig. 301: Inserting Punch Number 41 0 000 Into Guide Plate



2010 BMW M3


41 00... VEHICLE IDENTIFICATION NUMBER, GENERAL
In the event of repair 2 procedures are used, depending on the vehicle. Refer to the vehicle-specific repair
instructions for the correct procedure.
1. General notes for stamped vehicle identification numbers
The vehicle identification number is stamped with a special tool. There are different special tool numbers and
stamping procedures for the various vehicles. Refer to the relevant repair instructions.
identification number at front and rear by stamping a + in place of the BMW badge.
2. General notes for embossed vehicle identification numbers

2010 BMW M3
This procedure is used on all newly launching model series from model year 09/2008 (exception X1).
If a VIN is embossed into the replacement surface in addition to the original VIN (e.g. if the original VIN has
been tampered with), the following applies: The vehicle-specific repair instructions describe the procedure.
The protective film used as standard is omitted after the VIN has been embossed.
SIDE FRAME AND DOOR PILLARS


Fig. 302: Identifying B-Pillar

2010 BMW M3
Fig. 303: Identifying Welding Areas And Measurements On Left Door Pillar

Installation:
2010 BMW M3
Installation:
Fig. 304: Identifying Measurement From Roof Edge



2010 BMW M3


2010 BMW M3
Fig. 308: Identifying Adhesive Applying Areas And Cavity Acoustic Baffle
Apply window glass adhesive See 4100... INSTALLING A CAVITY ACOUSTIC BAFFLE (EXPANDED)
or 4100... INSTALLING A CAVITY ACOUSTIC BAFFLE (NOT EXPANDED) to cavity acoustic baffle
(1).
Apply ADHESIVE in areas (2).
41 21 510 REPLACING FRONT LEFT DOOR PILLAR (FRONT SIDE PANEL REMOVED)
Spot-weld bonding is used on this vehicle. Observe specific procedure See 4100... SPOT-WELD BONDING
STEEL PARTS or 4100... OPENING ADHESIVE BONDS.
2010 BMW M3
(1) A-pillar, outer

(3) Shaped part, support carrier (not shown)
(4) Shaped part, A-pillar, bottom inner (not shown)
Fig. 309: Identifying Outer (A-Pillar, Support Carrier And Wheel Arch)
2010 BMW M3
Fig. 310: Identifying Welding And Adhesive Applying Areas With Measurements On Left Door Pillar

Measurement a = approx. 130 mm from edge of rectangular hole.
Measurement b = approx. 160 mm from centerpoint of 12 mm dia. bore.
Installation:
Apply window glass adhesive to cavity acoustic baffles . See 4100... INSTALLING A CAVITY ACOUSTIC
(2).
2010 BMW M3
Fig. 311: Identifying Weld Joint Areas, Adhesive Bond Areas And Measuring Severance Cut Position

Measurement b = approx. 80 mm below severance cut a.
Measurement c = approx. 215 mm before hole dia. 20 mm.
Open adhesive bond in area (3).
Installation:
Sheet panel (2) is needed again to seal cowl.
Plug weld in area (3).
IMPORTANT: For following severance cut, do not damage sunroof water drain hose.

2010 BMW M3
Fig. 312: Identifying Roof Edge Cutting Dimension

IMPORTANT: Do not damage sunroof water drain hose (2).
Fig. 313: Identifying Sunroof Water Drain Hose And Welding Areas

2010 BMW M3
Fig. 314: Identifying Adhesive Bond And Weld Joint Areas

Mark new part in accordance with severance cuts above and cut.
Installation:
Apply window glass adhesive to cavity acoustic baffle . See 4100... INSTALLING A CAVITY ACOUSTIC
(1).
Apply ADHESIVE in area (2).
Fig. 315: Identifying Adhesive Applying Areas On Door Pillar

2010 BMW M3
ROOF OUTER SKIN

41 31 010 STRIPPING OPERATIONS - REPLACING ROOF OUTER SKIN E90 (VERSION
WITHOUT SLIDE/TILT SUNROOF)
Disconnect battery (FR number: 61 20 900)

Remove and install windscreen (FR number: 5131000)
Remove and install rear window (FR number: 5131200)
Remove and install roofliner (FR number: 5144001Q)
Remove and install left roof trim strip (FR number: 5113280)
Remove and install right roof trim strip (FR number: 5113280)
Remove and install roof aerial (FR number: 6520035)
Remove and install backrest (FR number: 5224010)
Tilt parcel shelf with seat belts towards front.
41 31 000 REPLACING ROOF OUTER SKIN (NORMAL ROOF)
Refer to repair instruction ROOF OUTER SKIN WITH SLIDE/TILT SUNROOF for procedure and carry
over schematically to the car.
STRIP DOWN vehicle.
Installing roof outer skin
Apply sealing compound in areas (1) analogously to Series.

2010 BMW M3
Fig. 316: Identifying Roof Outer Skin Sealing Applying Areas

41 31 010 STRIPPING OPERATIONS - REPLACING ROOF OUTER SKIN E90 (VERSION WITH
SLIDE/TILT SUNROOF)
Disconnect battery (FR number: 61 20 900)

Remove and install windscreen (FR number: 5131000)
Remove and install roofliner (FR number: 5144011)
Remove and install slide/tilt sunroof (FR number: 5412211)
Remove and install left roof trim strip (FR number: 5113280)
Remove and install right roof trim strip (FR number: 5113280)
Remove and install roof aerial (FR number: 6520035)
Remove and install backrest (FR number: 5224010)
Tilt parcel shelf with seat belts towards front.
41 31 010 REPLACING ROOF OUTER SKIN (VERSION WITH SLIDE/TILT SUNROOF)
STRIP DOWN vehicle.

2010 BMW M3
(1) Roof outer skin, slide/tilt sunroof

(2) 4 star screws, part number: 7 153 767
Additionally required parts (not pictured):

Material Quantity
Adhesive K5a 1
Adhesive K5b 1
Sealant D1
Punch rivets N4 14
EMC screws 2
R1 cleaning agent 1
Fig. 317: Identifying Roof Outer Skin

Tools also required:
Roof pliers set, part number: 2 158 707
BMW WORKSHOP EQUIPMENT CATALOGUE
Removing roof outer skin
Release 4 star screws (1) in roof channel.

2010 BMW M3
Fig. 318: Identifying Star Screws On Roof Channel

Fig. 319: Identifying Welded Connections Areas


2010 BMW M3
Fig. 320: Identifying Adhesive And Sealant Areas On Roof Outer Skin
Shown without roof outer skin for purposes of clarity.
Release adhesive in areas (1) and sealant (2).
Take off roof outer skin.
If necessary, place roof outer skin in position and fit in conjunction with roof trim strips.
Remove new part again.
Installing roof outer skin
Clean bonding surfaces on vehicle and on new part with cleaning agent R1.
2010 BMW M3
Fig. 321: Identifying Adhesive And Sealant Areas On Roof Outer Skin
Apply sealant D1 in areas (2).

2010 BMW M3
Fig. 322: Identifying Adhesive Areas On Roof Outer Skin

Apply adhesive in areas (1) and (2).
Apply a somewhat larger quantity of adhesive in the node areas of the A- and C-pillars.
NOTE: Excess material is later used for spreading to side frame.
Place roof outer skin with helpers evenly and centrally on vehicle.
Fit roof strips for positioning if necessary.
Insert 4 star screws (1) hand-tight.

2010 BMW M3
Fig. 323: Identifying Star Screws On Roof Channel

Fig. 324: Identifying Roof Pliers And Tensioning Straps

Secure roof outer skin with 4 roof pliers (1) and 2 tensioning straps (2).
NOTE: To generate an optimum contact pressure, mount roof pliers according to the
2010 BMW M3
graphics as left.
Fig. 325: Identifying Roof Pliers Correct Position

Fig. 326: Identifying Rivet And ECM Screws Area On Roof Outer Skin
2010 BMW M3
Rivet roof outer skin with 14 punch rivets in areas (2).
Set punch rivets in corners starting at a distance of approx. 200 mm.
NOTE: After the adhesive hardens, install two EMC SCREWS in areas (2).
In so doing, bear in mind subsequent fitting of roof trim strips.
Mounting surfaces of roof trim strip clips must not be moistened with adhesive.
Adapt step (1) between roof outer skin (2) and A-pillar with emerging adhesive. Remove excess adhesive.
IMPORTANT: Do not use any cleaning agents containing solvents.
Do not leave any traces of sharp edges as this could compromise the tightness of the subsequent bond.
Fig. 327: Identifying Stage And Roof Outer Skin

After the adhesive hardens, tighten 4 star screws in the roof channel.
DASH COWL
Observe specific procedure See 4100... SPOT-WELD BONDING STEEL PARTS or 4100... OPENING
2010 BMW M3
ADHESIVE BONDS.
(1) A-pillar, outer

Fig. 328: Identifying Outer (A-Pillar, Support Carrier And Wheel Arch)
2010 BMW M3
Fig. 329: Identifying Welding And Adhesive Applying Areas (With Measurements A And B On Left Door
Pillar)
Measurement b = approx. 160 mm from centerpoint of 12 mm dia. bore.
Installation:
Apply window glass adhesive to cavity acoustic baffles . See 4100... INSTALLING A CAVITY ACOUSTIC
(2).
2010 BMW M3
Fig. 330: Identifying Welding And Adhesive Applying Areas With Measurements On Left Door Pillar
Installation:

2010 BMW M3
Fig. 331: Identifying Roof Edge Cutting Dimension

Fig. 332: Identifying Sunroof Water Drain Hose And Welding Areas

2010 BMW M3
Fig. 333: Identifying Adhesive Bond And Weld Joint Areas

Installation:
Apply window glass adhesive to cavity acoustic baffle . See 4100... INSTALLING A CAVITY ACOUSTIC
(1).
Apply ADHESIVE in area (2).
Fig. 334: Identifying Adhesive Applying Areas On Door Pillar

2010 BMW M3
FRONT TRIM PANEL

41 33 040 REPLACING FRONT LEFT OR RIGHT SIDE WALL HOLDER
NOTE: Read general service information under BODY, GENERAL.
Side wall removed.
Transfer the systematic diagram onto the respective holder version.
General information:
Observe REPAIR STAGE 2!
Following new body parts are required (refer to BMW Electronic Parts Catalogue):
(1) Holder, side wall, front (variant 1)

(2) Holder, side wall, front (variant 2)
Material Quantity
Adhesive K5a 1
Blind rivets N3 2
Cleaning agent R1 1
Removal of side wall holder (variant 1)
Release welded connections in areas (1) and remove holder (2).

2010 BMW M3
Fig. 335: Removing Holder

Preparation of new part:
Adjust new part in conjunction with side panel in front to fit.
In area of bonding surfaces (1), set 2 4.2 mm dia. bore holes (2) for blind rivetsN3.
Remove new part and deburr holes.
IMPORTANT: Do not grind bonding surfaces down or off.
Fig. 336: Identifying Locations For Bore Holes

Installation of side wall holder:
Apply adhesive to bonding surfaces.
Install new part and rivet with blind rivets.
Removal of side wall holder (variant 2)
Release welded connection in area (1) and remove holder (2).

2010 BMW M3
Fig. 337: Removing Holder

Fit in new part.
In area of adhesive surface (1), drill a 4.2 mm dia. bore hole (2) for blind rivet N3.
Remove new part and deburr holes.
IMPORTANT: Do not grind bonding surfaces down or off.
Fig. 338: Identifying Location For Bore Hole

Installation of side wall holder:

2010 BMW M3
Apply adhesive to bonding surface.
Install new part and rivet with blind rivet.
41 33 040 REPLACING FRONT WALL
Remove carrier for bumper trim
IMPORTANT: Car must not be driven without the front wall.

Driving without the front wall may damage the body structure.
(1) Front panel

(2) Headlight holder, left
(3) Headlight holder, right
Fig. 339: Identifying Front Panel With Left And Right Headlight Holder
Carry over the following work steps symmetrically to the other side of the car.
NOTE: View, front side panel, in direction of travel
Release screw (1).

2010 BMW M3
Fig. 340: Identifying Front Side Panel Screw

Release screws (1).
Remove front panel (2) together with headlight holder (3).
Replacement:
Release screws (4) and remove headlight holder.
Fig. 341: Identifying Front Panel, Holder With Screws

REAR TRIM PANEL

2010 BMW M3
41 34 041 STRIPPING OPERATIONS - REPLACING TAIL PANEL
Remove and install rear bumper trim (FR number: 5112156)

Remove and install carrier for bumper trim (FR number: 5112050)
Remove and install guide for bumper, rear center (FR number: 5112825)
Remove and install guide for bumper, rear left (FR number: 5112801)
Remove and install guide for bumper, rear right (FR number: 5112801)
Remove both rear lights (FR number: 6321180)
Remove luggage compartment floor trim panel
Upper tail panel trim (FR number: 5146050)
Remove and install rear lid striker (FR number: 5124130)
Remove and install battery (FR number: 6121010)
Release wiring harness on tail panel and tie to one side
Release rear lid seal
41 34 041 REPLACING COMPLETE TAIL PANEL
STRIP DOWN vehicle.
(1) Rear trim panel
Additionally required parts (not pictured):

Material Quantity
Adhesive K5b 1
R1 cleaning agent 1
Blind rivets N3 16
2010 BMW M3
Punch rivets N4 6
Punch rivets N5 8
EMC screws 2
Sealant D1
Cavity wax remover
Fig. 342: Identifying Rear Trim Panel

Removing tail panel
Open weld joints in area (1) from inside.
Open brazed joints in areas (3).

2010 BMW M3
Fig. 343: Identifying Welding And Brazed Joint Areas

Slide in rear trim panel (1) from bottom upwards. Adjust in combination with tailgate and rear lights to fit and
secure.
Fig. 344: Sliding Rear Trim Panel

IMPORTANT: Retaining screws must not be used in area (1)
In areas (2 to 5) set 4.2 mm dia. holes for blind rivets N3:

Area Number
2 1
3 2
4 3
5 2
2010 BMW M3
Fig. 345: Identifying Blind Rivet Holes Area

Installing rear trim panel
Apply adhesive to bonding surfaces.
Slide in rear trim panel (1) from bottom upwards.
In so doing, pay attention to adhesive.
Rivet rear trim panel with blind rivets.

2010 BMW M3
Fig. 346: Sliding Rear Trim Panel

In area (1) alternately set 8 punch rivets N5.
Fig. 347: Areas For Setting Punch Rivets N5

In area (1) set 3 punch rivets N4.

2010 BMW M3
Fig. 348: Areas For Setting Punch Rivets N4

Press rear trim panel in area (1) and remove emerging adhesive.
Before the adhesive hardens, install the support for the bumper panel.
IMPORTANT: Prevent emerging adhesive from coming into contact with support.
Spread emerging adhesive on all adhesive areas. Remove excess adhesive.
Fig. 349: Identifying Rear Trim Panel Pressing Area


2010 BMW M3
In areas (1), fit 2 EMC SCREWS .
Fig. 350: Identifying Adhesive Areas

41 12 651 REPLACING LUGGAGE COMPARTMENT FLOOR, LEFT SECTION (TAIL PANEL OR

SIDE WALL REMOVED)

(2) Left tensioning strap C-pillar

Material Quantity
Adhesive K5a 1
Blind rivets N3 20
CleanerR1 1
Sealing compoundD1
2010 BMW M3
Fig. 351: Identifying Left Luggage Compartment Floor And Left Tensioning Strap C-Pillar

With removed tail panel:
Mark severance cut (1) and disconnect tensioning strap (2).
Installation:
2010 BMW M3
Mark severance cut on new part C-pillar reinforcement acc. to vehicle + 25 mm material extra and disconnect.
Bond tensioning strap in area of the overlap with 3 blind rivets N3 and rivet.
Fig. 353: Identifying Severance Cut And Tensioning Strap

For removed side wall:
Release welded connection in area (1) and remove tensioning strap (2).
Installation:
Bond tensioning strap in area (1) with 3 blind rivets N3 and rivet.
Fig. 354: Identifying Welded Connection Area And Tensioning Strap

2010 BMW M3
Mark severance cut (2) next to reinforcement (3) and disconnect.
Fig. 355: Identifying Welding Areas, Severance Cut And Reinforcement

Remove the trunk floor.
NOTE: Tail panel and side wall hidden for better overview.
Fig. 356: Identifying Welding Areas On Luggage Compartment Floor

2010 BMW M3
Mark severance cut on new part luggage compartment floor acc. to vehicle + 15mm material extra and
disconnect.
Adjust new part in combination with tail panel and side wall to fit and secure.

Set four 4.2 mm dia. bore holes for blind rivets N3 in area (2).
On vehicle clean the connection face for bonding with cavity sealing wax remover.
2010 BMW M3

Clean all bonding surfaces on new part and on vehicle with cleaning agent R1.
Apply adhesive K5a on all bonding and riveting surfaces.
Install new part and rivet with blind rivets N3.
When installing the new part, make sure that all bonding surfaces have sufficient adhesive.
41 12 557 STRIPPING OPERATIONS - REPLACING LUGGAGE COMPARTMENT FLOOR,

MIDDLE (TAIL PANEL REMOVED)

Partially detach wiring harness and tie to one side.
41 12 557 REPLACING LUGGAGE COMPARTMENT FLOOR, MIDDLE SECTION (TAIL PANEL

REMOVED)

2010 BMW M3

Material Quantity
Adhesive K5a 1
Punch rivets N5 8
CleanerR1 1
Sealing compoundD1
Fig. 359: Identifying Luggage Compartment Floor Frame

IMPORTANT: Cut only outer plates.
Open weld joints in areas (2) and remove luggage compartment floor (3).
2010 BMW M3
Clean all bonding surfaces (1) on vehicle and on new part with cleaning agent R1.
Apply adhesive K5b to bonding surfaces (1).
Fig. 361: Identifying Bonding Surfaces For Applying Adhesive K5b

2010 BMW M3
Adjust luggage compartment floor (1) to fit in conjunction with TAIL PANEL and secure.
Rivet luggage compartment floor with 6 punch rivets N5 in areas (2).
Fig. 362: Identifying Luggage Compartment Floor And Rivet Areas

41 12 535 STRIPPING OPERATIONS - REPLACING COMPLETE REAR LUGGAGE

COMPARTMENT FLOOR (TAIL PANEL REMOVED)
Remove heat shield
Remove carbon canister (FR number: 1612010)
Remove battery (FR number: 6121010)
Remove both backrests (FR number: 5226020)
Remove rear seat (FR number: 5224005)
Remove and install rear left and right wheel arch cover (FR number: 5171041)
Partially detach wiring harness and tie to one side

2010 BMW M3



2010 BMW M3

41 11 516 STRIPPING OPERATIONS - REPLACING LEFT CARRIER SUPPORT

Remove bumper trim (FR flat rate number: 51 11 156)
Remove headlight (FR number: 63 12 010)
Remove support for bumper trim (FR flat rate number: 51 11 050)
Remove front panel (FR number: 41 33 040)
Remove radiator (FR number: 17 11 000)
Remove A/C system condenser (FR number: 64 53 550)
If necessary, remove intercooler (FR number: 17 51 000)
Remove hydraulic steering cooling coil (FR number: 17 11 370)
Remove left wheel arch cover (front section) (FR number: 51 71 038)
Remove left wheel arch cover (rear section) (FR number: 51 71 039)
If necessary, remove intake silencer housing (FR number: 41 35 111)
If necessary, remove coolant expansion tank (FR number: 17 11 100)

2010 BMW M3

41 35 101 STRIPPING OPERATIONS - REPLACING REAR LEFT SIDE PANEL

Remove bumper trim (job number: 5112156)
Remove bumper support (job number: 5112050)
Remove center bumper guide (job number: 5112825)
Remove left bumper guide (job number: 5112828)
Remove tail panel trim (job number: 5146050)
Remove rear lid (FR number: 4162000)
Remove left rear lid hinge (FR number: 4162520)
Remove left rear lid (FR number: 6321180)
Remove left wheel arch panel (FR number: 5171478)
Remove side frame trim (job number: 5113280)
Remove and install left side window (FR number: 5136070)
Release rear seat and lay to one side.
Remove backrest (FR number: 5224010)
Remove left backrest side section (FR number: 5226008)
Remove front left lock striker (FR number: 5121003)
Remove left door mucket (FR number: 5172000)
2010 BMW M3
Remove left door sill cover strip (FR number: 5147030)

Remove left side member trim panel (FR number: 5171447)
SIDE PANELS
41 00... REINFORCEMENT PLATE WITH STUD BOLT (BONDED)
Reinforcement plates are available as new parts and must also be used.

repair work. They are applicable to sectional repairs in the outer skin area.
Overview of reinforcement plates:
1. Reinforcement plate, sill

2. Reinforcement plate, C-pillar
3. Reinforcement plate, universal
4. Reinforcement plate, C- or D-pillar
5. Lock nuts (not pictured)
Plastic nut 18 mm, part number 1 943 122
Clip nut 30 mm, part number 7 139 081
Fig. 363: Identifying Reinforcement Plate (Sill, C-Pillar, Universal And C- Or D-Pillar)
2010 BMW M3
Mark component in accordance with dimension a and cut.

The reinforcement plates must if necessary be reworked and cut to size.
Adjust reinforcement plate (1) to fit in component (2) on vehicle.
Make recesses (3) for stud bolts (4) in a semicircular shape.
Fig. 365: Adjusting Reinforcement Plate On Vehicle Components

2010 BMW M3
Secure reinforcement plate by screwing on lock nuts (1).
Fit new part (2). Make recesses (3) in new part in a semicircular shape.
NOTE: Width of joint between new part and component on vehicle approx. 3 - 8 mm (at
least 30 mm flange width per side).
Plastic nuts should be screwed on once before applying adhesive (no thread in
new plastic nut)!

Round off cutting edges (1) on joint by grinding.
(2) Component on vehicle

(3) New part
2010 BMW M3
Fig. 367: Identifying Cutting Edges

Procedure for using universal reinforcement plate
The universal reinforcement plate needs to be adapted. The plate must be divided if the distance between the
pins is too great.
Dimension a is between 40 and 80 mm depending on the space available.
Secure plates with N4 punch rivets.
NOTE: Ensure the rivet is positioned correctly! Rivet head is on the adhesion side!
Rivet the plate to the inside of the flange!
2010 BMW M3
Fig. 368: Identifying Universal Reinforcement Plate Dimension

Clean all bonding surfaces.
Apply adhesive to reinforcement plate in area (1). Apply more adhesive in the radii to avoid air pockets.
Carefully slide reinforcement plate into component on vehicle and secure by screwing on nuts (2). Screw on
nuts a few turns only.
bonding surfaces.
Fig. 369: Applying Adhesive To Reinforcement Plate Adhesive

2010 BMW M3
Apply adhesive to reinforcement plate bonding surface (1). Apply more adhesive in the radii to avoid air
pockets.
Fit new part (2).
Align new part to adjoining component and secure with gripping pliers.
Tighten nuts.
IMPORTANT: Check that the transition of the components is OK at the separation point.
Corrections can only be made before the adhesive has hardened. Straightening
at a later stage is not possible.

Concluding tasks at separation point:
In area visible to customer:
Cut off stud bolts with bodywork saw.
Completely remove adhesive residue in joint (1).
Round off sharp edges by grinding.

2010 BMW M3
IMPORTANT: Avoid heating the separation point by excessive grinding.

Reworking by pressing not permitted!
Fig. 371: Identifying Joint

Only the BMW-approved METAL FILLER should be used on the joint.
METAL FILLER - INSTRUCTIONS FOR USE
Not in area visible to customer:
Examples: The joint is covered by sill trim panel, windows, seals, etc.
Grind off stud bolts and surplus adhesive flush. Do not use metal filler. Paint area as specified in BMW Painting
Handbook.
NOTE: After painting, the joint becomes visible as the adhesive shrinks. This has no
affect on the quality.
41 35 010 REMOVING AND INSTALLING/REPLACING SIDE PANEL, FRONT LEFT OR RIGHT
CAUTION: Do not damage adjoining body parts.
GAP DIMENSIONS serve as basis for adjustment tasks.

2010 BMW M3
Fig. 372: Identifying Front Side Panel With Mounting Screws

Interior view of front side panel
Unfasten screws.
REMOVED)

2010 BMW M3



2010 BMW M3
Installation:

2010 BMW M3
Replacing complete rear left wheel arch (rear left side panel removed) Page 3 of 5
Installation:
Installation:

2010 BMW M3

Installation:

Installation:
2010 BMW M3


41 35 101 STRIPPING OPERATIONS - REPLACING REAR LEFT SIDE PANEL
2010 BMW M3

Remove bumper trim (job number: 5112156)
Remove bumper support (job number: 5112050)
Remove center bumper guide (job number: 5112825)
Remove left bumper guide (job number: 5112828)
Remove tail panel trim (job number: 5146050)
Remove rear lid (FR number: 4162000)
Remove left rear lid hinge (FR number: 4162520)
Remove left rear lid (FR number: 6321180)
Remove left wheel arch panel (FR number: 5171478)
Remove side frame trim (job number: 5113280)
Remove and install left side window (FR number: 5136070)
Release rear seat and lay to one side.
Remove backrest (FR number: 5224010)
Remove left backrest side section (FR number: 5226008)
Remove front left lock striker (FR number: 5121003)
Remove left door mucket (FR number: 5172000)
Remove left door sill cover strip (FR number: 5147030)
Remove left side member trim panel (FR number: 5171447)
41 35 101 REPLACING LEFT REAR SIDE PANEL M3
STRIP DOWN vehicle.
(1) Rear side wall

2010 BMW M3

Material Quantity
Adhesive K5b 1
Adhesive K5a 1
Sealant D1
Blind rivets N3 17
Punch rivets N4 19
EMC screws 1
R1 cleaning agent 1

Removing side wall

2010 BMW M3
Fig. 382: Identifying Weld Areas And Severance Cut Position

Dimensions b = approx. 250 mm from centerpoint of hole diameter 25 mm
Undo FOLD BONDED CONNECTION . in the area (2).
NOTE: In addition to the dimensions, the position of the separating cut can be
determined with a TEMPLATE (1).
2010 BMW M3


2010 BMW M3

Set 4.2 mm diameter bore hole for blind rivets in bulkhead of jacking point in the area (1):

2010 BMW M3

Apply adhesive to reinforcement plates. Install reinforcement plates.

2010 BMW M3

Apply adhesive (1) to inside of side wall (2) at distance a.
Dimension a = approx. 10 mm
2010 BMW M3
Fig. 389: Identifying Side Wall Adhesive Applying Area

Fig. 390: Identifying Blind Rivets And N4 Rivets Areas

surfaces.
2010 BMW M3
Use punch rivets N4 in areas (2) and (3):

Area Number
2 10
3 2
Side wall is glued and bordered in area (4).

Area Number
2 3
3 4

Also apply adhesive (2) to outer wheel arch section (3).
1. Rear side wall.

2010 BMW M3
Fig. 392: Identifying Outer Wheel Arch Section Adhesive Applying Area
Installation note:
Flange edge of wheel arch (3) of side wall flush to outer wheel arch section.
Do not create sharp edges when flanging as otherwise the flange edge may begin to tear.
Dimension (A) = 5 mm.
1. Adhesive
2. Rear side wall
Also seal in area (3) according to standard.

2010 BMW M3
Fig. 393: Identifying Rear Side Wall Adhesive Applying Area

IMPORTANT: Flange edge must be completely filled with adhesive (1).
hardens.
41 35 101 REPLACING LEFT REAR SIDE WALL
STRIP DOWN vehicle.
(1) Rear side wall


Material Quantity
Adhesive K5b 1
2010 BMW M3
Adhesive K5a 1
Sealant D1
Blind rivets N3 17
Punch rivets N4 26
EMC screws 1
R1 cleaning agent 1

Removing side wall

2010 BMW M3
Fig. 395: Identifying Welding Areas With Dimension a And b On Left Rear Side Panel
Before loosening the wheel arch welding connections:
Straighten wheel arch edge similarly to new part.
Dimension b = approx. 250 mm to centerpoint of 25 mm diameter hole.
NOTE: In addition to the dimensions, a TEMPLATE (1) may be used to determine the
position of the separating cut.
2010 BMW M3


2010 BMW M3

Set 4.2 mm diameter bore hole for blind rivets in bulkhead of jacking point in the area (1).

2010 BMW M3
In areas (1) and (2) set 4.2 mm diameter bore holes for blind rivets.
Remove new part again and deburr bore holes.

Apply adhesive to reinforcement plates. Install reinforcement plates.

2010 BMW M3


2010 BMW M3
Fig. 402: Identifying Rivet Areas On Left Rear Side Panel

surfaces.

Area Number
2 10
3 6

2010 BMW M3
Area Number
2 5
3 5

hardens.
REMOVED)
Observe specific PROCEDURE .

2010 BMW M3

2010 BMW M3
Installation:
(3).

2010 BMW M3
Installation:

FRONT SIDE DOORS

41 5.... ADJUST DOOR
IMPORTANT: Do not damage adjoining body parts.

Minor corrections (realignment work) are permitted if the existing adjustment
options are not sufficient.
NOTE: Observe GAP DIMENSIONS .

The door must be provided with all attachment parts for correct adjustment.
Adjust screwed body parts from rear to front.
The following illustrations are schematic representations and are to be applied
to the relevant vehicle type.
Slacken lock striker, remove if necessary.
Slacken nuts (1) until door can still just be moved.

2010 BMW M3
Fig. 408: Identifying Door Nuts

Fig. 409: Identifying Rear And Front Door With Shims

Adjust rear door in transition to front door (Y) by fitting shims.

2010 BMW M3
Installation:
To preset new part, carry over number of shims from damaged door.
Adjust door longitudinally (X) and vertically (Z).
Check that adjoining body parts are flush in terms of height and correct if necessary.
NOTE: Vertical adjustment of door must not be influenced by lock striker.

When the door is closed, the lock striker must not touch or scrape against the
door lock. Look out for scratches.
Fig. 410: Identifying Body Parts Alignment

Slacken screws (1) until lock striker can still just be moved.
Move lock striker sideways in order to adjust transition between door and rear side panel.
NOTE: When the door is closed, the lock striker must not touch or scrape against the
2010 BMW M3
Fig. 411: Moving Lock Sticker To Adjust Transition Between Door And Rear Door Side Panel
After installation
Tighten all screws and nuts to specified torque.

Touch up unpainted surfaces in the appropriate color.
If necessary, adjust front door.
41 5.... REMOVING AND INSTALLING DOOR
The illustrations are schematic representations and are to be applied to the relevant vehicle type.
Open door.
Release screw on connector frame.
Front door:
Rear door:

2010 BMW M3
Fig. 412: Locating Connector Frame Screw

NOTE: Secure door against closing.
Release screw (1) on door retainer.
Front door:
Rear door:
Fig. 413: Identifying Door Retainer Screw

IMPORTANT: Secure door against falling out.

2010 BMW M3
Release screws between both hinge elements at top and bottom.
Pull both screws out of hinges.
Front door:
Rear door:
Fig. 414: Locating Hinge Element Screws

Pull out door sideways and place it on a suitable surface.
Fig. 415: Locating Door Position

2010 BMW M3
Pull plug connection from door pillar, unlock by pulling out bar and detach.
Installation:
If necessary, adjust DOOR .
Fig. 416: Pulling Plug Connection From Door Pillar

41 5.... REPLACE DOOR
IMPORTANT: For production reasons the side impact beam is only screwed loosely.
Tighten screws of side impact beam.
41 51... REPLACING DOOR HINGE BUSHING (DOOR REMOVED)
Set of special tools 411150 comprises:
Bush41 1 151
Screw41 1 152
2010 BMW M3
Fig. 417: Identifying Bush (41 1 151) And Screw (41 1 152)
Cut off hinge bushing in area (1) with chisel.
Drive out remainder of hinge bushing with punch.
Fig. 418: Identifying Hinge Bushing Cut Off Area

Insert screw 41 1 152 with new hinge bushing (2) into hinge.
Screw bushing 41 1 151 with flat end (3) pointing upwards onto screw 41 1 152.
Turn bushing 41 1 151 until taper (1) borders hinge bushing.
Unscrew bushing 41 1 151 again.

2010 BMW M3
Fig. 419: Identifying Hinge Bushing With Special Tools

Twist bushing 41 1 151 with flat end (1) onto screw41 1 152.
Turn bushing 41 1 151 until gap dimensions (2) are identical.
Fig. 420: Identifying Bushing 41 1 151 Gap

REAR SIDE DOORS

41 5.... ADJUST DOOR

Minor corrections (realignment work) are permitted if the existing adjustment
options are not sufficient.
NOTE: Observe GAP DIMENSIONS .

2010 BMW M3
The following illustrations are schematic representations and are to be applied
to the relevant vehicle type.
Fig. 421: Identifying Door Nuts

2010 BMW M3
Fig. 422: Identifying Rear And Front Door With Shims

Installation:

2010 BMW M3
Fig. 423: Identifying Body Parts Alignment

Fig. 424: Identifying Lock Striker Screws

After installation

2010 BMW M3
41 5.... REMOVING AND INSTALLING DOOR
Open door.
Front door:
Rear door:
Fig. 425: Locating Connector Frame Screw

Front door:
Rear door:
2010 BMW M3

Front door:
Rear door:

2010 BMW M3
Fig. 427: Locating Hinge Element Screws

Fig. 428: Locating Door Position

Installation:
If necessary, adjust DOOR .

41 5.... REPLACE DOOR

2010 BMW M3
IMPORTANT: For production reasons the side impact beam is only screwed loosely.
Tighten screws of side impact beam.
41 51... REPLACING DOOR HINGE BUSHING (DOOR REMOVED)
Set of special tools 41 1 150 comprises:
Bush 41 1 151
Screw41 1 152
Fig. 430: Identifying Bush (41 1 151) And Screw (41 1 152)

2010 BMW M3
Fig. 431: Identifying Hinge Bushing Cut Off Area

Insert screw 41 1 152 with new hinge bushing (2) into hinge.
Screw bushing 41 1 151 with flat end (3) pointing upwards onto screw41 1 152.
Turn bushing 41 1 151 until taper (1) borders hinge bushing.
Unscrew bushing 41 1 151 again.
Fig. 432: Identifying Hinge Bushing With Special Tools

Twist bushing 41 1 151 with flat end (1) onto screw41 1 152.
Fig. 433: Identifying Bushing 41 1 151 Gap

2010 BMW M3
FRONT LID
41 61 014 ADJUSTING ENGINE COMPARTMENT LID
The specified GAP DIMENSIONS serve as the basis for adjustment tasks.
Make unpainted surfaces visible by also moving the hinges. Touch these up in the appropriate color.
Loosen screws (1) and (2) on left and right hinges.
Hood lid must be able to be moved.
NOTE: If the adjustment range is not sufficient, release retaining screws of engine
hood hinge on body and move hinge.
Fig. 434: Identifying Hood Hinge Screws

Locks and retaining hook must snap correctly into place.
Adjust engine hood.
NOTE: VERTICAL ADJUSTMENT of engine hood to side panel by means of stop pads.
2010 BMW M3
Fig. 435: Adjusting Engine Hood

NOTE: Height adjustment of bonnet to front wall:

Release screw (1) and remove cover (2).
Height adjustment by turning at closing hooks (3).
Fig. 436: Identifying Cover, Hooks And Screw

Tighten down all screw connections again.
IMPORTANT: Check function of retaining hook.
41 61 000 REMOVING AND INSTALLING ENGINE COMPARTMENT LID

2010 BMW M3
Disconnect all cable plug connections
IMPORTANT: For the following work step, secure the engine hood against falling closed.
Disconnect gas-pressure damper from engine hood (1).
Loosen screws (2).
Release screws (3).
Fig. 437: Identifying Gas-Pressure Damper With Screws

NOTE: This work step must be carried out with a second person assisting.
Remove hood lid.
Installation:
Install engine hood at screw locations to on hinge. This dispenses with the need for adjustment after installation.
If this is not possible, ADJUST ENGINE HOOD .
REAR LID
41 62 014 ADJUSTING REAR LID

2010 BMW M3
The GAP DIMENSIONS serve as the basis for adjustment work.
Make unpainted surfaces visible by also moving the hinges. Touch these up in the appropriate color.
Slacken screws (1) and (2) on rear lid hinge to rear lid until such stage that rear lid can still be moved.
Adjust rear lid.
Retighten all screws.
Fig. 438: Identifying Rear Lid Hinge To Rear Lead Mounting Screws
Adjusting height of rear lid in relation to side panel:
Slacken screws (1) on rear lid hinge to side panel until such stage that rear lid can still be moved.
Adjust rear lid.
Adjust REAR LID LOCK .

2010 BMW M3
Fig. 439: Identifying Hinge With Mounting Screws

41 62 000 REMOVING AND INSTALLING REAR LID
Remove PANEL FOR REAR LID

Disconnect all plug and socket cable connections on rear lid.
Slacken screws (1)
Remove rear lid.
Installation:
Adjust REAR LID .

2010 BMW M3
Fig. 440: Identifying Rear Lid Hinge To Rear Lead Mounting Screws
41 62 520 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT HINGE FOR REAR LID
(REAR LID REMOVED)
Release screws (1).
Remove hinge (2).
Adjust rear lid on the basis of the BODY GAP DIMENSIONS .
Replacing hinge only
Remove GAS-FILLED STRUT for rear lid.

2010 BMW M3
Fig. 441: Identifying Hinge With Mounting Screws

OTHER FLAPS
41 63 000 REMOVING AND INSTALLING FLAP FOR FUEL FILLER NECK

Open fuel filler flap.
Lever out lock (2) and detach fuel filler flap (1) in direction of arrow.
Fig. 442: Detaching Fuel Filler Flap

41 63 003 REPLACING COVER BOWL
Remove FLAP FOR FUEL FILLER NECK

Remove SERVODRIVE FOR TANK FILLER FLAP
Remove front wheel arch cover (rear section)
Unscrew nut (1).
Installation:
Make sure seal (2) is correctly seated.

2010 BMW M3
Fig. 443: Identifying Seal And Nut

Installation:
Clean contact surface on body and grounding lead on fuel filler pipe.
Ground connection must be guaranteed.
Release nuts (1).
Fig. 444: Identifying Nuts

Turn cover (1) through approx. 45 and lever out in direction of arrow.
2010 BMW M3
Fig. 445: Removing Cover Bowl

Press retaining strap (1) inwards and remove.
Remove cover (2).
Remove rubber pad (3).
Insert a suitable tool through bores (3) and release catches.
Installation:
Fig. 446: Removing Retaining Strap

Installation:
2010 BMW M3
Catches (1) on ejector (2) must not be damaged.
Check protective cap (3) for correct seating.
Fig. 447: Identifying Catches On Ejector

Installation:
Locks (1) on left/right of cover (2) must not be damaged.
Fig. 448: Identifying Locks And Cover

Close flap (1).
Twist cover bowl (2) in direction of arrow out of side panel and remove.
2010 BMW M3

Installation:
Following parts on cover bowl (6) must not be damaged or missing:
1. Rubber pad
2. Catches, top/bottom
3. Spring
4. Catch
5. Guide
Fig. 450: Identifying Cover Bowl With Related Parts

2010 BMW M3
ACCESSORIES AND BODY, CAB Body - M3
Body - M3
BODY
41 00 ... BONDING STEEL ON STEEL
IMPORTANT: Conform with safety precautions!
Overview of topics:
1. Equipment
2. Expiry date of adhesive
3. Grinding and cleaning
4. Gluing coat
5. Hardening times
6. Aftertreatment of bonding surfaces
7. Disposing of adhesive
1.0 Equipment
Emery paper
Cleaning agent: Isopropanol, acetone or spirit
Adhesive K1
Adhesive gun (standard cartridge gun)
Spatula for applying adhesive
2.0 Expiry date of adhesive:

3.0 Grinding and cleaning:
For better adhesion, remove oxide film, rust, paint and scale from the adhesive areas with a wire brush or
emery paper.
Clean adhesive areas with isopropanol, acetone or spirit.
Allow cleaned surfaces to dry for approx. 5 minutes.
Adhesive areas must be completely dry.
4.0 Adhesive application:

2010 BMW M3
Processing temperature of adhesive cartridge 15C - 25C.

Insert adhesive cartridge in adhesive gun, remove cap and allow both adhesive components to emerge.
Strip adhesive components uniformly and attach mixing tube.
Allow approx. 10 cm of mixed adhesive to emerge and then apply the mixed adhesive first on one side of
the adhesive area.
After applying the adhesive, check whether an adhesive component has emerged at the back of the
cartridge. If yes, break off the bonding procedure. Clean new component. Use new adhesive cartridge.
Contact national hotline.
Use a spatula to spread the adhesive over the adhesive area. Thickness of layer approx. 2 mm (dependent
on adhesive gap).
Potlife of mixed adhesive approx. 2 hours. A change of mixer is only necessary if over a period of 1 hour
no material has flowed through the mixer.
Join, secure and rivet and/or weld new parts in accordance with repair instructions.
Remove excessive glue with paper or cloths.
5.0 Hardening times:
The hardening time is:
Either 48 hours at a minimum of 15C (room temperature) up to vehicle operational strength.

Or 1 hour in the spraying booth (booth temperature 80C/ object temperature 60C) up to vehicle
operational strength.
Do not use radiant heaters for hardening. Risk of adhesive being destroyed at temperatures of > or = 120
C.
Do not apply load to glued parts until they have hardened!
6.0 Aftertreatment of bonding surfaces:
Seal all bonding surfaces with cavity sealant.
7.0 Disposing of adhesive:
Small amounts of mixed and hardened adhesive residue can be disposed of as domestic waste.
41 00 ... CARRYING OVER HOLE PATTERN
When replacing a body component, it is necessary to carry over the hole pattern from the existing body to the
new component.
The following pictures are a schematic representation of carrying over the hole pattern on the example of the
2010 BMW M3
front wheel arch.
Adjust new part to fit with straightening attachment.
Insert paper stencil (1) between new component (2) and engine carrier and secure with adhesive tape (3).
Carry over contour (4) of new component to stencil.
Remove new component.
Fig. 1: Identifying Paper Stencil, Component And Adhesive Tape

(1) = contour of new component.
Carry over positions of holes (2) to stencil by pressing down with thumbs.
Remove stencil.
Fig. 2: Identifying Holes (1 Of 2)

2010 BMW M3
Fig. 3: Identifying Holes (2 Of 2)

Lay stencil (1) on a flat surface.
Mark centrepoints of holes with crosses (2).
Then pierce paper through centrepoints (3) of holes with a pointed object.
Align stencil (1) according to contours (2) to inside of new component and secure with adhesive tape (3).
2010 BMW M3
Fig. 4: Identifying Stencil And Adhesive Tape

Turn over new component.
IMPORTANT: Crosses must not be visible in this view!
Set punch marks at pierced centrepoints (1).
Grip directly under punch marks for marking with punch.
Remove stencil (2).
Drill holes to approx. 3 - 4 mm dia. at punch marks (1).
Fig. 5: Identifying Stencil And Punch Marks

Position new component (1) with straightening attachment on vehicle.
Drill out holes (2) to 6.7 mm dia.

2010 BMW M3
Fig. 6: Identifying Holes And Component

41 00 ... CORROSION PROTECTION
NOTE: Following repairs, the corrosion protection work already begins with the correct
removal of the PVC undercoating, antinoise compound and seam seals.
The products recommended by BMW are optimized with regard to corrosion
protection.
1.0 Removing sealing materials:
IMPORTANT: Do not burn off PVC material (sealing compound) with a gas burner or
similar or heat to temperatures above 180C. This would generate highly
corrosive hydrochloric acid and release harmful fumes.
The new lining does not form a satisfactory bond with burnt PVC material
which means that subsequent sub-surface rust may set in.
Remove PVC material with a rotating steel brush, or heat PVC to maximum 180C with a hot air blower and
scrape off with a spatula.
2.0 Corrosion protection of sheet-metal parts:
All weld joints sealed off with body sealing compound in original state must be primed and sealed off again
thoroughly after repairing. Replace damaged or removed antinoise compounds.
NOTE: Spray gun required for body sealing compound (order no. 81 49 0 300 887).
Concluding cavity protection is the most important part of all corrosion protection measures.
Use the cavity protection spray only for smaller-scale straightening work where the parts in question are easily
accessible.
2010 BMW M3
Use the HRS spray gun with pressure container for all other repairs. Cavity protection agent is available in
different container sizes.
Use the relevant probes with tubes for the different cavity areas.
IMPORTANT: Incorrectly performed cavity protection can, especially in the case of

steel/aluminum joints, give rise to a non-calculable product liability and safety
risk.
The best repair is worth nothing if the subsequent cavity protection measures are not conscientiously carried
out.
2.1 Cavity protection of steel parts:
New doors and lids must be sealed with cavity protection agent after being painted.
New sheet-metal parts or cavities, weld seams and folds formed by new sheet-metal parts must be sealed with
cavity protection agent after being painted.
The cavities affected must be sealed with cavity protection agent after all straightening work.
2.2 Cavity protection of aluminum parts:
New doors, lids and side panels made of aluminum are not sealed with cavity protection agent.
After all straightening work on aluminum components, the cavities affected must be sealed with cavity
protection agent after being painted.
After all welding work (E52 only) on aluminum components, the cavities affected must be sealed with cavity
protection agent after being painted.
Cavities, seams and folds formed from new sheet-metal parts must be sealed with cavity protection agent after
being painted.
41 00 ... FRAME ALIGNMENT CONTROL DIMENSIONS, BODY
Dimensions in mm.
Measurement tolerances:
< or = 1000 mm 1.5 mm

> or = 1000 mm 2.5 mm
The control points shown serve to check the body and the straightening attachment.
The specified dimensions/measurements always refer to the centrepoint of the bore/screw.

2010 BMW M3
Underbody view 1
Fig. 7: Identifying Underbody Dimension

2010 BMW M3
Underbody view 2
Fig. 8: Identifying Underbody Dimension

2010 BMW M3
Top view, front end
Fig. 9: Identifying Top View, Front End Dimension

The specified dimensions refer to removed assemblies.
View, B-pillar (Saloon and Touring only)

2010 BMW M3
Fig. 10: Identifying B-Pillar (Saloon And Touring Only) Dimension

Measurement a=1551 mm between screw-on points of door brakes.
View, B-pillar (Coupe only)

2010 BMW M3
Fig. 11: Identifying B-Pillar (Coupe Only) Dimension

Measurement a=1543 mm between screw-on points of lock strikers.
41 00 ... GAP DIMENSIONS, BODY
Dimensions in mm
2010 BMW M3

2010 BMW M3

41 00 ... GENERAL CEMENTING INSTRUCTIONS

2010 BMW M3
The bonding surfaces must be kept free of all types of dirt and contamination. Avoid leaving fingerprints.
Cleanliness is the golden rule for all bonds!
Cleaning agent: isohexane
Expiry date of adhesive:

2-component adhesive application:
Insert adhesive cartridge in adhesive gun, remove cap and allow some adhesive to emerge. Strip adhesive
components uniformly and attach mixing tube.
Allow approx. 1 mixer length of mixed adhesive to emerge (there must be no smearing of colors). Only
Adhesive disposal:

Empty adhesive cartridges are disposed of as normal waste.
hazardous waste.
41 00 ... GRINDING STEEL PARTS
Tools are recommended for manual grinding work.

Machines/equipment are recommended for machine grinding work.
Always replace abrasives which have already been used to treat aluminum (risk of corrosion).
41 00 ... GUN FOR CAVITY SEALING

2010 BMW M3
Fig. 14: Identifying Vessel Gun, Angle Nozzle And Round Spray Nozzle
1.0 Scope of delivery:
Owner's Handbook
Pressure vessel gun (1) for cavity sealing
Spray set, consisting of spray hoses: angle nozzle (2) and round spray nozzle (3)
IMPORTANT: Before start-up, read Owner's Handbook and safety instructions.
2.0 Start-up:
Open pressure vessel and introduce cavity sealant in form of a 1-litre can.
Close pressure vessel.
Connect spray hose to quick-connect coupling.

Connect apparatus to compressed air supply.
Working pressure 2-6 bar, max. 8 bar!
3.0 Mode of operation:

2010 BMW M3
NOTE: Unlike previous apparatus, it is possible here to alter the spray pattern with the
air flow control screw (large knurled screw)!
Twisting the air flow control screw in decreases the air flow and thus reduces the material spray mist.
This facilitates optimum working when preserving open components/surfaces.
Twisting the air flow control screw out increases the air flow and thus the material spray mist (for closed
cavities).
The trigger lever has two stages.
Stage 1 - discharge of air only.
Stage 2 - discharge of air and material.
After finishing work, press the first stage to clean the spray hose with compressed air.
When storing, remember to twist the air flow control screw closed to prevent the material from drying
out.
Clean the gun prior to extended periods of non-use (approx. 2 weeks and upwards).
To ensure that the spray hoses function properly, do not store the hoses coiled up e.g. in the frame side
member area!
Store spray hoses stretched out.
4.0 Application examples:
Use the matching spray hoses for the different cavities or surfaces.
Example - doors and lids:
Spray hose with angle nozzle. Reduce air flow to keep spray mist to a minimum.
Example - frame side member:
Long spray hose with round spray nozzle. Depending on the type, increase the air flow slightly.
Always keep the spray mist to a minimum so as to avoid fouling and bad smells.
5.0 Safety instructions:
Do not inhale spray mist.

Use only in well ventilated rooms.
Working pressure max. 8 bar.
41 00 ... HANDLING AIRBAGS AND RESTRAINT SYSTEMS

2010 BMW M3
1.0 Airbags and restraint systems
On vehicles with airbags and restraint systems, observe the relevant safety instructions.
During straightening work on the body, you will be exposed to the risk of accidental airbag triggering
when the battery is connected.
Due to this potential hazard, it is essential to disconnect the battery negative lead prior to welding and
straightening work. Prior to disconnecting the negative lead, interrogate the fault memories of the control
units if necessary.
41 00 ... HANDLING ELECTRICAL AND ELECTRONIC EQUIPMENT
1.0 Battery
There is a risk of explosion when welding or grinding work is carried out in the vicinity of the battery.
The battery must be removed . Prior to removing the battery, interrogate the fault memories of the
control units if necessary.
2.0 Control units
The following hazards are present when the battery is connected:

Damage to control units during welding work on the body.
Accidental triggering of airbags during straightening work on the body.
Due to these potential hazards, it is essential to disconnect the battery negative lead prior to welding and
straightening work. Prior to disconnecting the negative lead, interrogate the fault memories of the control units
if necessary.
Control units are designed for a temperature of 65C. The temperatures in a spraying booth do not pose
any problems. If a vehicle is inside the spraying booth at an indicated temperature of 80C, the actual
temperature of the vehicle will be < or = 60C (object temperature).
Protects control units against the effects of heat at temperatures > 65C (e.g. during welding and drying
with an infrared radiator or hot air blower).
3.0 Electric cables and wiring harnesses
Protect electric cables and wiring harnesses against damage (e.g. during straightening and grinding work).
Protect electric cables and wiring harnesses against the effects of heat at temperatures > 65C (e.g. during
welding and drying with an infrared radiator or hot air blower).
Do not kink electric cables.
4.0 Optical fibers
Follow instructions for handling optical fibers . See 61 00 ... NOTES ON HANDLING OPTICAL
FIBERS .
2010 BMW M3
41 00 ... INFORMATION ON HAZARDS
1.0 Aluminum
HAZARDS INFORMATION
Hazards / effects Measures / regulations
Repair stage 1: When a vehicle outer shell is ground, aluminum
(replacement of bolted parts, dent removal) dust accumulates in small amounts. This dust
Repair stage 2: can be removed with conventional extractor
(structural repairs with bonding and riveting) systems.
Repair stage 3:
(structural repairs with welding)
Explosion hazard due to high concentration

of fine aluminum dust.
Avoid high concentration of fine aluminum dust
Arising e.g. during straight-through by means of continuous extraction.
grinding of coated parts in the base material Use explosion-proof extractor systems.
and large-surface grinding of bright-finish Do not use compressed air when cleaning the
parts. work bay.
Avoid swirling up dust when cleaning the work
Explosion hazard due to swirling up of fine
area.
aluminum dust in cavities.
Created by the necessary, thorough

cleaning of machining surfaces and tools
before and after machining aluminum.
Spontaneous combustion of fine aluminum
dust when ignition and fire sources are
drawn in. Do not operate ignition and fire sources in the
intake area of extractor systems.
E.g.: hot splinters, grinding sparks,
cigarettes etc.
41 00 ... INFORMATION ON VEHICLE PROTECTION
Vehicle components which are situated in the repair area or exposed to heat, flying sparks or dust must be
removed or covered.
IMPORTANT: Do not use combustible or contaminated coverings.
41 00 ... INSTALLATION SOLUTION FOR STRAIGHT SHANK/HEXAGON RIVET NUT
2010 BMW M3
Wear protective goggles

Straight shank rivet nut:

Fig. 15: Applying Punch-Mark For Bore


inserted
be used.
2010 BMW M3
Fig. 16: Drilling Bore

Fig. 17: Identifying Hole

IMPORTANT: To avoid corrosion, stop chips/swarf by means of cavity sealing.

Follow instructions on corrosion protection .
2010 BMW M3


5. Set straight shank rivet nut with hand rivet gun
NOTE: According to the manufacturer, the pictured tool is suitable up to an M8

thread.
Fig. 19: Setting Straight Shank Rivet Nut With Hand Rivet Gun
Hexagon rivet nut (up to M8 thread):

1. Set hexagon rivet nut with hand rivet gun

2010 BMW M3

thread.
Fig. 20: Setting Hexagon Rivet Nut With Hand Rivet Gun
Hexagon rivet nut (from M10 thread):
IMPORTANT: Ensure correct screw length. The complete thread length of the rivet nut
must be used for installation.
Replace screw after use.
1. Insert screw (tensile strength min. 10.9) with body washer into hexagon rivet nut
2. Insert hexagon rivet nut into pre-punched hexagon hole and install by turning screw
Notes on installation:
Rivet nut is upset (screw very difficult to move).
Rivet nut is contracted (screw comparatively easy to move).
Rivet nut is pressed onto the component (screw slowly becomes difficult to move). Procedure is finished with
the fitting of the relevant component and its tightening torque.
2010 BMW M3
Fig. 21: Identifying Rivet Nut

41 00 ... INSTALLING A CAVITY ACOUSTIC BAFFLE (EXPANDED)
The following repair represents the procedure for an already expanded cavity acoustic baffle.
The cavity acoustic baffle remains on the body in this instance.
Clean contact surface (1) with spirit.
Apply a bead approx. 15 mm high (2) of window glass adhesive to contact surface (1).
Fig. 22: Identifying Contact Surface And Window Glass Adhesive

2010 BMW M3
41 00 ... INSTALLING A CAVITY ACOUSTIC BAFFLE (NOT EXPANDED)
The following repair represents replacement of a cavity acoustic baffle.
Sand contact surface of cavity acoustic baffle (1) with coarse-grained abrasive paper (grain 50 - 100).
Clean contact surface (1) with spirit.
Apply a bead approx. 15 mm high of window glass adhesive to contact surface (1).
Attach cavity acoustic baffle in specified position (see old part).
Fig. 23: Identifying Contact Surface And Window Glass Adhesive

41 00 ... INSTALLING A CAVITY ACOUSTIC BAFFLE WITH 2-COMPONENT PU CAVITY FOAM

2010 BMW M3
IMPORTANT: The cavity foam may only be use for cavity sealing at the points at which cavity
sealing is present as standard!
The following repair represents the replacement of a shaped part for the cavity seal by the use of cavity foam.
This type of cavity sealing is used at points at which shaped parts cannot be used for repairs.
This is the case when large amounts of heat occur (e.g. due to welding, soldering or tin-plating) in the direct
vicinity or at the point of the standard cavity sealing.
It is not possible here to install shaped parts for the cavity seal because of the fire risk!
To replace shaped parts with cavity foam at further locations, adopt the procedure shown here and adapt it to the
relevant conditions.
It must be ensured that the cavity is completely sealed off.
NOTE: Check the accessibility for the spraying pipe of the cavity foam to the affected
cavity after removing the damaged part.

Ideal for use as insulating and sealing compound.
Information on dangers/hazards:
Do not inhale.

2010 BMW M3
(buildup of heat)!

Application instructions:
Use by date on can.
clean and free from
dust,
grease,

Before applying to the vehicle, fill a clearly visible cavity of corresponding size with foam on a used part.
This enables an optimal dosage (i.e. spraying time) to be specified for filling the cavity on the vehicle
with foam.
Tape off open passages to visible areas with adhesive tape to prevent foam from escaping.
Sourcing reference: BMW Parts Service.

2010 BMW M3
waste.
41 00 ... MATERIALS SCIENCE
1. Aluminum
1.1 Chassis and suspension components
Read and observe the Notes on chassis and suspension components before handling aluminum.
1.2 Material influences
MATERIAL INFLUENCES
Causes Effects / remedies
This plating process causes aluminum to be removed from
the joint.
This results in surface corrosion or pitting.
New parts and accessory parts which have been approved
by the BMW Group for aluminum (screws, washers, nuts
A galvanic element is created under the etc.) have undergone special surface treatment.
effects of moisture by contact with materials Such parts must not be replaced by conventional parts.
such as copper, tin, nickel, iron and zinc.
NOTE:
Damaged parts lose this protection and must be
specially coated or replaced.
Damage caused by contact corrosion is excluded from
the warranty.
Materials also used for work on steel Surface corrosion or pitting occurs.
components can implant steel particles in the A separate tool kit is available for processing/machining
softer surface of an aluminum component. aluminum.
Soldering is not permitted for joining aluminum
Surfaces are attacked when fluxing agents
components.
are used.
Risk of corrosion from chemical factors.
Aluminum/steel grinding dust from adjoining This results in surface corrosion.
work areas. Erection of protective barriers.
1.3 Machining properties
MACHINING PROPERTIES
Properties of aluminum
Effects
compared with steel
2010 BMW M3
Aluminum parts are

Attachment with magnetic tools/working aids is not possible.
magnetically neutral.
Elasticity is only 1/3 as high. Convertibility is limited in comparison with steel.
Elongation failure is approx. Overstretching the material results in strain-hardening and an increased
50% slighter. tendency of cracking.
Electrical conductivity is almost
Electric welding procedures require different equipment (MIG welding).
4 times higher.
Material expansion during The material expands more markedly. Shorter heat treatment is
heating is twice as high. necessary for removing dents.
Thermal conductivity is 3 times Heat is drained more quickly.
higher. Adjoining working areas are affected more heavily e.g. during welding.
Elongation characteristics and thus plasticity are improved.
Strength is reduced.
Microstructural change between
IMPORTANT:
200C and 250C.
No heat treatment when working on the vehicle structure!
Temperature cannot be monitored to sufficiently exact levels in
garages.
The melting point is 650C. Once the melting temperature has been
reached, the material begins to flow without any further indications.
The temperature can only be estimated by means of the paint coloring
Aluminum shows no annealing and the surface warpage.
colors.
IMPORTANT:
Do not use thermal applicators. Not suitable for garage use because
the paint runs too quickly.
1.4 Mounting
MOUNTING REFERENCE
Characteristic features of aluminum Special measures
Corrosion (ageing) in damp environments. Store aluminum parts in a dry place.
Contact corrosion in event of contact e.g. with Always store aluminum parts separately or in isolation
steel parts. from steel parts.
Do not damage protective surface layer since this would
cause oxidation.
Susceptibility to paint infiltration.
Failure to comply with this requirement would result in
more painting work.
41 00 ... NOTES ON REPAIRING THREADS
NOTE: Damaged threads may be repaired with Helicoil thread inserts. Comply with the
2010 BMW M3
procedure described in the example.
REPAIRING PROCEDURE
Screw/bolt fastening Helicoil thread
Screw/bolt connection Vehicle
point(s) insert
E46 All M12x1.5x18
E53 All M12x1.5x18
E60, E61, E63, Front, middle See
E64 Rear M12x1.5x18
E65, E66, E67 All M12x1.5x18
E70, E71 All M14x1.5x21
Front axle carrier to engine carrier E83 All M12x1.5x18
E85, E86 All M12x1.5x18
E81, E82, E87,
All M12x1.5x18
E88
E90, E91, E92,
All M12x1.5x18
E93
E92 with S65 All M10x1.5x15
Bracket, control arm, to engine
E46, E85, E86 All M10x1.5x15
carrier
E46 All M12x1.5x18
E53 All M14x1.5x21
E60, E61 All M14x1.5x21
E63, E64 All M14x1.5x21
E65, E66, E67 All M14x1.5x21
Rear axle carrier to frame side E70, E71 All M14x1.5x21
member E83 All M12x1.5x18
E85, E86 All M12x1.5x18
E81, E82, E87,
All M12x1.5x18
E88
E90, E91, E92,
All M12x1.5x18
E93
Bearing block, trailing arm to side E46, E83, E85,
All M12x1.5x18
member E86
41 00 ... OPENING ADHESIVE BONDS
1. Opening spot-weld bonds

Or open weld spot with Vario Drill spot-weld cutter.

2010 BMW M3
Heat connecting flange with a hot air blower.

Grind off residual adhesive from connecting flange.
2. Opening adhesive bonds on aluminum parts

Remove punch rivets or blind rivets .
Roughly cut out damaged component. The component can be peeled with the aid of pliers. If
necessary, heat bonding flange with hot air blower.
CAUTION: Heat only the damaged component with a hot air blower.

Extract vapors and gases.
Grind off residual adhesive from connecting flange.
If engine carrier part replacement on the GRAV is carried out repeatedly, cut the damaged part at

the existing cutting line. Heat bonding flanges with a hot air blower. Peel off remnants of expander
elements with pliers.
3. Opening adhesive bonds on carbon-fibre-reinforced plastic parts
41 00 ... OPENING WELD JOINTS
1. Opening weld spots (resistance pressure spot welding):
Sheet steel panels made from high- and super-high-strength materials make great demands on the tools
used.
2010 BMW M3
Only with special carbide milling cutters can weld spots be drilled out on these sheet panels.
Use BTR/BOR milling cutters only in conjunction with Vario Drill spot-weld remover.
Procedure:
2. Opening laser weld seams:
Laser weld seams are used in the roof outer skin area.
Procedure:
Roughly cut roof outer skin in the roof channel to improve accessibility.
Place angle grinder with grinding disc on laser weld seam and grind through top metal sheet. Be
careful not to cut through and damage sheet metal underneath. Remove sheet metal flange.
41 00 ... OVERVIEW OF CONSUMABLES (ELECTRONIC PARTS CATALOGUE - EPC)
1.0 Adhesives
ADHESIVES REFERENCE
Designation in Part
repair Designation EPC number Application examples
instruction EPC
Bonding and sealing
Window glass 83 19 0
compound for car Installation of cavity bulkheads
adhesive 152 031
window glass
Front end E60, front wheel arch E70, side
83 19 0 frame E65, rear apron/tail panel
K1 Adhesive 2C EP repair adhesive
413 015 F01/E89/MINI, rear side panels and roof outer
skin MINI
K2 Adhesive Dow Betamate 2816 Roof outer skin F01, F02
Adhesive set 83 19 0
K3 Adhesive Carbon-fibre reinforced plastic roof M6
Sikaforce 7888 417 144
83 19 0
K4 Adhesive 2C repair adhesive Clip repair roof strip F01
452 262
2.0 Rivets
2010 BMW M3
RIVETS REFERENCE
Designation in repair Designation Part number
Application examples
instruction EPC EPC
Blind rivet 83 19 0 301
N1 Rivet Hemlock 813 Engine carrier, wheel arch, E60
Hemlock 813 414
N2 Rivet Hemlock 815 Engine carrier, wheel arch, E60
Hemlock 815 419
N3 Rivet Support carrier E60
Avibulb 421
Rear apron/tail panel F01, E89, MINI; roof
N4 Punch rivet
outer skin MINI; rear side panels MINI
3.0 Primer
PRIMER REFERENCE
Designation in repair Part number
Designation EPC Application examples
instruction EPC
2C spray HS-AK filler 51 91 0 432 Corrosion protection of newly
Primer, potlife 5 hours
grey 612 welded sheet panels
2C spray EP priming 51 91 0 432 Corrosion protection of newly
Primer, potlife 8 hours
filler 615 welded sheet panels
INOX spray, welding 83 40 0 409
Welding primer Welding flanges internal only
primer 992
4.0 Sealing compounds
SEALING COMPOUNDS REFERENCE

Designation in repair Part number
instruction EPC
Polyurethane sealing 83 19 0 414
Sealing compound Roof bow, gap seal
compound white 598
Sprayable sealing 83 42 0 428
Seam seal Flange seal, front wheel arch
compound 349
IMPORTANT:
Due to insufficient adhesion, polyurethane-based sealing compounds and sprayable sealing
compounds must not be intermixed.
Underseal 51 91 0 42 Surface application, e.g. rear
Underseal
Grey 7673 wheel arch
51 91 0 427
675
Underseal AQUA black Surface application, e.g. rear
Underseal US version:
(water-based) wheel arch
51 91 0 427
677
IMPORTANT:
2010 BMW M3
Due to insufficient adhesion, grey underseal and AQUA underseal (water-based) must not be
intermixed.
5.0 Cavity sealing
CAVITY SEALING REFERENCE

Designation in Designation Part number
repair instruction EPC EPC
Cavity sealant 83 42 0 428 190 Minor straightening work with good
Cavity sealant
spray 83 42 0 428 351 accessibility
Cavity 83 42 0 428 348 Major straightening work, e.g. frame side
Cavity sealant
preserevation 83 42 0 428 352 members, engine carriers, pillars, side panels
6.0 Cavity foam
CAVITY FOAM REFERENCE

Designation in repair Designation Part number
instruction EPC EPC
83 42 9 410
Cavity foam Cavity foam Cavity bulkhead
694
83 19 0 007
361
E61 inner section of wheel arch, MINI R56
Structural foam Structural foam US version:
roof outer skin
83 19 0 445
721
41 00 ... POSITION OF SHAPED PARTS FOR CAVITY BULKHEAD
Because it is not possible to heat the body to this extent for a body repair, a different procedure has been
specified for this situation.
2010 BMW M3
Fig. 24: Identifying Cavity Sealing

41 00 ... POSITION OF SHAPED PARTS FOR CAVITY ACOUSTIC BAFFLE
Because it is not possible to heat the body to this extent for a body repair, a different procedure has been
specified for this situation.
2010 BMW M3
Fig. 25: Identifying Specific Body Areas

41 00 ... PROCEDURE FOR FOLDING ROOF AFTER AN ACCIDENT
The folding roof may be under tension after the vehicle has incurred damage following an accident. Moving the
folding roof by hydraulic means may result in irreparable damage. For this reason, the folding roof may only be
moved manually until the damaged has been repaired.
IMPORTANT: It is not possible to check the correct operation of the folding roof on the
damaged vehicle.
Different procedures are required, depending on the degree of damage which the vehicle has incurred. The
repair instructions for emergency actuation describe only the complete sequences for manually opening and
closing the folding roof.
When removing the roof module and/or the rear end module, it is possible to move the folding roof manually
into the necessary intermediate positions in each case.
WARNING: Risk of injury due to the heavy weight of the folding roof!
Since the hydraulic system may have to be depressurized during manual
movement of the folding roof, there is an increased risk of injury by
trapping. Always secure the folding roof adequately against unintentional
movement.
After body repairs to the vehicle
All the folding roof components screwed/bolted to the body are precisely screwed/bolted to the vehicle at the
2010 BMW M3
factory by means of gauges. This affects above all the base plates and mounting brackets of the roof and rear
end modules. To minimize extensive adjustment work after a body repair as much as possible, only remove
those components which are screwed/bolted to a damaged body part.
Gauge the base plates only after a body repair to the cowl panel.
41 00 ... QUALITY STANDARD
The overall requirements relating to a vehicle can only be implemented by including "all" components.
This applies in particular to the body. With regard to an optimum crash result, it is necessary to maintain
the structural measures.
It is absolutely essential to observe the procedures set out in the repair instructions. Any deviation from
these procedures will only be permitted after prior consultation with and approval by BMW. Should you
have any questions, please contact the country-specific Hotline.
The use of non-approved repair steps or tools may have serious consequences for the structure of the
vehicle (e.g. in the event of a crash). In the end, this can result in safety and product liability risks which
cannot be calculated.
Corrosion protection measures during and after repairs are absolutely essential to maintain the value of
the vehicle.
Use only genuine BMW parts and approved auxiliary devices, materials and operating fluids when
carrying out repairs.
41 00 ... REPAIR SOLUTION FOR STRAIGHT SHANK/HEXAGON RIVET NUT


2010 BMW M3
Fig. 26: Drilling Rivet Head

Fig. 27: Removing Rivet Head With Chisel


2010 BMW M3
Fig. 28: Identifying Rivet Shank Into Cavity



2010 BMW M3

IMPORTANT: To avoid corrosion and rattling noises, stop chips/swarf and rivet nut
shank with cavity foam.
Remove foam remnants with isohexane (cleaning-grade petroleum spirit).

Hexagon rivet nut (up to M8 thread), straight shank rivet nut:

2010 BMW M3


thread.
Fig. 32: Setting Rivet Nut With Hand Rivet Gun

Rivet nut is pressed onto the component (screw slowly becomes difficult to move). Procedure is finished
with the fitting of the relevant component and its tightening torque.
2010 BMW M3

41 00 ... REPAIRING PLASTIC PARTS
1.0 General information
Economic efficiency must always be checked prior to repair.

Only the following painted components in the outer skin area are approved for repair:
Bumper trims (exception: E52)
Sill trims
Front side panels
Hardtop/roof
Convertible top compartment lid
Rear lid
Prerequisite for professional repair:

Only minor deformations (without microcracks, usually visible in the paint)
Only minor damage, e.g. abrasions, cracks and holes up to 2.5 cm long
No damage (cracks) to the edge of the component!
CAUTION: The following are not approved for repair:

Fuel tanks, reservoirs for liquids/fluids (e.g. windscreen washer unit, brake fluid, coolant expansion
tank, etc.)
Headlight mountings (pedestrian protection)
2.0 Shaping plastic parts
Plastic parts can be reshaped using a hot-air blower.

Microcracks can occur in the plastic if plastic parts are deformed. After the component is reshaped and
2010 BMW M3
then painted, the cracks may become visible again on the surface after a period of time.
The component must be replaced if microcracks can be identified in the area of deformation.
3.0 Bonding plastic parts
A plastics repair box (sourcing reference: BMW Parts Service) is offered for cost-effective and time-
value-compatible repairs.
The plastics repair box contains the step-by-step instructions for repairing plastic parts.
41 00 ... RIVETING ALUMINUM PARTS
Stud welding apparatus with gas bottle containing inert gas (82 % argon, 18 % CO2 ).
Stainless steel stud (sourcing reference via BMW Parts Service picture board Aluminum and
steel/bonding and welding)
Universal riveting tool
Riveting tongs for blind rivet nuts and blind rivet studs.
2.1 Extracting punch rivets:
Grind off paint and dark grey coating of punch rivets.

Position bolt centrally on the rivet and weld on vertically. The area in which the bolts are welded on
should be between the two grounding terminals. Position both terminals, if possible, on the top side of the
metal plate on which the rivet is located.
Extract bolt with welded-on rivet using universal riveting tool. Use a large plastic nose piece if not
otherwise specified in the repair instructions. Check plastic nose piece prior to use for wear.
Plastic nose piece must rest on sheet metal all round; if necessary, grind off plastic noise piece in collision
area.
Do not push riveting tool forcefully onto special-steel bolts.
Do not use riveting tool to bend special-steel bolts.
Pay particular attention to central positioning of the bolt when using the small plastic mouthpiece.
2.2 Drilling out punch rivets:
Only if extraction proves repeatedly unsuccessful or the rivet cannot be accessed with the universal riveting
tool.
2010 BMW M3
Drill out rivets with a 6 mm dia. carbide drill bit.

Punch rivets can be drilled out on both sides. When drilling from the protruding rear side, spot-drill the
rivet shank only and remove the rest with a rivet punch.
Use a drift punch to remove punch rivet remnants in the aluminum (risk of corrosion).
Clean vehicle to remove chips (risk of corrosion).
2.3 Drilling out blind rivets:
Only when a part is repeatedly replaced.
Drill out rivet head only with 6 mm dia. metal drill bit. Knock out rivet remnants with a drift. Use
existing 6.7 mm hole for blind rivet.
Clean vehicle to remove chips and rivet remnants (risk of corrosion).
3.0 Blind riveting in conjunction with bonding
The standard punch rivets are always replaced by blind rivets in conjunction with bonding.
The required strength of the connection is only achieved through a combination of bonding and riveting.
4.0 Setting blind rivets:
Refer to repair instruction for rivet size.

Position blind rivets in the same locations as the extracted punch rivets. Exceptions are described in the
relevant repair instruction. If necessary, carry over the positions of the rivets to the new component.
Drill holes (0.2 mm bigger than the outside diameter of the rivet. Example 4.2 mm dia. for 4 mm rivet and
6.7 mm dia. for 6.5 mm rivet).
Apply adhesive.
Insert blind rivet. The riveting direction is the same as the line of vision in the picture shown in the repair
instruction (e.g. from wheel arch into engine carrier).
Universally rivet blind rivet with riveting tongs.
Seal blind rivet with sealing compound (risk of corrosion).
Seal cavities with cavity sealant (risk of corrosion).
5.0 Setting blind rivet nuts and blind rivet studs:
Studs welded as standard are always replaced by blind rivet studs.

Drill holes (0.2 mm larger than the outside diameter of the blind rivet nuts or blind rivet studs).
Blind rivet nuts and studs must have a special coating for anti-corrosion purposes (sourcing reference:
BMW Parts Service).
Use the blind rivet nuts and studs supplied in the case of the manual riveting tool for steel only!
Insert blind rivet nuts or studs and tighten down with the riveting tool.
2010 BMW M3
It will no longer be possible to set a blind rivet nut if the drilled hole is too big. In this event, set a clip nut
(sourcing reference: BMW Parts Service). This nut tightens itself automatically when screwed to the
component.
Seal blind rivet nuts and blind rivet studs with sealing compound (risk of corrosion).
41 00 ... RIVETING STEEL PARTS
Manual riveting tool for blind rivet nuts and bolts.
2.0 Setting blind rivet nuts and blind rivet bolts:
Blind rivet nuts and bolts must have a special coating for corrosion reasons.
Insert blind rivet nuts or bolts and tighten down with the riveting tool.
41 00 ... SAFETY AT WORK
1.1 Working with aluminum dust:
Wear a fine dust mask.

E52 only: Use an explosion-proof extractor system.
1.2 Removing sealing materials
Hydrochloric acid is created when PVC sealing material is heated to temperatures in excess of 180C.
Remove PVC sealing material with a rotating wire brush only or heat material with a hot air blower to
max. 180C and remove with a spatula.
Ensure that all enclosed areas are well ventilated or are provided with direct extractor facilities.
1.3 Arc welding and brazing:
IMPORTANT: The extremely bright arc during welding may cause serious injury to the eyes if
appropriate protective measures are not taken.
Use a special welding screen for the relevant welding process (MAG or MIG).
Partition off the work bays with beam protection screens.
Use a welding-emissions extractor facility.
The welder must wear protective clothing and gloves which are suitable for welding (i.e. flameproof).
2010 BMW M3
A fire extinguisher must be located within reach of the welding area.

Do not carry out any welding work in the proximity of a fuel tank e.g. when it is installed.
1.4 Working with adhesive products (adhesives, cleaning agents, primers etc.):
IMPORTANT: Handling adhesives can trigger off allergic skin and breathing reactions.

Avoid direct contact with eyes and skin.
Wear protective goggles, protective gloves and if necessary an apron.
Ensure that all enclosed areas are well ventilated or are provided with direct adhesive fume extractor
facilities.
Work clothing which has been contaminated with adhesive or solvent must be changed immediately.
Always keep an eye bath on hand, change the water regularly (once a month).
Store adhesive products in a secure cabinet only.
Keep adhesive products away from naked flames and other ignition sources.
Protect adhesive products against strong heat sources and direct sunlight.
First Aid:
In the event of eye contact, flush immediately with running water for approx. 10-15 minutes and, if necessary,
visit eye specialist.
In the event of skin contact and where applicable an allergic skin reaction, clean the affected areas immediately
with soap and water and then apply silicone-free skin cream. If necessary, consult a doctor.
If an adhesive product is swallowed, rinse mouth/parts of mouth thoroughly with running water. Drink 1-2
glasses of water. Do not induce vomiting. Consult a doctor.
If adhesive fumes are inhaled, ensure a constant supply of fresh air, keep calm, keep respiratory tracts
unobstructed and consult a doctor.
41 00 ... SPOT-WELD BONDING STEEL PARTS
The spot-weld bonding process is used starting from the E65 to increase vehicle rigidity. In partial
bodywork areas, a 1-component adhesive is applied to the spot flanges and this is followed by resistance
pressure spot welding. The adhesive is hardened only after the paint drying process (at approx. 180C).
In the case of repairs, adhesive is not applied to the spot flanges. The number of welding spots is doubled
as a substitute for the omitted adhesive.
The following processes are used as a substitute for spot-weld bonding:
2010 BMW M3

welding).
Adhesive is not applied between the spot flanges on new parts in the case of 2- or multi-sheet joints.
Areas which cannot be reached by the spot-welding tongs can be joined by MAG spot welding. The
number of welding spots is doubled as a substitute for the omitted adhesive.
Exceptions (e.g. E65) are described in the relevant repair instructions. Apply welding spots to existing
welding spots on new part. This is necessary because the adhesive between the spot flanges of the new
part acts as an insulator.
CAUTION: Extract smoke and fumes during welding work.

41 00 ... STAMPING VEHICLE IDENTIFICATION NUMBER
41 0 000
41 1 140
41 1 141
41 1 142
See BODY - SPECIAL TOOLS .
Read and comply with General Information .
Remove front right spring strut . See 31 31 003 REMOVING AND INSTALLING COMPLETE
FRONT LEFT OR RIGHT SPRING STRUT (M3) .
Special tool kit 41 1 140 for stamping vehicle identification number consists of:
Counter-plate 41 1 142
2010 BMW M3
Fig. 34: Identifying Guide Plate And Counter-Plate

Position counter-plate 41 1 142 at bottom on spring strut dome.
Position guide plate 41 1 141 at top on spring strut dome and tighten bolts (1) by hand.
Fig. 35: Tightening Bolt With SST

Tighten bolt (1) until counterholder 41 1 142 rests on spring strut dome.
2010 BMW M3

Tighten screws (1).


Insert punch numbers 41 0 000 (1) individually into guide plate (2) and stamp
vehicle identification number.
2010 BMW M3
Fig. 38: Identifying Punch Numbers And Guide Plate


41 00 ... STRAIGHTENING STEEL PARTS
taps.
paintwork. This work requires a special tool (5 04 98 328) and a trained worker.
Avoid cracking.
2010 BMW M3

European used-car regulations prohibit the use of tin containing lead in
motor vehicles introduced after 01.07.2003!
3.0 Straightening structure
the vehicle.
diagram.
Bearing body components such as e.g. engine carriers, door pillars, frame side members etc. with
deformations which can no longer be returned to their original shape by "cold straightening" must be
replaced.
points.
If using vehicle-specific/universal straightening attachment sets (Carbench/ Celette), it is necessary to

secure the body additionally with 4 retaining clips to the spot flange of entrance or to the 4 jacking
points. The spot flange (if available) is to be preferred.
If using universal electronic or mechanical straightening systems (Car-O-liner/ Celette), it is necessary to

secure the body with 4 retaining clips to the spot flange of entrance or to the 4 jacking points. The spot
flange (if available) is to be preferred. In addition anchor at least 2 points with the securing set.
41 00 ... USE OF MATERIALS IN OUTER SHELL

2010 BMW M3
The following illustration is a schematic representation of all the body variants.
Apply this illustration to the relevant vehicle.
Fig. 39: Identifying Body Components

All components not listed in the table below are composed of established sheet steel qualities.
MATERIAL CHART
Component Vehicle Material
(1) Side panel, front E52 (Z8) Aluminum
E60, E61 Aluminum
E63, E64 Plastic (thermoplastic)
E65, E66: Aluminum
E70, E92, E93 Plastic (thermoplastic)
E89 Aluminum
(2) Front door E36/C (M3) Aluminum or steel
E36/2 (M3) Aluminum or steel
E52 (Z8) Aluminum
E63, E64 Aluminum
(4) Side panel, rear E52 (Z8) Aluminum
2010 BMW M3
(5) Engine hood E38 (750i) Aluminum or steel

E46/C (M3) Aluminum
(5) Engine hood E46/2 (M3) Aluminum
E52 (Z8) Aluminum
E60, E61, E63, E64 Aluminum
E65, E66, E70, E71 Aluminum
E85 (Z4) Aluminum
E92 (M3) Aluminum
E89 Aluminum
(6) Hardtop/ roof E36/C Aluminum
E36/7 (Z3) Plastic (glass fibre / epoxy resin)
E46/C Aluminum
E46/2 (M3 CSL) Plastic (CFK)
E52 (Z8) Plastic (PU)
E85 (Z4) Plastic (SMC)
E63 (M6) Plastic (CFK)
E89 Aluminum
(7) Soft top lid E46/C Magnesium
E64 Plastic (SMC)
(8) Rear lid E46/2 (M3 CSL) Plastic (SMC)
E52 (Z8) Aluminum
E63, E64 Plastic (SMC)
41 00 ... VEHICLE IDENTIFICATION NUMBER, GENERAL
The vehicle identification number must be stamped with a special tool. There are different special tool numbers
and stamping procedures for the various vehicles. Refer to the relevant repair instructions.
identification number at front and rear by stamping a + in place of the BMW emblem.
2010 BMW M3
Observe country-specific regulations.
41 00 ... WELDING AND SOLDERING STEEL PARTS
A. Welding steel parts:

Resistance pressure spot welding.
Take the number and location of weld spots and MAG weld seams from the separated part.
Replace areas inaccessible to spot-welding tongs with MAG plug/spot welds at the same
distance. Diameter of bores for plug/spot welds 8 mm.
In the case of emissions extraction, observe a minimum distance of 30 cm for MAG welding
during the welding process. Otherwise the inert gas would be drawn off.
2. Work materials
MAG welding:
Steel welding apparatus.
Steel welding wire - G3SI1 (SG2) or alternatively G4SI1 (SG3)
Welding mask
Gas bottle containing inert gas (82 % argon, 18 % CO )

2
Resistance pressure spot welding:

Spot-welding apparatus.
Protective goggles
3. Preparations for MAG and spot-welding

Remove the paint coating in an area of approx. 30 mm around the weld seam or spot.
The zinc coating underneath must be removed during the MAG welding operation.
It is not necessary to remove the zinc coating underneath during spot-welding.
Remove the paint coating on the reverse side of the weld seam or spot.
Contaminants will otherwise enter the weld pool via the root of the weld seam.
An insufficient electron flow prevents an optimum spot-weld joint.
Coat all metal overlaps and weld spot flanges with welding primer.
To determine the optimum electrode contact force for spot-welding, carry out spot-weld
shear tests on sample metal sheets.
In order to keep the electron flow short during MAG welding on the body, you must if
possible attach the ground terminal directly to the component to be welded.
4. Welding
2010 BMW M3
During MAG welding, the weld gap must be kept as small as possible. The larger the weld
gap, the lower will be the strength of the joint.
During spot-welding, the metal flanges to be joined must be placed as close together as
possible without gaps.
The larger the gap, the lower will be the strength of the joint.
Minimum gap between welding spots 25 mm.
5. Subsequent treatment of weld joints:

When grinding a weld seam, do not grind thin the base material next to the seam.
After joining, clean all weld seams and spots with a stainless steel wire brush.
All weld joints sealed off with body sealing compound in original state must be primed and
sealed off again thoroughly after repairing. Replace damaged or removed antinoise
compounds.
B. Soldering steel parts:
Gas brazing
Tinning
The MIG soldering procedure is not used in repairs for strength reasons. MIG
soldered/brazed seams used in series production are replaced in repairs by MAG weld seams.
Areas brazed in vehicle production are joined during repairs with the same procedure.
It is possible when straightening steel parts to correct irregularities smaller than 2 mm with
filler.
If in exceptional cases the irregularities are in excess of 2 mm, these areas must be tinned.
Only visible areas of the outer skin and on the support carrier must be tinned.

European used-car regulations prohibit the use of tin containing
lead in motor vehicles introduced after 01.07.2003!
2. Work materials
Gas brazing:
Tube pack and torch (gas torch)
Brazing solder
Gas bottles (oxygen and acetylene)

2010 BMW M3
Welding goggles

Tinning:
Tube pack and torch (torch for tinning)
Tinning paste
Tin.
Gas bottle (acetylene)
Protective goggles
3. Preparations for brazing/tinning

Heat brazed joints to be opened with an autogenous flame. Lift off remaining metal and
remove remaining brazing solder with a wire brush.
Remove the paint and zinc coating in an area of approx. 30 mm around the seam to be
soldered.
Remove the paint and zinc coating in the tin-plating area and approx. 30 mm beyond.
4. Brazing/tinning
Execute brazed seam without overheating the solder and with low heat dissipation. If
necessary, use heat protecting paste.
5. Subsequent treatment of brazed joints:
Remove burnt residual zinc completely. Straighten, grind and tin visible connection points.
41 00 ... WELDING IN REINFORCEMENT PLATE (STEEL PLATE)
A reinforcement plate is welded in to ensure sufficient strength.
Follow notes for welding steel parts .
NOTE: The following illustrations serve as general illustrations of reinforcement plate

repair work. They are applicable to all cutting repairs.
Mark component in accordance with distance A and cut.

2010 BMW M3
Fig. 40: Applying Mark On Part

Cut new part (1) in accordance with cut and if necessary adjust to fit with straightening attachment or universal
mount.
Installation:
Adhere to a gap at severance cut of approx. one to max. two material thicknesses in order to ensure welding
with the reinforcement plate and to facilitate a more tolerant fit.
Fig. 41: Identifying Cutting Part

Clean inner and outer sides of connecting areas (1) on new part and (2) on body.
Coat inner sides with welding primer.

2010 BMW M3
Fig. 42: Identifying Inner And Outer Sides Of Connecting Areas

Drill holes (1) and (2) at distance of 25 mm to each other.
Hole diameter approx. 8 mm.
Fig. 43: Identifying Holes

Make reinforcement plate (1) from trim of new part.
If necessary, make further reinforcement plates.
Length of reinforcement plates is min. 40 mm.
Coat reinforcement plates (1) and (2) on both sides with welding primer.
2010 BMW M3
Fig. 44: Identifying Reinforcement Plates

Push reinforcement plate (1) into component on body up to half way and plug-weld (3).
Fig. 45: Identifying Reinforcement Plate And Holes

If necessary, adjust new part (1) to fit with straightening attachment or universal mount and plug-weld (2).
MAG weld joint (3).
Grind and clean weld seam and plug weld spots.
Only visible areas of the outer skin and worn areas on the support carrier must be tinned.

European used-car regulations prohibit the use of tin containing lead in motor
vehicles introduced after 01.07.2003!
2010 BMW M3
Fig. 46: Identifying Plug-Weld And MAG Weld Joint

41 00 ... WORKING WITH 2-COMPONENT PU CAVITY FOAM

Ideal for use as insulating and sealing compound
Information on dangers/hazards:
Do not inhale.

(buildup of heat)!
2010 BMW M3

Application instructions:
Use by date on can.
clean and free from
dust,
grease,

waste.

41 00 ... WORKSHOP EQUIPMENT
Minimum workshop equipment requirements in order to ensure the correct and expert performance of body
repairs:
2010 BMW M3
WORKSHOP EQUIPMENT CHART

Steel Aluminum
Tool Structure Outer skin Structure Outer skin
Bodywork tool x x
assortment
Aluminum x x
bodywork tool
assortment
Bodywork saw x x
grinder
Welding spot x x
remover
MAG welding x x
apparatus
MIG welding x (E52 only)
apparatus
Spot welding x x
apparatus
Gas welder x
Straightening x x
system
Stud welding x
apparatus
Flame coating set x
Universal riveting x
tool
IMPORTANT: In vehicles from model year 2001, higher-tensile and high-tensile steels are
used in certain areas.
It is essential to check whether the spot-welding apparatus used conforms to
the technical requirements of the currently recommended welding sets. Should
you have any questions, please contact the country-specific Hotline.
The use of technically obsolete equipment may have serious consequences for
the structure of the vehicle (e.g. in the event of a crash). In the end, this can
result in safety and product liability risks which cannot be calculated.
Use and restrictions:
Definition of Recommendation:
All currently recommended spot welding sets comply with the requirements relating to reliable welding of
today's and future BMW Group vehicles. A spot welding unit will loose its recommendation as soon as tests
with materials and material combinations designated for future use in BMW Group vehicles return negative
2010 BMW M3
results. All previous application before the withdrawal of the recommendation shall remain unaffected.
MANUFACTURER CHART
Device designation Manufacturer
CR500 Car-O-Liner
Group 1
Spot9000 Tecna
Devices currently no longer recommended
ATL 400V Wielander&Schill
MIDIspot QSVM9000 Celette
Group 2 MIDIspot QSVM9000 Elmatech
Devices currently recommended
(March 2007) CR600 Car-O-Liner
Multispot MI-100 Control Elektron
Application options and restrictions of above devices.
VEHICLE INFORMATION
Vehicle Group 1 Group 2
x
E93 x
x
E70 x
Except B-pillar
x
E64 x
NOTE: (March 2007)

All models not listed can be repaired using the Group 1 and Group 2 devices.
41 05 800 RELEASING BONDED FOLDED SEAM CONNECTIONS

2010 BMW M3
Fig. 47: Identifying Bead Edge On Wheel Arch Bend

Remove area (1) of bead edge on wheel arch bend with a one-hand angle grinder and rough grinding
wheel.
Heat area (2) with hot air blower.

Grind adhesive residue (4) off wheel arch connection flange.
Remove remnants of sealing material in area (3).
99 00 ... GENERAL INSTRUCTIONS ON PAINTING
General instructions and classification of paint stages are described on the KSD-CD (notes-general information
on flat rate unit data, passenger car explanation for FR specifications for painting).
2010 BMW M3
The marked area serves as the starting point for painting. This area may differ from the illustration for technical
painting reasons.
Touching-up areas are taken into account.
SUPPORT MEMBERS
Use only approved spot-welding apparatus for repairs.

Fig. 48: Identifying Wheel Arch And Support Carrier

Installation:
Apply window glass adhesive to cavity acoustic baffle (3).

2010 BMW M3
Fig. 49: Identifying Weld Joints Area And Cavity Acoustic Baffle
Mark severance cut (1) in accordance with measurement a and cut engine carrier.
Installation:
Weld in reinforcing panels at all severance cuts.
Fig. 50: Identifying Cut Area


2010 BMW M3


Installation:
Join both parts by spot-welding.

2010 BMW M3
Fig. 53: Identifying Weld Joint Areas And Compartment Partition Wall


2010 BMW M3

Take off holder.

Installation:

2010 BMW M3
Fig. 57: Identifying Universal Mount

Fig. 58: Identifying Additional MAG Weld Seams

Installation:
Vehicles with spring support plate insert:
Version (A) riveted

Version (B) screwed
Riveted version:
2010 BMW M3
Fig. 59: Identifying Spring Support Plate

41 11 028 REPLACING LEFT ENGINE CARRIER (PARTIAL REPLACEMENT BEFORE FRONT

AXLE)
(1) Partial section, engine carrier
Fig. 60: Identifying Partial Section, Engine Carrier

Mark severance cut (1) in middle of 20 mm dia. bore and cut.

2010 BMW M3
Installation:
Adjust all new parts to fit with straightening attachment or universal mount.
Weld in reinforcement plate at severance cut.
Fig. 61: Identifying Cut Mark

Take off holder.

2010 BMW M3
41 11 043 REPLACING FRONT SECTION OF LEFT ENGINE SUPPORT
(1) Engine carrier, front
Fig. 63: Identifying Engine Carrier, Front

Mark severance cut (1) in accordance with measurement a and cut engine carrier.
Installation:

2010 BMW M3
Fig. 64: Identifying Cut Area



2010 BMW M3


Take off holder.

2010 BMW M3

Installation:
Fig. 69: Identifying Universal Mount

2010 BMW M3
Fig. 70: Identifying Area Additional MAG Weld Seams


Fig. 71: Identifying B-Pillar With Entrance

2010 BMW M3
Fig. 72: Identifying Shaped Part, B-Pillar, Inner

Installation:

2010 BMW M3
Installation:
Fig. 73: Identifying Cut Mark Area



2010 BMW M3

Fig. 75: Identifying Adhesive Bonds Area



2010 BMW M3

41 11 141 REPLACING COVER FOR LEFT OR RIGHT FRAME SIDE MEMBER (PARTIAL
REPLACEMENT BETWEEN A-AND B-PILLARS)

2010 BMW M3
(1) Side frame, outer

(2) Shaped part, entrance (not shown)
Fig. 78: Identifying Side Frame, Outer

Fig. 79: Identifying Side Frame And Shaped Part

Mark severance cuts (1) in accordance with specified measurements and cut.
Measurement a = approx. 85 mm behind A-pillar

2010 BMW M3
Measurement b = approx. 35 mm before side panel at rear
Installation:
Weld reinforcement plates at all severance cuts (1).
41 11 516 REPLACING FRONT LEFT OR RIGHT SUPPORT CARRIER (PARTIAL

Fig. 80: Identifying Support Carrier, Wheel Arch, Outer

Mark severance cut in accordance with measurement a and cut support carrier.
Measurement a=240 mm from edge of rectangular hole.
Installation:

2010 BMW M3

Installation:

41 11 734 REPLACING COMPLETE REAR TENSION STRUT MOUNTING
(1) Bracket, tension strut, rear

2010 BMW M3
Fig. 83: Identifying Bracket, Tension Strut, Rear

Open weld joints in areas (2) on both sides of rear axle carrier (3).
To adjust new part to fit, screw down tension strut.
If vehicle is on straightening bench, adjust new part to fit with straightening attachment or universal mount.
Fig. 84: Identifying Weld Joint Areas And Rear Axle Carrier
41 11 915 REPLACING INNER LEFT OR RIGHT FRAME SIDE MEMBER COVER PARTIAL
REPLACEMENT
2010 BMW M3
Spot-weld bonding is used on this vehicle. Observe specific procedure .
Use only approved spot-welding apparatus for repairs!
(1) Inner side frame
Fig. 85: Identifying Inner Side Frame

Fig. 86: Identifying Inner Side Frame Dimension

2010 BMW M3
Remove cavity bulkhead (1).
Measurement a = approx. 30 mm after frame side member cover severance cut.
Measurement b = approx. 30 mm before frame side member cover severance cut.
Installation:
Replace adhesive in areas (3) with MAG weld seams from underside of vehicle.
Length of weld seams 20 mm with 15 mm distance.
Maintain a distance of 3 mm at severance cuts.
Adjust new part to fit and weld severance cuts.
Installation:
Grind weld seam (1) in area of reinforcement plate (2).
Make 40 mm wide reinforcement plate (2) and adjust to fit.
Weld reinforcement plate (2) with 20 mm long MAG weld seams at distance of 15 mm on both sides.
Repeat procedure at 2nd severance cut.

2010 BMW M3
Fig. 87: Identifying Weld Seam And Reinforcement Plate

LUGGAGE COMPARTMENT FLOOR

41 12 535 REPLACING COMPLETE REAR LUGGAGE COMPARTMENT FLOOR (TAIL PANEL
REMOVED)

(2) Frame side member, left
(3) Frame side member, top left
(5) Frame side member, top right
(6) Frame side member, right
(7) Luggage compartment floor, right
2010 BMW M3
Fig. 88: Identifying Luggage Compartment Floor, Frame Side Member And Frame
Mark severance cuts (1) at edge of 20 mm dia. bore.
Cut frame side member (2).
Installation:
Weld in reinforcement plates at severance cuts.
Fig. 89: Identifying Frame Side Member And Cut Mark

Installation:
2010 BMW M3


Touring only:

2010 BMW M3

Installation:
Weld new component in area (2) additionally.
Fig. 93: Identifying Weld Joint Areas And Component Area

41 12 560 REPLACING LUGGAGE COMPARTMENT FLOOR (COMPLETE WITH BOTH INNER

2010 BMW M3

(4) Wheel arch, rear, inner half, right
Touring only:
(5) Bracket, tension strut, rear (2 x) (not shown)
Fig. 94: Identifying Luggage Compartment Floor, Rear Axle Carrier And Wheel Arch
Installation:

2010 BMW M3
Fig. 95: Identifying Frame Side Member

Installation:
Fig. 96: Identifying Cut Mark Area And Weld Joint Areas
2010 BMW M3
Installation:


2010 BMW M3
Installation:
Fig. 99: Identifying Weld Joint Areas And Weld New Components Areas
Touring only:
Installation:

2010 BMW M3
clarity.

clarity.

2010 BMW M3
Installation:

Mark severance cuts (1) in accordance with measurement and cut.

2010 BMW M3
Installation:
Weld in reinforcement plate at severance cuts.

Installation:
The parts separated by cutting are still needed.

2010 BMW M3
Fig. 106: Identifying Weld Joint Areas And Cut Mark


2010 BMW M3
Installation:
The parts (2) separated by cutting are still needed.


2010 BMW M3
Fig. 109: Identifying Cut Mark And Weld Joint Areas

Installation:

Fig. 110: Identifying Rear Axle Carrier, Luggage Compartment Floor, Wheel Arch And Mounting
clarity.
Installation:
2010 BMW M3
Fig. 111: Identifying New Component Areas

Installation:
Touring only:
Adjust new parts (1) to fit with tension strut and weld.
Fig. 112: Identifying New Parts

41 12 590 REPLACING LUGGAGE COMPARTMENT FLOOR (COMPLETE WITH LEFT OR

RIGHT INNER WHEEL ARCH SECTION, TAIL PANEL REMOVED)

2010 BMW M3

Touring only:
(4) Bracket, tension strut, rear (not illustrated)
Fig. 113: Identifying Luggage Compartment Floor, Rear Axle Carrier And Wheel Arch
Installation:
Fig. 114: Identifying Frame Side Member

2010 BMW M3
Installation:

Installation:

2010 BMW M3


Installation:

2010 BMW M3
Fig. 118: Identifying Weld Joint And New Component Areas

Touring only:
Installation:
Fig. 119: Identifying Weld Joint And New Component Areas

clarity.
2010 BMW M3

clarity.
Installation:
Fig. 121: Weld New Components Areas

clarity.
Mark severance cut (1) centrally and cut.

2010 BMW M3
Cut floor pan and cross-member underneath.

Installation:

2010 BMW M3

Installation:
The cut part is not needed.

Fig. 125: Open Weld Joint Areas And Severance Cut Area
2010 BMW M3
Fig. 126: Identifying Weld Joint Areas To Be Opened

Installation:
The cut part (2) is not needed.
Fig. 127: Open Weld Joint Areas; Cut Part Is Not Needed

2010 BMW M3
Fig. 128: Open Weld Joints & Mark Severance Cut

Installation:

Fig. 129: Identifying Wheel Arch, Support, Luggage Compartment Floor And Rear Axle Carrier
clarity.
2010 BMW M3
Installation:
Fig. 130: Fit New Component From Above In Area (1)

Installation:
Touring only:
Adjust new part (1) with tension strut to fit and weld.
Fig. 131: Adjust New Part (1) With Tension Strut

WHEEL WELLS
2010 BMW M3
REMOVED)

Fig. 132: Identifying Wheel Arch And C-Pillar Reinforcement

2010 BMW M3
Fig. 133: Identifying Wheel Arch, Rear Entrance Shaped Part And C-Pillar Reinforcement
Installation:
Apply window glass adhesive to cavity acoustic baffles (3).

2010 BMW M3
Fig. 134: Identifying Weld Joint Areas And Cavity Acoustic Baffles
Installation:

2010 BMW M3
Fig. 135: Identifying Weld Joint Areas And Spot Flange Area
REMOVED)

2010 BMW M3
Fig. 136: Identifying C-Pillar Reinforcement, Wheel Arch, And Support

Fig. 137: Identifying Spot-Welding Flanges With Support Strut

2010 BMW M3
Fig. 138: Identifying Weld Joint Areas And Cut Mark Area
Installation:

2010 BMW M3
Fig. 139: Identifying Weld Joint Areas And Cut Mark Area
Installation:
Installation:

2010 BMW M3

Installation:

Installation:

2010 BMW M3
Fig. 143: Identifying Weld Joint Areas And Plug Weld Areas
SIDE FRAME AND DOOR


2010 BMW M3
(1) A-pillar, outer

Fig. 144: Identifying A-Pillar And Support Carrier

2010 BMW M3
Fig. 145: Identifying Support Carrier Dimension

Measurement b = approx. 160 mm from centrepoint of 12 mm dia. bore.
Installation:

2010 BMW M3
Fig. 146: Identifying Weld Joint Areas And Cavity Acoustic Baffles
Installation:

2010 BMW M3

Fig. 148: Identifying Weld Joint Areas And Sunroof Water Drain Hose

2010 BMW M3
Fig. 149: Identifying Weld Joint Areas And Adhesive Bond Area
Installation:
Apply adhesive in area (2).
Fig. 150: Identifying Cavity Acoustic Baffle And Adhesive Area

2010 BMW M3
41 21 540 REPLACING FRONT LEFT OUTER DOOR PILLAR SECTION
Use only approved spot-welding apparatus form repairs!
Remove front side panel

(2) Door hinge, top left
(3) A-pillar, outer
Fig. 151: Identifying Support Carrier, Door Hinge And A-Pillar


2010 BMW M3


Mark severance cut at top in accordance with specified measurement and cut.
2010 BMW M3
Measurement a = approx. 175 mm from edge of cowl panel.
Severance cut (1) at bottom through 20 mm dia. bore hole.
Installation:
Installation:

Installation:
MAG-weld hinge in area (1).

2010 BMW M3
Fig. 155: Identifying MAG-Weld Hinge Area

ROOF OUTER SKIN

41 31 010 REPLACING ROOF OUTER SKIN (VERSION WITH SLIDE/TILT SUNROOF)
(1) Roof outer skin, slide/tilt sunroof
Fig. 156: Identifying Roof Outer Skin, Slide/Tilt Sunroof

Release 4 screws (1) in roof channel.

2010 BMW M3
Fig. 157: Identifying Screws In Roof Channel


Release adhesive areas (layout, see next operation) and remove roof outer skin.
2010 BMW M3
Installation:
Fit new part on body. Fit windscreen for positioning.
Seal weld seams and screws with sealing compound.
Fig. 159: Identifying Sealing Compound Area And Adhesive Areas

Apply sealing compound in areas (2).
DASH COWL
41 32 010 REPLACING COMPLETE COWL PANEL

2010 BMW M3
Remove front side panel

(2) A-pillar, outer
Fig. 160: Identifying Support Carrier And A-Pillar


2010 BMW M3
Fig. 161: Identifying Weld Joint Areas (1 Of 2)

Fig. 162: Identifying Weld Joint Areas (2 Of 2)


2010 BMW M3
Measurement a = approx. 175 mm from edge of cowl panel.
Installation:
FRONT TRIM PANEL

41 33 040 REPLACING FRONT WALL
Remove carrier for bumper trim . See 51 11 050 REMOVING AND INSTALLING/REPLACING
CARRIER FOR FRONT BUMPER TRIM .
IMPORTANT: Car must not be driven without the front wall.

Driving without the front wall may damage the body structure.
(1) Front panel

(2) Headlight holder, left
(3) Headlight holder, right
Fig. 163: Identifying Front Panel And Headlight Holder

Carry over the following work steps symmetrically to the other side of the car.
NOTE: View, front side panel, in direction of travel

2010 BMW M3
Release screw (1).
Tightening torque 41 33 3AZ , see 41 33 FRONT TRIM PANEL .
Fig. 164: Identifying Screw

Release screws (1).
Remove front panel (2) together with headlight holder (3).
Replacement:
Release screws (4) and remove headlight holder.

2010 BMW M3
Fig. 165: Identifying Front Panel, Headlight Holder And Screws

REAR TRIM PANEL

41 34 041 REPLACING COMPLETE TAIL PANEL
(1) Rear trim
Fig. 166: Identifying Rear Trim

Fig. 167: Identifying Weld Joints Area And Brazed Joint Areas
2010 BMW M3

Remove reinforcements (2).
NOTE: This work step is omitted if the rear side panels are replaced at the same time.
Fig. 169: Identifying Weld Joint Areas And Reinforcements

Installation:
Slide in rear trim (1) from bottom upwards.

2010 BMW M3
Fig. 170: Identifying Rear Trim

SIDE PANELS
41 35 010 REMOVING AND INSTALLING/REPLACING SIDE PANEL, FRONT LEFT OR RIGHT
Gap dimensions serve as basis for adjustment tasks.

2010 BMW M3
Fig. 171: Identifying Bolt Locations

Interior view of front side panel
Unfasten screws.
Tightening torque 41 35 1AZ , see 35 SIDE PANELS .
41 35 101 REPLACING REAR LEFT SIDE PANEL (PARTIAL REPLACEMENT, LONGITUDINAL

MEMBER COVER BEFORE B-PILLAR)
(1) Side panel, rear

2010 BMW M3
Fig. 172: Identifying Side Panel, Rear



2010 BMW M3
Measurement a = approx. 100 mm from roof edge
Measurement b = approx. 375 mm from centrepoint of hole dia. 25 mm.

Fig. 174: Identifying Cut Mark Area And Brazed Joint Areas
41 35 101 REPLACING REAR LEFT SIDE PANEL

2010 BMW M3

Open brazed joint in area (2).
Fig. 176: Identifying Weld Joint Areas And Brazed Joint Area

2010 BMW M3
Open MIG soldered joints in area (1).
Installation:
MAG-weld new part in area (1).

2010 BMW M3
Fig. 179: Identifying MAG-Weld Area

Installation:
When sealing in area (2), ensure sufficient clearance for outer window cavity cover strip.
Fig. 180: Identifying Brazed Joint Area And Sealing Area

41 35 102 REPLACING REAR LEFT SIDE PANEL (PARTIAL REPLACEMENT BEFORE

LONGITUDINAL MEMBER COVER)
(1) Partial section, rear side panel

2010 BMW M3
Fig. 181: Identifying Partial Section, Rear Side Panel


Measurement a = 100 mm from roof edge

2010 BMW M3
Measurement b = approx. 90 mm from middle of lower lock striker screw point

Open brazed joint in areas (2).
Fig. 183: Identifying Cut Mark Area And Brazed Joint Areas
41 35 102 REPLACING REAR LEFT SIDE PANEL (PARTIAL REPLACEMENT BEHIND WHEEL
ARCH)

2010 BMW M3

Mark severance cut (1) in accordance with measurement a and cut.
Measurement a =240 mm from corner of side panel


2010 BMW M3
Fig. 186: Identifying Weld Joint Areas And Brazed Joint Areas
Fig. 187: Identifying Weld Joint Areas And Brazed Joint Areas

2010 BMW M3

Mark new part in accordance with severance cut (1) on car and cut.

Installation:
Procedure deviating from standard:
Make 15 mm wide reinforcement plate (1).
Adjust new part (2) to fit in conjunction with rear lid.

2010 BMW M3
Bring reinforcement plate from inside into contact with side panel.
Set tacking points in area of severance cut (3) from outer side. In so doing, exert pressure from inner side on
reinforcement plate to enlarge gap at severance cut (3) by approx. 0.5 mm. This reduces warpage in the welding
area.
Weld severance cut completely.
Fig. 190: Identifying Reinforcement Plate

41 35 401 REPLACING REAR LEFT SIDE PANEL (PARTIAL REPLACEMENT, DOOR OPENING)

2010 BMW M3

Measurement a = approx. 90 mm from middle of lower lock striker screw point
Measurement b = approx. 375 mm from centrepoint of 25 mm dia. hole

FRONT SIDE DOORS

41 5. ... ADJUSTING DOOR
2010 BMW M3
Minor corrections (realignment work) are permitted if the existing

adjustment options are not sufficient.
NOTE: Observe gap dimensions .
The following illustrations are schematic representations and are to be applied to the relevant vehicle type.
Tightening torque 41 51 2AZ , see 51 FRONT SIDE DOORS .
Tightening torque 41 52 2AZ , see 52 REAR SIDE DOORS .
Fig. 193: Slacken Nuts (1 Of 2)

2010 BMW M3

Installation:
When the door is closed, the lock striker must not touch or scrape against the door lock. Look out for scratches.
2010 BMW M3
Fig. 195: Adjusting Door

Tightening torque 51 21 2AZ , see 51 21 FRONT DOOR LOCKS .
Fig. 196: Adjusting Lock Striker Sideways

After installation:

2010 BMW M3
41 5. ... REMOVING AND INSTALLING DOOR
Open door.
Front door:
Rear door:
Fig. 197: Locating Screw On Connector Frame

Front door:
Rear door:
Tightening torque 51 22 3AZ , see 51 22 REAR DOOR LOCKS .

2010 BMW M3

Front door:
Rear door:
Fig. 199: Identifying Hinge Bolts

2010 BMW M3
Fig. 200: Pulling Out Door Sideways

Installation:
If necessary, adjust door .

41 51 ... REPLACING DOOR HINGE BUSHING (DOOR REMOVED)
41 1 150
2010 BMW M3
41 1 151
41 1 152
Special tool kit 41 1 150 comprises:
Bushing 41 1 151
Bolt 41 1 152
Fig. 202: Identifying Bushing And Bolt

Fig. 203: Identifying Hinge Bushing Area

2010 BMW M3
Insert bolt 41 1 152 with new hinge bushing (2) into hinge.
Screw bushing 41 1 151 with flat end (3) pointing upwards onto bolt 41 1 152 .
Turn bushing 41 1 151 until taper (1) borders hinge bushing (2).
Screw off bushing 41 1 151 again.
Fig. 204: Identifying Hinge Bushing And Bolt

Twist bushing 41 1 151 with flat end (1) onto bolt 41 1 152 .
Fig. 205: Identifying Flat End And Gap Dimensions

2010 BMW M3
REAR SIDE DOORS

41 5. ... ADJUSTING DOOR
Minor corrections (realignment work) are permitted if the existing

adjustment options are not sufficient.
NOTE: Observe gap dimensions .
The following illustrations are schematic representations and are to be applied to the relevant vehicle type.

2010 BMW M3

Installation:

2010 BMW M3
Fig. 208: Adjusting Door

Fig. 209: Slacken Screws (1) Until Lock Striker Can Still Just Be Moved
After installation:

2010 BMW M3
41 5. ... REMOVING AND INSTALLING DOOR
Open door.
Front door:
Rear door:
Fig. 210: Locating Screw On Connector Frame

Front door:
Rear door:

2010 BMW M3

Front door:
Rear door:
Fig. 212: Identifying Hinge Bolts

2010 BMW M3
Fig. 213: Pulling Out Door Sideways

Installation:
If necessary, adjust door .

41 51 ... REPLACING DOOR HINGE BUSHING (DOOR REMOVED)
41 1 150
2010 BMW M3
41 1 151
41 1 152
Special tool kit 41 1 150 comprises:
Bushing 41 1 151
Bolt 41 1 152
Fig. 215: Identifying Bushing And Bolt

Fig. 216: Identifying Hinge Bushing Area

2010 BMW M3
Insert bolt 41 1 152 with new hinge bushing (2) into hinge.
Screw bushing 41 1 151 with flat end (3) pointing upwards onto bolt 41 1 152 .
Turn bushing 41 1 151 until taper (1) borders hinge bushing (2).
Screw off bushing 41 1 151 again.
Fig. 217: Identifying Hinge Bushing And Bolt

Twist bushing 41 1 151 with flat end (1) onto bolt 41 1 152 .
Fig. 218: Identifying Flat End And Gap Dimensions

2010 BMW M3
FRONT LID
41 61 000 REMOVING AND INSTALLING HOOD/BONNET
Disconnect all cable plug connections
IMPORTANT: For the following work step, secure the engine hood against falling closed.
Disconnect gas-pressure damper from engine hood (1).
Loosen screws (2).
Release screws (3).
Tightening torque 41 61 1AZ , see 61 FRONT LID .
NOTE: This work step must be carried out with a second person assisting.
Fig. 219: Identifying Engine Hood And Screw

Remove hood lid.
Installation:
Install engine hood at screw locations to on hinge. This dispenses with the need for adjustment after installation.
If this is not possible, adjust engine hood .
41 61 014 ADJUSTING ENGINE BONNET/HOOD

2010 BMW M3
The specified gap dimensions serve as the basis for adjustment tasks.
Make unpainted surfaces visible by also moving the hinges.
Touch these up in the appropriate color.
Loosen screws (1) and (2) on left and right hinges.
Hood lid must be able to be moved.
NOTE: If the adjustment range is not sufficient, release retaining screws of engine
hood hinge on body and move hinge.
Fig. 220: Identifying Hinge Screws

Locks and retaining hook must snap correctly into place.
Adjust engine hood.
NOTE: Vertical adjustment of engine hood to side panel by means of stop pads.
2010 BMW M3
Fig. 221: Locating Stop Pads

NOTE: Height adjustment of bonnet to front wall:

Height adjustment by turning at closing hooks (3).
Fig. 222: Identifying Screw, Hooks And Cover

Tighten down all screw connections again.
Tightening torque 41 61 1AZ , see 61 FRONT LID .
IMPORTANT: Check function of retaining hook.
REAR LID
41 62 000 REMOVING AND INSTALLING REAR LID (CONVERTIBLE)
2010 BMW M3
00 9 450
54 0 180
Remove trim from tail panel . See 51 46 050 REMOVING AND INSTALLING/REPLACING TOP
TRIM ON REAR APRON .
Remove both gas-filled struts . See 51 24 300 REMOVING AND INSTALLING OR REPLACING
LEFT OR RIGHT GAS STRUT FOR REAR LID .
Unlock plug connections (1) without locking bar.
Fig. 223: Identifying Plug Connections
Cut through cable straps.

2010 BMW M3
Fig. 224: Identifying Cable Straps
Release screws and remove cable duct (1).
Fig. 225: Identifying Screws And Cable Duct
Release screw.
Tightening torque 19 Nm.
Slacken hexagon nut (1).
Twist out barrel screw (2) until wiring harness can be removed between body and frame (3).
Installation:
Bring barrel screw into contact with special tool 54 0 180 in conjunction with special tool 00 9 450.
Tightening torque 20 cNm (20 cNm = 0.2 Nm)

2010 BMW M3
Fig. 226: Identifying Hexagon Nut And Barrel Screw
Release bolts (1).
Tightening torque 41 62 1AZ, see 62 REAR LID .
Remove rear lid.
Installation:
Install rear lid at screw locations on hinge.
This dispenses with the need for adjustment after installation.
If necessary, adjust rear lid .
Fig. 227: Identifying Bolts
41 62 000 REMOVING AND INSTALLING REAR LID
Remove panel for rear lid . See 51 49 000 REMOVING AND INSTALLING/REPLACING PANEL
FOR REAR LID .
Disconnect all plug and socket cable connections on rear lid.
Slacken screws (1)

2010 BMW M3
Tightening torque 41 62 1AZ , see 62 REAR LID .
Remove rear lid.
Installation:
Adjust rear lid.
Fig. 228: Identifying Screws

41 62 014 ADJUSTING REAR LID
The gap dimensions serve as the basis for adjustment work.
Make unpainted surfaces visible by also moving the hinges.
Touch these up in the appropriate color.
Slacken screws (1) and (2) on rear lid hinge to rear lid until such stage that rear lid can still be moved.
Adjust rear lid.

2010 BMW M3
Fig. 229: Slacken Screws (1) And (2) On Rear Lid Hinge
Adjusting height of rear lid in relation to side panel:
Slacken screws (1) on rear lid hinge to side panel until such stage that rear lid can still be moved.
Adjust rear lid.
Adjust rear lid lock .
Fig. 230: Slacken Screws (1) On Rear Lid Hinge To Side Panel
41 62 520 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT HINGE FOR REAR LID
2010 BMW M3
Release screws (1).
Remove hinge (2).
Adjust rear lid on the basis of the body gap dimensions .
Replacing hinge only:
Remove gas-filled strut for rear lid.. See 51 24 300 REMOVING AND INSTALLING OR REPLACING
LEFT OR RIGHT GAS STRUT FOR REAR LID .
Fig. 231: Identifying Hinge And Screw

OTHER FLAPS
41 63 000 REMOVING AND INSTALLING FLAP FOR FUEL FILLER NECK

Open fuel filler flap.
Lever out lock (2) and detach fuel filler flap (1) in direction of arrow.
2010 BMW M3
Fig. 232: Identifying Lock And Fuel Filler Flap

41 63 003 REPLACING COVER BOWL (CONVERTIBLE)
00 9 321
Remove flap for fuel filler neck.

Remove servodrive for tank filler flap . See 67 11 555 REMOVING AND
INSTALLING/REPLACING SERVODRIVE FOR TANK FILLER FLAP (CONVERTIBLE) .
IMPORTANT: Deformation of the sheet metal flanges in the side panel and the wheel arch
results in permanent vehicle leakage. Carry out removal/installation with great
care.
(1) Filler bowl

2010 BMW M3
Fig. 233: Identifying Filler Bowl
Press retaining strap (1) inwards and lift out.
Pierce cover bowl at markings (3) with a small screwdriver.
Remove cover (2).
Fig. 234: Identifying Retaining Strap And Cover
Lift rubber collar (1) over plastic tabs in areas (2).
Release rubber collar (1) from cover bowl (3) by pressing inward.
NOTE: Rubber collar (1) remains attached to vehicle.

2010 BMW M3
Fig. 235: Identifying Rubber Collar, Plastic Tabs And Cover Bowl
Insert screwdriver to a depth of max. 5 mm and unlock cover bowl catch.
Fig. 236: Unlocking Cover Bowl Catch
Keep cover bowl tensioned with pliers (2).
Unlock catches individually with screwdriver (1).
Unlock catches in following order:
1. Top left
2. Bottom left
3. Top right
4. Bottom right
Move screwdriver in opposite direction at both lower catches.

2010 BMW M3
Fig. 237: Unlocking Catches With Screwdriver
Close hinge arm (1).
IMPORTANT: Do not damage sheet metal flange of side panel.
Carefully twist out cover bowl (2) at first at rear in direction of arrow from side panel and remove.
Fig. 238: Identifying Hinge Arm And Cover Bowl
Installation:
Fit approx. 0.5 m long cable (1) in groove on rubber collar (2).
2010 BMW M3
Fig. 239: Identifying Cable And Rubber Collar
Installation:
Install cover bowl (1).
Thread ends of cable (2) outwards.
Align bottom rubber collar (3) with recess.
Pull rubber collar (3) over the cover bowl by pulling the ends of cables (2).
Fig. 240: Identifying Cover Bowl And Rubber Collar
Installation:
Slowly pull out cable ends (2).
Press rubber collar (1) into groove with special tool 00 9 321.
2010 BMW M3
Fig. 241: Identifying Rubber Collar And Cable Ends
Installation:
Cover bowl must snap into place 4 times.
After installing, carefully check cover bowl at clips for secure fit.
There must be no discernible gap between sealing lip and side panel in area (4).
Check secure fit of rubber collar (1) in areas (2).
Fig. 242: Identifying Rubber Collar
Remove flap for fuel filler neck.

Remove servodrive for tank filler flap . See 67 11 555 REMOVING AND INSTALLING /
REPLACING SERVODRIVE FOR TANK FILLER FLAP (COUPE/SEDAN) .
2010 BMW M3
Remove front wheel arch cover (rear section) .
Unscrew nut (1).
Installation:

Installation:
Release nuts (1).

2010 BMW M3
Fig. 245: Identifying Cover

Remove cover (2).
Installation:

2010 BMW M3
Fig. 246: Identifying Retaining Strap And Cover

Installation:
Fig. 247: Identifying Catches, Ejector And Protective Cap

Installation:

2010 BMW M3
Fig. 249: Identifying Hinge Arm And Cover Bowl

Installation:
1. Rubber pad
3. Spring
4. Catch
5. Guide
Fig. 250: Identifying Rubber, Pad Catches, Spring, Catch And Guide
2010 BMW M3
54 0 240 , See Fig. 251.
Connect charger.
Open rear end module.
Clip special tool 54 0 240 onto hydraulic cylinder on left and right.
IMPORTANT: The opening in the assembly support must face towards the rear of the
vehicle.
Risk of damage!
Remove special tool after completing work.
Fig. 251: Identifying Special Tool (54 0 240)

Open rear lid with ignition key.

2010 BMW M3
Fig. 252: Opening Rear Lid With Ignition Key

Tape off rear lid (1) in area shown (2) on both sides with plastic adhesive tape.
Fig. 253: Tape Off Rear Lid (1) In Area Shown (2) On Both Sides With Plastic Adhesive Tape
Pay attention to spacer plates.
Release screws (2). Tightening torque 41 63 1AZ, see 41 63 CONVERTIBLE TOP COMPARTMENT LID .
Remove convertible top compartment lid (3).
Installation:
2010 BMW M3
To pre-adjust, mount the convertible top compartment lid at the screw impressions on the hinge.
Adjust convertible top compartment lid .
Fig. 254: Identifying Convertible Top Compartment Lid And Screw

41 63 068 ADJUSTING CONVERTIBLE TOP COMPARTMENT LID
The E93 gap dimensions serve as the basis for adjustment work.
Connect charger.
NOTE: Carry out adjustment first vertically, then longitudinally and laterally.
Work sequence starts with convertible top closed.
Height adjustment
Open convertible top compartment lid (3).
Slacken nuts (2). Pay attention to spacer plates (1).
Adjust convertible top compartment lid (3) to side panels by means of spacer plates (1).
Tightening torque 41 63 1AZ, see 41 63 CONVERTIBLE TOP COMPARTMENT LID .

2010 BMW M3
Fig. 255: Identifying Convertible Top Compartment Lid And Screw

Longitudinal and lateral adjustment
Open convertible top until rear module (1) is opened approx. 10 cm.
Stop opening operation in the position shown.
Fig. 256: Identifying Rear Module

Close rear end module (1) again.
Stop closing operation when the coupling fastener has locked the rear end module (1).
The correct position is reached when the rear end module (1) is flush with the side panel in area (2). If
necessary, repeat procedure.
2010 BMW M3
Fig. 257: Identifying Rear End Module And Side Panel

NOTE: In event of excessive height difference between convertible top compartment lid
and rear lid in area shown:
Tilt convertible top compartment lid in rear area downwards.
To do so, remove spacer plates from middle and rear screw fastening points.
Fig. 258: Identifying Spacer Plates

IMPORTANT: For purposes of clarity, picture shows and description refers to the opened
convertible top compartment lid.
However, adjustment in the longitudinal direction and to the side is carried out
with the convertible top compartment lid closed from the luggage
compartment.
Open rear lid with ignition key.

2010 BMW M3
Slacken nuts (2).
Adjust convertible top compartment lid (3) longitudinally and laterally.
Tighten down nuts (2).
Tightening torque 41 63 1AZ, see 41 63 CONVERTIBLE TOP COMPARTMENT LID .
Fig. 259: Identifying Convertible Top Compartment Lid And Nuts

51 71 ... REPLACING CONVERTIBLE TOP COMPARTMENT LID SEAL
Fig. 260: Opening Rear End Module

Release sheet screw (1) and thin sheet screw (2) on left and right.
2010 BMW M3
Installation:
Make sure screws are installed in correct positions.
Fig. 261: Release Sheet Screw (1) And Thin Sheet Screw (2)
Retract folding roof fully and open rear end cover.
IMPORTANT: Do not stretch, kink or crush seal.
Pull off seal (1) from left to right.
Installation:
Moisten seal with soapy water.
Carry out installation from left to right (check screw fastening points).
Fig. 262: Pull Off Seal (1) From Left To Right

2010 BMW M3

2010 BMW M3
ACCESSORIES AND BODY, CAB Body Equipment - Repair
Body Equipment - Repair
GENERAL
51 00... NOTES ON COMPONENT BONDING ADHESIVE TAPE
1. General notes
Bonding at room and object temperature of >+18C.

Newly painted parts may only be bonded after a drying time of at least 24 hours.
Optimal bonding/attachment to the background surface is achieved after approx. 48 hours. Components
must not be exposed to mechanical strain beforehand (car wash, strength test, etc.).
Do not touch bonding surface.
It is not the length of time that pressure is applied but rather the force of pressure applied that is crucial.
Detaching the adhesive tape after pressing destroys the adhesive layer.
After being pressed on gently, adhesive tape can be pulled off again up to 3 times.
2. Auxiliary materials and tools
CLEANING AGENT R1 OR CLEANING AGENT R2

Fluff-free cleaning cloths
Pressure roller
3. Preparations
Remove all adhesive residue or clean new part thoroughly

Clean the areas to be bonded immediately before bonding to remove silicone and grease residues.
NOTE: Observe air drying time > or =1 minute.
4. Bonding
4.1 Components without pre-fitted adhesive tape

Pull off liner* from adhesive tape
Position adhesive tape on component and stick on
Press down adhesive tape over entire adhesive area
Continue with Point 4.2
* Liner is the protective film on the adhesive tape
4.2 Components with pre-fitted adhesive tape

2010 BMW M3
Pull off liner (liner is the protective film on the adhesive tape) from adhesive side (if adhesive area
is large, do not pull off liner completely)
Align component in correct position on vehicle
Press down component over entire adhesive area
51 00... NOTES ON FITTING WINDOW GUIDE SEALS
1. Work safety when handling anti-friction agent G13

Do not eat, drink or smoke in the area of processing/application
Ensure rooms are well ventilated.
Keep heat and ignition sources well away
In event of skin contact: Wash areas of skin affected with soap and water immediately, change work
clothing which has been fouled with anti-friction agent immediately (keep spare work clothing in reserve)
In event of eye contact: Rinse eyes immediately with plenty of water and seek medical advice
2. General notes
Use only the BMW-approved anti-friction agent for fitting

Application only at room and object temperatures between 18 and 25C
Anti-friction agent dries at different rates depending on the quantity, temperature and ventilation and
becomes sticky
Anti-friction agent can only be used for fitting and not for fault elimination (e.g. grating)
Newly painted parts may only be brought into contact with the anti-friction agent after cooling
Optimal bonding/attachment to the background surface is achieved after approx. 48 hours. The window
guide seal must not be exposed to mechanical strain beforehand (car wash, strength test, etc.).
IMPORTANT: To avoid grating noises, do not use soapy water (low-surface-tension water
with washing-up liquid) or anti-friction agent containing silicone
Spirit, cleaning cloth, plastic squeegee, needle

Anti-friction agent G13 (manufactured by Zestron) part no. 83 23 0441 032
4. Preparations
Heat and remove anti-friction agent residues with a hot air blower or clean new part thoroughly
Immediately prior to fitting, clean the work area with spirit in order to remove silicone and grease
residues
NOTE: Air drying time approx. 1 minute

2010 BMW M3
5. Assembly
Apply a thin coating of anti-friction agent to the reverse side of the window guide seal only
Perform fitting within 30 minutes of applying anti-friction agent
Anti-friction agent dries after fitting and becomes sticky
51 00.. OVERVIEW OF FRONT DOOR
Fig. 1: Overview Of Front Door

1. Inner cover on door window frame

2. Rubber guide for door window glass
3. Seal on front door
4. Window
2010 BMW M3
5. Trim on window frame

6. Door lock
7. Front door
8. Window cavity cover strip
9. Door mirror
10. Acoustic insulation in front door
11. Door trim panel
51 21... OVERVIEW OF FRONT DOOR LOCKS
Fig. 2: Overview Of Front Door Locks

1. Door opener, inside

2. Bowden cable for inside door opener
2010 BMW M3
3. Door brake
4. Carrier for outside door handle
5. Outer handle on front door
6. Cover on outer handle
7. Lock barrel (on driver's door only)
8. Door lock striker
9. Door lock
10. Bowden cable for outside door handle
51 45... OVERVIEW OF INSTRUMENT PANEL
Fig. 3: Overview Of Instrument Panel

2010 BMW M3
1. Decorative strip on instrument panel, left

2. Dashboard trim panel
3. Decorative strip on instrument panel, right
4. Trim on instrument panel, right
5. Cup holder, front
6. Glovebox
7. Lower trim for instrument panel
8. Center console switch cluster
9. Insert for radio control key
10. Panel for pedals
11. Light operating unit
51 12.. OVERVIEW OF REAR BUMPER
Fig. 4: Overview Of Rear Bumper

2010 BMW M3
1. Guide, middle
2. Guide, side
3. Holder, side
4. Carrier, rear
5. Bumper trim, rear
6. Guide, bottom
7. Cover on towing eye
8. Ultrasonic transducer
51 12.. OVERVIEW OF REAR BUMPER (M TECHNIC AERODYNAMIC KIT)
Fig. 5: Overview Of Rear Bumper (M Technic Aerodynamic Kit)

2010 BMW M3
1. Carrier
2. Bumper trim
3. Trim, bottom middle
5. Holder, side
6. Guide, side
7. Guide, middle
8. Trim
51 00.. OVERVIEW OF REAR DOOR
Fig. 6: Overview Of Rear Door

2010 BMW M3

3. Trim for window guide
4. Trim on window frame (E91 only)
5. Windows
6. Door lock
7. Rear door
10. Seal on rear door
11. Door trim panel
12. Acoustic insulation in rear door
51 22... OVERVIEW OF REAR DOOR LOCKS

2010 BMW M3
Fig. 7: Overview Of Rear Door Locks


3. Door brake
8. Door lock
51 16... OVERVIEW OF STORAGE COMPARTMENT (CENTER CONSOLE)

2010 BMW M3
Fig. 8: Overview Of Storage Compartment (Centre Console)

1. Centre console
2. Trim for storage compartment
3. Controller
4. Fresh-air grille, rear cabin (not E92/E93)
5. Centre armrest
6. Storage tray
7. Trim for preselector lever
8. Insert for center console
9. AV connection socket

2010 BMW M3

function is active.

Fig. 9: Identifying MSA Button

Workshop mode
A = 10 mm
B = 7 mm
To make sure that the engine hood/bonnet contact is at the basic setting, if necessary press the hood/bonnet
contact up to the limit position before starting work and slowly release.
2010 BMW M3
Fig. 10: Identifying Basic Setting For Engine Hood/Bonnet

When working with diagnosis tools
Observe instructions in diagnosis tool
51 00... SAFETY INSTRUCTIONS FOR WORKING ON CARS WITH AIRBAG SYSTEMS
WARNING: If work is carried out in area of airbag systems, e.g. on:
Door trim panels

Interior trims
Instrument panel etc.
the ignition must be turned off in each case.
The ignition must always be off.

The ignition key must be removed from the ignition lock.
This eliminates the risk of injury.
51 00... SERVICE POSITION OF ENGINE COMPARTMENT LID
NOTE: Only the special tool pertaining to the model series can be selected.
SPECIAL TOOLS REFERENCE CHART

Series Special tool
E46, R50, R52, R53 51 2 160
E53, E60, E61, E63, E64, E71, E72, E81, E82, E88,
E85, E86, E87, E90, E91, E92, E93
2010 BMW M3
E65, E66, E67 51 2 180

E83 51 0 040
E70 51 2 240
WARNING: Risk of injury and damage!

Engine compartment lid must be held by a second person helping.
NOTE: The illustrations below serve as examples for all corresponding vehicles.
The operation is described on the left side; proceed in the same way for the right side.
Special tool can only be used on housing (1) of gas spring strut (thick part).
NOTE: Gas spring strut can also be installed the other way round (housing on
hood/bonnet).
Special tool can be used in both directions.
Fig. 11: Identifying Housing Of Gas Spring Strut

Release GAS SPRING STRUT on left/right housing side.
Slide special tool (1) over housing (2) of gas spring strut.
Clip ball socket of special tool on ball stud.
Proceed in same way on other side.

2010 BMW M3
Fig. 12: Sliding Special Tool Over Housing Of Gas Spring Strut
FRONT BUMPER
51 11... INSTALLING/REPLACING NUMBER/LICENSE PLATE (WITHOUT BASE)
NOTE: To obtain drilling template also refer to SI 00 11 09 (603).
Initial fitting
Place drilling hole template (1) on bumper (2).
NOTE: Hole diameter = 2.5 mm (see template).
Drill holes according to car registration number plate specifications.
Remove template (1) and secure car registration number plate with screws provided.
Fit protective caps.

2010 BMW M3
Fig. 13: Drilling Hole Template On Bumper

Place drilling hole template (1) on radiator grille (2) and bumper (3).
Drill holes according to car registration number plate specifications.
Remove template (1) and secure car registration number plate with screws provided.
Fig. 14: Identifying Drilling Hole Template, Radiator Grille And Bumper
Thread repair
Drill out defective hole in bumper (2) to 9.5 mm diameter.

2010 BMW M3
Insert blind rivet nut (1).
Secure car registration number plate (3) with car registration number plate (4).
Fig. 15: Identifying Rivet Nut, Bumper And Car Registration Number Plate
51 11 180 REMOVING AND INSTALLING/REPLACING CENTER GRILLE FOR BUMPER TRIM
Remove FRONT BUMPER TRIM
Release catches (1) and remove center grille (2).
Installation:
Catches (1) must not be damaged

2010 BMW M3
Fig. 16: Identifying Centre Grille And Catches

51 11 180 REMOVING AND INSTALLING/REPLACING CENTER GRILLE FOR BUMPER TRIM
Version with ACC:
Remove COVER FOR ACC SENSOR
6-cylinder models without ACC only:
Release catches (1) from inside, taking care not to damage catch (2).
Remove trim (3) towards front.
Installation:
Catches (1 and 2) must not be damaged.
Fig. 17: Releasing Catches

Release catches (1) on bumper trim (2).
Installation:
Catches (1) on bumper trim (2) must not be damaged.

2010 BMW M3
Fig. 18: Identifying Catches And Bumper Trim

51 11 156 REMOVING AND INSTALLING FRONT BUMPER TRIM
Release screws (1) on bumper trim (2).
Fig. 19: Identifying Bumper Trim Screws

Release screws (1) and plastic nuts (2) on left wheel arch cover (3).
Lever out left wheel arch cover (3) at side.
Installation:
Make sure left wheel arch cover (3) is in correct position.

2010 BMW M3
Fig. 20: Identifying Screws, Plastic Nuts And Left Wheel Arch Cover
Release screws (1 and 2) and remove right wheel arch cover (3).
Lever out right wheel arch cover (3) at side.
Installation:
Make sure right wheel arch cover (3) is in correct position.
Fig. 21: Identifying Right Wheel Arch Cover And Screws

Press wheel arch cover (1) on left and right to one side.
Release left and right screws (2).

2010 BMW M3
Fig. 22: Identifying Wheel Arch Cover And Screws


IMPORTANT: Do not damage bumper trim when pulling off.
Detach bumper trim (1) at sides.
Pull bumper trim (1) forwards slightly and if necessary disconnect plug connections on ultrasonic sensors.
Remove bumper trim (1) towards front with aid of a 2nd person.
Installation:
Height adjustment, refer to GAP DIMENSIONS, BODY .

2010 BMW M3
Fig. 24: Removing Bumper Trim

51 11 156 REMOVING AND INSTALLING FRONT BUMPER TRIM (FROM 09/08)
Version with headlight washer system:
Remove COVER FOR HEADLIGHT WASHER SYSTEM on left/right

NOTE: The operation is described on the left side; proceed in the same way for the
right side.
Release screws (1) on wheel arch trim (2).
Lift out wheel arch trim (2) at side.

2010 BMW M3
Installation:
Make sure wheel arch trim (2) is in correct position.
Fig. 26: Identifying Wheel Arch Trim And Screws

right side.
Press wheel arch cover (1) to one side.
Release screws (2).


2010 BMW M3
Fig. 28: Identifying Bumper Trim And Screws

Pull bumper trim (1) forwards slightly and if necessary disconnect plug connections on ultrasonic sensors
and/or fog lights.
Installation:

51 11 156 REMOVING AND INSTALLING FRONT BUMPER TRIM (UP TO 09/08)

2010 BMW M3
Remove COVER FOR HEADLIGHT WASHER SYSTEM on left/right
Fig. 30: Identifying Screws On Bumper Trim

right side.
Installation:
Fig. 31: Identifying Screws On Wheel Arch Trim

2010 BMW M3
right side.
Release screws (2).

Fig. 33: Identifying Bumper Trim And Screws

2010 BMW M3
and/or fog lights.
Installation:

51 11 050 REMOVING AND INSTALLING/REPLACING CARRIER FOR FRONT BUMPER TRIM
Remove front BUMPER TRIM
Release screws (1) on cooling air guide (2) on left and right.
Disconnect plug connection (3) on outside temperature sensor.
Remove left cooling air guide (2).

2010 BMW M3
Fig. 35: Identifying Cooling Air Guide Screws, Left Cooling Air Guide And Outside Temperature Sensor
Plug Connection
Press right wheel arch cover (1) to one side.
Release screw (2) and remove right cooling air guide.
Installation:
Make sure cooling air guide is installed in correct position.
NOTE: The following work step ends here:
"Removing and installing cooling air guide".
Fig. 36: Identifying Right Wheel Arch Cover And Screw

Release screw (1).

2010 BMW M3
Release nuts (2) and blind rivets (3).
Installation:
Blind rivets (3) are not refitted.
If necessary, feed out cable or hose and remove carrier (4).
Fig. 37: Identifying Carrier, Nuts And Blind Rivets

Replacement
Release screws (1) and convert fanfare horn holder (2).
Modify impact absorber (3) on left and right.
Fig. 38: Identifying Convert Fanfare Horn Holder, Impact Absorber And Screws
2010 BMW M3
51 11... REMOVING AND INSTALLING/REPLACING COVER FOR HEADLIGHT CLEANING

SYSTEM ON LEFT
Pull out spray nozzle (1) by cover (2).
IMPORTANT: When releasing cover (2), grip spray nozzle (1) firmly and then allow to slide
back slowly (risk of damage).
Release cover (2) sideways from spray nozzle (1).
Fig. 39: Releasing Cover From Spray Nozzle

Installation:
Guides (1) on cover (2) must not be damaged.
Fig. 40: Identifying Headlight Cleaning System Cover And Guides

2010 BMW M3
51 11... REMOVING AND INSTALLING/REPLACING COVER FOR HEADLIGHT WASHER UNIT

ON LEFT
Release catches (1) and remove cover (2).
Installation:
Fig. 41: Identifying Headlight Washer Unit Cover And Catches

51 11 158 REPLACING BASEPLATE FOR LICENSE PLATE
Release screws or rivets (1).
Remove license plate baseplate (2).

2010 BMW M3
Fig. 42: Identifying License Plate Baseplate And Rivets

51 11 157 REPLACING FRONT BUMPER TRIM

Remove FRONT GRILLE CENTRE SECTION
If necessary, remove NUMBER/LICENSE PLATE HOLDER
Remove MIDDLE GRILLE
If necessary, remove COVER FOR HEADLIGHT WASHER SYSTEM
Remove cover cap for tow lug
Version with Park Distance Control (PDC):
Remove ultrasonic transducer See 6620518 REMOVING AND INSTALLING/REPLACING AN

ULTRASONIC TRANSDUCER AT FRONT (OUTSIDE) (PARK DISTANCE CONTROL) or
6620520 REMOVING AND INSTALLING/REPLACING AN ULTRASONIC TRANSDUCER AT
FRONT (INSIDE) (PARK DISTANCE CONTROL)
Release expander rivets (1) and pull off seal (2) upwards in direction of arrow.
Installation:
If necessary, replace faulty expander rivets (1).

2010 BMW M3
Fig. 43: Pulling Off Seal

Remove sheet metal nuts (1) on left/right.
Installation:
If necessary, replace faulty metal nuts (1).
Fig. 44: Identifying Sheet Metal Nuts

Press down catches (2) on insert (1) and remove insert (1) in direction of arrow.
2010 BMW M3
Fig. 45: Removing Insert

REAR BUMPER
51 12.. OVERVIEW OF REAR BUMPER
2010 BMW M3

1. Guide, middle
2. Guide, side
3. Holder, side
4. Carrier, rear
5. Bumper trim, rear
6. Guide, bottom
51 12.. OVERVIEW OF REAR BUMPER (M TECHNIC AERODYNAMIC KIT)

2010 BMW M3
Fig. 47: Overview Of Rear Bumper (M Technic Aerodynamic Kit)

1. Carrier
2. Bumper trim
3. Trim, bottom middle
5. Holder, side
6. Guide, side
7. Guide, middle
8. Trim
51 12 156 REMOVING AND INSTALLING REAR BUMPER TRIM

2010 BMW M3
Remove left/right REAR LIGHT
Lever out cover (1) and release screw underneath.
Fig. 48: Identifying Rear Bumper Trim Cover

Release screw (1) on left/right.
Bend wheel arch trim (2) in area (A) to one side and release screw (3) on left/right.
Fig. 49: Identifying Wheel Arch Trim Bending Areas

Release screws (1).

2010 BMW M3


Do not detach bumper trim (1) at sides
The following work must be carried out with a second person assisting:
Pull bumper trim (1) towards rear and release from catches (2).
Fig. 51: Pulling Bumper Trim

Press down catch (2).
Remove bumper trim (1) towards rear with aid of a 2nd person.
If necessary, disconnect plug connection on ultrasonic transducers.

2010 BMW M3
Fig. 52: Identifying Bumper Trim And Catch

51 12... REMOVING AND INSTALLING/REPLACING BOTTOM MIDDLE TRIM ON REAR

BUMPER (M TECHNIC AERODYNAMIC KIT)
Release screws (1).
Release catches (2) and remove trim (3).
Fig. 53: Identifying Screws, Catches And Trim

51 12 050 REMOVING AND INSTALLING/REPLACING CARRIER FOR REAR BUMPER TRIM
IMPORTANT: During replacement, all the cavities of the carrier (1) and the crashbox (2) must
be sealed with cavity sealant.
2010 BMW M3
Fig. 54: Identifying Carrier And Crashbox

Remove bumper trim
If necessary, release rubber mount (1) on carrier (2).
Unscrew nuts (3).
Remove carrier (2).
Installation:
If necessary, replace faulty sheet nuts (4).
Replacement
If necessary, modify or replace weight on carrier (2).

2010 BMW M3
Fig. 55: Identifying Rubber Mount, Carrier, Nuts And Sheet Nuts
51 12... REMOVING AND INSTALLING/REPLACING GUIDE FOR BUMPER AT REAR BOTTOM

MIDDLE
Release screws (1 and 2) and remove guide (3).
Fig. 56: Identifying Bumper Guide And Screws

51 12 825 REMOVING AND INSTALLING/REPLACING GUIDE FOR REAR CENTER BUMPER
Remove rear bumper trim
Version with Comfort Access/CA:
Remove BUMPER AERIAL FOR COMFORT ACCESS
If necessary, feed out cable (1) of Park Distance Control.
Release nuts (2) and remove guide (3).

2010 BMW M3
Fig. 57: Identifying Park Distance Control Cable, Nuts And Guide
51 12 801 REMOVING AND INSTALLING/REPLACING HOLDER FOR REAR LEFT OR RIGHT

BUMPER
Remove REAR BUMPER TRIM
E93 only:
If necessary, release aerial/antenna holders (1 and 2) from holder (3).
Installation:
If necessary, replace faulty aerial/antenna holders (1 and 2).
Fig. 58: Identifying Antenna Holders And Holder

2010 BMW M3
Release nuts (3) and remove bracket (4).
Installation:
Make sure lugs (5) of underbody panelling run into guides on holder (4) at bottom.
Fig. 59: Identifying Nuts, Bracket, Lugs Of Underbody Panelling Run And Holder
Replacement
Modify sheet nuts (3)

Replace foam seal (4)
Installation:
Catches (1) and guides (2) must not be damaged.

2010 BMW M3
Fig. 60: Identifying Catches, Guides, Sheet Nuts And Foam Seal
51 12 828 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT GUIDE FOR REAR

BUMPER
right side.
Unscrew nuts (1).
Remove guide (2).
Fig. 61: Identifying Rear Bumper Nuts And Guide

2010 BMW M3
Installation:
Catches (1) on holder (2) must not be damaged or missing.
Fig. 62: Identifying Catches And Holder

51 12 090 REMOVING AND INSTALLING/REPLACING TRIM GRILLE IN BUMPER TRIM
Remove rear BUMPER TRIM
Installation:
Fig. 63: Identifying Catches And Centre Grille

2010 BMW M3
71 60... REPLACING COMPLETE TRAILER TOW HITCH
IMPORTANT: When retrofitting a trailer tow hitch, it is absolutely essential to read and
comply with the NOTES ON RETROFITTING A TRAILER TOWING DEVICE .

If necessary, release exhaust system suspension elements
Release screws (1) on both sides.
Unclip cable from fixture.
Remove trailer tow hitch support member (2).
Disconnect all plug connections.
Fig. 64: Identifying Trailer Tow Hitch Support Member And Screws
Installation:
Only vehicles up to production date 07 March 2005:
Knock out studs (1) towards inside and replace with M12x40 hexagon bolts.

2010 BMW M3
Fig. 65: Identifying Studs

51 12 157 REPLACING REAR BUMPER TRIM
Remove rear BUMPER TRIM
Remove cover cap (1) for tow lug.
Remove REAR TRIM GRILLE (2).
Version with PDC:
Remove all ULTRASONIC TRANSDUCERS (3).
Fig. 66: Identifying Tow Lug Cover Cap, Bumper Trim And Rear Left Ultrasonic Transducer
51 12... REPLACING TRIM ON REAR BUMPER (M TECHNIC AERODYNAMIC KIT)

2010 BMW M3

Remove BOTTOM MIDDLE TRIM ON REAR BUMPER
Carefully heat trim (1) with hot air blower and detach with special tool 009317 from bumper (2).
Fig. 67: Removing Trim

Installation:
Minimum object temperature of trim and bumper > or = 18C.
If this temperature is not achieved, the components must be preheated.
For cleaning, use a fluff-free disposable cloth or a clean cleaning cloth.
Clean adhesive area of bumper with spirit.
Air drying time at least 1 minute.
Installation:
Trim (1) is positioned over guides (2) on bumper.
Remove liner from trim (1).
Press down trim (1) firmly with back of your hands over entire surface, especially the ends.
2010 BMW M3
Fig. 68: Identifying Bumper Guides And Trim

TRIM, COVERS, HANDLE TRIM

51 13 047 REMOVING AND INSTALLING (REPLACING) TRIM GRILLE ON SIDE PANEL AT
FRONT LEFT OR RIGHT (M3)
The subsequent operation is described in REMOVING FRONT LEFT OR RIGHT AUXILIARY

DIRECTION INDICATOR .
51 13 116 REMOVING AND INSTALLING COWL PANEL COVER
Remove WINDSCREEN WIPER ARM on left/right

Remove microfilter housing See 6431062 REMOVING AND INSTALLING/REPLACING LEFT
LOWER MICROFILTER HOUSING SECTION or 6431063 REMOVING AND
INSTALLING/REPLACING RIGHT LOWER MICROFILTER HOUSING SECTION .
IMPORTANT: Danger of water ingress via fan into vehicle interior if cowl panel cover and
sealing strip are not correctly fitted.
Pull off hose (1).
Detach mucket (3).
Take off cover (4).
Installation:
2010 BMW M3
Make sure cover (4) is correctly seated.
Fig. 69: Identifying Hose, Plug Connections, Mucket And Cover

Installation:
Sealing strip (1) must be fitted (water ingress)
If necessary, retrofit sealing strip (1).
Fig. 70: Identifying Sealing Strip

Installation:
Make sure grommets (1) are correctly seated on wiper pivots.
Grommets (1) for wiper pivots must not be damaged.
If necessary, replace grommets (1).

2010 BMW M3
Fig. 71: Identifying Grommet

E90/E91 only
Installation:
Cowl panel cover (1) must be correctly guided on right and left under windscreen cover (2).
Fig. 72: Identifying Cowl Panel Cover And Windscreen Cover

E92/E93 only
Installation:
2010 BMW M3
Fig. 73: Identifying Cowl Panel Cover And Windscreen Cover

51 16 480 REMOVING AND INSTALLING OR REPLACING FRONT GRAB HANDLE
Fold finishers down and unfasten screws.
Fig. 74: Locating Front Grab Handle Screws

51 13 017 REMOVING AND INSTALLING/REPLACING FRAME FOR GRILLE IN ENGINE

HOOD/BONNET ON LEFT OR RIGHT
Lever out frame (1) with special tool 00 9 323 SCRAPER along dashed line.
Carefully pull frame (1) in direction of arrow out of guide and remove.
Installation:
Make sure frame (1) is correctly seated in respective locators.

2010 BMW M3
Fig. 75: Pulling Frame

Installation:
Fig. 76: Identifying Catches And Guides

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

LEFT OR RIGHT
Release screws (1) and pull bumper trim (3) forwards slightly.
Release catches (4) from inside and remove central radiator grille (2) towards front.
2010 BMW M3
Fig. 77: Removing Central Radiator Grille

Installation:
All catches and guides on middle front grille must not be damaged.
Press on chrome ring to push front radiator grille (2) into bumper trim.
Fixtures (1) must engage correctly.
Fig. 78: Pushing Front Radiator Grille Into Bumper Trim

Replacement
Release catches (1).
Remove chrome frame (2) from radiator grille (3).
Installation:
2010 BMW M3
Catches (1) on chrome frame (2) and radiator grille (3) must not be damaged.
Fig. 79: Identifying Catches, Chrome Frame And Radiator Grille

51 13 023 REMOVING AND INSTALLING/REPLACING GRILLE IN ENGINE HOOD/BONNET ON

LEFT OR RIGHT
Remove FRAME FOR GRILLE
Pull grille (1) in direction of arrow towards rear and remove.
Installation:
Make sure grille (1) is correctly installed in guides of engine hood/bonnet.
Fig. 80: Pulling Grille

2010 BMW M3
Installation:
Catches (1) on grille must not be damaged.
Fig. 81: Identifying Grille Catches

51 13 025 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT TRIM ON ENGINE

HOOD/BONNET
Release screws (1) and remove trim (2) in upwards direction.

2010 BMW M3
Installation:
Guides (1) on trim (2) must not be damaged.
Fig. 83: Identifying Guides On Trim

51 13 280 REMOVING AND INSTALLING/REPLACING TRIM STRIP ON ROOF FRAME AT LEFT

OR RIGHT
E84 and E91 only:
If necessary, remove roof rails
Lever out trim strip (1) with special tool 009321 starting at rear.
Unclip trim strip (1) in direction of arrow.
Fig. 84: Removing Trim Strip Using Special Tool (00 9 321)
2010 BMW M3
Installation note:
Clips (1) and seals (2) on trim strip (3) must not be damaged.
If necessary, replace faulty clips (1).
Position of clips (1) on trim strip (3) is determined by notch (4).
Fig. 85: Identifying Trim Strip Clips, Seals And Notch

Installation note:
Push trim strip (1) at front into seal (2).
Trim strip (1) must be flush with edge (3) at rear.
Fig. 86: Identifying Trim Strip And Seal

2010 BMW M3
51 13 316 REMOVING AND INSTALLING/REPLACING TRIM STRIP ON ROOF GUTTER AT

LEFT OR RIGHT
IMPORTANT: Make sure that body is not damaged.
Starting at front, release trim strip (1) with special tool 009317 from clips (2).
Installation:
To avoid leaks and noises, check all clips (2) for visible damage.
Align clips (2) on body and fit trim strip (1).
Fig. 87: Releasing Trim Strip

Installation:
Seals (1) must not be damaged.

2010 BMW M3
Fig. 88: Identifying Seals

IMPORTANT: Carry trim strip by its middle section only (risk of damage)
Perform installation work with a second person helping
Prepositioning of trim strip
Ensure drip molding runs parallel to side frame (risk of breakage)
51 13 286 REPLACING BRACKET FOR ROOF LUGGAGE RACK ON LEFT OR RIGHT
Remove TRIM STRIP FROM ROOF FRAME
Remove body sealing compound (1) with special tool 009322 and unfasten threaded pin (2).
Fig. 89: Identifying Body Sealing Compound And Threaded Pin

NOTE: Threaded pin is designed as Torx from E87 model series.

2010 BMW M3
Installation:
Threaded pin may not be wetted with screw securing adhesive on screw-in thread (1).
Before installing threaded pin, protect body against corrosion (e.g. apply zinc dust paint).
Fig. 90: Identifying Screw Thread

Apply body sealing compound (1) (Terostat 9320, sourcing reference: BMW Parts Service) to threaded pin (2)
all round.
After hardening time of body sealing compound (1) (refer to manufacturer's specifications), paint over body
sealing compound (1) and threaded pin (2) with paint pencil of corresponding car color.

51 13 117 REPLACING COWL PANEL COVER

2010 BMW M3
Remove COVER FOR COWL PANEL

Remove SPRAY NOZZLE on left/right
Release catches on grommets (1) and remove grommets (1) in outwards direction.
Release holder (2).
Remove washer fluid hose (3) and if necessary cable.
Installation:
Grommets (1) for wiper pivots must not be damaged; if necessary, replace grommets (1).
Fig. 92: Identifying Grommets Holder And Washer Fluid Hose

BMW EMBLEMS, MODEL EMBLEMS

51 14...GENERAL NOTES FOR LABELLING WITH ADHESIVE FILMS
In the event of a repair the adhesive films must be partially or completely replaced. The basic procedure for all
areas of the vehicle is described below.
In addition, vehicle-specific repair instructions are available.
1. Preparation:
Wash and dry vehicle. Rework with compressed air as required in area of joints.
Clean complete component surface with glass cleaner (BMW part number 83 12 0 396 775). Also clean the
inside of the component in areas, in which adhesive films are applied.
Only carry out repair work with clean hands!

2010 BMW M3
IMPORTANT: Labels can only be applied to recently painted components after a waiting
period of 2 weeks. The paint hardening is only fully completed after this time.
2. Procedure for applying labels:
All adhesive films in the repair kit are marked with numbers. Prepare the required plastic films prior to start of
repairs.
The templates included in the repair kit assist orientation. A straight line running over the different components
is the top priority.
Pull off the templates positioning of the adhesive films.
Only throw away templates after completion of all repair work, as some templates are used several times.
Templates are always applied along the light edge (1). The light edge is the reflection of the light source in
radius (see arrow).
Fig. 93: Identifying Light Edge

Roughly align the adhesive film using a template.

2010 BMW M3
For large adhesive films, pull off the first 20 cm of protective film and fold back the edge.
Align and lightly press down the adhesive film. Use only one finger for this and not the entire hand so that air
pockets are unable to form under the adhesive film.
Pull off the remaining protective film and press down the adhesive film from front to rear and from inside to
outside.
If faults are made in applying the adhesive film, it can be pulled off and repositioned several times. When no
further corrections have to be made, use a squeegee to press down the adhesive film firmly from inside to
outside.
Lay protruding ends of the adhesive film around the component edge and press down firmly.
Carefully pull off backing film (1) at an acute angle.
Fig. 94: Pulling Off Backing Film

51 14... INSTRUCTIONS FOR ATTACHING NUMBER/LETTER DESIGNATION COMBINATION
NOTE: The model designation is attached with adhesive and can not be reused.
The model designation must be attached at room temperature >18C.
2010 BMW M3
The model designation must be removed at stove-enameling temperatures

exceeding 80C.
NOTE: The following work steps are described using the "316 i" as the example.
Removing
Coat nylon string or strong yarn with tensides (e.g. washing-up liquid).
Cut through adhesive layer and remove model designation (1) from rear lid (2).
Remove remainder of adhesive layer with adhesive remover (sourcing reference: BMW Parts Service).
Fig. 95: Identifying Model Designation And Rear Lid

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

2010 BMW M3
Fig. 96: Identifying Letter Combinations, Liner And Backing Film

51 14 000 REMOVING AND INSTALLING/REPLACING FRONT BMW BADGE
To avoid damaging the paintwork on the engine hood/bonnet, tape off edge areas (1) to sides of guide pins.
So as not to subject the BMW badge to excessive deformation, lever out the badge with special tool 009325 at
guide pins (2).
Fig. 97: Removing BMW Badge Using Special Tool (00 9 326) At Guide Pins
Installation:
The following parts must not be damaged or missing, replace if necessary:
1. Badge
2. Guide pins
2010 BMW M3
3. Grommets
Adhesive tape (4)
Fig. 98: Identifying Badge, Guide Pins And Grommets

51 14 010 REMOVING AND INSTALLING/REPLACING REAR BMW BADGE
Removing and installing/replacing FRONT BMW BADGE .
51 14 110 REMOVING AND INSTALLING/REPLACING REAR MODEL DESIGNATION
IMPORTANT: The "INSTRUCTIONS FOR NUMBER/LETTER COMBINATION CEMENTING "

serve as the basis for these repair instructions and must be followed without
fail.
Fitting dimensions (E90/E91/E92/E93):

2010 BMW M3
Fig. 99: Identifying Rear Model Designation Fitting Dimensions (E90/E91/E92/E93)

Attach adhesive tape (1) between edge of rear lid (2) and top edge "A". Mark out measurement "B" from top
edge "A" to outer edge of rear lid on adhesive tape (1).
Dimensions:
E90 A = 25.2 mm B = 49.3 mm
E91 A = 26.6 mm B = 65.1 mm
E92 A = 21 mm B = 49.6 mm
E93 A = 20 mm B = 52.7 mm
NOTE: Measurements C, D and E are for information purposes only, as determined by

carrier film.
316 i, 318 i, 318 d: C = 4.8 mm, D = 7.2 mm, E = 11.6 mm
320i...335i: C = 7.2 mm, D = 7.2 mm, E = 11.6 mm
320 d...330 d: C = 7.2 mm, D = 7.2 mm, E = 11.6 mm

2010 BMW M3
320 si, 325 xi, 330 xi, 330 xd: C = 7.2 mm, D = 7.2 mm, E = 10.6 mm, F = 4.8 mm
M3 only
Attach adhesive tape (1) between edge of rear lid (2) and measurement "A".
Mark out measurement "B" at top edge of adhesive tape (1) to outer edge of rear lid.
E90:
A. A = 21 mm
B. B = 147 mm
E92/E93:
A. A = 21 mm
B. B = 139 mm
NOTE: Measurement "C" is for information purposes only, as it is determined by

carrier film.
C. C = 5.9 mm
Fig. 100: Identifying Rear Model Designation Fitting Dimensions (E90)


(BRILLIANCE)
IMPORTANT: The "INSTRUCTIONS FOR NUMBER/LETTER COMBINATION CEMENTING "

serve as the basis for these repair instructions and must be followed without
fail.
2010 BMW M3
Attach adhesive tape (1) between edge of rear lid (3) and top edge measurement "A".
Mark measurement "B" from outer edge of rear lid on adhesive tape (1) and stick on adhesive tape (2)
vertically.
Measurements E60:
A. A = 18 mm
B. B = 38 mm
Measurements E90:
A. A = 25 mm
B. B = 46 mm
Pull off liner (protective strip for adhesive surface).
Position characters on adhesive tapes (1 and 2) and stick into place.
Fig. 101: Identifying Rear Model Designation Measurements

MIRRORS/COVERS/ASHTRAYS/SHELVES/TRAYS
51 16... CALIBRATING COMPASS IN INSIDE MIRROR (UP TO 09/08)
NOTE: It may be necessary to alter the magnetic deflection zone if the vehicle is more
than two ranges away from the set deflection zone.
For numbers of magnetic deflection zone, refer to Owner's Handbook.
If may be necessary to calibrate the compass if:
vehicle battery has been clamped off for an extended period of time
"C" appears in compass display
2010 BMW M3
there is no compass display
Setting magnetic deflection zone:
Switch on ignition.
Using a suitable tool (1), press push-button in area (A) of mirror (2) until a number appears in compass
display (B)
Press push-button repeatedly until number of desired zone appears
Wait until direction display appears
Magnetic deflection zone is now set
Fig. 102: Identifying Compass Display

Calibrating compass:
Switch on ignition.
Using a suitable tool (1), press push-button in area (A) of mirror (2) until "C" appears in compass display
(B)
Drive vehicle 2 to 3 times in a circle at approx. 10 mph
Calibration process is completed when direction display appears
2010 BMW M3
Fig. 103: Calibrating Compass

51 16... CALIBRATING COMPASS IN INTERIOR REARVIEW MIRROR (FROM 09/08)
Adjusting magnetic field zone:
Fig. 104: Press And Hold Down Control Button On Inside Mirror With Suitable Tool
2010 BMW M3
Press and hold down control button (A) on inside mirror (2) with a suitable tool (1) for 3 - -6 seconds.
The currently set magnetic field zone is indicated in the compass display (B) (default setting "8" for
Central Europe). Release control button (A) briefly and select magnetic field zone (1 - -15) by pressing
control button (A) again. Release setting button (A) when the desired magnetic field zone is selected. The
selection menu is automatically exited after approx. 5 seconds.
The compass must be recalibrated after the magnetic field zone has been changed.
Press and hold down setting button (A) on interior mirror (2) for 6-9 seconds. Release setting button (A)
as soon as "C" is indicated in the compass display (B).
Drive vehicle 2 to -3 times in a full circle at approx. 7-10 km/h. The circle must be at least twice the
vehicle's turning circle. Calibration is complete as soon as a valid direction is displayed.
For convertibles and vehicles with hardtops only:
The digital compass must be calibrated once with the soft top or hardtop closed and once with the soft top or
hardtop open.
Fig. 105: Pressing And Hold Down Control Button On Inside Mirror With Suitable Tool
Setting right-hand drive or left-hand drive vehicle:
Press and hold down control button (A) on inside mirror (2) for 9 - -12 seconds. The currently set vehicle
type is indicated in the compass display (B) (default setting "L" for left-hand drive). Release setting
button (A) briefly and select vehicle ("L" or "R") by pressing setting button (A) again. Release setting
button (A) when the desired vehicle type is selected. The selection menu is automatically exited after
approx. 5 seconds.
2010 BMW M3
Setting language of compass display:
Press and hold down control button (A) on inside mirror (2) for 12 - -15 seconds. The currently set
language is indicated in the compass display (B) (default setting "E" for English). Release setting button
(A) briefly and select language (E for English or O for German) by pressing setting button (A) again.
Release setting button (A) when the desired language is selected. The selection menu is automatically
exited after approx. 5 seconds.
51 16 992 DISASSEMBLING AND ASSEMBLING LOCK CYLINDER (LOCK CYLINDER

REMOVED)
2010 BMW M3
If necessary, remove LOCK CYLINDER
NOTE: Lock cylinder repair kit (part number: 9 061 387) applicable to: E30
Lock cylinder repair kit (part number: 9 061 388) applicable to: E31, E32,
E34, E36, E38, E39
E53, E60, E61, E63, E64, E65, E66, E67, E85, E86, E90, E91, E92, E93
Sort supplied retainers (1) by stamped numerical sequence (X) in ascending order and number (Y).
Fig. 108: Identifying Retainers In Numerical Sequence

Insert spring (1) into first lock cylinder position (2).
NOTE: Lock cylinder version (2) differs from vehicle to vehicle.
Fig. 109: Identifying Spring And First Lock Cylinder Position

2010 BMW M3
Insert retainer (1) with lowest number (X) of first position (Y) in lock cylinder (2) and snap audibly into place.
NOTE: Number of retainers (1) differs from vehicle to vehicle.
Fig. 110: Identifying Retainer And Lock Cylinder

Insert ignition key (1) into lock cylinder (3) and check whether retainer (2) is flush with housing.
(A) OK
(B) not OK
Fig. 111: Checking Retainer Flush

If retainer (2) is not OK, press retainer (2) out of lock cylinder (3) with a suitable tool (1).
Continue with next number (X) higher of first position (Y) until retainer is OK.
2010 BMW M3
The continue with all the other positions in accordance with the above-mentioned procedure.
Fig. 112: Pressing Retainer Out Of Lock Cylinder Using Suitable Tool
51 16... GLUING OF MIRROR BASE
Material Requirements:
Repair set for gluing of mirror base
Primer XW 775
1. Preparation
1.1 Glue at room temperature and make sure that, in cold weather, the window glass and base are
brought to room temperature in the workshop long enough to prevent moisture forming on the
surface.
1.2 Mark location of the mirror mount on the outside of the windshield.
Scratch off glue residue on glass and base with a sharp tool.
1.3 Clean glue area on window and base with clean non-fluffing cloth and alcohol/acetone and
allow to dry!
Never use paint thinners!
2. Primer coat
Apply colorless, diluted primer to surface of windshield intended for gluing with help of cotton buds (Q-
Tips or similar).
Specified ventilation time at least 1 minutes, maximum 1 hour

2010 BMW M3
3. Gluing coat
3.1 Mixing Glue
Cut off sealing tips on containers of glue and hardener using a knife.
Make sure that both openings are equal in size, as otherwise there would be mistakes in mixing.
The sealing cap for subsequent plugging of the double injector is located between both pistons of
the injector. Break off sealing cap.
The required amount of glue and hardener is removed by applying light pressure on the pistons.
The mixture ratio of adhesive and hardener is 1 : 1 (weight and volume). It is important that the
same volumes of glue and hardener are removed (increase size of openings if necessary).
Both components react chemically with each other. Thorough, intensive and homogenous mixing is
a requirement for this reaction and for the quality of gluing.
Consequently both components must be mixed in such a way that there is a uniform, ream-free
color mixture.
3.2 Application
At 20... 25C the mix can be processed after approx. 5... 10 minutes (pot time).
Apply thin (approx. 0.5 mm), uniform coat of glue on base with spatula and press base onto glass in
such a way that glue obtains good contact with windshield across the entire surface area.
NOTE: The temperature for the hardening process should not be lower than
+18C.
3.3 Fixing Bonded Parts
Epoxy resin glue does not have an initial strength property. It is therefore necessary to fix all
bonded parts (adhesive tape or similar). The joining and fixing of bonded parts must be
accomplished within the potlife). Check that the arresting button is located correctly on the mirror
base to ensure that the mirror, when it is attached, is seated straight.
(Long side of mirror base hexagon parallel to upper edge of window).
3.4 Hardening of glue
Hardening speed depends on the ambient temperature.
For this reason, the mirror base must be secured with adhesive tape or similar for at least 3... 4
hours.
2010 BMW M3
After 12 hours have elapsed, clip mirror into place as soon as possible.
4. Working hygiene
IMPORTANT: Glue is dangerous for health when vapors are inhaled or through contact
with the skin.
As is the case for all epoxy resins, sensitive persons might be confronted with an allergy through contact
with the skin.
If the product gets on the skin, wash off with soap and water immediately.
If it gets in an eye, rinse the eye thoroughly in water and consult doctor.
Make sure that the room is well ventilated and gloves are worn for the application of glue.

2010 BMW M3

1. Decorative strip on instrument panel, left

3. Decorative strip on instrument panel, right
4. Trim on instrument panel, right
5. Cup holder, front
6. Glovebox
7. Lower trim for instrument panel
8. Center console switch cluster
9. Insert for radio control key
10. Panel for pedals
11. Light operating unit
2010 BMW M3
51 16... OVERVIEW OF STORAGE COMPARTMENT (CENTER CONSOLE)

1. Centre console
2. Trim for storage compartment
3. Controller
4. Fresh-air grille, rear cabin (not E92/E93) 9 AV connection socket
5. Centre armrest
6. Storage tray
7. Trim for preselector lever
8. Insert for center console
9. AV connection socket
2010 BMW M3
51 16 206 REMOVING AND INSTALLING/REPLACING CENTER ARMREST
Move both front seats forwards
IMPORTANT: Grip behind trim (1) from below and release catch (2) (risk of damage).
Pull trim (2) towards rear and release from catches (3).
Fig. 115: Pulling Trim

Installation:
Guides (2) must not be damaged.
If necessary, release REAR COMPARTMENT FRESH-AIR GRILLE in order to install trim correctly.
2010 BMW M3

NOTE: Open center armrest otherwise spring (1) will be under too much tension.
Disengage spring (1) with screwdriver (2).
Installation:
Make sure spring (1) is correctly seated.
Fig. 117: Disengaging Spring Using Screwdriver

Drive out hinge shafts (1).
NOTE: Hinge shafts (1) are secured on the outside with toothing (3).
Remove spring (2), open center armrest and feed out of storage compartment.
2010 BMW M3
Fig. 118: Removing Hinge Shaft And Spring

51 16... REMOVING AND INSTALLING DRAWER IN LUGGAGE COMPARTMENT
Release lock (1) and pull out drawer (2) in direction of arrow.
Fig. 119: Pulling Out Drawer


2010 BMW M3
Fig. 120: Locating Front Grab Handle Screws

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

DOOR MIRROR
Remove COVER CAP FROM DOOR MIRROR

Remove TRIM FROM DOOR MIRROR
Remove DRIVE for electrically adjustable door mirror
Release screws (1) on retaining ring (2).
Fig. 121: Identifying Door Mirror Screws And Retaining Ring

Unclip catch (1) and remove retaining ring (2).

2010 BMW M3
Fig. 122: Identifying Catch And Retaining Ring

Installation:
Catch (1) and guide (2) must not be damaged.
Locators (3) for multitooth catches must not be damaged.
Fig. 123: Identifying Catch And Guide

51 16 080 REMOVING AND INSTALLING OR REPLACING SUN VISOR AND LEFT OR RIGHT
COUNTER SUPPORT
NOTE: The operation is shown on the left side; proceed in the same way for the right
side.
Fold down sun visor (5).

2010 BMW M3
Lever out trim (2) on counter support (1) and release screw underneath.
Release screws (3) on holder (4).
Fig. 124: Identifying Sun Visor, Trim And Counter Support With Screws
Lift out sun visor (1).
If necessary, pull out cable (2) slightly and disconnect plug connection (3).
Installation:
Perform function check on lighting.
Fig. 125: Identifying Sun Visor And Cable With Plug Connection
51 16 360 REMOVING AND INSTALLING RIGHT GLOVE BOX

2010 BMW M3
Remove INSTRUMENT PANEL TRIM , bottom right
Release screws (1) and remove counter-support (2).
Installation:
Align glove box and screw down counter-support (2).
Check gap dimensions and closing comfort of glove box, realign if necessary.
Release clip (1).
Remove glove box (2) in inward direction.
If necessary, disconnect plug-in contacts.
51 16 366 REMOVING AND INSTALLING RIGHT GLOVEBOX WITH HOUSING
Version with can holder:
Remove both front CUP HOLDERS
Release screws (1).
Pull out glovebox (1) slightly.
Fig. 126: Pulling Out Glovebox

Disconnect plug connections (2) and feed cable out of guide (3).
Depending on version, disconnect further plug connections.

2010 BMW M3
Remove glovebox (1).
Fig. 127: Identifying Glovebox, Plug Connections And Guide

Installation:
Guides (1) for glovebox must not be damaged or missing.
Guides (2) for cup holders must not be damaged or missing.
Fig. 128: Identifying Glovebox And Cup Holder Guides

51 16 366 REMOVING AND INSTALLING RIGHT GLOVE BOX (WITH AIRBAG) WITH HOUSING
WARNING: Read and comply with SAFETY REGULATIONS for handling airbag
modules and pyrotechnical belt tensioners.

2010 BMW M3
IMPORTANT: Do not carry out any repairs on airbag module!
Always replace the passenger protection airbag module completely!
When working on trim panel components, make sure that the sensitive surfaces are not scratched or damaged.
Microencapsulated screws must be replaced and may not be reused

Screw connection must be completed within 20 minutes (start of curing)
Microencapsulated screws must not be retightened
Clean thread of nut beforehand in event of repeated use
Disconnect BATTERY NEGATIVE CABLE .

Open glove box.
Remove both front CUP HOLDERS at the front.
Release screws (1).
Fig. 129: Glovebox Screws And Removal Direction

Release screws (1).
Replace micro-encapsulated screws (1).
Pull out glove box (2) slightly.

2010 BMW M3
Fig. 130: Identifying Micro-Encapsulated Screws

Disconnect plug connections (1) and feed cable out of guides.
Depending on the version, disconnect additional plug connections.
Remove the glove box (2).
Fig. 131: Identifying Connectors

Installation note:

2010 BMW M3
Fig. 132: Identifying Guides For Glovebox And Cup Holder

51 16 200 REMOVING AND INSTALLING STORAGE COMPARTMENT
Remove TRIM FOR STORAGE TRAY
Lever out covers (1) and release screws underneath.
Fig. 133: Identifying Storage Compartment Covers

IMPORTANT: Carefully unclip catches (2) on trim (1) (risk of damage).
Move with special tool 00 9 323 SCRAPER from below behind trim (1) and release catches (2).
Release trim (1) towards rear from catches (3).
If necessary, disconnect plug connections and remove trim (1).

2010 BMW M3
Fig. 134: Releasing Catch

Installation:

Unscrew nuts (1).
Depending on equipment specification:
If necessary, disconnect cable strap (2) and plug connections (3 and 4).
2010 BMW M3
Fig. 136: Identifying Nuts, Cable Strap And Plug Connections

Pull off gaiter (1) towards top.
Specification with telephone:
Detach plug connection (2) from holder and disconnect plug connection (2).
Fig. 137: Detaching Plug Connection From Holder

Raise storage compartment (2) at rear and feed out gaiter (1) through opening.
If necessary, disconnect further plug connections and feed out cable.
Remove storage compartment (2) towards rear/top.

2010 BMW M3
Fig. 138: Removing Storage Compartment

Installation:
Guide (1) of storage compartment (2) must be fed behind panel (4) on left/right.
Specification with ventilated multifunction storage:
Air duct (3) must be correctly inserted in storage compartment (2).
Fig. 139: Identifying Storage Compartment Guide, Air Duct And Panel
51 16 212 REMOVING AND INSTALLING TRIM FOR STORAGE COMPARTMENT
Version with manual transmission:
Remove GAITER FOR GEAR LEVER

2010 BMW M3
Version with automatic transmission:
Remove finisher for preselector lever
Release trim (1) with special tool 009317 from retainers (2).
If necessary, disconnect plug connections and remove trim (1) towards top.
Fig. 140: Releasing Trim With Special Tool (00 9 317)

Installation:
Following parts on trim (3) must not be damaged or missing:
1. Clips
2. 4 x foam material
Fig. 141: Identifying Trim, Clips And Foam Material

51 16 060 REMOVING AND INSTALLING/RENEWING INTERIOR REAR-VIEW MIRROR (WITH

2010 BMW M3
JAPANESE TOLL MIRROR)
IMPORTANT: Work may only be carried out at a room/object temperature of 18... 28C.
If this can not be guaranteed (cold/hot countries), it is necessary to equalize
the temperature of the windscreen, mirror foot and rear-view mirror (e.g. car left
to stand indoors or in the shade for at least 30 minutes).
Version with remote control for central locking:
If necessary, disconnect negative lead from BATTERY .
Version with compass:
Check compass function if replacing or after disconnecting interior mirror plug connection or battery.
If necessary, CALIBRATE COMPASS IN INTERIOR REARVIEW MIRROR .
E60 Security version:
Rain sensor is not installed, cable connection is tied back in roofliner.
IMPORTANT: To avoid breaking windscreen:
Screw rear-view mirror off mirror mount.
Mirror must not be pulled or pressed off towards front or rear.
Press on end caps (1) and at same time pull them apart; this releases clip connection of both caps (1).
Fig. 142: Pressing Caps

Turn mirror (1) to right and left and feed out end caps (2).
2010 BMW M3
Fig. 143: Identifying Mirror And Caps

Installation:
Catches (1) and guides (2) of end caps (3) must not be damaged, replace if necessary.
Fig. 144: Identifying End Caps, Catches And Guides

Disconnect plug connections (1 and 2).
NOTE: Pay attention to cable guide for rain sensor.

2010 BMW M3

IMPORTANT: Do not pull or press rear-view mirror off towards front or rear.
Because of altered mirror foot, rearview mirror must be twisted off.
Twist mirror foot approx. 45 to right until mirror foot is released from mirror mount.
Fig. 146: Identifying Rear-View Mirror Angle

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

2. Turn mirror foot until it engages on mirror base.
2010 BMW M3
Fig. 147: Turning Mirror Foot

Only in case of replacement with version with remote control for central locking
If necessary, initialize all transmitters (ignition keys).
51 16... REMOVING AND INSTALLING/REPLACING COVER CAP ON LEFT OR RIGHT DOOR

MIRROR
Remove MIRROR GLASS
NOTE: Cover cap is secured without play by four multitooth catches (1) on retaining
ring (2).
Secure cover cap against falling off.
Fig. 148: Identifying Multitooth Catches And Retaining Ring

2010 BMW M3
Unlock multitooth catches (1) with a screwdriver.
Unclip cover cap forwards from retaining ring (2) and remove.
Installation:
Multitooth catches (1), catch (2) and guides (3) must not be damaged.
Fig. 149: Identifying Catches, Catch And Guides

Installation:
Locators (1) on retaining ring (2) must not be damaged.
Fig. 150: Identifying Locators And Retaining Ring

51 16 383 REMOVING AND INSTALLING/REPLACING DAMPER FOR GLOVEBOX

2010 BMW M3
Remove GLOVEBOX WITH HOUSING
Open glovebox.
Release clip (1).
Fig. 151: Identifying Glovebox Clip

Press catch (1) together and slide damper (2) in direction of arrow.
Remove damper (2) in inward direction.
Fig. 152: Removing Damper

Installation:
Catch (1) and guide (2) on damper (3) must not be damaged or missing.
2010 BMW M3
Fig. 153: Identifying Damper Catch And Guide

51 16 202 REMOVING AND INSTALLING/REPLACING FRONT (INNER OR OUTER) CUP

HOLDER
Remove COVER ON DASHBOARD on right
Release the screws (1) and pull out the cup holder (2) in direction of arrow.
Replacement
REPLACE THE COVER OF THE SECOND CUP HOLDER.
Fig. 154: Pulling Out Cup Holder

51 16 154 REMOVING AND INSTALLING/REPLACING INSERT FOR CENTER CONSOLE

2010 BMW M3
Remove TRIM FOR STORAGE COMPARTMENT
Remove foam material (1).
Release screws (2) and remove insert/ashtray (3).
Fig. 155: Identifying Insert/Ashtray, Foam Material And Screws

51 16 060 REMOVING AND INSTALLING/REPLACING INTERIOR REAR-VIEW MIRROR (WITH

RAIN SENSOR)
If this can not be guaranteed (cold/hot countries), it is necessary to equalize
the temperature of the windscreen, mirror foot and rear-view mirror (e.g. car left
to stand indoors or in the shade for at least 30 minutes).

2010 BMW M3
Snap out (press) rear-view mirror only in direction of travel towards windscreen.
Do not under any circumstances twist the mirror foot when removing.
Twisting the mirror off the mirror mount will damage the rear catch.
If the rear catch is damaged, the mirror will be loose when installed and must be replaced.
Press on end caps (1) and at same time press them apart; this releases clip connection of both caps (1).
Fig. 156: Pressing End Caps

Twist mirror (1) at an angle towards front and right/top.
Swivel left end cap (2) off ball neck in direction of arrow; this detaches the engagement clip (3) from the metal
foot.
Fig. 157: Twisting Mirror

2010 BMW M3
Twist mirror (1) at an angle towards front and left/top.
Swivel right end cap (2) off ball neck in direction of arrow; this detaches the engagement clip from the metal
foot.
Fig. 158: Swiveling Right End Cap Off Ball Neck

Installation:
Clips (1) and retaining hooks (2) of end caps (3) must not be damaged, replace if necessary.
Fig. 159: Identifying End Caps, Clips And Retaining Hooks

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

2010 BMW M3
Fig. 160: Identifying Plug Connection And Rain Sensor Cable Guide
Do not pull off rear-view mirror (1) from windscreen against direction of travel and or snap out by turning.
When snapping out, do not damage control unit (3) for rain sensor.
Rain sensor is not installed.
Snap out interior mirror (1) from mirror mount (2) towards front with increasing pressure (not abruptly) and
remove.
Fig. 161: Pulling Off Rear-View Mirror From Windscreen

Installation:

2010 BMW M3

Only in case of replacement with version with remote control for central locking
If necessary, initialize all transmitters (ignition keys), refer to Owner's Handbook.
51 16 060 REMOVING AND INSTALLING/REPLACING INTERIOR REARVIEW MIRROR

(OVERVIEW)
NOTE: Version with cable (X) for:
Automatic dim action (electrochrome technology) for interior rearview mirror

Condensation sensor
Remote control (infrared or radio)
High-beam assistant
Garage door openers
Compass
Rain sensor
Version without cable (X) with full foot (1).

2010 BMW M3
Fig. 163: Identifying Interior Rearview Mirror Full Foot

Version with cable (X) and plug trim cover (1).
Fig. 164: Identifying Plug Trim Cover And Cable

VERSION with mirror arm end caps (1).

2010 BMW M3
Fig. 165: Identifying Mirror Arm End Caps

VERSION with rain sensor.
Fig. 166: Identifying Rain Sensor

VERSION with Autobeam.
Fig. 167: Identifying Autobeam

VERSION with toll mirror for Japan.

2010 BMW M3
Fig. 168: Identifying Toll Mirror For Japan

51 16 060 REMOVING AND INSTALLING/REPLACING INTERIOR REARVIEW MIRROR (WITH

AUTOBEAM)
If this cannot be guaranteed (cold/hot countries), it is necessary to equalize the
temperature of the windscreen, mirror foot and rearview mirror (e.g. car left to
stand indoors or in the shade for at least 30 minutes).
Snap out (press) rearview mirror only in direction of travel towards windscreen.
Twist mirror (2) and detach end caps (1) from mirror and feed out.
2010 BMW M3
Fig. 169: Detaching End Caps From Mirror And Feed Out
Installation:
Retaining hooks (1 and 2) of end caps (3) must not be damaged.
Fig. 170: Identifying Retaining Hooks And End Caps

Disconnect plug connections (1 and 2).
Installation:
If necessary, pay attention to cable routing for rain sensor.

2010 BMW M3

Do not pull off rearview mirror (1) from windscreen against direction of travel and or snap out by turning.
When snapping out, avoid damaging rain sensor (3).
Carefully press mirror (1) forwards out of mirror base (2).
If mirror (1) rests on rain sensor (3), snap mirror (1) out in inward direction.
Fig. 172: Removing Mirror

Installation:

2. Turn mirror foot until it can be felt to engage on mirror base.
3. Visually inspect for positive locking.
2010 BMW M3

NOTE: Normalization or initialization is not necessary.
Autobeam is automatically aligned under the following conditions:
Driving on a motorway/ordinary road at night for approx. 50 km and

Clearly visible road markings
Only replace with version with remote control for central locking
Only when replacing seat cover for with build date up to 09/2009
Replace CAN plug (3-pin).
Remove existing plugs and dispose.
Plug in new plug part number 905 977 (sourcing reference BMW Parts department) similar to existing pins.

MIRROR ARM END CAPS)

2010 BMW M3
NOTE: Do not exert any pressure on mirror foot when removing end caps (1).
Press end caps (1) towards mirror housing (2); this releases clip connection of both caps (1).
In order not to create any tension at the mirror foot, simultaneously apply counterpressure to the mirror housing
when removing the end caps.
Fig. 174: Pressing End Caps Towards Mirror Housing

foot.
2010 BMW M3
Fig. 175: Detaching Engagement Clip From Metal Foot

foot.
Fig. 176: Removing Right End Cap

Installation:
2010 BMW M3
Fig. 177: Identifying Clips, Retaining Hooks And End Caps

Version with cable (X):

Do not pull off rearview mirror (1) from windscreen against direction of travel and or snap out by turning.
remove.
2010 BMW M3
Fig. 179: Removing Interior Mirror From Mirror Mount

Installation:


Only replace with version with remote control for central locking
Initialize all transmitters (ignition keys), refer to Owner's Handbook.
51 16 342 REMOVING AND INSTALLING/REPLACING LOCK CYLINDER FOR PASSENGER

AIRBAG DEACTIVATION
Individual parts, switch for passenger airbag deactivation

2010 BMW M3
Fig. 181: Identifying Lock Cylinder Parts For Passenger Airbag Deactivation
1. Ignition key
2. Lock cylinder
3. Switch housing
4. Sealing ring
5. Guide
6. Switch unit
7. Board
8. Case Covers
9. Bolts

2010 BMW M3
Release screws (1).
Remove housing cover (2) and PCB (3) underneath.
Fig. 182: Identifying Housing Cover, Screws And PCB

Remove switch unit (1) in upward direction.
Installation:
Switch unit (1) can only be installed in one position.
PCB (4) can be inserted turned through 180.
Position of magnet sensor (3) of PCB (4) must match up with permanent magnet (2) of switch unit (1).
Fig. 183: Identifying Switch Unit, PCB, And Magnet Sensor

Remove guide (1) in upward direction.

2010 BMW M3
Installation:
Guide (1) can only be installed in one position.
Fit seal (2) on guide (1) and insert in switch housing.
Fig. 184: Identifying Switch Housing Seal And Guide

IMPORTANT: Ignition key must be inserted in lock cylinder, otherwise this will be destroyed
when removed.
Insert ignition key in lock cylinder (2).
Carefully release catches (1) in outward direction and press out lock cylinder (2) with ignition key.
Installation:
Lock cylinder (2) can only be inserted in "ON" or "OFF" switch position.
Lock cylinder
2010 BMW M3
Fig. 185: Releasing Catches

51 16 340 REMOVING AND INSTALLING/REPLACING LOCK FOR RIGHT GLOVEBOX
Open glovebox.
Release screws (1).
Remove lower section (3) and upper section (2) of lock.
Fig. 186: Removing Lower Section And Upper Section Of Lock

Replacement
Insert ignition key (1) in lock cylinder (3).
Turn ignition key (1) slightly, carefully raise catches (2) and pull out lock cylinder (3) with ignition key (1) in
direction of arrow.
If necessary, force catches (2) open.

2010 BMW M3
Fig. 187: Identifying Ignition Key, Lock Cylinder And Catches

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

DOOR

Lever out COVER ON DOOR WINDOW FRAME at front
IMPORTANT: Secure door mirror against falling down.
Release screws (2).
Replacement
Due to the thread-tapping screws, the tightening torque of the new mirror is increased by 2 Nm.

2010 BMW M3
Fig. 188: Identifying Plug Connection And Screw

Remove mirror (1) outwards.
Installation:
Check function.
Fig. 189: Removing Mirror

Installation:
Acoustic insulation (1) must not be damaged.

2010 BMW M3
Fig. 190: Identifying Acoustic Insulation

51 16 450 REMOVING AND INSTALLING/REPLACING REAR LEFT/RIGHT GRAB HANDLE
REMOVING AND INSTALLING/REPLACING FRONT GRAB HANDLE.
51 16 400 REMOVING AND INSTALLING/REPLACING ROLLER SUN BLIND ON FIXED SIDE

WINDOW OF LEFT OR RIGHT REAR DOOR
Retract roller sun blind (1).
Open side window.
Unclip casing (2) of roller sun blind (1) with special tool 009317 in direction of arrow.
Installation:
Casing (2) must not be damaged.

2010 BMW M3
Fig. 191: Removing Casing

51 16 405 REMOVING AND INSTALLING/REPLACING ROLLER SUN BLIND ON SIDE WINDOW

OF LEFT OR RIGHT REAR DOOR
Remove REAR DOOR TRIM PANEL
Carefully release catches (1) and remove roller sun blind (2) in direction of arrow.
Installation:
Make sure catches (1) are correctly seated.
Fig. 192: Removing Roller Sun Blind

Fold up handle (1) and feed out with roller sun blind (2) through frame (3).
2010 BMW M3
Fig. 193: Folding Handle

Installation:
Roller sun blind must be correctly inserted in guides (1).
Fig. 194: Identifying Guides

Replacement up to build date 06/2005
NOTE: Because there are visual differences between the old and new build dates, it is
necessary to replaced the left and right roller sun blinds.
When installing roller sun blind in door trim panel (build date up to 06/2005), disconnect blocking finger (1)
from roller sun blind (2) and door trim panel (3).
2010 BMW M3
Fig. 195: Identifying Blocking Finger, Roller Sun Blind And Door Trim Panel
Replacement
Remove clip (2) before fitting sun roller blind (1).
Fig. 196: Identifying Sun Roller Blind And Clip

51 16... REMOVING AND INSTALLING/REPLACING TRIM ON LEFT OR RIGHT DOOR MIRROR
Remove COVER CAP FROM DOOR MIRROR
Release screws (1) and carefully remove trim (2) towards front.
Installation:
Make sure trim (2) is correctly seated on door mirror.

2010 BMW M3
Fig. 197: Identifying Trim And Screws

Installation:
Holders (1) and guide (2) must not be damaged.
Fig. 198: Identifying Holders And Guide

51 16 284 REPLACE ONE OF THE DRINK HOLDER COVERS IN FRONT (INNER OR OUTER)
Unclip the cover (1) from the drink holder (2) direction of arrow.
2010 BMW M3
Fig. 199: Removing Drink Holder Cover From Drink Holder

51 16 156 REPLACING ASHTRAY INSERT
Open ashtray cover (1) and pull ashtray lid (2) out of locator.
Installation:
Press ashtray insert (2) until it snaps into the locator.
Fig. 200: Opening Ashtray Cover

51 16 026 REPLACING MIRROR GLASS

Move mirror glass with hand carefully and slowly.
2010 BMW M3
If mirror glass is damaged:

Wear protective goggles and cut-proof gloves.
Risk of injury by flaking-off glass splinters.

Bring exterior mirror to room temperature to prevent catches from breaking off.
Graphics are only an example (The graphics used are from E60).

Secure mirror glass (1) against falling out.
NOTE: Graphics
Press mirror glass (1) on side vehicle by hand to full extent.
Unclip mirror glass (1) all around from outer side with special tool 009317.
Unlock and disconnect associated plug connections, remove mirror glass (1).
Fig. 201: Removing Mirror Glass From Outer Side Using Special Tool (00 9 317)
Installation:
Retaining lugs (1) must not be damaged.
Fit mirror glass (2) with retaining lugs (1) flush on mirror adjusting drive and clip into place.
Ensure correct locking.
Make sure mirror adjusting drive functions correctly.

2010 BMW M3
Fig. 202: Identifying Mirror Glass And Retaining Lugs

51 16 361 REPLACING RIGHT GLOVEBOX
Remove right GLOVEBOX with housing

Remove FASTENER FOR GLOVEBOX
Remove DAMPER FOR GLOVEBOX
Remove GLOVEBOX LIGHT
If necessary, remove hotel setting switch
If the replacement fuse chart (supplied with the new glovebox) does not match to the original fuse chart,
Continue to use the original fuse chart.

Dispose of the replacement fuse chart.
Release clips (1) and remove cover (2).
Fig. 203: Identifying Cover And Clips

2010 BMW M3
Remove all dummy platers.
Release screws (1) and remove locking catch (2) from glovebox housing.
Fig. 204: Identifying Glovebox Housing Locking Catch And Screws

51 16 201 REPLACING STORAGE COMPARTMENT

Remove CENTRE ARMREST
Version with telephone:
Remove EJECT BOX
Version with rear cabin air conditioning:
First feed air duct (1) to right out of guide (2) and duct (3), then remove to left out of storage compartment.
Installation:
Seal (4) must not be damaged.

2010 BMW M3
Fig. 205: Identifying Air Duct, Guide And Seal

Release catches (2) on coin holder (1) and remove coin holder (1) in inward direction.
Release catches (3) on multifunction storage compartment (4) and remove multifunction storage compartment
(4).
If necessary, remove AV CONNECTION SOCKET (5) .
Remove socket (6).
Fig. 206: Identifying Multifunction Storage Compartment, Catches And Coin Holder
51 16 213 REPLACING TRIM FOR STORAGE COMPARTMENT

Modify INSERT FOR CENTRE CONSOLE
MODIFY
2010 BMW M3
Version with controller:
Modify CONTROLLER
E93 only:
Modify switch for convertible top operation
Version without controller:
Carefully release catches (1) and remove storage tray (2).
Fig. 207: Identifying Storage Tray And Catches

LIDS
51 17 400 REMOVING AND INSTALLING/REPLACING BUMP STOP WITH EJECTOR FOR
FILLER FLAP
Release cover (1).
Press catches (2) together and pull out ejector (3).
Installation:
Install ejector (3) with fitted cover (1).

2010 BMW M3
Fig. 208: Pressing Catches

Installation:
Make sure cover (3) is correctly seated on ejector (2).
Fig. 209: Identifying Ejector, Catches And Cover

Remove FLAP FOR FUEL FILLER NECK

Remove SERVODRIVE FOR TANK FILLER FLAP
Remove front wheel arch cover (rear section)
2010 BMW M3
Unscrew nut (1).
Installation:

Installation:
Release nuts (1).

2010 BMW M3
Fig. 212: Turning Cover

Remove cover (2).
Installation:
Fig. 213: Removing Retaining Strap

2010 BMW M3
Installation:
Fig. 214: Identifying Ejector, Catches And Cover

Installation:

Close flap (1).
2010 BMW M3

Installation:
1. Rubber pad
3. Spring
4. Catch
5. Guide
Fig. 217: Identifying Rubber Pad, Catches, Top/Bottom, Spring, Catch And Guide
LOCK CYLINDERS, ASSEMBLY

2010 BMW M3

REMOVED)
E34, E36, E38, E39
E53, E60, E61, E63, E64, E65, E66, E67, E85, E86, E90, E91, E92, E93


2010 BMW M3


(A) OK
(B) not OK
2010 BMW M3

FRONT DOOR LOCKS, HANDLES, FITTINGS

51 21 004 ADJUSTING FRONT LEFT OR RIGHT DOOR DETENT (LOCK WEDGE)
ADJUSTING LEFT OR RIGHT FRONT DOOR .

2010 BMW M3
51 21 150 BLOCKING, IF NECESSARY INITIALIZING, CAR KEY IN IMMOBILIZER CONTROL

MODULE
NOTE: Execution in diagnosis system:
Service functions
Body
Locking and security functions
Remote control key

REMOVED)
E34, E36, E38, E39
E53, E60, E61, E63, E64, E65, E66, E67, E85, E86, E90, E91, E92, E93


2010 BMW M3


(A) OK
(B) not OK
2010 BMW M3


2010 BMW M3


3. Seal on front door
4. Window
6. Door lock
7. Front door
9. Door mirror
10. Acoustic insulation in front door
11. Door trim panel
2010 BMW M3
51 21... OVERVIEW OF FRONT DOOR LOCKS


3. Door brake
7. Lock barrel (on driver's door only)
9. Door lock
2010 BMW M3
51 21 225 REMOVING AND INSTALLING OR REPLACING INSIDE DOOR OPENER IN LEFT OR

RIGHT FRONT DOOR
Remove front DOOR TRIM PANEL
Unhook Bowden cable for release lever:
Tighten release lever (1).

Lever out lock (2).
Detach Bowden cable (3) towards rear/top.
Installation:
For fitting, press release lever (1) fully onto door trim panel.
Fig. 230: Removing Bowden Cable

NOTE: On initial installation there is no screw in area (A).
If necessary, release screw in area (A).
Release catches (1) and remove door opener (2).
Installation:
Repair screw must be inserted in area (A) when door opener is installed.
2010 BMW M3
Fig. 231: Identifying Catches And Door Opener

Installation:
Catches (1) on door opener (2) must not be damaged.
Fig. 232: Identifying Door Opener And Catches

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

LEFT OR RIGHT FRONT DOOR
Remove cover on outside door handle . See 5121180 REMOVING AND

INSTALLING/REPLACING COVER ON OUTSIDE DOOR HANDLE or 5121181 REMOVING
AND INSTALLING/RENEWING COVER ON OUTSIDE HANDLE WITH LOCK CYLINDER.
If necessary, lay outside door handle light (1) slightly to one side.
2010 BMW M3
Pull out outside door handle (2) and feed out in direction of arrow.
Carefully feed out outside door handle (2) and disconnect associated plug connection.
Fig. 233: Pulling Out Outside Door Handle

Installation:
Locator (1) must not be damaged.
Fig. 234: Identifying Locator And Seal

Installation:
2010 BMW M3
Seals (1 and 2) must not be damaged.
If necessary, pull lock actuator (3) outward until it engages retaining clasp (4).
Install outside handle and insert correctly into lock actuator (3).
Outside handle is in the correct position only after the cover has been fitted on the outside handle.
Carry out function check only with door open.
Fig. 235: Identifying Seals, Lock Actuator And Retaining Clasp

If replacing version with Comfort Access/CA
Reset CAS control unit with diagnosis system or by disconnecting and connecting BATTERY .
51 21 300 REMOVING AND INSTALLING OR REPLACING WINDOW CAVITY COVER STRIP ON

OUTSIDE OF LEFT OR RIGHT FRONT DOOR
IMPORTANT: Observe PROCEDURE for using special tool 00 9 324 PANEL WEDGE .
The "INSTRUCTIONS ON FITTING WINDOW GUIDE SEALS " serve as the basis
for this repair instruction and must be observed without fail.
Remove DOOR MIRROR
IMPORTANT: If reusing the existing window cavity cover strip (1), make sure it is not bent.
Lever out window cavity cover strip (1) with special tool 00 9 324 PANEL WEDGE (starting at A-pillar).
Feed window cavity cover strip (1) at rear out of guide (2) and remove.
2010 BMW M3
Installation:
Moisten window cavity cover strip (1) prior to fitting with APPROVED ANTI-FRICTION AGENT .
Window cavity cover strip (1) must be flush at front to door edge.
Fig. 236: Removing Window Cavity Cover Strip

Version with Chromeline:
Installation:
If chrome strip (2) has been pulled out of cover strip (3), both parts must be reassembled.
Feed guide (1) of chrome strip (2) into groove (3) of window cavity cover strip (4).
Fig. 237: Identifying Chrome Strip, Chrome Strip, Guide And Window Cavity Cover Strip
2010 BMW M3
Replacement
Window cavity cover strip (4) and chrome strip (2) are replaced completely.
51 21 181 REMOVING AND INSTALLING/RENEWING COVER ON OUTSIDE HANDLE WITH

LOCK CYLINDER
Removing and installing/renewing COMPLETE LOCK CYLINDER in left or right front door.
51 21 235 REMOVING AND INSTALLING/REPLACING BOWDEN CABLE FOR INSIDE DOOR

OPENER ON LEFT OR RIGHT FRONT DOOR
Remove FRONT DOOR TRIM

Lever out lock (2).
Installation:

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

HANDLE ON LEFT OR RIGHT FRONT DOOR
2010 BMW M3
Remove SOUND INSULATION in front door
Release Bowden cable (1) from door lock (2).
Installation:
Bowden cable (1) must be correctly engaged in locators in door lock (2).
Bowden cable (1) must be laid without kinks in bend to door lock (2).
IMPORTANT: Door cannot be opened if Bowden cable (1) is incorrectly laid.
Fig. 239: Identifying Bowden Cable And Door Lock

NOTE: Outside door handle shown removed for purposes of clarity.
If necessary, release cable strap (1).
Feed Bowden cable (2) out of carrier (3).

2010 BMW M3
Fig. 240: Identifying Cable Strap, Bowden Cable And Carrier

51 21 125 REMOVING AND INSTALLING/REPLACING CARRIER FOR LEFT OR RIGHT

OUTSIDE DOOR HANDLE WITH LOCK CYLINDER
Remove OUTER HANDLE

Remove SOUND INSULATION
If necessary, close door window glass
Installation:
IMPORTANT: Door can not be opened if Bowden cable (1) is incorrectly laid.
2010 BMW M3
Fig. 241: Releasing Bowden Cable From Door Lock

Remove seals (1) in direction of arrow.
Release screw (2).
Fig. 242: Removing Seals

If necessary, release cable holder on carrier (1).
Remove inner carrier (1) in direction of arrow and feed out of door.
2010 BMW M3
Fig. 243: Removing Inner Carrier

Replacement
If necessary, release cable connector (1).


OUTSIDE DOOR HANDLE WITHOUT LOCK CYLINDER
Removing and installing/replacing CARRIER FOR OUTSIDE DOOR HANDLE WITH LOCK
CYLINDER .
51 21 140 REMOVING AND INSTALLING/REPLACING COMPLETE LOCK BARREL IN LEFT OR

RIGHT FRONT DOOR
2010 BMW M3
Lever out cap (1) and release screw underneath.
Installation:
If necessary, replace faulty trim (1).
Fig. 245: Identifying Cap

Insert ignition key into lock barrel.
Turn ignition key slightly and pull off cover (1) in direction of arrow with outside door handle (2) opened
slightly.
Installation:
Lock barrel must be correctly seated in door lock.
Check function of lock barrel.
Fig. 246: Removing Cover

2010 BMW M3
Version with light package:
Installation:
Make sure outside door handle light (1) is correctly positioned in area (2).
Guides (3) of outside door handle light (1) must be correctly seated in carrier for outside door handle (4).
Fig. 247: Identifying Door Handle Light, Guides Door Handle Light And Outside Door Handle
Replacement
Remove catches (1) and detach cover (2) from lock barrel (3).
Installation:
Catches (1) of cover (2) must not be damaged.
Paddle (4) of lock barrel (3) must not be damaged.

2010 BMW M3
Fig. 248: Removing Catches And Cover From Lock Barrel

51 21 180 REMOVING AND INSTALLING/REPLACING COVER ON OUTSIDE DOOR HANDLE
Installation:

Pull off cover (1) in direction of arrow with outside door handle (2) opened slightly.
Fig. 250: Pulling Off Cover

Installation:
2010 BMW M3
Installation:

Replacement
NOTE: Similar to graphic.
Detach cover (2) from filler piece (3).

2010 BMW M3
Installation:
Fig. 253: Detaching Cover From Filler Piece

51 21 090 REMOVING AND INSTALLING/REPLACING DOOR LOCK IN LEFT OR RIGHT FRONT

DOOR
Remove rear section of POWER WINDOW REGULATOR
Driver's side only:
Remove LOCK BARREL
Unclip locking rod (1).
Unlock and disconnect plug connection (2) at tabs (3).

2010 BMW M3
Fig. 254: Identifying Locking Rod And Plug Connection

Unhook Bowden cable (1) from door lock (2).
If necessary, release cable clip on door lock (2).
Installation note:
Fig. 255: Releasing Bowden Cable From Door Lock

IMPORTANT: Do not damage door lock seal when removing.
Release screws (1).
Remove door lock (2) from inside.
Installation note:
Pull door lock (2) with special tool into corner (3).
2010 BMW M3
Fig. 256: Pulling Door Lock With Special Tool Into Corner
IMPORTANT: Observe the following notes on installation without fail in order to avoid
leakage and electrical malfunction.
Installation note:
Gasket (1) on door lock (2) must not be damaged.
Fig. 257: Identifying Gasket And Door Lock

E90/E91 driver's side only:
NOTE: Cover (1) protects against water ingress.
In event of problems with frozen door locks/lock barrels:
If necessary, retrofit cover (1) on door lock (2).

2010 BMW M3
Fig. 258: Identifying Cover On Door Lock

Installation note:
Install door lock and insert screws (1), do not tighten down.
Slide special tool 51 2 190 ADJUSTER into opened rotary striker until striker engages in first stage
Fig. 259: Installing Door Lock

Installation note:
Pre-tension door lock (1) with knurled screw (2) until special tool 51 2 190 ADJUSTER just contacts
corner points (3)
To tension door lock (1), it is only permitted to turn knurled screw (2) by a further 1 to 1.5 turns (max.).
Door lock seal must rest uniformly on inner door panel (water ingress).
2010 BMW M3
Tighten down door lock screws, tightening torque 51 21 1AZ .
Fig. 260: Installing Door Lock Using Special Tool (51 2 190)
51 21 280 REMOVING AND INSTALLING/REPLACING DOOR STOP ON LEFT OR RIGHT FRONT

DOOR
Close door windows

Remove SOUND INSULATION in front area
NOTE: Graphics used come from the E87.
NOTE: Secure front door against falling closed.
Release screw (1).
Remove seal (3).
Installation:

2010 BMW M3
Fig. 261: Identifying Seal And Screws

Remove door retainer (1) via cutout (2).
Fig. 262: Identifying Door Retainer And Cutout

Installation:
Following parts of door retainer (3) must not be damaged:
1. Hinge
2. Thread
2010 BMW M3
Fig. 263: Identifying Door Retainer With Hinge And Thread

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

INNER FRONT DOOR
IMPORTANT: The "INSTRUCTIONS ON FITTING WINDOW GUIDE SEALS " serve as the basis
Lever out cover (1) at rear slightly.
Start at rear with removal of window cavity cover strip (2).

Pull off window cavity cover strip (1) towards top.

2010 BMW M3
Installation:
If necessary, replace faulty retainers (3).
Insert window cavity cover strip (1) below cover (2).
Fig. 265: Inserting Window Cavity Cover Strip Below Cover

Installation:
Start with installation at front.
Fig. 266: Coating Window Cavity Cover Strip

51 21... REMOVING WEATHER STRIP WITH SPECIAL TOOL 00 9 324 AT FRONT OR REAR
Open side window completely.

2010 BMW M3
Front door:
Insert special tool 00 9 324 PANEL WEDGE at front (at A-pillar) in window cavity (1) (TOP label pointing
upwards).
Rear door:
Insert special tool 00 9 324 PANEL WEDGE at rear (at C-pillar) in window cavity (2) (TOP label pointing
upwards).
NOTE: For purposes of clarity, graphic shows inner door panel and side window
removed.
Fig. 267: Inserting Special Tool (00 9 324) At Front And Rear Window Cavity
Special tool 00 9 324 PANEL WEDGE must be correctly guided under weather strip (1).
2 Short leg, bottom

3 Long leg, top (TOP)
2010 BMW M3
Fig. 268: Identifying Special Tool 00 9 324 Under Weather Strip

NOTE: Start at the front or rear, depending on the model.

Raise weather strip (3) no more than 5 mm in each levering operation,
otherwise the strip will be bent.
Fig. 269: Positioning Special Tool (00 9 318) On Door Trim Panel
Position special tool 00 9 318 WEDGE on door trim panel (1).
Slide screwdriver (2) into special tool 00 9 324 PANEL WEDGE and weather strip (3) upwards no more than
5 mm.
Guide special tools 00 9 324 PANEL WEDGE and 00 9 318 WEDGE towards front/rear and lever out weather
strip (3).
51 21 182 REPLACING COVER ON OUTER HANDLE WITH LOCK BARREL
Operation is identical to
Removing COMPLETE LOCK BARREL FOR LEFT OR RIGHT FRONT DOOR .
51 21 003 REPLACING DOOR DETENT (LOCK STRIKER), FRONT LEFT OR RIGHT
Release screws (1) and remove door detent (2).
Installation:
If necessary, carry out basic adjustment by way of notches (3) on lock striker (2).
2010 BMW M3
Notches (3) must be vertical to B-pillar.
ADJUST LOCK STRIKER.
Fig. 270: Identifying Notches On Lock Striker

51 21 147 REPLACING LOCKS FOR SIMULTANEOUS CLOSING WITH CAS CONTROL UNIT
Necessary tasks
Replace COMPLETE LOCK CYLINDER FOR LEFT OR RIGHT FRONT DOOR

Replace INSERT FOR RADIO CONTROL KEY
Replace CONTROL UNIT FOR CAR ACCESS SYSTEM
Except E81, E87, E91:
Replace LOCK FOR REAR LID
Except E81, E82, E87 from MY 03/2007, E88:
Replace LOCK FOR RIGHT GLOVEBOX
REAR DOOR LOCKS, HANDLES, FITTINGS

51 22 004 ADJUSTING REAR LEFT OR RIGHT DOOR LOCK STRIKER
ADJUSTING LEFT OR RIGHT REAR DOOR .

2010 BMW M3


3. Trim for window guide
4. Trim on window frame (E91 only)
5. Windows
6. Door lock
7. Rear door
10. Seal on rear door
11. Door trim panel
2010 BMW M3
12. Acoustic insulation in rear door
51 22... OVERVIEW OF REAR DOOR LOCKS
Fig. 272: Overview Of Rear Door Locks


3. Door brake
8. Door lock
2010 BMW M3

OPENER ON LEFT OR RIGHT REAR DOOR

Lever out lock (2).
Installation:


HANDLE ON LEFT OR RIGHT REAR DOOR
Removing and installing/replacing CARRIER FOR OUTSIDE DOOR HANDLE on left or right rear door.
51 22 126 REMOVING AND INSTALLING/REPLACING CARRIER FOR OUTSIDE DOOR HANDLE

ON LEFT OR RIGHT REAR DOOR

2010 BMW M3
Remove OUTER HANDLE

E90 and E91 only:
Remove DOOR LOCK
E84 and 87 only:
Installation:

Release screw (2).

2010 BMW M3
Fig. 275: Removing Seals

Remove inner carrier (1) in direction of arrow.
Fig. 276: Removing Inner Carrier

Replacement

2010 BMW M3

51 22 180 REMOVING AND INSTALLING/REPLACING COVER ON OUTSIDE HANDLE, LEFT OR

RIGHT
Lever out cap (1) and frame (2).
Fig. 278: Identifying Cap And Frame

Release screw (1).

2010 BMW M3

Fig. 280: Removing Outside Door Handle Cover

Installation:
Make sure door handle light (1) is correctly positioned in area (2).
Guides (3) must be correctly seated in carrier for outside door handle (4).
2010 BMW M3
Installation:

Replacement
NOTE: Similar to graphic.
Detach cover (2) from filler piece (3).
Installation:

2010 BMW M3
Fig. 283: Removing Cover From Filler Piece

51 22 090 REMOVING AND INSTALLING/REPLACING DOOR LOCK IN LEFT OR RIGHT REAR

DOOR
Unlock and disconnect plug connection (2) at lugs (1).
Unclip lock knob control rod (5).
Fig. 284: Identifying Plug Connection At Lugs


2010 BMW M3
If necessary, release cable holder on door lock (2).
Installation:

IMPORTANT: Do not damage door lock seal during removal.
Release screws (1).
IMPORTANT: To avoid leaking and electrical malfunction:

2010 BMW M3
Fig. 286: Pulling Door Lock Using Special Tool Into Corner
Pull door lock (2) with special tool into corner (3), see Figs.
R51 3381 and R51 7594.
Installation:
Seal (1) on door lock (2) must not be damaged.
Fig. 287: Identifying Gasket And Door Lock

Installation:
Slide special tool 51 2 190 ADJUSTER into opened rotary latch until latch engages in first stage.
2010 BMW M3
Fig. 288: Installing Door Lock

Installation:
Pretension door lock (1) with knurled screw (2) until special tool 51 2 190 ADJUSTER just contacts
corner points (3).
IMPORTANT: To tension door lock (1), it is only permitted to turn knurled screw (2) by a
further 1 to 1.5 turns (max.) (risk of damage).
Door lock seal must rest uniformly on inner door plate (water ingress).
Fig. 289: Installing Door Lock Using Special Tool (51 2 190)
Tighten down door lock screws, tightening torque 51 22 1AZ .
Installation:
Check function of child lock (1) on door lock (2).

2010 BMW M3
Fig. 290: Checking Function Of Child Lock On Door Lock

51 22 280 REMOVING AND INSTALLING/REPLACING DOOR RETAINER ON REAR LEFT OR

RIGHT DOOR
Close door windows

Remove SOUND INSULATION in front area only
NOTE: Secure rear door against falling closed.
Release screw (1).
Remove seal (2).
Installation:

2010 BMW M3
Fig. 291: Identifying Seal And Screw

Release screws (1).


2010 BMW M3

Installation:
1. Hinge
2. Thread
Fig. 294: Identifying Door Retainer With Hinge And Thread

51 22 225 REMOVING AND INSTALLING/REPLACING INSIDE DOOR OPENER OF REAR LEFT

OR RIGHT DOOR
Remove rear DOOR TRIM PANEL

2010 BMW M3

Lever out lock (2).
Installation:

Installation:
2010 BMW M3

Installation:
Fig. 297: Identifying Door Opener And Catches

51 22 170 REMOVING AND INSTALLING/REPLACING OUTSIDE HANDLE ON LEFT OR RIGHT

BACK DOOR
Remove COVER ON OUTSIDE DOOR HANDLE
Pull out outside door handle (1) and feed out in direction of arrow.
2010 BMW M3
Fig. 298: Removing Outside Door Handle

Installation:
Guide (1) and locators (2) must not be damaged.
Fig. 299: Identifying Guide And Locators

Installation:
If necessary, pull lock actuator (3) outwards until it engages retaining clasp (4).
2010 BMW M3
Fig. 300: Identifying Seals, Lock Actuator And Retaining Clamp


INSIDE REAR DOOR
Pull window cavity cover strip at front (1) and rear (2) from rear door.
Installation:
Moisten window cavity cover strips (1 and 2) prior to fitting with APPROVED ANTI-FRICTION AGENT .
2010 BMW M3

Replacement with Security version
Cut front window cavity cover strip to length on side of fixed door window glass to 533 mm.
Cut rear window cavity cover strip (1) to length on straight side (2) to measurement a = 153 mm.
Fig. 302: Identifying Rear Window Cavity Cover Strip Measurement


REAR DOOR ON LEFT OR RIGHT
IMPORTANT: Observe PROCEDURE for using special tool 00 9 324 PANEL WEDGE .
The "INSTRUCTIONS ON FITTING WINDOW GUIDE SEALS " serve as the basis
E91 only:
2010 BMW M3
Remove trim on window frame at rear
Lever out window cavity cover strip (1) with special tool 00 9 324 PANEL WEDGE (starting at B-pillar).
Feed window cavity cover strip (1) at rear out of guide (2).
Installation:
Window cavity cover strip (1) must be flush at front and rear with door edge.

Installation:
2010 BMW M3
Fig. 304: Identifying Chrome Strip, Chrome Strip, Guide And Window Cavity Cover Strip
Replacement
51 22 001 REPLACING DOOR DETENT (LOCK STRIKER), REAR LEFT OR RIGHT
Replacing FRONT DOOR DETENT .
51 22 360 REPLACING SEAL FOR DOOR SEAM/ROOF FRAME ON LEFT OR RIGHT REAR
DOOR
Replacing RUBBER GUIDE FOR REAR LEFT OR RIGHT DOOR WINDOW GLASS .
HOOD LATCH, LOCKS

51 23 004Q ADJUSTING ENGINE COMPARTMENT LID CATCH
ADJUSTING ENGINE COMPARTMENT LID
51 23 131 ADJUSTING LEFT OR RIGHT STRIKER ON ENGINE HOOD
ADJUSTING HOOD/BONNET
2010 BMW M3
51 23... ADJUSTING/REPLACING BUMP STOPS
Version 1:
Following parts must not be damaged:
(1) Bump stop
Fig. 305: Identifying Bump Stop

Adjust bump stop (1) to correct height by turning left or right.
Fig. 306: Adjusting Bump Stop

Version 2:
Replace damaged bump stops (refer to EPC):
(1) Bump stop with ejector

2010 BMW M3
Fig. 307: Identifying Bump Stop With Ejector

Press ejector (1) into bump stop and, in this position, twist approx. 90 counterclockwise with a Phillips
screwdriver.
This locks the ejectors (1) in the bump stops.
Unlock the ejector (1) again after completing adjustment.
Fig. 308: Identifying Ejector And Bump Stop

Version 3:
Replace damaged bump stops (refer to EPC):
(1) Bump stop

2010 BMW M3

Turn lock (1) 45 counterclockwise.
Pull bump stop (2) upwards.
Close lid slowly until it is at the same height as the side panel.
Open lid and turn lock (1) clockwise.
Installation:
Press bump stop into panel and drive in expanding pins (3).
Fig. 310: Turning Lock 45 Counterclockwise

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

2010 BMW M3
Fig. 311: Identifying Arrester Hook And Screws

51 23 155 REMOVING AND INSTALLING/REPLACING BAR FOR RETAINING HOOK
Remove front bumper See 5111156 REMOVING AND INSTALLING FRONT BUMPER TRIM or
5111156 REMOVING AND INSTALLING FRONT BUMPER TRIM (UP TO 09/08)
Release screws (1) and clips (3).
Remove intake cover (2).
Fig. 312: Identifying Intake Cover With Screws And Clips

Release screws (1) on bar (2).

2010 BMW M3
Fig. 313: Identifying Screws On Bar

Release catches (1) on cooling air guide (2).
Feed out cooling air guide (2) with bar towards front.
Feed bar out of cooling air guide (2).
Fig. 314: Identifying Catches

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

LOCKS (TO PASSENGER COMPARTMENT)
Remove FOOTWELL SIDE TRIM PANEL

Remove LOWER SECTION OF MICROFILTER HOUSING ON LEFT
Disengage Bowden cable (1) from release lever (2) and feed out in direction of arrow.
2010 BMW M3
Fig. 315: Disconnecting Bowden Cable From Release Lever

Release expander rivet (1) and nut (2).
Feed out water channel (3) towards top.
Installation:
Make sure water channel (3) is correctly seated.
Fig. 316: Identifying Expander Rivet And Nut

Feed out Bowden cable (1) in direction of engine compartment.
Installation:
Lay Bowden cable (1) without kinks.
IMPORTANT: Grommet (2) must not be damaged.

2010 BMW M3
Check that grommet (2) is correctly seated (water ingress).
Fig. 317: Identifying Bowden Cable And Grommet

Unclip coupling (1) from side panel.
Lever out cover (2) at coupling (1).
Lever Bowden cable (3) out of coupling (1) and remove.
Fig. 318: Identifying Coupling, Cover And Bowden Cable

51 23 212 REMOVING AND INSTALLING/REPLACING CABLE FOR FRONT HOOD/BONNET

LOCKS (TO LOCKS)
Remove left/right hood/bonnet locks . See 5123110 REMOVING AND INSTALLING/REPLACING

LEFT HOOD/BONNET LOCK or 5123100 REMOVING AND INSTALLING/REPLACING
RIGHT ENGINE HOOD/BONNET LOCK.
2010 BMW M3
51 23 110 REMOVING AND INSTALLING/REPLACING LEFT HOOD/BONNET LOCK
Lever cable (3) out of coupling (1).
NOTE: The operation "Disconnect cable for hood/bonnet locks" ends here.

Release screws (1).

Release screws (1).
Carefully pull bumper (2) forwards and feed out hood/bonnet lock (3) with cable.
2010 BMW M3
Fig. 321: Identifying Bumper, Screws And Hood/Bonnet Lock

Disengage cable (1) from hood/bonnet lock (2).
When replacing cable for hood/bonnet locks
Feed cable (1) out of front wall.
Fig. 322: Identifying Cable And Hood/Bonnet Lock

51 23 265 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT GAS PRESSURE

SPRING FOR ENGINE COMPARTMENT LID

For the following tasks, you must take the appropriate measures to
support the engine compartment lid.
As an alternative, you can enlist the help of a second person to hold the
engine compartment lid.
2010 BMW M3
Raise engine compartment lid.
DISASSEMBLING BALL SOCKET (1).
Unclip gas spring strut (3) in direction of arrow from ball stud (2), top and bottom.
Detach gas pressurized prop.
Fig. 323: Removing Gas Spring Strut From Ball Stud

51 23 100 REMOVING AND INSTALLING/REPLACING RIGHT ENGINE HOOD/BONNET LOCK
Remove front intake duct.
Lever Bowden cable (3) out of coupling (1).
2010 BMW M3


Release Bowden cable (1) from holder (2).

2010 BMW M3
Fig. 326: Identifying Bowden Cable And Holder

Release screws (1).
Carefully pull bumper trim (2) forwards and feed out hood/bonnet lock (3) with cable.
Fig. 327: Identifying Bumper Trim, Screws And Hood/Bonnet Lock

When replacing cable for hood/bonnet locks
Feed cable (1) out of front wall (3).
Fig. 328: Identifying Cable And Front Wall

51 23... REMOVING/INSTALLING BALL SOCKETS WITH CLIP

2010 BMW M3
WARNING: Risk of injury! When installed, the gas pressurized shock absorber is
under preload. Minimize preload as far as possible before removing.
IMPORTANT: Never lift off ball socket with engaged retainer.
Disassembly/assembly:
1. Push on retainer in direction of groove with screwdriver

2. Lift off ball socket from ball pin
3. Slide retainer back
4. Fit ball socket on ball stud and snap into place with force
Installation:
Replace overstretched clips.
Pack grease into two opposite positions in socket. The grease spreads after installation on the ball pin all round
in the ball socket.
Fig. 329: Fitting Ball Socket On Ball Stud And Snap

TRUNK LATCH, LOCKS

51 24 004 ADJUSTING REAR LID LOCK (LOWER SECTION OF REAR LID LOCK)
NOTE: Rear lid must be correctly adjusted to fit before adjustment of rear lid lock.
If necessary ADJUST REAR LID .
For ideal adjustment, refer to BODY GAP DIMENSIONS .
Screw in detent buffers for rear lid on left/right completely.

2010 BMW M3
Fig. 330: Locating Screw In Detent Buffers

Check fulcrum pads on lower section of rear lid lock for damage and replace if necessary.
Fig. 331: Locating Rear Lid Lock Screws

Version with cover caps on rear apron trim:
If necessary, remove cover caps.
Slacken screws in lower section of rear lid lock until it is just able to move and centers itself.
The lower section of the rear lid lock must not scrape against the rear lid lock.
2010 BMW M3
Fig. 332: Locating Rear Lid Lock Lower Section Screws

NOTE: Adjusting lower section of rear lid lock:
Close rear lid.
This enables the lower section of the rear lid lock to adjust itself correctly.
Open rear lid.
Tighten down screws on lower section of rear lid lock.
Tightening torque 51 24 2AZ (E82, E88, E90, E92).
Check adjustment of rear lid and rear lid lock, repeating adjustment if necessary.
Fig. 333: Locating Rear Lid Lock Lower Section Screws

Unscrew detent buffer until closed rear lid abuts against left/right detent buffers.
2010 BMW M3
IMPORTANT: The rear lid must not be higher than the side panels, otherwise there is preload
on height adjustment!
Fig. 334: Locating Screw In Detent Buffers

51 24 300 REMOVING AND INSTALLING OR REPLACING LEFT OR RIGHT GAS STRUT FOR
REAR LID

When removing both gas struts, support rear lid in fully open position
with suitable apparatus.
Open rear lid.
NOTE: Make a written record of the alignment of gas strut (2) before removing.
Slide stop spring (1) to end of gas strut (2) and lever out gas strut (2).
Repeat the procedure at the other end of the gas strut (2) and remove.
2010 BMW M3
Fig. 335: Removing Gas Strut

51 24 145 REMOVING AND INSTALLING/REPLACING BUTTON FOR REAR LID ACTUATION
Slide special tool 00 9 323 SCRAPER under the front edge of button (1) and lift button (1) out.
Pull button (1) out of rear lid (2).
Fig. 336: Pulling Button Out Of Rear Lid

Disconnect plug (1) and remove button (2).
Installation:
Perform function check with rear lid open.
Fig. 337: Identifying Plug And Button

Replacement
2010 BMW M3
Carefully release catches (1) and remove microswitch (2).
Fig. 338: Identifying Microswitch With Catches

51 24 050 REMOVING AND INSTALLING/REPLACING LOCK ELEMENT (LOCK CYLINDER)

FOR REAR LID
Except E93:
NOTE: The mechanical lock cylinder is omitted as from 09/2008.
NOTE: Description is shown on the E90 by way of example. There may be differences
in detail in the case of other models.
E93 only:
Release clips (1) and feed out left cover (2) in direction of arrow.
2010 BMW M3
Fig. 339: Releasing Clips And Feed Out Left Cover

Unclip cover (1) in outward direction.

Disconnect Bowden cable (1).
Insert 2 mm dia. punch into hole (A) and press down catch (3).
Turn lock (2) counterclockwise through 90 and remove punch.
Release screws (4) and remove lock element (5) inwards.
Installation:
Position lock element (5) on rear lid and secure with screws (4).
Turn lock (2) 90 to right.

2010 BMW M3
Press lock element (5) on rear lid until seal is correctly positioned.
Fig. 341: Identifying Bowden Cable, Catch, Lock, Lock Element And Screws
Installation:
Seal (1) on lock element (2) must not be damaged.
Fig. 342: Identifying Seal And Lock Element

51 24 100 REMOVING AND INSTALLING/REPLACING REAR LID LOCK (UPPER SECTION)

2010 BMW M3
Release screws (2) and feed out upper section of rear lid lock (3).
Installation:
Use self-tapping screws when replacing upper section of rear lid lock (3).
Tightening torque 51 24 1AZ (E82, E88, E90, E92).
Tightening torque 51 24 5AZ (E60, E63, E64).

Remove lock (1).
Lever out actuating rod (2) and remove upper section of rear lid lock (3).
Installation:
Make sure lock (1) is correctly seated.

2010 BMW M3
Fig. 344: Removing Lock

Installation:
51 24 130 REMOVING AND INSTALLING/REPLACING STRIKER FOR REAR LID LOCK
Remove TRIM ON TAIL PANEL
Release screws (1) and remove striker.
Installation:
Adjust STRIKER .
Fig. 345: Identifying Striker Screws

2010 BMW M3
FRONT AND REAR WINDOW

51 70... FITTING SEALS
NOTE: All seals on the vehicle must be removed with the utmost care. Incorrect fitting
may result in among other things wind noises and water ingress, and may
compromise closing and opening comfort.
The following instructions always apply:
Seals which are attached to the side frame can be removed and fitted as often as desired.
Seals must not be damaged or cracked.

The clamping area must be pressed together by hand to such an extent that rigid attachment to the side
flange is still possible. The sides of the seal are permitted to touch each other slightly. A fully compressed
seal is not permitted.
Fig. 346: Identifying Seal Correct Position

A special tool to press the clamping area together is not needed. Careful fitting by hand is sufficient.
The seals must always be fitted over their full extent. There is no defined pressing force.
If seals are repeatedly removed and fitted in the rear lid area, a new seal must be fitted (water ingress in
event of sheet flaws).
Seals must be checked after fitting for correct seating. If necessary, the seals must be lifted over the
adjacent components with a suitable tool. Adjacent components must not be damaged.
2010 BMW M3
Fig. 347: Identifying Improper Position Of Seals

Seals must be replaced when the metal insert in the seal is visible (corrosion).
The clamping area must be uniform.
Fig. 348: Identifying Clamping Area

Joint seals which are fitted with plastic clips must rest rigidly on the body. Otherwise, the clips or the
joint seal must be replaced.
2010 BMW M3
Fig. 349: Identifying Clips Or Joint Seal

51 31... NOTES FOR BONDING SOUND INSULATION (SI), DOORS
IMPORTANT: Do not pull on the sound insulation in jerks (risk of damage)
Work steps for removing and installing sound insulation
Click on "underlined cross-reference" to display at the end of this document
General
Sound insulation is bonded to the inner door panel.
Bonded sound insulation must not be subjected to load (e.g. leak test) before 5 hours have elapsed.
On-the-job safety
When working with bonding products (adhesive, cleaning agent, etc.):

Change work clothing contaminated with adhesive immediately.
Change work clothing contaminated with solvents and swelling agents immediately (keep spare work
clothing on hand).
Take skin protection measures, provide washing facilities including hot water, use silicone-free skin
creams
Provide eye douche facilities, change water regularly (once a month).
Comply with the relevant safety regulations
2010 BMW M3
Handling adhesive area on inner door panel
Adhesive
a. Butyl bead applied to sound insulation with protective film

b. Butyl mini-round profile 1[] 3 mm from the roller
c. Butyl round profile [] 6 mm from the roller
Cleaning
a. Isohexane (benzine)
b. 2-propanol (isopropanol)
Under no circumstances: paint thinning
c. Carry out bonding only after an air drying time > or = 1 min. Air drying time may be omitted if the entire
bonding surface is wiped with a dry cloth
d. After cleaning, the bonding surface may not be touched with hands or fouled again
Repair in area of sound insulation, door
Repair
in the event of damaged sound insulation or leakage
Cut the butyl rope between the sound insulation and the inner door panel with a sharp knife
After the repair is finished, position a new butyl rope [] 3 mm directly on the original adhesive bead
Heat the butyl bead with a standard hot air blower until the butyl rope strings when touched slightly. Do
not damage the sound insulation in the process
Press down with special tool 51 0 300 . Perform this work extremely carefully because the increased
amount of adhesive requires pressure of > or = 20 N/cm2 (compared to firm thumb pressure ~ 30 N/cm2 )
Visually check the adhesive bead and its compression (no capillaries or broken adhesive bead permitted)
In the cases mentioned, the complete sound insulation must be replaced. After removing the sound
insulation, removal all butyl remnants from the inner door panel. Apply 6 mm [] butyl rope to new sound
insulation
Press down with special tool 51 0 300 to > or = 20 N/cm2 (compare to firm thumb pressure ~ 30 N/cm2 )
The sound insulation must be bonded watertight below the door lock
Flat bonding surface required all round

No bonding in event of moisture (e.g. condensation, etc.)
Bonding area must not show any traces of adhesion-reducing residues (e.g. separating agents, greases,
oils, paraffins, plastisols, cavity wax, polishing dust residues, etc.)
2010 BMW M3
Remove the protective film directly before joining (under no circumstances remove earlier, since the
butyl, because of its stickiness, will very quickly pick up adhesion-reducing dirt contaminants)
The sound insulation must be attached with positional accuracy to the inner door panel, because it is no
longer possible to change the position without damaging the butyl bead
With repainted areas, the maximum permitted temperature of 90C may not be exceeded in the area of the
sound insulation. Otherwise, the sound insulation must be removed (and replaced, if necessary).
Expiration date of adhesive
24 months, see label on packaging
Disposal of the cleaning cloth
Cleaning cloths and cleaning agent residues are hazardous waste (see also safety data sheet)
Hazardous waste (see also safety data sheet)
See repair instructions See 5148060 REMOVING AND INSTALLING/REPLACING SOUND

INSULATION IN LEFT OR RIGHT FRONT DOOR or 5148070 REMOVING AND
INSTALLING/REPLACING SOUND INSULATION ON LEFT OR RIGHT REAR DOOR.
51 31... NOTES ON WINDOW BONDING
IMPORTANT: For 03-2009
the "1 Hour System" was introduced.
Two different adhesive systems are described and identified accordingly

in the following:
"1-day system"
"1-hour system"
For 01-2010
the information for the Expiration date (Best Before) on the repair kit and
window glue cartridge was changed and now refers to Calendar week and
Year (CW/YYYY) .
2010 BMW M3
For 03-2010
a "Repair kit, large" was introduced for the "1 Hour System" under part
number 83 19 0 444 145.
In addition to the "Repair kit, small" delivery, this kit includes a second
window glue cartridge .
Recommended for 5-Series, 6-Series, 7-Series, X3, X5.
These instructions are not applicable to side window bonding (door "center") on the E38/L7:
Work steps for removing and installing window glass
Is located at the end of the document under the cross reference "Refer to repair instructions"
General
It is possible to tow or drive without windscreen or rear window.
The windscreen, rear window and side windows are glued to the body. This bonding will increase the torsional
rigidity of the vehicle. To obtain perfect bonding, comply with the installation procedure described in the
following.
The adhesive must be applied at room temperatures > 15C to avoid negatively affecting the bonded
connection.
Adjust the component and interior temperature accordingly.
An air humidity of < 30% significantly slows hardening.

The window glass must be secured against slipping with yellow plastic adhesive tape (sourcing reference:
BMW Parts Department) after being installed. The paint must be completely hardened after painting
work.
Always apply the adhesive in such a way as to achieve tension-free bonding!
On-the-job safety
When working with bonding products (adhesive, cleaning agent, bonding agent, etc.):

clothing on hand).
2010 BMW M3
creams
Do not eat, drink or smoke in areas of polyurethane processing.
All use and safety information of the safety data sheet (SDB) for the applicable product apply. The safety
data sheet (SDB) can be obtained from the Aftersales Assistance Portal (ASAP)
Replacement of windscreens
Version with Head-Up Display (HUD):
Marking for HUD must be present on the windscreen
Version with front passenger airbag:
Stick on LABEL
Tools for cutting through adhesive bead:
ADHESIVE BEAD CUTTING TOOL DESCRIPTION CHART

Type Type Order/part number
Special cutter (manufacturer: Compressed air operated 7 23 63 100 23 8
Fein) with oscillating knife Electrically operated 7 53 60 200 00 4
BMW knife set All required knives PN 81 43 9 428 596 or
6 39 03 167 05 4
Knife (U-shape) 19.5 mm (1) 6 39 03 118 01 3
24 mm 6 39 03 076 01 6
36 mm 6 39 03 079 01 2
45 mm 6 39 03 154 01 0
Knife (straight with stop roller) 16 to 35 mm (adjustable) 6 39 03 143 01 3
10 mm (fixed)(1) 6 39 03 189 01 0
14 mm (fixed) 6 39 03 082 01 6
" ROLL OUT 2000 Wire cutting system (1) PN 81 62 0 301 768
Cutting wire Wire cutting system (1) PN 83 19 2 150 267
Scalpel for heavy-duty applications (1)
Handles for cutting wire Self-locking (1) Special tool 13270
(1) not included in BMW blade set
Storage temperature
1-day system: Storage temperature of all adhesive products of 5C to 25C must be observed.
2010 BMW M3
1-hour system: Storage temperature of all adhesive products of more than 15C must be observed.
Adhesive
The BMW approved polyurethane adhesive must be used for bonding:
1-day system: Window glass adhesive (Part number 83 19 0 444 144*)
1-hour system: Repair kit, small (part number 83 19 0 444 141) or large (part number 83 19 0 444 145)
The repair kit, large contains a second window glass glue cartridge.
Adhesive is applied to window glass with cartridge gun (compressed airy or electrically operated, sourcing
reference: BMW Workshop Equipment and Planning Documentation).
When using accelerator (hot working, 3-hour system)
Temperature (min. 80 5C) of cartridge oven must be checked every morning. Connect temperature
sensor to diagnosis system
Heat adhesive for one hour in cartridge oven (sourcing reference: BMW Parts Department) to 80 5C
Write date and time on cartridge when inserting into cartridge oven
Insufficient heating (< 1 hour) results in the formation of bubbles/blisters (bonding not permitted)
Temperature < 80 5C results in the formation of bubbles/blisters (bonding not permitted)
Remove hardened adhesive prior to further processing.

Mistake in mixing in event of an interruption in application > 1 minute (bonding not permitted)
A sample bead of 50...70 mm must be rejected after an interruption in application
Expiration dates of accelerator and adhesive must not be more than 3 months apart
Expiration date >3 months results in the formation of bubbles/blisters (bonding not permitted)
Sealed adhesive:
May only be stored for a maximum of 8 hours once it has been heated up to 80 5C
The adhesive will be damaged if this time is exceeded (bonding not permitted)
Damaged adhesive must not be used and must be disposed of in compliance with national regulations
The glue cartridge may only be heated up once
If the lower label is black, this adhesive may only still be used cold without accelerator while
adhering to the expiration date.
IMPORTANT: Not all window glass may be bonded with accelerator (hot working).
If hot working is not permitted, this is described in the relevant document.
Adhesive expiration date

2010 BMW M3
Repair kit (A) and glue cartridges (B) are marked with a date (best before).
Date (1) refers to the calendar week and year (KW/JJJJ).
Fig. 350: Identifying Date On Kit And Glue Cartridges

The adhesive cannot be used after this date (1).
Adhesive disposal
Pure hardened adhesive is handled as normal waste.
The adhesive is disposed of in paper sacks so that it can react with moisture.
Non-hardened adhesive, cartridges and mixtures of adhesive and solvents and the like must be disposed of as
hazardous waste.
Accelerator (3-hour system)
Accelerator is screwed onto the glue cartridge and contains a reaction paste which is mixed with the heated
adhesive.
IMPORTANT: The accelerator may only be paired with the glue cartridge of an unopened
package (formation of bubbles/blisters).
Adhesive and accelerator must be paired while taking into account the
expiration dates.
The accelerator may no longer be used if the expiration dates are more than 3
months apart.
2010 BMW M3
Bonding agent (activator)
The BMW-approved bonding agents must be used to treat adhesive areas:
1-day system:
"Glass Activator 1" (on ceramic glass)

"Paint Activator A" (on sheet metal flange or residual adhesive bead)
1-hour system:
"Glass Activator (2)" (on ceramic glass), yellow stick, BMW part number: 83 19 0 444 142
"Paint Activator (B)" (on sheet metal flange), blue stick, BMW part number: 83 19 2 154 458
WARNING: Wear cut resistant gloves when breaking the glass ampoule
Prepare Glass Activator (2) and Paint Activator (B) for application by shaking and kinking (breaking glass
ampoule).
Apply Glass Activator (2) by pressing gently. There is no need for final wiping. Air drying time approx. 2
minutes.
Apply Paint Activator (B) by pressingly gently. Then wipe dry with a paper towel (included in the set).
Bonding agent expiration date
Repair kit and bonding agent are marked with a date (Best Before).
The bonding agent may only be used up to this date (if not already opened previously).
Once it has been opened (circlip broken), use for 1 week only even if the expiration date has not been
reached.
NOTE: Write the date on the bottle when opening the bonding agent for the first time.
Close the bottle immediately after extracting the bonding agent (reaction with
air).
Application of bonding agent
The bonding agent is used for adhesion between glass or ceramic glass and the adhesive. Therefore, a thin,
homogeneous and continuous line of bonding agent must be applied.
After compressing the adhesive bead, make sure that there is 1 to 2 mm wide bonding agent trace is on the
ceramic glass next to the adhesive bead (serves visual inspection).
2010 BMW M3
The adhesive bead may become up to 15 mm wide in compressed condition. The width of the adhesion agent is
therefore at least 17mm with windscreens and rear windows and at least 9 mm with door window glass.
The bonding agent may not be applied in the visible area or the point grid. Fresh bonding agent in the visible
area must immediately be wiped off with solvent because hardened bonding agent will leave a haze behind.
Fig. 351: Identifying Adhesive Bead And Bonding Agent

WINDOW GLASS ADHESIVE REFERENCE CHART

Graphic A Graphic B
Window glass with cover Window glass without cover.
If the adhesive bead (1) cannot expand further (a = 0 If the adhesive bead (1) can expand into both
mm) into one direction when pressing down, the directions while pressing down, the bonding agent
outer edge of the bonding agent bead (3) will run (3) and adhesive bead (2) will run toward each other
through Point a. in the center (m).
Removal of window glass
IMPORTANT: As of E63 and E87 it will only be possible to remove the rear window with the
"ROLL OUT 2000 ".
Cover side walls, roof-mounted aerial and if necessary interior equipment with protective covers.
Tape off body with fabric adhesive tape (e.g. Tesa) in those areas where the oscillating blade could damage the
window glass or the paint.
When using the cutting wire, pull the cutting wire ends through special tool 513270, bend and tape off with
fabric adhesive tape (e.g. Tesa) (risk of injury and damage).
2010 BMW M3
When removing the window glass:
Wear safety goggles and protective gloves.
Cut through adhesive bead of window glass:
With "ROLL OUT 2000 " (wire cutting system); no paint is damaged here in the case of narrow gaps
with special cutter and oscillating knife
Prior to each use, regrind the knife with a grindstone while the machine is running (new knives also).
Avoid paintwork damage on body aperture.
Guide knife carefully between body and window glass.
Run blade of knife parallel to window glass.
Cut through adhesive bead as closely as possible to window glass.
To remove residual adhesive bead in body aperture (and on window glass if reusing):
Use a scalpel for heavy-duty applications

Cut off adhesive residue to a thickness of approx. 0.5 mm
Remove residual adhesive bead only briefly before bonding
Damage to paintwork in body aperture
To ensure long-term corrosion protection, it is absolutely essential to touch up damage to paintwork!
The "BMW Color System" painting handbook forms the basis of these repair instructions and must be observed
without fail.
Touch up damage to paintwork on body aperture with BMW multibase filler.
Grind out scratches in non-visible areas and touch up with BMW multibase filler.
Grind extensive areas of damage down to the bare metal and coat with BMW multibase filler (layer thickness
30... 40 m).
Hardening time:
With infrared, at least 10 minutes

Without infrared for at least 60C, at least 30 minutes
Without infrared for at least 20C, at least 24 hours
2010 BMW M3
If a complete build-up of paint is required in the visible area:
Tape off primed adhesive flange before applying top coat
IMPORTANT: Observe hardening time of BMW multibase filler otherwise a perfect bond
cannot be guaranteed!
Treatment of adhesive area in body aperture:
ADHESIVE AREA TREATMENT DESCRIPTION CHART

Adhesive Treatment
Bonding and sealant for car window glass a. Clean with cleaning agent R2 (sourcing
reference: BMW Parts Department, part
number 83 19 0 417 324)
b. Observe an air drying time of at least 5
minutes (at least 15 minutes when applied to
residual adhesive bead)
c. 1-day system: Apply "Paint Activator A" to
paint and residual adhesive bead
d. 1-hour system: Apply "Paint Activator
B" (blue stick) to paint
e. Observe an air drying time of at least 1
minute (at least 10 minutes when applied to
IMPORTANT: Do not use Sika remover 208 for cleaning in the adhesive area.
Preparation for installation
Prepare plastic nozzle(s) for shaping adhesive bead (when not using the standard nozzle C), can be cut to size
during the air drying time.
Lay a sample bead of approx. 50 mm - watch out for formation of bubbles/blisters when hot bonding; if OK,
apply immediately to window glass.
Interruption must be < 5 seconds (incorrect mixture ratio).
Glue cartridge must be vertical to window glass.
Black ceramic glass impermeable to UV light is located on the peripheral zone of the inside edge of the window
to protect the adhesive bead.
Ceramic glass must not be damaged and must be treated as follows.

2010 BMW M3
1-day system: Treatment of ceramic glass surface (inside of window):
CERAMIC GLASS SURFACE TREATMENT - 1 DAY SYSTEM

Adhesive (with part numbers) Treatment
Repair kit Cold/Hot Bonding: a. Clean with cleaning agent R2 (sourcing
83 19 0 444 141/145 number 83 19 0 417 324)
Glue cartridge:
minute
83 19 0 444 144
c. Apply a thin coating of "Glass Activator (2)"
d. Observe an air drying time of at least 2
minutes
1-hour system: Treatment of ceramic glass surface (inside of window):
CERAMIC GLASS SURFACE TREATMENT - 1 HOUR SYSTEM

Repair kit: a. Clean with cleaning agent R2 (sourcing
83 19 0 444 141/145 number 83 19 0 417 324)
Glue cartridge:
minutes
83 19 0 444 144
minutes
Version with inspection glass for vehicle identification number in windscreen only
Close inspection glass (left bottom) with Sika bonding base VP 206 (part number 83 19 9 407 777*)
(*sourcing reference: BMW Parts Department)
Except for:
All US/GB models. In addition, all models or models on which the black I-panel cover means that the body
color can not be seen through the inspection glass.
Adhesive quantities
Approx. 1 1/4 glue cartridges are required to bond the windscreen on the following vehicles:
7 Series
5 Series from E60
2010 BMW M3
X5
X3
In the case of hot bonding (with accelerator), the missing residual adhesive bead is applied from a second glue
cartridge but while cold and without accelerator (formation of bubbles/blisters).
Minimum hardening time is thus not increased.
IMPORTANT: If a second cartridge is required for bonding:
First apply cold adhesive to cowl panel at bottom (skin formation time)
Accelerator from repair kit must not be used with the second glue cartridge (formation of bubbles/blisters)
Formation of bubbles/blisters results in leakage and insufficient bonding strength (torsional rigidity, front
passenger airbag).
Effect of differing adhesive quantities:
ADHESIVE QUANTITY EFFECT

Too little adhesive: Too much adhesive:
Window glass rests too low in body aperture Window glass rests too high in body aperture
Strains/tensions may occur (window glass Wind noise may occur
breakage) Strains/tensions may occur (window glass
Insufficient squeezing of adhesive bead breakage)
(leaking) Dirt contamination of add-on parts by
emerging adhesive
Adhesive on uninsulated strainer pressure
lines of aerial(s) (interference of reception)
Spacer buffers
Before sticking on new spacer buffers, remove all remaining traces of old spacer buffers completely.
Position of spacer buffers must be observed exactly.
Incorrectly fitted spacer buffers will result in:
Windscreen glass breakage

Leakage (if the spacer buffer is in the adhesive area)
Wind noises
Installation
2010 BMW M3
To prevent a pressure build-up in the passenger compartment when the doors are closed:
Open a side window
IMPORTANT: 1-day system:

After the adhesive bead has been applied, the window glass must be fitted
within 5 to 10 minutes (depending on air humidity, temperature and use of
accelerator).
After 5 to 10 minutes the adhesive bead forms a skin which can no longer
guarantee a perfect bond.
1-hour system:
Once the adhesive bead has been applied, the window glass must be installed
within 7 minutes (depending on air humidity, temperature).
After 7 minutes the adhesive bead forms a skin which can no longer guarantee
a perfect bond.
The general rule is:
To secure the window glass, use only the yellow plastic adhesive tape
(sourcing reference: BMW Parts Department, part number 83 19 9 410 979).
The window glass will slip down if other adhesive tapes are used.
Window glass slippage will result in leaks and wind noises.
Remove adhesive residue immediately with adhesive remover (Sika remover 208, sourcing reference: BMW
Parts Department). Do not press out the window glass again.
Check height of windscreen/rear window with special tool 510010 or 513210.
Assemble vehicle.
Hardening
The adhesive hardens as it reacts with air humidity (with accelerator also due to mixed-in reaction paste) at
room temperature.
Minimum hardening time (table) is obtained from 22C and 38 % relative air humidity.
At ambient temperatures above 23C and 50 % relative air humidity (hot countries), the adhesive open time is
shortened to approx. 5 minutes (skin formation time).
The adhesive hardening process is interrupted completely at ambient temperatures below 5C. In this event,
there will be no increase in the strength of the bonded connection.
Do not subject the vehicle to load on one side during the minimum hardening time (see table, without front
passenger airbag), such as e.g.:
2010 BMW M3
vehicle hoist
etc.
Maneuvering inside garage/workshop:
only permitted on level ground

do not under any circumstances drive over approach ramps, e.g. into multi-story parking structures
Remove adhesive tapes after hardening time.
If you fail to adhere to the minimum hardening times (see table, without front passenger airbag):
Leaks and/or wind noises may occur at the window glass
1-day system: Adhesives and their minimum hardening times:
ADHESIVE HARDENING TIME - 1 DAY SYSTEM

Minimum hardening time "with
Minimum hardening time front passenger
"without front passenger airbag" (countries where
airbag" (after which vehicle can seatbelt use is not required by
Adhesive be moved) law)
Hot working with accelerator 2 hours 3 hours(1)
Cold processing 9 hours 20 hours(1)
(1) Note
Vehicles with front passenger airbag:

The vehicle can be handed over to the customer after the hardening time (vehicle can be moved,
adhesive-dependent) with the following warning:
Once the windscreen glass has been bonded, all occupants must travel with their seatbelts attached
for "... hours"!
The time is taken from the "Minimum hardening time" table for countries where seatbelt use is not
required by law.
1-hour system: Adhesives and their minimum hardening times:
ADHESIVE HARDENING TIME - 1 HOUR SYSTEM

Cold processing 1 hour 2 hours(1)
2010 BMW M3
(1) Note

for "... hours"!
required by law.
IMPORTANT: If the minimum hardening time is not adhered to:
the front passenger together with the windscreen may fall out of the vehicle in the event of an accident
after the front passenger airbag has been triggered
Locate leaks
by spraying water underneath sealing lips

with ultrasonic leak detector (sourcing reference: BMW Parts Department)
If necessary, seal leakage with appropriate nozzle.
Version with GPS navigation system 1 (up to 9/97)
After installation of rear window:
Recalibrate magnetic field probe

Refer to functional description in ISID (Integrated Service Information Display/Diagnosis and
Information System)
Version with rain sensor, rain/light sensor or rain/light solar sensor
Remove complete rain sensor, rain/light sensor or rain/light solar sensor, see repair instructions.
After replacing windscreen:
Initialize rain sensor, rain/light sensor or rain/light solar sensor

Information System)
Version with automatic air conditioning
If condensation sensor is not mounted on new windscreen:

2010 BMW M3
Replace condensation sensor, REFER TO REPAIR INSTRUCTIONS .
Version with Head-Up Display (HUD)
When replacing windscreen in vehicles with rain/light solar sensor, replace this completely: See repair
instructions.
Before bonding, install windscreen with seal(s) and check HUD; if necessary, press expanding foam tape down
with hand roller.
After bonding windscreen, check and if necessary adjust HUD.
See Recommended Engine Oils For BMW Group Engines See 5134191 REPLACING LEFT OR RIGHT
FIXED DOOR WINDOW IN REAR WINDOW FRAME; or .
NOTE: If the document for the selected model is not required or not approved, the
following message will be displayed when clicking on the "cross-reference":
"No additional documents available in the current vehicle context".
51 31... REMOVE WINDSCREEN WITH "ROLL OUT 2000"
Windscreen removal system "Roll Out 2000"

2010 BMW M3
Fig. 352: Identifying Windscreen Removal System Components

NOTE: Both paint and ergonomic and health-endangering damage is minimized with
the "Roll Out 2000" system.
Sourcing reference:
WARNING: Follow See Recommended Engine Oils For BMW Group Engines See
5100... SAFETY INSTRUCTIONS FOR WORKING ON CARS WITH AIRBAG
SYSTEMS or 72 SAFETY PRECAUTIONS AND GENERAL INFORMATION
for working on vehicles with airbag systems (risk of injury).
IMPORTANT: Take care when handling sharp-edged tools and cutting wire (risk of damage to
head airbag and window glass).
2010 BMW M3
IMPORTANT: Always keep both suction cups dry and clean to ensure their optimum
adhesion on the windscreen.
Lubricate spool if lock rattling becomes too loud.
Always wear safety goggles and protective gloves for your own safety.
Mounting suction cup lifters on windscreen or rear window:
Fig. 353: Identifying Suction Cup Lifters Position On Windscreen

Secure position of suction cup lifters as shown:

1. Suction cup lifter with double spool
2. Suction cup lifter with single spool
3. Window
4. Cutting wire
2010 BMW M3
Fig. 354: Identifying Suction Cup Lifters Position On Windscreen

Preparatory work
Cut off required cutting wire length:
Length = 6 x window glass diagonal
The cutting wire loops must lie on top of each other in area (B).
They must not get caught up in each other. (Otherwise no possibility of cutting the adhesive bead/wire
will break.)
Overlapping of cutting wire loops approx. 10 cm.
Distance from right window edge approx. 30 cm.
Pulling cutting wire into vehicle
Cut off wire end (1) at an angle and pierce adhesive bead (2) with it.
Wire end must be bent towards window glass.
2010 BMW M3
Fig. 355: Identifying Wire End

Laying cutting wire around window glass
Starting from pull-in point, lay wire eyelet created on the outside around the window glass
Pull excess wire into passenger compartment
IMPORTANT: Make sure the cutting wire is located at all four corner points below the window
glass.
Check that the cutting wire is not caught on clamps or body.
Secure window glass on outside with adhesive tape against sliding.
Fig. 356: Laying Cutting Wire Around Window Glass

NOTE: Window glass (1) with installed seals (3) or molded-on surrounds:
Moisten cutting wire (4) and seals (3) on window glass (1) with water
Insert cutting wire (4) in bend (without kinking) between window glass(1)
2010 BMW M3
and body aperture (2)
Fig. 357: Inserting Cutting Wire Between Window Glass And Body Aperture
Protecting vehicle passenger compartment
To avoid damage and possible dirt contamination, protect A-pillars, roof and dashboard trim panel (3) by
means of plastic washer (1)
Always carry plastic washer (1) between respective wire (2) being tightened and trim panel components
Fig. 358: Identifying Plastic Washer, Respective Wire, Roof And Dashboard Trim Panel
Attaching wire in hoisting winch with double coil
Bend over cutting wire end (1) and insert into slot of spool (2)
Repeat process with other end of wire (1) and second spool (2)
Wind cutting wire (1) onto spools by hand until cutting wire (1) is under slight tension
2010 BMW M3
Fig. 359: Inserting Cutting Wire End Into Slot Of Spool

Starting the dismantling
NOTE: Spools can only be rotated in one direction.
Make sure the wire is always situated in the guide channel of the suction
cup lifter (1)
Fit reversible ratchet onto top spool shaft (2) and tighten wire
Start by cutting lower adhesive bead
At the end of the cutting process, the two wire loops join up at the lifting
winch (1)
Remove "Roll Out 2000"
Remove window glass
Fig. 360: Identifying Suction Cup Lifter And Spool Shaft

2010 BMW M3
51 31 021 REMOVING AND INSTALLING/REPLACING RUBBER FRAME FOR WINDSCREEN

(TOP)
Remove both gutter strips on windscreen
IMPORTANT: Rubber frame (1) features an aluminum section inlay (2).

If necessary, detach adhesive tape (9) between rubber frame (1) and roof outer
skin.
If necessary, remove fitted spacer buffers (8).
Carefully unwind rubber frame (1) (windscreen breakage).
Fig. 361: Removing Rubber Frame

NOTE: Tear-off lip (5) may be stuck to adhesive (4).

When rubber frame (1) is removed, tear-off lip (5) can tear off and remain in
vehicle.
3 Windscreen
6 Bridge
7 Pinched butyl
Replacement of rubber frame without windscreen removal
There is no sealing lip (2) in area (A) on left/right.
Detach tear-off lip (4) from rubber frame (1).
If adhesive leaks over tear-off lip (4), this area must be cut out partially.
2010 BMW M3
To facilitate installation, coat rubber frame (1) and body cutout with water.
Install rubber frame (1).
Fig. 362: Identifying Sealing Lip, Rubber Frame, Tear-Off Lip And Aluminum Strip
If necessary, pull liner* off adhesive tape (6) and press rubber frame (1) down firmly on roof outer skin.
3 Butylene tape
5 Aluminum strip
* Liner is the protective film on adhesive tape (6).
Replacement of rubber frame with removed or new windscreen
Fit rubber frame (1) with tear-off lip (4).
After installing windscreen: If necessary, pull liner* off adhesive tape (6) and press rubber frame (1) down
firmly on roof outer skin.
3 Butylene tape
5 Aluminum strip

2010 BMW M3
Fig. 363: Identifying Sealing Lip, Rubber Frame, Tear-Off Lip And Aluminum Strip
51 31 023 REMOVING AND INSTALLING OR REPLACING LEFT OR RIGHT GUTTER STRIP

ALONG WINDSCREEN
Unclip gutter strip (1) towards top.
IMPORTANT: Replace clips (2) after each removal.

Pay attention to installation position in event of different-colored clips (2).
Installation:
Locks (3) of clips (2) must not be damaged.
Fig. 364: Removing Gutter Strip

Replacement
only E70/71/72:
2010 BMW M3
Gutter strip is delivered cathodic dip-painted only and must be primed.
51 31 000 REMOVING AND INSTALLING/RENEWING WINDSCREEN
IMPORTANT: The "INSTRUCTIONS FOR WINDOW CEMENTING " serve as the basis for these
repair instructions and must be followed without fail.
51 31 200 REMOVING AND INSTALLING/REPLACING REAR WINDOW
IMPORTANT: The "INSTRUCTIONS FOR WINDOW CEMENTING " serve as the basis for these
51 31... REMOVING AND INSTALLING/REPLACING RETAINING STRIP FOR COWL PANEL

COVER
Remove COVER for cowl panel
IMPORTANT: Retaining strip (2) has an aluminum profile insert (1).

Carefully wind out retaining strip (2) (windscreen breakage).
4 Glue bead
5 Pinched butyl
6 Contact surfaces
Fig. 365: Removing Retaining Strip

Installation:
2010 BMW M3
Clean cutout.
Pay attention to center marking on retaining strip (1) and windscreen.
Insert positioner (2) for retaining strip (1) must be removed after it has been fitted on the windscreen but before
the windscreen itself is installed.
Replacement of retaining strip without windscreen removal
If adhesive has managed to get onto retaining strip (1), this area must be cut out partially.
To facilitate installation, coat and body cutout with water.
Replacement of retaining strip with removed or new windscreen
Fig. 366: Identifying Rubber Frame, Aluminum Strip, Contact Surfaces And Butyl
Fit rubber frame (1).
3 Aluminum strip
4 Contact surfaces
5 Butyl
51 48... REMOVING AND INSTALLING/REPLACING SOUND INSULATION ON COWL

PANEL/WINDSCREEN
NOTE: Sound insulation can only be replaced with the following removed:
WINDSCREEN
IMPORTANT: Press down expanding foam tape (5) shortly before installing windscreen (2)
2010 BMW M3
(with hand roller) or stick on if replacing. Relaxed expanding foam tape could
crush cement bead (3) (leaks, wind noises).
Replacement
Attach new expanding foam tape (5) to bulkhead upper section (6).
Expanding foam tape (5) may only be stuck up to corner point of bulkhead upper section (6).
Fig. 367: Identifying Dashboard Trim Panel, Windscreen, Glue Bead, Retaining Strip And Bulkhead
Upper Section

2. Windscreen
3. Glue bead
4. Retaining strip, bottom
5. Expanding foam tape (sound insulation, cowl panel)
6. Bulkhead upper section
51 31... REMOVING WINDOWS WITH AN OSCILLATING KNIFE
WARNING: Follow safety instructions for working on vehicles with airbag systems
(risk of injury).
IMPORTANT: Handle sharp-edged tools with care (risk of damage to the head airbag and the
window glass).
Follow the vehicle-specific repair instructions!
2010 BMW M3
Cover the working area (side walls, roof-mounted aerial and if necessary interior equipment) with protective
covers.
Tape off body with fabric adhesive tape (e.g. Tesa) in areas where the oscillating knife could damage the
Use suction cups (51 3 010) to lift out the window glass.
Always keep both suction cups dry and clean to ensure their optimum adhesion on the windscreen.
Secure window glass against falling out.
Fig. 368: Lifting Out Window Glass Using Suction Cups 51 3 010
Depending on the area of application, knife 1 or 2 is used.
1. Straight knife with adjustable thrust roller

2. U-shaped knife
Dimension (X) on the knife (1) can be adjusted individually, see vehicle-specific repair instructions.
NOTE: Sharpen knife blade before every use on a running machine with a grinding
stone (even with new knife blade).
2010 BMW M3
Fig. 369: Identifying Straight Knife With Adjustable Thrust Roller And U-Shaped Knife
Removing from the inside:
Run blade of knife parallel to glass.
Take care not to damage paintwork.
Cut through adhesive bead all the way around.
Pull window glass outwards to remove.
Fig. 370: Removing Window Glass From Inside

Removal from outside:

2010 BMW M3
Take care not to damage paintwork.
Cut through adhesive bead all the way around.
Pull window glass outwards to remove.
Fig. 371: Removing Window Glass From Outside

1. Body opening
2. Adhesive bead
3. Knife
4. Window
2010 BMW M3
Fig. 372: Cutting Through Adhesive Bead As Closely As Possible To Window Glass
51 31 015 REPAIRING DAMAGE TO WINDSCREENS CAUSED BY STONE CHIPS (CLEAR AND

TINTED LAMINATED SAFETY GLASS)
Field of vision (no repairs acceptable):
Fig. 373: Identifying Height, Width And Field View Gap

A. 50 mm (gap between field of view/center of vehicle)

B. Up to end of wiper range, outside (field of view width)
C. Restriction by wiper range (height of field of view)
IMPORTANT: Repairs must only be carried out outside of the field of vision (refer to sketch).
51 31 025 REPLACING LEFT OR RIGHT GUTTER STRIP ALONG WINDSCREEN
Remove GUTTER STRIP

2010 BMW M3
NOTE: To facilitate installation, coat seal and gutter strip with water.
Fit inner part (1) of seal in accordance with measurements (A and B) on gutter strip (2).
A= approx. 30 mm
B= approx. 15 mm
Push seal (1) onto gutter strip (2) until both are flush in area (3).
Fig. 374: Identifying Seal Onto Gutter Strip

Installation:
Outer part (2) and inner part (3) of seal must not be stretched.
Fit outer part (2) and inner part (3) of seal on complete gutter strip (1).
If necessary, use special tool 00 9 323 SCRAPER as an aid.

2010 BMW M3
Fig. 375: Identifying Seal Outer Part And Inner Part On Gutter Strip
Align seal (1) to gutter strip (2) and secure in area (3) with Loctite 380 (sourcing reference: BMW Parts
Service).
A= Gutter strip, top
B= Gutter strip, bottom
Fig. 376: Identifying Seal And Gutter Strip

51 31 242 REPLACING RUBBER FRAME (BOTTOM) FOR REAR WINDOW
Open rear lid.
NOTE: For purposes of clarity, illustrations do not show the rear lid.
IMPORTANT: Rubber frame (1) features a stainless steel section inlay (2).
2010 BMW M3
Carefully pull off rubber frame (1) (rear window breakage).

vehicle.
No tear-off lip (5) is fitted as of build date 03/2006.
3 Pinched butyl
4 Bridge
7 Rear window
Fig. 377: Pulling Rubber Frame (Rear Window Breakage)

NOTE: Clean rear window in assembly area thoroughly with spirit.

There must be no remnants of butyl on the rear window.
When replacing without removing rear window:
To be able to remove butyl remnants better, insert special tool 009340 under
tension between body flange and rear window.
To do so, wrap a cleaning cloth soaked in spirit around special tool 009340
several time and remove butyl remnants between body flange and rear window.
Replacement of rubber frame with removed or new rear window:
Pay attention to center marking (1) on rubber frame (3) and rear window.
Place rubber frame (3) over center marking on rear window and align laterally.
Starting from center, press down rubber frame (3) with firm thumb pressure onto rear window over full length.
2 Marking with adhesive tape (if necessary)

2010 BMW M3
Fig. 378: Identifying Rubber Frame, Centre Marking And Rear Window
4 Stainless steel section inlay
5 Butyl
Fig. 379: Identifying Nozzle Cutting Position

2010 BMW M3
Replacement of rubber frame without rear window removal:
NOTE: Rubber frame is secured at side with window glass adhesive.

Read and comply with NOTES AND INSTRUCTIONS on handling window glass
adhesive.
Cut nozzle (4) at an angle in accordance with measurement (A).
A= 10 mm
Apply adhesive bead (1) on left and right of rubber frame (2) up to fold (3)
between rear window and body.
NOTE: Adhesive bead (1) must not protrude over rear window.
If adhesive has managed to get onto bridge (6), this area must be cut out
partially.
Mark center marking of rear window with adhesive tape on rear window.
Mark center marking (1) of rubber frame (3) with adhesive tape (2).
Place rubber frame (3) over center markings on rear window and align laterally.
Starting from center, press down rubber frame (3) with firm thumb pressure
onto rear window over full length.
Fig. 380: Identifying Rubber Frame, Centre Marking And Rear Window
51 31 241 REPLACING RUBBER FRAME (TOP/SIDE) FOR REAR WINDOW
Open rear lid.

Carefully unwind rubber frame (1) (rear window breakage).

2010 BMW M3
vehicle.
3 Rear window
6 Bridge
7 Pinched butyl
Fig. 381: Removing Rubber Frame

Installation:
Pay attention to center marking on rubber frame (1) and windscreen.
If adhesive has managed to get onto bridge (4), this area must be cut out partially.

2010 BMW M3
Fig. 382: Identifying Tear-Off Lip And Rubber Frame

2 Aluminum strip
5 Butyl
51 31... WINDOW GLASS REMOVAL WITH WIRE PULL HANDLE
WARNING: Follow SAFETY INSTRUCTIONS for working on vehicles with airbag

systems (risk of injury).
Attention! Handle sharp-edged tools with care (risk of damage to the head airbag and the window glass).
Attention! Follow the vehicle-specific repair instructions! Protect inner and outer working area (body, trim
panels, cables etc.) against damage.
Depending on the area of application, a separating cord can also be used as an alternative to wire (Cutting cord,
part number 81 43 2 344 272, refer to BMW Electronic Parts Catalogue).
Using the separating cord prevents any damage to the body.
Do not pull the separating cord over any sharp edges (risk of tearing)!
Use tools:
Wire pull handle with suction element, part number 81 43 2 326 501, refer to BMW Electronic Parts
Catalogue
Dashboard protector for vehicle window removal, part number 83 30 2 337 983, refer to BMW Electronic
Parts Catalogue
Wire starter for window glass disassembly, part number 83 30 2 336 541, refer to BMW Electronic Parts
Catalogue
2010 BMW M3
Use suction cups 51 3 010 to lift out the window glass.
Always keep both suction cups dry and clean to ensure their optimum adhesion on the windscreen.
Secure window glass (if necessary with adhesive tape) against falling out.
Fig. 383: Lifting Out Window Glass Using Suction Cups 51 3 010
Pulling cutting wire into vehicle:
Grip wire with pliers (If access is difficult: using wire starter 2 150 267, feed wire through adhesive
bead.)
Wire end (1) must be bent towards window glass.
Heat wire end (1) and use it to pierce adhesive bead (2).
Pull approximately half of the wire into the passenger compartment
NOTE: When using the separating cord, always pull it in using the wire starter 2 150
267.
2010 BMW M3
Fig. 384: Identifying Wire End

Using wire starter:
Bend wire end approx. 10 mm and insert in notched tip.
Pierce wire starter with uniform pressure through adhesive bead, wire end (bent part) must be positioned on
window glass.
Fig. 385: Using Wire Starter

Attach wire pull handles:
Feed in cutting wire (1) in cutting handle (2) and clamping element (3) as illustrated.
Move back cutting handle (2) over clamping element (3) and trap wire end (4).
WARNING: Danger of injury! Wire end (4) must not protrude out of cutting handle (2).
2010 BMW M3
Cutting handle (2) can be secured with suction cup (5) to the vehicle window or body during each of the work
operations. This prevents damage to the paint.
Fit second wire pull handle to other wire end.
Fig. 386: Attaching Wire Pull Handles

Perform repair work with the aid of a second person.
Cutting wire (4) must be guided in cutting direction at an acute as possible angle (>45) to adhesive bead (1).
Cut through adhesive bead (1) by pulling cutting handle (2) and at the same time providing counter support with
cutting handle (3).
Pull back cutting wire (4) with cutting handle (3) and make sure that cutting wire (4) is always held under
tension.
Cut through remaining adhesive bead in the same way.

2010 BMW M3
Fig. 387: Cutting Through Adhesive Bead

FRONT MANUALLY OPERATED WINDOWS

2010 BMW M3

51 32 160 REMOVE AND INSTALL/REPLACE HOUSING COVER ON INNER LEFT OR RIGHT

SIDE WINDOW FRAME

Cover (2) must not be kinked.
If necessary, feed out cable (1) and disconnect plug connection.
Lever cover (2) out of retainers (3).

2010 BMW M3
Unclip cover (2) in direction of arrow and remove.
Fig. 389: Removing Clip Cover

Installation:
Following parts of cover (3) must not be damaged or missing:
1. Retainer (not on E87)

2. Sound insulation
Replacement
If necessary, remove SPEAKER .
Fig. 390: Identifying Sound Insulation, Retainer And Cover

51 32 170 REMOVING AND INSTALLING/REPLACING DOOR WINDOW GLASS, FRONT LEFT

OR RIGHT
2010 BMW M3
NOTE: When removing door lock, it is not necessary to remove window cavity cover
strips or seals.
Open door window to 105 mm.

Remove SOUND INSULATION IN FRONT DOOR
E87 only:
Remove OUTER WINDOW CAVITY COVER STRIP
E84/90 only:
Remove INNER WINDOW CAVITY SEAL
Door window glass (1) must be opened to dimension (A).
A = approx. 105 mm
IMPORTANT: Disconnect plug connection (2) from power window motor (3) (risk of trapping).
Lever out catches (4) with screwdriver (5) in direction of arrow.
Installation:
Catch (4) must be correctly clipped into place.
Fig. 391: Identifying Door Window Glass Dimension

Carry out function check on power window unit and anti-trapping protection.
2010 BMW M3
If necessary, NORMALIZE power window unit.
Installation:
Following parts of window guide (3) must not be damaged or missing:
1. Catch
2. Bump stop
Fig. 392: Identifying Catch, Bump Stop And Window Guide

When removing door lock:
Slide door window glass upwards and secure in door window frame with adhesive tapes or plastic wedge.
When removing door window glass:
Turn door window glass and lift out towards rear/top.
Fig. 393: Removing Door Window Glass

2010 BMW M3
51 32 420 REMOVING AND INSTALLING/REPLACING TRIM ON FRONT DOOR WINDOW

FRAME, LEFT OR RIGHT
E83 only:
Remove window cavity cover strip on outside of front door
Partially detach rubber window seal (1) at rear.
Fig. 394: Disconnecting Rubber Window Seal

Release screws (1).
Remove finisher (2) and press approx. 3 mm towards rear.
Fig. 395: Removing Finisher And Screws

Remove trim (1) towards top.

2010 BMW M3

Installation:
Following parts must not be damaged or missing:
1. Plastic nuts
2. Sound insulation
3. Seal
Fig. 397: Identifying Seal, Sound Insulation And Plastic Nuts

Installation:
Check trim (1) for damage, replace if necessary.

2010 BMW M3
Fig. 398: Identifying Trim

51 32 211 REPLACING FRONT LEFT OR RIGHT RUBBER GUIDE FOR LEFT OR RIGHT DOOR
WINDOW
Remove MIRROR
Remove TRIM ON WINDOW FRAME of front door
Remove sound insulation (1).
Fig. 399: Removing Sound Insulation

Detach rubber guide (1) in direction of arrow from front door (2).
Installation:
2010 BMW M3
Moisten rubber guide (2) prior to fitting with APPROVED ANTI-FRICTION AGENT .
Fig. 400: Detaching Rubber Guide From Front Door

Installation:
Rubber guide (1) must not be damaged in corners (2).
Fig. 401: Identifying Rubber Guide And Corners

FRONT ELECTRICALLY OPERATED WINDOWS

51 33 000 REMOVING AND INSTALLING (REPLACING) POWER WINDOW REGULATOR IN
NOTE: Disengage, but do not remove, door window and secure in the door window
frame.

2010 BMW M3
FRONT DOOR WINDOW
Unscrew nuts (1).
Feed out rear section of power window unit (2) in direction of arrow.
Fig. 402: Removing Power Window Unit Rear Section

Feed out front section of power window unit (1) with flat motor (2) in direction of arrow from front door.
Replacement
Remove FLAT MOTOR FOR POWER WINDOW UNIT .
Fig. 403: Removing Power Window Unit Front Section With Flat Motor
51 33... SLIGHTLY LOOSEN POWER WINDOW REGULATOR TO REMOVE DOOR LOCK IN

2010 BMW M3
NOTE: To remove door lock, move rear section of sound insulation (1) toward center.
Partly remove SOUND INSULATION FROM FRONT DOOR .
Fig. 404: Identifying Sound Insulation

Raise side window glass to dimension (A).
Dimension (A) is the distance between the window cavity cover strip and upper edge of the side window glass.
For E90/E91:
Measurement (A) = 310 mm
E87:
Measurement (A) = 225 mm

2010 BMW M3
Fig. 405: Identifying Side Window Glass Dimension

Fig. 406: Inserting Side Window Glass Using Special Tool (51 3 190)
Insert special tool 51 3 190 into designated opening (1) of side window glass (2)
2010 BMW M3
Unlock side window glass (2) from rear part of power window regulator (3) in direction of arrow.
NOTE: Avoid damaging the paint finish. (Risk of corrosion)
Unscrew nuts (1).
Remove rear part of power window regulator (2) and place down on door floor.
Tightening torque: 51 33 1AZ
Fig. 407: Identifying Power Window Regulator And Nuts

REAR MANUALLY OPERATED WINDOWS

2010 BMW M3

51 34 160 REMOVING AND INSTALLING/REPLACING HOUSING COVER ON INNER LEFT OR

RIGHT DOOR WINDOW FRAME
Open door window.

Version with roller sun blind:
Remove ROLLER SUN BLIND ON FIXED SIDE WINDOW

2010 BMW M3
Pull off hooks (2) in outwards direction.
Detach cover (1) sideways from clips (3) and unclip in inwards direction or lever out and remove.
Fig. 409: Pulling Hooks In Outwards Direction

Replacement
If necessary, release screw (1) on hook (2).
Remove hook (2) in direction of arrow from cover (4).
Fig. 410: Removing Hook From Cover

Version without roller sun blind:
Lever out cover (1) at clips (2).
Unclip cover (1) in direction of arrow or lever out and remove.

2010 BMW M3
NOTE: Do not tear off cover (1) in area (3).
Fig. 411: Removing Cover And Clips

Installation:
Following parts of cover (1) must not be damaged:
2 All-round guide
3 Connection point
Fig. 412: Identifying Cover And Connection Point

51 34... REMOVING AND INSTALLING/REPLACING TRIM FOR WINDOW GUIDE OF LEFT OR

RIGHT REAR DOOR

2010 BMW M3
Remove outer WINDOW CAVITY COVER STRIP
Remove COVER ON DOOR WINDOW FRAME
Remove ROLLER SUN BLIND ON FIXED SIDE WINDOW
Pull rubber guide (1) out of trim (2).
Fig. 413: Pulling Rubber Guide From Trim

IMPORTANT: FOLLOW INSTRUCTIONS FOR BONDING ACOUSTIC INSULATION .
Detach acoustic insulation (1) in area (A).
Release screw (2) behind acoustic insulation (1).
Grip trim firmly and release screws (3).

2010 BMW M3
Fig. 414: Identifying Acoustic Insulation And Screw

Push trim (1) downwards from rubber guide (2) and remove towards top.
Installation:
Make sure rubber guide (2) is correctly seated on trim (1).
Fig. 415: Pushing Trim Downwards From Rubber Guide

Installation:
Threads (1) of trim (2) must not be damaged.

2010 BMW M3
Fig. 416: Identifying Trim Threads

51 34 420 REMOVING AND INSTALLING/REPLACING TRIM ON WINDOW FRAME OF REAR

DOOR (FRONT), LEFT OR RIGHT
Open rear side window
Detach rubber seal (1) and rubber guide (2) from trim.
Fig. 417: Removing Rubber Seal And Rubber Guide From Trim
Release screws (1).
Carefully detach trim (2) towards front/top.
Installation:
Fitted foam pieces must not be damaged when trim (2) is pushed in.
2010 BMW M3
Fig. 418: Removing Trim On Window Frame

Installation:
If necessary, replace faulty plastic nuts (1).
Fig. 419: Identifying Plastic Nuts

51 34 191 REPLACING LEFT OR RIGHT FIXED DOOR WINDOW IN REAR WINDOW FRAME
IMPORTANT: The "INSTRUCTIONS FOR WINDOW BONDING " serve as the basis for these
51 34 171 REPLACING REAR LEFT OR RIGHT DOOR WINDOW
Remove SOUND INSULATION IN REAR DOOR

Remove inner WINDOW CAVITY COVER STRIP
2010 BMW M3
Remove TRIM ON REAR DOOR WINDOW FRAME
Open door window glass (1) down to distance (A)
A = approx. 120 mm
Fig. 420: Identifying Door Window Glass Distance

Installation:
Carry out function check on power window unit and anti-trapping protection.
If necessary, NORMALIZE power window unit.

2010 BMW M3
Fig. 421: Disconnecting Plug Connection From Power Window Motor

Installation:
1. Catch
2. Buffer stop
Fig. 422: Identifying Catch, Bump Stop And Window Guide

Remove door window glass (1) towards top.
Installation:
Door window glass does not need to be adjusted.

2010 BMW M3

51 34 211 REPLACING RUBBER GUIDE FOR REAR LEFT OR RIGHT DOOR WINDOW
Remove COVER ON INSIDE DOOR WINDOW FRAME

Release TRIM ON WINDOW GUIDE and slide downwards slightly, do not remove
E91 only:
NOTE: Window cavity cover strip does not have to be removed.
Lever out rubber guide (1) on door window frame at front (2) with special tool 00 9 317.
2010 BMW M3
Fig. 424: Removing Rubber Guide On Door Window Frame Using Special Tool (00 9 317)
Pull rubber guide (1) out of window guide.
Detach rubber guide (1) in direction of arrow from door.
Fig. 425: Pulling Rubber Guide From Window Guide

Installation:
Moisten rubber guide (2) prior to fitting with APPROVED ANTI-FRICTION AGENT .
Close door window glass (1) a little.
Push rubber guide (2) onto door window glass (1) and into window guide (3).
2010 BMW M3
Fig. 426: Pushing Rubber Guide On Door Window Glass And Window Guide
51 34... REPLACING THE LEFT OR RIGHT WINDOW GUIDE RAIL COVER
Remove outer WINDOW CAVITY COVER STRIP
Version without roller sunblind:
Remove COVER ON DOOR WINDOW FRAME
Version with roller sunblind:
Remove ROLLER SUNBLIND ON PERMANENT SIDE WINDOW
Pull rubber guide (1) out of cover (2).
Fig. 427: Pulling Rubber Guide Out Of Trim

2010 BMW M3
IMPORTANT: Follow the INSTRUCTIONS FOR BONDING SOUND INSULATION.
Open sound insulation (1) in area (A).
Release screw (2) behind the sound insulation (1).
Hold cover and undo screws (3).
Fig. 428: Identifying Acoustic Insulation And Screws

Push cover (1) downwards from rubber guide (2) and remove towards top.
Installation note:
Make sure rubber window seal (2) is correctly seated on cover (1).

Installation note:
2010 BMW M3
Threads (1) of cover (2) must not be damaged.
Fig. 430: Identifying Threads Of Trim

REAR ELECTRICALLY OPERATED WINDOWS

51 37 000 REMOVING AND INSTALLING/REPLACING COMPLETE REAR LEFT OR RIGHT
POWER WINDOW REGULATOR
frame.
DOOR WINDOW GLASS, REAR
Unscrew nuts (1).

2010 BMW M3
Fig. 431: Identifying Rear Power Window Unit Nuts

Turn power window unit (1) in rear door and feed out in direction of arrow.
Fig. 432: Removing Rear Door Power Window Unit

Replacement
Release screws (1) and detach flat motor (2) from power window unit (3).
Fig. 433: Detaching Flat Motor For Power Window Unit From Power Window Unit
ELECTRICAL POWER WINDOWS, BODY

51 31... NOTES ON WINDOW BONDING
2010 BMW M3
IMPORTANT: For 03-2009
the "1 Hour System" was introduced.
Two different adhesive systems are described and identified accordingly in the
following:
"1-day system"
"1-hour system"
For 01-2010
the information for the Expiration date (Best Before) on the repair kit and
window glue cartridge was changed and now refers to Calendar week and
Year (CW/YYYY).
For 03-2010
a "Repair kit, large" was introduced for the "1 Hour System" under part
number 83 19 0 444 145.
In addition to the "Repair kit, small" delivery, this kit includes a second
window glue cartridge.
Recommended for 5-Series, 6-Series, 7-Series, X3, X5.
These instructions are not applicable to side window bonding (door "center") on the E38/L7:
General
The windscreen, rear window and side windows are glued to the body. This bonding will increase the
torsional rigidity of the vehicle. To obtain perfect bonding, comply with the installation procedure
described in the following.
The adhesive must be applied at room temperatures > 15C to avoid negatively affecting the bonded
connection.
Adjust the component and interior temperature accordingly.
An air humidity of < 30% significantly slows hardening.

The window glass must be secured against slipping with yellow plastic adhesive tape (sourcing reference:
BMW Parts Department) after being installed. The paint must be completely hardened after painting
work.
2010 BMW M3
Always apply the adhesive in such a way as to achieve tension-free bonding!
On-the-job safety
When working with bonding products (adhesive, cleaning agent, bonding agent, etc.):

clothing on hand).
creams
Do not eat, drink or smoke in areas of polyurethane processing.
All use and safety information of the safety data sheet (SDB) for the applicable product apply. The safety
data sheet (SDB) can be obtained from the Aftersales Assistance Portal (ASAP)
Replacement of windscreens
Version with Head-Up Display (HUD):
Stick on LABEL
ADHESIVE BEAD CUTTING TOOLS

Type Type Order/part number
Special cutter (manufacturer: Compressed air operated 7 23 63 100 23 8
Fein) with oscillating knife Electrically operated 7 53 60 200 00 4
BMW knife set All required knives PN 81 43 9 428 596 or
6 39 03 167 05 4
Knife (U-shape) 19.5 mm (1) 6 39 03 118 01 3
24 mm 6 39 03 076 01 6
36 mm 6 39 03 079 01 2
45 mm 6 39 03 154 01 0
Knife (straight with stop roller) 16 to 35 mm (adjustable) 6 39 03 143 01 3
10 mm (fixed)(1) 6 39 03 189 01 0
2010 BMW M3
14 mm (fixed) 6 39 03 082 01 6
" ROLL OUT 2000 " Window Wire cutting system (1) PN 81 62 0 301 768
glass repair
Cutting wire Wire cutting system (1) PN 83 19 2 150 267
Scalpel for heavy-duty applications (1)
Handles for cutting wire Self-locking (1) Special tool 513270
Storage temperature
1-day system: Storage temperature of all adhesive products of 5C to 25C must be observed.
1-hour system: Storage temperature of all adhesive products of more than 15C must be observed.
Adhesive
The BMW approved polyurethane adhesive must be used for bonding:
1-day system: Window glass adhesive (Part number 83 19 0 444 144)
1-hour system: Repair kit, small (part number 83 19 0 444 141) or large (part number 83 19 0 444 145)
The repair kit, large contains a second window glass glue cartridge.
Adhesive is applied to window glass with cartridge gun (compressed airy or electrically operated.
When using accelerator (hot working, 3-hour system)
sensor to diagnosis system
Heat adhesive for one hour in cartridge oven to 80 5C
Write date and time on cartridge when inserting into cartridge oven
Insufficient heating (< 1 hour) results in the formation of bubbles/blisters (bonding not permitted)
Temperature < 80 5C results in the formation of bubbles/blisters (bonding not permitted)
Remove hardened adhesive prior to further processing.

Mistake in mixing in event of an interruption in application > 1 minute (bonding not permitted)
A sample bead of 50...70 mm must be rejected after an interruption in application
Expiration dates of accelerator and adhesive must not be more than 3 months apart
Expiration date >3 months results in the formation of bubbles/blisters (bonding not permitted)
Sealed adhesive:
2010 BMW M3
May only be stored for a maximum of 8 hours once it has been heated up to 80 5C
The adhesive will be damaged if this time is exceeded (bonding not permitted)
The glue cartridge may only be heated up once
If the lower label is black, this adhesive may only still be used cold without accelerator while
adhering to the expiration date.
IMPORTANT: Not all window glass may be bonded with accelerator (hot working).
If hot working is not permitted, this is described in the relevant document.
Adhesive expiration date
Repair kit (A) and glue cartridges (B) are marked with a date (best before).
Date (1) refers to the calendar week and year (KW/JJJJ).
Fig. 434: Identifying Adhesive Expiration Date On Kit And Glue Cartridges
The adhesive cannot be used after this date (1).
Adhesive disposal
The adhesive is disposed of in paper sacks so that it can react with moisture.
hazardous waste.
2010 BMW M3
Accelerator (3-hour system)
Accelerator is screwed onto the glue cartridge and contains a reaction paste which is mixed with the heated
adhesive.
IMPORTANT: The accelerator may only be paired with the glue cartridge of an unopened
package (formation of bubbles/blisters).
Adhesive and accelerator must be paired while taking into account the expiration dates.
The accelerator may no longer be used if the expiration dates are more than 3 months apart.
Bonding agent (activator)
The BMW-approved bonding agents must be used to treat adhesive areas:
1-day system:
"Glass Activator 1" (on ceramic glass)

1-hour system:
"Glass Activator (2)" (on ceramic glass), yellow stick, BMW part number: 83 19 0 444 142
"Paint Activator (B)" (on sheet metal flange), blue stick, BMW part number: 83 19 2 154 458
WARNING: Wear cut resistant gloves when breaking the glass ampoule
Prepare Glass Activator (2) and Paint Activator (B) for application by shaking and kinking (breaking glass
ampoule).
Apply Glass Activator (2) by pressing gently. There is no need for final wiping. Air drying time approx. 2
minutes.
Apply Paint Activator (B) by pressingly gently. Then wipe dry with a paper towel (included in the set).
Bonding agent expiration date
Repair kit and bonding agent are marked with a date (Best Before).
Once it has been opened (circlip broken), use for 1 week only even if the expiration date has not been
reached.
2010 BMW M3
air).
Application of bonding agent
The bonding agent is used for adhesion between glass or ceramic glass and the adhesive. Therefore, a thin,
homogeneous and continuous line of bonding agent must be applied.
After compressing the adhesive bead, make sure that there is 1 to 2 mm wide bonding agent trace is on the
ceramic glass next to the adhesive bead (serves visual inspection).
The adhesive bead may become up to 15 mm wide in compressed condition. The width of the adhesion agent is
therefore at least 17mm with windscreens and rear windows and at least 9 mm with door window glass.
The bonding agent may not be applied in the visible area or the point grid. Fresh bonding agent in the visible
area must immediately be wiped off with solvent because hardened bonding agent will leave a haze behind.
Fig. 435: Identifying Adhesive Bead And Bonding Agent

WINDOW GLASS ADHESIVE REFERENCE CHART

Graphic A Graphic B
Window glass with cover Window glass without cover.
If the adhesive bead (1) cannot expand further (a = 0 If the adhesive bead (1) can expand into both
mm) into one direction when pressing down, the directions while pressing down, the bonding agent
outer edge of the bonding agent bead (3) will run (3) and adhesive bead (2) will run toward each other
through Point a. in the center (m).
Removal of window glass

2010 BMW M3
"ROLL OUT 2000 ".
Cover side walls, roof-mounted aerial and if necessary interior equipment with protective covers.
Tape off body with fabric adhesive tape (e.g. Tesa) in those areas where the oscillating blade could damage the
When using the cutting wire, pull the cutting wire ends through special tool 51 3 270 , bend and tape off with
fabric adhesive tape (e.g. Tesa) (risk of injury and damage).
When removing the window glass:
Wear safety goggles and protective gloves.
With "ROLL OUT 2000 " * (wire cutting system); no paint is damaged here in the case of narrow gaps
with special cutter* and oscillating knife*
*Sourcing reference: BMW Workshop Equipment and Planning Documentation
Prior to each use, regrind the knife with a grindstone while the machine is running (new knives also).
Avoid paintwork damage on body aperture.
Run blade of knife parallel to window glass.
To remove residual adhesive bead in body aperture (and on window glass if reusing):

Cut off adhesive residue to a thickness of approx. 0.5 mm
Remove residual adhesive bead only briefly before bonding
Damage to paintwork in body aperture
without fail.
2010 BMW M3
Grind extensive areas of damage down to the bare metal and coat with BMW multibase filler (layer thickness
30... 40 m).
Hardening time:

Tape off primed adhesive flange before applying top coat
Treatment of adhesive area in body aperture:
ADHESIVE AREA TREATMENT DESCRIPTION CHART

Adhesive Treatment
Bonding and sealant for car window glass a. Clean with cleaning agent R2 (sourcing
number 83 19 0 417 324)
minutes (at least 15 minutes when applied to
c. 1-day system: Apply "Paint Activator A" to
paint and residual adhesive bead
d. 1-hour system: Apply "Paint Activator
B" (blue stick) to paint
e. Observe an air drying time of at least 1
minute (at least 10 minutes when applied to
IMPORTANT: Do not use Sika remover 208 for cleaning in the adhesive area.
Preparation for installation
Prepare plastic nozzle(s) for shaping adhesive bead (when not using the standard nozzle C), can be cut to size
Lay a sample bead of approx. 50 mm - watch out for formation of bubbles/blisters when hot bonding; if OK,
2010 BMW M3
Interruption must be < 5 seconds (incorrect mixture ratio).
Glue cartridge must be vertical to window glass.
Black ceramic glass impermeable to UV light is located on the peripheral zone of the inside edge of the window
to protect the adhesive bead.
Ceramic glass must not be damaged and must be treated as follows.
1-day system: Treatment of ceramic glass surface (inside of window):
CERAMIC GLASS SURFACE TREATMENT - 1 DAY SYSTEM

Repair kit Cold/Hot Bonding: a. Clean with cleaning agent R2 (sourcing
83 19 0 444 141/145 number 83 19 0 417 324)
Glue cartridge:
minute
83 19 0 444 144
minutes
1-hour system: Treatment of ceramic glass surface (inside of window):
CERAMIC GLASS SURFACE TREATMENT - 1 HOUR SYSTEM

Repair kit: a. Clean with cleaning agent R2 (sourcing
83 19 0 444 141/145 number 83 19 0 417 324)
Glue cartridge:
minutes
83 19 0 444 144
minutes
Version with inspection glass for vehicle identification number in windscreen only
Close inspection glass (left bottom) with Sika bonding base VP 206 (part number 83 19 9 407 777*)
(*sourcing reference: BMW Parts Department)
Except for:
2010 BMW M3
All US/GB models. In addition, all models or models on which the black I-panel cover means that the body
color can not be seen through the inspection glass.
Adhesive quantities:
Approx. 1 1/4 glue cartridges are required to bond the windscreen on the following vehicles:
7 Series
5 Series from E60
X5
X3
In the case of hot bonding (with accelerator), the missing residual adhesive bead is applied from a second glue
cartridge but while cold and without accelerator (formation of bubbles/blisters).
Minimum hardening time is thus not increased.
IMPORTANT: If a second cartridge is required for bonding:
Accelerator from repair kit must not be used with the second glue
cartridge (formation of bubbles/blisters)
Formation of bubbles/blisters results in leakage and insufficient bonding

strength (torsional rigidity, front passenger airbag).
ADHESIVE QUANTITY EFFECT DESCRIPTION CHART

Window glass rests too low in body aperture Window glass rests too high in body aperture
Strains/tensions may occur (window glass Wind noise may occur
breakage) Strains/tensions may occur (window glass
Insufficient squeezing of adhesive bead breakage)
(leaking) Dirt contamination of add-on parts by
emerging adhesive
Adhesive on uninsulated strainer pressure
lines of aerial(s) (interference of reception)
Spacer buffers
2010 BMW M3

Wind noises
Installation
To prevent a pressure build-up in the passenger compartment when the doors are closed:
Open a side window

accelerator).
1-hour system:
Once the adhesive bead has been applied, the window glass must be installed
within 7 minutes (depending on air humidity, temperature).
After 7 minutes the adhesive bead forms a skin which can no longer guarantee
a perfect bond.
The general rule is:
To secure the window glass, use only the yellow plastic adhesive tape
(sourcing reference: BMW Parts Department, part number 83 19 9 410 979).
The window glass will slip down if other adhesive tapes are used.
Window glass slippage will result in leaks and wind noises.
Remove adhesive residue immediately with adhesive remover (Sika remover 208, sourcing reference: BMW
Parts Department). Do not press out the window glass again.
Check height of windscreen/rear window with special tool 510010 or 513210.
Assemble vehicle.
Hardening
The adhesive hardens as it reacts with air humidity (with accelerator also due to mixed-in reaction paste) at
room temperature.
2010 BMW M3
At ambient temperatures above 23C and 50 % relative air humidity (hot countries), the adhesive open time is
shortened to approx. 5 minutes (skin formation time).
The adhesive hardening process is interrupted completely at ambient temperatures below 5C. In this event,
there will be no increase in the strength of the bonded connection.
Do not subject the vehicle to load on one side during the minimum hardening time (see table, without front
passenger airbag), such as e.g.:
one wheel on curb

vehicle hoist
etc.

do not under any circumstances drive over approach ramps, e.g. into multi-story parking structures
If you fail to adhere to the minimum hardening times (see table, without front passenger airbag):
Leaks and/or wind noises may occur at the window glass
1-day system: Adhesives and their minimum hardening times:
ADHESIVE MINIMUM HARDENING TIME - 1 DAY SYSTEM

Hot working with accelerator 2 hours 3 hours(1)
Cold processing 9 hours 20 hours(1)
(1) Note

for "... hours"!
required by law.
2010 BMW M3
1-hour system: Adhesives and their minimum hardening times:
ADHESIVE MINIMUM HARDENING TIME - 1 HOUR SYSTEM

Cold processing 1 hour 2 hours(1)
(1) Note

for "... hours"!
required by law.
Locate leaks

with ultrasonic leak detector (sourcing reference: BMW Parts Department)
Version with GPS navigation system 1 (up to 9/97)
Recalibrate magnetic field probe

Information System)
Version with rain sensor, rain/light sensor or rain/light solar sensor
Remove complete rain sensor, rain/light sensor or rain/light solar sensor, see repair instructions.

2010 BMW M3

Information System)
Version with automatic air conditioning
If condensation sensor is not mounted on new windscreen:
Replace condensation sensor, REFER TO REPAIR INSTRUCTIONS .
Version with Head-Up Display (HUD)
When replacing windscreen in vehicles with rain/light solar sensor , replace this completely: See repair
instructions.
Before bonding, install windscreen with seal(s) and check HUD; if necessary, press expanding foam tape down
with hand roller.
See repair instructions See 5134191 REPLACING LEFT OR RIGHT FIXED DOOR WINDOW IN
REAR WINDOW FRAME.
NOTE: the document for the selected model is not required or not approved, the
following message will be displayed when clicking on the "cross-reference":
"No additional documents available in the current vehicle context".

POWER WINDOW REGULATOR
frame.
DOOR WINDOW GLASS, REAR
Unscrew nuts (1).

2010 BMW M3
Fig. 436: Identifying Rear Power Window Unit Nuts

Fig. 437: Removing Rear Door Power Window Unit

Replacement

2010 BMW M3
Fig. 438: Disconnecting Flat Motor For Power Window Unit

FRONT DOOR TRIM PANEL WITH ARM REST

General
On-the-job safety

clothing on hand).
creams
2010 BMW M3
ADHESIVE AREA HANDLING DESCRIPTION CHART

Adhesive Cleaning
a. Butyl bead applied to sound insulation with a. Isohexane (benzine)
protective film b. 2-propanol (isopropanol)
b. Butyl mini-round profile 3 mm from the roller
c. Butyl round profile 6 mm from the roller Under no circumstances: paint thinning
c. Carry out bonding only after an air drying

time > or = 1 min. Air drying time may be
omitted if the entire bonding surface is wiped
with a dry cloth
d. After cleaning, the bonding surface may not
be touched with hands or fouled again
SOUND INSULATION AREA REPAIR

Repair Cut the butyl rope between the sound
in the event of damaged sound insulation or leakage insulation and the inner door panel with a
sharp knife
After the repair is finished, position a new
butyl rope 3 mm directly on the original
adhesive bead
Heat the butyl bead with a standard hot air
blower until the butyl rope strings when
touched slightly. Do not damage the sound
insulation in the process
Press down with special tool 51 0 300 .
Perform this work extremely carefully
because the increased amount of adhesive
requires pressure of > or = 20 N/cm2
(compared to firm thumb pressure ~ 30
N/cm2 )
Visually check the adhesive bead and its
compression (no capillaries or broken
adhesive bead permitted)
In the cases mentioned, the complete sound
insulation must be replaced. After removing
the sound insulation, removal all butyl
2010 BMW M3
remnants from the inner door panel. Apply 6

mm [] butyl rope to new sound insulation
Press down with special tool 51 0 300 to > or
= 20 N/cm2 (compare to firm thumb pressure
~ 30 N/cm2 )

See repair instructions See 5148060 REMOVING AND INSTALLING/REPLACING SOUND

INSTALLING/REPLACING SOUND INSULATION ON LEFT OR RIGHT REAR DOOR

2010 BMW M3

51 41 000 REMOVING AND INSTALLING LEFT OR RIGHT FRONT DOOR TRIM PANEL
Driver's side only:
Remove DECORATIVE STRIP FROM DOOR TRIM PANEL
Passenger side only:
Remove COVER ON DOOR HANDLE
Driver's side only:

2010 BMW M3
Release screws (1).
Fig. 440: Identifying Front Door Trim Panel Screws (Driver Side)
Release screws (1).
Fig. 441: Identifying Front Door Trim Panel Screws (Passenger Side)
NOTE: Start by unclipping door trim panel (2) at bottom.
Unclip clips (1) for door trim panel (2) with special tool 009317 .
2010 BMW M3
Fig. 442: Removing Door Trim Panel Clips

Carefully unclip door trim panel (1) at top from retainers (2).
Fig. 443: Removing Door Trim Panel Clip From Retainers

Disconnect all plug connections and remove door trim panel.

2010 BMW M3

Installation:
If necessary, replace faulty clips.
Fit all clips with sealing ring.
Make sure clips are installed in correct position.
1. Grey clip
2. White clip
US/CND version:
Crashpad (3) must be correctly fitted.
(SEE REPLACING DOOR TRIM PANEL)
Fig. 445: Identifying Grey Clip, White Clip And Crashpad

2010 BMW M3
Installation:
After assembling the door trim panel proceed as follows:
Open door window.

Lock with vehicle key.
Check for ease-of-movement on retaining button linkage
If necessary, align linkages
51 41 017 REMOVING AND INSTALLING/REPLACING COVER ON FRONT DOOR HANDLE

(PASSENGER SIDE)
Remove DECORATIVE STRIP from front door (passenger side)
Lever out cover (1) with special tool 009317 .
Fig. 446: Removing Cover On Front Door Handle (Passenger Side)

Installation:

2010 BMW M3
Fig. 447: Identifying Catches And Cover

51 41 030 REMOVING AND INSTALLING/REPLACING DECORATIVE STRIP ON FRONT LEFT

OR RIGHT DOOR TRIM PANEL
Starting at front, release decorative strip (1) with special tool 009317 from clips (2).
Feed decorative strip (1) towards rear out of retaining hook (3) and remove.
Installation:
No clip (Hutfix) must be fitted under third clip (2) from rear.
Fig. 448: Removing Decorative Strip Using Special Tool (00 9 317)
Installation:
Released or damaged Hutfix clips (1) must be replaced.

2010 BMW M3
Fig. 449: Identifying Hutfix Clips

Installation:
Clips (1) on decorative strip (2) and counterpiece on door trim panel must not be damaged.
Retaining hook (3) must not be damaged.
Fig. 450: Identifying Clips On Decorative Strip And Retaining Hook

51 41 019 REMOVING AND INSTALLING/REPLACING DOOR HANDLE ON DOOR TRIM PANEL

AT FRONT (PASSENGER SIDE) LEFT OR RIGHT

Only drill down to door trim panel area (2) so as not to damage the contact
2010 BMW M3
surface.
Drill out welding spots (1) on door trim panel (2) with 8 mm dia. welding spot drill bit.
Remove welding residue from door trim panel (2) and door handle with a scalpel (for heavy-duty applications)
if these components are to be reused.
Fig. 451: Identifying Welding Spots On Door Trim Panel

Replacement
Drill out holes (1) in door handle (2) to 3.0 mm dia.
Fig. 452: Identifying Door Handle

2010 BMW M3
Slide door handle (1) into door trim panel (2).
Fig. 453: Identifying Door Handle And Door Trim Panel

Installation:
Turn door trim panel over and lay with door handle on clean surface
Lay large washer (1) on welding pin (2) and mark
Remove door handle and saw off all welding pins (2) slightly below marking
Insert door handle
Fit large washer (1) and small washer (3)
Secure with screw (4)
Tighten down all 4 screws
Fig. 454: Identifying Large Washer On Welding Pin And Mark

2010 BMW M3
51 48 060 REMOVING AND INSTALLING/REPLACING SOUND INSULATION IN LEFT OR

RIGHT FRONT DOOR
IMPORTANT: INSTRUCTIONS FOR SOUND INSULATION are an essential part of these repair
instructions and must be followed without fail.
Do not detach sound insulation in jerks (risk of damage).
After every repair, check that the sound insulation is water-tight (water
ingress).
Remove DOOR TRIM PANEL
Position of sealing bead (1).
Feed cable (3) out of sound insulation (2).
Fig. 455: Identifying Sealing Bead And Sound Insulation

IMPORTANT: When cutting through sealing bead (1), do not damage sound insulation (2) and
if necessary cable.
With a suitable sharp cutting tool (3) cut through sealing bead (1) of sound insulation (2) in the area to be
detached.
2010 BMW M3
Fig. 456: Cutting Sealing Bead Of Sound Insulation Using Sharp Cutting Tool
Clean bonding area with adhesive remover (sourcing reference: BMW Parts Service).
Air drying time: 1 minute
NOTE: Replacement:
Lay 6 mm dia. butyl rope (sourcing reference: BMW Parts Department) in specified adhesive area.
Heat butyl cord (hot air blower) and press down firmly on sound insulation all round.
Contact pressure with hand roller: approx. 20 N/cm2
Manual contact pressure: approx. 10 N/cm2
NOTE: Firm thumb pressure has approx. 30 N/cm2
NOTE: Position of butyl rope (1) on sound insulation (2).

2010 BMW M3
Fig. 457: Identifying Butyl Rope On Sound Insulation

NOTE: A marking (2) is provided all round on the sound insulation (1).
Butyl rope (3) rests on or inside the marking (2).
Fig. 458: Identifying Marking On Sound Insulation And Butyl Rope

51 41 081 REPLACING ARMREST ON FRONT LEFT OR RIGHT DOOR TRIM PANEL (DRIVER'S
SIDE)
Removal
2010 BMW M3
IMPORTANT: Only drill down to door trim panel area (2) so as not to damage the contact
surface.
Armrest is welded to door trim panel only during initial installation, release
mounting elements if necessary.
Remove armrest.
Remove welding residue on door trim panel (2) with scalpel.
Fig. 459: Identifying Welding Spots On Door Trim Panel

Installation:
Armrest is secured in areas (A and C) with nuts (2).
Because of reduced height and risk of damage to acoustic insulation, locking washers (3) are used in area (B).
After armrest is secured, pins (1) must be sawn off to measurement (X) (exception: third, ninth and eleventh
pins from front).
IMPORTANT: Do not snip off pins (1) with side cutters as this will deform the pins so that the
retaining elements may work loose.
In order not to undershoot measurement (X) when sawing off, place suitable
shim on retaining elements (2 and 3) and saw off pins (1) above shim.
2010 BMW M3
Fig. 460: Identifying Locking Washers And Pins Dimension

Measurement (X) = 2 mm
Installation
Secure pins (1) in area (A and C) with nuts (2).
NOTE: Carefully tighten nuts (2) to ensure they are not overtightened.
Secure pins (1) in area "B" (fourth, fifth and sixth pins from front) with locking washer (3).
If necessary, grip armrest from outside with a suitable tool (tool must not damage door trim panel).
Saw off all pins (1), except third, ninth and eleventh pins (1), to measurement (X) (risk of damage to acoustic
insulation).
Dimension (X) = 2 mm
2010 BMW M3
Fig. 461: Identifying Locking Washers And Pins Dimension

51 41 001 REPLACING FRONT LEFT OR RIGHT DOOR TRIM PANEL

Remove
Remove SPEAKER TRIM
Remove INSIDE DOOR OPENER
Remove ROCKER SWITCH FOR SIDE WINDOW OPERATION
Remove FOOTWELL LIGHT .
Cut out cutout (1) for entrance light on new door trim panel with scalpel.
2010 BMW M3
Fig. 462: Identifying Cutout And Entrance Light On Door Trim Panel
US/CND national-market version:
If necessary, replace crashpad (1).
Pull off protective film from rear side of crashpad (1).
Stick crashpad (1) on door trim panel.
Installation:
Positioning by way of uniform distance to mounting (2) and outer edge (3).
Press on crashpad (1) firmly for approx. 20 seconds.
Fig. 463: Identifying Crashpad On Door Trim Panel

2010 BMW M3
51 41 018 REPLACING SPEAKER TRIM ON FRONT LEFT OR RIGHT DOOR TRIM PANEL
Remove mid-range speaker in door trim panel at front
Carefully release speaker trim (1) at catches (2) and remove in outwards direction.
NOTE: Catches (2) are held in position by installed speaker.
Installation:
Make sure catches (2) are in correct position. Speaker trim (1) can only be installed in one position.
Fig. 464: Identifying Speaker Trim And Catches

Installation:
Catches (1) must not be damaged or missing.

2010 BMW M3
REAR DOOR TRIM PANEL WITH ARM REST

General
On-the-job safety

clothing on hand).
creams
ADHESIVE AREA HANDLING DESCRIPTION CHART

Adhesive Cleaning
a. Butyl bead applied to sound insulation with a. Isohexane (benzine)
protective film b. 2-propanol (isopropanol)
b. Butyl mini-round profile 3 mm from the roller
c. Butyl round profile 6 mm from the roller Under no circumstances: paint thinning
c. Carry out bonding only after an air drying

time > or = 1 min. Air drying time may be
omitted if the entire bonding surface is wiped
2010 BMW M3
with a dry cloth

d. After cleaning, the bonding surface may not
be touched with hands or fouled again
SOUND INSULATION REPAIRING

Repair Cut the butyl rope between the sound
in the event of damaged sound insulation or leakage insulation and the inner door panel with a
sharp knife
After the repair is finished, position a new
butyl rope 3 mm directly on the original
adhesive bead
Heat the butyl bead with a standard hot air
blower until the butyl rope strings when
touched slightly. Do not damage the sound
insulation in the process
Press down with special tool 51 0 300 .
Perform this work extremely carefully
because the increased amount of adhesive
requires pressure of > or = 20 N/cm2
(compared to firm thumb pressure ~ 30
N/cm2 )
Visually check the adhesive bead and its
compression (no capillaries or broken
adhesive bead permitted)
In the cases mentioned, the complete sound
insulation must be replaced. After removing
the sound insulation, removal all butyl
remnants from the inner door panel. Apply 6
mm butyl rope to new sound insulation
Press down with special tool 51 0 300 to > or
= 20 N/cm2 (compare to firm thumb pressure
~ 30 N/cm2 )

2010 BMW M3
See repair instructions . See 5148060 REMOVING AND INSTALLING/REPLACING SOUND

INSTALLING/REPLACING SOUND INSULATION ON LEFT OR RIGHT REAR DOOR.

2010 BMW M3

51 42 000 REMOVING AND INSTALLING LEFT OR RIGHT REAR DOOR TRIM PANEL
Remove COVER ON DOOR HANDLE
Remove ROLLER SUN BLIND on fixed side window
Release screws (1).

2010 BMW M3
Fig. 467: Identifying Rear Door Trim Panel Screws

Unclip clips (1) for door trim panel (2) with special tool 009317.
Fig. 468: Identifying Door Trim Panel And Clips

Carefully unclip door trim panel (1) at top from retainers (2) and remove.
Disconnect plug on power window switch.

2010 BMW M3
Fig. 469: Removing Door Trim Panel And Retainers


Installation:
Clips (1) are white.
Clip (2) is brown and shorter than clips (1).

2010 BMW M3
Fig. 471: Identifying White Clips And Brown Clip

Installation:
Open door window.

51 42 017 REMOVING AND INSTALLING/REPLACING COVER ON DOOR HANDLE, REAR LEFT

OR RIGHT
Remove DECORATIVE STRIP from door trim panel at rear
Lever out cover (1) with special tool 009317 .

2010 BMW M3
Fig. 472: Removing Cover On Door Handle Using Special Tool (00 9 317)
Installation:

51 42 030 REMOVING AND INSTALLING/REPLACING DECORATIVE STRIP (LIGHT STRIP) ON

REAR LEFT OR RIGHT DOOR TRIM PANEL
Starting at rear, release decorative strip (1) with special tool 009317 from clips (2).
Feed decorative strip (1) towards front out of retaining hook (3) and remove.
Installation:
Released or damaged Hutfix clips must be replaced.

2010 BMW M3
Fig. 474: Removing Retaining Hook Decorative Strip

Installation:
Clips (1) on decorative strip (2) and counterpieces on door trim panel must not be damaged.
Fig. 475: Identifying Clips On Decorative Strip

51 48 070 REMOVING AND INSTALLING/REPLACING SOUND INSULATION ON LEFT OR

RIGHT REAR DOOR
It is essential to ensure the sound insulation is watertight (water intrusion)
every time any repair work has been carried out.
2010 BMW M3
Feed wires (2) out of sound insulation (3).
Fig. 476: Identifying Sealing Bead, Wires And Sound Insulation

if necessary cable.
detached.
2010 BMW M3
NOTE: Replacement:
Heat butylene tape (hot air blower) and press down firmly on sound insulation all round.
Contact pressure with hand roller: approx. 20 N/cm 2

2010 BMW M3


51 42 001 REPLACING LEFT OR RIGHT REAR DOOR TRIM PANEL

Remove INSIDE DOOR OPENER
Remove TOGGLE SWITCH
Specification with speaker:
Remove speaker cover . See 5142018 REPLACING SPEAKER TRIM ON REAR LEFT OR
2010 BMW M3
RIGHT DOOR TRIM PANEL or 6513080 REMOVING AND INSTALLING/REPLACING

SPEAKER (TWEETER IN REAR DOOR)
Remove mid-range speaker, door at rear
Specification with roller sun blind:
Remove ROLLER SUN BLIND
Remove entrance light.
Fig. 480: Identifying Cutout And Entrance Light On Door Trim Panel
51 42 018 REPLACING SPEAKER TRIM ON REAR LEFT OR RIGHT DOOR TRIM PANEL
Carefully lever out trim (1) with special tool 009317 and remove.
Installation:
Trim (1) can only be installed in one position.
Turn trim (1) until catches on trim (1) match up with mountings on door trim panel.
2010 BMW M3
Fig. 481: Removing Trim Using Special Tool (00 9 317)

Installation:

SIDE COVERING WITH ARMRESTS

51 43 075 REMOVING AND INSTALLING/REPLACING SIDE TRIM PANEL, FOOTWELL, ON A-
PILLAR, RIGHT
Remove FRONT ENTRANCE COVER STRIP (INSIDE)

Remove TRIM FOR INSTRUMENT PANEL, BOTTOM LEFT
Detach mucket (1) in area of side trim panel (2).

2010 BMW M3
Unclip side trim panel (2) with special tool in direction of arrow at retaining points (3) and remove.
Fig. 483: Removing Side Trim Panel And Mucket

Installation:
If necessary, lever out clips (1) remaining in bores.
Position side trim panel (2) pre-installed with clips (1) on associated bores and clip into place.
Fig. 484: Identifying Side Trim Panel With Clips

51 43 150 REMOVING AND INSTALLING OR REPLACING TRIM FOR LEFT OR RIGHT DOOR
PILLAR (BOTTOM)
Remove FRONT DOOR SILL COVER STRIP

2010 BMW M3
E84 only:
Remove REAR DOOR SILL COVER STRIP
Snap trim (2) out of clips (1) at bottom.
Feed out trim (2) for door pillar from door sill cover strip (3).
Fig. 485: Removing Trim Door Pillar From Door Sill Cover Strip
Partially detach edge protection in area of B pillar panel.
Carefully feed out bottom trim (1) from top trim (2).
Fig. 486: Removing Bottom Trim From Top Trim

Installation:

2010 BMW M3
Fig. 487: Identifying Guides On Trim And Clips

51 43 201 REMOVING AND INSTALLING OR REPLACING TRIM FOR ROOF PILLAR AT FRONT
(A-PILLAR), LEFT OR RIGHT
WARNING: Follow safety instructions for working on cars with airbag systems.
IMPORTANT: Do not use any sharp-edged tools to remove trim (risk of damage to head
airbag).
Unclip protective cap (1) with special tool 00 9 341 and remove.
Fig. 488: Opening Protective Cap Using Special Tool (00 9 341)
Release mucket (1) in area of trim for front roof pillar (2).
2010 BMW M3
Release screw (3), tightening torque 51 43 1AZ .
Unclip trim for front roof pillar (2) from mounting point (4).
Feed trim for front roof pillar (2) out of instrument panel trim (5) and remove.
Fig. 489: Removing Trim For Front Roof Pillar Of Instrument Panel Trim
Installation:
If necessary, lever out clips (1) remaining in bore.
If necessary, replace faulty clip (1).
Make sure guides (3) of trim for front roof pillar (2) are correctly seated in associated mountings.
Position trim for front roof pillar (2) pre-assembled with clip (1) on associated bore and clip into place.
Fig. 490: Identifying Front Roof Pillar Trim With Guides And Clip
2010 BMW M3
51 43 148 REMOVING AND INSTALLING OR REPLACING TRIM ON LEFT OR RIGHT DOOR

PILLAR (TOP)
Remove PANEL FOR DOOR PILLAR (BOTTOM)

Release SEAT BELT SCREW ON FRONT SEAT
Release clips (1).
Pull off panel (2) towards bottom.
Separate webbing.
Fig. 491: Pulling Door Pillar Trim Panel Towards Bottom

Installation:
Following parts of trim (1) must not be damaged or missing:
2 Guides
3 Clips
Fixtures for expansion rivets

Belt finisher strip
2010 BMW M3
Fig. 492: Identifying Door Pillar Trim Clips And Guides


PILLAR, LEFT (DRIVER SIDE)
Remove FRONT ENTRANCE COVER STRIP (INSIDE)

Remove TRIM PANEL FOR PEDAL ASSEMBLY .
Unscrew bolt (3).
Remove hood/bonnet release lever (4) from side trim panel (2).
Fig. 493: Detaching Mucket In Area Of Side Trim Panel

Release screw (1).

2010 BMW M3
Unclip side trim panel (4) in each case in direction of arrow at retaining points (2 and 3).
If necessary, disconnect associated plug connection and remove side trim panel (4).
Fig. 494: Removing Side Trim Panel

Installation:
Position side trim panel (2) pre-installed with clips (1) on associated bores and clip into place.
Replacement
Remove SWITCH FOR UNLOCKING REAR LID .

2010 BMW M3
Fig. 495: Identifying Side Trim Panel Clips

Replacement on right-hand drive up to model year 2005
NOTE: Because of altered locators on side trim panel and trim panel for pedals from
model year 2005, the trim panel for pedals must be reworked.
Cut off ribs (1) on trim panel for pedals (2) flat with scalpel.
Fig. 496: Identifying Ribs On Trim Panel For Pedals Flat

51 43 251 REMOVING AND INSTALLING/REPLACING TRIM PANEL FOR LEFT OR RIGHT

REAR ROOF PILLAR (C-PILLAR)
WARNING: Follow SAFETY INSTRUCTIONS for working on vehicles with airbag

systems.
airbag).
2010 BMW M3
Detach mucket (1) in area of trim panel for roof pillar (4).
Pull trim panel for roof pillar (4) in direction of arrow and detach from clips (3).
Installation:
Fit trim panel (4) over openings for clips (3) and snap into place.
Fig. 497: Pulling Trim Panel For Roof Pillar

Installation:
Clips (1 and 2) must not be damaged or missing.
If necessary, replace faulty clips (1 and 2).

2010 BMW M3
Fig. 498: Identifying Clips

ROOF TRIM PANEL

51 44 011 REMOVING AND INSTALLING OR REPLACING ROOFLINER (WITH SLIDE/TILT
SUNROOF)
Remove SUN VISORS AND COUNTER SUPPORTS on left/right

If necessary, remove both MIRROR LIGHTS
Remove ROOF LIGHT (FRONT)
Remove TRIM PANELS FOR ROOF PILLAR at front left/right (A-pillar trims)
Remove front/rear HANDLES
Remove TRIM PANELS FOR DOOR PILLAR on left/right (B-pillar trims)
Remove TRIM PANELS FOR ROOF PILLAR at rear left/right (C-pillar trims)
Remove ROOF LIGHT (REAR)
Remove TRIM FOR AUXILIARY BRAKE LIGHT
Remove left FRONT SEAT
IMPORTANT: When removing, do not touch edges of roofliner.
Move seat back of right front seat to maximum rear position.
Release expander rivets (1).
Detach roofliner (2) from Velcro-type fasteners (3).
Detach roofliner (2) from clips (4).

2010 BMW M3
Detach mucket (6) towards inside.
Detach mucket (5) from all doors in area of roofliner (2).
Lay roofliner (2) downwards.
Fig. 499: Identifying Roofliner Clips And Expander Rivets

IMPORTANT: The following tasks must be carried out with a second person assisting:
Tilt headliner and remove to left rear door.
Installation:
Following parts of roofliner must not be damaged or missing:
Mounting and frame (1) for front mounting bracket

Wiring harness (2)
Mounting and frame (3) for rear mounting bracket
Velcro-type fasteners (4)
Clips (5).
2010 BMW M3
Fig. 500: Identifying Roofliner Velcro-Type Fasteners And Clips

IMPORTANT: Depending on the build date/version, replacement can involve different Velcro-
type connections.
Mixed installation of the Velcro-type connection is not permitted.
In order to avoid mixed installation, remove the old Velcro-type material and attach the new Velcro-type
material.
New and old Velcro-type fasteners differ in color:
Black: Old Velcro-type fastener
White: New Velcro-type fastener
Only black/black or white/white pairings are permitted.
Procedure for replacing Velcro-type connection:
Detach Velcro-type connection from slide/tilt sunroof or console connection.
Remove adhesive residue.
Clean adhesive area with spirit.
Air drying time: = 1 minute
IMPORTANT: Adhesive area must be dry and free from dust and grease.
Attach new Velcro-type connections.

2010 BMW M3
Fig. 501: Locating Adhesive Area

If replacing version with mirror lights:
Cut out pre-marked cutout area (1) for left/right mirror light with a scalpel.
IMPORTANT: Ensure a clean cut so that the headliner material is not damaged on the inside.
Fig. 502: Identifying Pre-marked Cutout Area Of Left/Right Mirror Light

If replacing version with cable to inside rearview mirror:
Mark cutout (1) on roofliner.
A= Centre of roofliner
B= 14 mm
C= 20 mm
2010 BMW M3
Cut out cutout (1) with scalpel.
Fig. 503: Identifying Roofliner Cutout Dimensions

Installation:
Installation sequence:
1. Secure roof liner with mucket

2. Secure roofliner in middle to Velcro-type fastener
3. Snap roofliner at rear onto clips
4. Insert expander rivets at front
5. Screw down grab handles at front on left/right
6. Screw down grab handles at rear on left/right
7. Screw down sun visors and counter supports
8. Add final details to vehicle
51 44 001 REMOVING AND INSTALLING/REPLACING HEADLINER (WITHOUT SLIDE/TILT

SUNROOF)
Except for the steps relating to the slide/tilt sunroof, the work is identical to
REMOVING AND INSTALLING/REPLACING HEADLINER (WITH SLIDE/TILT SUNROOF)
INSTRUMENT CLUSTER TRIM PANEL

2010 BMW M3

51 45 370 REMOVING AND INSTALLING (REPLACING) LEFT DECORATIVE STRIP ON

INSTRUMENT PANEL
Lever out left decorative strip on instrument panel (2) at fastening points (1) with special tool 009317 and
remove in direction of arrow.
2010 BMW M3
Fig. 505: Removing Left Decorative Strip On Instrument Panel Using Special Tool 00 9 317
Replacement
Unlock left fresh-air grill (1) at retaining lugs (2) and remove in direction of arrow from left decorative strip on
instrument panel (3).
Installation:
Make sure left fresh-air grill (1) is correctly seated in mountings (4) of left decorative strip on instrument panel
(3).
Make sure retaining lugs (2) are correctly seated in left decorative strip on instrument panel (3).
Fig. 506: Removing Left Fresh-Air Grill From Left Decorative Strip On Instrument Panel
51 45 380 REMOVING AND INSTALLING (REPLACING) RIGHT DECORATIVE STRIP ON

DASHBOARD

2010 BMW M3
Avoid subjecting the CIC to shaking/shocks.

Do not turn special tool 00 9 317 when levering out and pay attention to
pressure points.
Lever out decorative strip (2) from left side beginning at retaining points (1)
with special tool 00 9 317.
Disconnect associated plug connection and remove decorative strip (2).
Fig. 507: Removing Decorative Strip Using Special Tool 00 9 317

Installation:
Clips (1) must be seated in associated mountings.
If necessary, remove clips (1) remaining on decorative strip.
Replace damaged clips (1):
A. Turn clip (1) with screwdriver to left by approx. 90.

B. Lever out clip (1) from below.
2010 BMW M3
Fig. 508: Removing Clips On Decorative Strip

Replacement
Remove START/STOP SWITCH

SWITCH FOR HAZARD WARNING SYSTEM/CENTRAL LOCKING
Remove RIGHT FRESH-AIR GRILLE
Remove CENTRE FRESH-AIR GRILLE
51 45... REMOVING AND INSTALLING CARRIER FOR INSTRUMENT PANEL
Remove INSTRUMENT PANEL TRIM

Disconnect all necessary cable ties on support tube
Release wiring harnesses/cable ducts and lay to one side
If necessary, remove control units/disconnect plug connections
WARNING: To avoid injury, cover holder (1) on support tube (2).

2010 BMW M3
Fig. 509: Identifying Cover Holder And Support Tube

Detach wiring harness (3) from support tube (2).
Release screws (1) of heater on support tube (2).
Fig. 510: Identifying Heater Screws And Support Tube

Release nuts (1) on right and left on support tube (2).

2010 BMW M3
Fig. 511: Identifying Nuts On Right And Left On Support Tube

Release screw (1) of heater on support tube (2).
Fig. 512: Identifying Heater Screw And Support Tube

Release screw (1) on support tube (2).

2010 BMW M3
Fig. 513: Identifying Screw And Support Tube

Release screws (1) on support tube (2) from bracket (3).
Detach support tube (2) with a 2nd person helping and remove.
Fig. 514: Identifying Screws, Support Tube And Bracket

51 45 030 REMOVING AND INSTALLING INSTRUMENT PANEL TRIM
PROTECTION) .

2010 BMW M3

Move front seats back completely and lower
Remove STEERING COLUMN
Remove both TRIMS FOR FRONT ROOF PILLAR
Remove TRIM PANEL FOR PEDAL ASSEMBLY
Remove INSTRUMENT CLUSTER
Remove LIGHT OPERATOR UNIT
Remove DECORATIVE STRIP ON INSTRUMENT PANEL ON RIGHT
Remove operator unit for heating and air conditioning system See 6411378 REMOVING AND
INSTALLING/REPLACING HEATING - A/C SYSTEM CONTROL PANEL (VERSION WITH
CCC/ASK AND CIC) or 6411377 REMOVING AND INSTALLING/REPLACING HEATER/AIR
CONDITIONER OPERATOR UNIT (VERSION
Remove INSERT FOR RADIO CONTROL KEY
In appropriate version:
Remove RADIO RECEIVER
Remove AUDIO SYSTEM CONTROLLER
If necessary, remove ON-BOARD MONITOR

Remove RIGHT GLOVEBOX WITH HOUSING
Remove mid-range speaker, in instrument panel
If necessary, remove SOLAR SENSOR
2010 BMW M3
Fig. 515: Pulling Back Instrument Panel Trim

Unfasten screws (1 and 3).
Pull back instrument panel trim (2) in direction of arrow.
Disconnect available plug connections and remove instrument panel trim (2).
Installation:
Make sure guides (2) on instrument panel trim (1) are correctly seated in respective mountings.
Make sure seals are correctly seated on air ducts.

2010 BMW M3
Fig. 516: Identifying Guides And Instrument Panel Trim

51 45 181 REMOVING AND INSTALLING/REPLACING BOTTOM RIGHT TRIM FOR

INSTRUMENT PANEL
NOTE: Move front passenger seat completely towards rear.
Release screws (1).
Feed out trim (2) bottom front.
If necessary, detach plug from footwell light.
Fig. 517: Removing Trim Bottom Front

Installation:
Replacement
2010 BMW M3
If necessary, remove FOOTWELL LIGHT
Fig. 518: Identifying Guides And Trim

51 45 263 REMOVING AND INSTALLING/REPLACING INSTRUMENT PANEL TRIM ON RIGHT
Carefully release trim (1) with special tool 00 9 321 from retainers (3) and lock pins (2).
Fig. 519: Removing Trim From Retainers And Lock Pins Using Special Tool (00 9 321)
Installation:
Clips (Hutfix) (1) must be seated in associated mountings.
Replace clips (Hutfix) (1) if they were released during removal.
A. Turn clip (Hutfix) (1) with screwdriver to left by approx. 90

B. Lever out clip (Hutfix) (1) from below
2010 BMW M3
Fig. 520: Removing Clips Remaining On Decorative Strip

Installation:
Lock pins (1) and retainers (3) on trim (2) must not be damaged.
If necessary, replace lock pins (1) and retainers (3).
Fig. 521: Identifying Pins And Retainers On Trim

51 45 185 REMOVING AND INSTALLING/REPLACING PANEL FOR PEDALS
Release screws (1).
Pull back trim for pedal assembly (2).
Disconnect associated plug connections and remove trim for pedal assembly (2).
IMPORTANT: Disconnecting the plug connection for the hands-free system speaker results
in fault memory entries in the telephone control unit (limitation in the
2010 BMW M3
emergency SOS call system).

After fitting, read out fault memory and if necessary delete entries.
Fig. 522: Identifying Screws And Pedal Assembly

Replacement (depending on Security version)
1. Modify SPEAKER (Park Distance Control)

2. Modify FOOTWELL LIGHT
3. Modify MOST direct access bracket
4. Modify BLUETOOTH AERIAL
5. Cut out opening for clutch pedal
Fig. 523: Identifying Clutch Pedal Opening Cut Out Mark

2010 BMW M3
Replacement on right-hand drive up to model year 2005
NOTE: It is necessary to rework the side trim panel because of modified locators on
the side trim panel and the panel for the pedal assembly from model year 2005.
Remove SIDE TRIM PANEL (DRIVER'S SIDE) .
Cut off the first three upper ribs (1) on side trim panel (2) flat with a scalpel to contact face (3).
Fig. 524: Identifying First Three Upper Ribs On Side Trim Panel
51 45 031 REPLACING INSTRUMENT PANEL TRIM
Release screws (1).
Remove center function carrier (2) from instrument panel trim (3).
2010 BMW M3
Fig. 525: Removing Centre Function Carrier From Instrument Panel Trim
Release screws (1).
Remove speaker receptacle (2) from instrument panel trim (3).
Fig. 526: Identifying Speaker Receptacle, Instrument Panel Trim And Screws
Remove AIRBAG MODULE ON PASSENGER SIDE .
Release screws (1).
Remove holder for airbag module on passenger side (2) from instrument panel trim (3).
Fig. 527: Identifying Holder For Airbag Module On Passenger Side And Instrument Panel Trim
Unclip both side fresh-air grills (1) with special tool 00 9 340 in direction of arrow from instrument panel trim
(2).
2010 BMW M3
Unclip cover for steering column opening (3) in direction of arrow from instrument panel trim (2).
Fig. 528: Unclipping Both Side Fresh-Air Grills Using Special Tool (00 9 340)
Remove all metal nuts (2) and clips (3) from instrument panel trim (1).
Fig. 529: Removing Instrument Panel Trim, Metal Nuts And Clips
51 45... REPLACING SIDE COVER ON INSTRUMENT PANEL
Pull off mucket of front door in area of cover
Unclip cover (1) with special tool 00 9 340 in direction of arrow from instrument panel trim (2).
If necessary, disconnect associated plug connection.

2010 BMW M3
Fig. 530: Unclipping Cover From Instrument Panel Trim Using Special Tool (00 9 340)

If replacing version with Isofix system version:
Remove switch for passenger airbag deactivation.
PARCEL SHELF TRIM PAN ROLLER SUN BLIND

51 46 001 REMOVING AND INSTALLING PANEL FOR REAR WINDOW SHELF (PARCEL SHELF)
Remove left/right TRIM PANEL FOR ROOF PILLAR (C-pillar)

Remove REAR MID-RANGE SPEAKER on left/right
Release bottom rear seat belts . See 7211101 REMOVING AND INSTALLING/REPLACING REAR
2010 BMW M3
CENTRE SEAT BELT or 7211092 REMOVING AND INSTALLING/REPLACING REAR LEFT

OR RIGHT SEAT BELTS .
Version with child seat holder:
Remove all TOP TETHER EYELETS FOR CHILD SEAT
Version without through-loading system:
Remove BACKREST for rear seats
Version with through-loading system:
Remove TRIM ON REAR WINDOW SHELF

Remove left/right ARMREST SIDE SECTIONS
If necessary, remove DRAWER in luggage compartment
Release screws (1).
Fig. 532: Identifying Rear Window Shelf Panel And Screws

Disconnect connector (1).

2010 BMW M3
Fig. 533: Identifying Connector

All versions:
Remove plate (1).
Pay attention to catches (2).
Remove trim (1) and feed out from belt (3).
Fig. 534: Removing Trim From Belt

Release clips (2).

2010 BMW M3
All versions:
Pull out rear window shelf (1) towards front and feed out belts (4).
Installation:
Make sure rear window shelf (1) is correctly fed under grid (3)
Fig. 535: Pulling Out Rear Window Shelf And Belts

51 46 005 REMOVING AND INSTALLING TRIM FOR ODDMENTS TRAY (BACK SHELF WITH
REAR WINDOW ROLLER BLIND AND THROUGH-LOADING SYSTEM)
Removing and installing/replacing TRIM FOR ODDMENTS TRAY (BACK SHELF) .
51 46 013 REMOVING AND INSTALLING/REPLACING REAR WINDOW ROLLER BLIND
51 46 050 REMOVING AND INSTALLING/REPLACING TOP TRIM ON REAR APRON
Remove LUGGAGE COMPARTMENT FLOOR TRIM (luggage compartment mat)
Detach seal (1) in covered area of trim (4).
Lever out protective caps (2) and release screws underneath.

2010 BMW M3
Release expansion rivets (3).
Lever out trim (4) inwards/upwards.
Installation:
If necessary, replace damaged protective caps (2) and expander rivets (3).
Fig. 536: Identifying Seal In Covered Area Of Trim

Replacement
Lift off cover (1).
If necessary, feed out universal holders (2).
Fig. 537: Identifying Feed Out Universal Holders And Cover

51 46... REMOVING AND INSTALLING/REPLACING TRIM ON REAR WINDOW SHELF

(PARCEL SHELF)
2010 BMW M3
Release rear-seat backrest and fold forward.
Release clips (1) and remove decorative trim (2) towards front.
Installation:
If necessary, replace clips (1).
Fig. 538: Removing Decorative Trim

51 46 007 REPLACING PANEL FOR REAR WINDOW SHELF (PARCEL SHELF)
Remove PANEL FOR REAR WINDOW SHELF
Equipment specification with tweeter:
Remove left/right TWEETER
Equipment specification with roller sun blind:
Remove trims (1).
Press roller sun blind (2) together at (A) in direction of arrow and press through from (A) to (B).
Remove roller sun blind (2) towards bottom.

2010 BMW M3
Fig. 539: Removing Roller Sun Blind

Equipment specification with through-loading system:
Release nut (1) on underside of rear window shelf (2) and remove cap (3).
Fig. 540: Identifying Rear Window Shelf With Cap And Nut
Remove insulating mat in area "A" on underside of new panel (1).
NOTE: Insulating mat is perforated in area "A".
Cut out opening (3) at molding (2).
Drill areas "B" of opening (3) with 8 mm dia. drill bit and cut out remaining material at molding (2) with a
scalpel.
IMPORTANT: Ensure a clean cut so that the panel material (1) is not damaged.
2010 BMW M3
Fig. 541: Identifying Insulating Mat In Area On Underside Of Panel

Equipment specification with Top Tether eyelets for child seat:
NOTE: Insulating mat is perforated in areas "A".
Cut out opening (3) at molding (2) with a scalpel.
Fig. 542: Identifying Insulating Mat In Area On Underside Of Panel

51 46 004 REPLACING TRIM FOR ODDMENTS TRAY (BACK SHELF WITH REAR WINDOW
ROLLER BLIND AND THROUGH-LOADING SYSTEM)

2010 BMW M3
FLOOR, LUGGAGE COMPARTMENT, ENGINE COMPARTMENT TRIM

PANELS
51 47 065 REMOVING AND INSTALLING/REPLACING FINISHING STRIP AT FRONT LEFT OR
RIGHT ENTRANCE

Do not raise finishing strip (2) over entire length simultaneously.
Unclip clips (1) for finishing strip (2) with special tool 00 9 317 .
Remove finishing strip (2).
Fig. 543: Removing Finishing Strip

Installation:

2010 BMW M3
Fig. 544: Identifying Finishing Strip Clips

51 47 315 REMOVING AND INSTALLING/REPLACING FRONT CARPET FOR PASSENGER

COMPARTMENT

Remove left/right FRONT SEAT
Remove GLOVEBOX
Remove side trim panel in footwell . See 5143070 REMOVING AND INSTALLING/REPLACING
SIDE TRIM PANEL, FOOTWELL, ON A-PILLAR, LEFT (DRIVER SIDE) or 5143075
REMOVING AND INSTALLING/REPLACING SIDE TRIM PANEL, FOOTWELL, ON A-
PILLAR, RIGHT on left/right
Remove ACCELERATOR PEDAL MODULE
Version with central bass speaker:
Remove left or right central bass speaker.
Remove holders (1) towards front.
Pull out air duct (2).

2010 BMW M3
Fig. 545: Pulling Out Air Duct

Cut out carpet (1) at cutting edge (2) on left/right.
Make the cut as far as possible in the direction of the middle of the car to ensure that the cutting edges are
covered by the storage compartment/panels.
Pay attention to cable(s) when cutting.
Fig. 546: Identifying Carpet And Cutting Edge


Cut out carpet (1) at cutting edge (2).
Guide cable back through carpet (1).

2010 BMW M3
Feed out carpet (1) towards rear/top.
Fig. 547: Identifying Guide Cable Back Through Carpet

Cutting edges (1) shown on removed carpet (2).
Installation:
Apertures (3) serve as alignment points for fitting the carpet (2).
Replacement
Place removed carpet on new carpet and carry over cuts to new carpet.
Fig. 548: Cutting Edges On Carpet

51 47 490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION
WARNING: Scalding hazard!

Only perform work after engine has cooled down.
2010 BMW M3

Release screws (1 and 2) on both sides.
Installation:
Fig. 550: Identifying Engine Compartment Shield With Mounting Screws

2010 BMW M3
WARNING: Danger of burning on oil line!
Turn catch (1) on cable through 90 and disengage in direction of arrow from bracket (2) on both sides.
Pull underbody protection (3) forwards under bumper trim and remove.
Installation:
Centre underbody protection (3).
Fig. 551: Removing Catch From Bracket

Replacement
Modify sheet nuts
Installation:
If necessary, replace faulty metal nuts.
51 47 151 REMOVING AND INSTALLING/REPLACING LEFT LUGGAGE COMPARTMENT

WHEEL ARCH TRIM
Remove TRIM ON REAR APRON

If necessary, remove STORAGE TRAY in luggage compartment on left

2010 BMW M3
Lever out socket (1) in direction of arrow and disconnect plug connection.
Fig. 552: Removing Socket

Installation:
Guide (1) and catches (2) must not be damaged.
Fig. 553: Identifying Guide And Catches

Remove warning triangle (1).
Turn bracket (2) approx. 90 in counterclockwise direction and remove.
Turn bracket (3) approx. 90 in clockwise direction and remove.

2010 BMW M3
Fig. 554: Identifying Warning Triangle, Expansion Rivets And Bracket

Release screw (1) and remove trim (2).
Pull out luggage compartment wheel arch trim (3) in inwards direction.
Fig. 555: Pulling Out Luggage Compartment Wheel Arch Trim

Installation in version without through-loading system only:
Installation:
To install luggage compartment wheel arch trim, proceed as follows:
Remove REAR SEAT

Unscrew screws (1).
Press backrest from luggage compartment in direction of vehicle interior and feed luggage compartment
2010 BMW M3
wheel arch trim between wheel arch and backrest
Fig. 556: Identifying Backrest Guides And Screws

Replacement
If necessary, release trim (1) at catches (2) from interior and remove rubber pull (3).
Fig. 557: Identifying Trim And Catches

51 47 161 REMOVING AND INSTALLING/REPLACING RIGHT LUGGAGE COMPARTMENT

WHEEL ARCH TRIM
Remove TRIM ON REAR APRON

Remove FLAP IN LUGGAGE COMPARTMENT PANEL

2010 BMW M3
Fold down backrest for right rear seat
Specification with pocket holder:
Pull expander rivets (1) out of pocket holder (2) and remove pocket holder (2).
Fig. 558: Identifying Expander Rivets And Pocket Holder

Release clips (1).
Feed out luggage compartment wheel arch trim (4) in direction of arrow.
Fig. 559: Removing Luggage Compartment Wheel Arch Trim

Installation:
2010 BMW M3
Remove REAR SEAT

Unscrew screws (1).
Fig. 560: Identifying Backrest Guides And Screws

Replacement
If necessary, release retainers (1) on back of luggage compartment wheel arch trim (2) and remove securing net
(3).
Fig. 561: Identifying Retainers On Back Of Luggage Compartment Wheel Arch Trim
2010 BMW M3
51 47... REMOVING AND INSTALLING STORAGE TRAY IN LUGGAGE COMPARTMENT ON

LEFT
Disengage storage tray (1) in upward direction from catches (2) and remove.

51 47 072 REMOVING AND INSTALLING/REPLACING FINISHING STRIP AT REAR LEFT OR

RIGHT ENTRANCE
Replacing front left or right ENTRANCE COVER STRIP .
51 47 171 REMOVING AND INSTALLING/REPLACING FLAP IN LUGGAGE COMPARTMENT

TRIM ON RIGHT
Turn fastener (1) 90 to left.
Open flap (2) in luggage compartment trim and remove.

2010 BMW M3
Fig. 563: Identifying Luggage Compartment Trim Flap And Fastener

51 47 000 REMOVING AND INSTALLING/REPLACING FRONT (INSIDE) LEFT OR RIGHT

ENTRANCE COVER STRIP
Operations on right side analogous to side shown.
Use graphics in a mirror-inverted way.
IMPORTANT: Do not raise entrance cover strip (1) over entire length simultaneously.
E84 only:
clipped 3 times(2).
Unclip entrance cover strip (1) from clip (2), starting from the rear and moving forward, using special tool
009317 .
Fig. 564: Removing Entrance Cover Strip From Clip

If necessary lift clip (1) from floorplate (2) and clip on entrance cover strip.
E84 only:
clipped 3 times(1).
2010 BMW M3
Fig. 565: Identifying Entrance Cover Strip Clip And Floorplate

Installation
If necessary, replace faulty clips (1) on entrance cover strip (2).
E84 only:
clipped 3 times(1).
Fig. 566: Identifying Clips On Entrance Cover Strip

51 75 001 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT UNDERBODY COVER
NOTE: Work shown on E90 by way of example, deviations in detail are possible in
other models.
Release clips (1).

2010 BMW M3
Release screws (2).
Remove underbody cover (3).
Installation:
Replaced damaged clips (1).
Make sure underbody cover (3) is correctly seated.
Fig. 567: Identifying Clips, Screws And Underbody Cover

51 47... REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT UNDERBODY

PANELLING
NOTE: Work is shown on the E92/M3 by way of example.

There may be differences in detail in the case of other vehicle models.
Release plastic nuts (3).
Release expander rivet (4) and remove underbody panelling.
Installation:
If necessary, replace faulty expander rivet (4).
Make sure underbody panelling is correctly seated.

2010 BMW M3
Fig. 568: Identifying Expander Rivet With Plastic Nuts And Screws
Replacement
Release expander rivets (1) and modify lip (2)
If necessary, replace faulty expander rivets (1)
Fig. 569: Identifying Expander Rivet And Lip

51 47 101 REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT FLOOR

TRIM PANEL
Open rear lid.

2010 BMW M3
Remove luggage compartment floor trim (1).
Fig. 570: Removing Luggage Compartment Floor Trim


TRIM PANEL
Open rear lid.
Fig. 571: Removing Luggage Compartment Floor Trim

51 47 030 REMOVING AND INSTALLING/REPLACING REAR (INSIDE) LEFT OR RIGHT

Remove rear seat . See 5226005 REMOVING AND INSTALLING/REPLACING REAR SEAT
(THROUGH-LOADING) or 5224005 REMOVING AND INSTALLING OR REPLACING REAR
2010 BMW M3
SEAT .
Release expansion rivet (1).
Unclip (2) the entrance cover strip (3) with special tool 00 9 317 .
Pull entrance cover strip (3) up and remove.
Fig. 572: Removing Entrance Cover Strip And Expansion Rivet Using Special Tool (00 9 317
Installation:
Fit entrance cover strip (2) with pre-installed clips (1).
Fig. 573: Identifying Entrance Cover Strip With Pre-installed Clips

2010 BMW M3
51 47 440 REMOVING AND INSTALLING/REPLACING REAR CARPET ON SEAT PAN
Remove left/right FRONT SEAT

SEAT .
Remove HANDBRAKE LEVER
Remove TRIM PANEL FOR DOOR PILLAR on left/right
Remove ENTRANCE COVER STRIP at rear inside
Remove left or right central bass speaker
Remove holder (1).
Pull back cable (2) with cable holder (3).
Feed out carpet (4).
Installation:
Make sure openings for air duct and attachment points are correctly positioned.
Fig. 574: Identifying Carpet And Back Cable With Cable Holder
51 47 491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION

Tasks should only be carried out on an exhaust system that has cooled
2010 BMW M3
down.
Unscrew nuts (3).
Pull out underbody protection (4) in direction of arrow towards bottom.
Installation:
Ensure correct seating.
Centre underbody protection (4) before tightening down screws (1 and 2).
Fig. 575: Removing Underbody Protection

Replacement
Modify sheet nuts
Installation:
51 47 312 REPLACING FOOTREST FOR FRONT PASSENGER COMPARTMENT
Remove TRIM PANEL FOR PEDAL ASSEMBLY
NOTE: Footrest is either bonded to carpet or secured with retaining rings from rear to
carpet.
2010 BMW M3
Attachments with retaining rings are drilled out

Bonded footrest is detached with a hot air blower
The attachment points must always be drilled out first.
Place drilling hole template (1) on footrest (2) and align to outer edge of footrest (2) (see arrows).
Mark bore holes with punch and remove drilling hole template (1).
Drill out attachment points.
I. Predrill to 3 mm dia.
II. Drill out to 10 mm dia.
NOTE: If the footrest (2) is not bonded, it can be removed now. Continue with the next
work step but one.
Fig. 576: Identifying Drilling Hole Template On Footrest

Bonded footrest only:
NOTE: Adhesive bead must remain on carpet (risk of damage).
Heat footrest (1) with hot air blower and thereby release adhesive bead from footrest (1).
If necessary, pull off footrest (1) in inward direction.

2010 BMW M3
Fig. 577: Identifying Footrest

Only when fitting retaining rings:
Remove LEFT FOOTWELL SIDE TRIM PANEL .
Drive through pins (1).
Fold carpet (2) inwards slightly and remove pins (1).
Fig. 578: Identifying Carpet And Pins

Installation:
Heat footrest (1) with hot air blower and apply adhesive bead along dashed line (2) with hot-melt adhesive gun.
Place footrest (1) on carpet and stick on.
Press footrest (1) down until adhesive bead has cooled down.
2010 BMW M3

FRONT LID INSULATION LINING

51 48 001 REMOVING AND INSTALLING/REPLACING INSULATION LINING ON
HOOD/BONNET
NOTE: Illustration created using the E87 as an example. There may be differences in
detail in the case of other vehicle models.
Release threaded rivets (1) on insulation lining (2).
Remove insulation lining (2).
Installation:
If necessary, replace defective threaded blind rivets (1).
Fig. 580: Identifying Rivets On Insulation Lining

2010 BMW M3

RIGHT FRONT DOOR
After every repair, check that the sound insulation is water-tight (water
ingress).
Remove DOOR TRIM PANEL
Fig. 581: Identifying Sealing Bead And Sound Insulation

if necessary cable.
detached.
2010 BMW M3
NOTE: Replacement:
Heat butyl cord (hot air blower) and press down firmly on sound insulation all round.
Contact pressure with hand roller: approx. 20 N/cm 2

2010 BMW M3


51 48... REMOVING AND INSTALLING/REPLACING SOUND INSULATION ON COWL

PANEL/WINDSCREEN
WINDSCREEN
2010 BMW M3
Replacement
Fig. 585: Identifying Dashboard Trim Panel, Windscreen, Glue Bead, Retaining Strip And Bulkhead
Upper Section

2. Windscreen
3. Glue bead

RIGHT REAR DOOR
It is essential to ensure the sound insulation is watertight (water intrusion)
every time any repair work has been carried out.

2010 BMW M3
Fig. 586: Identifying Sealing Bead, Wires And Sound Insulation

if necessary cable.
detached.
2010 BMW M3
NOTE: Replacement:

2010 BMW M3

REAR LID TRIM PANEL

51 49 000 REMOVING AND INSTALLING/REPLACING PANEL FOR REAR LID
Version with emergency release:
Detach handle (1) from clip (2).
Disconnect Bowden cable (3) from handle (1).
Installation:
Guide Bowden cable (3) through clip (2) and connect correctly in handle (1).
Fig. 590: Identifying Bowden Cable, Handle And Clip

Release clips (1) and remove panel (2).

2010 BMW M3
Installation:
If necessary, replace damaged clips (1).
Fig. 591: Identifying Clips On Panel

REINFORCEMENT, BODY
51 71... REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT SUSPENSION
CROSSBRACE RING

Driving without the suspension cross-brace is not permitted. (Risk of damage
to the body).
Remove left (or right) suspension cross-brace
right side.
IMPORTANT: It is essential to use the pictured nuts to ensure correct screw-fastening of the
dome cross-brace ring!
2010 BMW M3
Fig. 592: [Identifying Nut]

Unclip protective cap (1) and disconnect plug connection underneath.
Release nuts (2) and remove suspension crossbrace ring (3).
Installation:
Make sure protective cap (1) is correctly seated.
Replace nuts (2).
Fig. 593: Identifying Suspension Cross Brace Ring, Nuts And Protective Cap
GASKETS, SEALS, LOOSE BODY COMPONENTS

2010 BMW M3

Fig. 594: Identifying Correct Position Of Seal

2010 BMW M3


2010 BMW M3

51 71... NOTES ON FITTING COVERS IN FRONT WHEEL ARCH
IMPORTANT: Make sure all covers in wheel arch are correctly seated in relation to each
other.
E90/E91/E92:
Panel (1) overlaps cover (2, 3 and 5)

Cover (2) overlaps cover (3 and 4)
Cover (4) overlaps cover (3)
Fig. 598: Identifying Panel With Covers (E90/E91/E92)

E93:
2010 BMW M3

Fig. 599: Identifying Panel With Covers (E93)

51 71 000 REMOVING AND INSTALLING/REPLACING SEAL ON FRONT DOOR, LEFT OR

RIGHT
Follow REPAIR INSTRUCTIONS for bonded seals.

Release DOOR RETAINER FROM DOOR PILLAR
NOTE: The positioning of the seal must be established in three areas of the front door
with positioning aids to be stuck on.
Positioning aids are included with new seals.
Position of seal (3) on front door:

2010 BMW M3
Fig. 600: Identifying Front Door Sealing Areas

Area (A) at distance (G) to door rabbet.
Area (B) at line (1) of positioning aids (2) to be stuck on (see following work steps).
Area (C) at distance (E) to door inner panel.
Area (D) at distance (F) to door fold.
Clean bonding surfaces on paint with adhesive cleaner (sourcing reference: BMW Parts Service).
E = 57 mm
F = 4 mm
G = 2.8 mm
Positioning aid "A1" for front door, left ("B1" right)

2010 BMW M3
Fig. 601: Positioning Aid For Front Door (1 Of 3)

Detach pre-stamped positioning aid from backing.
Positioning aid "A1" front door, left (door lock, top)

Positioning aid "B1" front door, right (door lock, top)
If necessary, cut out cutout for bore from positioning aid. Align positioning aid with printed help markings (X,
Y), bores and contact edge (2) to front door and press.
Seal must rest on positioning edge (1) during sticking.
X Start of bend radius
Y Opening for door lock

2010 BMW M3

Positioning aid "A2" front door, left (door lock, bottom)

Positioning aid "B2" front door, right (door lock, bottom)

2010 BMW M3

Positioning aid "A3" front door, left (below door retainer)

Positioning aid "B3" front door, right (below door retainer)
Y Opening due to folding
IMPORTANT: Do not grip bonding surface

It is not the length of pressing in time but rather the level of pressing
(approx.
2010 BMW M3
10... 15 N/cm2 ) which is decisive here.
Separation of seal after pressing destroys the adhesive layer
NOTE: After being pressed on gently, seal can be pulled off again up to 3 times. Do not
dirty adhesive area.
Suspend seal (1) with open lip pointing inwards over door. Pull protection of positioning aid (liner) off seal in
sections.
Stick on seal (1) as follows:
Position seal with color coding on door window frame at rear top.
Gently press seal without stretching up to start of positioning aids.
Check positioning of seal, correct if necessary (sag max. 30 mm).
Firmly press down seal vertically to adhesive area up to above-mentioned area.
Fig. 604: Identifying Seal

Gently press seal without stretching up to entrance area.

Check positioning of seal, correct if necessary and firmly press.
Pull remaining protective film (liner) off seal.
Press remaining seal without stretching.
Remove positioning aids and assemble front door.
51 71 200 REMOVING AND INSTALLING/REPLACING SEAL ON REAR DOOR, LEFT OR RIGHT

2010 BMW M3
Follow REPAIR INSTRUCTIONS for bonded seals.

Release DOOR RETAINER FROM DOOR PILLAR
NOTE: The positioning of the seal must be established in six areas of the rear door
E90 only - Position of seal (3) on rear door:
Fig. 605: Position Of Seal On Rear Door (E90)

Area (A) at distance (D) to door rabbet.
Area (C) at distance (E) to door inner panel. Bond straight between positioning aid "C1"/"C4"/"D1"/"D4".
2010 BMW M3
D= 2.8 mm
E = 55... 70 mm
Fig. 606: Position Of Seal On Rear Door (E91)

Area (C) at distance (E) to door inner panel. Bond straight between positioning aid "C1"/"C4"/"D1"/"D4".
D= 2.8 mm
E = 55... 70 mm
Positioning aid "C2" for rear door, left ("D2" right)

2010 BMW M3
Fig. 607: Positioning Aid C2 For Rear Door (1 Of 3)

Positioning aid "C2" rear door, left (door retainer)

Positioning aid "D2" rear door, right (door retainer)
If necessary, cut out pre-stamped aperture (Y) from positioning aid. Align positioning aid with printed help
marking (X), aperture (Y) and contact edge (2) to rear door and press.
Y Aperture for door retainer

2010 BMW M3

Positioning aid "C1" rear door, left (below positioning aid "C2")
Positioning aid "D1" rear door, right (below positioning aid "D2")
If necessary, cut out pre-stamped cutout for bore from positioning aid. Align positioning aid with printed help
marking (X) and contact edge (2 and 3) to rear door and positioning aid "C2" or "D2" and press.

2010 BMW M3

Positioning aid "C3" rear door, left (above positioning aid "C2")
Positioning aid "D3" rear door, right (above positioning aid "D2")
Align positioning aid with printed help marking (X) and contact edge (2 and 3) to rear door and positioning aid
"C2" or "D2" and press.
E90 only - Positioning aid "C6" for rear door, left ("D6" right)
2010 BMW M3
Fig. 610: Positioning Aid C6 For Rear Door

NOTE: Positioning aid "C6" or "D6" for E90 only.

Positioning aid "C7" or "D7" for E91 only.
Positioning aid "C6" rear door, left (door lock, top)

Positioning aid "D6" rear door, right (door lock, top)
markings (X, Y), bores and contact edge (2) to rear door and press.
2010 BMW M3




2010 BMW M3

Positioning aid "C5" rear door, left (door lock, bottom)

Positioning aid "D5" rear door, right (door lock, bottom)
If necessary, cut out pre-stamped cutouts for bores from positioning aid. Align positioning aid with printed help
markings (X, Y), bore and contact edge (2) to rear door and press.

2010 BMW M3

Align positioning aid with printed help marking (X), opening and contact edge (2 and 3) to rear door and
positioning aid "C5" or "D5" and press.
IMPORTANT: Do not grip bonding surface.

(approx.
2010 BMW M3
10... 15 N/cm2 ) which is decisive here.
Separation of seal after pressing destroys the adhesive layer.
sections.
Position seal with color coding on door window frame at front top.



2010 BMW M3
Remove WINDSCREEN WIPER ARM on left/right

Remove microfilter housing . See 6431062 REMOVING AND INSTALLING/REPLACING LEFT
Pull off hose (1).
Detach mucket (3).
Take off cover (4).
Installation:
Fig. 615: Identifying Hose, Plug Connections, Mucket And Cover

Installation:

2010 BMW M3

Installation:
Fig. 617: Identifying Grommet

E90/E91 only:
Installation:
2010 BMW M3
Fig. 618: Identifying Cowl Panel Cover And Windscreen Cover (E90/E91 Only)
E92/E93 only:
Installation:
Fig. 619: Identifying Cowl Panel Cover And Windscreen Cover (E92/E93 Only)
51 71... REMOVING AND INSTALLING/REPLACING COVER FOR CARBON CANISTER
Version, carbon canister, side:
Press thermal insulation (3) to one side slightly and feed out cover (4).
2010 BMW M3
Fig. 620: Identifying Thermal Insulation With Screws

Version, carbon canister, middle:
Fig. 621: Identifying Cover With Screws

51 71 038 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH

COVER (FRONT SECTION)
If necessary, remove FRONT WHEEL
NOTE: Front axle removed for purposes of clarity.

2010 BMW M3
Release nuts (3) and remove wheel arch cover (4).
Installation:
Ensure wheel arch cover (4) is correctly seated.
Fig. 622: Identifying Wheel Arch Cover With Mounting Nuts

Replacement
Modify cover (1)
Fig. 623: Identifying Wheel Arch Cover


COVER (REAR SECTION)

2010 BMW M3
If necessary, remove FRONT WHEEL
NOTE: In event of further work, where possible, leave wheel arch cover on vehicle.
Wheel arch cover must not be cut.
In case of complete removal or replacement, release SPRING STRUT .
Release nuts (3) and loosen wheel arch cover (4) from installation position.
Installation:
Fig. 624: Identifying Wheel Arch Cover With Mounting Nuts

Replacement
Installation:

2010 BMW M3
Fig. 625: Identifying Sheet Nuts

51 71 345 REMOVING AND INSTALLING/REPLACING LEFT (OR RIGHT) SUSPENSION

CROSSBRACE
IMPORTANT: Driving without the suspension cross-brace is not permitted. (Risk of damage
to the body).
Suspension cross-brace screws must be tightened to torque and then
tightened down with special tool 009120 .
Remove lower section of microfilter housing . See 6431062 REMOVING AND

INSTALLING/REPLACING LEFT LOWER MICROFILTER HOUSING SECTION or 6431063
REMOVING AND INSTALLING/REPLACING RIGHT LOWER MICROFILTER HOUSING
SECTION
right side.
Release screw (1).
Release nuts (2) and remove suspension crossbrace (3).
Installation:
Make sure suspension cross-brace (3) is in correct installation position.
Replace screw (1) and nuts (2).
Tighten down screw (1) and nuts (2) to torque and then to angle of rotation using special tool 009120 .
2010 BMW M3
Tightening torque for screw (1) 51 71 18AZ .
Tightening torque for nuts (2) 51 71 19AZ .
Fig. 626: Identifying Suspension Cross Brace With Mounting Nuts

51 71... REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT STEERING GEAR COVER
If necessary, remove left or right FRONT WHEEL.
Prior to removing, pay attention to the exact installation position with respect to
the adjoining components.
The operation is described on the left side; proceed in the same way for the
right side.
NOTE: Spring strut removed for purposes of clarity.
Release screw (1) and plastic nuts (2).
Feed out cover (3) and remove.
Installation:
Observe NOTES ON FITTING cover (3).

2010 BMW M3
Fig. 627: Identifying Cover With Screw And Nuts


CROSSBRACE RING

to the body).
Remove left (or right) suspension cross-brace.
right side.
2010 BMW M3
Fig. 628: Identifying Nut

Release nuts (2) and remove suspension crossbrace ring (3).
Installation:
Replace nuts (2).
Fig. 629: Identifying Suspension Cross Brace Ring With Protective Cap And Nuts
2010 BMW M3
51 71... REMOVING AND INSTALLING/REPLACING LEFT SPRING SUPPORT PASSAGE COVER
If necessary, remove left FRONT WHEEL .

Release catch (1) and remove cover (2).
Installation:
Catch (1) must not be damaged.
Note correct position of cover (2).

51 71... REMOVING AND INSTALLING/REPLACING LEFT/RIGHT REINFORCEMENT COVER
Remove reinforcement cover (3).
Installation:
Make sure reinforcement cover (3) is correctly seated.

2010 BMW M3
Fig. 631: Identifying Reinforcement Cover With Mounting Screws

51 71... REMOVING AND INSTALLING/REPLACING MULTIFUNCTION PAN
Remove luggage compartment trim panels . See 5147161 REMOVING AND

WHEEL ARCH TRIM.
Remove exhaust system .

2010 BMW M3
Fig. 632: Identifying Heat Shield Vacuum Line With Mounting Screws
Release screws (1).
Fig. 633: Identifying Heat Shield Mounting Screws

Unclip line (1).
Fig. 634: Identifying Vacuum Line With Screws


2010 BMW M3
Fig. 635: Identifying Multifunction Pan Nuts

Installation:

51 71... REMOVING AND INSTALLING/REPLACING RADIATOR SEAL

IMPORTANT: Observe SAFETY INSTRUCTIONS for raising the vehicle

2010 BMW M3
Remove front underbody protection
NOTE: Prior to removing, pay attention to the exact installation position with respect to
Release screws (1).
If necessary, remove underbody protection bracket.
Release catches (2) and feed out radiator seal (3) towards rear.
Fig. 637: Removing Radiator Seal With Catches

Installation:

2010 BMW M3
51 71 041 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT WHEEL ARCH

COVER
If necessary, remove left or right REAR WHEEL
NOTE: Work shown on the E87 by way of example, deviations in detail are possible in
other models.
Release nuts (3) and expander rivet (4).
Carefully feed out wheel arch cover (5) towards bottom.
Installation:
If necessary, replace expander rivet (4).
Fig. 639: Identifying Screws, Nuts And Expander Rivet On Wheel Arch Cover
51 71... REMOVING AND INSTALLING/REPLACING RIGHT SPRING SUPPORT PASSAGE

COVER

2010 BMW M3
If necessary, remove right FRONT WHEEL .

Release expander rivet (1) and remove cover (2).
Installation:

51 71 348 REMOVING AND INSTALLING/REPLACING SUSPENSION CROSSBRACE MOUNTING
to the body).
Screws of suspension cross-brace and crossbrace mounting must be
tightened to torque and then tightened down with special tool 00 9 120 .
Remove both suspension cross-brace
Remove COWL PANEL COVER
NOTE: Air manifold is shown removed for purposes of clarity.
Release mucket in covered area.

2010 BMW M3
Remove suspension cross-brace mounting with middle heater bulkhead (3).
Installation:
Replace screw (1).
Tighten down screw (1) to torque and then to angle of rotation using special tool 00 9 120.
Fig. 641: Identifying Middle Heater Bulkhead With Mounting Screws

Replacement
Release studs (1) and feed suspension cross-brace mounting (2) out of middle heater bulkhead (3)
If necessary, release suspension crossbrace grommets (4)
Installation:
Replace studs (1).

2010 BMW M3
Fig. 642: Identifying Suspension Cross Brace Mounting And Grommets With Heater Bulkhead
51 71 447 REMOVING AND INSTALLING/REPLACING TRIM FOR COVER ON LEFT OR RIGHT

SIDE MEMBER (UP TO 09/08)
Detach WHEEL ARCH COVER from front/rear side member cover
Release screws (1).
Fig. 643: Identifying Side Sill Screws

Unclip panel (1) at holders (2) in direction of arrow and remove.

2010 BMW M3
Fig. 644: Removing Panel

Installation:
Before installation, soak holders (1) in water.
If necessary, detach holders (1) from body and fit on panel (3).
If necessary, detach grommets (2) from holders (1) and place on body.
If necessary, replace faulty holders (1) and grommets (2).
Fig. 645: Identifying Grommets And Holders


SIDE MEMBER (FROM 09/08)
Release screws (1).
Remove trim from front beginning at side.

2010 BMW M3
Lever off catch on rear wheel arch cover and remove side sill.
Fig. 646: Identifying Side Sill Screws

Installation:
Make sure spacers (1) are correctly positioned between underbody trim and bodyshell.
Fig. 647: Identifying Spacers

Installation:
If necessary, remove retaining strips (1) from bodyshell
Clip retaining strips (1) into sill cover (2).
Clip sill cover (2) into bodyshell.
Listen out for audible clicking noises.

2010 BMW M3
Visual check:
Make sure sill cover (2) is correctly seated and observe wheel arch GAP DIMENSIONS at front and rear.
Fig. 648: Identifying Clip Retaining Strips And Cover

Remove COVER FOR COWL PANEL

Remove SPRAY NOZZLE on left/right
Release holder (2).
Installation:
2010 BMW M3
Fig. 649: Identifying Grommets With Holder And Washer Fluid Hose
51 71 407 REPLACING REAR SPOILER (M)
IMPORTANT: The INSTRUCTIONS on component cementing with double-sided adhesive tape

serve as the basis for this repair instruction and must be observed without fail.
NOTE: To ensure correct bonding, it is essential to use the adhesive tape shaped parts
developed for the respective rear spoiler.
Removing rear spoiler
Carefully detach rear spoiler (1) from rear lid with special tool 00 9 318 WEDGE (assembly wedge) and hot air
blower.
Fig. 650: Removing Rear Spoiler From Rear Lid Using Special Tool 00 9 318
IMPORTANT: To avoid paintwork damage, make sure markings (1) are only applied to
adhesive tapes.
2010 BMW M3
Carry over markings (1) from bottom to top of rear spoiler.
Fig. 651: Identifying Markings On Rear Spoiler

Aligning rear spoiler for installation:
Fig. 652: Identifying Dimensions On Adhesive Tapes

Determine center of rear lid.
Mark dimensions (A, B, C, D and E) on adhesive tapes (1) on left and right. Adhesive tapes must not be situated
2010 BMW M3
on bonding surface of rear spoiler.
ADHESIVE TAPE MODEL DESCRIPTION CHART

Model series A B C D E
E90 250 200 330 332 334
E92 250 200 372 370 361
E82 250 200 371 372 376
Clean bonding surface on rear lid and rear spoiler with spirit.
NOTE: For cleaning, use a fluff-free disposable cloth or a clean cleaning cloth.
Fitting rear spoiler
IMPORTANT: Avoid the creation of bubbles and folds and do not overstretch when attaching
the adhesive tape.
Pull off adhesive tape shaped part (1) from carrier film.
Position adhesive tape shaped part (1) starting from point (A) on front groove (2) and stick on.
Repeat same procedure on other side.
NOTE: Groove (2) serves as a limit marker.
Fig. 653: Identifying Adhesive Tape Shaped Part And Groove

NOTE: To enable the liner to be pulled off, cut only the adhesive tape and not the liner
into lengths on the other side.
Fold back pull-off tabs of shaped parts and of adhesive tape towards rear. In so
doing, make sure adhesive tape is not exposed.
2010 BMW M3
Position adhesive tape (1) at distance (A) to adhesive tape shaped part (3) on front groove (2) and stick on.
A= 0.5... 2 mm
Fig. 654: Identifying Distance For Positioning Adhesive Tape

Align rear spoiler (1) using markings (2) and secure or press down slightly with a 2nd person helping.
Pull off liner using pull-off tabs (3).
Press down rear spoiler (1) firmly with thumbs or back of hands over entire surface, especially the ends.
Remove adhesive tapes, clean rear lid and rear spoiler.
Fig. 655: Identifying Rear Spoiler With Markings

MUCKET FOR DOORS

2010 BMW M3

Fig. 656: Identifying Correct Position Of Seal

2010 BMW M3


2010 BMW M3

2010 BMW M3
ACCESSORIES AND BODY, CAB Body Equipment - Repair - M3
Body Equipment - Repair - M3
GENERAL
51 00 .. OVERVIEW OF FRONT DOOR

51 00 .. OVERVIEW OF REAR DOOR

2010 BMW M3

51 00 ... NOTES ON BONDING/ATTACHING COMPONENTS WITH DOUBLE-SIDED ADHESIVE

TAPE
1. General notes
Bonding at room and object temperature of 18C to 25C.
Newly painted parts may only be bonded after a drying time of at least 24 hours.
Optimal bonding/attachment to the background surface is achieved after approx. 48 hours.

Components must not be exposed to mechanical strain beforehand (car wash, strength test, etc.).
Do not touch bonding area.
It is not the length of time that pressure is applied but rather the level of pressure applied that is
2010 BMW M3
crucial.
Detaching the adhesive tape after pressing destroys the adhesive layer.
After being pressed on gently, adhesive tape can be pulled off again up to 3 times.

Isohexane (spirit), adhesive remover (sourcing reference: BMW Parts Service)
Fluff-free cleaning cloths
Pressure roller
3. Preparations
Remove all remnants of adhesive or clean new part thoroughly
Clean the areas to be bonded immediately before bonding to remove silicone and grease residues.
NOTE: Observe ventilation time > or = 1 minute.
4. Bonding
1. Components without pre-fitted adhesive tape
Pull off liner* from adhesive tape
Position adhesive tape on component and stick on
Press down adhesive tape over entire bonding area
Continue with Point 4.2
2. Components with pre-fitted adhesive tape

Pull off liner* from adhesive side (if bonding area is large, do not pull off liner completely)
Align component in correct position on vehicle
Press down component over entire bonding area
51 00 ... NOTES ON FITTING WINDOW GUIDE SEALS
1. Work safety when handling anti-friction agent G13*

Do not eat, drink or smoke in the area of processing/application
Keep heat and ignition sources well away
In event of skin contact: Wash areas of skin affected with soap and water immediately, change
work clothing which has been fouled with anti-friction agent immediately (keep spare work
clothing in reserve)
In event of eye contact: Rinse eyes immediately with plenty of water and seek medical advice
2010 BMW M3
2. General notes
Use only the BMW-approved anti-friction agent for fitting
Application only at room and object temperatures between 18 and 25C
Anti-friction agent dries at different rates depending on the quantity, temperature and ventilation
and becomes sticky
Anti-friction agent can only be used for fitting and not for fault elimination (e.g. grating)
Newly painted parts may only be brought into contact with the anti-friction agent after cooling
Optimal bonding/attachment to the background surface is achieved after approx. 48 hours. The
window guide seal must not be exposed to mechanical strain beforehand (car wash, strength test,
etc.).
IMPORTANT: To avoid grating noises, do not use soapy water (low-surface-tension

water with washing-up liquid) or antifriction agent containing silicone

Spirit, cleaning cloth, plastic squeegee, needle
Anti-friction agent G13* (manufactured by Zestron) part no. 83 23 0441 032 (*sourcing reference:
BMW Parts Service)
4. Preparations
Heat and remove anti-friction agent residues with a hot air blower or clean new part thoroughly
Immediately prior to fitting, clean the work area with spirit in order to remove silicone and grease
residues
NOTE: Air drying time approx. 1 minute
5. Installation
Apply a thin coating of anti-friction agent to the reverse side of the window guide seal only
Perform fitting within 30 minutes of applying anti-friction agent
Anti-friction agent dries after fitting and becomes sticky
51 00 ... SAFETY INSTRUCTIONS FOR WORKING ON CARS WITH AIRBAG SYSTEMS
WARNING: If work is carried out in area of airbag systems, e.g. on:
Door trim panels

Interior trims
Instrument panel etc.
the ignition must be turned off in each case.

2010 BMW M3
The ignition must always be off.

The ignition key must be removed from the ignition lock.
This eliminates the risk of injury.
51 00 ... SERVICE POSITION OF ENGINE HOOD/BONNET
51 0 040
51 2 160
51 2 170
51 2 180
51 2 240
See BODY EQUIPMENT - SPECIAL TOOLS (CONVERTIBLE/COUPE) or BODY EQUIPMENT -

SPECIAL TOOLS (SEDAN) .
NOTE: Only the special tool pertaining to the model series can be selected.
SPECIAL TOOL REFERENCE CHART

Model series Special tool
E46, R50, R52, R53 51 2 160
E53, E60, E61, E63, E64, E71, E81, E82, E88, E85, E86, E87, E90, E91, E92, E93 51 2 170
E65, E66, E67 51 2 180
E83 51 0 040
E70 51 2 240

Engine hood/bonnet must be held by a second person helping.
NOTE: The illustrations below serve as examples for all corresponding vehicles.
right side.
Special tool can only be used on housing (1) of gas spring strut (thick part).
NOTE: Gas spring strut can also be installed the other way round (housing on
hood/bonnet).
Special tool can be used in both directions.

2010 BMW M3
Fig. 3: Identifying Housing Of Gas Spring Strut (Thick Part)

Release gas spring strut on left/right housing side.
Slide special tool (1) over housing (2) of gas spring strut.
Clip ball socket of special tool on ball stud.
Proceed in same way on other side.
Fig. 4: Sliding Special Tool Over Housing Of Gas Spring Strut

51 47 ... OVERVIEW OF LUGGAGE COMPARTMENT TRIM PANELS

2010 BMW M3
Fig. 5: Overview Of Luggage Compartment Trim Panels

FRONT BUMPER
51 11 ... INSTALLING/REPLACING NUMBER/LICENSE PLATE (WITHOUT BASE)
Initial fitting:
Place drilling hole template (1) on bumper (2).
Drill holes according to number/license plate.

2010 BMW M3
Remove template (1) and secure number/license plate with screws provided.
Tightening torque 51 11 3AZ , see 51 11 FRONT BUMPER .
Fig. 6: Placing Drilling Hole Template On Bumper

Place drilling hole template (1) on radiator grille (2) and bumper (3).
Drill holes according to number/license plate.
Remove template (1) and secure number/license plate with screws provided.
Tightening torque 51 11 3AZ , see 51 11 FRONT BUMPER ..
Fig. 7: Placing Drilling Hole Template On Radiator Grille And Bumper

2010 BMW M3
Repairing thread:
Drill out defective hole in bumper (2) to 9.5 mm diameter.
Insert blind rivet nut (1)*.
Secure number/license plate (3) with number/license plate screw (4)*.
NOTE: * Sourcing reference: BMW Parts Service
Fig. 8: Identifying Blind Rivet Nut, Number/License Plate And Screw

51 11 ... REMOVING AND INSTALLING/REPLACING COVER FOR HEADLIGHT CLEANING

SYSTEM ON LEFT
Pull out spray nozzle (1) by cover (2).
IMPORTANT: When releasing cover (2), grip spray nozzle (1) firmly and then allow to slide
back slowly (risk of damage).
Release cover (2) sideways from spray nozzle (1).

2010 BMW M3
Fig. 9: Pulling Out Spray Nozzle By Cover

Installation:
Guides (1) on cover (2) must not be damaged.
Fig. 10: Identifying Guides On Cover

51 11 ... REMOVING AND INSTALLING/REPLACING COVER FOR HEADLIGHT WASHER UNIT

ON LEFT
Remove front bumper trim or 51 11 156 Removing and installing front bumper trim (from 09/08)
Release catches (1) and remove cover (2).
Installation:
2010 BMW M3

51 11 050 REMOVING AND INSTALLING/REPLACING CARRIER FOR FRONT BUMPER TRIM
Remove front bumper trim or 51 11 156 Removing and installing front bumper trim (from 09/08)
Release screws (1) on cooling air guide (2) on left and right.
Disconnect plug connection (3) on outside temperature sensor.
Remove left cooling air guide (2).
Fig. 12: Identifying Screws, Cooling Air Guide And Plug Connection
2010 BMW M3
Press right wheel arch cover (1) to one side.
Release screw (2) and remove right cooling air guide.
Installation:
Make sure cooling air guide is installed in correct position.
NOTE: The following work step ends here:
"Removing and installing cooling air guide".
Fig. 13: Identifying Screw And Right Wheel Arch Cover

Release screw (1).
Release nuts (2) and blind rivets (3).
Installation:
Blind rivets (3) are not refitted.
If necessary, feed out cable or hose and remove carrier (4).

2010 BMW M3
Fig. 14: Identifying Nuts And Blind Rivets

Replacement:
Release screws (1) and convert fanfare horn holder (2).
Modify impact absorber (3) on left and right.
Fig. 15: Identifying Screws, Fanfare Horn Holder And Impact Absorber
51 11 156 REMOVING AND INSTALLING FRONT BUMPER TRIM

2010 BMW M3
Fig. 16: Identifying Screws And Bumper Trim

Release screws (1) and plastic nuts (2) on left wheel arch cover (3).
Lever out left wheel arch cover (3) at side.
Installation:
Make sure left wheel arch cover (3) is in correct position.
Fig. 17: Identifying Screws, Plastic Nuts And Left Wheel Arch Cover
Release screws (1 and 2) and remove right wheel arch cover (3).
Lever out right wheel arch cover (3) at side.
Installation:
Make sure right wheel arch cover (3) is in correct position.

2010 BMW M3
Fig. 18: Identifying Screws And Right Wheel Arch Cover

Press wheel arch cover (1) on left and right to one side.


2010 BMW M3

Pull bumper trim (1) forwards slightly and if necessary disconnect plug connections on ultrasonic sensors.
Installation:
Fig. 21: Identifying Bumper Trim

51 11 156 REMOVING AND INSTALLING FRONT BUMPER TRIM (FROM 09/08)

2010 BMW M3
Remove cover for headlight washer system on left/right

right side.
Installation:
Fig. 23: Identifying Screws And Wheel Arch Trim

2010 BMW M3
right side.
Release screws (2).


2010 BMW M3
and/or fog lights.
Installation:

51 11 156 REMOVING AND INSTALLING FRONT BUMPER TRIM (UP TO 09/08)
Remove cover for headlight washer system on left/right

2010 BMW M3
right side.
Installation:
Fig. 28: Identifying Screws And Wheel Arch Trim

right side.
Release screws (2).

2010 BMW M3


and/or fog lights.
Installation:

2010 BMW M3

51 11 157 REPLACING FRONT BUMPER TRIM
Remove front bumper trim

Remove front grille center section
If necessary, remove number/license plate holder
Remove middle grille
If necessary, remove cover for headlight washer system
Remove cover cap for tow lug
Version with Park Distance Control (PDC):
Remove ultrasonic transducer . See 66 20 518 REMOVING AND INSTALLING/REPLACING AN

ULTRASONIC TRANSDUCER AT FRONT (OUTSIDE) (PARK DISTANCE CONTROL) or 66
20 520 REMOVING AND INSTALLING/REPLACING AN ULTRASONIC TRANSDUCER AT
FRONT (INSIDE) (PARK DISTANCE CONTROL) .
Release expander rivets (1) and pull off seal (2) upwards in direction of arrow.
Installation:
If necessary, replace faulty expander rivets (1).

2010 BMW M3
Fig. 32: Identifying Expander Rivets And Seal

Remove sheet metal nuts (1) on left/right.
Installation:
Fig. 33: Identifying Sheet Metal Nuts

Press down catches (2) on insert (1) and remove insert (1) in direction of arrow.
2010 BMW M3
Fig. 34: Identifying Catches And Insert

51 11 158 REPLACING BASEPLATE FOR LICENSE PLATE
Release screws or rivets (1).
Remove license plate baseplate (2).
Fig. 35: Identifying License Plate Baseplate And Rivets

51 11 180 REMOVING AND INSTALLING / REPLACING CENTER GRILLE FOR BUMPER TRIM
Version with ACC:
Remove cover for ACC sensor

2010 BMW M3
6-cylinder models without ACC only:
Release catches (1) from inside, taking care not to damage catch (2).
Remove trim (3) towards front.
Installation:
Fig. 36: Identifying Catches And Catch

Release catches (1) on bumper trim (2).
Installation:
Catches (1) on bumper trim (2) must not be damaged.
Fig. 37: Identifying Catches And Bumper Trim

2010 BMW M3
REAR BUMPER
51 12 .. OVERVIEW OF REAR BUMPER

51 12 .. OVERVIEW OF REAR BUMPER (M TECHNIC AERODYNAMIC KIT)

2010 BMW M3
Fig. 39: Identifying Overview Of Rear Bumper (M Technic Aerodynamic Kit)

51 12 ... REMOVING AND INSTALLING/REPLACING BOTTOM MIDDLE TRIM ON REAR

BUMPER (M TECHNIC AERODYNAMIC KIT)
Release screws (1).
Release catches (2) and remove trim (3).

2010 BMW M3
Fig. 40: Identifying Screws, Catches And Trim

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

MIDDLE
Release screws (1 and 2) and remove guide (3).
Fig. 41: Identifying Screws And Guide

51 12 ... REPLACING TRIM ON REAR BUMPER (M TECHNIC AERODYNAMIC KIT)
00 9 317

2010 BMW M3

Remove bottom middle trim on rear bumper
Carefully heat trim (1) with hot air blower and detach with special tool 00 9 317 from bumper (2).
Fig. 42: Identifying Heat Trim, Special Tool 00 9 317 And Bumper
Installation:
Minimum object temperature of trim and bumper > or = 18C.
If this temperature is not achieved, the components must be preheated.
For cleaning, use a fluff-free disposable cloth or a clean cleaning cloth.
Clean adhesive area of bumper with spirit.
Installation:
Trim (1) is positioned over guides (2) on bumper.
Remove liner from trim (1).
Press down trim (1) firmly with back of your hands over entire surface, especially the ends.
2010 BMW M3
Fig. 43: Identifying Trim And Guides

51 12 050 REMOVING AND INSTALLING/REPLACING CARRIER FOR REAR BUMPER TRIM
IMPORTANT: During replacement, all the cavities of the carrier (1) and the crashbox (2) must
be sealed with cavity sealant.
Fig. 44: Identifying Carrier And Crashbox

Remove bumper trim
If necessary, release rubber mount (1) on carrier (2).
Unscrew nuts (3).
Remove carrier (2).

2010 BMW M3
Tightening torque 51 12 1AZ , see 51 12 REAR BUMPER .
Installation:
If necessary, replace faulty sheet nuts (4).
Replacement:
If necessary, modify or replace weight on carrier (2).
Fig. 45: Identifying Faulty Sheet Nuts

51 12 090 REMOVING AND INSTALLING/REPLACING TRIM GRILLE IN BUMPER TRIM
Installation:

2010 BMW M3
Fig. 46: Identifying Catches And Centre Grille

51 12 156 REMOVING AND INSTALLING REAR BUMPER TRIM
Remove left/right rear light . See 63 21 180 REMOVING AND INSTALLING/REPLACING LEFT
OR RIGHT REAR LIGHT (IN SIDE PANEL) .
Lever out cover (1) and release screw underneath.

Release screw (1) on left/right.
Bend wheel arch trim (2) in area (A) to one side and release screw (3) on left/right.
2010 BMW M3
Fig. 48: Identifying Wheel Arch Trim And Screw

Release screws (1).


Do not detach bumper trim (1) at sides
The following work must be carried out with a second person assisting:
Pull bumper trim (1) towards rear and release from catches (2).
2010 BMW M3
Fig. 50: Identifying Bumper Trim And Catches

Press down catch (2).
Remove bumper trim (1) towards rear with aid of a 2nd person.
If necessary, disconnect plug connection on ultrasonic transducers.
Fig. 51: Identifying Bumper Trim And Catch

51 12 157 REPLACING REAR BUMPER TRIM
Remove cover cap (1) for tow lug.
Remove rear trim grille (2).

2010 BMW M3
Version with PDC:
Remove all ultrasonic transducers (3). See 66 20 534 REMOVING AND INSTALLING/REPLACING
REAR LEFT ULTRASONIC TRANSDUCER (PARK DISTANCE CONTROL) .
Fig. 52: Identifying Cover Cap, Rear Trim Grille And Ultrasonic Transducers
51 12 798 REMOVING AND INSTALLING/REPLACING HOLDER FOR BUMPER AT REAR LEFT
Replacing both holders for bumper at rear .
51 12 799 REMOVING AND INSTALLING/REPLACING HOLDER FOR BUMPER AT REAR

RIGHT
Replacing both holders for bumper at rear .
51 12 801 REMOVING AND INSTALLING/REPLACING HOLDER FOR REAR LEFT OR RIGHT

BUMPER
Remove bumper trim
E93 only:
If necessary, release aerial/antenna holders (1 and 2) from holder (3).
Installation:
2010 BMW M3
If necessary, replace faulty aerial/antenna holders (1 and 2).
Fig. 53: Identifying Aerial/Antenna Holders

Release nuts (3) and remove bracket (4).
Installation:
Make sure lugs (5) of underbody panelling run into guides on holder (4) at bottom.
Fig. 54: Identifying Nuts, Bracket And Lugs

Replacement:

Replace foam seal (4)
2010 BMW M3
Installation:
Fig. 55: Identifying Catches, Guides And Faulty Metal Nuts

51 12 825 REMOVING AND INSTALLING/REPLACING GUIDE FOR REAR CENTER BUMPER
Remove bumper aerial for Comfort Access . See 61 35 975 REMOVING AND
INSTALLING/REPLACING BUMPER ANTENNA FOR COMFORT ACCESS SYSTEM .
If necessary, feed out cable (1) of Park Distance Control.
Release nuts (2) and remove guide (3).

2010 BMW M3
Fig. 56: Identifying Cable, Nuts And Guide

51 12 828 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT GUIDE FOR REAR

BUMPER
right side.
Unscrew nuts (1).
Remove guide (2).
Fig. 57: Identifying Nuts And Guide

2010 BMW M3
Installation:
Catches (1) on holder (2) must not be damaged or missing.
Fig. 58: Identifying Catches And Holder

71 60 051 REPLACING COMPLETE TRAILER TOW HITCH
See 71 60 051 REPLACING COMPLETE TRAILER TOW HITCH .
TRIM COVERS, HANDLE

51 13 001 REMOVING AND INSTALLING/REPLACING FRONT RADIATOR GRILLE, MIDDLE
LEFT OR RIGHT
Release screws (1) and pull bumper trim (3) forwards slightly.
Release catches (4) from inside and remove central radiator grille (2) towards front.
Fig. 59: Identifying Screws, Bumper Trim, Catches And Central Radiator Grille
2010 BMW M3
Installation:
All catches and guides on middle front grille must not be damaged.
Press on chrome ring to push front radiator grille (2) into bumper trim.
Fixtures (1) must engage correctly.
Fig. 60: Identifying Front Radiator Grille And Fixtures

Replacement:
Remove chrome frame (2) from radiator grille (3).
Installation:
Catches (1) on chrome frame (2) and radiator grille (3) must not be damaged.
2010 BMW M3
Fig. 61: Identifying Catches, Chrome Frame And Radiator Grille

51 13 017 REMOVING AND INSTALLING/REPLACING FRAME FOR GRILLE IN ENGINE

HOOD/BONNET ON LEFT OR RIGHT
00 9 323
Lever out frame (1) with special tool 00 9 323 along dashed line.
Carefully pull frame (1) in direction of arrow out of guide and remove.
Installation:
Make sure frame (1) is correctly seated in respective locators.
Fig. 62: Identifying Frame

2010 BMW M3
Installation:

51 13 023 REMOVING AND INSTALLING/REPLACING GRILLE IN ENGINE HOOD/BONNET ON

LEFT OR RIGHT
Remove frame for grille
Pull grille (1) in direction of arrow towards rear and remove.
Installation:
Make sure grille (1) is correctly installed in guides of engine hood/bonnet.

2010 BMW M3
Fig. 64: Identifying Grille

Installation:
Catches (1) on grille must not be damaged.
Fig. 65: Identifying Catches On Grille

51 13 025 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT TRIM ON ENGINE

HOOD/BONNET
Release screws (1) and remove trim (2) in upwards direction.
Tightening torque 51 13 7AZ , see 51 13 TRIM PARTS, COVERS, HANDLE TRIM .

2010 BMW M3
Fig. 66: Identifying Screws And Trim

Installation:

51 13 047 REMOVING AND INSTALLING (REPLACING) GRILLE ON SIDE PANEL AT FRONT

LEFT OR RIGHT
64 1 020
WARNING: Follow instructions for handling light bulbs (exterior lights). See 63 99 ...
2010 BMW M3
INSTRUCTIONS FOR HANDLING LIGHT BULBS (EXTERIOR LIGHTS) .
Unlock catches (1) under side panel grille (2) with special tool .
Unclip side panel grille (2) in direction of arrow from front side panel (3) and remove against direction of
travel.
Installation:
Make sure side panel grille (2) is correctly seated on front side panel (3).
Fig. 68: Unlocking Catches Under Side Panel Grille With Special Tool
Installation:
Catches (1) on side panel grille (2) must not be damaged.

2010 BMW M3
Fig. 69: Identifying Catches And Side Panel Grille

Remove windscreen wiper arm on left/right. See 61 61 100 REMOVING AND

INSTALLING/REPLACING BOTH WINDSCREEN WIPER ARMS .
Remove microfilter housing . See MICROFILTER .
Pull off hose (1).
Detach mucket (3).
Take off cover (4).
Installation:
Fig. 70: Identifying Hose And Plug Connections

Installation:

2010 BMW M3

Installation:
Fig. 72: Identifying Grommets

E90/E91 only:
Installation:
2010 BMW M3
Fig. 73: Identifying Cowl Panel Cover And Under Windscreen Cover
E92/E93 only:
Installation:
Fig. 74: Identifying Cowl Panel Cover And Under Windscreen Cover
Remove cover for cowl panel

Remove spray nozzle on left/right. See 61 71 015 REMOVING AND INSTALLING/REPLACING A
SPRAY NOZZLE IN WINDSCREEN WASHER SYSTEM .
2010 BMW M3
Release holder (2).
Installation:
Fig. 75: Identifying Grommets, Holder And Washer Fluid Hose

51 13 280 REMOVING AND INSTALLING/REPLACING TRIM STRIP ON ROOF FRAME AT LEFT

OR RIGHT
00 9 321
Lever out trim strip (1) with special tool 00 9 321 starting at rear.
Unclip trim strip (1) in direction of arrow.

2010 BMW M3
Fig. 76: Identifying Trim Strip And Special Tool 00 9 321

Installation:
Clips (1) and seals (2) on trim strip (3) must not be damaged.
Position of clips (1) on trim strip (3) is determined by notch (4).
Fig. 77: Identifying Seals, Clips, Trim Strip And Notch

Installation:
Push trim strip (1) at front into seal (2).
Trim strip (1) must be flush with edge (3) at rear.

2010 BMW M3
Fig. 78: Identifying Seal, Trim Strip And Edge

51 13 286 REPLACING BRACKET FOR ROOF LUGGAGE RACK ON LEFT OR RIGHT
00 9 322
Remove trim strip from roof frame
Remove body sealing compound (1) with special tool 00 9 322 and unfasten threaded pin (2).

NOTE: Threaded pin is designed as Torx from E87 model series.

2010 BMW M3
Installation:
Threaded pin may not be wetted with screw securing adhesive on screw-in thread (1).
Before installing threaded pin, protect body against corrosion (e.g. apply zinc dust paint).
Tightening torque 51 13 1AZ , see 51 13 TRIM PARTS, COVERS, HANDLE TRIM .
Fig. 80: Identifying Screw-In Thread

Apply body sealing compound (1) (Terostat 9320, sourcing reference: BMW Parts Service) to threaded pin (2)
all round.
After hardening time of body sealing compound (1), paint over body sealing compound (1) and threaded pin (2)
with paint pencil of corresponding car color.

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

LEFT OR RIGHT
2010 BMW M3
00 9 317
IMPORTANT: Make sure that body is not damaged.
Starting at front, release trim strip (1) with special tool 00 9 317 from clips (2).
Installation:
To avoid leaks and noises, check all clips (2) for visible damage.
Align clips (2) on body and fit trim strip (1).
Fig. 82: Identifying Clips And Trim Strip

Installation:
Seals (1) must not be damaged.

2010 BMW M3

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

51 14 ... INSTRUCTIONS FOR ATTACHING NUMBER/LETTER DESIGNATION COMBINATION
NOTE: The model designation is attached with adhesive and cannot be re-used.
The model designation must be attached at room temperature.
The model designation must be removed at stove-enameling temperatures
exceeding 80C.
NOTE: The following work steps are described using the "316 i" as the example.
Removing:
Coat nylon string or strong yarn with tensides (e.g. washing-up liquid).
Cut through adhesive layer and remove model designation (1) from rear lid (2).
Remove remainder of adhesive layer with adhesive remover (sourcing reference: BMW Parts Service).
2010 BMW M3
Fig. 84: Identifying Model Designation And Rear Lid

Assembly:
Number and letter combinations (1) of the model designation are not connected to each other and are supplied
on a carrier film (2).
Remove liner (3) (protective strip for adhesive surface).
Press on model designation firmly.
Remove carrier film (2).
Fig. 85: Identifying Number And Letter Combinations, Carrier Film And Liner
51 14 000 REMOVING AND INSTALLING/REPLACING FRONT BMW BADGE

2010 BMW M3
00 9 318
To avoid damaging the paintwork on the engine hood/bonnet, tape off edge areas (1) to sides of guide pins.
So as not to subject the BMW badge to excessive deformation, lever out the badge with special tool 00 9 318 at
guide pins (2).
Fig. 86: Tape Off Edge Areas, Special Tool 00 9 318 And Guide Pins
Installation:
1. Badge
2. Guide pins
3. Grommets
2010 BMW M3
Fig. 87: Identifying Badge, Guide Pins And Grommets

51 14 010 REMOVING AND INSTALLING/REPLACING REAR BMW BADGE
Removing and installing/replacing front BMW badge.
IMPORTANT: The "Instructions for number/letter combination cementing" serve as the basis
for these repair instructions and must be followed without fail.
Fitting dimensions (E90/E91/E92/E93):

2010 BMW M3
Fig. 88: Identifying Rear Model Designation Fitting Dimensions (E90/E91/E92/E93)

Attach adhesive tape (1) between edge of rear lid (2) and top edge "A". Mark out measurement "B" from top
edge "A" to outer edge of rear lid on adhesive tape (1).
Dimensions:
DIMENSIONS
E90 A = 25.2 mm B = 49.3 mm
E91 A = 26.6 mm B = 65.1 mm
E92 A = 21 mm B = 49.6 mm
E93 A = 20 mm B = 52.7 mm
NOTE: Measurements C, D and E are for information purposes only, as determined by

carrier film.
316 i, 318 i, 318 d: C = 4.8 mm, D = 7.2 mm, E = 11.6 mm
320i...335i: C = 7.2 mm, D = 7.2 mm, E = 11.6 mm
320 d...330 d: C = 7.2 mm, D = 7.2 mm, E = 11.6 mm
320 si, 325 xi, 330 xi, 330 xd: C = 7.2 mm, D = 7.2 mm, E = 10.6 mm, F = 4.8 mm
M3 only:
Attach adhesive tape (1) between edge of rear lid (2) and measurement "A".
2010 BMW M3
Mark out measurement "B" at top edge of adhesive tape (1) to outer edge of rear lid.
E90:
A = 21 mm
B = 147 mm
E92/E93:
A = 21 mm
B = 139 mm
Fig. 89: Identifying Rear Model Designation Fitting Dimensions - M3 Only

NOTE: Measurement "C" is for information purposes only, as it is determined by

carrier film.
C = 5.9 mm

(BRILLIANCE)
IMPORTANT: The "Instructions for number/letter combination cementing" serve as the basis
for these repair instructions and must be followed without fail.
Attach adhesive tape (1) between edge of rear lid (3) and top edge measurement "A".
Mark measurement "B" from outer edge of rear lid on adhesive tape (1) and stick on adhesive tape (2)
vertically.
2010 BMW M3
Measurements E60:
A = 18 mm
B = 38 mm
Measurements E90:
A = 25 mm
B = 46 mm
Pull off liner (protective strip for adhesive surface).
Position characters on adhesive tapes (1 and 2) and stick into place.
Fig. 90: Identifying Rear Model Designation Fitting Dimensions

MIRRORS, COVER, ASHTRAY

51 16 ... CALIBRATING COMPASS IN INTERIOR REARVIEW MIRROR (FROM 09/08)
Adjusting magnetic field zone:

2010 BMW M3
Press and hold down setting button (A) on interior mirror (2) with a suitable tool (1) for 3-6 seconds. The
currently set magnetic field zone is indicated in the compass display (B) (default setting "8" for Central
Europe). Release setting button (A) briefly and select magnetic field zone (1-15) by pressing setting
button (A) again. Release setting button (A) when the desired magnetic field zone is selected. The
selection menu is automatically exited after approx. 5 seconds.
Fig. 91: Calibrating Compass In Interior Rearview Mirror (From 09/08)

Press and hold down setting button (A) on interior mirror (2) for 6-9 seconds. Release setting button (A)
as soon as "C" is indicated in the compass display (B).
Drive vehicle 2 to 3 times in a full circle at approx. 7- 10 km/h. The circle must be at least twice the
vehicle's turning circle. Calibration is complete as soon as a valid direction is displayed.
For Convertibles and vehicles with hardtops only:
The digital compass must be calibrated once with the soft top or hardtop closed and once with the soft top
or hardtop open.
2010 BMW M3

Setting right-hand drive or left-hand drive vehicle:
Press and hold down setting button (A) on interior mirror (2) for 9-12 seconds. The currently set vehicle
type is indicated in the compass display (B) (default setting "L" for left-hand drive). Release setting
button (A) briefly and select vehicle ("L" or "R") by pressing setting button (A) again. Release setting
button (A) when the desired vehicle type is selected. The selection menu is automatically exited after
approx. 5 seconds.

Setting language of compass display:
Press and hold down setting button (A) on interior mirror (2) for 12-15 seconds. The currently set
language is indicated in the compass display (B) (default setting "E" for English). Release setting button
(A) briefly and select language (E for English or O for German) by pressing setting button (A) again.
2010 BMW M3
Release setting button (A) when the desired language is selected. The selection menu is automatically
exited after approx. 5 seconds.

51 16 ... CALIBRATING COMPASS IN INTERIOR REARVIEW MIRROR (UP TO 09/08)
Setting magnetic deflection zone:
Switch ignition on
Using a suitable tool (1), press pushbutton in area (A) of mirror (2) until a number appears in compass
display (B)
Press pushbutton repeatedly until number of desired zone appears
Wait until direction display appears
Magnetic deflection zone is now set
2010 BMW M3
Fig. 95: Calibrating Compass In Interior Rearview Mirror (Up To 09/08)

Switch ignition on
Using a suitable tool (1), press pushbutton in area (A) of mirror (2) until "C" appears in compass display
(B)
Drive vehicle 2 to 3 times in a circle at approx. 10 mph
Calibration process is completed when direction display appears
Fig. 96: Calibrating Compass In Interior Rearview Mirror (Up To 09/08)

51 16 ... GLUING OF MIRROR BASE
Material Requirements:
Repair set for gluing of mirror base (Sourcing Reference: BMW Parts Service)
Primer XW 775 (Sourcing Reference: BMW Parts Service)

2010 BMW M3
1. Preparations
1. Glue at room temperature and make sure that, in cold weather, the window glass and base are
brought to room temperature in the workshop long enough to prevent moisture forming on the
surface.
2. Mark location of the mirror mount on the outside of the windshield.
Scratch off glue residue on glass and base with a sharp tool.
3. Clean glue area on window and base with clean non-fluffing cloth and alcohol/acetone and allow to
dry!
Never use paint thinners!
2. Primer coat
Apply colorless, diluted primer to surface of windshield intended for gluing with help of cotton buds (Q-
Tips or similar).
Specified ventilation time at least 1 minutes, maximum 1 hour
3. Gluing coat
1. Mixing Glue
Cut off sealing tips on containers of glue and hardener using a knife.
Make sure that both openings are equal in size, as otherwise there would be mistakes in mixing.
The sealing cap for subsequent plugging of the double injector is located between both pistons of
the injector. Break off sealing cap.
The required amount of glue and hardener is removed by applying light pressure on the pistons.
The mixture ratio of glue and hardener is 1: 1 (weight and volume). It is important that the same
volumes of glue and hardener are removed (increase size of openings if necessary).
Both components react chemically with each other. Thorough, intensive and homogenous mixing is
a requirement for this reaction and for the quality of gluing.
Consequently both components must be mixed in such a way that there is a uniform, ream-free
color mixture.
2. Application
At 20 ... 25C the mix can be processed after approx. 5 ... 10 minutes (pot time).
Apply thin (approx. 0.5 mm), uniform coat of glue on base with spatula and press base onto glass in
2010 BMW M3
such a way that glue obtains good contact with windshield across the entire surface area.
NOTE: The temperature for the hardening process should not be lower than
+18C.
3. Fixing Bonded Parts
Epoxy resin glue does not have an initial strength property. It is therefore necessary to fix all
bonded parts (adhesive tape or similar). The joining and fixing of bonded parts must be
accomplished within the potlife). Check that the arresting button is located correctly on the mirror
base to ensure that the mirror, when it is attached, is seated straight.
(Long side of mirror base hexagon parallel to upper edge of window).
4. Hardening of glue
Hardening speed depends on the ambient temperature.
For this reason, the mirror base must be secured with adhesive tape or similar for at least 3 ... 4
hours.
After 12 hours have elapsed, clip mirror into place as soon as possible.
4. Working hygiene
IMPORTANT: Glue is dangerous for health when vapors are inhaled or through contact
with the skin.
As is the case for all epoxy resins, sensitive persons might be confronted
with an allergy through contact with the skin.
If the product gets on the skin, wash off with soap and water immediately.
If it gets in an eye, rinse the eye thoroughly in water and consult doctor.
Make sure that the room is well ventilated and gloves are worn for the application of glue.
51 16 ... OVERVIEW OF STORAGE COMPARTMENT (CENTER CONSOLE)

2010 BMW M3

51 16 ... REMOVING AND INSTALLING DRAWER IN LUGGAGE COMPARTMENT
Release lock (1) and pull out drawer (2) in direction of arrow.
2010 BMW M3
Fig. 98: Identifying Lock And Drawer

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

DOOR MIRROR
Remove cover cap from door mirror

Remove trim from door mirror
Remove drive for electrically adjustable door mirror. See 67 13 001 REPLACING DRIVE UNIT FOR
ELECTRICALLY OPERATED LEFT OR RIGHT DOOR MIRROR .
Fig. 99: Identifying Screws And Retaining Ring


2010 BMW M3

Installation:
Fig. 101: Identifying Catch, Guide And Locators

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

DOOR MIRROR

Remove trim from door mirror
Remove drive for electrically adjustable door mirror. See 67 13 001 REPLACING DRIVE UNIT FOR
2010 BMW M3
ELECTRICALLY OPERATED LEFT OR RIGHT DOOR MIRROR .
Fig. 102: Identifying Screws And Retaining Ring


Installation:

2010 BMW M3
Fig. 104: Identifying Locators, Catch And Guide

51 16 ... REMOVING AND INSTALLING/REPLACING TRIM ON LEFT OR RIGHT DOOR

MIRROR
Release screws (1) and carefully remove trim (2) towards front.
Installation:
Make sure trim (2) is correctly seated on door mirror.

Installation:
2010 BMW M3
Holders (1) and guide (2) must not be damaged.
Fig. 106: Identifying Holders And Guide

51 16 ... OVERVIEW OF REAR CONSOLE

2010 BMW M3
Fig. 107: Overview Of Rear Console

51 16 ... REMOVING AND INSTALLING/REPLACING COVER CAP ON LEFT OR RIGHT DOOR

MIRROR
Remove mirror glass.
NOTE: Cover cap is secured without play by four multitooth catches (1) on retaining
ring (2).
Secure cover cap against falling off.
Unlock multitooth catches (1) with a screwdriver.

2010 BMW M3
Unclip cover cap forwards from retaining ring (2) and remove.
Fig. 108: Identifying Multitooth Catches And Retaining Ring

Installation:
Multitooth catches (1), catch (2) and guides (3) must not be damaged.
Fig. 109: Identifying Multitooth Catches, Catch And Guides

Installation:
Locators (1) on retaining ring (2) must not be damaged.

2010 BMW M3
Fig. 110: Identifying Retaining Ring

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

FRONT DOOR (CONVERTIBLE)
Unclip trim (1) from retaining clip (2) in inward direction. Slide trim (1) upwards slightly out of guide (3) and
remove.

NOTE: On version with speaker, trim (1) can remain hanging over door trim panel.
Installation: Retaining clip (2) must be fitted on door.
Installation: Following parts of trim must not be damaged or missing:
1. Sound insulation
2. Retaining lug
2010 BMW M3
3. Guide
Fig. 112: Identifying Sound Insulation, Retaining Lug And Guide

IMPORTANT: Risk of damage! Secure mirror against falling down.
Disconnect plug connection (1). Fold seal (2) to one side slightly and release screws (3). Tightening torque 51
16 1AZ, see 51 16 MIRRORS, FINISHERS, ASHTRAYS, CONSOLES .
Fig. 113: Identifying Plug Connection And Seal

Installation: Rubber grommet for plug connection (1) must be correctly seated on door. Seal (2) must be
correctly seated on door trim panel and door.
Remove mirror (1) outwards. Installation: Check function.

2010 BMW M3
Fig. 114: Removing Mirror Outwards

Replacement:
Modify mirror glass, replace if necessary.

Modify cover cap, replace if necessary.
Modify mirror base cover, replace if necessary
51 16 000 REMOVING AND INSTALLING/REPLACING MIRROR ON LEFT OR RIGHT FRONT

DOOR
Remove front door trim panel

Lever out cover on door window frame at front
IMPORTANT: Secure door mirror against falling down.
Release screws (2).
Tightening torque 51 16 1AZ , see 51 16 MIRRORS, FINISHERS, ASHTRAYS, CONSOLES .
Replacement:
Due to the thread-tapping screws, the tightening torque of the new mirror is increased by 2 Nm.
Tightening torque 51 16 1AZ , see 51 16 MIRRORS, FINISHERS, ASHTRAYS, CONSOLES .

2010 BMW M3

Remove mirror (1) outwards.
Installation:
Check function.
Fig. 116: Identifying Mirror

Installation:
Acoustic insulation (1) must not be damaged.

2010 BMW M3
Fig. 117: Identifying Acoustic Insulation

51 16 026 REPLACING MIRROR GLASS
00 9 317

Move mirror glass with hand carefully and slowly.
If mirror glass is damaged:
Wear protective goggles and cut-proof gloves.
Risk of injury by flaking-off glass splinters.

Bring door mirror to room temperature to prevent catches from breaking off.

Secure mirror glass (1) against falling out.
Press mirror glass (1) on side vehicle by hand to full extent.
Unclip mirror glass (1) from outer side with special tool 00 9 317 all round.
Unlock and disconnect associated plug connections, remove mirror glass (1).
2010 BMW M3
Fig. 118: Removing Mirror Glass

Installation:
Retaining lugs (1) must not be damaged.
Fit mirror glass (2) with retaining lugs (1) flush on mirror adjusting drive and clip into place.
Ensure correct locking.
Make sure mirror adjusting drive functions correctly.
Fig. 119: Identifying Mirror Glass And Retaining Lugs

51 16 060 REMOVING AND INSTALLING/REPLACING INTERIOR REARVIEW MIRROR

(OVERVIEW)
NOTE: Version with cable (X) for:

2010 BMW M3
Automatic dim action (electro-chrome technology) for interior rearview mirror

Fogging sensor
Remote control (infrared or radio)
Autobeam
Garage door opener
Compass
Rain sensor
Version without cable (X) with full foot (1).
Fig. 120: Identifying Foot

Version with cable (X) and plug trim cover (1).
Fig. 121: Identifying Cable (X) And Plug Trim Cover

Version with mirror arm end caps (1).

2010 BMW M3
Fig. 122: Identifying Mirror Arm End Caps

Version with rain sensor.
Fig. 123: Identifying Rain Sensor

Version with Autobeam.

2010 BMW M3
Fig. 124: Identifying Autobeam

Version with toll mirror for Japan.
Fig. 125: Identifying Toll Mirror For Japan


JAPANESE TOLL MIRROR)
IMPORTANT: Work may only be carried out at a room/object temperature of 18 ... 28C.
If necessary, disconnect negative lead from battery .
If necessary, calibrate compass in interior rearview mirror .

Screw rearview mirror off mirror mount.
Mirror must not be pulled or pressed off towards front or rear.
2010 BMW M3
Fig. 126: Identifying End Caps

Turn mirror (1) to right and left and feed out end caps (2).
Fig. 127: Identifying Mirror And End Caps

Installation:
Catches (1) and guides (2) of end caps (3) must not be damaged, replace if necessary.
2010 BMW M3
Fig. 128: Identifying Catches, Guides And End Caps

Disconnect plugs (1 and 2).
NOTE: Pay attention to cable guide for rain sensor.
Fig. 129: Identifying Plugs

IMPORTANT: Do not pull or press rearview mirror off towards front or rear.
Because of altered mirror foot, rearview mirror must be twisted off.
Twist mirror foot approx. 45 to right until mirror foot is released from mirror mount.
2010 BMW M3
Fig. 130: Twisting Mirror Foot Approx. 45 To Right

Installation:

Fig. 131: Twisting Mirror Foot By Approx. 45

Only in case of replacement with version with remote control for central locking:

MIRROR ARM END CAPS)
If this cannot be guaranteed (cold/hot countries), it is necessary to equalize the temperature of the windscreen,
mirror foot and rearview mirror (e.g. car left to stand indoors or in the shade for at least 30 minutes).
2010 BMW M3
If necessary, disconnect negative lead from battery.
If necessary, calibrate compass in interior rearview mirror.

If the rear catch is damaged, the mirror will be loose when installed and must
be replaced.
NOTE: Do not exert any pressure on mirror foot when removing end caps (1).
Press end caps (1) towards mirror housing (2); this releases clip connection of both caps (1).
In order not to create any tension at the mirror foot, simultaneously apply counterpressure to the mirror housing
when removing the end caps.
Fig. 132: Identifying End Caps And Mirror Housing

foot.
2010 BMW M3
Fig. 133: Identifying Mirror, End Cap And Engagement Clip

foot.
Fig. 134: Identifying Mirror And Right End Cap

Installation:
2010 BMW M3

Version with cable (X):


Do not pull off rearview mirror (1) from windscreen against direction of travel
and or snap out by turning.
remove.
2010 BMW M3
Fig. 137: Identifying Interior Mirror And Mirror Mount

Installation:


Only replace with version with remote control for central locking:
Initialize all transmitters (ignition keys).

RAIN SENSOR)
2010 BMW M3
If necessary, disconnect negative lead from battery.
If necessary, calibrate compass in interior rearview mirror.

If the rear catch is damaged, the mirror will be loose when installed and must
be replaced.
Press on end caps (1) and at same time press them apart; this releases clip connection of both caps (1).
Fig. 139: Identifying End Caps

foot.
2010 BMW M3
Fig. 140: Identifying Mirror, Left End Cap And Engagement Clip
foot.
Fig. 141: Identifying Mirror And Right End Cap

Installation:
2010 BMW M3

NOTE: Pay attention to cable guide (2) for rain sensor.
Fig. 143: Identifying Plug Connection And Cable Guide


Do not pull off rearview mirror (1) from windscreen against direction of travel
and or snap out by turning.
When snapping out, do not damage control unit (3) for rain sensor.

2010 BMW M3
Rain sensor is not installed.
remove.
Fig. 144: Identifying Interior Mirror And Mirror Mount

Installation:


Only in case of replacement with version with remote control for central locking:
51 16 080 REMOVING AND INSTALLING OR REPLACING SUN VISOR AND LEFT OR RIGHT
COUNTER SUPPORT
2010 BMW M3
side.
Fold down sun visor (5).
Lever out trim (2) on counter support (1) and release screw underneath.
Release screws (3) on holder (4).
Fig. 146: Identifying Trim, Counter Support, Screws And Holder

Lift out sun visor (1).
If necessary, pull out cable (2) slightly and disconnect plug connection (3).
Installation:
Perform function check on lighting.
Fig. 147: Identifying Sun Visor, Cable And Plug Connection

2010 BMW M3
51 16 154 REMOVING AND INSTALLING/REPLACING INSERT FOR CENTER CONSOLE
Remove trim for storage compartment
Remove foam material (1).
Release screws (2) and remove insert/ashtray (3).
Fig. 148: Identifying Foam Material, Screws And Insert/Ashtray

51 16 156 REPLACING ASHTRAY INSERT
Open ashtray cover (1) and pull ashtray lid (2) out of locator.
Installation:
Press ashtray insert (2) until it snaps into the locator.
Fig. 149: Identifying Ashtray Cover And Ashtray Lid

2010 BMW M3
51 16 200 REMOVING AND INSTALLING STORAGE COMPARTMENT
00 9 323
Remove trim for storage tray
Fig. 150: Identifying Screw Covers

Move with special tool 00 9 323 from below behind trim (1) and release catches (2).

2010 BMW M3

Installation:

Unscrew nuts (1).
Depending on equipment specification:
If necessary, disconnect cable strap (2) and plug connections (3 and 4).
2010 BMW M3
Fig. 153: Identifying Cable Strap And Plug Connections

Specification with telephone:
Detach plug connection (2) from holder and disconnect plug connection (2).
Fig. 154: Identifying Gaiter And Plug Connection

Raise storage compartment (2) at rear and feed out gaiter (1) through opening.
If necessary, disconnect further plug connections and feed out cable.
Remove storage compartment (2) towards rear/top.

2010 BMW M3
Fig. 155: Identifying Storage Compartment And Gaiter

Installation:
Guide (1) of storage compartment (2) must be fed behind panel (4) on left/right.
Specification with ventilated multifunction storage:
Air duct (3) must be correctly inserted in storage compartment (2).
Fig. 156: Identifying Air Duct And Storage Compartment

51 16 201 REPLACING STORAGE COMPARTMENT
Remove storage compartment

Remove center armrest
2010 BMW M3
Version with telephone:
Remove eject box . See 84 11 519 REMOVING AND INSTALLING OR REPLACING EJECT
BOX .
Version with rear cabin air conditioning:
First feed air duct (1) to right out of guide (2) and duct (3), then remove to left out of storage compartment.
Installation:
Fig. 157: Identifying Air Duct, Guide And Duct

Release catches (2) on coin holder (1) and remove coin holder (1) in inward direction.
Release catches (3) on multifunction storage compartment (4) and remove multifunction storage compartment
(4).
If necessary, remove AV connection socket (5).
Remove socket (6).

2010 BMW M3
Fig. 158: Identifying Coin Holder And Catches

51 16 202 REMOVING AND INSTALLING/REPLACING FRONT (INNER OR OUTER) CUP

HOLDER
Remove trim on instrument panel on right
Release screws (1) and pull out cup holder (2) in direction of arrow.
Fig. 159: Identifying Screws And Cup Holder

51 16 204 REMOVING AND INSTALLING/REPLACING REAR CUP HOLDER
Open cup holder (1) and remove mat insert (2).

2010 BMW M3
Fig. 160: Identifying Cup Holder And Mat Insert

Lever out hinges (1).
Close lid (2) slightly and feed out completely with both hinges (1) in direction of arrow.
Repeat procedure on lid (3).
Fig. 161: Identifying Hinges And Lid

Reach through openings and release catches (1).
Remove housing (2).
Installation:
Catches (1) on housing (2) must not be damaged.

2010 BMW M3
Fig. 162: Identifying Catches On Housing

51 16 206 REMOVING AND INSTALLING / REPLACING CENTER ARMREST
Move both front seats forwards
Pull trim (2) towards rear and release from catches (3).

Installation:

2010 BMW M3
If necessary, release rear compartment fresh-air grille in order to install trim correctly. See 64 22 191
REMOVING AND INSTALLING/REPLACING REAR COMPARTMENT FRESH-AIR GRILLE .

NOTE: Open center armrest otherwise spring (1) will be under too much tension.
Disengage spring (1) with screwdriver (2).
Installation:
Make sure spring (1) is correctly seated.
Fig. 165: Disengaging Spring With Screwdriver

Drive out hinge shafts (1).

2010 BMW M3
NOTE: Hinge shafts (1) are secured on the outside with toothing (3).
Remove spring (2), open center armrest and feed out of storage compartment.
Fig. 166: Identifying Hinge Shafts, Toothing And Spring

51 16 212 REMOVING AND INSTALLING TRIM FOR STORAGE COMPARTMENT
00 9 317
Version with manual transmission:
Remove gaiter for gear lever . See 25 11 081 REPLACING GAITER (SHIFT LEVER COVER)
FOR SHIFT LEVER .
Version with automatic transmission:
Remove finisher for preselector lever
Release trim (1) with special tool 00 9 317 from retainers (2).
If necessary, disconnect plug connections and remove trim (1) towards top.
2010 BMW M3
Fig. 167: Identifying Trim, Special Tool 00 9 317 And Retainers

Installation:
Following parts on trim (3) must not be damaged or missing:
1. Clips
2. 4 x foam material
Fig. 168: Identifying Trim, Clips And 4 x Foam Material

51 16 213 REPLACING TRIM FOR STORAGE COMPARTMENT
Remove trim for storage compartment

Modify insert for center console
M3: Modify switch block . See 61 30 020 REMOVING AND INSTALLING/REPLACING SWITCH
BLOCK (M3) .
2010 BMW M3
Version with controller:
Modify controller . See 61 31 195 REMOVING AND INSTALLING (REPLACING) FRONT

CONTROLLER .
E93 only:
Modify switch for convertible top operation . See 61 31 078 REMOVING AND
INSTALLING/REPLACING SWITCH FOR CONVERTIBLE TOP OPERATION .
Version without controller:
Carefully release catches (1) and remove storage tray (2).
Fig. 169: Identifying Catches And Storage Tray

51 16 260 REMOVING AND INSTALLING/REPLACING FRONT SECTION OF REAR CONSOLE

TRIM
00 9 317
Apply special tool 00 9 317 at side and unclip trim (1) in upward direction from retaining clips (2).
Installation:
Clips (2) must not be damaged.

2010 BMW M3
Fig. 170: Identifying Retaining Clips And Trim

Replacement
Release screws (1) and remove ashtray/oddments tray (2).
Release screws (3) and remove oddments tray/fresh-air grille (4).
Fig. 171: Identifying Oddments Tray/Fresh-Air Grille And Ashtray/Oddments Tray

51 16 265 REMOVING AND INSTALLING/REPLACING REAR SECTION OF REAR CONSOLE

TRIM
00 9 317

2010 BMW M3
E92 only:
Remove filler element from rear seat. See 52 24 030 REMOVING AND INSTALLING COMPLETE
ARMREST (FILLER ELEMENT) FOR REAR SEAT BACKREST .
E93 only:
Remove armrest for rear seat backrest. See 52 24 030 REMOVING AND INSTALLING
COMPLETE ARMREST (FILLER ELEMENT) FOR REAR SEAT BACKREST .
Apply special tool 00 9 317 at side and unclip trim (1) in upward direction from retaining clips (2).
Installation:
Clips (2) must not be damaged.
Fig. 172: Identifying Retaining Clips And Trim With Special Tool (00 9 317)
Replacement
Release screws (1) and remove oddments tray (2) from trim (3).
2010 BMW M3
Fig. 173: Identifying Oddments Tray And Trim

51 16 340 REMOVING AND INSTALLING/REPLACING LOCK FOR RIGHT GLOVEBOX
Open glovebox.
Release screws (1).
Remove lower section (3) and upper section (2) of lock.
Fig. 174: Identifying Lower Section And Upper Section Of Lock

Replacement:
Insert ignition key (1) in lock cylinder (3).
Turn ignition key (1) slightly, carefully raise catches (2) and pull out lock cylinder (3) with ignition key (1) in
direction of arrow.
If necessary, force catches (2) open.

2010 BMW M3
Fig. 175: Identifying Ignition Key, Raise Catches And Lock Cylinder
51 16 342 REMOVING AND INSTALLING/REPLACING LOCK CYLINDER FOR PASSENGER

AIRBAG DEACTIVATION
Individual parts, switch for passenger airbag deactivation

2010 BMW M3
Fig. 176: Identifying Switch For Passenger Airbag Deactivation

Remove switch for passenger airbag deactivation . See 61 31 038 REMOVING AND INSTALLING
(REPLACING) SWITCH FOR PASSENGER AIRBAG DEACTIVATION .
Release screws (1).
Remove housing cover (2) and PCB (3) underneath.

2010 BMW M3
Fig. 177: Identifying Housing Cover And PCB

Remove switch unit (1) in upward direction.
Installation:
Switch unit (1) can only be installed in one position.
PCB (4) can be inserted turned through 180.
Position of magnet sensor (3) of PCB (4) must match up with permanent magnet (2) of switch unit (1).
Fig. 178: Identifying Magnet Sensor, PCB, Permanent Magnet And Switch Unit
Remove guide (1) in upward direction.
Installation:
Guide (1) can only be installed in one position.

2010 BMW M3
Fit seal (2) on guide (1) and insert in switch housing.
Fig. 179: Identifying Seal And Guide

IMPORTANT: Ignition key must be inserted in lock cylinder, otherwise this will be destroyed
when removed.
Insert ignition key in lock cylinder (2).
Carefully release catches (1) in outward direction and press out lock cylinder (2) with ignition key.
Installation:
Lock cylinder (2) can only be inserted in "ON" or "OFF" switch position.
Lock cylinder
Fig. 180: Identifying Catches And Lock Cylinder

51 16 361 REPLACING RIGHT GLOVEBOX

2010 BMW M3
Remove right glovebox with housing.

Remove fastener for glovebox.
Remove damper for glovebox.
Remove glovebox light . See 63 31 150 REMOVING AND INSTALLING/REPLACING
GLOVEBOX LIGHT .
If necessary, remove hotel setting switch
Release clips (1) and remove cover (2).
Fig. 181: Identifying Clips And Cover

Remove all dummy platers.
Release screws (1) and remove locking catch (2) from glovebox housing.
Fig. 182: Identifying Screws And Locking Catch

2010 BMW M3
51 16 366 REMOVING AND INSTALLING RIGHT GLOVEBOX WITH HOUSING
Remove both front cup holders.
Release screws (1).
Pull out glovebox (1) slightly.
Fig. 183: Identifying Screws And Glovebox

Disconnect plug connections (2) and feed cable out of guide (3).
Depending on version, disconnect further plug connections.
Remove glovebox (1).
Fig. 184: Identifying Plug Connections And Guide

2010 BMW M3
Installation:

51 16 383 REMOVING AND INSTALLING/REPLACING DAMPER FOR GLOVEBOX
Remove glovebox with housing.
Open glovebox.
Release clip (1).

2010 BMW M3
Fig. 186: Identifying Clip

Press catch (1) together and slide damper (2) in direction of arrow.
Remove damper (2) in inward direction.
Fig. 187: Identifying Catch And Damper

Installation:
Catch (1) and guide (2) on damper (3) must not be damaged or missing.
2010 BMW M3
Fig. 188: Identifying Catch, Guide And Damper

51 16 400 REMOVING AND INSTALLING/REPLACING ROLLER SUN BLIND ON FIXED SIDE

WINDOW OF LEFT OR RIGHT REAR DOOR
00 9 317
Retract roller sun blind (1).
Open side window.
Unclip casing (2) of roller sun blind (1) with special tool 00 9 317 in direction of arrow.
Installation:
Casing (2) must not be damaged.

2010 BMW M3
Fig. 189: Identifying Casing And Roller Sun Blind

51 16 405 REMOVING AND INSTALLING/REPLACING ROLLER SUN BLIND ON SIDE WINDOW

OF LEFT OR RIGHT REAR DOOR
Remove rear door trim panel
Carefully release catches (1) and remove roller sun blind (2) in direction of arrow.
Installation:
Make sure catches (1) are correctly seated.
Fig. 190: Identifying Catches And Roller Sun Blind

Fold up handle (1) and feed out with roller sun blind (2) through frame (3).
2010 BMW M3
Fig. 191: Identifying Handle, Roller Sun Blind And Frame

Installation:
Roller sun blind must be correctly inserted in guides (1).

Replacement up to build date 06/2005:
NOTE: Because there are visual differences between the old and new build dates, it is
necessary to replaced the left and right roller sun blinds.
When installing roller sun blind in door trim panel (build date up to 06/2005),
disconnect blocking finger (1) from roller sun blind (2) and door trim panel (3).
2010 BMW M3
Fig. 193: Identifying Blocking Finger, Roller Sun Blind And Door Trim Panel
Replacement:
Remove clip (2) before fitting sun roller blind (1).
Fig. 194: Identifying Clip And Sun Roller Blind

51 16 450 REMOVING AND INSTALLING/REPLACING REAR LEFT/RIGHT GRAB HANDLE
Removing and installing/replacing front grab handle.

2010 BMW M3
Fig. 195: Locating Front Grab Handle


REMOVED)
If necessary, remove lock cylinder.
NOTE: Lock cylinder repair kit *(part number: 9 061 387) applicable to:
E30
Lock cylinder repair kit *(part number: 9 061 388) applicable to:
E31, E32, E34, E36, E38, E39
Lock cylinder repair kit *(part number: 7 001 461) applicable to:
E46, E52, E53, E60, E61, E63, E64, E65, E66, E67, E85, E86, E90, E91, E92,
E93
* Sourcing reference: BMW Parts Service
2010 BMW M3
Fig. 196: Identifying Supplied Retainers



2010 BMW M3

(A) OK
(B) not OK
Fig. 199: Identifying Ignition Key, Lock Cylinder And Retainer

2010 BMW M3
Fig. 200: Identifying Retainer, Lock Cylinder And Tool

51 44 150 REPLACING TRIM FOR FRONT ROOFLINER
See 51 44 150 Replacing trim for front roofliner.
51 45 ... OVERVIEW OF INSTRUMENT PANEL

2010 BMW M3

LIDS
51 17 400 REMOVING AND INSTALLING/REPLACING BUMP STOP WITH EJECTOR FOR
FILLER FLAP
Release cover (1).
Press catches (2) together and pull out ejector (3).
Installation:
2010 BMW M3
Install ejector (3) with fitted cover (1).
Fig. 202: Identifying Catches, Ejector And Cover

Installation:
Make sure cover (3) is correctly seated on ejector (2).
Fig. 203: Identifying Catches, Ejector And Cover

FRONT DOOR LOCKS HANDLE

2010 BMW M3

51 21 ... OVERVIEW OF FRONT DOOR LOCKS

2010 BMW M3

51 21 ... REMOVING WINDOW CAVITY COVER STRIP WITH SPECIAL TOOL 00 9 324 AT
FRONT OR REAR
00 9 318
00 9 324
Open complete door window glass.
Front door:
2010 BMW M3
Insert special tool 00 9 324 at front (at A-pillar) in window cavity (1) (letters TOP pointing upwards).
Rear door:
Insert special tool 00 9 324 at rear (at C-pillar) in window cavity (2) (letters TOP pointing upwards).
Fig. 206: Identifying Window Cavity

NOTE: For purposes of clarity, picture shows inner door panel and door window glass
removed.
Special tool 00 9 324 must be correctly guided under window cavity cover strip (1).
2 Short leg, bottom

3 Long leg, top (TOP)
Fig. 207: Identifying Window Cavity Cover Strip

NOTE: Start at the front or rear, depending on the model.

2010 BMW M3

Raise window cavity cover strip (3) no more than 5 mm in each levering
operation, otherwise the strip will be bent.
Position special tool 00 9 318 on door trim panel (1).
Slide screwdriver (2) into special tool 00 9 324 and lever window cavity cover strip (3) upwards no more than 5
mm.
Guide special tools 00 9 324 and 00 9 318 towards front/rear and lever out window cavity cover strip (3) in the
process.
Fig. 208: Identifying Screwdriver And Window Cavity Cover Strip

51 21 003 REPLACING DOOR DETENT (LOCK STRIKER), FRONT LEFT OR RIGHT
Release screws (1) and remove door detent (2).
Installation:
If necessary, carry out basic adjustment by way of notches (3) on door detent (2).
Notches (3) must be vertical to B-pillar.
Adjust door detent. See 41 5. ... ADJUSTING DOOR .

2010 BMW M3
Fig. 209: Identifying Screws, Door Detent And Notches

51 21 004 ADJUSTING FRONT LEFT OR RIGHT DOOR DETENT (LOCK WEDGE)
Adjusting left or right front door. See 41 5. ... ADJUSTING DOOR .
51 21 090 REMOVING AND INSTALLING/REPLACING DOOR LOCK IN LEFT OR RIGHT FRONT

DOOR
51 2 190

Remove rear section of power window unit.
Driver's side only:
Remove lock cylinder lock cylinder.

2010 BMW M3
Fig. 210: Identifying Lock Knob Control Rod, Plug Connection And Lugs
Installation:

IMPORTANT: Do not damage door lock seal when removing.
Release screws (1).

2010 BMW M3
Installation:
Pull door lock (2) with special tool into corner (3).
IMPORTANT: Observe the following notes on installation without fail in order to avoid
leakage and electrical malfunction.
Fig. 212: Identifying Door Lock And Corner

Installation:
Fig. 213: Identifying Seal And Door Lock

E90/E91 driver's side only:

2010 BMW M3
NOTE: Cover (1) protects against water ingress.

In event of problems with frozen door locks/lock cylinders:
If necessary, retrofit cover (1) on door lock (2).
Fig. 214: Identifying Cover And Door Lock

Installation:
Slide special tool 51 2 190 into opened rotary latch until latch engages in first stage.
Fig. 215: Identifying Door Lock Screws

Installation:
Pretension door lock (1) with knurled screw (2) until special tool 51 2 190 just contacts corner points (3).

2010 BMW M3
To tension door lock (1), it is only permitted to turn knurled screw (2) by a further 1 to 1.5 turns (max.).
Tighten down door lock screws, tightening torque 51 21 1AZ , see 51 21 FRONT DOOR LOCKS .
Fig. 216: Identifying Door Lock And Knurled Screw


OUTSIDE DOOR HANDLE WITH LOCK CYLINDER
Remove outside handle.

Remove sound insulation.
If necessary, close door window glass
Installation:

2010 BMW M3

Release screw (2).
Fig. 218: Identifying Seals And Screw

If necessary, release cable holder on carrier (1).
Remove inner carrier (1) in direction of arrow and feed out of door.
2010 BMW M3
Fig. 219: Identifying Inner Carrier

Replacement:
If necessary, release cable connector (1).
Fig. 220: Identifying Bowden Cable And Carrier


OUTSIDE DOOR HANDLE WITHOUT LOCK CYLINDER
Removing and installing/replacing carrier for outside door handle with lock cylinder.
51 21 140 REMOVING AND INSTALLING/REPLACING COMPLETE LOCK CYLINDER IN LEFT

OR RIGHT FRONT DOOR
2010 BMW M3
Installation:
Fig. 221: Identifying Cap On Screw

Insert ignition key into lock cylinder.
Turn ignition key slightly and pull off cover (1) in direction of arrow with outside door handle (2) opened
slightly.
Installation:
Lock cylinder must be correctly seated in door lock.
Check function of lock cylinder.
Fig. 222: Identifying Cover And Outside Door Handle

2010 BMW M3
Installation:
Fig. 223: Identifying Guides, Outside Door Handle Light And Outside Door Handle (4)
Replacement:
Remove catches (1) and detach cover (2) from lock cylinder (3).
Installation:
Paddle (4) of lock cylinder (3) must not be damaged.

2010 BMW M3
Fig. 224: Identifying Catches, Cover Paddle And Lock Cylinder

51 21 147 REPLACING LOCKS FOR SIMULTANEOUS CLOSING WITH CAS CONTROL UNIT
Necessary tasks:
Replace complete lock cylinder for left or right front door.

Replace insert for radio control key . See 66 12 100 REMOVING AND
INSTALLING/REPLACING SLIDE-IN UNIT FOR RADIO CONTROL KEY .
Replace control unit for Car Access System . See 61 35 015 REMOVING AND INSTALLING
(REPLACING) CONTROL UNIT FOR CAR ACCESS SYSTEM .
Except E81, E87, E91:
Replace lock for rear lid .
Except E81, E82, E87 from MY 03/2007, E88:
Replace lock for right glovebox.
51 21 150 BLOCKING, IF NECESSARY INITIALIZING, CAR KEY IN IMMOBILIZER CONTROL

MODULE
NOTE: Execution in diagnosis system:
->Service functions->
->Body->
->Locking and security functions->
->Remote control key
51 21 170 REMOVING AND INSTALLING OR REPLACING OUTSIDE HANDLE FROM LEFT OR

RIGHT FRONT DOOR
Remove cover on outside handle . See 51 21 180 Removing and installing/replacing cover on outside
handle or 51 21 181 Removing and installing/replacing cover on outside handle with lock cylinder.
If necessary, lay outside door handle light (1) slightly to one side.
Pull out outside handle (2) and feed out in direction of arrow.
2010 BMW M3
Carefully feed out outside handle (2) and disconnect associated plug connection.
Fig. 225: Identifying Outside Door Handle Light And Outside Handle
Installation:
Locator (1) must not be damaged.
Fig. 226: Identifying Locator And Seal

Installation:

2010 BMW M3
Fig. 227: Identifying Lock Actuator And Retaining Clasp

If replacing version with comfort access/CA:
Reset CAS control unit with diagnosis system or by disconnecting and connecting battery.
51 21 180 REMOVING AND INSTALLING/REPLACING COVER ON OUTSIDE HANDLE
Installation:

2010 BMW M3
Fig. 228: Identifying Cap And Trim


Installation:
2010 BMW M3
Fig. 230: Identifying Guides, Outside Door Handle Light And Outside Door Handle
Installation:

51 21 181 REMOVING AND INSTALLING/REPLACING COVER ON OUTSIDE HANDLE WITH

LOCK CYLINDER
Removing and installing/replacing complete lock cylinder in left or right front door.
51 21 225 REMOVING AND INSTALLING OR REPLACING INSIDE DOOR OPENER IN LEFT OR

RIGHT FRONT DOOR

2010 BMW M3

Lever out lock (2).
Installation:
Fig. 232: Identifying Bowden Cable And Release Lever

Installation:
2010 BMW M3

Installation:


HANDLE ON LEFT OR RIGHT FRONT DOOR
Remove sound insulation in front door.
Installation:
2010 BMW M3

NOTE: Outside door handle shown removed for purposes of clarity.


OPENER ON LEFT OR RIGHT FRONT DOOR
2010 BMW M3
Remove front door trim

Lever out lock (2).
Installation:
Fig. 237: Identifying Lock And Bowden Cable

51 21 280 REMOVING AND INSTALLING OR REPLACING DOOR BRAKE ON LEFT OR RIGHT

FRONT DOOR
Close door windows

Remove sound insulation in front area.
NOTE: Secure front door against falling closed.
Release screw (1).

2010 BMW M3
Remove seal (3).
Installation:
Fig. 238: Identifying Screws And Seal


Installation:
1. Hinge
2. Thread
2010 BMW M3
Fig. 240: Identifying Parts Of Door Retainer

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

OUTSIDE OF LEFT OR RIGHT FRONT DOOR
00 9 324
IMPORTANT: Observe procedure for using special tool 00 9 324 .

The "Instructions on fitting window guide seals" serve as the basis for this
repair instruction and must be observed without fail.
Remove door mirror sedan.
Lever out window cavity cover strip (1) with special tool 00 9 324 (starting at A-pillar).
Feed window cavity cover strip (1) at rear out of guide (2) and remove.
Installation:
Moisten window cavity cover strip (1) prior to fitting with approved anti-friction agent.
2010 BMW M3

Window cavity cover strip (1) must be flush at front to door edge.
Installation:
Replacement:
Fig. 242: Identifying Window Cavity Cover Strip And Chrome Strip
2010 BMW M3

OUTSIDE OF FRONT DOOR
00 9 322
IMPORTANT: The Instructions on fitting window guide seals serve as the basis for this repair
instruction and must be observed without fail.
Remove mirror on front door.
Pop catch (1) out of window guide (2) of door.
Pull window guide (2) approx. 30 mm upwards.
Carefully lever window cavity cover strip (3) with special tool 00 9 322 out of door.
Installation:
Moisten window cavity cover strip (3) prior to fitting with approved anti-friction agent .
Window cavity cover strip (3) must be flush at front to door.
Fig. 243: Removing Window Cavity Cover Strip With Special Tool (00 9 322)
2010 BMW M3

INNER FRONT DOOR
IMPORTANT: The "Instructions on fitting window guides" serve as the basis for this repair
Remove outer window cavity cover strip

Remove front door trim
Pop window cavity cover strip (1) in direction of arrow out of front door.
Fig. 244: Popping Cover Strip Out Of Front Door

Installation : Molded section (1) and retaining elements (2) of window cavity cover strip (3) must not be
damaged. Molded section (1) must be correctly fed into door. Moisten window cavity cover strip (3) prior to
fitting with approved anti-friction agent.
Fig. 245: Identifying Molded Section And Retaining Elements Of Window Cavity Cover Strip
2010 BMW M3
Installation: Make sure window cavity cover strip (1) is installed in correct position on door (2) and door
window glass (3).
Fig. 246: Cavity Cover Strip On Door And Door Window Glass

INNER FRONT DOOR (SEDAN)
Remove front door trim panel.
IMPORTANT: The "Instructions on fitting window guide seals" serve as the basis for this
Lever out cover (1) at rear slightly.
Start at rear with removal of window cavity cover strip (2).

2010 BMW M3
Fig. 247: Identifying Cover And Window Cavity Cover Strip

Pull off window cavity cover strip (1) towards top.
Installation:
Insert window cavity cover strip (1) below cover (2).
Fig. 248: Identifying Cover And Window Cavity Cover Strip

Installation:
Start with installation at front.

2010 BMW M3
REAR DOOR LOCKS & HANDLE

51 22 ... OVERVIEW OF REAR DOOR LOCKS
Fig. 250: Identifying Overview Of Rear Door Locks

51 22 001 REPLACING DOOR DETENT (LOCK STRIKER), REAR LEFT OR RIGHT
Replacing front door detent.
51 22 004 ADJUSTING REAR LEFT OR RIGHT DOOR DETENT (LOCK WEDGES)

2010 BMW M3
Adjusting left or right rear door. See 41 5. ... ADJUSTING DOOR .
51 22 090 REMOVING AND INSTALLING/REPLACING DOOR LOCK IN LEFT OR RIGHT REAR

DOOR
51 2 190

Fig. 251: Identifying Lock Knob Control Rod

Installation:
2010 BMW M3

IMPORTANT: Do not damage door lock seal during removal.
Release screws (1).
IMPORTANT: To avoid leaking and electrical malfunction:

Pull door lock (2) with special tool into corner (3), see Fig. 255 and Fig. 256.
Fig. 253: Identifying Door Lock And Corner

Installation:
2010 BMW M3
Fig. 254: Identifying Seal And Door Lock

Installation:
Slide special tool 51 2 190 into opened rotary latch until latch engages in first stage.
Fig. 255: Identifying Door Lock And Screws

Installation:
Pretension door lock (1) with knurled screw (2) until special tool 51 2 190 just contacts corner points (3).
IMPORTANT: To tension door lock (1), it is only permitted to turn knurled screw (2) by a
further 1 to 1.5 turns (max.) (risk of damage).
2010 BMW M3
Tighten down door lock screws, tightening torque 51 22 1AZ , see 51 22 REAR DOOR LOCKS .
Fig. 256: Identifying Door Lock And Knurled Screw

Installation:
Check function of child lock (1) on door lock (2).
Fig. 257: Identifying Child Lock And Door Lock

51 22 126 REMOVING AND INSTALLING/REPLACING CARRIER FOR OUTSIDE DOOR HANDLE

ON LEFT OR RIGHT REAR DOOR
Remove outside handle.

E90 and E91 only:

2010 BMW M3
Remove door lock.
E87 only:
Installation:

Release screw (2).

2010 BMW M3
Fig. 259: Identifying Seals And Screw

Remove inner carrier (1) in direction of arrow.
Fig. 260: Identifying Inner Carrier

Replacement:

2010 BMW M3

51 22 170 REMOVING AND INSTALLING/REPLACING OUTSIDE HANDLE ON LEFT OR RIGHT

BACK DOOR
Remove cover on outside handle.
Pull out outside handle (1) and feed out in direction of arrow.
Fig. 262: Identifying Outside Handle

Installation:
Guide (1) and locators (2) must not be damaged.

2010 BMW M3
Fig. 263: Identifying Guide And Locators

Installation:
Fig. 264: Identifying Lock Actuator And Retaining Clasp

51 22 180 REMOVING AND INSTALLING/REPLACING COVER ON OUTSIDE HANDLE, LEFT OR

RIGHT
2010 BMW M3
Lever out cap (1) and frame (2).
Fig. 265: Identifying Cap And Frame

Release screw (1).

2010 BMW M3

Installation:
Guides (3) must be correctly seated in carrier for outside door handle (4).
Fig. 268: Identifying Guides And Outside Door Handle

Installation:

2010 BMW M3

51 22 225 REMOVING AND INSTALLING/REPLACING INSIDE DOOR OPENER OF REAR LEFT

OR RIGHT DOOR
Remove rear door trim panel.

Lever out lock (2).
Installation:

2010 BMW M3

Installation:

Installation:


HANDLE ON LEFT OR RIGHT REAR DOOR
2010 BMW M3
Removing and installing/replacing carrier for outside door handle on left or right rear door.

OPENER ON LEFT OR RIGHT REAR DOOR
Remove rear door trim panel.

Lever out lock (2).
Installation:
Fig. 273: Identifying Release Lever

51 22 280 REMOVING AND INSTALLING/REPLACING DOOR RETAINER ON REAR LEFT OR

RIGHT DOOR
Close door windows

Remove sound insulation in front area only.
NOTE: Secure rear door against falling closed.

2010 BMW M3
Release screw (1).
Remove seal (2).
Installation:
Fig. 274: Identifying Screw And Seal

Release screws (1).

2010 BMW M3

Installation:
1. Hinge
2. Thread
Fig. 277: Identifying Parts Of Door Retainer


REAR DOOR ON LEFT OR RIGHT

2010 BMW M3
00 9 324
IMPORTANT: Observe procedure for using special tool 00 9 324 .
The "Instructions on fitting window guide seals" serve as the basis for this repair instruction and must be
observed without fail.
E91 only:
Lever out window cavity cover strip (1) with special tool 00 9 324 (starting at B-pillar).
Feed window cavity cover strip (1) at rear out of guide (2).
Installation:
Window cavity cover strip (1) must be flush at front and rear with door edge.


2010 BMW M3
Replacement:
Fig. 279: Identifying Window Cavity Cover Strip And Chrome Strip

INSIDE REAR DOOR
Pull window cavity cover strip at front (1) and rear (2) from rear door.
Installation:
Moisten window cavity cover strips (1 and 2) prior to fitting with approved anti-friction agent.
2010 BMW M3
Fig. 280: Identifying Faulty Retainers And Window Cavity Cover Strips
Replacement with Security version:
Cut front window cavity cover strip to length on side of fixed door window glass to 533 mm.
Cut rear window cavity cover strip (1) to length on straight side (2) to measurement a = 153 mm.
Fig. 281: Identifying Rear Window Cavity Cover Strip And Straight Side
51 22 360 REPLACING SEAL FOR DOOR SEAM/ROOF FRAME ON LEFT OR RIGHT REAR
DOOR
Replacing rubber guide for rear left or right door window glass.
HOOD LATCH LOCKS

51 23 ... ADJUSTING/REPLACING BUMP STOPS
2010 BMW M3
Version 1:
Following parts must not be damaged:
(1) Bump stop

Fig. 283: Adjusting Bump Stop

Version 2:
Replace damaged bump stops:
(1) Bump stop with ejector

2010 BMW M3
Fig. 284: Identifying Bump Stop With Ejector

Press ejector (1) into bump stop and, in this position, twist approx. 90 counterclockwise with a Phillips
screwdriver.
This locks the ejectors (1) in the bump stops.
Unlock the ejector (1) again after completing adjustment.
Fig. 285: Identifying Ejector

Version 3:
Replace damaged bump stops:
(1) Bump stop

2010 BMW M3

Turn lock (1) 45 counterclockwise.
Pull bump stop (2) upwards.
Close lid slowly until it is at the same height as the side panel.
Open lid and turn lock (1) clockwise.
Installation:
Press bump stop into panel and drive in expanding pins (3).
Fig. 287: Identifying Bump Stop And Lock

51 23 004 ADJUSTING HOOD/BONNET LOCK

2010 BMW M3
Adjusting hood/bonnet . See 41 61 014 ADJUSTING ENGINE BONNET/HOOD .
51 23 100 REMOVING AND INSTALLING/REPLACING RIGHT ENGINE HOOD/BONNET LOCK
Remove front intake duct . See 13 71 000 REMOVING AND INSTALLING/REPLACING INTAKE
FILTER HOUSING (S65) .
Fig. 288: Removing Expansion Rivets (1), Screws (2) & Intake Duct (3 & 4)
Lever Bowden cable (3) out of coupling (1).
2010 BMW M3
Fig. 289: Identifying Bowden Cable And Coupling


Release Bowden cable (1) from holder (2).
Fig. 291: Identifying Bowden Cable And Holder

Release screws (1).
Tightening torque 51 23 2AZ , see 51 23 HOOD/BONNET LOCKS .
Carefully pull bumper trim (2) forwards and feed out hood/bonnet lock (3) with cable.
2010 BMW M3
Fig. 292: Identifying Bumper Trim And Hood/Bonnet Lock

When replacing cable for hood/bonnet locks:
Feed cable (1) out of front wall (3).
Fig. 293: Identifying Cable And Front Wall

51 23 110 REMOVING AND INSTALLING/REPLACING LEFT HOOD/BONNET LOCK
Lever cable (3) out of coupling (1).
2010 BMW M3
Fig. 294: Identifying Cable And Coupling

Release screws (1).

Release screws (1).
Carefully pull bumper (2) forwards and feed out hood/bonnet lock (3) with cable.

2010 BMW M3
Fig. 296: Identifying Bumper And Hood/Bonnet Lock

When replacing cable for hood/bonnet locks:
Feed cable (1) out of front wall.
Fig. 297: Identifying Cable And Hood/Bonnet Lock


2010 BMW M3
51 23 155 REMOVING AND INSTALLING/REPLACING BAR FOR RETAINING HOOK
Remove front bumper . See 51 11 156 Removing and installing front bumper trim or 51 11 156
Removing and installing front bumper trim (from 09/08).
Release screws (1) and clips (3).
Remove intake cover (2).
Fig. 298: Identifying Screws, Clips And Intake Cover

Release screws (1) on bar (2).
Fig. 299: Identifying Screws And Bar

Release catches (1) on cooling air guide (2).

2010 BMW M3
Feed out cooling air guide (2) with bar towards front.
Feed bar out of cooling air guide (2).
Fig. 300: Identifying Catches And Cooling Air Guide

51 23 160 REMOVING AND INSTALLING/REPLACING ARRESTER HOOK ON ENGINE HOOD
Release screws (1) and remove arrester hook (2).
Fig. 301: Identifying Screws And Arrester Hooks

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

LOCKS (TO PASSENGER COMPARTMENT)

2010 BMW M3
Remove footwell side trim panel

Remove lower section of microfilter housing on left. See MICROFILTER .
Disengage Bowden cable (1) from release lever (2) and feed out in direction of arrow.

Release expander rivet (1) and nut (2).
Feed out water channel (3) towards top.
Installation:
Make sure water channel (3) is correctly seated.
Fig. 303: Identifying Expander Rivet And Nut

Feed out Bowden cable (1) in direction of engine compartment.

2010 BMW M3
Lay Bowden cable (1) without kinks.
IMPORTANT: Grommet (2) must not be damaged.

Check that grommet (2) is correctly seated (water ingress).
Fig. 304: Identifying Bowden Cable And Grommet

Lever Bowden cable (3) out of coupling (1) and remove.
Fig. 305: Identifying Cover And Coupling

51 23 212 REMOVING AND INSTALLING/REPLACING CABLE FOR FRONT HOOD/BONNET

LOCKS (TO LOCKS)

2010 BMW M3
Remove left/right hood/bonnet locks
51 23 265 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT GAS STRUT FOR

ENGINE BONNET/HOOD

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

2. Remove gas spring strut from ball head.
Fig. 306: Identifying Gas Spring Strut At Top And Bottom

TRUNK LATCH LOOKS

51 24 004 ADJUSTING REAR LID LOCK
Prerequisite:
Rear lid must be correctly adjusted to fit; if necessary, adjust rear lid . See 41 62 014 ADJUSTING REAR
LID .
For ideal adjustment, refer to Body gap dimensions .
2010 BMW M3
side.
Remove trim for support tube.
Slacken screws (1) until striker (3) can be moved.
Slide striker (3) in direction of arrow.
Tightening torque 51 24 4AZ, see 51 24 REAR LID LOCKS .
Check alignment of rear lid and striker, readjust if necessary.
If necessary, remove shims (2) or insert additional.
Fig. 307: Checking Alignment Of Rear Lid And Striker

51 24 004 ADJUSTING REAR LID LOCK (LOWER SECTION OF REAR LID LOCK)
NOTE: Rear lid must be correctly adjusted to fit before adjustment of rear lid lock.
If necessary Adjust rear lid.
For ideal adjustment, refer to BODY GAP DIMENSIONS .
Screw in detent buffers for rear lid on left/right completely.

2010 BMW M3
Fig. 308: Locating Detent Buffers For Rear Lid On Left/Right

Check fulcrum pads on lower section of rear lid lock for damage and replace if necessary.
Fig. 309: Locating Fulcrum Pads On Lower Section Of Rear Lid Lock
Version with cover caps on rear apron trim:
If necessary, remove cover caps.
Slacken screws in lower section of rear lid lock until it is just able to move and centers itself.
The lower section of the rear lid lock must not scrape against the rear lid lock.
2010 BMW M3
Fig. 310: Locating Screws In Lower Section Of Rear Lid Lock

NOTE: Adjusting lower section of rear lid lock:

Close rear lid.
This enables the lower section of the rear lid lock to adjust itself correctly.
Open rear lid.
Tighten down screws on lower section of rear lid lock.
Tightening torque 51 24 2AZ (E82, E88, E90, E92), see 51 24 REAR LID LOCKS .
Check adjustment of rear lid and rear lid lock, repeating adjustment if necessary.
Fig. 311: Locating Screws On Lower Section Of Rear Lid Lock

Unscrew detent buffer until closed rear lid abuts against left/right detent buffers.
IMPORTANT: The rear lid must not be higher than the side panels, otherwise there is preload
2010 BMW M3
on height adjustment!
Fig. 312: Locating Detent Buffer

51 24 050 REMOVING AND INSTALLING/REPLACING LOCK ELEMENT (LOCK CYLINDER)

FOR REAR LID
Except E93:
NOTE: Remove panel for rear lid.
The mechanical lock cylinder is omitted as from 09/2008.
E93 only:
Release clips (1) and feed out left cover (2) in direction of arrow.
2010 BMW M3
Fig. 313: Identifying Clips And Left Cover

Unclip cover (1) in outward direction.

Disconnect Bowden cable (1).
Insert 2 mm dia. punch into hole (A) and press down catch (3).
Turn lock (2) counterclockwise through 90 and remove punch.
Release screws (4) and remove lock element (5) inwards.
Installation:
Position lock element (5) on rear lid and secure with screws (4).
Turn lock (2) 90 to right.

2010 BMW M3
Press lock element (5) on rear lid until seal is correctly positioned.
Tightening torque 51 24 3AZ , see 51 24 REAR LID LOCKS .

Installation:
Seal (1) on lock element (2) must not be damaged.
Fig. 316: Identifying Seal And Lock Element

51 24 100 REMOVING AND INSTALLING/REPLACING REAR LID LOCK (UPPER SECTION)

2010 BMW M3
Remove panel for rear lid
Release screws (2) and feed out upper section of rear lid lock (3).
Installation:
Use self-tapping screws when replacing upper section of rear lid lock (3).
Tightening torque 51 24 1AZ (E82, E88, E90, E92), see 51 24 REAR LID LOCKS .

Remove lock (1).
Lever out actuating rod (2) and remove upper section of rear lid lock (3).
Installation:
Make sure lock (1) is correctly seated.

2010 BMW M3
Fig. 318: Identifying Actuating Rod And Rear Lid Lock

Installation:
51 24 130 REMOVING AND INSTALLING/REPLACING STRIKER FOR REAR LID LOCK
Remove trim on tail panel.
Release screws (1) and remove striker.
Tightening torque 51 24 2AZ , see 51 24 REAR LID LOCKS .
Installation:
Adjust striker .
Fig. 319: Identifying Screws And Striker

2010 BMW M3
51 24 131 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT STRIKER FOR REAR

LID LOCK
Remove trim on support tube
Release screws (1).
Remove shims (2) and striker (3).
Tightening torque 51 24 4AZ, see 51 24 REAR LID LOCKS .
Installation:
Adjust striker .
Fig. 320: Checking Alignment Of Rear Lid And Striker

51 24 145 REMOVING AND INSTALLING/REPLACING BUTTON FOR REAR LID ACTUATION
00 9 323
Move special tool 00 9 323 under front edge of button (1) and lever out button (1).
Pull button (1) out of rear lid (2).

2010 BMW M3
Fig. 321: Identifying Button And Rear Lid

Disconnect plug (1) and remove button (2).
Installation:
Fig. 322: Identifying Plug And Button

Replacement:
Carefully release catches (1) and remove microswitch (2).

2010 BMW M3
Fig. 323: Identifying Catches And Microswitch

51 24 300 REMOVING AND INSTALLING OR REPLACING LEFT OR RIGHT GAS STRUT FOR
REAR LID

When removing both gas struts, support rear lid in fully open position
with suitable apparatus.
Open rear lid.
NOTE: Make a written record of the alignment of gas strut (2) before removing.
Slide stop spring (1) to end of gas strut (2) and lever out gas strut (2).
Repeat the procedure at the other end of the gas strut (2) and remove.
Fig. 324: Identifying Stop Spring, Gas Strut And Gas Strut
2010 BMW M3
FRONT AND REAR WINDOW

51 31 ... INSTRUCTIONS ON GLUING WINDSCREEN
IMPORTANT: The "1-hour" system will be introduced from 03/2009.

following:
"1-day system"
"1-hour system"
These instructions are not applicable to door window cementing (door "center") on the E38/L7:
Work steps for removing and installing windscreens:
is displayed at the end of this document by clicking on the "framed cross-reference"
General:
The windscreen and rear window (also the rear side windows if necessary) are bonded to the body. This
gluing will increase the torsional strength of the vehicle. To obtain perfect bonding, comply with the
installation procedure described in the following.
The windscreen must be secured with yellow plastic adhesive tape (sourcing reference: BMW Parts
Service) after being installed. The paint must be completely hardened after painting work.
Set down window glass and process on BMW-approved X-universal stand.

In winter, the vehicles must stand in a room with a temperature of at least 15C.
On-the-job safety:
When working with adhesive products (adhesive, cleaning agent, bonding agent etc.):

clothing on hand).
creams
Provide eye bath facilities, change water regularly (once a month).
Do not eat, drink or smoke in areas of PUR processing.
2010 BMW M3
Replacement of windscreens:
Version with head-up display (HUD):
Stick on reminder label

Order/part
Type Type
number
Special cutter (manufacturer: Fein) with oscillating Pneumatically operated 81 43 9 429 183
blade Electrically operated 81 43 9 427 786
BMW blade set All required blades 81 43 9 428 596
19.5 mm (1) 6 39 03 118 01 3
24 mm 6 39 03 076 01 6
Blade (U-shape)
36 mm 6 39 03 079 01 2
45 mm 6 39 03 154 01 0
16 to 35 mm (adjustable) 6 39 03 143 01 3
Blade (straight with stop roller) 10 mm (fixed)(1) 6 39 03 189 01 0
14 mm (fixed) 6 39 03 082 01 6
"Roll Out 2000" Wire cutting system (1) 81 62 0 301 76 8
for heavy-duty applications
Scalpel (1)
special tool 51 3
Handles for cutting wire Self-locking (1) 270
Storage temperature:
Storage temperature of all adhesive products of 5C to 25C must be observed.
Adhesive:
The BMW-approved 1-component polyurethane adhesive must be used for bonding.
1-day system: Adhesive cartridge* (part number 83 19 0 152 031)
1-hour system: Adhesive cartridge* (part number 83 19 0 444 144)

2010 BMW M3
Adhesive is applied to window glass with cartridge gun (pneumatically or electrically operated, sourcing
When using accelerator (hot processing, 3-hour system):
sensor to DIS (Diagnosis and Information System) or to ISID (Integrated Service Information Display), if
necessary in conjunction with MIB (Measurement Interface Box)
Heat adhesive for at least 1 hour in cartridge oven (sourcing reference: BMW Parts Service) to 80 5C
Write date and time on adhesive when inserting into cartridge oven
Insufficient heating (< 1 hour) results in the formation of bubbles/blisters (gluing/cementing not
permitted)
Temperature < 80 5C results in the formation of bubbles/blisters (gluing/cementing not
permitted)
Remove cured adhesive prior to further processing.
Mistake in mixing in event of an interruption in application >1 minute (gluing/cementing not permitted)
A test bead of 50...70 mm must be rejected after an interruption in application
Best before dates of accelerator and adhesive must not be more than 3 months apart
Best before date >3 months results in the formation of bubbles/blisters (gluing/cementing not
permitted)
Sealed adhesive:
May only be stored for a maximum of 8 hours once it has been heated up to 80 5C.
The adhesive will be damaged if this time is exceeded (gluing/cementing not permitted)
Cartridge may only be heated up once
If the lower label is black, this adhesive may only still be used cold without accelerator while adhering to
the Best before date.
IMPORTANT: Not all window glass may be bonded with accelerator (hot processing).
If hot processing is not permitted, this is described in the relevant document.
Adhesive Best before date:
Repair kit and adhesive cartridges are marked with a date (Best before).
The adhesive cannot be used after this date.
Adhesive disposal:
2010 BMW M3
The adhesive is disposed of in paper bags so that it can react with moisture.
special waste.
Accelerator (3-hour system):
Accelerator is screwed onto the adhesive cartridge and contains a reaction paste which is mixed with the heated
adhesive.
IMPORTANT: The accelerator may only be paired with the adhesive cartridge of an unopened
package (bubbling).
Adhesive and accelerator must be paired while taking into account the Best
before dates.
The accelerator may no longer be used if the Best before dates are more than 3
months apart.
Bonding agent (activator):
The BMW-approved bonding agents must be used to treat bonding areas:
1-day system:
"Glass Activator 1" (on glass ceramic material)

1-hour system:
"Glass Activator 2" (on glass ceramic material), yellow stick, BMW part number: 83 19 0 144 142
"Paint Activator B" (on sheet metal flange), blue stick, BMW part number: 83 19 0 154 458
Prepare Glass Activator 2 and Paint Activator B for processing by shaking and snapping (breaking glass
ampoule).
Apply Glass Activator (2) by pressing gently. There is no need for final wiping. Ventilation time approx. 2
minutes.
Apply Paint Activator B by pressingly gently. Then wipe dry with a paper towel (available in a set).
Bonding agent Best before date:
Repair kit and bonding agent are marked with a date (Best before).
2010 BMW M3
Once it has been opened (locking ring broken), use for 1 week only even if the Best before date has not
been reached.
air).
Removal of window glass:
"Roll Out 2000" .
Cover side panels, roof aerial and if necessary interior trim with protective covers.
Tape off body with fabric adhesive tape (e.g. Tesa) in areas where the oscillating blade could damage the
When using cutting wire, pull cutting wire ends through special tool 51 3 270 , bend and tape off with fabric
adhesive tape (e.g. Tesa) (risk of injury and damage).
air).
"Roll Out 2000" .
When using cutting wire, pull cutting wire ends through special tool 51 3 270 , bend and tape off with fabric
When removing the windscreen:
Wear protective goggles and gloves.
with "Roll Out 2000" * (wire cutting system); no paint is damaged here in the case of narrow gaps
with special cutter* and oscillating blade*
2010 BMW M3
Prior to each use, regrind the blade with a grinding stone while the machine is running (new blades also).
Avoid damage to paintwork on body cutout.
Guide blade carefully between body and window glass.
To remove adhesive bead in body cutout (and on window glass if reusing):

Cut off residual adhesive to a thickness of approx. 0.5 mm
Remove residual bead only briefly before bonding
Damage to paintwork in body aperture:
without fail.
Touch up damage to paintwork on body cutout with BMW multibase filler.
Grind extensive areas of damage down to the bare metal and coat with BMW multibase filler (coating thickness
30 ... 40 m).
Hardening time:

Tape off primed bonding flange before applying top coat
2010 BMW M3
Treatment of glued area in body:
TREATMENT REFERENCE CHART

Adhesive Treatment
Clean with spirit (available in pharmacies).
Observe an air drying time of at least 5 minutes (at least 15
minutes when applied to residual bead)
Bonding and sealing compound for 1-day system: Apply "Paint Activator A" to paint and residual
car window glass bead
1-hour system: Apply "Paint Activator B" (blue stick) to paint
IMPORTANT: Do not use Sika remover 208 for cleaning in the bonding area.
Preparation for assembly:
Prepare plastic nozzle(s) for shaping adhesive bead (when not using the standard nozzle), can be cut to size
Lay a test bead of approx. 50 mm - watch out for formation of bubbles/blisters when hot cementing; if OK,
Interruption must be < 5 second (incorrect mixture ratio).
Cartridge must be vertical to window glass.
Black ceramic material impermeable to UV light is located on the peripheral zone of the inside edge of the
window to protect the adhesive bead.
Glass ceramic material must not be damaged and must be treated as follows.
1-day system: Treatment of glass ceramic surface (inside of window):

Hot cementing: a. Clean with spirit (available in pharmacies).

83 19 0 147 370 b. Observe an air drying time of at least 1 minute
c. Apply a thin coating of "Glass Activator 1"
Cold cementing: d. Observe an air drying time of at least 10 minutes
83 19 0 147 369
2010 BMW M3
Adhesive cartridge:
83 19 0 152 031
1-hour system: Treatment of glass ceramic surface (inside of window):

a. Clean with spirit (available in pharmacies).
Glass Activator 2 (yellow stick):
b. Observe an air drying time of at least 5 minutes
83 19 0 144 142 c. Apply a thin coating of "Glass Activator 2"
d. Observe an air drying time of at least 2 minutes
Version with inspection window for vehicle identification number in windscreen only (all except US/GB):
Seal inspection window (bottom left) with Sika primer 206 G+P
Approx. 1 1/4 adhesive cartridges are required to cement the windscreen on the following vehicles:
7 Series
5 Series from E60
X5
X3
In the case of hot cementing (with accelerator), the missing residual bead is applied from a second adhesive
cartridge (not contained in the repair kit) but while cold and without accelerator (bubbling).
Minimum hardening period is thus not increased.
IMPORTANT: If a second cartridge is required for cementing:
Accelerator from repair kit must not be used with the second cartridge (bubbling)
Bubbling results in leakage and insufficient bonding strength (torsional rigidity, passenger airbag).
DIFFERING ADHESIVE QUANTITIES EFFECT CHART

Windscreen rests too high in body cutout
2010 BMW M3
Windscreen rests too low in body Wind noise may occur

cutout Strains/tensions may occur (windscreen breakage)
Strains/tensions may occur Fouling of add-on parts by emerging adhesive
(windscreen breakage)
Adhesive on uninsulated strainer pressure lines of aerial
Insufficient squeezing of adhesive (s) (interference of reception)
bead (leaking)
Spacer buffers:

Wind noises
Assembly:
To prevent a pressure increase in the vehicle interior when the doors are closed:
Open a window

accelerator).
To secure the windscreen, use only the yellow plastic adhesive tape
(sourcing reference: BMW Parts Service, part number 83 19 9 410 979).
The glass will slip down if other adhesive tapes are used.
Windscreen slippage will result in leaks and wind noises.
1-hour system:
Once the adhesive bead has been applied, the windscreen must be
installed within 7 minutes (depending on air humidity, temperature).
After 7 minutes the adhesive bead forms a skin which can no longer
2010 BMW M3
Remove adhesive residue immediately with adhesive remover (Sika remover 208, sourcing reference:
BMW Parts Service). Do not press out the window glass again.
Hardened adhesive can only be removed by machine.
Check height of windscreen/rear window with special tool 51 0 010 or 51 3 210 .
Assemble car.
Hardening:
The adhesive hardens as it reacts with air humidity (with accelerator also due to mixed-in reaction paste)
at room temperature.
At ambient temperatures above 23C and 50 % relative air humidity (hot countries), the adhesive open
time is shortened to approx. 5 minutes (skin formation time).
The adhesive hardening process is interrupted completely at ambient temperatures below 5C. In this
event, there will be no increase in the strength of the adhesive bond.
Do not subject the vehicle to load on one side during the minimum hardening time
one wheel on curb

lifting platform
etc.

do not under any circumstance driver over access ramps, e.g. into multi-store car parks
If you fail to adhere to the minimum hardening times
leaks and wind noises will occur when the windscreen is moved
1-day system: Glues and their minimum hardening times:
1-DAY SYSTEM - GLUES AND THEIR MINIMUM HARDENING TIMES

Minimum hardening time "without Minimum hardening time "with passenger
Adhesive passenger airbag" (after which vehicle airbag" (countries where seatbelt use is not
can be moved) required by law)
2010 BMW M3
Hot processing
2 hours 3 hours*
with accelerator
Cold processing 9 hours 20 hours*
1-hour system: Glues and their minimum hardening times:
1-HOUR SYSTEM - GLUES AND THEIR MINIMUM HARDENING TIMES

Cold
processing
1 hour 2 hours(1)
NOTE:
(1) Vehicles with passenger airbag:
The vehicle can be handed over to the customer after the hardening period (vehicle can be moved,
for "... hours"!
The time is taken from the "Minimum hardening period" table for countries where seatbelt use is not
required by law.
Locate leaks:

with ultrasonic leak detector (sourcing reference: BMW Parts Service)
Version with GPS navigation system 1 (up to 9/97):
Recalibrate magnetic field sensor

Refer to function description in ISID (Integrated Service Information Display)
Version with rain sensor, rain/light sensor or rain/light solar sensor:
Remove complete rain sensor, rain/light sensor or rain/light solar sensor.

2010 BMW M3

Version with automatic air conditioning:
If fogging sensor is not mounted on new windscreen:
Replace fogging sensor, refer to repair instructions.
When replacing windscreen in vehicles with rain/light solar sensor, replace this completely: refer to repair
instructions.
Before bonding, install windscreen with seal(s) and check HUD ; if necessary, press expanding foam tape down
with hand roller.
refer to repair instructions.
NOTE: If no document is displayed after you have clicked on a "framed cross-

reference":
It is not necessary or permitted for the model selected.
51 31 ... REMOVING AND INSTALLING/REPLACING RETAINING STRIP FOR COWL PANEL

COVER
Remove cover for cowl panel
IMPORTANT: Retaining strip (2) has an aluminum profile insert (1).

Carefully wind out retaining strip (2) (windscreen breakage).
4 Glue bead
5 Pinched butyl
6 Contact surfaces
2010 BMW M3
Fig. 325: Identifying Retaining Strip And Aluminum Profile Insert

Installation:
Clean cutout.
Pay attention to center marking on retaining strip (1) and windscreen.
Insert positioner (2) for retaining strip (1) must be removed after it has been fitted on the windscreen but before
the windscreen itself is installed.
Replacement of retaining strip without windscreen removal:
If adhesive has managed to get onto retaining strip (1), this area must be cut out partially.
To facilitate installation, coat and body cutout with water.
Replacement of retaining strip with removed or new windscreen:
Fig. 326: Identifying Positioner And Retaining Strip

2010 BMW M3
Fit rubber frame (1).
3 Aluminum strip
4 Contact surfaces
5 Butyl
51 31 ... REMOVING WINDSCREEN WITH "ROLL OUT 2000"
Windscreen removal system "Roll Out 2000"
Fig. 327: Identifying Windscreen Removal System "Roll Out 2000"

NOTE: Both paintwork and ergonomic and health-endangering damage is minimized

with the "Roll Out 2000" system.
2010 BMW M3
WARNING: Follow safety instructions for working on cars with airbag systems (risk
of injury).
IMPORTANT: Take care when handling sharp-edged tools and cutting wire (risk of damage to
head airbag and window glass).
IMPORTANT: Always keep both suckers dry and clean to ensure their optimum adhesion on
the windscreen.
Lubricate spool if interlock rattling becomes too loud.
Always wear protective goggles and gloves for your own safety.
Mounting suction cup lifters on windscreen or rear window:
Fig. 328: Mounting Suction Cup Lifters On Windscreen Or Rear Window

Secure position of suction cup lifters as shown:

1. Suction cup lifter with double spool
2. Suction cup lifter with single spool
3. Window glass
2010 BMW M3
4. Cutting wire
Fig. 329: Securing Position Of Suction Cup Lifters

Preparatory work:
Cut off required length from cutting wire:
Window glass diagonal x 6
The cutting wire loops must lie on top of each other in area (B).
They must not get caught up in each other. (Otherwise no possibility of cutting the adhesive bead / wire tears.)
Overlapping of cutting wire loops approx. 10 cm.
Distance from right window edge approx. 30 cm.
Pulling cutting wire into car:
Cut off wire end (1) at an angle and thus pierce adhesive bead (2).
2010 BMW M3
Wire end must be bent to window glass.
Fig. 330: Cutting Off Wire End At An Angle And Thus Pierce Adhesive Bead
Laying cutting wire around windscreen:
Starting from pull-in point, lay wire eyelet created on the outside around the window glass
Pull excess wire into car interior
IMPORTANT: Make sure the cutting wire is located at all four corner points below the
windscreen.
Check that the cutting wire is not caught on retainers or body.
Secure window glass on outside with adhesive tape against slipping.
Fig. 331: Laying Wire Eyelet Created On Outside Around Window Glass
NOTE: Windows (1) with fitted seals (3) or sprayed-on surrounds:

2010 BMW M3
Moisten cutting wire (4) and seals (3) on window (1) with water
Insert cutting wire (4) in bend (without kinking) between window (1) and body cutout (2)
Fig. 332: Inserting Cutting Wire In Bend (Without Kinking) Between Window And Body Cutout
Protecting car interior:
To avoid damage and if necessary dirt, protect A-pillars, roof and instrument panel trim (3) by means of
plastic disc (1)
Always carry plastic disc (1) between respective wire (2) being strained and trim panel components
Fig. 333: Identifying Plastic Disc And Respective Wire

Suspending wire in suction cup lifter with double spool:
Insert cutting wire (1) in spool (2) and thereby bend wire
Insert second wire end in second spool and likewise bend
Turn spool (2) by hand and wind up loose wire
2010 BMW M3
Fig. 334: Inserting Cutting Wire In Spool And Thereby Bend Wire
Starting removal:
NOTE: Spool can only be turned in one direction.
Make sure the wire is always situated in the guide channel of the suction cup lifter (1)
Fit reversible ratchet on spool (2) and tension wire
Start by cutting lower adhesive bead
Both wires meet ahead of both spools when removal is completed
Remove "Roll Out 2000"
Remove disc
Fig. 335: Identifying Suction Cup Lifter And Spool

51 31 000 REMOVING AND INSTALLING / REPLACING WINDSCREEN

2010 BMW M3
IMPORTANT: The 51 31 ... Instructions on gluing windscreen serve as the basis for these
51 31 015 REPAIRING DAMAGE TO WINDSCREENS CAUSED BY PITTING (STONE CHIPS)

(CLEAR AND TINTED LAMINATED SAFETY GLASS)
Field of vision (no repairs acceptable):
Fig. 336: Identifying Field Of Vision (No Repairs Acceptable)

A. A 50 mm (gap between field of view / center of vehicle)

B. B Up to end of wiper range, outside (field of view width)
C. C Restriction by wiper range (height of field of view)
IMPORTANT: Repairs must only be carried out outside of the field of vision (refer to sketch).
If the stone chip damage is outside the field of vision,
51 31 021 REMOVING AND INSTALLING / REPLACING RUBBER FRAME FOR WINDSCREEN

(TOP) (SEDAN)

2010 BMW M3
Remove both gutter strips on windscreen

If necessary, detach adhesive tape (9) between rubber frame (1) and roof outer
skin.
If necessary, remove fitted spacer buffers (8).
Carefully unwind rubber frame (1) (windscreen breakage).

vehicle.
Fig. 337: Identifying Fitted Spacer Buffers

3 Windscreen
6 Bridge
7 Pinched butyl
Replacement of rubber frame without windscreen removal:
If adhesive leaks over tear-off lip (4), this area must be cut out partially.
Install rubber frame (1).
If necessary, pull liner* off adhesive tape (6) and press rubber frame (1) down firmly on roof outer skin.
2010 BMW M3
3 Butylene tape
5 Aluminum strip
Fig. 338: Identifying Rubber Frame

Replacement of rubber frame with removed or new windscreen:
After installing windscreen: If necessary, pull liner* off adhesive tape (6) and press rubber frame (1) down
firmly on roof outer skin.
3 Butylene tape
5 Aluminum strip

2010 BMW M3
Fig. 339: Identifying Butylene Tape And Aluminum Strip

51 31 021 REMOVING AND INSTALLING/REPLACING RUBBER FRAME FOR WINDSCREEN

(CONVERTIBLE/COUPE)
IMPORTANT: Rubber frame (1) features an aluminum section inlay (2). Detach adhesive tape
(9) between rubber frame (1) and roof outer skin or A-pillar. Carefully unwind
rubber frame (1) (windscreen breakage).
NOTE: Tear-off lip (5) may be stuck to adhesive (4). When rubber frame (1) is removed,
tear-off lip (5) can tear off and remain in vehicle.
3 Windscreen
6 Bridge
7 Pinched butyl
8 Sealing lip fitted at side only
9 Adhesive tape
Fig. 340: Unwinding Rubber Frame

Replacement of rubber frame without windscreen removal:
Clean cutout. Detach tear-off lip (5) from rubber frame (1). If adhesive leaks over tear-off lip (5) at bridge (4),
this area must be cut out partially. To facilitate installation, coat rubber frame (1) and body cutout with water.
Fit rubber frame (1), paying attention to center marking on rubber frame (1) and windscreen. If necessary, pull
liner* off adhesive tape (6) and press rubber frame (1) down firmly on roof outer skin and A-pillar. *Liner is the
protective film on the adhesive tape
2010 BMW M3
Fig. 341: Identifying Rubber Frame, Aluminum Strip, Butyl And Bridge
Replacement of rubber frame with removed or new windscreen:
Pay attention to center marking on rubber frame (1) and windscreen. Fit rubber frame (1) with tear-off lip (5),
Aluminum strip (2), Butyl (3).
After installing windscreen, pull liner* off adhesive tape (6) and press rubber frame (1) down firmly on roof
outer skin and A-pillar. *Liner is the protective film on the adhesive tape
Fig. 342: Identifying Rubber Frame, Aluminum Strip, Butyl And Bridge
51 31 023 REMOVING AND INSTALLING LEFT OR RIGHT GUTTER STRIP ALONG

WINDSCREEN
Unclip gutter strip (1) towards top.
IMPORTANT: Replace clips (2) after each removal.

Pay attention to installation position in event of different-coloured clips (2).
2010 BMW M3
Installation:
Locks (3) of clips (2) must not be damaged.
Fig. 343: Identifying Gutter Strip

51 31 025 REPLACING LEFT OR RIGHT GUTTER STRIP ALONG WINDSCREEN
00 9 323
Remove gutter strip
NOTE: To facilitate installation, coat seal and gutter strip with water.
Fit inner part (1) of seal in accordance with measurements (A and B) on gutter strip (2).
A= approx. 30 mm
B= approx. 15 mm
Push seal (1) onto gutter strip (2) until both are flush in area (3).
2010 BMW M3
Fig. 344: Identifying Seal, Gutter Strip And Flush In Area

Installation:
Outer part (2) and inner part (3) of seal must not be stretched.
Fit outer part (2) and inner part (3) of seal on complete gutter strip (1).
If necessary, use special tool 00 9 323 as an aid.
Fig. 345: Identifying Seal (Outer Part, Inner Part) And Gutter Strip
Align seal (1) to gutter strip (2) and secure in area (3) with Loctite 380 (sourcing reference: BMW Parts
Service).
A= Gutter strip, top
B= Gutter strip, bottom

2010 BMW M3
Fig. 346: Identifying Seal And Gutter Strip

51 31 241 REPLACING RUBBER FRAME (TOP/SIDE) FOR REAR WINDOW
Open rear lid.

Carefully unwind rubber frame (1) (rear window breakage).

vehicle.
3 Rear window
6 Bridge
7 Pinched butyl
2010 BMW M3
Fig. 347: Identifying Rubber Frame And Tear-Off Lip

Installation:
Pay attention to center marking on rubber frame (1) and windscreen.
Fig. 348: Identifying Rubber Frame And Tear-Off Lip

2010 BMW M3
2 Aluminum strip
5 Butyl
51 31 242 REPLACING RUBBER FRAME (BOTTOM) FOR REAR WINDOW
00 9 340
Open rear lid.
IMPORTANT: Rubber frame (1) features a stainless steel section inlay (2).
Carefully pull off rubber frame (1) (rear window breakage).

vehicle.
No tear-off lip (5) is fitted as of build date 03/2006.
3 Pinched butyl
4 Bridge
7 Rear window
Fig. 349: Identifying Tear-Off Lip And Adhesive

NOTE: Clean rear window in assembly area thoroughly with spirit.

2010 BMW M3
There must be no remnants of butyl on the rear window.

When replacing without removing rear window:
To be able to remove butyl remnants better, insert special tool 00 9 340 under
tension between body flange and rear window.
To do so, wrap a cleaning cloth soaked in spirit around special tool 00 9 340
several time and remove butyl remnants between body flange and rear window.
Pay attention to center marking (1) on rubber frame (3) and rear window.
Place rubber frame (3) over center marking on rear window and align laterally.
2 Marking with adhesive tape (if necessary)

4 Stainless steel section inlay
5 Butyl
Fig. 350: Identifying Centre Marking And Rubber Frame

2010 BMW M3
Fig. 351: Identifying Stainless Steel Section Inlay

NOTE: Rubber frame is secured at side with window glass adhesive.

Read and comply with notes and instructions on handling window glass
adhesive.
Cut nozzle (4) at an angle in accordance with measurement (A).
A= 10 mm
Apply adhesive bead (1) on left and right of rubber frame (2) up to fold (3) between rear window and body.
NOTE: Adhesive bead (1) must not protrude over rear window.
Mark center marking of rear window with adhesive tape on rear window.
Mark center marking (1) of rubber frame (3) with adhesive tape (2).
2010 BMW M3
Place rubber frame (3) over center markings on rear window and align laterally.
Fig. 352: Identifying Centre Marking, Rubber Frame And Adhesive Tape
IMPORTANT: The Instructions on cementing windscreen serve as the basis for this repair
FRONT MANUALLY OPERATED WINDOW

51 32 154 ADJUSTING LEFT OR RIGHT FRONT DOOR WINDOW GLASS
51 0 320
51 0 341
51 0 342
51 3 010
51 3 080
51 3 300
51 3 301
51 3 303
51 3 304
51 3 310

2010 BMW M3
Prerequisite:
Vehicle must be standing on its wheels on a level floor

Front door correctly adjusted to fit
If necessary, close retractable hardtop
IMPORTANT: When closing, the door window glass must not jam on the trim strip in any area
of the window (window glass breakage).
If necessary, incoming check:
The following incoming check must be carried out prior to every adjustment operation:
NOTE: Incoming check must be carried out with the window cavity cover strip fitted.
Denormalize power window

Measure retraction depths with special tool 51 3 080
Insert special tool 51 0 341 in rotary striker and close rotary striker
Measure pretension with special tool 51 0 342
Initialize power windows
Denormalize power window

Remove outer window cavity cover strip (not for checking pretension)
Ideal adjustment, longitudinal direction
Open door window.
Fit special tool 51 0 320 in front door and press back as far as it will go.
NOTE: Special tool 51 0 320 must rest against door and reach the stop on guide (1).
2010 BMW M3
Fig. 353: Identifying Special Tool 51 0 320 On Guide

Ideal adjustment, retraction depth
Open door window

Attach special tool 51 3 080 to door window glass
Close front door and door window
Measure retraction depth
Fig. 354: Identifying Special Tool 51 3 080 To Door Window Glass

NOTE: 2 items of special tool 51 3 080 are required for adjustment of retraction depths.
Measure retraction depth (C) in areas (A and B).
Retraction depth (C):
A = 4 0.5 mm
2010 BMW M3
Gap between measuring point and triangular mirror section = 30 mm
B = 7.5 0.5 mm
Gap, measuring point = next to dot screen
Fig. 355: Measuring Retraction Depth In Areas

IMPORTANT: Front door must open and close without the door window glass touching the
roof trim strip.
Adjusting longitudinal direction/retraction depth
Slacken screws (1) with special tool 51 3 310 until door window glass can just be moved.
Fig. 356: Identifying Slacken Screws With Special Tool 51 3 310 Until Door Window Glass
Attach special tool 51 3 010 to door window (1).
Slide door window glass (1) up against special tool 51 0 320.

2010 BMW M3
Adjust retraction depth of door window (1) in area of A-pillar and B-pillar.
NOTE: Door window glass must rest against special tool 51 0 320 (longitudinal
adjustment) during adjustment of retraction depth.
Fig. 357: Identifying Door Window Glass On Special Tool 51 0 320

Installation:
The tightening torque of 10 Nm is reduced to 7 Nm when special tool 51 3 310 is used. Depending on the
torque wrench used, this must be calculated according to the adjacent equation:
Fig. 358: Identifying MDE Torque Wrench Length

MDE = Torque to be set
MDV = Prescribed torque (without special tool)
lj = Standard adjustment length with adjusting tool

2010 BMW M3
l1 = Effective length of torque wrench
l2 = Inside dimension of adjusting tool
lw = Inside dimension of insertion tool (here lw = 145 mm)
Tighten screws (1) with special tool 51 3 310.
Remove special tool 51 3 010 from door window glass.
Open door window and remove special tool 51 0 320.
The tightening torque 10 Nm is reduced to 7 Nm when special tool 51 3 310 is used. Depending on the torque
wrench used, this must be calculated according to the adjacent equation:
Fig. 359: Identifying Screws With Special Tool 51 3 310

Top edge of door window glass (1) must be adjusted parallel to contour (2) of water drain.
Seals on A-pillar and on retractable hardtop must not be damaged.
When the door window glass is retracted into the seals, the seals must not distorted.
2010 BMW M3
Fig. 360: Locating Door Window Glass To Contour Of Water Drain

Ideal adjustment, pretension
NOTE: Pretension can be checked with or without window cavity cover strip.
Pretension is 1.0 mm less with window cavity cover strip. Magnet in special tool
51 0 341 creates the correct door window glass pretension on the seal system
for measurement. No force must be exerted on the door or door window glass
during measurement.
Insert special tool 51 0 341 in rotary striker of door lock and close rotary striker manually. Carefully close door
Fig. 361: Identifying Magnet In Special Tool 51 0 341 On Seal System

Slide special tool 51 0 342 at distance (B) to door window glass side edge into seal (1) and measure dimension
(A) to outside edge of door window glass (2).
Dimension (A) with window cavity cover strip:

2010 BMW M3
A = 52 1 mm
Dimension (A) without window cavity cover strip:
A = 53 1 mm
B = 10 mm
Fig. 362: Measuring Dimension To Outside Edge Of Door Window Glass

Adjusting pretension
Slacken nut (3) with reversing ratchet (2) of special tool 51 3 300 (consisting of 51 3 301, 51 3 303, and 51 3
304 .
Turn the knob (1) on the special tool 51 3 300 to turn the stud (4) and thereby alter the pretension.
Tighten nut (3).
Tightening torque 51 33 1AZ, see 51 33 POWER WINDOWS, FRONT .
Check adjustment, repeat procedure if necessary.

2010 BMW M3
Fig. 363: Identifying Slacken Nut With Reversing Ratchet Of Special Tool 51 3 300
NOTE: After completing adjustment work, it is essential to initialize the power window
unit.
Checking run-in of door window glass:
Door window glass must strike the inside of the seal.
Check adjustment of rear side window , adjusting if necessary.

Remove front door trim panel.

Cover (2) must not be kinked.
If necessary, feed out cable (1) and disconnect plug connection.
Lever cover (2) out of retainers (3).
Unclip cover (2) in direction of arrow and remove.

2010 BMW M3
Fig. 364: Identifying Cover And Retainers

Installation:
Following parts of cover (3) must not be damaged or missing:
1. Retainer (not on E87)

2. Sound insulation
Replacement:
If necessary, remove speaker.
Fig. 365: Identifying Retainer And Sound Insulation

51 32 170 REMOVING AND INSTALLING / REPLACING DOOR WINDOW GLASS, FRONT LEFT
OR RIGHT (CONVERTIBLE/COUPE)

2010 BMW M3
Remove outer window cavity cover strip.

Remove inner window cavity cover strip.
Remove outside door handle.
Open door window glass (1) down to distance (A) A = approx. 335 mm
Fig. 366: Identifying Door Window Glass

Fig. 367: Identifying Plug Connection And Power Window Motor

Installation: Carry out function check on power window unit and anti-trapping protection. If necessary,
initialize power window.
Release screw (1) over opening on outside handle. Installation: Insert door window glass (4) with clamping
plate (2) in mounting (3). Tightening torque, see 51 32 1AZ in 51 32 FRONT DOOR WINDOWS .
2010 BMW M3
Fig. 368: Identifying Door Window Glass, Clamping Plate And Mounting
Slide locking clip (1) in direction of arrow. Unclip door window glass (3) with plain bearing from power
window unit. Turn door window glass (3) and feed towards top rear out of guide rail (2).
Fig. 369: Sliding Locking Clip

Installation: Sliding piece (1) with retaining clip must be correctly located in guide (2). If necessary, replace
defective sliding piece (1). Clamping plate (3) must be correctly engaged with shim (4) on door window glass
(5). If necessary, replace defective backing (4).
2010 BMW M3
Fig. 370: Identifying Sliding Piece, Guide, Clamping Plate, Door Window Glass And Shim
After installation: Adjust door window glass.
51 32 170 REMOVING AND INSTALLING / REPLACING DOOR WINDOW GLASS, FRONT LEFT
OR RIGHT (SEDAN)
NOTE: When removing door lock, it is not necessary to remove window cavity cover
strips or seals.
Open door window to 105 mm.

Remove sound insulation in front door
E87 only:
E90 only:
Remove inner window cavity seal

Door window glass (1) must be opened to dimension (A).
A = approx. 105 mm
IMPORTANT: Disconnect plug connection (2) from power window motor (3) (risk of
trapping).
Installation:
2010 BMW M3
Carry out function check on power window unit and antitrapping protection.
If necessary, normalize power window unit.
Fig. 371: Removing Catches With Screwdriver

Installation:
1. Catch
2. Buffer stop
Fig. 372: Identifying Catch And Buffer Stop

When removing door lock:
Slide door window glass upwards and secure in door window frame with adhesive tapes or plastic wedge.
2010 BMW M3
When removing door window glass:
Turn door window glass and lift out towards rear/top.

WINDOW (SEDAN)
Remove mirror
Remove trim on window frame of front door
Remove sound insulation (1).
Fig. 374: Identifying Sound Insulation

Detach rubber guide (1) in direction of arrow from front door (2).
2010 BMW M3
Installation:
Moisten rubber guide (2) prior to fitting with approved anti-friction agent.
Fig. 375: Identifying Rubber Guide

Installation:
Rubber guide (1) must not be damaged in corners (2).
Fig. 376: Identifying Rubber Guide And Corners

WINDOW (CONVERTIBLE/COUPE)

2010 BMW M3
Remove rear view mirror on front door.
Pop catch (1) of rubber guide (2) out of door. Pull rubber guide (2) out of window guide rail and remove.
Fig. 377: Pulling Rubber Guide Out Of Window Guide Rail

Installation: Rubber guide (1) must not be damaged particularly at the corners and at catch (2).
Fig. 378: Identifying Rubber Guide And Catch

Installation: Moisten rubber guide (2) prior to fitting with approved anti-friction agent.
Installation sequence: Raise the door window. Feed rubber guide (2) from above into window guide rail and
door window glass. Close door window glass and at same time slide rubber guide (2) downwards. Slide rubber
guide (2) downwards fully until it is correctly seated on door. Feed catch (1) into door.
2010 BMW M3
Fig. 379: Pulling Rubber Guide Out Of Window Guide Rail

51 32 420 REMOVING AND INSTALLING/REPLACING TRIM ON FRONT DOOR WINDOW

FRAME, LEFT OR RIGHT
E83 only:
Remove window cavity cover strip on outside of front door
Partially detach rubber window seal (1) at rear.
Fig. 380: Identifying Rubber Window Seal

Release screws (1).
Remove finisher (2) and press approx. 3 mm towards rear.

2010 BMW M3
Fig. 381: Identifying Screws And Finisher

Remove trim (1) towards top.

Installation:
1. Plastic nuts
2. Sound insulation
3. Seal
2010 BMW M3
Fig. 383: Identifying Plastic Nuts, Sound Insulation And Seal

Installation:
Check trim (1) for damage, replace if necessary.

FRONT ELECTRICALLY OPERATED WINDOW

51 33 ... NORMALIZATION OF POWER WINDOW UNITS
NOTE: Normalization must be carried out after the following work:
Removal or replacement of power window unit or window glass

Coding/programming of footwell module (or junction box)
The following functions are deactivated after a denormalization:

2010 BMW M3
Short-stroke function
Anti-trapping protection
Toll closing
Normalization/denormalization of the power window units is possible via the diagnosis system under the
following path:
=> Diagnosis
=> Footwell module (or junction box)
=> Control unit functions
=> Footwell module (or junction box)
=> Component activation
Fig. 385: Identifying Control Unit Functions

51 33 000 REMOVING AND INSTALLING (REPLACING) POWER WINDOW UNIT IN LEFT OR

RIGHT FRONT DOOR (CONVERTIBLE/COUPE)
Remove door window glass.
Lever out cover (1) and release nut (2).
Installation: Nut is tightened down when door window glass is adjusted. Tightening torque 51 33 1AZ, see 51
33 POWER WINDOWS, FRONT .
2010 BMW M3

Release drive cable from clips (1). Release nut (2) and feed out front power window rail (3). Release nuts (4 and
5) and feed out rear power window rail.
Installation: Clip drive cable correctly into clips (1). Nut (2) must again be correctly covered with adhesive
foil. Tightening torque 51 33 1AZ, see 51 33 POWER WINDOWS, FRONT .
Fig. 387: Identifying Clips And Front Power Window Rail

Replacement: Release screws (1) and detach flat motor (2). Tightening torque 6 Nm.
2010 BMW M3
Fig. 388: Detach Flat Motor

51 33 000 REMOVING AND INSTALLING (REPLACING) POWER WINDOW UNIT IN LEFT OR

RIGHT FRONT DOOR (SEDAN)
NOTE: When removing door lock, snap door window glass out only, do not remove,
secure in door window frame.
Remove front door window glass
Unscrew nuts (1).
Feed out rear section of power window unit (2) in direction of arrow.
Tightening torque 51 33 1AZ , see 51 33 POWER WINDOWS, FRONT .
Fig. 389: Identifying Nuts And Power Window Unit

2010 BMW M3
Feed out front section of power window unit (1) with flat motor (2) in direction of arrow from front door.
Replacement:
Remove flat motor for power window unit.
Fig. 390: Identifying Power Window Unit And Flat Motor

REAR MANUALLY OPERATED WINDOW

51 34 ... REMOVING AND INSTALLING/REPLACING TRIM FOR WINDOW GUIDE OF LEFT OR
RIGHT REAR DOOR
Remove cover on door window frame
Remove roller sun blind on fixed side window
Pull rubber guide (1) out of trim (2).

2010 BMW M3
Fig. 391: Identifying Rubber Guide And Trim

IMPORTANT: Follow instructions for bonding acoustic insulation.
Detach acoustic insulation (1) in area (A).
Release screw (2) behind acoustic insulation (1).
Grip trim firmly and release screws (3).
Fig. 392: Identifying Acoustic Insulation And Screws

Push trim (1) downwards from rubber guide (2) and remove towards top.
Installation:
Make sure rubber guide (2) is correctly seated on trim (1).

2010 BMW M3
Fig. 393: Identifying Trim And Rubber Guide

Installation:
Threads (1) of trim (2) must not be damaged.
Fig. 394: Identifying Threads And Trim


Open door window.


2010 BMW M3
Pull off hooks (2) in outwards direction.
Detach cover (1) sideways from clips (3) and unclip in inwards direction or lever out and remove.

Replacement:
If necessary, release screw (1) on hook (2).
Remove hook (2) in direction of arrow from cover (4).
Fig. 396: Identifying Screw And Hook

Lever out cover (1) at clips (2).

2010 BMW M3
Unclip cover (1) in direction of arrow or lever out and remove.
NOTE: Do not tear off cover (1) in area (3).

Installation:
Following parts of cover (1) must not be damaged:
2 All-round guide
3 Connection point
Fig. 398: Identifying All-Round Guide And Connection Point

51 34 171 REPLACING REAR LEFT OR RIGHT DOOR WINDOW

2010 BMW M3
Remove sound insulation in rear door.

Remove inner window cavity cover strip.
Remove trim on rear door window frame.
Open door window glass (1) down to distance (A)
A = approx. 120 mm

Installation:
Carry out function check on power window unit and antitrapping protection.
If necessary, normalize power window unit.

2010 BMW M3
Fig. 400: Removing Catches With Screwdriver

Installation:
1. Catch
2. Buffer stop
Fig. 401: Identifying Catch And Buffer Stop

Remove door window glass (1) towards top.
Installation:
Door window glass does not need to be adjusted.

2010 BMW M3

51 34 191 REPLACING LEFT OR RIGHT FIXED DOOR WINDOW IN REAR WINDOW FRAME
51 34 211 REPLACING RUBBER GUIDE FOR REAR LEFT OR RIGHT DOOR WINDOW
00 9 317
IMPORTANT: The "Instructions on fitting window guide seals " serve as the basis for this
Remove cover on inside door window frame

Release trim on window guide and slide downwards slightly, do not remove
E91 only:
NOTE: Window cavity cover strip does not have to be removed.
Lever out rubber guide (1) on door window frame at front (2) with special tool 00 9 317 .
2010 BMW M3

Pull rubber guide (1) out of window guide.
Detach rubber guide (1) in direction of arrow from door.

Installation:
Moisten rubber guide (2) prior to fitting with approved anti-friction agent.
Close door window glass (1) a little.
Push rubber guide (2) onto door window glass (1) and into window guide (3).
2010 BMW M3
Fig. 405: Identifying Rubber Guide, Door Window Glass And Window Guide
51 34 420 REMOVING AND INSTALLING/REPLACING TRIM ON WINDOW FRAME OF REAR

DOOR (FRONT), LEFT OR RIGHT
Open rear side window
Detach rubber seal (1) and rubber guide (2) from trim.
Fig. 406: Identifying Rubber Seal And Rubber Guide

Release screws (1).
Carefully detach trim (2) towards front/top.
Installation:
Fitted foam pieces must not be damaged when trim (2) is pushed in.
2010 BMW M3

Installation:
If necessary, replace faulty plastic nuts (1).
Fig. 408: Identifying Faulty Plastic Nuts

REAR ELECTRICALLY OPERATED WINDOW

51 37 000 REMOVING AND INSTALLING COMPLETE REAR LEFT OR RIGHT POWER
WINDOW UNIT (CONVERTIBLE/COUPE)
51 2 220

2010 BMW M3
WARNING: Power window unit has no anti-trapping mechanism.
Remove lower section of side trim at rear

Disconnect plug connections on aerial amplifier (1).
Release screws (2) and remove connecting bracket (3).
Tightening torque 51 37 3AZ, see 51 37 SIDE WINDOWS, ELECTR. ACTUATED .
Installation:
Ensure seal (4) is correctly seated.
Fig. 409: Disconnecting Plug Connections On Aerial Amplifier

Move side window into uppermost end position.
Release/feed out cable holders (1).
Lever out cover (2) and slacken bolt underneath.
Release screws (3).
Feed out power window unit completely in upward direction.

2010 BMW M3
Fig. 410: Identifying Lever Out Cover And Screws

Release cable holder (1).

The basic setting procedure for the power window must be carried out before
installing.
After installation, the power window regulator/side window must be adjusted
with respect to the vehicle body.
Fig. 411: Identifying Plug Connection And Cable Holder

Basic setting of power window:
Check dimension (X) at power window regulator.

2010 BMW M3
If necessary set dimension (X) with special tool 51 2 220 at screw (1).
Fig. 412: Checking Dimension (X) At Power Window Regulator

Presettings after fitting power window unit:
Adjust side window glass (1) in accordance with dimension (A) to body (2).
Measuring points in B-pillar area and release for rear screw connection of side window glass (1).
Dimension (A) = 7 1 mm
Check function.
Adjust side window glass (1) .

2010 BMW M3
Fig. 413: Measuring Points In B-Pillar Area


POWER WINDOW UNIT (SEDAN)
Remove rear door window glass 51 34 171 Replacing rear left or right door window
Unscrew nuts (1).
Tightening torque 51 35 2AZ , see 51 35 POWER WINDOWS, REAR .

2010 BMW M3
Fig. 415: Identifying Power Window Unit

Replacement:
Tightening torque 51 35 1AZ, see 51 35 POWER WINDOWS, REAR .
Fig. 416: Identifying Screws, Flat Motor And Power Window Unit
See 51 31 ... Instructions on gluing windscreen.
ELECTRICAL POWER WINDOW

2010 BMW M3
IMPORTANT: The "1-hour" system will be introduced from 03/2009.

following:
"1-day system"
"1-hour system"
These instructions are not applicable to door window cementing (door "center") on the E38/L7:
is displayed at the end of this document by clicking on the "framed cross-reference"
General:
The windscreen and rear window (also the rear side windows if necessary) are bonded to the body. This
gluing will increase the torsional strength of the vehicle. To obtain perfect bonding, comply with the
installation procedure described in the following.
The windscreen must be secured with yellow plastic adhesive tape (sourcing reference: BMW Parts
Service) after being installed. The paint must be completely hardened after painting work.
Set down window glass and process on BMW-approved X-universal stand.

In winter, the vehicles must stand in a room with a temperature of at least 15C.
On-the-job safety:
When working with adhesive products (adhesive, cleaning agent, bonding agent etc.):

clothing on hand).
creams
Provide eye bath facilities, change water regularly (once a month).
Do not eat, drink or smoke in areas of PUR processing.
Replacement of windscreens:

2010 BMW M3
Stick on reminder label

Order/part
Type Type
number
Special cutter (manufacturer: Fein) with oscillating Pneumatically operated 81 43 9 429 183
blade Electrically operated 81 43 9 427 786
BMW blade set All required blades 81 43 9 428 596
19.5 mm (1) 6 39 03 118 01 3
24 mm 6 39 03 076 01 6
Blade (U-shape)
36 mm 6 39 03 079 01 2
45 mm 6 39 03 154 01 0
16 to 35 mm (adjustable) 6 39 03 143 01 3
Blade (straight with stop roller) 10 mm (fixed)(1) 6 39 03 189 01 0
14 mm (fixed) 6 39 03 082 01 6
"Roll Out 2000" Wire cutting system (1) 81 62 0 301 76 8
for heavy-duty applications
Scalpel (1)
special tool 51 3
Handles for cutting wire Self-locking (1) 270
Storage temperature:
Storage temperature of all adhesive products of 5C to 25C must be observed.
Adhesive:
The BMW-approved 1-component polyurethane adhesive must be used for bonding.
1-day system: Adhesive cartridge* (part number 83 19 0 152 031)
1-hour system :Adhesive cartridge* (part number 83 19 0 444 144)
Adhesive is applied to window glass with cartridge gun (pneumatically or electrically operated, sourcing
2010 BMW M3
When using accelerator (hot processing, 3-hour system):
sensor to DIS (Diagnosis and Information System) or to ISID (Integrated Service Information Display), if
necessary in conjunction with MIB (Measurement Interface Box)
Heat adhesive for at least 1 hour in cartridge oven (sourcing reference: BMW Parts Service) to 80 5C
Write date and time on adhesive when inserting into cartridge oven
Insufficient heating (< 1 hour) results in the formation of bubbles/blisters (gluing/cementing not
permitted)
Temperature < 80 5C results in the formation of bubbles/blisters (gluing/cementing not
permitted)
Remove cured adhesive prior to further processing.
Mistake in mixing in event of an interruption in application >1 minute (gluing/cementing not permitted)
A test bead of 50...70 mm must be rejected after an interruption in application
Best before dates of accelerator and adhesive must not be more than 3 months apart
Best before date >3 months results in the formation of bubbles/blisters (gluing/cementing not
permitted)
Sealed adhesive:
May only be stored for a maximum of 8 hours once it has been heated up to 80 5C.
The adhesive will be damaged if this time is exceeded (gluing/cementing not permitted)
Cartridge may only be heated up once
If the lower label is black, this adhesive may only still be used cold without accelerator while adhering to
the Best before date.
IMPORTANT: Not all window glass may be bonded with accelerator (hot processing).
If hot processing is not permitted, this is described in the relevant document.
Adhesive Best before date:
Repair kit and adhesive cartridges are marked with a date (Best before).
The adhesive cannot be used after this date.
Adhesive disposal:
The adhesive is disposed of in paper bags so that it can react with moisture.
2010 BMW M3
special waste.
Accelerator (3-hour system):
Accelerator is screwed onto the adhesive cartridge and contains a reaction paste which is mixed with the heated
adhesive.
IMPORTANT: The accelerator may only be paired with the adhesive cartridge of an unopened
package (bubbling).
Adhesive and accelerator must be paired while taking into account the Best
before dates.
The accelerator may no longer be used if the Best before dates are more than 3
months apart.
Bonding agent (activator):
The BMW-approved bonding agents must be used to treat bonding areas:
1-day system:
"Glass Activator 1" (on glass ceramic material)

1-hour system:
"Glass Activator 2" (on glass ceramic material), yellow stick, BMW part number: 83 19 0 144 142
"Paint Activator B" (on sheet metal flange), blue stick, BMW part number: 83 19 0 154 458
Prepare Glass Activator 2 and Paint Activator B for processing by shaking and snapping (breaking glass
ampoule).
Apply Glass Activator (2) by pressing gently. There is no need for final wiping. Ventilation time approx.
2 minutes.
Apply Paint Activator B by pressingly gently. Then wipe dry with a paper towel (available in a set).
Bonding agent Best before date:
Repair kit and bonding agent are marked with a date (Best before).
Once it has been opened (locking ring broken), use for 1 week only even if the Best before date has not
been reached.
2010 BMW M3
air).
"Roll Out 2000".
When using cutting wire, pull cutting wire ends through special tool 51 3 270, bend and tape off with fabric
When removing the windscreen:
Wear protective goggles and gloves.
with "Roll Out 2000" * (wire cutting system); no paint is damaged here in the case of narrow gaps
with special cutter* and oscillating blade*
Prior to each use, regrind the blade with a grinding stone while the machine is running (new blades also).
Avoid damage to paintwork on body cutout.
Guide blade carefully between body and window glass.
To remove adhesive bead in body cutout (and on window glass if reusing):

Cut off residual adhesive to a thickness of approx. 0.5 mm
Remove residual bead only briefly before bonding
Damage to paintwork in body aperture:

2010 BMW M3
without fail.
Touch up damage to paintwork on body cutout with BMW multibase filler.
Grind extensive areas of damage down to the bare metal and coat with BMW multibase filler (coating thickness
30 ... 40 m).
Hardening time:

Tape off primed bonding flange before applying top coat
Treatment of glued area in body:

Adhesive Treatment
Clean with spirit (available in pharmacies).
Bonding and sealing compound for 1-day system: Apply "Paint Activator A" to paint and residual
car window glass bead
1-hour system: Apply "Paint Activator B" (blue stick) to paint
IMPORTANT: Do not use Sika remover 208 for cleaning in the bonding area.
Preparation for assembly:
Prepare plastic nozzle(s) for shaping adhesive bead (when not using the standard nozzle), can be cut to size
2010 BMW M3
Lay a test bead of approx. 50 mm - watch out for formation of bubbles/blisters when hot cementing; if OK,
Interruption must be < 5 second (incorrect mixture ratio).
Cartridge must be vertical to window glass.
Black ceramic material impermeable to UV light is located on the peripheral zone of the inside edge of
the window to protect the adhesive bead.
Glass ceramic material must not be damaged and must be treated as follows.
1-day system: Treatment of glass ceramic surface (inside of window):

Hot cementing:
83 19 0 147 370
Cold cementing:
b. Observe an air drying time of at least 1 minute
Adhesive cartridge:
83 19 0 152 031
1-hour system: Treatment of glass ceramic surface (inside of window):

Glass Activator 2 (yellow stick):
b. Observe an air drying time of at least 5 minutes
Version with inspection window for vehicle identification number in windscreen only (all except
US/GB):
Seal inspection window (bottom left) with Sika primer 206 G+P
Approx. 1 1/4 adhesive cartridges are required to cement the windscreen on the following vehicles:
2010 BMW M3
7 Series
5 Series from E60
X5
X3
In the case of hot cementing (with accelerator), the missing residual bead is applied from a second
adhesive cartridge (not contained in the repair kit) but while cold and without accelerator (bubbling).
Minimum hardening period is thus not increased.
IMPORTANT: If a second cartridge is required for cementing:
Accelerator from repair kit must not be used with the second cartridge (bubbling)
Bubbling results in leakage and insufficient bonding strength (torsional rigidity, passenger airbag).
DIFFERING ADHESIVE QUANTITIES EFFECT CHART

Windscreen rests too low in body Windscreen rests too high in body cutout
cutout Wind noise may occur
Strains/tensions may occur Strains/tensions may occur (windscreen breakage)
(windscreen breakage) Fouling of add-on parts by emerging adhesive
Insufficient squeezing of adhesive Adhesive on uninsulated strainer pressure lines of aerial
bead (leaking) (s) (interference of reception)
Spacer buffers:

Wind noises
Assembly:
To prevent a pressure increase in the vehicle interior when the doors are closed:
2010 BMW M3
Open a window

accelerator).
1-hour system:
Once the adhesive bead has been applied, the windscreen must be
installed within 7 minutes (depending on air humidity, temperature).
After 7 minutes the adhesive bead forms a skin which can no longer
Remove adhesive residue immediately with adhesive remover (Sika remover 208, sourcing reference:
BMW Parts Service). Do not press out the window glass again.
Hardened adhesive can only be removed by machine.
Check height of windscreen/rear window with special tool 51 0 010 or 51 3 210 .
Assemble car.
Hardening:
The adhesive hardens as it reacts with air humidity (with accelerator also due to mixed-in reaction paste)
at room temperature.
At ambient temperatures above 23C and 50 % relative air humidity (hot countries), the adhesive open
time is shortened to approx. 5 minutes (skin formation time).
The adhesive hardening process is interrupted completely at ambient temperatures below 5C. In this
event, there will be no increase in the strength of the adhesive bond.
Do not subject the vehicle to load on one side during the minimum hardening time
2010 BMW M3
one wheel on curb

lifting platform
etc.

do not under any circumstance driver over access ramps, e.g. into multi-store car parks
If you fail to adhere to the minimum hardening times
leaks and wind noises will occur when the windscreen is moved
1-day system: Glues and their minimum hardening times:
1-DAY SYSTEM - GLUES AND THEIR MINIMUM HARDENING TIMES

Hot processing
2 hours 3 hours*
with accelerator
Cold processing 9 hours 20 hours*
1-hour system: Glues and their minimum hardening times:
1-HOUR SYSTEM - GLUES AND THEIR MINIMUM HARDENING TIMES

Cold
processing
1 hour 2 hours(1)
NOTE:
(1) Vehicles with passenger airbag:
The vehicle can be handed over to the customer after the hardening period (vehicle can be moved,
for "... hours"!
The time is taken from the "Minimum hardening period" table for countries where seatbelt use is not
required by law.

2010 BMW M3
Locate leaks:

with ultrasonic leak detector (sourcing reference: BMW Parts Service)
Version with GPS navigation system 1 (up to 9/97):
Recalibrate magnetic field sensor

Version with rain sensor, rain/light sensor or rain/light solar sensor:
Remove complete rain sensor, rain/light sensor or rain/light solar sensor.

Version with automatic air conditioning:
If fogging sensor is not mounted on new windscreen:
Replace fogging sensor, refer to repair instructions.
When replacing windscreen in vehicles with rain/light solar sensor, replace this completely: refer to repair
instructions.
Before bonding, install windscreen with seal(s) and check HUD ; if necessary, press expanding foam tape down
with hand roller.

2010 BMW M3
refer to repair instructions.
NOTE: If no document is displayed after you have clicked on a "framed cross-

reference":
It is not necessary or permitted for the model selected.
54 37 ... REMOVING AND INSTALLING/REPLACING TRIM FOR SUPPORT TUBE IN LUGGAGE

COMPARTMENT ON LEFT OR RIGHT
Release clips (1). Feed out panel (2) in direction of arrow. Installation: If necessary, replace faulty clips (1).
Fig. 417: Feed Out Panel In Direction Of Arrow

51 37 154 ADJUSTING REAR LEFT OR RIGHT SIDE WINDOW
51 0 341
51 2 220
51 3 080
51 3 310

Prerequisite:
Vehicle must be standing on its wheels on a level floor

Door window glass correctly adjusted

2010 BMW M3
Remove rear window cavity seal

Open retractable hardtop
Move side window upwards (close)
Ideal adjustment, transversal direction
Side window glass (1) must be situated at distance (A) to body (2).
Distance A = 71 mm
Measuring points in B-pillar area and release for rear screw connection of side window glass (1).
Adjusting transversal direction
Remove side trim upper section .
Slacken screws (3) and adjust distance (A).
Fig. 418: Measuring Points In B-Pillar Area

Ideal adjustment, longitudinal direction
Side window glass (1) must be positioned at distance (A) to door window glass (2).
Measurement (A) = 19 1 mm
Parallelism deviation 1 mm.
Side window glass (1) may have a max. underprotrusion (B) to door window glass (2).
2010 BMW M3
Measurement (B) = 2 mm
Fig. 419: Identifying Side Window Glass At Distance

Adjusting longitudinal direction
Slacken screws (1) with special tool 51 3 310.
Adjust longitudinal direction by moving side window glass (2).
Fig. 420: Slacken Screws With Special Tool 51 3 310

Installation:
The tightening torque (3.5 Nm) is reduced when special tool 51 3 310 is used. Depending on the torque wrench
used, this must be calculated according to the adjacent equation:
2010 BMW M3
MDE = Torque to be set
MDV = Prescribed torque (without special tool)
Fig. 421: Identifying MDE And MDV Torque Wrench Of Length

lj = Standard adjustment length with adjusting tool
l1 = Effective length of torque wrench
l2 = Inside dimension of adjusting tool
lw = Inside dimension of insertion tool (here lw = 145 mm)
NOTE: If screwing is performed from the inside of the door (removed door trim panel),
the tightening torque (without special tool) must be observed, see 51 37 SIDE
WINDOWS, ELECTR. ACTUATED .
Checking retraction depth
Close retractable hardtop

Open door window
Attach special tool 51 3 080 to door window glass
Close side window completely
Measure retraction depth
NOTE: 2 items of special tool 51 3 080 are required for adjustment of retraction depths.
2010 BMW M3
Fig. 422: Identifying Special Tool 51 3 080 To Door Window Glass

Measure retraction depth (A) in areas (1 to 2).
Measurement (A):
(1) = 8 2 mm
(2) = 8 2 mm
If necessary, check or readjust settings on:
Door window glass

Side window
Fig. 423: Measuring Retraction Depth In Areas

Ideal adjustment, pretension

2010 BMW M3
NOTE: Pretension can be checked with or without window cavity cover strip.
Pretension is 1.0 mm greater with window cavity cover strip. Magnet in special
tool 51 0 341 creates the correct door window glass pretension on the seal
system for measurement. No force must be exerted on the door or door window
glass during measurement.
Insert special tool 51 0 341 in rotary striker of door lock and close rotary striker manually. Carefully close door.
Fig. 424: Identifying Magnet In Special Tool 51 0 341 On Seal System

Measure gap (A) between side window glass (1) and inside edge of door window glass (2).
NOTE: Measuring point 10 mm below top edge of window glass.
With window cavity cover strip fitted (front and rear): A = 20 +1 mm
Without window cavity cover strip fitted (rear): A = 19 +1 mm

2010 BMW M3
Fig. 425: Measuring Gap Between Side Window Glass And Inside Edge Of Door Window Glass
Adjusting pretension
Remove rear window cavity cover strip .
Turn adjusting screw (1) with special tool 51 2 220 until correct pretension is reached.
NOTE: With hardtop closed, side window glass (2) must run correctly into hardtop
seals (check only when window cavity cover strip fitted).
Fig. 426: Identifying Adjusting Screw With Special Tool 51 2 220

Checking adjustment
Open door window and side window.
Close both windows simultaneously and check run-in of side window glass to door window glass.
Close retractable hardtop.
Hardtop seals must not be damaged.
Check run-in of both windows in hardtop seals.
51 37 171 REPLACING REAR LEFT OR RIGHT SIDE WINDOW
WARNING: Power window unit has no anti-trapping mechanism.

2010 BMW M3
Remove rear power window unit
Release screws (1).
Feed side window glass (2) out of power window unit (3).
Installation:
Adjust rear side window .
Fig. 427: Identifying Power Window Unit And Side Window Glass
51 37 240 REMOVING AND INSTALLING OR REPLACING OUTER WINDOW CAVITY COVER

STRIP FOR DOOR WINDOW, REAR LEFT OR RIGHT
00 9 311
Open lid for retractable hardtop.
Open door window.
Detach window cavity cover strip (1) at clip (2).
Installation:
Make sure water drain channels (3) are in correct position.

2010 BMW M3
The weatherstrip (1) in area (A) must be sealed on the inner side with butyl tape.
Fig. 428: Identifying Weatherstrip In Area On Inner Side

Attach adhesive tape under window cavity cover strip (1) (damage to paintwork).
Starting at the rear, carefully lever weatherstrip (1) out of clips (2) on side panel with special tool 00 9 311.
IMPORTANT: The weatherstrip (1) can bend when lifted out too far.
Installation:
If one or several clips (2) detach from the vehicle body, they must be replaced.
If necessary, touch up any paintwork damage in the area of the detached clips (2).
Fig. 429: Lever Weatherstrip Out Of Clips On Side Panel

2010 BMW M3
Installation:
Ensure seal (1) is correctly seated.

FRONT DOOR TRIM PANEL

2010 BMW M3

(CONVERTIBLE/COUPE)
00 9 317

2010 BMW M3
Remove decorative strip from door trim panel.
Driver's side:
Remove rocker switch for side window operation . See 61 31 115 REPLACING ROCKER SWITCH
FOR SIDE WINDOW OPERATION (FRONT) .
Passenger side:
Remove cover on door handle.
Driver's side only:
Release screws (1).
Tightening torque 51 41 1AZ, see 51 41 FRONT DOOR TRIM PANEL WITH ARMRESTS .
Fig. 432: Identifying Driver's Side Screws

Release screws (1).
Tightening torque 51 41 1AZ, see 51 41 FRONT DOOR TRIM PANEL WITH ARMRESTS .
2010 BMW M3
Fig. 433: Identifying Passenger Side Screws

Release clips (2) for door trim panel (1) with special tool 00 9 317 .
Fig. 434: Identifying Door Trim Panel And Clips

IMPORTANT: On version with light package, pay attention to fibre-optic waveguide in area of
door mirror.
2010 BMW M3
Fig. 435: Identifying Door Trim Panel And Retainers

Disconnect all plug connections/cable holders and remove door trim panel.
Fig. 436: Identifying Door Lock And Bowden Cable

Installation:
1. Grey clip
2. White clip
3. Red clip
2010 BMW M3
Fig. 437: Identifying Sealing Ring And Clips

Installation:
Open door window.

(SEDAN)
00 9 317
Driver's side only:
Remove decorative strip from door trim panel
Remove cover on door handle
Driver's side only:

2010 BMW M3
Release screws (1).
Tightening torque 51 41 1AZ , see 51 41 FRONT DOOR TRIM PANEL WITH ARMRESTS .

Release screws (1).

Unclip clips (1) for door trim panel (2) with special tool 00 9 317 .
2010 BMW M3
Fig. 440: Identifying Clips And Door Trim Panel



2010 BMW M3

Installation:
1. Grey clip
2. White clip
US/CND version:
Crashpad (3) must be correctly fitted.
Fig. 443: Identifying Crashpad

2010 BMW M3
Installation:
Open door window.

51 41 001 REPLACING FRONT LEFT OR RIGHT DOOR TRIM PANEL (CONVERTIBLE/COUPE)

Remove speaker . See 65 13 070 REMOVING AND INSTALLING/REPLACING SPEAKER (MID-
RANGE SPEAKER IN DOOR TRIM PANEL AT FRONT) .
Remove speaker cover
Remove inside door opener
Remove armrest
E93 only:
Remove module for passenger compartment protection . See 65 13 080 REMOVING AND
INSTALLING/REPLACING SPEAKER (TWEETER IN REAR DOOR) .
51 41 001 REPLACING FRONT LEFT OR RIGHT DOOR TRIM PANEL (SEDAN)

RANGE SPEAKER IN DOOR TRIM PANEL AT FRONT) .
Remove speaker cover
Remove footwell light. See 63 31 020 REMOVING AND INSTALLING/REPLACING FOOTWELL

LIGHT (DOOR) .
2010 BMW M3
Fig. 444: Identifying Cutout

US/CND national-market version:
If necessary, replace crashpad (1).
Pull off protective film from rear side of crashpad (1).
Stick crashpad (1) on door trim panel.
Installation:
Positioning by way of uniform distance to mounting (2) and outer edge (3).
Press on crashpad (1) firmly for approx. 20 seconds.
Fig. 445: Identifying Crashpad, Mounting And Outer Edge

2010 BMW M3
51 41 017 REMOVING AND INSTALLING/REPLACING COVER ON FRONT DOOR HANDLE

(PASSENGER SIDE)
00 9 317
Remove decorative strip from door trim panel. from front door (passenger side)
Lever out cover (1) with special tool 00 9 317 .
Fig. 446: Removing Cover With Special Tool

Installation:

2010 BMW M3
Fig. 447: Identifying Cover Catches

51 41 018 REPLACING SPEAKER TRIM ON FRONT LEFT OR RIGHT DOOR TRIM PANEL
Remove speaker in door trim panel at front. See 65 13 070 REMOVING AND
INSTALLING/REPLACING SPEAKER (MID-RANGE SPEAKER IN DOOR TRIM PANEL AT
FRONT) .
Installation:
Fig. 448: Identifying Speaker Trim And Catches

Installation:

2010 BMW M3

51 41 019 REMOVING AND INSTALLING/REPLACING DOOR HANDLE ON DOOR TRIM PANEL

AT FRONT (PASSENGER SIDE) LEFT OR RIGHT

Only drill down to door trim panel area (2) so as not to damage the contact
surface.
Remove welding residue from door trim panel (2) and door handle with a scalpel (for heavy-duty applications)
if these components are to be reused.
Fig. 450: Identifying Welding Spots And Door Trim Panel

2010 BMW M3
Replacement:
Drill out holes (1) in door handle (2) to 3.0 mm dia.
Fig. 451: Identifying Holes And Door Handle

Slide door handle (1) into door trim panel (2).
Fig. 452: Identifying Door Handle And Door Trim Panel

Installation:
Turn door trim panel over and lay with door handle on clean surface
Lay large washer (1) on welding pin (2) and mark
Remove door handle and saw off all welding pins (2) slightly below marking
Insert door handle
Fit large washer (1) and small washer (3)
2010 BMW M3
Secure with screw (4)

Tighten down all 4 screws
Fig. 453: Identifying Large Washer And Small Washer


OR RIGHT DOOR TRIM PANEL (CONVERTIBLE/COUPE)
00 9 317
Starting at rear, release decorative strip (1) with special tool 00 9 317 from clips (2).
Remove decorative strip (1) towards rear.
Installation:
Clips (2) on decorative strip (1) must not be damaged.

2010 BMW M3
Fig. 454: Identifying Decorative Strip And Clips

Installation:


OR RIGHT DOOR TRIM PANEL (SEDAN)
00 9 317
Starting at front, release decorative strip (1) with special tool 00 9 317 from clips (2).
2010 BMW M3
Feed decorative strip (1) towards rear out of retaining hook (3) and remove.
Installation:
No clip (Hutfix) must be fitted under third clip (2) from rear.
Fig. 456: Identifying Decorative Strip And Retaining Hook

Installation:

Installation:
Clips (1) on decorative strip (2) and counterpiece on door trim panel must not be damaged.

2010 BMW M3
Fig. 458: Identifying Clips And Decorative Strip

51 41 081 REPLACING ARMREST ON FRONT LEFT OR RIGHT DOOR TRIM PANEL (DRIVER'S
SIDE)
Removal:
IMPORTANT: Only drill down to door trim panel area (2) so as not to damage the contact
surface.
Armrest is welded to door trim panel only during initial installation, release
mounting elements if necessary.
Remove armrest.
Remove welding residue on door trim panel (2) with scalpel.

2010 BMW M3
Fig. 459: Identifying Welding Spots And Door Trim Panel

Installation:
Armrest is secured in areas (A and C) with nuts (2).
Because of reduced height and risk of damage to acoustic insulation, locking washers (3) are used in area (B).
After armrest is secured, pins (1) must be sawn off to measurement (X) (exception: third, ninth and eleventh
pins from front).
IMPORTANT: Do not snip off pins (1) with side cutters as this will deform the pins so that the
retaining elements may work loose.
In order not to undershoot measurement (X) when sawing off, place suitable
shim on retaining elements (2 and 3) and saw off pins (1) above shim.
Fig. 460: Identifying Locking Washers

2010 BMW M3
Installation:
Secure pins (1) in area (A and C) with nuts (2).
NOTE: Carefully tighten nuts (2) to ensure they are not overtightened.
Secure pins (1) in area "B" (fourth, fifth and sixth pins from front) with locking washer (3).
If necessary, grip armrest from outside with a suitable tool (tool must not damage door trim panel).
Saw off all pins (1), except third, ninth and eleventh pins (1), to measurement (X) (risk of damage to acoustic
insulation).
Dimension (X) = 2 mm
Fig. 461: Identifying Pins And Nuts

51 41 090 REPLACING LIGHT STRIP ON DOOR TRIM PANEL AT FRONT
Remove LED for front door trim panel light . See 63 31 180 REPLACING LED FOR FRONT
DOOR TRIM PANEL LIGHT .
IMPORTANT: Risk of damage

Handle light strip with care.
Do not knock fibre optic cables.
Position new light strip on door trim panel (2) and mark welding spots (1) to be opened.
2010 BMW M3
Drill out welding spots (1).
NOTE: Only drill down to door trim panel area so as not to damage the contact surface.
Feed light strip out of door trim panel (2).
Remove all remnants of plastic from contact surface of door trim panel (2).
Fig. 462: Identifying Light Strip On Door Trim Panel And Mark Welding Spots
Installation:
Carefully feed light strip in area (1) into door trim panel.
Push welding pins (3) through holes into door trim panel and secure with locking washers (2).
Shorten welding pins (3) down to measurement (A).
A = 3 mm
Fig. 463: Identifying Locking Washers And Welding Pins Holes In Door Trim Panel
2010 BMW M3
51 41 241 REMOVING AND INSTALLING/REPLACING COVER FOR ARMREST ON DRIVER

DOOR
00 9 317
Release lock washers (1) on back of door trim panel (2).
Installation:
Studs for lock washers (1) must not be damaged.
If necessary, replace faulty lock washers (1).
Fig. 464: Identifying Lock Washers On Back Of Door Trim Panel

Unclip trim (1) with special tool 00 9 317 in upward direction from retainers (2).
Installation:

2010 BMW M3
Fig. 465: Identifying Door Trim Panel And Special Tool 00 9 317
Installation:
Catches (1) on trim (2) must not be damaged.
Fig. 466: Identifying Catches On Trim

51 41 270 REMOVING AND INSTALLING/REPLACING TRIM ON DOOR POCKET
00 9 317
Engage special tool 00 9 317 at side and release catches (1) on trim (2).
Feed trim (2) upwards out of door pocket.

2010 BMW M3
Installation:
Attach trim (2) from above to door pocket.
Align catches (1) on trim (2) to door pocket and secure trim (2) to door pocket.
Fig. 467: Identifying Catches On Trim And Special Tool 00 9 317 At Side
Installation:


RIGHT FRONT DOOR
See 51 48 060 Removing and installing/replacing sound insulation in left or right front door.
REAR DOOR TRIM PANEL

2010 BMW M3
51 00 .. OVERVIEW OF REAR DOOR
Fig. 469: Identifying Overview Of Rear Door

51 42 000 REMOVING AND INSTALLING LEFT OR RIGHT REAR DOOR TRIM PANEL
00 9 317

2010 BMW M3
Remove cover on door handle
Release screws (1).
Tightening torque 51 42 1AZ , see REAR DOOR TRIM PANEL WITH ARMRESTS .


Unclip clips (1) for door trim panel (2) with special tool 00 9 317 .
Fig. 471: Identifying Clips And Door Trim Panel

Carefully unclip door trim panel (1) at top from retainers (2) and remove.
2010 BMW M3
Disconnect plug on power window switch.


Installation:
Clips (1) are white.
Clip (2) is brown and shorter than clips (1).

2010 BMW M3

Installation:
Open door window.

51 42 001 REPLACING LEFT OR RIGHT REAR DOOR TRIM PANEL

Remove toggle switch . See 61 31 116 REPLACING ROCKER SWITCH FOR SIDE WINDOW
OPERATION (REAR) .
Specification with speaker:
Remove speaker cover and SPEAKER (TWEETER IN REAR DOOR) .

RANGE SPEAKER, DOOR AT REAR) .
Remove roller sun blind

2010 BMW M3
Remove entrance light.
Fig. 475: Identifying Cutout

51 42 017 REMOVING AND INSTALLING/REPLACING COVER ON DOOR HANDLE, REAR LEFT

OR RIGHT
00 9 317
Remove decorative strip from door trim panel at rear
Lever out cover (1) with special tool 00 9 317 .

2010 BMW M3
Fig. 476: Removing Cover With Special Tool

Installation:

51 42 018 REPLACING SPEAKER TRIM ON REAR LEFT OR RIGHT DOOR TRIM PANEL
00 9 317
Carefully lever out trim (1) with special tool 00 9 317 and remove.
Installation:
2010 BMW M3
Trim (1) can only be installed in one position.
Turn trim (1) until catches on trim (1) match up with mountings on door trim panel.

Installation:

51 42 030 REMOVING AND INSTALLING/REPLACING DECORATIVE STRIP (LIGHT STRIP) ON

REAR LEFT OR RIGHT DOOR TRIM PANEL
00 9 317

2010 BMW M3
Starting at rear, release decorative strip (1) with special tool 00 9 317 from clips (2).
Feed decorative strip (1) towards front out of retaining hook (3) and remove.
Installation:
Released or damaged Hutfix clips must be replaced.

Installation:
Clips (1) on decorative strip (2) and counterpieces on door trim panel must not be damaged.

2010 BMW M3

RIGHT REAR DOOR
See 51 48 070 Removing and installing/replacing sound insulation on left or right rear door.
SIDE COVERING WITH ARMREST

51 43 004 REMOVING AND INSTALLING/REPLACING DECORATIVE STRIP ON LEFT OR
RIGHT SIDE TRIM PANEL
00 9 317
Starting at front, detach decorative strip (1) with special tool 00 9 317 from clips (2) and remove.
Installation:
Clips (2) on decorative strip (1) must not be damaged.
Fig. 482: Identifying Clips On Decorative Strip

Installation:

2010 BMW M3

51 43 012 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT UPPER SIDE

TRIM SECTION
If necessary, open retractable hardtop.
Open lid for retractable hardtop.
Release clips (1).
Lever out protective cap (2) and release screw underneath.
Installation:
If necessary, replace defective clip (1) and protective cap (2).
Fig. 484: Identifying Defective Clip And Protective Cap

2010 BMW M3
Carefully release upper side trim section (1) at retainers (2) and clip (3) in upward direction.
Disconnect plug connection on aerial amplifier and remove upper side trim section (1).
Installation:
Spray area of retainers (2) with cavity sealant.
If necessary, replace faulty clips (3) and associated Hutfix in body.
Upper side trim section (1) must be correctly fed into guides (4).
Fig. 485: Identifying Upper Side Trim Section, Retainers And Clip
Replacement
Remove aerial . See AERIAL ANTENNA .
51 43 018 REMOVING AND INSTALLING/REPLACING SPEAKER TRIM ON LEFT OR RIGHT

SIDE TRIM PANEL
Remove speaker in side trim panel . See SPEAKERS .
Installation:
2010 BMW M3
Fig. 486: Identifying Speaker Trim At Catches

Installation:

51 43 034 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT LOWER SIDE

TRIM SECTION
Remove side trim upper section

Remove decorative strip from side trim panel
Remove rear seat . See 52 24 005 REMOVING AND INSTALLING OR REPLACING REAR
SEAT .
2010 BMW M3
Release screws (1).
Release lower side trim section (2) at clips (3).
Feed lower side trim section (2) out of entrance cover strip (4).
Disconnect all associated plug connections/cable holders and remove lower side trim section (2) in inward
direction.
Fig. 488: Identifying Lower Side Trim Section Of Entrance Cover Strip
Installation:
Fit all clips (1) with sealing ring.
Make sure clips (1 and 2) are in correct installation position.
1. White clip
2. Blue clip
2010 BMW M3
Fig. 489: Identifying Sealing Ring Clips

Replacement
Release retaining rings (1) and remove sound insulation (2).

If necessary, remove module for passenger compartment protection (3) . See 65 75 090 REMOVING
AND INSTALLING/REPLACING INTERIOR MOVEMENT DETECTION MODULE IN LEFT
OR RIGHT B-PILLAR .
Remove speakers (4) . See SPEAKERS .
If necessary, remove LED . See 63 31 185 REPLACING LED FOR SIDE TRIM PANEL LIGHT .
Remove top section on armrest
Fig. 490: Identifying Retaining Rings And Sound Insulation

51 43 063 REMOVING AND INSTALLING/REPLACING UPPER SECTION ON REAR LEFT OR

RIGHT ARMREST

2010 BMW M3
00 9 317
Unclip trim (1) upwards with special tool 00 9 317.
Fig. 491: Identifying Unclip Trim With Special Tool 00 9 317

Installation:
Catches (1) on trim (2) are secured with retaining clips (3) in door trim panel.
Catches (1) on trim (2) and retaining clips (3) on door trim panel must not be damaged.
Fig. 492: Identifying Catches On Trim With Retaining Clips


PILLAR, LEFT (DRIVER SIDE)

2010 BMW M3
Remove front entrance cover strip (inside)

Remove trim panel for pedal assembly.
Unscrew bolt (3).
Remove hood/bonnet release lever (4) from side trim panel (2).
Fig. 493: Identifying Hood/Bonnet Release Lever And Side Trim Panel
Release screw (1).
Unclip side trim panel (4) in each case in direction of arrow at retaining points (2 and 3).
If necessary, disconnect associated plug connection and remove side trim panel (4).
Fig. 494: Identifying Side Trim Panel

2010 BMW M3
Position side trim panel (2) preinstalled with clips (1) on associated bores and clip into place.
Replacement:
Remove switch for unlocking rear lid. See 61 31 083 REMOVING AND INSTALLING/REPLACING
SWITCH FOR UNLOCKING REAR LID .
Fig. 495: Identifying Side Trim Panel And Clips

Replacement on right-hand drive up to model year 2005:
NOTE: Because of altered locators on side trim panel and trim panel for pedals from
model year 2005, the trim panel for pedals must be reworked.
Cut off ribs (1) on trim panel for pedals (2) flat with scalpel.
Fig. 496: Identifying Ribs And Pedals

2010 BMW M3
51 43 075 REMOVING AND INSTALLING / REPLACING SIDE TRIM PANEL, FOOTWELL, ON A-

PILLAR, RIGHT
00 9 317
Remove front entrance cover strip (inside)

Remove trim for instrument panel, bottom left
Unclip side trim panel (2) with special tool 00 9 317 in direction of arrow at retaining points (3) and remove.
Fig. 497: Removing Side Trim Panel With Special Tool

Installation:
If necessary, lever out clips (1) remaining in bores.
Position side trim panel (2) preinstalled with clips (1) on associated bores and clip into place.
2010 BMW M3

51 43 090 REMOVING AND INSTALLING/REPLACING LIGHT STRIP IN SIDE TRIM PANEL
Remove side trim panel

If necessary, remove LED . See 63 31 185 REPLACING LED FOR SIDE TRIM PANEL LIGHT .

Handle light strip with care.
Do not knock fibre optic cables.
Release locking washers (1) on sound insulation (2) and remove sound insulation (2).
Fig. 499: Identifying Locking Washers On Sound Insulation

Position new light strip on side trim panel (2) and mark welding spots (1) to be opened.
2010 BMW M3
Drill out welding spots (1).
NOTE: Only drill down to door trim panel area so as not to damage the contact surface.
Feed light strip out of side trim panel (2).
Remove all remnants of plastic from contact surfaces of side trim panel (2).
Fig. 500: Identifying Light Strip On Side Trim Panel And Mark Welding Spots
Installation:
Carefully feed light strip in area (1) into side trim panel.
Push welding pins (3) through holes into side trim panel and secure with locking washers (2).
Shorten welding pins (3) down to measurement (A).
A = 3 mm
2010 BMW M3
Fig. 501: Identifying Locking Washers And Welding Pins Holes In Side Trim Panel
51 43 148 REMOVING AND INSTALLING OR REPLACING TRIM ON LEFT OR RIGHT DOOR

PILLAR (TOP)
Remove panel for door pillar (bottom)

Release seat belt screw on front seat . See 72 11 033 REMOVING AND
INSTALLING/REPLACING FRONT LEFT OR RIGHT SEAT BELT (SEDAN) .
Release clips (1).
Pull off panel (2) towards bottom.
Separate webbing.
Fig. 502: Identifying Clips And Panel

Installation:
2 Guides
3 Clips
Fixtures for expansion rivets

Belt finisher strip
2010 BMW M3
Fig. 503: Identifying Guides And Clips

51 43 150 REMOVING AND INSTALLING OR REPLACING TRIM FOR LEFT OR RIGHT DOOR
PILLAR (BOTTOM)
Remove front entrance cover strip
Snap trim (2) out of clips (1) at bottom.
Feed out trim (2) for door pillar from entrance cover strip (3).
Fig. 504: Identifying Trim And Clips

Partially detach mucket in area of B-pillar panel.
Carefully feed out bottom trim (1) from top trim (2).
2010 BMW M3
Fig. 505: Identifying Bottom Trim And Top Trim

Installation:

51 43 201 REMOVING AND INSTALLING OR REPLACING TRIM FOR ROOF PILLAR AT FRONT
(A-PILLAR), LEFT OR RIGHT
00 9 341
WARNING: Follow safety instructions for working on cars with airbag systems.
2010 BMW M3
airbag).
Unclip protective cap (1) with special tool 00 9 341 and remove.
Fig. 507: Identifying Protective Cap

Release mucket (1) in area of trim for front roof pillar (2).
Release screw (3), tightening torque 51 43 1AZ , see 51 43 SIDE TRIM PANEL WITH ARMRESTS .
Unclip trim for front roof pillar (2) from mounting point (4).
Feed trim for front roof pillar (2) out of instrument panel trim (5) and remove.
Fig. 508: Identifying Front Roof Pillar And Instrument Panel Trim
2010 BMW M3
Installation:
Make sure guides (3) of trim for front roof pillar (2) are correctly seated in associated mountings.
Position trim for front roof pillar (2) preassembled with clip (1) on associated bore and clip into place.
Fig. 509: Identifying Front Roof Pillar And Clip

51 43 251 REMOVING AND INSTALLING/REPLACING TRIM PANEL FOR LEFT OR RIGHT

REAR ROOF PILLAR (C-PILLAR)
WARNING: Follow safety instructions for working on vehicles with airbag systems.
airbag).
Detach mucket (1) in area of trim panel for roof pillar (4).
Tightening torque 51 43 2AZ , see 51 43 SIDE TRIM PANEL WITH ARMRESTS .
Pull trim panel for roof pillar (4) in direction of arrow and detach from clips (3).
Installation:
2010 BMW M3
Fit trim panel (4) over openings for clips (3) and snap into place.
Fig. 510: Identifying Trim Panel And Clips

Installation:
Clips (1 and 2) must not be damaged or missing.

51 46 025 REMOVING AND INSTALLING/REPLACING TRIM ON AIR OUTLET GRILLE
Removing front air outlet grille

2010 BMW M3
51 46 026 REMOVING AND INSTALLING OR REPLACING FRONT AIR OUTLET TRIM GRILLE
See 51 46 026 Removing and installing or replacing front air outlet trim grille.
ROOF TRIM PANEL

51 44 001 REMOVING AND INSTALLING/REPLACING HEADLINER (WITHOUT SLIDE/TILT
SUNROOF)
Except for the steps relating to the slide/tilt sunroof, the work is identical to:
Removing and installing/replacing headliner (with slide/tilt sunroof)
51 44 011 REMOVING AND INSTALLING OR REPLACING ROOFLINER (WITH SLIDE/TILT

SUNROOF)
Remove sun visors and counter supports on left/right.

If necessary, remove both mirror lights . See 63 31 050 REMOVING AND
INSTALLING/REPLACING MIRROR LIGHT .
Remove roof light (front) . See 61 31 043 REMOVING AND INSTALLING OR REPLACING
ROOF SWITCH CENTRE or 63 31 000 REMOVING AND INSTALLING OR REPLACING
COMPLETE ROOF LIGHT (FRONT) .
Remove trim panels for roof pillar at front left/right (A-pillar trims)
Remove front/rear handles
Remove trim panels for door pillar on left/right (B-pillar trims)
Remove trim panels for roof pillar at rear left/right (C-pillar trims)
Remove roof light (rear) . See 63 31 004 REMOVING AND INSTALLING OR REPLACING
COMPLETE CEILING LIGHT (REAR, WITH MODULE FOR PASSENGER COMPARTMENT
PROTECTION) .
Remove trim for auxiliary brake light . See 63 25 000 REMOVING AND
INSTALLING/REPLACING AUXILIARY BRAKE LIGHT .
Remove left front seat . See SEATS .
IMPORTANT: When removing, do not touch edges of roofliner.
Move seat back of right front seat to maximum rear position.
Release expander rivets (1).
Detach roofliner (2) from Velcro-type fasteners (3).
Detach roofliner (2) from clips (4).

2010 BMW M3
Detach mucket (6) towards inside.
Detach mucket (5) from all doors in area of roofliner (2).
Lay roofliner (2) downwards.
Fig. 512: Identifying Roofliner And Clips

IMPORTANT: The following tasks must be carried out with a second person assisting:
Tilt headliner and remove to left rear door.
Installation:
Following parts of roofliner must not be damaged or missing:
Mounting and frame (1) for front mounting bracket

Wiring harness (2)
Mounting and frame (3) for rear mounting bracket
Velcro-type fasteners (4)
Clips (5).
2010 BMW M3
Fig. 513: Identifying Velcro-Type Fasteners And Clips

IMPORTANT: Depending on the build date/version, replacement can involve different Velcro-
type connections.
Mixed installation of the Velcro-type connection is not permitted.
In order to avoid mixed installation, remove the old Velcro-type material and attach the new Velcro-type
material.
New and old Velcro-type fasteners differ in color:
Black: Old Velcro-type fastener
White: New Velcro-type fastener
Only black/black or white/white pairings are permitted.
Procedure for replacing Velcro-type connection:
Detach Velcro-type connection from slide/tilt sunroof or console connection.
Remove adhesive residue.
Clean adhesive area with spirit.
Air drying time: > or = 1 minute
Attach new Velcro-type connections.

2010 BMW M3
Fig. 514: Locating Adhesive Area

If replacing version with mirror lights:
Cut out premarked cutout area (1) for left/right mirror light with a scalpel.
Fig. 515: Identifying Premarked Cutout Area

If replacing version with cable to inside rearview mirror:
Mark cutout (1) on roofliner.
A= Centre of roofliner
B= 14 mm
2010 BMW M3
C= 20 mm
Cut out cutout (1) with scalpel.
Fig. 516: Identifying Cutout On Roofliner

Installation:
1. Secure roof liner with mucket

2. Secure roofliner in middle to Velcro-type fastener
3. Snap roofliner at rear onto clips
4. Insert expander rivets at front
5. Screw down grab handles at front on left/right
6. Screw down grab handles at rear on left/right
7. Screw down sun visors and counter supports
8. Add final details to vehicle
51 44 150 REPLACING TRIM FOR FRONT ROOFLINER
Open convertible top or retractable hardtop.

Remove front roofliner/roof switch center trim insert . See 61 31 043 REMOVING AND
INSTALLING OR REPLACING ROOF SWITCH CENTRE .
Remove both front mirror lights
Remove both sun visors .
2010 BMW M3
E93 only:
Unclip trim (1) on left/right towards top.
Installation:
Replace trim (1).
Fig. 517: Replacing Trim For Front Roofliner

Detach mucket (1) in area of trim (2).
Pull back trim (2) in direction of arrow and remove.
Installation:
Make sure mucket (1) is correctly seated.
Fig. 518: Detaching Mucket In Area Of Trim

2010 BMW M3
INSTRUMENT CLUSTER TRIM

51 45 ... OVERVIEW OF INSTRUMENT PANEL
Fig. 519: Identifying Overview Of Instrument Panel

51 45 ... REMOVING AND INSTALLING CARRIER FOR INSTRUMENT PANEL
Remove instrument panel trim

2010 BMW M3
Disconnect all necessary cable ties on support tube

Release wiring harnesses/cable ducts and lay to one side
If necessary, remove control units/disconnect plug connections
WARNING: To avoid injury, cover holder (1) on support tube (2).
Fig. 520: Identifying Cover Holder And Support Tube

Detach wiring harness (3) from support tube (2).
Release screws (1) of heater on support tube (2).
Tightening torque 64 11 6AZ , see 64 11 HOUSING, HEATER/AIR CONDITIONER .
Fig. 521: Identifying Screws And Support Tube

2010 BMW M3
Release nuts (1) on right and left on support tube (2).
Tightening torque 51 71 5AZ , see 51 71 SEALS AND LOOSE BODY PARTS .
Fig. 522: Identifying Nuts And Support Tube

Release screw (1) of heater on support tube (2).
Tightening torque 51 71 6AZ , see 51 71 SEALS AND LOOSE BODY PARTS ..

Release screw (1) on support tube (2).

2010 BMW M3

Release screws (1) on support tube (2) from bracket (3).
Detach support tube (2) with a 2nd person helping and remove.
Fig. 525: Identifying Screws, Support Tube And Bracket

51 45 ... REPLACING SIDE COVER ON INSTRUMENT PANEL
00 9 340

2010 BMW M3
Pull off mucket of front door in area of cover
Unclip cover (1) with special tool 00 9 340 in direction of arrow from instrument panel trim (2).
If necessary, disconnect associated plug connection.
Fig. 526: Identifying Cover And Instrument Panel Trim


If replacing version with Isofix system version:
Remove switch for passenger airbag deactivation.
51 45 030 REMOVING AND INSTALLING INSTRUMENT PANEL TRIM

2010 BMW M3
protection). See 61 35 ... NOTES ON ESD PROTECTION (ELECTRO STATIC
DISCHARGE) .

Move front seats back completely and lower
Remove steering column . See 32 31 090 REMOVING AND INSTALLING/REPLACING
STEERING COLUMN .
Remove both trims for front roof pillar
Remove trim panel for pedal assembly
Remove INSTRUMENT CLUSTER .
Remove light operator unit 61 31 037 REMOVING AND INSTALLING/REPLACING LIGHT
CONTROL UNIT
Remove decorative strip on instrument panel on right
Remove operator unit for heating and air conditioning system . See 64 11 377 REMOVING AND
WITHOUT CCC/ASK) or 64 11 378 REMOVING AND INSTALLING/REPLACING
HEATER/AIR CONDITIONER OPERATOR UNIT (VERSION WITH CCC/ASK) .
Remove insert for radio control key . See 66 12 100 REMOVING AND
INSTALLING/REPLACING SLIDE-IN UNIT FOR RADIO CONTROL KEY .
In appropriate version:
Remove radio receiver . See 65 11 080 REMOVING AND INSTALLING/REPLACING
RADIO RECEIVER .
Remove audio system controller . See 65 12 200 REMOVING AND INSTALLING
(REPLACING) AUDIO SYSTEM CONTROLLER .
Remove Car Communication Computer . See 65 83 010 REMOVING AND
INSTALLING/REPLACING CAR COMMUNICATION COMPUTER .
If necessary, remove on-board monitor . See 65 82 050 REMOVING AND INSTALLING
(REPLACING) ONBOARD MONITOR .
Remove right glovebox with housing
RANGE SPEAKER, IN INSTRUMENT PANEL) .
If necessary, remove solar sensor . See 64 11 992 REMOVING AND INSTALLING/REPLACING
SOLAR SENSOR .
2010 BMW M3
Fig. 528: Identifying Instrument Panel

Pull back instrument panel trim (2) in direction of arrow.
Disconnect available plug connections and remove instrument panel trim (2).
Installation:
Make sure guides (2) on instrument panel trim (1) are correctly seated in respective mountings.
Make sure seals are correctly seated on air ducts.

2010 BMW M3
Fig. 529: Identifying Guides And Instrument Panel Trim

51 45 031 REPLACING INSTRUMENT PANEL TRIM
00 9 340
Remove instrument panel trim
Release screws (1).
Remove center function carrier (2) from instrument panel trim (3).
Fig. 530: Identifying Centre Function Carrier And Instrument Panel Trim
2010 BMW M3
Release screws (1).
Remove speaker receptacle (2) from instrument panel trim (3).
Fig. 531: Identifying Speaker Receptacle And Instrument Panel Trim

Remove airbag module on passenger side. See 72 12 000 REMOVING AND INSTALLING/REPLACING
AIRBAG MODULE ON PASSENGER SIDE .
Release screws (1).
Remove holder for airbag module on passenger side (2) from instrument panel trim (3).
Fig. 532: Identifying Passenger Side And Instrument Panel Trim

Unclip both side fresh-air grills (1) with special tool 00 9 340 in direction of arrow from instrument panel trim
(2).
Unclip cover for steering column opening (3) in direction of arrow from instrument panel trim (2).
2010 BMW M3
Fig. 533: Identifying Steering Column Opening And Instrument Panel Trim
Remove all metal nuts (2) and clips (3) from instrument panel trim (1).
Fig. 534: Identifying Metal Nuts, Clips And Instrument Panel Trim
51 45 181 REMOVING AND INSTALLING/REPLACING BOTTOM RIGHT TRIM FOR

INSTRUMENT PANEL
NOTE: Move front passenger seat completely towards rear.
Release screws (1).
Feed out trim (2) bottom front.
If necessary, detach plug from footwell light.

2010 BMW M3

Installation:
Replacement:
If necessary, remove footwell light . See 63 31 020 REMOVING AND INSTALLING/REPLACING

FOOTWELL LIGHT (FOOTWELL) .

51 45 185 REMOVING AND INSTALLING/REPLACING PANEL FOR PEDALS
Release screws (1).
Pull back trim for pedal assembly (2).
Disconnect associated plug connections and remove trim for pedal assembly (2).
2010 BMW M3
IMPORTANT: Disconnecting the plug connection for the hands-free system speaker results
in fault memory entries in the telephone control unit (limitation in the
emergency SOS call system).
Fig. 537: Identifying Screws And Pedal Assembly

Replacement (depending on Security version):
1. Modify speaker (Park Distance Control). See 66 20 565 REMOVING AND

INSTALLING/REPLACING FRONT SIGNAL SENSOR (PARK DISTANCE CONTROL) .
2. Modify footwell light . See 63 31 020 REMOVING AND INSTALLING/REPLACING
FOOTWELL LIGHT (FOOTWELL) .
3. Modify MOST direct access bracket
4. Modify Bluetooth aerial . See 84 50 060 REMOVING AND INSTALLING OR REPLACING
BLUETOOTH AERIAL .
5. Cut out opening for clutch pedal
Fig. 538: Identifying Most Direct Access Bracket And Bluetooth Aerial
2010 BMW M3
Replacement on right-hand drive up to model year 2005:
NOTE: It is necessary to rework the side trim panel because of modified locators on
the side trim panel and the panel for the pedal assembly from model year 2005.
Remove side trim panel (driver's side).
Cut off the first three upper ribs (1) on side trim panel (2) flat with a scalpel to contact face (3).
Fig. 539: Identifying Upper Ribs, Side Trim Panel And Contact Face
51 45 263 REMOVING AND INSTALLING/REPLACING INSTRUMENT PANEL TRIM ON RIGHT
00 9 321
Carefully release trim (1) with special tool 00 9 321 from retainers (3) and lock pins (2).
2010 BMW M3
Fig. 540: Identifying Trim, Retainers And Lock Pins

Installation:
Clips (Hutfix) (1) must be seated in associated mountings.
Replace clips (Hutfix) (1) if they were released during removal.
A. A Turn clip (Hutfix) (1) with screwdriver to left by approx. 90

B. B Lever out clip (Hutfix) (1) from below
Fig. 541: Identifying Clip (Hutfix)

Installation:
Lock pins (1) and retainers (3) on trim (2) must not be damaged.
If necessary, replace lock pins (1) and retainers (3).
Fig. 542: Identifying Pins, Retainers And Trim

2010 BMW M3
51 45 370 REMOVING AND INSTALLING (REPLACING) LEFT DECORATIVE STRIP ON

INSTRUMENT PANEL
00 9 317
Lever out left decorative strip on instrument panel (2) at fastening points (1) with special tool 00 9 317 and
remove in direction of arrow.
Fig. 543: Identifying Instrument Panel And Fastening Points

Replacement:
Unlock left fresh-air grill (1) at retaining lugs (2) and remove in direction of arrow from left decorative strip on
instrument panel (3).
Installation:
Make sure left fresh-air grill (1) is correctly seated in mountings (4) of left decorative strip on instrument panel
(3).
Make sure retaining lugs (2) are correctly seated in left decorative strip on instrument panel (3).
2010 BMW M3
Fig. 544: Identifying Retaining Lugs And Instrument Panel

51 45 380 REMOVING AND INSTALLING (REPLACING) RIGHT DECORATIVE STRIP ON

INSTRUMENT PANEL
00 9 317

Do not turn special tool 00 9 317 when levering out and pay attention to
pressure points.
Lever out right decorative strip (2) from left side beginning at retaining points (1) with special tool 00 9 317 .
Disconnect associated plug connection and remove decorative strip (2).
Fig. 545: Identifying Decorative Strip And Retaining Points

2010 BMW M3
Installation:
Clips (1) must be seated in associated mountings.
If necessary, remove clips (1) remaining on decorative strip.
Replace damaged clips (1):
A. A Turn clip (1) with screwdriver to left by approx. 90.

B. B Lever out clip (1) from below.

Replacement:
Remove Start/Stop switch . See 61 31 023 REMOVING AND INSTALLING/REPLACING

START/STOP SWITCH .
Remove switch for hazard warning system /central locking. See 61 31 079 REMOVING AND
INSTALLING/REPLACING SWITCH FOR HAZARD WARNING FLASHERS/CENTRAL
LOCKING .
Remove right fresh-air grill . See 64 22 138 REMOVING AND INSTALLING/REPLACING
RIGHT FRESH-AIR GRILL .
Remove center fresh air grill . See 64 22 162 REMOVING AND INSTALLING/REPLACING
CENTER FRESH-AIR GRILL .
PARCEL SHELF TRIM PAN

51 46 ... REMOVING AND INSTALLING/REPLACING TRIM ON REAR WINDOW SHELF
(PARCEL SHELF)

2010 BMW M3
Release rear-seat backrest and fold forward.
Release clips (1) and remove decorative trim (2) towards front.
Installation:
If necessary, replace clips (1).
Fig. 547: Identifying Clips And Decorative Trim

51 46 001 REMOVING AND INSTALLING PANEL FOR REAR WINDOW SHELF (PARCEL SHELF)
Remove left/right trim panel for roof pillar (C-pillar)

Remove rear mid-range speaker on left/right. See SPEAKERS .
Release bottom rear seat belts . See 72 11 092 REMOVING AND INSTALLING/REPLACING
REAR LEFT OR RIGHT SEAT BELTS and 72 11 101 REMOVING AND
INSTALLING/REPLACING REAR CENTER SEAT BELT .
Version with child seat holder:
Remove all Top Tether eyelets for child seat . See 72 14 ... REMOVING AND
INSTALLING/REPLACING TOP TETHER EYELETS FOR CHILD SEAT .
Remove backrest for rear seats. See 52 24 010 REMOVING AND INSTALLING / REPLACING
BACKREST .

2010 BMW M3
Remove trim on rear window shelf

Remove left/right armrest side sections . See 52 26 008 REMOVING AND
INSTALLING/REPLACING REST SIDE SECTION ON LEFT OR RIGHT REAR SEAT
BACKREST .
If necessary, remove drawer in luggage compartment
Release screws (1).
Tightening torque 51 46 3AZ , see 51 46 PANEL, REAR PARCEL SHELF, ROLLER SUN BLIND .


2010 BMW M3

All versions:
Remove plate (1).
Pay attention to catches (2).
Remove trim (1) and feed out from belt (3).
Fig. 550: Identifying Trim And Belt

Release clips (2).
All versions:
2010 BMW M3
Pull out rear window shelf (1) towards front and feed out belts (4).
Installation:
Make sure rear window shelf (1) is correctly fed under grid (3)
Fig. 551: Identifying Rear Window Shelf And Grid

51 46 004 REPLACING TRIM FOR ODDMENTS TRAY (BACK SHELF WITH REAR WINDOW
ROLLER BLIND AND THROUGH-LOADING SYSTEM)
Removing and installing/replacing trim for oddments tray (back shelf).
51 46 005 REMOVING AND INSTALLING TRIM FOR ODDMENTS TRAY (BACK SHELF WITH
REAR WINDOW ROLLER BLIND AND THROUGH-LOADING SYSTEM)
Removing and installing/replacing trim for oddments tray (back shelf) .
51 46 007 REPLACING PANEL FOR REAR WINDOW SHELF (PARCEL SHELF)
Remove panel for rear window shelf
Specification with tweeter/treble speaker:
Remove left/right tweeter . See 65 13 195 REMOVING AND INSTALLING/REPLACING REAR

TREBLE SPEAKER (IN REAR SHELF) .
2010 BMW M3
Remove trims (1).
Press roller sun blind (2) together at (A) in direction of arrow and press through from (A) to (B).
Remove roller sun blind (2) towards bottom.
Fig. 552: Identifying Trims And Roller Sun Blind

Specification with through-loading system:
Release nut (1) on underside of rear window shelf (2) and remove cap (3).
Fig. 553: Identifying Nut, Rear Window Shelf And Cap


2010 BMW M3
NOTE: Insulating mat is perforated in area "A".
Cut out opening (3) at moulding (2).
Drill areas "B" of opening (3) with 8 mm dia. drill bit and cut out remaining material at moulding (2) with a
scalpel.
Fig. 554: Identifying Opening And Moulding

Specification with Top Tether eyelets for child seat:
NOTE: Insulating mat is perforated in areas "A".

Cut out opening (3) at moulding (2) with a scalpel.
2010 BMW M3
Fig. 555: Identifying Panel Material

51 46 013 REMOVING AND INSTALLING/REPLACING REAR WINDOW ROLLER BLIND
Removing and installing/replacing trim for oddments tray (back shelf) .
51 46 025 REMOVING AND INSTALLING/REPLACING TRIM ON AIR OUTLET GRILLE
Removing front air outlet grille
51 46 026 REMOVING AND INSTALLING OR REPLACING FRONT AIR OUTLET TRIM GRILLE
00 9 323
Remove trim cover on rear left/right rollover protection system . See 54 62 010 REMOVING AND
INSTALLING OR REPLACING TRIM COVER ON LEFT OR RIGHT ROLLBAR .
Remove upper section of side trim panel , left/right.
Tilt backrest forwards.
Open lid for retractable hardtop, fold in retractable hardtop if necessary
Lift trim cover (1) out of retainers (2) with special tool 00 9 323 and feed out towards rear.
2010 BMW M3
Installation:
Fig. 556: Lifting Trim Cover Of Retainers With Special Tool 00 9 323
Unclip trim cover (1) on left/right forwards.
Fig. 557: Identifying Trim Cover

Pull off cover (1) downwards.
Tightening torque 51 46 5AZ, see 51 46 PANEL, REAR PARCEL SHELF, ROLLER SUN BLIND .
2010 BMW M3
Fig. 558: Identifying Lever Out Covers

Release clips (1).
Release screws (2).
Remove seat belts (3) from trim grille (4).
Detach trim grille (4) by lifting upwards.
Installation:
Remove all screws/clips on trim grille (4).
Align trim grille (4) with rollover protection system and secure screws/clips.
Fig. 559: Identifying Seat Belts, Trim Grille With Clips And Screws
2010 BMW M3
51 46 050 REMOVING AND INSTALLING/REPLACING TOP TRIM ON REAR APRON
Remove luggage compartment floor trim (luggage compartment mat)
Detach seal (1) in covered area of trim (4).
Lever out protective caps (2) and release screws underneath.
Lever out trim (4) inwards/upwards.
Installation:
If necessary, replace damaged protective caps (2) and expander rivets (3).
Fig. 560: Identifying Protective Caps And Expander Rivets

Replacement:
Lift off cover (1).
If necessary, feed out universal holders (2).

2010 BMW M3
Fig. 561: Identifying Universal Holders

FLOOR LUGGAGE COMPARTMENT

51 47 ... OVERVIEW OF LUGGAGE COMPARTMENT TRIM PANELS
2010 BMW M3
Fig. 562: Identifying Luggage Compartment Trim Panels Components

51 47 ... REMOVING AND INSTALLING/REPLACING BATTERY COVER
Remove luggage compartment trim on side panel on right
Release clips (1).
Remove battery cover (2).
Installation:
2010 BMW M3
Make sure battery cover (2) is correctly seated on panel (3).
Fig. 563: Identifying Battery Cover On Panel

51 47 ... REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT UNDERBODY

PANELLING
Installation:

2010 BMW M3
Fig. 564: Identifying Expander Rivet And Plastic Nuts

Replacement
Fig. 565: Identifying Expander Rivets And Lip

51 47 ... REMOVING AND INSTALLING/REPLACING STORAGE TRAY IN LUGGAGE

COMPARTMENT ON LEFT
Remove luggage compartment trim on left side panel
Release clips (1).

2010 BMW M3
Remove storage tray (2).
Installation:
Make sure storage tray (2) is correctly seated on panel (3).
Fig. 566: Identifying Storage Tray On Panel

51 47 ... REMOVING AND INSTALLING STORAGE TRAY IN LUGGAGE COMPARTMENT ON

LEFT
Disengage storage tray (1) in upward direction from catches (2) and remove.

51 47 ... REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT UNDERBODY

PANELLING
2010 BMW M3

Installation:
Fig. 568: Identifying Faulty Expander Rivet

Replacement:

2010 BMW M3
Fig. 569: Identifying Expander Rivets And Modify Lip

51 47 000 REMOVING AND INSTALLING/REPLACING FRONT (INSIDE) LEFT OR RIGHT

00 9 317
IMPORTANT: Do not raise entrance cover strip (1) over entire length simultaneously.
Using special tool 00 9 317 , unclip entrance cover strip (1) from clips (2) starting at rear and proceeding
forwards.
Fig. 570: Identifying Entrance Cover Strip And Clips

2010 BMW M3
If necessary, lever clips (1) out of floor pan (2) and attach to entrance cover strip.
Fig. 571: Identifying Clips And Floor Pan

Installation:
If necessary, replace faulty clips (1) on entrance cover strip (2).
Fig. 572: Identifying Faulty Clips And Entrance Cover Strip

51 47 030 REMOVING AND INSTALLING/REPLACING REAR (INSIDE) LEFT OR RIGHT

00 9 317

2010 BMW M3
Remove rear seat . See SEATS - REPAIR .
Release expansion rivet (1).
Unclip clips (2) on entrance cover strip (3) with special tool 00 9 317 .
Remove entrance cover strip (3) towards top.
Fig. 573: Identifying Clips And Entrance Cover Strip

Installation:
Fit entrance cover strip (2) with preinstalled clips (1).
Fig. 574: Identifying Entrance Cover Strip And Clips

2010 BMW M3
51 47 065 REMOVING AND INSTALLING / REPLACING FINISHING STRIP AT FRONT LEFT OR

RIGHT ENTRANCE
00 9 317

Do not raise finishing strip (2) over entire length simultaneously.
Unclip clips (1) for finishing strip (2) with special tool 00 9 317 .
Remove finishing strip (2).
Fig. 575: Identifying Clips And Finishing Strip

Installation:

2010 BMW M3
Fig. 576: Identifying Faulty Clips

51 47 072 REMOVING AND INSTALLING/REPLACING FINISHING STRIP AT REAR LEFT OR

RIGHT ENTRANCE
Replacing front left or right entrance cover strip.

TRIM PANEL
Open rear lid.
Fig. 577: Identifying Luggage Compartment Floor Trim

51 47 140 REMOVING AND INSTALLING/REPLACING PANEL FOR LUGGAGE COMPARTMENT

PARTITION
2010 BMW M3
Version with ski bag:
Remove ski bag
Open lid for lowerable hardtop.
If necessary, extend lowerable hardtop.
Release screw (1).
Release clips (2).
Raise trim (3) slightly and feed out panel (4).
Installation:
Fig. 578: Identifying Feed Out Panel And Clips

51 47 143 REMOVING AND INSTALLING/REPLACING PANEL FOR PASSENGER

COMPARTMENT PARTITION
Remove rest side section on left/right. See SEATS - REPAIR .
Version with ski bag:

2010 BMW M3
Remove trim for ski bag
Pull off cover (1) downwards.
Unclip trims (2).
Release screw (3) and clips (4).
Fig. 579: Identifying Trims, Screw And Clips

Pull panel (1) towards rear and thereby release clips (2) and retainers (3).
Feed out trim (1).
Installation:
If necessary, replace faulty clips (2) and retainers (3).
Fig. 580: Identifying Feed Out Trim With Clips And Retainers
2010 BMW M3
Installation:
After removal clips can be in position A.
For installation clips must be in position B.
Fig. 581: Identifying Clips In Position A

51 47 151 REMOVING AND INSTALLING/REPLACING LEFT LUGGAGE COMPARTMENT

WHEEL ARCH TRIM (CONVERTIBLE/COUPE)
Remove luggage compartment trim on side panel . See 51 47 210 Removing and installing/replacing
trunk trim panel on left side panel or 51 47 220 Removing and installing/replacing luggage
compartment trim panel on right side panel.
Remove locating bracket for folding roof . See 54 37 232 REMOVING AND INSTALLING
SUPPORT BLOCK .
If necessary, remove storage tray . See 51 47 ... Removing and installing/replacing battery cover or
51 47 ... Removing and installing storage tray in luggage compartment on left.
Release clips (1).
Lever out panel (2) on mucket (3).
NOTE: Do not detach mucket (3) from body.
Feed out panel (2) in direction of arrow.

2010 BMW M3
Fig. 582: Identifying Lever Out Panel On Mucket And Clips

51 47 151 REMOVING AND INSTALLING / REPLACING LEFT LUGGAGE COMPARTMENT

WHEEL ARCH TRIM
Remove trim on rear apron

If necessary, remove storage tray. See 51 47 ... Removing and installing/replacing storage tray in
luggage compartment on left in luggage compartment on left.
Fold down backrest for left rear seat
Lever out socket (1) in direction of arrow and disconnect plug connection.
Fig. 583: Identifying Socket

2010 BMW M3
Installation:
Guide (1) and catches (2) must not be damaged.
Fig. 584: Identifying Guide And Catches

Remove warning triangle (1).
Turn bracket (2) approx. 90 in counterclockwise direction and remove.
Turn bracket (3) approx. 90 in clockwise direction and remove.
Fig. 585: Identifying Bracket And Expansion Rivets

Release screw (1) and remove trim (2).
Pull out luggage compartment wheel arch trim (3) in inwards direction.
2010 BMW M3
Fig. 586: Identifying Screw And Trim

Installation:
Remove rear seat . See SEATS .

Unscrew screws (1).
Tightening torque 52 24 01AZ , see 52 24 REAR SEAT (NORMAL), MANUAL .

2010 BMW M3
Replacement:
If necessary, release trim (1) at catches (2) from interior and remove rubber pull (3).
Fig. 588: Identifying Trim, Catches And Rubber Pull

51 47 161 REMOVING AND INSTALLING/REPLACING RIGHT LUGGAGE COMPARTMENT

WHEEL ARCH TRIM (CONVERTIBLE/COUPE)
Operation is identical to: Removing and installing/replacing trunk wheel housing trim, left.
51 47 161 REMOVING AND INSTALLING / REPLACING RIGHT LUGGAGE COMPARTMENT

WHEEL ARCH TRIM
Remove trim on rear apron

Remove flap in luggage compartment panel
Fold down backrest for right rear seat
Specification with pocket holder:
Pull expander rivets (1) out of pocket holder (2) and remove pocket holder (2).
2010 BMW M3
Fig. 589: Identifying Expander Rivets And Pocket Holder

Release clips (1).
Feed out luggage compartment wheel arch trim (4) in direction of arrow.
Fig. 590: Identifying Screw And Cover

Installation:
Remove rear seat . See SEATS - REPAIR .

Unscrew screws (1).
2010 BMW M3

Replacement:
If necessary, release retainers (1) on back of luggage compartment wheel arch trim (2) and remove securing net
(3).
Fig. 592: Identifying Retainers, Luggage Compartment Wheel Arch Trim And Securing Net
51 47 171 REMOVING AND INSTALLING/REPLACING FLAP IN LUGGAGE COMPARTMENT

TRIM ON RIGHT
Turn fastener (1) 90 to left.
Open flap (2) in luggage compartment trim and remove.

2010 BMW M3
Fig. 593: Identifying Fastener And Flap

51 47 202 REMOVING AND INSTALLING COVER FOR LUGGAGE COMPARTMENT
Raise cover (1) slightly.
Fig. 594: Identifying Cover And Screws

Installation:
Cover (1) must fit correctly into locators (2) on left and right.
2010 BMW M3
Fig. 595: Installing Cover In Locators

51 47 203 REMOVING AND INSTALLING/REPLACING TRIM FOR LUGGAGE COMPARTMENT

AT REAR LEFT OR RIGHT
IMPORTANT: Risk of damage to roofliner!

When the trim is removed, the lowerable hardtop must not be stowed in the
luggage compartment.
Tensioning straps can get caught in the hardtop mechanism and tear when the
hardtop is closed.
Turn clip (1) through 90.
Detach trim (2) in direction of arrow from retainers (2).
Installation:
Clip (1) and retainers (3) must not be damaged.

2010 BMW M3
Fig. 596: Identifying Clip And Retainers

51 47 205 REMOVING AND INSTALLING/REPLACING PANEL FOR LUGGAGE COMPARTMENT

SIDE MEMBER ON LEFT OR RIGHT

Remove panel for main bearing
Remove panel for luggage compartment at rear
Left side only
Version with CD changer:

Remove luggage compartment side panel
Version without CD changer:

Remove storage tray
Right side only
Remove battery cover

Remove luggage compartment light . See 63 31 080 REMOVING AND
INSTALLING/REPLACING LUGGAGE COMPARTMENT LIGHT .
Release clips (1).
Lever out panel (2) from trim (3) and feed out towards inside.
Fig. 597: Identifying Lever Out Panel From Trim And Clips
2010 BMW M3
51 47 207 REMOVING AND INSTALLING/REPLACING PANEL FOR MAIN BEARING ON LEFT

OR RIGHT
If necessary, close lowerable hardtop.
Slide luggage compartment cover until panel (1) is easily accessible.
Release panel (1) in upward direction from retainers (2) and catches (3).
Fig. 598: Identifying Panel In Upward Direction From Retainers And Catches
Installation:
(2) Clips
(3) Guides
(4) Catch
(5) Retainer
Make sure panel (1) is correctly seated on all retaining elements.

2010 BMW M3
Fig. 599: Identifying Clips, Guides, Catch And Retainer

51 47 210 REMOVING AND INSTALLING/REPLACING TRUNK TRIM PANEL ON LEFT SIDE

PANEL
Remove panel for luggage compartment at rear.
Release clip (1) and remove cover.
Fig. 600: Identifying Trunk Trim Panel Cover And Clip

Version with CD changer:

2010 BMW M3
Release clips (1).
Feed out panel (3) on mucket (2).
Release panel (3) at retainers (4) and feed out in upward direction.
Fig. 601: Identifying Feed Out Panel On Mucket And Clips

Installation:
If necessary, replace faulty clips (1) and retainers (4).
Version without CD changer:
Open flap (1).
Release clips (2).

2010 BMW M3
Fig. 602: Identifying Open Flap And Clips

Release clips (1).
Feed out panel (3) on mucket (2).
Fig. 603: Identifying Feed Out Panel On Mucket And Clips

Installation:
Lugs (1) of panel (2) must be correctly seated on storage tray (3).
2010 BMW M3
Fig. 604: Identifying Lugs Of Panel On Storage Tray

51 47 220 REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT TRIM

PANEL ON RIGHT SIDE PANEL
Remove panel for luggage compartment at rear.

Remove flap in luggage compartment panel.
Release clip (1) and remove cover (2).
Fig. 605: Identifying Clip And Cover

Release clips (1) and feed out panel (2).

2010 BMW M3
Fig. 606: Identifying Feed Out Panel And Clips

51 47 312 REPLACING FOOTREST FOR FRONT PASSENGER COMPARTMENT
Remove trim panel for pedal assembly
NOTE: Footrest is either bonded to carpet or secured with retaining rings from rear to
carpet.
Attachments with retaining rings are drilled out

Bonded footrest is detached with a hot air blower
The attachment points must always be drilled out first.
Place drilling hole template (1) on footrest (2) and align to outer edge of footrest (2).
Mark bore holes with punch and remove drilling hole template (1).
Drill out attachment points.
I. Predrill to 3 mm dia.
II. Drill out to 10 mm dia.
NOTE: If the footrest (2) is not bonded, it can be removed now. Continue with the next
work step but one.
2010 BMW M3

Bonded footrest only:
NOTE: Adhesive bead must remain on carpet (risk of damage).

Heat footrest (1) with hot air blower and thereby release adhesive bead from
footrest (1).
If necessary, pull off footrest (1) in inward direction.

Only when fitting retaining rings:
Remove left footwell side trim panel.
Drive through pins (1).
Fold carpet (2) inwards slightly and remove pins (1).

2010 BMW M3
Fig. 609: Identifying Carpet And Pins

Installation:
Heat footrest (1) with hot air blower and apply adhesive bead along dashed line (2) with hot-melt adhesive gun.
Place footrest (1) on carpet and stick on.
Press footrest (1) down until adhesive bead has cooled down.

51 47 315 REMOVING AND INSTALLING / REPLACING FRONT CARPET FOR PASSENGER

COMPARTMENT

Remove left/right front seat . See SEATS - REPAIR (CONVERTIBLE/COUPE) or SEATS -
2010 BMW M3
REPAIR (CONVERTIBLE/COUPE) .
Remove glovebox
Remove side trim panel in footwell on left/right. See 51 43 070 Removing and installing/replacing
side trim panel, footwell, on A-pillar, left (driver side) and 51 43 075 Removing and installing /
replacing side trim panel, footwell, on A-pillar, right.
Remove accelerator pedal module . See 35 40 001 REMOVING AND INSTALLING OR
REPLACING ACCELERATOR PEDAL MODULE .
Remove central bass speaker trim on left/right. See 65 12 050 REMOVING AND
INSTALLING/REPLACING LEFT OR RIGHT CENTRAL BASS SPEAKER (UNDER FRONT
SEAT) .
Remove holders (1) towards front.
Pull out air duct (2).
Fig. 611: Identifying Holders And Air Duct

Cut out carpet (1) at cutting edge (2) on left/right.

Make the cut as far as possible in the direction of the middle of the car to
ensure that the cutting edges are covered by the storage compartment/panels.
2010 BMW M3


Cut out carpet (1) at cutting edge (2).
Guide cable back through carpet (1).
Feed out carpet (1) towards rear/top.

Cutting edges (1) shown on removed carpet (2).
Installation:
Apertures (3) serve as alignment points for fitting the carpet (2).
2010 BMW M3
Replacement:
Place removed carpet on new carpet and carry over cuts to new carpet.
Fig. 614: Identifying Edges And Carpet

51 47 440 REMOVING AND INSTALLING/REPLACING REAR CARPET ON SEAT PAN (SEDAN)
Remove left/right front seat . See SEATS - REPAIR (CONVERTIBLE/COUPE) or SEATS -

REPAIR (CONVERTIBLE/COUPE) .
Remove rear seat . See SEATS - REPAIR (CONVERTIBLE/COUPE) or SEATS - REPAIR
(CONVERTIBLE/COUPE) .
Remove handbrake lever . See 34 41 000 REMOVING AND INSTALLING / REPLACING
HANDBRAKE LEVER .
Remove trim panel for door pillar on left/right.
Remove entrance cover strip at rear inside.
SEAT) .
Remove holder (1).
Installation:
2010 BMW M3
Fig. 615: Identifying Cable And Cable Holder

51 47 440 REMOVING AND INSTALLING/REPLACING REAR CARPET ON SEAT PAN

(CONVERTIBLE/COUPE)
Remove left/right front seat . See SEATS - REPAIR (CONVERTIBLE/COUPE) .

Remove handbrake lever . See 34 41 000 REMOVING AND INSTALLING / REPLACING
HANDBRAKE LEVER .
Remove rear side trim left/right.
Remove inside entrance cover strip
SEAT) .
E92 only:
Lever out cap (1).
Release bolt (2).
Tightening torque 72 11 5AZ, see 72 11 SEAT BELTS .
Feed out belt and slide bar.

2010 BMW M3
Installation:
Make sure slide bar and grommet are correctly positioned.
Check that spacer bushing (3) and rubber ring (4) are in correct position.
Fig. 616: Identifying Spacer Bushing And Rubber Ring

Remove holder (1).
Installation:
Fig. 617: Identifying Back Cable With Cable Holder

51 47 490 REMOVING AND INSTALLING / REPLACING FRONT UNDERBODY PROTECTION

2010 BMW M3


Release screws (1 and 2) on both sides.
Installation:
Fig. 619: Identifying Engine Compartment Shield

2010 BMW M3
WARNING: Danger of burning on oil line!
Turn catch (1) on cable through 90 and disengage in direction of arrow from bracket (2) on both sides.
Pull underbody protection (3) forwards under bumper trim and remove.
Installation:
Centre underbody protection (3).
Fig. 620: Identifying Underbody Protection

Replacement:
Modify sheet nuts
Installation:
51 47 491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION

Tasks should only be carried out on an exhaust system that has cooled
down.
Unscrew nuts (3).
Pull out underbody protection (4) in direction of arrow towards bottom.

2010 BMW M3
Installation:
Ensure correct seating.
Centre underbody protection (4) before tightening down screws (1 and 2).
Fig. 621: Identifying Underbody Protection

Replacement:
Modify sheet nuts
Installation:
See 51 75 001 Removing and installing/replacing left or right underbody cover.
FRONT LID INSULATION

51 48 ... REMOVING AND INSTALLING/REPLACING SOUND INSULATION ON COWL
PANEL/WINDSCREEN
Windscreen
2010 BMW M3
Replacement:
Fig. 622: Identifying Tape And Bulkhead Upper Section


2. Windscreen
3. Glue bead
51 48 001 REMOVING AND INSTALLING/REPLACING INSULATION LINING ON

HOOD/BONNET
NOTE: Illustration created using the E87 as an example. There may be differences in
Release threaded rivets (1) on insulation lining (2).
Remove insulation lining (2).
Installation:
If necessary, replace defective threaded blind rivets (1).

2010 BMW M3
Fig. 623: Identifying Threaded Rivets And Insulation Lining


RIGHT FRONT DOOR
00 9 317
Remove door trim panel (sedan) or 51 41 001 Replacing front left or right door trim panel
(convertible/coupe)
Using special tool 00 9 317 , lever out sealing bead (1) completely or if necessary partially.
Installation:
Ensure clean bonding and that there are no leaks at sealing bead.
2010 BMW M3
Fig. 624: Identifying Cable And Sound Insulation

Installation:
In case of replacement or partial detachments, lay butylene tape (sourcing reference: BMW Parts Service)
depending on the conditions on inner door panel or sound insulation.
Seal cable penetrations with butylene tape.
NOTE: Position of butylene tape (1) on sound insulation (2).
Fig. 625: Identifying Butylene Tape And Sound Insulation

Butylene tape (3) rests on or inside the marking (2).
2010 BMW M3

Clean adhesive area on inner door panel with adhesive cleaner (sourcing reference: BMW Parts Service).
Lay 6 mm dia. butylene tape in a single row (sourcing reference: BMW Parts Service) in specified adhesive
area on acoustic insulation.

RIGHT REAR DOOR
00 9 317

2010 BMW M3
Using special tool 00 9 317 , lever out sealing bead (1) of sound insulation (3) completely or if necessary
partially.
Installation:
Ensure clean bonding and that there are no leaks at sealing bead.
Fig. 627: Identifying Wires And Sound Insulation

Installation:
In case of replacement or partial detachments, lay butylene tape (sourcing reference: BMW Parts Service)
depending on the conditions on inner door panel or sound insulation.
Seal cable penetrations with butylene tape.
NOTE: Position of butylene tape (1) on sound insulation (2).

2010 BMW M3

Butylene tape (3) rests on or inside the marking (2).
Fig. 629: Identifying Sound Insulation And Butylene Tape

Clean adhesive area on inner door panel with adhesive cleaner (sourcing reference: BMW Parts Service).
Lay 6 mm dia. butylene tape in a single row (sourcing reference: BMW Parts Service) in specified adhesive
area on acoustic insulation.
2010 BMW M3
Manual contact pressure: approx. 10 N/cm 2
REAR LID TRIM PANEL

51 49 ... REMOVING AND INSTALLING/REPLACING TRIM FOR REAR LID ON LEFT OR RIGHT
Unfasten clip (1).
Remove trim (2) in direction of arrow.
Fig. 630: Removing Trim In Direction And Clip

51 49 000 REMOVING AND INSTALLING/REPLACING PANEL FOR REAR LID
Version with emergency release:
Detach handle (1) from clip (2).
Disconnect Bowden cable (3) from handle (1).
Installation:
Guide Bowden cable (3) through clip (2) and connect correctly in handle (1).
2010 BMW M3
Fig. 631: Identifying Bowden Cable, Clip And Handle

Release clips (1) and remove panel (2).
Installation:
If necessary, replace damaged clips (1).
Fig. 632: Identifying Clips And Panel

REINFORCEMENT BODY
51 61 ... REMOVING AND INSTALLING/REPLACING FRONT ROLLOVER PROTECTION
SYSTEM STRUT

Driving without the strut is not permitted!

2010 BMW M3
Remove backrest . See 52 24 010 REMOVING AND INSTALLING / REPLACING BACKREST .

Remove panel for passenger compartment partition
Release screws (1).
Tightening torque 51 71 27AZ, see 51 71 SEALS AND LOOSE BODY PARTS ..
Release screws (2) and remove strut (3).
Installation:
Replace all screws.
Fig. 633: Identifying Front Rollover Protection System Strut And Screws
51 61 ... REMOVING AND INSTALLING/REPLACING PROTECTING SKID/MOUNTING

BRACKET
IMPORTANT: Observe safety instructions for raising the vehicle.

Driving without the protective skid/mounting bracket is not permitted! See 00 ...
... LIFTING VEHICLE WITH A LIFTING PLATFORM .
Release screws (1).

2010 BMW M3
Release screw (3).
Release screws (2) and remove protective skid (4).
Installation:
Replace all screws.
Middle lug of protective skid must be situated between mounting bracket and left diagonal strut.
Fig. 634: Identifying Protective Skid And Screws

Mounting bracket
2010 BMW M3
Gently pull V-struts (1) downwards and remove mounting bracket (2) towards rear.
Installation:
Make sure mounting bracket is correctly positioned.
Fig. 635: Identifying V-Struts And Mounting Bracket

51 61 011 REMOVING AND INSTALLING/REPLACING V-STRUT, FRONT AXLE CARRIER, LEFT

OR RIGHT
IMPORTANT: Observe safety instructions for raising the vehicle

Driving without the V-strut is not permitted! See 00 ... ... LIFTING VEHICLE
WITH A LIFTING PLATFORM .
Release screws (1, 2, 3).
Remove V-strut (4) towards front.
Installation:
Replace screws.
Make sure bolts are installed in correct positions.
Screw (1) M8x55

Screw (2) M8x35
Screw (3) M10x35
2010 BMW M3
Fig. 636: Identifying V-Strut And Screws

51 61 017 REMOVING AND INSTALLING/REPLACING DIAGONAL STRUT, FRONT END, LEFT


Driving without the diagonal strut is not permitted! See 00 ... ... LIFTING
VEHICLE WITH A LIFTING PLATFORM .

If necessary, remove radiator seal
N51, N52, N53: Remove intake filter housing
IMPORTANT: Diagonal strut on right side must be installed in direction of travel ahead of
diagonal strut on left side.
Release screws (1) and nuts (2).
Feed out diagonal strut (3) towards top.
Installation:
Replace screws.
Replace self-locking nut.

2010 BMW M3
Fig. 637: Identifying Feed Out Diagonal Strut With Screws And Nuts
51 61 018 REMOVING AND INSTALLING/REPLACING DIAGONAL STRUT, FRONT END, RIGHT


Driving without the diagonal strut is not permitted! See 00 ... ... LIFTING
Remove front underbody protection .

If necessary, remove radiator seal.
IMPORTANT: Diagonal strut on right side must be installed in direction of travel ahead of
diagonal strut on left side.
Release screws (1) and nuts (2).
Feed out diagonal strut (3) towards top.
Installation:
Replace screws.

2010 BMW M3
Fig. 638: Identifying Feed Out Diagonal Strut With Screws And Nuts
GASKETS, SEALS
51 71 ... NOTES ON FITTING COVERS IN FRONT WHEEL ARCH
IMPORTANT: Make sure all covers in wheel arch are correctly seated in relation to each
other.
E90/E91/E92:

2010 BMW M3
Fig. 639: Identifying Covers

E93:

Fig. 640: Identifying Covers

51 71 ... REMOVING AND INSTALLING/REPLACING COVER FOR CARBON CANISTER
Version, carbon canister, side:
Press thermal insulation (3) to one side slightly and feed out cover (4).
Fig. 641: Identifying Thermal Insulation And Cover

2010 BMW M3
Version, carbon canister, middle:
Fig. 642: Identifying Screws And Cover

51 71 ... REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT STEERING GEAR

COVER
If necessary, remove left or right front wheel.
Prior to removing, pay attention to the exact installation position with respect to
right side.
Release screw (1) and plastic nuts (2).
Feed out cover (3) and remove.
Installation:
Observe notes on fitting cover (3).

2010 BMW M3
Fig. 643: Identifying Screw And Plastic Nuts

51 71 ... REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT SUSPENSION CROSS-

BRACE RING

to the body).
Remove suspension cross-brace
right side.
2010 BMW M3

Release nuts (2) and remove suspension cross-brace ring (3).
Tightening torque 31 31 1AZ , see 31 31 SPRING STRUTS .
Installation:
Replace nuts (2).
Fig. 645: Identifying Protective Cap And Nuts

51 71 ... REMOVING AND INSTALLING/REPLACING LEFT SPRING SUPPORT PASSAGE COVER
If necessary, remove left front wheel .

Release catch (1) and remove cover (2).
Installation:

2010 BMW M3
Fig. 646: Identifying Catch And Cover

51 71 ... REMOVING AND INSTALLING/REPLACING LEFT/RIGHT REINFORCEMENT COVER
Remove reinforcement cover (3).
Installation:
Make sure reinforcement cover (3) is correctly seated.
Fig. 647: Identifying Screws And Reinforcement Cover

51 71 ... REMOVING AND INSTALLING/REPLACING MULTIFUNCTION PAN (SEDAN)

2010 BMW M3
Remove luggage compartment trim panels

Remove exhaust system. See 18 00 018 REMOVING AND INSTALLING COMPLETE EXHAUST
SYSTEM (S65) .
Fig. 648: Identifying Vacuum Line And Screws

Release screws (1).
Fig. 649: Identifying Screws And Heat Shields

2010 BMW M3
Unclip line (1).
Fig. 650: Identifying Line And Screws

Fig. 651: Identifying Nuts And Multifunction Pan

Installation:
2010 BMW M3
Fig. 652: Identifying Seals And Multifunction Pan

51 71 ... REMOVING AND INSTALLING/REPLACING MULTIFUNCTION PAN

(CONVERTIBLE/COUPE)
Remove top trim from tail panel.

Disconnect battery negative lead. See 61 20 900 DISCONNECTING AND CONNECTING
Remove CD changer.
Release screws (1).
Remove guide (2).
Fig. 653: Identifying Guide And Screws

2010 BMW M3
Release screw (1).

Release screws (1).
Remove cover (2).

Release screw.
Release screws (1).
Carefully remove carbon canister (2) and secure against falling off.
2010 BMW M3
Fig. 656: Identifying Carbon Canister And Screws


Release screws and remove holder (1).

2010 BMW M3
Fig. 658: Identifying Holder And Screws

Cut open cable tie (1).
Lift out expansion rivet (2).
Unclip wiring harness (3).
Release screws and remove mounting (4).
Fig. 659: Identifying Wiring Harness And Expansion Rivet

Release screw.
Lift out expansion rivet (1).

2010 BMW M3
Carefully lay hydraulic lines (3) to one side.
Fig. 660: Identifying Expansion Rivet And Lay Hydraulic Lines

Unclip battery positive lead (1).
Unclip wiring harness (2).
Release nut (3) and disconnect ground cable.
Tightening torque 51 71 16AZ, see 51 71 SEALS AND LOOSE BODY PARTS .
Release screw and remove mounting (4).
Fig. 661: Identifying Battery Positive Lead, Wiring Harness And Nut
Release nuts along line.

2010 BMW M3
Remove video module (1) and carefully place to one side.
Remove hydraulic control unit (2), carefully place to one side and secure.
Unlock and disconnect holder (3).
Remove multifunction pan.
Fig. 662: Identifying Hydraulic Control Unit And Video Module

Installation:

2010 BMW M3
51 71 ... REMOVING AND INSTALLING/REPLACING RADIATOR SEAL

IMPORTANT: Observe safety instructions for raising the vehicle. See 00 ... ... LIFTING
Remove front underbody protection .
Release screws (1).
If necessary, remove underbody protection bracket.
Release catches (2) and feed out radiator seal (3) towards rear.
Fig. 664: Identifying Catches And Radiator Seal

Installation:

2010 BMW M3

51 71 ... REMOVING AND INSTALLING/REPLACING RIGHT SPRING SUPPORT PASSAGE

COVER
If necessary, remove right front wheel.

Release expander rivet (1) and remove cover (2).
Installation:

2010 BMW M3
Fig. 666: Identifying Expander Rivet And Cover

51 71 ... REMOVING AND INSTALLING/REPLACING REAR MIDDLE TENSION STRUT (FROM

03/2007)
Driving without the tension strut is not permitted!
Release bolts (1, 2, 4) and remove tension strut (3).
Installation:
First fasten all bolts provisionally and then tighten down.
Screw (1) M12x50
Screw (4) M8x25
Tightening torque 51 71 13AZ, see 51 71 SEALS AND LOOSE BODY PARTS

2010 BMW M3
Fig. 667: Identifying Tension Strut And Bolts

IMPORTANT: Rear tension strut must be installed below the right tension strut!
51 71 ... REMOVING AND INSTALLING/REPLACING REAR MIDDLE TENSION STRUT (UP TO

03/2007)
Release screws (1, 2).
Remove tension strut (3).
Installation:

2010 BMW M3
Fig. 668: Identifying Tension Strut And Screws

51 71 ... REPLACING CONVERTIBLE TOP COMPARTMENT LID SEAL
Fig. 669: Opening Rear End Module

Release sheet screw (1) and thin sheet screw (2) on left and right.
2010 BMW M3
Installation:
Fig. 670: Identifying Sheet Screw And Thin Sheet Screw

Retract folding roof fully and open rear end cover.
IMPORTANT: Do not stretch, kink or crush seal.
Pull off seal (1) from left to right.
Installation:
Moisten seal with soapy water.
Carry out installation from left to right (check screw fastening points).
Fig. 671: Pulling Off Seal

2010 BMW M3
51 71 000 REMOVING AND INSTALLING / REPLACING SEAL ON FRONT DOOR, LEFT OR

RIGHT (SEDAN)
Follow repair instructions for bonded seals. See 54 0 ... REPAIR INSTRUCTIONS FOR BONDED
SEALS .
Remove cover on inside door window frame.
Release door retainer from door pillar.
NOTE: The positioning of the seal must be established in three areas of the front door
Position of seal (3) on front door:
Fig. 672: Front Door Seal Position Chart

Area (A) at distance (G) to door rabbet.

2010 BMW M3
Area (C) at distance (E) to door inner panel.
Area (D) at distance (F) to door fold.
E = 57 mm
F = 4 mm
G = 2.8 mm
Fig. 673: Positioning Aid A1 For Front Door, Left (B1 Right)
Detach prestamped positioning aid from backing.
Positioning aid "A1" front door, left (door lock, top)

2010 BMW M3
Positioning aid "B1" front door, right (door lock, top)
Positioning aid "A2" front door, left (door lock, bottom)

Positioning aid "B2" front door, right (door lock, bottom)
2010 BMW M3
Positioning aid "A3" front door, left (below door retainer)

Positioning aid "B3" front door, right (below door retainer)

2010 BMW M3
IMPORTANT: Do not grip bonding surface

(approx. 10 ... 15 N/cm2 ) which is decisive here.
Separation of seal after pressing destroys the adhesive layer
sections.
Position seal with color coding on door window frame at rear top.

2010 BMW M3
51 71 000 REMOVING AND INSTALLING / REPLACING SEAL ON FRONT DOOR, LEFT OR

RIGHT (CONVERTIBLE/COUPE)
NOTE: Work shown on E92 way of example, deviations in detail are possible in other
vehicle models.
Unclip seal (1) in direction of arrow from front door.
Installation:
Make sure seal (1) is correctly seated on window guide (2).
Fig. 677: Identifying Seal On Front Door

Installation:
Clips (1) on seal (2) must not be damaged.
Fig. 678: Identifying Clips On Seal

2010 BMW M3

COVER (FRONT SECTION)
If necessary, remove front wheel

Release nuts (3) and remove wheel arch cover (4).
Installation:
Fig. 679: Identifying Nuts And Wheel Arch Cover

Replacement:
Modify cover (1)

2010 BMW M3


COVER (REAR SECTION)
If necessary, remove front wheel
NOTE: In event of further work, where possible, leave wheel arch cover on vehicle.
Wheel arch cover must not be cut.
In case of complete removal or replacement, release spring strut . See 33 53 000
REMOVING AND INSTALLING / REPLACING REAR LEFT OR RIGHT COIL
SPRING .
Release nuts (3) and loosen wheel arch cover (4) from installation position.
Installation:

2010 BMW M3
Fig. 681: Identifying Nuts And Wheel Arch Cover

Replacement:
Installation:
Fig. 682: Identifying Faulty Metal Nuts

51 71 041 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT WHEEL ARCH

COVER
2010 BMW M3
If necessary, remove left or right rear wheel
NOTE: Work shown on the E87 by way of example, deviations in detail are possible in
other models.
Release nuts (3) and expander rivet (4).
Carefully feed out wheel arch cover (5) towards bottom.
Installation:
Fig. 683: Identifying Nuts And Expander Rivet

51 71 103 REMOVING AND INSTALLING/REPLACING TOP COOLING AIR GUIDE
Removing and installing/replacing bar for retaining hook.
51 71 120 REMOVING AND INSTALLING/REPLACING COWL PANEL SEAL
Remove moulding on rain gutter on left/right

2010 BMW M3
right side.
Pull back tab (1) and release screw (2) underneath.
Installation:
Water drainage channel (3) must not be clogged.
Fig. 684: Identifying Water Drainage Channel With Back Tab And Screw
Detach seal (1) in direction of arrow from window frame.
Installation:
If necessary, moisten seal (1) with water for better fitting.
Fig. 685: Moisten Seal

2010 BMW M3
51 71 200 REMOVING AND INSTALLING / REPLACING SEAL ON REAR DOOR, LEFT OR

RIGHT
Follow repair instructions for bonded seals. See 54 0 ... REPAIR INSTRUCTIONS FOR BONDED
SEALS .
Remove cover on inside door window frame.
Release door retainer from door pillar.
NOTE: The positioning of the seal must be established in six areas of the rear door
Fig. 686: Rear Door Seal Position Chart - E90 Only

2010 BMW M3
Area (C) at distance (E) to door inner panel. Bond straight between positioning aid "C1"/"C4" / "D1"/"D4".
D= 2.8 mm
E = 55 ... 70 mm
Fig. 687: Rear Door Seal Position Chart - E91 Only

Area (C) at distance (E) to door inner panel. Bond straight between positioning aid "C1"/"C4" / "D1"/"D4".
D= 2.8 mm
2010 BMW M3
E = 55 ... 70 mm
Fig. 688: Positioning Aid C2 For Rear Door, Left (D2 Right)
Positioning aid "C2" rear door, left (door retainer)

Positioning aid "D2" rear door, right (door retainer)
If necessary, cut out prestamped aperture (Y) from positioning aid. Align positioning aid with printed help
marking (X), aperture (Y) and contact edge (2) to rear door and press.
Y Aperture for door retainer

2010 BMW M3
If necessary, cut out prestamped cutout for bore from positioning aid. Align positioning aid with printed help
marking (X) and contact edge (2 and 3) to rear door and positioning aid "C2" or "D2" and press.

2010 BMW M3
Positioning aid "C3" rear door, left (above positioning aid "C2")
Positioning aid "D3" rear door, right (above positioning aid "D2")
Align positioning aid with printed help marking (X) and contact edge (2 and 3) to rear door and positioning aid
"C2" or "D2" and press.
2010 BMW M3
Fig. 691: Positioning Aid C6 For Rear Door, Left (D6 Right) - E90 Only


2010 BMW M3
Fig. 692: Positioning Aid C7 For Rear Door, Left (D7 Right) - E91 Only



2010 BMW M3
Positioning aid "C5" rear door, left (door lock, bottom)

Positioning aid "D5" rear door, right (door lock, bottom)
If necessary, cut out prestamped cutouts for bores from positioning aid. Align positioning aid with printed help
markings (X, Y), bore and contact edge (2) to rear door and press.

2010 BMW M3
Align positioning aid with printed help marking (X), opening and contact edge (2 and 3) to rear door and
positioning aid "C5" or "D5" and press.
IMPORTANT: Do not grip bonding surface.

(approx. 10 ... 15 N/cm2 ) which is decisive here.
Separation of seal after pressing destroys the adhesive layer.
2010 BMW M3
sections.
Position seal with color coding on door window frame at front top.


51 71 345 REMOVING AND INSTALLING/REPLACING LEFT (OR RIGHT) SUSPENSION CROSS-

BRACE
00 9 120

2010 BMW M3
to the body).
tightened down with special tool 00 9 120 .
Remove lower section of microfilter housing See MICROFILTER .
right side.
Release screw (1).
Release nuts (2) and remove suspension cross-brace (3).
Installation:
Tighten down screw (1) and nuts (2) to torque and then to angle of rotation using special tool 00 9 120 .
Tightening torque for screw (1) 51 71 18AZ , see 51 71 SEALS AND LOOSE BODY PARTS .
Tightening torque for nuts (2) 51 71 19AZ , see 51 71 SEALS AND LOOSE BODY PARTS .
Fig. 696: Identifying Nuts And Suspension Cross-Brace

51 71 348 REMOVING AND INSTALLING/REPLACING SUSPENSION CROSS-BRACE

MOUNTING
2010 BMW M3
00 9 120
to the body).
Screws of suspension cross-brace and cross-brace mounting must be
tightened to torque and then tightened down with special tool 00 9 120 .
Remove both suspension cross-braces.
Remove cowl panel cover.

Installation:
Replace screw (1).
Tighten down screw (1) to torque and then to angle of rotation using special tool 00 9 120 .
Fig. 697: Identifying Middle Heater Bulkhead

2010 BMW M3
Replacement:
If necessary, release suspension cross-brace grommets (4)
Installation:
Replace studs (1).
Fig. 698: Identifying Suspension Cross-Brace Grommets

51 71 380 REMOVING AND INSTALLING / REPLACING VIBRATION DAMPER
Remove battery . See 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING

BATTERY .
Release screws (1) and remove battery carrier (2).

2010 BMW M3
Fig. 699: Identifying Battery Carrier And Screws

Replacement
Release nuts (1) and remove vibration absorber (2) from battery carrier (3).
Fig. 700: Identifying Vibration Absorber From Battery Carrier And Nuts
51 71 447 REMOVING AND INSTALLING OR REPLACING PANEL FOR COVER ON LEFT OR

RIGHT SIDE MEMBER
Remove entrance cover strip.
Release expansion rivets (1) and screws (2).

2010 BMW M3
Fig. 701: Identifying Expansion Rivets And Screws

Release screws (1).

Unclip panel (1) at front.
Unclip rear panel (1) from holder (2).
Open door and remove panel (1) in direction of arrow.

2010 BMW M3
Fig. 703: Identifying Rear Panel From Holder

Installation:
Catches (1) on holder (2) must not be damaged.
Fig. 704: Identifying Catches On Holder

Installation:
If necessary, replace faulty holders (1).

2010 BMW M3
Fig. 705: Detaching Holders From Body And Panel

51 71 407 REPLACING REAR SPOILER (M)
00 9 318
IMPORTANT: The Instructions on component cementing with double-sided adhesive tape

serve as the basis for this repair instruction and must be observed without fail.
NOTE: To ensure correct bonding, it is essential to use the adhesive tape shaped parts
developed for the respective rear spoiler.
Removing rear spoiler:
Carefully detach rear spoiler (1) from rear lid with special tool 00 9 318 (assembly wedge) and hot air blower.
Fig. 706: Identifying Rear Spoiler

2010 BMW M3
IMPORTANT: To avoid paintwork damage, make sure markings (1) are only applied to
adhesive tapes.
Carry over markings (1) from bottom to top of rear spoiler.
Fig. 707: Identifying Markings

Aligning rear spoiler for installation:

2010 BMW M3
Determine center of rear lid.
Mark dimensions (A, B, C, D and E) on adhesive tapes (1) on left and right. Adhesive tapes must not be situated
on bonding surface of rear spoiler.
DIMENSIONS REFERENCE CHART

Model series A B C D E
E90 250 200 330 332 334
E92 250 200 372 370 361
E82 250 200 371 372 376
Clean bonding surface on rear lid and rear spoiler with spirit.
NOTE: For cleaning, use a fluff-free disposable cloth or a clean cleaning cloth.
Fitting rear spoiler:
IMPORTANT: Avoid the creation of bubbles and folds and do not overstretch when attaching
the adhesive tape.
Pull off adhesive tape shaped part (1) from carrier film.
Position adhesive tape shaped part (1) starting from point (A) on front groove (2) and stick on.
Repeat same procedure on other side.
Fig. 709: Identifying Adhesive Tape Shaped Part And Front Groove
NOTE: Groove (2) serves as a limit marker.

2010 BMW M3
NOTE: To enable the liner* to be pulled off, cut only the adhesive tape and not the liner
into lengths on the other side.
Fold back pull-off tabs of shaped parts and of adhesive tape towards rear. In so
doing, make sure adhesive tape is not exposed.
Position adhesive tape (1) at distance (A) to adhesive tape shaped part (3) on front groove (2) and stick on.
A= 0.5 ... 2 mm
* Liner is protective film for bonding surface.
Fig. 710: Identifying Adhesive Tape, Adhesive Tape Shaped Part And Front Groove
Align rear spoiler (1) using markings (2) and secure or press down slightly with a 2nd person helping.
Pull off liner using pull-off tabs (3).
Press down rear spoiler (1) firmly with thumbs or back of hands over entire surface, especially the ends.
Remove adhesive tapes, clean rear lid and rear spoiler.
Fig. 711: Identifying Rear Spoiler And Markings

2010 BMW M3

SIDE MEMBER (FROM 09/08) (SEDAN)
Release screws (1).
Remove trim from front beginning at side.
Lever off catch on rear wheel arch cover and remove side sill.

Installation:
Make sure spacers (1) are correctly positioned between underbody trim and bodyshell.
Fig. 713: Identifying Spacers

2010 BMW M3
Installation:
If necessary, remove retaining strips (1) from bodyshell
Clip retaining strips (1) into sill cover (2).
Clip sill cover (2) into bodyshell.
Listen out for audible clicking noises.
Visual check:
Make sure sill cover (2) is correctly seated and observe wheel arch GAP DIMENSIONS at front and rear.
Fig. 714: Identifying Retaining Strips And Sill Cover


SIDE MEMBER (UP TO 08/09) (SEDAN)
Detach wheel arch cover from front/rear side member cover
Release bolts (1).

2010 BMW M3

Unclip panel (1) at holders (2) in direction of arrow and remove.
Fig. 716: Identifying Panel And Holders

Installation:
Before installation, soak holders (1) in water.
If necessary, detach grommets (2) from holders (1) and place on body.
If necessary, replace faulty holders (1) and grommets (2).

2010 BMW M3
Fig. 717: Identifying Faulty Holders And Grommets

51 71 447 REMOVING AND INSTALLING OR REPLACING PANEL FOR COVER ON LEFT OR

RIGHT SIDE MEMBER (COUPE/CONVERTIBLE)
Remove entrance cover strip
Release expansion rivets (1) and screws (2).
Fig. 718: Identifying Expansion Rivets And Screws

Release screws (1).

2010 BMW M3

Unclip panel (1) at front.
Unclip rear panel (1) from holder (2).
Open door and remove panel (1) in direction of arrow.
Fig. 720: Identifying Rear Panel From Holder

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

2010 BMW M3
Fig. 721: Identifying Catches On Holder

Installation:
If necessary, replace faulty holders (1).
Fig. 722: Detaching Holders From Body And Panel

51 71 482 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT TENSION STRUT (ON

REAR AXLE) (FROM 03/2007)
Left tension strut
Release bolts (1, 3, 4, 5) and remove left tension strut (2).

2010 BMW M3
Installation:
Replace screw (3).
Screw (1) M12x35
Fig. 723: Identifying Left Tension Strut And Bolts

Screw (3) M12x50
Screw (4) M10x25
Screw (5) M10x25
Right tension strut

2010 BMW M3
NOTE: Remove left tension strut.
Release screws (1, 3) and remove right tension strut (2).
Installation:
Screw (1) M12x35
Screw (3) M10x25
Fig. 724: Identifying Right Tension Strut And Screws

51 71 482 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT TENSION STRUT (ON

REAR AXLE) (UP TO 03/2007)
Release screws (1, 2, 3).
Remove tension strut (4).
Installation:
Replace screw (2).

2010 BMW M3
Screw (1) M12x35
Screw (2) M12x50
Screw (3) M10x25
Fig. 725: Identifying Tension Strut And Screws

IMPORTANT: Left tensions strut (1) must be installed under right tension strut (2).
Fig. 726: Identifying Left And Right Tension Strut Release Clips (1). Release Screws (2). Remove
2010 BMW M3
Underbody Cover (3).

other models.
Release clips (1). Release screws (2). Remove underbody cover (3).
Installation: Replaced damaged clips (1). Make sure underbody cover (3) is correctly seated.
Fig. 727: Identifying Clips, (1), Screws (2) & Underbody Cover
MUCKET FOR DOORS

51 70 ... FITTING SEALS

2010 BMW M3
Fig. 728: Inspecting Seals

Fig. 729: Inspecting Seals

2010 BMW M3

Fig. 731: Identifying Joint Seals

2010 BMW M3
Body - M3
BODYSHELL
Due to changes to the wheel arch and the carbon roof, the bodyshell components shown in blue have a different
part number to the series model E92.
Fig. 1: Overview Of E92 M3 Bodyshell - Above

2010 BMW M3
Fig. 2: Overview Of E92 M3 Bodyshell - Below

New body side panels which are 20mm wider each side over the flared rear wheel arches are typical of the 'M'
design.
To ensure the necessary M3 wheel clearance at the rear wheel arch, the side frame wheel arch has been
extended by approximately 20 mm, and the 180 joining lip edge inside the wheel arch has been rolled upwards
to further increase the wheel clearance in the wheel housing.
2010 BMW M3
Fig. 3: Identifying E92 M3 Rear Wheel Arc

ADDITIONAL REINFORCEMENTS
2010 BMW M3
Fig. 4: Overview Of E92 M3 Additional Bolted-On Reinforcements

The E92 M3 is equipped with a v-shaped reinforcement brace in the engine compartment, known as the dome
strut, which consists of five separate components. It is secured to the suspension strut dome and screwed
centrally to the middle of the bulkhead.
2010 BMW M3
Fig. 5: Identifying E92 M3 Dome Strut

The E92 M3, just like the E46 M3, is equipped with a reinforcement plate, known as the thrust panel, made
from aluminum alloy.
The thrust panel primarily increases the torsional strength while also acting as a lower motor cover and oil pan
protection. The thrust panel is fitted to the axle carrier with six bolts from below, and has two openings for
changing the oil.
Fig. 6: Identifying E92 M3 Thrust Panel

The V-shaped braces used in the rear underbody area of the series production E92 have been strengthened and
adapted.
M3 - Permanently welded to the tension strut and screwed to the body with the transmission tunnel bridge
Series E92 - they are screwed to the tension strut and welded to the bridge
The bridge has been strengthened and adapted. In the M3, it is also used to mount the exhaust line.
2010 BMW M3
Fig. 7: Identifying E92 M3 Rear Axle Braces And Transmission Tunnel Bridge
EXTERIOR BODY
2010 BMW M3
Fig. 8: Overview Of M3-Specific External Body

The doors and the tailgate are taken from the series-model E92. All other external body components are new
(shown in blue).
HOOD
New "Powerdome" aluminum hood lid with air apertures. The aperture on the left when viewed in the direction
of travel is used for incoming engine air, and the right-hand aperture offers optical symmetry.
2010 BMW M3
Fig. 9: Identifying Power Dome Aluminum Hood Lid

FENDERS
An advanced plastic material is used for the front side panels, which are wider than those used on the series
E92. The side panels include the model-specific "M side gills" with integrated side indicators and M3 emblem.
Fig. 10: Identifying Front Fender (Side Panel)

ROOF
The roof on the E92 M3 is manufactured from carbon fiber. This has reduced the overall vehicle mass on the
upper level of the car by approximately 5 kg, therefore considerably lowering the center of gravity.
2010 BMW M3
A roof rack system can be assembled on the E92 M3 with carbon fiber roof. The roof has specific inserts for
roof luggage rack brackets.
The repair procedures and options are similar to or the same as the M6.
If the sunroof option is selected, a steel roof similar to the series model E92 is fitted.
Fig. 11: Identifying E92 M3 Carbon Roof

SIDE SILLS
The side sills are more highly accentuated, in accordance with the M design criteria.
Fig. 12: Identifying Side Sill Trim

EXTERIOR REAR VIEW MIRRORS
The 'M' designed exterior door mirrors have an optimized air flow design. The mirror surface area is larger to
comply with future legislation. The mirror base mounting has been adapted to suit the new mirror unit.
2010 BMW M3
The functions of the outside mirrors are the same as the series production E92. Driver and passenger mirrors are
electrically heated and adjusted.
The cover cap of the exterior mirror housing is painted in the body color.
Fig. 13: Identifying Exterior Rear View Mirrors

TAILGATE
The tailgate is taken from the series production E92. The rear spoiler (Gurney) is attached as a standard feature
on the E92 M3.
2010 BMW M3
Fig. 14: Identifying Tailgate And Spoiler (Gurney)

WHEEL WELL COVERS
The new M3 is fitted with larger wheel housing covers that accommodate the larger wheels and flared wheel
arches. The front wheel housing cover has been adapted specifically to meet the M3 requirements.
Fig. 15: Identifying Front Wheel Housing Cover

2010 BMW M3
Fig. 16: Identifying Rear Wheel Housing Cover

FRONT END MODULE
The front end module has a new single piece M-specific thermoplastic bumper trim and is fitted to a reinforced
lightweight plastic bracket.
2010 BMW M3
Fig. 17: Identifying Bumper Bracket, Shock Absorber Foam And Bumper Trim (Front End Module)
Fig. 18: Identifying Plastic Bumper Brackets

Fig. 19: Identifying Front Bumper Trim

The bumper trim is color coded to the car.
The front M3 bumper has apertures for the kidney grill, engine air inlet, PDC ultrasonic sensors (optional), the
headlight-cleaning system and the mounting for the towing eye.
Front bi-xenon headlamp units are identical to the series E92. The M3 front bumper overhang is longer than that
of the series E92.
Headlight Cleaning System (SWR)
The container for the M3 headlight cleaning system is new. The design has been changed from the series E92 in
2010 BMW M3
order to provide the necessary space for installing the M3 side gills with integrated indicators in the M style.
The filler neck and the line for the headlight cleaning system are new, together with the fixed washer nozzles on
the bumper trim.
The wiring harness for the headlight cleaning system has been adapted accordingly.
Fig. 20: Identifying Headlight Cleaning System

REAR END MODULE

2010 BMW M3
Fig. 21: Identifying Bumper Bracket, Shock Absorber Foam And Bumper Trim (Rear End Module)
The rear end module also features a new, single-piece bumper trim in the M style made from a special
thermoplast material. The bracket is also made from reinforced lightweight plastic.
The module has apertures for the bumper grid, PDC ultrasonic sensors (optional) and the mounting for the
towing hook.
Fig. 22: Identifying Rear Bumper Trim

2010 BMW M3
SOUND/THERMAL INSULATING
New sound insulation and thermal insulation covers have been installed.
The sound-insulating mats are attached in the vehicle interior to the bulkhead and transmission tunnel, and the
thermal insulation is mounted in the underbody area of the exhaust system and the engine.
Fig. 23: Identifying Sound Insulating Mat And Thermal Insulation

Other Underbody Paneling
The underbody panels have been optimized to ensure the best possible vehicle aerodynamics and the maximum
possible cooling capacity for the driveline components.
2010 BMW M3
Fig. 24: Identifying Underbody Paneling

INTERIOR BODY
LUGGAGE COMPARTMENT
The M3 floor insert in the luggage compartment has been modified to accommodate the M Mobility System.
Fig. 25: Identifying M Mobility System

2010 BMW M3
SEATS
The front head restraints feature the M logo, as in the E6x M5.
The front seat backrests have been revised. The seat upholstery is the same as that used on the E92 series-model
sport seat.
The frame with rear seat bench with through-loading capability has enabled further weight savings. This is
achieved through the use of lighter materials, which are processed using a special method for seat construction
in a sandwich design (1).
Fig. 26: Identifying Rear Seat Back

Fig. 27: Identifying Rear Seat Bench

2010 BMW M3
BRAKES Brakes - Repair
BRAKES
Brakes - Repair
BRAKE TESTING AND BLEEDING

34 00 050 BLEEDING BRAKE SYSTEM WITH DSC
NOTE: READ AND COMPLY WITH GENERAL INFORMATION.

When replacing or repairing, observe the filling and bleeding instructions for
the following parts:
Tandem brake master cylinder

Hydraulic unit
Components and connecting lines which are fitted between these
assemblies.
Connect bleeder unit with max. 2 bar filling pressure.

A second person is needed to help carry out this work.
Unclip retaining tabs (1).
Pull cover (3) out of guide (2) and remove.
Fig. 1: Identifying Retaining Tabs, Guide And Cover

Connect DIS.
Select path: Service functions - Chassis/Suspension - Slip control systems - Bleeding procedure.
2010 BMW M3
Connect brake fluid changer to expansion tank and switch on.
Fig. 2: Connecting Bleeder Unit To Expansion Tank

IMPORTANT: Check relevant Operating Instructions for each device.

Charging pressure should not exceed 2 bar.
Always use BMW-approved brake fluids, refer to BRAKES - OPERATING FLUIDS
Fully rinse the brake system
Connect bleeder hose with collecting tray to bleeder valve on rear right brake caliper.
Open bleeder valve and purge until clear, bubble-free brake fluid emerges.
Close bleed valve.
Follow same procedure on rear left, front right and front left wheel brake.
Fig. 3: Bleeder Hose With Collecting Tray At Bleeder Valve On Rear Right Brake Caliper
2010 BMW M3
Bleeding rear-axle brake circuit
Close bleeder valve.
Run bleeding routine with DIS with bleeder valve open.
After completing routine, press brake pedal 5 times to floor; clear and bubble-free brake fluid must flow out.
Close bleed valve.
Repeat procedure at rear left.
Fig. 4: Bleeder Hose With Collecting Tray At Bleeder Valve On Rear Right Brake Caliper
Bleeding front-axle brake circuit
Connect bleeder hose with collecting tray to bleeder valve on front right brake caliper.

2010 BMW M3
Fig. 5: Connecting Bleeder Hose With Collecting Tray To Bleeder Valve On Front Right Brake Caliper
After completing routine, press brake pedal 5 times to floor, clear and bubble-free brake fluid must flow out.
Close bleed valve.
Repeat procedure at front left.
Switch off brake fluid changer and remove from expansion tank.
Check brake fluid level.
Close expansion tank.
NOTE: Pay attention to rubber seal (1) in sealing cap.
Fig. 6: Identifying Rubber Seal On Sealing Cap

2010 BMW M3
34 00... CHECKING BRAKE DISCS
Remove WHEELS .
Checking thickness difference:
Measure thickness difference within brake surfaces at 8 point (spread over the circumference) with a
micrometer gauge
Compare measurement result with SETPOINT VALUE
Fig. 7: Checking Brake Surface Thickness Using Micrometer Gauge

Check minimum brake disc thickness:
Position special tool 34 1 280 GAUGE at three measuring points in area (1) and measure.
Compare measurement result and lowest value with SETPOINT VALUE
2010 BMW M3
Fig. 8: Checking Minimum Brake Disc Thickness Using Special Tool 34 1 280
34 00 009 CHECKING BRAKES ON TEST STAND
Check tires for damage

Check tire treads
Checking tire inflation pressure
IMPORTANT: The corresponding system must be deactivated on vehicles equipped with

ASC+T or DSC.
The ASC+T or DSC telltale and warning light must light up in the instrument
cluster!
Fig. 9: Checking Brakes On Test Stand

2010 BMW M3
The brakes must be at normal operating temperature. To do so, gently warm up the brake disks and brake drums
while dry by braking the vehicle several times.
IMPORTANT: Only brake test stands with test speeds of 2.5-6 km/h may be used.
Max. bedding-in time 2 minutes.
You must follow without fail the guidelines contained in the operating
instructions of the relevant test stand manufacturer.
Failure to do so may result in damage to the vehicle and the system and also
personal injury.
34 00 513 CHECKING PARKING BRAKE SETTING (VEHICLE CHECK FOR SERVICE)
IMPORTANT: Follow instructions for BRAKE TESTING ON TEST STAND .
NOTE: If deviations are identified during the following check, the parking brake must
be adjusted:
0th tooth (handbrake released):
Vehicles with manual transmission: Shift lever in neutral position.
Vehicles with automatic transmission: Selector lever in "N" position.
Without locking differential < or = 150 N.

With locking differential < or = 200 N (possibly odd display).
1st tooth: No increase in braking force with regard to 0th tooth. Indicator lamp can be lit.
2nd tooth: Indicator lamp must be lit.
3rd tooth: Increase in braking force.
5th tooth: The brake force display must have reached > or = 400 N.
Checking brake force differential at wheel:
Apply handbrake until a wheel circumferential force (measured on brake test stand) of min. 1000 N is reached.
Max. permitted brake force differential right/left < or = 35 % (referred to greater brake value).
It must be possible to brake with locked wheels with the handbrake.
34 00 010 CHECKING THICKNESS OF BRAKE PAD

2010 BMW M3
NOTE: The thickness of the outer brake pads can be determined without removing the
wheels.
If necessary, move car until opening for brake pad wear indicator (brake pad)
can be seen through rim styling.
Insert special tool 34 1 260 GAUGE rim into opening for brake pad wear indicator.
Press special tool onto brake pad. Slide ring (1) in direction of arrow up to stop and read off measured value.
NOTE: A. Brake disc

B. Brake pad with backplate
SAFE LIMIT FOR LINING WEAR, FRONT BRAKE .
SAFE LIMIT FOR LINING WEAR, REAR BRAKE .
Fig. 10: Inserting Special Tool (34 1 260) Rim Into Opening For Brake Pad Wear Indicator
34 00... GENERAL INFORMATION
The brake system is one of the most important safety systems on any motor vehicle. It is therefore essential to
act with utmost care when working on the brake system and to follow the instructions below.
General
Ensure cleanliness and only use rags which do not lose lint.
Wash away or vacuum up brake dust, do not clear it away using compressed air. This dust is a health
hazard.
Do not under any circumstances allow any oil or grease to get into the brake system. This would result in
a complete malfunction of the brake system.
When cleaning brake components with brake cleaner (refer to BMW Parts Service), do not allow brake
2010 BMW M3
cleaner to get into in the brake system.

Even the most minute traces of brake cleaner must be avoided.
Brake fluid
Replace brake fluid at least every two years.

Never reuse drained brake fluid.
Always use BMW-approved brake fluid, refer to BRAKES - OPERATING FLUIDS
Dispose of brake fluid in approved appliances only, refer to BMW Service Workshop Equipment
Planning documentation.
Do not allow brake fluid to drain into drain pipes, into the outside environment or into unsuitable
facilities. This would create the risk of groundwater contamination since brake fluid is classed as a fluid
that is hazardous to water.
Do not allow brake fluid to come into contact with paintwork as this will destroy the paint.
Brake fluid must not be allowed to remain on bare skin too long in order to avoid skin problems. Wash
skin coated with brake fluid with water and soap.
If brake fluid makes contact with eyes, immediately flush with large quantity of clean water and visit eye
doctor.
Wheel brakes
Brake pads:
Brake pads must be replaced when the warning threshold of the brake pad wear indicator See REAR
BRAKE or FRONT BRAKE is reached.
Brake pads must always be replaced on both sides of any axle.
The friction surfaces of the brake pads must not come into contact with oil or grease. The brake pads must
be replaced if they are fouled by such substances.
In the case of rotation-dependent brake pads, make sure the arrow marking points in the direction of
rotation of the brake disc for when the vehicle is moving forward. Brake pads with left/right markings
must be fitted on the relevant side of the vehicle.
One-sided angled areas on the brake pads must be located on the disc contact side of the brake caliper for
when the vehicle is moving forward.
Brake discs:
Brake discs must not be scored or cracked. Furthermore, minimum brake disc thickness See REAR
BRAKE or FRONT BRAKE , disc runout, parallelism and surface roughness of the friction surfaces
must not exceed or drop below the permitted values.
Always strip preservative off new parts before installation. With the rear brake discs, also strip
2010 BMW M3
preservative off brake drum on parking brake.
Always strip preservative off new parts before installation.

Brake calipers:
Only approved pastes on the basis of glycol must be used for repairs on brake calipers.
All moving parts on the brake caliper must move freely: note grease specifications.
Use only BMW-approved lubricants to grease caliper guides (refer to BRAKES - OPERATING FLUIDS ).
Brake lines, brake hoses
Brake lines and brake hoses must be correctly routed and must not abut with body or components in a
way which would cause chafing.
To prevent damage, release and tighten brake line couplings with a special brake line wrench only.
The system must be bled each time any brake lines have been detached.
All connection points must be checked for leaks.
Only tighten down brake hoses on the front axle when wheels are in straight-ahead position.
Close off open connections of brake lines and individual components to prevent dirt from getting into the
brake system.
When tightening down brake line couplings, observe tightening torque 34 32 1AZ .
Traction control system
The wheel-slip control system is essentially maintenance-free; however the following must be observed:
When carrying out welding work with electric welding equipment, be sure to disconnect the plug from
the electronic control unit (ignition turned off).
During painting work, the control unit may be subjected for brief periods to loads of max. 95C and for
long periods (approx. 2 hours) to loads of max. 85C.
Terminals must be completely tight on end poles of battery.
Brake lines on hydraulic unit must not be swapped over: if applicable, mark them prior to disassembly.
On completion of repair work, carry out swap-over test with the DIS diagnosis system.
34 00... GENERAL INFORMATION ON BREAKING IN NEW BRAKE DISCS/BRAKE PADS
IMPORTANT: After completing work:
Carry out function check on brake test stand to ensure that the brakes
complies with legal requirements.
Carry out test braking while driving at low speed; the effectiveness of the
brakes may be reduced during the initial braking operations.
2010 BMW M3
Exaggerated drastic and continuous braking operations for faster braking

in are not permitted.
Advise the customer not to perform any wilful drastic braking in the first
200 km after brake replacement.
Attach mirror tag to interior rearview mirror.
34 00 012 PARKING BRAKE FUNCTION CHECK
IMPORTANT: Follow instructions for BRAKE TESTING ON TEST STAND .
be adjusted:
Drive vehicle onto chassis dynamometer.
Warm up brakes.
Check handbrake.
0th tooth (handbrake released):
Vehicles with manual transmission: Shift lever in neutral position.


2010 BMW M3
34 00 025 REPLACING FLUID IN BRAKE SYSTEM
NOTE: READ AND COMPLY WITH GENERAL INFORMATION.
IMPORTANT: When carrying out repairs to the brake system, follow the procedure set out in
BLEEDING BRAKE SYSTEM WITH DSC .
Only use brake fluids that have been approved by BMW, see BRAKES - OPERATING FLUIDS

NOTE: Check relevant equipment manufacturer's operating instructions for each

device.
2010 BMW M3
Fig. 12: Connecting Bleeder Unit To Expansion Tank

Fully rinse the brake system
Close vent valve.
Fig. 13: Locating Bleeder Hose With Collecting Tray To Bleeder Valve On Rear Right Brake Caliper
NOTE: The clutch slave cylinder must also be scavenged in vehicles with manual
transmissions.
Check brake fluid level. If necessary, top up/draw off to max. level.
2010 BMW M3
Fig. 14: Identifying Rubber Seal On Sealing Cap

After installation
Reset CBS in the vehicle according to factory specification.


the information "switch closed" is output.
The automatic engine start-stop function is active.

2010 BMW M3

Workshop mode
A = 10 mm
B = 7 mm
Fig. 16: Identifying Basic Setting For Engine Hood/Bonnet Basic

FRONT BRAKES
2010 BMW M3
Remove WHEELS .
micrometer gauge

2010 BMW M3
Fig. 18: Checking Minimum Brake Disc Thickness Using Special Tool 34 1 280
34 11 552 OVERHAULING LEFT OR RIGHT FRONT BRAKE CALIPER (BRAKE CALIPER

REMOVED)
WARNING: In the following work step, large forces occur at the brake caliper piston
(up to more than 2800 N).
Risk of injury!
NOTE: Use repair kit, refer to BMW Parts Department.
Check guide sleeves (5), fitting repair-kit guide sleeve if necessary.
Fig. 19: Identifying Guide Sleeve

2010 BMW M3
Carefully force piston out through connection bore with compressed air.
To protect piston, place a protective plate (e.g. hard wood or hard felt) in caliper recess.
Do not grip piston with fingers - risk of trapping!
Fig. 20: Forcing Piston Through Connection Bore Using Compressed Air
Press off dust sleeve (1).
Fig. 21: Identifying Dust Sleeve

Carefully remove sealing ring (1) special tool 009316 WEDGE .
Clean cylinder bores and parts with alcohol and dry with compressed air.
Thoroughly inspect cylinder bore, piston and flange surfaces. Machining of cylinders and pistons is not
permitted.
2010 BMW M3
Install new seal.
Fig. 22: Removing Sealing Ring Using Special Tool (00 9 316)
Installation:
Apply a light coat of brake fluid to cylinder bore, piston and seal,
refer to BRAKES - OPERATING FLUIDS .
Fit dust sleeve (1) in annular groove of piston (2).
IMPORTANT: Do not twist brake piston.
Fig. 23: Identifying Dust Sleeve And Piston

Press piston into cylinder bore.

2010 BMW M3
Evenly press dust sleeve (1) onto brake caliper housing as far as it will go.
Installation:
The area between the dust sleeve and the brake caliper housing must be kept dry. It must not come into contact
with Ate brake cylinder paste or brake fluid so as to ensure that the dust sleeve is perfectly seated.
34 21 812 OVERHAULING LEFT OR RIGHT REAR BRAKE CALIPER (BRAKE CALIPER

REMOVED)
Risk of injury!
NOTE: Use repair kit,

refer to BMW Parts Department.


2010 BMW M3

permitted.
Install new seal.

2010 BMW M3
Installation:
Apply a light coat of brake fluid to cylinder bore, piston and seal, refer to BRAKES - OPERATING FLUIDS .

Installation:
2010 BMW M3
34 11... OVERVIEW OF FRONT BRAKES
Fig. 29: Overview Of Front Brakes

1. Brake disc
2. Brake pad
3. Brake caliper
4. Brake guard plate
5. Checking thickness of brake pad
34 11 250 REMOVING AND INSTALLING/REPLACING A BRAKE CARRIER/BRAKE GUARD

PLATE AT FRONT

2010 BMW M3
Remove front BRAKE DISCS
Release screws (1) and remove brake guard plate (2).
Installation:
Fig. 30: Identifying Brake Guard Plate With Screws

34 11 020 REMOVING AND INSTALLING OR REPLACING FRONT LEFT OR RIGHT BRAKE

CALIPER (TEVES)
IMPORTANT: The brake pad wear sensor must be replaced once it has been removed (brake
pad wear sensor loses its retention capability in the brake pad).
Remove WHEELS .
After completing work: BLEED BRAKING SYSTEM
Press clutch pedal down to floor and secure with pedal support.
NOTE: The pedal support may only be released when the brake lines are reconnected.
This prevents brake fluid from emerging from the expansion tank and air from
entering the system when the brake lines are opened.
2010 BMW M3
Fig. 31: Identifying Brake Tensioner

If necessary, pull brake hose out of holder (1).
IMPORTANT: Grip brake hose at square head (3) to prevent connecting piece from turning in
retaining bracket.
Fig. 32: Identifying Brake Hose Of Holder, Brake Line And Brake Caliper
Disconnect brake hose from brake line (2).
Installation:
Detach brake hose from brake caliper (4).
Installation:
2010 BMW M3
IMPORTANT: Never twist brake hose when installing it and avoid all contact with parts
attached rigidly to the body.
NOTE: First tighten brake hose on brake caliper.

Move wheels into straight-ahead position.
Insert brake hose in bracket and screw onto brake pipe.
Unscrew guide bolts (1).
Remove brake caliper by pulling upwards.
Installation:
Clean guide screws only; do not grease.
Check threads.
Replace all guide screws which are not in perfect condition.
Fig. 33: Identifying Guide Bolts

34 11 220 REMOVING AND INSTALLING/REPLACING BOTH FRONT BRAKE DISCS
Remove FRONT WHEELS

Remove and clean BRAKE PADS
2010 BMW M3
NOTE: After completing work, read and comply with notes on BRAKING IN NEW
BRAKE DISCS/BRAKE PADS .
Compare measurement result and lowest value with SETPOINT VALUE .
Installation:
New brake pads may only be fitted if the brake disc thickness is greater than the MINIMUM BRAKE DISC
THICKNESS (MIN TH).
If the brake discs are replaced, you must also fit new brake pads.
Brake discs may only be replaced in pairs (on each axle).
Fig. 34: Checking Minimum Brake Disc Thickness Using Special Tool (34 1 280)
Release screws (1) and remove brake anchor plate (2).
Installation:

2010 BMW M3
Fig. 35: Identifying Screws Of Brake Anchor Plate

IMPORTANT: To release brake disc: Do not under any circumstances strike friction ring with
a hammer or similar!
If necessary, carefully tap on base of brake disc chamber with a rubber mallet.
Clean contact surface of brake disc at wheel hub thoroughly and remove traces
of corrosion.
Unevenness on contact surface may result in distortion of brake disc!
IMPORTANT: Brake discs must not be mixed up (directional ventilation).
Release screws (1) and remove brake disc.
Installation:
Brake disc must be correctly seated on guide pins (2).
Replace screw.

2010 BMW M3
Fig. 36: Identifying Guide Pins And Brake Disc Screws

34 11 000 REMOVING AND INSTALLING/REPLACING BRAKE PADS ON BOTH DISC BRAKES (6

PISTONS BREMBO)
IMPORTANT: Brake pad wear sensor: after removal it must be replaced (brake pad wear
sensor loses its retention capability in the brake pad).
IMPORTANT: So as not to damage the surface coating, if possible do not mechanically clean
the guide surfaces for the brake pads on the brake caliper mounting bracket.
Instead, clean with brake cleaner BMW part no. 83 19 2 154 780.
Remove FRONT WHEELS .

Remove brake pad wear sensor.
IMPORTANT: If the brake pads are old, they may be bonded to the brake pistons by an
adhesive layer.
After the brake pads are detached from the brake pistons, they must be
replaced with pads that are no longer bonded.
They must not be reused!
Brake pads that are not bonded can be reinstalled.
These brake pads must be greased with NEVER-SEEZ compound (see BMW
Electronic Parts Catalogue) before they are reinstalled.
Drive out retaining pin (1) in direction of arrow and remove retaining spring (2).
2010 BMW M3
Fig. 37: Identifying Retaining Spring And Retaining Pin

Release screws (1) and remove brake caliper rearwards(2).
NOTE: Picture shows E7x M
IMPORTANT: Tie brake caliper back and do not allow to hang from brake hose.
Installation note:
Replace screws (1).
Tightening torque: 110 Nm
Fig. 38: Releasing Screws To Remove Brake Caliper Rearwards

Press back brake pads and piston with special tool 34 1 050 and remove brake pads!
2010 BMW M3
NOTE: Picture shows E7xM
IMPORTANT: When forcing piston back:
Pay attention to brake fluid level in expansion tank; brake fluid that spills
over will damage paintwork.
Fig. 39: Pressing Back Brake Pads And Piston With Special Tool (34 1 050)
Installation note:
Rear side of brake pads (1) must be thinly greased with NEVER-SEEZ compound (see Electronic Parts
Catalogue).
Fig. 40: Identifying Rear Side Of Brake Pad


2010 BMW M3
Position special tool 34 1 280 at three measuring points in area (1) and measure.
IMPORTANT: New brake pads may only be fitted if the brake disc thickness is greater than
the minimum brake disc thickness (MIN TH).
Fig. 41: Checking Brake Disc Thickness Using Special Tool (34 1 280)
NOTE: Picture shows E7xM
So as not to damage the surface coating, if possible do not mechanically clean pad guides (2). Clean with a
brake cleaner instead.
IMPORTANT: Do not grease brake pad guides (2).
Fig. 42: Identifying Brake Pad Guides

2010 BMW M3
Observe installation sequence:
1. Insert brake pads in calliper

2. Install brake calliper on wheel carrier
Drive out 3rd retaining pin at bottom of brake calliper side (1) up to limit position.
Fig. 43: Locating 3rd Retaining Pin At Bottom Of Brake Calliper Side
Insert 4th retaining spring in brake calliper (see graphic) and press in far enough to drive in top retaining pin.
Graphic shows: retaining spring and retaining pin in installation position
Fig. 44: Inserting 4th Retaining Spring In Brake Calliper

2010 BMW M3
NOTE: After completing repair work:
Fully depress brake pedal several times so that brake pads contact brake
discs.
When installing new brake pads at front and rear axles, brake fluid level
must be brought up to "MAX" marking.
Read and comply with notes on BRAKING IN NEW BRAKE DISCS / BRAKE
PADS.
34 11 000 REMOVING AND INSTALLING/REPLACING BRAKE PADS ON BOTH FRONT DISC

BRAKES (M3)
sensor loses its retention capability in the break pad).
Retaining spring: for vehicles older than 48 months it is recommended to
replace the retaining spring!
So as not to damage the surface coating, if possible do not mechanically clean

the guide surfaces for the brake pads on the brake caliper mounting bracket.
Instead, clean with brake cleaner BMW part no. 83 19 2 154 780 and apply a thin
coating of brake pad paste BMW part no. 83 19 2 158 851.
IMPORTANT: European version only.

Sport brake pads for M3:
Due to the increased strain on the brake discs, we recommend that you
also replace the BRAKE DISCS when fitting a set of brake pads
It is absolutely essential to replace the BRAKE DISCS if cracked > or = 13
mm even before the brake pad is worn
Remove WHEELS .
Remove BRAKE PAD WEAR SENSOR
Lever out retaining spring (1) in direction of arrow towards rear.
Installation note:
Replace retaining spring (1).
Attach retaining spring (1) first at top and bottom and then allow retaining lug (2) to engage in recess of brake
caliper housing.
2010 BMW M3
Fig. 45: Removing Retaining Spring

Remove plastic plugs (1).
Fig. 46: Identifying Plastic Plugs

Left:
Pull brake pad wear sensor (1) towards rear out of pad.
Release guide screws (2) with special tool 34 1 080 BIT INSERT . Withdraw brake caliper backwards.
Installation note:
Only clean guide bolts; do not grease.

2010 BMW M3
Fig. 47: Pulling Brake Pad Wear Sensor

Check threads.
Replace all guide bolts which are not in perfect condition.
Press back brake pads and piston with special tool 34 6 320 LEVER .
Fig. 48: Pressing Back Brake Pads And Piston

Press brake pads inwards and remove.

2010 BMW M3
The two brake pads are seated with a spring in the piston or in the brake caliper housing and must not be mixed
up.
IMPORTANT: Mark any worn brake pads.
Fig. 49: Identifying Brake Pads

In the event of one-sided brake pad wear, do not change brake pads round.
Observe MINIMUM THICKNESS OF BRAKE LININGS .
Clean brake pads.
Do not apply grease to brake lining backplate.
2010 BMW M3
the MINIMUM BRAKE DISC THICKNESS (MIN TH).
Check dust boot (1) for damage and replace if necessary.
Clean contact surface (2) of brake piston with brake cleaner and apply a thin coating of brake pad paste.
IMPORTANT: Dust boot must not come into contact with brake pad paste as this may cause
the dust boot to swell.
Fig. 51: Identifying Dust Boot And Brake Pad Contact Surface
Clean contact surfaces (1) and (2) of brake pad tee heads/brake caliper housing with brake cleaner and apply a
thin coating of brake pad paste.
NOTE: Grease contact surfaces on brake caliper at top and bottom.

2010 BMW M3
Fig. 52: Identifying Brake Caliper Housing Contact Surface

IMPORTANT: Do not grease contact surface (1).

Clean contact surface (1) with brake cleaner.
Contact surface must be free from oil and grease.
Fig. 53: Identifying Contact Surface With Brake Cleaner

Brake pad with adhesive film must be installed in each case on the outside in direction of travel!
Detach protective film (1) from brake pad and install pad.
2010 BMW M3
Fig. 54: Identifying Protective Film Of Brake Pad

So as not to damage the surface coating, if possible do not mechanically clean the guide surfaces for the brake
pads on the brake caliper mounting bracket. Instead, clean with brake cleaner and apply a thin coating of brake
pad paste.
Fig. 55: Identifying Brake Pads Guide Surfaces On Brake Caliper Mounting Bracket
So as not to damage the surface coating, if possible do not mechanically clean pad guides (1). Instead, clean
with brake cleaner and apply a thin coating of brake pad paste.
2010 BMW M3
Fig. 56: Identifying Brake Pad Guides

NOTE: After completing work:
discs.
Read and comply with notes on BRAKING IN NEW BRAKE DISCS/BRAKE
PADS .
If necessary, when replacing pads, reset CBS display in accordance with
factory specification.
34 11 519 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT FRONT BRAKE

CALIPER
Remove WHEELS .
If necessary, replace BRAKE PAD SENSOR
2010 BMW M3

retaining bracket.
Fig. 58: Identifying Brake Caliper, Brake Lines And Brake Hose Square Head
Installation:

2010 BMW M3
Installation:

Installation:
Check threads.

REAR BRAKES

2010 BMW M3
Remove WHEELS .
micrometer gauge

2010 BMW M3

REMOVED)
Risk of injury!



2010 BMW M3

permitted.
Install new seal.
2010 BMW M3
Installation:
Apply a light coat of brake fluid to cylinder bore, piston and seal, refer to BRAKES - OPERATING FLUIDS .

Installation:
34 21... OVERVIEW OF REAR BRAKE

2010 BMW M3
Fig. 67: Overview Of Rear Brake

1. Brake disc
2. Brake pad
3. Brake caliper
4. Brake guard plate
5. Checking thickness of brake pad
34 21 320 REMOVING AND INSTALLING OR REPLACING BOTH REAR BRAKE DISCS
Remove WHEELS .
Remove and clean BRAKE PADS
After completing work:

2010 BMW M3
Adjusting PARKING BRAKE

Read and comply with notes on BRAKING IN NEW BRAKE DISCS/BRAKE PADS .
Compare measurement result and lowest value with setpoint value.
New brake pads may only be fitted if the brake disc thickness is greater than the minimum brake disc thickness
(MIN TH).
Always replace brake discs in pairs.
Release bolts (1) and detach brake anchor plate.
Installation:

2010 BMW M3
Fig. 69: Identifying Brake Anchor Plate Bolts

of corrosion.

Installation:
Replace screw.
Fig. 70: Identifying Brake Disc Screws

2010 BMW M3
34 21 200 REMOVING AND INSTALLING OR REPLACING BRAKE PADS ON BOTH REAR DISC
BRAKES (TRW FLOATING CALIPER)
Remove Wheels
Remove Rear Brake Pad Wear Sensor
Release guide screw (1).
If necessary, grip at hexagon head.
Tilt brake caliper upwards.
Installation:
Replace guide screws.
For tightening torque refer to 34 21 5AZ .
Fig. 71: Identifying Rear Brake Pad Guide Screws

Remove brake pads (1) in direction of arrow from brake console.
2010 BMW M3
Observe MINIMUM THICKNESS OF BRAKE PADS
Clean brake pads.
Do not apply grease to brake pad backplate.
Fig. 72: Identifying Brake Pads And Removal Direction

New brake pads may only be installed if the brake disc thickness is greater than or equal to the MINIMUM
BRAKE DISC THICKNESS (MIN TH) .
Fig. 73: Identifying Special Tool (34 1 280) And Brake Disc Measuring Points
2010 BMW M3
Press brake piston fully back with special tool 34 1 050 .
IMPORTANT: When pressing piston back, note brake fluid level in expansion tank.
Overflowing brake fluid will damage the paintwork.

Check dust sleeve (1) for damage and replace if necessary.
Clean contact face (2) of brake piston and apply a thin coating of anti-squeak compound.
IMPORTANT: Dust sleeve must not come into contact with anti-squeak compound as this
may cause the dust sleeve to swell.
Fig. 75: Identifying Brake Caliper Dust Sleeve And Face

2010 BMW M3
Clean contact face (1) of brake caliper and apply a thin coating of anti-squeak compound.
Fig. 76: Identifying Brake Caliper Contact Face

Clean hammerhead guides and apply a thin coating of anti-squeak compound.
IMPORTANT: Brake pad with indentation (1) is intended for accommodating the brake pad
wear sensor and must be fitted on the piston side.
Fig. 77: Identifying Brake Pad With Indentation

discs.
2010 BMW M3
Read and comply with notes On BREAKING IN NEW BRAKE DISCS /

BRAKE PADS.
When replacing linings, reset CBS display in accordance with factory
specification.
Replacement:
Remove lining retaining springs (1).
Installation:
Clean contact face of brake carrier and apply a thin coating of anti-squeak compound.
Fig. 78: Identifying Brake Pad Retaining Springs

BRAKES (TEVES FLOATING CALIPER)
sensor loses its retention capability in the break pad).
Retaining spring: for vehicles older than 48 months it is recommended to
replace the retaining spring!
pads on the brake caliper mounting bracket. Instead, clean with brake cleaner BMW part no. 83 19 2 154 780
and apply a thin coating of brake pad paste BMW part no. 83 19 2 158 851.

2010 BMW M3
also replace the BRAKE DISCS when fitting a new set of brake pads
It is absolutely essential to replace the BRAKE DISCS if cracked > or = 13
Remove WHEELS .
Remove BRAKE PAD WEAR SENSOR
Lift out retaining spring (1).
Fig. 79: Lifting Retaining Spring

Remove cover plug (1).
Fig. 80: Identifying Brake Pad Sensor Cover Plug

2010 BMW M3
Remove brake caliper (2) by pulling forward.
Installation note:
Fig. 81: Identifying Brake Caliper And Guide Bolts

Check threads.
Replace all guide bolts which are not in perfect condition.
Remove outer brake pad.
Inner brake pad is located with its spring in the piston.

2010 BMW M3
Fig. 82: Removing Brake Pad

Clean brake pads.
Do not grease backs of brake pads sleeve.
IMPORTANT: When pressing down piston, note brake fluid level in expansion tank.
Turn piston back fully with special tool 34 1 050 DEVICE .
Fig. 83: Pressing Piston Using Special Tool (34 1 050)

2010 BMW M3
the MINIMUM BRAKE DISC THICKNESS (MIN TH).
Check dust boot (1) for damage and replace if necessary.
IMPORTANT: Dust boot must not come into contact with brake pad paste as this may cause
the dust boot to swell.
Clean contact surface (2) of brake piston with brake cleaner and apply a thin coating of brake pad paste.
Fig. 85: Identifying Dust Boot And Brake Pad Contact Surface
Clean contact surfaces (1) of brake pad tee heads/brake caliper housing with brake cleaner and apply a thin
coating of brake pad paste.
2010 BMW M3
Fig. 86: Identifying Brake Pad Contact Surfaces

Clean contact surface (1) of brake caliper with brake cleaner and apply a thin coating of brake pad paste.
Fig. 87: Identifying Brake Caliper Contact Surface

So as not to damage the surface coating, if possible do not mechanically clean the guide surfaces (1) for the
brake pads on the brake caliper mounting bracket.
Instead, clean with brake cleaner and apply a thin coating of brake pad paste.
2010 BMW M3
Fig. 88: Identifying Brake Pad Guide Surface

discs.
Read and comply with notes on BRAKING IN NEW BRAKE DISCS/BRAKE
PADS .
When replacing pads, reset CBS display in accordance with factory
specification.
34 21 745 REMOVING AND INSTALLING OR REPLACING REAR LEFT OR RIGHT BRAKE

CALIPER (TEVES)
Remove WHEEL
After completing work: BLEED BRAKE SYSTEM .
2010 BMW M3

IMPORTANT: Grip brake hose at square head (2) so that connecting piece can not rotate in
retaining bracket.
Installation:
Installation:

2010 BMW M3

Fig. 91: Lifting Retaining Spring

Pull brake pad wear sensor out of brake pad (right side only).
If necessary, replace brake pad wear sensor.
Fig. 92: Identifying Brake Pad Sensor Cover Plug

2010 BMW M3
Installation:
Check threads.


Clean brake pads.

2010 BMW M3
Fig. 94: Removing Brake Pad

34 21 173 REPLACING REAR LEFT (OR RIGHT) BRAKE CARRIER
Remove EXPANDER LOCK

Remove WHEEL HUB
Release screws (1).
Installation:
Release screws (2) and remove brake carrier (3).
Installation:

2010 BMW M3
Fig. 95: Identifying Brake Carrier Screws

MASTER BRAKE CYLINDER

34 31... OVERVIEW OF BRAKE MASTER CYLINDER/BRAKE BOOSTER
2010 BMW M3
Fig. 96: Overview Of Brake Master Cylinder/Brake Booster

1. Expansion tank
2. Brake master cylinder
3. Non-return valve
4. Brake booster
5. Vacuum hose
6. Bleed braking system
34 31 181 REMOVING AND INSTALLING/REPLACING EXPANSION TANK FOR HYDRAULIC

BRAKE ACTUATION

Remove lower section of microfilter housing See 6431062 REMOVING AND
2010 BMW M3

SECTION
NOTE: Extract brake fluid out of expansion tank. Use a suction bottle used exclusively
for drawing off brake fluid.
Do not reuse drawn out brake fluid.
Fig. 97: Identifying Brake Cover, Supply Hose, Plug Connection And Fastener
Pull off supply hose (1) of clutch hydraulic system if necessary.
Unlock quick-release fastener (3) and disconnect vacuum line.
Feed brake line out of rubber grommet and remove cover (4).
Unclip locking pin (1) from retaining lugs (2) and pull out locking pin.
Pull expansion tank in direction of arrow vertically out of brake master cylinder.
2010 BMW M3
Fig. 98: Pulling Locking Pin

IMPORTANT: Check rubber plug in brake master cylinder for damage and replace if
necessary.
Push the expansion tank vertically onto the master brake cylinder.
Fig. 99: Pushing Expansion Tank Onto Master Brake Cylinder

After installation
BLEED BRAKING SYSTEM
34 31 505 REMOVING AND INSTALLING/REPLACING MASTER BRAKE CYLINDER FOR DSC
Remove EXPANSION TANK .

2010 BMW M3
Remove FOOTWELL TRIM .

IMPORTANT: The brake booster must be slackened so that the brake master cylinder can be
removed and installed without tilting!
Remove locking clip (1) and disengage and pull out locking pin.
Slacken nuts (2).
Installation:
Replace self-locking nuts.
Fig. 100: Identifying Brake Pedal Locking Clip With Mounting Nuts
IMPORTANT: Do not bend brake lines.
Unfasten brake lines (1).
Installation:

2010 BMW M3
Fig. 101: Disconnecting Hydraulic Line From Hydraulic Unit

Close off brake lines and brake master cylinder with plugs 32 1 270 PLUG .
If necessary, detach line (3) from hydraulic unit and press downwards slightly.
Installation:
Release nuts (2) and feed brake master cylinder out of brake booster.
Installation:
Installation
Replace sealing ring.

2010 BMW M3
Fig. 102: Identifying Sealing Ring

Installation:
When inserting the brake master cylinder (2) into the brake booster (1), make sure the pressure rod of the brake
booster and that of the brake master cylinder meet each other on one level.
Fig. 103: Identifying Brake Master Cylinder And Brake Booster

After installation
BLEEDING BRAKE SYSTEM WITH DSC
BRAKE LINES
34 32... OVERVIEW OF BRAKE LINES
2010 BMW M3
Fig. 104: Overview Of Brake Lines

1. Brake hose, front

2. Brake tubes
3. Brake hose, rear
34 32 861 REPLACING ALL BRAKE PIPES
NOTE: The brake lines are only supplied in the straight version and correct length with
connecting nipple.
After completing work, BLEED BRAKE SYSTEM .
OBSERVE SAFETY INSTRUCTIONS ON RAISING THE VEHICLE .
The new brake lines are bent into shape with bending tool 34 5 100 DEVICE .
Removed brake pipes can be used as templates for bending.

2010 BMW M3
IMPORTANT: Protective coating of brake line must not be damaged during bending.
Do not kink or bend back brake lines.
Watch distances to rigid and movable vehicle parts. Brake lines may not
make contact or rub.
Tighten down brake line couplings with torque wrench.
Fig. 105: Identifying Bending Tool (34 5 100)

Installation:
34 32 881 REPLACING FRONT LEFT OR RIGHT BRAKE HOSE
NOTE: Read and comply with GENERAL INFORMATION .
This prevents brake fluid from emerging from the expansion tank and air from entering the system when the
brake lines are opened.
2010 BMW M3

Vehicles up to model year approx. 07/05
Pull brake hose out of holder (1).
retaining bracket.
Detach brake hose from brake line (2).
Installation:
Installation:

2010 BMW M3
Vehicles as of model year approx. 07/05
Pull brake hose out of both holders (1).
retaining bracket.
Installation:

2010 BMW M3
Installation:
IMPORTANT: First tighten brake hose on brake caliper.

Never twist brake hose when installing it and avoid all contact with parts
34 32 980 REPLACING REAR LEFT OR RIGHT BRAKE HOSE (BETWEEN BRAKE CALIPER AND
PIPE)

retaining bracket.
2010 BMW M3
Installation:
Installation:
Installation:
First tighten brake hose on brake caliper.
34 32 951 REPLACING REAR LEFT OR RIGHT BRAKE HOSE (BETWEEN REAR AXLE
CARRIER AND BODY)
Remove REAR LEFT WHEEL

After completing work: BLEED BRAKE SYSTEM .
2010 BMW M3

IMPORTANT: Grip brake hose at square drive to prevent connecting piece from turning in
retaining bracket.
Never twist brake hose (3) when installing it and avoid all contact with parts
Fig. 112: Identifying Brake Hose And Brake Line

Detach brake hose from brake line (2) and remove brake hose (3).
Installation:
2010 BMW M3
Installation:
Use torque wrench (Hazet 6282-1CT with reversible ratchet head).
Tighten brake line using torque wrench (1) and special tool 34 3 170 SOCKET WRENCH .
Fig. 113: Tightening Brake Line Using Torque Wrench And Special Tool (34 3 170)
BRAKE BOOSTER
34 33 505 REMOVING AND INSTALLING OR REPLACING BRAKE BOOSTER

Remove BRAKE MASTER CYLINDER
Remove HYDRAULIC UNIT
Remove left FOOTWELL TRIM
Detach locking clip (1) from brake pedal, disengage and pull out locking pin.
Unscrew nuts (2).
Installation:

2010 BMW M3
Fig. 114: Identifying Brake Pedal Locking Clip With Mounting Bolts
IMPORTANT: Do not use any force when removing and installing the brake unit; the brake
unit can be damaged under certain circumstances.
Brake lines must not be bent.
Carefully pull brake booster (1) out of bulkhead and tilt out.
If necessary, disengage brake line from holder on bulkhead and press slightly to one side.
Replacement
Modify NON-RETURN VALVE .
Fig. 115: Pulling Brake Booster And Nuts

2010 BMW M3
34 33 075 REMOVING AND INSTALLING/REPLACING VACUUM PUMP (S65)
READ AND COMPLY WITH GENERAL INFORMATION .

Remove FRONT LEFT WHEEL
IMPORTANT: Before starting work, press the brake pedal to the floor several times to reduce
the vacuum pressure in the brake booster. This makes it easier to detach the
lines.
Release screws (1).
Press wheel arch cover (2) forwards slightly in direction of arrow.
Fig. 116: Pressing Wheel Arch Cover

Unlock quick-release fastener (2) and detach vacuum hose.
Release nut (3) and pull vacuum pump (1) upwards out of bracket.
2010 BMW M3

34 33 071 REPLACING VACUUM HOSE FOR BRAKE BOOSTER (ON BRAKE BOOSTER)
IMPORTANT: Before beginning work, fully press the brake pedal several times to reduce the
vacuum pressure in the brake booster. This makes it easier to remove the
vacuum hose.

Remove BRAKE MASTER CYLINDER
Unlock quick-release fastener (1) and pull out vacuum line (2).
Fig. 118: Pulling Vacuum Line

Disconnect plug connection (1) from differential pressure sensor.

2010 BMW M3
Unfasten hose clip (2).
Pull off vacuum hose (3).
Pull vacuum hose (4) out of brake booster.
Feed out vacuum hose (4).
Installation:
Replace hose clamp (2).
Check sealing ring (5) in brake booster and replace if necessary.
Fig. 119: Removing Sealing Ring From Brake Booster

ELECTRICAL COMPONENTS/WEAR INDICATOR

34 35 001 REPLACING A BRAKE PAD SENSOR (FRONT)
If a brake pad sensor that has already been ground has to be replaced even though the minimum brake pad
thickness has not yet been reached, you must observe the following: The new sliding contact must be filed
down with a file to the same length as the ground sliding contact.
Remove WHEEL
Open plug housing (1).

2010 BMW M3
Feed brake pad sensor out of holders (3).
Fig. 120: Identifying Brake Pad Sensor Holders And Plug Housing
Press clip (1) together and detach brake pad sensor (2) in direction of arrow from brake pad (3).
Installation:
Make sure clip (1) and brake pad sensor (2) are correctly seated in brake pad (3).
Fig. 121: Pressing Brake Pad Sensor Clip

34 35 003 REPLACING A BRAKE PAD SENSOR (REAR)
2010 BMW M3
If a brake pad wear sensor that has already been ground has to be replaced even though the minimum brake pad
thickness has not yet been reached, you must observe the following: The new sliding contact must be filed
down with a file to the same length as the ground sliding contact.
Remove rear right WHEEL
Slacken nut (1).
Pull wheel arch trim (2) gently to one side.
Disengage cable from holders (3).
Fig. 122: Identifying Wheel Arch Trim With Nut

Installation:
Ensure proper locking of the plug connector and proper seating of the cable in the brackets.
2010 BMW M3

Detach brake pad wear sensor (2) in direction of arrow from brake caliper (3).
Installation:
Make sure holders (1) and brake pad wear sensor (2) are correctly seated in brake caliper.
Fig. 124: Identifying Brake Pad Wear Sensor And Brake Caliper
PARKING BRAKE
34 10 014 ADJUSTING HANDBRAKE
Perform inspection in the following manner:
When 1st ratchet is engaged, no braking force should be exerted.
The difference in wheel circumferential forces between the left and right wheels may deviate by max. 30
% from the greater value (measured on brake analyzer).
In event of larger deviations of wheel circumferential force: carry out readjustment.
Braking with locked wheels must be possible with the parking brake.
The parking brake must be reset if the actuation stroke is greater than 10 teeth.
NOTE: Accurate adjustment of the parking brake is only possible if the parking brake
Bowden cables and all moving parts on the parking brake move easily and
function correctly.
2010 BMW M3
Basic setting of the parking brake is required:
Parking brake shoes and attachment parts are replaced

Brake discs are replaced
In event of excessive actuation stroke (10 teeth)
When replacing parking brake Bowden cables
1. Adjusting instructions for brake shoes (basic setting)
Unclip GAITER for parking brake lever.
Lock adjuster unit (ASZE).
Actuate parking brake lever. Insert special tool 32 1 030 LEVER . Press stop (1) of adjusting spring back to
such an extent that retaining hook (2) engages in stop (1).
Fig. 125: Adjusting Brake Shoes

Completely unscrew one wheel stud on each rear wheel.
Installation:
Turn wheel until adjustment screw is visible in tapped hole.

2010 BMW M3
Fig. 126: Locating Adjustment Screw

Turn adjusting screw with a screwdriver until wheel can not be turned anymore by hand.
Then at adjusting screw:
Release 185 dia. duo-servo brake 8 notches

Fig. 127: Turning Adjusting Screw Using Screwdriver

IMPORTANT: Basic adjustment with fewer than 8 notches on the duo-servo brake may lead
to the brake shoes being damaged. Reducing the number of notches on the
duo-servo brake to shorten lever travel is not permitted.
Unlock adjuster unit (ASZE).

2010 BMW M3
Lever out restraining hook (2) with a suitable screwdriver.
Restraining hook (2) must detach from stop (1) of adjusting spring.
Fig. 128: Removing Hook From Adjusting Spring

IMPORTANT: Follow instructions for BRAKE TESTING for test stand.
2. Adjusting instructions for parking brake Bowden cables
The parking brake lever must be applied 5 times with medium hand force.
2.1 On brake test stand
0th tooth (parking brake released): Vehicles with manual transmission: Shift lever in neutral position.
Vehicles with automatic transmission: Selector lever position "N".


2010 BMW M3
Apply parking brake until a wheel circumferential force (brake force display) of min. 1000 N is reached.
3. Bedding in the duo-servo parking brake
The following braking-in procedures are applicable in case of insufficient braking effect or after replacing brake
discs and/or brake shoes.
34 00... GENERAL INFORMATION ON BRAKING IN NEW BRAKE DISCS/BRAKE PADS
Carry out function check on brake test stand to ensure that the brakes
complies with legal requirements.
34 41... OVERVIEW OF HANDBRAKE

2010 BMW M3
Fig. 129: Overview Of Handbrake

1. Handbrake lever
2. Guide tube
3. Handbrake shoes
4. Expander lock
5. Handbrake Bowden cables
6. Adjusting handbrake
34 41 000 REMOVING AND INSTALLING/REPLACING HANDBRAKE LEVER

Remove AIRBAG CONTROL UNIT
NOTE: If the parking brake lever is replaced, the handbrake lever grip must also be
2010 BMW M3
replaced.
Actuate parking brake lever. Connect special tool 32 1 030 LEVER . Press stop (1) of adjusting spring back to
Installation:
Fig. 130: Removing Hook From Adjusting Spring

Release screws (1).
Remove bracket for center console (2).

2010 BMW M3
Fig. 131: Identifying Centre Console Bracket With Screws

Disconnect cable (1) from handbrake check switch.
Unclip cable bracket (2) at point (3).
Remove cable bracket and place forward.
Fig. 132: Identifying Handbrake Check Switch Cable And Cable Bracket
Press retainer (1) in balance arm (2) forward in direction of arrow.
Detach handbrake Bowden cables (3) from balance arm (2).

2010 BMW M3
Fig. 133: Pressing Retainer In Balance Arm

Release nuts (1) and remove parking brake lever (2).
Installation:
Parking brake lever and adjustment unit (ASZE) are only exchanged completely as a single unit.
Fig. 134: Identifying Parking Brake Lever With Nuts

34 41 120 REMOVING AND INSTALLING OR REPLACING BOTH HANDBRAKE BOWDEN

CABLES
2010 BMW M3
Fig. 135: Pressing Spring Back To Retaining Hook Using Special Tool (32 1 030)

2010 BMW M3
Release screw (1) and remove holder (2).
Installation:
Fig. 137: Identifying Parking Brake Holder With Screw

NOTE: To release the parking brake Bowden cable from the expander lock, it is
necessary to remove the BRAKE DISC on the following vehicles:
E90 320xd, 325xi, 328xi, 330i, 330xi, 330d, 330xd, 335i, 335xi, 335d, M3
All E91
E92 320xd, 325xi, 325d, 328xi, 330i, 330xi, 330d, 330xd, 335i, 335xi, 335d,
M3
E93 320i, 323i, 325i, 325d, 328i, 330i, 330d, 335i, M3
All E84
Release one wheel stud.
Bring wheel into position (tapped hole turned down approx. 20 from horizontal).
F = direction of travel
Installation:
Reinstall wheel stud only after handbrake has been adjusted.

2010 BMW M3
Fig. 138: Releasing Wheel Stud Angle

Nipple (1) and expander lock (2) are visible through tapped hole.
Push in core of handbrake cable in direction of expander lock as far as it will go and grip firmly.
Press nipple (1) downwards through tapped hole with a screwdriver.
Pull handbrake cables out of wheel carrier.
Fig. 139: Pressing Nipple

Installation:
Insert handbrake cable into brake carrier/brake guard plate. Sleeve must be inserted up to stop.
Nipple of handbrake cable must audibly snap into place in expander lock.
Disconnect handbrake cables from holders (1).

2010 BMW M3
Pull handbrake cables towards rear out of guide tube.
Fig. 140: Disconnecting Handbrake Cables From Holders

34 41... REMOVING AND INSTALLING OR REPLACING GAITER FOR HANDBRAKE LEVER
Unclip gaiter with special tool 00 9 317 WEDGE .
Fig. 141: Removing Gaiter Using Special Tool (00 9 317)

Pull gaiter (1) over handbrake lever.
Cut cable ties (2) and remove gaiter.
Installation:
Eye of cable tie must face downward

2010 BMW M3
Fig. 142: Identifying Handbrake Lever Gaiter And Cable Ties

34 41 140 REMOVING AND INSTALLING OR REPLACING GUIDE TUBE FOR HANDBRAKE

CABLES

Remove PROPELLER SHAFT
Actuate parking brake lever. Position special tool 32 1 030 LEVER . Press stop (1) of adjusting spring back to
Installation:
2010 BMW M3
Fig. 143: Disconnecting Hook From Adjusting Spring


Pull handbrake cables out of guide tube.
Release screws (1).
Release screws (2) and feed out guide tube (3) towards bottom.
Installation:
Replace seal.
2010 BMW M3
Fig. 145: Pulling Handbrake Cables Of Guide Tube

After installation
34 41 220 REMOVING AND INSTALLING/RENEWING ALL PARKING BRAKE SHOES
Remove rear BRAKE DISC
Installation:
2010 BMW M3
Disconnect return spring (1) with brake spring pliers.
Installation:
Return spring (1) must not be overelongated.
Check and if necessary replace return spring (1).
Pay attention to installation position of adjusting screw (2).
Apply a thin coat of grease to bush and screw threads.
Fig. 147: Identifying Return Spring With Screw


2010 BMW M3
Installation:
Fig. 148: Identifying Return Spring

Twist roll pins (1) 90 with special tool 34 4 000 and detach.
Remove brake pads (2).
Fig. 149: Twisting Roll Pins Using Special Tool 34 4 000

After installation

2010 BMW M3
34 41 250 REMOVING AND INSTALLING/REPLACING EXPANDER FOR PARKING BRAKE

SHOES
Remove PARKING BRAKE SHOES
Actuate parking brake lever. Insert special tool 32 1 030 LEVER . Press stop (1) of adjusting spring back to
Installation:
Pull brake shoe expander (1) forward, disconnect parking brake Bowden cable (2) and remove brake shoe
expander.
2010 BMW M3
Fig. 151: Disconnecting Parking Brake Bowden Cable

After installation
34 41 071 REPLACING HANDLE FOR HANDBRAKE LEVER
Remove GAITER FOR HANDBRAKE LEVER
Pull off handle for handbrake lever (1) in direction of arrow.
Installation:
Handbrake lever grip (1) must snap audibly into place.
Fig. 152: Pulling Handle For Handbrake Lever

2010 BMW M3
MECHANICAL/HYDRAULIC COMPONENTS
34 51 527 REMOVING AND INSTALLING/REPLACING DSC HYDRAULIC UNIT

SECTION
Extract brake fluid
Bleed BRAKING SYSTEM
IMPORTANT: Do not mix up brake lines.

If necessary, mark before removal.
Close off connecting bores with seal plugs.
Press cover (2) slightly to one side and disconnect plug connection (1).
Installation note:

2010 BMW M3
Fig. 153: Identifying Brake Lines, Plug Connection And Cover

Unscrew nuts (1).
Installation note:
Fig. 154: Identifying Brake Lines Nuts

IMPORTANT: If necessary, release brake lines from holder on bulkhead.

Brake lines must not be bent!
Tilt out hydraulic unit (1) in direction of side panel.

2010 BMW M3
Fig. 155: Tilting Hydraulic Unit Of Side Panel

When replacing hydraulic unit
Release screws (1) and convert holder (2).
Installation note:
Modify DSC CONTROL UNIT .
Fig. 156: Identifying Hydraulic Unit Convert Holder And Screws

When replacing control unit
Carry out Vehicle programming and encoding

2010 BMW M3
ADJUSTMENT OF STEERING ANGLE SENSOR

Brake line mix-up test:
ELECTRONIC COMPONENTS
34 52... OVERVIEW OF ELECTRONIC COMPONENTS
Fig. 157: Overview Of Electronic Components

1. DSC sensor
2. Pulse sensor, rear
3. Pulse sensor, front
4. DSC control unit
34 52 516 REMOVING AND INSTALLING/REPLACING DSC CONTROL UNIT

2010 BMW M3
Remove HYDRAULIC UNIT
IMPORTANT: Risk of damage to the contacts when removing and installing the hydraulic
unit.
Release screws (1) and carefully detach control unit (2) towards front.
Fig. 158: Identifying Front Brake Control Unit With Screws

IMPORTANT: Replace all seals in area (1).
Fig. 159: Identifying Seals Area

Installation:
2010 BMW M3
Keep sealing faces clean.
Replace screws.
Observe tightening sequence (1-4).
Fig. 160: Front Control Unit Screws Tightening Sequence

Replacement:
Carry out Vehicle programming and encoding

STEERING ANGLE SENSOR ADJUSTMENT
or
ADJUSTMENT FOR ACTIVE STEERING
Brake line interchange check:

Function check, hydraulic unit
34 52 550 REMOVING AND INSTALLING/REPLACING DSC SENSOR

Remove LEFT FRONT SEAT

Remove FRONT LEFT ENTRANCE COVER STRIP
2010 BMW M3
Lift carpet (1) and fold back to side.
Remove underlay (2).
Disconnect plug connection.
Installation:
Ensure proper locking of plug connector.
Slacken screws (3)
Release screws (4) and remove bracket with yaw sensor.
Installation:
Fig. 161: Identifying Carpet, Underlay And Screws

When replacing DSC sensor:
Release screws (1) and modify DSC sensor (2).
Installation:

2010 BMW M3
Fig. 162: Identifying DSC Sensor And Screws

Carry out calibration/adjustment of DSC sensor.
34 52 700 REPLACING DSC HYDRAULIC CONTROL UNIT (VALVE BLOCK)

Remove HYDRAULIC UNIT .

Immediately close off all hydraulic connections with protective caps!
Clean outside of control unit.
IMPORTANT: The hydraulic unit must not be more than 7 years old.
May only be replaced once. Check repair history!
No longer install hydraulic unit if subjected to mechanical stress
(dropped, impact).
Then use lint-free cloths and cleaning agent free of mineral oil.
Do not touch any contact surfaces on the connector, pressure sensor and
control unit with the hand or objects.
IMPORTANT: Control unit must not come into contact with dirt or moisture.
Contacts must not be bent!
Release screws (1).
Firmly hold pump motor (3) together with valve block (4).
2010 BMW M3
Carefully detach control unit (2).
Fig. 163: Disconnecting Control Unit

IMPORTANT: The white molding compound at the base of the control unit (2) serves as
a seal and must not be removed.
Do not touch the contacts of pressure sensors (A) and (B) at valve block
(1) and control unit (2) otherwise they could corrode.
Fig. 164: Identifying Pressure Sensors, Valve Block And Control Unit
Take valve block (2) out of packaging (part number 67 97 896).

2010 BMW M3
Place valve block (2) straight on control unit (1) without twisting.
Installation note:
Replace screws (3).
Tightening torque 34 51 1AZ
Fig. 165: Installing Valve Block On Control Unit

IMPORTANT: The hydraulic unit is completely sealed in the area of the pressure sensor
connection only after complete assembly.
Installation note
When installing the hydraulic unit, only remove retaining tab (4) and screw plug (5) directly before
connecting the brake lines.
Brake line mix-up test:
34 52 535 REPLACING A REAR PULSE SENSOR
Remove WHEELS .
Slacken nut (1).

2010 BMW M3
Fig. 166: Identifying Wheel Arch Trim With Nut

Installation:

Unfasten socket head cap screw (2).

2010 BMW M3
Withdraw wheel speed sensor (3) from bore hole.
Installation:
Clean bore for pulse generator and lubricate with Staburags NBU 12/K grease.
Fig. 168: Identifying Wheel Speed Sensor, Socket Head Cap Screw And Holder Cable
IMPORTANT: Check sensor head prior to installation for external damage, replacing if
necessary.
34 52 525 REPLACING ONE FRONT PULSE SENSOR
Open plug housing (1), pull plug connection (2) out of bracket and disconnect.
Pull cable with rubber grommet out of holders (3).
Installation:
Ensure proper locking of plug connector and proper seating of rubber grommets.
2010 BMW M3
Fig. 169: Identifying Plug Housing And Plug Connection

Release hexagon socket head cap screw (1) and pull wheel speed sensor (2) out of bore.
Installation:
IMPORTANT: Check sensor head prior to installation for external damage, replacing if
necessary.
Fig. 170: Identifying Wheel Speed Sensor And Hexagon Socket Head Cap Screw
2010 BMW M3
BRAKES Repair - M3
BRAKES
Repair - M3
BRAKE TESTING AND BLEEDING

34 00 ... CHECKING BRAKE DISCS
34 1 280
See BRAKES - SPECIAL TOOLS .
Remove wheels
micrometer gauge
Compare measurement result with setpoint value . See BRAKES - TECHNICAL DATA .
Fig. 1: Measuring Brake Disc Thickness

Position special tool 34 1 280 at three measuring points in measuring area (1) and measure
Compare measurement result and lowest value with setpoint value . See BRAKES - TECHNICAL
DATA .
2010 BMW M3
BRAKES Repair - M3
Fig. 2: Checking Brake Disc Thickness

34 00 ... GENERAL INFORMATION
The brake system is one of the most important safety systems on any motor vehicle. It is therefore essential to
act with utmost care when working on the brake system and to follow the instructions below.
General:
Ensure cleanliness and only use rags which do not lose lint.
Wash away or vacuum up brake dust, do not clear it away using compressed air. This dust is a health
hazard.
Do not under any circumstances allow any oil or grease to get into the brake system. This would result in
a complete malfunction of the brake system.
When cleaning brake components with brake cleaner do not allow brake cleaner to get into in the brake
system.
Even the most minute traces of brake cleaner must be avoided.
Brake fluid:
Replace brake fluid at least every two years.

Never reuse drained brake fluid.
Always use BMW-approved brake fluid, refer to BRAKES - OPERATING FLUIDS .
Dispose of brake fluid in approved appliances only.
Do not allow brake fluid to drain into drain pipes, into the outside environment or into unsuitable
facilities. This would create the risk of groundwater contamination since brake fluid is classed as a fluid
that is hazardous to water.
Do not allow brake fluid to come into contact with paintwork as this will destroy the paint.
Brake fluid must not be allowed to remain on bare skin too long in order to avoid skin problems. Wash
skin coated with brake fluid with water and soap.
2010 BMW M3
BRAKES Repair - M3
If brake fluid makes contact with eyes, immediately flush with large quantity of clean water and visit eye
doctor.
Wheel brakes:
Brake pads:
Brake pads must be replaced when the warning threshold of the brake pad wear indicator is reached.
See FRONT BRAKES or REAR BRAKES .
Brake pads must always be replaced on both sides of any axle.
The friction surfaces of the brake pads must not come into contact with oil or grease. The brake pads must
be replaced if they are fouled by such substances.
In the case of rotation-dependent brake pads, make sure the arrow marking points in the direction of
rotation of the brake disk for when the vehicle is moving forward. Brake pads with left/right markings
must be fitted on the relevant side of the vehicle.
One-sided angled areas on the brake pads must be located on the disk contact side of the brake caliper for
when the vehicle is moving forward.
Brake discs:
Brake disks must not be scored or cracked. Furthermore, minimum brake disk thickness , disk runout,
parallelism and surface roughness of the friction surfaces must not exceed or drop below the permitted
values. See FRONT BRAKES or REAR BRAKES .
Always strip preservative off new parts before installation. With the rear brake discs, also strip
preservative off brake drum on parking brake.
Always strip preservative off new parts before installation.

Brake calipers:
Only approved pastes on the basis of glycol must be used for repairs on brake calipers.
All moving parts on the brake caliper must move freely: note grease specifications.
Use only BMW-approved lubricants to grease caliper guides (refer to BRAKES - OPERATING
FLUIDS ).
Brake lines, brake hoses:
Brake lines and brake hoses must be correctly routed and must not abut with body or components in a
way which would cause chafing.
To prevent damage, release and tighten brake line couplings with a special brake line wrench only.
2010 BMW M3
BRAKES Repair - M3
The system must be bled each time any brake lines have been detached.
All connection points must be checked for leaks.
Only tighten down brake hoses on the front axle when wheels are in straight-ahead position.
Close off open connections of brake lines and individual components to prevent dirt from getting into the
brake system.
When tightening down brake line couplings, observe tightening torque 34 32 1AZ . See 34 32 BRAKE
LINES .
Wheel-slip control system:
The wheel-slip control system is essentially maintenance-free; however the following must be observed:
When carrying out welding work with electric welding equipment, be sure to disconnect the plug from
the electronic control unit (ignition turned off).
During painting work, the control unit may be subjected for brief periods to loads of max. 95C and for
long periods (approx. 2 hours) to loads of max. 85C.
Terminals must be completely tight on end poles of battery.
Brake lines on hydraulic unit must not be swapped over: if applicable, mark them prior to disassembly.
On completion of repair work, carry out swap-over test with the DIS diagnosis system.
34 00 ... GENERAL INFORMATION ON BRAKING IN NEW BRAKE DISCS / BRAKE PADS
Carry out function check on brake analyzer (test stand) to ensure that the
brakes complies with legal requirements.
34 00 009 CHECKING BRAKES ON TEST STAND
Check tires for damage

Check tire treads
Check tire pressure
2010 BMW M3
BRAKES Repair - M3
IMPORTANT: The corresponding system must be deactivated on vehicles equipped with

ASC+T or DSC.
The ASC+T or DSC telltale and warning light must light up in the instrument
cluster!
The brakes must be at normal operating temperature. To do so, gently warm up the brake disks and brake drums
while dry by braking the vehicle several times.
Fig. 3: Identifying Brake Test Stands (Analyzers)

IMPORTANT: Only brake test stands (analyzers) with test speeds of 2.5-6 km/h may be used.
You must follow without fail the guidelines contained in the operating
instructions of the relevant test stand manufacturer.
Failure to do so may result in damage to the vehicle and the system and also
personal injury.
34 00 010 CHECKING THICKNESS OF BRAKE PAD
34 1 260
NOTE: The thickness of the outer brake pads can be determined without removing the
wheels.
If necessary, move car until opening for brake pad wear indicator (brake pad)
can be seen through rim styling.
Insert special tool 34 1 260 through rim into opening for brake pad wear indicator.
Press special tool onto brake pad. Slide ring (1) in direction of arrow up to stop and read off measured value.
2010 BMW M3
BRAKES Repair - M3
NOTE: A. Brake disk

B. Brake pad with backplate
See FRONT BRAKES or REAR BRAKES .
Fig. 4: Identifying Brake Disk And Brake Pad With Backplate

34 00 012 PARKING BRAKE FUNCTION CHECK
IMPORTANT: Follow instructions for Brake testing on test stand .
be adjusted:
Drive vehicle onto chassis dynamometer.
Warm up brakes.
Check handbrake.
0th tooth (handbrake released): Vehicles with manual transmission: Shift lever in neutral position.

2010 BMW M3
BRAKES Repair - M3
34 00 025 REPLACING FLUID IN ABS/ASC+T BRAKE SYSTEM
NOTE: Read and comply with General Information.
IMPORTANT: When carrying out repairs to the brake system, follow the procedure set out in
Bleeding brake system with DSC .
Fig. 5: Identifying Cover, Guide And Retaining Tabs

NOTE: Check relevant Operating Instructions for each device.

2010 BMW M3
BRAKES Repair - M3
Fig. 6: Connecting Brake Fluid Changer To Expansion Tank

Flushing brake system completely
Close bleed valve.
Fig. 7: Connecting Bleeder Hose To Bleeder Valve On Rear Right Brake Caliper
NOTE: The clutch slave cylinder must also be scavenged in vehicles with manual
transmissions.
2010 BMW M3
BRAKES Repair - M3
Check brake fluid level. If necessary, top up/draw off to max. level.
Fig. 8: Identifying Rubber Seal And Brake Fluid Level

After installation:
Reset CBS display according to factory specification
34 00 050 BLEEDING BRAKE SYSTEM WITH DSC
NOTE: Read and comply with General Information.

When replacing or repairing, observe the filling and bleeding instructions for
the following parts:
Tandem brake master cylinder

Hydraulic unit
Components and connecting lines which are fitted between these
assemblies.
Connect bleeder unit with max. 2 bar filling pressure.

A second person is needed to help carry out this work.

2010 BMW M3
BRAKES Repair - M3
Fig. 9: Identifying Cover, Guide And Retaining Tabs

Connect DIS.
Select path: Service functions - Chassis/Suspension - Slip control systems - Bleeding procedure.

Fig. 10: Connecting Brake Fluid Changer To Expansion Tank

Flushing brake system completely
2010 BMW M3
BRAKES Repair - M3
Close bleed valve.
Bleeding rear-axle brake circuit
After completing routine, press brake pedal 5 times to floor; clear and bubble-free brake fluid must flow out.
Close bleed valve.
Repeat procedure at rear left.

2010 BMW M3
BRAKES Repair - M3
Bleeding front-axle brake circuit
Connect bleeder hose with collecting tray to bleeder valve on front right brake caliper.
After completing routine, press brake pedal 5 times to floor, clear and bubble-free brake fluid must flow out.
Close bleed valve.
Repeat procedure at front left.
Fig. 13: Connecting Bleeder Hose To Bleeder Valve On Front Right Brake Caliper
Check brake fluid level.

2010 BMW M3
BRAKES Repair - M3
Fig. 14: Identifying Rubber Seal And Brake Fluid Level

34 00 513 CHECKING PARKING BRAKE SETTING (VEHICLE CHECK FOR SERVICE)
IMPORTANT: Follow instructions for Brake testing on test stand .
be adjusted:
0th tooth (handbrake released): Vehicles with manual transmission: Shift lever in neutral position.


2010 BMW M3
BRAKES Repair - M3
FRONT BRAKES
34 11 ... OVERVIEW OF FRONT BRAKES
Fig. 15: Identifying Front Brake Components

34 11 000 REMOVING AND INSTALLING/REPLACING BRAKE PADS ON BOTH FRONT DISC

BRAKES (M3)
34 1 080
34 1 280
34 6 320

2010 BMW M3
BRAKES Repair - M3
the guide surfaces for the brake pads on the brake caliper holder. Instead,
clean with brake cleaner BMW part no. 83 19 2 147 681 and apply a thin coating
of Never Seez Compound brake pad paste BMW part no. 83 23 9 407 830.

Due to the increased strain on the brake discs, we recommend that you also replace the brake discs when
fitting this brake pad
It is absolutely essential to replace the brake discs if cracked > or = 13 mm even before the brake pad is
worn
Remove wheels .
Remove brake pad wear sensor
Lever out retaining spring (1) in direction of arrow towards rear.
Installation:
Attach retaining spring (1) first at top and bottom and then allow retaining lug (2) to engage in recess of brake
caliper housing.
Fig. 16: Identifying Retaining Spring And Retaining Lug

Remove plastic plugs (1).

2010 BMW M3
BRAKES Repair - M3
Fig. 17: Identifying Plastic Plugs

Left:
Pull brake pad wear sensor (1) towards rear out of pad.
Release guide screws (2) with special tool 34 1 080 . Withdraw brake caliper backwards.
Installation:
Only clean guide screws; do not grease.
Check threads.
Tightening torque 34 11 4AZ . See 34 11 FRONT BRAKE .
Fig. 18: Identifying Brake Pad Wear Sensor

2010 BMW M3
BRAKES Repair - M3
Press back brake pads and piston with special tool 34 6 320 .
Fig. 19: Pressing Back Brake Pads And Piston With Special Tool
Press brake pads inwards and remove.
The two brake pads are seated with a spring in the piston or in the brake caliper housing and must not be mixed
up.
Observe minimum thickness of brake linings . See BRAKES - TECHNICAL DATA .
Clean brake pads.
Do not apply grease to brake pad backplate.

2010 BMW M3
BRAKES Repair - M3
Fig. 20: Identifying Brake Pads

DATA .

IMPORTANT: In the case of M vehicles and perforated brake discs, new brake pads may only
be installed if the brake disc thickness is greater than the minimum brake disc
thickness (MIN TH). See BRAKES - TECHNICAL DATA .
NOTE: The minimum brake disc thickness is configured in such a way that it lasts the
life of a further set of brake pads (does not apply to M vehicles and perforated
brake discs).
2010 BMW M3
BRAKES Repair - M3
Check dust sleeve (1) for damage and replace if necessary. Clean contact surface (2) of brake piston with brake
cleaner and apply a thin coating of brake pad paste .
Fig. 22: Identifying Dust Sleeve And Contact Surface

Clean contact surfaces (1) and (2) of brake pad tee heads/brake caliper housing with brake cleaner and apply a
thin coating of brake pad paste .
NOTE: Grease contact surfaces on brake caliper at top and bottom.
Fig. 23: Identifying Contact Surfaces Of Brake Pad Tee Heads/Brake Caliper Housing
IMPORTANT: Do not grease contact surface (1).

Clean contact surface (1) with brake cleaner.
2010 BMW M3
BRAKES Repair - M3
Contact surface must be free from oil and grease.
Fig. 24: Identifying Contact Surface

Brake pad with adhesive film must be installed in each case on the outside in direction of travel!
Detach protective film (1) from brake pad and install pad.
Fig. 25: Identifying Protective Film

pads on the brake caliper holder. Instead, clean with brake cleaner and apply a thin coating of Never Seez
Compound brake pad paste.
2010 BMW M3
BRAKES Repair - M3
Fig. 26: Identifying Brake Caliper Holder

So as not to damage the surface coating, if possible do not mechanically clean pad guides (1). Instead, clean
with brake cleaner and apply a thin coating of Never Seez Compound brake pad paste.
Fig. 27: Identifying Pad Guides

discs.
Read and comply with notes on braking in new brake discs / brake pads .
If necessary, when replacing pads, reset CBS display in accordance with
factory specification.
34 11 020 REMOVING AND INSTALLING OR REPLACING FRONT LEFT OR RIGHT BRAKE

2010 BMW M3
BRAKES Repair - M3
CALIPER (TEVES)
Remove wheels .
After completing work: Bleed braking system
Fig. 28: Pressing Pedal Down To Floor (Brake Pedal Shown)

retaining bracket.
Installation:
Tightening torque See 34 32 BRAKE LINES .

2010 BMW M3
BRAKES Repair - M3
Fig. 29: Identifying Brake Caliper, Holder And Brake Line

Installation:
Tightening torque 34 32 2AZ . See 34 32 BRAKE LINES .

Installation:
Check threads.

2010 BMW M3
BRAKES Repair - M3

34 11 220 REMOVING AND INSTALLING OR REPLACING BOTH FRONT BRAKE DISCS
34 1 280
Remove front wheels

Remove and clean brake pads
NOTE: After completing work, read and comply with notes on braking in new brake
discs / brake pads .
DATA .
Installation:
New brake pads may only be fitted if the brake disc thickness is greater than the minimum brake disc
2010 BMW M3
BRAKES Repair - M3

Brake discs may only be replaced in pairs (on each axle).
Installation:
Fig. 32: Identifying Screws And Brake Carrier

of corrosion.
2010 BMW M3
BRAKES Repair - M3
Installation:
Brake disc must be correctly seated on guide pins (2).
Replace screw.
Fig. 33: Identifying Screws And Guide Pins

34 11 250 REMOVING AND INSTALLING / REPLACING A BRAKE CARRIER / BRAKE GUARD

PLATE AT FRONT
Remove front brake disks.
Release screws (1) and remove brake guard plate (2).
Installation:

2010 BMW M3
BRAKES Repair - M3
Fig. 34: Identifying Screws And Brake Guard Plate

34 11 519 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT FRONT BRAKE

CALIPER
Remove wheels .
If necessary, replace brake pad sensor
2010 BMW M3
BRAKES Repair - M3

retaining bracket.
Installation:

2010 BMW M3
BRAKES Repair - M3

Installation:
Check threads.

34 11 552 OVERHAULING LEFT OR RIGHT FRONT BRAKE CALIPER (BRAKE CALIPER

REMOVED)
00 9 316
2010 BMW M3
BRAKES Repair - M3
See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS -- 128I .
Risk of injury!
Fig. 38: Identifying Guide Sleeves

Fig. 39: Precaution For Piston


2010 BMW M3
BRAKES Repair - M3

Carefully remove seal (1) with special tool 00 9 316 .
Thoroughly inspect cylinder bore, piston and flange surfaces.
Machining of cylinders and pistons is not permitted.
Install new seal.
Installation:
Apply a light coat of Ate brake cylinder paste to cylinder bore, piston and seal,
Refer to BRAKES - OPERATING FLUIDS .

2010 BMW M3
BRAKES Repair - M3
Fig. 41: Removing Seal With Special Tool

Installation:


REMOVED)
00 9 316
Risk of injury!

2010 BMW M3
BRAKES Repair - M3



2010 BMW M3
BRAKES Repair - M3

Install new seal.
Installation:

2010 BMW M3
BRAKES Repair - M3

Installation:

REAR BRAKES
34 21 ... OVERVIEW OF REAR BRAKE
2010 BMW M3
BRAKES Repair - M3
Fig. 48: Identifying Rear Brake Components

34 21 173 REPLACING REAR LEFT (OR RIGHT) BRAKE CARRIER
Remove expander lock

Remove wheel hub
Release screws (1).
Installation:
Tightening torque 34 21 3AZ . See 34 21 REAR BRAKE .

2010 BMW M3
BRAKES Repair - M3
Installation:
Fig. 49: Identifying Screws And Brake Carrier

BRAKES (TEVES FLOATING CALIPER)
34 1 050
34 1 280
the guide surfaces for the brake pads on the brake caliper holder. Instead,
clean with brake cleaner BMW part no. 83 19 2 147 681 and apply a thin coating
of Never Seez Compound brake pad paste BMW part no. 83 23 9 407 830.

also replace the brake discs when fitting this brake pad
It is absolutely essential to replace the brake discs if cracked > or = 13
2010 BMW M3
BRAKES Repair - M3
Remove wheels
Remove brake pad wear sensor
Fig. 50: Identifying Retaining Spring

Fig. 51: Identifying Cover Plug


2010 BMW M3
BRAKES Repair - M3
Installation:
Check threads.


Clean brake pads.

2010 BMW M3
BRAKES Repair - M3
Fig. 53: Removing Outer Brake Pad

IMPORTANT: When pressing down piston, note brake fluid level in expansion tank.
Turn piston fully back with special tool 34 1 050 .
Fig. 54: Turning Piston Fully Back With Special Tool

DATA .
2010 BMW M3
BRAKES Repair - M3

IMPORTANT: New brake pads may only be installed if the brake disc thickness is greater
than or equal to the minimum brake disc thickness (MIN TH) (not incl. M
vehicles).
In the case of M vehicles and perforated brake discs, new brake pads may only
be installed if the brake disc thickness is greater than the minimum brake disc
NOTE: The minimum brake disc thickness is configured in such a way that it lasts the
life of a further set of brake pads (does not apply to M vehicles and perforated
brake discs).
Check dust sleeve (1) for damage and replace if necessary.
Clean contact surface (2) of brake piston with brake cleaner and apply a thin coating of brake pad paste .
2010 BMW M3
BRAKES Repair - M3
Fig. 56: Identifying Dust Sleeve And Contact Surface

Clean contact surfaces (1) of brake pad tee heads/brake caliper housing with brake cleaner and apply a thin
coating of brake pad paste .
Fig. 57: Identifying Contact Surfaces Of Brake Pad Tee Heads/Brake Caliper Housing
Clean contact surface (1) of brake caliper with brake cleaner and apply a thin coating of brake pad paste .
2010 BMW M3
BRAKES Repair - M3
Fig. 58: Identifying Contact Surface Of Brake Caliper

So as not to damage the surface coating, if possible do not mechanically clean the guide surfaces (1) for the
brake pads on the brake caliper holder. Instead, clean with brake cleaner and apply a thin coating of Never
Seez Compound brake pad paste.
Fig. 59: Identifying Guide Surfaces For Brake Pads

discs.
When replacing pads, reset CBS display in accordance with factory
specification.
34 21 320 REMOVING AND INSTALLING OR REPLACING BOTH REAR BRAKE DISCS
34 1 280
Remove wheels
Remove and clean brake pads

2010 BMW M3
BRAKES Repair - M3
Adjust parking brake

DATA .
New brake pads may only be fitted if the brake disc thickness is greater than the minimum brake disc
Always replace brake discs in pairs.

Release bolts (1) and detach brake anchor plate.
Installation:

2010 BMW M3
BRAKES Repair - M3
Fig. 61: Identifying Bolts And Brake Anchor Plate

of corrosion.
Installation:
Replace screw.

2010 BMW M3
BRAKES Repair - M3
Fig. 62: Identifying Screws And Brake Disc


CALIPER (TEVES)
Remove wheel
After completing work: Bleed brake system .

IMPORTANT: Grip brake hose at square head (2) so that connecting piece cannot rotate in
retaining bracket.
Installation:
2010 BMW M3
BRAKES Repair - M3
Installation:
Fig. 64: Identifying Brake Caliper, Brake Line And Square Head


2010 BMW M3
BRAKES Repair - M3
Fig. 65: Identifying Retaining Spring

Pull brake pad wear sensor out of brake pad (right side only).
If necessary, replace brake pad wear sensor.
Fig. 66: Identifying Cover Plug

Installation:
Check threads.

2010 BMW M3
BRAKES Repair - M3
Fig. 67: Identifying Guide Bolts And Brake Caliper


Clean brake pads.
Fig. 68: Removing Outer Brake Pad


REMOVED)
00 9 316
2010 BMW M3
BRAKES Repair - M3
Risk of injury!
NOTE: Use repair kit, refer to .


2010 BMW M3
BRAKES Repair - M3

Install new seal.
Installation:

2010 BMW M3
BRAKES Repair - M3

Installation:

MASTER BRAKE CYLINDER

2010 BMW M3
BRAKES Repair - M3
34 31 ... OVERVIEW OF BRAKE MASTER CYLINDER / BRAKE BOOSTER
Fig. 74: Identifying Brake Master Cylinder / Brake Booster Components

34 31 181 REMOVING AND INSTALLING / REPLACING EXPANSION TANK FOR HYDRAULIC

BRAKE ACTUATION

Remove lower section of microfilter housing
Pull off supply hose (1) of clutch hydraulic system if necessary.

2010 BMW M3
BRAKES Repair - M3
Unlock quick-release fastener (3) and disconnect vacuum line.
Feed brake line out of rubber grommet and remove cover (4).
Fig. 75: Identifying Quick-Release Fastener, Plug Connection, Cover And Supply Hose
Unclip locking pin (1) from retaining lugs (2) and pull out locking pin.
Pull expansion tank in direction of arrow vertically out of brake master cylinder.
Fig. 76: Identifying Locking Pin And Retaining Lugs

IMPORTANT: Check rubber plug in brake master cylinder for damage and replace if
necessary.
Push the expansion tank vertically onto the master brake cylinder.
2010 BMW M3
BRAKES Repair - M3
Fig. 77: Identifying Expansion Tank Vertically Onto Master Brake Cylinder
After installation:
Bleed braking system
34 31 505 REMOVING AND INSTALLING/REPLACING MASTER BRAKE CYLINDER FOR DSC
32 1 270
See STEERING AND WHEEL ALIGNMENT - SPECIAL TOOLS
Remove expansion tank .

Remove footwell trim .
IMPORTANT: The brake booster must be slackened so that the brake master cylinder can be
removed and installed without tilting!
Remove locking clip (1) and disengage and pull out locking pin.
Slacken nuts (2).
Installation:

2010 BMW M3
BRAKES Repair - M3
Fig. 78: Identifying Locking Clip And Nuts

IMPORTANT: Do not bend brake lines.
Installation:
Close off brake lines and brake master cylinder with plugs 32 1 270 .
If necessary, detach line (3) from hydraulic unit and press downwards slightly.
Fig. 79: Identifying Brake Lines And Nuts

2010 BMW M3
BRAKES Repair - M3
Installation:
Release nuts (2) and feed brake master cylinder out of brake booster.
Installation:
Installation:

Installation:
When inserting the brake master cylinder (2) into the brake booster (1), make sure the pressure rod of the brake
booster and that of the brake master cylinder meet each other on one level.
2010 BMW M3
BRAKES Repair - M3
Fig. 81: Identifying Brake Master Cylinder And Brake Booster

After installation:
Bleeding brake system with DSC
BRAKE LINES
34 32 ... OVERVIEW OF BRAKE LINES
2010 BMW M3
BRAKES Repair - M3
Fig. 82: Identifying Brake Lines Components

34 32 861 REPLACING ALL BRAKE PIPES
34 5 100
NOTE: The brake lines are only supplied in the straight version and correct length with
connecting nipple.
After completing work, Bleed brake system .
Observe safety instructions on raising the vehicle . See 00 ... ... LIFTING
New brake lines are bent into shape with bending tool 34 5 100 .
2010 BMW M3
BRAKES Repair - M3
Removed brake pipes can be used as templates for bending.
IMPORTANT: Protective coating of brake line must not be damaged during bending.
Do not kink or bend back brake lines.
Watch distances to rigid and movable vehicle parts. Brake lines may not
make contact or rub.
Tighten down brake line couplings with torque wrench.
Fig. 83: Identifying Bending Tool 34 5 100

Installation:
34 32 881 REPLACING FRONT LEFT OR RIGHT BRAKE HOSES
NOTE: Read and comply with General Information .
2010 BMW M3
BRAKES Repair - M3

Cars up to model year approx. 07/05:
Pull brake hose out of holder (1).
retaining bracket.
Installation:

2010 BMW M3
BRAKES Repair - M3
Installation:
Cars from model year approx. 07/05:
Pull brake hose out of both holders (1).
retaining bracket.
Installation:
Fig. 86: Identifying Brake Caliper, Brake Line, Square Head And Holder
Installation:
IMPORTANT: First tighten brake hose on brake caliper.

2010 BMW M3
BRAKES Repair - M3
34 32 951 REPLACING REAR LEFT OR RIGHT BRAKE HOSE (BETWEEN REAR AXLE
CARRIER AND BODY)
34 3 170
Remove rear left wheel

After completing work: Bleed brake system .

IMPORTANT: Grip brake hose at square drive to prevent connecting piece from turning in
retaining bracket.
Never twist brake hose (3) when installing it and avoid all contact with parts

2010 BMW M3
BRAKES Repair - M3
Detach brake hose from brake line (2) and remove brake hose (3).
Installation:
Fig. 88: Identifying Brake Line And Brake Hose

Installation:
Use torque wrench (Hazet 6282-1CT with reversible ratchet head).
Tighten brake line using torque wrench (1) and special tool 34 3 170 .
Fig. 89: Tightening Brake Line Using Torque Wrench

34 32 980 REPLACING REAR LEFT OR RIGHT BRAKE HOSE (BETWEEN BRAKE CALIPER AND
2010 BMW M3
BRAKES Repair - M3

retaining bracket.
Installation:

2010 BMW M3
BRAKES Repair - M3
Fig. 91: Identifying Brake Caliper, Brake Line And Square Head
Installation:
Installation:
First tighten brake hose on brake caliper.
BRAKE BOOSTER
34 33 071 REPLACING VACUUM HOSE FOR BRAKE BOOSTER (ON BRAKE BOOSTER)
IMPORTANT: Before beginning work, fully press the brake pedal several times to reduce the
vacuum pressure in the brake booster. This makes it easier to remove the
vacuum hose.

Remove brake master cylinder
Unlock quick-release fastener (1) and pull out vacuum line (2).
2010 BMW M3
BRAKES Repair - M3
Fig. 92: Identifying Quick-Release Fastener And Vacuum Line

Disconnect plug connection (1) from differential pressure sensor.
Pull off vacuum hose (3).
Pull vacuum hose (4) out of brake booster.
Feed out vacuum hose (4).
Installation:
Replace hose clamp (2).
Check sealing ring (5) in brake booster and replace if necessary.
Fig. 93: Identifying Plug Connection, Vacuum Hose, Hose Clamp And Sealing Ring
2010 BMW M3
BRAKES Repair - M3
34 33 075 REMOVING AND INSTALLING/REPLACING VACUUM PUMP (S65)

Remove front left wheel
IMPORTANT: Before starting work, press the brake pedal to the floor several times to reduce
the vacuum pressure in the brake booster. This makes it easier to detach the
lines.
Release screws (1).
Press wheel arch cover (2) forwards slightly in direction of arrow.

Unlock quick-release fastener (2) and detach vacuum hose.
Release nut (3) and pull vacuum pump (1) upwards out of bracket.
2010 BMW M3
BRAKES Repair - M3
Fig. 95: Identifying Plug Connection, Quick-Release Fastener, Nut And Vacuum Pump
34 33 505 REMOVING AND INSTALLING OR REPLACING BRAKE BOOSTER

Remove brake master cylinder
Remove hydraulic unit
Remove left footwell trim. See 51 45 185 REMOVING AND INSTALLING/REPLACING PANEL
FOR PEDALS .
Detach locking clip (1) from brake pedal, disengage and pull out locking pin.
Unscrew nuts (2).
Installation:
Tightening torque 35 11 1AZ . See 35 11 PEDAL ASSEMBLY CONSOLE .

2010 BMW M3
BRAKES Repair - M3
Fig. 96: Identifying Locking Clip And Nuts

IMPORTANT: Do not use any force when removing and installing the brake unit; the brake
unit can be damaged under certain circumstances.
Brake lines must not be bent.
Carefully pull brake booster (1) out of bulkhead and tilt out. If necessary, disengage brake line from holder on
bulkhead and press slightly to one side.
Replacement:
Modify non-return valve .
Fig. 97: Identifying Brake Booster

ELECTRICAL COMPONENTS/WEAR INDICATOR

2010 BMW M3
BRAKES Repair - M3
34 35 001 REPLACING A BRAKE PAD SENSOR (FRONT)
If a brake pad sensor that has already been ground has to be replaced even
though the minimum brake pad thickness has not yet been reached, you must
observe the following: The new sliding contact must be filed down with a file to
the same length as the ground sliding contact.
Remove wheel
Open plug housing (1).
Feed brake pad sensor out of holders (3).
Fig. 98: Identifying Plug Housing, Plug Connection And Holder

Press clip (1) together and detach brake pad sensor (2) in direction of arrow from brake pad (3).
Installation:
Make sure clip (1) and brake pad sensor (2) are correctly seated in brake pad (3).
2010 BMW M3
BRAKES Repair - M3
Fig. 99: Identifying Clip, Brake Pad Sensor And Brake Pad
34 35 003 REPLACING A BRAKE PAD SENSOR (REAR)
If a brake pad wear sensor that has already been ground has to be replaced
even though the minimum brake pad thickness has not yet been reached, you
must observe the following: The new sliding contact must be filed down with a
file to the same length as the ground sliding contact.
Remove rear right wheel
Slacken nut (1).

2010 BMW M3
BRAKES Repair - M3
Fig. 100: Identifying Wheel Arch Trim, Nut And Holder

Installation:

Detach brake pad wear sensor (2) in direction of arrow from brake caliper (3).
Installation:
Make sure holders (1) and brake pad wear sensor (2) are correctly seated in brake caliper.
2010 BMW M3
BRAKES Repair - M3
Fig. 102: Identifying Holders And Brake Pad Wear Sensor

PARKING BRAKE
34 10 014 ADJUSTING HANDBRAKE
32 1 030
Perform inspection in the following manner:
When 1st ratchet is engaged, no braking force should be exerted.
The difference in wheel circumferential forces between the left and right wheels may deviate by max. 30 %
from the greater value (measured on brake analyzer).
In event of larger deviations of wheel circumferential force: carry out readjustment.
Braking with locked wheels must be possible with the parking brake.
The parking brake must be reset if the actuation stroke is greater than 10 teeth.
NOTE: Accurate adjustment of the parking brake is only possible if the parking brake
Bowden cables and all moving parts on the parking brake move easily and
function correctly.
Basic setting of the parking brake is required whenever:
Parking brake shoes and attachment parts are replaced

Brake discs are replaced
In event of excessive actuation stroke (10 teeth)
2010 BMW M3
BRAKES Repair - M3
When replacing parking brake Bowden cables
1. Setting instruction for brake shoes (basic setting)
Unclip gaiter for parking brake lever.
Actuate parking brake lever. Screw in special tool 32 1 030 partially. Press stop (1) of adjusting spring
back to such an extent that retaining hook (2) engages in stop (1).
Fig. 103: Identifying Retaining Hook And Stop

Completely unscrew one wheel stud on each rear wheel.
Installation:
Tightening torque 36 10 1AZ . See 36 10 WHEELS .
Turn wheel until adjustment screw is visible in tapped hole.

2010 BMW M3
BRAKES Repair - M3
Fig. 104: Locating Adjustment Screw

Turn adjusting screw with a screwdriver until wheel cannot be turned anymore by hand.
Then at adjusting screw:

IMPORTANT: Basic adjustment with fewer than 8 notches on the duo-servo brake may
lead to the brake shoes being damaged. Reducing the number of notches
on the duo-servo brake to shorten lever travel is not permitted.
Fig. 105: Identifying Adjustment Screw


2010 BMW M3
BRAKES Repair - M3

IMPORTANT: Follow instructions for Brake testing for test stand.
2. Setting instruction for parking brake Bowden cables
The parking brake lever must be applied 5 times with medium hand force.
1. On brake analyzer
0th tooth (parking brake released): Vehicles with manual transmission: Shift lever in neutral
position.
Vehicles with automatic transmission: Selector lever position "N".

1st tooth: No increase in braking force with regard to 0th tooth.
Indicator lamp can be lit.
2010 BMW M3
BRAKES Repair - M3
Apply parking brake until a wheel circumferential force (brake force display) of min. 1000 N is reached.
3. Braking in the duo-servo parking brake
The following braking-in procedures are applicable in case of insufficient braking effect or after replacing
brake discs and/or brake shoes.
1. On brake analyzer
Apply parking brake lever until wheel circumferential force at first wheel is 800 N.
Lock parking brake lever in next lower tooth.
Release parking brake lever after approx. 2 minutes.
2. When driving on road
(If possible inside the company grounds or on an unused road)
When driving at low speed (max. 40 km/h) apply parking brake lever until a braking effect can be
felt.
Pull parking brake lever into the next notch and continue driving for approx. 400 metres (max. 40
km/h).
A basic requirement is that parking brake is adjusted uniformly.
NOTE: If necessary, repeat braking-in procedure. Allow brake to cool down sufficiently.
34 41 ... OVERVIEW OF HANDBRAKE

2010 BMW M3
BRAKES Repair - M3
Fig. 107: Identifying Handbrake Components

34 41 ... REMOVING AND INSTALLING OR REPLACING GAITER FOR HANDBRAKE LEVER
00 9 317
Unclip gaiter with special tool 00 9 317 .

2010 BMW M3
BRAKES Repair - M3
Fig. 108: Uncliping Gaiter With Special Tool

Pull gaiter (1) over handbrake lever.
Cut cable ties (2) and remove gaiter.
Installation:
Eye of cable tie must face downward
Fig. 109: Identifying Gaiter And Cable Ties

34 41 000 REMOVING AND INSTALLING / REPLACING HANDBRAKE LEVER
32 1 030
2010 BMW M3
BRAKES Repair - M3
Disconnect battery negative lead

Remove airbag control unit. See 65 77 016 REMOVING AND INSTALLING/REPLACING
AIRBAG CONTROL UNIT .
NOTE: If the parking brake lever is replaced, the handbrake lever grip must also be
replaced.
Actuate parking brake lever. Screw in special tool 32 1 030 partially. Press stop (1) of adjusting spring back to
Installation:

Release screws (1).
Tightening torque 34 41 5AZ . See 34 41 PARKING BRAKE .
Remove bracket for centre console (2).

2010 BMW M3
BRAKES Repair - M3
Fig. 111: Identifying Centre Console And Screws

Disconnect cable (1) from handbrake check switch.
Unclip cable bracket (2) at point (3).
Remove cable bracket and place forward.
Fig. 112: Identifying Cable Bracket And Cable


2010 BMW M3
BRAKES Repair - M3
Fig. 113: Identifying Retainer, Balance Arm And Bowden Cables

Release nuts (1) and remove parking brake lever (2).
Installation:
Tightening torque 34 41 1AZ . See 34 41 PARKING BRAKE
Parking brake lever and adjustment unit (ASZE) are only exchanged completely as a single unit.
Fig. 114: Identifying Nuts And Parking Brake Lever

34 41 071 REPLACING HANDLE FOR HANDBRAKE LEVER

2010 BMW M3
BRAKES Repair - M3
Remove gaiter for handbrake lever
Pull off handle for handbrake lever (1) in direction of arrow.
Installation:
Handbrake lever grip (1) must snap audibly into place.
Fig. 115: Identifying Handbrake Lever

34 41 120 REMOVING AND INSTALLING OR REPLACING BOTH HANDBRAKE BOWDEN

CABLES
32 1 030
Remove airbag control unit . See 65 77 016 REMOVING AND INSTALLING/REPLACING

Adjusting parking brake
2010 BMW M3
BRAKES Repair - M3

Fig. 117: Identifying Retainer, Balance Arm And Handbrake Bowden Cables
Release screw (1) and remove holder (2).
Installation:

2010 BMW M3
BRAKES Repair - M3
Fig. 118: Identifying Screw And Holder

NOTE: To release the parking brake Bowden cable from the expander lock, it is
necessary to remove the brake disc on the following vehicles:
E90 320xd, 325xi, 328xi, 330i, 330xi, 330d, 330xd, 335i, 335xi, 335d, M3
All E91
E92 320xd, 325xi, 325d, 328xi, 330i, 330xi, 330d, 330xd, 335i, 335xi, 335d, M3
E93 320i, 323i, 325i, 325d, 328i, 330i, 330d, 335i, M3
Release one wheel stud.
Bring wheel into position (tapped hole turned down approx. 20 from horizontal).
F = direction of travel
Installation:
Reinstall wheel stud only after handbrake has been adjusted.
Tightening torque 36 10 1AZ . See 36 10 WHEELS .

2010 BMW M3
BRAKES Repair - M3
Fig. 119: Identifying Wheel Stud

Nipple (1) and expander lock (2) are visible through tapped hole.
Push in core of handbrake cable in direction of expander lock as far as it will go and grip firmly.
Press nipple (1) downwards through tapped hole with a screwdriver.
Pull handbrake cables out of wheel carrier.
Fig. 120: Identifying Nipple And Expander Lock

Installation:
Insert handbrake cable into brake carrier/brake guard plate. Sleeve must be inserted up to stop.
Nipple of handbrake cable must audibly snap into place in expander lock.
Disconnect handbrake cables from holders (1).

2010 BMW M3
BRAKES Repair - M3
Pull handbrake cables towards rear out of guide tube.
Fig. 121: Identifying Holders

34 41 140 REMOVING AND INSTALLING OR REPLACING GUIDE TUBE FOR HANDBRAKE

CABLES
32 1 030

Remove airbag control unit . See 65 77 016 REMOVING AND INSTALLING/REPLACING
Remove propeller shaft. See 26 11 000 REMOVING AND INSTALLING COMPLETE
PROPELLER SHAFT (CONSTANT-VELOCITY JOINT) .
Installation:

2010 BMW M3
BRAKES Repair - M3

Fig. 123: Identifying Retainer, Balance Arm And Handbrake Bowden Cables
Pull handbrake cables out of guide tube.
Release screws (1).
Release screws (2) and feed out guide tube (3) towards bottom.
Installation:
2010 BMW M3
BRAKES Repair - M3
Replace seal.
Fig. 124: Identifying Screws And Guide Tube

After installation:
34 41 220 REMOVING AND INSTALLING/REPLACING ALL HANDBRAKE SHOES
32 1 030
34 4 000
Remove rear brake disc
Installation:
2010 BMW M3
BRAKES Repair - M3

Installation:
Pay attention to installation position of adjustment screw (2).
Apply a thin coat of grease to bush and screw threads.

2010 BMW M3
BRAKES Repair - M3
Fig. 126: Identifying Return Spring And Adjustment Screw

Installation:

Turn clamping pins (1) with special tool 34 4 000 through 90 and disconnect.
Remove brake shoes (2).

2010 BMW M3
BRAKES Repair - M3
Fig. 128: Identifying Brake Shoes And Clamping Pins

After installation:
34 41 250 REMOVING AND INSTALLING/REPLACING EXPANDER LOCK FOR HANDBRAKE

SHOES
32 1 030
Remove handbrake shoes
Installation:
2010 BMW M3
BRAKES Repair - M3

Pull expander lock (1) forwards, disconnect handbrake Bowden cable (2) and remove expander lock.
Fig. 130: Identifying Expander Lock And Handbrake Bowden Cable

After installation:
MECHANICAL/HYDRAULIC COMPONENTS
34 51 527 REMOVING AND INSTALLING OR REPLACING DSC HYDRAULIC UNIT

2010 BMW M3
BRAKES Repair - M3
Remove lower section of microfilter housing . See MICROFILTER .

Extract brake fluid
Bleeding braking system
IMPORTANT: Do not mix up brake lines.

If necessary, mark before removal.
Close off connection bores with plugs.
Press cover (2) slightly to one side and disconnect plug connection (1).
Installation:
Fig. 131: Identifying Brake Lines, Cover And Plug Connection

Unscrew nuts (1).
Installation:
Tightening torque 34 51 6AZ . See 34 51 SLIP CONTROL SYSTEM (DSC) .

2010 BMW M3
BRAKES Repair - M3

IMPORTANT: If necessary, release brake lines from holder on bulkhead.

Brake lines must not be bent!
Tilt out hydraulic unit (1) in direction of side panel.
Fig. 133: Identifying Hydraulic Unit

When replacing hydraulic unit:
Release screws (1) and convert holder (2).
Installation:

2010 BMW M3
BRAKES Repair - M3
Modify DSC control unit .
Fig. 134: Identifying Screws And Convert Holder

When replacing control unit:
Carry out programming/coding and Adjustment of steering angle sensor using scan tool.
Mix-up check of brake lines
ELECTRONIC COMPONENTS
34 52 ... OVERVIEW OF ELECTRONIC COMPONENTS
2010 BMW M3
BRAKES Repair - M3
Fig. 135: Identifying Electronic Components

34 52 516 REMOVING AND INSTALLING / REPLACING DSC CONTROL UNIT
protection) .
Remove hydraulic unit
IMPORTANT: Risk of damage to the contacts when removing and installing the hydraulic
unit.
Release screws (1) and carefully detach control unit (2) towards front.
2010 BMW M3
BRAKES Repair - M3
Fig. 136: Identifying Screws And Control Unit

IMPORTANT: Replace all seals in area (1).

Installation:
Keep sealing faces clean.
Replace screws.
Observe tightening sequence (1-4).

2010 BMW M3
BRAKES Repair - M3

Replacement:
Carry out programming/coding , Steering angle sensor adjustment and adjustment for active front
steering using scan tool.
Mix-up check of brake lines
Function check, hydraulic unit
34 52 525 REPLACING ONE FRONT PULSE GENERATOR
Open plug housing (1), pull plug connection (2) out of bracket and disconnect.
Pull cable with rubber grommet out of holders (3).
Installation:
Ensure proper locking of plug connector and proper seating of rubber grommets.
2010 BMW M3
BRAKES Repair - M3
Fig. 139: Identifying Plug Housing, Plug Connection And Holder

Release hexagon socket head cap screw (1) and pull wheel speed sensor (2) out of bore.
Installation:
Fig. 140: Identifying Hexagon Socket Head Cap Screw And Wheel Speed Sensor
34 52 535 REPLACING A REAR PULSE GENERATOR
Remove wheels .
2010 BMW M3
BRAKES Repair - M3
Slacken nut (1).
Fig. 141: Identifying Wheel Arch Trim, Nut And Holder

Installation:

2010 BMW M3
BRAKES Repair - M3
Unfasten socket head cap screw (2).
Withdraw wheel speed sensor (3) from bore hole.
Installation:
Fig. 143: Identifying Wheel Speed Sensor, Socket Head Cap Screw And Holder
34 52 550 REMOVING AND INSTALLING / REPLACING DSC SENSOR
protection ).
Remove left front seat . See SEATS - REPAIR INSTRUCTIONS (SEDAN/COUPE) or SEATS -
REPAIR INSTRUCTIONS (CONVERTIBLE) .
Remove front left entrance cover strip . See 51 47 000 REMOVING AND
INSTALLING/REPLACING FRONT (INSIDE) LEFT OR RIGHT ENTRANCE COVER STRIP .
Lift carpet (1) and fold back to side.
Remove underlay (2).

2010 BMW M3
BRAKES Repair - M3
Installation:
Ensure proper locking of plug connector.
Slacken screws (3)
Release screws (4) and remove bracket with yaw sensor.
Installation:
Fig. 144: Identifying Carpet, Underlay And Screw

When replacing DSC sensor:
Release screws (1) and modify DSC sensor (2).
Installation:

2010 BMW M3
BRAKES Repair - M3
Fig. 145: Identifying Screws And Modify DSC Sensor

Carry out calibration/adjustment of DSC sensor.
34 52 700 REPLACING DSC VALVE BLOCK
protection .
Remove hydraulic unit.

Immediately close off all hydraulic connections with protective caps!
Clean outside of control unit.
IMPORTANT: The hydraulic unit must not be more than 7 years old.
May only be replaced once. Check repair history!
No longer install hydraulic unit if subjected to mechanical stress
(dropped, impact)
Then use lint-free cloths and cleaning agent free of mineral oil.
Do not touch any contact surfaces on the connector, pressure sensor and
control unit with the hand or objects.
Control unit must not come into contact with dirt or moisture
Contacts must not be bent!
Release screws (1). Firmly hold pump motor (3) together with valve block (4). Carefully detach control unit (2).
2010 BMW M3
BRAKES Repair - M3
Fig. 146: Release Screws And Firmly Hold Pump Motor Together With Valve Block
IMPORTANT: The white moulding compound at the base of the control unit (2) serves
as a seal and must not be removed.
Do not touch the contacts of pressure sensors (A) and (B) at valve block
(1) and control unit (2) otherwise they could corrode.
Fig. 147: Do Not Touch The Contacts Of Pressure Sensors

Remove valve block (2) from original packaging. Place valve block (2) straight on control unit (1) without
twisting. Installation note: Replace screws (3). Tightening torque 35-53 INCH lbs. (4-6 N.m.)
2010 BMW M3
BRAKES Repair - M3
Fig. 148: Place Valve Block Straight On Control Unit Without Twisting
IMPORTANT: The hydraulic unit is completely sealed in the area of the pressure sensor
connection only after complete assembly.
Installation note: When installing the hydraulic unit, only remove retaining tab (4) and screw plug (5) directly
before connecting the brake lines. Bleed braking system
TROUBLESHOOTING
34 90 ... TROUBLESHOOTING BRAKE SYSTEM
TROUBLESHOOTING CHART
Fault Cause Remedy
Remove and install, clean and
1. Fouled brake system grease brake calipers
Clean and grease brake pads
2. Pad wear excessive or one-
Replace brake pads
sided
a. Clean guide screws, do not
3. Brake disc not flush with grease
floating caliper b. Clean contact face between
Brake squeaks wheel hub and brake disc
a. Visually inspect brake discs
and pads
4. Contact pattern of pads and b. If necessary, precision-
brake discs turn brake discs
c. If necessary, replace brake
discs and pads
Precision-turn brake discs or
2010 BMW M3
BRAKES Repair - M3
5. Rust edges on brake discs replace

6. Pad loose Replace brake pads
7. Wrong type of pads Replace brake pads
Rattling, humming, steering wheel 1. Fouling of contact surface
Clean contact surface between
torsional vibrations during brake between brake disc and wheel
brake disc and wheel hub
operation hub
2. Excessive thickness Measure brake disc thickness
deviation within braking Precision-turn brake discs or
surface replace
a. Visually inspect discs and
pads
3. Contact pattern of pads and b. If necessary, precision-
brake discs turn brake discs
c. If necessary, replace brake
discs and pads
Precision-turn brake discs ,
4. Brake disc runout
replace if necessary
5. Excessive wheel bearing play Replace wheel bearing
2010 BMW M3
GENERAL INFORMATION Breakout Boxes & Connectors - Overview
GENERAL INFORMATION
Breakout Boxes & Connectors - Overview
BREAKOUT BOXES AND CONNECTORS

Model: All
CONNECTOR CONTACT KIT
Connector Contact Removal Kit
The connector contact removal kit provides tools for the disassembly of connectors. Proper use of these tools
enable the technician to access wiring connectors for repairs equal to factory quality.
Always refer to the latest appropriate articles for up to date information regarding new tools.
2010 BMW M3
Fig. 1: Identifying Connector Contact Removal Kit

Current P/N 88 88 6 611 150.
The Connector Contact Removal Kit is used for:
Releasing round plug housings.

Releasing relay carriers.
Pressing out contacts.
Pulling out indicator lamps.
Socket and Spring Contacts
Fig. 2: Identifying Spring Contacts

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Fig. 3: View Of Socket Types

Socket and Spring contacts compress the springs while the connector is pushed from the housing.
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Fig. 4: Identifying Different Sockets

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Fig. 5: View Of Socket And Spring Contacts

Flat spring contacts depress the spring allowing the connector to be pushed or gently pulled from the connector
housing.
Instrument Cluster Illumination Bulb Holder Removal Socket
The backlighting illumination bulbs are removed from the cluster by placing square head of the socket on the
bulb holder and turning 90 counter clockwise.
The bulb removal socket is used on all instrument clusters.

2010 BMW M3
Fig. 6: Identifying Instrument Cluster Illumination Bulb Holder Removal Socket

Relay Holder Disengaging Tool
This tool allows the relay holder (2) to disengage the relay connector (1).
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Fig. 7: Identifying Relay Holder Disengaging Tool

Circular Connector Lock Disengager
These tools unlock the circular connector housings allowing the individual connectors to be removed.
2010 BMW M3
The various sizes are reflected in the part numbers:
4 pin = 61 1 141.
7 pin = 61 1 142.
10 pin = 61 1 145.
12 pin = 61 1 143.
25 Pin = 61 1 144.
Fig. 8: Identifying Circular Connector Lock Disengager (1 Of 4)

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BMW PLUG SYSTEM ABBREVIATIONS

2010 BMW M3
BMW PLUG SYSTEM ABBREVIATIONS

D 1.5/2.5 Round contacts of 1.5mm or 2.5mm diameter
MDK 3 Plus Miniature double flat spring contact
JPT ELA Junior Power Timer flat spring contacts with strand
sealing
DFK ELA Double flat spring contacts with strand sealing
Elo Electronic contacts with and without strand sealing
Manufacturer: Siemens
Elo Power Electronic contacts for heavy loads with and
without strand sealing
Manufacturer: Siemens
MQS Micro Quadlock System electronic contacts with and
without strand sealing
Manufacturer: AMP
MPQ Micro Power Quadlock electronic contacts for heavy
loads with and without strand sealing
Manufacturer: AMP
PLUG SYSTEM D1.5/D2.5
Circular Plug 7--8 Pin System D2.5
Pull off the rubber boot (1).

Push the retaining lugs (2) of the inner connector section 3 inward carefully to disengage the lock notch.
Push the inner connector section (3) in the direction of the arrow in the illustration until the retaining lugs
(2) are in the recessed notch (4) and use the appropriate sized spring contact tool and remove the
connector from the housing.
2010 BMW M3
Fig. 12: Identifying Inner Connector Retaining Lugs

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Fig. 13: Locating Recessed Notch In Inner Connector

Circular plug 13 Pin System D2.5
Carefully pull off the rubber grommet (1).

Pull the lock retainers (2) outward (direction of arrows) to allow the lock notch to disengage.
Pull the inner section (3) upward as shown in the illustration until the lock notches (4) are in the released
position of the lock retainers (5) and use the appropriate size spring contact and remove the connector
from the housing.
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Fig. 14: Locating Circular Plug Lock Retainers

2010 BMW M3
Fig. 15: View Of Lock Notch In Circular Plug

Circular Plug 20 Pin System D2.5
With the boot pulled back, press the lock tabs (1) of the inner connector section (2) inward.
Simultaneously, rotate the inner connection section (2) counter clockwise to allow the lock tabs (1) to
engage in the unlocked position and use the appropriate sized spring contact and remove connector from
the housing.
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Fig. 16: Identifying Circular Plug Lock Tabs

2010 BMW M3
Fig. 17: View Of Inner Connection Of Circular

Circular Plug 4-7-10-12-25 Pin System D1.5/D2.5
Insert the appropriate unlocking tool (determined by the number of pins) into the connector.
The connector is unlocked when the lock tab (3) is in the unlocked position (1). The connector is locked
when the lock tab (3) is in the locked position (2).
Use the appropriate sized spring contact and remove connector from the housing.
2010 BMW M3
Fig. 18: View Of Circular Plug And Special Tool

2010 BMW M3
Fig. 19: Identifying Lock Tab Of Circular Plug

In-line Plug 15 Pin System D2.5
Pull the outer connector section (1) slightly outward in the area of lock tabs (2).
Simultaneously, slide the inner connector section (3) in the direction of the arrow to the unlocked
position.
Use the appropriate sized spring contact and remove connector from housing.
2010 BMW M3
Fig. 20: Identifying In-Line Plug Lock Tabs

2010 BMW M3
Fig. 21: Locating In-Line Plug Inner Connector Section

In-line Plug 8-, 12 Pin System D2.5
Slide the upper section (1) and the lower section (2) of the connector in opposite directions to unlock the
connector.
Using special tool 61 1 132 press the spring latch down and pull the connector (3) from the housing.
2010 BMW M3
Fig. 22: Separating In-Line Plug Lower And Upper Sections

2010 BMW M3
Fig. 23: View Of In-Line Plug Connector

Pull locking slide (1) completely out of connector (2).

Using special tool 61 1 132 press the spring latch down and pull the connector from the housing.
2010 BMW M3
Fig. 24: Removing Locking Slide From Connector

2010 BMW M3
Fig. 25: View Of In-Line Plug Connector

Pull the outer section (1) slightly outward in the area of lock tabs (2).
Simultaneously, slide the inner connector section (3) in the direction of the arrow to the unlocked
position.
Use the appropriate sized spring contact and remove connector from housing.
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Fig. 26: Identifying In-Line Plug Outer Section

2010 BMW M3
Fig. 27: View Of Inner Section Of In-Line Plug

PLUG SYSTEM JPT/MDK/DFK
In-line plug 2 Pin System JPT ELA
Press lock (1) in direction of arrow and slide plug forward.

Press lock (1) downward and slide out to one side.
Unlock contact with special tool 61 1 136 and pull out cable (2) and contact towards rear.
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Fig. 28: Locating Lock For In-Line Plug

2010 BMW M3
Fig. 29: View Of In-Line Plug Lock

2010 BMW M3
Fig. 30: Removing In-Line Plug Contact Using Special Tool

In-line plug 2 Pin System MDK 3 plus 2.8

2010 BMW M3
Unlock lock (1) on outside at arrester hook and slide out lock (1) side.
Unlock contact with special tool 61 1 136 and pull out cable (2) and contact towards rear.
Fig. 31: View Of Lock On In-Line Plug Arrester Hook

2010 BMW M3
Fig. 32: Identifying In-Line Plug And Special Tool

In-line plug 4 Pin System DFK ELA
Press arrester hook in direction of arrow and remove lock (1).

Unlock contact with special tool 61 1 136 and pull cable and contact out towards rear.
Installation Instructions:
If necessary, slide lock must also be unlocked with screw driver.

2010 BMW M3
Fig. 33: Locating Lock In Plug

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Fig. 34: Unlocking With Special Tool (61 1 136)

2010 BMW M3
Fig. 35: View Of Slide Lock In Plug

PLUG SYSTEM ELO/ELO POWER
In-line Plug 3-,6 Pin System Elo-Power 2.8
Press unlocking hook (1) in direction of arrow and disengage. Then unlock locking hook (2) and remove
lock.
Press down arrestor hook (3) with screwdriver and pull out cable with contact towards rear.
2010 BMW M3
Fig. 36: Identifying Hook On In-Line Plug

2010 BMW M3
Fig. 37: View Of In-Line Plug Arrester Hook

In-line plug 4-,10 Pin System Elo
Slide connector lock (1) off of main connector body.

Push the lock tab of the connector being removed down (3) with pin or small screwdriver in the primary
lock slot (4) and pull the wire out (5) to the secondary lock position (6).
Push the lock tab down again in the secondary lock position and remove wire completely.
2010 BMW M3
Fig. 38: Locating Connector Lock For In-Line Plug

2010 BMW M3
Fig. 39: Identifying In-Line Plug Lock Tab

2010 BMW M3
Fig. 40: View Of In-Line Plug 4-, 10 Pin System Elo

In-line Plug 6-,50 Pin System Elo
Unlock lock (Fig. 41).

Unfasten cable clip (Fig. 42).
Slide connector lock (1) off of main connector body (2) (Fig. 43).
Push the connector plate (3) out of connector shell using a small screwdriver through hole on end of
connector body (Fig. 44).
Push the lock tab of the connector being removed down (6) with pin or small screw driver in the primary
lock slot (7) and pull the wire out to the secondary lock position (8) (Fig. 45).
Push the lock tab down again in the secondary lock position and remove wire completely (Fig. 46).
2010 BMW M3
Fig. 41: Identifying Lock On In-Line Plug

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Fig. 42: View Of Clip On In-Line Plug

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Fig. 43: Removing Connector Lock From In-Line

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Fig. 44: Removing Connector Plate From In-Line Plug

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Fig. 45: Removing Wire From Secondary Lock Position

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Fig. 46: Removing Wire Using Screwdriver

PLUG SYSTEM MQS/MPQ
In-line Plug 6-,8 Pin System MQS

Press locking hook (2) downward and slide lock (1) out.
Press down arrester hook (3) with screwdriver and pull out cable with contact towards rear.
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Fig. 47: View Of In-Line Plug Lock

2010 BMW M3
Fig. 48: Identifying In-Line Plug Locking Hook

2010 BMW M3
Fig. 49: Removing Cable From In-Line Plug

In-line Plug 2 Pin System MPQ 2.8
Press catch on outside in direction of arrow and remove towards top.

Press down arrestor hook (1) with screwdriver and pull out cable and contact (2) towards rear.
2010 BMW M3
Fig. 50: Identifying Catch On In-Line Plug

2010 BMW M3
Fig. 51: Removing Cable And Contact From In-Line Plug

Control Unit Plug 25-, 35-, 55-,83-,88 Pin

2010 BMW M3
Remove phillips head screws (1) from connector. Gently pivot the connector plate (2) with seal (3) out of
the connector shell.
Remove seal (3) and pull connector plate lock (4) out of locked position.
Using the appropriate sized spring contact and remove connector (5) from housing.
Fig. 52: Identifying Control Unit Plug Retaining Screws

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Fig. 53: View Of Control Unit Plug Seal

2010 BMW M3
Fig. 54: Removing Connector From Control Unit Plug

In-line Plug 24 Pin Hybrid System MQS/MPQ
Manufactured by AMP : The following contact types without strand sealing can be fitted in the plug housings:
MQS (Micro Quadlock System).
MPQ, width 2.8 mm (Micro Power Quadlock).
Socket Housing
Press locks (1) on cap (2) upwards on both sides.

2010 BMW M3
Detach cap from contact carrier (3).
NOTE: Detaching the cap releases the secondary lock of the socket contacts.
Fig. 55: Removing Cap From Contact Carrier

Hold down retaining hook (1) of socket contact carrier with a small screwdriver.
Pull wire with socket contact in direction of arrow as far as secondary lock (2). (Fig. 56)
Hold down retaining hook in secondary lock (1) again and pull cable with socket contact (2) completely
out of contact carrier (3). (Fig. 57)
2010 BMW M3
Fig. 56: View Of Retaining Hook In Secondary Lock

Pin Housing

Detach cap from housing carrier (3)(Fig. 58).
NOTE: Detaching the cap releases the secondary locks of the pin contacts in the
contact carriers.
Pull contact carrier (1) out of housing carrier (2) (Fig. 59).
The pin contacts are pulled of a contact carrier as described under "Socket Housing".
2010 BMW M3
Fig. 57: Identifying Pin Housing Locks

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Fig. 58: Removing Cap From Pin Housing

2010 BMW M3
Fig. 59: Removing Contact Carrier From Housing

Socket Housing 42-,43 Pin Hybrid Systems MQS/MPQ
Manufactured by AMP: The following contact types without strand sealing can be fitted in the socket
housings:
Open secondary locks (1) on socket housing.

Press back retaining hook of MQS contacts (2) with special tool 61 1 134 and pull out cable with contact.
2010 BMW M3
Press back retaining hook of MPQ contacts (3) with screwdriver or similar tool and pull out cable with
contact.
Installation:
Bend open retaining hook of contacts gently before inserting into plug housing.
To install contacts, observe cavity numbers on reverse side of socket housing.
Fig. 60: Identifying MQS Contact Retaining Hook

2010 BMW M3
Fig. 61: Identifying Cavity Numbers On Socket Housing

Socket Housing 2x27-, 2x27 Pin Hybrid System MQS/MPQ, Elo/Elo Power
Manufactured by Amp: The following contact types without strand sealing can be fitted in the socket
housings:
MQS, width 2.8 mm (Micro Power Quadlock).
Manufactured by Siemens: The following contact types without strand sealing can be fitted in the socket
housings:
Elo (electronic contact).
Elo-Power 2.8 mm wide (electronic contact for heavy loads).
Elo-Power 5.2 mm wide (electronic contact for heavy loads).
Raise lock (1) on housing (2).

Push contact carrier (3) from rear out of housing.
NOTE: The second carrier is pushed out in the same way.
Pushing out the contact carrier releases the secondary locks of the secondary contacts.
2010 BMW M3
Procedure for removing contacts are same as for other Elo/Elo-Power Systems, refer to the appropriate article.
Fig. 62: Removing Contact Carrier From Rear Housing

In-line Plug 30 Pin Hybrid System MQS/MPQ
Manufactured by AMP: The following contact types without strand sealing can be fitted in the plug housings:
Socket Housing
2010 BMW M3

Push contact carrier (3) from rear out of housing (2).
NOTE: Pushing out the contact carrier releases the secondary locks of the socket
contacts. Procedure for removing contacts are same as for other Elo/Elo-Power
Systems, refer to the appropriate article.
Fig. 63: Removing Contact Carrier From Rear Out Of Housing

Pin Housing
Contact 1-13 and 19-27.

Raise locking slide (1) on both sides (2) of housing and detach.
2010 BMW M3
NOTE: Detaching the locking slide releases the secondary locks of the pin
contacts.
Contacts 14-18 and 28-30.

Pull slide (1) outward completely.
Raise lock (2) on housing.
Pull contact carrier out of housing.
NOTE: Pulling out the contact carrier releases the secondary locks of the pin contacts.
Fig. 64: Identifying Pin Housing Slide

2010 BMW M3
Fig. 65: Removing Pin Housing Contact Carrier

Socket Housing 5-, 8 Pin System MQS/MPQ
housings:
Socket housing 5 pin (Hybrid System MQS/MPQ)

2010 BMW M3
Raise fastener (1) (slide) by way of retaining lug (2) and detach from contact carrier (3).
Fig. 66: Identifying Socket Housing Fastener

Socket Housing 8 Pin (MQS)
Raise fastener (1) (slide) by way of retaining lug (2) and detach from contact carrier (3).
Procedure for removing contacts are same as for other Elo/Elo-Power Systems, refer to the appropriate article.
2010 BMW M3
Fig. 67: Identifying Socket Housing 8 Pin (MQS)

Socket Housing (Radio Plug) Hybrid system MQS/MPS
Removing MPQ contacts from radio plug:
Press lock (1) in direction of arrow, detach secondary lock (2) from radio plug.
2010 BMW M3
Feed special tool 61 1 135 past side of contact.

Press special tool 61 1 135 in direction of arrow.
Pull wire (1) with socket contact out of radio plug (2).
Fig. 68: Locating Radio Plug Lock

2010 BMW M3
Fig. 69: Identifying Special Tool In Radio Plug

Removing MQS contacts from carrier
Press lock (1) in direction of arrow and pull housing (2) out of radio plug (Fig. 70).
Press lock (1) in direction of arrow. Pull contact carrier (2) out of housing (Fig. 71).
NOTE: When the contact carrier is pulled out, the secondary locks of the socket
contacts are raised. Procedure for removing contacts are same as for other
Elo/Elo-Power Systems, refer to the appropriate article.
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Fig. 70: Removing Housing From Radio Plug

2010 BMW M3
Fig. 71: Removing Contact Carrier Out Of Housing

Removing MPQ contacts from contact carrier
Remove contact carrier (1) with MQS contacts from radio plug. Raise lock (2) on radio plug. Pull contact
carrier (3) out of radio plug (Fig. 72).
Press lock (1) in direction of arrow. Pull secondary lock (2) in direction of arrow completely out of
contact carrier (3) (Fig. 73).
Press special tool 61 1 135 on inside of contact into contact carrier (2). Pull wire with socket contact (1)
out of contact carrier (2) (Fig. 74).
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Fig. 72: Removing MPQ Contacts From Contact Carrier

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Fig. 73: Removing Secondary Lock From Contact Carrier

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Fig. 74: Removing Socket Contact From Contact Carrier

MISCELLANEOUS CONNECTORS
Fuse Strip
Pull appropriate fuse from fuse strip (1).Note: Mark fuse rating and position for reinstallment.
Pull locking slide (2) out of fuse strip until stop is felt.
Using special tool 61 1 136 or 61 1 137 press the spring latch down (3) and pull the connector from the
2010 BMW M3
housing.
Fig. 75: Removing Locking Slide From Fuse Strip

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Fig. 76: Removing Connector From Housing Using Special Tool

ECM Main Relay Connector
Unlock wire flap (1) of connector being removed.

Using special tool 61 1 136 or 61 1 137 press the spring latch down (2) and pull the connector from the
housing.
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Fig. 77: Removing Wire Flap Of Connector

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Fig. 78: Locating Spring Latch

SOLDERLESS TERMINALS AND CONNECTORS
Mechanical strength of solderless terminal design and electrical conductivity must be maintained at all times.
To ensure these characteristics are maintained in the vehicles electrical system several BMW repair kits are
available.
The repair kits listed contain all the approved connectors, pins, and tools required for proper repair of BMW's
electrical, electronics components.
Electrical Repair Kit IV
P/N 90 88 6 619 020
The Electrical Repair Kit IV (Ref. SI. 04 18 92) is used in conjunction with the detailed repair procedures.
2010 BMW M3
Fig. 79: Identifying Electrical Repair Kit IV

Disassembling, replacing a plug connection on the various types of connectors.

Cutting cable to length.
Crimping stop parts (Contacts).
Butt connectors for repairing a plug connection.
Operating instructions for special tools and the handling of individual parts in the repair kit are available under
PN 61 9 029.
Three previous kits issued by BMW are:
Electrical Repair Kit I (Black Case)
P/N 81 24 9 408 080
Electrical Repair Kit II (Blue Case)

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P/N 81 24 9 408 300
Electrical Repair Kit III (Red Case)
P/N 82 11 9 408 400
Electrical repair kits I, II and III are primarily needed for repairing wiring harness and connectors of older
vehicles (E30 and earlier).
Operating instructions for special tools in these kits are available under PN 61 8 084.
2010 BMW M3
Fig. 80: Identifying Electrical Repair Kits

ELECTRICAL REPAIR KIT IV
The Electrical Repair Kits (I, II, III and IV) have gone through various upgrades.
Electrical Repair Kit IV (PN 90 88 619 020) has been developed to handle repairs of the specialized state of the
art wiring and harnesses of the newest BMW products.
2010 BMW M3
Fig. 81: Identifying Electrical Repair Kit IV

CAUTION: The special tools contained in the Electrical Repair Kits I, II, III are not state
of the art and are not suitable for specialized wiring harness repairs. Use
exclusively Electrical Repair Kit IV for those repairs.
Electrical Repair Kit IV (61 9 020)
Contains the following:
61 9 041 Crimping Tool.
61 9 042 Matrix.
61 9 043 Cable Stripper.
61 9 044 Matrix.
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Assorted Individual Parts.
Cable Stripper
Special Tool 61 9 043 Cable stripper with wire cutter for cutting and stripping insulation from cables.
Fig. 82: Identifying Cable Stripper

Crimping Tool
Special Tool 61 9 041 Crimping Tool with special tool 61 9 044 (matrix) for crimping cable guide and strain
relief device on antenna elbow plug.
Supplementary kits for Electrical Repair Kit IV are released periodically.

2010 BMW M3
Fig. 83: Identifying Crimping Tool

CABLE STRIPPING
Proper wire stripping and connector replacement is essential to ensure the integrity of the electrical connection.
Always follow specific instructions in the Electrical Repair Kit IV instruction manual.
The length of wire to be stripped is determined by the wire gauge.
WIRE CROSS-SECTION SIZE SPECIFICATIONS

Wire cross-section size stripped length:
mm2 mm
0.35... 0.50 4.0
0.75... 1.00 4.5
1.00... 2.50 5.0
2010 BMW M3
Fig. 84: Inserting Wire Into Cable Stripping Tool

Proper use of the wire stripping tool will provide consistently positive results. Insert the wire (1) into the
stripper. Stop the wire when the required strip length is past the cutter (2). Squeeze the handle of the tool.
2010 BMW M3
Fig. 85: View Of Wire In Stripper

When the top jaw of the tool touches the wire (3) the mechanism shifts the clamping action to a pulling action
which strips the wire of the insulation (4).
2010 BMW M3
Fig. 86: Removing Insulation Using Stripper

CRIMPING
Use the wire crimper from the BMW Electrical Repair Kit. This crimper is designed for the specific connectors
found in BMW automobiles. Proper use of the tools will provide consistent good quality connector crimps.
The crimper is designed to apply just the right amount of pressure based on the wire gauge and connector size.
2010 BMW M3
Fig. 87: Identifying Removable Crimper Jaws

The tool has removable crimper jaws (3). This feature allows for an unlimited number of connector types for
future compatibility. The article refers to the different sized crimping slots as "Nests". The gauge of the wire
being crimped determines which "Nest" is used.
2010 BMW M3
Fig. 88: Identifying Crimper Jaw Dimensions

WIRE CROSS-SECTION SIZE SPECIFICATIONS

Nest Wire Cross-section size
1 0.035....0.50mm2
2 0.75......1.0mm2
3 1.5mm2
4 2.5mm2
Example:
A. 75 - 1.0mm gauge wire requires nest 2 for proper crimping.
Throughout the Electrical Repair Kit instruction manual are illustrations of various connectors being crimped.
The highlighted box of the 16 box grid in these illustrations refers to the storage compartment in the electrical
kit drawers in which that specific connector can be found.
Insert the "crimping end" of the connector into the appropriate "nest". Illustration provides example of comb
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replacement connector (4) and inline splice connector (5).
Fig. 89: Identifying Comb Replacement Connector

Squeeze the tool handle slightly to set the tool in the first ratchet latch position. This will hold the connector in
the tool without closing the crimp (6).
Insert the stripped wire into the receiving end of the crimper tool making sure the wire is inserted far enough to
ensure that only the wire insulation will be inside the insulation support barrel (7).
Properly crimped connectors exhibit the following characteristics:

2010 BMW M3
Fig. 90: View Of Connector In Tool

The insulation support barrel will be crimped consistently and snug against the insulation. The insulation
will not be crushed (8).
A bellmouth crimp will be visible at the wire end of the of the wire barrel (9).
Wire strands will be visible at the contact end of the wire barrel (10).
Insulation end will be visible in this area (11) (Fig. 92).
2010 BMW M3
Fig. 91: View Of Wire Insulation In Support Barrel

The following are examples of unacceptable crimps: (Fig. 93)
Excessive or no wire strands at the contact end of the wire barrel (10).
Excessive or no insulation end in the acceptable area (11).
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Fig. 92: Identifying Properly Crimped Connector

2010 BMW M3
Fig. 93: Identifying Unacceptable Crimps

PREPACKAGED WIRING REPAIR SETS
Included with the Electrical Repair Kit IV are a variety of wiring repair sets. These sets contain various pre-
crimped wiring connectors on assorted gauge wire lengths for simple splice connection repair into a wiring
harness.
The repair kits also contain:

2010 BMW M3
1. Various gauge lengths of wire with precrimped connectors.

2. In-line splice connectors.
3. Heat shrink tubing.
Fig. 94: Identifying Prepackaged Wiring Repair Sets

When used correctly the in-line splice connectors provide a BMW factory approved wire crimp. Use the correct
size nest in the crimper tool and connect one side of the in-line crimp with the wire.
Slide a piece of heat shrink tubing on the wire and crimp the other side of the in-line connector.
2010 BMW M3
Fig. 95: Using Correct Size Crimper Tool

Use a heat gun to shrink the tube around the splice connector to provide a moisture resistant seal.
Part numbers for the wire sets or any component of all four electrical repair kits can be reordered from:
The P/N reference card inside each repair kit.

Special tools microfiche.
The Electrical Repair Kit 1-4 component catalog (SD 92-036).
2010 BMW M3
Fig. 96: Identifying Electrical Connectors

As new connectors are developed for new vehicles, the repair kits will be added to appropriate articles.
Soldering Connections
In the event that a wiring connection must be soldered in a vehicle's electrical system, there are certain
procedures which must be followed. Improper soldering will result in poor electrical connections or damage to
electrical components.
SAFETY: Adhere to the following basic guidelines when preparing to solder.
Safety glasses must be worn.

Disconnect vehicle battery.
Cover vehicle trim surfaces.
Exercise your common sense.
Provide adequate ventilation, it's the best safety precaution!
2010 BMW M3
Fig. 97: Identifying Correct Amount Of Wire For Soldering

Soldering Preparation and Procedure
The wire insulation must be stripped to expose an adequate amount of bare wire (not too little-not to
much.)
The wires and or connectors must be clean and free of grease, dirt, wax, etc.
A thin coating of rosin core flux must be applied to the soldering connection.
Have enough 60/40 (tin/lead) general electrical solder on hand prior to starting.
If heat transfer to a heat sensitive component is possible use "heat sinks".
Use a soldering gun tip that is the right size for the job. Do not use an overly large tip which could melt
wire insulation and block your view of what is being soldered.
The soldering tip must be "tinned" . This means to keep a thin layer of solder on the tip at all times
during soldering. This will transfer the heat quickly and allow the solder to flow easily into the joint being
soldered.
2010 BMW M3
Preheat the wires or connector. Introduce the solder into the joint not the soldering tip.
When the solder starts to flow allow it to infiltrate the joint only for a moment. Almost simultaneously,
pull the tip off of the joint to prevent overheating.
A properly soldered joint will be smooth, shinny, and even surfaced.
Fig. 98: Identifying Soldering Procedure

BREAKOUT BOXES AND "V" CABLES
Breakout Boxes are used to:
Provide a convenient "tap" into an electrical circuit.

Minimize the possibility of damage to control unit connections and wire harnesses during diagnosis of
electrical/electronic systems.
Ensure solid meter connections for proper diagnosis, this in turn will help the technician to be more
organized and efficient.
Provide easier access to circuits for testing with equipment such as, multimeter, DISplus tester or other
2010 BMW M3
diagnostic tools.
CAUTION: Breakout box cable connections are universal in order to fit the varying
coded connectors found in the vehicles. Always confirm that you are
connecting the correct control module into the system harness that is on
the other side of the breakout box. System damage will occur if it is not
the correct system.
Example: DME and EGS/AGS control modules both utilize an 88 or 134 pin control module. These control
modules reside in the same E-Box on most vehicles. The control modules are coded to prevent unintentional
cross connecting at the vehicle harness. But, this connector coding is not present on the 88 or 134 pin breakout
box(s). Result: A DME control module could be connected to a transmission control system. Damage will
result!
Several different types of breakout boxes are available depending on the particular system being diagnosed.
Fig. 99: View Of Breakout Box

55 pin Breakout Box P/N 81 12 9 425 091
Used with control modules that have single multipin plugs from 25 to 55 pins.
L-jetronic.
ABS.
Motronic.
2010 BMW M3
EGS.
Adapter cables are required.
Fig. 100: Identifying 55 Pin Breakout Box P/N 81 12 9 425 091

83 Pin Breakout Box (Red Face) P/N 90 88 6 614 420

2010 BMW M3
When used with ABS/ASC 5 system, no adapter cables are required. There is an adapter harness for use with
the Teves Mark IV G ABS system of the E36.
Fig. 101: View Of 83 Pin Breakout Box (Red Face) P/N 90 88 6 614 420
88 Pin Breakout Box (Green Face) P/N 88 88 6 614 410
Used with control units that have up to 88 pins;
DME.
EGS/AGS.
ZAE/MRS.
LCM.
No adapter cables are required when connected to a DME or EGS/AGS control module. There are adapter
harnesses for ZAE/MRS and LCM systems.
2010 BMW M3
Fig. 102: Identifying 88 Pin Breakout Box (Green Face) P/N 88 88 6 614 410
134 Pin SKE Control Module Breakout Box Set P/N 90 88 6 121 300
The 134 pin modular connector DME and AGS control modules use a combination of breakout boxes for
2010 BMW M3
troubleshooting. The part number above provides three breakout boxes and five adapter harnesses. The two
outside edge connectors use the familiar 26 pin breakout boxes. The three inside connectors use the boxes from
the ordered set.
Fig. 103: View Of 134 Pin SKE Control Module Breakout Box Set P/N 90 88 6 121 300
26 Pin Breakout Box P/n 88 88 6 611 459
Used with system or peripheral control module that have up to 26 pins. This breakout box is used in conjunction
with adapter cables called "V" Cables. There are many different types of "V" cables for the various connectors
found on the vehicles.
2010 BMW M3
Fig. 104: Identifying 26 Pin Breakout Box P/N 88 88 6 611 459

60 Pin Breakout Box P/N 90 88 6 614 390

2010 BMW M3
Used for connecting all adapter leads with 27 pin to 60 pin plug connections.
Fig. 105: View Of 60 Pin Breakout Box P/N 90 88 6 614 390

TESTER AND ADAPTER SET FOR RELAYS
The Relay Adapter provides a platform to test a relay while allowing the relay to remain active in a circuit.
The adapters included enable different pin configurations of relays to be tested using a single tester.
2010 BMW M3
Fig. 106: Identifying Tester And Adapter Set For Relays

Remove relay and compare plug in adapter with plug pattern on relay. Choose correct adapter (Fig. 107).
Fit adapter to Measuring bridge, noting the marker arrows (A). Fit the relay to the measuring bridge (Fig. 108).
Plug the assemble measuring bridge into the socket of the relay to be checked. Test using a multimeter. See the
circuit diagram, testing instructions in the appropriate article for subsequent procedure (Fig. 109).
2010 BMW M3
Fig. 107: Identifying Relay And Compare Plug

2010 BMW M3
Fig. 108: Fitting Adapter To Measuring Bridge

2010 BMW M3
Fig. 109: View Of Measuring Bridge In Socket

"V" Cables
"V" cables are available in different versions depending on the system being diagnosed. Always refer to the
most recent information for the required special tools.
"V" cables are only used with the 26 pin breakout box to access input and output signals of peripheral modules
and systems.
2010 BMW M3
Fig. 110: Identifying "V" Cables

The appropriate cable is distinguished by the color of the connector end.

The color will match the particular modules connector color. Unless the color matches, the cable will not
fit the connector on the module being tested.
Each colored "V" cable has a series of alignment tabs that will only fit it's particular module or system.
"V" cables with ELO connectors are also being used with the 26 pin breakout box. These cables are unique in
that they have a locking arm on the component side of the cable. They are light green in color, and the number
of pins will vary depending on the system being tested.
"V" harness adapters were introduced with the E38. These also have light green ELO connectors on the
component side, but they do not require a breakout box.
There is a black plug on one side with same number of pins as the component being tested.
2010 BMW M3
The plug has numbers stamped on it's side that corresponds with the pins on that particular component.
You access the signals by plugging the test equipment directly into those pin numbers.
As new systems and components are being introduced, new breakout boxes and cables will also be introduced.
2010 BMW M3
CABIN AIR FILTER BMW - M3
CABIN AIR FILTER
BMW - M3
CABIN AIR FILTER
NOTE: Manufacturer's terminology for this filter is Microfilter.
REMOVAL & INSTALLATION
64 31 062 Removing and installing/replacing left lower microfilter housing section
Remove UPPER SECTION OF MICROFILTER HOUSING
Release screws (1).
Pull out rubber tab (2).
Remove cover (3) and remove lower microfilter housing section (4).
Installation:
Ensure correct lead routing.
Fig. 1: Identifying Rubber Tab, Microfilter Housing Section And Cover With Screws
Installation:
Retaining lugs (1) must be correctly inserted in cowl panel (2).

2010 BMW M3
Fig. 2: Identifying Retaining Lugs And Cowl Panel

64 31 072 Removing and installing/replacing left upper microfilter housing section
Release screws (1).
Remove upper microfilter housing section (2) and if necessary disconnect plug connection for bonnet/hood
contact switch (3).
Installation:
Make sure upper microfilter housing section is correctly seated.
Fig. 3: Identifying Bonnet/Hood Contact Switch And Microfilter Housing Section With Screws
Replacement
2010 BMW M3
Modify HOOD/BONNET CONTACT SWITCH

Modify MICROFILTER FOR INTERIOR VENTILATION
6431092 Removing and installing/replacing microfilter housing (lower section)
Release holder (1).
Remove right cover (2).
Installation note:
Make sure right cover (2) is correctly seated.
Fig. 4: Identifying Right Cover, Holder And Catches

Left cover (4) is removed in same way as right cover.
Also for E90:
Release cable holder (2) and remove hose (1) from cover (4).
Installation note:
Make sure cable holder (2) and hose (1) are correctly seated in opening (3).
2010 BMW M3
Fig. 5: Identifying Left Cover, Cable Holder And Hose

E8x:
Unclip cable from guides (2).
Fig. 6: Identifying Plug Connection And Guides

Unclamp cable from guides (2).

2010 BMW M3
Fig. 7: Identifying Connector And Cable Guides

E81, E82, E87, E88:
Open hose clamps (2) on hose (1).

Press detent lugs (3).
Release cable strip (1) in direction of arrow from lower section of microfilter housing (2).
Installation note:
Retaining lugs (3) must not be damaged or missing.
Make sure cable strip is correctly seated.

2010 BMW M3
Fig. 9: Pressing Detent Lugs

Release holder (2) on both sides.
Release screw (1) on both sides on lower section of microfilter housing (3).
Fig. 10: Identifying Microfilter Housing Lower Section, Holder And Screw
Feed out microfilter housing lower section (1) in direction of arrow and remove.
Installation note:
Make sure microfilter housing lower section (1) is correctly seated.

2010 BMW M3
Fig. 11: Installing Microfilter Housing Lower Section

Installation note:
Seal (2) of microfilter housing lower section (1) must not be damaged or missing.
Fig. 12: Identifying Seal Of Microfilter Housing Lower Section

6431081 Removing and installing/replacing microfilter housing (upper section)
NOTE: Example shown on E87:

Release screws (1).
Remove upper section of microfilter housing (4).
Installation:
2010 BMW M3
Make sure upper section of microfilter housing (4) is correctly seated.
Fig. 13: Identifying Microfilter Housing Upper Section And Screws

Replacement
Release microfilter (2) in direction of arrow from upper section of housing (3).
Installation:
Make sure microfilter (2) is correctly seated.
Fig. 14: Identifying Microfilter, Upper Section Of Housing And Catches

64 31 063 Removing and installing/replacing right lower microfilter housing section

2010 BMW M3
Remove RIGHT UPPER MICROFILTER HOUSING SECTION
Release screw (1).
Pull off rubber tabs (2) and remove cover (3).
Unclip AUC sensor (4) with electrical lead and remove lower microfilter housing section.
Installation:
Fig. 15: Identifying AUC Sensor, Rubber Tabs With Screws

Installation:

2010 BMW M3

64 31 074 Removing and installing/replacing right upper microfilter housing section
Release screws (1) and remove upper microfilter housing section (2).
Installation:
Fig. 17: Identifying Microfilter Housing Section With Screws

Replacement
Replace MICROFILTER FOR INTERIOR VENTILATION .
64 31 011 Replacing microfilter for interior ventilation

2010 BMW M3

A/C system must not be operated without the prescribed filter element.
Follow manufacturer's instructions.
Note on cleaning:
Spray microfilter housing from inside with BMW pollen filter housing cleaner* (observe instructions for use).
Comply WITH NOTES AND INSTRUCTIONS ON HANDLING CLEANING AGENTS !
Wipe away excess liquid.
This kills off germs, bacteria and fungi that cause smells.
The smell that results on the plastic parts of the microfilter housing is eliminated.
*BMW part number: 0 447 913
Remove upper microfilter housing section See : 6431074 REMOVING AND

INSTALLING/REPLACING RIGHT UPPER MICROFILTER HOUSING SECTION or 6431072
REMOVING AND INSTALLING/REPLACING LEFT UPPER MICROFILTER HOUSING SECTION
on left and right
Unclip microfilter (1) with suitable tool and remove.
Installation note:
Reset Condition Based Service display according to factory specification.
Fig. 18: Identifying Microfilter

2010 BMW M3
GENERAL INFORMATION Charging Systems - Overview
GENERAL INFORMATION
Charging Systems - Overview
CHARGING SYSTEMS
Model: All
PURPOSE OF THE CHARGING SYSTEM
The purpose of the charging system is to convert the mechanical energy of the engine into electrical energy that
is used to recharge the battery and power the electrical accessories. When the engine is first started, the battery
(s) supplies all the current required by the starting and ignition systems.
As the battery drain continues and engine speed increases the charging system is able to produce more voltage
than the battery can deliver. When this occurs, the electrons from the charging device are able to flow in a
reverse direction through the battery's positive terminal. The charging device now supplies the electrical
system's load requirements and recharges the battery.
The charging system consists of:
Battery.
Generator.
Drive Belt.
Rectifier Assembly.
Voltage Regulator.
Charge Indicator.
Ignition Switch.
Cables and Wiring Harness
2010 BMW M3
Fig. 1: Identifying Battery Charging System

SYSTEM COMPONENTS
Battery
The Battery is the primary EMF source in the automobile. The automotive battery is an electromechanical
device that provides the potential difference (voltage). The battery does not store electrical energy. It stores
chemical energy that is converted to electrical energy as it discharges.
Generator
The Generator produces free electrons necessary to charge the battery. The electron flow is produced through
inductance, a magnetized rotor spinning inside a stator. The generator produces AC voltage which is converted
to DC voltage or rectified.
Generator styles:
Brush Type.
Brushless Type.
2010 BMW M3
NOTE: In an attempt to standardize terminology in the industry, the term alternator is

being replaced with generator. Often an alternator is referred to as an AC
generator.
Air or liquid (coolant) is used for generator cooling.
BRUSH TYPE GENERATORS
Brush Type generators consist of the following main components:
Generator Housing.
Stator Assembly.
Rotor Assembly.
Generator Housing
The Housing is made of two pieces of die-cast aluminum. Aluminum is used because it is nonmagnetic, light
weight and provides good heat dissipation.
Bearings for support of the rotor assembly are mounted in the front and rear housings.
Fig. 2: Exploded View Of Generator Housing

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Stator Assembly
The Stator is fixed to the housing of the generator and does not turn. It contains three main sets of windings
wrapped in slots around a laminated, circular iron frame. Each of the three windings has the same number of
coils as the rotor has pairs of north and south poles. The coils of each winding are evenly spaced around the
core.
Fig. 3: View Of Stator Assembly (Y Connection)

The three sets of windings alternate and overlap as they pass through the core in order to produce the required
phase angles.
Each group of windings occupy one third of the stator, or 120 degrees of the circle.
The voltage produced by each loop of the stator is at a different phase angle, as a result the output of the stator
is divided into three phases.
Two common methods of connecting the windings are:
Y Connection.
Delta Connection.
2010 BMW M3
The parallel path of the Delta connection makes more current available.
Fig. 4: Identifying Stator Assembly (Delta Connection)

Rotor Assembly
The Rotor Assembly consists of the rotor shaft, a winding around an iron core, two pole pieces and slip rings.
The rotor shaft is pressed into the core, then six-fingered malleable iron pole pieces are assembled on the shaft
against each end of the winding core.
The pole pieces are placed so that the fingers mesh but do not touch. When direct current is passed through the
field coil winding, the fingers become alternately North and South poles.
2010 BMW M3
Fig. 5: View Of Rotor Assembly

As a result of this arrangement of poles, the magnetic flux lines will move in opposite directions between
adjacent poles.
(Flux lines always move from North to South.)
This arrangement provides for several alternating magnetic fields to intersect the stator as the rotor is turning.
2010 BMW M3
Fig. 6: Identifying Rotor Assembly

A slip ring pressed on to the rotor shaft is connected to the two ends of the field winding.
Two brushes are held by springs against the slip rings. One brush is connected through a switch to the battery
B+, the other to the voltage regulator.
The brushes conduct only the field current (2 to 5 amps).

2010 BMW M3
Fig. 7: Locating Brushes On Rotor Assembly

BRUSHLESS TYPE GENERATORS
Brushless Type generators are liquid cooled (coolant) and consist of the following main components:
Generator Housing.
Stator Assembly.
Rotor Assembly.
2010 BMW M3
Fig. 8: Cross Sectional View Of Brushless Type Generator

Generator Housing Water Cooled

2010 BMW M3
The Water Cooled Generator is housed in an encapsulated metal shell enclosure. The enclosure is installed an
aluminum shell.
The space between the inner surface of the shell and the outer surface of the generator creates a water jacket that
engine coolant flows through.
Coolant flows from the engine into the shell through internal ports and exits via hose connections.
Liquid cooling minimizes noise generation through elimination of generator cooling fan.
Stator Assembly
Although different in appearance the Stator Assembly in a brushless generator performs the same functions as
the brush type.
Rotor Assembly
Fig. 9: Identifying Rotor Assembly

2010 BMW M3
The brushless generator Rotor does not contain the field coil. The pole-finger crowns rotate around a fixed field
coil and are magnetized by the flux field of the field coil.
The two crowns form claw-pole half sections and are retained by a non-magnetic ring positioned below the pole
fingers.
Rectifier Assembly
The Rectifier Assembly consists of six diodes, a pair of diodes for each stator winding. Each pair contain one
positive biased diode and one negative biased diode. By using a pair of diodes that are reversed biased to each
other, rectification of both sides of the AC sine wave is achieved. The negative biased diodes allow for
conducting current from the negative side of the AC sine wave and putting this current into the circuit as
positive current. The use of positive and negative biased diodes provide for full wave rectification because both
halves of the sine wave are used.
Drive Belt
It is the function of the Drive Belt to transfer rotating energy from the engine to the generator. The drive belt
rotates the rotor, spinning the magnetic field. A loose belt can inhibit charging system efficiency and a belt that
too tight causes early bearing failure.
VOLTAGE REGULATOR
Voltage Regulators prevent excessively high voltage output of the generator. Excessive voltage would cause
damage to the battery (through overcharging), light bulbs, motors, and particularly sensitive electronic
components.
The regulator prevents these problems by limiting the current output of the generator.
Two types of regulators that are used:
Standard Regulator.
Multifunction Controller.
Standard Regulator
Electronic Voltage Regulators are mounted internally in the back of the generator assembly. Generator output is
controlled by varying the amount of time the field coil is energized. The duty cycle of the field coil ground side
is varied based on the demand placed on the electrical system.
The electronic voltage regulator compares field current supply voltage (from the stator windings through the
diode trio) against a set voltage level ( using a zener diode).
As the field current supply voltage surpasses the zener diode's breakdown voltage, the field current to the rotor
is switched off. When the field current voltage to the rotor is off, the generator is not producing voltage. A rapid
2010 BMW M3
switching of the field current allows a fixed voltage output to be maintained. Additional diodes in the regulator,
prevent current flow when the ignition is off preventing battery drain.
Multifunction Controller
In addition to voltage regulation, the Muti-function Control electronic regulator provides the following features:
Load response during start-up.

Load response during driving.
Fault display (under voltage, drive belt breakage, field coil interruption).
NOTE: Multi-function Control electronic regulators are available with and without start
load response. The only difference is the time limitation of the rated current
during the start procedure.
The start-up load response system provides for the alternator exciter current (field coil) to be started by a
transistor two seconds after the battery indicator goes out. This means that engine start-up is unaffected by
generator induced drag.
The load response during driving ensures that when large current consumers are switched on the generator
output increases linearly allowing the DME/EML system to stabilize the engine speed and/or modify injection
time if necessary.
Charge Indicator
The purpose of the Charge Indicator is to advise the driver that the vehicle's electrical system is not operating at
peak efficiency and service should be performed.
The charge indicator operates differently depending on which type of regulator the vehicle is equipped with.
Standard Regulator
The charge indicator operates on the basis of opposing voltages. If there is no output through the diode trio, then
the lamp circuit is completed to ground through the rotor field. Diode output applies voltage to the previously
grounded side of the bulb, turning the bulb off (No current flow with equal voltage on both sides of the bulb).
The charge indicator is activated by an electronic switch integrated in the controller. This internal switch
receives its voltage supply from KL15 of the 2 pin generator connector. The controller measures internally the
difference in voltage between KL30 and KL15 and switches the indicator circuit low in case of a fault.
Ignition Switch
The Ignition Switch provides initial power for the field circuit of the alternator, reducing the time required for
the field to develop the magnetic field. Depending on which type of regulator is employed the ignition switch
supplies power to the charge indicator to check bulb integrity.
2010 BMW M3
Cables and Wiring Harness
The Cables and Wiring Harness are used to deliver the voltage produced by the generator to the battery for
storage, and to vehicle systems to supplement battery voltage.
CHARGING SYSTEM PRINCIPLE OF OPERATION
Charging Systems (Brush or Brushless) use the principle of electromagnetic induction to generate electrical
power. Electromagnetic induction occurs in a generator when a magnetic field is rotated within a stationary
conductor. The magnetic field can be generated by permanent magnets or as in the case of the automotive
generator by powerful electromagnets.
Passing electric current through a wire or winding causes a magnet field to surround the wire or winding. The
number of turns in the winding and the magnitude of the current flowing through the winding determine the
magnetic field strength.
The strength of the field is further increased by surrounding the coil with pole pieces. The poles will take on the
polarity (North or South) of the side of the coil they touch or the ones they are closest to. The combined
windings (field coil) and pole pieces are referred to as the rotor. Output of the generator is regulated through
control of field coil intensity.
An examination of single phase AC voltage generation, will aid in the understanding of 3 phase AC voltage
generation.
SINGLE-PHASE AC VOLTAGE GENERATION
Single Phase AC Voltage Generation requires one stator frame with windings and one magnetic field (North
and South pole pieces).
2010 BMW M3
Fig. 10: View Of North/South Poles And Stator Frame

As the North pole of the rotor pole piece approaches the winding of the stator, induced voltage level in the
stator begins to rise. The closer the North pole gets to the stator winding the higher the induced voltage. As the
North pole reaches 90 to the stator winding the maximum amount of flux lines are acting on the winding,
induced voltage is at its highest positive value (1/4 turn).
2010 BMW M3
Fig. 11: Identifying Stator Rotation (1/4 Turn)

The rotor continues to rotate and the North pole gets further away from the winding. The voltage drops, until 0
voltage is induced through the stator (1/2 turn).
2010 BMW M3

With the South pole now approaching the winding voltage begins to increase negatively. When the South pole
reaches 90 to the winding, again the maximum amount of flux lines are acting on the winding and induced
voltage is at its greatest negative value (3/4 turn).
2010 BMW M3

The South pole continues to travel farther away from the winding decreasing the negative voltage value until 0
voltage is again reached (1 full turn).
This comprises one cycle or 360 rotation of the magnetic field.

2010 BMW M3
Fig. 14: Identifying Stator Rotation (1 Full Turn)

Sine wave produced by a single winding of the stator during a single revolution of one pair of pole pieces
is called single phase voltage.
THREE-PHASE AC VOLTAGE GENERATION
Most AC generators use either a twelve or a fourteen pole rotor. Each pair of poles (North and South) produce
one complete sine wave in each winding per revolution.
2010 BMW M3
Fig. 15: Three-Phase AC Voltage Graph

Voltage of each stator winding is added together to create three-phase voltage.
During one revolution a fourteen pole rotor will produce seven sine waves. (The stator has one winding (coil)
for each pair of rotors.)
The rotor generates three overlapping sine wave voltage cycles in the stator (one rotor three sets of windings in
the stator).
The total output would be twenty one sine wave cycles per revolution (3 sets of stator windings, each with 7
coils).
2010 BMW M3
Fig. 16: Identifying Wave Cycle

Sine wave cycle of a fourteen pole rotor and three phase stator.
VOLTAGE RECTIFICATION
The battery and the electrical system cannot store or use the 3-phase AC voltage produced by a generator, it
must be rectified or converted to DC voltage.
A diode rectifier bridge is used to make the conversion.
The diode is similar to a non-return or one way valve which permits the passage of a fluid or gas in only one
direction.
2010 BMW M3
Fig. 17: Identifying Voltage Rectification

In a simple conversion the rectifier diode suppresses the negative half waves and allows only positive half
waves to pass.
To make use of the negative value half waves full rectification is applied.
Full rectification of the negative half waves invert them into positive half waves.
The result is a rectified pulsating direct current.

2010 BMW M3
Fig. 18: Identifying Half Waves

Rectified Pulsating DC current
THREE-PHASE VOLTAGE REGULATION
Six diodes are used to achieve three-phase AC voltage rectification. Three diodes are positive biased and three
are negative biased.
The positive half-waves pass through the positive biased diodes and the negative halfwaves through the
negative biased diodes.
Diode rectification of the negative half-waves invert them into positive half-waves.
With full rectification DC voltage supplied to vehicle by generator is not ideally smooth, but exhibits a slight
ripple. This ripple is further smoothed by the battery which is connected in parallel with the generator.
The rectifier diodes in the generator not only convert the current but also prevent battery discharging through
the 3 phase windings of the stator. Current flow can only take place from the generator to the battery.
2010 BMW M3
Fig. 19: Rectifier Diodes Circuit Diagram

Current flow through Y wound stator.

2010 BMW M3
Fig. 20: Oscilloscope Graph

Rectified AC output has a ripple as seen on oscilloscope.

2010 BMW M3
Fig. 21: Identifying Current Flow Through Delta Wound Stator

Current flow through Delta wound stator.
Voltage Regulation
Standard Regulator
The Electronic Regulator uses a zener diode that blocks current flow until a specified voltage is obtained.
Sensing current from terminal 2 passes through a thermistor to the zener diode (D2). As the system voltage
exceeds the breakdown voltage of the zener diode, current flows through the zener diode turning transistor 2
(TR2) on. With TR2 on transistor 1 (TR1) is shut off.
2010 BMW M3
Fig. 22: Regulator Circuit Diagram (1 Of 2)

Transistor 1 controls field current to the rotor. With TR1 off no current flows to the field coil and the generator
has no output.
A voltage drop below the breakdown voltage of the zener diode stops the current flow to TR2 which turns on
TR1.
Voltage is again applied to the field allowing the generator to produce voltage.
2010 BMW M3
Fig. 23: Regulator Circuit Diagram (2 Of 2)

Field coil off, no charging.
The Multifunction Controller regulates voltage in the same manner as the standard voltage regulator. Regulation
is through duty cycle control of the field coil.
The differences as compared to the standard regulator are:
Manner in which malfunction indicator lamp is controlled.

Connections to wiring harness.
2010 BMW M3
Fig. 24: Identifying Multifunction Controller Circuit Diagram

Terminal 1:
KL 15 from fused source.
Terminal 2:
D+ (KL61) to DME.
B+
Generator output to Battery.

2010 BMW M3
Fig. 25: Identifying Two Pin Wiring Harness Connector

Two Pin wiring harness connector
Harness connector
B+ connection.
2010 BMW M3
Fig. 26: Identifying Harness Connector

CHARGE SYSTEM INDICATOR
Standard Regulator
The Charging System Indicator light operates on the principle of opposing voltage. Battery voltage is supplied
to one side of the light bulb, the other side of the bulb is connected to the voltage regulator. With the key turned
on, power is sent to the light bulb, through to the regulator. No voltage is being produced by the stator, so there
is no voltage from the diode trio. This lack of voltage from the diode trio, allows the voltage from the ignition
switch to flow through the regulator to ground. This completes the circuit allowing the charge indicator bulb to
burn.
As the generator begins to produce voltage, the output of the diode trio equals battery voltage. This equal
2010 BMW M3
voltage is supplied to the light bulb. With equal voltage on each side of the light bulb, no current can flow and
the light is turned off.
Fig. 27: View Of Charge Indicator System Circuit Diagram

The charge indicator light is activated by means of an electronic switch integrated into the controller. This
switch receives its voltage supply from terminal 15 on the 2 or 3 pin connector on the generator. Terminal D+ is
replaced by an isolated electronic terminal 61E in generators with a multifunction controller. The task on this
terminal is to activate the battery charge indicator lamp and to indicate to the various loads that the generator is
in charge mode.
The indicator lamp is supplied with voltage via terminal 15 from the instrument cluster. The lamp is illuminated
when the voltage at terminal 61E is below 1.5v and goes out when the voltage is above 8v.
2010 BMW M3
The indicator is on during the following conditions:
Key on, engine off.

Generator not charging.
Failure of drive belt.
Interruption of field coil.
Controller overvoltage.
Break in charging cable.
Fig. 28: View Of Multifunction Controller Circuit Diagram

GENERATOR DIAGNOSIS
Before beginning any generator diagnosis, ensure that the battery is in good condition and has passed all testing
procedures. A weak or defective battery will influence the generator testing.
The generator may be tested using:
DISplus.
VAT testing equipment.
2010 BMW M3
Workshop Hint:
Before beginning diagnostic procedures on the charging system do the following:
Run engine at idle speed for about 5 minutes.

Switch off all electrical loads.
This is done to ensure the battery is charged to such a level that the generator will not be fully utilized and that
loads required during starting (e.g. starter, secondary air pump) will be already switched off.
Testing Generator With DISplus
Two modes of testing are available when using DISplus.
Testing using Test Plan.

Testing using Preset Measurement.
Testing Generator Using Test Plan
Testing the charging system using a test plan is the more complete method of testing.
When selecting this mode of testing, other components in the charging system are tested in addition to the
generator.
Test plans available:
Generator (Checks voltage and current output).

Wiring from generator to battery (Performs voltage drop test).
Charge indicator lamp (Condition of bulb, wiring and signal to bulb).
ON delay and Start ON delay (If applicable).
Ground side circuit wiring (Voltage drop test).
Sub-tests may be available with some of the component testing.
There are many advantages to using the test plan.
1. Complete system testing.

2. Functional description of system on screen.
3. Proper wiring diagrams provided during testing.
4. Test instructions and notes.
5. Instructions for proper test set-up.
6. Display of nominal values.
7. Solutions.
2010 BMW M3
Fig. 29: Identifying DISplus Screen

Testing Generator Using Measurement System
Enter the measurement system and select Preset Measurements.
Instruction on the proper hook-ups required are available through the HELP button, selecting Help using
Preset Measurement.
The oscilloscope will display pre-configured for the testing.
Diagnostic information available through oscilloscope.
Voltage Graph.
Charging Current.
2010 BMW M3
Harmonic Content.
Rotation Speed (Engine RPM).
Fig. 30: View Of Special Tool 61 2 300

Harmonic Content:
This is an expression of AC voltage contained in DC voltage.
The higher the percentage of harmonic content the larger the amount of residual AC voltage in the DC voltage.
High residual AC voltage is caused by weak or failing diodes in the generator. Generators which have harmonic
content readings higher than specified (In TIS) should be replaced.
2010 BMW M3
Fig. 31: Functional Description Of System On Screen

2010 BMW M3
GENERAL INFORMATION CIP Programming - Overview
GENERAL INFORMATION
CIP Programming - Overview
CIP PROGRAMMING
CIP PROGRAMMING SCREENS
Fig. 1: CIP Programming Screen

The opening screen when CIP is started.
Choose which vehicle you will be programming.

2010 BMW M3
Fig. 2: Vehicle Selecting Programming Screen

2010 BMW M3
Fig. 3: Programming Screen - Retrofit Select

Select depending upon programming required.
To retrofit select Load SW.
To update a vehicle select Vehicle.
Selecting Vehicle will ensure that complete encoding is performed.

2010 BMW M3
Fig. 4: Programming Screen - Load Software

Regardless of whether you have selected Load SW or Vehicle, the VO will be determined.
2010 BMW M3
Fig. 5: Programming Screen - Determine

A YES selection will lead you to choose which control module(s) have been replaced.
A NO selection will lead you to Retrofits .

2010 BMW M3
Fig. 6: Programming Screen - Measure Plan

After selecting YES fitted control modules will be determined.

2010 BMW M3
Fig. 7: Programming Screen - Control Modules

After determining the fitted modules, a measures plan will be made. At this point you will be notified if control
modules need to be replaced.
Control module replacement is required if the hardware level in a module can not be upgraded to a high enough
software level.
In the case above no modules need replacement, in fact on the DSC needs to be reprogrammed.
2010 BMW M3
Fig. 8: Programming Screen - DSC Being

DSC programming is being carried out.

2010 BMW M3
Fig. 9: Programming Screen - Retrofit Programming

If you selected no earlier (Have any control modules been replaced?) you would come to this screen.
Here selections to reprogram individual modules can be made or entry into retrofit programming.
2010 BMW M3
Fig. 10: Programming Screen - Selecting Retrofit

Selecting retrofit on the previous screen brings you here.
More selections (such as mobile phone USA) are on the next page, accessed by pressing retrofits on bottom of
selection list.
2010 BMW M3
Fig. 11: Programming Screen - Retrofit

Select the retrofit, in this case the Mobile phone USA.

2010 BMW M3
Fig. 12: Programming Screen - Battery

You will be asked which battery the car has installed.

2010 BMW M3
Fig. 13: Programming Screen - Measures Plan

A measures plan will be determined and displayed to accomplish the retrofit.
Press Accept.
2010 BMW M3
Fig. 14: Programming Screen - Retrofit Being Carried Out

The retrofit is being carried out.

2010 BMW M3
Fig. 15: Programming Screen - Vehicle Function

By selecting Vehicle initially when entering CIP, you will save time when updating the vehicle.
Updating through Load SW differs from Measures Plan determined through Vehicle.
When updating through Load SW only the module programmed is re-coded. You still need to come to this
screen and perform Complete Encoding.
By updating through Vehicle, the entire car is automatically encoded, after the programming is complete.
2010 BMW M3
Fig. 16: Programming Screen - Pressing Start

Press start to begin the programming and encoding procedure.

2010 BMW M3
TRANSMISSION Clutch - Repair
TRANSMISSION
Clutch - Repair
MAINTENANCE AND INSPECTIONS

21 00 006 BLEEDING CLUTCH HYDRAULIC SYSTEM
Remove transmission underbody protection if necessary.

Remove microfilter housing is necessary.
IMPORTANT: From 08.06 a plastic clutch slave cylinder . See 2100006 BLEEDING CLUTCH
HYDRAULICS (PLASTIC SLAVE CYLINDER) or 2152510 REMOVING AND
INSTALLING/REPLACING CLUTCH SLAVE CYLINDER (PLASTIC) is installed in
the E8X, E9X.
Important notes on installation are described in this work step.
Unfasten nuts and remove clutch slave cylinder (pressure line remains connected).
Fig. 1: Identifying Clutch Slave Cylinder Nuts

Fit special tool 21 5 030 on clutch slave cylinder (1).
Press piston rod (2) with aid of spindle completely into clutch slave cylinder.
2010 BMW M3
Fig. 2: Pressing Piston Rod Into Clutch Slave Cylinder Using Special Tool (21 5 030)
Connect bleeder unit to brake fluid expansion tank.
Connect bleeder hose to bleed valve (1).
Hold clutch slave cylinder in illustrated position (refer to figure) with special tool 21 5 030.
Open bleeder valve (1).
If bubble-free brake fluid emerges, retract piston rod (2) of clutch slave cylinder with aid of spindle a little and
press in again.
If no air bubbles escape, close bleeder valve (1), otherwise repeat procedure.
IMPORTANT: Do not under any circumstances remove special tool 21 5 030 from clutch slave
cylinder when brake system is pressurized.
Piston with push rod can jump out of clutch slave cylinder.
2010 BMW M3
Fig. 3: Removing Clutch Slave Cylinder Using Special Tool (21 5 030)
Switch off bleeder unit or remove from brake fluid expansion tank.
Slowly retract piston rod (2) of clutch slave cylinder (1) with special tool 21 5 030.
Remove special tool 21 5 030 from clutch slave cylinder (1).
Fig. 4: Pressing Piston Rod Into Clutch Slave Cylinder Using Special Tool (21 5 030)
Fit clutch slave cylinder to transmission.
Installation:

2010 BMW M3

Correct brake fluid level in expansion tank.
21 00 006 BLEEDING CLUTCH HYDRAULICS (PLASTIC SLAVE CYLINDER)
Remove underbody protection from transmission.

Open bleed valve (1) and flush until clear brake fluid emerges without air bubbles.
Close bleed valve.

2010 BMW M3
Fig. 6: Identifying Bleed Valve

CLUTCH WITH DRIVING DISC

21 21 500 REMOVING AND INSTALLING/REPLACING CLUTCH (GS6-53BZ) S65
Remove TRANSMISSION .
IMPORTANT: When reinstalling the removed clutch, be sure when disassembling the clutch
to use special tool 21 2 180 .
Failure to comply with this instruction will result in total failure.
Block flywheel with special tools 11 9 260 HOLDER and 11 9 265.

2010 BMW M3
Fig. 7: Blocking Flywheel Using Special Tools (11 9 265) And (11 9 260)
NOTE: Locking hooks (1) of special tool 21 2 180 must engage in openings of pressure
spring.
Fig. 8: Locking Hooks Using Special Tool (21 2 180)

Insert special tool 21 2 180 in clutch.
Press special tool 21 2 180 together at handles (1) as far as it will go and tighten down knurled screws (2).
Adjustment ring of clutch is now secured in its original position (wear position).
Release screws and remove clutch from flywheel.

2010 BMW M3
Fig. 9: Inserting Special Tool (21 2 180) In Clutch

IMPORTANT: Observe the following procedure when reinstalling the removed clutch and
clutch discs.
Pressure plate and dual-mass flywheel with line markings:
Pressure plate and dual-mass flywheel are balanced together.

Line markings must be located one on top of the other during assembly
Pressure plate and dual-mass flywheel with dot markings:
Dot markings must be located one on top of the other during assembly
Centre clutch disc (2) with special tool 21 2 280 MANDREL on flywheel.
IMPORTANT: Install clutch disc in correct position.

Note designation for "engine side"/"transmission side".
Handle clutch disc with care. Do not touch surfaces of friction linings.
2010 BMW M3
Fig. 10: Centering Of Clutch Disc Using Special Tool (21 2 280) On Flywheel
NOTE: Clutch (1) must be secured by way of dowel pins (2).

Bolt clutch (1) to flywheel.
Remove special tool 21 2 180 .
Fig. 11: Removing Special Tool (21 2 180)

Withdraw special tool from clutch disc with aid of accompanying screw (1).
2010 BMW M3

Installing new clutch
IMPORTANT: Locking element may only be removed clutch is screwed down!
NOTE: From 09/08 pressure plate and dual-mass flywheel are no longer balanced
together!
IMPORTANT: On vehicles which had pressure plate and dual-mass flywheel with line
markings installed:
When installing a new clutch, also replace the dual-mass flywheel and install a
reinforced overcenter helper spring.
On vehicles which had pressure plate and dual-mass flywheel with dot
markings installed:
Clutch and dual-mass flywheel can be replaced individually.
Centre clutch disc (2) with special tool 21 2 280 MANDREL on flywheel.
IMPORTANT: Install clutch disc in correct position.

Note designation for "engine side"/"transmission side".
Handle clutch disc with care. Do not touch surfaces of friction linings.
2010 BMW M3
Fig. 13: Centering Of Clutch Disc Using Special Tool (21 2 280) On Flywheel
Fit clutch to flywheel.
IMPORTANT: Clutch must be secured by way of dowel pins (1).
Fig. 14: Locating Dowel Pins

Carefully unscrew locking element (1) clockwise or counterclockwise with WAF 14 Allen key (2).
NOTE: A slight snapping of the plate spring while unscrewing the lock is possible.
2010 BMW M3
Fig. 15: Removing Clutch Plate Screw Using Special Tool

Withdraw special tool from clutch disc with aid of accompanying screw (1).

11 22 513 REPLACING ROLLER BEARING FOR DUAL-MASS FLYWHEEL
NOTE: Flywheel removed!
Position special tool 11 2 010 in roller bearing.
Twist out roller bearing with special tool 11 2 343.

2010 BMW M3
Fig. 17: Twisting Out Roller Bearing Using Special Tool (11 2 343)
Assemble special tools 11 2 350 and 00 5 500 MANDREL .
Drive in roller bearing with special tools 11 2 350 and 00 5 500 MANDREL in direction of arrow as far as it
will go.
Fig. 18: Driving Roller Bearing Using Special Tools (11 2 350) And (00 5 500)
Assemble engine.
Using hydraulic press (1) and special tool 21 2 051, press out dual-mass flywheel downwards on engine side.
2010 BMW M3
IMPORTANT: Risk of damage:

Roller bearing must not be driven out.
Fig. 19: Pressing Dual-Mass Flywheel Using Special Tool (21 2 051) And Hydraulic Press
Push roller bearing (2) onto special tool 21 2 052.
Using hydraulic press (1), press roller bearing into dual-mass flywheel as far as it will go on clutch side.

Observe press-in instruction:
Roller bearing must not be driven in.

Roller bearing mounting force/travel monitored:
Min. 2000N 1 mm before end of pressing in.
Max. 15000N during entire press-in procedure.

2010 BMW M3
Fig. 20: Pressing Roller Bearing Into Dual-Mass Flywheel Using Hydraulic Press
CLUTCH RELEASE CONTROLLER WITH LEVER

21 51 500 REMOVING AND INSTALLING OR REPLACING CLUTCH RELEASE BEARING/LEVER
NOTE: (transmission removed)
New version (except M models)
Release bearing and release lever have been combined to form a single release module.
If possible, do not disassemble the release module. Otherwise, there is a risk of the release module being
incorrectly reassembled.
Installation:
Make sure that the correct cam (1) of the release bearing is on the sliding surface (2) of the release lever.
NOTE: Do not grease sliding surfaces (2).

2010 BMW M3
Fig. 21: Identifying Release Bearing And Lever Surface

Fig. 22: Cam (1) of release bearing (A=12 mm) is on sliding surface of release lever.
This version is for 4-cylinder gasoline engines.
Fig. 22: Cam (1) of release bearing (A=7 mm) is on sliding surface of release lever.
This version is for 6-cylinder gasoline and diesel engines.
Fig. 22: Identifying Release Bearing And Lever Surface

Remove release module (1) from spring wire clip.
Remove release module.
NOTE: Illustration similar.

2010 BMW M3
Fig. 23: Removing Release Module From Spring Wire Clip

Installation:
Check spring wire clip (5) and ball pin (6) for damage and replace if necessary.
Fig. 24: Identifying Spring Wire Clip And Ball Pin

Previous version
Detach release bearing (1).
Installation:
Clean all sliding surfaces on clutch release bearing, check for damage and replace if necessary.
2010 BMW M3
Do not grease clutch release bearing.
Sliding surfaces (2) of clutch release bearing must rest on sliding surfaces (3) of release lever.
Apply a thin coating of grease to sliding surfaces (2) of release bearing.
NOTE: Graphic similar
Fig. 25: Removing Release Bearing

IMPORTANT: Only on E60/E61M5 M5 and E63/E64 M6 (7-speed SMG transmission) - lightly

grease guide sleeve.
Previous clutch release bearing:
Clutch release bearing with moving thrust plate (1).
Swivel motion of thrust plate (1) possible.

2010 BMW M3
Fig. 26: Moving Thrust Plate

Withdraw release lever (4) from spring wire clip (5) and remove.
Installation:
Clean release lever.
Fig. 27: Removing Release Lever From Spring Wire Clip

Previous release lever
Installation:
Apply a thin coating of grease to release lever at sliding surfaces (1 and 2) only.
2010 BMW M3
Fig. 28: Identifying Grease Applying Area

Installation
Apply a thin coating of grease to ball pin (6).
NOTE: The spring wire clip and ball pin must always be replaced on the S6S 420G
transmission.
Illustration similar.

Clean guide sleeve (7).
Installation:
2010 BMW M3
Except for E60/61 M5 and E63/64 M6 (7-speed SMG transmission) - do not grease guide sleeve.
If guide sleeve is greased, the release lever can stick on the guide sleeve.

CLUTCH OPERATION (HYDRAULIC)

21 52 510 REMOVING AND INSTALLING OR REPLACING CLUTCH SLAVE CYLINDER
NOTE: After completing work bleed CLUTCH HYDRAULIC SYSTEM .
IMPORTANT: From 08.06 a plastic CLUTCH SLAVE CYLINDER is installed in the E81, E87 and
E9X.
Seal supply hose to clutch master cylinder with special tool 13 3 010 TERMINAL .
NOTE: Illustration shows E46.

2010 BMW M3
Fig. 31: Sealing Hose To Clutch Master Cylinder Using Special Tool (13 3 010)
Release union screw (1) on hydraulic line.
Release nut (2) and remove hydraulic line (3) with bracket.
Installation:
Version with throttle valve, tightening torque 21 52 12AZ .
Fig. 32: Identifying Hydraulic Line With Screw And Nut

2010 BMW M3
Release nut and remove clutch slave cylinder.
Installation:
IMPORTANT: N47 with H-transmission only

Clutch slave cylinder must not rest at the side on the transmission.
Failure to comply with this instruction may result in leaks at the clutch slave
cylinder.
Fig. 33: Locating Clutch Slave Cylinder Screw

Installation
Clean thrust member (1) and contact face on release lever (2).
Lightly grease thrust member (1) on contact face (3).

2010 BMW M3
Fig. 34: Identifying Thrust Member And Contact Face On Release Lever
IMPORTANT: Spacer between fuel line and pressure hose of clutch slave cylinder must be
correctly fitted.
Fig. 35: Identifying Spacer Between Fuel Line And Pressure Hose Of Clutch Slave Cylinder
21 52 500 REMOVING AND INSTALLING/REPLACING CLUTCH MASTER CYLINDER
NOTE: After completing work, bleed clutch hydraulic system See 2100006 BLEEDING
CLUTCH HYDRAULIC SYSTEM or 2100006 BLEEDING CLUTCH HYDRAULICS
(PLASTIC SLAVE CYLINDER).
Remove TRIM PANEL for pedal assembly.

2010 BMW M3

Draw off brake fluid up to supply hose of clutch hydraulic system (1). For this purpose, use only a vacuum pipe
that is exclusively used for removing brake fluid.
Detach supply hose (1) from expansion tank.
Fig. 37: Identifying Supply Hose

Release screws (1) on cylinder (2).

2010 BMW M3
Fig. 38: Identifying Clutch Master Cylinder And Screws

Disconnect return spring (1).
Detach locking clip (3) and pull clutch pedal with clutch master cylinder off bearing block.
Press pin ends (2) together and remove pin.
Installation:
Replace locking clip.
The locking clip must be seated with both legs in the pin groove.
Fig. 39: Identifying Return Spring, Pin And Locking Clips

Detach retainer (1) with a screwdriver (2).

2010 BMW M3
NOTE: Do not foul carpet with brake fluid.
Detach hydraulic line from clutch master cylinder.
Fig. 40: Identifying Hydraulic Line Retainer

Detach supply hose (1) from clutch master cylinder.
IMPORTANT: Do not pull supply hose completely into interior.
Fig. 41: Identifying Clutch Master Cylinder Supply Hose

Lever out shift element (1) from clutch master cylinder (2) with screwdriver.
Release plug connection (3) and disconnect plug (4) from shift element (1).
2010 BMW M3
Fig. 42: Disconnecting Plug From Housing

Installation:
Shift element is secured against incorrect installation.
Shift element must snap audibly into place.
Fig. 43: Identifying Clutch Switch Module

21 52 510 REMOVING AND INSTALLING/REPLACING CLUTCH SLAVE CYLINDER (PLASTIC)
NOTE: After completing work bleed CLUTCH HYDRAULIC SYSTEM .
Seal hydraulic line to clutch slave cylinder with special tool 13 3 010 TERMINAL .
2010 BMW M3
Fig. 44: Sealing Hydraulic Line To Clutch Slave Cylinder Using Special Tools (13 3 010)
Release nuts and remove clutch slave cylinder (1) with holder (2).
Installation:

cylinder.

2010 BMW M3
Unlock spring retainer (1).
Disconnect hydraulic line (2).
Fig. 46: Identifying Hydraulic Line And Spring Retainer

Press cylinder together by hand.
Connect hydraulic line with cylinder pressed.
Fig. 47: Connecting Hydraulic Line With Cylinder

Remove special tool 13 3 010 TERMINAL .
Hold cylinder piston vertically downwards.
Press piston 5 times into cylinder.

2010 BMW M3
Fig. 48: Holding Cylinder Piston

IMPORTANT: All-wheel drive vehicles only
Installation:
Check pressure hose for traces of abrasion.
If no traces of abrasion by the propeller shaft can be detected on the pressure hose:
The pressure hose must be bent approx. 30 mm away from the propeller shaft.
If traces of abrasion by the propeller shaft can be detected on the pressure hose:
The pressure hose must be replaced.
After replacement, the clutch hydraulics must be BLED .
Press in piston until it engages.
Install clutch slave cylinder.
Bleed CLUTCH HYDRAULICS .
Installation:
Clean thrust member (1) and contact face on release lever.

2010 BMW M3
Fig. 49: Pressing Piston

2010 BMW M3
TRANSMISSION Clutch - Repair - M3
TRANSMISSION
Clutch - Repair - M3
MAINTENANCE AND INSPECTION

21 00 006 BLEEDING CLUTCH HYDRAULIC SYSTEM
21 5 030
See CLUTCH - SPECIAL TOOLS .

Remove microfilter housing is necessary.
IMPORTANT: From 08.06 a plastic clutch slave cylinder is installed in the E8X, E9X.
Unfasten nuts and remove clutch slave cylinder (pressure line remains connected).
Fig. 1: Locating Clutch Slave Cylinder Nuts

Fit special tool 21 5 030 on clutch slave cylinder (1).
Press piston rod (2) with aid of spindle completely into clutch slave cylinder.
2010 BMW M3
Fig. 2: Identifying Special Tool (21 5 030) On Clutch Slave Cylinder


Hold clutch slave cylinder in illustrated position (refer to figure) with special tool 21 5 030 .
Open bleeder valve (1).
If bubble-free brake fluid emerges, retract piston rod (2) of clutch slave cylinder with aid of spindle a little and
press in again.
If no air bubbles escape, close bleeder valve (1), otherwise repeat procedure.
Fig. 3: Connecting Bleeder Hose To Bleed Valve

2010 BMW M3
IMPORTANT: Do not under any circumstances remove special tool 21 5 030 from clutch slave
cylinder when brake system is pressurized.
Piston with push rod can jump out of clutch slave cylinder.
Slowly retract piston rod (2) of clutch slave cylinder (1) with special tool 21 5 030 .
Remove special tool 21 5 030 from clutch slave cylinder (1).
Fig. 4: Identifying Special Tool (21 5 030) On Clutch Slave Cylinder

Fit clutch slave cylinder to transmission.
Installation:
Tightening torque 21 52 5AZ , see 21 52 CLUTCH OPERATION (HYDRAULIC)
Fig. 5: Locating Clutch Slave Cylinder Nuts

2010 BMW M3
21 00 006 BLEEDING CLUTCH HYDRAULICS (PLASTIC SLAVE CYLINDER)
Remove underbody protection from transmission.

Open bleed valve (1) and flush until clear brake fluid emerges without air bubbles.
Close bleed valve.
Fig. 6: Connecting Bleeder Hose To Bleed Valve

CLUTCH WITH DRIVING DISC

2010 BMW M3
21 21 500 REMOVING AND INSTALLING/REPLACING CLUTCH (GS6-53BZ) S65
11 9 260
11 9 265
21 2 180
21 2 280
See ENGINE - SPECIAL TOOLS .
Remove transmission. See 23 00 018 REMOVING AND INSTALLING TRANSMISSION (GS6-53BZ)

(S65) .
IMPORTANT: When reinstalling the removed clutch, be sure when disassembling the clutch
to use special tool 21 2 180 .
Failure to comply with this instruction will result in total failure.
Block flywheel with special tools 11 9 260 and 11 9 265 .
Fig. 7: Identifying Special Tool (11 9 260 And 11 9 263)

NOTE: Locking hooks (1) of special tool 21 2 180 must engage in openings of pressure
spring.
2010 BMW M3
Fig. 8: Locking Hooks Of Special Tool (21 2 180)

Insert special tool 21 2 180 in clutch.
Press special tool 21 2 180 together at handles (1) as far as it will go and tighten down knurled screws (2).
Adjustment ring of clutch is now secured in its original position (wear position).
Release screws and remove clutch from flywheel.
Tightening torque 21 21 1AZ , see 21 21 CLUTCH DISC AND DRIVE PLATE .
IMPORTANT: Observe the following procedure when reinstalling the removed clutch and
clutch plates.
Pressure plate and dual-mass flywheel with line markings:
Pressure plate and dual-mass flywheel are balanced together.

Line markings must be located one on top of the other during assembly
Pressure plate and dual-mass flywheel with dot markings:
Dot markings must be located one on top of the other during assembly
Centre clutch plate (2) with special tool 21 2 280 on flywheel.

2010 BMW M3
Fig. 9: Identifying Clutch Plate Screws

IMPORTANT: Install clutch plate in correct position.

Note designation for "engine side" / "transmission side".
Handle clutch plate with care. Do not touch surfaces of friction linings.
Fig. 10: Identifying Centre Clutch Plate With Special Tool (21 2 280) On Flywheel
NOTE: Clutch (1) must be secured by way of dowel pins (2).
Bolt clutch (1) to flywheel.

2010 BMW M3
Fig. 11: Identifying Special Tool (21 2 180) With Dowel Pins
Withdraw special tool from clutch plate with aid of accompanying screw (1).
Fig. 12: Identifying Accompanying Screw

Installing new clutch
IMPORTANT: Locking piece may only be removed clutch is screwed down!
IMPORTANT: On vehicles which had pressure plate and dual-mass flywheel with line
markings installed:
When installing a new clutch, also replace the dual-mass flywheel and install a
reinforced over-centre helper spring.
On vehicles which had pressure plate and dual-mass flywheel with dot
markings installed:
Clutch and dual-mass flywheel can be replaced individually.
2010 BMW M3
Centre clutch plate (2) with special tool 21 2 280 on flywheel.
IMPORTANT: Install clutch plate in correct position.

Note designation for "engine side" / "transmission side".
Handle clutch plate with care. Do not touch surfaces of friction linings.
Fig. 13: Identifying Centre Clutch Plate With Special Tool (21 2 280) On Flywheel
Fit clutch to flywheel.
IMPORTANT: Clutch must be secured by way of dowel pins (1).
Fig. 14: Identifying Clutch Screws

Carefully unscrew locking piece (1) clockwise or counterclockwise with a WAF 14 hexagon socket wrench (2).
2010 BMW M3
NOTE: A slight snapping of the plate spring while unscrewing the lock is possible.
Fig. 15: Removing Clutch

Withdraw special tool from clutch plate with aid of accompanying screw (1).
Fig. 16: Identifying Accompanying Screw

CLUTCH RELEASE CONTROL

21 51 500 REMOVING AND INSTALLING OR REPLACING CLUTCH RELEASE BEARING/LEVER
NOTE: (transmission removed)
New version (except M models)
Release bearing and release lever have been combined to form a single release module.
2010 BMW M3
If possible, do not disassemble the release module. Otherwise there is a risk of the release module being
incorrectly reassembled.
Installation:
Make sure that the correct cam (1) of the release bearing is on the sliding surface (2) of the release lever.
The positioning in relation to each other is identified by white dots on the cam (1) and the sliding surface (2).
NOTE: Do not grease sliding surfaces (2).
Fig. 17: Positioning Cam

Fig. A: Cam (1) of release bearing (A=12 mm) is on sliding surface of release lever.
This version is for 4-cylinder petrol/gasoline engines.
Fig. B: Cam (1) of release bearing (A=7 mm) is on sliding surface of release lever.
This version is for 6-cylinder petrol/gasoline and diesel engines.

2010 BMW M3
Fig. 18: Identifying Cam Distance

Remove release module (1) from spring wire clip.
Remove release module.
Fig. 19: Removing Release Module From Spring Wire Clip

Installation:

2010 BMW M3
Previous version
Detach release bearing (1).
Installation:
Clean all sliding surfaces on clutch release bearing, check for damage and replace if necessary.
Do not grease clutch release bearing.
Sliding surfaces (2) of clutch release bearing must rest on sliding surfaces (3) of release lever.
Apply a thin coating of grease to sliding surfaces (2) of release bearing.
Grease, refer to CLUTCH - OPERATING FLUIDS .
Fig. 21: Detaching Release Bearing

NOTE: Illustration similar
IMPORTANT: Only on E60/E61 M5 and E63/E64 M6 (7-speed SMG transmission) - lightly

grease guide sleeve.
Previous clutch release bearing:
Clutch release bearing with moving thrust plate (1).
Swivel motion of thrust plate (1) possible.

2010 BMW M3
Fig. 22: Moving Thrust Plate

Withdraw release lever (4) from spring wire clip (5) and remove.
Installation:
Clean release lever.
Fig. 23: Removing Release Lever From Spring Wire Clip

Previous release lever
Installation:
Apply a thin coating of grease to release lever at sliding surfaces (1 and 2) only.

2010 BMW M3
Fig. 24: Applying Thin Coating Of Grease To Release Lever

Installation:
Apply a thin coating of grease to ball pin (6).

NOTE: The spring wire clip and ball pin must always be replaced on the S6S 420G
transmission.
Illustration similar.
2010 BMW M3

Clean guide sleeve (7).
Installation:
Except for E60/61 M5 and E63/64 M6 (7-speed SMG transmission) - do not grease guide sleeve.
If guide sleeve is greased, the release lever can stick on the guide sleeve.
CLUTCH OPERATION (HYDRAULIC)

21 52 500 REMOVING AND INSTALLING/REPLACING CLUTCH MASTER CYLINDER
NOTE: After completing work, bleed clutch hydraulic system.
Remove trim panel for pedal assembly.

2010 BMW M3
Fig. 27: Identifying Retaining Tabs With Guide

Draw off brake fluid up to supply hose of clutch hydraulic system (1). For this purpose, use only a vacuum pipe
that is exclusively used for removing brake fluid.
Detach supply hose (1) from expansion tank.
Fig. 28: Identifying Supply Hose

Release screws (1) on cylinder (2).
Tightening torque: 21 52 4AZ , see 21 52 CLUTCH OPERATION (HYDRAULIC) .

2010 BMW M3
Fig. 29: Identifying Cylinder Screws

Detach locking clip (3) and pull clutch pedal with clutch master cylinder off bearing block.
Press pin ends (2) together and remove pin.
Installation:
Replace locking clip.
The locking clip must be seated with both legs in the pin groove.
2010 BMW M3
Fig. 30: Identifying Return Spring And Locking Clip

Detach retainer (1) with a screwdriver (2).
NOTE: Do not foul carpet with brake fluid.
Detach hydraulic line from clutch master cylinder.
Fig. 31: Detaching Retainer With Screwdriver

Detach supply hose (1) from clutch master cylinder.
IMPORTANT: Do not pull supply hose completely into interior.
Fig. 32: Identifying Clutch Master Cylinder Supply Hose

Lever out shift element (1) from clutch master cylinder (2) with screwdriver.
2010 BMW M3
Release plug connection (3) and disconnect plug (4) from shift element (1).
Fig. 33: Disconnecting Plug From Shift Element

Installation:
Shift element is secured against incorrect installation.
Shift element must snap audibly into place.
Fig. 34: Identifying Shift Element Incorrect Installation Position

21 52 510 REMOVING AND INSTALLING OR REPLACING CLUTCH SLAVE CYLINDER
13 3 010
See .
NOTE: After completing work bleed clutch hydraulic system.

2010 BMW M3
IMPORTANT: From 08.06 a plastic clutch slave cylinder is installed in the E81, E87 and E9X.
Seal supply hose to clutch master cylinder with special tool 13 3 010 .

Release union screw (1) on hydraulic line.
Release nut (2) and remove hydraulic line (3) with bracket.
Installation:
Tightening torque 21 52 1AZ , see 21 52 CLUTCH OPERATION (HYDRAULIC) .

Version with throttle valve, tightening torque 21 52 12AZ , see 21 52 CLUTCH
OPERATION (HYDRAULIC) .
Release nut and remove clutch slave cylinder.

2010 BMW M3
Fig. 36: Hydraulic Line With Bracket

Installation:

cylinder.
Fig. 37: Locating Clutch Slave Cylinder

Installation:
Clean thrust member (1) and contact face on release lever (2).

2010 BMW M3
Fig. 38: Grease Thrust Member On Contact Face

IMPORTANT: Spacer between fuel line and pressure hose of clutch slave cylinder must be
correctly fitted.
Fig. 39: Connecting Spacer Between Fuel Line And Pressure Hose Of Clutch Slave Cylinder
21 52 510 REMOVING AND INSTALLING/REPLACING CLUTCH SLAVE CYLINDER (PLASTIC)
13 3 010
NOTE: After completing work bleed clutch hydraulic system.
Seal hydraulic line to clutch slave cylinder with special tool 13 3 010 .
2010 BMW M3

Release nuts and remove clutch slave cylinder (1) with holder (2).
Installation:
Fig. 41: Identifying Clutch Slave Cylinder With Holder

2010 BMW M3

cylinder.
Unlock spring retainer (1).
Disconnect hydraulic line (2).
Fig. 42: Identifying Hydraulic Line And Spring Retainer

Press cylinder together by hand.
Connect hydraulic line with cylinder pressed.

2010 BMW M3
Fig. 43: Pressing Cylinder Together By Hand

Hold cylinder piston vertically downwards.
Press piston 5 times into cylinder.
Fig. 44: Holding Cylinder Piston Vertically Downwards

IMPORTANT: All-wheel drive vehicles only

2010 BMW M3
Installation:
Check pressure hose for traces of abrasion.
If no traces of abrasion by the propeller shaft can be detected on the pressure hose:
The pressure hose must be bent approx. 30 mm away from the propeller shaft.
If traces of abrasion by the propeller shaft can be detected on the pressure hose:
The pressure hose must be replaced.
After replacement, the clutch hydraulics must be bled.
Press in piston until it engages.
Install clutch slave cylinder.
Bleed clutch hydraulics. See bleeding clutch hydraulic system.
Installation:
Clean thrust member (1) and contact face on release lever.
Fig. 45: Pressing Grease Thrust Member On Contact Face

2010 BMW M3
TROUBLESHOOTING
21 90 ... TROUBLESHOOTING THE CLUTCH
Fault Cause Remedy
a. Clutch pressure too low.
b. Lining too heavily worn.
c. Lining oiled-
Leaks:
Engine a. Replace clutch

Crankshaft radial seal at front and rear Refer to 21 21 500.
incl. end cover, oil sump, cylinder
head gasket, cylinder head, oil filler
b. Replace clutch plate
cap, timing case cover, flywheel
mounting bolts
Refer to 21 21 500.
Cooling system
c. Carefully rectify leaks, clean
Clutch slipping oil contamination and replace
Hoses and connections, heating
clutch plate
valves, sealing plugs on engine block
Refer to 21 21 500.
Steering unit
d. Replace clutch
Steering gear, servo pump, hydraulic
lines and connections
Refer to 21 21 500.
Transmission
e. Install original-equipment
BMW part.
Drive shaft radial seal, sealing plugs
of countershaft
Release bearing
d. Clutch was overheated.
e. Clutch is not an original-equipment BMW
part.
a. Replace clutch plate
Refer to 21 21 500.
a. Lining not acc. to specification.
b. Lining oiled: b. Replace clutch plate
2010 BMW M3
Causes: refer to "clutch slipping, point c" Refer to 21 21 500.
c. Release unit presses on one side. c. Check release lever.

d. Clutch presses at an angle. d. Replace clutch
e. Crankshaft does not align with transmission
input shaft. Refer to 21 21 500.
f. Engine and transmission suspension
e. Check engine/transmission
Clutch defective.
contact face, adapter sleeves
stick/slip g. Clutch plate not an original-equipment and cover plate for damage.
BMW part.
f. Replace engine and
h. Engine, speed characteristics not O.K. transmission suspension.
i. Engine management not OK (particularly on g. Install original-equipment
diesel engine). BMW part.
h. Eliminate causes according to
engine test.
i. Check engine control unit.
Clutch releases
poorly
(Gear difficult
to engage)
a. Replace clutch plate
Refer to 21 21 500.
b. Replace guide bearing in

crankshaft.
a. Lining of clutch plate broken.
c. Replace faulty parts and bleed
b. Lining rusted onto flywheel.
Clutch does not clutch hydraulics
c. Guide bearing for transmission input shaft in
separate (Gear
crankshaft defective. Refer to 21 00 006.
cannot be
engaged) d. Leak in clutch hydraulic system.
e. Tangential leaf springs of clutch bent down. d. Replace clutch
f. Release unit binds on guide sleeve.
Refer to 21 21 500.
e. Clean guide sleeve, remove

and install release unit
Refer to 21 51 500.
Fault Cause Remedy
a. Replace clutch/clutch plate
2010 BMW M3
Refer to 21 21 500.
b. Replace clutch plate
Refer to 21 21 500.
a. Imbalance of clutch and clutch plate too great. or if necessary replace dualmass
b. Torsional-vibration damper defective. flywheel,
Clutch c. Release unit defective. c. Replace release unit
noise d. Guide bearing for transmission input shaft in
crankshaft defective. Refer to 21 51 500.
e. Clutch rivet connection loose.
d. Replace guide bearing in
crankshaft.
e. Replace clutch
Refer to 21 21 500.
2010 BMW M3
SPECIFICATIONS INDEX M3
SPECIFICATIONS INDEX
M3
M3 SPECIFICATIONS INDEX
System Specification/Procedure
Air Conditioning
Service TECHNICAL DATA
Torque TIGHTENING TORQUES
Axle Nut/Hub Nut (Collar Nut)
Front WHEEL BEARINGS AND STEERING KNUCKLE
Rear WHEEL BEARINGS
Battery BATTERY
Brakes
Bleeding Sequence RR, LR, RF, LF
Disc Brakes TECHNICAL DATA
Charging
Generator ALTERNATOR WITH DRIVE
Torque ALTERNATOR WITH DRIVE
Drive Belts
Adjustment NA
Belt Routing V-RIBBED BELT WITH TENSIONER
Engine Cooling
General Service Specifications NA
Radiator Cap Pressure COOLING SYSTEM - TECHNICAL DATA
Thermostat R & I COOLANT THERMOSTAT
Water Pump R & I WATER PUMP WITH DRIVE
Engine Mechanical
Compression ENGINE GENERAL
Oil pressure Oil pressure at idle: 15 psi (103 kPa); control pressure: 58-
87 psi (400-600 kPa)
Overhaul TECHNICAL DATA
Fluid Specifications See FLUIDS under MAINTENANCE tab. From within
Manager or Service Writer, click the "30/60/90 Interval" or
"Maint." button.
Flywheel/Flex Plate Torque FLYWHEEL
Fuel System
Fuel Filter Location Pressure Regulator And Fuel Filter Are Incorporated In A
2010 BMW M3
SPECIFICATIONS INDEX M3
Single Unit In The Tank

Fuel Filter R & I FUEL FILTER WITH PRESSURE REGULATOR
Pressure Release Procedure NA
Pressure Specification 87 psi (600 kPa)
Fuel Pressure Test Procedure CHECKING FUEL FEED PRESSURE
Ignition
Firing Order FIRING ORDER & CYLINDER IDENTIFICATION
Ignition Wires (Routing) Coil on plug
Spark Plug
Type NGK LKR8AP
Gap Not Adjustable
Torque 17 Ft. Lbs. (23 N.m)
Starting
Starter STARTER
Torque STARTER
Wheel Alignment
Adjustment Specifications TECHNICAL DATA
Wheel & Tire
Wheel Lug Nut Torque 88 Ft. Lbs. (120 N.m)
2010 BMW M3
SPECIFICATIONS INDEX M3 - Sedan
M3 - Sedan
M3 SPECIFICATIONS INDEX
System Specification/Procedure
Air Conditioning
Service TECHNICAL DATA
Axle Nut/Hub Nut (Collar Nut)
Front WHEEL BEARINGS AND STEERING KNUCKLE
Rear WHEEL BEARINGS
Battery BATTERY
Brakes
Bleeding Sequence RR, LR, RF, LF
Disc Brakes TECHNICAL DATA
Charging
Generator ALTERNATOR WITH DRIVE
Torque ALTERNATOR WITH DRIVE
Drive Belts
Adjustment NA
Belt Routing V-RIBBED BELT
Engine Cooling
General Service Specifications NA
Radiator Cap Pressure TECHNICAL DATA
Thermostat R & I COOLANT THERMOSTAT
Water Pump R & I WATER PUMP WITH DRIVE
Engine Mechanical
Compression ENGINE IN GENERAL
Oil pressure Oil pressure at idle: 15 psi (103 kPa); control pressure: 58-
87 psi (400-600 kPa)
Overhaul TECHNICAL DATA
Fluid Specifications See FLUIDS under MAINTENANCE tab. From within
Manager or Service Writer, click the "30/60/90 Interval" or
"Maint." button.
Flywheel/Flex Plate Torque FLYWHEEL
Fuel System
Fuel Filter Location Pressure Regulator And Fuel Filter Are Incorporated In A
2010 BMW M3
SPECIFICATIONS INDEX M3 - Sedan
Single Unit In The Tank

Fuel Filter R & I FUEL FILTER WITH PRESSURE REGULATOR
Pressure Release Procedure NA
Pressure Specification 87 psi (600 kPa)
Fuel Pressure Test Procedure CHECKING FUEL FEED PRESSURE
Ignition
Firing Order FIRING ORDER & CYLINDER IDENTIFICATION
Ignition Wires (Routing) Coil on plug
Spark Plug
Type NGK LKR8AP
Gap Not Adjustable
Torque 17 Ft. Lbs. (23 N.m)
Starting
Starter STARTER
Torque STARTER
Wheel Alignment
Adjustment Specifications TECHNICAL DATA
Wheel & Tire
Wheel Lug Nut Torque 88 Ft. Lbs. (120 N.m)
2010 BMW M3
ACCESSORIES AND BODY, CAB Communication Systems - Repair
Communication Systems - Repair
CELLULAR TELEPHONE
84 10 050 REMOVING AND INSTALLING (REPLACING) USB HUB
PROTECTION) .

Fold back carpet for passenger compartment at front left in direction of travel.
Remove USB hub protective socket (1) from footwell insert (2).
Unlock catches (3) with a suitable tool and remove USB hub protective socket cover (5).
Installation:
Make sure USB hub protective socket cover (5) engages correctly on USB hub protective socket lower section.
Seal (4) must not be damaged; if necessary, replace USB hub protective socket cover (5).
Fig. 1: Identifying USB Hub Protective Socket With Cover, Seal And Catches
Remove USB hub (1) from USB hub protective socket lower section (2).
Installation:
2010 BMW M3
Make sure rubber grommet (4) is correctly seated on USB hub protective socket lower section (2).
Fig. 2: Identifying USB Hub With USB Hub Protective Socket Lower Section And Rubber Grommet
TRANSCEIVER, HANDSET AND SUPPORT, CARD READER

84 11 519 REMOVING AND INSTALLING OR REPLACING EJECT BOX
Unclip plug connection for antenna lead from mounting and disconnect.
Fig. 3: Pulling Gaiter

Snap out eject box (1) with special tool 00 9 340 REMOVAL AID on inner side of trim (2).
2010 BMW M3
Pull eject box (1) on inner side upwards slightly.
Fig. 4: Removing Eject Box Using Special Tool (00 9 340)

Snap out eject box (1) with special tool 00 9 340 REMOVAL AID on outer side of trim (2).
Lift out eject box (1) and feed out wiring harness.
Installation:
Make sure wiring harness is correctly laid.
Eject box (1) must snap audibly into trim (2).
Fig. 5: Removing Eject Box Using Special Tool (00 9 340)

Installation:
2010 BMW M3
Catches (1) on trim (2) must not be damaged or missing.

84 11 555 REMOVING AND INSTALLING/REPLACING HANDS-FREE MICROPHONE
Remove ROOF SWITCH CLUSTER
Unlock catch (2) and feed hands-free microphone (3) in direction of arrow out of roof switch cluster (4).
Installation:
Arrow on hands-free microphone (3) must point in direction of travel.
Hands-free microphone must snap audibly into place.

2010 BMW M3
Fig. 7: Removing Hands-Free Microphone Out Of Roof Switch Cluster

84 11 660 REMOVING AND INSTALLING/REPLACING TELEMATICS CONTROL UNIT (TCU)

(OPTION SA633/SA638/SA639/SA664)
IMPORTANT: Replacement with option SA638/SA664:
Carry out VEHICLE PROGRAMMING/CODING

If necessary, carry out coupling procedure
Replacement with option SA633/SA639:
Carry out VEHICLE PROGRAMMING/CODING

Via Diagnosis and Information System (DIS):
Service functions
Start subsequent assessment
PROTECTION) .

Remove LUGGAGE COMPARTMENT FLOOR TRIM .
E91:
2010 BMW M3
Release retaining clips (1) and remove storage pan (2).
Fold panel (3) upwards.
Fig. 8: Identifying Retaining Clips And Storage Pan

E88/E93:
Unscrew nuts (1).
Remove holder for telematics control unit / SES (2) in direction of arrow from body.
Raise panel for luggage compartment partition (4) slightly and feed out holder for telematics control unit / SES
(2) in direction of luggage compartment.
Release wiring harness fastener (3) from holder for telematics control unit / SES (2).
Installation:
Make sure guides (5) are correctly seated in associated body holders.
2010 BMW M3
Fig. 9: Removing Holder For Telematics Control Unit/SES

Release nuts (1) and unclip cable ties (2).
Fig. 10: Identifying Unclip Cable Ties And Nuts


Disconnect plug connections of aerial cables (1).
Remove TCU (2).

2010 BMW M3
Fig. 12: Identifying Plug Connections Of Aerial Cables

NOTE: TCU Everest is replaced from 03/2007 by TCU 1.5.
1. Unclip cable holder (1) from TCU holder (2).

2. Connect aerial leads according to new layout (new cable routing as
pictured)
3. Secure cable holder (1) to TCU holder (2) with cable tie
Fig. 13: Secure Cable Holder To TCU Holder

HANDHELD COMPUTER
84 21 542 REMOVING AND INSTALLING (REPLACING) HANDS-FREE CHARGING
2010 BMW M3
ELECTRONICS (HIGH)
PROTECTION) .

E91:
Fig. 14: Identifying Retaining Clips, Panel And Storage Pan

Unscrew nuts (1).
Remove holder for telematics control unit/SES (2) in direction of arrow from body.
2010 BMW M3
Fig. 15: Removing Holder For Telematics Control Unit/SES From Body
E88/E93:
Raise panel for luggage compartment partition (4) slightly and feed out holder for telematics control unit/SES
Release wiring harness fastener (3) from holder for telematics control unit/SES (2).
Installation:
Release all nuts.
Remove hands-free charging electronics (3) from holder for telematics control unit/SES (2).
Fig. 16: Identifying Telematics Control Unit/SES With Charging Electronics And Plug Connection
2010 BMW M3
Replacement:
Carry out vehicle programming and encoding vehicle programming and encoding
If necessary, log mobile phone on to vehicle
84 21 535 REMOVING AND INSTALLING/REPLACING HANDS-FREE CHARGING

ELECTRONICS
PROTECTION) .

E91:
Fig. 17: Identifying Retaining Clips, Panel And Storage Pan

E88/E84/E93:
Unscrew nuts (1).

2010 BMW M3
Fig. 18: Removing Holder For Telematics Control Unit/SES From Body
Installation:
Unscrew nuts (1).
Remove charging hands-free electronics and disconnect associated plug connections.
Fig. 19: Identifying Charging Hands-Free Electronics Nuts

2010 BMW M3
Replacement:
Carry out vehicle programming and encoding

HANDS-FREE SYSTEM, MICROPHONE, SPEAKER

Unlock catch (2) and feed hands-free microphone (3) in direction of arrow out of roof switch cluster (4).
Installation:
Fig. 20: Removing Hands-Free Microphone Out Of Roof Switch Cluster

84 31 020 REMOVING AND INSTALLING/REPLACING HANDS-FREE SYSTEM SPEAKER
TRIM FOR PEDAL ASSEMBLY

2010 BMW M3
If necessary, release cable tie from catches (2).
Unlock catches (2) and remove speaker (3) from mounting.
Installation:
Catches (2) must not be damaged.
Guide lugs of mounting must be seated in grooves of speaker (3).
Speaker (3) must snap audibly into place in mounting.
Fig. 21: Identifying Speaker, Catches And Plug Connections

ANTENNA
84 50 060 REMOVING AND INSTALLING OR REPLACING BLUETOOTH AERIAL
Remove PEDAL ASSEMBLY TRIM
Version A:
Disconnect plug connection (1) and unclip aerial (3) from mountings (2).
2010 BMW M3
Fig. 22: Identifying Plug Connection And Aerial On Mountings

Version B:
Disconnect associated plug connection.
Release retaining clips (1).
Installation:
Do not damage pedal assembly panelling in working area.
Replace damaged retaining clips.
Remove Bluetooth aerial (2).
Fig. 23: Identifying Retaining Clips And Bluetooth Aerial

2010 BMW M3

MOUNTED AERIAL
NOTE: Clean roof.
Tape off roof surface (2) around aerial cover (3) with yellow adhesive tape (1).
To do so, slide adhesive tape slightly under roof aerial.
Fig. 24: Identifying Masking Roof, Roof-Mounted Aerial And Yellow Plastic Adhesive Tape

the roof.

Make sure your arms do not cross over (1) when holding special tool 65 20 10
KNIFE .
2010 BMW M3
Fig. 25: Caution For Holding Special Tool

Cut through adhesive bead all round with special tool 65 20 10 KNIFE . Pull on handle (1) and align blade on
handle (2).

Installation:
All preparatory operations correspond to the WINDOW CEMENTING INSTRUCTIONS .

2010 BMW M3
Fig. 27: Identifying Aerial Centering Pin With Bonding Surface

Dimensions:
A. 10 mm
B. 14 mm

2010 BMW M3
Fig. 28: Identifying Spacer Position Dimensions

A. 6.5 mm 1 mm
exceed 3 mm 1 mm.
Fig. 29: Applying Trace Of Adhesive Bead Over Outer Contour

2010 BMW M3
If necessary, secure aerial cover with adhesive tape and do not press down on one side of the aerial more firmly
than the other.

2010 BMW M3
ACCESSORIES AND BODY, CAB Communication Systems - Repair - M3
Communication Systems - Repair - M3
CELLULAR TELEPHONE
protection) . See 61 35 ... NOTES ON ESD PROTECTION (ELECTRO STATIC
DISCHARGE) .
Remove left front seat . See SEATS - REPAIR INSTRUCTIONS or SEATS - REPAIR
INSTRUCTIONS -- M3 CONVERTIBLE .
Remove front left entrance cover strip . See 51 47 000 REMOVING AND
INSTALLING/REPLACING FRONT (INSIDE) LEFT OR RIGHT ENTRANCE COVER STRIP .
Fold back carpet for passenger compartment at front left in direction of travel
Installation:
Fig. 1: Removing USB Hub Protective Socket From Footwell Insert

2010 BMW M3
Installation:
Fig. 2: Removing USB Hub From USB Hub Protective Socket Lower Section
TRANSCEIVER, HANDSET
84 11 519 REMOVING AND INSTALLING OR REPLACING EJECT BOX
00 9 340
Unclip plug connection for antenna lead from mounting and disconnect.
2010 BMW M3

Snap out eject box (1) with special tool 00 9 340 on inner side of trim (2).
Pull eject box (1) on inner side upwards slightly.
Fig. 4: Pull Eject Box On Inner Side Upward

Snap out eject box (1) with special tool 00 9 340 on outer side of trim (2).
Lift out eject box (1) and feed out wiring harness.
Installation:
Eject box (1) must snap audibly into trim (2).

2010 BMW M3
Fig. 5: Eject Box (1) Must Snap Audibly Into Trim (2)
Installation:
Catches (1) on trim (2) must not be damaged or missing.

Remove roof switch cluster . See 61 31 043 REMOVING AND INSTALLING OR REPLACING
ROOF SWITCH CENTRE .

2010 BMW M3
Installation:
Fig. 7: Unlock Catch (2) And Feed Hands-Free Microphone (3) In Direction Of Arrow Out Of Roof
Switch Cluster (4)
84 11 660 REMOVING AND INSTALLING/REPLACING TELEMATICS CONTROL UNIT (TCU)

(OPTION SA633/SA638/SA639/SA664)
IMPORTANT: Replacement with option SA638/SA664:
Carry out vehicle programming/coding

If necessary, carry out coupling procedure
Replacement with option SA633/SA639:

Via Diagnosis and Information System (DIS):
Service functions
Start subsequent assessment
DISCHARGE) .
2010 BMW M3

E91:

E88/E93:
Unscrew nuts (1).
Installation:
2010 BMW M3
Fig. 9: Removing Holder For Telematics Control Unit/SES

Release nuts (1) and unclip cable ties (2).
Fig. 10: Identifying Unclip Cable Ties And Nuts


2010 BMW M3

Disconnect plug connections of aerial cables (1).
Remove TCU (2).
Fig. 12: Identifying Plug Connections Of Aerial Cables

NOTE: TCU Everest is replaced from 03/2007 by TCU 1.5.
1. Unclip cable holder (1) from TCU holder (2).

2. Connect aerial leads according to new layout (new cable routing as
pictured)
3. Secure cable holder (1) to TCU holder (2) with cable tie
2010 BMW M3
Fig. 13: Secure Cable Holder To TCU Holder

HANDHELD COMPUTER
84 21 535 REMOVING AND INSTALLING/REPLACING HANDSFREE CHARGING ELECTRONICS
DISCHARGE) .

E91:

2010 BMW M3

E88/E93:
Unscrew nuts (1).
Installation:
Fig. 15: Removing Holder For Telematics Control Unit / SES In Direction Of From Body
2010 BMW M3
Unscrew nuts (1).
Remove charging hands-free electronics and disconnect associated plug connections.
Fig. 16: Identifying Charging Hands-Free Electronics And Nuts

Replacement:


ELECTRONICS (HIGH)
DISCHARGE) .

E91:
2010 BMW M3

Unscrew nuts (1).
E88/E93:
Installation:

2010 BMW M3
Fig. 18: Removing Holder For Telematics Control Unit / SES In Direction Of From Body
Release all nuts.
Remove hands-free charging electronics (3) from holder for telematics control unit / SES (2).
Fig. 19: Locating Nuts And Plug Connection

Replacement:

HANDS-FREE SYSTEM, MICROPHONE

84 31 020 REMOVING AND INSTALLING/REPLACING HANDS-FREE SYSTEM SPEAKER

2010 BMW M3
Remove trim for pedal assembly . See 51 45 185 REMOVING AND INSTALLING/REPLACING
PANEL FOR PEDALS .
If necessary, release cable tie from catches (2).
Unlock catches (2) and remove speaker (3) from mounting.
Installation:
Catches (2) must not be damaged.
Guide lugs of mounting must be seated in grooves of speaker (3).
Speaker (3) must snap audibly into place in mounting.
Fig. 20: Identifying Hands-Free System Speaker And Mounting

ANTENNA
MOUNTED AERIAL
65 2 010
NOTE: Clean roof.
2010 BMW M3
Fig. 21: Tape Off Roof Surface And Aerial Cover With Adhesive Tape

the roof.

Make sure your arms do not cross over (1) when holding special tool 65 2 010 .
Fig. 22: Make Sure Your Arms Do Not Cross Over (1) When Holding Special Tool
2010 BMW M3
Cut through adhesive bead all round with special tool 65 2 010 .
Pull on handle (1) and align blade on handle (2).

Fig. 23: Removing Cover Of Multiband Telephone Aerial

Installation:
Fig. 24: Identifying Centering Pins And Bonding Surface

2010 BMW M3
Dimensions:
A. 10 mm
B. 14 mm
Fig. 25: Positioning Spacers On Aerial Cover

A. 6.5 mm 1 mm
exceed 3 mm 1 mm.
2010 BMW M3
Fig. 26: Identifying Distance Between Adhesive Bead And Edge Of Aerial Cover
If necessary, secure aerial cover with adhesive tape and do not press down on
one side of the aerial more firmly than the other.
84 50 060 REMOVING AND INSTALLING OR REPLACING BLUETOOTH AERIAL
Remove pedal assembly trim . See 51 45 185 REMOVING AND INSTALLING/REPLACING

PANEL FOR PEDALS .
Version A:
Disconnect plug connection (1) and unclip aerial (3) from mountings (2).
2010 BMW M3
Fig. 27: Identifying Plug Connection And Unclip Aerial From Mountings
Version B:
Release retaining clips (1).
Installation:
Do not damage pedal assembly panelling in working area.
Replace damaged retaining clips.
Remove Bluetooth aerial (2).
Fig. 28: Identifying Retaining Clips And Bluetooth Aerial

2010 BMW M3
ACCESSORIES AND BODY, CAB Convertible Top - Repair - M3 Convertible
Convertible Top - Repair - M3 Convertible
SUNROOF
54 0 ... REPAIR INSTRUCTIONS FOR BONDED SEALS
1. General information on handling rubber seal profiles
If seals reveal partly detached protective film on delivery, they must not be bonded.
Store seals at 15C to 25C.
If, during the handling, the protective film has come off before bonding, it can still be bonded.
Bonding at room and object temperature >20C. Temperatures between 40 and 50C significantly
increase initial adhesion.
Seals, which are subjected to temperatures above 80C after gluing, will be very difficult to remove.
2. Damage pattern and repair
2.1 Partially detached bond (rubber-adhesive tape or adhesive tape-paint)

Up to 120 mm for retouching without auxiliary resources
Up to 200 mm repaired with pressing-on tools on straight surfaces
a. Cleaning damaged areas:

Degrease bonded area with adhesive cleaner (refer to BMW Parts Service) and remove other
residues.
NOTE: Use necessary cotton- or fluff-free paper towel once only.

When using solvent:
expose repair area to air for at least 2 minutes.
b. Applying adhesive:
With a fine nozzle, apply a wafer-thin bead to adhesive tape.
NOTE: Use contact adhesive (e.g. Terokal 2444)
CAUTION: Avoid contact to skin!

Do not apply adhesive to visible painted surfaces.
c. Pressing on rubber seal:

Press down seal using contact pressure (forced pressure not necessary) for at least 1 minute.
CAUTION: Load can only be applied to the bond after a period of 2

2010 BMW M3
minutes. This waiting time is absolutely essential.
2.2 Larger defects (mechanical damage and larger separations of seal)

Complete replacement of rubber seal necessary
a. Peeling off damaged rubber seal:

Pull off rubber seal slowly at an angle up to 20 under uniformly strong tension.
NOTE: Make sure the connection between adhesive tape and seal is
retained.
If the connection between adhesive tape and seal is detached:
Carefully and slowly detach adhesive tape at an angle of 20
from roof opening or lid.
When existing seals are being peeled off with a hot air blower:
Do not damage paintwork.
Do not detach rubber-adhesive tape connection if at all
possible.
b. Cleaning bonded area:

Degrease bonded area with adhesive cleaner (refer to BMW Parts Service) and remove other
residues.
NOTE: Use necessary cotton- or fluff-free paper towel once only.

When using solvent:
expose repair area to air for at least 2 minutes.
c. Detaching protective film from bonded area:

Detach protective film from rubber seal in sections.
CAUTION: Once the protective film has been removed, do not under
any circumstances touch the exposed bonded area.
d. Applying rubber seal:

Apply rubber seal on roof opening edge beginning at rear center. Use upper lip as application
edge. Press on seal continuously by hand. Carefully unwrap seal at radii without tension and
press down (critical area).
NOTE: If positioned incorrectly, the seal can still be pulled off,

repositioned and pressed on again.
e. Establishing seal joint:

Mark contact point at joint by pressing down loose end on seal of already bonded end. Then
cut and press down loose end at same height.
2010 BMW M3
NOTE: Small areas of seal can remain stuck to adhesive tape of loose
end.
f. Pressing on seal:
Press on seal using a roller
Adhesive tape width up to 5 mm Application pressure approx. 5 N
Adhesive tape width up to 10 mm Application pressure approx. 10 N
Sliding sunroof seal only:
Press against seal strongly with a roller. Application pressure approx. 70 N.
E36 sliding sunroof seal only:
Application pressure approx. 30 N.

Tear off tear-off lip at rear and side in area of narrower flange.
3. Checking rubber seal
Check the bonded seals for correct positioning and perfect adhesion. The bonding can be checked by
pressing back the sealing lip.
The force required to peel off the seal immediately after gluing must be greater than 10 N/cm.
MOTOR OPERATED CONVERTIBLE

54 34 ... REPAIR INSTRUCTIONS FOR HYDRAULIC SYSTEM OF CONVERTIBLE TOP AND
CONVERTIBLE TOP COMPARTMENT LID
1. Definitions of terms
DEFINITIONS OF TERMS CHART

Hydraulic system at zero pressure Turn ignition lock to "0"
Hydraulic system has no or only
or position. very low pressure
Untensioned state:
E46c: Wait 15 seconds
E52: Wait 2 minutes
E85: Emergency actuation

or wait 2 minutes
E64: Wait 5 seconds.

Mechanical actuation: Observe Point 3
2010 BMW M3
Emergency actuation: Convertible top is opened or

closed by hand
Always move convertible
top with aid of a second
person
Closed system: All lines are connected Even "short-circuiting" of lines is
possible
Function Test: Open and close convertible
top several times (min. 3
times)
Check fluid level in
hydraulic unit; if necessary,
top up fluid
Short circuit (E46c only): Unfastening of quick- Hydraulic system cannot build up
release couplings pressure
Convertible top can be moved
Connection of supply and
return lines
Function Test: Checking of convertible top Convertible top must be secured!
function if possible on Move 2-3 times
removed convertible top
Convertible top stowed: Convertible top fully open When the convertible top is
(folded together) installed, it is in the closed
convertible top compartment
2. When working on hydraulic system, observe the following
Once it has been removed, the convertible top must be safely stowed or tensioned (e.g. with screw clamps
to work bench).
On some models, the special tool must be used.
The universal lever is required here.
When the hydraulic system is open (unscrewing of lines, topping up of fluid, etc.), always provide
sufficient cloths to catch leak-off fluid.
Also provide an adherent protective cover to cover/protect fittings.
Hydraulic system must be at zero pressure.

E46c only: The disconnected supply and return lines to the convertible top can be connected to each other
(establish "short circuit"). The system is thereby closed again. The clutches are protected against damage.
The hydraulic system cannot build up a high pressure. The convertible top can be moved.
Disconnect or unscrew feed and return lines if possible at a later stage, when the convertible top is stowed
and untensioned (check fluid, see also POINT 3).
2010 BMW M3
Once the hydraulic system has been opened, first check the fluid level after completing the tasks before
carrying out a function test.
After disconnecting the hydraulic lines from hydraulic components, do not move the convertible top if at
all possible (fluid can escape from joints).
Piston rods must not be damaged (e.g. scratches). Even paint mist and welding spots are harmful.
When working in the vicinity of hydraulic cylinders, cover the cylinders with suitable materials.
If the hydraulic unit or the lines stay removed for an extended period of time, the bores on the hydraulic
unit and the hose connections must be sealed off (observe fitting instructions).
3. Mechanical operation of convertible top
E46c: only with ignition switched off.
If lines are disconnected, connect them to each other if at all possible.
E52/E85: Emergency actuation

In the event of repeated actuation, the system fluid is pumped into the supply tank of the hydraulic unit. If
hydraulic components are now replaced, there will be too much fluid in the system. This may cause
damage to the system in event of actuation. (Checking fluid level, see POINTS 4 and 5).
4. Checking fluid level
E46c: only when convertible top is stowed and convertible top compartment lid is closed.
E52, E85: only with convertible top closed.
Observe brief instructions .

Fluid level must be within the markings (circle/cross).
Fluid is supplied with the repair kits (e.g. banjo bolts/seals, hoses, cylinders) and is available separately
(refer to BMW Parts Service).
5. Topping up/extracting fluid
E46c: only when convertible top is stowed and convertible top compartment lid is closed.
E52, E85: only with convertible top closed.
E64: the hydraulic fluid does not have to be changed because the system is filled with life-time fluid.
Only the approved hydraulic fluid may be used in the event of leaks.
Observe brief instructions .
Remove hydraulic unit without detaching lines.
Fluid is supplied with the repair kits (e.g. banjo bolts/seals, hoses, cylinders) and is available separately
(refer to BMW Parts Service).
2010 BMW M3
Pour in fluid with bottle through filling orifice.

Hydraulic unit must be removed if overfilled. Allow fluid to escape through filling orifice and collect.
6. Bleeding hydraulic system
E64: if there is a significant build-up of noise while the convertible top is moving, the convertible top
must be opened and closed several times. The hydraulic system is automatically bled in the fluid reservoir
in the process.
54 34 ... TOPPING UP/EXTRACTING FLUID, CHECKING FLUID LEVEL
NOTE: No changing of the hydraulic fluid necessary.
The hydraulic fluid does not have to be changed because the system is filled with life-time fluid.
Only the approved hydraulic fluid may be used in the event of leaks.
All hydraulic cylinders must be completely extended.
Checking fluid level:
Fluid level must be within the markings (arrow) when the unit is horizontal.
Fig. 1: Locating Fluid Level Mark

Topping up fluid:
Align hydraulic unit horizontally.
Open oil filler plug.
Pour in required amount of fluid from fluid bottle.
Installation:
2010 BMW M3
Check fluid level in the meantime.
Pour in hydraulic fluid only up to marking on fluid reservoir.
Fig. 2: Locating Oil Filler Plug Mark

IMPORTANT: Protect components and work area with suitable materials (e.g. cloths).
Extracting fluid:
Open oil filler plug.
Tilt hydraulic unit and let fluid flow out or draw off with a suitable auxiliary apparatus.
Fig. 3: Locating Oil Filler Plug Mark

FOLDING ROOF
41 00 ... PROCEDURE FOR FOLDING ROOF AFTER AN ACCIDENT
2010 BMW M3
The folding roof may be under tension after the vehicle has incurred damage following an accident. Moving the
folding roof by hydraulic means may result in irreparable damage. For this reason, the folding roof may only be
moved manually until the damaged has been repaired.
IMPORTANT: It is not possible to check the correct operation of the folding roof on the
damaged vehicle.
Different procedures are required, depending on the degree of damage which the vehicle has incurred. The
repair instructions for emergency actuation describe only the complete sequences for manually opening and
closing the folding roof.
When removing the roof module and/or the rear end module, it is possible to move the folding roof manually
into the necessary intermediate positions in each case.
WARNING: Risk of injury due to the heavy weight of the folding roof!
Since the hydraulic system may have to be depressurized during manual
movement of the folding roof, there is an increased risk of injury by
trapping. Always secure the folding roof adequately against unintentional
movement.
After body repairs to the vehicle
All the folding roof components screwed/bolted to the body are precisely screwed/bolted to the vehicle at the
factory by means of gauges. This affects above all the base plates and mounting brackets of the roof and rear
end modules. To minimize extensive adjustment work after a body repair as much as possible, only remove
those components which are screwed/bolted to a damaged body part.
Gauge the base plates only after a body repair to the cowl panel.
54 37 ... ADJUSTING REAR ROOF SHELL
Convertible top compartment lid must be correctly adjusted. See 41 63 068 ADJUSTING
CONVERTIBLE TOP COMPARTMENT LID .
Open convertible top until screws are accessible.
IMPORTANT: Lock barrel screws with a flat wrench without fail.

Barrel screws on roof shell must not move out of position.
Slacken screws (1) on left and right (do not unscrew completely).
2010 BMW M3
Fig. 4: Identifying Slacken Screws

Slacken screw (1) on left and right (do not unscrew completely).
Fig. 5: Identifying Slacken Screw

Close convertible top.
Carefully press roof shell at convertible top compartment lid.
Press roof shell until:
a uniform gap dimension and

lower edge parallel with convertible top cover
are obtained over the entire length.
Hold roof shell in position while screwing down.

2010 BMW M3
NOTE: Carry out this operation on the left and right sides in succession.
Fig. 6: Holding Roof Shell In Position Screwing Down

Carefully pull roofliner downwards.
Tighten down screw (1) on left and right.
Tightening torque: 54 37 06AZ, see 54 37 POWER CONVERTIBLE TOP .
Fig. 7: Pulling Roofliner Downwards And Screw

Tightening torque: 54 37 11AZ, see 54 37 POWER CONVERTIBLE TOP . .

2010 BMW M3
Fig. 8: Identifying Down Screw

Open convertible top until screw (1) is accessible.
Tightening torque: 54 37 06AZ, see 54 37 POWER CONVERTIBLE TOP . .
Fig. 9: Identifying Convertible Top Until Screw

Adjusting pretension on fastener:
NOTE: Mark position of screw.
Slacken screw (1) (do not unscrew fully).
Turn locking element upwards through 0.5 mm.

2010 BMW M3
Tighten screw (1).
Fig. 10: Identifying Slacken Screw

Check gap dimensions for convertible top. See 41 00 ... GAP DIMENSIONS, BODY .
Carry out leak test .
54 37 ... ALIGNING BASIC GAUGE
00 9 251
54 0 121
54 0 122
54 0 123
See .
IMPORTANT: Always install and remove basic gauge with 2 helpers.

To prevent damaging the basic gauge, set the gauge down only in the
transportation crate or on the vehicle side wall.
The basic gauge is a highly sensitive measuring instrument which reacts even
to light impacts with distortion.
The basic gauge must be checked for dimensional accuracy on a master gauge
after being subjected to impact or dropped.
The basic gauge stipulates the basic setting in the X-, Y- and Z- axes.
2010 BMW M3
The basic gauge is absolutely essential for the following work operations:
Gauging coupling fastener

Gauging roof module bracket
Lift out cover (1) on left base plate.
Installation:
Cover (1) for base plate must be replaced after each removal.
IMPORTANT: The outer left hole in the base plate is the reference point for the following jobs.
Fig. 11: Locating Cover On Left Base Plate

Basic gauge
2010 BMW M3
Fig. 12: Identifying Basic Gauge And Special Tool 00 9 251

NOTE: Use only special tool 00 9 251 to screw the gauge into position.
Remove butyl strip in side panel in area of basic gauge and clean with
Isohexane.
Grind off protruding soldered seams.
Re-establish corrosion protection.
Carefully position special tool 54 0 121 (cross beam) on side panel.
Connect special tool 54 0 122 (extension arm for X-axis clearance) to cross beam and left cowl panel base plate.
IMPORTANT: Insert guide pin of extension arm 54 0 122 in extreme left hole of base plate.
Connect special tool 54 0 123 (right extension arm) to cross beam and extension arm 54 0 122.
Observe tightening sequence:
1. Tighten down rear screws on basic gauge to 2 Nm.

2. Tighten down screw to connect extension arms to 2 Nm.
2010 BMW M3
Check basic gauge for contact at all four contact points.
NOTE: On account of the body tolerances there may be on one side a gap dimension
between extension arm and body.
Do not exert any pressure on the extension arms.
Fig. 13: Locating Basic Gauge Four Contact Points

2010 BMW M3
Fig. 14: Identifying Body Tolerances On One Side Gap Dimension Between Extension Arm
IMPORTANT: Adjustment work should be carried out by one person only.
Adjust knurled screws without exerting force.
Centre basic gauge with knurled screw to body.
Set identical value on scale on both sides (this value may differ from vehicle to vehicle because of the body
tolerances).
Signs (+ or -) must be identical on both sides.
Basic gauge must rest without play on inner side panel.
54 37 ... CHECKING ROOF SHELL SEAL FOR LEAKS
Cover capping and place collecting container underneath.
Fig. 15: Placing Collecting Container Underneath And Cover Capping

Middle roof shell seal at corner of case:
Partially check corner of case with water bottle.
Raise sealing lip slightly.
Squirt water at base.

2010 BMW M3
Fig. 16: Checking Corner Of Case With Water Bottle

Middle roof shell seal at S-bend:
Partially check at S-bend with water bottle.
Fig. 17: Checking S-Bend With Water Bottle

Check whether water is present in pocket.
NOTE: Middle roof shell is leaking if water is present in pocket.

2010 BMW M3
Fig. 18: Checking Whether Water Is Present In Pocket

Middle roof shell seal at corner of case:
Partially check corner of case with water bottle.
Fig. 19: Checking Corner Of Case With Water Bottle

Middle roof shell seal at hinge channel:
Partially check seat at hinge channel with water bottle.

2010 BMW M3
Fig. 20: Checking Seat At Hinge Channel With Water Bottle

Check whether water is present in pocket.
NOTE: Middle roof shell is leaking if water is present in pocket.
Fig. 21: Checking Whether Water Is Present In Pocket

Cowl panel seal in A-pillar area:
Squirt water at base with water bottle and check for leaks.
NOTE: A-pillar seal is leaking if water is present on inside of marking.

2010 BMW M3
Fig. 22: Checking A-Pillar Seal For Water Present On Inside Of Marking
54 37 ... CONVERTIBLE TOP ASSEMBLY POSITION
Move convertible top so that angle of hinges is greater than 90.
Fig. 23: Identifying Convertible Top Angle

IMPORTANT: Risk of damage! Pressure in hydraulic system drops and convertible top loses
its position.
Support rear roof shell to convertible top cover with suitable auxiliary material, e.g. hard foam.
Rear roof shell is supported by auxiliary material on convertible top cover.
Auxiliary material must lie over wide area and over entire length.
Select auxiliary material with a smooth surface, as otherwise pressure points in the outer skin and seal may
2010 BMW M3
arise.
Roof shells block each other.
Fig. 24: Locating Convertible Top Position

54 37 ... CONVERTIBLE TOP SERVICE POSITIONS
54 0 170
Work step service position for convertible top:
Partially remove roofliner for roof shell at rear
Move convertible top into position.
Move convertible top cover so that angle of hinges is approx. 100.

2010 BMW M3
Fig. 25: Identifying Convertible Top Cover Angle

NOTE: Remove roof hinge bracket with a 2nd person helping.
Release screws (1) on roof hinge bracket (2).
Tilt roof shell forwards over center of gravity.
Fig. 26: Identifying Roof Hinge Bracket And Screws

IMPORTANT: Secure roof shell with cable tie (1) in order to prevent roof shell from tilting
over.
2010 BMW M3
Fig. 27: Secure Roof Shell With Cable Tie

Fig. 28: Identifying Hooks And Special Tool 54 0 170

NOTE: Picture shows roofliner removed for purposes of clarity.

Protect roofliner against damage and dirt.
2010 BMW M3
Suspend special tool 54 0 170 with hooks as follows in front frame and rear roof shell:
Suspend hooks (2) in rear roof shell.

Suspend hook (1) with opening pointing outwards in front frame.
NOTE: Hooks (1) can otherwise slip out of frame.
Feed and tensioning strap and tighten down.
54 37 ... GAUGING BASE PLATE (COWL PANEL FASTENER)
54 0 110
NOTE: Cowl panel gauge to be used only after:
Accident repairs to the cowl panel

Removal and installation of base plate
Trim strips on cowl panel must be fitted (reference point for adjustment).
IMPORTANT: Observe body gap dimensions for ideal adjustment of convertible top in
relation to body.
Always install and remove the cowl panel gauge with 2 helpers.
To prevent damaging the cowl panel gauge, set the gauge down only in the
transportation crate or on the cowl panel.
The cowl panel gauge is a highly sensitive measuring instrument which reacts
even to light impacts with distortion.
The cowl panel gauge must be checked for dimensional accuracy on a master
gauge after being subjected to impact or dropped. See 41 00 ... GAP
DIMENSIONS, BODY .
Lift out cover (1) on left and right base plate.
Installation:
Cover (1) for base plate must be replaced after each removal.
2010 BMW M3
Fig. 29: Lifting Out Cover On Base Plate

Gauge, cowl panel
Fig. 30: Base Plate On Cowl Panel With Special Tool 54 0 110
NOTE: Base plates must be screwed down loosely for gauging.

2010 BMW M3
Base plates should still be able to be slid in order to center themselves.
Position special tool 54 0 110 with journal in base plate on cowl panel.
Bring gauge with stop for X- and Z-axes into contact with cowl panel.
Fig. 31: Bring Gauge With Stop For X- And Z-Axes Into Contact With Cowl Panel
2010 BMW M3
Fig. 32: Locating Adjusting Screws And Centre Cowl Panel Gauge
IMPORTANT: Adjustment work should be carried out by one person only.
Adjust adjusting screws without exerting force.
Cowl panel gauge must rest without play on cowl panel trim strips (partially only point contact).
Centre cowl panel gauge by means of adjusting screw to cowl panel (alignment of Y-axis).
In this way, the base plates are positioned with respect to the vehicle.
Set identical value on scale on both sides (this value may differ from vehicle to vehicle because of the body
tolerances).
Signs (+ or -) must be identical on both sides.
Installation:
Screw down base plates on cowl panel.
The windscreen cowl panel gauge can be raised in the Z-direction by screwing down the base plates (gap
dimension between cowl panel gauge and cowl panel). This gap dimension cannot be adjusted and is thus
permissible.
54 37 ... GAUGING COUPLING FASTENER (AFTER REMOVING AND INSTALLING ROOF

MODULE)
00 9 251
00 9 450
54 0 130
54 0 131
54 0 132
54 0 180
IMPORTANT: To prevent damaging the coupling fastener gauge, set the gauge down only in
the transportation crate or on the cross beam.
The coupling fastener gauge is a highly sensitive measuring instrument which
reacts even to light impacts with distortion.
The coupling fastener gauge must be checked for dimensional accuracy on a
2010 BMW M3
master gauge after being subjected to impact or dropped.
NOTE: The coupling fastener must be gauged after each removal and installation of the
roof module .
Roof module must be installed

Align basic gauge
IMPORTANT: Tape off corners of roof shell 1 and 3. Risk of damage when positioning gauge
for coupling fastener and assembly.
Fig. 33: Tape Off Corners Of Roof Shell

Gauge, coupling fastener

2010 BMW M3
Fig. 34: Locating Gauge, Coupling Fastener And Rubber Stop

NOTE: Coupling fastener must not be screwed into place for adjustment work (barrel
screws move freely).
Slacken screw for rubber stop (1) and pull back.
Insert special tool 54 0 130 in coupling fastener.
Screw gauge for coupling fastener 54 0 131 on left and 54 0 132 right onto basic gauge with special tool 00 9
251 .
2010 BMW M3
Fig. 35: Locating Screw Gauge For Coupling Fastener

Turn L-piece (2) under stop screw (3) of coupling fastener.
Adjust coupling fastener as follows:
Set stop screw (3) with adjusting screw (1) such that it comes up against stop (4).
Stop screw (3) of the coupling fastener is aligned flush at stop (4)
The L-piece (2) should ideally rest against the gauge
Bring barrel screws into contact with special tool 54 0 180 in conjunction with 00 9 450.
Tightening torque: 0.2 Nm (=20 cNm).
Fig. 36: Identifying Adjusting Screw And Stop Screw With L-Piece
Installation:
2010 BMW M3
Observe screwing sequence of coupling fastener:
Refer to INSTALLING ROOF MODULE.
1. Z-direction (coupling fastener to screwing plate, rollover protection system)

2. Y-direction (coupling faster to side panel)
3. X-direction (roof frame to partition wall)
54 37 ... GAUGING COUPLING FASTENER (WITHOUT REMOVING AND INSTALLING ROOF

MODULE)
00 9 251
00 9 450
54 0 130
54 0 131
54 0 132
54 0 180
54 0 190
IMPORTANT: To prevent damaging the coupling fastener gauge, set the gauge down only in
the transportation crate or on the cross beam.
The coupling fastener gauge is a highly sensitive measuring instrument which
The coupling fastener gauge must be checked for dimensional accuracy on a
master gauge after being subjected to impact or dropped.
NOTE: Gauging of coupling fastener must be checked.
Roof module must be installed

Remove air outlet grille trim . See 51 46 026 REMOVING AND INSTALLING OR REPLACING
FRONT AIR OUTLET TRIM GRILLE
Remove window cavity cover strip . See 51 37 240 REMOVING AND INSTALLING OR
REPLACING OUTER WINDOW CAVITY COVER STRIP FOR DOOR WINDOW, REAR
LEFT OR RIGHT
Remove side trim upper section . See 51 43 012 REMOVING AND INSTALLING/REPLACING
2010 BMW M3
REAR LEFT OR RIGHT UPPER SIDE TRIM SECTION

Align basic gauge
Tape off corners of roof shell 1 and 3. Risk of damage when positioning gauge for coupling fastener.
NOTE: Close convertible top (roof module extended).
Slacken lock nut with special tool 54 0 190.
Turn barrel screws back with special tool 54 0 180.
Installation:
Tighten barrel screws with special tool 54 0 180 in conjunction with 00 9 450.
Fig. 37: Identifying Barrel Screws

NOTE: Open convertible top (roof module lowered).
IMPORTANT: Tape off corners of roof shell 1 and 3. Risk of damage when positioning gauge
for coupling fastener and assembly.
2010 BMW M3
Fig. 38: Tape Off Corners Of Roof Shell

Remove holder on left and right.


2010 BMW M3

Slacken lock nuts (1) with special tool 54 0 190.
Turn barrel screws back with special tool 54 0 180.
Installation:
Tighten barrel screws with special tool 54 0 180 in conjunction with 00 9 450.
Tightening torque 0.2 Nm (= 20 cNm): .
Fig. 41: Slacken Lock Nuts

Release screws (1) on left and right coupling fasteners.

2010 BMW M3
Fig. 42: Identifying Screws On Coupling Fasteners

Installation:
Bushing (1) stretches as screw (2) is tightened against coupling fastener (3).
Fig. 43: Bushing Stretches As Screw Is Tightened Against Coupling Fastener

Gauge, coupling fastener
NOTE: Coupling fastener must not be screwed into place for adjustment work (barrel
screws move freely).
Slacken screw for rubber stop (1) and pull back.

2010 BMW M3
Fig. 44: Slacken Screw For Rubber Stop (1) And Pull Back
Insert special tool 54 0 130 in coupling fastener.
Screw gauge for coupling fastener 54 0 131 on left and 54 0 132 right onto basic gauge with special tool 00 9
251.
2010 BMW M3
Fig. 45: Locating Screw Gauge For Coupling Fastener

Turn L-piece (2) under stop screw (3) of coupling fastener.
Adjust coupling fastener as follows:
Set stop screw (3) with adjusting screw (1) such that it comes up against stop (4).
Stop screw (3) of the coupling fastener is aligned flush at stop (4)
The L-piece (2) should ideally rest against the gauge
Fig. 46: Identifying Adjusting Screw And Stop Screw With L-Piece
Installation:
Refer to INSTALLING ROOF MODULE.

54 37 ... GAUGING REAR MODULE

2010 BMW M3
00 9 450
54 0 150
54 0 151
54 0 152
54 0 180
IMPORTANT: The rear module brackets are gauged and the screw connection sealed at the
factory.
Gauging of the brackets is only to be carried out after a repair to the body.
It is necessary in the warranty period to consult the country-specific hotline
before opening the screw connection seal.
Always install and remove rear module gauge with 2 helpers.
To prevent damaging the rear module gauge, set the gauge down only in the
transportation crate or on brackets.
The rear module gauge is a highly sensitive measuring instrument which reacts
even to light impact with distortion.
The rear module gauge must be checked for dimensional accuracy on a master
gauge after being subjected to impact or dropped.
Gauge roof module bracket
Tighten down rear module bracket (1) with suitable screws to special tool 54 0 150.
Turn back all barrel screws on rear module bracket (1) and check for ease of movement.
Fig. 47: Locating Rear Module Bracket With Screws

2010 BMW M3
Gauge, bracket, rear module
NOTE: In order to gauge the rear module bracket, the roof module bracket must be
gauged.
Adjustment work should be carried out by one person only.
Left gauge: 54 0 151
Right gauge: 54 0 152
Place special tool, with rear module bracket screwed, over centering pin.
Insert centering pin (2) in gauge and screw down.
Screw gauge with nut (1) to bracket for roof module.
Fig. 48: Screw Gauge With Nut (1) To Bracket For Roof Module
Using special tool 54 0 180 in conjunction with 00 9 450, turn all barrel screws (1) until contact is made with
2010 BMW M3
body.
Screw down bracket with shims.
Release screw connection (1) for gauge on rear module bracket.
Fig. 49: Release Screw Connection (1) For Gauge On Rear Module Bracket
Release screw connections for gauge on roof module bracket.
Remove rear module bracket gauge.
Fig. 50: Release Screw Connections For Gauge On Roof Module Bracket
2010 BMW M3
54 37 ... GAUGING ROOF MODULE BRACKETS
00 9 251
00 9 450
54 0 140
54 0 141
54 0 142
54 0 143
54 0 180
IMPORTANT: The roof module brackets are gauged and the screw connection sealed at the
factory.
Gauging of the brackets is only to be carried out after a repair to the body.
It is necessary in the warranty period to consult the country-specific hotline
before opening the screw connection seal.
Align basic gauge
IMPORTANT: Always install and remove roof module gauge with 2 helpers.
To prevent damaging the roof module gauge, set the gauge down only in the
transportation crate or on brackets.
The roof module gauge is a highly sensitive measuring instrument which
The roof module gauge must be checked for dimensional accuracy on a master
gauge after being subjected to impact or dropped.
Gauge, bracket, roof module
NOTE: Do not position special tool on basic gauge yet.
Mount special tool kit 54 0 140.
Connect left gauge 54 0 141 and right gauge 54 0 142 to cross strut 54 0 143.
2010 BMW M3
Fig. 51: Identifying Left/Right Gauge With Special Tool 54 0 141 And 54 0 142 To 54 0 143
Fig. 52: Identifying Brackets For Roof Module To Special Tool 54 0 140
Attach brackets (1) for roof module to special tool 54 0 140.
Left gauge: 54 0 141

2010 BMW M3
Right gauge: 54 0 142
Turn barrel screws (2) back and check for ease of movement.
NOTE: Use only special tool 00 9 251 to screw the gauge into position.
Tighten down screws to 2 Nm.
Fig. 53: Identifying Brackets And Barrel Screws

Carefully position roof module bracket gauge on basic gauge and screw to special tool 00 9 251.
1. Tighten down front screws on basic gauge to 2 Nm.

2. Tighten down rear screws on basic gauge to 2 Nm.
Screw roof module bracket on basic gauge crosswise in specified sequence (1 to 4) with torque wrench.
2010 BMW M3
Fig. 54: Locating Screw Roof Module Bracket On Basic Gauge Crosswise In Sequence
Fig. 55: Identifying Special Tool 54 0 180

NOTE: Adjustment work should be carried out by one person only.

Carry out following tasks only with special tool 54 0 180 in conjunction with 00 9
450.
2010 BMW M3
Tighten down barrel screws to 0.05 Nm (=5 cNm).
1. Barrel screw, rear left

2. Barrel screw, rear right
3. Barrel screw, front left
4. Barrel screw, front right
Screw down bracket with shims.
Release screw connection (1) for gauge on bracket.
Release screw connection for roof module bracket gauge on basic gauge.
Remove bracket gauge for roof module.
Fig. 56: Identifying Screw Connection For Gauge On Bracket

54 37 ... INSTALLING GUIDE PLATE FOR COWL PANEL BASEPLATE (BUILD DATE UP TO
07/2007)
Remove cowl panel trim . See 51 44 150 REPLACING TRIM FOR FRONT ROOFLINER .
Release screw (1).

2010 BMW M3
Fig. 57: Identifying Screw (1)

Pull back microswitch lever (3).
Mount guide plate (2) loose with screw (1).
Fig. 58: Mount Guide Plate (2) Loose With Screw (1)
Align guide plate (2) with 6.5 mm dia. dowel pin (or drill bit shank).
Tighten screw (1).

2010 BMW M3
Fig. 59: Locating Guide Plate With Dowel Pin And Screw
Carry out visual inspection from above.
Guide plate aligned uniformly to bore.
Fig. 60: Identifying Guide Plate Dimension

54 37 ... LOWERING ROOFLINER FOR ROOF SHELL IN MIDDLE
51 0 310
Installation:
Microencapsulated screws (Loctite) must be replaced and may not be reused

Screw connection must be completed within 20 min. (start of curing)
2010 BMW M3

Thread of nut must be cleaned beforehand in event of repeated use
Move convertible top into service position.
Move convertible top so that angle of hinges is not < or =90.
its position.
Support rear roof shell to convertible top cover with suitable auxiliary material.
Fig. 61: Identifying Convertible Top Angle

Tie a safety knot into tensioning strap on left and right to prevent the tensioning strap from coiling up.
IMPORTANT: Release safety knot after installation.

2010 BMW M3
Fig. 62: Identifying Tensioning Strap

Release retainers (2) with screwdriver and pull roof liner (1) off roof shell.
Installation:
Retainers (2) must not be damaged and must be pre-installed.
Check that roofliner is firmly seated. If necessary, bend retainers closed prior to installation.
Fig. 63: Pulling Roof Liner Off Roof Shell

Unclip roof liner at front with special tool 51 0 310.
Installation:

2010 BMW M3
Fig. 64: Unclip Roof Liner At Front With Special Tool 51 0 310
Unclip roof liner at rear with special tool 51 0 310.
Installation:
Fig. 65: Roof Liner At Rear With Special Tool 51 0 310

Pull tensioning strap completely out of automatic reel.
Tie a safety knot into tensioning strap to prevent the tensioning strap from coiling up.
Unscrew nuts (1).

2010 BMW M3
Installation:
Replace compression nuts.
Fig. 66: Identifying Automatic Reel And Nuts

Remove automatic reel (2).
Lower roofliner and stow in vehicle.
54 37 ... REMOVING AND INSTALLING/REPLACING ALL ROOF SHELLS
Only ever replace roof shells individually in succession.
Installation:
After replacing each individual roof shell, always adjust each roof shell completely and check the folding roof
for leaks.
This procedure is the only way of ensuring that no adjustment errors are carried over to the next roof shell.
Only when the folding roof is functionally and visually problem-free again can you proceed to replace the next
roof shell.
Adhere to the procedure described below without fail.
Any deviations from this procedure will result in irreparable damage to the roof mechanism.
2010 BMW M3
Sequence:
1. Roof shell, middle

2. Roof shell, front
3. Roof shell, rear
54 37 ... REMOVING AND INSTALLING/REPLACING REAR ROOF SHELL FASTENER
Support convertible top compartment lid in service position

Remove rear roofliner
Installation:

NOTE: Before removing, mark position of screws to ensure correct alignment when
installing.
Release screws (1).
Fig. 67: Release Screws

Replacement only:
2010 BMW M3
Slide locking element upwards fully and screw on loosely.
Locking element should still be able to be slid in order to center itself.
Install roof shell without roofliner.
Locking element glides into place.
Open convertible top.
Adjusting pretension on fastener:
NOTE: Mark position of screw.
Slacken screw (1) (do not unscrew fully).
Turn locking element upwards through 0.5 mm.
Tighten screw (1).
Fig. 68: Slacken Screw, Turn Locking Element Upward

Check gap dimensions of roof shell and trim strip. See 41 00 ... GAP DIMENSIONS, BODY .
2010 BMW M3
54 37 ... REMOVING AND INSTALLING/REPLACING TRIM FOR SUPPORT TUBE IN LUGGAGE

COMPARTMENT ON LEFT OR RIGHT
Release clips (1).
Feed out panel (2) in direction of arrow.
Installation:
Fig. 69: Feed Out Panel In Direction And Clips

54 37 ... REMOVING BUTYL
00 9 321
Following parts are required (refer to Electronic Parts Catalogue ETK):
Adhesive tape 83 19 9 410 979

Adhesive cleaner 83 11 0 009 712
Press out excess butyl with fishbone 00 9 321 under seal (1).
2010 BMW M3
Fig. 70: Press Out Excess Butyl With Fishbone 00 9 321 Under Seal
Stick adhesive strip (1) onto butyl and press down gently with fishbone 00 9 321.
IMPORTANT: Risk of paintwork damage!
Fig. 71: Identifying Stick Adhesive Strip

Pull off adhesive strip (1).
If necessary, repeat procedure with new adhesive strip until butyl is removed.
2010 BMW M3
Fig. 72: Identifying Adhesive Strip

Remove butyl remnants between seal and roof outer skin with toothpick (1).
Slide toothpick (1) approx. 5 mm deep under seal. Butyl sticks to the toothpick when the latter is turned. After a
few turns, pull out toothpick and scrape off butyl.
Repeat procedure if necessary.
Clean painted surfaces with adhesive cleaner.
IMPORTANT: Adhesive cleaner attacks paint surfaces if allowed to act on surface for an
extended period of time!
Fig. 73: Identifying Toothpick

54 37 005 REPLACING FRONT ROOF SHELL SEAL

2010 BMW M3
00 9 470
Installation:
Screws with sealing compound must be replaced and must not be reused
Thread of nut must be cleaned beforehand
New parts required:
Seal
Butylene thread dia. 4 mm and dia. 7 mm
Butylene flat tape 1.5 mm x 15 mm
Measure gap dimensions in following areas with special tool 00 9 470:
A. between roof shell and trim strip

B. between front and middle trim strips
Note down gap dimensions.
Fig. 74: Measuring Gap Dimensions With Special Tool

Move into assembly position

Bring vehicle to garage/workshop temperature

2010 BMW M3

Remove seal from roof shell.
Fig. 76: Identifying Roof Shell Left And Right Screws

On-the-job safety
Remove remnants of adhesive from roof shell.

2010 BMW M3
Clean adhesive area with Isohexane.
Use 4 mm and 7 mm dia. butylene thread (see BMW Parts Service).
Use 1.5 mm x 15 mm butylene flat tape (see BMW Parts Service).
Overview of butylene thread laying on front roof shell, side:
1. Apply 4 mm dia. butylene thread up to middle of threaded bushes in sheet metal groove.
2. Laying on front roof shell area, see below.
3. Laying on rear roof shell area, see below.
Butylene thread resting on threaded bushes.
Fig. 77: Identifying Butylene Thread Laying On Front Roof Shell

Overview of butylene flat tape application on front roof shell corner, left/right:
1. Apply butylene flat tape approx. 3 cm in length to roof shell corner on each side.
2010 BMW M3
Fig. 78: Identifying Butylene Flat Tape On Front Roof Shell Corner, Left/Right
Overview of butylene thread laying on front roof shell, rear left/right:
1. Apply 7 mm dia. butylene thread from middle of threaded bush rising slightly up to elongated hole.
2. Allow butylene thread to run out thinner closed around elongated hole.
Fig. 79: Identifying Butylene Thread Laying On Front Roof Shell, Rear Left/Right
Overview of butylene thread laying on front roof shell, rear left/right:
1. Apply 7 mm dia. butylene thread from middle of threaded bushes rising slightly.
Installation:
Connect and smooth butylene thread joints with plastic wedge.

2010 BMW M3
Fig. 80: Identifying Butylene Thread Laying On Front Roof Shell, Rear Left/Right
Overview of butylene thread laying on front roof shell, front left/right:
1. Butylene flat tap on roof shell corner.

2. Apply 7 mm dia. butylene thread from middle of threaded bush rising slightly up to seal carrier.
Installation:
Fig. 81: Identifying Butylene Thread Laying On Front Roof Shell, Front Left/Right
Overview of butylene thread laying on front roof shell, front left/right:
1. Butylene flat tap on roof shell corner.

2. Allow 7 mm dia. butylene thread to run out from middle of threaded bush rising slightly up to seal carrier.
2010 BMW M3
Fig. 82: Identifying Butylene Thread Laying On Front Roof Shell, Front Left/Right
Installation:
A second person will be need to help install the seal.
Position seal at front corner on left and right of roof shell.
Align seal with screw fastening point (1) to thread in roof shell.
Press seal down in front area.
Fig. 83: Aligning Seal With Screw Fastening Point To Thread In Roof Shell
Installation:
Press seal down at side.

2010 BMW M3
Carry over noted gap dimensions and screw down seal.
Fig. 84: Measuring Gap Dimensions

Press seal (1) down at rear left and right at sealing bead and pop into roof shell.

Check retraction depth of windows and adjust if necessary.
54 37 015 REPLACING MIDDLE ROOF SHELL SEAL

2010 BMW M3
00 9 470
Installation:
New parts required:
Seal
Butylene thread dia. 4 mm and dia. 7 mm
Butylene flat tape 1.5 mm x 15 mm
Measure gap dimensions in following areas with special tool 00 9 470:
A. between roof shell and trim strip

B. between front and middle trim strips
Note down gap dimensions.
Fig. 86: Measuring Gap Dimensions With Special Tool

Move into service position

Installation:
2010 BMW M3
Fig. 87: Releasing Retainers With Screwdriver

Fig. 88: Releasing Left And Right Screws

Release screws (1) at rear left and right.
Pull seal off roof shell.

2010 BMW M3
Fig. 89: Identifying Screws At Rear Left And Right

On-the-job safety
Use 4 mm and 7 mm dia. butylene thread (see BMW Parts Service).
Use 1.5 mm x 15 mm butylene flat tape (see BMW Parts Service).
Overview of butylene flat tape laying on front roof shell corner, left/right:
1. Apply butylene flat tape from threaded bush to shortly after metal overlap to roof shell corner.
2010 BMW M3
Fig. 90: Identifying Butylene Flat Tape Laying On Front Roof Shell Corner, Left/Right
Overview of butylene thread laying on middle roof shell, front:
1. Apply 4 mm dia. butylene thread in sheet metal groove.

Installation:
Fig. 91: Identifying Butylene Thread Laying On Middle Roof Shell, Front
Overview of butylene flat tape laying on rear roof shell corner, left/right:
1. Apply butylene flat tape from threaded bush to shortly after metal overlap to roof shell corner.
2010 BMW M3
Fig. 92: Identifying Butylene Flat Tape Laying On Rear Roof Shell Corner, Left/Right
Overview of butylene thread laying on middle roof shell, side/rear left and right:
1. Apply 4 mm dia. butylene thread at distance of 2-3 mm to roof edge.

Installation:
Fig. 93: Identifying Butylene Thread Laying On Middle Roof Shell, Side/Rear Left And Right
Installation:
A second person will be need to help install the seal.

2010 BMW M3
Position seal (1) at front corner on left and right of roof shell.
Press seal down in area (1).
Fig. 94: Positioning Seal At Front Corner On Left And Right Of Roof Shell
Installation:
Press seal down at side.
Carry over noted gap dimensions and screw down seal.
Mount seal at rear on roof shell.
Fig. 95: Mounting Seal At Rear On Roof Shell

2010 BMW M3
54 37 025 REPLACING REAR ROOF SHELL SEAL
00 4 430
51 0 300
Installation:
New parts required:
Seal
Butylene thread dia. 4 mm
Remove roof lining .

Move into assembly position
Release screws (1).
Release screw (2) with special tool 00 4 430.
Pull seal off roof shell at rear.

2010 BMW M3
Fig. 96: Identifying Roof Shell Screws

On-the-job safety
Use 4 mm dia. butyl bead (see BMW Parts Service).
Overview of butyl bead laying on roof shell, front:
1. Apply butylene bead with dia. 4 mm 1 mm with a length of at least 40 mm in sheet metal bead.
2. Apply butylene bead with dia. 4 mm 1 mm above push pin bores.
3. Apply butylene bead with dia. 4 mm 1 mm with a length of 70 mm in center of flange to roof shell.
2010 BMW M3
Fig. 97: Identifying Butyl Bead Laying On Roof Shell, Front

Installation:
Press seal with trim strip (1) firmly onto roof shell.
Align screw fastening point to thread in roof shell.
Fig. 98: Identifying Trim Strip

Installation:
Press seal onto butyl bead
Pop in seal in marked area (1).

2010 BMW M3
Fig. 99: Identifying Seal Marked Area

Installation:
For optimum securing of seal (2), press down entire upper area with special tool 51 0 300.
If necessary, use plastic hammer and impact protection.
Fig. 100: Pressing Down Entire Upper Area With Special Tool
54 37 035 REMOVING AND INSTALLING/REPLACING ROOFLINER FOR ROOF SHELL AT

FRONT

2010 BMW M3
51 0 310
its position.
Auxiliary material must lie over wide area and if possible over entire length.
Fig. 101: Identifying Convertible Top Service Position

Lever out left and right clips (1).
Installation:

2010 BMW M3

Lever all clips out of roofliner at front.
Installation:
Fig. 103: Identifying Roofliner Clips

Unclip roofliner at rear left and right from roof shell.
Installation:

2010 BMW M3
Fig. 104: Identifying Retainers

Unclip roofliner in rear area with special tool 51 0 310.
Installation:

Installation:
Pre-install clips in roofliner (1).

2010 BMW M3

54 37 040 REMOVING AND INSTALLING OR REPLACING ROOFLINER FOR ROOF SHELL IN

MIDDLE
00 4 430
51 0 310
54 0 230
Installation:

Move soft top into service position.
Move soft top so that angle of hinges is not < or =90.
IMPORTANT: Risk of damage! Pressure in hydraulic system drops and soft top loses its
position.

2010 BMW M3
Fig. 107: Identifying Soft Top Service Position

Tie a safety knot into tensioning strap on left and right to prevent the tensioning strap from coiling up.
Fig. 108: Tying Safety Knot Into Tensioning Strap On Left And Right To Prevent Tensioning Strap
From Coiling Up

2010 BMW M3

NOTE: Different build dates (versions) possible.
Release Torx screw (1) of reversing lug or reversing bar for tensioning cable on left and right.
Fig. 110: Release Torx Screw (1) Of Reversing Lug Or Reversing Bar For Tensioning Cable On Left And
Right
Installation:

2010 BMW M3
Fig. 111: Releasing Retainers With Screwdriver

Release Torx screw (1) of reversing lugs for tensioning cable on left and right of roof shell at rear.
Fig. 112: Release Torx Screw Of Reversing Lugs

Release Torx screw (1) for fastening tensioning cable on left and right of convertible top frame.

2010 BMW M3
Fig. 113: Identifying Torx Screw For Fastening Tensioning Cable

NOTE: Convertible top compartment lid opened.
Using special tool 00 4 430, release Torx screw from tensioning cable mounting on main bearing.

Detach rubber protective sleeve (1) from spring on tensioning strap (2).
2010 BMW M3
Fig. 115: Detaching Rubber Protective Sleeve From Spring On Tensioning Strap
Disengage spring (1) from tensioning strap eyelet (2).
Fig. 116: Disengaging Spring From Tensioning Strap Eyelet

Feed tensioning cable (1) out of reversing lug (2).

2010 BMW M3
Fig. 117: Identifying Tensioning Cable And Reversing Lug

Release water valve (1).
Fig. 118: Identifying Water Valve

Feed out tensioning strap (1) from holder (2) for water valve and reversing lug .
2010 BMW M3
Fig. 119: Identifying Tensioning Strap And Holder

Mark tensioning strap on one side before retainer.
Open retainer (1).
Replacement only:
Roof shell in middle in "closed" position, convertible top compartment lid open.
Feed tensioning strap into reversing lug and pull until roofliner contacts seal.
Turn tensioning strap over into a loop and crimp retainer (1).
Fig. 120: Identifying Retainer

IMPORTANT: Risk of damage to tensioning strap.

2010 BMW M3
Edges (2) must be free of sharp corners and burrs. Deburr if necessary.
Make sure tensioning strap is correctly laid. Do not feed tensioning strap through plastic guide (1).
Fig. 121: Identifying Plastic Guide

Installation:
Replace faulty retainer.
Insert tensioning strap (1) with marking in positioner (2) of special tool 54 0 230.
If necessary, adjust measured length (see above).
Fig. 122: Inserting Tensioning Strap With Marking In Positioner Of Special Tool
Insert new retainer (1) in special tool 54 0 230 and crimp.

2010 BMW M3
Fig. 123: Inserting Retainer In Special Tool

Feed tensioning cable (1) out of guide (2).
Fig. 124: Identifying Tensioning Cable And Guide

Release Torx screws (1) for C-pillar flap.

2010 BMW M3
Fig. 125: Identifying Torx Screws For C-Pillar Flap

Unclip roof liner at front with special tool 51 0 310 .
Installation:
Fig. 126: Identifying Front Roof Liner And Special Tool

Unclip roof liner at rear with special tool 51 0 310.
Installation:

2010 BMW M3
Fig. 127: Identifying Rear Roof Liner And Special Tool

Pull tensioning strap completely out of automatic reel.
Tie a safety knot into tensioning strap to prevent the tensioning strap from coiling up.
Unscrew nuts (1).
Installation:
Replace compression nuts.
Fig. 128: Tying Safety Knot Into Tensioning Strap To Prevent Tensioning Strap From Coiling Up
2010 BMW M3
54 37 045 REMOVING AND INSTALLING/REPLACING ROOFLINER FOR ROOF SHELL AT

REAR
its position.

Carefully insert retainer lifter between roofliner and roof shell.
Lever clips (1) out of roof shell with roof shell.
Installation:

2010 BMW M3
Fig. 130: Inserting Retainer Lifter Between Roofliner And Roof Shell
Detach roofliner in area (1).
Fig. 131: Identifying Roofliner

Unclip roofliner at top from retainers (1).

2010 BMW M3
Fig. 132: Identifying Roofliner Retainers

Pull roofliner upwards out of retainers in marked area (1).
Installation:
Make sure roofliner is correctly seated in retainers.
Fig. 133: Identifying Roofliner Retainers

54 37 060 REMOVING AND INSTALLING/REPLACING TRIM STRIP FOR ROOF SHELL,

MIDDLE LEFT OR RIGHT
2010 BMW M3
its position.
Fig. 134: Move Convertible Top Into Service Position

Lever out covers of clips (1).
Fig. 135: Identifying Cover Clips

Release and remove clips (1).

2010 BMW M3

Remove trim strip (2) from roof hinge bracket.
Installation:
Guide lug (1) must not be damaged.
Make sure guide lug (1) is correctly seated in roof hinge bracket.
Fig. 137: Identifying Lug And Trim Strip

NOTE: Secure spring wire with adhesive tape. Risk of damage!

2010 BMW M3
Fig. 138: Identifying Spring Wire Adhesive Tape

54 37 065 REMOVING AND INSTALLING/REPLACING COVER FOR HINGE FOR ROOF SHELL,
MIDDLE LEFT AND RIGHT
Remove trim strip
its position.

2010 BMW M3

Carefully unclip cover (1) with plastic wedge.

Installation:
Retainers must not be damaged and must be pre-installed.

2010 BMW M3
Fig. 141: Locating Retainers

Installation:
Insert cover (1) with guide (2) in roof hinge bracket.
Pull cover (1) towards rear and clip into place.
Fig. 142: Identifying Cover And Guide

54 37 067 REMOVING AND INSTALLING/REPLACING HINGE
Remove hinge cover
Installation:
2010 BMW M3

Screw connection must be completed within 20 mins. (start of curing)
NOTE: A helper is required for the following operations.
IMPORTANT: Tape off cover (1) of roof hinge bracket in marked area.
Risk of damage!
With a second person helping, secure roof shell at front against tilting.
Release screws (2).
Installation:
Replace microencapsulated screws.
Fig. 143: Identifying Cover Of Roof Hinge Bracket

Release nuts (1) on roof hinge bracket.
Installation:
Replace nuts.
Screw on bracket loosely.
Bracket should still be able to be slid in order to center itself.

2010 BMW M3
Screw down rear nut and open convertible top.
Screw down front nut.
Fig. 144: Identifying Front And Rear Nut

Check gap dimensions for convertible top.
54 37 070 REMOVING AND INSTALLING/REPLACING ROOF SHELL AT FRONT
Remove roofliner for roof shell at front
Installation:

its position.
2010 BMW M3

Detach cable tie.
Installation:
Replace cable tie.

2010 BMW M3
Release screws (1).
Remove shaper (2) from roof shell.
Fig. 147: Identifying Screws And Shaper

IMPORTANT: Tape off cover (1) of roof hinge bracket in marked area.
Risk of damage!
With a second person helping, secure roof shell at front against tilting.
Release screws (2).
Installation:
Turn roof hinge bracket.

2010 BMW M3
Fig. 148: Identifying Cover Of Roof Hinge Bracket And Screws

Mark screws (1) and release.
Remove roof shell with a second person helping.

IMPORTANT: Do not adjust barrel screws.
Fig. 150: Locating Barrel Screws

2010 BMW M3
NOTE: The scope of work for removing and installing the roof shell ends here.
Replacement only:
Remove locking mechanism
Fig. 151: Identifying Locking Mechanism

Remove seal (2) .
Release screws (1) and remove retaining strip (3) for seal.
Fig. 152: Identifying Seal, Screws And Retaining Strip

Drill out rivets (1) from guide element (2) on left and right.
Remove guide element (2).

2010 BMW M3
Fig. 153: Identifying Rivets And Guide Element

Release screws (1).
Remove shaper (2) from roof shell.
Fig. 154: Identifying Screws And Shaper

Measure heights of all barrel screws with a depth gauge and note down.
Carry over adjustment to new roof shell.
Installation:
Insert barrel screws with Loctite.

2010 BMW M3
Fig. 155: Identifying Heights Of Barrel Screws

54 37 075 REMOVING AND INSTALLING/REPLACING ROOF SHELL IN MIDDLE
Lower roofliner for roof shell
(From roof shells and front and middle only)
Remove cover
Secure SOFT Top in service position
Installation:

Carefully unclip water valve (1).

2010 BMW M3
Fig. 156: Identifying Water Valve

Pull water valve (1) off water drain hose (2).
Fig. 157: Identifying Water Valve And Water Drain Hose

Mark tensioning strap at deflection point (1).
Carefully open retainer (2) without damaging the tensioning strap.
Installation:
Replace faulty retainer.

2010 BMW M3
Fig. 158: Identifying Retainer

Installation:
Make sure tensioning strap is correctly laid. Do not feed tensioning strap through plastic guide (1).
Fig. 159: Identifying Plastic Guide

Feed tensioning strap (1) out of holder (3) on frame.
Open holder (3) and remove water drain hose (2).

2010 BMW M3
Fig. 160: Identifying Holder And Water Drain Hose

Unclip metal retainer (1) from frame.
Feed water drain hose (2) out of frame.
Fig. 161: Identifying Metal Retainer And Water Drain Hose

NOTE: A second person will be needed to help with the following work steps for
removing the roof shell in the middle.
If necessary, remove roof hinge bracket:
Release nuts (1) on roof hinge bracket.
Installation:
Replace nuts.
2010 BMW M3
Screw on bracket loosely.
Bracket should still be able to be slid in order to center itself.
Close soft top.
Screw down rear nut and open soft top.
Screw down front nut.
Fig. 162: Identifying Nuts On Roof Hinge Bracket

Remove roof shell.
NOTE: Plug connection on right roof shell cylinder can be incorrectly positioned.
The plug connection must be repositioned if it does not point to the outside of
the vehicle.
2010 BMW M3

Replacement only:
Remove fastener, roof shell, middle (1) .
Remove seal, roof shell, middle (2) .
Fig. 164: Identifying Fastener, Roof Shell, Middle

Measure height of barrel screws for roof shell fastener and carry over to new roof shell.
Installation:

2010 BMW M3

Measure height of barrel screws for roof shell screw fastening points and carry over to new roof shell.
Installation:

Release screw (1).
Release screw (2) on opposite side.
Remove water drain hose (3).
Installation:
2010 BMW M3
Replace water drain hose.
Fig. 167: Identifying Water Drain Hose

Check gap dimensions for soft top.
54 37 080 REMOVING AND INSTALLING/REPLACING ROOF SHELL AT REAR
Remove roofliner for roof shell

Measure and note down gap dimensions
Installation:

its position.
2010 BMW M3

Unscrew left and right nuts (1).
Remove grounding strap.
Fig. 169: Identifying Grounding Strap Nuts

Roof shell, left side:
Unlock plug connections (1) on antenna amplifier and disconnect.

2010 BMW M3
Unclip wiring harness.
Unlock plug connection (2) on blocking circuit and disconnect.
Fig. 170: Identifying Plug Connection (Left Side)

Roof shell, right side:
Fig. 171: Identifying Plug Connection (Right Side)

Unclip wiring harness (1) from roof shell.
Installation:

2010 BMW M3
Fig. 172: Identifying Wiring Harness

NOTE: A second person is required to help in removing the roof shell.
Mark screws (1) on left and right.
Release screws (1).
Remove roof shell.
Do not adjust barrel screws on roof shell.

2010 BMW M3
Replacement only:
Drill out rivets (2).
Remove retainers (1).
Fig. 174: Identifying Rivets And Retainers

Remove retainers (1) from roof shell.
Fig. 175: Identifying Retainers

Left side on roof shell:

2010 BMW M3
Release nut (2) and remove blocking circuit.
Fig. 176: Identifying Plug Connection Nut

Right side on roof shell:
Release nut (2) and remove antenna amplifier.
Release nut (4) and remove blocking circuit.
Fig. 177: Identifying Plug Connection With Nut


2010 BMW M3
Remove locking part (2).
Remove seal (3).
Fig. 178: Identifying Locking Part

Measure heights of all barrel screws (1) to roof shell with a depth gauge and note down.
Carry over adjustment to new roof shell.
Installation:

2010 BMW M3
54 37 090 REMOVING AND INSTALLING/REPLACING FRONT COWL PANEL FASTENER
Remove roofliner at front
Installation:

its position.
Fig. 180: Moving Convertible Top Into Service Position


2010 BMW M3
Slide open retaining clip (1) and unclip ball head.
NOTE: Before removing, mark position of nuts to ensure correct alignment when
installing.
Unscrew nuts (2).
Tightening torque 54 37 08AZ, see 54 37 POWER CONVERTIBLE TOP .
Installation:
Replace nuts.
Fig. 181: Identifying Retaining Clip With Nuts

Replacement only:
Screw on new fasteners loosely.
Fastener should still be able to be slid in order to center itself.
Fasteners glide into place.
Tighten down nuts (1).
Check gap dimensions and if necessary adjust. See 41 00 ... GAP DIMENSIONS, BODY .
2010 BMW M3

54 37 105 REMOVING AND INSTALLING/REPLACING COMPLETE FRONT ROOF SHELL

FASTENER PACK
Remove roof shell at front

Installation:

its position.

2010 BMW M3

Slide open retaining clip (1) and unclip ball head.
Fig. 184: Sliding Open Retaining Clip

NOTE: Before removing fasteners, mark position of screws to ensure correct alignment
when installing.
Release screws (1).

2010 BMW M3

NOTE: Before removing fasteners, mark position of screws to ensure correct alignment
when installing.
Release screws (1).

Do not adjust barrel screws (1) for height adjustment.
When replacing roof shell, measure height of barrel screws and carry over to new roof shell.
2010 BMW M3

NOTE: Before removing fasteners, mark position of nuts to ensure correct alignment
when installing.
Unscrew nuts (1).
Installation:
Replace nuts.
Remove motor carrier with drive unit.
Fig. 188: Identifying Motor Carrier Nuts

Installation:
2010 BMW M3
Guide cylinder must run into counter-support without noises and tension.
Check gap (A) and adjust if necessary.
(A) = 19 mm
Fig. 189: Measuring Middle Roof Shell Fastener To Front Roof Shell Fastener And Necessary Adjust
Gap
Installation:
The scope of work for removing and installing the front roof shell fastener pack ends here.
Replacement only:
Align new motor carrier with drive unit centrally to threaded pin.
Tighten down new nuts (1).

2010 BMW M3
Fig. 190: Identifying Motor Carrier Nuts

Screw on new fasteners loosely.
Installation:
Guide cylinder must run into counter-support without noises and tension.
Check gap (A) and adjust if necessary.
(A) = 19 mm
Fig. 191: Measuring Middle Roof Shell Fastener To Front Roof Shell Fastener And Necessary Adjust
2010 BMW M3
Gap
Adjust gap (A) = approx. 19 mm.
Tighten down screws.

Installation:
Strikers must be completely closed.

2010 BMW M3
Fig. 193: Identifying Striker Correct And Incorrect Position

NOTE: Check gap dimensions and if necessary adjust.

See 41 00 ... GAP DIMENSIONS, BODY .
54 37 110 REMOVING AND INSTALLING/REPLACING FASTENER FOR ROOF SHELL IN

MIDDLE
Remove roofliner in middle
Installation:

its position.

2010 BMW M3

installing.
Release screws (1).
Tightening torque 54 37 09A, see 54 37 POWER CONVERTIBLE TOP .

NOTE: The scope of work for removing and installing the roof shell fastener ends here.
Screw on fastener loosely.

2010 BMW M3
Fastener centers itself.
Mark screw position and open convertible top.
Slacken screws and slide center fastener 0.5 mm in opposite direction to direction of travel.
The required pretension is thus obtained.
Fig. 196: Identifying Gap Dimensions

54 37 115 REMOVING AND INSTALLING/REPLACING MIDDLE ROOF SHELL FASTENER PACK
Remove roof shell in middle
Installation:

2010 BMW M3
its position.

installing.
Release screws (1).
Remove fastener.
2010 BMW M3

NOTE: The scope of work for removing and installing the roof shell fastener pack ends
here.
Replacement only:
Screw on fastener (4) loosely.
Fastener (4) should still be able to be slid in order to center itself.
Aligning fastener (4) manually:
1. Slide fastener in X towards rear

2. Slide fastener in X 1 mm towards front
3. Centre fastener in Y
2010 BMW M3
Fig. 199: Sliding Fastener In Towards Rear

Centre fastener (1) and screw on loosely.
Fastener (1) should still be able to be slid in order to center itself.
Fig. 200: Adjusting Still


2010 BMW M3
Fig. 201: Identifying Roof Shell Screws

Measure middle roof shell fastener to front roof shell fastener and if necessary adjust gap (A).
A) 19 mm
Fig. 202: Measuring Middle Roof Shell Fastener To Front Roof Shell Fastener
NOTE: Check gap dimensions and if necessary adjust. See 41 00 ... GAP DIMENSIONS,
BODY .
54 37 130 REMOVING AND INSTALLING ROOF MODULE
00 9 450
54 0 101
54 0 102
54 0 180
54 0 190
54 0 220
Connect battery charger

Remove panel for passenger compartment partition . See 51 47 143 REMOVING AND
INSTALLING/REPLACING PANEL FOR PASSENGER COMPARTMENT PARTITION .
2010 BMW M3
Remove luggage compartment trim panel . See 51 47 210 REMOVING AND

INSTALLING/REPLACING TRUNK TRIM PANEL ON LEFT SIDE PANEL and 51 47 220
REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT TRIM PANEL
ON RIGHT SIDE PANEL .
Remove air outlet trim grille . See 51 46 026 REMOVING AND INSTALLING OR REPLACING
FRONT AIR OUTLET TRIM GRILLE .
Remove rear module .
Remove window cavity cover strip . See 51 37 240 REMOVING AND INSTALLING OR
REPLACING OUTER WINDOW CAVITY COVER STRIP FOR DOOR WINDOW, REAR
LEFT OR RIGHT .
Remove lower section of side trim . See 51 43 034 REMOVING AND INSTALLING/REPLACING
Move convertible top for following work into position.
Fig. 203: Moving Convertible Top For Following Work Into Position
Release screws (1).
Remove cover (2) for hydraulic unit.

2010 BMW M3
Fig. 204: Identifying Cover Screws

Unclip all cable holders on hydraulic lines on left and right.
Fig. 205: Uncliping Cable Holders

NOTE: Only in case of optional extra with CD changer.
Slacken screws and slide CD changer back.

2010 BMW M3
Fig. 206: Identifying CD Changer Screws

Unlock plug connections (1) on left in luggage compartment and disconnect.

Lever out clips (1) on left and right trim.
Remove trim (2) on right and left.

2010 BMW M3
Fig. 208: Identifying Trim And Clips

Release screws (1).
Remove load protective plate on left and right.
NOTE: For right load protective plate, remove control unit if necessary. See 65 77 770
REMOVING AND INSTALLING (REPLACING) ROLLOVER CONTROLLER .
Fig. 209: Identifying Protective Plate Screws


Fit special tool 54 0 220 to prevent unintentional triggering of rollover
protection system.
2010 BMW M3

Tightening torque: 54 37 13AZ, see 54 37 POWER CONVERTIBLE TOP ..
Slacken lock nut with special tool 54 0 190.
Turn back barrel screws by approx. 3 mm.
Installation:
Tighten barrel screws only with special tool 54 0 180 together with 00 9 450.
Fig. 211: Identifying Back Barrel Screws

2010 BMW M3
Fig. 212: Identifying Coupling Screws

Installation:
Bushings (1) must be replaced and screwed before installation of convertible top into body up to shortly before
stop.
Bushing (1) stretches as screw (2) is tightened against coupling fastener (3).
Fig. 213: Identifying Bushings

Secure metal plate (1) over Hall sensor in left mounting cover (2).
2010 BMW M3
Metal plate (1) simulates a closed luggage compartment partition.
Fig. 214: Identifying Metal Plate And Mounting Cover

Place both legs of special tool 54 0 101 as close together as possible.

Carefully insert folded special tool 54 0 101.

2010 BMW M3

NOTE: The bolts have different lengths. Install bolts as follows:
1. Short bolts
2. Long bolts
Tighten down bolts on main mounts on left and right.
Fig. 217: Identifying Short And Long Bolts

Assemble linkage and screw down.
Adjust rotary sleeve (1) if necessary.

2010 BMW M3
Fig. 218: Adjusting Rotary Sleeve

Adjust the length of the linkage with rotary sleeve (1) until the fastening point fits in the barrel screw.
IMPORTANT: Brass pin can break off.

Tightening torque for nut (2): 8 Nm.
Tighten nut (2) on left and right. The cone is secured in the barrel screw.
Fig. 219: Adjusting Length Of Linkage With Rotary Sleeve

Lay linkage (1) for luggage compartment partition.

2010 BMW M3
Fig. 220: Laying Linkage For Luggage Compartment Partition

Fig. 221: Sliding Locking Sleeve Over Pivot Joint

Installation:
The assembly carrier must rest free of tension on the main mount. Otherwise stress may occur at the main
mount that could cause faulty installation.
2010 BMW M3
Without using excessive force, pull tensioning rods outwards over rotary sleeves.
Slide locking sleeve (1) over pivot joint.
Secure hydraulic control unit (1) with cable ties to assembly carrier.
Fig. 222: Securing Hydraulic Control Unit With Cable Ties

Secure hydraulic cylinders (1) on left and right to assembly carrier with cable tie.
Fig. 223: Securing Hydraulic Cylinders On Left And Right To Assembly

Unclip cable holder (1).

2010 BMW M3
Fig. 224: Identifying Cable Holder

Fig. 225: Identifying Roof Module Main Bearings Nuts

Release front nuts (1) on left and right roof module main bearings.

2010 BMW M3
Open hardtop (roof module lowered) .
IMPORTANT: Tape off corners (1) of roof shells. Risk of damage when positioning gauge for
coupling fastener and assembly.
Fig. 226: Taping Corners Of Roof Shells

Remove holder on left and right.

Release screws (2) on grounding strap on left and right.

2010 BMW M3
Fig. 228: Identifying Coupling Screws

Release lock nut (1) with special tool 54 0 190.
Turn barrel screw back.
Installation:
Fig. 229: Identifying Lock Nut

Installation:
2010 BMW M3
Gauge coupling fastener .

Fig. 230: Identifying Roof Module Main Bearings Nuts

Release rear nuts (1) on left and right roof module main bearings.
IMPORTANT: Convertible top must not be moved after the nuts on the main bearing have
been released.
NOTE: Shown here without roof shells for a better overview.

2010 BMW M3
Unlock plug connection (1) on right in luggage compartment and disconnect.


Detach water drain hose (1).
Unclip cable holder (2).

2010 BMW M3
Fig. 233: Identifying Water Drain Hose And Cable Holder

Unclip cable holders.

2010 BMW M3
Fig. 235: Lifting Roof Module With Special Tool (54 0 102)
NOTE: Carry out this part of the work with the assistance of two other persons.
Position special tool 54 0 102 with workshop crane over roof module.
IMPORTANT: Use lifting gear and assembly carrier only in conjunction with BMW WJN.10
workshop crane (special lifting arm with 1690 mm arm length - refer to BMW
Workshop Equipment Catalogue) or a crane with comparable specifications.
Feed in belts between rollover protection system and roof module.
Do not twist straps!
Attach strap to assembly carrier.
Attach rear strap to assembly carrier.
IMPORTANT: Straps must not be twisted!

2010 BMW M3
Fig. 236: Attaching Rear Strap To Assembly Carrier

Fig. 237: Lifting Out Roof Module Carefully

To lift out the convertible top uniformly, make sure the special tool is aligned parallel to the roof module.
Lifting out roof module carefully and in stages with lifting gear.
2010 BMW M3
Check freedom of movement of roof module with respect to body.
Carefully set roof module down on a suitable surface (e.g. squared beams on pallet).
Replacement only:
Refer to REPLACING ROOF MODULE.
Set removed roof module down on inside of lid of transportation crate and bolt down.
Change assembly carrier to new roof module and install roof module in vehicle.
Set down removed roof module with assembly carrier from inside of transportation crate and bolt down.
Remove assembly carrier.
Fig. 238: Removing Roof Module

Installation:
Carry out diagnosis
54 37 140 REPLACING ROOF MODULE
54 0 101
2010 BMW M3
Remove roof module
Fig. 239: Identifying Special Tool (54 0 101) To Roof Module

Set removed roof module down on inside of lid of transportation crate and bolt down.
Changeover special tool 54 0 101 to new roof module.
Check distanced between left and right brackets and left and right main mounts:
1. Measure distance between guide pins.

2. Measure distance between rear threaded studs.
2010 BMW M3
Fig. 240: Measuring Distance Between Guide Pins

Check measured lengths between the main mounts.
If necessary, use rotary sleeve (1) to adjust measured distance between the guide pins.
If necessary, use rotary sleeve (2) to adjust measured distance between the threaded studs.
Fig. 241: Identifying Rotary Sleeve

Install roof module in vehicle.
Set down removed roof module with assembly carrier from inside of transportation crate and bolt down.
Remove assembly carrier.

2010 BMW M3
54 37 160 REMOVING REAR MODULE
00 9 450
54 0 180
54 0 200
Connect charger
Remove luggage compartment partition . See 51 47 202 REMOVING AND INSTALLING COVER
FOR LUGGAGE COMPARTMENT .
Remove trim from rear apron . See 51 46 050 REMOVING AND INSTALLING/REPLACING
TOP TRIM ON REAR APRON .
Installation:

Open convertible top compartment lid.
Mechanically open rear lid.
Fig. 242: Opening Convertible Top Compartment Lid

IMPORTANT: Convertible top compartment lid can tilt forwards when hydraulic cylinders are
2010 BMW M3
removed and must be supported with suitable apparatus.
Fig. 243: Removing Convertible Top Compartment Lid

Measure distance A between rear module kinematics.
Installation:
Adjust distance A.
Basic adjustment dimension e.g. for replacement:
A = 770.3 mm.
Fig. 244: Measuring Distance Between Rear Module Kinematics

Removing hydraulic cylinder for rear lid:

2010 BMW M3
Release screw (1).
Fig. 245: Identifying Hydraulic Cylinder Screw

Slide retaining clip (1) upwards.
Detach ball socket at side.
NOTE: Close trunk lid carefully.
Fig. 246: Identifying Ball Socket Retaining Clip

Disconnect all cable ties.
Installation:
Replace faulty cable ties.

2010 BMW M3
Fig. 247: Identifying Cable Ties

Feed hydraulic line (1) with hydraulic cylinder out of wiring harness (2).
Installation:
Make sure hydraulic line is correctly routed behind wiring harness.
Close rear lid.
Fig. 248: Identifying Hydraulic Line And Wiring Harness

Remove locating cover (2) on left and right.

2010 BMW M3

NOTE: Operation not absolutely necessary, only if roof module still has to be
subsequently moved.
Secure metal plate (1) over Hall sensor in left mounting cover (2).
Metal plate (1) simulates a closed luggage compartment partition.
Fig. 250: Identifying Metal Plate And Mounting Cover

IMPORTANT: Observe disconnection sequence of plug connections without fail.
Plug connection (1) with locking bar must first be unlocked and disconnected.
NOTE: If the Soft Close Automatic of the rear lid opens, close plug connection again
and change disconnection sequence.
2010 BMW M3
Rear lid must be closed.

Connect special tool 54 0 200 to vehicle-side plug for rear module.
NOTE: Adapter simulates closed rear lid. Retractable hardtop without rear lid not in
working order.
Fig. 252: Connecting Special Tool (54 0 200) To Vehicle-Side Plug For Rear Module
Unlock plug connections (1) without locking bar.
US only:
Unlock plug connection for SDARS and disconnect.

2010 BMW M3

NOTE: Do not adjust barrel screws.
Replacement only:
Bring barrel screws into contact with special tool 54 0 180 in conjunction with special tool 00 9 450.

NOTE: Before removing, mark position of screws (1) to ensure correct alignment
during installation.
Do not release screws.
2010 BMW M3

IMPORTANT: Proceed with the greatest possible caution when carrying out the following
tasks.
Risk of damage!
Three persons are essential for helping to carry out the following tasks.
Generously cover bumper area (loading sill) with protective covers (1).
Fig. 256: Identifying Protective Covers

IMPORTANT: Rear module sinks if incorrectly supported. Risk of damage!
Position a helper on both the left and right sides of the rear module.
Grip rear module with two hands on rear module kinematic assembly and support Z-direction.
2010 BMW M3
NOTE: Bracket is double-jointed and bends.
Fig. 257: Griping Rear Module

With one person on other side, simultaneously release screws (1) from bearing block.
Remove rear module.
Set down rear module on a suitable surface.
IMPORTANT: Do not damage any surrounding parts.

Installation:
2010 BMW M3
Carry out diagnosis.
54 37 185 REMOVING AND INSTALLING/REPLACING HYDRAULIC UNIT (DRIVE) FOR

RETRACTABLE HARDTOP
Remove luggage compartment floor trim panel . See 51 47 101 REMOVING AND
CAUTION: Hydraulic fluid may emerge from the disconnected lines and the open
connections on the hydraulic unit (drive).
Protect components and work area with suitable materials (e.g. cloths).
Follow repair instructions for hydraulic system.
Do not fit hydraulic lines in kinked, crushed or transposed condition.
Release screws (1).

Installation:
Detach foam part from hydraulic unit.
Remove relay (2) from holder.

2010 BMW M3
Fig. 260: Removing Relay From Holder

Installation:
Plug connections are coded against incorrect assembly.
Installation:
Order of plug connection specified by wiring harness.

Disconnecting hydraulic lines from hydraulic unit:

2010 BMW M3
Release screws and push lockplates (1) in direction of arrow.

Detach hydraulic lines.
Remove hydraulic unit (drive).
Installation:
Hydraulic lines and connections are marked with numbers to prevent mix-ups.
Check fluid level or top up if necessary.
Fig. 262: Identifying Screws And Lockplates

54 37 190 REMOVING AND INSTALLING/REPLACING LEFT HYDRAULIC CYLINDER FROM

ROOF SHELL, MIDDLE
NOTE: Except for the operations covering the plug connections for the Hall sensors,
this task is identical to:
Removing and installing/replacing hydraulic cylinder for roof shell , right.
54 37 195 REMOVING AND INSTALLING/REPLACING RIGHT HYDRAULIC CYLINDER FROM

ROOF SHELL, MIDDLE

Have roof module supported partially by helpers
connections on the hydraulic cylinder.
2010 BMW M3
NOTE: Hydraulic system must be at zero pressure.

Open screw on hydraulic unit 1.5 turns.
Lever out clips (1).
Fig. 263: Identifying Hydraulic Unit Clips

Drive out bearing pins (1 and 2).
Installation:
Bearing pin (1) is shorter than bearing pin (2).
Remove hydraulic cylinder.
Fig. 264: Identifying Hydraulic Unit Bearing Pin


2010 BMW M3
NOTE: Plug connection on right roof shell cylinder can be incorrectly positioned.
The plug connection must be repositioned if it does not point to the outside of
the vehicle.

Disconnecting hydraulic lines from cylinder:
Disconnect cable straps.
Installation:
Replace cable straps.
Slide open retaining rings (1) with screwdriver.
Detach hydraulic lines (2).
IMPORTANT: Protect joints (lines and cylinder) against dripping fluid, e.g. with a cleaning
cloth.
Observe hose markings.
Make sure airbag hydraulic lines and wiring harness are exactly routed.
2010 BMW M3
Fig. 266: Detaching Hydraulic Lines

NOTE: Carry out operational check.

Check fluid level.
54 37 200 REMOVING AND INSTALLING/REPLACING LEFT COUPLING FASTENER

HYDRAULIC CYLINDER
Removing and installing/replacing right coupling fastener hydraulic

cylinder
54 37 205 REMOVING AND INSTALLING/REPLACING RIGHT COUPLING FASTENER

HYDRAULIC CYLINDER
Remove side trim upper section . See 51 43 012 REMOVING AND INSTALLING/REPLACING
REAR LEFT OR RIGHT UPPER SIDE TRIM SECTION .

Removing hydraulic cylinder:

2010 BMW M3

Detach ball socket at side.
Remove retaining ring (2).
Drive through bearing pin (3).
Feed out hydraulic cylinder.
Fig. 267: Removing Retaining Ring

Replacing hydraulic cylinder:

2010 BMW M3

Check fluid level.
54 37 210 REMOVING AND INSTALLING/REPLACING LEFT MAIN KINEMATICS HYDRAULIC

CYLINDER
Removing and installing/replacing right main kinematics hydraulic

cylinder
54 37 215 REMOVING AND INSTALLING/REPLACING RIGHT MAIN KINEMATICS

HYDRAULIC CYLINDER
Remove luggage compartment wheel arch trim on left or right. See 51 47 210 REMOVING AND
INSTALLING/REPLACING TRUNK TRIM PANEL ON LEFT SIDE PANEL and 51 47 220
REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT TRIM PANEL
ON RIGHT SIDE PANEL .
Remove panel for main bearing on left or right. See 51 47 207 REMOVING AND
INSTALLING/REPLACING PANEL FOR MAIN BEARING ON LEFT OR RIGHT .
Trunk lid opened


2010 BMW M3

Installation:
Make sure wiring harness is exactly routed in main bearing.
Fig. 270: Identifying Wiring Harness

Remove retaining ring (1)

Drive out pin in inward direction (middle of vehicle)
Detach locking clip (2)
Drive out pin in outward direction (side of vehicle)
Feed hydraulic cylinder out of main bearing
2010 BMW M3
Fig. 271: Identifying Retaining Ring And Locking Clip

Installation:
Detach locking clip (1).
Release screw (2) and remove tab washer.
Detach hydraulic lines.
cloth.
2010 BMW M3


Check fluid level.
54 37 220 REMOVING AND INSTALLING/REPLACING LEFT CONVERTIBLE TOP

COMPARTMENT LID HYDRAULIC CYLINDER
Removing and installing/replacing right convertible top compartment lid

hydraulic cylinder
54 37 225 REMOVING AND INSTALLING/REPLACING RIGHT CONVERTIBLE TOP

COMPARTMENT LID HYDRAULIC CYLINDER
Remove support tube trim on left or right

IMPORTANT: Convertible top compartment lid can tilt forwards when hydraulic cylinders are
removed and must be supported with suitable apparatus.
2010 BMW M3
Fig. 273: Removing Convertible Top Compartment Lid

Open rear lid.
Release screw (1).
Installation:
Replace screw (1) and insert with Loctite.
Fig. 274: Identifying Hydraulic Cylinder Screw


Detach ball sockets at sides.
Feed out hydraulic cylinder.
2010 BMW M3
Fig. 275: Identifying Ball Socket Retaining Clip

Detach cable connectors.
Installation:
Feed out wiring harness.

cloth.
Detach cable connectors.
Installation:

2010 BMW M3
Fig. 277: Sliding Open Retaining Rings

Installation:
Carry out operational check.

Check convertible top settings.
Check fluid level.
54 37 232 REMOVING AND INSTALLING SUPPORT BLOCK
Move roof module into following intermediate station.
Fig. 278: Moving Roof Module

NOTE: Illustration shows removal of left side.

The right side is removed in the same way as the left side.
2010 BMW M3
Remove trim (2) for support block.
Fig. 279: Identifying Expansion Rivets And Trim

Unscrew nuts (1).
Remove support block.
Fig. 280: Identifying Support Block Nuts

NOTE: Observe following work steps for installing support block:
Observe screwing sequence for support block (4).
Turn banjo bolt (2) back.
Tighten nut (1).

2010 BMW M3
Insert banjo bolt lock (2) until contact is made with body.
Tighten nut (3).
Fig. 281: Identifying Banjo Bolt Lock With Nut

Release screw (1).
Move support element (2) upwards to maximum extent.
Insert screw (1) until contact is made.
It must still be possible to slide the support element (2).
Fig. 282: Moving Support Element Upwards To Maximum Extent

2010 BMW M3
Insert screw (1) until contact is made.
It must still be possible to slide the guide element (2).
Stow roof module.
Storage element (3) adjusts itself to support height.
Guide element (2) slides into correct position.
Extend roof module until support block is accessible.
Tighten screws (1) and (4).
Fig. 283: Sliding Guide Element

Installation:
Install trim for support block.
54 37 235 REMOVING AND INSTALLING/REPLACING HOLDER FOR C-PILLAR FLAP
Installation:

Release Torx screws (1) for C-pillar flaps.

2010 BMW M3
Fig. 284: Identifying C-Pillar Flap Torx Screws

Pull off snap ring (1).
Drive out pin and remove holder with spring.
Remove tension spring.
Fig. 285: Removing Tension Spring

Overview of single parts .

2010 BMW M3
Fig. 286: Overview Of Single Parts

54 37 240 REMOVING AND INSTALLING/REPLACING MICROSWITCH FOR BASEPLATE
Remove cowl panel trim . See 51 44 150 REPLACING TRIM FOR FRONT ROOFLINER .
Release screws (1).
Remove microswitch (2).
Fig. 287: Identifying Microswitch Screws

Removing guide plate if necessary only on build date (version) up to 07/2007:

2010 BMW M3
Release screw (1).
Pull back microswitch lever (3).
Remove guide plate (2).
Fig. 288: Pulling Back Microswitch Lever

54 37 260 REPLACING REAR-END MODULE HALL SENSOR ON PARTITION WALL
Open convertible top compartment lid.
Installation:

Release screw (2).
Feed out Hall sensors.
Installation:
Hall sensor for convertible top cover must be readjusted.

2010 BMW M3

If there is no signal from the Hall sensors, perform the following adjustments:
Adjusting Hall sensor for roof module:
Loosely tighten screws (1) on holder.
Holder should still be able to be slid in order to center itself.
Stow roof module.
The optimum position of the holders is determined by the retraction of the centering pins into the fastener.
Fig. 290: Identifying Roof Module Screws

2010 BMW M3
Adjusting Hall sensor for convertible top compartment lid:
Insert screw (2) only loosely.
Pull back Hall sensor (1).
IMPORTANT: Risk of damage! Switch plate must not rest on Hall sensor.
Close convertible top compartment lid carefully.
Fig. 291: Pulling Back Hall Sensor

Adjust Hall sensor (1) in relation to switch plate.
A) 0.4 mm
Tighten screw (2).
Check function of Hall sensor.
If necessary, reduce gap between Hall sensor and switch plate.

2010 BMW M3
Fig. 292: Identifying Gap Between Hall Sensor And Switch Plate
54 37 290 HARDTOP EMERGENCY OPENING
13 5 250
54 0 161
54 0 163
54 0 240
Remove both side trim panel upper sections . See 51 43 012 REMOVING AND
Open all windows
IMPORTANT: Always perform the emergency opening procedure with the aid of an assistant.
The applied force must always be even on the left and right otherwise the
linkage will bend.
Always execute all movements of the roof module with the assistance of a
second person.
Risk of injury by trapping!
Unclip cover cap.
Attach special tool 54 0 163 together with special tool 13 5 250.
Drive out square pin.

2010 BMW M3

The fasteners open by turning the square pin.
IMPORTANT: Risk of damage! Always sink the square pin again after opening.
Turn back square pin a few degrees if necessary.
Fig. 294: Turning Back Square Pin

Open rear lid.
Take out luggage compartment floor trim panel.

2010 BMW M3
Fig. 295: Removing Luggage Compartment Floor Trim Panel

Release screws (1).

Use Allen key to open shutoff valve on hydraulic unit by one turn.
NOTE: System is now depressurized and can be moved manually.
Close luggage compartment cover.
Close rear lid.

2010 BMW M3
Fig. 297: Opening Shutoff Valve

Unlocking coupling fastener:
Turn hydraulic cylinder (1) to passenger compartment.
Fit special tool 54 0 161 on piston rod.
Fig. 298: Identifying Special Tool (54 0 161) On Piston Rod

Tilt special tool 54 0 161 upwards.
As a result, the coupling fastener (1) snaps over the dead center position.
Now slide open coupling fastener (1).

2010 BMW M3
Fig. 299: Sliding Open Coupling Fastener

To join the roof shells, have one person positioned on either side.
It is absolutely essential to grip the front and rear roof shells simultaneously.
Move roof shells carefully and uniformly.
Fig. 300: Moving Roof Shells

Join roof shells uniformly and without tilting.

2010 BMW M3
Fig. 301: Joining Roof Shells

NOTE: Have special tool 54 0 240 ready.
Open rear-end module manually.
Fig. 302: Opening Rear-End Module

Clip special tool 54 0 240 on to hydraulic cylinder (1) on left and right.
IMPORTANT: The opening in the assembly support must face towards the rear of the vehicle.
2010 BMW M3
Fig. 303: Identifying Special Tool (54 0 240) To Hydraulic Cylinder

NOTE: Remove any luggage from the luggage compartment (boot).
IMPORTANT: Allow for weight of roof shells.
Only grasp the front roof shell when setting down the roof shells.
Fig. 304: Removing Luggage From Luggage Compartment

Carefully set down the roof shells.
NOTE: Remove special tool 54 0 240.
Close rear-end module.

2010 BMW M3
Fig. 305: Identifying Roof Shells

IMPORTANT: The convertible top must not be moved any further after emergency opening.
To avoid vibrations, do not subject the vehicle to further movement.
Roof shells which are not locked may cause irreparable damage.
54 37 295 EMERGENCY CLOSING HARDTOP
13 5 250
54 0 161
54 0 162
54 0 163
54 0 240
Remove both side trim panel upper sections . See 51 43 012 REMOVING AND
Open all windows
IMPORTANT: Always perform the emergency closing procedure with the aid of an assistant.
The applied force must always be even on the left and right otherwise the
linkage will bend.
Always execute all movements of the roof module with the assistance of a
second person.
Risk of injury by trapping!
Turn hydraulic cylinder (1) to inside of vehicle.

2010 BMW M3
Fit special tool 54 0 161 on piston rod.
Fig. 306: Identifying Special Tool (54 0 161) On Piston Rod

Tilt special tool 54 0 161 upwards.
As a result, the coupling fastener (1) snaps over the dead center position.
Now slide open coupling fastener (1).
Fig. 307: Sliding Open Coupling Fastener

Open rear-end module manually.
Clip special tool 54 0 240 on to hydraulic cylinder (1) on left and right.
IMPORTANT: The opening in the assembly support must face towards the rear of the vehicle.
2010 BMW M3
Fig. 308: Identifying Special Tool (54 0 240) To Hydraulic Cylinder

Mask off air outlet grille with adhesive fabric tape (1).
Carefully press air outlet grille to the side.
Release screws (2) on base plate on left and right.
Installation:
Replace screws.
Right side of vehicle only:
Release screw (3) on Hall sensor.
Fig. 309: Release Screws (2) On Base Plate On Left And Right And Screw (3) On Hall Sensor
2010 BMW M3
Manually open rear lid with key.
Release screw (1) for locking part on left and right.
Installation:
Replace screws.

NOTE: Remove any luggage from the luggage compartment (boot).

Roof shells cannot yet be lifted out completely!
If necessary, raise roof shells and have third assistant remove items of luggage.
Only grasp the front roof shell when raising the roof shells.

2010 BMW M3
Take out luggage compartment floor trim panel.
Fig. 312: Removing Luggage Compartment Floor Trim Panel

Release screws (1).

Use Allen key to open shutoff valve on hydraulic unit by one turn.
NOTE: System is depressurized.

2010 BMW M3
Fig. 314: Opening Shutoff Valve

Only grasp the front roof shell when raising the roof shells.

IMPORTANT: Allow for of weight of roof shell!
Lift out roof shells evenly.
NOTE: Plug connection for Hall sensor disconnects as the roof shells are lifted out.
2010 BMW M3
Fig. 316: Moving Roof Module

Remove locking element (1) at rear left and right.
Fig. 317: Identifying Rear Left And Right Locking Element

Remove locking element (1) at front left and right.

2010 BMW M3
Fig. 318: Identifying Front Left And Right Locking Element

NOTE: Remove special tool 54 0 240.
Close rear end module (1).
Fig. 319: Closing Rear End Module

IMPORTANT: Use suitable aid to prevent placing roof shell on base plates.
Otherwise the extended lock pins of the front roof shell will rest on the middle
roof shell. Risk of damage!
2010 BMW M3
Fig. 320: Placing Roof Shell On Base Plates

Unfold roof shells evenly.
Fig. 321: Unfolding Roof Shells

Unclip cover cap.
Attach special tool 54 0 163 together with special tool 13 5 250 .
Drive out square pin.

2010 BMW M3

The fasteners open by turning the square pin.
Fig. 323: Turning Back Square Pin

Press down on roof shells and convertible top compartment lid on left and right side in marked area.
Use square pin to lock roof shells with fasteners (turn back as far as it will go).
Lower square pin and install cover cap.
Installation:
Square pin is tensioned.
If necessary, use fork wrench to move square pin back and forth while driving in.
2010 BMW M3
Fig. 324: Locating Roof Shells Area

Fig. 325: Fitting Special Tool (54 0 162) On Connection Joint Of Hydraulic Cylinder
NOTE: Shown here with convertible top open for a better overview.
Fit special tool 54 0 162 on connection joint of hydraulic cylinder.

2010 BMW M3
Tighten knurled screw (1).
WARNING: Risk of injury! The special tool can slip of if installed incorrectly.
Take appropriate protective measures without fail.
Cover sharp-edged areas.
Wear work clothing with long sleeves and protective gloves.
With the aid of an assistant, press down rear roof shell and convertible top compartment lid and lock coupling
fastener on left and right with special tool 54 0 162.
Pull back coupling fastener over dead center position.
Use Allen key to close shutoff valve on hydraulic unit.
IMPORTANT: The customer must no longer operate the convertible top after it has been
closed with the emergency closing procedure!
To prevent operation, remove fuse 12 for convertible top.
Place removed individual parts in vehicle.
The emergency closing procedure is now completed.
Installation:
Replace screws.
Screw on locking elements loosely.
Locking elements should still be able to be slid in order to center themselves.
Open convertible top.
Open convertible top compartment lid manually with wrench and tighten down screws for rear locking
elements.
Tighten down screws for front locking elements.
Add final details to vehicle.
00 9 322
51 0 020
51 3 010
2010 BMW M3
IMPORTANT: Cover front side panels with protective covers.

When reusing the rear window:
Avoid damaging lines for rear window heating/aerial.
Do not damage cosmetic lip.
Remove rear roof shell

Remove roofliner for roof shell
NOTE: Removal is performed with Roll Out 2000 .
Paint coat must not be damaged

All attachment parts must not be damaged
Roof shell, left side:
Unlock plug connections (2) on aerial amplifier and disconnect.
Fig. 326: Identifying Plug Connection (Left Side)

Roof shell, right side:

2010 BMW M3
Fig. 327: Identifying Plug Connection (Right Side)

NOTE: To avoid rear window breakage, it is absolutely essential to use wire puller/flat
awl (1).
Slide wire puller/flat awl (1) from Roll Out 2000 from inside between roof shell and rear window through
adhesive bead.
Fig. 328: Identifying Wire Puller/Flat Awl

IMPORTANT: When cutting in area of electric cables (1), insert guard from Roll Out 2000
between electric cables (1), cutting wire and sheet metal.
Components and sheet metal will be damaged if guard is not fitted.
Cut out rear window with Roll Out 2000 .
Lift out rear window with special tool 51 3 010.

2010 BMW M3
NOTE: Replace rear window if cosmetic lip is damaged.
Fig. 329: Cutting Area Of Electric Cables

Fitting 4 spacer buffers
Only the following spacer buffers may be used:
Dia. 9.5 mm and 3.8 mm high
IMPORTANT: To avoid rear window breakage and leaks, remove remnants of removed spacer
buffers.
Position new spacer buffers outside adhesive bead.
Adopt position of old spacer buffers on body (outside outer bore holes).
Fig. 330: Identifying Spacer Buffers

Installation:
2010 BMW M3
Set roof shell down on an absolutely level surface.
Roof shell must not sag or warp.
Place special tool 51 0 020 at top on rear window corners on left and right.
Bring tool exactly into contact with rear window edge and tighten.
NOTE: Position gauge on rear window edge and not on cosmetic lip.
Fig. 331: Placing Special Tool (51 0 020) Top On Rear Window Corners On Left And Right
Overview for rear window cementing (E93)

2010 BMW M3
Fig. 332: Overview For Rear Window Cementing (E93)

Attach special tool 51 3 010 twice to tool trolley. Moisten suction surfaces and secure rear window from
outside.
If reusing the removed rear window, remove the adhesive residue with a blunt scraper or knife.
Observe treatment of adhesive area in body-cutout and on rear window, see 51 31 ... INSTRUCTIONS ON
GLUING WINDSCREEN .
Position and width of adhesive bead:
Overlapping and closed

Not visible from outside and inside
The contact point becomes noticeable through an increase in the adhesive volume (approx. 1.5 - 2 x bead
width after crushing).
2010 BMW M3
Position adhesive bead only where the glass ceramic material offers a sufficient overlap and the body
flange offers sufficient space.
The adhesive bead is not permitted in the window radii and in the cowl panel area
Spread adhesive bead with special tool 00 9 322
IMPORTANT: The position of the rear window may not be changed after 5 minutes from
the start of adhesive application as adhesive curing is already too far
advanced.
The window may become detached if this period of time is not maintained.
Window cementing not OK = renewed window cementing necessary.
Position rear window with special tool 51 0 020 on roof shell and press down uniformly.
X: Stop, gauge on roof shell
Y: Centre optically to roof shell
Z: Press down rear window on roof shell until flush
Fig. 333: Identifying Rear Window Cutting Area

Check that rear window (1) is flush with roof outer skin (2).
Z: 0 to -1 mm underprotrusion.
If necessary, press down rear window.
Secure rear window with yellow plastic adhesive tape to roof shell.
NOTE: After pressing down, do not move the rear window any more as this may case
the window to become detached.
2010 BMW M3
Cementing otherwise not OK and renewed cementing necessary.

Adhesive curing time is adhesive-dependent and must be observed without fail.
Fig. 334: Checking Rear Window Flush With Roof Outer Skin
IMPORTANT: The instructions on cementing windscreen serve as the basis for this repair
instruction and must be observed without fail. See 51 31 ... INSTRUCTIONS ON
GLUING WINDSCREEN .
ROLL BAR FOLDING

54 62 000 TRIGGERING/RETRACTING ROLLOVER PROTECTION SYSTEM (BMW DIAGNOSIS
SYSTEM)

When the actuators are electrically activated, there must be no persons
present in the vicinity of the rollover protection system.
When rollover protection is mechanically triggered, only one person may
be present underneath the rollover bar.
IMPORTANT: Stow rear end module in convertible top compartment (open).

When the actuators are activated, both rollover bars are simultaneously
triggered.
Triggering rollover protection system:
Refer to diagnostic program "Restraint and rollover protection function / rollover system".
NOTE: The rollover bar can be triggered mechanically if it fails to extend of its own
2010 BMW M3
accord.
Triggering rollover protection system mechanically:
NOTE: Mechanical triggering only possible up to build date/version 03/08.
Remove backrest. See SEATS - REPAIR INSTRUCTIONS or SEATS - REPAIR INSTRUCTIONS -

- M3 CONVERTIBLE .
Insert L-shaped Allen key into opening on actuator.
Effect emergency release of rollover bar by pressing.
Fig. 335: Inserting L-Shaped Allen Key Into Opening On Actuator

IMPORTANT: When retracting, make sure rollover bar snaps into place on lower stop.
Slowly relieve load on rollover bar.
Hold locking pawl (1) and press rollover bar (2) down as far as it will go until actuator is locked.
NOTE: Rollover bar must snap audibly into place!

2010 BMW M3
Fig. 336: Pressing Rollover Bar

54 62 005 REMOVING AND INSTALLING/REPLACING ROLLOVER PROTECTION SYSTEM

When the actuators are electrically activated, there must be no persons
present in the vicinity of the rollover protection system.
When a rollover bar is mechanically triggered, only one person may be
present underneath the rollover bar.
IMPORTANT: When the actuators are activated, both rollover bars are simultaneously
triggered.
Trigger rollover bars .
Installation:

Remove Roof module

Remove air outlet trim grille . See 51 46 026 REMOVING AND INSTALLING OR REPLACING
FRONT AIR OUTLET TRIM GRILLE .
Remove both panels for main bearing . See 51 47 207 REMOVING AND
INSTALLING/REPLACING PANEL FOR MAIN BEARING ON LEFT OR RIGHT .
2010 BMW M3
Remove control unit . See 65 77 770 REMOVING AND INSTALLING (REPLACING)
ROLLOVER CONTROLLER .
Remove inertia reel mechanism and sash guide on left and right. See 72 11 092 REMOVING AND
INSTALLING/REPLACING REAR LEFT OR RIGHT SEAT BELTS .
Unlock plug connection (1) on left and right and disconnect.

Release screws (1).
Remove rollover protection system strut.

Release screws (1).

2010 BMW M3
Tightening torque: 54 62 01AZ, see 54 62 ROLLOVER PROTECTION SYSTEM, FOLDING .
Remove screw fastening plate.
Fig. 339: Identifying Screw Fastening Plate

Release screws (1).
Tightening torque: 54 62 03AZ, see 54 62 ROLLOVER PROTECTION SYSTEM, FOLDING .
Lift out rollover protection system.
Installation:
Carry out function check .

2010 BMW M3
Replacement only:
Release screws (1) on all holders for middle trim grille.
Tightening torque: 54 37 04AZ, see 54 37 POWER CONVERTIBLE TOP ..
Remove holders for trim grille.
Release screws (2) on holders for rear trim grille.
Remove holders for trim grille.
Modify all holders for control units.
Fig. 341: Identifying Holder Screws

Release screws (1).
Modify striker with holders.

2010 BMW M3

54 62 010 REMOVING AND INSTALLING OR REPLACING TRIM COVER ON LEFT OR RIGHT

ROLLBAR
Remove both rear headrests . See SEATS - REPAIR INSTRUCTIONS or SEATS - REPAIR
INSTRUCTIONS -- M3 CONVERTIBLE .
Undo left/right screws (1) and detach left/right trim panel (2) by lifting upwards.
Fig. 343: Identifying Trim Panel Screws

2010 BMW M3
ENGINE Cooling System - Repair
ENGINE
Cooling System - Repair
COOLANT, CHECKING COOLING SYSTEM

17 00 009 CHECKING COOLING SYSTEM FOR LEAKS (S65)
WARNING: Danger of scalding!

Only perform this work after engine has cooled down.
Protective measures/rules of conduct

Observe national/country-specific regulations
IMPORTANT: Risk of slipping due to coolant on the floor.
Danger of injury!
Catch and dispose of drained coolant in drip tray (1) and if necessary special tool 00 2 030 00 2 030 DEVICE
(universal hydraulic lifter).
Recycling:
Fig. 1: Identifying Drip Tray And Special Tool (00 2 030)

Checking pressure drop in cooling system

2010 BMW M3
Open cap on coolant expansion tank. Fit special tools 17 0 101/17 0 113.
Build up gauge pressure of 2 bar, wait approx. 2 minutes.
Cooling system is impervious to leaks if pressure drop is max. 0.1 bar.
Fig. 2: Checking Pressure Drop In Cooling System Using Special Tool (17 0 101/17 0 113)
Checking pressure relief valve in cap
NOTE: Coolant residue can cause the pressure relief valve in the cap to stick, therefore
repeat the check procedure on the cap 2-3 times.
Screw cap (1) onto special tool 17 0 114.
Build up pressure with special tool 17 0 101 (hand pump); observe pressure gauge to ascertain when opening
pressure is achieved.
OPENING PRESSURE OF PRESSURE RELIEF VALVE .

2010 BMW M3
Fig. 3: Checking Pressure Relief Valve In Cap Using Special Tool (Hand Pump 17 0 101)
17 00 005 DRAINING AND ADDING COOLANT (S65)
WARNING: Risk of scalding!

Only carry out repair work on the cooling system after the engine has
cooled down!
Risk of skidding due to coolant on the floor.
Wear safety goggles

IMPORTANT: Lifetime coolant filling:

Never reuse used coolant!
When replacing and removing components which rely on the corrosion
protection effect of the coolant, it is essential to change the coolant. The
cooling system must therefore be drained and refilled.
In the case of other removal work involving the draining of partial quantities of
coolant, replace these quantities which have been drained with new coolant.
IMPORTANT: For dirt contamination of the cooling system (e.g. by engine oil), the cooling
system must be rinsed with water until all dirt contamination is removed!
IMPORTANT: Risk of skidding due to coolant on the floor.
Danger of injury!
2010 BMW M3
Catch and dispose of drained coolant in drip tray (1) and if necessary special tool 002030 DEVICE (universal
hydraulic lifting equipment).
Recycling

Remove FRONT UNDERBODY PROTECTION

FOLLOW NOTES FOR REPAIR WORK ON COOLING SYSTEM
Draining coolant
Open sealing cap (1) on coolant expansion tank (2).

2010 BMW M3
If fitted, release drain connector (1) on coolant radiator.
On coolant radiators which do not have a drain connector, remove coolant hose.
Drain, catch and dispose of coolant from radiator.
Fig. 6: Identifying Coolant Drain Plug On Radiator

Installation note:
Adding coolant
FILL AND BLEED COOLING SYSTEM.
Check COOLING SYSTEM FOR WATERTIGHTNESS .
17 00... INSTRUCTIONS FOR WORKING ON COOLING SYSTEM
WARNING: Danger of scalding! Work on the cooling system should only be carried
out when the engine has cooled down.
IMPORTANT: Wear protective gloves and safety goggles.

Never reuse used coolant.
2010 BMW M3

IMPORTANT: Open cooling system only when it has cooled down.

Opening the cooling system while hot can result in air entering the system.
This can cause overheating with permanent damage to the engine.
IMPORTANT: You must protect the alternator against contamination before carrying out any
work on the cooling circuit.
Cover alternator with suitable materials.
Failure to comply with this procedure may result in an alternator malfunction.
IMPORTANT: Do not fill coolant expansion tank over MAX level as overfilling will cause the
coolant to overflow. This may give rise to traces of residual coolant on the
expansion tank or in the engine compartment and wrongly suggest possible
leakages.
Recycling
Catch and dispose of drained coolant.
NOTE: To disconnect coolant hoses, use commercially available disconnect tools such
as HAZET brand tools (see table).
HAZET BRAND TOOLS REFERENCE CHART

HAZET no.: Description
4590-1 Disconnect tool, length (mm): 150
4590/2 Disconnect/plier set
4590/3 Disconnect/plier set
2010 BMW M3
Fig. 7: Identifying Disconnect Tools

NOTE: Tightening torque, hose clamps 17 00 1AZ .
Fig. 8: Disconnecting Coolant Hose

Instructions for disassembly/assembly of coolant hose quick-connect couplings
Disassembly of quick-connect coupling
Pull out lock (1) and (2). Pull off hose.

2010 BMW M3
Fig. 9: Disassembling Quick-Connect Coupling

Installation
Check O-rings (1).
Do not coat O-rings (1) with antiseize agent.
Fig. 10: Identifying O-rings

Assembly of quick-connect coupling
Press in lock (1) before installing fast-release coupling.
Push on hose.
Quick-connect coupling must clearly snap audibly into place.

2010 BMW M3
Fig. 11: Assembling Quick-Connect Coupling

17 00... NOTES ON RETROFITTING A TRAILER TOWING DEVICE
Starting with delivery of the E90, in certain vehicle types, the size of the electric cooler fan will be linked to the
optional extra trailer tow hitch or trailer provision.
A larger fan may therefore be required for retrofits.
The larger fan is necessary to ensure mountain driving with a full trailer load in accordance with BMW-internal
specifications. Otherwise the engine electronics will detect possible overheating of the cooling system and
activate protective functions.
For the customer, this involves impaired A/C output, automatic transmission and engine power. These will be
continuously reduced, which in the end may result in the vehicle coming to a standstill in the mountain area.


function is active.

2010 BMW M3

Workshop mode
A = 10 mm
B = 7 mm

17 00 039 VENTING AND FILLING COOLING SYSTEM WITH VACUUM FILLING UNIT
2010 BMW M3
SPECIAL TOOLS DESCRIPTION CHART

Type Engine Number
E60/E61/E63/E64 All 17 0 113
E65/E66 M54/N52/N62/N62T/N73 17 0 105
E65/E66 M57S/M57T/M67/M67T 17 0 113
E70/E71/E72 All 17 0 113
E81/E82/E84/E87/E88/E89 All 17 0 113
E83 M54/N46/N52K 17 0 105
E83 M47S/M57S/M57T/M57Y/N47 17 0 113
E85/E86 All 17 0 105
E90/E91/E92/E93 All 17 0 113
F01/F02/F03/F04/F07/F10 All 17 0 113
R50/R52 W10 17 0 107 and 17 0 102
R50 W17 17 0 109
R52/R53 W11 17 0 109
R55/R56/R57/R60 All 17 0 109
F25 All 17 0 113

Never reuse used coolant!
In the case of other removal work involving the draining of part quantities of
IMPORTANT: You must protect the alternator against contamination by coolant when
carrying out repair work on the cooling circuit.
Note on ordering:
Workshop equipment
Workshop equipment catalogue
Filler unit no. 81 39 2 152 473
Collecting vessel no. 81 49 2 152 347
Adapter: 170100

Danger of injury!
2010 BMW M3
Catch and dispose of emerging coolant in drip tray (1) and if necessary special tool 00 2 030 DEVICE
(universal hydraulic lifting equipment).
Recycling
IMPORTANT: Check all the coolant hoses before filling the cooling system with the vacuum
filling unit.
If necessary, replace damaged and porous coolant hoses.
2010 BMW M3
Fig. 15: Identifying Cooling Loops For Hydraulic Steering In Radiator Package
1) Filling unit with vacuum meter and shut-off valves

2) Filler hose
3) Coolant container
4) Venturi nozzle
5) Compressed air connection (max. 6 bar)
6) Outgoing-air hose (lead outgoing-air hose into a collecting container)
Requirements
Cooling system expansion tank must be empty.

There must be sufficiently premixed coolant in the filling unit container, 1-2 liters more than the vehicle
filling capacity.
Observe capacities.
Position the filling unit container at the same height as the coolant expansion tank.
Compressed-air connection with 6 bar pressure present.
Set vehicle heater to maximum temperature.
2010 BMW M3
Select adapter (Y) according to table and connect to coolant expansion tank.
Connect filler unit to adapter connection (X).
Fig. 16: Identifying Adapter And Adapter Connection

Shut-off valves (A) and (B) of the filling unit (1) must be closed.
X) Expansion tank connection
Fig. 17: Identifying Filling Unit Shut-Off Valves

Connect venturi nozzle (1) to filling unit (2).

2010 BMW M3
Fig. 18: Connecting Venturi Nozzle To Filling Unit

Connect compressed air (1).
Fig. 19: Connecting Compressed Air Line

Open shut-off valve (B).
The venturi nozzle produces a flow noise.

2010 BMW M3
Fig. 20: Opening Shut-Off Valve

Then open shut-off valve (A) until the filling hose (1) is free of bubbles.
Close shut-off valve (A) again. The filling hose (1) is vented in this way.
Fig. 21: Opening And Closing Of Shut-Off Valve

Shut-off valve (B) remains open. Generate vacuum in coolant system for approx. 2 minutes. The final vacuum
is reached at a vacuum of -0.7 to -0.95 bar. Green scale on the vacuum meter.
NOTE: The coolant hoses contract during vacuum build-up.
Then close shut-off valve (B) again.

2010 BMW M3
Fig. 22: Checking Shut-Off Valve Opening Time

Both shut-off valves (A) and (B) must be closed. Then seal Venturi nozzle (1).
Fig. 23: Closing Shut-Off Valve

The cooling system must hold the vacuum for 30 seconds. If the needle in the vacuum meter falls, this indicates
a leak in the cooling system.
If the vacuum remains constant, proceed with filling.
In event of leaks, check cooling system for leaks.

2010 BMW M3
Fig. 24: Identifying Vacuum Meters

IMPORTANT: There must be sufficiently premixed coolant in the filling unit container, 1-2
liters more than the vehicle filling capacity.
Position the filling unit container at the same height as the coolant expansion
tank.
Shut-off valve (B) remains closed during the filling process.
To fill the cooling system, open shut-off valve (A) to filling unit container.
Fig. 25: Opening Shut-Off Valve To Filling Unit Container

Coolant is now added.

2010 BMW M3
The filling process is finished when the needle in the vacuum meter is at 0 bar or no longer falls.
If necessary, reduce remaining vacuum. Open shut-off valve (B) to do so.
Fig. 26: Filling Coolant

Remove filling unit with adapter from expansion tank.
Adjust coolant level to max.
Close coolant expansion tank.
Fig. 27: Adjusting Coolant Level To Max

2010 BMW M3
Check function of cooling system.
Check cooling system for leaks.
17 00 039 VENTING COOLING SYSTEM AND CHECKING FOR WATER LEAKS (S65)

Open sealing cap only after engine has cooled down.
Only when refilling!
leakages.
See COOLING SYSTEM - OPERATING FLUIDS .
Perform filling operation slowly.
Adjust coolant level to MAX.
Installation:
Close cap (1) until the arrow marks line up.

2010 BMW M3
IMPORTANT: The following venting procedure is necessary e.g. when a part is replaced in
the cooling system or when the cooling system is refilled.
Only when filling!

Set heater to maximum temperature and turn fan down to lowest speed.
Start engine and run at idle speed.
Fill coolant expansion tank with 250 ml above max. (250 ml correspond to A=18 mm).
Run engine for 15 mins.
Cooling system vents itself.
Coolant level must drop to marking.
If necessary, correct coolant level.
Close cap on expansion tank.
Fig. 29: Identifying Coolant Expansion Tank Dimension

NOTE: If necessary, check COOLING SYSTEM FOR WATER LEAKS .
RADIATOR, EXPANSION TANK, PIPES

64 53... INSTRUCTIONS FOR REPLACEMENT OF AIR CONDITIONING CAPACITORS AND
RADIATOR/COOLERS
IMPORTANT: Even when they are correctly installed or due to normal driving, coolers (oil
cooler, radiator, charge air cooler) or air conditioning capacitors may show
2010 BMW M3
slight impressions or deformations on their discs (picture).
This is not damage.
Radiators, cooler or capacitors are not to be replaced in this case.
NOTE: The deformations shown in illustration "1" (see Fig. 30) can be bent back with a
standard fin comb.
Damage to lines carrying media or on the flat pipe require replacement of the radiator/ or air conditioning
condenser. Examples of such damage are shown in illustrations "2", "3", "4", "5", and "6" (see Fig. 30).
Fig. 30: Identifying Damage And Deformations

ENGINE RADIATOR WITH ATTACHMENT

RADIATOR/COOLERS
See INSTRUCTIONS FOR REPLACEMENT OF AIR CONDITIONING CAPACITORS AND

RADIATOR/COOLERS.
2010 BMW M3
17 11 046 REMOVING AND INSTALLING/REPLACING MODULE CARRIER
Remove coolant cooler

If necessary, slacken power steering cooling coil; refer to REMOVING POWER STEERING
COOLING COIL
If necessary, slacken A/C condenser and secure against damage and against falling down. Refer to
REMOVE A/C CONDENSER .
Release damping pieces.
Fig. 31: Locating Damping Pieces

Press lock (1) and remove holder (2) downwards.
Illustration shows the left holder: The same procedure applies to the opposite side.
Installation:
Rubber mounts fall out easily, ensure correct installation position.
S65 only: Engine oil cooler loose, see REMOVING OIL COOLER .
2010 BMW M3
Fig. 32: Pressing Lock

Remove module carrier (1) individually towards bottom.
Fig. 33: Identifying Module Carrier

When replacing module carrier:
Convert power steering COOLING LOOP .
17 11 000 REMOVING AND INSTALLING RADIATOR (N51, S65)

IMPORTANT: Wear protective goggles and gloves.

2010 BMW M3
Follow INSTRUCTIONS FOR WORKING on cooling system

Remove intake duct (S65).
Remove INTAKE FILTER HOUSING
Remove FAN COWL
Draining COOLANT
Unlock coolant hoses and detach
If fitted:
Remove heat exchanger for automatic transmission fluid
Automatic only
Release bolt and detach hose (1).
Fig. 34: Locating Hose

Release screws.
Carefully feed out radiator (1) towards top and remove.
NOTE: Illustration shows N54.

2010 BMW M3
Fig. 35: Removing Radiator Using Special Tool (11 8 670)

17 11 100 REMOVING AND INSTALLING/REPLACING COOLANT EXPANSION TANK (S65)
Drain COOLANT from radiator
Unlock coolant hoses and detach.
Release screws.
Raise expansion tank slightly until plugs on coolant level switch and lower coolant hose are accessible.
Unlock plugs on coolant level switch and lower coolant hose and disconnect.
Remove coolant expansion tank.
Installation:
Insert locating pin in rubber grommet.

2010 BMW M3
Fig. 36: Identifying Coolant Expansion Tank

VENT COOLING SYSTEM and check for leaks.
17 11 370 REMOVING AND INSTALLING/REPLACING COOLING LOOP FOR POWER

STEERING (N54, N52, N52K, N51, N53, S65)

IMPORTANT: When working on the oil and cooling circuits, protect the alternator against
dirt/contaminants.
After completing this operation, check FLUID LEVEL in power steering fluid reservoir.
Remove RADIATOR
Press lines (1) in direction of cooling coil (2), pull back locking ring towards rear. Keep locking ring pressed
and detach lines (1) from cooling coil (2).
IMPORTANT: Catch and dispose of emerging oil.

2010 BMW M3
Fig. 37: Identifying Cooling Coil With Connecting Lines

Unlock seal (1) in direction of arrow and remove.
Release screw.
NOTE: Lines of A/C system remain connected to condenser.
Fig. 38: Removing Seal

Press lock (1) upwards.
Carefully tilt condenser (2) in direction of engine, taking care not to damage the condenser or lines in the
process.
2010 BMW M3
Fig. 39: Tilting Condenser In Direction Of Engine

Press lock (1).
Unclip cooling coil (2) from holder (3) and remove.
Fig. 40: Removing Cooling Coil From Holder

17 11 150 REMOVING AND INSTALLING/REPLACING ENGINE OIL COOLER (S65)
Remove FRONT BUMPER TRIM Remove FRONT UNDERBODY PROTECTION

2010 BMW M3
Recycling
Engine oil escapes when oil lines are released. Catch and dispose of emerging engine oil.
Slacken nut (1).
Detach oil line from engine oil cooler.
Catch and dispose of escaping oil.
Installation:
Unscrew screws (2).
Fig. 41: Identifying Nut And Screws

Slacken nut (1).
Release screw (2).
Remove engine oil cooler (3).
Installation:
2010 BMW M3
After completing work, check engine oil level and top up if necessary.
Fig. 42: Identifying Nut, Screw And Engine Oil Cooler

17 11 035 REMOVING AND INSTALLING/REPLACING FAN COWL WITH ELECTRIC FAN (S65)
IMPORTANT: Risk of short circuits!

When removing fan cowl, protect plug and housing against moisture; dry with
compressed air if necessary.
Read out fault memory of DDE control unit; if necessary, work through test schedules
Switch off ignition
Remove intake duct (S65).
Unclip coolant lines from fan cowl.
Unlock connector and remove.
When removing fan cowl, protect plug and housing against moisture; dry with compressed air if necessary.
2010 BMW M3
Fig. 43: Identifying Plug

Release retaining screw (1) for fan cowl.
Unclip cable.
Unclip vent lines.
Turn lower hose holder through 90.
Remove fan cowl (2) towards top.
Fig. 44: Identifying Retaining Screw And Fan Cowl

Installation:
When installing fan cowl, make sure guide tabs are correctly positioned.
2010 BMW M3
Clear DME fault memory.
17 11 190 REMOVING AND INSTALLING/REPLACING OIL LINE FOR ENGINE OIL COOLER
(S65)

IMPORTANT: Wear protective gloves and goggles.
Recycling
Catch and dispose of drained oil in a suitable container.
Comply with the waste disposal regulations applicable in the relevant countries.
Remove underbody protection
Disconnect lines on engine oil cooler, refer to REMOVING ENGINE OIL COOLER
IMPORTANT: When working on the oil, coolant or fuel circuit, you must protect the alternator
against contamination.
Unfasten nut.
Remove holder from oil cooler line (1).

2010 BMW M3
Fig. 45: Identifying Oil Cooler Line

Unclip coolant hoses from holders.
Cover ribbed V-belt with cleaning cloth or similar.
Release nuts and remove oil lines from filter housing.
Fig. 46: Removing Oil Lines From Filter Hosing

NOTE: Add final details to vehicle.

After completing work, check and correct engine oil level.
OIL COOLER
RADIATOR/COOLERS
2010 BMW M3

RADIATOR/COOLERS.
Remove FRONT BUMPER TRIM . Remove FRONT UNDERBODY PROTECTION

Recycling
Slacken nut (1).
Installation:
Unscrew screws (2).

2010 BMW M3
Slacken nut (1).
Release screw (2).
Installation:

(S65)

Recycling

2010 BMW M3
Unfasten nut.


2010 BMW M3


17 21 010 REMOVING AND INSTALLING/REPLACING TRANSMISSION OIL COOLER
IMPORTANT: It is essential to adhere to the exact filling capacities specified.

Fill transmission at room temperature only (approx. 20-30C).
Gear oil:
refer to AUTOMATIC TRANSMISSION - OPERATING FLUIDS .
Failure to comply with this instruction will result in serious damage to the
transmission.
Recycling
Catch and dispose of gear oil with suitable equipment.
Remove right WHEEL ARCH COVER

Drain TRANSMISSION OIL
Release connections for transmission oil cooler.

2010 BMW M3
Fig. 51: Identifying Transmission Oil Cooler Connections

Release brackets for transmission oil cooler.
Check system for leaks.
Fig. 52: Removing Brackets For Transmission Oil Cooler

17 21 500 RINSE GEARBOX OIL COOLER AND LINES OF TWIN CLUTCH GEARBOX
NOTE: Follow work steps for:

Installing a new or replacement transmission.
Procedure
Double twin clutch gearbox removed.

2010 BMW M3
Connect the respective adapters to all oil pipes leaving the double TCT (see description below).
Use quick-release coupling to connect line 17 2 019 from oil collecting unit.
Use quick-release coupling to connect drain line 17 2 018.
Hold and direct open end of drain line into a suitable drip tray.
Using oil collection unit, flush approx. 1 liter of transmission fluid (refer to BMW Service AUTOMATIC
TRANSMISSION - OPERATING FLUIDS ) through oil lines and transmission oil cooler.
Reposition quick-release couplings.
Flush oil lines/transmission oil cooler in opposite direction with approx. 1 liter of transmission fluid (refer to
BMW Service AUTOMATIC TRANSMISSION - OPERATING FLUIDS ).
Disconnect quick-release couplings.
Remove adapter.
NOTE: Dispose of flushing oil correctly.

Do not reuse under any circumstances.
Press hydraulic lines (1) into adapters (2).
Slide clamping bar (3) into guides and secure with screw (4).
Fig. 53: Identifying Hydraulic Lines, Adapters, Clamping Bar With Screws
Arrangement of flushing apparatus for TCT

2010 BMW M3
Fig. 54: Arrangement Of Flushing Apparatus For TCT

1. Transmission-oil cooler with lines

2. Oil collection unit
2010 BMW M3
17 2 015 Connection for oil collection unit (2), manufacturer: Deutsche Tecalemit or
17 2 016 Connection for oil collection unit (2), manufacturer: Horn
17 2 017 Quick-release coupling (2 pieces)
17 2 019 Hose to oil collection unit (2)
3. Oil drip tray
17 2 018 Hose to oil drip tray (3)
4. Adapter with clamping bar
17 2 060 Adapter with clamping bar for aluminum lines and steel lines with aluminum connection (line
diameter 12 mm) TCT for engine
17 2 070 Adapter with clamping bar (line diameter15 mm) TS65TCT for TCT engine
OIL COOLER LINES

(S65)

Recycling
2010 BMW M3
Unfasten nut.



2010 BMW M3
17 21 500 RINSE GEARBOX OIL COOLER AND LINES OF TWIN CLUTCH GEARBOX
NOTE: Follow work steps for:

Installing a new or replacement transmission.
Procedure
Double twin clutch gearbox removed.
Connect the respective adapters to all oil pipes leaving the double TCT (see description below).
Use quick-release coupling to connect line 17 2 019 from oil collecting unit.
Use quick-release coupling to connect drain line 17 2 018.
Hold and direct open end of drain line into a suitable drip tray.
Using oil collection unit, flush approx. 1 liter of transmission fluid (refer to BMW Service Gear oil for dual
clutch transmission AUTOMATIC TRANSMISSION - OPERATING FLUIDS ) through oil lines and
transmission oil cooler.
Reposition quick-release couplings.
Flush oil lines/transmission oil cooler in opposite direction with approx. 1 liter of transmission fluid (refer to
BMW Service Gear oil for dual clutch transmission AUTOMATIC TRANSMISSION - OPERATING
FLUIDS ).
Disconnect quick-release couplings.
Remove adapter.
NOTE: Dispose of flushing oil correctly.

Do not reuse under any circumstances.
Press hydraulic lines (1) into adapters (2).
Slide clamping bar (3) into guides and secure with screw (4).
2010 BMW M3
Fig. 57: Identifying Hydraulic Lines, Adapters, Clamping Bar And Screw
Arrangement of flushing apparatus for TCT

2010 BMW M3
Fig. 58: Arrangement Of Flushing Apparatus For TCT

1. Transmission-oil cooler with lines

2. Oil collection unit
2010 BMW M3
17 2 015 Connection for oil collection unit (2), manufacturer: Deutsche Tecalemit or
17 2 016 Connection for oil collection unit (2), manufacturer: Horn
17 2 017 Quick-release coupling (2 pieces)
17 2 019 Hose to oil collection unit (2)
3. Oil drip tray
17 2 018 Hose to oil drip tray (3)
4. Adapter with clamping bar
17 2 060 Adapter with clamping bar for aluminum lines and steel lines with aluminum connection (line
diameter 12 mm) TCT for engine
17 2 070 Adapter with clamping bar (line diameter15 mm) TS65TCT for TCT engine
2010 BMW M3
ENGINE Cooling System - Repair Instructions - M3
ENGINE
Cooling System - Repair Instructions - M3
COOLANT CHECKING
17 00 ... INSTRUCTIONS FOR WORKING ON COOLING SYSTEM
WARNING: Danger of scalding! Work on the cooling system should only be carried
out when the engine has cooled down.

Never reuse used coolant.
IMPORTANT: Open cooling system only when it has cooled down.

Opening the cooling system while hot can result in air entering the system.
This can cause overheating with permanent damage to the engine.
IMPORTANT: When working on the oil, coolant or fuel circuit, protect the alternator against
contamination.
leakages.
Recycling
Catch and dispose of drained coolant.
NOTE: Tightening torque, hose clamps, see 17 00 1AZ in 17 00 COOLANT .

2010 BMW M3
Fig. 1: Identifying Hose Clamps

Instructions for disassembly/assembly of coolant hose fast-release couplings
Disassembly of fast-release coupling
Withdraw lock (1/2), disconnect hose.
Fig. 2: Disconnecting Hose

Installation:
Check O-rings (1).
Do not coat O-rings (1) with antiseize agent.

2010 BMW M3
Fig. 3: Identifying O-Rings

Assembly of fast-release coupling
Press in lock (1) before installing fast-release coupling.
Push on hose.
Fast-release coupling must clearly snap audibly into place.
Fig. 4: Connecting Hose

17 00 ... NOTES ON RETROFITTING A TRAILER TOWING DEVICE
Starting with delivery of the E90, in certain vehicle types, the size of the electric cooler fan will be linked to the
optional extra trailer tow hitch or trailer provision.
2010 BMW M3
specifications. Otherwise the engine electronics will detect possible overheating of the cooling system and
activate protective functions.
For the customer, this involves impaired A/C output, automatic transmission and engine power. These will be
continuously reduced, which in the end may result in the vehicle coming to a standstill in the mountain area.
17 00 005 DRAINING AND ADDING COOLANT (S65)
00 2 030

Only carry out work on the cooling system after the engine has cooled
down!
Risk of slipping due to coolant on the floor.
Protective measures/rules of conduct:


Danger of injury!
Catch and dispose of drained coolant in drip tray (1) and if necessary special tool 00 2 030 (universal hydraulic
lifter).
Recycling:

2010 BMW M3

Remove front underbody protection . See 51 47 490 REMOVING AND INSTALLING /

REPLACING FRONT UNDERBODY PROTECTION .
Follow instructions for working on cooling system
Use only recommended coolant
Draining coolant:
Open cap (1) on coolant expansion tank (2).
Fig. 6: Identifying Cap On Coolant Expansion Tank

If fitted, release drain plug (1) on coolant radiator.
On coolant radiators which do not have a drain plug, remove coolant hose.
2010 BMW M3
Drain, catch and dispose of coolant from radiator.
Fig. 7: Identifying Drain Plug

Installation:
Adding coolant:
Vent cooling system and check for leaks.
17 00 009 CHECKING COOLING SYSTEM FOR LEAKS (S65)
00 2 030
17 0 101
17 0 113
17 0 114
See COOLING SYSTEM - SPECIAL TOOLS .


2010 BMW M3


Danger of injury!
Catch and dispose of drained coolant in drip tray (1) and if necessary special tool 00 2 030 (universal hydraulic
lifter).
Recycling:

Checking pressure drop in cooling system:
Open cap on coolant expansion tank. Fit special tools 17 0 101 / 17 0 113 .
Build up gauge pressure of 2 bar, wait approx. 2 minutes.
Cooling system is impervious to leaks if pressure drop is max. 0.1 bar.

2010 BMW M3

Checking pressure relief valve in cap:
NOTE: Coolant residue can cause the pressure relief valve in the cap to stick, therefore
repeat the check procedure on the cap 2-3 times.
Screw cap (1) onto special tool 17 0 114 .
Build up pressure with special tool 17 0 101 (hand pump); observe pressure gauge to ascertain when opening
pressure is achieved.
Opening pressure of pressure relief valve.
Fig. 10: Identifying Special Tool (17 0 101, 17 0 102 And 17 0 114)
17 00 039 VENTING COOLING SYSTEM AND CHECKING FOR WATER LEAKS (S65)
2010 BMW M3

Open sealing cap only after engine has cooled down.
leakages.
Use only recommended coolant.
Adjust coolant level to MAX.
Installation:
Close cap (1) until the arrow marks line up.
Fig. 11: Identifying Cap On Coolant Expansion Tank

IMPORTANT: The following venting procedure is necessary e.g. when a part is replaced in
the cooling system or when the cooling system is refilled.
Only when filling!

2010 BMW M3
Set heater to maximum temperature and turn fan down to lowest speed.
Start engine and run at idle speed.
Fill coolant expansion tank with 250 ml above max. (250 ml correspond to A=18 mm).
Run engine for 15 mins.
Cooling system vents itself.
Coolant level must drop to marking.
If necessary, correct coolant level.
Close cap on expansion tank.

NOTE: If necessary, check cooling system for water leaks .
ENGINE RADIATOR
17 11 000 REMOVING AND INSTALLING RADIATOR (N51, S65)

IMPORTANT: Wear protective goggles and gloves.
Follow instructions for working on cooling system

Remove expansion rivets (1). Release screws (2). Remove intake duct (3 and 4). Remove intake duct .
2010 BMW M3
Fig. 13: Removing Intake Duct

Remove intake filter housing . See 13 71 000 REMOVING AND INSTALLING/REPLACING

INTAKE FILTER HOUSING (S65) .
Remove fan cowl
Draining coolant
Unlock coolant hoses and detach
If fitted:
Remove heat exchanger for automatic transmission fluid
Automatic only:
Release bolt and detach hose (1).
Fig. 14: Identifying Hose

2010 BMW M3
Release screws.
Carefully feed out radiator (1) towards top and remove.
Fig. 15: Removing Radiator

17 11 035 REMOVING AND INSTALLING/REPLACING FAN COWL WITH ELECTRIC FAN (S65)

Read out fault memory of DDE control unit; if necessary, work through test schedules
Switch off ignition
Remove intake duct . See Fig. 13.
Unclip coolant lines from fan cowl.

2010 BMW M3
Fig. 16: Unlock Connector And Remove


Release retaining screw (1) for fan cowl.
Unclip cable.
Unclip vent lines.
Turn lower hose holder through 90.
Remove fan cowl (2) towards top.
Fig. 17: Identifying Retaining Screw And Fan Cowl

2010 BMW M3
Installation:
When installing fan cowl, make sure guide tabs are correctly positioned.
17 11 046 REMOVING AND INSTALLING / REPLACING MODULE CARRIER
Remove coolant cooler

If necessary, slacken power steering cooling coil.
If necessary, slacken A/C condenser and secure against damage and against falling down. See 64 53 550
REMOVING AND INSTALLING OR REPLACING CONDENSER FOR A/C SYSTEM .
Release damping pieces.
Fig. 18: Locating Damping Pieces

Press lock (1) and remove holder (2) downwards.
Illustration shows the left holder: The same procedure applies to the opposite side.
Installation:
Rubber mounts fall out easily, ensure correct installation position.
S65 only: Engine oil cooler loose, see oil cooler.

2010 BMW M3
Fig. 19: Identifying Lock And Holder

Remove module carrier (1) individually towards bottom.
Fig. 20: Identifying Module Carrier

When replacing module carrier:
Convert power steering cooling loop .
17 11 100 REMOVING AND INSTALLING/REPLACING COOLANT EXPANSION TANK (S65)
Drain coolant from radiator
Release screws.
2010 BMW M3
Raise expansion tank slightly until plugs on coolant level switch and lower coolant hose are accessible.
Unlock plugs on coolant level switch and lower coolant hose and disconnect.
Remove coolant expansion tank.
Installation:
Insert locating pin in rubber grommet.

Remove front bumper trim . See 51 11 156 REMOVING AND INSTALLING FRONT BUMPER
TRIM (FROM 09/08) .
Remove front underbody protection . See 51 47 490 REMOVING AND INSTALLING / REPLACING
FRONT UNDERBODY PROTECTION .

Recycling:

2010 BMW M3
Slacken nut (1).
Installation:
Unscrew screws (2).
Fig. 22: Identifying Engine Oil Cooler Nut And Screws

Slacken nut (1).
Release screw (2).
Installation:
2010 BMW M3
Fig. 23: Identifying Engine Oil Cooler And Screws

(S65)

Recycling:
Remove underbody protection . See 51 47 490 REMOVING AND INSTALLING / REPLACING FRONT
UNDERBODY PROTECTION .
Disconnect lines on engine oil cooler.
Unfasten nut.
2010 BMW M3
Fig. 24: Identifying Oil Cooler Line Nut

Fig. 25: Locating Oil Lines Nuts


17 11 370 REMOVING AND INSTALLING/REPLACING COOLING COIL FOR POWER STEERING

(N54, N52, N52K, N51, N53, S65)
2010 BMW M3

After completing this operation, check fluid level in tank of power steering system . See 32 13 006
BLEEDING POWER STEERING UNIT .
Remove radiator
Press lines (1) in direction of cooling coil (2), pull back locking ring towards rear. Keep locking ring pressed
and detach lines (1) from cooling coil (2).
IMPORTANT: Catch and dispose of emerging fluid.
Fig. 26: Detaching Lines From Cooling Coil

Unlock seal (1) in direction of arrow and remove.
Release screw.
NOTE: Lines of A/C system remain connected to condenser.

2010 BMW M3
Fig. 27: Unlocking Seal

Press lock (1) upwards.
Carefully tilt condenser (2) in direction of engine, taking care not to damage the condenser or lines in the
process.
Fig. 28: Pressing Lock Upwards

Press lock (1).
Unclip cooling coil (2) from holder (3) and remove.

2010 BMW M3
Fig. 29: Uncoupling Cooling Coil From Holder

OIL COOLER
TRIM (FROM 09/08) .
Remove front underbody protection . See 51 47 490 REMOVING AND INSTALLING / REPLACING

Recycling:
Slacken nut (1).
Installation:
2010 BMW M3
Unscrew screws (2).
Fig. 30: Identifying Engine Oil Cooler Nut And Screws

Slacken nut (1).
Release screw (2).
Installation:
2010 BMW M3
Fig. 31: Identifying Engine Oil Cooler And Screws

(S65)

Recycling:
Unfasten nut.

2010 BMW M3

Fig. 33: Locating Coolant Hoses Bolt


17 21 010 REMOVING AND INSTALLING/REPLACING TRANSMISSION OIL COOLER

Fill transmission at room temperature only (approx. 20-30C).
Gear oil:
2010 BMW M3
refer to AUTOMATIC TRANSMISSION - OPERATING FLUIDS .

transmission.
Recycling:
Catch and dispose of gear oil with suitable equipment.
Remove right wheel arch cover . See 51 71 038 REMOVING AND INSTALLING/REPLACING
FRONT LEFT OR RIGHT WHEEL ARCH COVER (FRONT SECTION) .
Drain transmission oil . See 00 11 229 CHANGING / TOPPING UP / CHECKING GEAR OIL IN
MANUAL TRANSMISSION .
Release connections for transmission oil cooler.
Fig. 34: Locating Transmission Oil Cooler

Release brackets for transmission oil cooler.
Check system for leaks.

2010 BMW M3
Fig. 35: Locating Transmission Oil Cooler Screws

OIL COOLER LINES

(S65)

Recycling:
Unfasten nut.
2010 BMW M3

Fig. 37: Locating Coolant Hoses Bolt


2010 BMW M3
GENERAL INFORMATION Diagnostic Connector (DLC) Locations
GENERAL INFORMATION
Diagnostic Connector (DLC) Locations
DOMESTIC CARS
CHRYSLER GROUP LLC
NOTE: This table provides a quick reference for self-diagnostic connector locations,
when available from manufacturer, that ARE NOT located at the lower left side
of the dash, as mandated in 1996 by the Federal government.
CHRYSLER GROUP LLC - DOMESTIC CARS

Application Connector Location
Acclaim
1989-90 Under Left Side Of Dash
1991-92 On Left Front Fender Panel, Near
Shock Tower
1993-94 Near Battery
1995 Behind Left Side Of Dash, Near Fuse
Block
Aries, Caravelle, Dynasty, E Class, Executive Sedan, LeBaron Sedan, New Yorker, Reliant, Town &
Country, 400 & 600
1984-85 On Left Fender Apron, Behind Battery
(2.2L Only)
1986-87 On Front Of Right Shock Tower (2.2L
& 2.5L Only)
1988-89 On Left Fenderwell
1990 Under Left Side Of Dash
Shock Tower
1993 (Except New Yorker) Near Battery
1993 (New Yorker) On Left Fender Panel Near PCM
Under Center Of Dash, Near Center
Avenger (1995-00) Console
Breeze, Cirrus & Stratus (1995) Left Of Steering Column, On BCM
Charger, Horizon, Omni, Rampage, Scamp & Turismo
1985-89
2.2L Carbureted On Left Fender Apron
2.2L Turbo On Front Of Right Shock Tower
Concorde, Intrepid, LHS, New Yorker, Vision & 300M
1993-95 Behind Left Side Of Dash
1996-97 Under Left Side Of Dash, Near Center
2010 BMW M3
Console
Daytona
1984-87 On Front Of Right Shock Tower
Shock Tower
1993 On Left Front Inner Fender Or Under
Steering Column
Dynasty
1991-93 On Left Fender Panel, Near
SBEC/PCM
Fifth Avenue
1991-93 On Left Fender Panel Near SBEC/PCM
Horizon & Omni (1989-90) Under Left Side Of Dash
Imperial
1981-83 CCC Connector Left Of Air Cleaner
1991-93 On Left Fender Panel Near SBEC/PCM
LeBaron Coupe & Convertible
1985-87 On Right Front Shock Tower
Shock Tower
1993 On Left Front Inner Fender Or Under
Steering Column
1994 Near Battery
Block
Lancer
Laser
1990-94 Above Left Kick Panel, Near Fuse
Block
1995 Under Left Side Of Dash, Near Center
Console
Monaco & Premier
1990 On Right Front Fender Panel
1991-92 On Left Fender Panel, Next To SBEC
Under Headlight Switch, Under Left Side
2010 BMW M3
Neon (1995) Of Dash

Shadow
1988 On Left Fenderwell
1989 Under Dash, To Right Of Steering
Column
1990 On Left Fender Front Panel, Near
SBEC
Shock Tower
Spirit & Sundance
Shock Tower
Block
Talon
1990-94 Above Left Kick Panel, Near Fuse
Block
1995-98 Under Left Side Of Dash, Near Center
Console
FORD MOTOR CO.
FORD MOTOR CO. - DOMESTIC CARS

Bobcat & Pinto On Center Of Right Fender Apron
Capri
1980-85 On Center Of Left Front Fender Apron
1986 On Left Rear Corner Of Engine
Compartment
Continental
1984-89 On Right Rear Corner Of Engine
Compartment
1990-91 On Right Rear Corner Of Firewall, On
Electronic Assembly Cover
2010 BMW M3
1992 On Right Fender Apron

1993-94 VIP Connectors (2) On Right Rear Of
Engine Compartment, On PCM Cover
Contour & Mystique
Compartment
Cougar & Thunderbird
1982-90 On Left Fender Apron
1991 On Rear Of Right Front Fender Panel
1992 Front Of Right Shock Tower
1993 2 Connectors In Right Rear Corner Of
Engine Compartment
1994 On Right Side Of Engine Compartment
& Below Glove Box
1995
3.8L On Right Side Of Engine
Compartment & Below Glove Box
4.6L Behind Right Side Of Dash, Below
Glove Box
1996 Lower Right Side Of Dash, Below
Glove Box
Crown Victoria, Grand Marquis & Lincoln Town Car
1983 & 1987 On Right Fender Apron
1985-86 & 1988-90 On Left Fender Apron
1992 On Left Front Fender Panel
1993-94 On Top Of Left Front Wheelwell
Escort, EXP, Lynx & Tracer
1985-90 On Right Fender Apron Near Firewall
1991 On Left Rear Of Engine Compartment
1992 On Right Rear Of Engine
Compartment, Near Cowl
1993-95 On Left Side Of Firewall
LTD & Marquis
1983 On Left Fender Apron
1984-86 On Left Rear Corner Of Engine
Compartment
Mark VII
Compartment
1988-90 Front Of Right Fender Apron
1991 On Right Side Of Engine
Compartment, Near Thermactor
2010 BMW M3
Solenoids
Mark VIII
1993-96 On Top Of Left Wheelwell
Mustang
1980-85 On Center Of Left Front Fender Apron
Compartment
1992 On Left Shock Tower, Near Ignition
Coil
1993 2 Connectors On Right Front Strut
Tower
1994-95 Behind Right Front Strut Tower &
Right Of Steering Column
Probe
Compartment
1993 DLC - Behind Left Side Of Dash; STI
Connector - On Left Inner Fender Panel
1994-95 On Left Front Inner Fender Panel
Sable & Taurus
1986-87 (3.0L Only) Near Alternator
1988-90
2.5L On Engine Harness Near PCV Hose
3.0L On Right Rear Corner Of Engine
Compartment
1991 On Right Rear Corner Of Engine
Compartment, On ECA Cover
1992 On Right Rear Corner Of Engine
Compartment, Below MAP Sensor
1993-95 Right Rear Of Engine Compartment
Tempo & Topaz
Compartment
1993-94 In Engine Compartment, On Left Strut
Tower
GENERAL MOTORS
GENERAL MOTORS - DOMESTIC CARS

2010 BMW M3

Allante Enter Diagnostic Mode By Pressing
OFF & WARM Buttons On Instrument
Panel
Bonneville (1980-81) ECU Connector On Upper Right Kick
Panel
Brougham (1987-92) Bottom Center Of Instrument Panel
Camaro & Firebird (1980) Diagnostic Ground Lead Connector On
Right Shroud Above ECM
Caprice Classic
1980-81 ECU Connector On Upper Right
Kick Panel
1982-88 Under Center Of Instrument Panel
Catalina ECU Connector On Upper Right Kick
Panel
Cavalier (1982-88) On Side Of Fuse Block
Cimarron On Side Of Fuse Block
Century Under Left Of Dash Ashtray
Corvette (1980-83) In Center Console, Under Ashtray
Custom Cruiser
1980-81 ECU Connector On Upper Right
Kick Panel
1982-88 Under Center Of Instrument Panel
DeVille (1981-88) Enter Diagnostic Mode By Pressing
OFF & WARMER Buttons On
Instrument Panel
Delta 88 ECU Connector On Upper Right Kick
Panel
Eldorado (1981-88) Enter Diagnostic Mode By Pressing
Instrument Panel
Electra (1980-81) ECU Connector On Upper Right Kick
Panel
Estate Wagon ECU Connector On Upper Right Kick
Panel
Fiero Under Ashtray Or Cigar Lighter Panel
Within Center Console
Firenza On Side Of Fuse Block
Fleetwood (1981-88) Enter Diagnostic Mode By Pressing
Instrument Panel
Fleetwood Brougham On Bottom Center Of Dash, Near
Ashtray
2010 BMW M3
Impala (1982-88) Under Center Of Instrument Panel

LeMans ECM Connector On Right Kick Panel
Or Under Left Side Of Dash
LeSabre (1980-81) ECU Connector On Upper Right Kick
Panel
LeSabre Wagon (1982-88) Under Center Of Instrument Panel
Monza Under Right Side Of Dash
Ninety-Eight (1980-81) ECU Connector On Upper Right Kick
Pane
Nova Behind Right Strut Tower
Parisienne Under Center Of Instrument Panel
Reatta
1988-92 (MFI) Enter Diagnostic Mode By Pressing
OFF & WARM Buttons On
Instrument Panel
1991-93 Above Parking Brake Pedal
Riviera
1980-85 (Carbureted) Under Left Or Center Of Dash
Instrument Panel
Safari Under Center Of Instrument Panel
Seville (1981-88) Enter Diagnostic Mode By Pressing
Instrument Panel
Skyhawk Under Right Side Of Dash
Starfire Under Right Side Of Dash
Sunbird On Side Of Fuse Block, Under Right
Side Of Dash
Toronado
1980-85 (Carbureted) Under Left Or Center Of Dash
Instrument Panel
Trofeo
Instrument Panel
1991-93 Above Parking Brake Pedal
2000 On Side Of Fuse Block
DOMESTIC LIGHT TRUCKS & VANS

2010 BMW M3
CHRYSLER GROUP LLC
CHRYSLER GROUP LLC - DOMESTIC LIGHT TRUCKS & VANS

Caravan, Grand Caravan, Grand Voyager, Mini Ram Van, Town & Country, & Voyager
1984-92 On Left Side Fender Apron
1993 On Left Fender Front Fender Panel, Near
SBEC
1994-95 On Wiring Harness, On Center Of
Firewall
Dakota
1987-88 On Right Side Fender Apron
1989 On Left Side Of Firewall
1990-92 On Right Side Of Firewall
Compartment
Jeep
Cherokee (1992-95) On Left Front Fender Apron, Behind Air
Cleaner
Comanche On Left Front Fender Apron, Behind Air
Cleaner
Grand Cherokee & Wagoneer
1993-95
PCM On Right Rear Of Engine
Compartment, Near PCM
TCM Behind Left Side Of Instrument
Panel
Wrangler (1992-95) On Left Side Of Firewall, Near PCM
Pickup & Ramcharger
1991-93 On Left Front Fender Panel, Next To
SBEC/PCM
1995 Pickup On Right Side Of Firewall
Ram Wagon & Van
1991-95 On Center Of Firewall, Near SBEC/PCM
FORD MOTOR CO.

2010 BMW M3
FORD MOTOR CO. - DOMESTIC LIGHT TRUCKS & VANS

Aerostar
1986-90 On Left Front Fender
1991 Near Starter Relay
1992 On Left Front Inner Fender Panel
Bronco
1982-85
6-Cylinder On Left Front Fender
V8 On Right Inner Fender Panel
1986-87 On Right Front Fender, Near Starter
Relay
1993-95 2 Connectors In Left Rear Of Engine
Compartment, On Bracket
1996- Below Glove Box
Bronco II
1983-85 On Right Front Inner Fender Panel
(2.3L Only)
1986-90 On Right Front Fender Apron
Excursion Behind Center Of Dash
Explorer & Mountaineer (1991-94) On Right Rear Of Engine Compartment,
Near A/C-Heater Blower
Pickup
1982-85
6-Cylinder On Left Front Fender
V8 On Right Inner Fender Panel
1986-87 On Right Front Fender, Near Starter
Relay
1993-95 2 Connectors In Left Rear Of Engine
Compartment, On Bracket
1996- Below Center Of Instrument Panel
Pickup (F250 Heavy Duty & F350) Under Right Side Of Dash
Ranger
1983-85 On Right Front Inner Fender Panel
(2.3L Only)
2010 BMW M3

1991 Behind Engine Compartment
Fuse/Relay Block
1992 On Left Front Inner Fender Panel
1993-95 On Rear Of Engine Compartment
Fuse/Relay Block
Van
1986-92 On Right Fender Apron
1993-95 On Left Front Corner Of Engine
Compartment
1996
5.8L (49 State, Over 8600 GVW) & 7.5L (Except On Left Front Corner Of Engine
Calif.) Compartment
All Others Under Left Side Of Dash
1997-98
Diesel Under Left Side Of Dash
All Others Left Front Corner Of Engine
Compartment
Villager (1993) On Left Side Of Engine Compartment,
Below Coolant Reservoir
GENERAL MOTORS
GENERAL MOTORS - DOMESTIC LIGHT TRUCKS & VANS

Astro & Safari Van (1986-87) Under Left Corner Of Cowl
"S" & "T" Series Blazer, Bravada, Envoy, Jimmy, Pickup & Sonoma
1982-85
1.9L Under Left Side Of Dash, Behind
ECM
2.0L & 2.8L Under Ashtray
2.5L Under Left Side Of Dash
1986-87 Under Ashtray
Van ("G" Series) (1982-87) Under Driver's Seat
IMPORTED CARS & TRUCKS

ACURA
2010 BMW M3
ACURA - IMPORTED CARS & TRUCKS

Integra
1991-93 Behind Right Kick Panel
1994-97 Behind Glove Compartment
1998-02 Behind Right Side Of Center
Console
Legend
1991-93 Under Right Side Of Dash, Above
PGM-FI ECU/PCM
NSX (1997-01) Under Glove Compartment
SLX Behind Lower Left Corner Of Dash,
Behind Cover
Vigor
1992-93 Under Right Side Of Dash, Near
Center Console
1994 Behind Glove Compartment
2.2CL & 2.3CL In Front Of Shift Lever, Behind Ashtray
2.5TL In Front Of Shift Lever, Behind Ashtray
3.0CL In Front Of Shift Lever, Behind Ashtray
3.2TL & 3.5RL In Front Of Shift Lever, Behind Ashtray
AUDI
AUDI - IMPORTED CARS & TRUCKS

A4
1996 Next To Rear Ashtray
1997-01 (1.8L Turbo) Behind Cover, Under Left Side Of
Steering Column
1997-99 (2.8L V6) Under Cover, Next To Rear Ashtray
1997- Under Left Side Of Dash, Behind
Cover
2010 BMW M3
A6
1995 Under Ashtray, In Front Storage
Compartment Of Center Console
1996-97 Under Cover, Next To Parking
Brake Handle
Cabriolet
1994-96 In Fuse/Relay Block, On Left Side
Of Dash
1997-98 Under Ashtray, At Rear Of Center
Console
Coupe GT, 4000S & 4000S Quattro In Fuse Socket, On Fuel Pump Relay
80 In Fuse Socket, On Fuel Pump Relay
90
1988-92 In Fuse Socket, On Fuel Pump Relay
1993 In Main Fuse/Relay Block, On
Plenum Tray
1994-95 In Fuse/Relay Block, On Left Side
Of Dash
100
1992-94 In Auxiliary Relay Station No. 1, On
Left Rear Of Engine Compartment
5000CS Quattro, 5000CS Turbo & 5000S In Fuse Socket, On Fuel Pump Relay
BENTLEY
BENTLEY - IMPORTED CARS & TRUCKS

1996-00
All Models In Glove Compartment
2001-04
Arnage Below Left Side Of Dash
2001-
Azure Convertible In Glove Compartment
Continental In Glove Compartment
BMW
2010 BMW M3
BMW - IMPORTED CARS & TRUCKS

Z3 Behind Cover, On Right Side Of Center
Console
Z4 & Z8 Under Left Side Of Dash, Left Of Steering
Column, Behind Cover
318 & 325
1991 On Bracket, Above Thermostat Housing
1992-95 On Right Rear Of Engine Compartment
1996 Under Left Side Of Dash, Behind Panel
Labeled OBD
330 Behind Cover, Under Left Side of Dash
Above Hood & Trunk Releases
524t On Top Rear Of Engine
525i & 535i
1990-91 (Black 20-Pin Connector) Left Rear Corner Of Engine Compartment
1992-95 Outside Of Engine Compartment
Fuse/Relay Block
528e On Intake Manifold Bracket, Behind
Thermostat Housing
635CSi On Bracket, Next To Fuse/Relay Block
735i
1986-87 On Bracket, On Top Of Engine
1988-92 On Right Side Of Engine Compartment,
On Shock Tower
740 & 750 Under Left Side Of Dash, Behind Panel
Labeled OBD
740i & 740iL (1993-01) Behind Cover On Lower Left Corner Of A/C
Control Panel
745Li In Left Side Kickpanel, Behind Cover
Labeled OBD
750iL Behind Cover On Lower Left Corner Of A/C
Control Panel
DAIHATSU
2010 BMW M3
DAIHATSU - IMPORTED CARS & TRUCKS

Charade At Upper Section Of Transmission
Rocky On Right Front Fender Panel
CHRYSLER GROUP LLC
CHRYSLER GROUP LLC - IMPORTED CARS & TRUCKS

Colt & Summit
1986-87 Above Inside Of Glove
Compartment
Compartment
1989-98 Under Left Side Of Dash, Near
Fuse/Relay Block
Colt Vista
Hood Release Handle
1990-96 Under Right Side Of Dash
Conquest & Starion Behind Glove Compartment
Expo Under Left Side Of Dash, Near
Fuse/Relay Block
Medallion On Left Side Of Firewall
Pickup Under Left Side Of Dash, Near
Fuse/Relay Block
Ram-50 Under Left Side Of Dash, Near
Fuse/Relay Block
Sigma In Glove Compartment
Stealth
1991-98 Under Left Side Of Dash, On
Fuse/Relay Block
1999 Under Left Side Of Dash, Left Of
Center Console
Summit Wagon Under Right Side Of Dash
Vista Wagon Under Right Side Of Dash
FERRARI
2010 BMW M3
FERRARI - IMPORTED CARS & TRUCKS

All Models
1996- Behind Left Side Of Dash
FORD MOTOR CO.
FORD MOTOR CO. - IMPORTED CARS & TRUCKS

Aspire
Compartment
Capri
1991 Behind Right Side Of Dash, Behind
Glove Compartment
1992
1.3L On Left Rear Corner Of Engine
Compartment
Compartment
Compartment
Festiva
1992-93
1.3L On Left Rear Corner Of Engine
Compartment
Compartment
Merkur XR4Ti On Right Front Fender Apron, Near
Battery
Scorpio On Right Rear Corner Of Engine
Compartment
Tracer On Left Rear Corner Of Engine
Compartment
GENERAL MOTORS
2010 BMW M3
GENERAL MOTORS & GEO - IMPORTED CARS & TRUCKS

LeMans Behind Right Kick Panel, Above ECM
Metro
1989-95 Under Left Side Of Dash, Near Fuse
Block
1996 Under Right Side Of Dash, Near
Center Console
Prizm & Prizm LSi
1989-95 On Left Front Strut Tower
Spectrum Under Right Side Of Dash, Above A/C-
Heater Blower Motor
Sprint On Left Front Shock Tower, Near
Battery
Storm
1990-91 Behind Right Side Of Dash, Above
A/C-Heater Blower Motor
Tracker
Block
1996 In Engine Compartment, Near MAP
Sensor
1997- Under Left Side Of Dash
HONDA
HONDA - IMPORTED CARS & TRUCKS

Accord
1990-95 Behind Right Side Of Dash, Above
Kick Panel
1996-97 Behind Ashtray In Center Console
Civic (1992-95) Behind Right Side Of Dash, Near
2010 BMW M3
PGM-FI ECM
Civic Del Sol
1992-95 Behind Right Side Of Dash, Near
PGM-FI ECM
1996-97 Under Removable Cover On Right
Side Of Center Console
CR-V Behind Passenger Side Of Center
Console
Element
2003-11 Above Gas Pedal, Below Fuse
Block
Insight (2010-11) Below Left-of-Center Of Dash
Odyssey
1995 Behind Right Side Of Dash, Above
Kick Panel
1996-98 Behind Passenger Side Of Center
Console
Passport (1995) Behind Left Kick Panel
Prelude
1992-95 Behind Center Console
1996 Under Beverage Holder In Center
Console
1997-02 Under Removable Cover On Right
Side Of Center Console
S2000 Behind Right Side Of Center Console
HYUNDAI
HYUNDAI - IMPORTED CARS & TRUCKS

Accent (1995) In Coin Box
Sonata
1989 Under Left Side Of Dash, In Fuse
Block
1990
W/Passive Seat Belt Restraints In Fuse Block
W/O Passive Seat Belt Restraints On Lower Left Of Steering Column
INFINITI
2010 BMW M3
INFINITI - IMPORTED CARS & TRUCKS

In ECCS Control Unit, Behind Center
G20 (1993-95) Console
I30 (1995) Beside Fuse Box
J30
1994-95 In ECM, Behind Right Kick Panel
M30 Under Left Side Of Dash, Near Fuse
Block
Q45
Block
1994-95 In ECM, Behind Right Kick Panel
ISUZU
ISUZU - IMPORTED CARS & TRUCKS

Amigo & Pickup
1990-95 Behind Left Kick Panel, Near ECM
1998-00 Lower Left Corner Of Dash, Behind
Small Cover
Hombre Under Lower Left Side Of Dash, Behind
Cover
Impulse
1986-89 Under Left Side Of Dash, Above ECU
1993-95 Behind Left Kick Panel, Near ECM
I-Mark Behind Right Side Of Dash, Above A/C-
Heater Blower Motor
Oasis Behind Right Side Of Center Console
2010 BMW M3
Rodeo
1991-95 Behind Left Kick Panel
1996- Lower Left Side Of Dash, Behind
Small Cover
Stylus Behind Right Kick Panel
Trooper & Trooper II
1987-91 Under Center Console
1992
DOHC Behind Center Of Dash, Right Of
Steering Column
SOHC Under Left Side Of Dash
1993-95 Under Left Side Of Dash, Right Of
Steering Column
1996-02 Lower Left Side Of Dash, Behind
Small Cover
VehiCROSS Under Left Side Of Dash
JAGUAR
JAGUAR - IMPORTED CARS & TRUCKS

XJR (1995-97) Near Center Console
XJS
1992 On Left Rear Trunk Wheel Arch,
Behind Trim Panel
1993-94 Under Battery Tray, On Right Front
Of Luggage Compartment
1995-96 Near Center Console
XJ6
1992 On Left Rear Of Engine
Compartment
1993-94 Under Battery Tray, On Right Front
Of Luggage Compartment
Center Console
XJ12 Near Center Console
KIA
2010 BMW M3
KIA - IMPORTED CARS & TRUCKS

Sephia
1994 On Center Of Firewall
1995 & 1996
1.6L Under Center Of Dash, Mounted On
Floorboard
2.0L Under Right Side Of Dash, Near
Kick Panel
Sportage
1994 On Center Of Firewall
1995 & 1996
1.6L Under Center Of Dash, Mounted On
Floorboard
2.0L Under Right Side Of Dash, Near
Kick Panel
LAND ROVER
LAND ROVER - IMPORTED CARS & TRUCKS

Defender 90 Behind Fuse Cover, In Center Of Console
Range Rover Under Right Side Of Dash, In Footwell
LEXUS
LEXUS - IMPORTED CARS & TRUCKS

ES Series
1990-91
DLC Near Left Shock Tower
2010 BMW M3
Total Diagnostic Communication Link Connector Under Left Side Of Dash

1992-94
DLC No. 1 On Bracket, Behind Right Front
Strut Tower
DLC No. 2 & 3 Under Left Side Of Dash
1995-97 In Fuse Box At Lower Left Of Dash
GS Series
1990-95
DLC No. 1 On Bracket, On Top Of Engine
DLC No. 2 Under Left Side Of Dash
LS Series
1990-94
DLC No. 1 On Bracket, On Top Of Engine
DLC No. 2 Under Left Side Of Dash
SC Series
1992-95
DLC No. 1 On Bracket, Behind Right Front
Strut Tower
DLC No. 2 & 3 Under Left Side Of Dash
MAZDA
MAZDA - IMPORTED CARS & TRUCKS

B-Series
1989-93
Engine Control Check Connector (Black 6-Pin) Near Windshield Washer Motor
Trouble Codes Connector (Green 1-Pin) Near Black 6-Pin Connector (Engine
Control)
1994-95 On Right Front Fender Panel
Miata (1990-95) On Left Rear Of Engine Compartment,
Near Master Cylinder
MPV (1989-95)
Engine Control Unit (Green 6-Pin & 1-Pin Connectors) On Left Side Of Engine Compartment,
2010 BMW M3
Near Inner Fender Panel

MX-3 Mounted On Bracket, On Left Front Strut
Tower
MX-6 & 626
1988 Behind Left Front Shock Tower
1989 On Left Front Corner Of Engine
Compartment
1990-91 At ECU Connector Terminal
Compartment
1993 On Side Of Fuse/Relay Block, Near
Battery
1994-95 On Left Front Fender Apron
Navajo
Compartment
1994-95 On Right Front Fender Panel
Protege
1987-89 On Passenger's Footwell (Left Foot
Area)
1990-95 On Left Side Of Firewall, Near Wiper
Motor
RX7
1986-88 (3 Check Connectors) At Left & Right Corners Of Engine
Compartment
1989-91 (Green 6-Pin Connector) Behind Ignition Coil
1993-95 On Bracket, On Left Front Strut Tower
323
1986-88 Front Left Of Engine Compartment,
Near Ignition Coil
1989 (Green 6-Pin & Green 1-Pin Connectors) On Left Side Of Firewall
1990-95 On Left Side Of Firewall, Near Wiper
Motor
929
1989 Near Air Cleaner
1990-91 (Green 6-Pin Connector) In Left Front Corner Of Engine
Compartment
1992-93 Mounted On Air Cleaner Housing
MERCEDES-BENZ
2010 BMW M3
MERCEDES-BENZ - IMPORTED CARS & TRUCKS

C-Class (1994) On Right Rear Of Engine Compartment
E-Class
1994-97 On Right Rear Of Engine
Compartment
G-Class Under Left Side Of Dash, Behind Cover
ML-Class Under Left Side Of Dash, Behind Cover
S-Class
140 Platform (1994-99) On Right Rear Of Engine
Compartment
190 Series
1986-87 On Left Rear Of Engine Compartment
1988-93
All Models In Engine Compartment, On Left
Front Fender
California (OBD) On Right Side Of Firewall, Near
Battery
1994 On Right Rear Of Engine
Compartment
260E
1987 On Left Front Fender Apron, Next To
Ignition Control Module
1988-89
Front Fender
Battery
300 Series
1986-87 On Left Front Fender Apron, Next To
Ignition Control Module
1988-92
Front Fender
Battery
1993
Except 300E Left Fender Apron
300E Right Rear Corner Of Engine
2010 BMW M3
Compartment
1994-95 (All Models) On Right Rear Of Engine
Compartment
400 & 500 Series
1993
12-Pin Connector On Rear Of Left Front Inner Fender
Panel
38-Pin (Impulse Readout) In Module Box, On Right Rear Of
Engine Compartment
Compartment
420SEL & 560 Series (Except 2.2L)
1986-89
Front Fender
Battery
1990-91 In Engine Compartment, On Left Front
Fender
560 Series (2.2L) On Lower Left Side Of Engine Connector
MITSUBISHI
MITSUBISHI - IMPORTED CARS & TRUCKS

Diamante (1992-98) Under Left Side Of Dash, Near
Fuse/Relay Block
Expo Under Left Side Of Dash, Near
Fuse/Relay Block
Montero
1986-88 Left Rear Corner Of Engine
Compartment
Pickup Under Left Side Of Dash, Near
Fuse/Relay Block
Raider
Compartment
2010 BMW M3
3000GT
1991-98 Under Left Side Of Dash, On
Fuse/Relay Block
1999 Under Left Side Of Dash, Left Of
Center Console
NISSAN
NISSAN - IMPORTED CARS & TRUCKS

Altima
1993-94 On Driver-Side Of Center Console,
Above Accelerator Pedal
1995-96 Below Fuse Box
Maxima
1995-96 Below Fuse Box
NX & Sentra Under Left Side Of Dash, Near Fuse
Block
Pulsar NX
1986 Above Right Side Of Dash, Below
Wiper Motor
1987 Above Steering Column
Quest (1993-95)
CONSULT Tester Connector On Driver-Side Of Center Console,
Above Accelerator Pedal
Self-Test Connector Located Near Starter
Stanza Below Center Of Dash, Near Center
Console
Van On Right Side Of Engine Compartment,
Behind Fuel Filter
200SX (1995-96) Below Fuse Box
240SX
1991-94 Under Left Side Of Dash, Below
Fuse Block
1995-96 In Glove Box
300ZX (1990) Near Parking Brake
PEUGEOT
2010 BMW M3
PEUGEOT - IMPORTED CARS & TRUCKS

505 Series On Lower Left Side Of Engine Connector
PORSCHE
PORSCHE - IMPORTED CARS & TRUCKS

911 Series
1992-95 In Passenger's Footwell
1996 Left Side Of Center Console
928S Top Front Of Engine
944 Series On Left Side Of Engine Compartment
RENAULT
RENAULT - IMPORTED CARS & TRUCKS

Sportwagon
Engine Diagnostic On Center Of Firewall
Fuel Injection Diagnostic Right Rear Of Engine Compartment,
Behind Airflow Meter
ROLLS-ROYCE
ROLLS-ROYCE - IMPORTED CARS & TRUCKS

2010 BMW M3
All Models
1996-00 In Glove Compartment
2001- Under Left Side Of Dash
SAAB
SAAB - IMPORTED CARS & TRUCKS

900 Series
1986-90 In Front Of Fuse/Relay Panel
1991-93 Under Back Seat, On Right Side
1994
Convertible Under Rear Seat
Hatchback Under Steering Column
All Others Under Right Front Seat
9000 Series
1990 On Left Side Of Engine Compartment
1991-92 Under Passenger's Seat
1993 On Left Of Firewall
1994-95 Under Right Front Seat
SUBARU
SUBARU - IMPORTED CARS & TRUCKS

Brat, Coupe, Hatchback, Sedan & Wagon
1987
Read Memory Connector Under Left Side Of Dash, Next To
MFI/SMFI Control Unit
Test Mode Connector
MFI On Left Side Of Dash, Next To MFI
Control Unit
Sequential MFI On Left Side Of Firewall
1988-89 On Left Side Of Dash, Next To ECU
2010 BMW M3
Forester Under Left Side of Dash, Behind Cover

Justy
1987-88
Read Memory Connector (Factory) On Right Front Fender, Near Strut
Tower
Test Mode Connector On Driver-Side Kick Panel Or ECU
1989-95
Read Memory Connector (Factory) Under Left Side Of Dash
Test Mode Connector On Driver-Side Kick Panel Or ECU
Legacy
1990-94
Check Connector (Black Connector) Behind Right Side Of Steering
Column, Near Heater Case
Diagnostic Connector (Black 4-Pin Connector) Behind Right Side Of Steering
Read Memory Connector (Black Connector) Behind Knee Panel, Right Of Steering
Column
Select Monitor Connector (Yellow Connector) Behind Right Side Of Steering
Test Mode Connector (Green Connector) Behind Knee Panel, Right Of Steering
Column
1995- Under Left Side Of Dash, Behind Cover
Loyale
1990-91
MFI (5-Pin Connector) In Front Of ECU
SMFI (Yellow 9-Pin & Black 13-Pin Connectors) Near Brake Booster
1992-95
Diagnostic Check Connector Behind Brake Booster
(Yellow 9-Pin & Black 13-Pin Connectors)
Diagnostic Read-Memory Connector Behind Left Front Strut Tower
(2-Single Wire Connectors)
Outback & Outback Sport Under Center Of Dash
SVX
1997 Right Of Steering Column, On Center
Console
SUZUKI
2010 BMW M3
SUZUKI - IMPORTED CARS & TRUCKS

Esteem (1995) Near Battery
Samurai
1986-90 Under Right Side Of Dash, Behind
Glove Compartment
1991-92 On Right Side Of Firewall
1993-95 Under Left Side Of Dash, In Fuse
Block
Sidekick & X90
Block
1992-93
ALDL Connector Under Left Side Of Dash
Engine Connector Under Left Side Of Dash, Near
Fuse Block
1994-96 In Engine Compartment, Near
Battery
Swift
Block
1992
ALDL Connector Under Left Side Of Dash
Diagnostic Test Terminal In Fuse Block
Block
TOYOTA
TOYOTA - IMPORTED CARS & TRUCKS

Camry
1983-90 Next To Brake Master Cylinder
1991 Near Left Front Shock Tower
1992-95
4-Cylinder Near Wiper Motor
V6 Under Left Side Of Dash
Celica
2010 BMW M3
1983-84 Next To Battery

1985-95 Behind Left Front Shock Tower
Celica Supra Rear Of Battery, Near Relay Panel (2-Pin
Connector)
Corolla
Front Wheel Drive
1987 Side Of Left Front Shock Tower (2-
Pin Connector)
1988-94 Behind Left Front Shock Tower
Rear Wheel Drive
1985-86 Side Of Right Front Shock Tower
(2-Pin Connector)
1987 Right Rear Corner Of Engine
Compartment
Cressida
1988-93
Check Connector On Left Front Shock Tower
Total Diagnostic Communication Link Connector Under Left Side Of Dash
Land Cruiser (1988-94) Near Wiper Motor
MR2
1986-90 Near Airflow Meter
Compartment, Near MAP Sensor
Paseo (1992-95) On Side Of Engine Compartment
Fuse/Relay Block No. 2, Near Battery
Pickup
1984-86 Near Ignition Coil, Near Master
Cylinder (2-Pin Connector)
1987-90 Right Front Inner Fender Panel, Near
Relay Block
1992-94 On Side Of Engine Compartment
Previa
1992-93 Under Front Of Driver's Seat
1994
Except Supercharged Under Center Console, Near Parking
Brake Lever
Supercharged Under Cover, On Top Center Of
Instrument Panel
1995-97 On Top Center Of Instrument Panel
RAV4 Under Dash, Near Center Console
Starlet
2010 BMW M3
1981-82 On Instrument Panel Fuse Block, On

Top Of Dash
1983-84 Right Rear Of Engine Compartment
Supra
1986-90 Rear Of Battery, Near Relay Panel
1991-92 On Left Front Shock Tower
1993-94
DLC No. 1 On Right Side Of Firewall
DLC No. 2 Under Left Side Of Dash, Near Kick
Panel
Tacoma & T100
1993 On Side Of Engine Compartment
1994-95
Except OBD-II DLC On Side Of Engine Compartment
Fuse/Relay Block No. 2, Near
Battery
OBD-II DLC Under Left Side Of Dash
Tercel
1987-90 In Engine Compartment, Next To
Master Cylinder
1995-98 Near Steering Column
Van Near Airflow Meter
4Runner
1985-86 Near Ignition Coil, Next To Master
Cylinder (2-Pin Connector)
VOLKSWAGEN
VOLKSWAGEN - IMPORTED CARS & TRUCKS

Cabrio
1996 In Center Console, Below
Tachometer
1997-02 On Center Dash, Behind Panel Near
2010 BMW M3
Ashtray
Corrado Under Center Console Trim Plate
Fox Under Center Console, Near Shift Lever
Golf
1993 On Center Of Dash, Below A/C-
Heater Control Knobs
1994 Under Center Console
1998-03 In Center Console
Golf III 2.0L
1995-96 Below A/C-Heater Control Panel
1997-98 On Center Dash, Behind Panel
Adjacent To Ashtray
GTI
GTI 2.8L On Center Dash, Behind Panel Adjacent
To Ashtray
Jetta
Jetta III 2.0L
1995-96 Below A/C-Heater Control Panel
1997-98 On Center Dash, Behind Panel
Adjacent To Ashtray
Jetta/Jetta III 2.8L On Center Dash, Behind Panel Adjacent
To Ashtray
New Beetle Lower Part of Dash, In Front Of Shift
Lever
Passat
1992-94 Under Center Console, Forward Of
Shift Lever
1995-97 On Center Dash, Behind Panel Near
Ashtray
Toureg
2004-2007 In the cover of the drivers side
footwell, to right of engine hood
release lever
VOLVO
2010 BMW M3
VOLVO - IMPORTED CARS & TRUCKS

C30 Under Left Center Of Dash
C70 Behind Cover, Below Parking Brake
Lever
S40 Under Left Center Of Dash
S70 Behind Cover, Below Parking Brake
Lever
S90 Behind Cover, Below Parking Brake
Lever
V40 Under Left Center Of Dash
V70 (1997-00) Behind Cover Below Parking Brake Lever
V90 Behind Cover, Below Parking Brake
Lever
240
Compartment
1993 Behind Left Front Strut Tower
740 & 760
1986-92
Ignition System On Left Front Fender Apron
Fuel Injection (1990-92 Only) Left Rear Corner Of Engine
Compartment
780 On Left Front Fender, Behind Air Cleaner
Housing
850
1993 On Center Console, Forward Of Shift
Lever & Near ECM
1994-95
Non-Turbo On Right Front Strut Tower
Turbo Behind Cover, Forward Of Shift
Lever
1996-97 Behind Cover, Forward Of Shift Lever
940
1991-93
Ignition System On Left Front Fender Apron
Fuel Injection Left Rear Corner Of Engine
Compartment
1994-95 Behind Left Front Strut Tower
2010 BMW M3
960
1996 In Center Console, To Right Of
Parking Brake Lever
1997 Behind Cover, Forward Of Shift Lever
2010 BMW M3
ACCESSORIES AND BODY, CAB Distance Systems, Cruise control - Repair
Distance Systems, Cruise control - Repair
RADIO-CONTROLLED LOCKING SYSTEM

66 12 100 REMOVING AND INSTALLING/REPLACING SLIDE-IN UNIT FOR RADIO CONTROL
KEY
Lever out trim (1) with special tool 00 9 340 at retaining points (2) in direction of arrow.
Fig. 1: Removing Trim Using Special Tool (00 9 340)

Release screws (1).
Pull back slide-in unit for radio control key (2) with associated ribbon cable.
IMPORTANT: Carefully unlock ribbon cable plug connection.

Replace the ribbon cable if damaged.
The ribbon cable leads to:
CONTROL UNIT FOR CAR ACCESS SYSTEM

START/STOP SWITCH
Remove slide-in unit for radio control key (2).

2010 BMW M3
Fig. 2: Identifying Radio Control Key With Screws

PARK DISTANCE CONTROL

66 20 508 REMOVING AND INSTALLING (REPLACING) CONTROL UNIT (PARK DISTANCE
CONTROL)

Remove TRIM FROM REAR APRON

Remove RIGHT LUGGAGE COMPARTMENT TRIM PANEL
Partially detach insulating mat.
Release screws (1) and pull back device holder (2).

2010 BMW M3
Fig. 3: Pulling Device Holder

Unlock catch (2) in direction of arrow and remove control unit (3) upwards from device carrier (4).
Fig. 4: Disconnecting Catch

Replacement:
66 20 520 REMOVING AND INSTALLING/REPLACING A FRONT (INNER) ULTRASONIC

SENSOR (PARK DISTANCE CONTROL)
Remove front bumper trim See 5111156 REMOVING AND INSTALLING FRONT BUMPER
TRIM or 5111156 REMOVING AND INSTALLING FRONT BUMPER TRIM (UP TO 09/08) .
Unlock retaining tabs (1) in direction of arrow and pull ultrasonic transducer (2) out of holder (3).
2010 BMW M3
Fig. 5: Removing Retaining Tabs

Installation:
Retaining hooks (1) of ultrasonic transducer (2) must engage exactly in mountings (3).
Fig. 6: Identifying Hooks Of Ultrasonic Transducer With Mountings

Installation:
Make sure rubber ring (1) is correctly seated on ultrasonic transducer (2).
2010 BMW M3
Fig. 7: Identifying Rubber Ring On Ultrasonic Transducer

66 20 518 REMOVING AND INSTALLING/REPLACING A FRONT (OUTER) ULTRASONIC

SENSOR (PARK DISTANCE CONTROL)
Remove FRONT WHEEL ARCH TRIM (front section)

Installation:
2010 BMW M3

Installation:

66 20 565 REMOVING AND INSTALLING/REPLACING FRONT SIGNAL SENSOR (PARK

DISTANCE CONTROL)

2010 BMW M3

Unclip signal sensor on both sides from fixture (1).
Installation:
Signal sensor (2) must snap audibly into retaining tabs.
Fig. 12: Identifying Fixture Of Signal Sensor

66 20 534 REMOVING AND INSTALLING/REPLACING REAR LEFT ULTRASONIC

TRANSDUCER (PARK DISTANCE CONTROL)
Remove REAR BUMPER TRIM .

2010 BMW M3

Installation:

Installation:
2010 BMW M3

66 20 560 REMOVING AND INSTALLING/REPLACING REAR SIGNAL SENSOR (PARK

DISTANCE CONTROL)
Vehicles with HiFi or Top HiFi system:
No acoustic sensors fitted because the PDC control unit activates the respective speaker on the side of
obstruction.
Remove PANEL FOR ROOF PILLAR AT REAR RIGHT

Remove REAR RIGHT MIDRANGE SPEAKER
Release screw (1).
Remove holder (2) from C-pillar (3) and feed out of rear window shelf.
2010 BMW M3
Fig. 16: Identifying Holder Of C-Pillar Screws

Installation:
Holder (1) must snap into guide hole (2) in C-pillar.
Fig. 17: Identifying Holder And Guide Hole

Remove signal sensor (2).

2010 BMW M3
Fig. 18: Identifying Plug Connection, Signal Sensor And Holder

Replacement
Detach signal sensor (2) from holder (3).
If necessary, mark position of signal sensor on holder.
ADAPTIVE CRUISE CONTROL

66 31 001 ADJUSTING ACC SENSOR
Unclip trim (1) at points (2) and remove towards front from bumper trim (3).
Installation:
Make sure trim (1) is correctly seated.
Locking hooks (2) must not be damaged.

2010 BMW M3
Fig. 19: Identifying Trim Removing Points And Bumper Trim

E90/E91 up to build date 09/2008:
Installation:
If necessary, cut off front retaining lug (1) from trim (2).
Distance: A = 10 mm
Fig. 20: Identifying Retaining Lug And Trim

IMPORTANT: Before adjusting ACC sensor, check ease of movement at ACC sensor.
2010 BMW M3
Measure gap dimension between front bumper trim (1) and ACC sensor (2).
Minimum dimension: A = 3 - 5 mm
Maximum dimension: A = 6 - 7 mm
Fig. 21: Identifying Gap Dimension Between Front Bumper Trim And ACC Sensor
If minimum dimension not obtained:
Carry out preliminary work for ACC sensor adjustment.
Carry out adjustment of ACC sensor (1) with special tool 66 3 150 by means of adjusting screws (2).
Fig. 22: Adjusting ACC Sensor Using Special Tool (66 3 150)
Special tool required:

2010 BMW M3
Active Cruise Control ACC adjusting device, complete.
Order number: 81 10 0 021 292
Consisting of:
1. Mirror, complete
2. Wheel laser
3. Slotted diaphragm
4. Control bracket (for initial installation of rail)
5. Rail
6. Setup and Owner's Handbook (not shown)
Fig. 23: Identifying Mirror, Wheel Laser And Slotted Diaphragm

NOTE: A holder which is not included in the scope of delivery is required to support
the wheel laser. Use either the quick-action clamp from the existing KDS or ACC
wheel holder (36 1 100).
NOTE: Follow instructions for ACC adjustment tool.
NOTE: To adjust the ACC sensor, connect the BMW diagnosis system and fit the ACC
adjusting device.
Select ACC system in diagnosis. Start test module "ACC adjustment" (service
functions) and proceed in accordance with instructions.
Handle ACC adjusting device in accordance with mounting and Owner's
Handbook provided with device.
NOTE: Further information on the ACC adjusting device can be found in the BMW
2010 BMW M3
Workshop Equipment and Planning Documentation.
66 31 006 REMOVING AND INSTALLING (REPLACING) ACC SENSOR
Unclip ACC sensor (2) from ACC holder (3) towards front.
Installation:
Make sure ACC sensor (2) is correctly engaged in ACC holder (3).
Fig. 24: Identifying ACC Sensor With Holder And Plug Connection
IMPORTANT: Always replace plastic nuts (1).
Turn plastic nuts (1) with a suitable tool through approx. 90 and pull towards rear out of holder (2).
2010 BMW M3
Fig. 25: Turning Plastic Nuts

Check preliminary adjustment of ACC sensor (1).
If necessary, carry out preliminary adjustment at retaining pins (2).
Basic dimension A: 43 0.5 mm

Final dimension A: is adapted by means of ACC SENSOR ADJUSTMENT
Fig. 26: Identifying ACC Sensor With Dimensions For Adjusting Retaining Pins
IMPORTANT: After fitting front bumper trim, check concentric position of

ACC sensor eye (1) in relation to trim (3).
If necessary, carry out position adjustment by means of screws (2).
Tightening torque 66 31AZ1 .

2010 BMW M3
Make sure plain ACC sensor (1) can move freely.
Fig. 27: Identifying ACC Sensor Eye, Trim With Screws

Replacement
Carry out PROGRAMMING/CODING using scan tool.
Carry out ACC SENSOR ADJUSTMENT using BMW diagnostic system.
66 31 100 REMOVING AND INSTALLING/REPLACING LONGITUDINAL DYNAMICS MODULE

Remove CONTROL UNIT FOR CAR ACCESS SYSTEM
Release bolts (1) and disconnect associated plug connection.
Remove longitudinal dynamics module (2).

2010 BMW M3
Fig. 28: Identifying Longitudinal Dynamics Module Bolts

2010 BMW M3
ACCESSORIES AND BODY, CAB Distance Systems, Cruise Control - Repair - M3
Distance Systems, Cruise Control - Repair - M3
RADIO-CONTROLLED LOCKING
66 12 100 REMOVING AND INSTALLING/REPLACING SLIDE-IN UNIT FOR RADIO CONTROL
KEY
00 9 340
Lever out trim (1) with special tool 00 9 340 at retaining points (2) in direction of arrow.
Fig. 1: Lever Out Trim With Special Tool 00 9 340

Release screws (1).
Pull back slide-in unit for radio control key (2) with associated ribbon cable.
IMPORTANT: Carefully unlock ribbon cable plug connection.

Control unit for Car Access System . See 61 35 015 REMOVING AND
INSTALLING (REPLACING) CONTROL UNIT FOR CAR ACCESS SYSTEM .
Start/Stop switch . See 61 31 023 REMOVING AND
INSTALLING/REPLACING START/STOP SWITCH .
2010 BMW M3
Remove slide-in unit for radio control key (2).
Fig. 2: Identifying Slide-In Unit For Radio Control Key And Screws
PARK DISTANCE CONTROL

CONTROL) (COUPE/CONVERTIBLE)
DISCHARGE) .

2010 BMW M3
Fig. 3: Disconnect Plug Connection (1)
Unlock catch (1) and remove control unit (2) from device carrier (3).
Fig. 4: Unlock Catch (1) And Remove Control Unit (2) From Device Carrier (3)
Replacement: Carry out programming/coding.

CONTROL) (SEDAN)
DISCHARGE) .
2010 BMW M3
Remove right luggage compartment trim panel . See 51 47 161 REMOVING AND INSTALLING /
REPLACING RIGHT LUGGAGE COMPARTMENT WHEEL ARCH TRIM .
Partially detach insulating mat.
Fig. 5: Pulling Back Device Holder

Unlock catch (2) in direction of arrow and remove control unit (3) upwards from device carrier (4).
Fig. 6: Removing Control Unit Upwards From Device Carrier

Replacement:

2010 BMW M3
66 20 518 REMOVING AND INSTALLING/REPLACING AN ULTRASONIC TRANSDUCER AT

FRONT (OUTSIDE) (PARK DISTANCE CONTROL)
Remove front wheel arch trim (front section). See 51 71 038 REMOVING AND
INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH COVER (FRONT
SECTION) .
Fig. 7: Pulling Ultrasonic Transducer Out Of Holder

Installation:
2010 BMW M3
Fig. 8: Identifying Retaining Hooks Of Ultrasonic Transducer And Mountings

Installation:

66 20 520 REMOVING AND INSTALLING/REPLACING AN ULTRASONIC TRANSDUCER AT

FRONT (INSIDE) (PARK DISTANCE CONTROL)
TRIM .
2010 BMW M3

Installation:

Installation:
2010 BMW M3

66 20 534 REMOVING AND INSTALLING/REPLACING REAR LEFT ULTRASONIC

TRANSDUCER (PARK DISTANCE CONTROL)
Remove rear bumper trim . See 51 12 156 REMOVING AND INSTALLING REAR BUMPER
TRIM .

Installation:
2010 BMW M3

Installation:


DISTANCE CONTROL) (COUPE/CONVERTIBLE)
obstruction.

DISTANCE CONTROL) (SEDAN)
2010 BMW M3
obstruction.
Remove panel for roof pillar at rear right . See 51 43 251 REMOVING AND
INSTALLING/REPLACING TRIM PANEL FOR LEFT OR RIGHT REAR ROOF PILLAR (C-
PILLAR) .
Remove rear right mid-range speaker . See 65 13 188 REMOVING AND
INSTALLING/REPLACING REAR MID-RANGE SPEAKER (IN REAR SHELF) .
Release screw (1).
Remove holder (2) from C-pillar (3) and feed out of rear window shelf.
Fig. 16: Identifying Holder From C-Pillar And Screw

Installation:
Holder (1) must snap into guide hole (2) in C-pillar.

2010 BMW M3
Fig. 17: Identifying Holder Must Snap Into Guide Hole In C-Pillar
Remove signal sensor (2).
Replacement:
Detach signal sensor (2) from holder (3).
If necessary, mark position of signal sensor on holder.
Fig. 18: Identifying Plug Connection And Signal Sensor

66 20 565 REMOVING AND INSTALLING/REPLACING FRONT SIGNAL SENSOR (PARK

DISTANCE CONTROL)
2010 BMW M3
Remove trim panel for pedal assembly . See 51 45 185 REMOVING AND
INSTALLING/REPLACING PANEL FOR PEDALS .

Unclip signal sensor on both sides from fixture (1).
Installation:
Signal sensor (2) must snap audibly into retaining tabs.
Fig. 20: Identifying Signal Sensor On Both Sides From Fixture

ADAPTIVE CRUISE CONTROL

2010 BMW M3
66 31 ... PRELIMINARY WORK FOR ACC SENSOR ADJUSTMENT
66 3 150
See DISTANCE SYSTEMS, CRUISE CONTROL - SPECIAL TOOLS .
Remove underbody protection .
Release screws (2) and remove engine compartment shield brackets (1).
Remove radiator seal (3).
Installation:
Make sure engine compartment shield brackets (1) are correctly seated.
Fig. 21: Identifying Engine Compartment Shield Brackets And Radiator Seal
IMPORTANT: Spray all screw threads with rust remover

Insert all screws evenly
Insert locating bearing screw (1) on ACC sensor holder (2) with Torx screwdriver max. four turns in clockwise
direction.
2010 BMW M3
Fig. 22: Inserting Locating Bearing Screw On ACC Sensor Holder

Insert adjusting screws (2) with special tool 66 3 150 max. four turns in counterclockwise direction.
Fig. 23: Inserting Adjusting Screws With Special Tool 66 3 150

66 31 001 ADJUSTING ACC SENSOR
36 1 100
66 3 150
See WHEEL AND TIRES - SPECIAL TOOLS .

2010 BMW M3
See DISTANCE SYSTEMS, CRUISE CONTROL - SPECIAL TOOLS .
Unclip trim (1) at points (2) and remove towards front from bumper trim (3).
Installation:
Make sure trim (1) is correctly seated.
Locking hooks (2) must not be damaged.
Fig. 24: Identifying Trim And Locking Hooks

Installation:
If necessary, cut off front retaining lug (1) from trim (2).
Distance: A = 10 mm
2010 BMW M3
Fig. 25: Cutting Off Front Retaining Lug From Trim

IMPORTANT: Before adjusting ACC sensor, check ease of movement at ACC sensor.
Measure gap dimension between front bumper trim (1) and ACC sensor (2).
Minimum dimension: A = 3 - 5 mm
Maximum dimension: A = 6 - 7 mm
If minimum dimension not obtained:
Carry out preliminary work for ACC sensor adjustment .

2010 BMW M3
Fig. 26: Measuring Gap Dimension Between Front Bumper Trim And ACC Sensor
Carry out adjustment of ACC sensor (1) with special tool 66 3 150 by means of adjusting screws (2).
Fig. 27: Identifying ACC Sensor With Special Tool 66 3 150

Special tool required:
Active Cruise Control ACC adjusting device, complete.
Order number: 81 10 0 021 292
Consisting of:
1. Mirror, complete
2. Wheel laser
3. Slotted diaphragm
4. Control bracket (for initial installation of rail)
5. Rail
6. Setup and Owner's Handbook (not shown)
2010 BMW M3
Fig. 28: Identifying Mirror Complete, Wheel Laser, Slotted Diaphragm And Control Bracket
NOTE: A holder which is not included in the scope of delivery is required to support
the wheel laser. Use either the quick-action clamp from the existing KDS or ACC
wheel holder (36 1 100 ).
NOTE: Follow instructions for ACC adjusting device .
NOTE: To adjust the ACC sensor, connect the BMW diagnosis system and fit the ACC
adjusting device.
Select ACC system in diagnosis. Start test module "ACC adjustment" (service
functions) and proceed in accordance with instructions.
Handle ACC adjusting device in accordance with mounting and Owner's
Handbook provided with device.
NOTE: Further information on the ACC adjusting device can be found in the BMW
Workshop Equipment and Planning Documentation.
66 31 006 REMOVING AND INSTALLING (REPLACING) ACC SENSOR (COUPE/CONVERTIBLE)
Remove cover for ACC sensor
IMPORTANT: Secure ACC sensor (2) against falling out. Cover bumper in working area with
adhesive tape (1).
2010 BMW M3
Fig. 29: Identifying ACC Sensor, Adhesive Tape And Special Tool (00 9 317)
Using special tool 00 9 317, unclip ACC sensor (2) from holders on both sides. Installation: ACC sensor must
be felt and heard to snap into place.
IMPORTANT: Secure ACC sensor (1) against falling out.
Fig. 30: Identifying ACC Sensor And Plug Connection
After installation: Carry out programming/coding and ACC sensor adjustment using BMW diagnostic system.
Replacement: Check preliminary adjustment of ACC sensor (1). If necessary, carry out preliminary adjustment
at retaining pins (2). Measurement A: 43 0.5 mm
2010 BMW M3
Fig. 31: Identifying Retaining Pins
66 31 006 REMOVING AND INSTALLING (REPLACING) ACC SENSOR (SEDAN)
TRIM .
Unclip ACC sensor (2) from ACC holder (3) towards front.
Installation:
Make sure ACC sensor (2) is correctly engaged in ACC holder (3).
Fig. 32: Identifying Plug Connection And ACC Sensor From ACC Holder
2010 BMW M3
IMPORTANT: Always replace plastic nuts (1).
Turn plastic nuts (1) with a suitable tool through approx. 90 and pull towards rear out of holder (2).
Fig. 33: Turning Plastic Nuts

Check preliminary adjustment of ACC sensor (1).
If necessary, carry out preliminary adjustment at retaining pins (2).
Basic dimension A: 43 0.5 mm

Final dimension A: is adapted by means of ACC sensor adjustment
Fig. 34: Identifying Preliminary Adjustment Of ACC Sensor And Dimension

IMPORTANT: After fitting front bumper trim, check concentric position of ACC sensor eye (1)
in relation to trim (3).
2010 BMW M3
If necessary, carry out position adjustment by means of screws (2).
Tightening torque 6 Nm .
Make sure plain ACC sensor (1) can move freely.
Fig. 35: Identifying Concentric Position Of ACC Sensor Eye In Relation To Trim
Replacement:
Carry out ACC sensor adjustment using BMW diagnostic system.
66 31 100 REMOVING AND INSTALLING/REPLACING LONGITUDINAL DYNAMICS MODULE
DISCHARGE) .
Remove control unit for Car Access System . See 61 35 015 REMOVING AND INSTALLING
(REPLACING) CONTROL UNIT FOR CAR ACCESS SYSTEM .
Release bolts (1) and disconnect associated plug connection.
Remove longitudinal dynamics module (2).

2010 BMW M3
Fig. 36: Identifying Longitudinal Dynamics Module And Bolts

2010 BMW M3
ACCESSORIES AND BODY, CAB Distance Systems, Cruise Control - Service Techniques - M3
Distance Systems, Cruise Control - Service Techniques - M3
DISTANCE SYSTEM, CRUISE CONTROL

COMFORT ACCESS : E60, E61, E63, E64, E70, E81, E87, E90, E91, E92, E93
Introduction
The BMW 1-Series, 3-Series and X5 can be equipped with option 322 "Comfort Access".
This comfort system has been derived from the BMW 7-Series.
From 09/2005, Comfort Access will also be introduced to the BMW 5-Series and BMW 6-Series. The system
has been taken from the BMW 3-Series, albeit with a few modifications.
With Comfort Access, an ID transmitter is needed instead of the usual remote control. The ID transmitter also
performs standard remote control functions.
Comfort Access can be used to carry out the following functions:
Passive Entry
Opening the vehicle or luggage compartment without actively using the ID transmitter
Passive Go
Engine start without actively using the ID transmitter
Passive Exit
Closing the vehicle without actively using the ID transmitter
Comfort Access prevents an ID transmitter being disabled accidentally.
The CAS control unit is the master control unit for all functions carried out via Comfort Access. Vehicles with
Comfort Access are fitted with a CA control unit.
New or modified features on E90, E91, E92 compared to E81, E87, E93
The detection range of the interior aerials has been modified as a consequence of the different vehicle
design.
The remote control (FBD) receiver is integrated into the aerial amplifier. (E81, E87, E93: FBD receiver
integrated in interior mirror)
2010 BMW M3
The outside door handle electronics is on the reverse of the door handle mounting bracket.
The CA control unit is installed in the carrier behind the glove compartment.
Brief description of components
The following components are described for Comfort Access:
Interior and exterior aerials
Different aerials are required for communication with the ID transmitter: Interior and exterior aerials
The number of aerials depends on the model concerned:
INTERIOR AND EXTERIOR AERIALS DIFFERENCE CHART

Interior aerials E60 E61 E63 E64 E70 E81 E87 E90 E91 E92 E93
Front centre console x x x x x x x x x x x
Rear centre console x x x x x x x x x x x
Rear window shelf (parcel shelf) x - x - - - - - - - -
Back of rear seat - x - - - - - - - - -
Luggage compartment, middle x - x x - x x x x x x
Luggage compartment, right - - x x x - - - - - -
Luggage compartment, left - - - - x - - - - - -
Luggage compartment, load edge - x - - - - - - - - -
Exterior aerials E60 E61 E63 E64 E70 E81 E87 E90 E91 E92 E93
Rear bumper, left x - x x - - - - - - -
Rear bumper, middle - x - - x x x x x x x
Outside door handle electronics 4 4 2 2 4 2 2 2 2 2 2
The aerials emit 125 kHz radio signals which are evaluated by the ID transmitter.
Outside door handle electronics
The number of outside door handle electronic units depends on the model concerned (see table above).
The 3 sensors in the outside door handle electronics send the following signals to the CAS control unit
and the CA control unit:
Unlock: When a hand reaches into the handle recess via capacitive sensor 1
Unlock: When a hand pulls on the outside door handle via tension sensor (redundant to capacitive
sensor 1)
Locking and deadlocking: On contact with the sensitive area of the door handle via capacitive
sensor 2
A built-in aerial also sends radio signals in order to check for an ID transmitter located on the outside of
2010 BMW M3
the driver's door or front-passenger door.
E70, E81, E87, E90, E91, E92, E93
The outside door handle electronics are installed in the outside door handle.
E60, E61, E63, E64
The outside door handle electronics are behind the grip recess plate.
ID transmitter
The ID transmitter evaluates the signals from the aerials. It also sends high-frequency radio signals to the
FBD receiver.
Inserting the ID transmitter into the slot deactivates all Comfort Access functions.
Remote control receiver for remote control services

E64, E81, E87, E93
The remote control receiver is integrated in the interior mirror.
E60, E61, E63, E70, E90, E91, E92
The remote control receiver is integrated into the aerial amplifier.
The remote control (FBD) receiver picks up radio signals from the ID transmitter and forwards them to
the CAS control unit. The Comfort Access control unit (CA control unit) activates the FBD receiver.
CAS control unit
The CAS control unit (CAS: Car Access System) is the master control unit for all Comfort Access
functions. The CAS control unit is the interface to the START/STOP button and to the slot for the ID
transmitter. The electronic steering lock is also activated by the CAS control unit.
The CAS control unit is connected with the following components via the K-bus (sub-bus):
Outside door handle electronics (number depends on model concerned)

Comfort Access control unit (CA control unit)
Electronic steering lock
When the vehicle is idle, communication may take place on the K-bus without waking up the vehicle.
START/STOP button
The START/STOP button can be used to switch the terminals in sequence (0, R, 15, R, 0). The engine
2010 BMW M3
can be started by depressing the clutch or the brake (manual transmission/automatic transmission) and
pressing the START-STOP button.
Slot for the ID transmitter/remote control

On vehicles without Comfort Access:
In order to start the engine, the remote control must be latched in place in the slot.
On vehicles with Comfort Access:
The remote control must be inserted into the slot if the battery in the ID transmitter is discharged.
The engine can then be started up.
Inserting the ID transmitter into the slot deactivates Comfort Access.
JBE: Junction box electronics

E70, E81, E87, E90, E91, E92, E93
The junction box electronics activates the central locking system.
If the CAS control unit approves the unlocking of the vehicle, for example, the doors will be unlocked.
KGM and KBM: Body gateway module and body basic module
E60, E61, E63, E64
The body gateway module actuates the central locking in the front doors.
The body basic module controls the central locking in the rear doors.
If the CAS control unit approves the unlocking of the vehicle, for example, the doors will be unlocked.
Comfort Access control unit
The Comfort Access control unit (CA control unit) actuates the internal and exterior aerials.
An ID transmitter scan is carried out. At the same time, the FBD receiver is activated for any ID
transmitters which may respond.
System functions
Comfort Access is used to implement the following functions:
Passive Entry via driver's door or front passenger door

Passive Entry via tailgate
Passive Go
2010 BMW M3
Passive Exit
Disabling an ID transmitter located inside the vehicle
Disabling an opposing command
Tamperproof lock
Passive Entry via doors
The vehicle is unlocked when the outside door handle is gripped or pulled. Condition: The ID transmitter must
be located no further than 1.5 m from the aerial in the outside door handle.
Ideally, the user should carry the ID transmitter in a pocket.
First, the user is authenticated (= authenticity check).
The data transferred during the authenticity check is of course encrypted.
If the ID transmitter authenticity check is successful, the user will be granted access to the vehicle. The central
locking is unlocked. The door can be opened.
The same principle is applied for the authenticity check for Passive Entry and Passive Go.
Authenticity check using the example of Passive Entry
Trigger signal at outside door handle electronics via capacitive sensor 1.

Request sent to outside door handle electronics to locate an ID transmitter via the aerials in the outside
door handle. All ID transmitters associated with the vehicle and located outside of it are included in the
search (low-frequency radio signal at 125 kHz).
The search determines whether an ID transmitter associated with the vehicle is located in the operating
range of the aerials in the outside door handle.
At the same time, the outside door handle electronics send a message to the CAS control unit via the sub
bus (K-bus).
All ID transmitters located register with the CAS control unit by sending a radio signal via the FBD
receiver (high-frequency radio signal, country-specific, e.g. 868 MHz).
The CAS control unit decides which of the registered ID transmitters will be used for the subsequent
authenticity check.
This selection is sent to the outside door handle electronics in a message via the K-bus. At the same time,
a request is sent to the outside door handle electronics to carry out a selective scan of the ID transmitter
concerned.
All ID transmitters not picked up in this scan end reception readiness for the communication operation
currently in progress.
The ID transmitter picked up via the selective scan responds by sending a radio signal to the CAS control
unit via the FBD receiver (high-frequency radio signal at 868 MHz).
2010 BMW M3
The CAS control unit evaluates the response signal and, if confirmation is valid, authorizes Passive Entry.
The vehicle is unlocked.
In order that the vehicle can be opened quickly, the door lock is mechanically pretensioned with a spring.
The spring ensures that the door unlocks whenever the user pulls the outside door handle to its full extent.
The tension sensor is set up with redundancy to the capacitive sensor (e.g. capacitive sensor 1 deactivated
due to long-term lack of use).
When the tension sensor detects the "Outside door handle pulled" signal, the door is unlocked. The door
can be opened by pulling on the outside door handle again.
Passive Entry via the tailgate or front rear window
Comfort Access can be used to open the tailgate without actively using the ID transmitter. Condition: The ID
transmitter must be located no further than 1.5 m from the aerial. Ideally, the user should carry the ID
transmitter in a pocket.
To open the tailgate, it is necessary to press and hold the tailgate button for approximately 500 ms (top half of
BMW logo on the E81, E87, grip on all other vehicles). If an ID transmitter is located in the vicinity of the
luggage compartment, the tailgate will open.
If an ID transmitter is located inside the luggage compartment when the tailgate is closed (and there are no
authorized ID sensors outside the vehicle), the tailgate will open up again.
The user's attention is drawn to the anti-theft alarm as follows:
Visual signal via turn signal lights

Acoustic signal via siren, US version only
E61, E91: rear window
To open the rear window, the rear window button must be pressed for approx. 500 ms (under the rear window
wiper arm).
If an ID transmitter is located in the vicinity of the rear of the vehicle, the rear window will open.
If an ID transmitter is located inside the luggage compartment when the rear window is closed (and there are no
authorized ID sensors outside the vehicle), the rear window will open again.
The user's attention is drawn to this as follows: Visual signal via indicators and acoustic signal via sirens (on
anti-theft alarm system).
Passive Go
In order to switch the terminal and/or start up the engine, the ID transmitter must simply be located inside the
2010 BMW M3
vehicle (not necessarily in the slot).
On the following models, the luggage compartment counts as part of the interior: E61, E70, E81, E87, E91.
On all other models, it is not possible to start the engine if an ID transmitter is detected in the luggage
compartment.
In principle, the authenticity check required is the same as that for Passive Entry (except that it is run via the
interior aerials).
If there are no ID transmitters inside the vehicle when the START-STOP button is pressed: Check-Control
message on instrument cluster.
Press the START/STOP button to switch the terminals. The terminal switching sequence is as follows: 0 ->
terminal R -> terminal 15 -> terminal R -> 0.
The START/STOP button must be pressed for approximately 500 ms in order to start up the engine. The clutch
pedal or brake pedal (manual transmission or automatic transmission respectively) must be depressed at the
same time.
The engine may be started up in any terminal position.
Once the engine has been switched off, it may be restarted within 5 seconds even if no ID transmitter is detected
inside the vehicle (i.e. no valid drive authorization). This safety measure is required for possible emergencies.
Passive Exit
The sensitive area on the outside door handle must be touched (depends on model concerned) for the vehicle to
be locked and then secured. Your hand must touch the middle of the sensitive area for at least 1 second.
If the locking area is touched for approx. 3 seconds, auto-remote closing will start. The side windows and
sliding/tilting sunroof or Panorama glass sunroof on the E61/E91 then close. On the E64, the convertible top
closes. If applicable, the exterior mirrors are folded in.
Auto-remote opening via the outside door handle is not possible.
Terminal R is deactivated when the outside door handle is locked.
Terminal 15 is not deactivated when the vehicle is locked. A Check-Control message appears as a warning
when the driver's door is opened with terminal 15 ON.
Special feature: Comfort Access allows the vehicle to be locked whilst the engine is running.
E93
NOTE: No convenience closing of the hardtop via the exterior door handle electronics.
2010 BMW M3
It is not possible to close the hardtop via the exterior door handle electronics. Convenience closing is performed
at the lock cylinder.
Disabling an ID transmitter located inside the vehicle
When the vehicle is closed via the outside door handle, any ID transmitter inside the vehicle will be detected.
This ID transmitter is disabled for all Comfort Access functions. However, it is still possible to access the
luggage compartment. The ID transmitter is reactivated when the vehicle is unlocked again.
Disabling an opposing command
When the vehicle is unlocked via the outside door handle, it cannot be locked again for approx. 2 seconds.
Similarly, when the vehicle is locked via the outside door handle, it cannot be unlocked again for approximately
2 seconds.
This allows the user to pull on the outside door handle to check that the vehicle is actually locked.
Tamperproof lock
The vehicle may only be locked and unlocked consecutively a maximum of 8 times. After this, the tamperproof
lock is activated.
Operation is disabled for 10 seconds. The tamperproof lock is deactivated completely after 5 minutes. Once
again, the vehicle may then only be locked and unlocked consecutively a maximum of 8 times.
National versions
The following details are available with regard to national versions:
E93
Convenience functions performed using the remote control or ID transmitter depend on the national version
concerned.
Conditions for operating Comfort Access (option 322) with the remote control or ID transmitter
COMFORT ACCESS CHART

without option 322 (Comfort
with option 322 (Comfort Access)
Access)
Roof OPEN: possible with remote Roof OPEN: even if the ID transmitter is more
control than 4 metres away
EURO and rest Roof CLOSED: only if the ID transmitter is
Convenience function for loading and
of worlds less than 4 metres away
unloading: possible with remote
control Convenience function for loading and
unloading: even if the ID transmitter is more
2010 BMW M3
than 4 metres away

Roof OPEN: only if the ID transmitter is less
than 4 metres away
Roof CLOSED: only if the ID transmitter is
USA/Canada - (not encoded) less than 4 metres away
Convenience function for loading and
unloading: only if the ID transmitter is less
than 4 metres away
PARK DISTANCE CONTROL : E70, E87, E90, E91, E92, E93, R56
Fig. 1: Identifying Park Distance Control

Introduction
Park Distance Control (PDC) is an item of special equipment. Park Distance Control (i.e.: parking aid) assists
the driver when he is parking and maneuvering in tight spaces. This means that even small parking spaces can
be used. At the same time, parking damage is reduced.
PDC uses ultrasonic sensors to measure the distance to objects within the effective range.
PDC is available in the following versions:
Option 507: Park Distance Control (PDC), rear

Option 508: Park Distance Control (PDC), front and rear
2010 BMW M3
The PDC button in the center console switch cluster is only provided with option 508.
Compared to earlier systems, PDC has the following new features:
Modified ultrasonic sensor with decoupling element on sensor housing

Increased range for ultrasonic sensor: 2.5 meters front and rear
Good detection of obstacles while remaining insensitive to echo pulses from the ground
The driver is warned of an object that could cause a collision as follows:
Acoustic warning via (depends on equipment fitted):

E70
Mid-range loudspeakers with Multimedia Platform (CHAMP), Multi-audio system controller

(M-ASK) or Car Communication Computer (CCC)
E87, E90, E91, E92, E93
2 acoustic generators (1 front, 1 rear) with radio without audio system
Mid-range loudspeaker with BMW "Professional" radio, multi-audio system controller or Car
Communication Computer
R56
1 acoustic generators (rear) with Radio Wave
Mid-range loudspeaker with Radio Wave CD, Radio Boost CD or Car Communication
Computer
Visual warning by PDC image with multi-audio system controller and Car Communication Computer
The visual warning function in particular enables PDC to provide assistance for drivers who are hard of hearing
or have restricted mobility.
The visual warning has additional benefits if the noise level inside the vehicle is very high (e.g. loud music).
IMPORTANT: The driver remains responsible at all times
PDC is not a substitute for the driver's personal judgement with respect to obstacles.
The ultrasonic sensors also have a "blind spot". In this blind spot, objects can no longer be detected.
The detection of objects can test the physical limits of ultrasonic measurements if the ultrasonic waves are
reflected either poorly or not at all (e.g. due to trailer tow bars or narrow objects).
Objects close to the ground can suddenly "disappear", before a continuous tone sounds (e.g. a high curbstone).
Loud noises outside and inside the vehicle can drown out the PDC signal tone.
It therefore remains the driver's responsibility to watch for obstacles, even in vehicles with PDC.
2010 BMW M3
PDC consists of the following components:
Ultrasonic sensors
E70
8 ultrasonic sensors with option 508: Park Distance Control (PDC), front and rear
E87, E90, E91, E92, E93
4 ultrasonic sensors with option 507: Park Distance Control (PDC), rear
8 ultrasonic sensors with option 508: Park Distance Control (PDC), front and rear
R56
4 ultrasonic sensors with option 507: Park Distance Control (PDC), rear
There are 4 ultrasonic sensors in each of the front and rear bumpers.
The ultrasonic sensors emit ultrasonic pulses. These ultrasonic pulses are reflected by obstacles (echo
pulses).
The ultrasonic sensors receive and amplify these echo pulses. The amplified echo pulses are then
converted into a digital signal. Each ultrasonic sensor has its own electronics, its own power supply and
its own data connection to the PDC control unit.
IMPORTANT: Measuring range of ultrasonic sensors
The measuring range of the ultrasonic sensors is between approx. 25 centimeters and a maximum of approx.
250 centimeters. A continuous warning tone sounds when the distance is less than about 25 centimeters.
Dirty sensors, moisture, ice and snow can also cause the continuous warning tone to sound.
NOTE: Cleaning the ultrasonic sensors
To make sure the system remains fully operational, keep the ultrasonic sensors clean and free from ice. Do not
clean by spraying high-pressure washers directly at the ultrasonic sensors. When cleaning, always maintain a
minimum distance of at least 10 centimeters.
NOTE: Make sure the decoupling element on ultrasonic sensor is correctly located.
The respective decoupling element must be correctly located. Otherwise, transmission and reception will be
impaired.
2010 BMW M3
PDC button
E70, E87, E90, E91, E92, E93
The PDC button is integrated in the center console switch cluster (no control unit). The signal from the
PDC button is read by the IHKA (or IHKR/IHR control unit) control unit. In turn, the IHKA control unit
sends a signal on the K-CAN.
The PDC button is used to manually switch the Park Distance Control system on and off. When the PDC
is switched on, the function LED in the PDC button lights up.
If a fault develops in the PDC, the function LED in the PDC button flashes.
PDC control unit
The PDC control unit controls the ultrasonic sensors for transmitting ultrasonic pulses. The PDC control
unit also receives the digital signals from the individual ultrasonic sensors. From the individual digital
signals, the PDC control unit calculates the minimum distance between the ultrasonic sensor and the
object.
When an object is detected, an acoustic warning and a visual warning are given.
The PDC control unit is connected to various other control units via the bus system:
RAD2, CHAMP, M-ASK or CCC: BMW "Professional" radio, Multimedia Platform, multi-audio
system controller or Car Communication Computer
E70, E87, E90, E91, E92, E93
Depending on the equipment fitted, the audio master emits acoustic PDC warnings via the mid-range
loudspeaker.
Radio Wave CD, Radio Boost CD or CCC: Radio Wave CD, Radio Boost CD or Car
Communication Computer
R56
Depending on the equipment fitted, the audio master emits acoustic PDC warnings via the mid-range
loudspeaker.
CID: Central Information Display

E70, E87, E90, E91, E92, E93
The visual PDC warnings are given in the Central Information Display (CID).
In addition, information regarding a Check-Control message that may be present is shown.
KOMBI: Instrument cluster

2010 BMW M3
E70, E87, E90, E91, E92, E93
A current Check-Control message is indicated by a symbol in the LCD display in the instrument cluster.
Moreover, the instrument cluster also provides the exterior temperature and the kilometer reading for the
PDC control unit.
The PDC control unit is then able to correct the calculated distance with a factor corresponding to the
outside temperature.
KOMBI and CID: Instrument cluster and Central Information Display

R56
The instrument cluster has two section. The instrument cluster itself is in the middle of the dashboard.
The auxiliary instrument is on the steering column.
The KOMBI and the CID are both control units. These control units are plugged into one another an
installed together in the dashboard.
All equipment versions are connected to the auxiliary instrument via a K-bus.
The auxiliary instrument is the gateway to the K-CAN.
A current Check-Control message is indicated by a symbol in the LCD display in the auxiliary
instrument.
The instrument cluster provides the exterior temperature and the kilometer reading for the PDC control
unit. The PDC control unit is then able to correct the calculated distance with a factor corresponding to
the outside temperature.
EGS: Electronic transmission control
On vehicles with automatic transmission, the electronic transmission control (ESG) supplies the signal
that reverse gear is engaged.
The PDC control unit activates PDC after a short delay (approx. 1 second).
This prevents PDC from being unexpectedly activated on vehicles with automatic transmission, fro
example when the selector lever is moved from "P" to "N" via "R".
DSC: Dynamic Stability Control
The DSC control unit supplies the PDC with information about the road speed and distance travelled.
FRM: Footwell module
On vehicles with manual transmission, the footwell module (FRM) supplies the signal that reverse gear is
2010 BMW M3
engaged.
CAS: Car access system
The CAS control unit supplies the PDC with the terminal status (e.g. terminal 15).
AHM: Trailer module
The trailer module (AHM) sends a signal indicating whether the vehicle is towing a trailer or if a rear
carrier rack is fitted. If a trailer or rear carrier rack is recognized, the acoustic and visual warnings for the
rear bumper are deactivated.
System functions
PDC incorporates the following functions:
Acoustic warnings
Visual warning with multi-audio system controller and Car Communication Computer
Check Control
System limits
Acoustic warnings
The acoustic warnings are emitted by:
E70
Mid-range loudspeaker with CHAMP, M-ASK or CCC
If an object is detected by 2 ultrasonic sensors, the loudspeaker closest to the object is actuated. The
mid-range loudspeakers can be actuated.
(depending on the model concerned, the mid-range loudspeakers in the left/right front doors or
left/right rear doors are actuated, for example)
If an object is detected by the central ultrasonic sensors, the mid-range loudspeakers on the left and
right-hand sides are actuated together.
E87, E90, E91, E92, E93

2 acoustic generators (1 front, 1 rear) with radio without audio system
The PDC control unit directly actuates the acoustic generators (front/rear in vehicle interior).
Within the acoustic generator, the control signal is transformed to approx. 48 volts. This voltage
excites a piezoceramic element that together with the resonator (housing) generates a warning tone.
Up to 09/2006, the tone is in the frequency range of approximately 1 kHz.

2010 BMW M3
From 09/2006 the tone is in the frequency range of approximately 1.5 kHz (front) or 1.0 kHz (rear).
Mid-range loudspeaker with RAD 2, M-ASK or CCC
If an object is detected by 2 ultrasonic sensors, the loudspeaker closest to the object is actuated.
The mid-range loudspeakers can be actuated.
(e.g. the mid-range loudspeakers in the front doors, left/right, in the rear shelf, left/right, in the rear
doors, left/right, in the rear shelf, left/right or in the rear side trim, left/right are actuated, depending
on the vehicle model.)
R56
1 acoustic generator (rear) with Radio Wave
The PDC control unit directly actuates the acoustic generators (in rear of vehicle interior). Within
the acoustic generator, the control signal is transformed to approx. 48 volts. This voltage excites a
piezoceramic element that together with the resonator (housing) generates a warning tone. The tone
is in the frequency range of approximately 1 kHz.
Mid-range loudspeakers with Radio Wave CD, Radio Boost CD or CCC
If an object is detected by 2 ultrasonic sensors, the loudspeaker closest to the object is actuated. The
midrange loudspeaker on the left/right can be actuated.
The distance to the object determines the tone sequence for the acoustic warning (the smaller the distance, the
faster the tone sequence).
A distance of less than approx. 25 centimeters is indicated by a continuous tone. The continuous tone is emitted
alternately from the front and the rear.
If the vehicle moves away from the object, the warning tone will be cancelled when the distance increases by
more than 10 centimeters.
Effective range for acoustic warnings:
approx. 60 centimeters for the ultrasonic sensors at the two corners of the front bumper
approx. 70 centimeters for the two middle ultrasonic sensors in the front bumper
approx. 60 centimeters for the ultrasonic sensors at the two corners of the rear bumper
approx. 150 centimeters for the two middle ultrasonic sensors in the rear bumper
2010 BMW M3
Optical warning with multimedia platform or multi audio system controller or Car Communication Computer
The visual PDC warnings are given in the Central Information Display (CID). This is subject to the PDC
display in the CID being active.
The visual warnings are given earlier than the acoustic warnings.
The effective range is approx. 2.5 meters at the front and rear.
The graphic display is shown on the CID. The PDC control unit supplies the distance between the ultrasonic
sensor and the object detected via the K-CAN.
The PDC display on the CID is an overhead view of the vehicle with the effective range of the ultrasonic
sensors.
The distance to objects detected is shown in the colors of traffic lights:
Distance between 200 (250) and 101 centimeters: green

Distance between 100 an 51 centimeters: yellow
Distance less than 50 centimeters: Red
The PDC display appears as soon as the PDC is switched on (manually or automatically). The PDC display
overrides other displays in the CID. When the PDC is switched off again, the previous display automatically
appears again in the Central Information Display.
Check Control
If a fault should develop in the PDC, the function LED in the PDC button will flash with a frequency of 2 Hz.
In this situation, PDC cannot be switched on.
At the same time, a Check-Control message is displayed in the following form
Symbol in the LCD display in the instrument cluster

The following text appears in the status line of the Central Information Display:
"PDC failure!"
In the menu "BMW Service", the following text can be called up in the submenu "Check-Control
messages":
"Park Distance Control
No acoustic warning available for Park Distance Control PDC.
Have the problem checked by BMW Service as soon as possible."

2010 BMW M3
If a fault memory entry is recorded, the kilometer reading and the outside temperature are recorded along with
the type of fault.
System limits
IMPORTANT: The driver remains responsible at all times
PDC is not a substitute for the driver's personal judgement with respect to obstacles.
The ultrasonic sensors also have a "blind spot". In this blind spot, objects can no longer be detected.
The detection of objects can test the physical limits of ultrasonic measurements if the ultrasonic waves are
reflected either poorly or not at all (e.g. due to trailer tow bars or narrow objects).
Objects close to the ground can suddenly "disappear", before a continuous tone sounds (e.g. a high curbstone).
Loud noises outside and inside the vehicle can drown out the PDC signal tone.
It therefore remains the driver's responsibility to watch for obstacles, even in vehicles with PDC.
During operation, the following system functions, which require explanation, can occur due to the limits of the
functional range (for the driver):
Under the following conditions, it could happen that the PDC gives a warning, even though there is no
obstacle within the effective range:
Ultrasonic sensor incorrectly located in its bracket
Heavy rainfall
Ultrasonic sensors covered in snow
Exhaust gases
Echo pulses caused by ground, e.g. extremely coarse road surface or high grass
Very smooth walls in large, enclosed, rectangular spaces, e.g. in underground car parks
(interference from previously reflected echo pulses)
Protective cap for trailer coupling ball head incorrectly seated or objects being transported
protruding into the effective range of the ultrasonic sensors.
Under the following conditions, the PDC may not recognize an obstacle that is present:
Objects close to the ground (no reflection)
Objects with corners and sharp edges (no reflection)
If you drive alongside a wall for more than 3 seconds, the acoustic warning will be deactivated.
Here, the distance must be greater than the effective range for the continuous tone (approx. 25
centimeters). As soon as the distance drops below 25 centimeters, the continuous tone will sound
again.
If the vehicle approaches an object too fast
Starting up and moving away too quickly while PDC is starting

2010 BMW M3
Conditions for switching on and off
PDC is switched on under the following conditions:
PDC button pressed (PDC switched on manually), option 508 only

Reverse gear engaged (PDC switched on automatically)
PDC is switched off under the following conditions:
Reverse gear disengaged, option 507 only

PDC button pressed (PDC switched off manually), option 508 only
Ignition switched off (PDC switched off automatically
After driving approx. 50 meters
After exceeding a speed of 30 km/h
When towing a trailer or driving with a rear carrier rack, the acoustic and visual warnings for the rear bumper
are deactivated by the trailer module (AHM).
The trailer or rear carrier rack must be electrically connected.
Operation
The visual warning (PDC display) is switched on in the Central Information Display (CID) as follows:
"Settings (i)" menu

"Vehicle settings" menu
"PDC" menu
Activate "Display on"
CRUISE CONTROL : E90, E91, E92, E93

2010 BMW M3
Fig. 2: Identifying Cruise Control

Introduction
The following cruise controls are available at the start of series production of the E90 (12/2004):
Option 540 "Cruise control"
The set speed is maintained via the engine. (Set speed = stored desired speed)
Accelerating to the set speed: Engine intervention via the DME/DDE (DME = "digital engine
electronics"; DDE = "digital diesel electronics")
Decelerating to the set speed: Via the engine drag-torque
Option 541 "Active Cruise Control"
With Active Cruise Control, a timed separation is maintained from the vehicle ahead. The separation can
be adjusted.
Accelerating to the set speed: Engine intervention via the DME/DDE

Decelerating to the set speed: Brake intervention via the DSC (Dynamic Stability Control)
Option 544 "Cruise control with brake function"

2010 BMW M3
The set speed is maintained via engine and brake intervention.
Accelerating to the set speed: Engine intervention via the DME/DDE

Decelerating to the set speed: Brake intervention via the DSC
IMPORTANT: Cruise control does not relieve the driver of his personal responsibility.
Cruise control is a comfort system. Adjustments by the driver will always have a higher priority (= importance)
than cruise control.
The driver should decide whether (and how) the system is used based on road and traffic conditions and
visibility.
With the start of series production of the E90, longitudinal dynamics management (LDM) will also be
introduced. Longitudinal dynamics management consists of various function blocks (e.g.: Cruise control with
brake function or Active Cruise Control option). These function blocks are grouped together into a control unit
by the corresponding software. The control unit is called the LDM control unit.
The LDM control unit evaluates all relevant data for cruise control. (e.g.: The ACC sensor sends the
information "Vehicle monitored". This information is evaluated in the LDM control unit).
E92 from 06/2006 and
E90, E91 from 09/2006 and
E93 from 12/2006
The LDM control unit is no longer fitted on vehicles with option 544 "Cruise control with brake
function". Because of a software modification in the DSC control unit (DSC Mk60E5), the DSC control
unit assumes control of the functions of the LDM control unit.
In this SI Technology (SBT) bulletin, only longitudinal dynamic management and thus the Cruise control with
brake function or Active Cruise Control option is described.
Longitudinal dynamics management is available in connection with the following option (special equipment):
or

E90, E91 from 09/2006 and
E93 from 12/2006

2010 BMW M3
function". Because of a software modification in the DSC control unit (DSC Mk60E5), the DSC
control unit assumes control of the functions of the LDM control unit.
The 2nd generation Active Cruise Control option will be used for the first time with the E63/E64 from 09/2004.
Active Cruise Control is a comfortable spacing and cruise control.
The distance from the vehicle ahead can be selected from 4 fixed timed separations. (EURO version: 1.0 - 1.5 -
2.0 - 2.5 seconds)
This means that the as speed changes, so does the distance to the vehicle ahead.
The legally prescribed minimum distance is not undershot when control is active.
Differences between option "Active Cruise Control" on E90, E91, E92, E93 and option "Active Cruise Control"
on E60, E61, E63, E64, E65, E66:
On the E90, E91, E92 (including all-wheel drive) and E93, the data for the longitudinal dynamic
management are evaluated in the LDM control unit.
On the E60, E61, E63, E64, E65, E66, the data for the longitudinal dynamic management are evaluated in
the ACC control unit (i.e.: there is no LDM control unit fitted).
Differences between "cruise control with brake function" and "cruise control":
Constant roadspeed, even downhill:
The set speed is also maintained when going downhill. (Brake intervention via the DSC)
The lateral acceleration in bends is restricted to a comfortable level.

Indicator disc in the instrument cluster:
The indicator disc shows the set speed.
Brief display in the LCD display of the instrument cluster:
The newly selected set speed is shown briefly in the LCD display.
The following components send signals for the cruise control:
Cruise-control system steering-column stalk

2010 BMW M3
Cruise control is set and called up using the cruise control system steering-column stalk.
ACC sensor
The ACC sensor monitors the distance, angle and relative speed of vehicles driving ahead. (Relative
speed: The relative speed is the speed difference between the two moving objects, that is, the speed
difference of the two objects relative to each other.)
The ACC sensor is a radar sensor. The ACC sensor has a limited monitoring range (approx. 120 meters).
LDM control unit
The LDM control unit is the interface to the engine and to the brakes.
In the LDM control unit, the driver's entries regarding the cruise control system are monitored and
evaluated.
The "cruise control with brake function" option is integrated in the LDM control unit.
E90, E91 from 09/2006 and
E93 from 12/2006
If Active Cruise Control is fitted, the LDM control unit evaluates the data sent from the ACC sensor.
The LDM also communicates with the following control units:
Instrument cluster
The instrument cluster shows all displays for cruise control.
An indicator disc in the round instrument shows the set speed.

The LCD display briefly shows the newly selected set speed (approximately 6 seconds).
In addition, the LCD display also shows a Check-Control message.
With Active Cruise Control, there are also the following displays:
Monitored vehicle
(Display through lit icon in the instrument cluster)

2010 BMW M3
Request for action to driver
(Display through flashing icon in the instrument cluster. Depending on the national version, an
acoustic warning is also made.)
Selected distance from vehicle driving ahead
(Display via icon in the instrument cluster)
The current status of the vehicle is detected by the DSC, e.g. by evaluating the following sensor signals:
Rate of yaw (measure of movement of the car about its vertical axis)
Steering angle
Information on the brake pressure
Circumferential wheel speed
The DSC then transmits data about the current vehicle status to the LDM.
The following data is transmitted by the LDM to the DSC:
Request for vehicle deceleration
The request for vehicle deceleration from the LDM is received by the DSC via the PT-CAN. DSC
reduces the speed. To do this, DSC intervenes in the brake system. (goal: comfortable vehicle
deceleration. No DSC intervention in the sense of enhanced operating stability.)
E90, E91 from 09/2006 and
E93 from 12/2006
The LDM control unit is no longer fitted on vehicles with option 544 "Cruise control with
brake function". Because of a software modification in the DSC control unit (DSC Mk60E5),
the DSC control unit assumes control of the functions of the LDM control unit.
With automatic braking, the brake lights are activated depending on vehicle deceleration (legally
prescribed).
DME or DDE: Digital engine electronics or digital diesel electronics
The DME/DDE controls the engine intervention. The following data is transmitted by the LDM to the
DME or DDE:
2010 BMW M3
Current torque request
The following data is transmitted to the LDM from the DME or the DDE:
Driver's command (signals from accelerator pedal module)

E90, E91 from 09/2006 and
E93 from 12/2006
JBE: Junction box electronics
The JBE is the data interface (= gateway) between the K-CAN and the PT-CAN.
(K-CAN = body CAN; PT-CAN = powertrain CAN.)
Signals from the F-CAN (Chassis CAN) are simply looped through. (No signal processing in the JBE.
The F-CAN cables are simply routed through the junction box housing.)
The junction box consists of the junction box electronics and the electrical distribution center.
The diagnosis cable is connected to the junction-box electronics.
FPM: Accelerator pedal module
The accelerator pedal module signals the driver's command. This signal is required to check the
respective driving status. (evaluation via DME/DDE)
By pressing the accelerator pedal, the specified speed of the cruise control can be overridden at any time.
Brake light switch
The brake light switch tells the cruise control system when the brake pedal has been pressed. Cruise
control is deactivated if braking actions are necessary.
Clutch mode (manual transmission only)
Clutch engagement/disengagement is recognized by the signal from the clutch module.
During the clutch engagement/disengagement process, the engine speed is maintained at an optimal speed
range by the DME or DDE.
2010 BMW M3
After the clutch has been reengaged, the DME/DDE will adjust back to the current torque request from
the Active Cruise Control.
If the engine speed is too high or too low, an audible signal and a Check-Control message prompt the
driver to change gear. The prompt to upshift when the engine speed is too high is only made during the
warm-up phase of the engine.
IMPORTANT: Only install prescribed rear differential unit.
Active Cruise Control has a variant encoding which is coordinated with the differential ratio. If a different rear
differential unit is installed, it may be the case that Active Cruise Control will deactivate itself in manual
transmissions, particularly in the higher gears. In this case, no fault is entered in the fault memory.
EGS: Electronic transmission control
The evaluated cruise control data is sent from the LDM control unit to the DME or DDE. The EGS
evaluates the data from the DME or DDE.
The adaptive transmission control (constituent component of electronic transmission control) adapts the
shift characteristics of the driving programme to the driver's commands and the driving situation.
SZL: Steering column switch cluster
The SZL processes all data from the cruise-control system steering-column stalk.
The evaluated switch signals are sent by the SZL through the F-CAN to the LDM control unit.
Signal path:
Cruise control system steering-column stalk -> SZL -> F-CAN -> DSC control unit (acts as a gateway) ->
PT-CAN -> LDM control unit
E90, E91 from 09/2006 and
E93 from 12/2006
When cruise control is in operation, the brake lights are actuated during automatic braking (legal
requirement). To this end, a signal must be sent from the DSC to the footwell module via the PT-CAN.
2010 BMW M3
The option "Active Cruise Control" uses the "turn signals" signal from the footwell module for assistance
when changing lanes. In other words, if a left turn signal is given before overtaking, the distance to the
vehicle in front is reduced. The vehicle to be overtaken is "ignored" more easily. Conversely, in the event
of a change to the right-hand lane, a vehicle driving there is registered more quickly.
With the vehicle's own calculated expected lane, the sideways deviation of each monitored object can be
determined for the vehicle's own lane.
M-ASK or CCC and CID: Multi-audio system controller/Car Communication Computer and
Central Information Display
For the instrument cluster, the M-ASK or CCC serves as the interface to the CID. Amongst other things,
the CID displays detailed information about the Check-Control messages. To back up the Check-Control
message, the MASK /CCC emit audible warnings through the loudspeakers (depending on national
version). The instrument cluster controls these warnings by means of the K-CAN.
System functions
The system functions of "cruise control with brake function" and "Active Cruise Control" are described below.
Option "Cruise control with brake function"
Cruise control
Cruise control has the following subfunctions:
Cruise control system

Limited lateral acceleration when cornering (up to max. 4.0 m/s2)
Depending on the driving situation, the LDM control unit reports to the DME or DDE or the DSC as
follows:
DME or DDE: Accelerate

DSC: Brake
E90, E91 from 09/2006 and
E93 from 12/2006
Option "Active Cruise Control"

2010 BMW M3
Cruise control
Lens heating
Low-voltage cutout and high-voltage protection for ACC sensor
Self-diagnosis and compensation for minor horizontal adjustments
System limits
Monitor object ahead
Objects are all vehicles in the same lane. The vehicles on other lanes are of no interest for Active Cruise
Control.
In the same lane, the vehicle immediately ahead is selected as the object.
With the calculated expected same lane, the lateral deviation of each monitored object to the same lane can be
determined.
The radar waves received cannot distinguish between animals, vehicles and traffic signs. In order to prevent
incorrect reactions, stationary objects and traffic in the other direction are ignored in the distance control.
Cruise control
Active Cruise Control differentiates between 2 driving conditions:
Cruise control with specified set speed
A selected set speed (in the range 30 km/h - 180 km/h) is automatically maintained on open roads without
vehicles driving ahead.
Cruise control with speed adapted to that of vehicle driving ahead
If a slower vehicle is detected on the vehicle's own track, the vehicle's own speed will be adapted to that
of the vehicle driving ahead
At the same time, a distance from this vehicle preset by the driver is established (4 fixed timed
separations can be selected).
The timed separation from a vehicle driving ahead is no less than 1 second under stationary conditions. In
certain conditions (e.g. when a vehicle cuts in a short distance ahead), this timed separation may briefly
be less than 1 second.
Lens heating
The lens of the ACC sensor is made of plastic. The built-in lens heating ensures better availability of Active
Cruise Control in winter weather conditions.
The lens heating is activated by the ACC sensor. The heating is controlled via a pulse-width modulated signal
2010 BMW M3
(PWM signal). The heating coil is integrated into the lens of the ACC sensor
The lens heating is only activated within a certain ambient temperature range (approx. +5 C to -5 C). Reason:
Only at temperatures around zero is snow wet or moist. At temperatures well below this, snow will be dry. To
prevent snow from thawing on the lens and creating an artificial coating, the heating is switched off below a
certain ambient temperature. The current ambient temperature value is transmitted by the instrument cluster.
Conditions required for switch-on

Engine ON
ACC ON
Ambient temperature between -5 C and +5C
Safety cutout
Temperature in ACC sensor over 50 C
(measured by interior temperature sensor in ACC sensor control unit)
Voltage greater than 16 volts
The safety cutout shuts down the lens heating. Active Cruise Control remains activated. (No fault
memory entry)
Monitoring
The lens heating is monitored for open and short circuits in the heating coil.
If the monitoring reports a fault, Active Cruise Control will be shut down. (Fault memory entry)
Low-voltage cutout and high-voltage protection for ACC sensor
The ACC sensor works with a supply voltage of 9 to 16 volts.
Low-voltage cutout
If the on-board supply voltage drops below about 9 volts, the ACC sensor will perform a low-voltage
cutout and a fault memory entry will be stored.
The ACC sensor will be reactivated when the on-board supply voltage exceeds 9.8 volts again.
Overvoltage protection
If the on-board supply voltage exceeds about 17.5 volts, the ACC sensor will perform a cutout with a
fault memory entry.
The ACC sensor will be reactivated when the on-board supply voltage drops below 17.0 volts again.
Self-diagnosis and compensation for minor horizontal adjustments

2010 BMW M3
External forces may change the alignment of the ACC sensor. A horizontal change leads to function limitations.
(Function limitations encountered are, e.g.: reaction to vehicles in the next lane or late reaction to vehicles in the
same lane).
Self-diagnosis allows the ACC sensor to compensate for minor horizontal adjustments of up to 1.
If a horizontal adjustment of more than 1 is detected, Active Cruise Control will be deactivated and a fault will
be stored in the fault memory. A Check-Control message will be issued.
System limits
If the limit of the functional range is reached, the driver is prompted to act (brake or swerve) as follows: Display
for the monitored vehicle flashes red and an acoustic signal sounds.
During operation, the following system functions, which require explanation, can occur due to the limits of the
functional range (for the driver):
Limited range and deceleration

The range of the ACC sensor is limited (approximately 120 meters).
Rain, snow and fog absorb radar waves.
This will significantly reduce the range of the ACC sensor.
Active Cruise Control is only able to effect limited deceleration via the DSC (a maximum of 2.5
m/s2)
This means that cruise control is only able to compensate for a limited relative speed.
Active Cruise Control operation is only possible in flowing traffic in a road speed range from 30 km/h to
180 km/h.
Lateral monitoring range
The lateral monitoring range of the ACC sensor is limited, meaning that a monitored vehicle ahead could
be lost due to a tight bend.
In such cases, cruise control will not accelerate to the set speed for approximately 2 seconds. This will
prevent the vehicle from accelerating too close to the vehicle ahead, which is possibly only briefly not
being monitored.
When driving straight ahead, this can cause a delayed reaction to another vehicle cutting in close in front.
The vehicle cutting in will not be monitored by the cruise control until it is clearly in the same lane as the
vehicle with Active Cruise Control.
Display for monitored vehicle does not light up, the vehicle remains below the set speed and does
not accelerate further
2010 BMW M3
Causes:
On sharp bends, the vehicle's speed will be controlled in such a way that lateral acceleration does
not exceed a maximum of 4.0 m/s2 to maintain driving comfort.
Timed separation less than 1 second
The timed separation from a vehicle driving ahead is no less than 1 second when cruise control is active.
In certain conditions (e.g. when a vehicle cuts in a short distance ahead), this timed separation may briefly
be less than 1 second.
If the deceleration induced by the cruise control is not sufficient, the driver will have to intervene directly.
ACC sensor blind
If the ACC sensor is blinded, Active Cruise Control shuts down. (Blinding, e.g. due to extremely heavy
snowfall, through a layer of ice on the sensor or through dirt)
Cruise control can be reactivated after the ACC sensor has been cleaned.
Bends cannot be detected in an anticipatory manner
Active Cruise Control is unable to work in an anticipatory manner when the vehicle is cornering. It is
only able to react to existing lateral acceleration when it is already on the bend. For this reason, the driver
is responsible for ensuring that an appropriate speed is being driven as the vehicle enters the bend.
Active Cruise Control deactivated after DSC intervention or brake application by the driver
Cruise control will be deactivated following DSC intervention or a brake application by the driver. (DSC
intervention in the sense of enhanced operating stability.)
Cruise control will then have to be reactivated at the cruise control system steering-column stalk.
National versions
US and CDN national versions
Different timed separations encoded for following mode (1.5 - 1.8 - 2.2 - 2.5 seconds)
US and GB national versions
The option "Active Cruise Control" is effective in the speed range 20 mph to 110 mph.
Speed can be selected in steps of 1 mph and 5 mph.
Subject to change.
2010 BMW M3
TRANSMISSION Double Clutch Gearbox - Repair
TRANSMISSION
Double Clutch Gearbox - Repair
DOUBLE CLUTCH GEARBOX (DKG)

28 00.. CHECKING/TOPPING UP FLUID LEVEL IN TWIN-CLUTCH GEARBOX (GS7D36SG)
Checking fluid level
Call up Service functions (Drive) in BMW diagnosis system

Carry out fluid level check in accordance with instructions
IMPORTANT: On the twin-clutch gearbox a run-in check fluid change is not required at 2000
km.
Use only the approved gear oil for dual clutch transmission.
Failure to comply with this instruction will result in serious damage to the twin-
clutch gearbox.
IMPORTANT: The testing and filling procedure must be completed before the transmission
fluid temperature of 40C is reached.
If a temperature in excess of 40C is reached and no fluid has emerged, insert
the fluid adjusting screw and repeat the testing and filling procedure when it
has cooled down.
Installation:
Tighten down filler plug using
1. Hexagon wrench 8 A/F

2. Torque wrench
3. Socket 8 A/F
2010 BMW M3
Fig. 1: Identifying Filler Plug

Topping up transmission fluid after a repair
Stand vehicle on a level surface and secure against rolling off.
Open fluid adjusting screw (1). If fluid emerges, close screw again immediately
If no fluid emerges, top up until fluid emerges and close fluid adjusting screw (1) again
NOTE: If fluid has been replenished here, a further refill must be carried out
during the actual fluid adjustment
2010 BMW M3
Fig. 2: Identifying Adjusting Screw

Connect diagnosis system and start service functions (drive).

Start engine (drive position N or P)
Record transmission temperature using Tester
(Drive position P)
Permissible starting temperature < or = 32C
Idle speed: maintain at approx. 2000 RPM for 1 minute.
Open fluid adjusting screw (1)
Fill until fluid emerges
Max. transmission fluid temperature 40C
Insert screw
Installation:
Replace screw.
28 00 101 INSTALLING REPLACEMENT TRANSMISSION (GS7D36SG)
Drain gear oil at oil drain plug.
Tightening torque: see 28 00 DOUBLE CLUTCH GEARBOX .
IMPORTANT: After completion of work, program transmission control unit.
Recycling
Catch and dispose of escaping transmission fluid.
Observe country-specific waste-disposal regulations
IMPORTANT: In case of TCT N54, before installing replacement transmission, always

flush TRANSMISSION FLUID COOLER TOGETHER WITH LINES .
After completion of work, check TRANSMISSION OIL LEVEL .
Replacement transmission is supplied filled with transmission fluid.
Failure to comply with this instruction will result in serious damage to the twin-clutch gearbox.
2010 BMW M3
Remove TWIN-CLUTCH GEARBOX .
NOTE: Release screws.

Remove and convert transmission bearing block (1).
Fig. 3: Locating Bearing Block Screw

Picture shows N54.
Modify all transportation retainers.
Convert all cable holders.
Convert all seal plugs.
Convert protective cap on input shaft.
Transmission identification:

On type plate
2010 BMW M3
Fig. 4: Identifying Transportation Retainers, Cable Clips, Seal Plugs And Protective Cap
28 50 001 MANUAL EMERGENCY RELEASE OF TRANSMISSION LOCK (GS7D36SG) S65
In the event of a power supply interruption, e.g. flat battery or electrical fault, the transmission lock must be
manually released, otherwise the wheel will be locked and the vehicle cannot be moved.
IMPORTANT: Secure vehicle with appropriate means/equipment against rolling off. (e.g.
chocks, parking brake).
Press the brake pedal when manually releasing the transmission lock.
Press installation frame of gaiter (1) a little from front to rear and release gaiter from center console.
Fig. 5: Pressing Installation Frame Of Gaiter

2010 BMW M3
Insert a suitable tool in cover (1) and fold open towards front.
Fig. 6: Inserting Suitable Tool On Cover

Insert tool in lock (1) and fold towards rear.
Transmission lock is released.
Fig. 7: Inserting Tool On Lock

28 00.. OVERVIEW OF TRANSMISSION HOUSING (GS7D36SG)

2010 BMW M3
Fig. 8: Overview Of Transmission Housing (GS7D36SG)

0 General information Transmission designations, complete transmission, check fluid level, mechatronics
1. Transmission housing, front section

2. Transmission housing, rear section
3. Cooling line connection
4. Transmission connector
2010 BMW M3
5. Mechatronics module
6. Transmission interlock
7. Radial seal For output flange
8. Output flange
9. Output shaft
28 02 020 REMOVING AND INSTALLING OR REPLACING TRANSMISSION OIL SUMP

(GS7D36SG)
IMPORTANT: Remove transmission oil sump only after it has cooled down.
It is essential to adhere to conditions of absolute cleanliness.
Any dirty parts must be cleaned before the hydraulic cap is loosened.
clutch gearbox.
Recycling
Catch and dispose of escaping transmission oil.
Remove rear UNDERBODY PROTECTION
Remove oil drain plug (1).
Drain off transmission oil.

2010 BMW M3
Fig. 9: Identifying Oil Drain Plug

Unscrew all bolts.
Remove transmission oil sump (1).
Installation note:
Clean sealing ring groove with fluff-free cloth.
Fig. 10: Identifying Transmission Oil Sump With Bolts

2010 BMW M3
Installation note:
Insert screws until contact with screw heads is made.
Screw down to torque in specified sequence (1-14).
Tightening torque, see 28 00 4AZ in 28 00 DOUBLE CLUTCH GEARBOX .
28 00 001 REMOVING AND INSTALLING TWIN CLUTCH TRANSMISSION (GS7D36SG) S65
Special tools required
IMPORTANT: The specific transmission data must be read out before removing the gearbox.
Failure to comply with this instruction will result in serious damage to the twin clutch transmission.
Apply a thin coating of "MI - Setral-43N" grease to transmission input shaft!
Read out transmission data of the gearbox to be replaced with the BMW diagnosis system
Clamp off battery . See INSTRUCTIONS FOR DISCONNECTING AND CONNECTING
BATTERY or DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD
Remove both left/ right suspension cross-brace. See 51 71 345 REMOVING AND
INSTALLING/REPLACING LEFT (OR RIGHT) SUSPENSION CROSSBRACE .
Remove underbody protection . See 5147490 REMOVING AND INSTALLING/REPLACING
FRONT UNDERBODY PROTECTION or 5147491 REMOVING AND
INSTALLING/REPLACING REAR UNDERBODY PROTECTION at front and rear.
Remove REINFORCEMENT PLATE
Remove COMPLETE EXHAUST SYSTEM
Release screw (1).
Unlock and disconnect plug (2).
Release cable (3) from holders.

2010 BMW M3
Fig. 11: Identifying Cable Of Holders And Plug Screw

Release screws (1).
Remove retaining plate (2).
Fig. 12: Identifying Retaining Plate With Screws

Release screws (1).
Tightening torque, see DOUBLE CLUTCH GEARBOX - TIGHTENING TORQUES .

2010 BMW M3
Release screw (2).
Remove input speed sensor (3).
Fig. 13: Identifying Speed Sensor With Screws

Release screw (1).
Unlock retainer (2).
Release cable from lever and holder.

2010 BMW M3
Fig. 14: Identifying Retainer With Screw

Release screw (1).
Disconnect hydraulic lines (2) to transmission fluid cooler.
Close off hydraulic lines and connecting bores on thermostat with plugs.
Fig. 15: Identifying Hydraulic Lines With Screws

2010 BMW M3
Installation:
Replace sealing rings (1).
IMPORTANT: During installation:

mount O-rings (1) onto line.
wet O-rings (1) and connecting bores with transmission oil DCTF-1.
do not install dry O-rings.
Fig. 16: Identifying Sealing Rings

Supporting transmission
Support transmission with special tools 23 4 050 FIXTURE , 00 2 030 DEVICE .
Secure transmission to mounting with tensioning strap (1).
After completion of work, check transmission oil level.

2010 BMW M3
Fig. 17: Supporting Transmission Using Special Tools (23 4 050, 00 2 030)
Bolt special tool 11 9 990 DEVICE with bolt (1) to front axle support.
Bolt (2) is required to secure the engine in the correct position.
Fig. 18: Identifying Special Tool 11 9 990 With Bolt

Adjust special tool 11 9 990 DEVICE until dimension A=50 mm is obtained between front axle support and
tensioner.
2010 BMW M3
Fig. 19: Identifying Front Axle Support And Tensioner Dimension

Remove CROSSMEMBER FOR TRANSMISSION MOUNTING (S65) .
Release screw (1).
Remove transmission fluid thermostat (2).
Close off connecting bores on transmission and thermostat with plugs.
Fig. 20: Identifying Transmission Fluid Thermostat And Screw

Installation:
2010 BMW M3
Replace sealing rings.
Clean screw thread.
IMPORTANT: During installation:

mount O-rings (1) onto line.
wet O-rings (1) and connecting bores with transmission oil DCTF-1.
do not install dry O-rings.
Screw (2) must be coated with Loctite 243 prior to installation.
Fig. 21: Identifying O-Rings With Screw

Unlock and disconnect plug (1) by turning.

Do not touch pins.
Release cable from retainers.
Insert special tool 24 2 390 CAP in sealing sleeve.
Operations are described in:
NOTES ON MECHATRONICS
IMPORTANT: Read and comply with important note.

2010 BMW M3
Fig. 22: Turning Plug

Installation:
Pay attention to routing and length of wiring harness.
Insert special tool 24 2 390 CAP in sealing sleeve (1).
Fig. 23: Inserting Special Tool (24 2 390) On Sealing Cup

Release screws (1).

2010 BMW M3
Tightening torque, see 28 10 HOUSING WITH ADD-ON PARTS .
Pull oil - coolant heat exchanger towards rear out of guide (2).
IMPORTANT: Guide (2) breaks if oil-coolant heat exchanger is twisted during removal.
Installation:
Oil-coolant heat exchanger and transmission oil thermostat remain on vehicle during removal of transmission.
Fig. 24: Identifying Oil - Coolant Heat Exchanger With Screws

Release wiring harness.
IMPORTANT: Do not mix up connections for monitoring sensors.
Installation:
Connection (1), monitoring sensor, left: shortened corrugated tubing (wiring visible between end of
corrugated tubing and plug housing).
2010 BMW M3
Fig. 25: Identifying Wiring Harness Connection

Connection (2), monitoring sensor, right: cable lug with designation "R", corrugated tubing closed off at
plug housing (wiring not visible).
Release screws (1) and (2).
IMPORTANT: Bolts (2) are longer than bolts (1)
Tightening torque, see 28 00 DOUBLE CLUTCH GEARBOX .
NOTE: Bolt (3) must not be released.

Bolt (3) is for securing the starter.
2010 BMW M3
Fig. 26: Identifying Starter Screws And Bolt

Installation:
Apply a thin coating of "MI-Setral-43N" grease to transmission input shaft.
BMW part number EU: 83 23 2 152 082
BMW part number USA: 83 23 2 152 081
28 00 060 REPLACING OUTPUT FLANGE RADIAL SHAFT SEAL (GS7D36SG)
IMPORTANT: It is essential to adhere to conditions of absolute cleanliness.

After completion of work, check GEARBOX OIL LEVEL .
clutch gearbox.

INSTALLING/REPLACING REAR UNDERBODY PROTECTION .
Remove heat shields
2010 BMW M3
Remove EXHAUST SYSTEM

Support transmission using universal BMW transmission take-up.
Remove CROSSMEMBER FOR TRANSMISSION MOUNTING (S65) .
Unflange propeller shaft from transmission and tie to one side

Tasks are described in removing PROPELLER SHAFT .
NOTE: To rotate propeller shaft, unlock parking lock.
Release screws.
Remove transmission bearing block (1).
Tightening torque: 22 32 2AZ .
Fig. 27: Identifying Bearing Block With Screw

Grip output flange (1) with special tool 23 0 020 HOLDER .
Release nut with special tool 23 2 320 SOCKET WRENCH INSERT .
Tightening torque: see 28 10 HOUSING WITH ADD-ON PARTS .
Installation note:
Replace nut and secure with Loctite 243.

2010 BMW M3
Fig. 28: Gripping Output Flange Using Special Tool (23 2 320)
Detach output flange (1) with special tool 33 1 150 DEVICE and adapter plate 33 1 154 from output shaft.
Fig. 29: Disconnecting Output Flange Using Special Tool (33 1 150) And Adapter Plate (33 1 154)
Attach special tool 24 2 353 to output shaft (1).
Graphic shows: Automatic transmission

2010 BMW M3
Fig. 30: Connecting Special Tool (24 2 353) To Output Shaft

Screw in special tool 24 2 351 until it is firmly connected with radial shaft seal.
Pull out radial shaft seal by screwing in special tool 24 2 352.
Fig. 31: Pulling Out Radial Shaft Seal Using Special Tool (24 2 352)
Oil sealing lip on radial shaft seal (1). Drive in radial shaft seal (1) with special tool 23 0 410 MANDREL as
far as it will go.

2010 BMW M3
Fig. 32: Applying Oil To Radial Shaft Seal Sealing Lip

28 60 000 REPLACING PRESSURE FILTER (GS7D36SG)

clutch gearbox.
Recycling

2010 BMW M3
Only on S65
Release screw (1).
Disconnect hydraulic lines (2) to transmission oil cooler.
Close off lines with plugs.
Installation note:

Secure transmission with tensioning strap (1).

2010 BMW M3
Lower engine with transmission until pressure filter lid (1) is accessible.
Remove retainer (2).
Installation note:
Replace retainer.
Fig. 35: Identifying Filter Lid And Retainer

Lever out lid (1) with sealing ring.
Installation note:
Replace lid with sealing ring.

2010 BMW M3
Lubricate sealing ring with transmission oil before installing.
IMPORTANT: Catch and dispose of escaping transmission oil.
Fig. 36: Identifying Filter Lid With Sealing Ring

Remove pressure filter (1).
Fig. 37: Identifying Pressure Filter

28 10 000 REPLACING SUCTION FILTER (GS7D36SG)

2010 BMW M3
IMPORTANT: After completion of work, check TRANSMISSION OIL LEVEL .

Recycling
Remove TRANSMISSION FLUID SUMP
Release screw (1).
Pull suction jet pump (2) out of housing.
Installation:
Moisten seals with transmission oil before installing.
Replace suction jet pump.
Fig. 38: Pulling Suction Jet Pump From Housing

2010 BMW M3
IMPORTANT: Screws have different torques.
Pull suction filter out of housing.
Installation:
Moisten seal with transmission oil before installing.
Fig. 39: Pulling Suction Filter From Housing

HOUSING WITH ADD-ON PARTS

28 10 020 REMOVING AND INSTALLING OR REPLACING COMBINATION SENSOR (GS7D36SG)

clutch gearbox.


2010 BMW M3
Remove TWIN-CLUTCH GEARBOX

Remove CLUTCH
Release screw (1).
Tightening torque see 28 10 HOUSING WITH ADD-ON PARTS .
Release combination sensor (2) from housing.
Installation:
Replace screw.
IMPORTANT: Do not where possible release cable (4) from holder (5).
Fig. 40: Identifying Connector And Combination Sensor With Screw

Installation:
If holder (5) does have to be released, replace aluminium screw (6).
IMPORTANT: To disconnect combination sensor plug:

Press lock together in area (1) and simultaneously detach plug.
2010 BMW M3
Fig. 41: Identifying Combination Connector Sensor Locks Pressing Area

28 10 010 REMOVING AND INSTALLING OR REPLACING PUMP UNIT (GS7D36SG)
IMPORTANT: After completion of work, check GEARBOX OIL LEVEL .
clutch gearbox.


Remove CLUTCH
Release screws (1).
Remove oil separator (2).

2010 BMW M3
Fig. 42: Identifying Oil Separator With Screws

Release screw (1).
Fig. 43: Identifying Connector And Combination Sensor With Screw

2010 BMW M3
Installation note:
Observe installation position and screw length.
Replace sealing washer on screw (2).
Fig. 44: Identifying Sealing Washer Screws

Release screws (1).
Release oil pump with pressure pipe (2) and return line (3) from housing.
Installation note:
Replace flat seal (4).
During reinstallation O-ring remains on return line.
IMPORTANT: The pressure pipe must not be detached from the pump.
2010 BMW M3
Fig. 45: Identifying Return Line, Flat Seal And Pressure Pipe With Screws
IMPORTANT: Before installing oil pump:

Depending on version, there is a bore hole and a recess for the O-ring (1).
If the bore hole is present, attention must be paid to ensuring the O-ring (1) is
in the right installation position and correctly seated behind the pump.
Fig. 46: Identifying O-Ring

IMPORTANT:
2010 BMW M3
Installation sequence, oil pump
1. Moisten O-ring with transmission oil

2. Position pump in transmission using centering sleeves.
3. Gently insert screws (1) with pressure pipe
4. Press in return line (2) until it audibly snaps into place
5. Screw in oil pump
6. The tightening sequence from 1-8 is mandatory
Fig. 47: Identifying Return Line With Screws

Installation note:
Centering sleeves must not be damaged or crushed.

2010 BMW M3
Fig. 48: Bolts Tightening Sequence Of Oil Pump

28 10 000 REPLACING SUCTION FILTER (GS7D36SG)

Recycling
Remove TRANSMISSION FLUID SUMP
Release screw (1).

2010 BMW M3
Pull suction jet pump (2) out of housing.
Installation:
Moisten seals with transmission oil before installing.
Replace suction jet pump.
Fig. 49: Pulling Out Jet Pump From Housing

IMPORTANT: Screws have different torques.
Pull suction filter out of housing.
Installation:
Moisten seal with transmission oil before installing.

2010 BMW M3
Fig. 50: Pulling Suction From Housing

DOUBLE CLUTCH
28 40 000 REMOVING AND INSTALLING OR REPLACING CLUTCH COVER (GS7D36SG)

Any dirty parts must be cleaned before removing the clutch cover.
clutch gearbox.

Installation note:
Removal and installation of clutch cover:
Replace RADIAL SHAFT SEAL , O-ring and snap ring.
Replacement clutch cover:
Replace as a single assembly only (incl. radial shaft seal, O-ring, bearing, retaining plate and snap ring).
2010 BMW M3
To prevent the gearbox oil from spilling out, tilt the gearbox back before removing the clutch cover.
Installation note:
After completing work, add gearbox oil and check GEARBOX OIL LEVEL .
Lever snap ring (1) out of housing with a suitable tool.
Installation note:
Replace snap ring.
Fig. 51: Identifying Snap Ring

Graphic shows: Twin-clutch gearbox S65
Slip bush 23 0 390 BUSH must be used when clutch cover is removed and installed.
Pull clutch cover with special tool 13 5 250 PULLER and adapter 54 0 163 out of housing.
IMPORTANT: Ensure uniform (non-tilting) detachment by alternately using the 3 tightening

threads.
2010 BMW M3
Fig. 52: Pulling Clutch Cover Using Special Tool (13 5 250)And Adapter (54 0 163) Out Of Housing
Graphic shows: Twin-clutch gearbox S65
Remove oil fouling with fluff-free cloth.
Clean snap ring groove before installing clutch plate.
Press clutch cover (1) into housing with arrow pointing up and strike evenly with a plastic mallet.
Then secure clutch cover with snap ring.
Make sure snap ring is correctly seated.
Installation note:
Moisten O-ring and radial shaft seal with gearbox oil.

2010 BMW M3
Fig. 53: Identifying Clutch Cover

28 40 020 REMOVING AND INSTALLING OR REPLACING CLUTCH SUPPORT (GS7D36SG)

clutch gearbox.


Remove CLUTCH
Remove OIL PUMP (1).
Remove clutch support (3).
Installation:
Replace screws and seal.

2010 BMW M3
Fig. 54: Identifying Clutch Cover, Oil Pump With Screws

IMPORTANT: Before installing clutch support:

Make sure without fail that seal (1) is installed in correct position and piston
rings are correctly seated on input shaft.
Secure clutch support screw connections in diagonal sequence.
Fig. 55: Identifying Clutch Support Seal With Screw

28 40 010 REMOVING AND INSTALLING OR REPLACING TWIN CLUTCH (GS7D36SG)

2010 BMW M3
Check TRANSMISSION FLUID LEVEL .
Perform clutch adaptation (Service Functions)

Teach in valve characteristics (Service Functions)
clutch gearbox.

IMPORTANT: Twin-clutch gearbox must be on neutral (position "N") prior to removal of

clutch or gear box!
Changing gears is only possible with engine running!
To prevent gearbox oil from escaping, move gearbox into an upright position
before removing the twin clutch.

Remove CLUTCH COVER
IMPORTANT: The clutch cage can only be removed and installed with special tool 23 0 400
KEY .
Special tool 23 0 400 KEY must be pushed in entirely and rest flush on clutch
cage.
Twist gearbox input shafts towards each other if necessary.
2010 BMW M3
Fig. 56: Installing Clutch Cage Using Special Tool (23 0 400)
Push parking lock lever (1) as far upwards as possible and secure with cable straps (2).
Fig. 57: Identifying Parking Lock Lever And Cable Strap

Rotate drive shaft (1) until holes (2) are directly visible.
Check clearance with a suitable tool.

2010 BMW M3
Fig. 58: Rotating Drive Shaft

Insert special tool 23 0 400 KEY and release clutch by rotating counter-clockwise (approx. 8 turns).
Pull clutch out of housing.
Installation note:
Put gearbox in an upright position.
The clutch is correctly installed if the oil pump gear turns.
Install the clutch with special tool 23 0 400 KEY while constantly rotating.
Turn clockwise up to stop, then screw down to torque.
Tightening torque, see 28 40 DOUBLE CLUTCH GEARBOX (DKG) .

2010 BMW M3
Fig. 59: Installing Clutch Using Special Tool (23 0 400)

IMPORTANT: Warning: Installing the clutch may involve the danger of injury!
Installation note:
Under no circumstances are hammers or other pounding tools to be used when installing the clutch.
The clutch must be slid over the piston rings and onto the clutch support.
IMPORTANT: When reinstalling the clutch, check that the piston rings (1) and the needle
bearings (2) are present and correctly seated on the clutch support.
Mount clutch carefully to clutch support/do not tilt, to avoid damaging the
piston rings (1).
2010 BMW M3
Fig. 60: Identifying Piston Rings And Needle Bearing

28 40 050 REPLACING RADIAL SHAFT SEAL FOR CLUTCH COVER (GS7D36SG)

Any dirty parts must be cleaned before removing the clutch cover.
Remove CLUTCH COVER
To prevent the transmission oil from spilling out, tilt the gearbox back before removing the clutch cover.
Installation note:
Failure to comply with this instruction will result in serious damage to the twin clutch transmission.
Use a suitable tool to take the radial shaft seal (1) off the clutch cover.

Damage to the clutch cover will result in oil leaks!
If the CLUTCH COVER was damaged on removing the radial shaft seal, it is
imperative that the cover be replaced.
2010 BMW M3
Fig. 61: Removing Radial Shaft Seal From Clutch Cover Using Suitable Tool
Place the clutch cover (1) out flat on a workbench.
IMPORTANT: Pay attention to lug (2).
Coat sealing lips of radial shaft seal with transmission oil.
Press the radial shaft seal (3) lightly into the clutch cover.
Fig. 62: Identifying Clutch Cover, Lug And Radial Shaft Seal
2010 BMW M3
Use special tool 242 370 to drive the radial shaft seal into the clutch cover until the sealing ring is flush.
Fig. 63: Driving Radial Shaft Seal Into Clutch Cover Using Special Tools 24 2 370
Use a suitable tool to take the O-ring of the clutch cover out of the groove.
Use a lint-free cloth to remove oil contamination from the O-ring groove.
Installation note:
Replace O-ring.
Coat O-ring with transmission oil before installing.

2010 BMW M3
Fig. 64: Removing Clutch Cover O-Ring From Groove Using Suitable Tool
CONTROL UNIT, MECHATRONICS, HYDRAULICS

28 60.. NOTES ON MECHATRONICS (GS7D36SG)
Load specific data status with the BMW diagnosis system

Check TRANSMISSION OIL LEVEL
Use only automatic transmission fluid for ZF transmission. See

AUTOMATIC TRANSMISSION - OPERATING FLUIDS .
twin clutch transmission.

Unscrew plug (1) and disconnect.

2010 BMW M3
Fig. 65: Turning Plug

Insert special tool 24 2 390 CAP in sealing sleeve (1).
Fig. 66: Inserting Special Tool (24 2 390) In Sealing Cup

28 60 010 REMOVING AND INSTALLING MECHATRONICS (GS7D36SG)
NOTE: When replacing mechatronics:
Import present gearbox data into new mechatronics

2010 BMW M3

clutch gearbox.

Read out gearbox data of mechatronics to be replaced

Place twin-clutch gearbox on a suitable surface.
To prevent the gearbox oil from spilling out, make sure that the hydraulic cap point upward.
Remove HYDRAULIC COVER (1).
Fig. 67: Identifying Hydraulic Cap

Ensure correct installation position.
Press holder (2) together from right and release cable (1).
Installation note:
2010 BMW M3
Replace holder, retaining lug must point to the right.
If fitted: Pull out CPA pin (7) to second locking position.
Release connector lock (6) and at same time detach connector (3) from retaining tabs (5) towards right.
IMPORTANT: Bridge (4) of connector must not break.

Wiring harness must be replaced if bridge breaks.
Fig. 68: Identifying Cable, Holder, Connector Bridge, Connector Lock And CPA Pin
CPA (1) in second locking position.
Installation note:
Press CPA pin downward until it is flush with the housing.

2010 BMW M3
Fig. 69: Identifying CPA Pin

Fig. 70: Identifying Mounting Template With Screws Position

Place mounting template over mechatronics.

2010 BMW M3
Open screws 1-20.
NOTE: Replace screws 1-12.
Screws 13-20 remain captive on module.
Remove mounting template.
Lift mechatronics out of housing.
Remove metal bead gasket.
Fig. 71: Lifting Mechatronics Out Of Housing

IMPORTANT: Check the installation location of the centering pins (1).

The centering pins (1) of the mechatronics remain in the housing.
2010 BMW M3
Fig. 72: Identifying Centering Pins

Installing mechatronics
Install a new metal bead gasket.
Install mechatronics.
Fit mounting template.

2010 BMW M3

IMPORTANT: Adhere without fail to the screwing sequence indicated on the template.
The screw length can be checked by means of the insert pockets shaped in the
template.
1. Insert screws in sequence 1-12 and pre-tighten to 2 Nm.

2. Tighten down screws 1-12 to tightening torque and angle of rotation. See
28 60 CONTROL UNIT, MECHATRONICS, HYDRAULICS .
3. Tighten down screws in sequence 13-20 to 5 Nm.
4. Remove mounting template.
28 60 030 REMOVING AND INSTALLING/REPLACING THE HYDRAULIC CAP (GS7D36SG)

Failure to comply with this instruction will result in serious damage to the twin
clutch transmission.
2010 BMW M3

Remove TWIN CLUTCH TRANSMISSION
Place twin clutch transmission on a suitable surface.
To prevent the gearbox oil from spilling out, make sure that the hydraulic cap point upward.
Release screws.
Remove hydraulic cover (1).
Installation note:
Replace seal.
Replace screws.

Installation of hydraulic cap:
Make sure seal is exactly seated.
It is mandatory to comply with the specified order of screw connections 1-12.

2010 BMW M3
Tightening torque, see 28 60 CONTROL UNIT, MECHATRONICS, HYDRAULICS . .
Fig. 75: Identifying Hydraulic Cover Mounting Screws Tightening Sequence

28 60 025 REPLACING O-RING FOR WIRING HARNESS (GS7D36SG)
IMPORTANT: After completion of repair work, check TRANSMISSION OIL LEVEL .
Use only the APPROVED TRANSMISSION OIL .
clutch gearbox.

DISCHARGE (ESD PROTECTION)
Remove TWIN-CLUTCH GEARBOX.
Transmission must be cleaned around the sealing cup to prevent dirt penetration.
Failure to comply with this instruction may result in serious damage to the twin-clutch gearbox!
Release screw (1).

2010 BMW M3

Pull out sealing cup (1).
Remove sealing ring (2).
Clean sealing cup (1).
Pull out sealing cup only up to first edge (broken line).
Fig. 77: Pulling Out Sealing Cup For Removal Of Sealing Ring
Attach new sealing ring (1) to sealing cup.
Carefully pull sealing ring over screwing flange and install.

2010 BMW M3
IMPORTANT: Inside and outside of sealing ring (1) have sealing lips of different heights (2).
The higher sealing lips must point outwards (rest on the transmission housing
in the preinstalled state).
Fig. 78: Attaching New Sealing Ring To Sealing Cup

28 60 514 REPLACING MECHATRONICS (GS7D36SG)
NOTE: When replacing mechatronics:
Import present transmission data into new mechatronics

clutch gearbox.

Read out transmission data of mechatronics to be replaced

Place twin clutch transmission on a suitable surface.
To prevent the transmission oil from spilling out, make sure that the hydraulic cap points upward.
2010 BMW M3
REMOVE HYDRAULIC CAP (1).

Ensure correct installation position.
Press holder (2) together from right and release cable (1).
Installation note:
Replace holder.
Retaining lugs must point to the right.
If fitted: Pull out CPA pin (7) to second locking position.
Release connector lock (6) and at same time detach connector (3) from retaining tabs (5) towards right.
IMPORTANT: Bridge (4) of connector must not break.

Wiring harness must be replaced if bridge breaks.
2010 BMW M3
Fig. 80: Identifying Cable, Holder, Connector Bridge, Connector Lock And CPA Pin
CPA (1) in second locking position.
Installation note:
Press CPA pin down until it is flush with the housing.
Fig. 81: Identifying CPA Pin

2010 BMW M3

Place mounting template over mechatronics.
Open screws 1-20.
NOTE: Replace screws 1-12.
Screws 13-20 remain captive on module.
Remove mounting template.
Lift mechatronics out of housing.
Remove metal bead gasket.

2010 BMW M3
Fig. 83: Lifting Mechatronics Out Of Housing

IMPORTANT: Check the installation position of the centering pins (1).

The centering pins (1) of the mechatronics remain in the housing.
Fig. 84: Identifying Centering Pins

The new mechatronics ship as shown here, with the shift piston in the neutral position.
2010 BMW M3
Fig. 85: Identifying Mechatronics Neutral Shift Position

In the gearbox, the gearshift rods have to be set to the neutral position'(N) as shown here before the new
mechatronics are installed.
Fig. 86: Identifying Gearshift Rods On Neutral Position

Installing mechatronics
Install a new metal bead gasket.
Install mechatronics.
2010 BMW M3
Fit mounting template.

IMPORTANT: Adhere without fail to the screwing sequence indicated on the template.
The screw length can be checked by means of the insert pockets shaped in the
template.
1. Insert screws in sequence 1-12 and pre-tighten to 2 Nm.

2. Tighten down screws 1-12 to tightening torque and angle of rotation, see
28 60 CONTROL UNIT, MECHATRONICS, HYDRAULICS .
3. Tighten down screws in sequence 13-20 to 5 Nm.
4. Remove mounting template.
28 60 000 REPLACING PRESSURE FILTER (GS7D36SG)

2010 BMW M3

clutch gearbox.
Recycling
Remove underbody protection See REMOVING AND INSTALLING/REPLACING FRONT

UNDERBODY PROTECTION or REMOVING AND INSTALLING/REPLACING REAR
UNDERBODY PROTECTION at front and rear
Only on S65
Release screw (1).
Disconnect hydraulic lines (2) to transmission oil cooler.
Close off lines with plugs.
Installation note:

2010 BMW M3

Secure transmission with tensioning strap (1).
Lower engine with transmission until pressure filter lid (1) is accessible.
Remove retainer (2).
Installation note:
2010 BMW M3
Replace retainer.
Fig. 90: Identifying Filter Lid And Retainer

Lever out lid (1) with sealing ring.
Installation note:
Replace lid with sealing ring.
Lubricate sealing ring with transmission oil before installing.
IMPORTANT: Catch and dispose of escaping transmission oil.

2010 BMW M3
Fig. 91: Identifying Filter Lid With Sealing Ring

Remove pressure filter (1).
Fig. 92: Identifying Pressure Filter

28 60 020 REPLACING WIRING HARNESS (GS7D36SG)

clutch gearbox.
2010 BMW M3


Remove MECHATRONICS
Remove CLUTCH
Release screw (1).
Fig. 93: Identifying Wiring Harness Screw

Release screw (1).
Release aluminium screw (6).
Installation:
Replace aluminium screw.

2010 BMW M3
Removing wiring harness (4) with earth terminal (5) from housing.
Fig. 94: Identifying Connector And Combination Sensor Screw

IMPORTANT: Guide earth terminal (5) carefully through transmission connector bore.
Risk of damage to sealing surface.
IMPORTANT: To disconnect combination sensor plug:

Press lock together in area (1) and simultaneously detach plug.
Fig. 95: Identifying Combination Connector Sensor Locks Pressing Area

2010 BMW M3

2010 BMW M3
DTC INDEX M3
DTC INDEX
M3
SELF-DIAGNOSTICS DTCS
SELF-DIAGNOSTICS DIAGNOSTIC TROUBLE CODE (DTC) LIST
DTC Description
DTC P000A 'A' Camshaft Position Slow Response (Bank 1) (MAX)
DTC P000A 'A' Camshaft Position Slow Response (Bank 1) (PLAUS)
DTC P000B 'B' Camshaft Position Slow Response (Bank 1) (MAX)
DTC P000B 'B' Camshaft Position Slow Response (Bank 1) (PLAUS)
DTC P000C 'A' Camshaft Position Slow Response (Bank 2) (MAX)
DTC P000C 'A' Camshaft Position Slow Response (Bank 2) (PLAUS)
DTC P000D 'B' Camshaft Position Slow Response (Bank 2) (MAX)
DTC P000D 'B' Camshaft Position Slow Response (Bank 2) (PLAUS)
DTC P0010 'A' Camshaft Position Actuator Circuit/Open (Bank 1) (SIG)
DTC P0011 'A' Camshaft Position - Timing Over-Advanced or System Performance (Bank 1)
(MAX)
DTC P0012 'A' Camshaft Position - Timing Over-Retarded (Bank 1) (MIN)
DTC P0013 'B' Camshaft Position Actuator Circuit/Open (Bank 1) (SIG)
DTC P0014 'B' Camshaft Position - Timing Over-Advanced or System Performance (Bank 1)
(MAX)
DTC P0015 'B' Camshaft Position - Timing Over-Retarded (Bank 1) (MIN)
DTC P0017 Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor B)
(PLAUS)
DTC P0020 'A' Camshaft Position Actuator Circuit/Open (Bank 2) (SIG)
DTC P0021 'A' Camshaft Position - Timing Over-Advanced or System Performance (Bank 2)
(MAX)
DTC P0022 'A' Camshaft Position - Timing Over-Retarded (Bank 2) (MIN)
DTC P0023 'B' Camshaft Position Actuator Circuit/Open (Bank 2) (SIG)
DTC P0024 'B' Camshaft Position - Timing Over-Advanced or System Performance (Bank 2)
(MAX)
DTC P0025 'B' Camshaft Position - Timing Over-Retarded (Bank 2) (MIN)
DTC P0030 HO2S Heater Control Circuit (Bank 1 Sensor 1) (SIG)
DTC P0031 HO2S Heater Control Circuit Low (Bank 1 Sensor 1) (MIN)
DTC P0032 HO2S Heater Control Circuit High (Bank 1 Sensor 1) (MAX)
2010 BMW M3
DTC INDEX M3
DTC P0068 MAP/MAF - Throttle Position Correlation (MIN)
DTC P0068 MAP/MAF - Throttle Position Correlation (MIN)
DTC P0068 MAP/MAF - Throttle Position Correlation (SIG)
DTC P0068 MAP/MAF - Throttle Position Correlation (SIG)
DTC P0071 Ambient Air Temperature Sensor Range/Performance (MIN)
DTC P0072 Ambient Air Temperature Sensor Circuit Low (MIN)
DTC P0072 Ambient Air Temperature Sensor Circuit Low (PLAUS)
DTC P0073 Ambient Air Temperature Sensor Circuit High (MAX)
DTC P0091 Fuel Pressure Regulator 1 Control Circuit Low (MIN)
DTC P0092 Fuel Pressure Regulator 1 Control Circuit High (MAX)
DTC P0106 Manifold Absolute Pressure/Barometric Pressure Circuit Range/Performance
(MAX)
(MAX)
(MAX)
(MAX)
(PLAUS)
DTC P0107 Manifold Absolute Pressure/Barometric Pressure Circuit Low (MIN)
DTC P0108 Manifold Absolute Pressure/Barometric Pressure Circuit High (MAX)
DTC P0111 Intake Air Temperature Sensor 1 Circuit Range/Performance (Bank 1) (PLAUS)
DTC P0112 Intake Air Temperature Sensor 1 Circuit Low (Bank 1) (MIN)
DTC P0113 Intake Air Temperature Sensor 1 Circuit High (Bank 1) (MAX)
DTC P0116 Engine Coolant Temperature Sensor 1 Circuit Range/Performance (MIN)
DTC P0116 Engine Coolant Temperature Sensor 1 Circuit Range/Performance (PLAUS)
DTC P0117 Engine Coolant Temperature Sensor 1 Circuit Low (MAX)
DTC P0118 Engine Coolant Temperature Sensor 1 Circuit High (MIN)
DTC P0122 Throttle/Pedal Position Sensor/Switch 'A' Circuit Low (MIN)
DTC P0123 Throttle/Pedal Position Sensor/Switch 'A' Circuit High (MAX)
DTC P0128 Coolant Thermostat (Coolant Temperature Below Thermostat Regulating
Temperature) (SIG)
DTC P0131 O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) (MIN)
DTC P0132 O2 Sensor Circuit High Voltage (Bank 1 Sensor 1) (MAX)
DTC P0133 O2 Sensor Circuit Slow Response (Bank 1 Sensor 1) (MAX)
DTC P0135 O2 Sensor Heater Circuit (Bank 1 Sensor 1) (PLAUS)
2010 BMW M3
DTC INDEX M3
DTC P0136 O2 Sensor Circuit (Bank 1 Sensor 2) (MIN)

DTC P013A O2 Sensor Slow Response - Rich to Lean (Bank 1 Sensor 2) (MAX)
DTC P013C O2 Sensor Slow Response - Rich to Lean (Bank 2 Sensor 2) (MAX)
DTC P013E O2 Sensor Delayed Response - Rich to Lean (Bank 1 Sensor 2) (SIG)
DTC P013F O2 Sensor Delayed Response - Lean to Rich (Bank 1 Sensor 2) (MAX)
DTC P0140 O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2) (SIG)
DTC P014A O2 Sensor Delayed Response - Rich to Lean (Bank 2 Sensor 2) (SIG)
DTC P014B O2 Sensor Delayed Response - Lean to Rich (Bank 2 Sensor 2) (MAX)
DTC P0153 O2 Sensor Circuit Slow Response (Bank 2 Sensor 1) (MAX)
DTC P0156 O2 Sensor Circuit (Bank 2 Sensor 2) (MIN)
DTC P0160 O2 Sensor Circuit No Activity Detected (Bank 2 Sensor 2) (SIG)
DTC P0171 System Too Lean (Bank 1) (MIN)
DTC P0171 System Too Lean (Bank 1) (PLAUS)
DTC P0172 System Too Rich (Bank 1) (MAX)
DTC P0172 System Too Rich (Bank 1) (SIG)
DTC P0174 System Too Lean (Bank 2) (PLAUS)
DTC P0175 System Too Rich (Bank 2) (SIG)
DTC P0191 Fuel Rail Pressure Sensor 'A' Circuit Range/Performance (MAX)
DTC P0191 Fuel Rail Pressure Sensor 'A' Circuit Range/Performance (MAX)
DTC P0191 Fuel Rail Pressure Sensor 'A' Circuit Range/Performance (MIN)
DTC P0191 Fuel Rail Pressure Sensor 'A' Circuit Range/Performance (SIG)
DTC P0191 Fuel Rail Pressure Sensor 'A' Circuit Range/Performance (SIG)
DTC P0191 Fuel Rail Pressure Sensor 'A' Circuit Range/Performance (PLAUS)
DTC P0191 Fuel Rail Pressure Sensor 'A' Circuit Range/Performance (PLAUS)
2010 BMW M3
DTC INDEX M3
Fuel Rail Pressure Sensor 'A' Circuit Low (MIN)

DTC P0193 Fuel Rail Pressure Sensor 'A' Circuit High (MAX)
DTC P0195 Engine Oil Temperature Sensor Circuit (PLAUS)
DTC P0196 Engine Oil Temperature Sensor Range/Performance (SIG)
DTC P0196 Engine Oil Temperature Sensor Range/Performance (PLAUS)
DTC P0201 Injector Circuit/Open - Cylinder 1 (SIG)
DTC P0222 Throttle/Pedal Position Sensor/Switch 'B' Circuit Low (MIN)
DTC P0223 Throttle/Pedal Position Sensor/Switch 'B' Circuit High (MAX)
DTC P025B Fuel Pump Module Control Circuit Range/Performance (MIN)
DTC P025B Fuel Pump Module Control Circuit Range/Performance (SIG)
DTC P025C Fuel Pump Module Control Circuit Low (MIN)
DTC P025D Fuel Pump Module Control Circuit High (MAX)
DTC P0261 Cylinder 1 Injector Circuit Low (MIN)
DTC P0262 Cylinder 1 Injector Circuit High (MAX)
DTC P0300 Random/Multiple Cylinder Misfire Detected (MAX)
DTC P0300 Random/Multiple Cylinder Misfire Detected (MIN)
DTC P0300 Random/Multiple Cylinder Misfire Detected (MIN)
DTC P0300 Random/Multiple Cylinder Misfire Detected (SIG)
2010 BMW M3
DTC INDEX M3
Random/Multiple Cylinder Misfire Detected (PLAUS)

DTC P0301 Cylinder 1 Misfire Detected (MAX)
DTC P0301 Cylinder 1 Misfire Detected (MIN)
DTC P0301 Cylinder 1 Misfire Detected (SIG)
DTC P0301 Cylinder 1 Misfire Detected (PLAUS)
2010 BMW M3
DTC INDEX M3
Cylinder 6 Misfire Detected (PLAUS)

DTC P0308 Cylinder 8 Misfire Detected (2 3)
DTC P0308 Cylinder 8 Misfire Detected (No Info.)
DTC P0335 Crankshaft Position Sensor 'A' Circuit (SIG)
DTC P0337 Crankshaft Position Sensor 'A' Circuit Low (MIN)
DTC P0338 Crankshaft Position Sensor 'A' Circuit High (MAX)
DTC P0339 Crankshaft Position Sensor 'A' Circuit Intermittent (PLAUS)
DTC P0341 Camshaft Position Sensor 'A' Circuit Range/Performance (Bank 1 or Single
Sensor) (MIN)
DTC P0342 Camshaft Position Sensor 'A' Circuit Low (Bank 1 or Single Sensor) (MIN)
DTC P0343 Camshaft Position Sensor 'A' Circuit High (Bank 1 or Single Sensor) (SIG)
DTC P0344 Camshaft Position Sensor 'A' Circuit Intermittent (Bank 1 or Single Sensor)
(MAX)
DTC P0346 Camshaft Position Sensor 'A' Circuit Range/Performance (Bank 2) (MIN)
DTC P0347 Camshaft Position Sensor 'A' Circuit Low (Bank 2) (MIN)
DTC P0348 Camshaft Position Sensor 'A' Circuit High (Bank 2) (SIG)
DTC P0349 Camshaft Position Sensor 'A' Circuit Intermittent (Bank 2) (MAX)
DTC P0351 Ignition Coil 'A' Primary/Secondary Circuit (SIG)
DTC P0352 Ignition Coil 'B' Primary/Secondary Circuit (SIG)
DTC P0353 Ignition Coil 'C' Primary/Secondary Circuit (SIG)
DTC P0354 Ignition Coil 'D' Primary/Secondary Circuit (SIG)
DTC P0355 Ignition Coil 'E' Primary/Secondary Circuit (SIG)
DTC P0356 Ignition Coil 'F' Primary/Secondary Circuit (SIG)
DTC P0357 Ignition Coil 'G' Primary/Secondary Circuit (SIG)
DTC P0358 Ignition Coil 'H' Primary/Secondary Circuit (SIG)
DTC P0365 Camshaft Position Sensor 'B' Circuit (Bank 1) (PLAUS)
DTC P0366 Camshaft Position Sensor 'B' Circuit Range/Performance (Bank 1) (MIN)
DTC P0367 Camshaft Position Sensor 'B' Circuit Low (Bank 1) (MIN)
2010 BMW M3
DTC INDEX M3
DTC P0368 Camshaft Position Sensor 'B' Circuit High (Bank 1) (SIG)
DTC P0369 Camshaft Position Sensor 'B' Circuit Intermittent (Bank 1) (MAX)
DTC P0390 Camshaft Position Sensor 'B' Circuit (Bank 2) (PLAUS)
DTC P0391 Camshaft Position Sensor 'B' Circuit Range/Performance (Bank 2) (MIN)
DTC P0392 Camshaft Position Sensor 'B' Circuit Low (Bank 2) (MIN)
DTC P0393 Camshaft Position Sensor 'B' Circuit High (Bank 2) (SIG)
DTC P0394 Camshaft Position Sensor 'B' Circuit Intermittent (Bank 2) (MAX)
DTC P0411 Secondary Air Injection System Incorrect Flow Detected (MAX)
DTC P0420 Catalyst System Efficiency Below Threshold (Bank 1) (MAX)
DTC P0430 Catalyst System Efficiency Below Threshold (Bank 2) (MAX)
DTC P0441 Evaporative Emission System Incorrect Purge Flow (SIG)
DTC P0442 Evaporative Emission System Leak Detected (small leak) (MAX)
DTC P0443 Evaporative Emission System Purge Control Valve Circuit (MAX)
DTC P0444 Evaporative Emission System Purge Control Valve Circuit Open (SIG)
DTC P0445 Evaporative Emission System Purge Control Valve Circuit Shorted (MIN)
DTC P0456 Evaporative Emission System Leak Detected (very small leak) (MIN)
DTC P0458 Evaporative Emission System Purge Control Valve Circuit Low (MIN)
DTC P0459 Evaporative Emission System Purge Control Valve Circuit High (MAX)
DTC P0461 Fuel Level Sensor 'A' Circuit Range/Performance (MAX)
DTC P0461 Fuel Level Sensor 'A' Circuit Range/Performance (MIN)
DTC P0461 Fuel Level Sensor 'A' Circuit Range/Performance (PLAUS)
DTC P0462 Fuel Level Sensor 'A' Circuit Low (MIN)
DTC P0462 Fuel Level Sensor 'A' Circuit Low (SIG)
DTC P0463 Fuel Level Sensor 'A' Circuit High (MAX)
DTC P0463 Fuel Level Sensor 'A' Circuit High (PLAUS)
DTC P0480 Fan 1 Control Circuit (SIG)
DTC P0483 Fan Rationality Check (PLAUS)
DTC P0491 Secondary Air Injection System Insufficient Flow (Bank 1) (SIG)
DTC P0492 Secondary Air Injection System Insufficient Flow (Bank 2) (SIG)
DTC P0500 Vehicle Speed Sensor 'A' (MAX)
DTC P0500 Vehicle Speed Sensor 'A' (MIN)
DTC P0500 Vehicle Speed Sensor 'A' (SIG)
DTC P0506 Idle Air Control System RPM Lower Than Expected (MIN)
DTC P0507 Idle Air Control System RPM Higher Than Expected (MAX)
DTC P0604 Internal Control Module Random Access Memory (RAM) Error (MIN)
DTC P0604 Internal Control Module Random Access Memory (RAM) Error (MIN)
DTC P0605 Internal Control Module Read Only Memory (ROM) Error (SIG)
DTC P0605 Internal Control Module Read Only Memory (ROM) Error (SIG)
DTC P0606 Control Module Processor (PLAUS)
DTC P0606 Control Module Processor (PLAUS)
DTC P060A Internal Control Module Monitoring Processor Performance (MAX)
2010 BMW M3
DTC INDEX M3
Internal Control Module Monitoring Processor Performance (MAX)

DTC P060A Internal Control Module Monitoring Processor Performance (MIN)
DTC P060A Internal Control Module Monitoring Processor Performance (MIN)
DTC P060A Internal Control Module Monitoring Processor Performance (SIG)
DTC P060A Internal Control Module Monitoring Processor Performance (SIG)
DTC P060A Internal Control Module Monitoring Processor Performance (PLAUS)
DTC P060A Internal Control Module Monitoring Processor Performance (PLAUS)
DTC P0620 Generator Control Circuit (SIG)
DTC P0620 Generator Control Circuit (SIG)
DTC P0620 Generator Control Circuit (PLAUS)
DTC P0620 Generator Control Circuit (PLAUS)
DTC P062A Fuel Pump 'A' Control Circuit Range/Performance (SIG)
DTC P0638 Throttle Actuator Control Range/Performance (Bank 1) (MIN)
DTC P0638 Throttle Actuator Control Range/Performance (Bank 1) (PLAUS)
DTC P0639 Throttle Actuator Control Range/Performance (Bank 2) (MIN)
DTC P0639 Throttle Actuator Control Range/Performance (Bank 2) (PLAUS)
DTC P064A Fuel Pump Control Module (PLAUS)
DTC P0691 Fan 1 Control Circuit Low (MIN)
DTC P0692 Fan 1 Control Circuit High (MAX)
DTC P0A3B Generator Over Temperature (MAX)
DTC P103C 'A' Camshaft Position Actuator Over Temperature (Bank 1) (PLAUS)
DTC P103D 'A' Camshaft Position Actuator Over Temperature (Bank 2) (PLAUS)
DTC P103E 'B' Camshaft Position Actuator Over Temperature (Bank 1) (PLAUS)
DTC P103F 'B' Camshaft Position Actuator Over Temperature (Bank 2) (PLAUS)
DTC P112C O2 Sensor Negative Current or Positive Current Control Circuit/Open (Bank 1
Sensor 1) (SIG)
DTC P112D O2 Sensor Negative Current or Positive Current Control Circuit/Open (Bank 2
Sensor 1) (SIG)
DTC P114A Post Catalyst Fuel Trim Via Oxygen Sensor System Too Rich (Bank 1) (MAX)
DTC P114B Post Catalyst Fuel Trim Via Oxygen Sensor System Too Lean (Bank 1) (MIN)
DTC P114C Post Catalyst Fuel Trim Via Oxygen Sensor System Too Rich (Bank 2) (MAX)
DTC P114D Post Catalyst Fuel Trim Via Oxygen Sensor System Too Lean (Bank 2) (MIN)
DTC P1208 Brake Booster Pump Shutoff Valve Open Circuit (SIG)
DTC P1209 Brake Booster Pump Shutoff Valve Plausibility (PLAUS)
DTC P120E Brake Booster Pump Circuit High (MAX)
DTC P120F Brake Booster Pump Circuit Low (MIN)
DTC P1291 Fuel Volume Regulator Output Stage Over Temperature (MAX)
DTC P130B Ionic Current Control Module Control Line Ignition Cylinder 1 Low (MIN)
DTC P130C Ionic Current Control Module Control Line Ignition Cylinder 2 Low (MIN)
DTC P130D Ionic Current Control Module Control Line Ignition Cylinder 3 Low (MIN)
DTC P130E Ionic Current Control Module Control Line Ignition Cylinder 4 Low (MIN)
2010 BMW M3
DTC INDEX M3
DTC P130F Ionic Current Control Module Control Line Ignition Cylinder 5 Low (MIN)
DTC P131A Ionic Current Control Module Control Line Ignition Cylinder 6 Low (MIN)
DTC P131B Ionic Current Control Module Control Line Ignition Cylinder 7 Low (MIN)
DTC P131C Ionic Current Control Module Control Line Ignition Cylinder 8 Low (MIN)
DTC P131F Ionic Current Control Module Control Line Ignition Cylinder 1 High (MAX)
DTC P132A Ionic Current Control Module Control Line Ignition Cylinder 2 High (MAX)
DTC P132B Ionic Current Control Module Control Line Ignition Cylinder 3 High (MAX)
DTC P132C Ionic Current Control Module Control Line Ignition Cylinder 4 High (MAX)
DTC P132D Ionic Current Control Module Control Line Ignition Cylinder 5 High (MAX)
DTC P132E Ionic Current Control Module Control Line Ignition Cylinder 6 High (MAX)
DTC P132F Ionic Current Control Module Control Line Ignition Cylinder 7 High (MAX)
DTC P133A Ionic Current Control Module Control Line Ignition Cylinder 8 High (MAX)
DTC P133D Ionic Current Control Module Control Line Ignition Cylinder 1 Open Circuit
(SIG)
DTC P133E Ionic Current Control Module Control Line Ignition Cylinder 2 Open Circuit
(SIG)
DTC P133F Ionic Current Control Module Control Line Ignition Cylinder 3 Open Circuit
(SIG)
DTC P134A Ionic Current Control Module Control Line Ignition Cylinder 4 Open Circuit
(SIG)
DTC P134B Ionic Current Control Module Control Line Ignition Cylinder 5 Open Circuit
(SIG)
DTC P134C Ionic Current Control Module Control Line Ignition Cylinder 6 Open Circuit
(SIG)
DTC P134D Ionic Current Control Module Control Line Ignition Cylinder 7 Open Circuit
(SIG)
DTC P134E Ionic Current Control Module Control Line Ignition Cylinder 8 Open Circuit
(SIG)
DTC P136D Ion Ignition Coil Cylinder 1 (MAX)
DTC P136E Ion Ignition Coil Cylinder 2 (MAX)
DTC P136F Ion Ignition Coil Cylinder 3 (MAX)
DTC P1376 Ion Ignition Coil Cylinder 4 (MAX)
DTC P1389 Ion Ignition Coil Cylinder 5 (MAX)
DTC P138A Ion Ignition Coil Cylinder 6 (MAX)
DTC P138B Ion Ignition Coil Cylinder 7 (MAX)
DTC P138C Ion Ignition Coil Cylinder 8 (MAX)
DTC P138C Ion Ignition Coil Cylinder 8 (MIN)
DTC P138C Ion Ignition Coil Cylinder 8 (MIN)
DTC P138C Ion Ignition Coil Cylinder 8 (SIG)
DTC P1411 Secondary Air Pump No Activity Detected (PLAUS)
2010 BMW M3
DTC INDEX M3
DTC P1412 Secondary Air Pump/Secondary Air Valve Large Leak (MAX)
DTC P1412 Secondary Air Pump/Secondary Air Valve Large Leak (MAX)
DTC P1412 Secondary Air Pump/Secondary Air Valve Large Leak (MIN)
DTC P1412 Secondary Air Pump/Secondary Air Valve Large Leak (MIN)
DTC P1412 Secondary Air Pump/Secondary Air Valve Large Leak (SIG)
DTC P1412 Secondary Air Pump/Secondary Air Valve Large Leak (PLAUS)
DTC P1413 Secondary Air Injection Pump Relay Control Circuit Signal Low (MIN)
DTC P1414 Secondary Air Injection Pump Relay Control Circuit Signal High (MAX)
DTC P1418 Secondary Air Injection Valve/Secondary Air Hose Clamped (SIG)
DTC P1434 Diagnostic Module Tank Leakage (DM-TL) (MAX)
DTC P1434 Diagnostic Module Tank Leakage (DM-TL) (MAX)
DTC P1434 Diagnostic Module Tank Leakage (DM-TL) (MIN)
DTC P1434 Diagnostic Module Tank Leakage (DM-TL) (MIN)
DTC P1434 Diagnostic Module Tank Leakage (DM-TL) (SIG)
DTC P1447 Diagnostic Module Tank Leakage (DM-TL) Pump Current Too High during
Switching Solenoid Test (MIN)
DTC P1448 Diagnostic Module Tank Leakage (DM-TL) Pump Current Too Low (SIG)
DTC P1449 Diagnostic Module Tank Leakage (DM-TL) Pump Current Too High (PLAUS)
DTC P1453 Secondary Air Injection Pump Relay Control Circuit Electrical (SIG)
DTC P150A Battery Sensor BSD (Bit Serial Data Interface) Extended Communication Circuit
(MAX)
DTC P150B Battery Sensor BSD (Bit Serial Data Interface) Communication Circuit (MAX)
DTC P150B Battery Sensor BSD (Bit Serial Data Interface) Communication Circuit (MAX)
DTC P150B Battery Sensor BSD (Bit Serial Data Interface) Communication Circuit (SIG)
DTC P150B Battery Sensor BSD (Bit Serial Data Interface) Communication Circuit (PLAUS)
DTC P1515 Engine Off Timer Plausibility (MAX)
DTC P1515 Engine Off Timer Plausibility (MIN)
DTC P1515 Engine Off Timer Plausibility (SIG)
DTC P1515 Engine Off Timer Plausibility (SIG)
2010 BMW M3
DTC INDEX M3
DTC P1515 Engine Off Timer Plausibility (PLAUS)

DTC P1515 Engine Off Timer Plausibility (PLAUS)
DTC P1521 Engine Oil Quality Sensor Communication Error (SIG)
DTC P152C Idle-Speed Control Valve Monitoring Dissimilar Desired Values (Bank 1)
(MAX)
DTC P152D Idle-Speed Control Valve Monitoring Incorrect Actual Value (Bank 1) (MIN)
DTC P152E Idle-Speed Control Valve Monitoring Actual Value / Desired Value Correlation
(Bank 1) (SIG)
DTC P152F Idle-Speed Control Valve Monitoring Reset Error (Bank 1) (PLAUS)
DTC P153B Throttle Valve Initialization Number of Valid Initializations Exceeded (Bank 1)
(SIG)
(MAX)
(MAX)
(MAX)
(MAX)
(MIN)
(SIG)
(PLAUS)
DTC P154C Throttle Actuator Monitoring Dissimilar Desired Values (Bank 1) (MAX)
DTC P154D Throttle Actuator Monitoring Incorrect Actual Value (Bank 1) (MIN)
DTC P154E Throttle Actuator Monitoring Actual Value / Desired Value Correlation (Bank 1)
(SIG)
DTC P154F Throttle Actuator Monitoring Reset Error (Bank 1) (PLAUS)
DTC P155C Throttle Actuator Monitoring Dissimilar Desired Values (Bank 2) (MAX)
DTC P155D Throttle Actuator Monitoring Incorrect Actual Value (Bank 2) (MIN)
DTC P155E Throttle Actuator Monitoring Actual Value / Desired Value Correlation (Bank 2)
(SIG)
DTC P155F Throttle Actuator Monitoring Reset Error (Bank 2) (PLAUS)
DTC P1561 Cold Start Idle Air Control System RPM Lower Than Expected (Bank 1) (MIN)
DTC P1562 Cold Start Idle Air Control System RPM Higher Than Expected (Bank 1)
(MAX)
DTC P156A Throttle Valve Adaptation Range Monitoring Error (Bank 1) (MIN)
DTC P156B Throttle Valve Adaptation Satellite Signals Adaptation Error (Bank 1) (MAX)
DTC P156C Throttle Valve Adaptation Difference Monitoring Error (Bank 1) (SIG)
DTC P156C Throttle Valve Adaptation Difference Monitoring Error (Bank 1) (PLAUS)
2010 BMW M3
DTC INDEX M3
DTC P156D Throttle Valve Enable Line Input Low (Bank 1) (MIN)
DTC P156E Throttle Valve Enable Line Input High (Bank 1) (MAX)
DTC P156E Throttle Valve Enable Line Input High (Bank 1) (SIG)
DTC P156F Throttle Valve Enable Line Circuit Open (Bank 1) (PLAUS)
DTC P157A Throttle Valve Adaptation Range Monitoring Error (Bank 2) (MIN)
DTC P157B Throttle Valve Adaptation Satellite Signals Adaptation Error (Bank 2) (MAX)
DTC P157C Throttle Valve Adaptation Difference Monitoring Error (Bank 2) (SIG)
DTC P157C Throttle Valve Adaptation Difference Monitoring Error (Bank 2) (PLAUS)
DTC P157D Throttle Valve Enable Line Input Low (Bank 2) (MIN)
DTC P157E Throttle Valve Enable Line Input High (Bank 2) (MAX)
DTC P157E Throttle Valve Enable Line Input High (Bank 2) (SIG)
DTC P157F Throttle Valve Enable Line Circuit Open (Bank 2) (SIG)
DTC P157F Throttle Valve Enable Line Circuit Open (Bank 2) (PLAUS)
DTC P1586 Engine Oil Quality Sensor Temperature Measurement (MAX)
DTC P1587 Engine Oil Quality Sensor Level Measurement (MIN)
DTC P1587 Engine Oil Quality Sensor Level Measurement (SIG)
DTC P1588 Engine Oil Quality Sensor Permeability Measurement (PLAUS)
DTC P158A Idle-Speed Control Valve Fail Safe Modus (Bank 1) (MAX)
DTC P158B Internal Idle-Speed Control Valve Diagnostic Error (Bank 1) (MIN)
DTC P158C Idle-Speed Control Valve Adaptation Failure (Bank 1) (SIG)
DTC P158D Idle-Speed Control Valve Position Control Error (Bank 1) (PLAUS)
DTC P1602 Control Module Self-Test, Control Module Defective (MAX)
DTC P1602 Control Module Self-Test, Control Module Defective (MIN)
DTC P1602 Control Module Self-Test, Control Module Defective (PLAUS)
DTC P1605 Safety Concept Torque Limitation Level 1 (MAX)
DTC P1605 Safety Concept Torque Limitation Level 1 (MIN)
DTC P1605 Safety Concept Torque Limitation Level 1 (SIG)
DTC P1605 Safety Concept Torque Limitation Level 1 (PLAUS)
DTC P1606 Fault Memory Plausibility (MAX)
DTC P1606 Fault Memory Plausibility (MAX)
DTC P1606 Fault Memory Plausibility (MIN)
DTC P1606 Fault Memory Plausibility (MIN)
DTC P1606 Fault Memory Plausibility (SIG)
DTC P1606 Fault Memory Plausibility (SIG)
DTC P1606 Fault Memory Plausibility (PLAUS)
DTC P1606 Fault Memory Plausibility (PLAUS)
DTC P160A Powermanagement Exhaustive Discharge (MIN)
DTC P160B Powermanagement Defective (PLAUS)
DTC P160C Powermanagement Overvoltage (MAX)
DTC P160D Powermanagement Undervoltage (MIN)
DTC P160E Powermanagement Operation Without Charging of Battery (SIG)
2010 BMW M3
DTC INDEX M3
Powermanagement No-Load Current Error (PLAUS)

DTC P161D Throttle Valve Adaptation Spring Test Failed (Bank 2) (SIG)
DTC P161E Throttle Valve Actuator Spring Test (Bank 2) (PLAUS)
DTC P161F Throttle Valve Actuator Spring Test Malfunction during Opening (Bank 2)
(MAX)
(MIN)
DTC P161F Throttle Valve Actuator Spring Test Malfunction during Opening (Bank 2) (SIG)
(PLAUS)
DTC P1628 Throttle Valve Actuator Spring Test Malfunction during Opening (Bank 1)
(MAX)
(MIN)
DTC P1628 Throttle Valve Actuator Spring Test Malfunction during Opening (Bank 1) (SIG)
(PLAUS)
DTC P162B Throttle Valve Position Control, Control Deviation (Bank 2) (MAX)
DTC P162B Throttle Valve Position Control, Control Deviation (Bank 2) (MIN)
DTC P162B Throttle Valve Position Control, Control Deviation (Bank 2) (SIG)
DTC P162B Throttle Valve Position Control, Control Deviation (Bank 2) (PLAUS)
DTC P162C Throttle Valve Position Control Throttle Stuck Temporarily (Bank 2) (MAX)
DTC P162D Throttle Valve Position Control Throttle Stuck Permanently (Bank 2) (MIN)
DTC P1630 Throttle Valve Control Circuit (Bank 2) (MAX)
DTC P1631 Throttle Valve Actuator Spring Test (Bank 1) (PLAUS)
DTC P1634 Throttle Valve Adaptation Spring Test Failed (Bank 1) (SIG)
DTC P1636 Throttle Valve Control Circuit (Bank 1) (MAX)
2010 BMW M3
DTC INDEX M3
DTC P1637 Throttle Valve Position Control, Control Deviation (Bank 1) (SIG)
DTC P1637 Throttle Valve Position Control, Control Deviation (Bank 1) (PLAUS)
DTC P1638 Throttle Valve Position Control Throttle Stuck Temporarily (Bank 1) (MAX)
DTC P1639 Throttle Valve Position Control Throttle Stuck Permanently (Bank 1) (MIN)
DTC P1666 EWS (Electronic Immobilizer) Tampering via KWDTC P2000UE / Start Value
not Accepted (PLAUS)
DTC P1681 Electronic Throttle Control Monitor Level 2/3 Engine Speed Calculation Error
(MIN)
DTC P1681 Electronic Throttle Control Monitor Level 2/3 Engine Speed Calculation Error
(MIN)
DTC P1684 Electronic Throttle Control Monitor Level 2/3 Clutch Torque Min Error (SIG)
DTC P1685 Electronic Throttle Control Monitor Level 2/3 Clutch Torque Max Error
(PLAUS)
DTC P1686 Electronic Throttle Control Monitor Level 2/3 Pedal Position Sensor Diagnostic
Error (MIN)
DTC P1689 Electronic Throttle Control Monitor Level 2/3 Torque Calculation Error (MAX)
DTC P1689 Electronic Throttle Control Monitor Level 2/3 Torque Calculation Error (MAX)
DTC P1691 Electronic Throttle Control Monitor Level 2/3 Motorized Throttle Control
Engine Speed Limitation Error (SIG)
DTC P1691 Electronic Throttle Control Monitor Level 2/3 Motorized Throttle Control
Engine Speed Limitation Error (SIG)
DTC P16B1 Control Module Self-Test, Idle Air Control System Integrated Component
Plausibility (MAX)
Plausibility (MIN)
Plausibility (PLAUS)
DTC P16B3 Control Module Self-Test, MSR (Engine-Drag-Torque Control) Monitoring
(SIG)
DTC P16B7 Control Module Self-Test, Clutch Torque Monitoring Maximum Value
Plausibility (MIN)
DTC P16B8 Control Module Self-Test, Clutch Torque Monitoring Minimum Value
Plausibility (SIG)
DTC P16C1 Control Module Self-Test, Torque Monitoring Current Indicated Value
Plausibility (MAX)
DTC P16C6 CAN Timeout BSD (Bit Serial Data Interface) (PLAUS)
DTC P2067 Fuel Level Sensor 'B' Circuit Low (MIN)
DTC P2067 Fuel Level Sensor 'B' Circuit Low (SIG)
DTC P2068 Fuel Level Sensor 'B' Circuit High (MAX)
DTC P2068 Fuel Level Sensor 'B' Circuit High (PLAUS)
DTC P2088 'A' Camshaft Position Actuator Control Circuit Low (Bank 1) (MIN)
DTC P2089 'A' Camshaft Position Actuator Control Circuit High (Bank 1) (MAX)
DTC P2090 'B' Camshaft Position Actuator Control Circuit Low (Bank 1) (MIN)
2010 BMW M3
DTC INDEX M3
DTC P2091 'B' Camshaft Position Actuator Control Circuit High (Bank 1) (MAX)
DTC P2092 'A' Camshaft Position Actuator Control Circuit Low (Bank 2) (MIN)
DTC P2093 'A' Camshaft Position Actuator Control Circuit High (Bank 2) (MAX)
DTC P2094 'B' Camshaft Position Actuator Control Circuit Low (Bank 2) (MIN)
DTC P2095 'B' Camshaft Position Actuator Control Circuit High (Bank 2) (MAX)
DTC P2096 Post Catalyst Fuel Trim System Too Lean (Bank 1) (MIN)
DTC P2096 Post Catalyst Fuel Trim System Too Lean (Bank 1) (PLAUS)
DTC P2097 Post Catalyst Fuel Trim System Too Rich (Bank 1) (MAX)
DTC P2097 Post Catalyst Fuel Trim System Too Rich (Bank 1) (SIG)
DTC P2098 Post Catalyst Fuel Trim System Too Lean (Bank 2) (MAX)
DTC P2098 Post Catalyst Fuel Trim System Too Lean (Bank 2) (SIG)
DTC P2098 Post Catalyst Fuel Trim System Too Lean (Bank 2) (SIG)
DTC P2099 Post Catalyst Fuel Trim System Too Rich (Bank 2) (MAX)
DTC P2099 Post Catalyst Fuel Trim System Too Rich (Bank 2) (SIG)
DTC P2100 Throttle Actuator 'A' Control Motor Circuit/Open (MAX)
DTC P2122 Throttle/Pedal Position Sensor/Switch 'D' Circuit Low (MIN)
DTC P2123 Throttle/Pedal Position Sensor/Switch 'D' Circuit High (MAX)
DTC P2127 Throttle/Pedal Position Sensor/Switch 'E' Circuit Low (MIN)
DTC P2128 Throttle/Pedal Position Sensor/Switch 'E' Circuit High (MAX)
DTC P2138 Throttle/Pedal Position Sensor/Switch 'D' / 'E' Voltage Correlation (MAX)
DTC P2138 Throttle/Pedal Position Sensor/Switch 'D' / 'E' Voltage Correlation (MIN)
DTC P2177 System Too Lean Off Idle (Bank 1) (MIN)
DTC P2177 System Too Lean Off Idle (Bank 1) (PLAUS)
DTC P2178 System Too Rich Off Idle (Bank 1) (MAX)
DTC P2178 System Too Rich Off Idle (Bank 1) (SIG)
DTC P2179 System Too Lean Off Idle (Bank 2) (SIG)
DTC P2180 System Too Rich Off Idle (Bank 2) (MAX)
DTC P2180 System Too Rich Off Idle (Bank 2) (SIG)
DTC P2191 System Too Lean at Higher Load (Bank 1) (PLAUS)
2010 BMW M3
DTC INDEX M3
System Too Lean at Higher Load (Bank 1) (PLAUS)

DTC P2195 O2 Sensor Signal Biased/Stuck Lean (Bank 1 Sensor 1) (MAX)
DTC P2196 O2 Sensor Signal Biased/Stuck Rich (Bank 1 Sensor 1) (MIN)
DTC P2197 O2 Sensor Signal Biased/Stuck Lean (Bank 2 Sensor 1) (MAX)
DTC P2198 O2 Sensor Signal Biased/Stuck Rich (Bank 2 Sensor 1) (MIN)
DTC P2227 Barometric Pressure Sensor 'A' Circuit Range/Performance (PLAUS)
DTC P2228 Barometric Pressure Sensor 'A' Circuit Low (MIN)
DTC P2229 Barometric Pressure Sensor 'A' Circuit High (MAX)
DTC P2243 O2 Sensor Reference Voltage Circuit/Open (Bank 1 Sensor 1) (SIG)
DTC P2247 O2 Sensor Reference Voltage Circuit/Open (Bank 2 Sensor 1) (SIG)
DTC P2270 O2 Sensor Signal Biased/Stuck Lean (Bank 1 Sensor 2) (PLAUS)
DTC P2271 O2 Sensor Signal Biased/Stuck Rich (Bank 1 Sensor 2) (MAX)
DTC P2272 O2 Sensor Signal Biased/Stuck Lean (Bank 2 Sensor 2) (PLAUS)
DTC P2273 O2 Sensor Signal Biased/Stuck Rich (Bank 2 Sensor 2) (MAX)
DTC P2288 Injector Control Pressure Too High (MAX)
DTC P2290 Injector Control Pressure Too Low (MIN)
DTC P2297 O2 Sensor Out of Range During Deceleration (Bank 1 Sensor 1) (MIN)
DTC P2298 O2 Sensor Out of Range During Deceleration (Bank 2 Sensor 1) (MIN)
DTC P2300 Ignition Coil 'A' Primary Control Circuit Low (MIN)
DTC P2301 Ignition Coil 'A' Primary Control Circuit High (MAX)
DTC P2303 Ignition Coil 'B' Primary Control Circuit Low (MIN)
DTC P2304 Ignition Coil 'B' Primary Control Circuit High (MAX)
DTC P2306 Ignition Coil 'C' Primary Control Circuit Low (MIN)
DTC P2307 Ignition Coil 'C' Primary Control Circuit High (MAX)
DTC P2309 Ignition Coil 'D' Primary Control Circuit Low (MIN)
DTC P2310 Ignition Coil 'D' Primary Control Circuit High (MAX)
DTC P2312 Ignition Coil 'E' Primary Control Circuit Low (MIN)
DTC P2313 Ignition Coil 'E' Primary Control Circuit High (MAX)
DTC P2315 Ignition Coil 'F' Primary Control Circuit Low (MIN)
DTC P2316 Ignition Coil 'F' Primary Control Circuit High (MAX)
DTC P2318 Ignition Coil 'G' Primary Control Circuit Low (MIN)
DTC P2319 Ignition Coil 'G' Primary Control Circuit High (MAX)
DTC P2321 Ignition Coil 'H' Primary Control Circuit Low (MIN)
DTC P2322 Ignition Coil 'H' Primary Control Circuit High (MAX)
DTC P2402 Evaporative Emission System Leak Detection Pump Control Circuit High
(MAX)
DTC P240A Evaporative Emission System Leak Detection Pump Heater Control
Circuit/Open (SIG)
DTC P240B Evaporative Emission System Leak Detection Pump Heater Control Circuit Low
2010 BMW M3
DTC INDEX M3
(MIN)
DTC P240C Evaporative Emission System Leak Detection Pump Heater Control Circuit High
(MAX)
DTC P2414 O2 Sensor Exhaust Sample Error (Bank 1 Sensor 1) (SIG)
DTC P2415 O2 Sensor Exhaust Sample Error (Bank 2 Sensor 1) (SIG)
DTC P2418 Evaporative Emission System Switching Valve Control Circuit/Open (SIG)
DTC P2419 Evaporative Emission System Switching Valve Control Circuit Low (MIN)
DTC P2420 Evaporative Emission System Switching Valve Control Circuit High (MAX)
DTC P2430 Secondary Air Injection System Air Flow/Pressure Sensor Circuit (Bank 1)
(PLAUS)
DTC P2430 Secondary Air Injection System Air Flow/Pressure Sensor Circuit (Bank 1)
(PLAUS)
DTC P2432 Secondary Air Injection System Air Flow/Pressure Sensor Circuit Low (Bank 1)
(MIN)
DTC P2433 Secondary Air Injection System Air Flow/Pressure Sensor Circuit High (Bank 1)
(MAX)
DTC P2440 Secondary Air Injection System Switching Valve Stuck Open (Bank 1) (MIN)
DTC P2448 Secondary Air Injection System High Air Flow (Bank 1) (PLAUS)
DTC P2449 Secondary Air Injection System High Air Flow (Bank 2) (PLAUS)
DTC P250F Engine Oil Level Too Low (MIN)
DTC P2526 Vacuum Reservoir Pressure Sensor Circuit Range/Performance (SIG)
DTC P2526 Vacuum Reservoir Pressure Sensor Circuit Range/Performance (PLAUS)
DTC P2527 Vacuum Reservoir Pressure Sensor Circuit Low (MAX)
DTC P2528 Vacuum Reservoir Pressure Sensor Circuit High (MAX)
DTC P2528 Vacuum Reservoir Pressure Sensor Circuit High (MIN)
DTC P2528 Vacuum Reservoir Pressure Sensor Circuit High (SIG)
DTC P2528 Vacuum Reservoir Pressure Sensor Circuit High (PLAUS)
DTC P252A Engine Oil Quality Sensor Circuit (MAX)
DTC P252A Engine Oil Quality Sensor Circuit (MIN)
DTC P252A Engine Oil Quality Sensor Circuit (SIG)
2010 BMW M3
DTC INDEX M3
DTC P252A Engine Oil Quality Sensor Circuit (SIG)

DTC P252A Engine Oil Quality Sensor Circuit (PLAUS)
DTC P2626 O2 Sensor Pumping Current Trim Circuit/Open (Bank 1 Sensor 1) (SIG)
DTC P2629 O2 Sensor Pumping Current Trim Circuit/Open (Bank 2 Sensor 1) (SIG)
DTC P3005 Fuel Rail Pressure Pressure-Rate-Controlled, Pressure Too Low (MIN)
DTC P3006 Fuel Rail Pressure Pressure-Rate-Controlled, Pressure Too High (MAX)
DTC P3016 O2 Sensor Calibration Resistance at WRAF-IC Plausibility (Bank 1 Sensor 1)
(SIG)
DTC P3017 O2 Sensor Calibration Resistance at WRAF-IC Plausibility (Bank 2 Sensor 1)
(SIG)
DTC P3022 O2 Sensor Disturbed SPI Communication to WRAF-IC (Bank 1 Sensor 1) (SIG)
DTC P3023 O2 Sensor Disturbed SPI Communication to WRAF-IC (Bank 2 Sensor 1) (SIG)
DTC P3026 O2 Sensor Operating Temperature not Reached (Bank 1 Sensor 1) (PLAUS)
DTC P3027 O2 Sensor Operating Temperature not Reached (Bank 2 Sensor 1) (PLAUS)
DTC P3032 O2 Sensor Internal Resistance Measurement Path Amplification Factor
Plausibility (Bank 1 Sensor 1) (PLAUS)
Plausibility (Bank 2 Sensor 1) (MAX)
Plausibility (Bank 2 Sensor 1) (MAX)
Plausibility (Bank 2 Sensor 1) (MIN)
Plausibility (Bank 2 Sensor 1) (MIN)
Plausibility (Bank 2 Sensor 1) (SIG)
Plausibility (Bank 2 Sensor 1) (SIG)
Plausibility (Bank 2 Sensor 1) (PLAUS)
DTC P316A Engine Coolant Temperature Signal Stuck High (MAX)
DTC P3198 Engine Coolant Temperature 1 Gradient Too High (SIG)
DTC P3200 Powertrain CAN, CAN Chip Defective (MAX)
DTC P3200 Powertrain CAN, CAN Chip Defective (SIG)
DTC P3200 Powertrain CAN, CAN Chip Defective (SIG)
DTC U0109 Lost Communication With Fuel Pump Control Module (SIG)
DTC U0137 Lost Communication With Trailer Brake Control Module (0 1 2)
DTC U0137 Lost Communication With Trailer Brake Control Module (MAX)
DTC U0137 Lost Communication With Trailer Brake Control Module (MIN)
DTC U0137 Lost Communication With Trailer Brake Control Module (SIG)
2010 BMW M3
DTC INDEX M3
DTC U0137 Lost Communication With Trailer Brake Control Module (3 0)

DTC U0137 Lost Communication With Trailer Brake Control Module (PLAUS)
DTC U0137 Lost Communication With Trailer Brake Control Module (No Info.)
DTC U0410 Invalid Data Received From Fuel Pump Control Module (MAX)
DTC U0410 Invalid Data Received From Fuel Pump Control Module (MIN)
DTC U0410 Invalid Data Received From Fuel Pump Control Module (SIG)
DTC U0410 Invalid Data Received From Fuel Pump Control Module (PLAUS)
DTC U1101 Lost Communication With Ambient Temperature/Relative Time (MAX)
DTC U1101 Lost Communication With Ambient Temperature/Relative Time (MAX)
DTC U1101 Lost Communication With Ambient Temperature/Relative Time (SIG)
DTC U1102 Message Monitoring Actuation Cruise Control/ACC Alive Check (MAX)
DTC U1102 Message Monitoring Actuation Cruise Control/ACC Alive Check (PLAUS)
DTC U1103 Lost Communication With Actuation Cruise Control/ACC (SIG)
DTC U1104 Message Monitoring Actuation Cruise Control/ACC Check Sum Error (MIN)
DTC U110B Message Monitoring Torque Request DSC Alive Check (MAX)
DTC U110B Message Monitoring Torque Request DSC Alive Check (MAX)
DTC U110B Message Monitoring Torque Request DSC Alive Check (MIN)
DTC U110B Message Monitoring Torque Request DSC Alive Check (MIN)
DTC U110B Message Monitoring Torque Request DSC Alive Check (SIG)
DTC U110B Message Monitoring Torque Request DSC Alive Check (PLAUS)
DTC U110B Message Monitoring Torque Request DSC Alive Check (PLAUS)
DTC U110C Lost Communication With Torque Request DSC (SIG)
DTC U110D Message Monitoring Torque Request DSC Check Sum Error (MIN)
DTC U1118 Lost Communication With Speed (MAX)
2010 BMW M3
DTC INDEX M3
Lost Communication With Speed (MAX)

DTC U1118 Lost Communication With Speed (MIN)
DTC U1118 Lost Communication With Speed (MIN)
DTC U1118 Lost Communication With Speed (SIG)
DTC U1118 Lost Communication With Speed (PLAUS)
DTC U111C Lost Communication With Mileage/Range (SIG)
DTC U111D Message Monitoring Terminal Status Alive Check (MAX)
DTC U111D Message Monitoring Terminal Status Alive Check (PLAUS)
DTC U111E Lost Communication With Terminal Status (SIG)
DTC U111F Message Monitoring Terminal Status Check Sum Error (MIN)
DTC U1120 Lost Communication With Steering Wheel Angle (SIG)
DTC U1126 Lost Communication With DSC Status (MAX)
DTC U1126 Lost Communication With DSC Status (SIG)
DTC U1126 Lost Communication With DSC Status (SIG)
DTC U112A Message Monitoring Instrument Pack Status Alive Check (PLAUS)
DTC U112B Lost Communication With Instrument Pack Status (MAX)
DTC U112B Lost Communication With Instrument Pack Status (SIG)
DTC U112C Lost Communication With Heat Flow/Load Moment A/C (MAX)
DTC U112C Lost Communication With Heat Flow/Load Moment A/C (SIG)
DTC U112C Lost Communication With Heat Flow/Load Moment A/C (SIG)
DTC U1132 Lost Communication With Generator via BSD (Bit Serial Data Interface) (1 2 3
0)
DTC U1132 Lost Communication With Generator via BSD (Bit Serial Data Interface) (SIG)
DTC U1132 Lost Communication With Generator via BSD (Bit Serial Data Interface) (No
Info.)
DTC U1132 Lost Communication With Generator via BSD (Bit Serial Data Interface) (No
Info.)
DTC U1136 Lost Communication With Idle-Speed Control Valve (Bank 1) (SIG)
DTC U1137 Message Monitoring Idle-Speed Control Valve Alive Check (Bank 1) (MAX)
DTC U1137 Message Monitoring Idle-Speed Control Valve Alive Check (Bank 1) (MIN)
DTC U1137 Message Monitoring Idle-Speed Control Valve Alive Check (Bank 1) (SIG)
DTC U1137 Message Monitoring Idle-Speed Control Valve Alive Check (Bank 1) (PLAUS)
DTC U1137 Message Monitoring Idle-Speed Control Valve Alive Check (Bank 1) (PLAUS)
DTC U1138 Message Monitoring Idle-Speed Control Valve DPR Overwrite Error (Bank 1)
(MIN)
DTC U1138 Message Monitoring Idle-Speed Control Valve DPR Overwrite Error (Bank 1)
(No Info.)
2010 BMW M3
DTC INDEX M3
DTC U1139 Idle-Speed Control Valve / AMT Communication Bus Off (SIG)
DTC U1140 Throttle Valve Communication Bus off (SIG)
DTC U1141 Lost Communication With Throttle Actuator (Bank 1) (SIG)
DTC U1142 Message Monitoring Throttle Actuator Alive Check (Bank 1) (PLAUS)
DTC U1143 Message Monitoring Throttle Actuator DPR Overwrite Error (Bank 1) (MAX)
DTC U1143 Message Monitoring Throttle Actuator DPR Overwrite Error (Bank 1) (MIN)
DTC U1151 Lost Communication With Throttle Actuator (Bank 2) (SIG)
DTC U1152 Message Monitoring Throttle Actuator Alive Check (Bank 2) (MAX)
DTC U1152 Message Monitoring Throttle Actuator Alive Check (Bank 2) (MIN)
DTC U1152 Message Monitoring Throttle Actuator Alive Check (Bank 2) (SIG)
DTC U1152 Message Monitoring Throttle Actuator Alive Check (Bank 2) (SIG)
DTC U1153 Message Monitoring Throttle Actuator DPR Overwrite Error (Bank 2) (MAX)
DTC U1153 Message Monitoring Throttle Actuator DPR Overwrite Error (Bank 2) (MIN)
2010 BMW M3
GENERAL INFORMATION DVOM - Overview
GENERAL INFORMATION
DVOM - Overview
THE DVOM
Model: All
INTRODUCING THE DVOM
The ability to measure voltage, current flow, and resistance is important in the diagnosing of electrical
problems. Without the results of these measurements troubleshooting in an electrical system is a futile process.
The instrument most commonly used to make electrical measurements is called the Digital Voltage-Ohm Meter
(DVOM).
Basic DVOM's are capable of measuring:
AC Voltage.
DC Voltage.
Millivolts.
Resistance.
Conductance.
Capacitance.
Continuity.
Diode Test.
Amps/Milliamps.
Microamps.
Advanced DVOM's add:
Frequency.
RPM.
Duty Cycle.
Pulse Width.
2010 BMW M3
Fig. 1: Identifying DVOM

The DVOM provides for a method of accurate measurements.

2010 BMW M3
Even though accurate measurements are the key to electrical diagnosis, the following four factors determine the
effectiveness of the measurements:
Accuracy of the measuring instrument.

Correct installation in the circuit of the measuring instrument.
Ability of the Technician to read the instrument.
Skill of the Technician in interpreting the results.
As it is clearly seen, only one of the factors depends on the DVOM (e.g. accuracy), the rest will always depend
the ability of the technician to read and interpret the results.
CHOOSING A DVOM
A good choice of a DVOM is the DISplus or the MoDic, as the measuring system of each contains a highly
accurate DVOM.
Choosing a handheld DVOM from a reputable manufacturer, however, leaves the DISplus and MoDic free to
perform other tasks that a DVOM can not do (e.g. Retrieval of fault codes).
In choosing a DVOM several factors need to be considered, one of which is Impedance.
Impedance is the combined resistance to current created by the resistance, capacitance and inductance of the
meter. Impedance is measured in 'Ohms per Volt'.
Meters with the highest 'Ohms per Volt' impedance are the most accurate. More importantly using a meter
with high impedance will not cause damage to sensitive electronic circuitry.
When a Meter is connected across a circuit to measure voltage, it must be connected in parallel. This adds
parallel resistance. The total resistance in a parallel circuit is less than the lowest resistance in that circuit (Ohms
Law). Using a Meter with low impedance will reduce the total resistance of the circuit and allow more current
to flow.
A meter with low impedance can draw enough current to cause inaccurate measurement, voltage drops or
damage sensitive electronic circuit boards. A high impedance meter will draw little current and insure accurate
readings.
Using older type meters with low impedance values (20,000 to 30,000 ohms-per-volt) can damage modern
electronic circuits and components or give inaccurate readings.
Test lights should be avoided for the same reason. They lower the total resistance of the circuit and cause
increased current flow.
Other factors in choosing the proper DVOM are:
Cost.
Features.
2010 BMW M3
Basic DVOM's are available reasonably priced. These basic models may be more than sufficient for use in
BMW Centers, given the availability of the DISplus and MoDic for advanced measurement and scope
functions.
Advanced features and price go hand in hand. The more features added the higher the cost. Some of those
features may be worth the increase in cost (e.g. frequency, duty cycle and pulse width). Other features may not
(e.g. oscilloscope, graphing).
Choose a DVOM wisely based on personal preference and cost. Like many other tools it is valuable in the
diagnosis and repair of BMW's. Experience has shown if the technician is not comfortable with the DVOM or
confident in the results of the measurements, the DVOM will not be used. Considering the technology in BMW
automobiles, diagnosing with a quality DVOM certainly makes repairing the problem correctly and expediently
a more manageable task.
THE FUNCTIONS
Function Selector Rotary Switch
Fig. 2: Identifying Function Selector Rotary Switch (Off)

Power to the meter is turned off.

2010 BMW M3
Fig. 3: Identifying Function Selector Rotary Switch (Volts AC)

Volts AC.
Measures AC voltage.
Ranges 400mV, 4V, 400V, 1000V.

2010 BMW M3
Fig. 4: Identifying Function Selector Rotary Switch (Volts DC, RPM)

Volts DC, RPM.
Measures DC Voltage.
Ranges 4V, 40V, 400V, 1000V.

2010 BMW M3
Fig. 5: Identifying Function Selector Rotary Switch (mV)

mV.
Measures DC Millivolts.
Range: 400mV.
2010 BMW M3
Fig. 6: Identifying Function Selector Rotary Switch (Continuity/Ohms)

Continuity/Ohms.
Measures Continuity and Ohm.
Ranges: 400ohms,4kohms, 400kohms, 4Mohms, 40Mohms.

2010 BMW M3
Fig. 7: Identifying Function Selector Rotary Switch (Diode Test)

Diode Test.
Test diode operation.
Range: 3.000V.
2010 BMW M3
Fig. 8: Identifying Function Selector Rotary Switch (Amps DC)

Milliamp or Amps DC.
Measures DC Milliamps or amps.
Ranges: 40mA or 400mA for mA input 4000mA or 10 A for A input.

2010 BMW M3
Fig. 9: Identifying Function Selector Rotary Switch (Amps AC)

Milliamps or Amps AC.
Measures AC Milliamps or amps.
Ranges: 40mA or 400mA for mA input 4000mA or 10 A for A input.
PUSH BUTTON FUNCTIONS

2010 BMW M3
Fig. 10: Identifying Push Button Functions

Zero (Relative Reading) Function:
Displays difference between the measured value and the stored value.
2010 BMW M3
Fig. 11: Identifying Zero (Relative Reading) Push Button

Minimum (Min), Maximum (Max), Average (AVG) Recording:
Records minimum, maximum and calculates the true average.

2010 BMW M3
Fig. 12: Identifying Min/Max, AVG Recording Push Button

Manual Range or Autorange:
In Manual Range user selects fixed range. Meter stays in that range until user changes it, selects Autorange or
turns meter off. In Autorange meter selects range automatically.
2010 BMW M3
Fig. 13: Identifying Manual Range or Autorange Push Button

Touch Hold:
Touch Hold holds last stable reading on display. A new stable reading causes beeper to sound and display to
update.
If meter is in MIN MAX Recording, RPM, Duty Cycle, Pulse Width or Hz, Touch Hold interrupts the function.
The display is frozen, but recorded readings are not erased.
2010 BMW M3
Fig. 14: Identifying Touch Hold Push Button

RPM / HZ.
RPM 2, RPM 1, or frequency.
RPM 2, 4-cycle engines.
RPM 1, 2-cycle engines.
Hz. counts frequency between 0.5 Hz and 200 kHz.

2010 BMW M3
Fig. 15: Identifying RPM / HZ Push Button

Duty Cycle or Pulse Width.
Duty Cycle between 0.0 and 99.9% displayed.
Pulse Width between 0.002 and 1999.9 ms displayed.

2010 BMW M3
Fig. 16: Identifying Duty Cycle Or Pulse Width Push Button

Change Alert, Continuity Beeper or +/- Trigger.
In voltage or current functions selects Change Alert.
In ohms function selects Continuity Tests.
In Duty Cycle or Pulse Width selects trigger slope.

2010 BMW M3
Fig. 17: Identifying Change Alert Push Button

Smoothing Function and Back-light display (advance model only).
Smooth displays average of last eight readings.
Press Yellow button to turn on or off back-light.

2010 BMW M3
2010 BMW M3
Fig. 18: Identifying Smoothing Function Push Button

INPUT TERMINALS
Fig. 19: Identifying Input Terminals

DISPLAY
2010 BMW M3
Fig. 20: View Of Functions Display

INFINITY DISPLAY
While most displays of DVOMs are standard ( i.e. mV means millivolt, mA means milliamp) the display or
symbol for infinity or open circuit can be confusing. A display of 0ohms indicates no or little resistance. It
means the circuit or portion of the circuit being measured has continuity or is complete. A reading of OL means
the circuit is open or not complete, the resistance is said to be "INFINITY". Some meters may use the symbol
"INFINITY" for Infinity. Be aware of which reading the meter being used will give for infinity or open circuit.
Fig. 21: Infinity Display

VOLTAGE TESTING
The voltmeter (DVOM) must be connected in parallel with the load or circuit.
The DVOM has a high resistance and taps off a small amount of current.
A voltmeter must be used with the current on and with the correct polarity.
The red lead should be connected to the B+ side of the circuit and the black lead to the B- side of the circuit.
If the leads are reversed the reading will be a negative number.
Typical Application of Voltage Testing

2010 BMW M3
Checking Power Supply.

Charging System.
Complete Basic Circuits.
Control Module Functions (Input/Output).
2010 BMW M3
Fig. 22: Identifying Voltage Testing

2010 BMW M3
Measure at different points checking for change or interruption in the voltage supply.
Select proper function and range of DVOM.

Connect (-) lead of meter to battery B- or known good ground.
Connect (+) lead of meter to test circuit.
DVOM will indicate supply or available voltage at that point.
AMPERAGE TESTING
To measure amperage the meter must be installed in series in the circuit. The current flow of the circuit must
flow through the meter itself.
Current must be flowing in the circuit.
Installing the meter in parallel with the circuit may cause damage to the meter, because of the increased current
flow in the circuit, due to the low resistance in the meter.
CAUTION: Most ampere meters or DVOMs are rated for no more than 10 amps.
Current flow above 10 amps will damage the internal fuse of the DVOM and
render it unable to measure amperage.
Typical Application of Amperage Testing
Proper Component Operation (Correct Current Draw).

Parasitic Draw Testing.
2010 BMW M3
Fig. 23: Identifying Amperage Testing

Ensure meter is capable of handling current flow.

2010 BMW M3
Use caution when activating additional consumers.
Select proper function of DVOM and move leads to proper position.

Connect meter in series with (+) lead on the B+ side of the circuit.
Connect (-) lead of meter to complete circuit.
NOTE: If the expected load may exceed the range of the meter, use a meter with a
higher range (DISplus inductive pick-up) for initial testing.A convenient location
to apply meter (e.g. across fuse terminals). DVOM will indicate current flow
(Amps) through circuit.
RESISTANCE TESTING
When set for resistance testing (Ohms) the DVOM must never be connected in a live circuit.
The component or portion of a circuit being measured, must be isolated from the power source.
Most modern day DVOM's are self ranging when set to measure resistance, so the meter can not be damaged by
out of range measurements.
The test leads may be used without regard for polarity, unless the circuit contains a diode.
The DVOM functions by placing a very small amount of current on the circuit being tested, the red lead must be
placed on the anode side of the diode.
Typical Application of Resistance Testing
Locating a Short to Ground (As Shown).

Determining Resistance of Components (e.g. Temp Sensors and Injectors).
2010 BMW M3
Fig. 24: Identifying Resistance Testing

An Ohmmeter uses its internal power to test a circuit or component.

2010 BMW M3
Select correct function and range (Most meters are self ranging in this function).
Disconnect power to circuit.
Disconnect any circuit wired in parallel with circuit being tested.
Connect test leads.
NOTE: There must be NO current available to the circuit during the resistance (Ohmic)
test. DVOM will indicate resistance (Ohms) of component or circuit being
tested.
CONTINUITY TESTING
The DVOM may have a separate setting for continuity testing.
When set for continuity testing the DVOM must never be connected in a live circuit.
The power source must be disconnected from the circuit being tested. Any circuits wired in parallel with the
circuit being tested must also be disconnected.
The DVOM uses its own internal power supply to test the continuity of the circuit.
Continuity testing verifies that circuit connections are intact. The continuity mode is extremely fast and is used
to detect either shorts or opens that last as little as 1ms.
When a change is detected the beeper tone is stretched to last at least 1/4 second so both shorts and opens can be
audibly detected.
This is a valuable troubleshooting aid when diagnosing intermittent faults associated with wiring, connections,
switches and other components of the circuit.
Typical Application of Continuity Testing:
Circuit Continuity.
Intermittent Wiring Harness Faults.
2010 BMW M3
Fig. 25: Identifying Continuity Testing

2010 BMW M3
Select correct function and range of DVOM.

Disconnect power to the circuit.
Disconnect any circuits wired in parallel.
Connect DVOM leads to the circuit to be tested.
NOTE: There must be NO current available to the circuit during the continuity test.
DVOM display will indicate continuity of circuit.
VOLTAGE DROP TESTING
Voltage Drop Tests determine the resistance of an active circuit, a circuit with current flowing.
Voltage drop tests are preferred over simple resistance measurements because the power source is not removed
from the circuit.
By measuring the voltage on both sides of a load, the amount of voltage consumed by the load is measured.
The voltage drops of each part of a series circuit added together must equal the power supply for that circuit
while it is active.
Typical Application of Voltage Drop Testing:
Determine proper component operation.

Active circuit continuity.
Active circuit resistance.
2010 BMW M3
Fig. 26: Identifying Voltage Drop Testing

As a "Dynamic" test with the circuit operational, a voltage drop in any non-resistive part of the circuit indicates
a fault in the circuit,
Select proper function and range of DVOM.

Connect (+) lead to the B+ side of the circuit or component being tested.
Connect (-) lead to the B- side of the circuit or component.
NOTE: All consumers of the test circuit should be active during the test. Always
include ground circuit as part of voltage drop test. DVOM display will indicate
the voltage drop in the circuit tested between the DVOM leads.
2010 BMW M3
2005 GENERAL INFORMATION Electronic Signals - Overview - All Models
2005 GENERAL INFORMATION
Electronic Signals - Overview - All Models
ELECTRONIC SIGNALS
Model: All
PURPOSE OF SIGNALS
Electronic signals move information much like cars move passengers down the highway. It would be difficult to
get to work without transportation, and there would be no transportation with out signals.
Signals allow devices (e.g. sensors or switches) to communicate with control modules (either complicated
processors or simple relays) which in turn perform or request (through more signaling) other functions to be
carried out.
Signals inform the Climate Control of the outside air temp or tell the brake lights the right time to illuminate.
The use of electronic signals goes far beyond the basic application of electron flow to control components,
enabling complex information to be passed from one component to another.
The data (input or output) is conveyed through various forms of changing voltages, resistances, current or
frequency modulation.
1. AC Voltage Signals:
A. Inductive Signals.
B. Phase Shifted Signals.
2010 BMW M3
Fig. 1: Identifying AC Voltage Signals

2. DC Voltage Signals:
A. Analog Signals.
B. Digital Signals:
1. Switched (High/Low) Signals.
2. Modulated Square Wave Signals:
a. Frequency Controlled Signals.
b. Pulse Width Controlled Signals.
c. Duty Cycle Controlled Signals.
C. Designated Value Signals.
D. Coded Ground Signals.
E. Transistor Signals:
1. Modulated B+/B- Signals.
2. Momentary B+/B- Signals.
2010 BMW M3
3. Constant B+/B- Signals.
Fig. 2: Identifying DC Voltage Signals

AC VOLTAGE SIGNALS
Two types of AC Voltage signals are used:
Inductive Signals (Induced Voltage).

Phase Shifted Signals (Angle Pulse Generator).
INDUCTIVE SENSORS
Inductive sensors produce an AC Sine Wave signal. The AC voltage is induced by the shifting of a magnetic
field. The sensor consists of an impulse wheel (the moving part) and a coil wound magnetic core (the stationary
part).
2010 BMW M3
As each tooth of the impulse wheel approaches the sensor tip, the magnetic field of the sensor shifts toward the
impulse wheel and induces a voltage pulse in the windings.
As the teeth move away from the sensor, the magnetic field shifts back inducing a voltage pulse in the opposite
direction.
This shifting of the magnetic field produces an alternating current (positive to negative).
Control modules which receive this alternating current, count the impulses (shifts from positive to negative) and
interpret the speed of rotation of the impulse wheel.
2010 BMW M3
Fig. 3: Inductive Sensor Circuit Diagram

Typical Application of Inductive Sensors:

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Crankshaft Speed Sensor.

Camshaft Speed Sensor.
Transmission Input/Output Speed Sensor.
Wheel Speed Sensor.
Fig. 4: Identifying AC Sine Wave Signal

Voltage levels are dependent on sensor design.
Not all inductive sensors produce 12 volts.
ANGLE PULSE GENERATOR
An Angle Pulse Generator Sensor acts on an existing AC voltage signal rather than produce a new one.
The sensor consists of two windings (primary and secondary) that are connected together at one end and a
2010 BMW M3
magnetic iron core (stationary) along with a trigger wheel (movable).
Fig. 5: Checking Angle Pulse Generator

2010 BMW M3
The primary winding (coil) is supplied with a 120kHz AC signal by the control module. The magnetic coupling
(core) causes a voltage at the same frequency to be induced in the secondary winding. The induced frequency
has a slight phase shift due the induction time delay.
The trigger wheel influences the magnetic field of the sensor and causes the phase shift to increase as the disc of
the wheel moves closer to the sensor.
This changing of the phase shift (time delay) from a smaller time period to a larger time period and back again
provides the control module with trigger wheel position.
The angle pulse generator provides position information regardless of movement. Trigger wheel position is
established with the application of an output frequency from the control module and the return of the phase
shifted signal.
Typical Application of Angle Pulse Generator
Camshaft Sensor MS41.1.

Pedal Request Sensor EML.
(a bank of three)
2010 BMW M3
Fig. 6: Angle Pulse Generator Wave Signal

DC VOLTAGE SIGNALS
Five Types of DC Voltage Signals Are Used:
Analog Signals.
Digital Signals.
Designated Value Signals.
Coded Ground Signals.
Transistor Signals.
DC voltage signals are based on either 5 volts or 12 volts.

2010 BMW M3
Fig. 7: Identifying DC Voltage Signals

ANALOG SIGNALS
Analog signals transmit information through an electrical circuit by regulating or changing the current or
voltage.
The voltage of the signal has no fixed value. The value may be anywhere in the operating range of the signal.
Three sources of analog signals are:
NTC Sensors.
PTC Sensors.
Potentiometers.
2010 BMW M3
Fig. 8: Identifying Analog Signals

NTC SENSORS
NTC (Negative Temperature Coefficient) sensors change resistance based on temperature. As the temperature
goes up the resistance goes down. This decrease in resistance causes the voltage drop across the sensor to
decrease and the input signal voltage at the control module decreases.
2010 BMW M3
Fig. 9: NTC Sensor Circuit Diagram

Examples Of NTC Sensors

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Intake Air Temperature Sensor
The intake air temp sensor provides a 0--5 volt analog signal to the DME indicating temperature of the
incoming air.
The intake air temp sensor is located either in the intake manifold or integrated in the mass air flow meter.
Fig. 10: Checking Intake Air Temperature Sensor

Engine Coolant Temperature Sensor
A dual sensor is used for engine temp. Operation is the same as other NTC sensors, 0-5 volt operating range,
except that two independent sensors are housed in one assembly.
One is for the engine temperature input to the DME.
The other sensor is used to input engine temp to the instrument cluster.
2010 BMW M3
Fig. 11: Checking Engine Coolant Temperature Sensor

Typical Application of NTC Type sensor:
Engine Coolant Temp Sensor.

Intake Air Temp Sensor.
Transmission Temp Sensor.
PTC SENSOR
PTC (Positive Temperature Coefficient) sensors also change resistance based on temperature. In a PTC sensor
as the temperature goes up the resistance also goes up. The increase in resistance causes the voltage drop across
the sensor to increase and the input voltage signal at the control module increases.
2010 BMW M3
Fig. 12: PTC Sensor Circuit Diagram

Typical Application of A PTC Type Sensor:

2010 BMW M3
Exhaust Temp Sensor.

Transmission Temp Sensor.
Example of PTC Sensor
A M5 Catalytic Convertor uses a PTC type sensor to monitor exhaust temperature.
A 0-12v signal is supplied to the DME indicating catalyst temperature.
Workshop Hints NTC/PTC Sensors:
When troubleshooting a faulty input display, the input signal must be verified as "good" BEFORE the control
module is replaced.
When checking a NTC Sensor look for these voltages and problems:
0 volts = no supply voltage or shorted to ground.
2v = sensor is indicating a warm condition for system being measured.
4v = sensor is indicating a cold condition for system being measured.
5v = sensor or wiring harness is open.
Remember a PTC type sensor will indicate opposite results on intermediate readings (i.e. 4 volts = warm).
POTENTIOMETERS
A Potentiometer produces a gradually changing voltage signal to a control module. The signal is infinitely
variable within the operating range of the sensor.
This varying voltage reflects a mechanical movement or position of the potentiometer wiper arm and its related
components.
2010 BMW M3
Fig. 13: Identifying Potentiometer

Typical Application of Potentiometers:
Air Flow Meter.

Pedal Position Sensors.
Seat and Mirror Memory Position.
Throttle Position Sensors (Also Feedback Potentiometers).
DIGITAL SIGNALS
Digital Signals transfer information through an electrical circuit by switching the current on or off. Unlike
analog signals which vary voltage, a digital signal has only two possible states, control voltage or 0 voltage.
Two types of Digital Signals:
Switched (High/Low) Signals.

Modulated Square Wave signals.
SWITCHED B+ SIGNAL
2010 BMW M3
This DC voltage signal produces a YES/NO type input to the control module. The voltage level will indicate a
specific operating condition.
Fig. 14: Digital Signals Transfer Information Chart

2010 BMW M3
2010 BMW M3
Fig. 15: Identifying Brake Light Switch

Hall effect Brake Light Switch
Fig. 16: Identifying DC Voltage Signal

Typical Application of Switched B+:
Ignition Switch.
Seat Belt Switch.
Light Switch.
Hall Effect Switch (e.g. Brake Light Switch).
Reed Switch.
SWITCHED B- SIGNAL
2010 BMW M3
Fig. 17: Identifying (High/Low) Signal

This Ground Signal produces a YES/NO type input to the control module. The voltage level will indicate a
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specific operating condition.
Fig. 18: Identifying Ground Signal

Typical Application of Switched B-
Door Position Switch.

Kickdown Position Switch.
A/C Pressure Switch.
MODULATED SQUARE WAVE
A Modulated Square Wave is a series of High/Low signals repeated rapidly.
Like the switched signals (B+, B-) the square wave has only two voltage levels.
A high level and a low level.

2010 BMW M3
Fig. 19: Identifying Modulated Square Wave

A modulated square wave has 3 characteristics that can be modified to vary the signal:
Frequency.
Pulse Width.
Duty Cycle.
Frequency
The frequency of a modulated square wave signal is the number of complete cycles or pulses that occur in one
second. This number of cycles or frequency is expressed in Hertz (Hz) . 1Hz = 1 complete cycle per second.
An output function may use a fixed or varied frequency.

2010 BMW M3
Fig. 20: Identifying Modulated Square Wave Signal

Pulse Width
The Pulse Width of a square wave is the length of time one pulse is ON. Vehicle systems may use fixed or
varied ON times or pulse width. Pulse width is expressed in milliseconds (ms).
2010 BMW M3
Fig. 21: Identifying Pulse Width Display

Duty Cycle
The Duty Cycle of a square wave is the ratio of ON time to OFF time for one cycle.
Duty cycle is expressed in %.
Vehicle systems use both fixed duty cycle signals and variable duty cycle signals.
2010 BMW M3
Fig. 22: Identifying Duty Cycle (1 Of 2)

2010 BMW M3
Fig. 23: Identifying Duty Cycle (2 Of 2)

Time
1 second = 1000 milliseconds (ms).
1/2 second = 500 milliseconds.

2010 BMW M3
HALL-EFFECT SENSORS
Hall Effect Sensors produce a modulated square wave.
Hall Effect Sensors are electronic switches that react to magnetic fields to rapidly control the flow of current or
voltage ON and OFF.
The Hall Sensor consists of an epoxy filled non-magnetic housing containing a hall element and a magnet, and a
trigger wheel.
2010 BMW M3
Fig. 24: View Of Hall Effect Sensors

The Hall element is a thin non-magnetic plate which is electrically conductive. (Voltage will flow through the
plate.) Electron flow is equal on both sides of the plate.
Since everything between the magnet and the hall element is non-magnetic the magnet (magnetic field) has no
effect on the current flow.
As a metal disk or solid area of a toothed wheel, flywheel or other trigger device approaches the sensor, a
magnetic field is created between the magnet and the disk.
2010 BMW M3
Fig. 25: Identifying Magnetic Field

The magnetic field cause the electron flow to stop on one side of the plate. Electrons continue to flow on the
other side of the plate.
The Hall Sensor Signal is a measurement of the voltage drop between the two sides of the plate or element.
When the magnetic field increases (disc or solid toothed area in front of sensor) the voltage drop across the two
sides of the element increases. High voltage on one side, little on the other. The signal output from the sensor is
High.
As the disc moves away from the sensor the magnetic fields weakens and is lost. The loss of the magnetic field
( blank toothed or open area of the wheel in front of the sensor) produces very little voltage drop across the two
sides of the element. The output signal is Low.
This rapid switching of the voltage ON/OFF produces a HIGH/LOW signal that the control module uses to
recognize speed and position.
2010 BMW M3
Examples of Hall Effect Sensors
Motor Position Hall Sensors
Hall sensors are used on many electric motors to monitor speed and position. (i.e. electric window motors and
sunroof motors.)
The Hall Effect principal is the same except the magnet is placed on the shaft of the motor.
The magnet is aligned to rotate in a precise position in front of the element. The polarization of the magnetic
ring causes a polarity switch in the Hall element to occur as it rotates The square wave produced provides speed
and position information to the control module.
2010 BMW M3
Fig. 26: Identifying Motor Position Hall Sensors

Wheel Speed Hall Effect Sensors
Hall Effect sensors are used to indicate wheel speed.
Conventional Hall Effect Sensors use three wires, power supply (usually 5v or 12v) a ground wire and a signal
wire back to the control module.
The Hall Effect sensors used as wheel speed sensors are unique in that they are two wire Hall Effect Sensors.
2010 BMW M3
The two wire sensors eliminate the separate ground wire and the signal wire functions as the ground also.
Fig. 27: Identifying Wheel Speed Hall Effect Sensors

The unique two wire arrangement provides the control module with a HIGH/LOW signal having a low voltage
2010 BMW M3
of .75 volts and a high voltage of 2.5 volts.
Typical Application of Hall Effect sensors
Crankshaft Sensors.
Motor Position and Speed Sensors (e.g. Window Motor, Sunroof Motor).
Camshaft Sensors.
Wheel Speed Sensors.
MAGNETORESISTIVE SENSORS
The active sensing of the Magnetoresistive Sensor is particularly suitable for advanced stability control
applications in which sensing at zero or near zero speed is required.
A permanent magnet in the sensor produces a magnetic field with the magnetic field stream at a right angle to
the sensing element.
2010 BMW M3
Fig. 28: Exploded View Of Magnetoresistive Sensors

The sensor element is a ferromagnetic alloy that changes its resistance based on the influence of magnetic
fields.
As the high portion of the pulse wheel approaches the sensing element a deflection of the magnetic field stream
is created. This creates a resistance change in the thin film ferromagnetic layer of the sensor element.
Fig. 29: View Of Sensor Element

The sensor element is affected by the direction of the magnetic field, not the field strength. The field strength is
not important as long as it is above a certain level. This allows the sensor to tolerate variations in the field
strength caused by age, temperature, or mechanical tolerances.
The resistance change in the sensor element affects the voltage that is supplied by the evaluation circuit. The
small amount of voltage provided to the sensor element is monitored and the voltage changes (1 to 100mv) are
converted into current pulses by the evaluation module.
2010 BMW M3
Fig. 30: Identifying High And Low Current Pulses

Signal Low-7mA .
Signal High-14mA .
The sensor is supplied 12V by the control unit. Output voltage from the sensor is approximately 10V. The
control unit counts the high and low current pulses to determine the wheel speed.
Typical Application of Magnetoresistive Sensor:
Found Currently on E46 with Teves DSCIII MK-60.
DESIGNATED VALUE SIGNALS
Designated values are produced through fixed resistance positions of a multi-position switch. As the switch is
2010 BMW M3
operated the voltage drop across the resistor(s) of each switch position causes the voltage level of the input
signal to change to a predetermined voltage value.
These predetermined (designated) voltages signal the control module to perform specific functions.
Fig. 31: Identifying Designated Value Signals

Voltage Values seen as input by control module.
Fig. 32: Voltage Values Display

2010 BMW M3
Typical Application of Designated Values:
Cruise Control Switch On E 32.

Seat and Mirror Memory Position Buttons.
Coded Ground Signals
Coded ground signals produce a set of High/Low requests, the combination (pattern) of which is interpreted by
the control module to perform a specific function. Coded ground signals are generated through a switch or
series of switches signaling the control module requests for operation.
Fig. 33: Identifying E 36 Wiper Circuit

2010 BMW M3
Fig. 34: Identifying E 39 Wiper Circuit

TRANSISTOR FUNCTION
The transistor takes on a number of applications that must be understood to effectively analyze a circuit.
The transistor in operation functions as two parts much like a relay. Both the relay and the transistor control
high currents with a low current signal.
2010 BMW M3
Fig. 35: Identifying Transistor Final Stage Function (1 Of 2)

The base/emitter path functions as the control circuit activated by the control module to oversee or control the
work.
The collector/emitter path functions as the work side of the circuit, supplying power or switching on the work.
In operation the transistor can be switched ON momentarily, or supply a constant power or ground.
The transistor can also be modulated or pulsed to supply a modulated square wave signal.
2010 BMW M3
Fig. 36: Identifying Transistor Final Stage Function (2 Of 2)

Modulated, Momentary, Constant B- as Input/Output
The input signal of control module 1 is an output signal of control module 2.

2010 BMW M3
Control module 2 through activation of its internal transistor provides a ground input for control module 1.
Fig. 37: Identifying Modulated, Momentary, Constant B- As Input/Output Function

The input signal at control module 1 is either a momentary/constant signal (i.e torque convertor signal from
TCM to DME) or a modulated signal (i.e. vehicle speed signal ASC to DME).
2010 BMW M3
Fig. 38: Identifying Wheel Speed Signal And Output Pulse

Typical Application of Modulated, Momentary, Constant B- as Input/Output Signal:
A/C KO Signal.
Speed Signal From ABS/ASC.
TI/TD Output Signal From DME.
Momentary/Constant B+ as an Input/Output Signal

2010 BMW M3
Fig. 39: Identifying Momentary/Constant B As An Input/Output Signal Function

Typical Application of Momentary/Constant B+ as an Input/Output Signal:
OBC Code Signal to DME.

A/C Signal to DME.
Constant B-/B+ To Energize a Component
Constant B-
Output function to energize a component.
Relay is energized by control module.
Internal activation of the transistor provides a ground for the relay coil.
2010 BMW M3
Fig. 40: Identifying Output Function To Energize Component (Constant B-)

Constant B+
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Fig. 41: Identifying Output Function To Energize Component (Constant B+)

Control module output function to energize a component.
Transistor controls output function of the control module.

2010 BMW M3
Control module supplies power to the relay. The relay is activated by the control module through internal
activation of the transistor which provides a ground for the relay coil.
Modulated B-/B+ To Operate A Component
Modulated B-
Output function to operate a component.
The idle valve motor is operated by the control module through internal activation of the transistor which
provides a ground for the open winding of the valve.
The idle control valve is operated by regulation of the duty cycle at a specific frequency.
2010 BMW M3
Fig. 42: Identifying Output Function To Operate Component (Modulated B-)

Typical Application of modulated B-
Idle Control Motor.

Purge Valve.
Injector.
Ignition Coil.
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Modulated B+
Fig. 43: Identifying Output Function To Operate Component (Modulated B+)

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Output function to operate a component.
The motor is controlled by a transistorized function of the control module, which provides a modulated voltage
at a specific frequency to the motor. The throttle position is changed by altering the Duty Cycle of the pulses.
2010 BMW M3
ACCESSORIES AND BODY, CAB Electrical Drives - Repair
Electrical Drives - Repair
ELECTRIC DRIVES

function is active.

Fig. 1: Identifying Automatic Engine Start/Stop Function (MSAs) Button

Workshop mode
A = 10 mm
B = 7 mm
2010 BMW M3
Fig. 2: Identifying Basic Setting For Engine Hood/Bonnet Open

CENTRAL LOCKING UNIT/UNLOCKING UNITS

67 11 555 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR TANK FILLER FLAP
Remove TOP TRIM FROM TAIL PANEL

Partially remove LUGGAGE COMPARTMENT WHEEL ARCH TRIM ON RIGHT
Feed out emergency actuation pull strap (1) in direction of arrow.
Fold acoustic insulation (2) forwards.

2010 BMW M3
Fig. 3: Pulling Strap

Slacken screws (2)
Feed servodrive for fuel filler flap (3) in direction of arrow out of retaining plate (4) and remove.
Installation:
Carry out adjustment of servodrive for tank filler flap (3) via both elongated holes. It must be possible to lock or
unlock the fuel filler flap completely.
Fig. 4: Removing Servodrive Out Of Retaining Plate

Turn sleeve (1) with a suitable tool (e.g.: pointed pliers) approx. 45 in direction of arrow and pull out of cover
housing (2).
2010 BMW M3
Fig. 5: Turning Sleeve

Installation:
Slide sleeve (1) over locking pin (2).
Make sure sleeve (1) is correctly engaged in cover housing (3).
Fig. 6: Sliding Sleeve Over Locking Pin

Replacement:
Release screws (1).
Disengage emergency actuation pull strap (2) from retainer (5) and remove towards front.
If necessary, unclip locking pin (3) in direction of arrow from servodrive for tank filler flap (4).
2010 BMW M3
Fig. 7: Removing Locking Pin From Servodrive

67 11 510 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR FRONT LEFT OR

RIGHT DOOR LOCKING MECHANISM
NOTE: Servodrive for door locking mechanism is integrated in door lock in front door.
Procedure is described in DOOR LOCK IN FRONT DOOR .
67 11 530 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR REAR LEFT OR

"REMOVING DOOR LOCK FOR REAR DOOR ."
67 11 560 REPLACING ACTUATOR DRIVE FOR REAR LID LOCKING
"Removing REAR LID LOCK "
MIRROR ADJUSTMENT
67 13 001 REPLACING DRIVE UNIT FOR ELECTRICALLY OPERATED LEFT OR RIGHT DOOR
MIRROR
Remove MIRROR GLASS for mirror
Release screw (1).

2010 BMW M3
Remove drive for electrically operated door mirror (2) in direction of arrow from mirror housing (3).
Fig. 8: Removing Drive For Electrically Operated Door Mirror

Installation:
Fit drive for electrically operated door mirror (1) so that pin housing (2) engages exactly in plug housing (3) and
locators (4) slide into guides (5).
Fig. 9: Identifying Electrically Operated Door Mirror, Pin Housing, Plug Housing And Locators
67 13 025 REPLACING MIRROR ELECTRONICS FOR ELECTRICALLY OPERATED LEFT OR

RIGHT DOOR MIRROR
Remove DRIVE FOR DOOR MIRROR

2010 BMW M3
Remove HOUSING ON DOOR MIRROR

Remove DOOR MIRROR
Release screw (1).
Remove cover cap (2).
Fig. 10: Identifying Cover Cap With Screws

Press together catches (1) of plug (2) and press plug (2) through in outward direction.
Unlock plug (2) on contact carrier (3) and pull out.
Fig. 11: Identifying Catches, Plug On Contact Carrier

2010 BMW M3
Carefully release latch mechanisms (1).
Feed out mirror electronics (2) with cable.
Fig. 12: Identifying Latch Mechanisms And Mirror Electronics

SERVO POSITIONING DRIVES

67 16 011 REMOVING AND INSTALLING/REPLACING LEFT VERTICAL AIM ADJUSTER
(XENON HEADLIGHT)
WARNING: Version with xenon headlights: Danger to life due to high voltage!
Therefore disconnect all components from voltage supply before removal.
Work on the entire xenon lighting system (control unit, ignition unit with
lamp) may only be carried out by specialist personnel.
Remove WHEEL ARCH COVER FRONT SECTION at front
NOTE: For purposes of clarity, following illustrations show headlight removed.

2010 BMW M3
Fig. 13: Identifying Cover With Screws

Release screws (1).

Slide headlight insert (2) upwards in direction of arrow.
Move vertical aim adjuster (3) downwards in direction of arrow and feed out.
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Fig. 15: Sliding Headlight Insert

Installation:
Feed ball head of vertical aim adjuster (1) into mounting (2).
Fig. 16: Identifying Vertical Aim Adjuster Into Mounting

After installation
ADJUST HEADLIGHTS
67 16 016 REMOVING AND INSTALLING/REPLACING RIGHT HEADLIGHT VERTICAL AIM

ADJUSTER
REMOVING AND INSTALLING/REPLACING LEFT HEADLIGHT VERTICAL AIM ADJUSTER

2010 BMW M3
DRIVE, SEAT ADJUSTMENT

67 31 531 REMOVING AND INSTALLING/REPLACING DRIVE UNIT FOR BACKREST ANGLE
ADJUSTMENT
Remove OUTER COVER
Release screws (1).
Remove drive for backrest angle adjustment from flange.
Installation:
Make sure drive shaft is correctly seated in gearbox.
Fig. 17: Identifying Screws And Plug Connections

67 31 501 REMOVING AND INSTALLING/REPLACING DRIVE UNIT FOR LONGITUDINAL SEAT

ADJUSTMENT
Remove FRONT SEAT

2010 BMW M3

Bend metal tab (1) open.
Fig. 19: Identifying Metal Tab

Lift drive (1) and flex shaft (2) out of guide (4) in direction of arrow.
Detach drive (1) from rubber mounts (3).
Detach flex shaft (2) from drive (1).

2010 BMW M3
Fig. 20: Lifting Drive And Flex Shaft Out Of Guide

Fig. 21: Identifying Short And Long Flex Shafts

Installation:
Slide short flex shaft (1) into longitudinal seat adjustment gearing square.
Bend long flex shaft (2) upwards and slide into longitudinal seat adjustment gearing.
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Clip motor and flex shafts into carrier plate.
Make sure flex shafts are correctly seated in gearboxes.
67 31 521 REMOVING AND INSTALLING/REPLACING DRIVE UNIT FOR SEAT HEIGHT

ADJUSTMENT
Remove FRONT SEAT
Remove drive unit for seat height adjustment.
Installation:
Fig. 22: Identifying Plug Connections And Screws

67 31 511 REMOVING AND INSTALLING/REPLACING DRIVE UNIT FOR SEAT TILT

ADJUSTMENT
Remove FRONT SEAT

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Installation:
Fig. 23: Identifying Plug Connections And Screws

DRIVE, SLIDE/TILT SUNROOF/CONVERTIBLE TOP

67 61 005 REPLACING DRIVE WITH GEAR (FRONT) FOR ACTUATING SLIDE/TILT SUNROOF
NOTE: Secure drive with gear for actuating slide/tilt sunroof (3) against falling out.
Release screws (2), tightening torque 54 13 1AZ .
NOTE: Screws (2) are microencapsulated.

Remove drive with gear for actuating slide/tilt sunroof (3).
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Fig. 24: Identifying Actuating Slide/Tilt Sunroof With Plug Connection And Screws
Installation:
Insert gear wheel (1) of drive with gear for actuating slide/tilt sunroof (2) exactly in gear teeth (3).
Fig. 25: Identifying Gear Wheel, Actuating Slide/Tilt Sunroof And Gear Teeth
Installation:
Initialize GLASS SLIDE/TILT SUNROOF (INITIALIZATION/NORMAL OF

CHARACTERISTIC CURVE)
DRIVE, POWER WINDOW

67 62... NOTES ON INITIALIZING POWER WINDOW UNIT IN FRONT DOOR
2010 BMW M3

There is no anti-trapping protection during initialization.
An initialization must be performed:
In the event of malfunctions, e.g. no one-touch control function, no opening or if available no comfort
function is possible
After the power window drive has been replaced
After work is carried out on the power window mechanism
If necessary, after an open circuit, e.g. disconnection of the battery or disconnection of the power supply
to the door
After the door window glass has been removed and installed or replaced
After adjustment work on the door window glass
After adjustment work on the convertible top
After replacement of seals
Initialization is performed on the power window switch of the relevant door.
Requirements for correct initialization:
Terminal "R" activated

Doors and windows closed
Sufficient battery voltage; connect charger if necessary
Initialization comprises:
Erasure of initialization
Reinstallation
Erasure of initialization:
Open door window glass fully

Actuate power window switch in "Open" position (second switch position) and hold down for between 15
and 20 seconds
This clears initialization of the power window. Anti-trapping protection and one-touch control (toll) function
are inactive.
Check whether one-touch control (toll) function is inactive, otherwise repeat procedure.
Reinstallation:
Close door window completely

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After upper end position is reached, interrupt actuation of power window switch and then hold switch
again for approx. 1 second in "Close" position (second switch position)
again for approx. 1 second in "Open" position (second switch position)
This completes initialization.
NOTE: Carry out function check (one-touch control function, anti-trapping protection
and, if necessary, comfort function).
NOTE: The power window can also be initialized in the BMW diagnosis system by
means of a diagnosis job.
67 62 000 REMOVING AND INSTALLING/REPLACING FLAT MOTOR FOR FRONT LEFT OR

RIGHT POWER WINDOW UNIT
Remove POWER WINDOW UNIT in front door
Release screws (1).
Detach flat motor for power window unit (2) from power window unit and remove.
Installation:
Fit flat motor for power window unit (2) exactly on teeth of power window unit.
Carry out function check (one-touch function, anti-trapping protection and, if necessary, comfort function).
2010 BMW M3
Fig. 26: Identifying Power Window Unit With Screws

Replacement
A normalization must be carried out in order to activate anti-trapping protection.
Operating sequence for normalization:
Operate corresponding power window switch in "Close" setting.

Once the upper end position has been reached, hold power window switch down for approx. 1 second
more.
Normalization is thus completed.
67 62 020 REMOVING AND INSTALLING/REPLACING FLAT MOTOR FOR REAR LEFT OR

Remove rear POWER WINDOW UNIT
Release screws (1), tightening torque 51 35 1AZ .
Detach flat motor for power window unit (2) in direction of arrow from power window unit (3).
Installation:
2010 BMW M3
Fig. 27: Disconnecting Flat Motor From Power Window Unit

Replacement:

more.
If necessary, repeat procedure again.
NOTE: Carry out function check (one-touch function, anti-trapping protection and, if
necessary, comfort function).
DRIVE, WIPER/HEADLIGHT WASHER SYSTEM

67 63 512 REPLACING WIPER MOTOR
Removing complete CONSOLE FOR WINDSCREEN WIPER SYSTEM .

67 66 010 REMOVING AND INSTALLING/REPLACING LUMBAR SUPPORT DRIVE MECHANISM
ON FRONT SEAT, LEFT OR RIGHT
2010 BMW M3
Remove REAR PANEL ON FRONT SEAT BACKREST
Remove drive unit for lumbar support (2) with jacket from backrest frame and expose.
Installation:
Make sure drive unit for lumbar support (2) is in correct installation position.
Fig. 28: Identifying Plug Connection And Lumbar Support

Detach hose (1) from drive unit (2).
NOTE: Gently heat hose (1) if stuck.
Installation:
Hose (1) on drive unit (2) must not be kinked.
Pull jacket (3) off drive unit (2).
Remove drive unit for lumbar support (2).

2010 BMW M3
Fig. 29: Disconnecting Hose From Drive Unit

2010 BMW M3
ACCESSORIES AND BODY, CAB Electrical Drives - Repair - M3
Electrical Drives - Repair - M3
CENTRAL LOCKING UNIT

67 11 510 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR FRONT LEFT OR
NOTE: Servodrive for door locking mechanism is integrated in door lock in front door.
Procedure is described in 51 21 090 REMOVING AND INSTALLING/REPLACING DOOR LOCK IN

LEFT OR RIGHT FRONT DOOR .
67 11 530 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR REAR LEFT OR

"Removing door lock for rear door."
67 11 555 REMOVING AND INSTALLING / REPLACING SERVODRIVE FOR TANK FILLER FLAP
(COUPE/SEDAN)
Remove top trim from tail panel . See 51 46 050 REMOVING AND INSTALLING/REPLACING
Partially remove luggage compartment wheel arch trim on right . See REMOVING AND
INSTALLING / REPLACING RIGHT LUGGAGE COMPARTMENT WHEEL ARCH TRIM
Feed out emergency actuation pull strap (1) in direction of arrow.
Fold acoustic insulation (2) forwards.

2010 BMW M3
Fig. 1: Pulling Strap

Slacken screws (2)
Feed servodrive for fuel filler flap (3) in direction of arrow out of retaining plate (4) and remove.
Installation:
Carry out adjustment of servodrive for tank filler flap (3) via both elongated holes. It must be possible to lock or
unlock the fuel filler flap completely.
Fig. 2: Identifying Plug Connection, Fuel Filler Flap And Retaining Plate
housing (2).
2010 BMW M3
Fig. 3: Pulling Cover Housing

Installation:
Slide sleeve (1) over locking pin (2).
Make sure sleeve (1) is correctly engaged in cover housing (3).
Fig. 4: Sliding Sleeve And Locking Pin

Replacement:
Release screws (1).
Disengage emergency actuation pull strap (2) from retainer (5) and remove towards front.
If necessary, unclip locking pin (3) in direction of arrow from servodrive for tank filler flap (4).
2010 BMW M3
Fig. 5: Pulling Strap From Retainer

67 11 555 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR TANK FILLER FLAP

(CONVERTIBLE)
Remove right luggage compartment wheel arch trim . See REMOVING AND INSTALLING /
REPLACING RIGHT LUGGAGE COMPARTMENT WHEEL ARCH TRIM
Lay sound insulation in working area to one side
Slacken screws. Feed out servodrive with emergency actuator pull strap.
housing (2).
Fig. 6: Pulling Sleeve Out Of Cover Housing

2010 BMW M3
Installation: Slide sleeve (1) over locking pin (2). Make sure sleeve (1) is correctly engaged in cover housing
(3).
Fig. 7: Sliding Sleeve

Replacement: Release screws (1). Disengage emergency actuation pull strap (2) from retainer (5) and remove
towards front. If necessary, unclip locking pin (3) in direction of arrow from servodrive for tank filler flap (4).
Fig. 8: Pulling Strap From Retainer

67 11 560 REPLACING SERVODRIVE FOR REAR LID LOCK
This operation is described under:
Removing rear lid lock . See 51 24 100 REMOVING AND INSTALLING/REPLACING REAR LID
LOCK (UPPER SECTION) .
2010 BMW M3
MIRROR ADJUSTMENT
67 13 001 REPLACING DRIVE UNIT FOR ELECTRICALLY OPERATED LEFT OR RIGHT DOOR
MIRROR
Remove mirror glass for mirror. See 51 16 026 REPLACING MIRROR GLASS .
Release screw (1).
Remove drive for electrically operated door mirror (2) in direction of arrow from mirror housing (3).
Fig. 9: Identifying Electrically Operated Door Mirror And Screw

Installation:
Fit drive for electrically operated door mirror (1) so that pin housing (2) engages exactly in plug housing (3) and
locators (4) slide into guides (5).
2010 BMW M3
Fig. 10: Identifying Door Mirror, Pin Housing And Plug Housing
SERVO POSITIONING DRIVE

(XENON HEADLIGHT)
Remove wheel arch cover front section at front. See 51 71 038 REMOVING AND
SECTION) .

2010 BMW M3
Fig. 11: Identifying Headlight Cover And Screw

Release screws (1).
Fig. 12: Identifying Headlight And Screw

2010 BMW M3

Installation:
Fig. 14: Identifying Aim Adjuster Into Mounting

After installation:
Adjust headlights

ADJUSTER
Removing and installing / replacing left headlight vertical aim adjuster .

2010 BMW M3
DRIVE, SLIDE/TILT SUNROOF

67 61 005 REPLACING DRIVE WITH GEAR (FRONT) FOR ACTUATING SLIDE/TILT SUNROOF
NOTE: Secure drive with gear for actuating slide/tilt sunroof (3) against falling out.
Release screws (2).
NOTE: Screws (2) are microencapsulated.
Remove drive with gear for actuating slide/tilt sunroof (3).
Fig. 15: Identifying Tilt Sunroof And Screws

Installation:
Insert gear wheel (1) of drive with gear for actuating slide/tilt sunroof (2) exactly in gear teeth (3).
2010 BMW M3
Fig. 16: Identifying Gear Wheel, Tilt Sunroof And Gear Teeth
Installation:
Initialize slide/tilt sunroof 54 0 ... NOTES ON STEEL AND GLASS SLIDE/TILT SUNROOFS
(INITIALIZATION/NORMALIZATION/LEARNING OF CHARACTERISTIC CURVE)
DRIVE, POWER WINDOW

67 62 ... NOTES ON INITIALIZING POWER WINDOW UNIT IN FRONT DOOR

There is no anti-trapping protection during initialization.
An initialization must be performed:
In the event of malfunctions, e.g. no one-touch control function, no opening or if available no comfort
function is possible
After the power window drive has been replaced
After work is carried out on the power window mechanism
If necessary, after an open circuit, e.g. disconnection of the battery or disconnection of the power supply
to the door
After the door window glass has been removed and installed or replaced
After adjustment work on the door window glass
After adjustment work on the convertible top
After replacement of seals
Initialization is performed on the power window switch of the relevant door.

2010 BMW M3
Requirements for correct initialization:
Terminal "R" activated

Doors and windows closed
Sufficient battery voltage; connect charger if necessary
Initialization comprises:
Erasure of initialization
Reinitialization
Erasure of initialization:

Actuate power window switch in "Open" position (second switch position) and hold down for between 15
and 20 seconds
This clears initialization of the power window. Anti-trapping protection and one-touch control (toll) function
are inactive.
Check whether one-touch control (toll) function is inactive, otherwise repeat procedure.
Reinitialization:

again for approx. 1 second in "Open" position (second switch position)
This completes initialization.
NOTE: Carry out function check (one-touch control function, anti-trapping protection
and, if necessary, comfort function).
NOTE: The power window can also be initialized in the BMW diagnosis system by
means of a diagnosis job.
67 62 000 REMOVING AND INSTALLING/REPLACING FLAT MOTOR FOR FRONT LEFT OR

2010 BMW M3
Remove power window unit in front door. See 51 33 000 REMOVING AND INSTALLING
(REPLACING) POWER WINDOW UNIT IN LEFT OR RIGHT FRONT DOOR .
Release screws (1).
Tightening torque 67 62 1AZ . See 67 62 DRIVES, POWER WINDOWS
Detach flat motor for power window unit (2) from power window unit and remove.
Installation:
Carry out function check (one-touch function, anti-trapping protection and, if necessary, comfort function).
Fig. 17: Identifying Power Window Unit

Replacement:

more.
67 62 020 REMOVING AND INSTALLING/REPLACING FLAT MOTOR FOR REAR LEFT OR

2010 BMW M3
Remove rear power window unit . See 51 37 000 REMOVING AND INSTALLING/REPLACING
COMPLETE REAR LEFT OR RIGHT POWER WINDOW UNIT .
Release screws (1), tightening torque 51 35 1AZ . See 51 35 POWER WINDOWS, REAR .
Detach flat motor for power window unit (2) in direction of arrow from power window unit (3).
Installation:
Fig. 18: Identifying Power Window Unit And Screw

Replacement:

more.
If necessary, repeat procedure again.

2010 BMW M3
NOTE: Carry out function check (one-touch function, anti-trapping protection and, if
necessary, comfort function).
DRIVE, WIPER/HEADLIGHT
67 63 512 REPLACING WIPER MOTOR
Removing complete console for windscreen wiper system . See 61 61 270 REMOVING AND
INSTALLING/REPLACING BRACKET FOR WINDSCREEN WIPER SYSTEM COMPLETE WITH
MOTOR .

67 66 010 REMOVING AND INSTALLING/REPLACING LUMBAR SUPPORT DRIVE MECHANISM
ON FRONT SEAT, LEFT OR RIGHT
Remove rear panel on front seat backrest . See SEATS - REPAIR (SEDAN) or SEATS - REPAIR
INSTRUCTIONS (CONVERTIBLE/COUPE) .
Remove drive unit for lumbar support (2) with jacket from backrest frame and expose.
Installation:
Make sure drive unit for lumbar support (2) is in correct installation position.
Fig. 19: Identifying Lumbar Support And Screw

2010 BMW M3
Detach hose (1) from drive unit (2).
NOTE: Gently heat hose (1) if stuck.
Installation:
Hose (1) on drive unit (2) must not be kinked.
Pull jacket (3) off drive unit (2).
Remove drive unit for lumbar support (2).
Fig. 20: Identifying Hose, Drive Unit And Lumbar Support

2010 BMW M3
2010 ENGINE PERFORMANCE Emission Applications - BMW M3
2010 ENGINE PERFORMANCE
Emission Applications - BMW M3
EMISSION APPLICATIONS
M3
Engine & Fuel System (1) Emission Control Systems & Devices
2010
4.0L (242") V8 SFI PCV, EVAP, TWC, FR, SPK, (2) HO2S, AIS, CEC, MIL,
EVAP-CPCS, EVAP-LDP, EVAP-VC, SPK
(1) Major emission control systems and devices are listed in bold type; components and other related
devices are listed in light type.
(2) Equipped with 4.
ABBREVIATIONS
AIS
CEC
Computerized Engine Controls
EVAP
EVAP-CPCS
EVAP Canister Purge Control Solenoid
EVAP-LDP
EVAP Leak Detection Pump
EVAP-VC
EVAP Vapor Canister
FR
Fill Pipe Restrictor

2010 BMW M3
2010 ENGINE PERFORMANCE Emission Applications - BMW M3
HO2S
MIL
PCV
SFI
Sequential Fuel Injection
SPK
Spark Controls
SPK-CC
SPK Computer Controlled
TWC
Three-Way Catalytic Converter

2010 BMW M3
ENGINE Engine and Gearbox Suspension - Repair
ENGINE
Engine and Gearbox Suspension - Repair
ENGINE SUSPENSION
22 11 011 REPLACING LEFT ENGINE MOUNT (S65)
Secure ENGINE IN INSTALLATION POSITION

LOWER FRONT AXLE SUPPORT
Slacken nut (1).
Installation:
Replace nuts.

Installation:
Installation position of engine mount determined by locating pin.
22 11 110 REPLACING LEFT ENGINE SUPPORT ARM (S65)
Remove 18 40 020 REMOVING AND INSTALLING/REPLACING RIGHT EXHAUST

MANIFOLD (S65)
2010 BMW M3
Observe SAFETY INSTRUCTIONS on raising the vehicle.
Release screws (2).
Remove engine support arm.
Fig. 2: Identifying Engine Support Arm And Screws

22 11 001 REPLACING RIGHT ENGINE MOUNT (S65)
Remove RIGHT ENGINE SUPPORT ARM
Slacken nut (1).
Installation:
Replace nuts.
2010 BMW M3

Installation:
22 11 100 REPLACING RIGHT ENGINE SUPPORT ARM (S65)

Release TIE ROD ON STEERING GEAR
Observe SAFETY INSTRUCTIONS on raising the vehicle.
Release screws (1).
Remove engine support arm (2).

2010 BMW M3
Fig. 4: Identifying Screws And Engine Support

TRANSMISSION SUSPENSION, MANUAL TRANSMISSION

22 31 050 REPLACING CROSSMEMBER FOR TRANSMISSION MOUNTING
NOTE: Operations are identical to Replacing RUBBER MOUNT for transmission

mounting.
22 31 001 REPLACING RUBBER MOUNT FOR TRANSMISSION MOUNTING
Remove rear underbody protection.

Support transmission with lifter.
Remove screws and nuts.
Remove transmission cross-member (1).
Remove rubber mount from transmission cross-member.
Tightening torque 22 32 3AZ/4AZ .

2010 BMW M3
Fig. 5: Identifying Transmission Cross-Member With Mounting Screws And Nuts

22 31 001 REPLACING RUBBER MOUNT FOR TRANSMISSION MOUNTING (S65)
Remove REAR UNDERBODY PROTECTION

Support transmission with hydraulic lifter.
Release screws (1) and nuts (2) and remove transmission cross-member.
Fig. 6: Identifying Screws And Nuts

2010 BMW M3
TRANSMISSION SUSPENSION, AUTOMATIC TRANSMISSION

22 31 050 REPLACING CROSSMEMBER FOR TRANSMISSION MOUNTING
NOTE: Operations are identical to Replacing RUBBER MOUNT for transmission

mounting.
22 32 050 REPLACING CROSSMEMBER FOR TRANSMISSION MOUNTING (S65)
Support transmission with hydraulic jack.
Release screws (1).
Unscrew nuts (2).
Remove cross-member.
Fig. 7: Identifying Screws And Nuts

Remove rear underbody protection.

2010 BMW M3
Fig. 8: Identifying Transmission Cross-Member With Mounting Screws And Nuts

2010 BMW M3
ENGINE Engine and Gearbox Suspension - Repair Instructions - M3
ENGINE
Engine and Gearbox Suspension - Repair Instructions - M3
ENGINE SUSPENSION
22 11 001 REPLACING RIGHT ENGINE MOUNT (S65)
Remove right engine support arm
Slacken nut (1).
Tightening torque 22 11 1AZ , see 22 11 ENGINE SUSPENSION .
Installation:
Replace nuts.
Fig. 1: Slacken Nut

Installation:
22 11 011 REPLACING LEFT ENGINE MOUNT (S65)
Secure engine in installation position . See 11 00 670 SECURING ENGINE IN INSTALLATION

POSITION (S65) .
Lower front axle support . See 31 11 506 LOWERING/RAISING FRONT AXLE CARRIER (M3,
2010 BMW M3
UNIVERSAL LIFTER) .
Slacken nut (1).
Installation:
Replace nuts.
Fig. 2: Slacken Nut

Installation:
22 11 100 REPLACING RIGHT ENGINE SUPPORT ARM (S65)

POSITION (S65) .
Release tie rod on steering gear . See 32 21 231 REPLACING (REMOVING AND INSTALLING)
LEFT OR RIGHT TIE ROD .
Observe safety instructions on raising the vehicle. See 00 ... ... LIFTING VEHICLE WITH A LIFTING
PLATFORM .
Release screws (1).
Remove engine support arm (2).

2010 BMW M3
Fig. 3: Identifying Engine Support Arm With Screws

22 11 110 REPLACING LEFT ENGINE SUPPORT ARM (S65)
Remove left exhaust manifold . See 18 40 010 REMOVING AND INSTALLING/REPLACING

LEFT EXHAUST MANIFOLD (S65) .
Observe safety instructions on raising the vehicle. See 00 ... ... LIFTING VEHICLE WITH A LIFTING
PLATFORM .
Release screws (2).
Remove engine support arm.

2010 BMW M3
Fig. 4: Identifying Engine Support Arm With Screws

TRANSMISSION SUSPENSION
Remove rear underbody protection. See 51 47 491 REMOVING AND INSTALLING/REPLACING

REAR UNDERBODY PROTECTION .
Tightening torque 22 32 3AZ/4AZ , see 22 32 TRANSMISSION MOUNTS .

2010 BMW M3
Fig. 5: Identifying Transmission Cross-Member

22 31 001 REPLACING RUBBER MOUNT FOR TRANSMISSION MOUNTING (S65)
Remove rear underbody protection . See 51 47 491 REMOVING AND

Support transmission with hydraulic lifter.
Release screws (1) and nuts (2) and remove transmission cross-member.
Fig. 6: Identifying Screws And Nuts With Transmission Cross-Member

2010 BMW M3
22 31 050 REPLACING CROSS-MEMBER FOR TRANSMISSION MOUNTING
NOTE: Operations are identical to Replacing rubber mount for transmission mounting.
TRANSMISSION SUSPENSION
Remove rear underbody protection. See 51 47 491 REMOVING AND INSTALLING/REPLACING

REAR UNDERBODY PROTECTION .
Fig. 7: Identifying Screws And Nuts With Transmission Cross-Member

22 31 050 REPLACING CROSS-MEMBER FOR TRANSMISSION MOUNTING
NOTE: Operations are identical to Replacing rubber mount for transmission mounting.
22 32 050 REPLACING CROSS-MEMBER FOR TRANSMISSION MOUNTING (S65)

2010 BMW M3

Support transmission with hydraulic jack.
Release screws (1).
Tightening torque: 22 32 4AZ , see 22 32 TRANSMISSION MOUNTS .
Unscrew nuts (2).
Tightening torque: 22 32 3AZ , see 22 32 TRANSMISSION MOUNTS .
Remove cross-member.
Fig. 8: Identifying Transmission Screws

2010 BMW M3
ENGINE Engine - Repair
ENGINE
Engine - Repair
ENGINE, GENERAL
11 00 039 CHECKING COMPRESSION OF ALL CYLINDERS (S65)
IMPORTANT: High tension - mortal danger!

Disconnect all supply leads from ignition coils (interrupt power supply to
ignition coils).
IMPORTANT: Check Schrader valve on special tool 11 0 235 for correct seating (engine
damage).
The throttle valves cannot be opened by opening the throttle.
The compression check is carried out exclusively by means of the idle
actuators.
A compression check is only possible with the diagnosis tester.
The catalytic converter will incur damage if the fuel injectors are not switched
off.
Remove microfilter housing See 6431062 REMOVING AND INSTALLING/REPLACING LEFT

Remove all spark plugs See 1213512 REMOVING AND INSTALLING/REPLACING ALL
IGNITION COILS (S65) or 1212011 REPLACING ALL SPARK PLUGS (S65) .
Connect diagnosis tester.

1. Service function.
2. Drive.
3. Engine electronics
4. Switch off fuel injection.
IMPORTANT: Fuel injectors are switched off.
5. Actuate starter motor for 8 seconds.
Screw special tool 11 0 235 into spark plug hole.
Check that sealing ring is in perfect condition on special tool 11 0 235.
Connection (1) for diagnosis tester or special tool 11 0 224.

2010 BMW M3
NOTE: Picture shows S85.
Fig. 1: Inserting Special Tool 11 0 235 Into Spark Plug Hole

Connect special tool 11 0 224 or 25 bar pressure adapter to diagnosis tester.
COMPRESSION PRESSURE .
Fig. 2: Connecting Special Tool (11 0 224) Or 25 Bar Pressure Adapter To Diagnosis Tester
Now clear the fault memory.
00 DANGER OF POISONING IF OIL IS INGESTED/ABSORBED THROUGH THE SKIN
Danger of poisoning!
Ingesting oil or absorbing through the skin may cause poisoning!
Possible symptoms are:

2010 BMW M3
Headaches
Dizziness
Stomach aches
Vomiting
Diarrhoea
Cramps/fits
Unconsciousness
Pour oil only into appropriately marked containers

Do not pour oil into drinking vessels (drinks bottles, glasses, cups or mugs)
Observe country-specific safety regulations
First aid measures
Do not induce vomiting.
If the person affected is still conscious, he/she must rinse out their mouth with water, drink plenty of water and
consult a doctor immediately.
If the person affected is unconscious, do not administer anything by mouth, place the person in the recovery
position and seek immediate medical attention.
ENGINE IDENTIFICATION
Punch engine numbers at marked surface with number punch.
Magnesium crankcase with sticker
M47/M47TU/M47T2
2010 BMW M3
Fig. 3: Identifying Engine (M47/M47TU/M47T2)

M57/M57TU/M57T2
Fig. 4: Identifying Engine (M57/M57TU/M57T2)

M67/M67TU
Fig. 5: Identifying Engine (M67/M67TU)

N47/N47S/N47C/N57 N57S
2010 BMW M3
Fig. 6: Identifying Engine (N47/N47S/N47C/N57 N57S)

M52/M52TU
Fig. 7: Identifying Engine (M52/M52TU)

M54
2010 BMW M3
Fig. 8: Identifying Engine (M54)

M56
Fig. 9: Identifying Engine (M56)

N40/N45/N45T/N43
2010 BMW M3
Fig. 10: Identifying Engine (N40/N45/N45T/N43)

N42/N46/N46T
Fig. 11: Identifying Engine (N42/N46/N46T)

N51/N52/N52K/N52T/N53/N54/N55
2010 BMW M3
Fig. 12: Identifying Engine (N51/N52/N52K/N52T/N53/N54/N55)

N62/N62TU
Fig. 13: Identifying Engine (N62/N62TU)

N73
2010 BMW M3
Fig. 14: Identifying Engine (N73)

S54
Fig. 15: Identifying Engine (S54)

S85/S65
2010 BMW M3
Fig. 16: Identifying Engine (S85/S65)

W10/W11
Fig. 17: Identifying Engine (W10/W11)

N12/N14/N16/N18
2010 BMW M3
Fig. 18: Identifying Engine (N12/N14/N16/N18)

W17
Fig. 19: Identifying Engine (W17)

Assemble engine.
11 00 091 INSTALLING REPLACEMENT ENGINE (S65)
IMPORTANT: No running-in engine oil required.

10W-60
Remove and install ENGINE .

2010 BMW M3
Flush cooling system.
Installation:
If necessary, replace following components.
Clutch
Drive belt.
All outer seals.
Replace all anti-fatigue bolts on flywheel and vibration damper.
Change coolant.
Fill engine with engine oil.
MOUNTING ENGINE ON ASSEMBLY STAND (S65)
Remove engine.
Remove rear water pipe.
Secure special tool 11 5 260 PLATE to crankcase with bolts (2).
Tighten bolts (2) evenly.
NOTE: Bolts (1) are not required on the S65.
Fig. 20: Securing Special Tool (11 5 260) To Crankcase With Bolts
Secure engine with special tool 11 5 260 PLATE to special tool 00 2 300 ASSEMBLY STAND .
2010 BMW M3
Fig. 21: Securing Engine With Special Tool (11 5 260)

11 00... OVERVIEW OF CONSUMABLES (ELECTRONIC PARTS CATALOGUE)
1.0 Sealing compound for injection.
INJECTION SEALING COMPOUND CHART

Part number,
Repair instructions Designation, Electronic
Electronic Parts Application examples
(engine) Parts Catalogue
Catalogue
N40, N42, N45, N46, For hardening Loctite
1.1 Loctite 171000 primer 83 19 7 515 683
N43, N45N, N46N 128367 sealing compound
N40, N42, N45, N46, Loctite 128357 liquid Sealing between crankcase
1.2 83 19 7 536 051
N43, N45N, N46N gasket upper and lower halves
N51, N52, N53, N54, For hardening Loctite
1.3 Loctite 171000 primer 83 19 7 515 683
N52N, N55 193140 sealing compound
N51, N52, N53, N54, Loctite 193140 liquid Sealing between crankcase
1.4 83 19 0 439 030
N52N, N55 gasket upper and lower halves
For hardening Loctite
1.5 S65, S85 Loctite 171000 primer 83 19 7 515 683
193140 sealing compound
Loctite 193140 liquid Sealing between crankcase
1.6 S65, S85 83 19 0 439 030
gasket upper and lower halves
2.0 Sealing compound for application.
APPLICATION SEALING COMPOUND CHART

Designation, Part number,
Designation in repair
Electronic Parts Electronic Parts Application examples
instructions
Catalogue Catalogue
2010 BMW M3
M41, M47, M47TU, M47T2,

M50, M51, M52, M52TU, M54,
M57, M57TU, M57T2, M60,
M62
N40, N42, N45, N45N, N46,
N46N, N43, N47, N47top, N47C
N47D1 Drei Bond 1209 For sealing separation
2.1 07 58 9 062 376
N51, N52, N52N, N53, N54, liquid gasket points on crankcase
N55, N57, N57S
N62, N62TU, N63, N73, N73H,
N74
S14, S38, S50, S52, S54, S62,
S65, S85
N12, N14, N16, N18
Sealing between crankcase
N12, N14, N16, N18
upper and lower sections.
W16, Loctite 5970 liquid 83 19 0 404 517
2.2 Sealing of gear case cover,
N47top, N47D1, N47C1 gasket 83 19 0 404 517
oil sump, coolant pump,
N57D1,
component carrier.
N12, N14, N16, N18 Loctite 648 liquid Sealing between cover
2.3 07 58 9 067 732
W16 gasket sleeve and crankcase
3.0 Cleaning agent.
CLEANING AGENT CHART

Application
Designation in repair instructions Electronic Parts Electronic Parts
examples
Catalogue Catalogue
N45, N46, N45T, N46T, N43, N51, Cleaning
Cold cleaner
3.1 N52, N52Kp, N52TU, N53, N55, 83 19 0 026 956 assemblies,
(chlorine free)
N63, N63S, N63Hyprid, N74 washing engine
4.0 Lubricant for application.
APPLICATION CHART
Designation in repair
Electronic Parts Electronic Parts Application examples
instructions
Catalogue Catalogue
For greasing the splined
N20, N42, N46, N46TU,
Lubricating grease shaft on actuator
4.1 N51, N52, N52KP, N52TU, 83 19 2 160 340
Longtime PD1 drive/gearing of intermediate
N55, N62, N62TU, N73
shaft.
M47, M47TU, M47T2, High temperature For greasing the threads on
4.2 83 19 2 152 323
M57, M57TU, M57T2, paste the exhaust turbocharger.
N12, N14, N16, N18

2010 BMW M3
N40, N42, N45, N45TU

N46, N46TU, N43.
N51, N52, N52Kp, N52TU, High temperature
For greasing the threads on
4.3 N53, N54, N55. paste (NEVER-SEEZ 83 23 0 140 233
the oxygen sensors.
N62, N62TU, N63, compound)
N73, N73H, N74.
S65, S85.
N47, N47O1 N47C1, N47T For greasing the double hex
4.4 N47D1 Copper paste 81 22 9 400 794 head bolt on the exhaust
N57 N57D1 turbocharger.
5.0 Lubricants to loosen locked screw connections.
SCREW CONNECTIONS CHART

Part number,
Designation in repair Designation, Electronic Application
Electronic Parts
instructions Parts Catalogue examples
Catalogue
M47, M47TU, M47TU2,
M57, M57TU, M57TU2.
Brunox lubricating For releasing the
5.1 N47, N47C, N47D1, N57, 83 23 0 445 529
grease glow elements
N57D1,
W16, W17,
11 00 050 REMOVING AND INSTALLING ENGINE (S65)
Engine hood/bonnet in assembly position.

Drain ENGINE OIL .
Remove SUCTION FILTER HOUSING .
Remove INTAKE AIR MANIFOLD .
Remove TRANSMISSION (Important observe repair instructions).
Remove ELECTRIC FAN .
Remove RADIATOR with coolant hoses.
Drain coolant.
Remove EXPANSION TANK with coolant hose.
Draw off A/C SYSTEM .
Remove all lines . See 6453670 REPLACING LINE FROM COMPRESSOR TO EVAPORATOR
(S85) , 6453660 REPLACING LINE FROM CONDENSER TO EVAPORATOR (S65) or 6453642
REPLACING LINE FROM COMPRESSOR TO CONDENSER (S65) from A/C compressor.
2010 BMW M3
Remove SECONDARY-AIR PUMP .

Detach B+ LEAD in engine compartment.
Detach VACUUM HOSE from brake booster.
Release SUSPENSION CROSSBRACE in engine compartment.
Release grounding strap on engine support arm.
Release stabilizer (1) on front axle carrier at front.
Allow stabilizer (1) to hang loose.
Fig. 22: Identifying Stabilizer

Remove complete STEERING SPINDLE .
Remove heat shield.
Release screws (1).
Detach steering spindle extension (2).

2010 BMW M3
Fig. 23: Identifying Steering Spindle Extension And Screws

Release nuts (1 and 4).
Detach oil lines (2 and 3).
Recycling:
Have a cloth ready to catch a residual amount of engine oil.
Fig. 24: Identifying Oil Lines And Nuts

Secure oil lines (1) with a cable tie (2) to front panel.
2010 BMW M3
Fig. 25: Securing Oil Lines With Cable Tie

Unclip heater hose (1) and set down with heating valve on engine.
Disconnect both hoses (2) from secondary-air valves.
Fig. 26: Identifying Heater And Secondary-Air Valves Hoses

IMPORTANT: Risk of damage to steering gear and oil sump.
Disconnect fuel line (1) and lock with special tool 13 5 280.
Disconnect flushing line (2).

2010 BMW M3
Fig. 27: Locking Fuel Line With Special Tool (13 5 280)
Unfasten engine wiring harness (1) on engine completely.
Secure engine wiring harness (1) with a cable tie (2) to engine hood/bonnet damper.
Fig. 28: Securing Engine Wiring Harness With Cable Tie

Release both clamps (1) with special tool 17 2 050.
Remove coolant hose (2).

2010 BMW M3
Fig. 29: Identifying Coolant Hose And Clamps

NOTE: Do not release any hydraulic lines on the power steering pump.
Release power steering pump (1) on engine block.
Set down power steering pump (1) on front axle carrier.
Fig. 30: Identifying Power Steering Pump

Unscrew left and right engine mounts . See 2211001 REPLACING RIGHT ENGINE MOUNT (S65) or
2211011 REPLACING LEFT ENGINE MOUNT (S65) .
Secure special tool 11 0 000 LIFTING GEAR to suspension eyes (1).
Remove engine with 2 persons.

2010 BMW M3
Fig. 31: Securing Special Tool (11 0 000) To Suspension Eyes

Assemble engine.
Top up COOLANT and vent cooling system.
Pour in specified engine oils for BMW Group engines. See ENGINE - OPERATING FLUIDS .
Install REPLACEMENT ENGINE .
Correct CBS data status.
00 RISK OF INJURY IF OIL COMES INTO CONTACT WITH EYES AND SKIN
Danger of injury!
Contact with eyes or skin may result in injury!
Impaired sight
Irritation of the eyes
Reddening of the skin
Rough and cracked skin

Wear oil-resistant protective gloves
2010 BMW M3
First aid measures
Eye contact: Rinse eyes immediately with plenty of water for at least 15 minutes; if available, use an
eye-rinsing bottle. If irritation of the eyes persists, consult a doctor.
Skin contact: Wash off with soap and water immediately. If irritation persists, consult a doctor.
NOTE: Do not use solvents/thinners.


the information "switch closed" is output. The automatic engine start stop
function is active.

Fig. 32: Identifying MSA Button

Workshop mode A = 10 mm
Basic setting (engine hood/bonnet open) B = 7 mm
2010 BMW M3
Fig. 33: Identifying Engine Hood/Bonnet Basic Setting

00 SAFETY INSTRUCTIONS FOR HANDLING OIL
WARNING: DANGER OF POISONING if oil is ingested/absorbed through the skin!

RISK OF INJURY if oil comes into contact with eyes and skin!
Recycling
Measures if oil is unintentionally released
Personal precautionary measures: Danger of slipping! Keep non-involved persons away from the work
area. Wear personal protective clothing/equipment.
Environmental protection measures: Prevent oil from draining into drain channels, sewerage systems,
pits, cellars, water and the ground.
Limiting spread: Use oil blocks to prevent the surface spread of oil.
Cleaning procedure: Bind and dispose of escaped oil with nonflammable absorbents.
NOTE: Do not flush oil away with water or aqueous cleaning agents.
11 00 670 SECURING ENGINE IN INSTALLATION POSITION (S65)

Observe following instructions relating to special tool:
2010 BMW M3
1. Prior to each use, check the special tools for defects, modifications
and operational reliability.
2. Damaged/modified special tools must not be used!
3. No changes or modifications may be made to the special tools!
4. Keep special tools dry, clean and free of grease.
Secure ENGINE BONNET/HOOD IN SERVICE POSITION

Remove INTAKE AIR MANIFOLD
Assemble cross member 00 0 200 DEVICE with special tools 00 0 202, 00 0 204, 00 0 208.
Fig. 34: Identifying Cross Member (00 0 200)

IMPORTANT: Avoid a change of engine position in the transverse or longitudinal direction.

Always make sure there is sufficient clearance between the engine (or its
attachment parts) and the body.

Position transverse member 00 0 200 DEVICE with a 2nd person helping by way
of rests (1) on bolt connections of side panels.
Secure special tool 11 0 020 to spindle 00 0 202.
Attach suitable chains to special tool 11 0 020 and suspend from both engine suspension eyelets.
2010 BMW M3
Fig. 35: Securing Special Tool (11 0 020) To Spindle (00 0 202)

Tighten down all adjusting screws and nuts on cross member 00 0 200
DEVICE .

Unscrew nuts (1).
Raise engine approx. 10 mm with cross member.
Installation:

2010 BMW M3
Fig. 37: Identifying Engine Mount Nut

11 00... SERVICE - ENGINE OIL (S65)

Carry out all tasks only when wearing oil-resistant, heat-resistant
protective gloves incl. underarm protection, face guard and protective
apron.
IMPORTANT: Perform engine oil service only when engine is at normal operating
temperature (>70C engine oil temperature).
An exact engine oil level reading can only be obtained from an engine oil
temperature > or = 70.
Engine oil temperature can be read off in the instrument cluster.
Observe the exact engine oil filling capacity.
Overfilling the engine with engine oil will result in engine damage.
Inspection and drain-off times must be observed.
Determining the oil level via the BC button detects only changes > +/- 0.5 liter.
Recycling
Catch and dispose of drained engine oil in a suitable container.
NOTE: The remaining engine oil can flow off into the oil sump only when the oil filter
cap is opened.
2010 BMW M3
Release oil filter cover (1).
Installation:
Replace oil filter element and sealing rings.
Fig. 38: Identifying Oil Filter Cover


apron.
Open screw plug (1) with socket and a long extension (2).
Fig. 39: Opening Screw Plug

2010 BMW M3
Tilt long extension (1) with socket and screw plug in direction of arrow.
Recycling
Catch and dispose of engine oil with suitable equipment.
Fig. 40: Draining Engine Oil

Drain-off time of 10 minutes must be observed without fail.
Installation:
Assemble engine.
Pour in engine oil . See ENGINE - OPERATING FLUIDS or OIL SUPPLY E90, E92, E93/S65/B40 .
2010 BMW M3

Checking engine oil level:
Park vehicle on a horizontal surface

Start engine and run at idle until an engine oil temperature > or = 70C is reached
Pressing the BC button for more 3 seconds results in the oil level been determined again.
Only changes > +/- 0.5 liter are detected.
If necessary, perform odometer reset.
Top up engine oil if necessary
Pre-delivery inspection/engine replacement
Carry out distance travelled reset only with the BMW diagnosis system.
Observe vehicle-specific maintenance scopes.
CYLINDER HEAD WITH COVER

11 12 729 CHECKING CYLINDER HEAD FOR WATERTIGHTNESS (S65)
NOTE: Special tool 11 5 230 can be used for both cylinder heads.
Remove cylinder head See 1112105 REMOVING AND INSTALLING LEFT CYLINDER HEAD
(S65) or 1112106 REMOVING AND INSTALLING RIGHT CYLINDER HEAD (S65).
Disassemble cylinder head . See 1134552 REMOVING AND INSTALLING/REPLACING ALL
VALVES (S65), 1134715 REPLACING ALL VALVE SPRINGS (S65) or 1134560 REPLACING
ALL VALVE STEM SEALS (S65).
2010 BMW M3
Secure special tool 11 5 231 with old cylinder head bolts.
Secure special tool 11 5 235 with special tool 11 5 237.
Fig. 42: Identifying Special Tools (11 5 235 And 11 5 237)

Secure special tool 11 9 961 with special tool 11 5 237 to 10 Nm.

NOTE: Immerse cylinder head in a water bath.
Test pressure: 4.5 bar.
Check cylinder head for escaping air (cracks).

2010 BMW M3
If necessary, add cleaning agent to water bath.
Assemble engine.
11 12 105 REMOVING AND INSTALLING LEFT CYLINDER HEAD (S65)
Remove EXHAUST SYSTEM .

Remove left EXHAUST MANIFOLD (S65) .
Remove left CYLINDER HEAD COVER
Remove LEFT INLET CAMSHAFT .
Remove left EXHAUST CAMSHAFT .
Partially unfasten ENGINE WIRING HARNESS and lay to one side.
Remove THROTTLE VALVES from cylinders 5 to 8.
Remove THERMOSTAT HOUSING .
Remove rear water pipe from cylinder head.
Release screws (1).
Remove water fitting (2).
Installation:
Replace seal.
Fig. 44: Identifying Water Fitting And Screws

Release screws (1).

2010 BMW M3
IMPORTANT: Screws (1) can fall into the chain drive. Risk of damage to the timing chain.

Remove screw (1) with a magnet from gearcase.
Fig. 46: Identifying Screw On Magnet

Release cylinder head bolt (1) with special tool 11 2 250.

2010 BMW M3
Fig. 47: Identifying Cylinder Head Bolt

Release cylinder head bolts from outside to inside in sequence (10 to 1).
Fig. 48: Identifying Cylinder Head Bolts Removal Sequence

NOTE: Replace CYLINDER HEAD GASKET .

Check CYLINDER HEAD for water leaks.
Installation:
Fit new cylinder head screws.
Tighten down cylinder head bolts from inside to outside in sequence (1 to 10).

2010 BMW M3
Fig. 49: Identifying Cylinder Head Bolts Tightening Sequence

Insert bolts (1).

Assemble engine.
11 12 106 REMOVING AND INSTALLING RIGHT CYLINDER HEAD (S65)
Remove EXHAUST SYSTEM .

Remove right EXHAUST MANIFOLD .
Remove right CYLINDER HEAD COVER .
Remove right INLET CAMSHAFT .
Remove right EXHAUST CAMSHAFT .
2010 BMW M3
Partially unfasten ENGINE WIRING HARNESS and lay to one side.

Remove THROTTLE VALVES from cylinders 1 to 4.
Remove THERMOSTAT HOUSING .
Release screws (1).
Remove coolant fitting (2).
Installation:
Replace seal.
Fig. 51: Identifying Coolant Fitting And Screws

Release screw (1).

2010 BMW M3
Remove bearing pin (1) with special tool 11 5 290.
Fig. 53: Identifying Bearing Pin

Release screws (1).

Remove screw (1) with a magnet (2) from gearcase.

2010 BMW M3
Fig. 55: Identifying Screw On Magnet

Release cylinder head bolt (1) with special tool 11 2 250.

2010 BMW M3
Fig. 57: Identifying Cylinder Head Bolts Removal Sequence

NOTE: Replace CYLINDER HEAD GASKET .

Check CYLINDER HEAD for water leaks.
Installation:

Insert bolts (1).

2010 BMW M3

Assemble engine.
11 12 005 REMOVING AND INSTALLING/SEALING LEFT CYLINDER HEAD COVER (S65)
IMPORTANT: Magnesium material.
No steel screws/bolts may be used due to the threat of electrochemical corrosion.
A magnesium material requires aluminum screws/bolts exclusively.
Aluminum screws/bolts must be replaced each time they are released.
The end faces of aluminum screws/bolts are painted blue for the purposes of reliable identification.
Jointing torque and angle of rotation must be observed without fail (risk of damage).
Scratching of the cylinder head cover is not permitted (risk of corrosion).

Remove ROD-TYPE IGNITION COILS .
Disconnect plug connection at camshaft sensors.
Release bolts along line (1).

2010 BMW M3
Fig. 60: Identifying Cylinder Head Cover

Installation:
Replace seal (1).
Align gasket (1) on cylinder head cover groove.
Press in gasket (1) so that it is free from tension.
Release park plug tube (2).
Installation:
Check rubber on spark plug tube (2) for damage; replace spark plug tube (2) if necessary.
Fig. 61: Identifying Park Plug Tube And Gasket

2010 BMW M3
Apply a light coating of engine oil to spark plug tube (2) prior to installation.
Installation:
Clean seal residue from sealing surfaces.
Coat contact surfaces of joint (1) with Drei Bond 1209.
Fig. 62: Identifying Contact Surfaces Of Joint

Installation:
Check decoupling element (1) for damage and replace if necessary.
Fig. 63: Identifying Decoupling Element

2010 BMW M3
Fit cylinder head cover.
Align spark plug tubes.
Tighten down all retaining elements diagonally from inside to outside.

Assemble engine.
11 12 006 REMOVING AND INSTALLING/SEALING RIGHT CYLINDER HEAD COVER (S65)

Remove ROD-TYPE IGNITION COILS .
2010 BMW M3

Installation:
Replace seal (1).
Fig. 66: Identifying Park Plug Tube And Gasket

2010 BMW M3
Installation
Installation:
Fig. 67: Identifying Contact Surfaces Of Joint

Installation:

2010 BMW M3


Assemble engine.
11 12 112 REPLACING BOTH CYLINDER HEAD GASKETS (S65)
Remove left cylinder head.

Remove right cylinder head.
Check cylinder head for leaks.
IMPORTANT: Do not open screw plugs.

The screw plug must always be replaced if it is opened by mistake.
Installation:
Make sure oil bore (1) is clean.

2010 BMW M3
Fig. 70: Identifying Oil Bore

Check dowel sleeves (1) for damage and correct installation position.
Clean sealing faces with special tool 11 4 470.
Do not use any metal-cutting tools.
Fig. 71: Identifying Dowel Sleeves


2010 BMW M3

Remove spacer sleeves (1) in direction of arrow.
NOTE: Picture show cylinder bank 2. Procedure for cylinder bank 1 is identical.
Fig. 73: Removing Spacer Sleeves

Remove non-return valves (1) in direction of arrow.

2010 BMW M3
Fig. 74: Removing Non-Return Valves

Installation:
Replace spacer sleeves (1) and non-return valves (2).
Note installation direction of non-return valves (2).
Fig. 75: Identifying Spacer Sleeves And Non-Return Valves

Replace head gasket (1) for cylinders 1-4.

2010 BMW M3
Fig. 76: Identifying Head Gasket

Fig. 77: Identifying Head Gasket

NOTE: There is no oversize gasket for the S65 engine.
Assemble engine.
OIL SUMP
11 13 000 REMOVING AND INSTALLING OR REPLACING OIL SUMP (S65)
Recycling
Catch and dispose of used oil in a suitable container.

2010 BMW M3
Drain engine oil.

Secure ENGINE IN INSTALLATION POSITION .
Lower FRONT AXLE .
Remove ribbed V-belt.
Release 4x transmission bolts.
Release screws (1).

2010 BMW M3
Fig. 79: Oil Sump Screw/Bolt Locations

Clean sealing faces (1) with special tool 11 4 470.

2010 BMW M3
Fig. 80: Identifying Sealing Faces

Installation:
Replace oil sump gasket (1).
Fig. 81: Identifying Oil Sump Gasket

Assemble engine.
HOUSING COVER
11 14 151 REPLACING CRANKSHAFT SEAL (S65)
Remove clutch.
2010 BMW M3
Remove FLYWHEEL .
Drill a 3 mm hole into shaft seal.
IMPORTANT: Risk of damage! Remove chips/shavings immediately.
Screw in special tool 23 0 490 PULLER .
Drive out radial shaft seal with impact weight.
Fig. 82: Removing Radial Shaft Seal With Impact Weight

Remove remnants of sealant from sealant outlet (1) on left and right.
Apply Drei Bond sealant 1209 to sealant outlet (1) on left and right.
Fig. 83: Identifying Sealant Outlet

2010 BMW M3
IMPORTANT: Pay attention to fitting sleeve.

Special tool 11 5 311 must rest flat on crankshaft (pay attention to fitting
sleeve).
Install special tool 11 5 311 with bolts (1).
Fig. 84: Installing Special Tool (11 5 311) With Bolts

Position support ring (1) with radial shaft seal (2) on special tool 11 5 311.
Push radial shaft seal (2) uniformly in direction of arrow over support ring onto special tool 11 5 311.
Fig. 85: Pushing Radial Shaft Seal

Position shaft seal (1) approx. 5 mm before crankcase.

2010 BMW M3
Remove support ring (2).
NOTE: Support ring (2) is no longer needed.
Fig. 86: Identifying Shaft Seal Position

Press in radial shaft seal (1) with special tools 11 5 312 and 11 5 313.
Fig. 87: Pressing Radial Shaft Seal Using Special Tools

Assemble engine.
Settling time of radial shaft seal approx. 1 hour.
Correct ENGINE OIL LEVEL if necessary.
11 14 005 REPLACING FRONT CRANKSHAFT SEAL (S65)

2010 BMW M3
Remove FAN COWL with electric fan.

Remove RADIATOR .
Remove VIBRATION DAMPER .
Lay special tool 11 2 386 on crankshaft.
Fig. 88: Identifying Special Tool (11 2 386) On Crankshaft

Screw special tool 11 6 360 PULLER to 80 Nm into radial shaft seal.
Release radial seal from housing.
Repeat the operation several times if necessary.
NOTE: Carefully saw open old radial shaft seal with an iron saw from special tool 11 6
360 PULLER .
2010 BMW M3
Fig. 89: Inserting Special Tool (11 6 360) Into Radial Shaft Seal
Apply Drei Bond sealant (refer to Electronic Parts Catalogue) to sealant outlet (1) on left and right.

Secure special tool 11 5 331 with bolts (1).
IMPORTANT: Pay attention to dowel pin.
Fig. 91: Securing Special Tool (11 5 331) With Bolts

Push special tool 11 7 231 onto special tool 11 5 331 in direction of arrow.
2010 BMW M3
Fig. 92: Pushing Special Tool (11 7 231) Onto Special Tool (11 5 331)
Installation:
Remove support ring from shaft seal.
Push radial shaft seal (1) uniformly by way of fitting aid 11 7 231 onto special tool 11 5 331.
Position shaft seal approx. 5 mm before crankcase.
Remove special tool 11 7 231.

2010 BMW M3
Fig. 94: Pressing Radial Shaft Seal

Assemble engine.
Setting time of shaft seal approx. 1 hour.
CORRECT engine oil level if necessary.
CRANKSHAFT WITH BEARING

11 21 531 REPLACING ALL CRANKSHAFT MAIN BEARINGS (S65)
IMPORTANT: 1. Repair crankcase worn St.0 or 1/crankshaft worn St.0.
If the bearing channel is opened and closed again after engine operation,
all main bearing shells must be replaced with special repair bearing
shells.
Altered settling behavior at the crankcase.
Repair bearing shells are marked with an (R) on their backs.
2. Repair crankcase worn St.0 or 1/crankshaft new St.0.
Repair bearing shells marked with (R) must be used.
The crankshaft comes as a set together with the bearing shells. The
bearing shells for the bedplate are provided in accordance with the
crankshaft classification. For the crankcase bearing shells, the green
bearing shells are always provided. The half classification is retained.
3. Repair crankcase new St.0 or 1/crankshaft worn St.0.

2010 BMW M3
The bearing shells also designated for initial installation must be used.
The crankcase comes as a set together with the bearing shells. The
bearing shells for the crankcase are provided in accordance with the
crankcase classification. For the bedplate, the green bearing shells are
always provided. The half classification is retained.
4. Repair crankcase new St.0 or 1/crankshaft new St.0.
The bearing shells provided with the crankcase must be used.
always provided. The half classification is retained.
ENGINE removed
Remove CRANKSHAFT .
Installation:
Bearing shell (1) with lubricant groove must be fitted in crankcase upper section.
Bearing shell (2) without lubricant groove must be fitted in crankcase lower section (bedplate).
Determine bearing play with special tool 002590 MEASUREMENT AID .
Insert crankshaft without engine oil, bolt crankcase upper and lower sections together.
2010 BMW M3
Fig. 95: Identifying Bearing Shells

Lay plastic thread (Plastigage) on crankshaft.
Fit crankcase upper section on lower section and bolt together.
NOTE: Do not twist crankshaft.
Remove crankshaft.
Read off bearing play at width of flattened plastic thread and measurement scale.
Crankshaft bearing clearance radial See CRANKSHAFT AND BEARINGS S65 or CRANKSHAFT AND
BEARINGS S65 .
Fig. 96: Reading Bearing Play At Width Of Flattened Plastic Thread

Crankcase upper half
Installation:
Bearing shell (2) is a guide bearing.
Pay attention to guide lugs on bearing shells (see arrow).
Remove all bearing shells with lubricant groove.
Observe bearing classification See CRANKSHAFT AND BEARINGS S65 or CRANKSHAFT AND
BEARINGS S65 .
2010 BMW M3
Fig. 97: Identifying Crankcase Upper Half Guide Lugs Position

Crankcase lower half
Installation:
Remove all bearing shells without lubricant groove.
Observe bearing classification See CRANKSHAFT AND BEARINGS S65 or CRANKSHAFT AND
BEARINGS S65 .
Fig. 98: Identifying Crankcase Lower Half Guide Lugs Position

Clean sealing face (1) with special tool 11 4 470.

2010 BMW M3
Insert bearing shells (2) without lubricant groove.
Insert guide bearing (3) without lubricant groove on bearing seat 5.
Fig. 99: Identifying Sealing Face, Bearing Shells And Guide Bearing
Release screws (1).
Remove oil nozzle (2) towards top.
Fig. 100: Identifying Oil Nozzle And Screws

Bearing classification on bedplate bearing seat.
Observe color allocation on crankshaft (1 to 5).
V = Violet.
2010 BMW M3
G = Green.
Y = Yellow.
Fig. 101: Identifying Bearing Classification On Bedplate Bearing Seat

Bearing classification on crankcase bearing seat.
Observe color allocation in crankcase (1 to 5).
V = Violet.
G = Green.
Y = Yellow.
Fig. 102: Identifying Bearing Classification On Crankcase Bearing Seat

2010 BMW M3
Assemble engine.
11 21 500 REPLACING CRANKSHAFT (S65)
IMPORTANT: Unscrew all M9 fit bolts first before releasing the crankshaft lower section.
Altered settling behavior at the crankcase!
If the main bearing channel is opened after engine operation, all main bearing
shells must be replaced with special repair bearing shells marked with an (R).
There are two different groups of main bearing shells.
Remove ENGINE .
Mount engine on assembly stand Mounting engine on assembly stand (S65) .
Remove FLYWHEEL .
Removing OIL SUMP .
Remove ENGINE OIL PUMP .
Remove OIL RETURN PUMP .
Remove cylinder head See LEFT CYLINDER HEAD (S65) or RIGHT CYLINDER HEAD (S65) on
left and right.
Remove all PISTONS .
Remove both TIMING CHAINS .
IMPORTANT: Unscrew all M9 fit bolts (2) first before releasing the crankshaft lower section -
risk of damage!
Bearing seat bolts (1) M11.
Fig. 103: Identifying Bearing Seat And M9 Fit Bolts

2010 BMW M3
IMPORTANT: Release all M9 fit bolts and remove.
Release fit bolts (M9) in sequence 1-10 and remove.
Fig. 104: Identifying M9 Fit Bolts Removal Sequence

Release bearing seat bolts M11 in sequence 1-10.
Fig. 105: Identifying M11 Bearing Seat Bolts Removal Sequence

Release screws (3).
Bolts (1) from inside outwards.
Lift out bedplate.

2010 BMW M3
Fig. 106: Identifying Bedplate Screws

Lever out crankshaft (1) with aid of a second person in direction of arrow.
NOTE: Weight of crankshaft approx. 22 kg.
Picture shows S85.
Fig. 107: Levering Out Crankshaft

IMPORTANT: If the lower crankcase section (bedplate) is opened and closed again, fit special
main bearing shells marked with (R) on the bearing backs.
Replace all bearing shells (2).
Replace guide bearing (3).
Installation:
2010 BMW M3
Clean sealing surface (1) with special tool 11 4 470.
Fig. 108: Identifying Sealing Face, Bearing Shells And Guide Bearing
Remove sealing compound from joint (1).
Carefully clean threads and contact surfaces in upper and lower sections of crankcase.
Installation:
Replace injector nozzles (2).
Clean sealing surface (1) with special tool 11 4 470.
Fig. 109: Identifying Sealing Surface And Injector Nozzles

Installation:
2010 BMW M3
Replace main bearing shells.
Apply a light coating of engine oil to bearing shells.
Lay crankshaft (1) with a second person helping in direction of arrow into crankcase.
Picture shows S85.
Fig. 110: Laying Crankshaft

Insert seal (1).
IMPORTANT: Make sure oil bore is clean.

2010 BMW M3
IMPORTANT: Adhere without fail to the specified sequence of bedplate bolt connections.
Risk of damage to crankshaft.
Leaks at bedplate/crankcase.
IMPORTANT: There are no more fitting sleeves in the crankcase.

Do not use new bolts.
If new bolts are used, observe special tightening/torque specifications.
Fit lower crankcase section (bedplate) on crankcase.
Position lower section diagonally on bearing seats (1 and 5) using two fit bolts (1 and 2).
Fig. 112: Identifying Crankshaft Fit Bolts

Join fit bolts (1 and 2) to 8 Nm.
Insert fit bolts (1-8).
Join fit bolts (1-8) to 8 Nm.

2010 BMW M3
Fig. 113: Identifying Crankshaft Bolt Tightening Sequence

Insert all M11 bolts (1).
Join bearing seat bolts in sequence (1- -10) to 30 Nm.
Fig. 114: Identifying M11 Bearing Seat Bolts

Mark all M11 bearing seat bolts with a colored line (1).
2010 BMW M3
Fig. 115: Identifying M11 Bearing Seat Bolts Mark

Secure bearing seat bolts M11 with special tools 00 9 120 TORQUE ANGLE MEASURING DIAL and 00 9
130 .
Fig. 116: Securing M11 Bearing Seat Bolts With Special Tools (00 9 120)
Tighten M11 bolts to 130 angle of rotation.
IMPORTANT: Observe bolting sequence when using new bolts.

2010 BMW M3
Fig. 117: Identifying M11 Bolts Tightening Sequence

Join all fitting bolts in sequence 1 to 10 to 15 Nm.
Fig. 118: Identifying Fitting Bolts Tightening Sequence

Mark all fit bolts with a colored line (1).

2010 BMW M3
Fig. 119: Identifying Seat Bolt Mark

Tighten fit bolts with special tools 00 9 120 TORQUE ANGLE MEASURING DIAL and 00 9 130 .
Fig. 120: Tightening Fit Bolts With Special Tools (00 9 120)
Secure all fit bolts (1-10) to 130 angle of rotation.

2010 BMW M3
Fig. 121: Identifying Fitting Bolts Tightening Sequence

Insert bolts (1).
Insert bolts (2).
Insert bolts (3).

Secure bolts (1) M8x65 (22 x) with special tools 00 9 120 TORQUE ANGLE MEASURING DIAL and 00 9
130 .
Tightening torque, see 11 11 3 AZ in 11 11 ENGINE BLOCK .

2010 BMW M3
Fig. 123: Securing M8x65 (22 x) Bolts With Special Tools

Secure bolts (1) M8x40 (4 x) with special tools 00 9 120 TORQUE ANGLE MEASURING DIAL and 00 9
130 .
Fig. 124: Securing M8x40 (4 x) Bolts With Special Tools

Secure bolts (1) M6x30 (2 x).
Installation:
Insert timing chains.

2010 BMW M3
Fig. 125: Identifying M6x30 (2 x) Bolts

Insert gear (2) for oil pump drive.
Tighten bolt (1).
Fig. 126: Identifying Oil Pump Drive Gear And Bolt


2010 BMW M3

Installation:
Push radial shaft seal (1) uniformly by way of fitting aid 11 7 231 onto special tool 11 5 331.

2010 BMW M3


IMPORTANT: Pay attention to fitting sleeve.

Special tool 11 5 311 must rest flat on crankshaft (pay attention to fitting
sleeve).
Install special tool 11 5 311 with bolts (1).

2010 BMW M3
Fig. 131: Installing Special Tool (11 5 311) With Bolts

Position support ring (1) with radial shaft seal (2) on special tool 11 5 311.
Push radial shaft seal (2) uniformly in direction of arrow over support ring onto special tool 11 5 311.


2010 BMW M3
Fig. 133: Identifying Shaft Seal Position


Drive both injector nozzles with special tool 11 9 360 on left and right into crankcase.
Installation:
Always replace injector nozzles.

2010 BMW M3
Fig. 135: Driving Injector Nozzles With Special Tool (11 9 360)
Installation:
Use PRIMER 1.5 AND LIQUID SEALING COMPOUND 1.6 .
Prepare liquid sealing compound (2) in special tool 11 4 370.
Screw on nozzle (1) for injecting liquid sealing compound.
Fig. 136: Identifying Nozzle And Liquid Sealing Compound

Press sealing compound nozzle in direction of arrow onto nozzle at 90.
Slowly and evenly insert liquid sealing compound (1) with special tool 11 4 370 in direction of arrow.
2010 BMW M3
Fig. 137: Inserting Liquid Sealing Compound Using Special Tool (11 4 370)
Stop (seal off) escaping liquid sealing compound with PRIMER (2) 1.5 at outlet bore (1).
The procedure is identical as on the rear radial shaft seal.
Fig. 138: Applying Liquid Sealing Compound At Outlet Bore

Assemble engine.
11 21 571 REPLACING GROOVED BALL BEARINGS IN CRANKSHAFT (S65)
Remove CLUTCH .
2010 BMW M3
Remove grooved ball bearing with special tool 11 2 340 in conjunction with special tool 11 2 016.
Fig. 139: Removing Grooved Ball Bearing With Special Tool (11 2 340)
Installation:
Replace guide bearing.
Drive in guide bearing as far as it will go with special tools 11 2 350 and 005500 MANDREL .
Fig. 140: Driving Guide Bearing

Assemble engine.
FLYWHEEL
11 22 500 REMOVING AND INSTALLING/REPLACING FLYWHEEL (S65)

2010 BMW M3
Remove CLUTCH .
Secure flywheel (1) with special tools 11 9 263 and 11 9 260 HOLDER .
Fig. 141: Securing Flywheel Using Special Tools (11 9 263 And 11 9 260)
Release flywheel screws with special tool 11 4 180.
Fig. 142: Removing Flywheel Screws Using Special Tool (11 4 180)
Assemble engine.

2010 BMW M3
Twist out roller bearing with special tool 11 2 343.
Fig. 143: Removing Roller Bearing Using Special Tool (11 2 343)
Assemble special tools 11 2 350 and 005500 MANDREL .
Drive in roller bearing with special tools 11 2 350 and 005500 MANDREL in direction of arrow as far as it will
go.
Fig. 144: Driving Roller Bearing Using Special Tools (11 2 350 And 00 5 500)
Assemble engine.
VIBRATION DAMPER
2010 BMW M3
11 23 010 REMOVING AND INSTALLING/REPLACING VIBRATION DAMPER (S65)
Remove FAN COWL WITH ELECTRIC FAN .

Remove A/C compressor DRIVE BELT .
Remove alternator DRIVE BELT .
Release screws (1).
Remove cover (2) with belt pulley (3).
Fig. 145: Identifying Cover, Belt Pulley And Screws

NOTE: Engine or transmission removed.
Secure special tool 119260 HOLDER to flywheel (1).
Screw in special tool 11 9 263 with bolt (2) on crankcase.

2010 BMW M3
Fig. 146: Securing Special Tool (11 9 260) To Flywheel

Release screws (2).
Remove vibration damper (1).
Fig. 147: Identifying Vibration Damper And Screws

NOTE: Engine or transmission installed.
Attach special tool 11 0 280 to vibration damper.
Support special tool 11 0 280 on holder (1).
Release all anti-fatigue bolts (2).

2010 BMW M3
Installation:
Replace stress bolts.
Fig. 148: Supporting Special Tool (11 0 280) On Holder

Tighten anti-fatigue bolts (1) with special tool 00 9 120 TORQUE ANGLE MEASURING DIAL .
Fig. 149: Supporting Special Tool (11 0 280) On Holder

Assemble engine.
CONNECTING ROD WITH BEARING

2010 BMW M3
11 24 571 REPLACING ALL CONNECTING ROD BEARINGS (S65)
IMPORTANT: Note grinding stages on crankshaft . See TED-TED-TDMUC1121-S65-01B1S2

CRANKSHAFT AND BEARINGS S65 or TED-TED-TDMUC1121-S65-01B1S1
CRANKSHAFT AND BEARINGS S65 .
Remove all PISTONS .
Install new conrod bearing shells.
Installation:
Install one blue (1) and one red (2) bearing shell in each conrod.
Install all PISTONS .
Fig. 150: Identifying Bearing Shell

NOTE: Check connecting rod bearing clearance.
Piston in BDC position.
Place special tool 00 2 590 (Plastigage model PG 1) on oil-free crankshaft.
Place bearing caps in position, making sure that matching numbers are paired.
2010 BMW M3
Fig. 151: Identifying Bearing Caps Position

IMPORTANT: Do not distort connecting rods or crankshaft.
Use the old conrod bearing bolts to check conrod clearance.
Tighten down conrod bolts with special tool 00 9 120 TORQUE ANGLE MEASURING DIAL .
Fig. 152: Tightening Connecting Rod Bolts Using Special Tool (00 9 120)
Remove conrod bearing cap and read off bearing clearance at width of pinched plastic thread on measuring
scale.
Conrod bearing clearance: Refer to TECHNICAL DATA .
Remove plastic thread.

Lubricate crankshaft and bearing shells.
Install new conrod bolts and tighten down.
2010 BMW M3
Fig. 153: Locating Bearing Clearance At Width Of Crushed Plastic Thread (Plastigage)
Assemble engine.
PISTON WITH RINGS AND PIN

11 25 530 REMOVING AND INSTALLING/REPLACING ALL PISTONS (S65)
WARNING: Safety goggles must be worn when working on the gudgeon pin circlip.
IMPORTANT: If pistons, connecting rods and bearing shells are reused, they must be
reinstalled in the same places.
Piston and piston pin are matched to each other and can only be replaced as a
pair.
Connecting rod and connecting rod bearing cap are cracked.
Identification is effected by means of identical pairing letters on the connecting
rod big end.
Mixing up the components will result in engine damage.
Setting of special tool 11 5 343 must not be altered.
Remove ENGINE .
Mount engine on assembly stand (S65) .
Remove cylinder head on left and right . See 1112105 REMOVING AND INSTALLING LEFT
CYLINDER HEAD (S65) or 1112106 REMOVING AND INSTALLING RIGHT CYLINDER
HEAD (S65).
2010 BMW M3
Remove ENGINE OIL SUMP .

Remove OIL PUMP .
Remove OIL SUCTION PUMP .
IMPORTANT: Do not bend oil nozzle (2) at outlets.
It is not possible to adjust the nozzles.
Oil nozzle (2) must be replaced if it is maladjusted or bent.
NOTE: Graphic shows crankshaft removed.

Release screws (1).
Remove holder for oil pipes.

2010 BMW M3

Release connecting rod bolts (1) with special tool 12 2 100.
Remove connecting rod bearing cap with bearing shell.
Fig. 156: Removing Connecting Rod Bolts

Special tool 11 5 250 without locating rod must be screwed in on the connecting rod at the bottom.
Special tool 11 5 250 with locating rod must be screwed in on the connecting rod at the top.
Fig. 157: Identifying Special Tool (11 5 250) On Connecting Rod

Rotate crankshaft (1) in direction of arrow, risk of damage to special tool 11 5 250.
Remove piston with connecting rod and special tool 11 5 250.

2010 BMW M3
Depiction of function on cylinders 1-4.
IMPORTANT: Risk of damage to oil nozzle.
Fig. 158: Rotating Crankshaft

Clamp special tool 11 5 341 in a vice.
NOTE: Piston and piston pin are optimized to each other.
There are two different inside diameters on the piston pin.
Screw matching special tool 11 5 342 into special tool 11 5 341.

Secure piston (1) with connecting rod to special tool 11 5 341.

2010 BMW M3
Fig. 160: Securing Piston With Connecting Rod To Special Tool (11 5 341)
WARNING: Safety goggles must be worn for the next operation.
WARNING: Safety goggles must be worn.
Lever out piston circlip with special tool 11 4 492 in direction of arrow.
Fig. 161: Removing Piston Circlip With Special Tool (11 4 492)
If necessary, replace connecting rods.
Installation:
The gudgeon pin must be able to be pressed through the liner by hand with little force and must not display any
2010 BMW M3
significant play.
Fig. 162: Installing Gudgeon Pin

Measure piston installation clearance:
Measure piston diameter with micrometer at measuring point A from bottom edge of piston and offset at 90 to
the axis of the gudgeon pin.
Piston diameter at measuring point A.
Fig. 163: Measuring Piston Diameter

Adjust micrometer to cylinder bore of engine block. Set internal calliper on micrometer to zero. Measure
bottom, center and top of cylinder bore in direction of travel and direction of engine rotation.
Diameter of cylinder bore.
Piston installation clearance.
Total permissible wear tolerance See ENGINE BLOCK, CYLINDER CRANKCASE S65 ; PISTONS
WITH RINGS AND PINS S65 or PISTONS WITH RINGS AND PINS S65 .
If necessary, replace piston.

2010 BMW M3
Fig. 164: Measuring Cylinder Bore Diameter

IMPORTANT: The connecting rods are not symmetrical.
Pay attention to elevation to direction of travel arrow.
Fig. 165: Identifying Elevation To Direction Of Travel Arrow

Make sure the connecting rod is in the correct installation position during preliminary installation.
On cylinders 6-10 the elevation (2) must point forwards with the arrow.
On cylinders 1-4 the elevation (1) must point rearwards against the arrow.
Valve pockets (E) point to inlet side.
Arrow direction is identical to direction of travel.

2010 BMW M3
Fig. 166: Identifying Valve Pockets And Cylinders Elevation

On cylinders 5-8 the elevation must point forwards with the arrow.
IMPORTANT: No elevations on the connecting rod big end are permitted to point to each
other during installation, risk of damage to connecting rod.
Fig. 167: Identifying Cylinders Elevation

Installation:
When installed, the two lugs on connecting rods (1 and 2) must point outwards.
2010 BMW M3
Fig. 168: Locating Lugs On Connecting Rods

Secure piston (1) with connecting rod to special tool 11 5 341.
IMPORTANT: Setting of special tool 11 5 343 must not be altered.
Installation:
Insert piston circlip (2) so that opening points to window.
Insert piston circlip (2) into groove (1) of special tool 11 5 343.
2010 BMW M3
Fig. 170: Identifying Piston Circlip Groove

NOTE: Graphic shows N52.
Position special tool 11 5 343 with window to recess on piston (see arrow).
Fig. 171: Positioning Special Tool (11 5 343) With Window To Recess On Piston
Position special tool 11 5 343 with window to recess on piston (see arrow).
2010 BMW M3
Fig. 172: Positioning Special Tool (11 5 343) With Window To Recess On Piston
Guide lug and aperture on special tool 11 5 343 must point to piston crown.
When special tools 11 5 343 and 11 5 344 are correctly positioned, the piston circlip must be driven in with a
plastic hammer in the direction of the arrow.
NOTE: See graphic.
Fig. 173: Installing Piston Circlip

Installation:
Piston circlip (1) is correctly installed when the opening points upwards.
2010 BMW M3
See graphic.
It must still be possible for piston pin to moved easily.

Install all PISTON RINGS .
Install all BEARING SHELLS .
Screw special tool 11 5 250 into connecting rod.
Always screw in special tool 11 5 250 with rod to exhaust side.
Preinstall piston with piston rings in special tool 11 9 500.
Fig. 175: Inserting Special Tool (11 5 250) Into Connecting Rod
Insert piston with connecting rod in cylinder.

2010 BMW M3
IMPORTANT: Risk of damage to oil spray nozzle.

Danger of piston ring failure.
Insert piston so that arrow (direction of travel pointing forwards) on piston crown points to camshaft drive.
Piston cyl. 1-4 right side, cyl. 5-8 left side.
Press in piston with special tool 11 9 500.
Fig. 176: Inserting Piston With Connecting Rod In Cylinder

Arrow on piston crown must point to camshaft drive (direction of travel towards front).
Fig. 177: Identifying Piston Crown Position

IMPORTANT: Connecting rod and connecting rod bearing cap are identified with pairing
2010 BMW M3
letters (1) and must not be mixed up.

Mixing them up or incorrectly fitting the connecting rod bearing cap on the big
end will result in engine damage.
Fig. 178: Identifying Connecting Rod Bearing Cap Pairing Letters

Rotate crankshaft (1) in direction of arrow, risk of damage to special tool 11 5 250.
Insert piston with connecting rod and special tool 11 5 250.

Moisten connecting rod bearing shell and crankshaft journal slightly with engine oil.
Assemble connecting rod and crankshaft journal.

2010 BMW M3
Fig. 180: Identifying Special Tool (11 5 250) On Connecting Rod

Install connecting rod bearing cap with bearing shell.
Secure connecting rod bolts (1) with special tools 12 2 100 and 00 9 120 TORQUE ANGLE MEASURING
DIAL .
Fig. 181: Securing Connecting Rod Bolts With Special Tools (12 2 100)
Assemble engine.
11 25 671 REPLACING PISTON RINGS ON ALL PISTONS (S65)

2010 BMW M3
Remove all PISTONS
Remove piston rings with a piston-ring compressing pliers.
NOTE: It might not be possible to find the identification on used piston rings.
Put aside piston rings in correct sequence and installation position.
Fig. 182: Removing Piston Rings

Installation:
Piston rings marked with "R" must point to piston crown.
Groove (2), plain compression ring.
Groove (3), stepped ring.
Groove (4), bevel-edged oil control ring.
Fig. 183: Identifying Piston Ring Groove

2010 BMW M3
Piston ring (1), bevel-edged oil control ring.
Piston ring (2), stepped ring.
Piston ring (3), plain compression ring.
Fig. 184: Identifying Piston Rings

Installation:
Plain compression ring is marked with (R).
Stepped ring is marked with (R1).
Fig. 185: Identifying Ring Marks

2010 BMW M3
Measure AXIAL PLAY .
Fig. 186: Measuring Piston Ring Axial Play

Measure END CLEARANCE .
Fig. 187: Measuring Piston Ring End Clearance

Offset the contact points of the piston rings by approx. 120 to each other but do not position above the piston
pin boss.
NOTE: See picture S85.

2010 BMW M3
Fig. 188: Identifying Piston Rings Contact Points

Assemble engine.
V-RIBBED BELT WITH TENSION DEFLECTION ELEMENT

11 28 060 REMOVING AND INSTALLING/REPLACING BELT TENSIONER FOR A/C
COMPRESSOR (S65)
IMPORTANT: Mixed installation of the assemblies is not permitted.

Mixed installation will result in failure of the steering assistance.
Mark the direction of rotation of the drive belt if it is to be reused.
Replace the drive belt if it is fouled with coolant or engine oil.

Remove A/C COMPRESSOR DRIVE BELT .
Release screw (1).
Release screw for power steering high-pressure line.
Release screws (2).
Remove belt tensioner (3) with fixture.
Installation:
Observe the installation direction if the belt tensioner is replaced individually.
The lettering TOP must point upwards.

2010 BMW M3
Different idler pulleys for c.c.w.- and c.w.-rotating power steering pumps.
Tightening torque, see 11 28 1-2AZ .
Fig. 189: Identifying Belt Tensioner And Screws

Assemble engine.
11 28 050 REPLACING A/C COMPRESSOR DRIVE BELT (S65)
IMPORTANT: Mixed installation of the assemblies is not permitted.

Mixed installation will result in failure of the steering assistance.
Tightening torque: 11 28 1-2AZ .
IMPORTANT: Note belt routing of clockwise-rotating power steering pump (see arrow).
Press down tensioning device (1) on damper in direction of arrow and hold.
Take off ribbed V-belt.
Installation:
Observe direction of rotation if reusing the drive belt.
Ensure drive belt is in correct installation position.

2010 BMW M3
Fig. 190: Pressing Down Tensioning Device

IMPORTANT: Belt routing of counterclockwise-rotating power steering pump (see arrow).

Double-sided ribbed V-belt.
Installation:
Fig. 191: Pressing Down Tensioning Device

Assemble engine.
2010 BMW M3
11 28 010 REPLACING ALTERNATOR DRIVE BELT (S65)
IMPORTANT: Mark the direction of rotation of the drive belt if it is to be reused.

Remove drive belt for A/C system.
Release cover (1) with a screwdriver.

Press down tensioning device (1) with standard tool in direction of arrow.
Remove drive belt.
Installation:
Make sure drive belt is installed in correct position.

2010 BMW M3
Fig. 193: Pressing Down Tensioning Device In Direction Of Arrow

Assemble engine.
11 28 020 REPLACING TENSIONING DEVICE FOR ALTERNATOR DRIVE BELT (S65)

Remove fan cowl with electric fan.

Remove A/C compressor drive belt.
Release screws (1).
Remove alternator drive belt.
Remove belt pulley (2) from coolant pump.

2010 BMW M3
Fig. 194: Identifying Belt Pulley And Screws

Remove belt tensioner (3) with tensioning pulley.
Installation:

Assemble engine.
CAMSHAFT
2010 BMW M3
11 31 575 ADJUSTING CAMSHAFT TIMING (S65)
IMPORTANT: Central bolts on VANOS gears have left-hand threads.
IMPORTANT: The procedure for adjusting the timing is different from that for checking the
timing.
The letters/numbers on the camshafts (E1 and A1) and (E2 and A2) must point
upwards.
Do not release the central bolts of the adjustment units without the special tool
11 9 970 GAUGE (risk of damage!).
If the special tool 11 9 970 GAUGE cannot be positioned on the dihedron of the
camshafts, bar the engine at the central bolt until the special tool 11 9 970
GAUGE can be secured on the cylinder head.
Release bolts (1) on cylinder bank 1.
Remove timing case cover (2).
Installation:
Replace seal.
Fig. 196: Identifying Timing Case Cover And Bolts

Installation:
Replace seal.
2010 BMW M3

IMPORTANT: Both inlet and exhaust camshafts can be adjusted in the 1st cylinder firing TDC
position.
Danger of mixing up both special tool bores.
10 before TDC
TDC= top dead center.
Before the crankshaft can be secured, the gauges 119970 GAUGE must be positioned on the camshafts.
Fig. 198: Identifying Timing Marks

Rotate crankshaft at central bolt.
IMPORTANT: Always start timing with bank 1 (cylinders 1-4).

2010 BMW M3
Position of inlet camshaft, cylinders 1-4.
Designation (E1) on dihedron points upwards.
Fig. 199: Identifying Inlet Camshaft Designation

Position of exhaust camshaft, cylinders 1-4.
Designation (A1) on dihedron (1) points upwards.
Fig. 200: Identifying Exhaust Camshaft Designation

Rotate inlet camshaft with open-end wrench (1) with minimal effort at hexagon head in direction of arrow until
special tool 11 9 972 can be attached.
Secure special tool 11 9 972 with bolts (2) on cylinder head to 10 Nm.
2010 BMW M3
Fig. 201: Rotating Inlet Camshaft Using Open-End Wrench

Rotate exhaust camshaft with open-end wrench with minimal effort in direction of arrow until special tool 11 9
971 can be attached.
Designation (A1) on dihedron points upwards.
Fig. 202: Securing Special Tool (11 9 971) With Bolts On Cylinder Head
IMPORTANT: CCW thread!
Release central bolt (1).
Installation:
2010 BMW M3
Replace central bolts (1 and 2).
Fig. 203: Identifying Central Bolts

IMPORTANT: Rotate crankshaft at central bolt back until special tool 11 5 320 can be secured
in the 10 position.
Fig. 204: Identifying Crankshaft Position

IMPORTANT: Replace central bolts of adjustment units.

Central bolts must be fully screwed once (refer to SCREW FASTENING LIST ).
Cylinders 1 to 4:
Always start screwing on the inlet side.
Secure central bolt (1) with special tool 00 9 120 TORQUE ANGLE MEASURING DIAL .
2010 BMW M3
IMPORTANT: Screw central bolt fully once.
1. Joining 20 Nm
2. Settling torque 80 Nm
3. Torsion angle 200
4. Unscrew central bolt.
5. Preload central bolt to 10 Nm.
Fig. 205: Securing Central Bolt Using Special Tool (00 9 120)
1. Joining 20 Nm
2010 BMW M3
Camshafts, cylinders 1-4, remain secured with special tool 119970 GAUGE .
Release special tool 11 5 320 and continue barring engine at central bolt 10 to firing TDC position of
cylinder no. 1.
Installation:
This minimizes timing chain play.
Secure crankshaft with special tool 11 5 320.

Cylinders 1 to 4:

2010 BMW M3
IMPORTANT: Central bolt final tightening.
1. Joining 20 Nm
1. Joining 20 Nm
IMPORTANT: Remove all special tools.

2010 BMW M3
Installation:
If necessary, crank at crankshaft central bolt.


2010 BMW M3

Secure inlet camshaft with special tool 11 9 971.
Secure exhaust camshaft with special tool 11 9 972.
Secure special tools 11 9 971 and 11 9 972 with bolts (1) on cylinder head to 10 Nm.
Fig. 212: Securing Camshafts With Special Tools (11 9 971 And 11 9 972)
Installation:
2010 BMW M3

in the 10 position.


Central bolts must be fully screwed once (refer to SCREW FASTENING LIST ).
Cylinders 5 to 8:
2010 BMW M3
1. Joining 20 Nm
1. Joining 20 Nm
2010 BMW M3
cylinder no. 1.
Installation:

Cylinders 5 to 8:

2010 BMW M3
1. Joining 20 Nm
1. Joining 20 Nm
Remove all special tools.

2010 BMW M3
Check TIMING .
Assemble engine.
11 31 072 CHECKING CAMSHAFT TIMING (S65)
IMPORTANT: Bank (2), cylinders (5 - 8), is checked first.

The timing of bank (1) at cylinders (1-4) can only be checked at overlap TDC.
The lettering (E1 and A1) must point downwards.
Remove FAN COWL with electronic fan.

Remove left CYLINDER HEAD COVER .
Remove right CYLINDER HEAD COVER
Remove all SPARK PLUGS .
IMPORTANT: Danger of mixing up both special tool bores.
10 before TDC (top dead center)
OT Top dead center

2010 BMW M3

IMPORTANT: Only bank 2, cylinders (5 - 8), can be checked in cylinder no. 1 firing TDC
position.
The 10 position is required only to adjust the timing.
Crank engine at central bolt until the firing TDC position appears on the vibration damper.
Engine installed: Secure vibration damper in position with special tool 110480 MANDREL .

Engine removed: Secure vibration damper in position with special tool 11 5 320.
IMPORTANT: Bank 2 is checked first.
The lettering (A2 and E2) points upwards.

2010 BMW M3
The positions of the cams on the exhaust camshaft point vertically upwards (see picture).
The positions of the cams on the inlet camshaft point at an angle downwards (see picture).
Fig. 222: Identifying Camshaft Lettering

Position special tool 11 9 972 on twin surface of exhaust camshaft (A2).
Position special tool 11 9 971 on twin surface of inlet camshaft (E2).
The timings are correctly set when special tool 119970 GAUGE rests without a gap on the cylinder head.
Permissible tolerance: A maximum gap of 1.0 mm is permitted on the non-contacting side of special tool
119970 GAUGE .
Fig. 223: Positioning Special Tool (11 9 972) On Twin Surface Of Exhaust Camshaft
IMPORTANT: Remove special tools 119970 GAUGE and 11 5 320.

2010 BMW M3
Crank engine at central bolt 360 in direction of rotation.

The timing of bank 1 at cylinders (1-4) can only be checked at overlap TDC.
Engine installed: Secure vibration damper in position with special tool 110480 MANDREL .

Engine removed: Secure vibration damper in position with special tool 11 5 320.
IMPORTANT: Position of camshaft at overlap TDC

The lettering (E1 and A1) points downwards.
The cams on cylinder no. 1 on the inlet camshaft point at an angle downwards (see picture).
The cams on cylinder no. 1 on the exhaust camshaft point at an angle downwards (see picture).
Fig. 225: Positioning Special Tool (11 9 971) On Twin Surface Of Inlet Camshaft
2010 BMW M3
The timings are correctly set when special tool 119970 GAUGE rests without a gap on the cylinder head.
Permissible tolerance: A maximum gap of 1.0 mm is permitted on the non-contacting side of special tool
119970 GAUGE .
Adjust VALVE TIMING .
Fig. 226: Adjusting Valve Timing

Assemble engine in reverse sequence to its disassembly.
11 31 032 REMOVING AND INSTALLING OR REPLACING LEFT INLET CAMSHAFTS (S65)
Remove LEFT CYLINDER HEAD COVER .

Remove left VANOS EXHAUST GEAR
Remove left VANOS INLET GEAR
Release screws (1).
E Intake camshaft
2010 BMW M3
A Exhaust camshaft.
IMPORTANT: Risk of mix-up with cylinder bank 1-5.

Arrow (2) must point in direction of travel to chain drive.
Installation:
Lubricate all bearing points with engine oil.
Fig. 227: Identifying Camshaft Screws

Release screws (1) from outside inwards in 1/2 turns.
Remove inlet camshaft for cylinders 5 to 8.

2010 BMW M3
Do not place timing chain in gearcase.
Secure timing chain (1) against falling down with a cable tie (3) to one screw (2).
Fig. 229: Securing Timing Chain

Check plain compression rings for damage and replace if necessary.
The plain compression rings have catches at the joint.
Press plain compression rings apart upwards and downwards and remove towards front.
IMPORTANT: Plain compression rings can break easily.
Fig. 230: Removing Plain Compression Rings

Insert inlet camshaft for cylinders 5 to 8.

2010 BMW M3
Cams on cylinder no. 6 point upwards.
Installation:
Fig. 231: Positioning Camshaft Lobs

Installation:
All bearing shells are assigned to one cylinder.
E and A from (1 to 8), e.g. E 5= inlet side on cylinder no. 5.
Arrow must point in direction of travel to chain drive.
Fig. 232: Positioning Travel Direction To Chain Drive

2010 BMW M3
Release screws (1) from inside outwards in 1/2 turns.

Assemble engine.
11 31 036 REMOVING AND INSTALLING/REPLACING LEFT EXHAUST CAMSHAFT (S65)
Remove LEFT CYLINDER HEAD COVER .

Remove left VANOS EXHAUST GEAR
Release screws (1).
E Intake camshaft
A Exhaust camshaft.

Remove bearing cap (2).

2010 BMW M3
Installation:

Installation:


2010 BMW M3

Insert exhaust camshaft for cylinders 5 to 8.
Designation (A 2) on dihedron points upwards.
Cams (1) on cylinder no. 5 point upwards.
Installation:

2010 BMW M3

Installation:

Installation:
2010 BMW M3

Assemble engine.
11 31 094 REMOVING AND INSTALLING/REPLACING LEFT HYDRAULIC CHAIN TENSIONER

(S65)
Remove left INTAKE FILTER HOUSING

Release chain tensioner (1).
Installation:

2010 BMW M3
Fig. 240: Identifying Chain Tensioner

Assemble engine.
11 31 038 REMOVING AND INSTALLING/REPLACING RIGHT EXHAUST CAMSHAFT (S65)

Remove right VANOS EXHAUST GEAR
Release screws (1).
E Intake camshaft
A Exhaust camshaft.

Remove bearing caps.
Installation:

2010 BMW M3

Remove exhaust camshaft for cylinders 1 to 4.


2010 BMW M3

Installation:
Fig. 244: Positioning Exhaust Camshaft Lobs

Installation:

2010 BMW M3
E and A from (1 to 8), e.g. A 1= exhaust side on 1st cylinder.


Adjust valve timing.
Assemble engine.
11 31 095 REMOVING AND INSTALLING/REPLACING RIGHT HYDRAULIC CHAIN TENSIONER

(S65)
2010 BMW M3
Remove EXPANSION TANK .

Unfasten both A/C LINES on A/C compressor.
Installation:

Assemble engine.
11 31 034 REMOVING AND INSTALLING/REPLACING RIGHT INLET CAMSHAFT (S65)

Remove right VANOS EXHAUST GEAR
Remove right VANOS INLET GEAR
Release screws (1).
E Intake camshaft
A Exhaust camshaft.
2010 BMW M3

Installation:

NOTE: Illustration shows cylinders 5-8.
Installation:

2010 BMW M3


Insert inlet camshaft (1) for cylinders 1 to 4.
Cams on cylinders (1 and 3) point upwards at an angle.
Installation:

2010 BMW M3
Fig. 251: Positioning Inlet Camshaft Lobes

Installation:
E and A from (1 to 8), e.g. E 1= inlet side on 1st cylinder.
Fig. 252: E 1= Inlet Side On 1st Cylinder

Installation:
2010 BMW M3

Assemble engine.
11 31 051 REPLACING BOTH TIMING CHAINS (S65)
Remove all VANOS gears . See 1136142 REMOVING AND INSTALLING/REPLACING LEFT
INLET VANOS GEAR (S65); 1136144 REMOVING AND INSTALLING/REPLACING LEFT
EXHAUST VANOS GEAR (S65); 1136148 REMOVING AND INSTALLING/REPLACING
RIGHT INLET VANOS GEAR (S65) or 1136150 REMOVING AND INSTALLING/REPLACING
RIGHT EXHAUST VANOS GEAR (S65).
Remove RADIAL SHAFT SEAL at front.
Remove OIL PUMP .
Remove OIL RETURN PUMP .
Remove OIL FILTER HOUSING .
Release screw plug (1) on bank 1.

2010 BMW M3
Fig. 254: Identifying Screw Plug

Release screw plugs (1).
Release screw (2).
Remove intermediate piece (3) without gearwheel towards front.
IMPORTANT: Gearwheel can fall out.
Fig. 255: Identifying Screw Plugs, Screw And Intermediate Piece

Arrangement of gearwheel and intermediate piece
Gearwheel (1) with dowel pin.

2010 BMW M3
Intermediate piece (2).
Central bolt (3).
Fig. 256: Identifying Intermediate Piece, Gearwheel And Central Bolt

NOTE: Bearing pin (1) is only inserted.
Bearing pin (2) for two tensioning rails.
Remove bearing pin with special tool 11 5 290.
Fig. 257: Removing Bearing Pin


2010 BMW M3
Screw in special tool 11 5 292 at bearing pin (1) and pull out.

Remove bearing pin with special tool 11 5 290.

Arrangement of both timing chains
1. Timing chain, bank 2.

3. Guide rail, bank 1.
5. Tensioning rail, bank 1.
2010 BMW M3
6. Bearing pin, inserted type.

7. Bearing pin for two tensioning and guide rails.
8. Bearing pin, screwed type.
Fig. 260: Identifying Tensioning Rail, Bank 1, Timing Chain, Bank 1 And Guide Rail, Bank 1
Remove timing chain, bank 2.
Fig. 261: Removing Timing Chain, Bank 1

Assemble engine.
ROCKER ARM WITH BEARING MOUNT

2010 BMW M3
11 33 062 REMOVING AND INSTALLING/REPLACING ALL HVCA (HYDRAULIC VALVE

CLEARANCE ADJUSTMENT) ELEMENTS (S65)
IMPORTANT: Used HVCA elements may only be reused in the same position.
Set HVCA elements down in a clean and orderly manner.
Remove inlet camshaft . See 1131032 REMOVING AND INSTALLING OR REPLACING LEFT
INLET CAMSHAFTS (S65) or 1131034 REMOVING AND INSTALLING/REPLACING RIGHT
INLET CAMSHAFT (S65).
Remove exhaust camshaft See 1131036 REMOVING AND INSTALLING/REPLACING LEFT
EXHAUST CAMSHAFT (S65) or 1131038 REMOVING AND INSTALLING/REPLACING
RIGHT EXHAUST CAMSHAFT (S65).
Remove HVCA element (1) in upward direction.
Installation:
Turning lock (2) on cylinder head.
Fig. 262: Identifying HVCA Element And Lock

Check surface (1) of HVCA element for damage.
Installation:
Turning lock (2) on HVCA element.

2010 BMW M3
Fig. 263: Identifying HVCA Element Lock

Installation:
Check valve keys (1) for correct seating.
Check turning lock (2) on cylinder head for damage.
Fig. 264: Identifying Valve Keys

Assemble engine.
VALVES WITH SPRINGS

11 34 552 REMOVING AND INSTALLING/REPLACING ALL VALVES (S65)
IMPORTANT: Risk of damage to cylinder head.

Use only the approved special tools.
2010 BMW M3
Plastic rings on the special tools must not be damaged.
Remove INTAKE AIR MANIFOLD.

Remove cylinder head cover and cylinder heads on left and right.
Remove all SPARK PLUGS .
If necessary, remove and install engine.
NOTE: Place cylinder head (1) on special tool 11 9 001.
Prepare special tool 11 9 006 with special tool 11 9 008.
Fig. 265: Identifying Cylinder Head On Special Tool

Insert aluminum profile rail (1) and align.
Secure eccentric clamping levers (2 and 3).

2010 BMW M3
Fig. 266: Securing Eccentric Clamping Levers

IMPORTANT: Special tools S85 11 5 281 and 11 5 282 must be modified to S65.
Special tool 11 5 281 for removing valve keys.
Special tool 11 5 282 for installing valve keys.

Unscrew valve cage from special tool 11 5 281.
Special tool 11 9 951 (1 to 3) must be replaced.

2010 BMW M3
Fig. 268: Identifying Valve Cage

Remove all washers of special tool 11 5 281 (S85).
Insert special tool 11 9 951 in correct order.
Insert washer (1) with collar facing down in valve cage (2).
Fig. 269: Identifying Washer And Valve Cage

Insert felt washer (2) with smooth side facing down in valve cage (1).
2010 BMW M3
Fig. 270: Identifying Felt Washer And Valve Cage

Insert washer (3) in valve cage (1).
Screw down special tool 11 5 281 with inserted special tool 11 9 951 again.

Modify special tool 11 5 281 with special tool 11 9 951.

2010 BMW M3

IMPORTANT: In order to avoid damaging the HVCA guide, use only the designated special
tools.
Adjust special tool 11 9 009 so that special tool 11 5 281 can press vertically onto the valve spring.
Fig. 273: Pressing Special Tool Onto Valve Spring

NOTE: Special tool 11 5 281 incorporates a lever (1) which is tensioned with a spring.
Press down valve spring with special tool 11 9 009 and keep pressed.
Pretension lever (1) in direction of arrow.
Release lever (1) in tensioned position.
The valve keys still installed are thus forced out and drop into the working chamber of special tool 11 5 281.
2010 BMW M3
Fig. 274: Releasing Lever

Repeat the operation several times if necessary until all the valve keys are forced out.
Pull back lever on special tool 11 5 281.
Valve keys (1) can now be ejected from the working chamber (2).
Fig. 275: Identifying Valve Keys And Working Chamber

All the engine valves are now accessible.
Installation:
Set the engine valves down in neat and tidy order if they are to be reused.
Check valve seat for damage.

2010 BMW M3
IMPORTANT: The cylinder head must be replaced if the valve seat is damaged.
Remachining the valve seat ring is not permitted.

IMPORTANT: Use only special tool 11 9 953 to install the valve keys - risk of damage!
Press valve key (1) in direction of arrow into special tool 11 9 953.
Fig. 277: Pressing Valve Key

Secure valve keys (1).

2010 BMW M3

Special tool 11 9 952 must be replaced.

Remove insert washer of special tool 11 5 282 (S85).
Insert special tool 11 9 952 with taper facing up in valve cage (1) (see arrow).
2010 BMW M3
Fig. 280: Inserting Special Tool (11 9 952) Into Valve Cage
Press valve keys into special tool 11 9 953 with special tool 11 5 283.

Press valve keys in direction of arrow into special tool 11 5 282 with special tool 11 9 953.
2010 BMW M3
Fig. 282: Pressing Valve Keys

Make sure valve keys (1) are correctly positioned.
Special tool 11 5 282 is prepared.
Fig. 283: Identifying Valve Keys Position

Press down special tool 11 5 282 with special tool 11 9 009 in direction of arrow.
Installation:
Both valve keys are now pressed into their initial positions.
2010 BMW M3
Fig. 284: Pressing Down Special Tool (11 5 282) With Special Tool (11 9 009)
Installation:
Check that valve keys are in correct installation position.

Assemble engine.
11 34 715 REPLACING ALL VALVE SPRINGS (S65)

Special tools 11 5 821 and 11 5 282 must be modified to special tool 119950
DEVICE .
2010 BMW M3
Remove cylinder head.

Remove all HVCA elements.
NOTE: Place cylinder head (1) with cylinder head bolts on special tool 11 9 001.
Prepare special tool 11 9 006 with special tool 11 9 008.

Secure eccentric clamping levers (2 and 3) in direction of arrow.
Fig. 287: Securing Eccentric Clamping Levers

2010 BMW M3
IMPORTANT: Special tools S85 11 5 281 and 11 5 282 must be modified to S65 119950
DEVICE .
Special tool 11 9 953 for securing valve keys.



2010 BMW M3

Fig. 291: Identifying Felt Washer And Valve Cage

2010 BMW M3

Modify special tool 11 5 281 with special tool 11 9 951.

IMPORTANT: Use only approved special tools.

Risk of damage to the HVCA guide.
2010 BMW M3
Fig. 294: Pressing Special Tool Onto Valve Spring

NOTE: Lever (1) on special tool 11 5 281 is tensioned with a spring.
The valve keys still installed are thus forced out and drop into the working chamber of special tool 11 5 281.

Pull back lever on special tool 11 5 281.

2010 BMW M3
Fig. 296: Identifying Valve Keys And Working Chamber

NOTE: Lower spring plate (1).

Progressive valve spring (2).
Upper spring plate (3).
Installation:
Incorrect installation is not possible.
Fig. 297: Identifying Lower Spring Plate, Progressive Valve Spring And Upper Spring Plate
Insert lower spring plate (1).

2010 BMW M3
Fig. 298: Identifying Lower Spring Plate

Press valve key (1) in direction of arrow into special tool 11 9 953.
Fig. 299: Pressing Valve Key


2010 BMW M3


2010 BMW M3
Fig. 302: Pressing Valve Keys

Special tool 11 5 282 is prepared for installation.
Installation:
Positioning of valve keys (1).
Fig. 303: Identifying Valve Keys Position

Installation:
2010 BMW M3
Fig. 304: Pressing Down Special Tool (11 5 282) With Special Tool (11 9 009)
Installation:
Check that valve keys (1) are in correct installation position.

Assemble engine.
11 34 560 REPLACING ALL VALVE STEM SEALS (S65)
Remove cylinder head See 1112105 REMOVING AND INSTALLING LEFT CYLINDER HEAD
(S65) or 1112106 REMOVING AND INSTALLING RIGHT CYLINDER HEAD (S65).
Remove all VALVE SPRINGS .
2010 BMW M3
Remove valve stem seal with special tool 11 1 480 in direction of arrow.
Fig. 306: Removing Valve Stem Seal Using Special Tool (11 1 480)
Installation:
Attach the mounting sleeve (1) supplied with the new part to the valve stem.
Fig. 307: Identifying Mounting Sleeve

Attach valve stem seal (2) over mounting sleeve (1).

2010 BMW M3
Fig. 308: Identifying Valve Stem Seal And Mounting Sleeve

Press on valve stem seal with special tool 11 5 270 in direction of arrow as far as it will go.
Fig. 309: Pressing Valve Stem Seal Using Special Tool (11 5 270)
Assemble engine.
VARIABLE CAMSHAFT TIMING

11 36 144 REMOVING AND INSTALLING/REPLACING LEFT EXHAUST VANOS GEAR (S65)

Do not release the central bolt of the adjustment units without the special tool
119970 GAUGE .
Grease contact surfaces of central bolts with copper paste.

2010 BMW M3
Installation:
Replace seal.

position.
The procedure for CHECKING TIMING is different from that for adjusting.

2010 BMW M3
Crank engine at central bolt.
Secure crankshaft with special tool 11 5 320 in firing TDC position of cylinder no. 1.

Position of inlet camshafts, cyl. 5-8, in firing TDC position of cylinder no. 1.
Dihedron of inlet camshafts is vertical to cylinder axis, letters/numbers on camshafts point upwards (E2).

Position of exhaust camshafts, cyl. 5-8, in firing TDC position of cylinder no. 1.
Dihedron of camshafts is vertical to cylinder axis, letters/numbers on camshafts point upwards (A2).
2010 BMW M3

Place special tool 11 9 971 on inlet camshaft.
Place special tool 11 9 972 on exhaust camshaft.
Align gearwheels on exhaust adjustment unit with special tool 11 5 370.

2010 BMW M3
Fig. 316: Aligning Gearwheels On Exhaust Adjustment Unit Using Special Tool (11 5 370)
IMPORTANT: Removal/installation is not possible without hexagon socket screw (2).

Hexagon socket screw (1) must not be longer than 10 mm.
Gearwheels of exhaust VANOS gear are pretensioned with a spring.
Insert M5x10 hexagon socket screw on VANOS gear.
Fig. 317: Identifying Hexagon Socket Screw

NOTE: Picture shows cylinders 1-4.

Release central bolts (1 and 2).
Installation:
2010 BMW M3

Installation:
If the hexagon socket screw is released or forgotten by mistake, the gear teeth can be readjusted with special
tool 11 5 370.
Screw in knurled screw on special tool 11 5 370 until gearwheel (1) lines up with bore (see arrow) on thread.
Failure to tension the exhaust VANOS gear (1) will result in rattling noises at idle.
Fig. 319: Identifying Exhaust VANOS Gear

NOTE: Picture shows (S85).
Installation:
2010 BMW M3
Check O-ring (1) on VANOS gear, replace if necessary.
Fig. 320: Identifying VANOS Gear O-Ring

IMPORTANT: Replace central bolt of adjustment unit.

Central bolt must be fully screwed once (refer to SCREW FASTENING LIST ).
in the 10 position.

Installation:
Coat contact face of new central bolt (1) with copper paste.
2010 BMW M3
Fig. 322: Identifying Contact Face Of Central Bolt

Position VANOS adjustment unit on camshaft.
Hexagon socket screw points upwards.
Insert central bolts (1 and 2) and screw with special tool 00 9 120 TORQUE ANGLE MEASURING DIAL .
1. Joining 10 Nm
2. Joining 20 Nm
6. Joining 10 Nm
Fig. 323: Inserting Central Bolts

2010 BMW M3
Remove hexagon socket screw (1) or special tool 11 5 370.

Release special tool 11 5 320 and continue barring engine at central bolt 10 to firing TDC position of cylinder
no. 1.
Installation:
This minimizes timing chain and gearwheel play.

2010 BMW M3
Cylinders 5 to 8:
1. Joining 20 Nm
1. Joining 20 Nm
2010 BMW M3
Check TIMING , cylinders (5 to 8).
Assemble engine.
11 36 142 REMOVING AND INSTALLING/REPLACING LEFT INLET VANOS GEAR (S65)

119970 GAUGE .
Remove left CYLINDER HEAD COVER .
Installation:
Replace seal.
2010 BMW M3

position.

2010 BMW M3


2010 BMW M3


2010 BMW M3
Fig. 334: Aligning Gearwheels On Exhaust Adjustment Unit Using Special Tool (11 5 370)



Installation:
2010 BMW M3
Replace central bolt (2).
Fig. 336: Identifying Central Bolt

Remove exhaust adjustment unit (1).
Fig. 337: Identifying Exhaust Adjustment Unit

Installation:
tool 11 5 370.
2010 BMW M3

Installation:

Installation:

2010 BMW M3

Installation:
Remove inlet adjustment unit (2).
Fig. 341: Identifying Inlet Adjustment Unit And Central Bolt

Open plug (1).
Installation:
2010 BMW M3
Replace seal.

Secure screw connection against falling out with special tool 11 5 292.
Release screw connection at chain guide with special tool 11 5 291.

Remove inlet adjustment unit.
Lay timing chain (1) on inlet camshaft.
IMPORTANT: Do not bar engine at central bolt.

Risk of damage! to engine valves and timing chain.
2010 BMW M3
Fig. 344: Identifying Timing Chain

EIN Inlet adjustment unit
AUS Exhaust adjustment unit
Fig. 345: Identifying Inlet And Exhaust Adjustment Unit


Central bolt must be fully screwed
once (refer to SCREW FASTENING LIST ).
in the 10 position.
2010 BMW M3

Installation:

Insert central bolts (1 and 2) without play.

2010 BMW M3


Secure timing chain tensioning rail.

2010 BMW M3

Install chain tensioner (1).
Installation:

Insert central bolt (1) and screw with special tool 00 9 120 TORQUE ANGLE MEASURING DIAL .
1. Joining 10 Nm
2. Joining 20 Nm
2010 BMW M3

6. Joining 10 Nm
1. Joining 10 Nm
2. Joining 20 Nm
6. Joining 10 Nm
119970 GAUGE
2010 BMW M3
cylinder no. 1.
Installation:

Cylinders 5 to 8:
1. Joining 20 Nm
2010 BMW M3
1. Joining 20 Nm
Check TIMING , cylinders (5 to 8).
Assemble engine.
2010 BMW M3
11 41 050 REMOVING AND INSTALLING/REPLACING OIL SUCTION PUMP (S65)
IMPORTANT: Excessively low or high play between the gearwheel pairs results in failure of
the oil supply.

Remove OIL PUMP .
Release screws (1).
Tightening torque. 11 41 3AZ .
Remove oil pump (2).
Fig. 357: Identifying Oil Pump And Screws

Replacing gear wheels

Mount special tool 11 6 254 on crankcase.
Secure special tool 11 6 252 with magnetic base to special tool 11 6 254.
NOTE: Special tool 11 6 254 can only be secured to the crankcase with one screw.
2010 BMW M3
Picture shows (S85).
Fig. 358: Securing Special Tool (11 6 252) With Magnetic Base To Special Tool (11 6 254)
IMPORTANT: The oil pump chain of the oil suction pump must be removed.
The chain tensioner must not exert any tension on the oil suction pump.
Align special tool 11 6 251 with its measuring shaft (2) vertically to gearwheel (1).
Turn oil suction pump gearwheel (1) to stop.
Fig. 359: Turning Oil Suction Pump Gearwheel

Set special tool 11 6 251 to zero.
Turn oil suction pump gearwheel (1) in direction of arrow to stop.

2010 BMW M3

Backlash on oil suction pump min. 0.06 to max. 0.08 mm.
If necessary, correct oil suction pump adjustment.
Fig. 361: Measuring Oil Suction Pump Backlash

Adjust oil suction pump (2) with a rubber mallet on pump housing in direction of arrow.

2010 BMW M3
Fig. 362: Adjusting Oil Suction Pump

Assemble engine.
11 36 150 REMOVING AND INSTALLING/REPLACING RIGHT EXHAUST VANOS GEAR (S65)

119970 GAUGE .
Installation:
Replace seal.
2010 BMW M3

position.

2010 BMW M3


Dihedron of camshafts is vertical to cylinder axis, letters/numbers (A1) on camshafts (1) point upwards.
2010 BMW M3

Fig. 368: Rotating Inlet Camshaft

Rotate exhaust camshaft with open-end wrench (1) with minimal effort at hexagon head in direction of arrow
until special tool 11 9 971 can be attached.
2010 BMW M3
Fig. 369: Rotating Exhaust Camshaft

Fig. 370: Aligning Gearwheels On Exhaust Adjustment Unit With Special Tool (11 5 370)


2010 BMW M3

Installation:

Installation:
tool 11 5 370.
2010 BMW M3

Installation:


in the 10 position.
2010 BMW M3

Installation:

1. Joining 10 Nm
2. Joining 20 Nm
2010 BMW M3

6. Joining 10 Nm
1. Joining 10 Nm
2. Joining 20 Nm
6. Joining 10 Nm
2010 BMW M3

cylinder no. 1.
Installation:

Cylinders 5 to 8:
2010 BMW M3
1. Joining 20 Nm
1. Joining 20 Nm
2010 BMW M3
Check TIMING , bank 1, cylinders (1 to 4).
Assemble engine.
11 36 148 REMOVING AND INSTALLING/REPLACING RIGHT INLET VANOS GEAR (S65)

119970 GAUGE .
Installation:
Replace seal.
2010 BMW M3

position.

2010 BMW M3


2010 BMW M3

Fig. 388: Rotating Inlet Camshaft

2010 BMW M3
Fig. 389: Rotating Exhaust Camshaft

Fig. 390: Aligning Gearwheels On Exhaust Adjustment Unit With Special Tool (11 5 370)


2010 BMW M3

Installation:
Remove exhaust adjustment unit

Installation:
tool 11 5 370.
2010 BMW M3

Installation:

Installation:
2010 BMW M3

Installation:
Fig. 396: Identifying Inlet Adjustment Unit And Central Bolt

2010 BMW M3
Lay timing chain (1) on inlet camshaft (2).
Fig. 397: Identifying Timing Chain And Inlet Camshaft

Fig. 398: Identifying Inlet And Exhaust Adjustment Unit


in the 10 position.
2010 BMW M3

Installation:

Position inlet adjustment unit with timing chain on inlet camshaft.
Screw in central bolt (2) hand-tight.
Position exhaust adjustment unit on exhaust camshaft.

2010 BMW M3


Screw in central bolt (1) with special tool 00 9 120 TORQUE ANGLE MEASURING DIAL .
1. Joining 10 Nm
2. Joining 20 Nm
6. Joining 10 Nm
2010 BMW M3
1. Joining 10 Nm
2. Joining 20 Nm
6. Joining 10 Nm

2010 BMW M3

cylinder no. 1.
Installation:

Cylinders 1 to 4:
2010 BMW M3
1. Joining 20 Nm
1. Joining 20 Nm
2010 BMW M3
Check TIMING , bank 1, cylinders (1 to 4).
Assemble engine.
11 36 715 REMOVING AND INSTALLING/REPLACING SOLENOID VALVES ON LEFT VANOS

ADJUSTMENT UNIT (S65)
Release screw (1).
Remove solenoid valve (3), exhaust adjustment.
Installation:
Replace O-rings.
Fig. 409: Identifying Solenoid Valve, Plug Connections And Screw

Release screw (1).
Unfasten plug connection.
Remove solenoid valve (2), inlet adjustment.
Installation:
2010 BMW M3
Replace O-ring.
Fig. 410: Identifying Solenoid Valve And Screw

Assemble engine.
Perform VANOS test.
11 36 720 REMOVING AND INSTALLING/REPLACING SOLENOID VALVES ON RIGHT VANOS

Remove INTAKE MANIFOLD (inlet solenoid valve only).
Disconnect plug connection (2) on solenoid valve for exhaust adjustment.
Release screw (1).
Remove exhaust solenoid valve.
Installation:
Replace O-rings.
2010 BMW M3
Fig. 411: Identifying Screw And Plug Connection

Disconnect plug connection on solenoid valve for inlet adjustment.
Release screws (1).
Remove inlet solenoid valve (2).
Installation:
Replace O-ring.
Fig. 412: Identifying Screws And Inlet Solenoid Valve

Assemble engine.
Perform VANOS test.

2010 BMW M3
OIL PUMP WITH FILTER AND DRIVE

11 41 000 REMOVING AND INSTALLING/REPLACING OIL PUMP (S65)
Remove OIL PAN
Release screws (1).
Release screws (2).
Installation:
Replace screws.
Clean threads before installation.
Fig. 413: Identifying Oil Pipe Screws

Release screw (1).
Release screw (2).
Detach oil pipes from oil pump.

2010 BMW M3

Release screw (1).
Fig. 415: Identifying Oil Pipe Screw

Detach oil pipes (1 and 2) from oil pump.
Installation:
To facilitate fitting, apply a light coating of engine oil to sealing rings.
Clean all sealing surfaces.

2010 BMW M3
Fig. 416: Detaching Oil Pipes

Slacken nut (1).
Installation:
If reusing the sprocket wheel, check dihedron for damage and if necessary replace.
Replace microencapsulated nut (1).
Tightening torque:11 41 1AZ .
Fig. 417: Identifying Microencapsulated Nut

Release screw (1).
Release screw (2).

2010 BMW M3
Fold sliding rail (3) downwards.
Fig. 418: Identifying Sliding Rail And Screw

Remove sprocket wheel (1) from shaft.
Fig. 419: Identifying Sprocket Wheel

IMPORTANT: Chain tensioner piston may fall out.
Remove piston (1) in direction of arrow.

2010 BMW M3
Fig. 420: Removing Piston

Installation:
Arrangement, chain tensioner, oil pump.
1. Base valve
2. Spring
3. Piston
Fig. 421: Identifying Base Valve, Spring And Piston

Release screws (1) on oil pump (2).

2010 BMW M3
Fig. 422: Identifying Screws And Oil Pump

Installation:

Assemble engine.
the oil supply.

2010 BMW M3
Remove OIL PUMP .
Release screws (1).
Tightening torque, see 11 41 3AZ .

REPLACING GEAR WHEELS

Secure special tool 11 6 252 with magnetic base to special tool 11 6 254.

2010 BMW M3
Fig. 425: Securing Special Tool (11 6 252) With Magnetic Base To Special Tool (11 6 254)


2010 BMW M3



2010 BMW M3
Fig. 429: Adjusting Oil Suction Pump

Assemble engine.
OIL FILTER AND LINES

11 42 020 REMOVING AND INSTALLING, SEALING/REPLACING MAIN FLOW OIL FILTER
(S65)

Recycling
Remove fan cowl with electronic fan.

Remove front underbody protection.
Remove A/C system DRIVE BELT .
Remove water pump BELT PULLEY .
Remove coolant hoses.
Release POWER STEERING PUMP and lay to one side (do not open pressure lines).

2010 BMW M3

Detach lines (2 and 3).
Installation:
Replace O-rings.
Fig. 431: Identifying Lines And Nuts

2010 BMW M3
Release screws (1).
Release screws (2).
Release screws (3).
Lift out oil filter housing.

Installation:
Replace seal (1).

2010 BMW M3
Assemble engine.
Park vehicle on a horizontal surface.
Allow engine at normal operating temperature to run for 3 minutes with increased revs (min. 1000/max. 1500
RPM).
Read off engine oil level in instrument cluster or on Control Display.
Top up engine oil if necessary.
11 42 080 REMOVING AND INSTALLING/REPLACING OIL PRESSURE HOSE - FEED - (S65)

Recycling
Catch and dispose of emerging engine oil with suitable equipment.

Remove front UNDERBODY PROTECTION .
Slacken nut (1).
Disconnect oil line (2).
Installation:
Replace O-ring.
2010 BMW M3
Fig. 434: Identifying Oil Line And Nut

Slacken nut (1).
Unclip bracket (2).
Fig. 435: Identifying Bracket And Nut

Slacken nut (1).
Installation:
Replace O-ring.
2010 BMW M3

Assemble engine.
RPM).
11 42 085 REMOVING AND INSTALLING/REPLACING OIL PRESSURE HOSE - RETURN - (S65)

Recycling

Remove front UNDERBODY PROTECTION .
Slacken nut (4).
Installation:
2010 BMW M3
Replace O-ring.

Slacken nut (1).
Unclip retainer (2).
Fig. 438: Identifying Retainer And Nut

Slacken nut (1).
Installation:
Replace O-ring.
2010 BMW M3

Assemble engine.
RPM).
WATER PUMP WITH DRIVE

11 51 000 REMOVING AND INSTALLING/REPLACING WATER PUMP (S65)
Remove FAN COWL WITH ELECTRONIC FAN .

Remove RADIATOR .
Remove upper IDLER PULLEY for A/C compressor.
Release screw (1).
Remove alternator DRIVE BELT .
Remove belt pulley (2).

2010 BMW M3
Fig. 440: Identifying Belt Pulley And Screw

Release screws (1).
To facilitate removal of the coolant pump, it is possible to insert M6 screws on left and right (see arrows).
Installation:
Replace all sealing rings.
Fig. 441: Inserting M6 Screws

Assemble engine.
Vent COOLING SYSTEM and check for leaks.
THERMOSTAT AND CONNECTIONS

2010 BMW M3
11 53 000 REMOVING AND INSTALLING/REPLACING COOLANT THERMOSTAT (S65)
Remove intake air MANIFOLD .

Drain COOLANT .
Release unlocking element (1).
Detach vent line (2).
Fig. 442: Identifying Vent Line And Unlocking Element

Disconnect FUEL LINE from fuel rail.
Release screws (2).
Unlock wiring harness of fuel injectors (1).

2010 BMW M3
Fig. 443: Identifying Fuel Injectors And Screws

Clip injection pipe (1) out of holder (2).
Lay injection pipe, cylinders 5 to 8, to one side.
Fig. 444: Identifying Injection Pipe And Holder

Disconnect plug connection (1) on coolant temperature sensor.
Disconnect plug connection (2) on solenoid valve.

Release screws (1).

2010 BMW M3
Installation:

Remove thermostat housing with thermostat forwards in direction of arrow.
Clean sealing surfaces.
Fig. 447: Removing Thermostat Housing

Remove thermostat (1).
Check rubber section (2) for damage.
Remove connecting pipes (2).

2010 BMW M3
Installation:
Replace all O-rings on connecting pipes.
Fig. 448: Identifying Connecting Pipes And Thermostat

Assemble engine.
Vent COOLING SYSTEM and check for leaks.
INTAKE MANIFOLD
11 61 050 REMOVING AND INSTALLING AIR INTAKE MANIFOLD (S65)
IMPORTANT: Do not use antiseize agents to install the air intake manifold.
Remove AIR CLEANER HOUSING .
Disconnect plug connection (1) on intake air temperature sensor.

2010 BMW M3

Unlock hose (2) for idle actuator incoming air at fastener (1) and detach in direction of arrow.
Fig. 450: Unlocking Hose

Unlock hose (2) for condensate drain line at fastener (1) and detach in direction of arrow.
2010 BMW M3
Fig. 451: Unlocking Hose

Installation:
Each hose clamp on the decoupling element is exactly positioned.
Loosen hose clamps (1).
Secure hose clamps with special tool 009250 .
NOTE: Picture shows hose clamps (1 to 3).

Release hose clamp (1) on cylinder 4.

2010 BMW M3
Fig. 453: Identifying Hose Clamp

Release hose clamp (1) on cylinders 5 to 8.
Remove intake air manifold towards top.

IMPORTANT: Do not lay any tools or foreign bodies in intake area.

Risk of damage to throttle valves/engine.
2010 BMW M3
Fig. 455: Precaution For Throttle Valve

NOTE: Assemble engine.
AIR PUMP, LINES AND CONTROL VALVES

11 72 060 REMOVING AND INSTALLING/REPLACING BOTH SECONDARY-AIR VALVES (S65)
Carry out system test: secondary air with BMW diagnosis system.
Disconnect battery at negative lead.
Remove LEFT EXHAUST MANIFOLD (S65) .
Remove right EXHAUST MANIFOLD .
Unfasten engine wiring harness partially and lay to one side.
Removing secondary-air valve, bank 1:
Unscrew nuts (1).
Remove secondary-air valve (2).
Installation:
Replace seal.
2010 BMW M3
Fig. 456: Identifying Secondary-Air Valve And Nuts

Unscrew nuts (1).
Installation:
Replace seal.

Assemble engine.
2010 BMW M3
Carry out system test: secondary air.
11 72 000 REMOVING AND INSTALLING/REPLACING SECONDARY-AIR PUMP (S65)
Release screws (arrow) on holding frame.
Release nuts on secondary-air pump.
Unlock and detach both air hoses.
Lift out secondary-air pump.
Remove holding frame from secondary-air pump.
Fig. 458: Locating Holding Frame Screws

Assemble engine.
Check function of DME.
EMISSION CONTROL, OXYGEN SENSOR

11 78 530 REPLACING LEFT LAMBDA OXYGEN CONTROL SENSOR (S65)

Only perform these tasks after exhaust system has cooled down.
2010 BMW M3
Read out fault memory in Digital Motor Electronics (DME).

Remove transmission underbody protection.
Pull plug connection (1) from holder (2).
Fig. 459: Identifying Plug Connection And Holder

Remove oxygen control sensor with special tool 11 7 030.
If the oxygen control sensor is reused, apply a thin and even coat of Never Seez Compound to the thread only.
The part of the oxygen control sensor which projects into the exhaust system branch (sensor ceramic) must not
be cleaned or come into contact with lubricant.
2010 BMW M3
Fig. 460: Removing Oxygen Control Sensor Using Special Tool (11 7 030)
Secure oxygen control sensor with special tool 11 7 030 and a torque wrench (1).
11 78 540 REPLACING LEFT MONITOR SENSOR (S65)

Read out fault memory in Digital Motor Electronics (DME)

Remove transmission underbody protection
Remove monitor sensor with special tool 11 7 030.
Installation:
If the monitor sensor is reused, only apply a thin and uniform coat of Never Seez Compound to thread.
The part of the oxygen monitor sensor which projects into the exhaust system branch (sensor ceramic) must not
Fig. 461: Identifying Monitor Sensor And Plug Connection

2010 BMW M3
IMPORTANT: Reinstall plug connection (1) and cable routing without fail in condition on
delivery (see illustration).
Risk of damage if this instruction is not observed!
Secure monitor sensor (2) with special tool 11 7 030 and a torque wrench.
11 78 543 REPLACING RIGHT LAMBDA OXYGEN MONITOR SENSOR (S65)


Remove oxygen monitor sensor with special tool 11 7 030.
Installation:
If the oxygen monitor sensor is reused, apply a thin and even coat of Never Seez Compound (refer to BMW
Parts Service) to the thread only.
2010 BMW M3
Fig. 462: Removing Oxygen Monitor Sensor Using Special Tool (11 7 030)
Secure oxygen monitor sensor with special tool 11 7 030 and a torque wrench.

2010 BMW M3
ENGINE Engine - Repair - M3
ENGINE
Engine - Repair - M3
ENGINE GENERAL
Headaches
Dizziness
Stomach aches
Vomiting
Diarrhoea
Cramps/fits
Unconsciousness

First aid measures:
If the person affected is still conscious, he/she must rinse out their mouth with water, drink plenty of
water and consult a doctor immediately.
If the person affected is unconscious, do not administer anything by mouth, place the person in the
recovery position and seek immediate medical attention.
Danger of injury!

2010 BMW M3
Impaired sight

First aid measures:
WARNING: Danger of poisoning if oil is ingested/absorbed through the skin!

Risk of injury if oil comes into contact with eyes and skin!
Recycling:
Measures if oil is unintentionally released:
11 00 ... OVERVIEW OF CONSUMABLES (ELECTRONIC PARTS CATALOGUE - EPC)

2010 BMW M3
1.0 Sealing compound for injection.
SEALING COMPOUND FOR INJECTION REFERENCE

Repair instructions Part number
(engine) EPC
N40, N42, N45, N46, N43, Loctite 171000 83 19 7 515 For hardening Loctite 128367
1.1
N45N, N46N primer 683 sealing compound
N40, N42, N45, N46, N43, Loctite 128357 liquid 83 19 7 536 Sealing between crankcase upper
1.2
N45N, N46N gasket 051 and lower halves
N51, N52, N53, N54, N52N, Loctite 171000 83 19 7 515 For hardening Loctite 193140
1.3
N55 primer 683 sealing compound
N51, N52, N53, N54, N52N, Loctite 193140 liquid 83 19 0 439 Sealing between crankcase upper
1.4
N55 gasket 030 and lower halves
Loctite 171000 83 19 7 515 For hardening Loctite 193140
1.5 S65, S85
primer 683 sealing compound
Loctite 193140 liquid 83 19 0 439 Sealing between crankcase upper
1.6 S65, S85
gasket 030 and lower halves
2.0 Sealing compound for application.
SEALING COMPOUND FOR APPLICATION REFERENCE

Part
Designation in repair instruction Designation EPC number Application examples
EPC
M41, M47, M47TU, M47T2, M50, M51,
M52, M52TU, M54, M57, M57TU,
M57T2, M60, M62
N40, N42, N45, N45N, N46, N46N, N43,
Drei Bond 1209 07 58 9 062 For sealing junction
2.1 N47, N47S
liquid gasket 376 points on crankcase
N51, N52, N52N, N53, N54, N55, N57,
N57S
N62, N62TU, N73, N73H
S14, S38, S50, S52, S54, S62, S65, S85
Sealing between
Loctite 5970 83 19 0 404
2.2 N12, N14, W16 crankcase upper and
liquid gasket 517
lower halves
Loctite 273 liquid 83 19 0 443 Sealing between cover
2.3 N12, N14, W16
gasket 083 sleeve and crankcase
11 00 ... SERVICE - ENGINE OIL (S65)

2010 BMW M3
Carry out all tasks only when wearing oil-resistant, heat-resistant protective gloves incl. underarm protection,
face guard and protective apron.
IMPORTANT: Perform engine oil service only when engine is at normal operating
temperature (>70C engine oil temperature). An exact engine oil level reading
can only be obtained from an engine oil temperature > or = 70.
Engine oil temperature can be read off in the instrument cluster.
Observe the exact engine oil filling capacity.
Inspection and drain-off times must be observed.
Determining the oil level via the BC button detects only changes > +/- 0.5 litre.
Recycling:
Catch and dispose of drained engine oil in a suitable container.
NOTE: The remaining engine oil can flow off into the oil sump only when the oil filter
cap is opened.
Tightening torque 11 42 1AZ . See 11 42 OIL FILTER AND PIPES .

Installation:
Replace oil filter element and sealing rings.

2010 BMW M3

apron.
Open screw plug (1) with socket and a long extension (2).
Fig. 2: Opening Screw Plug With Socket And Long Extension

Tilt long extension (1) with socket and screw plug in direction of arrow.
Recycling:
Fig. 3: Screwing Plug Using Extension With Socket


2010 BMW M3
Tightening torque 11 13 1AZ . See OIL SUMP .
Installation:
Assemble engine.
Pour in engine oil. See 11 40 OIL SUPPLY E90/E92/E93/S65 B40 .

Checking engine oil level:
Park vehicle on a horizontal surface

Start engine and run at idle until an engine oil temperature > or = 70C is reached
Pressing the BC button for more 3 seconds results in the oil level been determined again.
Only changes > +/- 0.5 litre are detected.
If necessary, perform odometer reset.
Top up engine oil if necessary
Pre-delivery inspection / engine replacement
Carry out distance travelled reset only with the BMW diagnosis system.
Observe vehicle-specific maintenance scopes.

2010 BMW M3
11 00 039 CHECKING COMPRESSION OF ALL CYLINDERS (S65)
11 0 224
11 0 235
IMPORTANT: High tension - mortal danger!

Disconnect all supply leads from ignition coils (interrupt power supply to
ignition coils).
IMPORTANT: Check Schrader valve on special tool 11 0 235 for correct seating (engine
damage).
The throttle valves cannot be opened by opening the throttle.
The compression check is carried out exclusively by means of the idle
actuators.
A compression check is only possible with the diagnosis tester.
The catalytic converter will incur damage if the fuel injectors are not switched
off.
Remove microfilter housing. See MICROFILTER .

Remove all spark plugs. See 12 12 011 REPLACING ALL SPARK PLUGS (S65) .
1. Service function.
2. Drive.
3. Engine electronics
4. Switch off fuel injection.
IMPORTANT: Fuel injectors are switched off.
5. Actuate starter motor for 8 seconds.
Screw special tool 11 0 235 into spark plug hole.
Check that sealing ring is in perfect condition on special tool 11 0 235.
Connection (1) for diagnosis tester or special tool 11 0 224.

2010 BMW M3

Connect special tool 11 0 224 or 25 bar pressure adapter to diagnosis tester.
Compression pressure.
Fig. 6: Connecting Special Tool (11 0 224) And Bar Pressure Adapter To Diagnosis Tester
11 00 050 REMOVING AND INSTALLING ENGINE (S65)
11 0 000
13 5 280
17 2 050

2010 BMW M3
See FUEL SYSTEM - SPECIAL TOOLS .
See COOLING SYSTEM - SPECIAL TOOLS .
Engine hood/bonnet in assembly position.

Drain engine oil.
Remove suction filter housing. See 13 71 000 REMOVING AND INSTALLING/REPLACING
Remove intake air manifold.
Remove underbody protection at front and rear. See 51 47 490 REMOVING AND INSTALLING /
REPLACING FRONT UNDERBODY PROTECTION and 51 47 491 REMOVING AND
Remove transmission (Important observe repair instructions). See 23 00 018 REMOVING AND
INSTALLING TRANSMISSION (GS6-53BZ) (S65) .
Remove electric fan. See 17 11 035 REMOVING AND INSTALLING/REPLACING FAN COWL
WITH ELECTRIC FAN (S65) .
Remove radiator with coolant hoses. See 17 11 000 REMOVING AND INSTALLING RADIATOR
(N51, S65) .
Drain coolant.
Remove expansion tank with coolant hose. See 17 11 100 REMOVING AND
INSTALLING/REPLACING COOLANT EXPANSION TANK (S65) .
Draw off A/C system.
Remove all lines from A/C compressor. See 64 53 660 REPLACING LINE FROM CONDENSER TO
EVAPORATOR (S65) , 64 53 670 REPLACING LINE FROM COMPRESSOR TO
EVAPORATOR (S85) and 64 53 642 REPLACING LINE FROM COMPRESSOR TO
CONDENSER (S65) .
Remove secondary-air pump.
Detach B+ lead in engine compartment.
Detach vacuum hose from brake booster. See 34 33 071 REPLACING VACUUM HOSE FOR
BRAKE BOOSTER (ON BRAKE BOOSTER) .
Release suspension cross-brace in engine compartment. See 51 71 345 REMOVING AND
INSTALLING/REPLACING LEFT (OR RIGHT) SUSPENSION CROSS-BRACE .
Release grounding strap on engine support arm.
Release stabilizer (1) on front axle carrier at front.
Allow stabilizer (1) to hang loose.

2010 BMW M3
Fig. 7: Identifying Stabilizer On Front Axle Carrier

Remove complete steering spindle. See 32 31 070 REMOVING AND INSTALLING / REPLACING
LOWER SECTION OF STEERING SPINDLE .
Remove heat shield.
Release screws (1).
Fig. 8: Identifying Steering Spindle Extension And Screw

Detach steering spindle extension (2).
Tightening torque: 32 31 1AZ . See 32 31 STEERING COLUMN .
Detach oil lines (2 and 3).

2010 BMW M3
Recycling:
Have a cloth ready to catch a residual amount of engine oil.

Secure oil lines (1) with a cable tie (2) to front panel.
Fig. 10: Securing Oil Lines With Cable Tie To Front Panel
Unclip heater hose (1) and set down with heating valve on engine.
Disconnect both hoses (2) from secondary-air valves.

2010 BMW M3
Fig. 11: Identifying Heater Hose And Secondary-Air Valves Hose

IMPORTANT: Risk of damage to steering gear and oil sump.
Disconnect fuel line (1) and lock with special tool 13 5 280.
Disconnect flushing line (2).
Fig. 12: Identifying Fuel Line, Flushing Line And Special Tool (13 5 280)
Unfasten engine wiring harness (1) on engine completely.
Secure engine wiring harness (1) with a cable tie (2) to engine hood/bonnet damper.
2010 BMW M3
Fig. 13: Identifying Engine Wiring Harness And Cable Tie

Release both clamps (1) with special tool 17 2 050.
Remove coolant hose (2).
Fig. 14: Identifying Clamp And Coolant Hose

NOTE: Do not release any hydraulic lines on the power steering pump.
Release power steering pump (1) on engine block.
Set down power steering pump (1) on front axle carrier.

2010 BMW M3
Fig. 15: Identifying Power Steering Pump

Unscrew left and right engine mounts. See ENGINE AND GEARBOX SUSPENSION - REPAIR .
Secure special tool 11 0 000 to suspension eyes (1).
Remove engine with 2 persons.
Fig. 16: Identifying Special Tool (11 0 000) And Suspension Eyes
Assemble engine.
Top up coolant and vent cooling system. See 17 00 039 VENTING COOLING SYSTEM AND CHECKING
FOR WATER LEAKS (S65) .
Pour in engine oil.
Install replacement engine.

2010 BMW M3
Correct CBS data status.
11 00 091 INSTALLING REPLACEMENT ENGINE (S65)
IMPORTANT: No running-in engine oil required.

Oil grade 10W-60
Remove and install engine.

Flush cooling system.
Installation:
If necessary, replace following components.
Clutch
Drive belt.
All outer seals.
Replace all anti-fatigue bolts on flywheel and vibration damper.
Change coolant.
Fill engine with engine oil.
11 00 670 SECURING ENGINE IN INSTALLATION POSITION (S65)
00 0 200
00 0 202
00 0 204
00 0 208
11 0 020

Observe following instructions relating to special tool:
1. Prior to each use, check the special tools for defects, modifications
and operational reliability.
2010 BMW M3

4. Keep special tools dry, clean and free of grease.
Secure engine bonnet/hood in service position . See 51 00 ... SERVICE POSITION OF ENGINE
HOOD/BONNET .
Remove intake air manifold
Assemble cross member 00 0 200 with special tools 00 0 202 , 00 0 204 , 00 0 208 .

IMPORTANT: Avoid a change of engine position in the transverse or longitudinal direction.

Always make sure there is sufficient clearance between the engine (or its
attachment parts) and the body.

Position transverse member 00 0 200 with a 2nd person helping by way of rests
(1) on bolt connections of side panels.
Secure special tool 11 0 020 to spindle 00 0 202 .
Attach suitable chains to special tool 11 0 020 and suspend from both engine suspension eyelets.
2010 BMW M3
Fig. 18: Identifying Special Tool (11 0 020) (00 0 202) And (11 0 020)

Tighten down all adjusting screws and nuts on cross member 00 0 200.

Unscrew nuts (1).
Raise engine approx. 10 mm with cross member.
Installation:
Tightening torque 22 11 2AZ . See 22 11 ENGINE SUSPENSION .

2010 BMW M3
Fig. 20: Identifying Self-Locking Nut

ENGINE IDENTIFICATION
Drive in engine numbers at marked surface with impact tool.
M47 / M47TU / M47T2
Fig. 21: Identifying Engine Identification Label (M47 / M47TU / M47T2)

M57 / M57TU / M57T2

2010 BMW M3
Fig. 22: Identifying Engine Identification Label (M57 / M57TU / M57T2)

M67 / M67TU
Fig. 23: Identifying Engine Identification Label (M67 / M67TU)

N47 / N47S
2010 BMW M3
Fig. 24: Identifying Engine Identification Label (N47 / N47S)

M52 / M52TU
Fig. 25: Identifying Engine Identification Label (M52 / M52TU)

M54
2010 BMW M3
Fig. 26: Identifying Engine Identification Label (M54)

M56
Fig. 27: Identifying Engine Identification Label (M56)

N40 / N45 / N45T / N43

2010 BMW M3
Fig. 28: Identifying Engine Identification Label (N40 / N45 / N45T / N43)
N42 / N46 / N46T
Fig. 29: Identifying Engine Identification Label (N42 / N46 / N46T)

N51 / N52 / N52K / N53 / N54

2010 BMW M3
Fig. 30: Identifying Engine Identification Label (N51 / N52 / N52K / N53 / N54)
N62
Fig. 31: Identifying Engine Identification Label (N62)

N73
2010 BMW M3
Fig. 32: Identifying Engine Identification Label (N73)

S54
Fig. 33: Identifying Engine Identification Label (S54)

S85 / S65
2010 BMW M3
Fig. 34: Identifying Engine Identification Label (S85 / S65)

W10 / W11
Fig. 35: Identifying Engine Identification Label (W10 / W11)

W17
2010 BMW M3
Fig. 36: Identifying Engine Identification Label (W17)

Assemble engine.
MOUNTING ENGINE ON ASSEMBLY STAND (S65)
00 2 300
11 5 260
Remove engine.
Remove rear water pipe.
Secure special tool 11 5 260 to crankcase with bolts (2).
Tighten bolts (2) evenly.
NOTE: Bolts (1) are not required on the S65.

2010 BMW M3
Fig. 37: Securing Special Tool (11 5 260) To Crankcase With Bolts
Secure engine with special tool 11 5 260 to special tool 00 2 300 .
Fig. 38: Securing Engine With Special Tool (00 2 300)

CYLINDER HEAD WITH COVER

11 12 005 REMOVING AND INSTALLING/SEALING LEFT CYLINDER HEAD COVER (S65)

2010 BMW M3

Remove rod-type ignition coils. See 12 13 512 REMOVING AND INSTALLING/REPLACING
ALL IGNITION COILS (S65) .
Fig. 39: Identifying Bolts Along Line

Installation:
Replace seal (1).

2010 BMW M3
Fig. 40: Identifying Seal And Park Plug Tube

Installation:
Installation:
Fig. 41: Identifying Sealing Surfaces Joint

2010 BMW M3
Installation:

Tightening torque: 11 12 8AZ . See CYLINDER HEAD .

Assemble engine.
2010 BMW M3
11 12 006 REMOVING AND INSTALLING/SEALING RIGHT CYLINDER HEAD COVER (S65)

Remove rod-type ignition coils. See 12 13 512 REMOVING AND INSTALLING/REPLACING
ALL IGNITION COILS (S65) .
Fig. 44: Identifying Bolts Along Line

Installation:
Replace seal (1).

2010 BMW M3
Fig. 45: Identifying Seal And Park Plug Tube

Installation:
Installation:

2010 BMW M3
Fig. 46: Identifying Sealing Surfaces Joint

Installation:


2010 BMW M3

Assemble engine.
11 12 105 REMOVING AND INSTALLING LEFT CYLINDER HEAD (S65)
11 2 250
SYSTEM (S65) .
Remove left exhaust manifold. See 18 40 010 REMOVING AND INSTALLING/REPLACING
Remove left cylinder head cover
Remove left inlet camshaft.
Remove left exhaust camshaft.
Partially unfasten engine wiring harness and lay to one side. See 12 51 001 REPLACING WIRING
HARNESS SECTION FOR ENGINE (S65) .
Remove throttle valves from cylinders 5 to 8. See 13 54 045 REMOVING AND
INSTALLING/SEALING A THROTTLE VALVE ASSEMBLY (S65) .
Remove thermostat housing.
Release screws (1).

2010 BMW M3
Remove water fitting (2).
Installation:
Replace seal.
Fig. 49: Identifying Water Fitting And Screws

Release screws (1).
Fig. 50: Identifying Cylinder Head Screws

Remove screw (1) with a magnet from gearcase.

2010 BMW M3
Fig. 51: Identifying Screw And Gearcase

Release cylinder head bolt (1) with special tool 11 2 250 .

2010 BMW M3

NOTE: Replace cylinder head gasket.

Check cylinder head for water leaks.
Installation:

Insert bolts (1).

2010 BMW M3
Fig. 55: Identifying Cylinder Head Screws

Assemble engine.
11 12 106 REMOVING AND INSTALLING RIGHT CYLINDER HEAD (S65)
11 2 250
11 5 290
SYSTEM (S65) .
Remove right exhaust manifold. See 18 40 010 REMOVING AND INSTALLING/REPLACING
Remove right cylinder head cover.
Remove right inlet camshaft.
Remove right exhaust camshaft.
Partially unfasten engine wiring harness and lay to one side. See 12 51 001 REPLACING WIRING
Remove throttle valves from cylinders 1 to 4. See 13 54 045 REMOVING AND
INSTALLING/SEALING A THROTTLE VALVE ASSEMBLY (S65) .
Remove thermostat housing.
Release screws (1).

2010 BMW M3
Remove coolant fitting (2).
Installation:
Replace seal.
Fig. 56: Identifying Coolant Fitting And Screws

Release screw (1).

Remove bearing pin (1) with special tool 11 5 290 .

2010 BMW M3

Release screws (1).
Remove screw (1) with a magnet (2) from gearcase.
Fig. 59: Identifying Screw And Gearcase

Release cylinder head bolt (1) with special tool 11 2 250 .

2010 BMW M3

Fig. 61: Identifying Cylinder Head Bolts

2010 BMW M3

NOTE: Replace cylinder head gasket.

Check cylinder head for water leaks.
Installation:

Insert bolts (1).

2010 BMW M3
Fig. 64: Identifying Cylinder Head Bolts

Assemble engine.
11 12 112 REPLACING BOTH CYLINDER HEAD GASKETS (S65)
11 4 470
Remove left cylinder head.

Remove right cylinder head.
Check cylinder head for leaks.
IMPORTANT: Do not open screw plugs.

The screw plug must always be replaced if it is opened by mistake.
Installation:
Make sure oil bore (1) is clean.

2010 BMW M3
Fig. 65: Identifying Oil Bore



2010 BMW M3

Remove spacer sleeves (1) in direction of arrow.
NOTE: Picture show cylinder bank 2. Procedure for cylinder bank 1 is identical.
Fig. 68: Removing Spacer Sleeves

Remove non-return valves (1) in direction of arrow.

2010 BMW M3
Fig. 69: Removing Non-Return Valves

Installation:
Replace spacer sleeves (1) and non-return valves (2).
Note installation direction of non-return valves (2).
Fig. 70: Identifying Spacer Sleeves And Non-Return Valves


2010 BMW M3
Fig. 71: Identifying Cylinders 1-4 Head Gasket

Fig. 72: Identifying Cylinders 5-8 Head Gasket

NOTE: There is no oversize gasket for the S65 engine.
Assemble engine.
11 12 729 CHECKING CYLINDER HEAD FOR WATERTIGHTNESS (S65)
11 5 230
11 5 231
11 5 235
2010 BMW M3
11 5 237
11 9 961
NOTE: Special tool 11 5 230 can be used for both cylinder heads.
Remove left cylinder head or 11 12 106 Removing and installing right cylinder head (S65).
Disassemble cylinder head.
Secure special tool 11 5 231 with old cylinder head bolts.
Secure special tool 11 5 235 with special tool 11 5 237 .
Fig. 73: Identifying Special Tools (11 5 231), (11 5 235) And (11 5 233)
Secure special tool 11 9 961 with special tool 11 5 237 to 10 Nm.

2010 BMW M3
Fig. 74: Identifying Special Tool 11 9 961 And Cylinder Head Bolts
NOTE: Immerse cylinder head in a water bath.

Test pressure: 4.5 bar.
Check cylinder head for escaping air (cracks).
If necessary, add cleaning agent to water bath.
Assemble engine.
OIL SUMP
11 13 000 REMOVING AND INSTALLING OR REPLACING OIL SUMP (S65)
Recycling:
Catch and dispose of used oil in a suitable container.
Drain engine oil.

Secure engine in installation position.
Lower front axle. See 31 11 506 LOWERING/RAISING FRONT AXLE CARRIER (M3,
UNIVERSAL LIFTER) .
Remove ribbed V-belt.
Release 4x transmission bolts.
Release screws (1).

2010 BMW M3
Fig. 75: Identifying Screws And Holder

2010 BMW M3
Fig. 76: Overview Of Oil Sump Screw/Bolt Connections

Overview of oil sump screw/bolt connections
1. Torx bolt M6x30 (16 x)

Tightening torque. 11 13 2AZ . See OIL SUMP .
Clean sealing faces (1) with special tool 11 4 470.
Fig. 77: Identifying Sealing Faces

Installation:
Replace oil sump gasket (1).

2010 BMW M3
Fig. 78: Identifying Oil Sump Gasket

Assemble engine.
HOUSING COVER
11 14 005 REPLACING FRONT CRANKSHAFT SEAL (S65)
11 2 386
11 5 331
11 5 332
11 5 333
11 6 360
11 7 231
Remove fan cowl with electric fan. See 17 11 035 REMOVING AND INSTALLING/REPLACING
FAN COWL WITH ELECTRIC FAN (S65) .
Remove radiator. See 17 11 000 REMOVING AND INSTALLING RADIATOR (N51, S65) .
Remove vibration damper.
Lay special tool 11 2 386 on crankshaft.
Fig. 79: Identifying Special Tool (11 2 386) On Crankshaft

2010 BMW M3
Screw special tool 11 6 360 to 80 Nm into radial seal.
Release radial seal from housing.
Repeat the operation several times if necessary.
NOTE: Carefully saw open old radial shaft seal with an iron saw from special tool 11 6
360 .
Fig. 80: Screwing Special Tool (11 6 360) Into Radial Seal
Apply Drei Bond sealant to sealant outlet (1) on left and right.
Fig. 81: Identifying Sealant Outlet On Left And Right


2010 BMW M3

Installation:
Push shaft seal (1) uniformly by way of fitting aid 11 7 231 onto special tool 11 5 331 .

2010 BMW M3
Fig. 84: Pushing Shaft Seal (11 7 231) Onto Special Tool (11 5 331)
Press in shaft seal (1) with special tools 11 5 332 and 11 5 333 .
Fig. 85: Pressing Shaft Seal With Special Tools (11 5 332) And (11 5 333)
Assemble engine.
Setting time of shaft seal approx. 1 hour.
Correct engine oil level if necessary.
11 14 151 REPLACING CRANKSHAFT SEAL (S65)
11 5 311
11 5 312
2010 BMW M3
11 5 313
23 0 490
See MANUAL TRANSMISSION - SPECIAL TOOLS .
Remove transmission. See 23 00 018 REMOVING AND INSTALLING TRANSMISSION (GS6-

53BZ) (S65) .
Remove clutch. See 21 21 500 REMOVING AND INSTALLING/REPLACING CLUTCH (GS6-
53BZ) S65 .
Remove flywheel. .
Drill a 3 mm hole into shaft seal.
Screw in special tool 23 0 490 .
Drive out radial shaft seal with impact weight.
Fig. 86: Drilling Hole Into Shaft Seal

Apply Drei Bond sealant 1209 to sealant outlet (1) on left and right.
2010 BMW M3

IMPORTANT: Pay attention to adapter sleeve.

Special tool 11 5 311 must rest flat on crankshaft (pay attention to adapter
sleeve).
Mount special tool 11 5 311 with bolts (1).
Fig. 88: Identifying Special Tool (11 5 311) On Bolts

Position support ring (1) with shaft seal (2) on special tool 11 5 311 .
Push shaft seal (2) uniformly in direction of arrow over support ring onto special tool 11 5 311 .
2010 BMW M3
Fig. 89: Pushing Shaft Seal Over Support Ring Onto Special Tool (11 5 311)
Fig. 90: Identifying Shaft Seal And Support Ring

Press in shaft seal (1) with special tools 11 5 312 and 11 5 313 .
2010 BMW M3
Fig. 91: Identifying Shaft Seal And Special Tools (11 5 312) And (11 5 313)
Assemble engine.
Settling time of radial shaft seal approx. 1 hour.
Correct engine oil level if necessary.
CRANKSHAFT WITH BEARING

11 21 500 REPLACING CRANKSHAFT (S65)
00 9 120
00 9 130
11 4 370
11 4 470
11 9 360
IMPORTANT: Unscrew all M9 fit bolts first before releasing the crankshaft lower section.
Altered settling behavior at the crankcase!
If the main bearing channel is opened after engine operation, all main bearing
shells must be replaced with special repair bearing shells marked with an (R).
There are two different groups of main bearing shells.

2010 BMW M3
Remove engine.
Mount engine on assembly stand.
Remove flywheel.
Removing oil sump.
Remove engine oil pump.
Remove oil return pump.
Remove cylinder head on left and right.
Remove all pistons.
Remove both timing chains.
Release screws (1).
Remove holder for oil intake pipe.
Fig. 92: Identifying Oil Intake Pipe Screws

IMPORTANT: Unscrew all M9 fit bolts (2) first before releasing the crankshaft lower section -
risk of damage!
2010 BMW M3
Fig. 93: Identifying Bearing Seat Bolts

Bearing seat bolts (1) M11.
IMPORTANT: Release all M9 fit bolts and remove.
Release fit bolts (M9) in sequence 1-10 and remove.
Fig. 94: Identifying Fit Bolts (M9) Tightening Sequence

Release M11 bearing seat bolts in sequence 1-10.

2010 BMW M3
Fig. 95: Identifying M11 Bearing Seat Bolts Tightening Sequence

Release screws (3).
Bolts (1) from inside outwards.
Remove bedplate upwards.
Fig. 96: Identifying Bedplate Bolts And Screws

Lever out crankshaft (1) with aid of a second person in direction of arrow.

Picture shows S85.
2010 BMW M3
Fig. 97: Removing Crankshaft

IMPORTANT: If the bedplate is opened and closed again, fit special main bearing shells
marked with (R) on the bearing backs.
Replace all bearing shells (2).
Replace guide bearing (3).
Installation:
Fig. 98: Identifying Bearing Shells And Guide Bearing

Remove sealing compound from joint (1).
Carefully clean threads and contact faces in upper and lower sections of crankcase.
2010 BMW M3
Installation:
Replace nozzles (2).
Fig. 99: Identifying Sealing Face And Nozzles

Installation:
Replace main bearing shells.
Apply a light coating of engine oil to bearing shells.
Lay crankshaft (1) with a second person helping in direction of arrow into crankcase.

Picture shows S85.
2010 BMW M3
Fig. 100: Removing Crankshaft

Insert seal (1).
IMPORTANT: Make sure oil bore is clean.

IMPORTANT: Adhere without fail to the specified sequence of bedplate bolt connections.
Risk of damage to crankshaft.
Leaks at bedplate/crankcase.
IMPORTANT: There are no more dowel sleeves in the crankcase.

Do not use new bolts.
If new bolts are used, observe special tightening/torque specifications.
Position bedplate on crankcase.
Position lower section diagonally on bearing seats (1 and 5) using two fit bolts (1 and 2).
Join fit bolts (1 and 2) to 8 Nm.

2010 BMW M3
Fig. 102: Identifying Dowel Sleeves And Bolts

Insert fit bolts (1-8).
Join fit bolts (1-8) to 8 Nm.
Fig. 103: Identifying Fit Bolts Tightening Sequence (1-8)

Insert all M11 bolts (1).
Joint bearing seat bolts in sequence (1-10) to 30 Nm.

2010 BMW M3
Fig. 104: Identifying Joint Bearing Seat Bolts Tightening Sequence

Mark all M11 bearing seat bolts with a colored line (1).
Fig. 105: Identifying M11 Bearing Seat Bolts With Colored Line
Secure M11 bearing seat bolts with special tools 00 9 120 and 00 9 130 .
2010 BMW M3
Fig. 106: Identifying Special Tools (00 9 120)

Tighten M11 bolts to 130 angle of rotation.
Tightening torque: 11 11 1AZ . See 11 11 ENGINE BLOCK .
IMPORTANT: Observe bolting sequence when using new bolts.

Mark all fit bolts with a colored line (1).

2010 BMW M3
Fig. 108: Identifying Bolts With Colored Line

Tighten fit bolts with special tools 00 9 120 and 00 9 130 .
Fig. 109: Identifying Special Tools (00 9 120)

Secure all fit bolts (1-10) to 130 angle of rotation.

2010 BMW M3

Insert bolts (1).
Insert bolts (2).
Insert bolts (3).
Fig. 111: Identifying Bedplate Bolts And Screws

Secure bolts (1) M8x65 (22 x) with special tools 00 9 120 and 00 9 130 .
Tightening torque: 11 11 3AZ. See 11 11 ENGINE BLOCK .

2010 BMW M3
Fig. 112: Tightening Bolts Using Special Tool

Secure bolts (1) M8x40 (4 x) with special tools 00 9 120 and 00 9 130 .
Fig. 113: Identifying Bolts M8x40 (4 X)

Secure bolts (1) M6x30 (2 x).
Tightening torque: 11 11 5AZ. See 11 11 ENGINE BLOCK .

2010 BMW M3
Fig. 114: Identifying Bolts M6x30 (2 X)

Drive in both nozzles with special tool 11 9 360 on left and right into crankcase.
Installation:
Always replace nozzles.
Fig. 115: Driving Nozzles Special Tool (11 9 360)

Installation:
Use primer 1.5 and liquid gasket 1.6 .
Prepare liquid gasket (2) in special tool 11 4 370 .
Screw on nozzle (1) for injecting liquid gasket.

2010 BMW M3
Fig. 116: Identifying Liquid Gasket And Nozzle

Press sealing compound nozzle in direction of arrow onto nozzle at 90.
Slowly and evenly insert liquid gasket (1) with special tool 11 4 370 in direction of arrow.
Fig. 117: Pressing Sealing Compound Nozzle Onto Nozzle

Stop (seal off) escaping liquid gasket with primer 1.5 at outlet bore (1).
Install radial shaft seal at front.
Install radial shaft seal at rear.

2010 BMW M3
Fig. 118: Applying Liquid Gasket With Primer At Outlet Bore

Assemble engine.
11 21 531 REPLACING ALL CRANKSHAFT MAIN BEARINGS (S65)
00 2 590
11 4 470
IMPORTANT: 1. Repair crankcase worn St.0 or 1 / crankshaft worn St.0 .
If the bearing channel is opened and closed again after engine operation,
all main bearing shells must be replaced with special repair bearing
shells.
Altered settling behavior at the crankcase.
Repair bearing shells are marked with an (R) on their backs.
2. Repair crankcase worn St.0 or 1 / crankshaft new St.0 .
Repair bearing shells marked with (R) must be used.
The crankshaft comes as a set together with the bearing shells. The
bearing shells for the bedplate are provided in accordance with the
crankshaft classification. For the crankcase bearing shells, the green
2010 BMW M3
bearing shells are always provided. The half classification is retained.
3. Repair crankcase new St.0 or 1 / crankshaft worn St.0 .
always provided.
The half classification is retained.
4. Repair crankcase new St.0 or 1 / crankshaft new St.0 .
The bearing shells provided with the crankcase must be used.
always provided.
The half classification is retained.
Engine removed
Remove crankshaft.
Installation:
Bearing shell (1) with lubricant groove must be fitted in crankcase upper section.
Bearing shell (2) without lubricant groove must be fitted in crankcase lower section (bedplate).
Determine bearing play with special tool 00 2 590 .
Insert crankshaft without engine oil, bolt crankcase upper and lower sections together.
2010 BMW M3
Fig. 119: Identifying Bearing Shell

Lay plastic thread (Plastigage) on crankshaft.
Fit crankcase upper section on lower section and bolt together.
NOTE: Do not twist crankshaft.
Remove crankshaft.
Read off bearing play at width of flattened plastic thread and measurement scale.
Crankshaft bearing clearance radial. See CRANKSHAFT WITH BEARING .
Fig. 120: Laying Plastic Thread (Plastigage) On Crankshaft

Crankcase upper half:
Installation:
2010 BMW M3
Remove all bearing shells with lubricant groove.
Observe bearing classification. See CRANKSHAFT WITH BEARING .
Fig. 121: Removing Bearing Shells

Crankcase lower half:
Installation:
Remove all bearing shells without lubricant groove.
Observe bearing classification. See CRANKSHAFT WITH BEARING .

2010 BMW M3
Fig. 122: Removing Bearing Shells Without Lubricant Groove

Insert bearing shells (2) without lubricant groove.
Insert guide bearing (3) without lubricant groove on bearing seat 5.
Fig. 123: Identifying Bearing Shells And Guide Bearing

Release screws (1).
Remove oil nozzle (2) towards top.

2010 BMW M3

Bearing classification on bedplate bearing seat.
Observe color allocation on crankshaft (1 to 5).
V= Violet.
G = Green.
Y = Yellow.
Fig. 125: Identifying Color Allocation On Crankshaft

Bearing classification on crankcase bearing seat.
Observe color allocation in crankcase (1 to 5).

2010 BMW M3
V= Violet.
G = Green.
Y = Yellow.
Fig. 126: Identifying Color Allocation In Crankcase

Assemble engine.
11 21 571 REPLACING GROOVED BALL BEARINGS IN CRANKSHAFT (S65)
00 5 500
11 2 016
11 2 340
11 2 350

53BZ) S65 .
Remove grooved ball bearing with special tool 11 2 340 in conjunction with special tool 11 2 016 .
2010 BMW M3
Fig. 127: Removing Grooved Ball Bearing With Special Tool (11 2 340) And (11 2 016)
Installation:
Replace guide bearing.
Drive in guide bearing as far as it will go with special tools 11 2 350 and 00 5 500 .
Fig. 128: Driving Guide Bearing With Special Tools (11 2 350) And (00 5 500)
Assemble engine.
FLYWHEEL
11 22 500 REMOVING AND INSTALLING/REPLACING FLYWHEEL (S65)
11 4 180
2010 BMW M3
11 9 260
11 9 263
Remove transmission. See 23 00 018 REMOVING AND INSTALLING TRANSMISSION (GS6-

53BZ) (S65)
53BZ) S65 .
Secure flywheel (1) with special tools 11 9 263 and 11 9 260 .
Fig. 129: Securing Flywheel With Special Tools (11 9 263) And (11 9 260)
Release flywheel screws with special tool 11 4 180 .
Tightening torque: 11 22 1AZ . See 11 22 FLYWHEEL .

2010 BMW M3
Fig. 130: Releasing Flywheel Screws With Special Tool (11 4 180)
Assemble engine.
21 2 051
21 2 052
Using hydraulic press (1) and special tool 21 2 051 , press out dual-mass flywheel downwards on engine side.

Roller bearing must not be driven out.
2010 BMW M3
Fig. 131: Pressing Out Dual-Mass Flywheel Using Hydraulic Press And Special Tool (21 2 051)
Push roller bearing (2) onto special tool 21 2 052 .
Using hydraulic press (1), press roller bearing into dual-mass flywheel as far as it will go on clutch side.

Observe press-in instruction:
Roller bearing must not be driven in.

Roller bearing mounting force/travel monitored:
Min. 2000N 1 mm before end of pressing in.
Max. 15000N during entire press-in procedure.
Fig. 132: Pressing Roller Bearing Into Dual-Mass Flywheel Using Hydraulic Press
2010 BMW M3
00 5 500
11 2 010
11 2 343
11 2 350
NOTE: flywheel removed!
Twist out roller bearing with special tool 11 2 343 .
Fig. 133: Twisting Out Roller Bearing With Special Tool (11 2 343)
Assemble special tools 11 2 350 and 00 5 500 .
Drive in roller bearing with special tools 11 2 350 and 00 5 500 in direction of arrow as far as it will go.
2010 BMW M3
Fig. 134: Driving Roller Bearing With Special Tools (11 2 350) And (00 5 500)
Assemble engine.
VIBRATION DAMPER
11 23 010 REMOVING AND INSTALLING/REPLACING VIBRATION DAMPER (S65)
00 9 120
11 0 280
11 9 260
11 9 263
Release screws (1).
Remove cover (2) with belt pulley (3).

2010 BMW M3
Fig. 135: Identifying Screws, Cover And Belt Pulley

NOTE: Engine or transmission removed.
Secure special tool 11 9 260 to flywheel (1).
Screw in special tool 11 9 263 with bolt (2) on crankcase.
Fig. 136: Identifying Flywheel, Special Tool (11 9 260) And (11 9 263)
Release screws (2).
Remove vibration damper (1).
Tightening torque: 11 23 1AZ . See VIBRATION DAMPER .

2010 BMW M3
Fig. 137: Identifying Vibration Damper And Screws

NOTE: Engine or transmission installed.
Attach special tool 11 0 280 to vibration damper.
Release all anti-fatigue bolts (2).
Installation:
Replace stress bolts.
Fig. 138: Identifying Special Tool (11 0 280) On Holder


2010 BMW M3
Tighten anti-fatigue bolts (1) with special tool 00 9 120 .
Tightening torque: 11 23 1AZ . See VIBRATION DAMPER .
Fig. 139: Tightening Anti-Fatigue Bolts With Special Tool (00 9 120)
Assemble engine.
CONNECTING ROD WITH BEARINGS

11 24 571 REPLACING ALL CONNECTING ROD BEARINGS (S65)
00 9 120
IMPORTANT: Note grinding stages on crankshaft. See ENGINE - TECHNICAL DATA .
Remove all pistons.
Install new conrod bearing shells.
Installation:
Install one blue (1) and one red (2) bearing shell in each conrod.
Install all pistons.

2010 BMW M3
Fig. 140: Identifying Blue And Red Bearing Shell In Conrod

NOTE: Check connecting rod bearing clearance.
Piston in BDC position.
Place special tool 00 2 590 (Plastigage model PG 1) on oil-free crankshaft.
Place bearing caps in position, making sure that matching numbers are paired.
Fig. 141: Checking Connecting Rod Bearing Clearance

IMPORTANT: Do not distort connecting rods or crankshaft.
Use the old conrod bearing bolts to check conrod clearance.
Tighten down conrod bolts with special tool 00 9 120 .
Tightening torque: 11 24 1AZ . See 11 24 CONNECTING RODS AND BEARINGS .

2010 BMW M3
Fig. 142: Tightening Down Conrod Bolts With Special Tool (00 9 120)
Remove conrod bearing cap and read off bearing clearance at width of pinched plastic thread on measuring
scale.
Conrod bearing clearance: Refer to ENGINE - TECHNICAL DATA .
Remove plastic thread.

Lubricate crankshaft and bearing shells.
Install new conrod bolts and tighten down.
Fig. 143: Checking Bearing Clearance At Width Of Pinched Plastic Thread On Measuring Scale
Assemble engine.
PISTON WITH RINGS

11 25 530 REMOVING AND INSTALLING/REPLACING ALL PISTONS (S65)
2010 BMW M3
00 9 120
11 4 492
11 5 250
11 5 341
11 5 342
11 5 343
11 5 344
11 9 500
12 2 100
WARNING: Protective goggles must be worn when working on the gudgeon pin
circlip.
IMPORTANT: If pistons, connecting rods and bearing shells are reused, they must be
reinstalled in the same places.
Piston and piston pin are matched to each other and can only be replaced as a
pair.
Connecting rod and connecting rod bearing cap are cracked.
Identification is effected by means of identical pairing letters on the connecting
rod big end.
Mixing up the components will result in engine damage.
Setting of special tool 11 5 343 must not be altered.
Remove engine.
Mount engine on assembly stand.
Remove engine oil sump.
Remove oil pump.
Remove oil suction pump.
Do not bend oil nozzle (2) at outlets.

2010 BMW M3
It is not possible to adjust the nozzles.
Oil nozzle (2) must be replaced if it is maladjusted or bent.
Remove crankshaft.

Release connecting rod bolts (1) with special tool 12 2 100 .
Remove connecting rod bearing cap with bearing shell.
Fig. 145: Releasing Connecting Rod Bolts With Special Tool (12 2 100)
Special tool 11 5 250 without locating rod must be screwed in on the connecting rod at the bottom.
Special tool 11 5 250 with locating rod must be screwed in on the connecting rod at the top.
2010 BMW M3

Rotate crankshaft (1) in direction of arrow, risk of damage to special tool 11 5 250 .
Remove piston with connecting rod and special tool 11 5 250 .
Depiction of function on cylinders 1-4.

Clamp special tool 11 5 341 in a vice.
NOTE: Piston and piston pin are optimized to each other.

There are two different inside diameters on the piston pin.
Screw matching special tool 11 5 342 into special tool 11 5 341 .

2010 BMW M3
Fig. 148: Identifying Special Tools (11 5 342) And (11 5 341)
Secure piston (1) with connecting rod to special tool 11 5 341 .
WARNING: Protective goggles must be worn for the next work step.
WARNING: Protective goggles must be worn.
Lever out piston circlip with special tool 11 4 492 in direction of arrow.
2010 BMW M3
Fig. 150: Removing Piston Circlip With Special Tool (11 4 492)
If necessary, replace connecting rods.
Installation:
The gudgeon pin must be able to be pressed through the liner by hand with little force and must not display any
significant play.
Fig. 151: Pressing Gudgeon Pin

Measure piston installation clearance:
Measure piston diameter with micrometer at measuring point A from bottom edge of piston and offset at 90 to
the axis of the gudgeon pin.
Piston diameter at measuring point A.

2010 BMW M3
Fig. 152: Measuring Piston Diameter With Micrometer

Adjust micrometer to cylinder bore of engine block. Set internal calliper on micrometer to zero. Measure
bottom, center and top of cylinder bore in direction of travel and direction of engine rotation.
Diameter of cylinder bore.
Piston installation clearance.
Total permissible wear tolerance.
If necessary, replace piston.
Fig. 153: Measuring Cylinder Bore Diameter

IMPORTANT: The connecting rods are not symmetrical.
Pay attention to elevation to direction of travel arrow.

2010 BMW M3
Fig. 154: Identifying Connecting Rod

Make sure the connecting rod is in the correct installation position during preliminary installation.
On cylinders 6-10 the elevation (2) must point forwards with the arrow.
Valve pockets (E) point to inlet side.
Arrow direction is identical to direction of travel.
Fig. 155: Identifying Correct Installation Position Of Connecting Rod

On cylinders 5-8 the elevation must point forwards with the arrow.
2010 BMW M3
IMPORTANT: No elevations on the connecting rod big end are permitted to point to each
other during installation, risk of damage to connecting rod.
Fig. 156: Identifying Cylinder Elevation

Installation:
When installed, the two lugs on connecting rods (1 and 2) must point outwards.
Fig. 157: Identifying Connecting Rods

Secure piston (1) with connecting rod to special tool 11 5 341 .

2010 BMW M3
IMPORTANT: Setting of special tool 11 5 343 must not be altered.
Installation:
Insert piston circlip (2) so that opening points to window.
Insert piston circlip (2) into groove (1) of special tool 11 5 343 .
Fig. 159: Inserting Piston Circlip Into Groove Of Special Tool (11 5 343)
Position special tool 11 5 343 with window to opening on piston (see arrow).
2010 BMW M3
Fig. 160: Identifying Special Tool (11 5 343) And Piston

Position special tool 11 5 343 with window to opening on piston (see arrow).
Fig. 161: Positioning Special Tool (11 5 343) On Piston

Guide lug and cutout on special tool 11 5 343 must point to piston crown.
When special tools 11 5 343 and 11 5 344 are correctly positioned, the piston circlip must be driven in with a
plastic hammer in the direction of the arrow.
2010 BMW M3
Fig. 162: Driving Piston Circlip With Plastic Hammer And Special Tools
NOTE: See illustration.
Installation:
Piston circlip (1) is correctly installed when the opening points upwards.
See illustration.
It must still be possible for piston pin to moved easily.

Install all piston rings.
Install all bearing shells.

2010 BMW M3
Screw special tool 11 5 250 into conrod.
Always screw in special tool 11 5 250 with rod to exhaust side.
Preinstall piston with piston rings in special tool 11 9 500 .
Fig. 164: Screwing Special Tool (11 5 250) Into Conrod

Insert piston with connecting rod in cylinder.
IMPORTANT: Risk of damage to oil spray nozzle.

Danger of piston ring failure.
Insert piston so that arrow (direction of travel pointing forwards) on piston crown points to camshaft drive.
Piston cyl. 1-4 right side, cyl. 5-8 left side.
Press in piston with special tool 11 9 500 .

2010 BMW M3
Fig. 165: Inserting Piston On Piston Crown Points To Camshaft Drive

Arrow on piston crown must point to camshaft drive (direction of travel towards front).
Fig. 166: Installing Piston Crown To Camshaft Drive

IMPORTANT: connecting rod and connecting rod bearing cap are identified with pairing
letters (1) and must not be mixed up.
Mixing them up or incorrectly fitting the conrod bearing cap on the big end will
result in engine damage.
Fig. 167: Identifying Connecting Rod And Connecting Rod Bearing Cap Identification Pairing Letters
Rotate crankshaft (1) in direction of arrow, risk of damage to special tool 11 5 250 .
2010 BMW M3
Insert piston with connecting rod and special tool 11 5 250 .

Moisten conrod bearing shell and crank pin slightly with engine oil.
Assemble connecting rod and crank pin.
Fig. 169: Identifying Special Tool (11 5 250) On Connecting Rod And Crank Pin
Install connecting rod bearing cap with bearing shell.
Secure connecting rod bolts (1) with special tools 12 2 100 and 00 9 120 .

2010 BMW M3
Fig. 170: Securing Connecting Rod Bolts With Special Tools (12 2 100)
Assemble engine.
11 25 671 REPLACING PISTON RINGS ON ALL PISTONS (S65)
Removing all pistons
Remove piston rings with a piston-ring compressing pliers.
NOTE: It might not be possible to find the identification on used piston rings.
Put aside piston rings in correct sequence and installation position.
Fig. 171: Removing Piston Rings With Piston-Ring Compressing Pliers

Installation:

2010 BMW M3
Groove (2), plain compression ring.
Groove (3), stepped ring.
Groove (4), bevel-edged oil control ring.
Fig. 172: Identifying Piston Rings Groove

Piston ring (1), bevel-edged oil control ring.
Piston ring (2), stepped ring.
Piston ring (3), plain compression ring.
Fig. 173: Identifying Bevel-Edged Oil Control Ring And Stepped Ring, Plain Compression Ring
Installation:

2010 BMW M3
Plain compression ring is marked with (R).
Stepped ring is marked with (R1).
Fig. 174: Identifying (R) Marks On Plain Compression Ring And (R1) Marks On Stepped Ring
Measure axial play. See ENGINE - TECHNICAL DATA .
Fig. 175: Measuring Axial Play

Measure end clearance. See ENGINE - TECHNICAL DATA .

2010 BMW M3
Fig. 176: Measuring End Clearance

Offset the contact points of the piston rings by approx. 120 to each other but do not position above the piston
pin boss.
NOTE: See picture S85.
Fig. 177: Identifying Offset Contact Points Of Piston Rings

Assemble engine.
V-RIBBED BELT WITH TENSIONER

11 28 010 REPLACING ALTERNATOR DRIVE BELT (S65)

2010 BMW M3
Remove drive belt for A/C system.
Release cover (1) with a screwdriver.
Fig. 178: Identifying Drive Belt Cover

Press down tensioning device (1) with standard tool in direction of arrow.
Remove drive belt.
Installation:
Make sure drive belt is installed in correct position.
Fig. 179: Pressing Down Tensioning Device With Tool

2010 BMW M3
Assemble engine.
11 28 020 REPLACING TENSIONING DEVICE FOR ALTERNATOR DRIVE BELT (S65)

Release screws (1).
Remove belt pulley (2) from coolant pump.
Fig. 180: Identifying Alternator Drive Belt Screws And Belt Pulley
Remove belt tensioner (3) with tensioning pulley.
Installation:

2010 BMW M3

Assemble engine.
11 28 050 REPLACING A/C COMPRESSOR DRIVE BELT (S65)
IMPORTANT: Mixed installation of the assemblies is not permitted. Mixed installation will
result in failure of the steering assistance.
Tightening torque: 11 28 1-2AZ . See 11 28 DRIVE BELT .
IMPORTANT: Belt routing of clockwise-rotating power steering pump (see arrow).
Installation:

2010 BMW M3
Fig. 182: Pressing Down Tensioning Device On Damper

IMPORTANT: Belt routing of counterclockwise-rotating power steering pump (see arrow).

Double-sided ribbed V-belt.
Fig. 183: Pressing Down Tensioning Device On Damper

Installation:
Assemble engine.
2010 BMW M3
11 28 060 REMOVING AND INSTALLING/REPLACING BELT TENSIONER FOR A/C

COMPRESSOR (S65)
IMPORTANT: Mixed installation of the assemblies is not permitted. Mixed installation will
result in failure of the steering assistance.
Release screw (1).
Release screw for power steering high-pressure line.
Release screws (2).
Remove belt tensioner (3) with fixture.
Installation:

2010 BMW M3
Tightening torque: 11 28 1-2AZ . See 11 28 DRIVE BELT .
Assemble engine.
CAMSHAFT
11 31 032 REMOVING AND INSTALLING OR REPLACING LEFT INLET CAMSHAFTS (S65)
Remove left cylinder head cover.

Remove left VANOS exhaust gear
Remove left VANOS inlet gear
Release screws (1).
E Intake camshaft
A Exhaust camshaft.

Fig. 185: Identifying Screws And Bearing Cap

Installation:

2010 BMW M3
Remove inlet camshaft for cylinders 5 to 8.

Do not place timing chain in gearcase.
Secure timing chain (1) against falling down with a cable tie (3) to one screw (2).
Fig. 187: Securing Timing Chain With Cable Tie To Screw


2010 BMW M3
Fig. 188: Pressing Plain Compression Rings Upwards And Downwards

Insert inlet camshaft for cylinders 5 to 8.
Installation:
Fig. 189: Locating Inlet Camshaft For Cylinders 5 To 8

2010 BMW M3
Installation:
Fig. 190: Identifying Bearing Shells Mark



2010 BMW M3
Assemble engine.
11 31 034 REMOVING AND INSTALLING/REPLACING RIGHT INLET CAMSHAFT (S65)

Remove right VANOS exhaust gear.
Remove right VANOS inlet gear
Release screws (1).
E Intake camshaft
A Exhaust camshaft.

Fig. 192: Identifying Inlet Camshaft Screws

Installation:
NOTE: Illustration shows cylinders 5-8.

2010 BMW M3
Installation:
Fig. 193: Identifying Bearing Cap Screws


2010 BMW M3
Insert inlet camshaft (1) for cylinders 1 to 4.
Cams on cylinders (1 and 3) point upwards at an angle.
Installation:
Fig. 195: Identifying Cams On Cylinders

Installation:
E and A from (1 to 8), e.g. E 1= inlet side on 1st cylinder.

2010 BMW M3

Installation:
Fig. 197: Identifying Bearing Cap Screws

Assemble engine.
11 31 036 REMOVING AND INSTALLING/REPLACING LEFT EXHAUST CAMSHAFT (S65)

Remove left VANOS exhaust gear
Release screws (1).
E Intake camshaft
A Exhaust camshaft.
2010 BMW M3


Remove bearing cap (2).
Installation:
Installation:

2010 BMW M3
Fig. 199: Identifying Exhaust Camshaft Screws


Designation (A 2) on dihedron points upwards.
Cams (1) on cylinder no. 5 point upwards.
Installation:

2010 BMW M3
Fig. 201: Identifying Cylinder No. 5 Cams

Installation:

Installation:
2010 BMW M3

Assemble engine.
11 31 038 REMOVING AND INSTALLING/REPLACING RIGHT EXHAUST CAMSHAFT (S65)

Remove right VANOS exhaust gear
Release screws (1).
E Intake camshaft
A Exhaust camshaft.

2010 BMW M3

Remove bearing caps.
Installation:
Remove exhaust camshaft for cylinders 1 to 4.


2010 BMW M3

Installation:
Fig. 207: Identifying Cylinder No. 4 Cams

2010 BMW M3
Installation:
E and A from (1 to 8), e.g. A 1= exhaust side on 1st cylinder.
Fig. 208: Identifying Bearing Shells Marks


2010 BMW M3
Assemble engine.
11 31 051 REPLACING BOTH TIMING CHAINS (S65)
11 5 290
11 5 292
Remove all VANOS gears. See 11 36 142 Removing and installing/replacing left inlet VANOS gear
(S65), 11 36 144 Removing and installing/replacing left exhaust VANOS gear (S65), 11 36 148
Removing and installing/replacing right inlet VANOS gear (S65) and 11 36 150 Removing and
installing/replacing right exhaust VANOS gear (S65).
Remove radial shaft seal at front.
Remove oil pump.
Remove oil return pump.
Remove oil filter housing.
Release screw plug (1) on bank 1.

Release screw plugs (1).

2010 BMW M3
Release screw (2).
Remove intermediate piece (3) without gearwheel towards front.
IMPORTANT: Gearwheel can fall out.
Fig. 211: Identifying Screw Plugs, Screw And Intermediate Piece

Arrangement of gearwheel and intermediate piece:
Gearwheel (1) with dowel pin.
Intermediate piece (2).
Central bolt (3).
Fig. 212: Identifying Gearwheel, Intermediate Piece And Central Bolt

2010 BMW M3

Bearing pin (2) for two tensioning rails.
Remove bearing pin with special tool 11 5 290 .
Tightening torque: 11 31 2AZ . See 11 31 CAMSHAFT .
Fig. 213: Identifying Bearing Pin And Special Tool (11 5 290)
Screw in special tool 11 5 292 at bearing pin (1) and pull out.
Fig. 214: Screwing Special Tool (11 5 292) At Bearing Pin

Remove bearing pin with special tool 11 5 290 .

2010 BMW M3

Arrangement of both timing chains:

5. Tensioning rail, bank 1.
6. Bearing pin, inserted type.
7. Bearing pin for two tensioning and guide rails.
8. Bearing pin, screwed type.
Fig. 216: Identifying Arrangement Of Timing Chains

2010 BMW M3
Fig. 217: Removing Timing Chain (Bank 1 And Bank 2)

Assemble engine.
11 31 072 CHECKING CAMSHAFT TIMING (S65)
11 0 480
11 5 320
11 9 970
11 9 971
11 9 972
IMPORTANT: Bank (2), cylinders (5 - 8), is checked first.

The timing of bank (1) at cylinders (1-4) can only be checked at overlap TDC.
The lettering (E1 and A1) must point downwards.
Remove fan cowl with electronic fan. See 17 11 035 REMOVING AND INSTALLING/REPLACING
2010 BMW M3

IMPORTANT: Danger of mixing up both special tool bores.
10 10 before TDC (top dead center)
OT Top dead center

IMPORTANT: Only bank 2, cylinders (5 - 8), can be checked in cylinder no. 1 firing TDC
position.
The 10 position is required only to adjust the timing.
Engine installed: Secure vibration damper in position with special tool 11 0 480 .
Engine removed: Secure vibration damper in position with special tool 11 5 320 .
2010 BMW M3
Fig. 219: Identifying Special Tool (11 5 320) On Vibration Damper

IMPORTANT: Bank 2 is checked first.
The lettering (A2 and E2) points upwards.
The positions of the cams on the exhaust camshaft point vertically upwards (see picture).
The positions of the cams on the inlet camshaft point at an angle downwards (see picture).
Fig. 220: Identifying Letters (A2 And E2) On Cam

The timings are correctly set when special tool 11 9 970 rests without a gap on the cylinder head.
2010 BMW M3
Permissible tolerance: A maximum gap of 1.0 mm is permitted on the non-contacting side of special tool 11 9
970 .
IMPORTANT: Remove special tools 11 9 970 and 11 5 320 .

Crank engine at central bolt 360 in direction of rotation.
The timing of bank 1 at cylinders (1-4) can only be checked at overlap TDC.

Engine installed: Secure vibration damper in position with special tool 11 0 480 .
Engine removed: Secure vibration damper in position with special tool 11 5 320 .
IMPORTANT: Position of camshaft at overlap TDC

2010 BMW M3
The lettering (E1 and A1) points downwards.
The cams on cylinder no. 1 on the inlet camshaft point at an angle downwards (see picture).
The cams on cylinder no. 1 on the exhaust camshaft point at an angle downwards (see picture).
Fig. 223: Identifying Special Tools On Inlet Camshaft And Exhaust Camshaft
The timings are correctly set when special tool 11 9 970 rests without a gap on the cylinder head.
Permissible tolerance: A maximum gap of 1.0 mm is permitted on the non-contacting side of special tool 11 9
970 .

2010 BMW M3
Fig. 224: Identifying Gap Between Timings Chain And Cylinder Head
Assemble engine in reverse sequence to its disassembly.
11 31 094 REMOVING AND INSTALLING/REPLACING LEFT HYDRAULIC CHAIN TENSIONER

(S65)
Remove left intake filter housing . See 13 71 000 REMOVING AND INSTALLING/REPLACING
Installation:
Fig. 225: Identifying Left Hydraulic Chain Tensioner Bolt

Assemble engine.
11 31 095 REMOVING AND INSTALLING/REPLACING RIGHT HYDRAULIC CHAIN TENSIONER

(S65)

2010 BMW M3
Remove expansion tank. See 17 11 100 REMOVING AND INSTALLING/REPLACING

COOLANT EXPANSION TANK (S65) .
Unfasten both A/C lines on A/C compressor.
Installation:
Fig. 226: Identifying Right Hydraulic Chain Tensioner Bolt

Assemble engine.
11 31 575 ADJUSTING CAMSHAFT TIMING (S65)
00 9 120
11 5 320
11 9 970
11 9 971
11 9 972

2010 BMW M3
IMPORTANT: The procedure for adjusting the timing is different from that for checking the
timing.
The letters/numbers on the camshafts (E1 and A1) and (E2 and A2) must point
upwards.
Do not release the central bolts of the adjustment units without the special tool
11 9 970 (risk of damage!).
If the special tool 11 9 970 cannot be positioned on the dihedron of the
camshafts, bar the engine at the central bolt until the special tool 11 9 970 can
be secured on the cylinder head.
Installation:
Replace seal.
Fig. 227: Identifying Cylinder Bank 1 Bolts And Timing Case Cover
Installation:
Replace seal.
2010 BMW M3
position.
10 before TDC
TDC= top dead center.
Before the crankshaft can be secured, the gauges 11 9 970 must be positioned on the camshafts.
Rotate crankshaft at central bolt.

IMPORTANT: Always start timing with bank 1 (cylinders 1-4).

2010 BMW M3
Fig. 230: Identifying Letters/Numbers On Camshafts Point (E1)

Designation (A1) on dihedron (1) points upwards.
Fig. 231: Identifying Letters/Numbers (A1) On Camshafts

2010 BMW M3
Fig. 232: Rotating Inlet Camshaft With Open-End Wrench

Rotate exhaust camshaft with open-end wrench with minimal effort in direction of arrow until special tool 11 9
971 can be attached.
Fig. 233: Identifying Special Tool (11 9 971) On Cylinder Head Bolts
Installation:
2010 BMW M3

in the 10 position.
Fig. 235: Rotating Crankshaft At Central Bolt With Special Tool (11 5 320)

Central bolts must be fully screwed once.
Cylinders 1 to 4:
Secure central bolt (1) with special tool 00 9 120 .

2010 BMW M3
1. Joining 20 Nm
Fig. 236: Securing Central Bolt With Special Tool (00 9 120)
1. Joining 20 Nm
2010 BMW M3
Camshafts, cylinders 1-4, remain secured with special tool 11 9 970 .
cylinder no. 1 .
Installation:
Secure crankshaft with special tool 11 5 320 .

Cylinders 1 to 4:

2010 BMW M3
1. Joining 20 Nm
1. Joining 20 Nm
IMPORTANT: Remove all special tools.

2010 BMW M3
Installation:
If necessary, crank at crankshaft central bolt.
Fig. 241: Identifying Letters/Numbers On Camshafts Point Upwards (E2)


2010 BMW M3
Fig. 242: Identifying Letters/Numbers On Camshafts Point Upwards (A2)

Secure inlet camshaft with special tool 11 9 971 .
Secure exhaust camshaft with special tool 11 9 972 .
Installation:
2010 BMW M3

in the 10 position.


Central bolts must be fully screwed once.
Cylinders 5 to 8:

2010 BMW M3
1. Joining 20 Nm
1. Joining 20 Nm
2010 BMW M3
cylinder no. 1 .
Installation:

Cylinders 5 to 8:

2010 BMW M3
1. Joining 20 Nm
1. Joining 20 Nm

2010 BMW M3
Check timing.
Assemble engine.
ROCKER ARM WITH BEARING

11 33 062 REMOVING AND INSTALLING/REPLACING ALL HVCA (HYDRAULIC VALVE
CLEARANCE ADJUSTMENT) ELEMENTS (S65)
IMPORTANT: Used HVCA elements may only be reused in the same position.
Set HVCA elements down in a clean and orderly manner.
Remove inlet camshaft. See 11 31 032 Removing and installing or replacing left inlet camshafts
(S65) and 11 31 034 Removing and installing/replacing right inlet camshaft (S65).
Remove exhaust camshaft. See 11 31 036 Removing and installing/replacing left exhaust camshaft
(S65) and 11 31 038 Removing and installing/replacing right exhaust camshaft (S65).
Remove HVCA element (1) in upward direction.
Installation:
Turning lock (2) on cylinder head.

2010 BMW M3
Fig. 251: Identifying HVCA Element And Cylinder Head Lock

Check surface (1) of HVCA element for damage.
Installation:
Turning lock (2) on HVCA element.
Fig. 252: Identifying Surface Of HVCA Element And HVCA Element Lock
Installation:
Check valve keys (1) for correct seating.
Check turning lock (2) on cylinder head for damage.

2010 BMW M3
Fig. 253: Identifying Valve Keys And Turning Lock

Assemble engine.
VALVES WITH SPRINGS

11 34 552 REMOVING AND INSTALLING/REPLACING ALL VALVES (S65)
11 5 281
11 5 282
11 5 283
11 9 001
11 9 006
11 9 008
11 9 009
11 9 951
11 9 952
11 9 953


2010 BMW M3
Remove left cylinder head cover and right cylinder head cover.
If necessary, remove and install engine.
NOTE: Place cylinder head (1) on special tool 11 9 001 .
Prepare special tool 11 9 006 with special tool 11 9 008 .
Fig. 254: Identifying Cylinder Head, Special Tool (11 9 001) And (11 9 006)
Secure eccentric clamping levers (2 and 3).
Fig. 255: Inserting Aluminum Profile Rail

2010 BMW M3
IMPORTANT: Special tools S85 11 5 281 and 11 5 282 must be modified to S65.
Unscrew valve cage from special tool 11 5 281 .


2010 BMW M3

Fig. 259: Identifying Valve Cage And Felt Washer

2010 BMW M3

Modify special tool 11 5 281 with special tool 11 9 951 .
IMPORTANT: In order to avoid damaging the HVCA guide, use only the designated special
tools.
2010 BMW M3
NOTE: Special tool 11 5 281 incorporates a lever (1) which is tensioned with a spring.
The valve keys still installed are thus forced out and drop into the working chamber of special tool 11 5 281 .

Pull back lever on special tool 11 5 281 .

2010 BMW M3
Fig. 264: Identifying Keys, Working Chamber And Special Tool (11 5 281)
All the engine valves are now accessible.
Installation:
Set the engine valves down in neat and tidy order if they are to be reused.
Check valve seat for damage.
Fig. 265: Identifying Cylinder Head, Special Tool (11 9 001) And (11 9 006)
IMPORTANT: The cylinder head must be replaced if the valve seat is damaged.
Remachining the valve seat ring is not permitted.
2010 BMW M3
Press valve key (1) in direction of arrow into special tool 11 9 953 .
Fig. 266: Pressing Valve Key Into Special Tool (11 9 953)

Special tool 11 9 952 must be replaced.

2010 BMW M3
Fig. 268: Identifying Valve Cage And Special Tool (11 5 952)
Remove insert washer of special tool 11 5 282 (S85).
Insert special tool 11 9 952 with taper facing up in valve cage (1) (see arrow).
Fig. 269: Inserting Special Tool (11 9 952) In Valve Cage

Press valve keys into special tool 11 9 953 with special tool 11 5 283 .

2010 BMW M3
Fig. 270: Pressing Valve Keys Into Special Tool (11 9 953) With (11 5 283)
Press valve keys in direction of arrow into special tool 11 5 282 with special tool 11 9 953 .
Make sure valve keys (1) are correctly positioned.
Special tool 11 5 282 is prepared.

2010 BMW M3
Fig. 272: Identifying Valve Keys And Special Tool (11 5 282)
Installation:
Fig. 273: Pressing Down Special Tool (11 5 282) With (11 9 909)
Installation:
Check that valve keys are in correct installation position.

2010 BMW M3

Assemble engine.
11 34 560 REPLACING ALL VALVE STEM SEALS (S65)
11 1 480
11 5 270
Remove cylinder head. See left and right.

Remove all valve springs.
Remove valve stem seal with special tool 11 1 480 in direction of arrow.
2010 BMW M3
Fig. 275: Removing Valve Stem Seal With Special Tool (11 1 480)
Installation:
Attach the mounting sleeve (1) supplied with the new part to the valve stem.
Fig. 276: Identifying Mounting Sleeve

Attach valve stem seal (2) over mounting sleeve (1).

2010 BMW M3
Fig. 277: Identifying Valve Stem Seal And Mounting Sleeve

Press on valve stem seal with special tool 11 5 270 in direction of arrow as far as it will go.
Fig. 278: Pressing On Valve Stem Seal With Special Tool (11 5 270)
Assemble engine.
11 34 715 REPLACING ALL VALVE SPRINGS (S65)
11 5 281
11 5 282
11 5 821
11 9 001
11 9 006
2010 BMW M3
11 9 008
11 9 009
11 9 950
11 9 951
11 9 953

Special tools 11 5 821 and 11 5 282 must be modified to special tool 11 9 950 .
Remove cylinder head. See left and right.

Remove all HVCA elements.
NOTE: Place cylinder head (1) with cylinder head bolts on special tool 11 9 001 .
Prepare special tool 11 9 006 with special tool 11 9 008 .
Fig. 279: Identifying Cylinder Head, Special Tools (11 9 001) And (11 9 006)
Secure eccentric clamping levers (2 and 3) in direction of arrow.

2010 BMW M3
Fig. 280: Inserting Aluminum Profile Rail

IMPORTANT: Special tools S85 11 5 281 and 11 5 282 must be modified to S65 11 9 950 .
Special tool 11 9 953 for securing valve keys.

2010 BMW M3


2010 BMW M3
Fig. 284: Identifying Valve Cage And Felt Washer


Modify special tool 11 5 281 with special tool 11 9 951 .

2010 BMW M3
IMPORTANT: Use only approved special tools.

Risk of damage to the HVCA guide.
NOTE: Lever (1) on special tool 11 5 281 is tensioned with a spring.
The valve keys still installed are thus forced out and drop into the working chamber of special tool 11 5 281 .
2010 BMW M3

Pull back lever on special tool 11 5 281 .
Fig. 289: Identifying Keys, Working Chamber And Special Tool (11 5 281)
NOTE: Lower spring plate (1).

Progressive valve spring (2).
Upper spring plate (3).
Installation:
Incorrect installation is not possible.

2010 BMW M3
Fig. 290: Identifying Lower Spring Plate, Progressive Valve Spring And Upper Spring Plate
Insert lower spring plate (1).
Fig. 291: Identifying Lower Spring Plate

Press valve key (1) in direction of arrow into special tool 11 9 953 .
2010 BMW M3
Fig. 292: Pressing Valve Key Into Special Tool (11 9 953)


2010 BMW M3
Special tool 11 5 282 is prepared for installation.
Installation:
Positioning of valve keys (1).

2010 BMW M3
Fig. 296: Identifying Valve Keys And Special Tool (11 5 282)
Installation:
Fig. 297: Pressing Down Special Tool (11 5 282) With (11 9 909)
Installation:
Check that valve keys (1) are in correct installation position.

2010 BMW M3

Assemble engine.
VARIABLE CAMSHAFT TIMING

11 36 142 REMOVING AND INSTALLING/REPLACING LEFT INLET VANOS GEAR (S65)
00 9 120
11 5 291
11 5 292
11 5 320
11 5 370
11 9 970
11 9 971
11 9 972

11 9 970 .

2010 BMW M3
Installation:
Replace seal.
position.
The procedure for checking timing is different from that for adjusting.

2010 BMW M3
Secure crankshaft with special tool 11 5 320 in firing TDC position of cylinder no. 1 .


Dihedron of camshafts is vertical to cylinder axis,
letters/numbers on camshafts point upwards (A2).

2010 BMW M3

Align gearwheels on exhaust adjustment unit with special tool 11 5 370 .

2010 BMW M3
Fig. 305: Identifying Special Tool (11 5 370) On Gearwheels


Fig. 306: Identifying Socket Screw


Installation:
2010 BMW M3

Remove exhaust adjustment unit (1).
Fig. 308: Identifying Exhaust Adjustment Unit

Installation:
tool 11 5 370 .

2010 BMW M3
Fig. 309: Identifying Special Tool (11 5 370) And Gearwheel

Installation:

Installation:

2010 BMW M3

Installation:
Fig. 312: Identifying Central Bolt And Inlet Adjustment Unit

Open plug (1).
Installation:
2010 BMW M3
Replace seal.

Secure screw connection against falling out with special tool 11 5 292 .
Release screw connection at chain guide with special tool 11 5 291 .
Remove inlet adjustment unit.
Lay timing chain (1) on inlet camshaft.
IMPORTANT: Do not bar engine at central bolt.

Risk of damage! to engine valves and timing chain.
2010 BMW M3
Fig. 315: Identifying Timing Chain And Central Bolt

Fig. 316: Identifying EIN Inlet Adjustment Unit And AUS Exhaust Adjustment Unit

Central bolt must be fully screwed once.
in the 10 position.
2010 BMW M3
Installation:

Insert central bolts (1 and 2) without play.

2010 BMW M3

Remove hexagon socket screw (1) or special tool 11 5 370 .

Secure timing chain tensioning rail.

2010 BMW M3
Installation:

Insert central bolt (1) and screw with special tool 00 9 120 .
1. Joining 10 Nm
2. Joining 20 Nm
2010 BMW M3

6. Joining 10 Nm
1. Joining 10 Nm
2. Joining 20 Nm
6. Joining 10 Nm
11 9 970
2010 BMW M3
cylinder no. 1 .
Installation:

Cylinders 5 to 8:

2010 BMW M3
1. Joining 20 Nm
1. Joining 20 Nm
Check timing , cylinders (5 to 8).
Assemble engine.
11 36 144 REMOVING AND INSTALLING/REPLACING LEFT EXHAUST VANOS GEAR (S65)
00 9 120
11 5 320
11 5 370
2010 BMW M3
11 9 970
11 9 971
11 9 972

11 9 970 .
Remove right cylinder head cover
Installation:
Replace seal.
position.
2010 BMW M3


2010 BMW M3


2010 BMW M3
Fig. 334: Identifying Special Tool (11 5 370) On Gearwheels



2010 BMW M3


Installation:

Installation:
tool 11 5 370 .
2010 BMW M3

Installation:


in the 10 position.
2010 BMW M3
Installation:

Insert central bolts (1 and 2) and screw with special tool 00 9 120 .
1. Joining 10 Nm
2. Joining 20 Nm
2010 BMW M3

6. Joining 10 Nm


cylinder no. 1 .
Installation:
2010 BMW M3
Fig. 343: Securing Crankshaft With Special Tool (11 5 320)

Cylinders 5 to 8:
1. Joining 20 Nm
2010 BMW M3
1. Joining 20 Nm
Check timing , cylinders (5 to 8).
Assemble engine.
11 36 148 REMOVING AND INSTALLING/REPLACING RIGHT INLET VANOS GEAR (S65)
00 9 120
11 5 320
11 5 370
11 9 970
11 9 971
11 9 972
2010 BMW M3

11 9 970 .
Installation:
Replace seal.
position.
2010 BMW M3


2010 BMW M3


2010 BMW M3


2010 BMW M3



Installation:

2010 BMW M3
Remove exhaust adjustment unit

Installation:
tool 11 5 370 .

Installation:
2010 BMW M3

Installation:


2010 BMW M3
Installation:
Fig. 359: Identifying Central Bolt And Inlet Adjustment Unit

Lay timing chain (1) on inlet camshaft (2).
Fig. 360: Identifying Timing Chain And Inlet Camshaft


2010 BMW M3
Fig. 361: Identifying EIN Inlet Adjustment Unit And AUS Exhaust Adjustment Unit

in the 10 position.
Installation:
2010 BMW M3
Fig. 363: Coat Contact Face Of New Central Bolt (1) With Copper Paste
Position inlet adjustment unit with timing chain on inlet camshaft.
Position exhaust adjustment unit on exhaust camshaft.


2010 BMW M3

Screw in central bolt (1) with special tool 00 9 120 .
1. Joining 10 Nm
2. Joining 20 Nm
6. Joining 10 Nm
1. Joining 10 Nm
2. Joining 20 Nm
2010 BMW M3
6. Joining 10 Nm

cylinder no. 1 .
Installation:

2010 BMW M3

Cylinders 1 to 4:
1. Joining 20 Nm
2010 BMW M3
1. Joining 20 Nm
Check timing , bank 1, cylinders (1 to 4).
Assemble engine.
11 36 150 REMOVING AND INSTALLING/REPLACING RIGHT EXHAUST VANOS GEAR (S65)
00 9 120
11 5 320
11 5 370
11 9 970
11 9 971
11 9 972

2010 BMW M3

11 9 970 .
Installation:
Replace seal.
position.
2010 BMW M3


2010 BMW M3


2010 BMW M3


2010 BMW M3



Installation:

2010 BMW M3

Installation:
tool 11 5 370 .

Installation:

2010 BMW M3


in the 10 position.
Installation:
2010 BMW M3

1. Joining 10 Nm
2. Joining 20 Nm
6. Joining 10 Nm
2010 BMW M3
1. Joining 10 Nm
2. Joining 20 Nm
6. Joining 10 Nm

2010 BMW M3
cylinder no. 1 .
Installation:

Cylinders 5 to 8:
1. Joining 20 Nm
2010 BMW M3
1. Joining 20 Nm
Check timing , bank 1, cylinders (1 to 4).
Assemble engine.
2010 BMW M3
11 36 715 REMOVING AND INSTALLING/REPLACING SOLENOID VALVES ON LEFT VANOS

Release screw (1).
Remove solenoid valve (3), exhaust adjustment.
Installation:
Replace O-rings.
Fig. 392: Identifying Screw, Solenoid Valve And Plug Connections

Release screw (1).
Unfasten plug connection.
Remove solenoid valve (2), inlet adjustment.
Installation:
Replace O-ring.
2010 BMW M3
Fig. 393: Identifying Solenoid Valve And Screw

Assemble engine.
Perform VANOS test.
11 36 720 REMOVING AND INSTALLING/REPLACING SOLENOID VALVES ON RIGHT VANOS

Remove intake manifold (inlet solenoid valve only).
Disconnect plug connection (2) on solenoid valve for exhaust adjustment.
Release screw (1).
Remove exhaust solenoid valve.
Installation:
Replace O-rings.
2010 BMW M3
Fig. 394: Identifying Plug Connection, Exhaust Solenoid Valve And Screw
Disconnect plug connection on solenoid valve for inlet adjustment.
Release screws (1).
Remove inlet solenoid valve (2).
Installation:
Replace O-ring.
Fig. 395: Identifying Inlet Solenoid Valve And Screw

Assemble engine.
Perform VANOS test.

2010 BMW M3
OIL PUMP WITH FILTER

11 41 000 REMOVING AND INSTALLING/REPLACING OIL PUMP (S65)
Remove oil pan
Release screws (1).
Release screws (2).
Installation:
Replace screws.
Clean threads before installation.
Fig. 396: Identifying Oil Pump Screws

Release screw (1).
Release screw (2).

2010 BMW M3

Release screw (1).
Fig. 398: Identifying Oil Pipe Screw

Detach oil pipes (1 and 2) from oil pump.
Installation:
To facilitate fitting, apply a light coating of engine oil to sealing rings.
Clean all sealing surfaces.

2010 BMW M3
Fig. 399: Identifying Oil Pipes

Slacken nut (1).
Installation:
If reusing the sprocket wheel, check dihedron for damage and if necessary replace.
Replace microencapsulated nut (1).
Tightening torque:11 41 1AZ . See 11 41 OIL PUMP WITH STRAINER AND DRIVE .
Fig. 400: Identifying Microencapsulated Nut

Release screw (1).
Release screw (2).

2010 BMW M3
Fold sliding rail (3) downwards.
Fig. 401: Identifying Screws And Sliding Rail

Remove sprocket wheel (1) from shaft.
Fig. 402: Identifying Sprocket Wheel

IMPORTANT: Chain tensioner piston may fall out.
Remove piston (1) in direction of arrow.

2010 BMW M3
Fig. 403: Removing Piston

Installation:
Arrangement, chain tensioner, oil pump.
1. Base valve
2. Spring
3. Piston
Fig. 404: Identifying Base Valve, Spring And Piston

Release screws (1) on oil pump (2).

2010 BMW M3
Fig. 405: Identifying Screws And Oil Pump

Installation:

Assemble engine.
11 6 251
11 6 252
11 6 254
2010 BMW M3
the oil supply.
Remove engine oil sump.

Remove oil pump.
Release screws (1).
Tightening torque. 11 41 3AZ . See 11 41 OIL PUMP WITH STRAINER AND DRIVE .

Replacing gear wheels

Remove radial shaft seal at front.
Secure special tool 11 6 252 with magnetic base to special tool 11 6 254 .
2010 BMW M3
Fig. 408: Mounting Special Tool (11 6 254) On Crankcase



2010 BMW M3


Tightening torque 11 41 3AZ . See 11 41 OIL PUMP WITH STRAINER AND DRIVE .
2010 BMW M3
Fig. 412: Adjusting Oil Suction Pump With Rubber Mallet On Pump Housing
Assemble engine.
OIL FILTER AND LINES

11 42 020 REMOVING AND INSTALLING, SEALING/REPLACING MAIN FLOW OIL FILTER
(S65)

Recycling:
Remove front underbody protection. See 51 47 490 REMOVING AND INSTALLING /
Remove A/C system drive belt.
Remove water pump belt pulley.
Remove coolant hoses.
Release power steering pump and lay to one side (do not open pressure lines). See 32 41 060
REMOVING AND INSTALLING (REPLACING) VANE PUMP FOR POWER STEERING
(S65) .
2010 BMW M3
Installation:
Tightening torque: 11 42 1AZ . See 11 42 OIL FILTER AND PIPES .

Detach lines (2 and 3).
Installation:
Replace O-rings.
2010 BMW M3

Release screws (1).
Release screws (2).
Release screws (3).
Lift out oil filter housing.
Fig. 415: Identifying Oil Filter Housing Screws

Installation:
Replace seal (1).

2010 BMW M3

Assemble engine.
Allow engine at normal operating temperature to run for 3 minutes with increased revs (min. 1000 / max. 1500
RPM).
Top up engine oil if necessary.
11 42 080 REMOVING AND INSTALLING/REPLACING OIL PRESSURE HOSE - FEED - (S65)

Recycling:
Slacken nut (1).

2010 BMW M3
Installation:
Replace O-ring.

Slacken nut (1).
Unclip bracket (2).
Fig. 418: Identifying Nut And Bracket

Slacken nut (1).

2010 BMW M3
Installation:
Replace O-ring.

Assemble engine.
RPM).
11 42 085 REMOVING AND INSTALLING/REPLACING OIL PRESSURE HOSE - RETURN - (S65)

Recycling:
2010 BMW M3
Slacken nut (4).
Installation:
Replace O-ring.

Slacken nut (1).
Unclip retainer (2).
Fig. 421: Identifying Nut And Retainer

Slacken nut (1).

2010 BMW M3
Installation:
Replace O-ring.

Assemble engine.
RPM).
WATER PUMP WITH DRIVE

11 51 000 REMOVING AND INSTALLING/REPLACING WATER PUMP (S65)
Remove fan cowl with electronic fan. See 17 11 035 REMOVING AND
INSTALLING/REPLACING FAN COWL WITH ELECTRIC FAN (S65) .
Remove radiator. See 17 11 000 REMOVING AND INSTALLING RADIATOR (N51, S65) .
Remove upper idler pulley for A/C compressor.
Release screw (1).

2010 BMW M3
Remove belt pulley (2).
Fig. 423: Identifying Alternator Drive Belt Screws And Belt Pulley
Release screws (1).
To facilitate removal of the coolant pump, it is possible to insert M6 screws on left and right (see arrows).
Installation:
Replace all sealing rings.
Fig. 424: Locating M6 Screws On Left And Right

Assemble engine.
2010 BMW M3
THERMOSTAT AND CONNECTOR

11 53 000 REMOVING AND INSTALLING/REPLACING COOLANT THERMOSTAT (S65)

Drain coolant. See 17 00 005 DRAINING AND ADDING COOLANT (S65) .
Release unlocking element (1).
Detach vent line (2).
Fig. 425: Identifying Unlocking Element And Vent Line

Disconnect fuel line from fuel rail. See 13 53 240 REPLACING COMPLETE INJECTION PIPE (S65) .
Release screws (2).
Unlock wiring harness of fuel injectors (1).

2010 BMW M3
Fig. 426: Identifying Fuel Injectors And Screws

Clip injection pipe (1) out of holder (2).
Lay injection pipe, cylinders 5 to 8, to one side.
Fig. 427: Identifying Injection Pipe And Holder

Disconnect plug connection (1) on coolant temperature sensor.
Disconnect plug connection (2) on solenoid valve.

2010 BMW M3
Fig. 428: Identifying Solenoid Valve Plug Connection And Coolant Temperature Sensor Plug Connection
Release screws (1).
Installation:

Remove thermostat housing with thermostat forwards in direction of arrow.

2010 BMW M3
Fig. 430: Removing Thermostat Housing With Thermostat

Remove thermostat (1).
Check rubber section (2) for damage.
Remove connecting pipes (2).
Installation:
Replace all O-rings on connecting pipes.
Fig. 431: Identifying Thermostat And Rubber Section

Assemble engine.
Vent cooling system and check for leaks. See 17 00 039 VENTING COOLING SYSTEM AND
CHECKING FOR WATER LEAKS (S65) .
2010 BMW M3
INTAKE MANIFOLD
11 61 050 REMOVING AND INSTALLING AIR INTAKE MANIFOLD (S65)
00 9 250
IMPORTANT: Do not use antiseize agents to install the air intake manifold.
Remove air cleaner housing. See 13 71 000 REMOVING AND INSTALLING/REPLACING

Disconnect plug connection (1) on intake air temperature sensor.
Fig. 432: Identifying Intake Air Temperature Sensor Plug Connection

Unlock hose (2) for idle actuator incoming air at fastener (1) and detach in direction of arrow.
2010 BMW M3
Fig. 433: Identifying Idle Actuator Incoming Air Fastener And Hose
Unlock hose (2) for condensate drain line at fastener (1) and detach in direction of arrow.
Fig. 434: Identifying Condensate Drain Line Fastener And Hose

Installation:
Each hose clamp on the decoupling element is exactly positioned.
Secure hose clamps with special tool 00 9 250 .
Tightening torque: 11 61 1AZ . See INTAKE MANIFOLD .
NOTE: Picture shows hose clamps (1 to 3).

2010 BMW M3

Release hose clamp (1) on cylinder 4.
Fig. 436: Identifying Hose Clamp On Cylinder 4

Release hose clamp (1) on cylinders 5 to 8.
Remove intake air manifold towards top.

2010 BMW M3
Fig. 437: Identifying Hose Clamp (1) On Cylinders 5 To 8

IMPORTANT: Do not lay any tools or foreign bodies in intake area.

Risk of damage to throttle valves / engine.
Fig. 438: Identifying Throttle Valves

AIR PUMP LINES

11 72 000 REMOVING AND INSTALLING/REPLACING SECONDARY-AIR PUMP (S65)

2010 BMW M3
Release screws (arrow) on holding frame.
Release nuts on secondary-air pump.
Unlock and detach both air hoses.
Lift out secondary-air pump.
Remove holding frame from secondary-air pump.
Fig. 439: Locating Secondary-Air Pump Nuts

Assemble engine.
11 72 060 REMOVING AND INSTALLING/REPLACING BOTH SECONDARY-AIR VALVES (S65)
Carry out system test: secondary air with BMW diagnosis system.
Disconnect battery at negative lead. See 61 20 900 DISCONNECTING AND CONNECTING
Remove left exhaust manifold. See 18 40 010 REMOVING AND INSTALLING/REPLACING
Remove right exhaust manifold. See 18 40 020 REMOVING AND INSTALLING/REPLACING
RIGHT EXHAUST MANIFOLD (S65) .
Remove secondary-air pump.
Unfasten engine wiring harness partially and lay to one side. See 12 51 001 REPLACING WIRING
2010 BMW M3
Unscrew nuts (1).
Installation:
Replace seal.

Unscrew nuts (1).
Installation:
Replace seal.
2010 BMW M3

Assemble engine.
Carry out system test: secondary air.
EMISSION CONTROL OXYGEN SENSOR

11 78 530 REPLACING LEFT LAMBDA OXYGEN CONTROL SENSOR (S65)
11 7 030


Pull plug connection (1) from holder (2).

2010 BMW M3
Fig. 442: Identifying Plug Connection And Holder

Remove oxygen control sensor with special tool 11 7 030 .
If the oxygen control sensor is reused, apply a thin and even coat of Never Seez Compound to the thread only.
The part of the oxygen control sensor which projects into the exhaust system branch (sensor ceramic) must not
Secure oxygen control sensor with special tool 11 7 030 and a torque wrench (1).
Tightening torque: 11 78 1AZ . See EMISSION CONTROL .
Fig. 443: Securing Oxygen Control Sensor With Special Tool (11 7 030) And Torque Wrench
11 78 533 REPLACING RIGHT OXYGEN CONTROL SENSOR (S85)

2010 BMW M3
11 7 030


Unclip oxygen sensor cable (1).
Release screws (2).
Fig. 444: Identifying Oxygen Sensor Cable And Screws

11 78 540 REPLACING LEFT MONITOR SENSOR (S65)
11 7 030

2010 BMW M3
Read out fault memory in Digital Motor Electronics (DME)

Remove transmission underbody protection
Remove monitor sensor with special tool 11 7 030 .
Installation:
If the monitor sensor is reused, only apply a thin and uniform coat of Never Seez Compound to thread.
Fig. 445: Identifying Plug Connection And Monitor Sensor

IMPORTANT: Reinstall plug connection (1) and cable routing without fail in condition on
delivery (see illustration).
Risk of damage if this instruction is not observed!
Secure monitor sensor (2) with special tool 11 7 030 and a torque wrench.
11 78 543 REPLACING RIGHT LAMBDA OXYGEN MONITOR SENSOR (S65)

2010 BMW M3
11 7 030


Remove oxygen monitor sensor with special tool 11 7 030 .
Installation:
If the oxygen monitor sensor is reused, apply a thin and even coat of Never Seez Compound to the thread only.
Fig. 446: Removing Oxygen Monitor Sensor With Special Tool (11 7 030)
Secure oxygen monitor sensor with special tool 11 7 030 and a torque wrench.

2010 BMW M3

2010 BMW M3
ENGINE Engine Electrical System - Repair
ENGINE
Engine Electrical System - Repair
TROUBLESHOOTING
61 20... BATTERY REPLACEMENT INFORMATION
A vehicle battery is constructed for the installation location and the individual power requirements of the
particular vehicle. These individual power requirements depend on the motorization and different types of
optional equipment. The individually assigned vehicle battery is the ideal compromise between the power
requirements of the vehicle electrical system and the weight and service life of the vehicle battery.
Vehicles with the automatic engine start-stop function or particular motorization and optional equipment are
equipped with a special vehicle battery (AGM battery), since only this battery type can provide elevated power
requirements over the extended service life. Installing a different vehicle battery can cause problems with
vehicle electronics, can reduce functions or can cause leakage of battery acid.
In the event of an accident where the airbags are deployed in vehicles with a vehicle battery in the luggage
compartment, the electrical connection between the vehicle battery and the trigger is automatically disconnected
through pyrotechnics. This prevents a possible short circuit.
Proper operation of all of these safety and convenience functions requires a battery that conforms with
specifications and that is properly registered in vehicles with energy management systems (IBS, power module).
Vehicles with energy management systems (IBS, power module): Register battery replacement
The vehicle electrical system is informed about the vehicle battery characteristic data, such as type, size, age
and current power capacity. Therefore, only one work scope will be provided that is permitted by the current
status of information.
When installing a new vehicle battery, the battery must be registered and thus must also be registered with the
vehicle electrical system.
Diagnosis system:
Register battery replacement
Service functions
Body
Voltage supply
Test plan
When retrofitting, a more powerful battery may be used. Standard batteries may always be replaced by AGM
batteries with the same specifications.
2010 BMW M3
When installing a battery of a different size or a different battery type, this change in vehicle data must be
programmed into the vehicle data in accordance with specifications.
Programming system:
Battery retrofitting
12 00... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY
Observe SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY .
Before disconnecting battery
Turn off the ignition and other electrical loads/consumers to prevent sparking when reconnecting.
NOTE: If the ignition is not turned off when the battery is disconnected, fault memories
may be set in some control units.
IMPORTANT: There is a danger of mixing up battery leads: If the battery positive and
negative leads are the same color and you are in doubt, follow the polarity
to the battery, then mark and cover the leads.
On vehicles with radio code: After disconnecting the battery, the radio
code must be re-entered. Therefore obtain the radio code card from the
customer beforehand. Note stored stations and restore them after
connecting the battery.
Stored settings of the on-board computer and clock will also be lost.
All available central keys must be recoded for cars with first generation
infrared transmitter locking systems.
General notes on disconnecting battery
Do not disconnect battery leads and leads from alternator and starter motor while engine is running.
Cars with IBS on battery negative terminal:
Do not under any circumstances pull/lever off pole shoes by force.
Do not under any circumstances release socket-head cap screw of IBS.
Detach TERMINAL OF BATTERY NEGATIVE lead from car battery and second battery if fitted.
Cover battery negative terminal(s) and secure.
When work is carried out on the electrical system, faults may be caused in the fault memories of some
control units when the battery is connected.
When installing battery terminal: Tightening torque 61 21 1AZ .
2010 BMW M3
After connecting battery
IMPORTANT: The scope of application of some systems may be restricted after a power
supply interruption.
Likewise, individual settings may be lost.
Settings or activations must be carried out, depending on the equipment
specification.
For example:
Vehicles with AUTOMATIC ENGINE START-STOP FUNCTION (MSA) :
MSA function is active only after learning period (vehicle must not be
woken for a period of approx. 6 hours) > if necessary, notify customer of
the situation
E46 Perform (four-wheel drive)/E53/E83: STEERING ANGLE SENSOR

ADJUSTMENT
If necessary, carry out ADJUSTMENT OF ACTIVE STEERING
If necessary, activate slide/tilt sunroof See 54 0... NOTES ON GLASS
SLIDE/TILT SUNROOF (INITIALIZATION/NORMAL OF CHARACTERISTIC
CURVE)
If necessary, activate power windows See 6762... NOTES ON INITIALIZING
POWER WINDOW UNIT IN FRONT DOOR or 6762... NOTES ON
INITIALIZING POWER WINDOW UNIT IN FRONT DOOR
If necessary, activate MIRROR WITH COMPASS
Please refer to the Progman user documentation for further information on vehicle-specific activation.
Vehicles with a two-battery system
Starter and system battery
A two-battery system has a starter battery circuit and a system battery circuit. An auxiliary control unit monitors
both battery circuits. Depending on the situation, the battery circuits are connected to or isolated from the
auxiliary control unit via an cut-off relay.
Two AGM batteries, whose design and properties are described in AGM BATTERIES , are used as a storage
battery.
IMPORTANT: These batteries must not under any circumstances be charged with a voltage in
excess of 14.8 V. Rapid programs must not be used either.
Receiving/giving starting aid via jump start terminal point
The engine can be jump-started with an external voltage supply via the jump start terminal on the right side of
2010 BMW M3
the engine compartment.
NOTE: The starter battery is isolated from the alternators when the engine hood/bonnet
is open.
Giving starting assistance via the jump start terminal is thus limited by the capacity of the starter battery when
the engine hood/bonnet is open.
Charging starter and system batteries via jump start terminal point
The starter battery is charged as a matter of priority with a charger connected to the jump start terminal. The
voltage at the starter battery is the decisive factor in determining whether the system battery is also included in
the charging operation. The auxiliary control unit automatically detects a charging operation at a charging
voltage at the starter battery of > or = 13.5 V. The cut-off relay is closed and thus the system battery is
connected in parallel. Both batteries are now charged.
Prerequisite:
Terminal 61 inactive
If terminal 15 becomes "active" during the charging operation, the cut-off relay is opened immediately and
again only the starter battery is charged.
NOTE: When the engine hood is open, the cut-off relay is also opened in normal
operation when the engine is running.
A special mode can be set by means of diagnosis for workshop/garage
operation. The cut-off relay is closed from terminal R in this operating mode.
This mode is automatically reset once a distance of 5 km has been driven.
Trickle charging
The increased standby current consumption can be compensated for via the jump-start connection point with the
aid of the "Acctiva easy" battery trickle charger.
IMPORTANT: The cigarette lighter is isolated from the electrical system after terminal R
"OFF" on a timed basis (60 mins.), thereby interrupting charging of the system
battery via the cigarette lighter. This is prevented if the battery switch (on the
right side of the luggage compartment behind the panel) is turned on and off
again twice within 2 seconds. (Cigarette lighter battery charging function).
12 00... INSTRUCTIONS FOR WORKING ON THE IGNITION SYSTEM
CAUTION: Always switch off ignition before working on ignition system.

Use only test leads which have been approved and belong to these testing
2010 BMW M3
instruments (e.g. DIS Tester).

Comply with operating instructions of the respective testing instrument
used.
Comply with the country-specific safety regulations.
Never touch components under current with engine running!
Comply with instructions of DIS tester.
Do not connect any suppression capacitors or inspection lamps to
terminal 1 on the ignition coil.
Terminal 1 of ignition coil must not be connected to ground or battery
positive lead.
If an alarm system is subsequently installed, lead of terminal 1 must not be
used for start prevention.
When working on ignition system, always disconnect supply leads to
ignition coils.
High tension! - High tension!
IMPORTANT: Hazardous voltages occur at:
Ignition lead
spark-plug connectors
spark plugs
Ignition coil (high voltage at terminal 4 is approx. 40 kV)
Lead of terminal 1 from ignition coil to DME control unit (high voltage approx. 350 V)
12 13 NOTES ON CHECKING IGNITION SYSTEM
Troubleshooting
Fault in fuel injection system

Spark plug faults
Ignition coil faults
Further fault patterns with evaluation
Additional fault notes for troubleshooting
Oscillograms
Normal oscillogram
Oscillograms of ignition coils from different manufacturers
Check
Secondary signal for stationary ignition distribution

2010 BMW M3
61 00... NOTES ON HANDLING WIRING HARNESSES AND CABLES
The following applies in general:
To avoid damage, observe the following instructions:
Avoid compressive and tensile loads

Make sure cables are laid without kinks or abrasions
Ensure non-contacting routing at sharp-edged body components; use edge protection if necessary
Secure additionally laid cables/lines with cable straps
The following additionally applies
Shielded lines
Contact points in the shield can cause problems with regard to noise radiation and interference immunity.
Consequently, distinctions have to be drawn between the following types:
Coaxial line
Shielded RTK031 coaxial lines may only be repaired with special Crimping tool for repairing the coaxial
line.
CVBS lines
CVBS lines may not be repaired.

CVBS lines must be replaced in their entirety.
HSD lines
HSD lines may not be repaired.

HSD lines must be replaced in their entirety.
Optical fibre cable:
NOTE: Optical fibre cables are colored differently as follows:
Green = MOST (M edia O riented S ystems T ransport) optical fibre

Yellow = ISIS (I ntelligent S afety I ntegration S ystem) optical fibre
Orange = repair optical fibre cables
IMPORTANT: Optical fibre cables are permitted to show only one separation point
(bridge), replace optical fibre cables if necessary
Smallest permissible bending radius is 25 mm
2010 BMW M3
Avoid influence of heat > or = 85
TREATING CABLES AND OPTICAL FIBRE CABLES
FlexRay:
It is possible to repair the FlexRay. In the event of damage, the cables can be joined with conventional BUTT
CONNECTORS .
NOTE: The line is a twisted cable. If possible, maintain twist in line after repair.
Airbag lines:
REPAIRING AIRBAG CABLES
Ribbon cables:
REPAIRING RIBBON CABLES Z
12 00... NOTES/INFORMATION ON REMOVING AND INSTALLING CONTROL UNITS
IMPORTANT: Disconnecting the vehicle battery will cancel the fault memories of control
units. Consequently, before disconnecting the car's battery, always
interrogate the fault memories. Investigate stored faults and, once any
faults have been remedied, cancel the fault memory.
Control unit plugs should only ever be connected and disconnected while
the ignition is turned off.
The removal and installation of components, relays, fuses etc. can cause
faults to be stored in fault memories capable of self diagnosis. Always
interrogate the fault memories after completing work on the electrical
system.
Investigate stored faults and, once any faults have been remedied, cancel
the fault memory.
If necessary, initialize power window units
When replacing the DME/DDE control unit, observe the following
In each case read out the hardware/software status of the relevant control unit using the BMW diagnosis
system.
Comply with the instructions of the DIS diagnosis system on the steps pertaining to coding and
programming.
On vehicles with electronic vehicle immobilization, comply with the instructions of the BMW diagnosis
2010 BMW M3
system.
Each control unit is programmed with certain basic values, which serve as mean values. The control unit
receives different input values, depending on engine condition, which are compared with the stored
values. The adaptive system compares the input values with the stored map values. The control
commands are routed to the relevant actuators.
If the DME control unit is without current for a long time (more than one hour), its adaptive system loses
the stored values. When a cleared control unit is restarted or a new control unit is installed, the adaptive
system must read in and store the input values of the associated engine as new basic values itself.
This procedure could lead to erratic idling and disturbed overrunning of the engine after starting.
Depending on the engine it could require some time before all values are adapted to the engine condition.
Therefore observe the following procedure before replacing or reinstalling a DME/DDE control unit:
1. If possible before exchanging control unit, run engine up to operating temperature.
2. Exchange control units and run the vehicle at alternating engine speeds.
12 00... NOTES/INFORMATION ON START ASSISTANCE (JUMP STARTING)
Do not start the engine with help of starting sprays.
Preparation
Conform with the following when starting the engine with a jump starting cable.
Ensure that the jump starting cable wires are of appropriate cross-section size.
Only use fuse-protected jump starting cables.
Check whether the current-supplying battery has 12 V voltage.
If the engine is started from the battery of another vehicle, ensure that there is no contact between the
bodies of both vehicles.
IMPORTANT: Never touch electrically live ignition system components: high voltage - danger
of injury!
If the battery in the vehicle supplying power is weak, start the engine of this vehicle and let it run at idling
speed.
Operation
It is essential to conform to the procedures so as to avoid injury to persons or damage to parts.
Automatic transmission: select drive position "P", apply parking brake.

Manual transmission: move gear lever to neutral position, apply parking brake.
Ensure that the jump leads cannot get caught in rotating parts, e.g. fan.
First connect both positive poles of the batteries with one jump starting cable (red).
2010 BMW M3
Use the battery positive terminal in the engine compartment for vehicles with the battery in the luggage
compartment.
Then use the second jump starting cable (black) to connect the negative post of the current-supplying
battery with the earth/ground point (not the negative pole or the body) of the vehicle to be started.
IMPORTANT: Do not connect the second jump starting cable (black) with the negative pole of
the battery in the vehicle to be started. Produced gas could be ignited by
sparks.
Risk of explosion!
After the engine of the vehicle to be started has fired, first disconnect the jump starting cable between the
negative pole and the earth/ground point. Then remove the starting cable from the positive poles.


function is active.


2010 BMW M3
Workshop mode
A = 10 mm
B = 7 mm

IGNITION WIRES, SPARK PLUGS

12 12 011 REPLACING ALL SPARK PLUGS (S65)
Switch off ignition.

REMOVE ALL IGNITION COILS.
IMPORTANT: Wear safety goggles.

Oil and dirt particles may get into your eyes!
Clean spark connector slot with compressed air.
Unscrew spark plugs with special tool 12 1 171 and an extension with a joint.
2010 BMW M3
Installation note:
First, hand-tighten the spark plugs with special tool 12 1 171 and with an extension with a joint into the engine.
Then tighten the spark plugs using a torque wrench, special tool 12 1 171 and an extension with a joint.
Observe tightening torque.
Fig. 3: Removing Spark Plug Using Special Tool (12 1 171)

IGNITION COIL
12 13 NOTES ON CHECKING IGNITION SYSTEM
Troubleshooting
Fault in fuel injection system

Spark plug faults
Ignition coil faults
Further fault patterns with evaluation
Additional fault notes for troubleshooting
Oscillograms
Normal oscillogram
Oscillograms of ignition coils from different manufacturers
2010 BMW M3
Check
Secondary signal for stationary ignition distribution
12 13 512 REMOVING AND INSTALLING/REPLACING ALL IGNITION COILS (S65)
Read out fault memory of DME control unit

Switch off ignition
REMOVE AIR FILTER HOUSING
Release and raise coolant expansion tank, do not kink hoses
Remove ignition coil cover on left and right
Pull off plug (1).
Pull out ignition coil (2) in upward direction with aid of 11 9 980 EXTRACTOR .
This tool is essential to ensure damage-free removal of the ignition coils.
This procedure is applicable to all ignition coils.
Installation
Insert rubber seal on ignition coils between guides in cylinder head cover.
Fig. 4: Identifying Plug And Ignition Coil


Check stored fault messages.
2010 BMW M3
ELECTRONIC SWITCHING
12 14 700 CODING CONTROL MODULE (DME/DDE)
Switch off ignition
Connect MoDiC or DIS/GT1 Tester.
Switch on ignition.
Select "Coding" program.
For subsequent procedure, follow instructions in MoDiC or DIS/GT1 Tester.
Carry out adjustment of following control units:
EWS (electronic immobilizer)

DME (Digital Motor Electronics)
or
DDE (Digital Diesel Electronics)
Refer to "Diagnosis and Coding" service information bulletins on subject of coding.
12 14 705 PROGRAMMING CONTROL UNIT (DME/DDE)
Switch off ignition
Switch on ignition.
Select "Programming".

DME (Digital Motor Electronics)
or

2010 BMW M3
Refer to "Diagnosis and Coding" service information bulletins on subject of programming.
12 90... REMOVING AND INSTALLING/REPLACING ELECTRONICS BOX

NOTE: Follow instructions for REMOVING AND INSTALLING ELECTRONIC CONTROL

UNITS
Read fault memory.

Disconnect NEGATIVE BATTERY CABLE
Remove microfilter housing
Remove tension strut on spring strut dome on right
Release screws (1).
Slacken nut (2).
Lift out right heater end plate (3).
Installation:
Ensure gasket (4) is correctly seated.
Fig. 5: Lifting Out Right Heater End Plate

Unlock fasteners (1) from below and slide upwards approx. 10 mm.
2010 BMW M3
Remove cover (3).
Fig. 6: Opening Locks

Lift out plug connection (2), fuse carrier (3) and wiring harness grommet (4) from electronics box (1).
Installation:
Make sure wiring harness grommets (4) are correctly seated in electronics box (1).
Fig. 7: Identifying Electronics Box With Plug Connection, Fuse Carrier And Wiring Harness Grommet
Unlock DME control unit at holders (1) and raise slightly.
Pull tab (3) in direction of arrow out of housing and disconnect plug connections (2) on DME control unit.
2010 BMW M3
Fig. 8: Pulling DME Control Unit Tabs

If necessary, press locking tabs (1) in direction of arrow and pull contact carrier (2) out of housing.
Fig. 9: Pressing Carrier Locking Tabs

If necessary, press locking tab (1) in direction of arrow and pull contact carrier (2) out of housing.
2010 BMW M3

Unlock device holder (2) at holder (1) and remove.
Remove DME control unit (3).
Fig. 11: Identifying DME Control Unit With Holders


2010 BMW M3
Fig. 12: Identifying DME Control Unit Holders

Remove device holder (1) from electronics box.
Fig. 13: Identifying DME Control Unit Holder

Release screws (1).
Replacement
Modify water drain valve (2) and bump stop (3).

2010 BMW M3
Fig. 14: Identifying Screws, Water Drain Valve And Bump Stop
Installation:
Make sure gasket (1) is correctly seated on electronics box.
Fig. 15: Identifying Electronics Box Gasket

12 63 520 REPLACING DME MASTER RELAY (S65)
Switch off ignition

Open electronics box, refer to REMOVING CONTROL UNIT
Remove DME master relay (1).

2010 BMW M3
Fig. 16: Identifying DME Master Relay

Notes on troubleshooting:
If the starter motor cranks the engine during the starting sequence but the engine fails to fire, then:
1. Check engine fuses

2. If the fuses have blown, replace them completely with the fuse holder
3. Find out why fuses have blown
Continue troubleshooting as per DIS instructions.
12 14 550 REPLACING CONTROL UNIT (DME) (S65)

DISCONNECT BATTERY .
Remove lower section of MICROFILTER HOUSING on right.
IMPORTANT: Follow instructions for REMOVING AND INSTALLING CONTROL UNITS

Replacement:
IMPORTANT: It is absolutely essential to read out the fault memory with the MoDiC or the
BMW DIS and to create a fault memory printout Switch off ignition.
Unlock locks (2) in direction of arrow.

2010 BMW M3
Remove cover (3).

Unlock plug (1) and remove.
Release grommet (2) from electronics box.
Installation:
Make sure grommet (2) is correctly seated in housing (watertightness).
Unlock control unit (3) and raise slightly.
Fig. 18: Identifying Electronics Box Grommet, Control Unit And Connector
Unlock plugs (1) using slide in direction of arrow and remove.
Remove control unit (2).

2010 BMW M3
Installation:
Replacement:
Note device identification number and coding.
Fig. 19: Unlocking Plug Connectors

NOTE: Check stored fault message.
12 90 100 REPLACING FAN FOR ELECTRONICS BOX

Follow INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .
Disconnect BATTERY ground terminal.
Detach fuse box in passenger compartment and pull back; to do so, refer to REMOVING FUSE BOX
IMPORTANT: FOLLOW INSTRUCTIONS FOR REMOVING AND INSTALLING ELECTRONIC

CONTROL UNITS .
Pull back carpet.
Release lower nut on fuse carrier holder.
Pull holder slightly towards front.

2010 BMW M3
Fig. 20: Identifying Lower Nut On Fuse Carrier Holder

Disconnect plug connections for fan motor (1).
Release screws (2). Remove fan.
Fig. 21: Identifying Fan Motor With Screws

Read fault memory.
13 62 610 REPLACING PULSE GENERATOR ON CRANKSHAFT/TRANSMISSION (S65)
Read out fault memory of DME control unit; if necessary, work through test schedules
Switch off ignition
REMOVE UNDERBODY PROTECTION
2010 BMW M3
Release screws (1).
Remove cover.

Release screw (1).
Remove pulse generator.

NOTE: Now clear the fault memory.

2010 BMW M3
13 62 604 REPLACING PULSE GENERATOR ON LEFT EXHAUST CAMSHAFT (S65)
(cylinder bank 5 to 8)
Switch off ignition
Remove left ignition coil cover
Release plug connector (1) and pull off.
Release screw.
Remove pulse generator (2).
Installation:
Aluminium screws must always be replaced.
Replace sealing ring and coat with antiseize agent.
Tightening torque, 13 62 5AZ
Fig. 24: Identifying Plug Connector And Pulse Generator

13 62 601 REPLACING PULSE GENERATOR ON LEFT INLET CAMSHAFT (S65)

2010 BMW M3
Switch off ignition
Release screw.
Installation

13 62 605 REPLACING PULSE GENERATOR ON RIGHT EXHAUST CAMSHAFT (S65)

2010 BMW M3
Switch off ignition
Release and raise coolant expansion tank. Do not kink hoses.
Remove right ignition coil cover
Release screw.
Installation:
Aluminium screws must always be replaced.

13 62 602 REPLACING PULSE GENERATOR ON RIGHT INLET CAMSHAFT (S65)
Switch off ignition
2010 BMW M3

Release screw.
Installation:

13 62 607 REPLACING PULSE GENERATOR ON TRANSMISSION (S65)
Switch off ignition
Remove underbody protection See 5147490 REMOVING AND INSTALLING/REPLACING
INSTALLING/REPLACING REAR UNDERBODY PROTECTION
IMPORTANT: Oil emerges when the pulse generator is removed. Catch oil in a suitable
container and dispose of this oil in accordance with country-specific
2010 BMW M3
regulations.
Release screw (1).

NOTE: TOP UP TRANSMISSION FLUID.
13 62 029 REPLACING SUCTION PRESSURE SENSOR ON AIR INTAKE MANIFOLD (S65)

Switch off ignition
REMOVE INTAKE AIR MANIFOLD
REMOVE SECONDARY-AIR PUMP
Release cable duct for engine wiring harness; for information, refer to REMOVING ENGINE WIRING
HARNESS
Remove idle actuator suction hose
NOTE: The installation location for the intake manifold pressure sensor is on the idle
air duct at cylinder no. 8.
2010 BMW M3
Release screws and pull suction pressure sensor (2) out of intake air housing.
Fig. 29: Identifying Plug And Suction Pressure Sensor

Installation:
Check sealing ring for damage, replace if necessary.
When installing, coat sealing ring with suitable antiseize agent.
Fig. 30: Locating Sealing Ring


2010 BMW M3
12 31 009 CHECKING ALTERNATOR (BSD)
Correct connections on charged battery

Correct connections on alternator and starter motor
Good ground connection between engine and body
Tensioned ribbed V-belt
Read out DME/DDE fault memory.
NOTE: The alternator with BSD interface can communicate with the engine control unit
(DME/DDE).
The alternator is not connected to the charge telltale light.
The alternator can identify various faults.
BSD alternator can be recognized by the plug connection on the alternator.
Function selection
Complete vehicle
Drive
Voltage and current regulation
Voltage and current generation
Alternator
Follow instruction in diagnostic program
Oscillogram for a fault-free alternator

2010 BMW M3
Fig. 31: Oscillogram For Fault-Free Alternator

Oscillogram for a faulty alternator
One phase interrupted.
Repair/exchange alternator.
Fig. 32: Oscillogram For Faulty Alternator (One Phase Interrupted)

Interturn fault.
2010 BMW M3
Fig. 33: Oscillogram For Faulty Alternator (Interturn Fault)

Open circuit in negative diode.
Fig. 34: Oscillogram For Faulty Alternator (Open Circuit In Negative Diode)
Short circuit in positive diode.
2010 BMW M3
Fig. 35: Oscillogram For Faulty Alternator (Short Circuit In Positive Diode)
Open circuit in positive diode.
Fig. 36: Oscillogram For Faulty Alternator (Open Circuit In Positive Diode)
Open circuit in exciter diode.
2010 BMW M3
Fig. 37: Oscillogram For Faulty Alternator (Open Circuit In Exciter Diode)
Assemble engine.
Check function of DME/DDE.

(DME/DDE).
Function selection
Complete vehicle
Drive
2010 BMW M3

Alternator
Oscillogram for a fault-free alternator
Fig. 38: Oscillogram For Fault-Free Alternator

Oscillogram for a faulty alternator
Fig. 39: Oscillogram For Faulty Alternator (One Phase Interrupted)

Interturn fault.
2010 BMW M3
Fig. 40: Oscillogram For Faulty Alternator (Interturn Fault)

Fig. 41: Oscillogram For Faulty Alternator (Open Circuit In Negative Diode)
2010 BMW M3
Fig. 42: Oscillogram For Faulty Alternator (Short Circuit In Positive Diode)
Fig. 43: Oscillogram For Faulty Alternator (Open Circuit In Positive Diode)
2010 BMW M3
Fig. 44: Oscillogram For Faulty Alternator (Open Circuit In Exciter Diode)
Assemble engine.
12 31 020 REMOVING AND INSTALLING OR REPLACING ALTERNATOR (S65)
Switch off ignition

Follow INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY
Remove AIR FILTER HOUSING
Remove ALTERNATOR DRIVE BELT
Release screws.
Unclip hoses from hose holders on radiator.
Carefully press leads (1) to one side.

2010 BMW M3
Fig. 45: Pressing Leads

Release screws.
Pull alternator (1) forwards until connections are accessible.
Fig. 46: Pulling Alternator Forward

Release nut (2), remove battery positive lead from alternator.
Pull alternator (3) upwards to remove.
Read fault memory.

2010 BMW M3
Fig. 47: Removing Nut Using Special Tool (12 7 110)

12 31... REPLACING ALTERNATOR BELT PULLEY
Remove and install alternator drive belt.
Depending on alternator type, grip shaft with:
hexagon socket
multi-tooth socket or
Torx socket wrench
Release nut with special tool 12 7 110 SOCKET WRENCH INSERT .
Installation:
TIGHTENING TORQUE, 12 31 2AZ/12 31 3AZ .

2010 BMW M3
12 31... REPLACING ALTERNATOR BELT PULLEY (WITH OVERRUNNING CLUTCH)
Grip alternator shaft with:
internal serration
Release nut using Special Tool 12 7 120.
Installation:

ALTERNATOR WITH DRIVE

12 31... REPLACING ALTERNATOR BELT PULLEY
12 7 110
hexagon socket
Torx socket wrench
2010 BMW M3
Installation:
Tightening torque, 12 31 2AZ / 12 31 3AZ , see 12 31 ALTERNATOR WITH DRIVE AND MOUNTING
PARTS .
Fig. 50: Releasing Nut With Special Tool (12 7 110)

12 31... REPLACING ALTERNATOR BELT PULLEY (WITH OVERRUNNING CLUTCH)
12 7 120
internal serration
Release nut with special tools 12 7 120 .
Installation:
Tightening torque 12 31 3AZ , see 12 31 ALTERNATOR WITH DRIVE AND MOUNTING PARTS .
2010 BMW M3
Fig. 51: Identifying Special Tools (12 7 120) And (12 31 3AZ)

(DME/DDE).
Function selection
Complete vehicle
Drive
Alternator
Oscillogram for a fault-free alternator:

2010 BMW M3
Fig. 52: Oscillogram Graph For Fault-Free Alternator

Oscillogram for a faulty alternator:
Fig. 53: Oscillogram Graph For Faulty Alternator - One Phase Interrupted
Interturn fault.
2010 BMW M3
Fig. 54: Oscillogram Graph For Faulty Alternator - Interturn Fault

Fig. 55: Oscillogram Graph For Faulty Alternator - Open Circuit In Negative Diode
2010 BMW M3
Fig. 56: Oscillogram Graph For Faulty Alternator - Short Circuit In Positive Diode
Fig. 57: Oscillogram Graph For Faulty Alternator - Open Circuit In Positive Diode
2010 BMW M3
Fig. 58: Oscillogram Graph For Faulty Alternator - Open Circuit In Exciter Diode
Assemble engine.
Switch off ignition

Disconnect BATTERY NEGATIVE LEAD.
Remove air filter housing . See 13 71 000 REMOVING AND INSTALLING/REPLACING
Remove underbody protection . See 5147 FLOOR, LUGGAGE COMPARTMENT, ENGINE
COMPARTMENT, TRIM PANELS .
Remove alternator drive belt . See 11 28 010 REPLACING ALTERNATOR DRIVE BELT (S65) .
Release screws.

2010 BMW M3
Fig. 59: Locating Screws

Release screws.
Fig. 60: Identifying Alternator

Tightening torque 12 31 1AZ , see 12 31 ALTERNATOR WITH DRIVE AND MOUNTING PARTS .
Read fault memory.

2010 BMW M3
Fig. 61: Identifying Alternator, Plug And Nut

REGULATOR
12 32 501 REPLACING VOLTAGE REGULATOR
Switch off ignition

Remove alternator
Bosch:
Release protective caps (1).
Fig. 62: Identifying Protective Caps

2010 BMW M3
Bosch:
Release screw (1) and nuts (2), remove cover.
Fig. 63: Identifying Screw And Nuts

Bosch:
Release screws and remove regulator switch (1) in direction of arrow.
Fig. 64: Removing Regulator Switch

Bosch:
Installation
Clean contact surfaces and check pretension of contact spring, replace regulator switch if necessary.
Measurement A = min. 5 mm.

2010 BMW M3
Check collector ring for wear and recondition if necessary.
Fig. 65: Checking Contact Spring Pretension And Collector Ring

Valeo:
Slacken nut (1).
Slacken nut (2).
Release screws (3).
Release cover (4).
Fig. 66: Identifying Nut, Screw And Cover

Valeo:
Release screws.
2010 BMW M3
Remove regulator switch (1) towards top.
Fig. 67: Locating Regulator Switch Screws

Valeo:
Installation
Fig. 68: Checking Regulator Switch

Installation:
Fit new regulator (1) with attached mounting sleeve (2) or locked carbon brush.
2010 BMW M3
Pull off mounting sleeve (2) and replace with cover (3).
Fig. 69: Identifying Regulator, Mounting Sleeve And Cover

STARTER WITH MOUNTING

12 41 020 REMOVING AND INSTALLING/REPLACING STARTER (S65)
Switch off ignition

Disconnect BATTERY NEGATIVE LEAD and cover
Remove IDLE ACTUATOR
Remove THROTTLE VALVE ACTUATING MOTOR on left
Remove idle actuator mounting.

2010 BMW M3
Fig. 70: Locating Idle Actuator Mounting

Unfasten nut.
Remove battery positive lead (2).
Fig. 71: Identifying Plug And Battery Positive Lead

Release screw (1).
Release screws (2).
Pull starter motor out of transmission mount and remove.

2010 BMW M3

Installation
Check starter pinion and ring gear for damage, replace damaged parts if necessary.
12 41 041 REPLACING SOLENOID SWITCH
Turn off ignition
STARTER LEAD
12 42 510 REPLACING BATTERY POSITIVE LEAD (BETWEEN STARTER AND B+ TERMINAL)
(S65)
Read fault memory. Switch off ignition
OBSERVE INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .
Disconnect battery negative lead from battery and lay to one side.
REMOVE INTAKE AIR MANIFOLD .
Release and raise cable duct for engine wiring harness; refer to REMOVING ENGINE WIRING HARNESS
Release nut (2) on B+ lead.

2010 BMW M3
Remove B+ leads.
Installation:

Release clamp for B+ lead on cylinder no. 4.
Unclip lead from cable holders.
Fig. 74: Unclipping Lead From Cable Holders

Remove cover from B+ terminal. Unfasten nut. Remove B+ lead.
Installation:
2010 BMW M3
Fig. 75: Identifying Battery Positive Lead On Battery Positive Terminal

Interrogate fault memory of DME control unit.
Rectify faults and clear fault memory.
ENGINE WIRING LOOM

12 51... EXCHANGING PLUG-IN CONTACT OF COOLANT TEMPERATURE SENSOR (S65)
Read out the fault memory of the DDE control unit.

Follow instructions for disconnecting and connecting BATTERY.
Disconnect BATTERY EARTH LEAD and cover.
Remove INTAKE PLENUM .
Carefully open locks on cable duct.

2010 BMW M3
Fig. 76: Locating Cable Duct Locks

Carefully lift the front of the upper part of the cable duct by approx. 10 cm and secure, e.g. with panel wedge set
00 9 310 or a screwdriver.
Fig. 77: Securing Duct In Lifted Position Using Special Tool 00 9 310
Unlock connector (1) from coolant temperature sensor and pull off.
2010 BMW M3
Fig. 78: Identifying Coolant Temperature Sensor Connector

The cable repair kit consists of:
Length of corrugated tubing (1) 60 mm.

Heat-shrink tubing (2).
Chamber 1, brown cable.
Chamber 2, yellow/green cable.
Crimp connectors (3).
Fig. 79: Identifying Cable Repair Kit Components

Cut lines of engine wiring harness for coolant temperature sensor according to the repair kit (1) and strip
insulation.
2010 BMW M3
Fig. 80: Identifying Repair Kit

Connect cable ends of repair kit and engine wiring harness with crimp connectors (1).
Crimp the crimp connectors with suitable pliers.
Fig. 81: Connecting Cable Ends Of Repair Kit And Engine Wiring Harness With Crimp Connectors
Pull heat-shrink tubing (1) over the crimped cable ends.
Bond heat-shrink tubes watertight with hot-air blower.
IMPORTANT: Make sure that no cables are damaged by the hot air blower!
2010 BMW M3
Fig. 82: Pulling Heat-Shrink Tubing Over Crimped Cable Ends

Insert wiring harness in cable duct and secure with cable strap. Close cable duct again.
Fig. 83: Inserting Wiring Harness In Cable Duct And Securing With Cable Strap
Delete fault memory of DDE control unit.
Assemble engine.
12 51 001 REPLACING WIRING HARNESS SECTION FOR ENGINE (S65)
Read out fault memory of control unit of Digital Engine Electronics (DME)
Switch off ignition
2010 BMW M3
Disconnect BATTERY
Remove SECONDARY-AIR PUMP
Unlock all plug connections in electronics box and disconnect
Release nuts at cable duct (1).
Fig. 84: Locating Cable Duct Nuts

WIRE HARNESSING REPLACEMENT PROCEDURE

Work step Note:
Unlock plug on A/C compressor and disconnect
Disconnect plug connection, exhaust VANOS, bank 1
Disconnect plug connection on oil pressure switch
Disconnect plug connection, inlet VANOS, bank 1
Disconnect plug connections for both camshaft sensors, bank 1
Disconnect plug connections for ignition coils 1, 2 and 3
Release grounding cable
Disconnect plug connection, ignition coil 4
Disconnect plug connections on injectors 1-4
Release B+ lead holder
Disconnect plug connections, oxygen sensors
Disconnect plug connections in electronics box
Disconnect BSD lead on alternator
If necessary, disconnect B+ lead on alternator Tightening torque 12 31 1AZ .
2010 BMW M3
Disconnect plug connection, coolant temperature sensor

Disconnect plug connection, extension, Hall sensor, bank 2
Disconnect plug connection for ignition coil 8
Disconnect plug connections for injectors 5-8
Disconnect plug connection for air-mass sensor, secondary air
Disconnect plug connection, secondary-air pump
Disconnect plug connection, throttle valve actuating motor, bank 2
Disconnect plug connection, extension, pressure sensor/starter
Disconnect plug connection, idle actuator
Disconnect plug connection, tank venting valve
Lower transmission See 2300018 REMOVING AND INSTALLING TRANSMISSION (GS6-53BZ) (S65)
or 2800001 REMOVING AND INSTALLING TWIN CLUTCH TRANSMISSION (GS7D36SG) S65
Release bracket on underside of transmission.
Lay wiring harness, oxygen sensor plug, oil level sensor and crankshaft sensors over bracket or right catalytic
converter.
Feed out cable towards top.
Remove wiring harness.
Installation:
Pay attention to cable routing/mounting points.
OIL PRESSURE, OIL TEMPERATURE, OIL GAUGE

12 61 285 REMOVING AND INSTALLING/REPLACING OIL LEVEL SENSOR FOR ENGINE OIL
(S65)


2010 BMW M3
Switch off ignition

Drain off ENGINE OIL
Release connector (1) and remove.
Unscrew nuts.
Remove oil level sensor (2).
Installation note:
Clean sealing surface on oil sump.
Replace gasket on oil level sensor.
An excessively low torque value will result in oil leaks.
An excessively high torque value will result in damage to the oil level sensor.
Top up engine oil.
Fig. 85: Identifying Oil Level Sensor And Connector

12 61 280 REPLACING OIL PRESSURE SWITCH (S65)
Switch off ignition

2010 BMW M3
Unlock plug and remove
Remove oil pressure switch.
Installation:
Fig. 86: Removing Oil Pressure Switch

NOTE: Check and clear fault memory.
SWITCHES AND RELAYS

Switch off ignition

Open electronics box, refer to REMOVING CONTROL UNIT

2010 BMW M3


CONTROL UNIT BOX

12 90... REMOVING AND INSTALLING/REPLACING ELECTRONICS BOX

NOTE: Follow instructions for REMOVING AND INSTALLING ELECTRONIC CONTROL

UNITS
Read fault memory.

Remove microfilter housing
Release screws (1).

2010 BMW M3
Slacken nut (2).
Installation:

Remove cover (3).

2010 BMW M3
Installation:
Fig. 90: Identifying Electronics Box With Plug Connection, Fuse Carrier And Wiring Harness Grommet
Fig. 91: Pulling DME Control Unit Tabs

2010 BMW M3



2010 BMW M3
Fig. 94: Identifying DME Control Unit With Holders

Fig. 95: Identifying DME Control Unit Holders


2010 BMW M3
Fig. 96: Identifying DME Control Unit Holder

Release screws (1).
Replacement
Fig. 97: Identifying Screws, Water Drain Valve And Bump Stop
Installation:

2010 BMW M3


Follow INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .
Disconnect BATTERY ground terminal.
Detach fuse box in passenger compartment and pull back; to do so, refer to REMOVING FUSE BOX
IMPORTANT: FOLLOW INSTRUCTIONS FOR REMOVING AND INSTALLING ELECTRONIC

CONTROL UNITS .
Pull back carpet.

2010 BMW M3
Fig. 99: Identifying Lower Nut On Fuse Carrier Holder

Fig. 100: Identifying Fan Motor With Screws

Read fault memory.

2010 BMW M3
ENGINE Engine Electrical System - Repair - M3
ENGINE
Engine Electrical System - Repair - M3
TROUBLESHOOTING
12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY
Observe safety instructions for handling vehicle battery. See 61 00 ... SAFETY INSTRUCTIONS FOR
HANDLING VEHICLE BATTERY .
Before disconnecting battery:
negative leads are the same colour and you are in doubt, follow the
polarity to the battery, then mark and cover the leads.
All available central keys must be recorded for cars with first generation
General notes on disconnecting battery:
Detach terminal of battery negative lead from car battery and second battery if fitted. Cover battery
negative terminal(s) and secure.
When installing battery terminal: Tightening torque 61 21 1AZ , see 61 21 BATTERY WITH
TERMINAL .
2010 BMW M3
After connecting battery:
Settings or activations must be carried out, depending on the equipment specification.
Example:
Vehicles with automatic engine start-stop system (MSA):
MSA function is active only after learning period (vehicle must not be woken for a period of approx. 6
hours) > if necessary, notify customer of the situation
E46 (AWD)/ E53/ E83: Carry out steering angle sensor adjustment
If necessary, carry out adjustment of active front steering
If necessary, activate sliding sunroof
If necessary, activate power windows
If necessary, activate mirror with compass
Starter and equipment batteries
A two-battery system has a starter battery circuit and an equipment battery circuit. A supplementary control unit
monitors both battery circuits. Depending on the situation, the battery circuits are connected to or isolated from
the supplementary control unit via an isolating relay.
Two AGM batteries, whose design and properties are described in AGM batteries , are used as a storage
battery.
Receiving/giving starting assistance via jump start terminal
is open.
2010 BMW M3
Charging starter and equipment batteries via jump start terminal
voltage at the starter battery is the decisive factor in determining whether the equipment battery is also included
in the charging operation. The supplementary control unit automatically detects a charging operation at a
charging voltage at the starter battery of > or = 13.5 V. The isolating relay is closed and thus the equipment
battery is connected in parallel. Both batteries are now charged.
Prerequisite:
If terminal 15 becomes "active" during the charging operation, the isolating relay is opened immediately and
NOTE: When the engine hood is open, the isolating relay is also opened in normal
operation. The isolating relay is closed from terminal R in this operating mode.
Trickle charging
The increased closed-circuit current consumption can be compensated for via the jump-start connection point
with the aid of the "Acctiva easy" battery trickle charger.
"OFF" on a timed basis (60 mins.), thereby interrupting charging of the
equipment battery via the cigarette lighter. This is prevented if the battery
master switch (on the right side of the luggage compartment behind the panel)
is turned on and off again twice within 2 seconds. (Cigarette light battery
charging function).
12 00 ... INSTRUCTIONS FOR WORKING ON THE IGNITION SYSTEM
CAUTION: Always switch off ignition before working on ignition system.

Use only test leads which have been approved and belong to these testing
instruments (e.g. DIS Tester).
Comply with operating instructions of the respective testing instrument
used.
Comply with the country-specific safety regulations.
Never touch components under current with engine running!
Comply with instructions of DIS tester.
2010 BMW M3
Do not connect any suppression capacitors or inspection lamps to

terminal 1 on the ignition coil.
Terminal 1 of ignition coil must not be connected to ground or battery
positive lead.
If an alarm system is subsequently installed, lead of terminal 1 must not be
used for start prevention.
When working on ignition system, always disconnect supply leads to
ignition coils.
High tension! - High tension!
IMPORTANT: Hazardous voltages occur at:
Ignition lead
spark-plug connectors
spark plugs
Ignition coil (high voltage at terminal 4 is approx. 40 kV)
Lead of terminal 1 from ignition coil to DME control unit (high voltage approx. 350 V)
12 00 ... NOTES/INFORMATION ON REMOVING AND INSTALLING CONTROL UNITS
IMPORTANT: Disconnecting the vehicle battery will cancel the fault memories of control
units. Consequently, before disconnecting the car's battery, always
interrogate the fault memories. Investigate stored faults and, once any
faults have been remedied, cancel the fault memory.
Control unit plugs should only ever be connected and disconnected while
the ignition is turned off.
The removal and installation of components, relays, fuses etc. can cause
faults to be stored in fault memories capable of self diagnosis. Always
interrogate the fault memories after completing work on the electrical
system.
Investigate stored faults and, once any faults have been remedied, cancel
the fault memory.
If necessary, initialize power window units
When replacing the DME/DDE control unit, observe the following:
In each case read out the hardware/software status of the relevant control unit using the BMW diagnosis
system.
Comply with the instructions of the DIS diagnosis system on the steps pertaining to coding and
programming.
2010 BMW M3
On vehicles with electronic vehicle immobilization, comply with the instructions of the BMW diagnosis
system.
Each control unit is programmed with certain basic values, which serve as mean values. The control unit
receives different input values, depending on engine condition, which are compared with the stored
values. The adaptive system compares the input values with the stored map values. The control
commands are routed to the relevant actuators.
If the DME control unit is without current for a long time (more than one hour), its adaptive system loses
the stored values. When a cleared control unit is restarted or a new control unit is installed, the adaptive
system must read in and store the input values of the associated engine as new basic values itself.
This procedure could lead to erratic idling and disturbed overrunning of the engine after starting.
Depending on the engine it could require some time before all values are adapted to the engine condition.
Therefore observe the following procedure before replacing or reinstalling a DME/DDE control unit:
1. If possible before exchanging control unit, run engine up to operating temperature.
2. Exchange control units and run the vehicle at alternating engine speeds.
12 00 ... NOTES/INFORMATION ON START ASSISTANCE (JUMP STARTING)
Preparation:
of injury!
speed.
Operation:

2010 BMW M3
compartment.
sparks.
Risk of explosion!
IGNITION WIRES, SPARK PLUGS

12 12 011 REPLACING ALL SPARK PLUGS (S65)
12 1 171
12 1 172

Remove all ignition coils .
IMPORTANT: Wear protective goggles.

Oil and dirt particles may get into your eyes!
Clean spark plug slot with compressed air.
Unscrew spark plugs with special tool 12 1 171 .
Installation:
Tighten down spark plugs with special tool 12 1 171 and special tool 12 1 172 (torque limiter).
Without special tool 12 1 172 , observe tightening torque.
Tightening torque 12 12 1AZ , see IGNITION WIRES, SPARKPLUGS .

2010 BMW M3
Fig. 1: Tightening Spark Plugs With Special Tools (12 1 171) And (12 1 172)
IGNITION COIL
12 13 512 REMOVING AND INSTALLING/REPLACING ALL IGNITION COILS (S65)
11 9 980

Switch off ignition
Release and raise coolant expansion tank, do not kink hoses
Pull off plug (1).
Pull out ignition coil (2) in upward direction with aid of 11 9 980 .
This tool is essential to ensure damage-free removal of the ignition coils.
This procedure is applicable to all ignition coils.
Installation:
Insert rubber seal on ignition coils between guides in cylinder head cover.
2010 BMW M3
Fig. 2: Identifying Plug And Ignition Coil


ELECTRONIC SWITCHING
12 14 550 REPLACING CONTROL UNIT (DME) (S65)

Disconnect battery . See 61 20 900 DISCONNECTING AND CONNECTING BATTERY
NEGATIVE LEAD .
Remove lower section of microfilter housing on right. See 64 31 063 REMOVING AND
IMPORTANT: Follow instructions for removing and installing control units .
DISCHARGE) .
Replacement:
Carry out programming/coding
IMPORTANT: It is absolutely essential to read out the fault memory with the MoDiC or the
BMW DIS and to create a fault memory printout.
2010 BMW M3
Remove cover (3).
Fig. 3: Unlocking Cover Fasteners

Release grommet (2) from electronics box.
Installation:
Make sure grommet (2) is correctly seated in housing (watertightness).
Unlock control unit (3) and raise slightly.

2010 BMW M3
Fig. 4: Identifying Plug, Grommet And Control Unit

Unlock plugs (1) using slide in direction of arrow and remove.
Installation:
Replacement:
Note device identification number and coding.
Fig. 5: Removing Control Unit

NOTE: Check stored fault message.

12 14 700 CODING CONTROL MODULE (DME / DDE)
Switch on ignition.
Select "Coding" program.

2010 BMW M3
DME (Digital Motor Electronics) or

12 14 705 PROGRAMMING CONTROL UNIT (DME / DDE)
Switch on ignition.
Select "Programming".

DME (Digital Motor Electronics) or
See Replacing Suction Pressure Sensor On Air Intake Manifold (S65) in FUEL SYSTEM - REPAIR
article.
See Replacing Pulse Generator On Left Inlet Camshaft (S65) in FUEL SYSTEM - REPAIR article.
See Replacing Pulse Generator On Right Inlet Camshaft (S65) in FUEL SYSTEM - REPAIR article.
See Replacing Pulse Generator On Left Exhaust Camshaft (S65) in FUEL SYSTEM - REPAIR article.
See Replacing Pulse Generator On Right Exhaust Camshaft (S65) in FUEL SYSTEM - REPAIR article.
See Replacing Pulse Generator On Transmission (S65) in FUEL SYSTEM - REPAIR article.
2010 BMW M3
See Replacing Pulse Generator On Crankshaft/Transmission (S65) in FUEL SYSTEM - REPAIR article.
ALTERNATOR WITH DRIVE

12 31 ... REPLACING ALTERNATOR BELT PULLEY
12 7 110
hexagon socket
Torx socket wrench
Release nut with special tool 12 7 110 .
Installation:
Tightening torque, 12 31 2AZ / 12 31 3AZ , see 12 31 ALTERNATOR .
Fig. 6: Releasing Nut With Special Tool (12 7 110)

12 31 ... REPLACING ALTERNATOR BELT PULLEY (WITH OVERRUNNING CLUTCH)

2010 BMW M3
12 7 120
internal serration
Release nut with special tools 12 7 120 .
Installation:
Tightening torque 12 31 3AZ , see 12 31 ALTERNATOR .
Fig. 7: Identifying Special Tools (12 7 120) And (12 31 3AZ)


(DME/DDE).
2010 BMW M3

Function selection
Complete vehicle
Drive
Alternator
Oscillogram for a fault-free alternator:
Fig. 8: Oscillogram Graph For Fault-Free Alternator

Oscillogram for a faulty alternator:
2010 BMW M3
Fig. 9: Oscillogram Graph For Faulty Alternator - One Phase Interrupted

Interturn fault.
Fig. 10: Oscillogram Graph For Faulty Alternator - Interturn Fault

2010 BMW M3
Fig. 11: Oscillogram Graph For Faulty Alternator - Open Circuit In Negative Diode
Fig. 12: Oscillogram Graph For Faulty Alternator - Short Circuit In Positive Diode
2010 BMW M3
Fig. 13: Oscillogram Graph For Faulty Alternator - Open Circuit In Positive Diode
Fig. 14: Oscillogram Graph For Faulty Alternator - Open Circuit In Exciter Diode
Assemble engine.
Switch off ignition

Follow instructions for disconnecting and connecting battery
2010 BMW M3

Remove underbody protection . See 51 47 490 REMOVING AND INSTALLING / REPLACING
Remove alternator drive belt . See 11 28 010 REPLACING ALTERNATOR DRIVE BELT (S65) .
Release screws.

Release screws.
Fig. 16: Identifying Alternator

2010 BMW M3
Tightening torque 12 31 1AZ , see 12 31 ALTERNATOR .
Read fault memory.
Fig. 17: Identifying Alternator, Plug And Nut

REGULATOR
12 32 501 REPLACING VOLTAGE REGULATOR
Switch off ignition

Notes on removing and installing electronic control units
Remove alternator
Bosch:
Release protective caps (1).

2010 BMW M3
Fig. 18: Identifying Protective Caps

Bosch:
Release screw (1) and nuts (2), remove cover.
Fig. 19: Identifying Cover Screw And Nuts

Bosch:
Release screws and remove regulator switch (1) in direction of arrow.

2010 BMW M3
Fig. 20: Identifying Regulator Switch

Bosch:
Installation:
Fig. 21: Identifying Regulator Switch Dimension

Valeo:
Slacken nut (1).
Slacken nut (2).

2010 BMW M3
Release screws (3).
Release cover (4).
Fig. 22: Identifying Cover, Screws And Nut

Valeo:
Release screws.
Remove regulator switch (1) towards top.
Fig. 23: Identifying Regulator Switch

Valeo:
Installation:
2010 BMW M3
Fig. 24: [Identifying Regulator Switch Dimension]

Installation:
Fit new regulator (1) with attached mounting sleeve (2) or locked carbon brush.
Pull off mounting sleeve (2) and replace with cover (3).
Fig. 25: Identifying Regulator, Mounting Sleeve And Cover

STARTER WITH MOUNTING

12 41 020 REMOVING AND INSTALLING/REPLACING STARTER (S65)

2010 BMW M3
Switch off ignition

Disconnect battery negative lead and cover. See 61 20 900 DISCONNECTING AND CONNECTING
Remove intake air manifold . See 11 61 050 REMOVING AND INSTALLING AIR INTAKE
MANIFOLD (S65) .
Remove idle actuator . See 13 41 550 REPLACING IDLE ACTUATOR (S65) .
Remove throttle valve actuating motor on left. See 13 62 540 REMOVING AND
INSTALLING/REPLACING THROTTLE VALVE ACTUATING MOTOR (S65) .
Remove idle actuator mounting.
Fig. 26: Locating Idle Actuator Mounting Screws

Unfasten nut.
Tightening torque 12 41 1AZ , see STARTER WITH MOUNTING .
Remove battery positive lead (2).

2010 BMW M3
Fig. 27: Identifying Plug And Battery Positive Lead

Release screw (1).
Release screws (2).
Tightening torque 12 41 2AZ , see STARTER WITH MOUNTING .
Pull starter motor out of transmission mount and remove.
Fig. 28: Identifying Transmission Mount Screws

Installation:
Check starter pinion and ring gear for damage, replace damaged parts if necessary.

2010 BMW M3
12 41 041 REPLACING SOLENOID SWITCH
Turn off ignition.
Remove starter motor.
Release nut (1).
Remove cable lug (2).
Fig. 29: Identifying Starter Motor Nut And Cable Lug

CAUTION: Do not turn cable lug (2) while tightening down - risk of short circuit to
starter motor housing.
Tightening torque, 12 41 4AZ , see STARTER WITH MOUNTING .
Release screws (1).

2010 BMW M3
Fig. 30: Identifying Starter Motor Housing Nut

Remove solenoid switch (1) and spring (2).
Unhook pin (3).
Installation:
Check pin (3) for wear and apply grease.
Fig. 31: Identifying Solenoid Switch, Spring And Pin

STARTER LEAD
(S65)
Read fault memory. Switch off ignition.
Observe safety instructions for handling vehicle battery . See 61 00 ... SAFETY INSTRUCTIONS FOR
Observe instructions for disconnecting and connecting battery .
Disconnect battery negative lead from battery and lay to one side.. See 61 20 900 DISCONNECTING AND
MANIFOLD (S65) .
2010 BMW M3
Release and raise cable duct for engine wiring harness.
Remove B+ leads.
Installation:
Fig. 32: Identifying B+ Lead Nut

Fig. 33: Locating B+ Lead Clamp

2010 BMW M3
Installation:
Tightening torque, 12 42 1AZ , see STARTER LEAD .
Fig. 34: Locating B+ Terminal Nut


(S65)
Read fault memory. Switch off ignition.
Observe safety instructions for handling vehicle battery . See 61 00 ... SAFETY INSTRUCTIONS FOR
Observe instructions for disconnecting and connecting battery .
Disconnect battery negative lead from battery and lay to one side.. See 61 20 900 DISCONNECTING AND
MANIFOLD (S65) .
2010 BMW M3
Release and raise cable duct for engine wiring harness.
Remove B+ leads.
Installation:
Fig. 35: Identifying B+ Lead Nut

Fig. 36: Locating B+ Lead Clamp

2010 BMW M3
Installation:
Tightening torque, 12 42 1AZ , see STARTER LEAD .
Fig. 37: Locating B+ Terminal Nut

ENGINE WIRING LOOM

12 51 001 REPLACING WIRING HARNESS SECTION FOR ENGINE (S65)
Read out fault memory of control unit of Digital Engine Electronics (DME)
Switch off ignition
Disconnect battery
MANIFOLD (S65) .
Remove secondary-air pump . See 11 72 000 REMOVING AND INSTALLING/REPLACING
SECONDARY-AIR PUMP (S65) .
2010 BMW M3
Unlock all plug connections in electronics box and disconnect
Release nuts at cable duct (1).
Fig. 38: Locating Cable Duct Nuts

WORK STEP REFERENCE

Work step Note:
Unlock plug on A/C compressor and disconnect
Disconnect plug connection on oil pressure switch
Disconnect plug connection, ignition coil 4
Disconnect plug connections on injectors 1-4
Release B+ lead holder
Disconnect plug connections, oxygen sensors
Disconnect plug connections in electronics box
Disconnect BSD lead on alternator
If necessary, disconnect B+ lead on alternator Tightening torque 12 31 1AZ .
Disconnect plug connection, coolant temperature sensor
2010 BMW M3
Disconnect plug connection for ignition coil 8

Disconnect plug connections for injectors 5-8
Disconnect plug connection for air-mass sensor, secondary air
Disconnect plug connection, secondary-air pump
Disconnect plug connection, extension, pressure sensor/starter
Disconnect plug connection, idle actuator
Disconnect plug connection, tank venting valve
Lower transmission
Release bracket on underside of transmission.
Lay wiring harness, oxygen sensor plug, oil level sensor and crankshaft sensors over bracket or right catalytic
converter.
Feed out cable towards top.
Remove wiring harness.
Installation:
Pay attention to cable routing/mounting points.
OIL PRESSURE OIL TEMPERATURE

Switch off ignition

MANIFOLD (S65) .
Installation:
2010 BMW M3
Tightening torque, 13 62 2AZ , see 13 62 SENSORS (S65) .
Fig. 39: Locating Oil Pressure Switch

12 61 285 REPLACING ENGINE OIL LEVEL SENSOR (S65)
DISCHARGE) .
Switch off ignition

Remove reinforcement plate . See 31 10 010 REMOVING AND INSTALLING/REPLACING
REINFORCEMENT PLATE (M3) .
Drain off engine oil . See 11 00 ... SERVICE - ENGINE OIL (S65) .
Unscrew nuts.
Tightening torque 13 62 3AZ , see 13 62 SENSORS (S65)
Remove oil level sensor (2).
Installation:
Clean sealing face on oil sump.

2010 BMW M3
Replace seal on oil level sensor.
An excessively low torque value will result in oil leaks.
An excessively high torque value will result in damage to the oil level sensor.
Top up engine oil.
Fig. 40: Identifying Oil Level Sensor And Plug

SWITCHES AND RELAYS

Switch off ignition

Open electronics box.

2010 BMW M3


CONTROL UNIT BOX

12 90 ... REMOVING AND INSTALLING/REPLACING ELECTRONICS BOX
DISCHARGE) .
NOTE: Follow instructions for removing and installing electronic control units
Read fault memory.

Remove microfilter housing . See 64 31 063 REMOVING AND INSTALLING/REPLACING
RIGHT LOWER MICROFILTER HOUSING SECTION .
2010 BMW M3
Release screws (1).
Slacken nut (2).
Installation:

Remove cover (3).
Fig. 43: Unlocking Cover Fasteners

2010 BMW M3
Installation:
Fig. 44: Identifying Electronics Box, Plug Connection, Fuse Carrier And Wiring Harness Grommet
Fig. 45: Pulling Tab Out Of Housing

2010 BMW M3
Fig. 46: Pulling Contact Carrier Out Of Housing



2010 BMW M3
Fig. 48: Identifying Device Holder, Holder And DME Control Unit
Fig. 49: Identifying Holder And Device Holder


2010 BMW M3
Fig. 50: Identifying Device Holder

Release screws (1).
Replacement:
Fig. 51: Identifying Screw, Water Drain Valve And Bump Stop
Installation:

2010 BMW M3


Follow instructions for disconnecting and connecting battery .
Disconnect battery ground terminal. See 61 20 900 DISCONNECTING AND CONNECTING
Detach fuse box in passenger compartment and pull back.
IMPORTANT: Follow instructions for removing and installing electronic control units.
Pull back carpet.

2010 BMW M3
Fig. 53: Locating Lower Nut On Fuse Carrier Holder

Fig. 54: Identifying Fan Motor And Screws

Read fault memory.

2010 BMW M3
ENGINE S65B40 Engine - M3
ENGINE
S65B40 Engine - M3
CRANKCASE AND CRANKSHAFT DRIVE

ENGINE BLOCK WITH BEDPLATE CONSTRUCTION
The construction and materials are identical to the S85; the upper low-pressure die-cast crankcase is made from
an aluminum-silicon alloy.
The cylinder bores are formed using exposed hard silicon crystals, rendering the use of cylinder liners
redundant.
The lower crankcase (bedplate) is also constructed using die-cast aluminum. Due to the extreme forces, grey
cast iron inlays are used to reinforce the bedplate construction.
These also limit crankshaft bearing clearances over a greater temperature range and thus have a positive effect
on the oil flow rate.
Fig. 1: S65B40 Engine Block With Bedplate Construction

2010 BMW M3
INDEX EXPLANATION REFERENCE CHART

Index Explanation
1 Engine block (upper section)
2 Grey cast iron inlays
3 Bedplate construction (lower section)
CRANKSHAFT
The five-bearing crankshaft is forged from a single piece, including the two double-chain wheels for driving the
valve gear. The gear wheel for the oil pump drive is flange mounted.
The cylinder spacing is 98 mm. The crankshaft possesses a high level of bend resistance and high torsional
strength at a relatively low weight. The crank pin offset is 90. The diameter of the main bearing journal is 60
mm. The crankshaft end float is controlled by a thrust bearing located at the fifth main bearing.
For design reasons, the firing order 1-5-4-8-7-2-6-3 was chosen for the S65, instead of the firing order 1-5-4-8-
6-3-7-2 more commonly employed in BMW V8 engines.
CONNECTING RODS
The weight-optimized, high tensile steel connecting rods split by fracture separation and the pistons are the
same as those used in the S85 engine. For weight reduction, the upper section of the connecting rod has a
trapezoidal shaped cross-section.
2010 BMW M3
Fig. 2: Identifying S65B40 Crankshaft With Magnification Of Upper Section Of Connecting Rod
NOTE: The large connecting rod eye is asymmetrically ground to reduce the length of
the engine. This means that the installation is direction-specific. For the
workshop, bearing shells are available in a repair stage. The identification
marking of the bearing shells is engraved on the crankcase and on the first
crank web.
PISTONS
A piston is manufactured from a cast aluminum alloy and weighs approximately 480 grams including gudgeon
pin and piston rings. The piston design is the same as the S85 piston (piston shaft with galvanized iron coating
[Ferrostan] and a running-in layer containing tin. The installation position is direction-specific.
2010 BMW M3
Fig. 3: Identifying Piston Components


Index Explanation
1 Pistons
2 Taper-faced ring
3 Gudgeon pin
4 Piston skirt
5 Oil scraper ring (VF system)
6 Compression ring (plain compression ring with spherical contact face)
OIL SUPPLY
Two oil pumps are installed in the S65 engine; the oil return pump, which is driven via a gearwheel by a
crankshaft, and the volume flow-controlled main oil pump, driven via chain drive by the oil return pump.
In the S85, the VANOS high pressure pump is installed instead of the S65 oil return pump, and the S85 oil
return pump is contained in a housing together with the main oil pump (tandem pump).
Since there is no space to install a tandem pump in the S65, the oil return pump has been moved from the main
oil pump housing and installed instead of the VANOS high-pressure pump. This allows the pump drive
principle (crankshaft => gearwheel => pump => chain => pump) to be maintained. As in the S85, the volume
flow-controlled main oil pump is a hinged-valve oil pump with a feed capacity adjusted to suit the VANOS
low-pressure system.
The duocentric design of the oil return pump ensures that oil is always available at the inlet pipe of the main oil
pump in the rear area of the oil pan, even when braking sharply from high speeds.
The electrical oil return pumps installed in the S85 for scavenging the cylinder heads are no longer required,
which results in a further weight saving.
2010 BMW M3
This is made possible by the lower number of cylinders, modification of the oil return routes, and the large
capacity of the oil pan.
The oil pan has a capacity of 8.3 liters (S85 9.3 liters).
The oil supply is also guaranteed at extreme longitudinal and lateral accelerations of up to 1.4 times the normal
gravitational acceleration.
The oil filter housing is installed on the engine.
Fig. 4: Identifying S65B40 Oil Pump Components


Index Explanation
1 Oil intake area of the oil return pump
2 Front, smaller section of the oil pan
3 Main oil pan
4 Oil intake area of the main oil pump
2010 BMW M3
OIL SUPPLY HYDRAULIC CIRCUIT DIAGRAM
Fig. 5: Oil Supply Hydraulic Circuit Diagram

Legend for Oil Supply Circuit Diagram

Index Explanation
1 Cylinder bank 1 VANOS exhaust hydraulic motor
2 Cylinder bank 1 VANOS inlet hydraulic motor
3 Cylinder bank 2 VANOS inlet hydraulic motor
2010 BMW M3
4 Cylinder bank 2 VANOS exhaust hydraulic motor

5 Cylinder bank 1 VANOS exhaust multi-way adjustment valve
6 Cylinder bank 1 VANOS sieve filter (max. 300 m) before multi-way adjustment valve
7 Cylinder bank 1 VANOS inlet multi-way adjustment valve
8 Cylinder bank 2 VANOS inlet multi-way adjustment valve
9 Cylinder bank 2 VANOS sieve filter (max. 300 m) before multi-way adjustment valve
10 Cylinder bank 2 VANOS exhaust multi-way adjustment valve
11 Cylinder bank 1 VANOS non-return valve
12 Cylinder bank 2 VANOS non-return valve
13 Cylinder bank 1 chain tensioner
14 Cylinder bank 1 and 2 non-return valve from chain lubrication
15 Cylinder bank 2 chain tensioner
16 Main oil channel (lubrication points engine block and cylinder head)
17 Oil pressure switch
18 Oil filter bypass valve
19 Oil filter
20 Oil filter outlet aperture
21 Non-return valve
22 Pressure limiting valve
23 Piston cooling nozzles
24 Oil pressure regulation line
25 Volume flow-controlled hinged valve main oil pump
26 Oil return pump
27 Sump
VALVETRAIN
CYLINDER HEAD
The cylinder head is constructed from a single piece of aluminum alloy. To reduce the number of sealing faces,
the secondary air channel has been integrated back into the cylinder head.
The design of the cylinder head is based on the S85. Changes have been made in the front engine compartment
to the VANOS and the timing chain.
The inlet and exhaust tracts have been further airflow-optimized. The integrated idle air channel has been
discontinued and replaced by an idle air bar for each cylinder bank.
As in the S85, the camshafts are manufactured as a hollow-cast, one-piece construction with integrated sensor
gears.
2010 BMW M3
Fig. 6: Identifying S65B40 Cylinder Head Components


Index Explanation
1 Camshaft
2 Bucket tappet with hydraulic valve clearance adjustment
3 Beehive-shaped valve springs
4 Cylinder head
5 Intake passage
6 Valve
7 Connection flange of the integrated secondary air channel
HYDRAULIC BUCKET TAPPET
The weight-optimized valves with a 5 mm shaft diameter and the spherical bucket tappets with hydraulic valve
clearance adjustment are also used.
2010 BMW M3
These bucket tappets with a cylindrical camshaft contact surface and rotational lock allow a high level of
convexity. This results in effective valve lift characteristics with the smallest possible tappet diameter and hence
tappet mass (ideal for high engine speeds).
Fig. 7: Identifying Spherical Contact Surface, Box Tappet And Guide Lug

Index Explanation
1 Spherical contact surface
2 Box tappet
3 Guide lug
CAMSHAFT DRIVE
As in the S85, the inlet camshafts are driven by chain drive and the exhaust camshafts are driven by a gearwheel
drive. This means that the inlet and exhaust camshafts always have an opposite direction of rotation. In contrast
to the S85, which works with two single-roller chains between the crankshaft and the inlet crankshafts, in the
S65, two double-roller chains are installed. This is because of the higher chain drive load in the V8 S65.
The VANOS adjustment units are an integral component of the valve control and are mounted on the relevant
camshaft by a central bolt.
2010 BMW M3
Fig. 8: Identifying S65B40 Drive Valve Control

TECHNICAL DATA REFERENCE

Technical Data E92 M3 E46 M3 E6x M5/M6
Engine identifier S65B40 S54B32 S85B50
Camshaft drive 2x double-roller chain Double-roller chain 2x single-roller chain
NOTE: The central bolts of the inlet and exhaust side have a CCW thread.
VANOS
The compact double VANOS system fitted to the S65 engine operates at normal oil pressure, unlike the S85
engine (which uses high oil pressure). The low-pressure system means that the high-pressure pump and
additional pressure lines and reservoir are unnecessary. This results in a space saving as well as a weight
reduction of approximately 8.4 kg.
This has been made possible by the considerably stronger switching moments at the camshaft compared to the
10-cylinder and 6-cylinder engine, particularly in the lower engine speed range. The low-pressure system uses
these switching moments to adjust the overall gear ratio.
The oil is directed to the sealed oil chambers (3 and 4) of the VANOS adjustment unit.
When the chambers are pressurized with oil pressure, one chamber allows the camshaft to advance whilst the
other chamber allows the camshaft to retard.
2010 BMW M3
Fig. 9: Identifying S65B40 VANOS Hydraulic Motor Components


Index Explanation
1 Optimized hydraulic rotor pressure surfaces
2 Optimized inlet channel oil chamber 1
3 Oil chamber 1
4 Oil chamber 2
5 Optimized inlet channel oil chamber 2
2010 BMW M3
Fig. 10: S65B40 VANOS Hydraulic Schematic Of Cylinder Bank


Index Explanation
1 Oil supply from the main oil gallery
2 Non-return valves
3 Sieve filter upstream from control valves
4 Hydraulic motor at the inlet and exhaust camshaft
5 Multi-way adjustment valves inlet and exhaust side
6 Oil return flange to the oil sump
The VANOS oil pressure is supplied by the engine's main oil pump. The VANOS oil flow is controlled by one
multi-way valve for each camshaft. These VANOS multi-way valves are controlled by the MSS60 and are
directly installed in the cylinder head.
2010 BMW M3
Fig. 11: Identifying Locking Pin Spring, Locking Pin And Spiral-Wound Spring

Index Explanation
1 Locking pin spring
2 Locking pin
3 Spiral-wound spring
As with the S85, the VANOS adjustment unit of the inlet camshaft drives the VANOS adjustment unit of the
exhaust camshaft by means of a constantly meshed gear.
At zero pressure, a locking pin (2) also holds the VANOS unit in the normal position or engine start position.
The spiral-wound spring (3) is also used for coordinating the adjustment time between the advance and retard
adjustment. In contrast to AG petrol engines, the spiral wound spring for the inlet and exhaust sides is mounted
in the opposite working direction, since the camshafts in the S65 rotate in the opposite direction.
The principle of action of the hydraulic motor in this M VANOS is based on the VANOS in current BMW
petrol engines and is optimized for the S65 in terms of oil supply and drainage diameters, and in the rotor
surface area.
2010 BMW M3
Fig. 12: Crankshaft Angle Graph

The setting angle of the inlet camshaft is 58 in relation to the crankshaft. The exhaust camshaft has a setting
angle of 48. As in the S85 engine, this VANOS also reaches an adjustment rate of 360 camshaft per second.
NOTE: The service instructions should be followed exactly. The VANOS adjustment
unit must not be disassembled.
TECHNICAL DATA REFERENCE

Technical Data E92 M3 E46 M3 E6x M5/M6
Engine identifier S65B40 S54B32 S85B50
Variable camshaft 2x double (engine oil pressure) Double high- 2x double high-
control (VANOS) oscillating rotor VANOS pressure VANOS pressure VANOS
Adjustment range E/A [
72-130/81-129 70-130/83-128 79-145/91-128
KW]
Kingpin inclination E/A
58/48 60/45 66/37
[KW]
Response time E/A [
256/256 260/260 268/260
KW]
BELT DRIVE
The main belt drive drives the coolant pump and the generator, while the auxiliary belt drive drives the air
conditioning compressor and the power-assisted steering pump.
2010 BMW M3
The generator and the coolant pump are in the same position as in the S85. The coolant pump is identical to the
S85, but has a larger belt pulley.
Fig. 13: Identifying S65B40 Drive Belt

AIR SUPPLY
AIR INTAKE GUIDE/OIL SEPARATOR/SECONDARY AIR SYSTEM
2010 BMW M3
Fig. 14: Identifying Air Intake Guide, Oil Separator And Secondary Air System Components

Index Explanation
1 Engine hood air inlet
2 Air inlet behind the ornamental grills of the BMW kidney
3 Air inlet in the bumper
4 Air filter element
The combustion air enters the engine via three flow-optimized air guides. An air inlet is located on the left side
of the engine hood when viewed in the direction of travel. To maintain an optical balance in the appearance of
the engine hood, another intake grill is located on the right-hand side, but this is blinded and does not perform
any function.
The second air inlet guide is located behind the kidney grills of the BMW kidney.
The third air inlet guide is on the left below the front bumper.
The S65 has a large, single-piece air collector for the intake air to both cylinder banks.
A cylindrical air filter element (4) with an enlarged surface area is used.
The filtered air flows into the intake manifold, from where it flows through eight integrated individual inlet
2010 BMW M3
pipes and into the individual throttle valve assemblies.
To optimize air resistance, no air-mass sensor is installed in the intake area.
The air flow is determined using a model based calculation from the aperture of the throttle valve assemblies
and the idle speed actuator, the VANOS adjustment position, the engine speed, the air temperature and the
atmospheric pressure.
For safety reasons, an additional pressure sensor is mounted in the idle speed system.
OIL SEPARATORS
The oil separators are bolted onto the cylinder head covers. The connection between the oil separator and the
intake manifold is not screwed but plugged. This reduces the risk of incorrect assembly.
As is typical for the M series, no crankcase pressure control is mounted/integrated.
Fig. 15: Identifying Oil Separator Connection Point To Intake Manifold

SECONDARY AIR SYSTEM
The secondary air pump is mounted on the rear side of the engine in the "V" of the cylinder banks. The
secondary air is guided into the relevant exhaust channel via a check valve and an air channel integrated in the
cylinder head.
An upstream secondary air pump hot-film air mass sensor measures the secondary air flow. The structure and
function are the same as the system in the E60M5.
2010 BMW M3
INDIVIDUAL THROTTLE BUTTERFLY SYSTEM
Single throttle valve system
Fig. 16: Identifying Single Throttle Valve System Components


Index Explanation
1 Double throttle valve sensor cylinder bank 1 and 2
2 Individual throttle valve assemblies
3 Electrical throttle-valve actuator
The design principle of the S65 individual throttle valve air intake system is the same as the S85 and consists of
eight individual throttle valve assemblies and two electrical throttle valve actuators. One electric throttle valve
positioner activates four individual throttle butterflies of one cylinder bank, which are mechanically coupled.
The throttle valve position for each cylinder bank is recorded using a double throttle valve sensor on the shared
throttle body shaft. A signal is sent directly to the throttle valve actuator responsible for this cylinder bank. The
throttle valve actuator can therefore independently adjust the throttle valve position specified by the MSS60.
2010 BMW M3
The second signal is sent to the MSS60 for checking purposes.
For communication with the MSS60, the two electrical throttle valve actuators use a shared DK-CAN bus (DK-
CAN).
IDLE CONTROL SYSTEM
Fig. 17: Identifying Idle Control System Components


Index Explanation
1 Pressure sensor on idle air bar, cylinders 5-8
2 Throttle valve
3 Idle air bar, cylinders 1-4
One common idle speed actuator for both cylinder banks controls the air supply at idle speed and at low engine
loads. The idle speed actuator is located in the V formed by the two cylinder banks, and controls the idle air
supply using a throttle valve. The air enters the shared bar for each cylinder bank via the relevant air ducts, and
from there is guided into each throttle body below the throttle valve.
The idle speed actuator receives control instructions from the MSS60 via its own local CAN bus (LoCAN).
To ensure emergency operation in the event of the failure of one or both throttle valve sensors (even without the
hot film air-mass sensor), an additional pressure sensor is integrated on the idle air bar (as in the S54B32HP
(M3 CSL)). This allows evaluation of the pressure conditions behind the throttle valves. This pressure is also
2010 BMW M3
used for the plausibility check of filling and load in normal operation.
FUEL SUPPLY
Fig. 18: Identifying Fuel Supply System


Index Explanation
1 Tank filling supports
2 Tank leakage diagnosis unit
3 Right fuel supply unit
4 Fuel tank
5 Left fuel supply unit
6 Tank vent valve
7 Engine fuel supply line
2010 BMW M3
The fuel tank is based on the series E92 tank, although the shape has been changed to accommodate the exhaust
system. Both in tank units are new. The fuel pump is installed in the right-hand unit, and the pressure regulator
is installed in the left-hand unit in front of the fuel filter.
The ventilation lines have been adapted, while all other lines have been taken from the E92 335i. The US
release is fitted with a tank leakage diagnosis unit.
The electrical controls are described in the MSS60 engine control system.
COOLING SYSTEM
The mechanical coolant pump was taken from the S85.
The water pump belt pulley has been adapted due to the reduced water flow rate in the S65 compared with the
S85. It has a larger diameter, which has allowed a reduction in pump speed.
A one-piece crossflow radiator is used to cool both banks, unlike the S85 engine which has a two-piece radiator,
one part for each bank.
The following components have been adjusted for the M3: The expansion tank for the coolant, the crossflow
radiator, the radiator hoses, the thermostat and the electric fan.
The gear oil and steering oil coolers are also installed in the series-model E92.
The control of the electric fan is described in the MSS60 engine control system.
2010 BMW M3
Fig. 19: Identifying Gearbox And Engine Oil Cooler


Index Explanation
1 Gearbox oil cooler
2 Engine oil cooler
2010 BMW M3
Fig. 20: Identifying Complete Cooler Package Components


Index Explanation
0 Gearbox oil cooler
1 Engine oil cooler
3 Engine coolant cooler
4 Steering oil cooler
2010 BMW M3
Fig. 21: Identifying Engine Cooler Package, Cooler Fan And Expansion Tank

Index Explanation
1 Engine cooler package
2 Cooler fan
3 Expansion tank
EXHAUST SYSTEM
The exhaust pipes of the M vehicles are manufactured using the innovative internal high pressure forming
technology (IHU). The "IHU" technology was used for the first time in the world in 1992 in the BMW M3,
since when it has undergone continual refinement.
Using the IHU technology, the seamless stainless steel exhaust pipes are formed under a pressure of up to 800
bar. This results in extremely thin wall thicknesses of between 0.65 and 1.0 millimeters, which means both the
weight of the exhaust system and the response characteristics of the catalytic converters can be optimized. At
the same time, the IHU technology enables unprecedented styling and even more efficient geometric tolerances.
The largest possible pipe cross-sections are used, thus minimizing flow resistance.
The complete exhaust system is manufactured in stainless steel and has a dual flow.
The 4-in-1 exhaust manifold in each cylinder bank, as used in motor sport, has a length and cross-section
designed to enable optimal use of dynamics in the exhaust flow and to avoid unnecessary exhaust backpressure.
2010 BMW M3
The exhaust system has one quick responding metal catalytic converter close to the engine per exhaust line,
(approx. 20 cm behind the exhaust manifold), followed by the metal main catalytic converter. The front silencer
and the final muffler shared by both exhaust lines with a volume of 35 liters are constructed in an absorption
design.
The lambda oxygen sensors are located before and after both engine-side catalytic converters. The exhaust
temperature sensor installed in previous M models is no longer required and is replaced by an internal
calculation model in the control device.
The S65 fulfills the requirements of the LEV 2 classification.
NOTE: At maximum operating temperatures, the entire exhaust system can expand in
length by 35 mm.
Fig. 22: Identifying M3 Exhaust System


Index Explanation
1 Manifold
2 Catalytic converter close to the engine
3 Main catalytic converter
2010 BMW M3
4 Front exhaust silencer

5 Final muffler
2010 BMW M3
ENGINE PERFORMANCE Engine Management System - M3
ENGINE PERFORMANCE
Engine Management System - M3
MSS60 ENGINE CONTROL SYSTEM

The S65 features a revised engine control system, the MSS60, which is based on the MSS65 in the S85 engine.
This engine control system is designed for engine speeds of up to 9,000 RPM.
These engine control units belong to the latest generation and are characterized by an extremely high data
processing capability, processing millions of calculations per second.
The main functions are described in the product information for the E60 M5.
The following is a description of the areas of the system that differ from the MSS65.
Fig. 1: Identifying Engine Control Unit

ON-BOARD CONNECTION
2010 BMW M3
Fig. 2: On-Board Connection Diagram

2010 BMW M3
Index for On-Board Connection

Index Explanation
1 Electrical cooling fan
2 Alternator
3 Starter
4 Control valve in the air conditioning compressor
5 Oil condition sensor
6 Secondary air pump relay
7 Injection nozzle supply relay
8 Engine control unit MSS60
9 OBD2 diagnosis connector (TD output from MSS60 and D-CAN to JB)
10 Junction box (JB) and distribution box (SV)
11 Evacuating pump relay for brake servo action
12 High-current circuit breaker (250 A)
13 Safety battery terminal (SBK)
14 AGM battery.
15 Intelligent battery sensor (IBS)
16 Electric fuel pump control unit
17 IHKR/IHKA control unit
18 Multiple restraint system (MRS5)
19 Clutch module (KS)
20 Brake light switching module
21 Instrument cluster
22 Car Access System (CAS3)
23 Dynamic Stability Control (DSC)
ION CURRENT COMBUSTION MONITORING
The ion current combustion monitoring is also used in the MSS60 for knock identification and misfiring
identification. In principle, the method of action is identical to the S85 and its MSS65.
The S85 has two ion current monitoring devices, each of which covers a whole cylinder bank. In the S65, the
electronic ion current system is integrated into each ignition coil and the ion current monitoring devices are not
required.
During ignition, the measurement current is stored in a capacitor integrated in the ignition coil, and after
ignition, is available at the spark plug electrode. In the S65, the ion current measurement and evaluation is also
performed exclusively by the MSS60.
The functional range of the ion current electronics has been further refined. There is no longer a need for two
measurement control lines, and the ignition current and the ion current measurement signal have been combined
2010 BMW M3
into a single transmission route (separate in the S85).
For the purposes of smoothing the voltage and electromagnetic compatibility, an "ignition suppression
capacitor" is installed in the wiring harness of each cylinder bank (in the S85 this is in the ion current control
device). This is electrically connected using terminal 87 and the vehicle earth.
The same spark plugs are used as in the S85 (basic value approx. 60,000 km).
NOTE: If the ignition suppression capacitor is defective, this can lead to faults in the
communications and/or audio electronics when the engine is running.
For design reasons, the firing order 1-5-4-8-7-2-6-3 is used in the S65, instead of
the firing order 1-5-4-8-6-3-7-2 more commonly employed in BMWV8 engines
until now.
SIMPLIFIED BASIC LAYOUT OF ION CURRENT MONITORING
Fig. 3: Basic Layout Of Ion Current Monitoring


Index Explanation
1 Microcontroller ignition
2 Output amplifier of the ignition signal
3 Ion current input amplifier
2010 BMW M3
4 Digital signal processor for ion current measurement signal

5 MSS60 Engine control system
6 Ignition suppression capacitor (one per cylinder bank for 4 cylinders)
7 Input amplifier for ignition signal
8 Output amplifier of the ion current measurement signal
9 Ignition coil with integrated ion current electronics
10 Ignition output stage
11 Capacitor for storing measured flow
12 Zener diode for limiting the measured voltage
13 Primary and secondary coil
14 Spark plugs
The following diagrams show the ion current curve (bottom) in relation to the development of combustion
pressure (top). This curve is used for the evaluation of combustion quality and the identification of misfiring.
Fig. 4: Combustion Curve (Top) And Ionic Current (Bottom)

2010 BMW M3
Fig. 5: MSS60 Representation Of Normal Combustion And Combustion Knock Graph


Index Explanation
1 Ionic current maximum by induction of ignition coil
2 Ionic current maximum due to ignition (flame front directly in area of spark plugs)
3 The ionic current progression is a function of the pressure curve

Index Explanation
A Ionic current (mA)
B Section of measuring window
1 Normal combustion (no knocking)
2 Combustion knock
2010 BMW M3
A and is only measured by the electronic system in the mA range.
Combustion knock is identified in the ionic current measurement signal in the form of oscillations within a
defined measuring window. The measuring window is after position 3 of the above diagram.
FUEL SUPPLY SYSTEM

A separate control unit is used for the electric fuel pump (EKP-SG). The EKP control signals from the MSS60
are produced via a dedicated CAN bus (LoCAN) (M5: PWM signal). The EKP control unit is made ready for
operation by the MSS60 via the input terminal 87. The load current is controlled via a relay at the terminal 30g
by CAS3.
In the event of a crash that reaches the relevant threshold value, the MRS5 requests an interrupt to the fuel
supply via the K-CAN connection to CAS3.
There is now only one fuel pump (the M5 has two). This has a three-phase motor, which ensures sufficient
torque across the whole pump speed range. The pump speed is used to provide the required fuel pressure of 3-6
bar, depending on the engine operating state.
A fuel pressure sensor sends its signal to the MSS60. The fuel pressure sensor is located behind the inner
fenderwell.
If the pressure sensor fails or there is a fault in the CAN bus and in the engine emergency program, the fuel
pump is operated at full speed. In this process, the pressure is limited to 6 bar by the mechanical pressure
sensor.
The signals from both tank fill level sensors are sent to the junction box and are forwarded to the instrument
cluster via the K-CAN, where they are evaluated and displayed.
MSS60 FUEL SUPPLY SYSTEM CIRCUIT DIAGRAM

2010 BMW M3
Fig. 6: MSS60 Fuel Supply System Circuit Diagram


Index Explanation
2010 BMW M3
1 Engine control unit MSS60

2 Junction box
3 Electric fuel pump control unit
4 Fuel pump with three-phase motor
5 Tank fill level sensor, right
6 Tank fill level sensor, left
7 Fuel tank
8 Multiple restraint system 5th generation (MRS5)
9 Car Access System 3rd generation (CAS3)
11 Fuel pressure sensor
COOLING SYSTEM
In the E92 M3, an electric fan is installed (as in the E70), which initially reaches a maximum output of 850
Watts. The fan is activated by the MSS60 via a pulse width-modulated signal (PWM signal) with a frequency of
100-300 Hz for fan operation, wake-up function, and interface diagnosis function.
A frequency of 10 Hz is used for overrun requests.
The signal voltage is approximately the same as the on-board supply voltage. The following cycle ratio
specifications (in %) refer to the "low" proportion of the signal period.
The cooling fan power supply is produced using a 100 A high-current circuit breaker in the luggage
compartment distributor and a high-voltage relay near the front passenger footwell. The relay is control by
terminal 30g (CAS).
The performance of the cooling fan depends on the coolant temperature, the IHKA request, the intake air
temperature, the calculated exhaust gas temperature downstream from the catalytic converter, and the request by
the generator (overheating protection).
The control valve in the air conditioning compressor and the coolant pressure sensor are electrically connected
to the junction box (JB). The IHKA/IHKR can use the K-CAN connection to evaluate the pressure and send the
appropriate control requests for the control valve in the air conditioning compressor to the JB. A resulting load
torque for the torque correction and an electric fan speed request are also sent to the MSS60 via the K-CAN.
The junction box only activates the control valve in the air conditioning compressor following release by the
MSS60. The MSS60 adapts the idle speed control accordingly and activates the electric fan.
The switching state of the coolant level switch is also transmitted to the junction box and evaluated by the
instrument cluster via the K-CAN connection. If there is insufficient coolant, a corresponding warning is sent to
the driver.
COOLING SYSTEM CIRCUIT DIAGRAM

2010 BMW M3
Fig. 7: Cooling System Circuit Diagram


Index Explanation
2010 BMW M3
1 Electric fan (850 W)

2 Coolant level switch
3 Coolant temperature sensor
4 Control valve in the air conditioning
5 Coolant pressure sensor
6 MSS60 Engine control system
7 Junction box
8 Electric fan relay
9 High-current circuit breakers
10 IHKA
FUNCTION/CONTROL OF THE ELECTRIC FAN
Fan Operation
The adjusted fan speed increases in a linear fashion as the cycle ratio increases. The rated speed (nNom ) in the
M3 is the same as the maximum number of revolutions (2,400 RPM).
The engine speed of the M3 is controlled in a linear relationship with the cycle ratio(10-91%), starting with 800
RPM (1/3 of nNom ) up to 2,400 RPM.
NOTE: In the E6x M5/M6 (600 W fan), an additional unregulated increase in engine
speed to at least 2,700 RPM (nmax) is produced, from a 92% to 95% cycle ratio.
"Wake-up" Function
If they are in sleep mode, the fan electronics can be "woken" by a PWM signal (100-300 Hz) with a cycle ratio
of 5-9%. In the E92 M3, in normal operation, the waking is triggered by activation of the terminal 30g with
"Ignition ON".
Interface Diagnosis Function
An interface diagnosis is triggered by the MSS60 and used to check the interface. The MSS60 sends a PWM
signal (100-300 Hz) for approx. 1 second with a cycle ratio of 96-99%.
If the interface is intact, the fan electronics for confirming the PWM signal cable are set to "low" for 2.5-3
seconds (M5 fan 1-1.5 s).
Overrun Request
If an overrun of the fan is required after "Ignition OFF", approximately 7 seconds after "Ignition off", the
MSS60 emits a PWM signal with a frequency of 10 Hz for at least 3 seconds. At the issued cycle ratio, the
electrical fan system detects at which speed and for what duration the overrun should occur.
2010 BMW M3
The cycle ratio is between 15 and 85% in 5% increments.
It contains the information displayed in the following graphic:
Engine speeds of 35, 45 or 50% of the rated speed.

Run-on time of 3-11 minutes in increments of 2 minutes.
Fig. 8: Cycle Ratio Graph


Index Explanation
A Percentage of rated speed
B Overrun in minutes
1 Cycle ratio in percent
Fan Self-diagnosis and Fault Signal
The electronic fan system performs an internal diagnosis procedure. If a fault is detected, fan operation is
continued as far as possible, if necessary at reduced power.
The following faults lead to a diagnosis message:
Engine is blocked
A fault has occurred in the electronic fan system, which means that fan operation is permanently
restricted or impossible.
In response to the fault message, the electronic fan system changes the PWM signal to "low" for at least 5, to a
maximum of 7 seconds.
NOTE: A fault message is issued with a delay of approx. one minute, since the
electronic fan system first executes a triple internal test cycle.
2010 BMW M3
ENGINE Engine - Operating Fluids
ENGINE
Engine - Operating Fluids
1.0 GENERAL INFORMATION

The specified engine oil is extremely important for the operation and service life of an engine.
Engine oil requirements will depend on the engine design, operating conditions, oil change intervals and, in the
case of diesel engines, the fuel grade.
A modern engine oil provides more than just a lubrication function. The following qualities are required:
GOOD WEAR PROTECTION AND FRICTION REDUCTION
Frictional losses will lead to a reduction of engine power and efficiency. An approved engine oil will minimize
frictional losses. Excessive wear will lead to a reduction in service life (e.g. wear of bearings, piston rings, cam
lobes) or to mechanical failure.
LIMITED TENDENCY TO PRODUCE COMBUSTION RESIDUE
During engine operation, a limited amount of oil enters the combustion chamber, where it is burned.
Combustion residues or deposits, which build up in the combustion chamber, lead to unwanted increases in
compression and promote surface ignition ("pinging"). Any approved engine oil will help prevent such a
condition.
FAVORABLE VISCOSITY TEMPERATURE BEHAVIOR
Viscosity is the tendency of oil to resist flowing. Engine oil, when cold, should be thin enough so that the
engine can be cranked over. Hot oil should be thick enough to maintain proper lubrication.
ANTI-FOAMING
The oil is forcefully mixed with air during engine operation. Heavy foaming will lead to impaired lubrication
and reduction in oil flow rate. To prevent foaming, antifoaming additives are mixed with the oil.
GOOD CORROSION INHIBITION
The engine oil must prevent corrosion on engine components under all circumstances. Corrosion and rust
inhibitors are added to displace water and acids from metal surfaces so that oil coats them.
MIXING ABILITY/COMPATIBILITY
It must be possible to mix all engine oils with each other, even synthetic with mineral oils, without causing any
incompatibility problems. A further requirement is the compatibility with all materials contacted by oil, in
particular oil seals, hoses and paint.
2010 BMW M3
GOOD THERMAL CONDUCTIVITY/GOOD COOLING PROPERTY
Engine oil makes an important contribution to the cooling of an engine. It must transfer heat from friction
surfaces, and combustion heat away from affected areas. The oil absorbed heat is carried back to the oil pan
where it is transferred to the surrounding air.
GOOD DISPERSANT/DETERGENT QUALITIES
To limit or slow down the formation of combustion deposits and acidic components, together with abrasive
particles and dirt from the intake air, good engine oils contain a detergent additive. Deposits of carbon and dirt
are loosened and suspended in the oil, being drained away at the next oil change.
OXIDATION INHIBITORS AND AGING STABILITY
Oxidation can be described as the oxygen absorption of hydrocarbons formed in the oil. The results of oxidation
have a negative impact on viscosity causing corrosion on certain metals and the formation of sludge. Inhibitors
are added to prevent oxidation from occurring. A good engine oil must maintain its stability during the required
oil change intervals.
Good Lubricating Oil Must:
1. Lubricate moving parts to minimize wear.

2. Lubricate moving parts to minimize loss from friction.
3. Remove heat from engine parts by acting as a cooling agent.
4. Absorb shocks between bearings and other engine parts, reducing engine noise and extending engine life.
5. Form a good seal between piston rings and cylinder walls.
6. Act as a cleaning agent.
2.0 GRADING OF OILS

VISCOSITY NUMBER
A method of classifying an oil by number, based on its resistance to flow at a high temperature.
These numbers are usually prefixed by SAE which is the abbreviation for the Society of Automotive Engineers.
A lower SAE Number (i.e. SAE 5W) indicates a thinner oil with a higher flow rate, for use at lower
temperatures. A higher SAE Number (i.e. SAE 30) indicates a thicker oil with a slower flow rate, for use at
higher temperatures.
MULTIGRADE OILS
A multigrade, or multiviscosity oil has the qualities of a lower number oil at low temperatures and those of a
higher number oil at high temperatures. Multigrade oils have numbers such as SAE 5W-30 and SAE 10W-40.
For reliable engine performance in all temperature ranges mineral based engine oil viscosity must be matched to
the temperature range at which the vehicle will be operated.
2010 BMW M3
SINGLE GRADE OILS
A single grade viscosity oil has a limited temperature/viscosity range compared with multigrade oils. Due to the
limited temperature/viscosity range of these oils they are no longer used in BMW engines and thus no longer
listed in the BMW Engine Oil Temperature/Viscosity Table.
OIL CLASSIFICATIONS
A method of classifying oil was jointly developed by the SAE, API (American Petroleum Institute), and ASTM
(American Society for Testing and Materials). Engine oils are rated according to two engine use categories:
C = Compression Ignition (i.e. CC)
Compression Ignition (C) oils are those that are used for diesel engines. The current service ratings for diesel-
engine lubricating oils are: CA, CB, CC, CD, CE, CF and CG. The oils differ in their properties and in the
additives they contain.
S = Spark Ignition (i.e. SE)
Spark Ignition (S) oils are those that are used for gasoline engines. The current service ratings for gasoline-
engine lubricating oils are: SA, SB, SC, SD, SE, SF, SG, SH and SJ. These oils differ in their properties and in
the additives they contain.
Another method of classifying minimum performance standards for gasoline-fueled engine oils has been
developed through ILSAC (International Lubrication Standardization Approval Committee). Oils that meet
ILSAC GF-1 performance standards must have a "starburst" certification mark displayed on the print of the oil
product packaging.
3.0 ENGINE OIL REQUIREMENTS AND SPECIFICATIONS

APPROVED ENGINE OILS
For BMW gasoline engines with two valves per cylinder, all reputable multiple grade engine oils* which
meet or exceed the API classification of SH. (Combination with diesel oil specifications CD or CE
quality classifications are also permitted, e.g. SH/CE etc.)
For BMW gasoline engines with four valves per cylinder, only reputable multiple grade engine oils*
which meet or exceed the API classification of SH. (Combination with diesel oil specifications CD or CE
quality classifications are also permitted, e.g. SH/CE etc.)
For BMW turbocharged diesel engines, all reputable multiple grade engine oils* which meet or exceed
the API classification CD/CE.
*Engine oil may be mineral or synthetic based.
Special Oils category has been replaced by BMW High Performance Synthetic Engine Oil (5W-30). It
eliminates the need for seasonal oil changes since it covers all ambient temperature ranges.
2010 BMW M3
BMW of North America has introduced a line of exclusively formulated High Performance Engine Oils which
exceed existing international quality specifications (SAE/CCMC) for motor oils. BMW part numbers are:
ENGINE OIL REQUIREMENTS AND SPECIFICATIONS

SAE 5W-30 (SJ/CF) BMW High 1 quart Part No. 07 51 0 017 866
Performance Synthetic Oil
SAE 15W-40 (SJ/CF) BMW High 1 quart Part No. 07 51 0 017 868
Performance Mineral Oil
Motorsport Engines
E46 M3 / S54E36 M roadster, M coupe / S54 from start of production
E39 M5 / S62 Up to 3/2000
E52 Z8 / S62 Up to 3/2000
E60 M5 / S85 From start of production
E63 M6 From start of production
E64 M6 From start of production
E85 Z4 M Coupe / Z4 M Roadster From start of production
BMW High Performance Synthetic Oil Castrol RS SAE 10W-60 also called Castrol TWS Motorsport SAE
10W-60 Synthetic Oil Part No. 07 51 0 009 420 (1quart)
E39 M5 / S62 From 3/2000
E52 Z8 / S62 From 3/2000
BMW High Performance Synthetic Oil SAE 5W-30 Part No. 07 51 0 017 866 Or BMW High Performance
Synthetic Oil Castrol RS SAE 10W-60 also called Castrol TWS Motorsport SAE 10W-60 Synthetic Oil Part
No. 07 51 0 009 420 (1quart)
BMW High Performance Synthetic Oil 5W-30 and 10W-60 offer several benefits over conventional mineral
based oils.
SUPERIOR THERMAL STABILITY
The synthetic based oil resists thickening at very low ambient temperatures providing improved flow,
lubrication and less internal engine resistance during cold starts.
Under high heat conditions, the oil resists thermal breakdown/shearing which causes a loss of lubrication
quality compared with conventional oils.
2010 BMW M3
SUPERIOR LUBRICATION THROUGHOUT THE LIFE OF THE OIL
Compared to conventional engine oils, BMW High Performance Synthetic Oil is better able to keep engine
combustion contaminants in suspension and is less susceptible to the harmful effects of oxidation.
The oil resists sludge buildup thus allowing extended oil change intervals. Synthetic based oils also have a
lower volatility which makes them less susceptible to evaporation thereby reducing oil consumption.
This oil has been durability tested on BMW engines and supplies superior lubrication under all operating
conditions and over the extended BMW oil change intervals.
4.0 ENGINE OIL CHANGE INTERVALS

With the introduction of the 1999 Model Year vehicles BMW has introduced an extended oil change interval of
approximately 15,000 miles (depending on engine operating conditions) on most models.
To coincide with the increased oil change interval, BMW has also introduced "BMW High Performance
Synthetic Oil" which must be used on all 1999 Model Year vehicles (except E36 318ti, 323is/iC, 328is/iC, M3,
M Roadster and M Coupe models) whenever a service is necessary to avoid engine damage.
NOTE: Only if it is necessary to top up the engine oil between oil changes is it
permissible to use synthetic low viscosity engine oils which conform to the API
classification SJ or higher.
A label in the engine compartment states the oil specifications and refers to the BMW website
(www.bmwusa.com) and toll free number (1-800-831-1117) for additional information.
Fig. 1: Identifying Label In Engine Compartment States

BMW High Performance Synthetic Engine Oil may also be used on Model Year 1999 E36 (3-Series and
M models) as well has Model Year 1998 and earlier BMW models.
The oil change intervals should not be extended due to the greater durability of a fully synthetic engine oil. The
engine oil and filter should always be changed as per the vehicle's Service Interval Indicator when the "Oil
Service" or the "Inspection" display appears regardless of the type of oil being used.
2010 BMW M3
BMW mineral-based High Performance engine oil is also offered for model year 1998 and earlier BMW
models. However, for reliable engine performance in all temperature ranges mineral-based engine oil viscosity
must be matched to the temperature range at which the vehicle will be operated. See Engine Oil
Temperature/Viscosity Table below.
Fig. 2: Identifying BMW Engine Oil Temperature/Viscosity Table

Other Oil Changes For Cars Without Service Indicator:
MODEL YEAR/MILLAGE REFERENCE

Model Year(s) Mileage
1980 and later 7,500
1975 thru 1979 6,500
1974 or earlier 4,000
Including oil filter. However, at least twice annually, preferably before and after the winter season.
Under severe driving conditions it is recommended to increase the number of oil services.
5.0 CONDITION BASED SERVICE

Models: E90, 91, 92, E60, E61, E63, E64 E65, E66
Condition Based Service measures, monitors, and determines the required maintenance of several service items
independent from each other. This technology prompts the customer to bring the vehicle for service whenever
2010 BMW M3
one of the CBS items requires maintenance or replacement. CBS strikes a compromise between too frequent
maintenance and too rigid service intervals that call for the replacement of service items which may still have
substantial remaining useful life. CBS also details the recommended, due, and overdue required maintenance
during and after the BMW Vehicle Maintenance Program Agreement. Thus, CBS allows BMW customers to
experience a technology that makes service more convenient, transparent and structured.
6.0 ENGINE OIL ADDITIVES

The use of engine oil additives is not recommended and not necessary on BMW engines. Instead, it is
mandatory to use BMW High Performance Synthetic Oil in 1999 model year and later BMW models and
recommended to use either BMW High Performance Synthetic Oil, BMW High Performance Mineral Oil or
one of today's highly advanced brand name lubricating oils conforming to API classification SH or higher in
1998 and earlier BMW models.
7.0 BREAK-IN INSTRUCTIONS

During the break-in period of a new engine or parts of a reconditioned engine (new bearings, crankshaft,
pistons, etc.) BMW engines do not require special break-in oils.
All of the multiple grade engine oils can be used, as long as they conform with BMW specifications.
8.0 N52, N52KP AND N54 FRONT AND REAR RADIAL SEAL SEALANT
When replacing the front or rear radial crankshaft seals on new generation 6 cylinder engines, a special
Loctite sealant must be applied to fill the seal grooves at the bedplate seam. Follow the appropriate repair
instruction in TIS:
RA 11 14 005 - Front radial crankshaft seal replacement
RA 11 14 151 - Replacing crankshaft radial seal (rear)
All special tools required to perform these repairs have been sent out through the automatic tool shipment
program and are listed in S.I. Bulletin 04 01 06.
Required Materials:
P/N 83 19 7 536 051 - Loctite 128357 sealant compound\
P/N 83 19 7 515 683 - Loctite 171000 primer
P/N 83 19 7 515 684 - Stamp
10.0 LUBRICANT FOR OXYGEN SENSOR

Apply Bostik NEVER-SEEZ (Part No. NSBT-16) to threads of oxygen sensor.
2010 BMW M3
11.0 OIL CONSUMPTION

All engines normally consume a certain amount of oil. This is necessary in order to properly lubricate the
cylinder walls, pistons, piston rings etc. In addition, engines with less than 6,000 miles will generally consume
additional oil because the components are not fully seated. Therefore, oil consumption complaints received
prior to 6,000 miles cannot be considered.
Once a new or rebuilt engine has accumulated 6,000 miles this procedure should be used if there is a drastic
change in the oil consumption rate (i.e. the oil consumption rate triples) under similar driving conditions or if
the oil consumption rate exceeds 1 qt. per 750 miles at any time..
All Motorsport Engines:
Due to their increased output and maximum engine speeds, these engines are allowed a maximum consumption
of 2.5 quarts per 1,000 miles.
13.0 OPERATING FLUIDS TABLE AND ALTERNATE SUPPLIERS

OPERATING FLUIDS TABLE AND ALTERNATE SUPPLIERS
BMW Part Description /
Number Application 3M Wurth Loctite CRC
11 12 1 262 Silicone Sealant 8661 80050/PX66BR
571 (1)
81 12 9 400 Hylogrip/Loctite 8932700 21438
086 (1) 270 Thread Sealant
Secures and seals

bolts, studs, nuts,
threaded inserts,
screw plugs against
impact and vibration.
Fastens ball, roller
and sliding bearings
onto shafts or in
housings, with play
up to 0.25mm. Quick
setting.
Oil filter flange bolt
-
81 22 9 400 Sealer Permatex 3D
243(1) Low viscosity, non- Aviation Form a
hardening, Gasket 80017
removeable. For
sealing off against
mineral oils, grease,
gases, air and many
2010 BMW M3
chemicals.
Application: from-
40C to approx. 200
C.
Tacking cylinder
gasket -
81 22 9 400 Hylomar SQ32M
339 Sealant
Universal sealing
compound,
applicable by brush.
For sealing
interfaces between
surfaces that require
excellent
temperature
resistance and
sealing elasticity.
Material: Polyester-
urethane mixture.
81 22 9 407 Loctite 380 Epoxy 8155 8934103 38050
394(1) Cement
Black cyanacrylate
adhesive for joining
metals, rubber, PVC.
81 22 9 400 Copper Paste 8945 3046010
794(1) Multi-purpose grease
for all detachable
joints at high
temperatures and
corrosive conditions,
also after long
operating periods.
Able to withstand
high pressures,
protection against
undesired weld
contact, seizure and
corrosion, active
adhesion properties,
effective as lubricant
and separator up to
1100C.
Applications: parts
subject to high
temperatures, such
as bolts and flanges
2010 BMW M3
on exhaust system,
engine, disk brakes,
etc.
81 22 9 407 07 58 9 062 376(1) Silicone Sealer 8670 8661 81157/PX16B
439(1) 80050/PX66BR
A black colored
silicone-based
sealant for
large areas.
Resists
temperatures
up to 250C.
For engine or
gearbox;
particularly
suitable for
sealing the
timing case on
M70 engine,
and eliminating
oil seepage
from E36 M42
cylinder head.
81 22 9 407 Engine Cleaner 8899 890923 80043 14045
760(1) Spray Fast acting
cleaner for dirty
engines and engine
parts. Does not
attack painted,
rubber, or plastic
parts.
N/A Lubro Moly
Lecksucher
Intake and vacuum
system leak detector.
N/A J-B Weld
Repairs pitting in
cylinder head sealing
surfaces.
N/A Bostik Never-Seez
Thread lubricant for
oxygen sensors.
(1) *These items are no longer available through BMW NA Parts Department.
2010 BMW M3
GENERAL INFORMATION TROUBLE SHOOTING
GENERAL INFORMATION
TROUBLE SHOOTING
NOTE: This article is generic in nature and all information does not apply to all
vehicles. For vehicle specific information, see the appropriate articles in the
ENGINE PERFORMANCE category.
ENGINE PERFORMANCE
TUNE-UP TROUBLE SHOOTING

Problem & Possible Cause Action
Carbon Fouled Plugs
Clogged Air Filter Replace Air Filter
Incorrect Idle Speed Reset Idle Speed
Faulty Ignition Wiring Replace Ignition Wiring
Sticky Valves/Worn Valve Seal Check Valve Train
Fuel Injection Operation Check Fuel Injection
Wet/Oil Fouled Plugs
Worn Rings/Pistons Overhaul/Replace Engine
Excessive Cylinder Wear Overhaul/Replace Engine
Plug Gap Bridged
Combustion Chamber Carbon Deposits Clean Combustion
Chamber
Blistered Electrode
Engine Overheating Check Cooling System
Loose Spark Plugs Clean/Torque Plugs
Over-Advanced Timing Reset Timing
Wrong Plug Heat Range Install Correct Plug
Melted Electrodes
Incorrect Timing Reset Timing
Burned Valves Replace Valves
Wrong Plug Heat Range Install Correct Plug
Engine Won't Start
Loose Connections Check Connections
2010 BMW M3
No Power Check Fuses/Battery

Loose/Worn Timing Belt/Chain/Gears Check Belt/Chain/Gears
Engine Runs Rough
Leaky/Clogged Fuel Injectors Repair Fuel Injectors
Leaky/Clogged Fuel Lines Repair Fuel Lines
Clogged Fuel Filter Replace Fuel Filter
Incorrect Timing Reset Timing/Check
Advance
Faulty Plugs/Wires Replace Plugs/Wires
Uneven Compression Overhaul/Replace Engine
Poor Acceleration
Incorrect Ignition Timing Reset Timing
Leaky Valves Check Compression
Component Failure
Spark Arcing Replace Faulty Part
Defective Pick-Up Coil Replace Pick-Up Coil
Defective Ignition Coil Replace Ignition Coil
Defective Control Unit Replace Control Unit
Ignition Diagnosis By Scope Pattern
All Firing Lines Abnormally High
Retarded Ignition Timing Reset Ignition Timing
Lean Air/Fuel Mixture Adjust Fuel Mixture
High Secondary Resistance Repair Secondary
Ignition
All Firing Lines Abnormally Low
Rich Air/Fuel Mixture Adjust Air/Fuel Mixture
Arcing Coil Wire Replace Coil Wire
Cracked Coil Replace Coil
Low Coil Output Replace Coil
Low Compression Check/Repair Engine
Several High Firing Lines
Fuel Mixture Unbalanced Check Fuel System
EGR Valve Stuck Open Clean/Replace EGR
Valve
High Plug Wire Resistance Replace Plug Wire
Cracked/Broken Plugs Replace Plugs
Intake Vacuum Leak Repair Leak
Several Low Firing Lines
Fuel Mixture Unbalanced Adjust Fuel Mixture
Plug Wires Arcing Replace Plug Wires
Cracked Coil Arcing Replace Coil
2010 BMW M3
Uneven Compression Check/Repair Engine

Faulty Spark Plugs Replace Plugs
Cylinders Not Firing
Cracked Distributor Cap Replace Cap
Shorted Plug Wires Replace Plug Wires
Mechanical Engine Fault Check/Repair Engine
Spark Plugs Fouled Replace Plugs
Carbon Track in Distributor Cap Replace Cap
Hard Starting
Defective Ignition Coil(s) Replace Coil(s)
Fouled Spark Plugs Replace Plugs
Incorrect Timing Reset Ignition Timing
FUEL INJECTION TROUBLE SHOOTING

Problem & Possible Cause Action
Cold Start Valve Inoperative Test Cold Start Valve
Poor Vacuum/Electrical Connection Repair Connections
Contaminated Fuel Test Fuel for Water/Alcohol
Bad Fuel Pump Relay/Circuit Test Relay/Wiring
Battery Voltage Low Charge/Test Battery
Low Fuel Pressure Test Press. Regulator/Pump
No Distributor Reference Pulse Repair Ignition System
Coolant Temp. Sensor Defective Test Temp. Sensor/Circuit
No Power To Injectors Check Injector Fuse/Relay
Hard Starting
Defective Idle Air Control (IAC) Test IAC and Circuit
EGR Valve Open Test EGR Valve/Control
Circuit
Restricted Fuel Lines Inspect/Replace Fuel Lines
Poor MAP Sensor Signal Test MAP Sensor/Circuit
Engine Stalls During Parking Maneuver Check P.S. Press. Switch
Rough Idle
Dirty Fuel Injectors Clean/Replace Injectors
Poor MAP Sensor Signal Test MAP Sensor/Circuit
Intermittent Fuel Injector Operation Check Harness Connectors
Erratic Vehicle Speed Sensor Inputs Harness Too Close to Plug
Wires
2010 BMW M3
Poor O2 Sensor Signal Test O2 Sensor/Circuit

Faulty PCV System Check PCV Valve and
Hoses
Poor Acceleration
Weak Fuel Pump Replace Fuel Pump
Dirty Fuel Injectors Clean/Replace Injectors
Excessive Intake Valve Deposits Clean Intake System
Poor High Speed Operation
Low Fuel Pump Volume Faulty Fuel Pump/Filter
Poor MAP Sensor Signal Test Speed Sensor/Circuit
Acceleration Ping/Knock
Faulty EGR System Check EGR Valve and
Hoses
Poor Knock Sensor Signal Test Knock Sensor/Circuit
Poor Baro Sensor Signal Test Baro Sensor/Circuit
Improper Ignition Timing Adjust Timing
Poor Quality Fuel Use Different Fuel
Carbon Build-Up Decarbon Engine
2010 BMW M3
ENGINE Exhaust System - Repair
ENGINE
Exhaust System - Repair
EXHAUST SYSTEM, COMPLETE

18 00 018 REMOVING AND INSTALLING COMPLETE EXHAUST SYSTEM (S65)
E93 only: Remove tension strut
Support exhaust system with special tools 31 2 220 SUPPORT and 00 2 030 DEVICE .
Disconnect all oxygen sensors.
The description refers only to one side of the two-flow exhaust system. The procedure is identical for both
sides.
Fig. 1: Supporting Exhaust System Using Special Tool (31 2 220)

Unscrew nuts.

2010 BMW M3
Fig. 2: Locating Self Locking Nuts

Release screws.

Release screws (1).
Installation:

2010 BMW M3
Fig. 4: Identifying Reinforcement Plate Mounting Screws

Release nuts.
Fig. 5: Locating Nuts

Unscrew nuts.

2010 BMW M3
Fig. 6: Locating Grounding Strap Mounting Nuts

Release screws (1) on rear apron.
Unscrew nuts (2).
Lower exhaust system and remove with assistance of a second person.
Fig. 7: Identifying Screws And Nuts On Rear Apron

Installation:
Check exhaust system for leaks.

2010 BMW M3
WARNING: Danger of burning and other injuries!

Removal of the exhaust system must be carried out with the assistance of
a second person.
NOTE: Weight of exhaust system is approx. 40 kg.
18 32 040 REMOVING AND INSTALLING/REPLACING CATALYTIC EXHAUST-GAS

CONVERTER WITH CENTER MUFFLER (S65)

Support rear silencer with special tool 31 2 220 SUPPORT .
NOTE: Description of one side of two-flow exhaust system.

The procedure is identical on both sides.

Release screws.

2010 BMW M3

Release screws.

Release screws (1).
Installation:

2010 BMW M3

Release screws on clamps.
Remove catalytic exhaust-gas converter with center muffler.
Remove catalytic exhaust-gas converter with a second person helping.
Fig. 12: Identifying Screws On Clamps


18 12 030 REMOVING AND INSTALLING/REPLACING REAR MUFFLER (S65)

2010 BMW M3

Unfasten nut.
2010 BMW M3

Unscrew nuts.
Remove grounding straps.

Unscrew nuts (2).

2010 BMW M3
Remove rear muffler with a second person helping.


MUFFLERS


2010 BMW M3
Release screws.

Release screws.

2010 BMW M3

Release screws (1).
Installation:


2010 BMW M3




2010 BMW M3

Unfasten nut.

Unscrew nuts.

2010 BMW M3

Unscrew nuts (2).


EXHAUST CATALYTIC CONVERTER

2010 BMW M3



Release screws.

2010 BMW M3
Release screws.

Release screws (1).
Installation:


2010 BMW M3


EXHAUST MANIFOLD WITH INTEGRATED CATALYTIC CONVERTER

18 40010 REMOVING AND INSTALLING/REPLACING LEFT EXHAUST MANIFOLD (S65)

Only perform these tasks on an engine that has cooled down.
Remove ALTERNATOR (S65) .

Secure ENGINE IN INSTALLATION POSITION (S65)
Lower FRONT AXLE CARRIER
NOTE: For purposes of clarity, the following work steps are shown on the engine after
it has been removed.
Release screws.
2010 BMW M3
Remove 5 heat shield bolts.
Release 2 nuts of individual flange pairs. Remove exhaust manifold. Installation: Replace nuts. Tightens nuts on
each flange. Tightening torque, see 18 40 1AZ in EXHAUST MANIFOLD, EXHAUST SYSTEM . Replace
seals.
18 40 020 REMOVING AND INSTALLING/REPLACING RIGHT EXHAUST MANIFOLD (S65)


Secure ENGINE IN INSTALLATION POSITION WITH SPECIAL TOOL
Lower FRONT AXLE SUPPORT
Remove RIGHT ENGINE SUPPORT ARM
Release screws.
Remove heat shield.
Fig. 33: Locating Heat Shield Mounting Screws

Unscrew nuts.
Remove exhaust manifold (1).

2010 BMW M3
Installation:
Replace nuts.
Tightens nuts on each flange.
Replace seals, paying attention to installation location of seals.
Fig. 34: Locating Exhaust Manifold Mounting Nuts

2010 BMW M3
ENGINE Exhaust System - Repair Instructions - M3
ENGINE
Exhaust System - Repair Instructions - M3
EXHAUST SYSTEM COMPLETE

18 00 018 REMOVING AND INSTALLING COMPLETE EXHAUST SYSTEM (S65)
00 2 030
31 2 220
See FRONT AXLE - SPECIAL TOOLS .
WARNING: Danger of burning and other injuries!

Removal of the exhaust system must be carried out with the assistance of
a second person.
NOTE: Weight of exhaust system is approx. 40 kg.
E93 only: Remove tension strut . See 51 71 482 REMOVING AND INSTALLING/REPLACING
LEFT OR RIGHT TENSION STRUT (ON REAR AXLE) (FROM 03/2007) .
Support exhaust system with special tools 31 2 220 and 00 2 030 .
Disconnect all oxygen sensors.
The description refers only to one side of the two-flow exhaust system. The procedure is identical for both
sides.
2010 BMW M3
Fig. 1: Supporting Exhaust System With Special Tools (31 2 220 And 00 2 030)
Unscrew nuts.
Tightening torque, see 18 40 2AZ in 18 40 EXHAUST MANIFOLD, EXHAUST SYSTEM .
Fig. 2: Locating Self-Locking Nuts

Release screws.

2010 BMW M3

Release screws (1).
Installation:
Fig. 4: Identifying Reinforcement Plate Screws

Release nuts.

2010 BMW M3

Unscrew nuts.
Fig. 6: Locating Grounding Strap

Unscrew nuts (2).
Lower exhaust system and remove with assistance of a second person.

2010 BMW M3
Fig. 7: Identifying Screws And Nut

Installation:
31 2 220

Support rear silencer with special tool 31 2 220 .

2010 BMW M3
Fig. 9: Identifying Clamps Screws

Unfasten nut.

2010 BMW M3

Unscrew nuts.

Unscrew nuts (2).

2010 BMW M3



CONVERTER WITH CENTRE MUFFLER (S65)
31 2 220


2010 BMW M3
Release screws.

Release screws.

2010 BMW M3

Release screws (1).
Installation:

Remove catalytic exhaust-gas converter with centre muffler.

2010 BMW M3


MUFFLERS PETROL
31 2 220


2010 BMW M3

Unfasten nut.

2010 BMW M3

Unscrew nuts.

Unscrew nuts (2).

2010 BMW M3



31 2 220


2010 BMW M3
Release screws.

Release screws.

2010 BMW M3

Release screws (1).
Installation:


2010 BMW M3


EXHAUST CATALYTIC CONVERTER

31 2 220


2010 BMW M3
Release screws.

Release screws.

2010 BMW M3

Release screws (1).
Installation:


2010 BMW M3


EXHAUST MANIFOLD
18 40 010 REMOVING AND INSTALLING/REPLACING LEFT EXHAUST MANIFOLD (S65)
WARNING: Scalding hazard! Only perform these tasks on an engine that has cooled
down.
Remove alternator. See ALTERNATOR WITH DRIVE .

Remove complete exhaust system.
Secure engine in installation position with special tool.
Lower front axle carrier. See 31 11 001 REPLACING FRONT AXLE CARRIER (M3) .
Remove heat shield.
Release nuts of individual flange pairs. Remove exhaust manifold. To install, replace nuts. Tightens nuts on
each flange. Tightening torque, see 18 40 1AZ in 18 40 EXHAUST MANIFOLD, EXHAUST SYSTEM .
Replace seals.
18 40 020 REMOVING AND INSTALLING/REPLACING RIGHT EXHAUST MANIFOLD (S65)

2010 BMW M3
Remove complete exhaust system.

Secure engine in installation position with special tool . See 11 00 670 SECURING ENGINE IN
INSTALLATION POSITION (S65) .
Lower front axle support . See 31 11 506 LOWERING/RAISING FRONT AXLE CARRIER (M3,
UNIVERSAL LIFTER) .
Remove right engine support arm . See 22 11 100 REPLACING RIGHT ENGINE SUPPORT ARM
(S65) .
Release screws.
Remove heat shield.
Fig. 33: Identifying Heat Shield Screws

Unscrew nuts.
Remove exhaust manifold (1).
Installation:
Replace nuts.
Tightens nuts on each flange.

2010 BMW M3
Replace seals, paying attention to installation location of seals.
Fig. 34: Identifying Exhaust Manifold With Nuts

2010 BMW M3
ENGINE PERFORMANCE Firing Order & Cylinder Identification - BMW - All Models
ENGINE PERFORMANCE
Firing Order & Cylinder Identification - BMW - All Models
FIRING ORDER & CYLINDER IDENTIFICATION
NOTE: This information is intended as a quick reference for firing order and cylinder
identification only. The information provided covers many vehicles and may
include some information that does not apply to the vehicle you have currently
selected.
4 CYLINDER ENGINE
Engine Configuation Firing Order Cylinder Identification
In-Line 4 1-3-4-2
6 CYLINDER ENGINE

2010 BMW M3
In-Line 6 1-5-3-6-2-4
V8 ENGINE
V8 1-5-4-8-6-3-7-2
V10 ENGINE

2010 BMW M3
V10 1-6-5-10-2-7-3-8-4-9
V12 ENGINE
V12 1-7-5-11-3-9-6-12-2-8-4-10
2010 BMW M3
SUSPENSION Front Axle - Repair
SUSPENSION
Front Axle - Repair
GENERAL
Headaches
Dizziness
Stomach aches
Vomiting
Diarrhoea
Cramps/fits
Unconsciousness

First aid measures
31 00... FRONT AXLE + STEERING: WHEEL/CHASSIS ALIGNMENT CHECK MUST BE

CARRIED OUT AFTER THE FOLLOWING WORK
2010 BMW M3
Fig. 1: Identifying Front Axle And Steering Wheel/Chassis Components

A wheel/chassis alignment check See 3200150 KDS CHASSIS/WHEEL ALIGNMENT CHECK WITH
VEHICLE LOAD UP TO DESIGN POSITION or 3200155 KDS CHASSIS/WHEEL ALIGNMENT
CHECK WITH RIDE HEIGHT MEASUREMENT WITHOUT VEHICLE LOAD must be carried out
after the following work:
Release of following screw/bolt connections:

Steering gear to front axle carrier
Control arm to front axle carrier
Support bearing to body (if centering pin is missing)
Tie rod end to tie rod
Replacement of following parts:

1. Front axle carrier
2. Steering gear
3. Gaiter (if the tie rod end has to be screwed off)
4. Control arm
5. Support bearing (if centering pin is missing)
6. Swivel bearing
2010 BMW M3
7. Tie rod end

8. Tie rod
31... FRONT AXLE OVERVIEW

2010 BMW M3
Fig. 2: Front Axle Overview

2010 BMW M3
31 00... INFORMATION ON REPLACING SHOCK ABSORBERS
Situation
When a shock absorber is faulty on one side (leaking, noises, limit values exceeded on the shock tester), often
both shock absorbers on the axle in question are replaced.
Effect
This is not necessary for technical reasons and causes the manufacturer not to recognize the unnecessarily
removed shock absorbers as defective parts. Unnecessarily high costs for the customer can be avoided by
replacing the shock absorber on one side only.
Procedure
If one shock absorber is damaged, it is only necessary to replace both shock absorbers when the car has driven
in excess of 80 000 km.
Exception: On all M-GmbH models, when a limit value is exceeded on one side, it is still necessary always to
replace both shock absorbers on the relevant axle.
Information on replacing shock absorbers on E65/E66 models with EDC before production 03/07
Component version (build date) before 03/07:
Both shock absorbers must be replaced
Component version (build date) after 03/07:
The shock absorbers can be replaced again individually.
If in doubt, always replace both shock absorbers.

EQUIPMENT)
reactions!

of ignition.
2010 BMW M3

sunlight.
month).


directly.
First Aid:
doctor.
Recycling

2010 BMW M3
31 00... INSTRUCTIONS (CHASSIS COMPONENTS MADE OF ALUMINUM)
Due to the chemical and corrosion characteristics of aluminum, always comply with the following points when
handling aluminum components:
Do not bring into contact with battery acid!

Do not clean with wire brushes made of brass or iron! Always use wire brushes with stainless steel
bristles!
Do not expose to flying sparks when grinding/separating! Cover components!
Do not strike with steel welding splashes! Cover components!
Do not expose to temperatures > 80C, even for brief periods! Temperatures in paint facilities do not have
the same impact
31.... LAYOUT OF SPRING STRUT SHOCK ABSORBER

2010 BMW M3
Fig. 3: Identifying Spring Strut Shock Absorber Components

31 00 MOBILE TABLE LIFT
WARNING: Danger of injury!

Before beginning work, position table lift with the lower frame securely on
the floor.
Danger area around mechanism below platform.
Do not reach into or step into the danger area.

Note permissible bearing capacity of table lift.
Mount load centrally (danger of tipping) and secure against shifting.
2010 BMW M3
Follow the operating instructions from the equipment manufacturer.
The mobile table lift is used for collision repairs and when removing large engines.
Adaptations for mounting front axle with engine and transmission.
ADAPTATIONS FOR MOUNTING FRONT AXLE WITH ENGINE AND TRANSMISSION

REFERENCE CHART
No. 10 For mounting swivel bearing with brake disc
No. 20 Retaining element for adjustable fixture
No. 30 Adjustable fixture
No. 40 Distance pin 40 x 160 mm
No. 70 Fixture with U-profile
No. 80 Plate fixture =100 mm
Fig. 4: Adaptations For Mounting Front Axle With Engine And Transmission
2010 BMW M3
Release star knob screw on working plate (B) of table lift; the working surface (B) can be extended by approx.
310 mm.
Release all push-pull clamps and the working plates can be shifted by approx. 20 mm.
Working plate (A and B) can be raised and lowered by 3 on the long side and by 5 on the transverse side.
Working plate (A and B) is subdivided by a coordinate system and a possible installation position is
recommended in the respective repair manual.
Fig. 5: Identifying Working Plates

IMPORTANT: Follow the operating instructions from the equipment manufacturer.
NOTE: Damaged threads in engine support may be repaired with Helicoil thread
inserts. Comply with the procedure described in the example.
2010 BMW M3
Fig. 6: Identifying Damaged Helicoil Thread

Procedure
1. Create a clean core hole; if necessary, drill out screw remnants
Fig. 7: Creating Clean Core Hole

2. Create locating thread for Helicoil thread insert

2010 BMW M3
Fig. 8: Creating Thread For Helicoil Thread Insert

3. Pick out Helicoil thread insert in accordance with the TABLE and screw into the locating thread until
flush with the original thread
Fig. 9: Inserting Helicoil Thread Into Locating Thread

4. Break drive pin and remove

2010 BMW M3
Fig. 10: Breaking Drive Pin

31 00... NOTES ON THREADED CHASSIS M3 CTR
See NOTES ON THREADED CHASSIS M3 CTR .
31..... PROCEDURE FOR BASE SUSPENSION SETTING M3 GTS/CTR
See PROCEDURE FOR BASE SUSPENSION SETTING M3 GTS/CTR .
00...... RAISING VEHICLE WITH TROLLEY JACK
IMPORTANT: Observe the following trolley-jack-related instructions:
1. Use only BMW-distributed/approved trolley jacks which have rubber plate

contact points.
2. Trolley jacks must be regularly serviced and always checked for
functional reliability before they are used!
3. Check the rubber plate on the trolley jack prior to each use, replacing if
necessary.
2010 BMW M3
Fig. 11: Identifying Trolley Jack With Rubber Plate

WARNING: The vehicle may be raised with a trolley jack only at the following jacking
points!
1. Car jacking point on reinforcement strut (rear-wheel drive)

2. Side car jacking points
3. Rear differential
Risk of damage: It is not permitted to raise the vehicle at the rear differential cover!
Fig. 12: Identifying Car Jacking Points

1. Car jacking point on front axle carrier (all-wheel drive)

2010 BMW M3
Fig. 13: Identifying Car Jacking Point On Front Axle Carrier (All-Wheel Drive)
31..... REBOUND AND COMPRESSION DAMPING SETTING SHOCK ABSORBER M3 GTS/CTR
See REBOUND AND COMPRESSION DAMPING SETTING SHOCK ABSORBER M3 GTS/CTR .
Danger of injury!
Impaired sight

First aid measures
2010 BMW M3


function is active.


Workshop mode
A = 10 mm
B = 7 mm
2010 BMW M3


Recycling
31..... SETTING FOR THREADED SUSPENSION M3 GTS/CTR
See SETTING FOR THREADED SUSPENSION M3 GTS/CTR .
FRONT AXLE SUSPENSION

2010 BMW M3
31 10 000 REMOVING AND INSTALLING COMPLETE FRONT AXLE (WITH SPRING STRUTS)
(M3)
IMPORTANT: Before removing front axle carrier:

In order to avoid damage to lifting platform, perform weight compensation on
vehicle.
Load spring strut domes with sand bags.
WARNING: SECURE ENGINE IN INSTALLATION POSITION WITH SPECIAL TOOL to

prevent it from falling down.
DANGER OF POISONING if oil is ingested/absorbed through the skin!
IMPORTANT: Adhere to the utmost cleanliness. Do not allow any dirt to enter the hydraulic
system.
Close off pipe connections with plugs.
Recycling
Catch and dispose of hydraulic fluid in a suitable container.

Draw off and dispose off hydraulic fluid from fluid reservoir
Disengage both brake hoses from spring strut holder, remove both BRAKE CALIPERS FROM
SWIVEL BEARING and tie up
Disconnect both plug connections for pulse generators and expose lines up to holder on spring strut
Disconnect both plug connections for brake pad sensor and expose lines up to holder on spring strut
Remove REINFORCEMENT COVER ON LEFT AND RIGHT
Remove both STABILIZER LINKS FROM SPRING STRUT
Disconnect PRESSURE LINE FROM POWER STEERING GEAR
Disconnect RETURN LINE FROM POWER STEERING GEAR
Remove LOWER SECTION OF STEERING SPINDLE FROM STEERING GEAR
Release nut (1) for return line (2).
Installation:
2010 BMW M3
Fig. 16: Identifying Return Line With Nut

Unscrew nut (1) and bolts (2).
Disconnect pressure line (3) from front axle carrier holder.
Installation:
Fig. 17: Identifying Pressure Line Nut And Bolts

Release screws (1).
Fold both holders (2) downwards.
Tie up hydraulic lines.

2010 BMW M3
Installation:

IMPORTANT: Guide spring struts with your hand when lowering and raising in order to avoid
damaging the wheel arches.
After lowering, the spring struts must be aligned to the front axle carrier and
secured in such a way that the ball joints of the control arms, tension struts
and tie rod ends are not damaged.
Remove both SPRING STRUTS FROM SPRING STRUT DOME .
Lower FRONT AXLE SUPPORT .
After installation
Fill and bleed HYDRAULIC SYSTEM

Check pipe connections for leaks
Carry out wheel alignment check See 3200150 KDS CHASSIS/WHEEL ALIGNMENT CHECK
WITH VEHICLE LOAD UP TO DESIGN POSITION or 3200155 KDS CHASSIS/WHEEL
ALIGNMENT CHECK WITH RIDE HEIGHT MEASUREMENT WITHOUT VEHICLE LOAD
if a spring strut with support bearing was or has been installed without centering pin.
Carry out STEERING ANGLE SENSOR ADJUSTMENT
31 10 010 REMOVING AND INSTALLING/REPLACING REINFORCEMENT PLATE (M3)

Driving without reinforcement plate is not permitted!

2010 BMW M3
Release screws (1).
Release screws (2) and remove reinforcement plate (3).
Installation:
Replace screws (2).
Fig. 19: Identifying Reinforcement Plate With Screws

FRONT SUB-FRAME
31 11 506 LOWERING/RAISING FRONT AXLE CARRIER (M3, UNIVERSAL LIFTER)
IMPORTANT: Before lowering front axle carrier:

vehicle.
WARNING: Danger to life!

SECURE ENGINE IN INSTALLATION POSITION WITH SPECIAL TOOL to
Secure ENGINE IN INSTALLATION POSITION WITH SPECIAL TOOL

2010 BMW M3

Disconnect plug connection (1) on ride-height sensor.
Disconnect plug connection (2) for Servotronic electrohydraulic converter.
Fig. 20: Identifying Plug Connection On Ride-Height Sensor


Failure to comply with the following instructions may result in the vehicle
slipping off the lifting platform and critically injuring other persons.
When supporting components, make sure that
the vehicle can no longer be raised or lowered

the vehicle does not lift off the locating plates on the lifting platform
Engage special tool 31 5 251 with a 2nd person helping completely on workshop jack.
Insert special tools 31 5 253 in telescopic supports of a profile rail pair.
NOTE: In a profile rail pair two profile rails are connected to each by toothing.
Insert special tools 31 5 256 in telescopic supports of other profile rail pair.
2010 BMW M3
Fig. 21: Identifying Special Tools 31 5 253 And 31 5 256 In Telescopic Supports
NOTE: The jacking points on the left side are shown.
Align special tools 31 5 253 and 31 5 256 to front axle carrier.
Support front axle carrier by operating workshop jack.
Fig. 22: Aligning Special Tools 31 5 253 And 31 5 256 To Front Axle Carrier
IMPORTANT: Pay attention to power steering hoses and lines when lowering and raising.
Hoses/lines must not be kinked/tensioned/bent!
Release bolts (1-4).
Lower front axle carrier by max. 10 cm.
Installation:
2010 BMW M3
Check threads for damage; if necessary, repair with HELICOIL THREAD INSERTS .
Screw (1) M12x90

Screw (2) M12x145
Screw (3) M12x53
Screw (4) M10x42
Fig. 23: Identifying Front Axle Carrier Bolts

Tighten down first screws (1) and then screws (2, 3, 4).
After installation
31 11 001 REPLACING FRONT AXLE CARRIER (M3)

vehicle.
WARNING: SECURE ENGINE IN INSTALLATION POSITION WITH SPECIAL TOOL to


2010 BMW M3

Remove BOTH FRONT WHEELS
Remove FRONT STABILIZER BAR
If necessary, disconnect plug connection from ride-height sensor
Remove both TENSION STRUTS FROM FRONT AXLE CARRIER
Remove both CONTROL ARMS FROM FRONT AXLE CARRIER
Remove both TIE RODS ON POWER STEERING GEAR
Disconnect plug connection on Servotronic electrohydraulic converter, remove POWER STEERING
GEAR FROM FRONT AXLE CARRIER and tie up
Lower FRONT AXLE CARRIER
Installation:
Fig. 24: Identifying Pressure Line With Nuts And Bolts

Release screws (1).
Fold holders (2) downwards and tie up.
Installation:
2010 BMW M3

Remove connecting lead (1) for Servotronic electrohydraulic converter.
Remove both engine mounts See 2211001 REPLACING RIGHT ENGINE MOUNT (S65) or 2211011
REPLACING LEFT ENGINE MOUNT (S65) (2).
Installation:
Use previous front axle carrier as a template for modifying or replacing small parts.
Fig. 26: Identifying Connecting Lead And Engine Mounts

After installation
Perform CHASSIS ALIGNMENT CHECK

2010 BMW M3
STRUTS WITH RUBBER MOUNTS

31 12 080 REMOVING AND INSTALLING/REPLACING BOTH TENSION STRUTS
Except M3: Remove BOTH FRONT WHEELS

Release nut (1); if necessary, grip at Torx socket.
Installation:
Keep tension strut to swivel bearing connection clean and free from oil and grease.
Fig. 27: Identifying Tension Strut Nut

Release bolt (1) and remove tension strut.
Raise locking nut (2) in area of bore and detach from front axle support.
Installation:
Replace locking nut.
Tighten bolt connection in NORMAL POSITION .
31 12 1AZ
2010 BMW M3
Fig. 28: Identifying Tension Strut Bolt And Front Axle Support Nut
31 12 000 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT CONTROL ARM
NOTE: If the control arm is detached from the front axle carrier, it is necessary after
reinstallation to carry out a wheel/chassis alignment check.
Except M3:
Remove FRONT WHEEL

Except M3:
If necessary, remove jointed rod of ride-height sensor from control arm.

2010 BMW M3
Fig. 29: Locating Jointed Rod Of Ride-Height Sensor

M3 only:
Slacken nut (1).
Remove jointed rod (2) from control arm.
Installation:
Sensor lever (3) must point from ride-height sensor to left front wheel.
Fig. 30: Identifying Jointed Rod And Ride Height Sensor Lever With Nut
Release nut (1); if necessary, grip at Torx socket (T40).
Installation:
Keep control arm to swivel bearing connection clean and free from oil and grease.

2010 BMW M3
Fig. 31: Identifying Control Arm Nut

Slacken nut (1).
Remove screw towards front; if necessary remove bracket (2) with ride-height sensor.
Take off control arm.
Installation:
Screw head must point in direction of travel.
Tighten down bolt connection in NORMAL POSITION .

2010 BMW M3
Fig. 32: Identifying Ride-Height Sensor Bracket And Nut

After installation
Perform wheel/chassis alignment check See 3200150 KDS CHASSIS/WHEEL ALIGNMENT

CHECK WITH VEHICLE LOAD UP TO DESIGN POSITION or 3200155 KDS
CHASSIS/WHEEL ALIGNMENT CHECK WITH RIDE HEIGHT MEASUREMENT WITHOUT
VEHICLE LOAD
Carry out steering angle sensor adjustment/adjustment for active front steering See 6131996
CARRYING OUT STEERING ANGLE SENSOR ADJUSTMENT or 3210005 ADJUSTMENT
FOR ACTIVE FRONT STEERING
31 12 138 REPLACING RUBBER MOUNTS ON BOTH TRAILING LINKS
IMPORTANT: For driving dynamic reasons the rubber mounts of both tension struts must
always be replaced!
Because the tension strut is made of aluminum, the rubber mount may only be
changed once!
Marking of rubber mount replacement must be made with a center punch in
area (A)!
Tension struts which already have a punch mark in area (A) must be replaced!
Changing the rubber mount again is prohibited!
Fig. 33: Identifying Tension Struts With Punch Mark Area

Check ball joints of tension struts while installed for damage, replace TENSION STRUTS if necessary
Remove both TENSION STRUTS
NOTE: Special tool 31 5 271 serves to remove and install the rubber mount.
2010 BMW M3
AUS Removal
EIN Installation
Fig. 34: Installing Rubber Mount Using Special Tool 31 5 271


Special tool 31 5 271 must be exactly flush with rubber mount bushing.
Press rubber mount with special tools 31 5 271 and 31 5 272 out of tension strut.
Fig. 35: Pressing Rubber Mount Using Special Tools 31 5 271 And 31 5 272 Out Of Tension Strut
Mount take-up 31 5 273 on special tool 33 4 450 DEVICE .
Install rubber mount (1) in special tool and pull together.

2010 BMW M3
Fig. 36: Installing Rubber Mount In Special Tool 33 4 450

IMPORTANT: Align rubber mount as pictured by way of slot to arrow marking (P). Deviation
must not exceed 5.
A = 30 5
NOTE: Keep rubber mount and bushing in tension strut clean and free from grease.
Fig. 37: Identifying Rubber Mount With Aligning Marking

Draw in rubber mount (1) with special tools 31 5 271 and 31 5 272 until special tool 31 5 273 rests on tension
strut.
Remove special tools 33 4 450 DEVICE and 31 5 273.
Install rubber mount (1) as far as it will go.

2010 BMW M3
Fig. 38: Installing Rubber Mount Using Special Tools 31 5 271 And 31 5 272
Installation:
Protrusion (A) equally large.
Fig. 39: Identifying Protrusion

IMPORTANT: Mark replacement of tension strut rubber mounts by means of a punch mark in
area (A).
2010 BMW M3
Fig. 40: Identifying Tension Struts With Punch Mark Area

WHEEL BEARINGS AND STUB AXLE

31 21 180 REMOVING AND INSTALLING/REPLACING BEARING FOR FRONT WHEEL
Remove BRAKE DISK
Release screws (1).
Press wheel bearing (2) off swivel bearing with a suitable tool.
Installation:

2010 BMW M3
Fig. 41: Identifying Wheel Bearing With Screw

Installation:
When reusing, recut all the threads in the wheel bearing.
Keep contact surface (1) of swivel bearing and wheel bearing clean and free from oil and grease.
Fig. 42: Identifying Contact Surface Of Swivel Bearing And Wheel Bearing
31 21 090 REPLACING (REMOVING AND INSTALLING) LEFT OR RIGHT SWIVEL BEARING

(M3)
IMPORTANT: To ensure optimum power transmission from the swivel bearing to the spring
strut, it is essential to use special tool 31 5 230 for mounting on the spring
strut!
Special tool 31 5 230 only be removed after the bolt connection has been
2010 BMW M3
tightened down!
Remove FRONT BRAKE DISC
Slacken nut (1).
Installation:
Fig. 43: Identifying Jointed Rod And Ride Height Sensor Lever With Nut
Remove CONTROL ARM FROM SWIVEL BEARING .
Remove TIE ROD END FROM SWIVEL BEARING .
Remove TENSION STRUT FROM SWIVEL BEARING
Support swivel bearing with workshop jack and a suitable mounting.
Release nut (1), remove holder (3) and remove screw (2).
Installation:

2010 BMW M3
Fig. 44: Identifying Holder Screw And Nut

Release screw (1).
Remove pulse generator (2) from swivel bearing.
Installation:
Clean bore hole for pulse generator and grease with Staburags NBU 12/K lubricating grease.
Fig. 45: Identifying Pulse Generator Of Swivel Bearing With Screw

2010 BMW M3
IMPORTANT: Spread swivel bearing under bolt opening to avoid damaging the swivel
bearing.
Spread swivel bearing with special tool 31 2 230 SOCKET .
Lower workshop jack and remove swivel bearing.
Installation:
Keep press fit of swivel gearing and spring strut in lower area clean and free from oil and grease.
Fig. 46: Identifying Swivel Bearing With Special Tool 31 2 230

IMPORTANT: Align special tool 31 5 230 as pictured in order to ensure correct contact with
swivel bearing.
tightened down!
Installation:
Spread swivel bearing with special tool 31 2 230 SOCKET , align by means of gap to web (1) on back of
spring strut and push upwards.
Pull swivel bearing with special tool 31 5 230 up to stop (tightening torque = 20 Nm).
Remove special tool 31 2 230 SOCKET .

2010 BMW M3
Fig. 47: Aligning Special Tool 31 5 230

Replacement
Modify WHEEL BEARING

Modify BRAKE CARRIER/BRAKE GUARD PLATE
After installation
Replacement: Perform chassis alignment check See 3200150 KDS CHASSIS/WHEEL ALIGNMENT
VEHICLE LOAD
SPRING STRUT
Situation
Effect
Procedure
2010 BMW M3
31.... LAYOUT OF SPRING STRUT SHOCK ABSORBER

2010 BMW M3
Fig. 48: Identifying Spring Strut Shock Absorber Components

31 31 003 REMOVING AND INSTALLING COMPLETE FRONT LEFT OR RIGHT SPRING STRUT
(M3)
NOTE: If a spring strut with support bearing is released on the body without the
centering pin, a chassis/wheel alignment check must be carried out after
installation.
Remove SWIVEL BEARING

2010 BMW M3

Secure spring strut against falling out.
Unscrew nuts (2).
Installation:
Make sure protective cap is correctly seated.
Fig. 49: Identifying Protective Cap With Nuts

Installation:

2010 BMW M3
Fig. 50: Identifying Self-Locking Nuts

Remove spring strut towards bottom.
Installation:
Clean contact surface in spring strut dome.
Align spring strut by means of centering pin to bore in wheel arch and slide upwards.
Fig. 51: Identifying Spring Strut

After installation
if a spring strut with support bearing was or has been installed without centering pin.
2010 BMW M3
51 71 345 REMOVING AND INSTALLING/REPLACING LEFT (OR RIGHT) SUSPENSION

CROSSBRACE
IMPORTANT: Driving without the suspension crossbrace is not permitted. (Risk of damage to
the body).
tightened down with special tool 00 9 120 TORSION ANGLE GAUGE .

SECTION
right side.
Release screw (1).
Release nuts (2) and remove suspension cross-brace (3).
Installation:
Tighten down screw (1) and nuts (2) to torque and then to angle of rotation using special tool 00 9 120
TORSION ANGLE GAUGE .
Tightening torque for screw (1) 51 71 18AZ .

2010 BMW M3
Fig. 52: Identifying Suspension Cross-Brace With Screw And Nuts

Tightening torque for nuts (2) 51 71 19AZ .

CROSSBRACE RING

Driving without the suspension crossbrace is not permitted. (Risk of damage to
the body).
Remove SUSPENSION CROSSBRACE MOUNTING
right side.

Release nuts (2) and remove suspension cross-brace ring (3).
Installation:
2010 BMW M3
Replace nuts (2).
Fig. 54: Identifying Protective Cap And Suspension Cross-Brace Ring With Nuts
51 71 348 REMOVING AND INSTALLING/REPLACING SUSPENSION CROSSBRACE MOUNTING
IMPORTANT: Driving without the suspension crossbrace is not permitted. (Risk of damage to
the body).
Screws of suspension cross-brace and cross-brace mounting must be
tightened to torque and then tightened down with special tool 00 9 120
TORSION ANGLE GAUGE .
Remove SUSPENSION CROSSBRACE MOUNTING
Installation:
Replace screw (1).

2010 BMW M3
Tighten down screw (1) to torque and then to angle of rotation using special tool 00 9 120 TORSION ANGLE
GAUGE .
Fig. 55: Identifying Heater Bulkhead With Screws

Replacement
If necessary, release suspension cross-brace grommets (4)
Installation:
Replace studs (1).
Fig. 56: Identifying Stud, Cross-Brace Mounting, Grommets And Heater Bulkhead
2010 BMW M3
31 31 041 REPLACING FRONT LEFT OR RIGHT SPRING STRUT (M3)
IMPORTANT: When replacing shock absorber/spring strut, renew auxiliary damper!
WARNING: Before using the special tool 313340 SPRING TENSIONER take care to
read through the Owner's Handbook!
All the safety information and instructions contained in the Owner's
Handbook must be strictly observed!
Failure to observe these safety precautions and instructions increases
the risk of serious physical injury, damage to your health and damage to
property and equipment!
IMPORTANT: 1. Prior to each use, check the special tools for defects, modifications and
operational reliability.
4. These special tools are intended solely for the purpose of tightening and
relieving cylindrical and tapered suspension springs.
5. Keep special tools dry, clean and (down to the spindle) free from grease.
6. The use of an impact screwdriver on special tool 31 3 341 is prohibited!
7. Do not compress coil spring to full extent.
Remove FRONT SPRING STRUT .
Removing
Clamp special tool 31 3 341 in vice.
Fit special tools 31 3 351 from above on special tool 31 3 341 until retaining bolts (1) can be felt and heard to
snap into place.
Check seating of special tools 31 3 351 and, if necessary, correct.

2010 BMW M3
Fig. 57: Fitting Special Tools 31 3 351 On Special Tool 31 3 341

Clean coil spring to remove all coarse dirt and mount on special tools 31 3 351.
Turn spring strut until lower end of coil spring (1) points upwards.
Fig. 58: Turning Spring Strut Of Coil Spring


The upper and lower coils of the coil spring must be situated entirely in
the recess of special tools 31 3 351.
Compress coil spring until stress on piston rod is relieved.

2010 BMW M3
Fig. 59: Compressing Coil Spring On Piston Rod


Nut may only be released if:
1. the coil spring has been sufficiently tensioned with special tools 31
3 341 and 31 3 351
2. the upper and lower coils of the coil spring are situated entirely in
the recess of special tools 31 3 351
Fig. 60: Removing Support Bearing

Release nut (1) (grip piston rod in so doing) and remove support bearing (2).
IMPORTANT: Risk of contamination!

Ensure conditions of absolute cleanliness when handling the two-part support
bearing.
2010 BMW M3
Fig. 61: Identifying Support Bearings

Pull off support disc (1) and auxiliary damper (2) with gaiter (3) from piston rod of shock absorber (4).
Remove shock absorber (4) sideways from coil spring.
Fig. 62: Pulling Support Disc From Piston Rod Of Shock Absorber
Relieve tension on coil spring and remove from special tools 31 3 351.
2010 BMW M3
Fig. 63: Relieving Tension On Coil Spring Using Special Tools 31 3 351
Installation
IMPORTANT: Risk of mixing up

The lower coil of the coil spring is slightly smaller than the upper coil.
Fig. 64: Identifying Lower And Upper Coil Of Spring

Accommodate coil spring with special tools 31 3 351.
Turn coil spring until lower end of coil spring (1) points upwards.
2010 BMW M3
Fig. 65: Positioning Lower End Of Coil Spring


Do not compress coil spring to full extent.
the recess of special tools 31 3 351.
Tension coil spring.
Fig. 66: Compressing Upper And Lower Coils Of Coil Spring Using Special Tools 31 3 351
Replace spring pad (1).
IMPORTANT: Make sure spring pad (1) is correctly seated on shock absorber. Guide (2) must
be correctly seated in opening (3) in shock absorber!
2010 BMW M3
Fig. 67: Identifying Spring Pad And Guide Opening On Shock Absorber
Check auxiliary damper and gaiter for damage, replace if necessary.
Fig. 68: Identifying Damper And Gaiter

IMPORTANT: Make sure support disc and folding of gaiter are correctly positioned (see
graphic).
Insert shock absorber (4) in tensioned coil spring.
Slide auxiliary damper (2) with gaiter (3) onto piston rod.
Attach support disc (1) to piston rod.

2010 BMW M3
Fig. 69: Inserting Shock Absorber In Tensioned Coil Spring

IMPORTANT: Make sure spring pad (1) is correctly seated on support bearing.
Fig. 70: Identifying Spring Pad

Check support bearing (1) for damage, replace if necessary.
Attach support bearing (1) to piston rod.
Coat mounts (2) with Circo Light (sourcing reference: BMW Parts Service).
2010 BMW M3
Fig. 71: Identifying Support Bearing And Coat Mounts With Circo Light
NOTE: Joint plate (1) is correctly seated in support bearing mounts after tension is
relieved on coil spring.
Attach joint plate (1) to piston rod.
Replace nut (2) and tighten down (gripping piston rod in so doing).
Fig. 72: Identifying Joint Plate With Nut

IMPORTANT: Upper coil of coil spring must rest positively on support bearing!
Lower end of coil spring (2) must rest on stop of spring pad (1)!
Relieve tension on coil spring.

2010 BMW M3
Check installation position of gaiter (3), correct folds if necessary.
Fig. 73: Checking Installation Position Of Gaiter

After installation
if a spring strut with support bearing was or is installed without centering pin.
SPRING WITH SUSPENSION

31 33 001 (REMOVING AND INSTALLING) REPLACING FRONT LEFT OR RIGHT SPRING
STRUT SUPPORT BEARING (M MODEL)
NOTE: Procedure is described in the document "REPLACING FRONT LEFT OR RIGHT

SPRING STRUT ".
Replacement
If necessary, twist out centering pin (1).
NOTE: If a support bearing (2) was fitted without centering pin (1), the centering pin (1)
of the new support bearing (2) must be twisted out.
2010 BMW M3
Fig. 74: Identifying Support Bearing And Centering Pin

31 33 095 MEASURING RIDE-LEVEL HEIGHT OF VEHICLE
Move vehicle into NORMAL POSITION
Determine actual ride height (A) - to do so, attach tape measure to rim flange (2) at bottom middle and measure
to lower edge of wheel arch (1).
Fig. 75: Identifying Actual Ride Height From Lower Edge Of Wheel Arch To Rim Flange
31 33 100 REMOVING AND INSTALLING/REPLACING COIL SPRING FOR FRONT LEFT OR

RIGHT SPRING STRUT (M MODEL)
IMPORTANT: For safety reasons, both coil springs on the relevant axle must always be
replaced on motorsport vehicles!
2010 BMW M3
NOTE: The coil spring is allocated in the Electronic Parts Catalogue (ETK) under the
menu item "Spring table" after the vehicle identification number has been
entered and the relevant optional extra of the car has been selected.
NOTE: Procedure is described in the document "REPLACING FRONT LEFT OR RIGHT

SPRING STRUT ".
STABILIZER BAR
31 35 000 REMOVING AND INSTALLING/REPLACING FRONT STABILIZER
IMPORTANT: To avoid complaints being made by the customer about noise (e.g. grating), set
the car on its wheels and tighten down the stabilizer mounting to specified
torque.

E88: Remove V-strut on left and right
Remove ANTI-ROLL BAR LINK ON BOTH SIDES FROM STABILIZER
M3:
Remove REINFORCEMENT PLATE .
Installation:

2010 BMW M3
Except M3: Release screws (1) and remove brackets.
Release nuts (2); if necessary, grip screws after repair.
Remove stabilizer (3); if necessary, press off front axle carrier with a suitable tool.
Installation:
Check both RUBBER MOUNTS FOR DAMAGE and replace if necessary.
Replace self-locking nuts (do not tighten down).
Set car on its wheels and tighten down nuts to tightening torque 31 35 1AZ .
Fig. 77: Identifying Stabilizer, Bracket Screws And Nuts

Repair solution for studs
Release screw (1).
Raise lock nut (2) in area of bore and detach from front axle carrier.
Drive out studs (3) in upwards direction and remove/feed out through an opening in front axle carrier.
Installation:
Insert new screws from above.
Replace lock nut.

2010 BMW M3
Fig. 78: Identifying Stud, Front Axle Carrier Nuts And Screws
Replacement
Remove both RUBBER MOUNTS FROM STABILIZER
31 35 005 REMOVING AND INSTALLING/REPLACING PUSH ROD (STABILIZER LINK) FOR

LEFT/RIGHT STABILIZER
Note (M3 only):
Make sure stabilizer link is installed in correct position.
A. Connection, stabilizer link to spring strut

B. Connection, stabilizer link to stabilizer
Fig. 79: Identifying Connections Of Stabilizer Link To Spring Strut And Stabilizer Link To Stabilizer
Release nut (1) and remove bracket for brake hose.

2010 BMW M3
Release nut (3) and remove stabilizer link (2).
Installation:
Fig. 80: Identifying Nuts For Brake House Bracket And Stabilizer Link
31 35 021 REPLACING BOTH RUBBER MOUNTS OF STABILIZER MOUNTING ON FRONT AXLE

CARRIER (M3)
NOTE: Rubber mounts (consisting of upper and lower sections) must be replaced in
pairs.
Remove STABILIZER FROM FRONT AXLE CARRIER
IMPORTANT: When installing the stabilizer, make sure the rubber mount lower section is
correctly engaged on both sides.
NOTE: Insert a screwdriver on both sides between retaining bracket (1) and rubber
mount lower section (3).
Snap out retaining bracket (1).
Remove rubber mount lower section (3) and rubber mount upper section (2).
Installation:
2010 BMW M3
Make sure rubber mount halves contact stabilizer stop correctly.
Fig. 81: Identifying Retaining Bracket, Rubber Mount Of Lower And Upper Section
Installation:
Keep retaining bracket (1), rubber mount upper section (2), rubber mount lower section (3) and stabilizer clean
and free from oil and grease.
Insert rubber mount upper section (2) in retaining bracket (1). Guide (4) must be correctly seated in opening (5)
in the process.
Catches on rubber mount lower section (3) must not be damaged and must be located in the designated recesses
in the retaining bracket (1).
Fig. 82: Identifying Retaining Bracket, Rubber Mount Of Lower And Upper Section And Guide
2010 BMW M3
SUSPENSION Front Axle - Repair - M3
SUSPENSION
Front Axle - Repair - M3
GENERAL
Headaches
Dizziness
Stomach aches
Vomiting
Diarrhoea
Cramps/fits
Unconsciousness

First aid measures:
Danger of injury!

2010 BMW M3
Impaired sight

First aid measures:

Recycling:
00 ... ... RAISING VEHICLE WITH TROLLEY JACK

2010 BMW M3
1. Use only BMW-distributed/approved trolley jacks which have rubber plate contact points.
2. Trolley jacks must be regularly serviced and always checked for functional reliability before they are
used!
3. Check the rubber plate on the trolley jack prior to each use, replacing if necessary.
Fig. 1: Identifying Trolley Jack

points!

2010 BMW M3
Fig. 2: Identifying Car Jacking Point On Reinforcement Strut

Fig. 3: Identifying Car Jacking Point On Front Axle Carrier

31 ... . FRONT AXLE OVERVIEW

2010 BMW M3
Fig. 4: Overview Of Front Axle

Safety precautions and general information
31 .. .. LAYOUT OF SPRING STRUT SHOCK ABSORBER

2010 BMW M3
Fig. 5: Layout Of Spring Strut Shock Absorber

31 00 ... FRONT AXLE + STEERING: WHEEL/CHASSIS ALIGNMENT CHECK MUST BE

CARRIED OUT AFTER THE FOLLOWING WORK
2010 BMW M3
Fig. 6: Identifying Front Axle And Steering Components

A wheel/chassis alignment check must be carried out after the following work:

Steering gear to front axle carrier
Control arm to front axle carrier
Support bearing to body (if centering pin is missing)
Tie rod end to tie rod

1. Front axle carrier
2. Steering gear
3. Gaiter (if the tie rod end has to be screwed off)
4. Control arm
5. Support bearing (if centering pin is missing)
6. Swivel bearing
7. Tie rod end
8. Tie rod
2010 BMW M3
31 00 ... INFORMATION ON REPLACING SHOCK ABSORBERS
Facts:
Consequence:
removed shock absorbers as damaged parts. Unnecessarily high costs for the customer can be avoided by
Procedure:
in excess of 50,000 km.
Both shock absorbers must be replaced.
31 00 ... INSTRUCTIONS (CHASSIS COMPONENTS MADE OF ALUMINUM)
Due to the chemical and corrosion characteristics of aluminum, always comply with the following points when
handling aluminum components:
Do not bring into contact with battery acid!

Do not clean with wire brushes made of brass or iron! Always use wire brushes with stainless steel
bristles!
Do not expose to flying sparks when grinding/separating! Cover components!
Do not strike with steel welding splashes! Cover components!
Do not expose to temperatures > 80C, even for brief periods! Temperatures in paint facilities do not have
the same impact
2010 BMW M3
NOTE: Damaged threads in engine carrier may be repaired with Helicoil thread inserts.
Comply with the procedure described in the example.
Fig. 7: Identifying Helicoil Thread Damaged Area

Procedure:
1. Create a clean core hole; if necessary, drill out screw remnants
Fig. 8: Drilling Out Screw

2. Create locating thread for Helicoil thread insert

2010 BMW M3
Fig. 9: Inserting Helicoil Thread

3. Pick out Helicoil thread insert in accordance with the table and screw into the locating thread until flush
with the original thread
Fig. 10: Identifying Helicoil Thread Insert In Accordance

4. Break drive pin and remove

2010 BMW M3
Fig. 11: Removing Break Drive Pin

FRONT AXLE SUSPENSION

31 10 000 REMOVING AND INSTALLING COMPLETE FRONT AXLE (WITH SPRING STRUTS)
(M3)

vehicle.
WARNING: Secure engine in installation position with special tool to prevent it from
falling down. See 11 00 670 SECURING ENGINE IN INSTALLATION
POSITION (S65) .
Danger of poisoning if oil is ingested/absorbed through the skin!
IMPORTANT: Adhere to the utmost cleanliness. Do not allow any dirt to enter the hydraulic
system.
Close off pipe connections with plugs.
Recycling:
Catch and dispose of hydraulic fluid in a suitable container.

2010 BMW M3
POSITION (S65) .
Draw off and dispose off hydraulic fluid from fluid reservoir
Disengage both brake hoses from spring strut holder, remove both brake calipers from swivel bearing
and tie up. See 34 11 519 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT
FRONT BRAKE CALIPER .
Disconnect both plug connections for pulse generators and expose lines up to holder on spring strut
Disconnect both plug connections for brake pad sensor and expose lines up to holder on spring strut
Remove reinforcement plate
Remove reinforcement cover on left and right. See 51 71 ... REMOVING AND
INSTALLING/REPLACING LEFT/RIGHT REINFORCEMENT COVER .
Remove both stabilizer links from spring strut
Disconnect pressure line from power steering gear . See 32 13 060 REMOVING AND
INSTALLING (REPLACING) POWER STEERING GEAR (M3) .
Disconnect return line from power steering gear . See 32 13 060 REMOVING AND INSTALLING
(REPLACING) POWER STEERING GEAR (M3) .
Remove lower section of steering spindle from steering gear . See 32 31 070 REMOVING AND
INSTALLING / REPLACING LOWER SECTION OF STEERING SPINDLE .
Installation:
Tightening torque, see 32 41 PUMP AND OIL SUPPLY .


2010 BMW M3
Installation:
Fig. 13: Identifying Pressure Line Bolts With Nut

Release screws (1).
Fold both holders (2) downwards.
Tie up hydraulic lines.
Installation:

2010 BMW M3
Fig. 14: Identifying Both Holders With Screws

IMPORTANT: Guide spring struts with your hand when lowering and raising in order to avoid
damaging the wheel arches.
After lowering, the spring struts must be aligned to the front axle carrier and
secured in such a way that the ball joints of the control arms, tension struts
and tie rod ends are not damaged.
Remove both spring struts from spring strut dome .
Lower front axle support .
After installation:
Fill and bleed hydraulic system . See 32 13 006 BLEEDING POWER STEERING UNIT .
Check pipe connections for leaks
Carry out wheel alignment check if a spring strut with support bearing was or has been installed without
centering pin. See 32 00 150 KDS CHASSIS/WHEEL ALIGNMENT CHECK WITH LOAD UP TO
DESIGN POSITION or 32 00 155 KDS CHASSIS/WHEEL ALIGNMENT CHECK WITH RIDE-
HEIGHT MEASUREMENT WITHOUT LOAD .
Carry out steering angle sensor adjustment . See 61 31 996 CARRYING OUT STEERING ANGLE
SENSOR ADJUSTMENT .
31 10 010 REMOVING AND INSTALLING/REPLACING REINFORCEMENT PLATE (M3)

Driving without reinforcement plate is not permitted!

2010 BMW M3
Release screws (1).
Release screws (2) and remove reinforcement plate (3).
Installation:
Replace screws (2).
Tightening torque, see 31 10 FRONT AXLE SUSPENSION .
Fig. 15: Identifying Reinforcement Plate With Screws

FRONT SUB-FRAME
31 11 001 REPLACING FRONT AXLE CARRIER (M3)

vehicle.
WARNING: Secure engine in installation position with special tool to prevent it from
POSITION (S65) .
Secure engine in installation position

2010 BMW M3

Remove both front wheels . See WHEEL AND TIRES - REPAIR .
Remove front stabilizer bar
Remove reinforcement cover on left and right . See 51 71 ... REMOVING AND
Remove lower section of steering spindle from steering gear . See 32 31 070 REMOVING AND
INSTALLING / REPLACING LOWER SECTION OF STEERING SPINDLE .
If necessary, disconnect plug connection from ride-height sensor
Remove both tension struts from front axle carrier.
Remove both control arms from front axle carrier.
Remove both tie rods on power steering gear . See 32 21 231 REPLACING (REMOVING AND
INSTALLING) LEFT OR RIGHT TIE ROD .
Disconnect plug connection on Servotronic electrohydraulic converter, remove power steering gear
from front axle carrier and tie up. See 32 13 060 REMOVING AND INSTALLING (REPLACING)
POWER STEERING GEAR (M3) .
Lower front axle carrier.
Installation:
Tightening torque 32 41 11AZ . See 32 41 PUMP AND OIL SUPPLY .
Fig. 16: Identifying Pressure Line Bolts With Nut

Release screws (1).

2010 BMW M3
Fold holders (2) downwards and tie up.
Installation:
Fig. 17: Identifying Both Holders With Screws

Remove connecting lead (1) for Servotronic electrohydraulic converter.
Remove both engine mounts (2). See ENGINE AND GEARBOX SUSPENSION .
Installation:
Use previous front axle carrier as a template for modifying or replacing small parts.
Fig. 18: Identifying Engine Mounts And Connecting Lead

2010 BMW M3
After installation:
Perform chassis alignment check . See 32 00 150 KDS CHASSIS/WHEEL ALIGNMENT CHECK
WITH LOAD UP TO DESIGN POSITION .
SENSOR ADJUSTMENT .
31 11 506 LOWERING/RAISING FRONT AXLE CARRIER (M3, UNIVERSAL LIFTER)
00 2 030
MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS
31 5 251
31 5 253
31 5 256
FRONT AXLE - SPECIAL TOOLS

vehicle.

Secure engine in installation position with special tool to prevent it from
POSITION (S65) .
Secure engine in installation position with special tool .

Remove reinforcement cover on left and right . See 51 71 ... REMOVING AND
Remove lower section of steering spindle from steering gear .
Disconnect plug connection (1) on ride-height sensor.
Disconnect plug connection (2) for Servotronic electrohydraulic converter.

2010 BMW M3



Engage special tool 31 5 251 with a 2nd person helping completely on workshop jack 00 2 030 .
Fig. 20: Identifying Special Tool (31 5 256, 31 5 253 And 31 5 251 With 00 2 030)
2010 BMW M3
Support front axle carrier by operating workshop jack 00 2 030 .
Fig. 21: Aligning Special Tools (31 5 253 And 31 5 256) To Front Axle Carrier
IMPORTANT: Pay attention to power steering hoses and lines when lowering and raising.
Hoses/lines must not be kinked/tensioned/bent!
Release bolts (1-4).
Installation:
Check threads for damage; if necessary, repair with Helicoil thread inserts .
Screw (1) M12x90

Screw (2) M12x145
Screw (3) M12x53
Screw (4) M10x42
2010 BMW M3
Fig. 22: Identifying Front Axle Carrier Screws

Tighten down first screws (1) and then screws (2, 3, 4).
After installation:
SENSOR ADJUSTMENT .
31 11 506 LOWERING/RAISING FRONT AXLE CARRIER (SPECIAL TOOL SWZ00-2040)
00 2 030
00 2 040
MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS
31 4 051
31 4 100
31 4 170

vehicle.
2010 BMW M3

Secure engine in installation position with special tool to prevent it from
POSITION (S65) .
Secure engine in installation position with special tool . See 11 00 670 SECURING ENGINE IN
INSTALLATION POSITION (S65) .
Remove front wheels . See WHEEL AND TIRES - REPAIR .
IMPORTANT: Use special tool to avoid preliminary damage to ball joint in upper control arm
and the necessary removal of the swivel bearing.
Press plug on left and right out of spring strut dome.
Secure swivel bearing (1) on left and right with special tool 31 4 170 in
installation position.
Fig. 23: Identifying Swivel Bearing Installation Position

Remove underbody protection at front and rear .
Remove steering gear cover at top left and right .
Remove reinforcement plate .
Partially detach front left and right wheel arch covers (rear section) in rear area.
Remove lower control arm from spring strut holder .
Version with active steering:
Disconnect plug connection (1) and unclip line (2) from front axle carrier.
2010 BMW M3
Fig. 24: Identifying Plug Connection And Unclip Line

Release nuts and remove screws (1) towards bottom.
Tie up power steering gear (2).
Installation:
Replace screws and nuts.
Tightening torque, see 32 00 1AZ in 32 00 STEERING .
Fig. 25: Identifying Power Steering Gear With Screws

If necessary, position special tool 00 2 040 with a 2nd person helping on workshop jack 00 2 030 .
Insert special tools 31 4 051 and 31 4 100 into corresponding mountings of special tool 00 2 040 .
Lower special tool 33 3 274.

2010 BMW M3
Fig. 26: Identifying Special Tool Position

Support front axle carrier by operating workshop jack 00 2 030 .
Fig. 27: Aligning Special Tools (31 4 051 And 31 4 100) To Front Axle Carrier
Installation:
Tighten down first screws (1) and then screws (2).

2010 BMW M3


Follow operations must be carried out during lowering:
Remove heat exchanger from front axle carrier and tie up

Remove stabilizer (conventional) from front axle carrier and tie back
Remove all hydraulic lines on front axle carrier or stabilizer retaining
bracket and tie up
Version with active front steering: Disconnect plug connection and
expose connecting line up to power steering gear
After installation:
Carry out steering angle sensor adjustment/adjustment for active front steering . See 61 31 996
CARRYING OUT STEERING ANGLE SENSOR ADJUSTMENT .
STRUTS WITH RUBBER MOUNTS

31 12 000 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT CONTROL ARM
NOTE: If the control arm is detached from the front axle carrier, it is necessary after
Except M3:
2010 BMW M3
Remove front wheel . See WHEEL AND TIRES - REPAIR .

Except M3:
If necessary, remove jointed rod of ride-height sensor from control arm.
Fig. 29: Locating Jointed Rod Clip

M3 only:
Slacken nut (1).
Installation:
2010 BMW M3
Fig. 30: Identifying Jointed Rod And Sensor Lever

Installation:
Keep control arm to swivel bearing connection clean and free from oil and grease.
Tightening torque 31 12 4AZ , see 31 12 CONTROL ARMS AND STRUTS
Fig. 31: Identifying Self-Locking Nut

Slacken nut (1).
Remove screw towards front; if necessary remove bracket (2) with ride-height sensor.
Take off control arm.

2010 BMW M3
Installation:
Tighten down bolt connection in normal position . See 32 00 ... MOVING VEHICLE INTO NORMAL
POSITION .
Tightening torque 31 12 3AZ , see 31 12 CONTROL ARMS AND STRUTS .
Fig. 32: Identifying Bracket With Ride-Height Sensor

After installation:
Carry out steering angle sensor adjustment/adjustment for active front steering . See 61 31 996
CARRYING OUT STEERING ANGLE SENSOR ADJUSTMENT .
31 12 003 REMOVING AND INSTALLING / REPLACING TOP RIGHT WISHBONE
NOTE: Control arms with + or - marking (see illustration) are camber correction arms:
- Underdimension variant
+ Overdimension variant
These camber correction arms are used to correct the camber values by 30
minutes. To be used only if the tolerance values are exceeded or undershot! An
unmarked control arm is a standard part.
2010 BMW M3
Fig. 33: Identifying Control Arms

Necessary preliminary tasks: Remove control unit box
Important! The spring strut/lower wishbone screw connection does not have to be released!
Further procedure is identical to: Removing and installing/replacing top left control arm.
31 12 024 REPLACE WHEEL CONTROL JOINT IN WISHBONE (ALL-WHEEL DRIVE VEHICLE)
Necessary preliminary tasks: Remove front wheel
Release screws. If necessary, push wheel control joint off swivel bearing using a suitable tool.
Installation note: Recondition thread in swivel bearing. Keep recess for wheel control joint, bushing in trailing
link and wheel control joint journal clean and free from grease. Replace microencapsulated screws.
Tightening torque, see 31 12 21AZ in 31 12 CONTROL ARMS AND STRUTS .
31 12 080 REMOVING AND INSTALLING/REPLACING BOTH TENSION STRUTS
Except M3: Remove both front wheels See WHEEL AND TIRES - REPAIR .
Installation:
Keep tension strut to swivel bearing connection clean and free from oil and grease.
2010 BMW M3
Fig. 34: Identifying Tension Strut Nut

Release bolt (1) and remove tension strut.
Raise locking nut (2) in area of bore and detach from front axle carrier.
Installation:
Tighten bolt connection in normal position . See 32 00 ... MOVING VEHICLE INTO NORMAL
POSITION .

2010 BMW M3
Fig. 35: Identifying Front Axle Carrier Locking Nut

31 12 138 REPLACING RUBBER MOUNTS ON BOTH TENSION STRUTS
31 5 271
31 5 272
31 5 273
33 4 450
REAR AXLE - SPECIAL TOOLS
IMPORTANT: For driving dynamic reasons the rubber mounts of both tension struts must
always be replaced!
Because the tension strut is made of aluminum, the rubber mount may only be
changed once!
Marking of rubber mount replacement must be made with a center punch in
area (A)!
Tension struts which already have a punch mark in area (A) must be replaced!
Changing the rubber mount again is prohibited!
Fig. 36: Identifying Punch Mark Area

Check ball joints of tension struts while installed for damage, replace tension struts if necessary.
2010 BMW M3
Remove both tension struts.
NOTE: Special tool 31 5 271 serves to remove and install the rubber mount.
AUS Removal
EIN Installation


Special tool 31 5 271 must be exactly flush with rubber mount bushing.
Press rubber mount with special tools 31 5 271 and 31 5 272 out of tension strut.
Fig. 38: Pressing Rubber Mount With Special Tools (31 5 271 And 31 5 272) Out Of Tension Strut
2010 BMW M3
Mount take-up 31 5 273 on special tool 33 4 450 .
Install rubber mount (1) in special tool and pull together.
Fig. 39: Identifying Rubber Mount In Special Tool

IMPORTANT: Align rubber mount as pictured by way of slot to arrow marking (P). Deviation
must not exceed 5.
A = 30 5
NOTE: Keep rubber mount and bushing in tension strut clean and free from grease.
Fig. 40: Aligning Rubber Mount

Draw in rubber mount (1) with special tools 31 5 271 and 31 5 272 until special tool 31 5 273 rests on tension
strut.
Remove special tools 33 4 450 and 31 5 273 .

2010 BMW M3
Install rubber mount (1) as far as it will go.
Fig. 41: Installing Rubber Mount With Special Tool

Installation:
Protrusion (A) equally large.
Fig. 42: Identifying Protrusion Equally Large Position

IMPORTANT: Mark replacement of tension strut rubber mounts by means of a punch mark in
area (A).
2010 BMW M3
Fig. 43: Identifying Punch Mark Area

WHEEL BEARING
31 21 090 REPLACING (REMOVING AND INSTALLING) LEFT OR RIGHT SWIVEL BEARING
(M3)
31 2 230
31 5 230
IMPORTANT: To ensure optimum power transmission from the swivel bearing to the spring
strut, it is essential to use special tool 31 5 230 for mounting on the spring
strut!
tightened down!
Remove front brake disc . See 34 11 220 REMOVING AND INSTALLING OR REPLACING
BOTH FRONT BRAKE DISCS .
Slacken nut (1).
Installation:
2010 BMW M3
Fig. 44: Identifying Jointed Rod And Sensor Lever

Remove control arm from swivel bearing .
Remove tie rod end from swivel bearing . See 32 21 151 REPLACING LEFT OR RIGHT TIE ROD .
Remove tension strut from swivel bearing.
Support swivel bearing with workshop jack and a suitable mounting.
Release nut (1), remove holder (3) and remove screw (2).
Installation:
Tightening torque, see 31 31 3AZ in 31 31 SPRING STRUTS .

2010 BMW M3
Fig. 45: Identifying Holder Screw

Release screw (1).
Remove pulse generator (2) from swivel bearing.
Installation:
Clean bore hole for pulse generator and grease with Staburags NBU 12/K lubricating grease.
Tightening torque 34 51 4AZ , see 34 51 SLIP CONTROL SYSTEM (DSC) .
Fig. 46: Identifying Pulse Generator Screw

IMPORTANT: Spread swivel bearing under bolt opening to avoid damaging the swivel
bearing.
Spread swivel bearing with special tool 31 2 230 .

2010 BMW M3
Lower workshop jack and remove swivel bearing.
Installation:
Keep press fit of swivel gearing and spring strut in lower area clean and free from oil and grease.
Fig. 47: Removing Swivel Bearing With Special Tool

IMPORTANT: Align special tool 31 5 230 as pictured in order to ensure correct contact with
swivel bearing.
tightened down!
Installation:
Spread swivel bearing with special tool 31 2 230 , align by means of gap to web (1) on back of spring strut and
push upwards.
Pull swivel bearing with special tool 31 5 230 up to stop (tightening torque = 20 Nm).

2010 BMW M3
Fig. 48: Pulling Swivel Bearing With Special Tool (31 5 230) Up To Stop
Replacement:
Modify wheel bearing.

Modify brake carrier/brake guard plate . See 34 11 250 REMOVING AND INSTALLING /
REPLACING A BRAKE CARRIER / BRAKE GUARD PLATE AT FRONT .
After installation:
Replacement: Perform chassis alignment check . See 32 00 150 KDS CHASSIS/WHEEL

ALIGNMENT CHECK WITH LOAD UP TO DESIGN POSITION .
31 21 180 REMOVING AND INSTALLING/REPLACING BEARING FOR FRONT WHEEL
Remove brake disk . See 34 11 220 REMOVING AND INSTALLING OR REPLACING BOTH
FRONT BRAKE DISCS .
Release screws (1).
Press wheel bearing (2) off swivel bearing with a suitable tool.
Installation:
Tightening torque 31 21 1AZ , see 31 21 WHEEL BEARINGS AND STEERING KNUCKLE .

2010 BMW M3
Fig. 49: Identifying Wheel Bearing Screws

Installation:
When reusing, recut all the threads in the wheel bearing.
Keep contact surface (1) of swivel bearing and wheel bearing clean and free from oil and grease.
Fig. 50: Identifying Swivel Bearing And Wheel Bearing Contact Surface Area
SPRING STRUT
31 .. .. LAYOUT OF SPRING STRUT SHOCK ABSORBER
2010 BMW M3
Fig. 51: Layout Of Spring Strut Shock Absorber

Facts:
Consequence:
2010 BMW M3
Procedure:
31 31 003 REMOVING AND INSTALLING COMPLETE FRONT LEFT OR RIGHT SPRING STRUT
(M3)
NOTE: If a spring strut with support bearing is released on the body without the
centering pin, a chassis/wheel alignment check must be carried out after
installation.
Remove swivel bearing

Secure spring strut against falling out.
Unscrew nuts (2).
Installation:
Make sure protective cap is correctly seated.
Tightening torque 31 31 1AZ , see 31 31 SPRING STRUTS

2010 BMW M3
Fig. 52: Identifying Protective Cap With Nuts

Installation:

Remove spring strut towards bottom.
Installation:
Clean contact surface in spring strut dome.
Align spring strut by means of centering pin to bore in wheel arch and slide upwards.
2010 BMW M3
Fig. 54: Aligning Spring Strut By Means Of Centering Pin To Bore In Wheel Arch And Slide Upwards
After installation:
31 31 041 REPLACING FRONT LEFT OR RIGHT SPRING STRUT (M3)
31 3 340
31 3 341
31 3 351
WARNING: Prior to each use of the special tool 31 3 340 , it is essential to read the
associated Owner's Handbook fully!
All the safety precautions and instructions contained in the Owner's
2010 BMW M3
6. The use of an impact screwdriver on special tool 31 3 341 is prohibited!
Remove front spring strut
Removing:
Clamp special tool 31 3 341 in vice.
Fit special tools 31 3 351 from above on special tool 31 3 341 until locking pins (1) can be felt and heard to
snap into place.
Check seating of special tools 31 3 351 , correct if necessary.
Fig. 55: Clamping Special Tool (31 3 341) In Vice

Clean coil spring to remove all coarse dirt and mount on special tools 31 3 351 .
Turn spring strut until lower end of coil spring (1) points upwards.
2010 BMW M3
Fig. 56: Identifying Coil Spring With Special Tool (31 3 351)

the recess of special tools 31 3 351 .
Compress coil spring until stress on piston rod is relieved.
Fig. 57: Compressing Coil Spring


Nut may only be released if:
1. the coil spring has been sufficiently tensioned with special tools 31
3 341 and 31 3 351
2. the upper and lower coils of the coil spring are situated entirely in
the recess of special tools 31 3 351
2010 BMW M3
Release nut (1) (grip piston rod in so doing) and remove support bearing (2).
Fig. 58: Removing Support Bearing

IMPORTANT: Risk of contamination!

Ensure conditions of absolute cleanliness when handling the two-part support
bearing.
Fig. 59: Identifying Two-Part Support Bearing

Pull off thrust washer (1) and auxiliary damper (2) with gaiter (3) from piston rod of shock absorber (4).
Remove shock absorber (4) sideways from coil spring.

2010 BMW M3
Fig. 60: Identifying Thrust Washer And Auxiliary Damper With Gaiter
Relieve tension on coil spring and remove from special tools 31 3 351 .

Assembly:
IMPORTANT: Risk of mixing up

The lower coil of the coil spring is slightly smaller than the upper coil.
2010 BMW M3
Fig. 62: Identifying Coil Spring Installation Position

Accommodate coil spring with special tools 31 3 351 .
Turn coil spring until lower end of coil spring (1) points upwards.
Fig. 63: Identifying Coil Spring Installation Position


Do not compress coil spring to full extent.
the recess of special tools 31 3 351 .
Tension coil spring.

2010 BMW M3

IMPORTANT: Make sure spring pad (1) is correctly seated on shock absorber. Guide (2) must
be correctly seated in opening (3) in shock absorber!
Fig. 65: Identifying Spring Pad, Guide And Shock Absorber

Check auxiliary damper and gaiter for damage, replace if necessary.

2010 BMW M3
Fig. 66: Identifying Auxiliary Damper

IMPORTANT: Make sure thrust washer and folding of gaiter are correctly positioned (see
picture).
Insert shock absorber (4) in tensioned coil spring.
Slide auxiliary damper (2) with gaiter (3) onto piston rod.
Attach thrust washer (1) to piston rod.
Fig. 67: Identifying Thrust Washer And Auxiliary Damper With Gaiter
IMPORTANT: Make sure spring pad (1) is correctly seated on support bearing.
2010 BMW M3
Fig. 68: Identifying Spring Pad

Check support bearing (1) for damage, replace if necessary.
Attach support bearing (1) to piston rod.
Coat mounts (2) with Circo Light (sourcing reference: BMW Parts Service).
Fig. 69: Checking Support Bearing For Damage

NOTE: Joint plate (1) is correctly seated in support bearing mounts after tension is
relieved on coil spring.
Attach joint plate (1) to piston rod.
Replace nut (2) and tighten down (gripping piston rod in so doing).
Tightening torque 31 31 2AZ , see 31 31 SPRING STRUTS

2010 BMW M3
Fig. 70: Identifying Joint Plate With Nut

IMPORTANT: Upper coil of coil spring must rest positively on support bearing!
Lower end of coil spring (2) must rest on stop of spring pad (1)!
Relieve tension on coil spring.
Check installation position of gaiter (3), correct fold if necessary.
Fig. 71: Identifying Installation Position Of Gaiter

After installation:
2010 BMW M3
SPRING WITH SUSPENSION

31 33 001 (REMOVING AND INSTALLING) REPLACING FRONT LEFT OR RIGHT SPRING
STRUT SUPPORT BEARING (M MODEL)
NOTE: Procedure is described in Replacing front left or right spring strut .
Replacement:
If necessary, twist out centering pin (1).
NOTE: If a support bearing (2) was fitted without centering pin (1), the centering pin (1)
of the new support bearing (2) must be twisted out.
Fig. 72: Identifying Support Bearing With Centering Pin

31 33 095 MEASURING RIDE-LEVEL HEIGHT OF VEHICLE
Move vehicle into normal position . See 32 00 ... MOVING VEHICLE INTO NORMAL
POSITION .
2010 BMW M3
Fig. 73: Measuring Ride-Level Height Of Vehicle

31 33 100 REMOVING AND INSTALLING/REPLACING COIL SPRING FOR FRONT LEFT OR

RIGHT SPRING STRUT (M MODEL)
IMPORTANT: For safety reasons, both coil springs on the relevant axle must always be
replaced on motorsport vehicles!
NOTE: The coil spring is allocated in the Electronic Parts Catalogue (ETK) under the
menu item "Spring table" after the vehicle identification number has been
entered and the relevant optional extra of the car has been selected.
NOTE: Procedure is described in Replacing front left or right spring strut.
STABILIZER BAR
31 35 000 REMOVING AND INSTALLING/REPLACING FRONT STABILIZER
IMPORTANT: To avoid complaints being made by the customer about noise (e.g. grating), set
the car on its wheels and tighten down the stabilizer mounting to specified
torque.

Remove stabilizer link on both sides from stabilizer
M3:
Remove reinforcement plate .

2010 BMW M3
Installation:
Fig. 74: Identifying Reinforcement Plate Nuts

Except M3: Release screws (1) and remove brackets.
Release nuts (2); if necessary, grip screws after repair.
Remove stabilizer (3); if necessary, press off front axle carrier with a suitable tool.
Installation:
Check both rubber mounts for damage , replace if necessary.
Replace self-locking nuts (do not tighten down).
Set car on its wheels and tighten down nuts to tightening torque. See 31 35 1AZ in 31 35 STABILIZER BAR .
2010 BMW M3
Fig. 75: Identifying Brackets Screws

Repair solution for studs:
Release screw (1).
Raise locking nut (2) in area of bore and detach from front axle carrier.
Drive out studs (3) in upwards direction and remove/feed out through an opening in front axle carrier.
Installation:
Insert new screws from above.

2010 BMW M3
Replacement:
Remove both rubber mounts from stabilizer
31 35 005 REMOVING AND INSTALLING/REPLACING PUSH ROD (STABILIZER LINK) FOR

LEFT/RIGHT STABILIZER
Note (M3 only):
Make sure stabilizer link is installed in correct position.
A. Connection, stabilizer link to spring strut

B. Connection, stabilizer link to stabilizer
Fig. 77: Identifying Stabilizer Link Connection

Release nut (1) and remove bracket for brake hose.
Release nut (3) and remove stabilizer link (2).
Installation:
Tightening torque 31 35 2AZ , see 31 35 STABILIZER BAR .

2010 BMW M3
Fig. 78: Identifying Stabilizer Link Nut

31 35 021 REPLACING BOTH RUBBER MOUNTS OF STABILIZER MOUNTING ON FRONT AXLE

CARRIER (M3)
pairs.
Remove stabilizer from front axle carrier
IMPORTANT: When installing the stabilizer, make sure the rubber mount lower section is
correctly engaged on both sides.
NOTE: Insert a screwdriver on both sides between retaining bracket (1) and rubber
mount lower section (3).
Remove rubber mount lower section (3) and rubber mount upper section (2).
Installation:
Make sure rubber mount halves contact stabilizer stop correctly.

2010 BMW M3
Fig. 79: Identifying Rubber Mount Lower And Upper Section

Installation:
Keep retaining bracket (1), rubber mount upper section (2), rubber mount lower section (3) and stabilizer clean
and free from oil and grease.
Insert rubber mount upper section (2) in retaining bracket (1). Guide (4) must be correctly seated in opening (5)
in the process.
Catches on rubber mount lower section (3) must not be damaged and must be located in the designated recesses
in the retaining bracket (1).
Fig. 80: Identifying Rubber Mount Lower And Upper Section Installation Position
TROUBLESHOOTING
31 90 ... FRONT AXLE TROUBLESHOOTING
2010 BMW M3
Fault Cause Remedy
Grinding noise (or humming)
IMPORTANT:
Tyre rolling noises can sound
very similar to wheel bearing
noises.
Test: Drive car
Noise reduces when Most probably a

cornering tyre problem
Noises increases when Right wheel bearing
Replace wheels
cornering to left faulty
Replace wheel bearings
Noises increases when Left wheel bearing
cornering to left faulty Replace wheel bearings
Wheel imbalance Balance wheels

Vibration Radial/lateral rim runout Check rims , replace if necessary
Radial tyre runout Match or replace tyres
Radial/lateral rim runout Check rims , replace if necessary
Rubber mount of control
Replace control arms
arm faulty
Ball joint in control arm
Steering-wheel shake worn
Rubber mount of tension Replace rubber mounts on both tension
strut faulty struts
Ball joint on tension strut
Replace both tension struts
worn
Refer to TROUBLESHOOTING for steering
Excessive steering wheel Refer to BMW diagnosis system (scan tool) troubleshooting/chassis
play/steering wheel inclination alignment check
Bolts for reinforcement
Tighten down bolts reinforcement strut )
strut loose
Bolt for V-strut loose Tighten down bolts
Bolt connection for
Tighten down bolts
diagonal struts loose
Bolts for reinforcement
Tighten down bolts
plate loose
Bolts for front axle carrier
Replace bolts
to engine carrier loose
Bolt for spring strut to
2010 BMW M3
swivel bearing loose Replace bolt & nut

Ball joint in control arm
worn
Ball joint on tension strut
Replace both tension struts
worn
Rattling noise
Rubber mounts for
Replace both rubber mounts of stabilizer
stabilizer bar bracket
bar bracket
faulty
Ball joints on stabilizer
Replace both stabilizer links
link(s) worn
Front or rear axle Check suspension components for damage;
Excessive tyre wear alignment incorrectly if necessary, carry out chassis/wheel
adjusted alignment check
31 90 ... TROUBLESHOOTING SHOCK ABSORBER
Fault Cause Remedy
Visually inspect auxiliary spring for
cracking, replace auxiliary spring
Auxiliary spring faulty
Wheel knocking (bottoming) AWD only: Visually inspect support
ring for damage
Shock absorber leaking (oil/gas) Replace shock absorber
shock absorber mounting loose Tighten shock absorber
Rattling noise Support bearing faulty/hardened Replace support bearing
Shock absorber leaking (gas/oil) Replace shock absorber
Worn down areas (flattened
Shock absorber leaking (gas/oil) Replace shock absorber
areas) on tyre profile
Shock absorber leaking
Long after-swinging of body
(insufficient shock absorber Replace shock absorber
after driving over rough road
effect)
Building-up of body in case of
successive uneven surfaces
effect)
Wheels jumping even on
normal road surfaces
effect)
Separating skin in vent holes of
Whistling noises Remove separating skin
auxiliary spring
2010 BMW M3
ENGINE PERFORMANCE Fuel System - Repair
ENGINE PERFORMANCE
Fuel System - Repair
CHECKING SETTING ENGINE EMISSION


function is active.


Workshop mode
A = 10 mm
B = 7 mm
2010 BMW M3

FUEL PUMP WITH DRIVE AND LINE

13 31 028 CHECKING FUEL FEED PRESSURE (S65)
Connect DIS Tester

Switch off ignition
REMOVE AIR INTAKE FILTER HOUSING
Recycling
Catch and dispose of escaping fuel in a suitable container.
Disconnect quick-release coupling (1) from feed line (2).
Insert special tool 13 5 270 between lines (1) and (2).
Connect pressure sensor (3) of BMW DIS Tester. Or connect special tool 13 3 060 DEVICE .
2010 BMW M3
Fig. 3: Identifying Quick-Release Coupling And Pressure Sensor With Special Tool (13 5 060)
Measuring fuel pressure
Connect pressure sensor to DIS tester

Connect DIS tester to vehicle
Select Drive
Select Engine electronics
Select Fuel supply
Select Fuel pressure sensor
Read off fuel pressure
NOTE: The vehicle has different fuel pressures when starting and when idling.
Test pressure, REFER TO TECHNICAL DATA .
Switch off engine.
Assemble vehicle and check fuel system for leaks.
13 31... NOTES ON FUEL PRESSURE CHECK (REFERENCE PRESSURE: SURROUNDING AREA)
Feature of this version with ambient pressure
The connection for the vacuum hose of the fuel pressure regulator is located between the throttle and the air
cleaner or on the air cleaner.
Test precondition
The correct fuel pressure regulator is fitted.

2010 BMW M3
Using the EPC, check whether the fuel pressure regulator suitable for the car is fitted:
Connect test adapter.
Description of operation
The control function of the fuel pressure regulator must be guaranteed under all operating conditions. The fuel
pump must always be able to generate a higher fuel pressure than the pressure regulated by the pressure
regulator.
The injection rate is adjusted by means of the injection time; the injection time is controlled by the DME.
Description of operation: fuel return line
When the engine is at a standstill and the ignition key is in position 0, the fuel return line after the pressure
regulator is at zero pressure.
Description of operation: pressure retaining function
The pressure regulator closes when the engine is at a standstill and the ignition key is in position 0. The fuel
pressure in the delivery line is retained over an extended period. A non-return valve closes in the fuel pump.
These measures help to retain the fuel pressure in the fuel system. Extended starting times are thus avoided.
Complaint: drive characteristic faults, lack of power
Run engine at idle speed and measure fuel pressure.
If the measured value is less than the nominal value - 0.2 bar:
Line cross-sections in fuel feed are constricted or fuel filter is clogged, or

Fuel pump voltage supply is not O.K.: e.g. as a result of high contact resistance (corrosion) in plug
connection between wiring harness and fuel pump.
If the measured value is greater than the nominal value + 0.2 bar:
Turn off engine stop and then observe measured value.

If measured value drops to nominal value, then line cross-sections in fuel return are constricted or
clogged.
Check the fuel lines for kinks.
If no kinks are visible:
Replace return lines
If measured value remains too high, then pressure regulator is in all probability faulty.
2010 BMW M3
IMPORTANT: With less likelihood, the return line may be completely blocked. When the
pressure regulator is removed, fuel could escape under pressure!
Have a cleaning cloth ready and catch and dispose of escaping fuel.
Replace the return line but not the pressure regulator.
Complaint: starting problems
Run engine briefly at idle speed and switch off.

Note down measured value while engine is stopped.
Read off measured value again after approx. 20 to 30 minutes while engine is stopped.
Special tool 13 3 010 (hose clamp) is required for the following test.
If the measured value has dropped by more than 0.5 bar:
Start engine and wait briefly for a stable pressure increase.

Switch off the engine and immediately pinch off the delivery line just before the pressure gauge with the
special tool 13 3 010.
Note down measured value
Read off measured value again after approx. 20 to 30 minutes while engine is stopped
If the measured value has now dropped by less than 0.5 bar, the following faults can be present:
Fault in delivery lines

Fault in in-tank delivery hose
Faulty pressure-holding non-return valve in fuel pump
Check components. Replace faulty components.
If the measured value has dropped by more than 0.5 bar again:
Replace pressure regulator
NOTE: All the fuel hoses and hose clips which were detached within the
framework of the checks must be replaced.
Interrogate fault memory of DME control unit. Check stored fault
messages. Rectify faults. Now clear the fault memory.
SPEED GOVERNOR
13 41 100 REMOVING AND INSTALLING/REPLACING SUPPLEMENTARY AIR LINE (S65)
2010 BMW M3

Partially disconnect and raise ENGINE WIRING HARNESS
Unclip holders for supplementary wiring harness
Remove idle air hose (2).
Replace clamps.
Lever idle actuator out of holder.
Fig. 4: Identifying Idle Air Hose

Release screws, detach idle air line.
Remove INTAKE MANIFOLD PRESSURE SENSOR on bank 2.

2010 BMW M3
Before installing, check O-rings on unions and apply a light coating of grease.
Assemble engine.

13 41 550 REPLACING IDLE ACTUATOR (S65)

Check stored fault messages
Switch off ignition
Partially disconnect ENGINE WIRING HARNESS , raise cable duct.
Remove TANK VENTING VALVE
Release air intake hose (1).
Release idle air hose (2).
Replace clamps.
2010 BMW M3
Fig. 7: Identifying Air Intake Hose And Idle Air Hose

Unlock plug connection and disconnect.
Carefully lever idle actuator out of holder.
Fig. 8: Identifying Idle Actuator

Assemble engine.
INJECTION NOZZLE AND LINES


2010 BMW M3

Replace clamps.


2010 BMW M3
Assemble engine.
Fig. 11: Identifying O-Ring

13 53 240 REPLACING COMPLETE INJECTION PIPE (S65)
Switch off ignition
Recycling
Fuel escapes when fuel line is detached. Catch and dispose of escaping fuel.
Release screws (1).
Unclip fuel line (2).
Unlock plugs on fuel injectors and disconnect.
Unlock, disconnect and seal fuel line (3).
Remove injection pipe.
Seal openings for fuel injectors in throttle valve housings with special tool 11 5 210.
2010 BMW M3
Fig. 12: Identifying Fuel Line With Screws

Seal fuel hose with special tool 13 5 281.

Lever out retainers (1).
Pull fuel injectors out of injection pipe.
Installation
Replace sealing rings on fuel injectors and coat with anti-friction agent.
2010 BMW M3
Fig. 14: Pulling Out Retainers

THROTTLE AND OPERATION

13 54 010 PERFORMING THROTTLE VALVE BASIC SETTING (S65)
IMPORTANT: Idle stops of throttle valve assemblies must not be altered! They have been set
at the factory and secured against turning with locking paint.
Read out fault memory of DME control unit.

REMOVE INTAKE AIR MANIFOLD .
IMPORTANT: The throttle valve assembly must be replaced if the locking paint is damaged or
the idle speed stop screw (1) is twisted!
Plastic caps (2) on idle speed top screws must not be removed!
2010 BMW M3
Fig. 15: Identifying Idle Speed Stop Screw And Plastic Caps
Checking throttle valve basic setting
Gap between stop screw (1) and actuator (2) of throttle valve must be less than 0.05 mm.
To check gap, use a feeler gauge with a thickness of 0.05 mm.
Checking gap:
Pull the pull rod of throttle valve actuator in opening direction of throttle valves.
Slide feeler gauge (3) between stop screw (1) and actuator (2) of throttle valve.
Return throttle valves slowly to stops.
When correctly adjusted, feeler gauge will jam between stop screw (1) and actuator (2) of throttle valve.
2010 BMW M3
Fig. 16: Checking Throttle Valve Basic Setting Using Feeler Gauge
Perform check on each throttle valve assembly.
Performing throttle valve basic setting
A basic setting must be performed if the gap is larger than 0.05 mm at one or more throttle valve assemblies.
NOTE: To perform correct throttle valve setting, it is necessary to slacken all the screw
connections (3) of the actuating lever (2) with the actuating shaft (1). (Replace
nuts).
However, if increased play is ascertained, the corresponding cylinder bank
must be reset.
Do not slacken the screw connections of the actuating levers for the long pull
rods.
The long pull rods must not be disengaged from the actuating levers for the
setting procedure.
Fig. 17: Identifying Screw Connections, Actuating Lever And Actuating Shaft
To slacken screw connection of actuating lever (1), grip screw (3) and release nut (2). (Replace nuts).
Release screw connections of actuating levers of throttle valve assemblies 1-4 and 5-8.
2010 BMW M3
Fig. 18: Identifying Actuating Lever With Screws And Nut

Adjusting a throttle valve assembly
Move actuating lever (1) in direction of arrow, i.e. "close throttle valve", until actuator (2) of throttle valve rests
without play on stop screw (3).
IMPORTANT: Do not exert any pressure!
Fig. 19: Identifying Throttle Valve Assembly

Tighten down screw connection of actuating lever (1) again to actuating shaft. Observe the following
instructions in so doing:
Use nuts only once.

When pre-tightening screw connection (approx. 5 Nm), hold actuating lever (1) of throttle valve in
direction of arrow at "close throttle valve".
Only turn nut and grip screw.
2010 BMW M3
To screw down, use two open-end wrenches which are to be placed at right angles to actuating shaft.
In this way, no lever action is exerted on the throttle valve mechanism; such torque would impair the
quality of adjustment.
After pre-tightening actuating lever, actuate throttle valve several times at full load.
Fig. 20: Tightening Actuating Lever Screw Connection

NOTE: If necessary, carry out adjustment with a second person.
Adjusting throttle valve assemblies 1 - 4 and 5 - 8
The previously described procedure applies to adjusting/setting throttle valve assemblies 1 - 4 and 5 - 8.
Adjust throttle valve assemblies 1 - 4 and 5 - 8 in sequence.
After successfully completing throttle valve basic setting and checking, tighten down all screw connections of
throttle valve levers to specified torque 13 54 1AZ .
2010 BMW M3
Fig. 21: Throttle Valve Assemblies Screw Sequence

NOTE: After completing adjustment, it is necessary to check the throttle valve basic
setting!
If during the checking of one or more throttle valve assemblies excessively
large or small play is ascertained, it will be necessary to perform the throttle
valve basic setting again!
IMPORTANT: After performing work on the throttle valve system (throttle valve assembly,
servomotor, Hall sensor), it is absolutely essential to carry out a throttle valve
actuator system test with the BMW diagnosis system!
Function selection:
Complete vehicle
Drive
Engine electronics
Air supply
Throttle valves
Throttle valve actuator
NOTE: Check stored fault messages.

Then clear fault memory.
13 54 544 REMOVING AND INSTALLING/REPLACING LEFT HALL SENSOR (S65)

Switch off ignition
2010 BMW M3
Unlock and disconnect plug-in contact in wiring harness (not on sensor).
Release screws and detach Hall sensor towards front.
Installation:
Make sure Hall sensor is installed in correct position.
Fig. 22: Identifying Hall Sensor With Screws

Function selection:
Complete vehicle
Drive
Engine electronics
Air supply
Throttle valves
NOTE: Check stored fault messages

Clear fault memory
13 54 544 REMOVING AND INSTALLING/REPLACING RIGHT HALL SENSOR (S65)

2010 BMW M3

Switch off ignition
Release and raise cable duct for engine wiring harness; for information, refer to REMOVING ENGINE
WIRING HARNESS
Installation:
Assemble engine.

Function selection:
Complete vehicle
Drive
Engine electronics
2010 BMW M3
Air supply
Throttle valves

Clear fault memory

Replace clamps.


2010 BMW M3

Assemble engine.

13 54 045 REMOVING AND INSTALLING/SEALING A THROTTLE VALVE ASSEMBLY (S65)

Switch off ignition
Follow instructions on CONNECTING AND DISCONNECTING BATTERY
2010 BMW M3
Remove all INJECTORS

Release and raise cable duct for engine wiring harness; to do so, partially remove ENGINE WIRING
HARNESS .
Disengage pull rods of throttle valve actuating motor.
Release all nuts of throttle valve flanges.
Release idle air hose connection.
Lift out throttle valve bank.
Fig. 27: Removing Throttle Valve Flanges Nuts

Release idle air duct on throttle valve bank.
Fig. 28: Identifying Idle Air Duct On Throttle Valve Bank

Release all screw connections on shaft (1).

2010 BMW M3
Grip screws, release nuts only. Replace screws and nuts (3).
Installation:
Actuating lever (2) of throttle valve actuating motor is offset by 180 to throttle valve actuating levers.
Fig. 29: Identifying Actuator Lever With Nuts And Screws

Mounting sequence of actuating levers, bank 1
1. Levers for throttle valves

2. Lever from actuator motor
Fig. 30: Actuator Levers Mounting Sequence

Installation:
Clean sealing surfaces on cylinder head.

2010 BMW M3
Replace O-rings (1) on cylinder head.
Check adapter sleeves on throttle valves.


Perform BASIC THROTTLE VALVE SETTING
SENSOR FOR CONTROL UNIT

13 62 540 REMOVING AND INSTALLING/REPLACING THROTTLE VALVE ACTUATING
MOTOR (S65)
Switch off ignition
Partially remove ENGINE WIRING HARNESS
NOTE: Illustration shows and description refers to the left throttle valve servomotor.
The procedure is identical for the right intake duct.
Remove thrust rod (1).
Release screws.
Remove throttle valve servomotor (2).

2010 BMW M3
Fig. 32: Identifying Thrust Rod And Throttle Valve Servomotor With Screws
Function selection:
Complete vehicle
Drive
Engine electronics
Air supply
Throttle valves

13 62 531 REPLACING COOLANT TEMPERATURE SENSOR (S65)
Switch off ignition
Remove temperature sensor.
Installation:
2010 BMW M3
Fig. 33: Identifying Temperature Sensor

13 62 511 REPLACING INTAKE AIR TEMPERATURE SENSOR (S65)
Switch off ignition
Intake air temperature sensor (1) without retaining clip.
Intake air temperature sensor (2) with large ribs for retaining clip (3).
Fig. 34: Identifying Intake Air Temperature Sensor Without/With Retaining Clip
2010 BMW M3
Version 1:
Turn temperature sensor through 45 and remove.
Fig. 35: Identifying Temperature Sensor With Plug

Version 2:
Unlock plug and remove.
Pull off retaining clip (1).
Fig. 36: Identifying Temperature Sensor Retaining Clip

2010 BMW M3

Switch off ignition

Installation:
Fig. 37: Identifying Oil Pressure Switch

Switch off ignition
2010 BMW M3

Release screws (1).
Remove cover.

Release screw (1).


2010 BMW M3
Switch off ignition
Release screw.
Installation
Aluminum screws must always be replaced.


2010 BMW M3
Switch off ignition
Release screw.
Installation

2010 BMW M3
Switch off ignition
Release screw.
Installation


2010 BMW M3
Switch off ignition
Release screw.
Installation

Switch off ignition
Remove underbody protection See 5147490 REMOVING AND INSTALLING/REPLACING
INSTALLING/REPLACING REAR UNDERBODY PROTECTION
2010 BMW M3
regulations.
Release screw (1).

NOTE: TOP UP TRANSMISSION FLUID.


Switch off ignition
REMOVE SECONDARY-AIR PUMP
Release cable duct for engine wiring harness; for information, refer to REMOVING ENGINE WIRING
HARNESS
2010 BMW M3

Installation:

2010 BMW M3

START VALVES

Replace clamps.


2010 BMW M3
Fig. 48: Identifying Idle Air Line Screws

Assemble engine.

13 64 541 REPLACING ALL FUEL INJECTORS
This work step is described in the section "REMOVING COMPLETE INJECTION PIPE" .
INTAKE SILENCER
13 71 000 REMOVING AND INSTALLING/REPLACING INTAKE FILTER HOUSING (S65)

2010 BMW M3
REMOVE INTAKE FILTER ELEMENT
Release screws.
Raise intake filter housing, pull out of intake duct and remove in upward direction.
Installation:
Pay attention to position of spacer buffers during installation.
Fig. 50: Pulling Out Intake Duct


Switch off ignition
Installation:

2010 BMW M3

Function selection
Complete vehicle
Drive
Engine electronics
Air supply
Throttle valves

Clear fault memory

Switch off ignition
Release and raise cable duct for engine wiring harness; for information, refer to REMOVING ENGINE
WIRING HARNESS

2010 BMW M3
Installation:
Assemble engine.

Function selection
Complete vehicle
Drive
Engine electronics
Air supply
Throttle valves

Clear fault memory
AIR CLEANER
13 72 001 REPLACING AIR FILTER ELEMENT (S65)
2010 BMW M3
Release screws.
Remove top section (1) of intake filter housing.
Fig. 53: Identifying Intake Filter Housing With Screws

Release clamp (1) for intermediate flange.
Press air filter element outwards against spring force and remove.
Assemble engine.
Fig. 54: Removing Clamp For Intermediate Flange

CARBON CANISTER VENTILATION

13 90 500 REPLACING TANK VENTING VALVE (S65)
2010 BMW M3
Switch off ignition
NOTE: The tank venting valve is fitted under the intake air manifold.
Unlock hose on tank venting valve and disconnect.
Release clamp, detach hose.
Release bolt on bracket.
Remove tank venting valve.
Fig. 55: Locating Bolt On Bracket


2010 BMW M3
ENGINE PERFORMANCE Fuel System - Repair - M3
ENGINE PERFORMANCE
Fuel System - Repair - M3
FUEL PUMP WITH DRIVE

13 31 ... NOTES ON FUEL PRESSURE CHECK (REFERENCE PRESSURE: ENVIRONMENT)
Feature of this version with ambient pressure:
The connection for the vacuum hose of the fuel pressure regulator is located between the throttle and the air
cleaner or on the air cleaner.
Test precondition:
The correct fuel pressure regulator is fitted.
Using the EPC, check whether the fuel pressure regulator suitable for the car is fitted:
Connect test adapter.
Description of operation:
The control function of the fuel pressure regulator must be guaranteed under all operating conditions. The fuel
pump must always be able to generate a higher fuel pressure than the pressure regulated by the pressure
regulator.
The injection rate is adjusted by means of the injection time; the injection time is controlled by the DME.
Description of operation: fuel return line
When the engine is at a standstill and the ignition key is in position 0, the fuel return line after the pressure
regulator is at zero pressure.
Description of operation: pressure retaining function
The pressure regulator closes when the engine is at a standstill and the ignition key is in position 0. The fuel
pressure in the delivery line is retained over an extended period. A non-return valve closes in the fuel pump.
These measures help to retain the fuel pressure in the fuel system. Extended starting times are thus avoided.
Complaint: drive characteristic faults, lack of power
Run engine at idle speed and measure fuel pressure.
If the measured value is less than the nominal value - 0.2 bar:
2010 BMW M3
Line cross-sections in fuel feed are constricted or fuel filter is clogged,
or
Fuel pump voltage supply is not O.K.: e.g. as a result of high contact resistance (corrosion) in plug
connection between wiring harness and fuel pump.
If the measured value is greater than the nominal value + 0.2 bar:
Turn off engine stop and then observe measured value.

If measured value drops to nominal value, then line cross-sections in fuel return are constricted or
clogged.
Check the fuel lines for kinks.
If no kinks are visible:
Replace return lines
If measured value remains too high, then pressure regulator is in all probability faulty.
IMPORTANT: With less likelihood, the return line may be completely blocked. When the
pressure regulator is removed, fuel could escape under pressure!
Have a cleaning cloth ready and catch and dispose of escaping fuel.
Replace the return line but not the pressure regulator.
Complaint: starting problems
Run engine briefly at idle speed and switch off.

Note down measured value while engine is stopped.
Read off measured value again after approx. 20 to 30 minutes while engine is stopped.
Special tool 13 3 010 (hose clamp) is required for the following test.
If the measured value has dropped by more than 0.5 bar:
Start engine and wait briefly for a stable pressure increase.

Switch off the engine and immediately pinch off the delivery line just before the pressure gauge with the
special tool 13 3 010 .
Note down measured value
Read off measured value again after approx. 20 to 30 minutes while engine is stopped
If the measured value has now dropped by less than 0.5 bar, the following faults can be present:
2010 BMW M3
Fault in delivery lines

Fault in in-tank delivery hose
Faulty pressure-holding non-return valve in fuel pump
Check components. Replace faulty components.
If the measured value has dropped by more than 0.5 bar again:
Replace pressure regulator
NOTE: All the fuel hoses and hose clips which were detached within the
framework of the checks must be replaced.
Interrogate fault memory of DME control unit. Check stored fault
messages. Rectify faults. Now clear the fault memory.
13 31 028 CHECKING FUEL FEED PRESSURE (S65)
13 3 060
13 5 270
Connect DIS Tester

Switch off ignition
Remove air intake filter housing
Recycling:
Catch and dispose of escaping fuel in a suitable container.
Disconnect quick-release coupling (1) from feed line (2).
Insert special tool 13 5 270 between lines (1) and (2).
Connect pressure sensor (3) of BMW DIS Tester. Or connect special tool 13 3 060 .
2010 BMW M3
Fig. 1: Identifying Quick-Release Coupling, Feed Line, Pressure Sensor And Special Tool (13 5 270)
Measuring fuel pressure:
Connect pressure sensor to DIS tester

Connect DIS tester to vehicle
Select Drive
Select Engine electronics
Select Fuel supply
Select Fuel pressure sensor
Read off fuel pressure
NOTE: The vehicle has different fuel pressures when starting and when idling.
Test pressure, refer to FUEL SYSTEM - TECHNICAL DATA .
Switch off engine.
Assemble vehicle and check fuel system for leaks.
SPEED GOVERNOR
MANIFOLD (S65) .
Partially disconnect and raise engine wiring harness . See 12 51 001 REPLACING WIRING
2010 BMW M3
Replace clamps.
Fig. 2: Identifying Idle Air Hose And Air Intake Hose

Remove intake manifold pressure sensor on bank 2.
Fig. 3: Locating Idle Air Line Screws

2010 BMW M3
Assemble engine.
Fig. 4: Locating O-Rings On Unions

13 41 550 REPLACING IDLE ACTUATOR (S65)

Check stored fault messages
Switch off ignition
MANIFOLD (S65) .
Partially disconnect engine wiring harness , raise cable duct. See 12 51 001 REPLACING WIRING
Remove tank venting valve
Release air intake hose (1).
Release idle air hose (2).
Replace clamps.
2010 BMW M3
Fig. 5: Identifying Idle Air Hose And Air Intake Hose

Unlock plug connection and disconnect.
Carefully lever idle actuator out of holder.
Fig. 6: Identifying Plug Connection And Idle Actuator

Assemble engine.
INJECTION NOZZLE
13 53 240 REPLACING COMPLETE INJECTION PIPE (S65)

2010 BMW M3
11 5 210
13 5 281
Switch off ignition
MANIFOLD (S65) .
Recycling
Fuel escapes when fuel line is detached. Catch and dispose of escaping fuel.
Release screws (1).
Unclip fuel line (2).
Unlock plugs on fuel injectors and disconnect.
Unlock, disconnect and seal fuel line (3).
Remove injection pipe.
Seal openings for fuel injectors in throttle valve housings with special tool 11 5 210 .
2010 BMW M3
Fig. 7: Identifying Screws, Fuel Line And Seal Fuel Line

Seal fuel hose with special tool 13 5 281.

Lever out retainers (1).
Pull fuel injectors out of injection pipe.
Installation:
Replace sealing rings on fuel injectors and coat with antifriction agent.
Fig. 9: Pulling Fuel Injectors Out Of Injection Pipe

2010 BMW M3
THROTTLE AND OPERATION

13 54 010 PERFORMING THROTTLE VALVE BASIC SETTING (S65)
IMPORTANT: Idle stops of throttle valve assemblies must not be altered! They have been set
at the factory and secured against turning with locking paint.
Read out fault memory of DME control unit.

Remove intake air manifold. . See 11 61 050 REMOVING AND INSTALLING AIR INTAKE
MANIFOLD (S65) .
IMPORTANT: The throttle valve assembly must be replaced if the locking paint is damaged or
the idle speed stop screw (1) is twisted!
Plastic caps (2) on idle speed top screws must not be removed!
Fig. 10: Identifying Idle Speed Stop Screw And Caps

Checking throttle valve basic setting:
Gap between stop screw (1) and actuator (2) of throttle valve must be less than 0.05 mm.
To check gap, use a feeler gauge with a thickness of 0.05 mm.
Checking gap:
Pull pull rod of throttle valve actuator in opening direction of throttle valves.
2010 BMW M3
Slide feeler gauge (3) between stop screw (1) and actuator (2) of throttle valve.
Return throttle valves slowly to stops.
Fig. 11: Checking Gap Between Stop Screw And Actuator Of Throttle Valve Using Feeler Gauge
When correctly adjusted, feeler gauge will jam between stop screw (1) and actuator (2) of throttle valve.
Perform check on each throttle valve assembly.
Performing throttle valve basic setting:
A basic setting must be performed if the gap is larger than 0.05 mm at one or more throttle valve assemblies.
NOTE: To perform correct throttle valve setting, it is necessary to slacken all the screw
connections (3) of the actuating lever (2) with the actuating shaft (1). (Replace
nuts).
However, if increased play is ascertained, the corresponding cylinder bank
must be reset.
Do not slacken the screw connections of the actuating levers for the long pull
rods.
The long pull rods must not be disengaged from the actuating levers for the
setting procedure.
2010 BMW M3
Fig. 12: Identifying Actuating Shaft, Actuating Lever And Screw Connections
To slacken screw connection of actuating lever (1), grip screw (3) and release nut (2). (Replace nuts).
Release screw connections of actuating levers of throttle valve assemblies 1-4 and 5-8.
Fig. 13: Identifying Actuating Lever, Screw And Nut

Adjusting a throttle valve assembly:
Move actuating lever (1) in direction of arrow, i.e. "close throttle valve", until actuator (2) of throttle valve rests
without play on stop screw (3).
IMPORTANT: Do not exert any pressure!

2010 BMW M3
Fig. 14: Identifying Throttle Valve Assembly

Tighten down screw connection of actuating lever (1) again to actuating shaft. Observe the following
instructions in so doing:
Use nuts only once.

When pretightening screw connection (approx. 5 Nm), hold actuating lever (1) of throttle valve in
direction of arrow at "close throttle valve".
Only turn nut and grip screw.
To screw down, use two open-end wrenches which are to be placed at right angles to actuating shaft.
In this way, no lever action is exerted on the throttle valve mechanism; such torque would impair the
quality of adjustment.
After pretightening actuating lever, actuate throttle valve several times at full load.
NOTE: If necessary, carry out adjustment with a second person.

2010 BMW M3
Adjusting throttle valve assemblies 1 - 4 and 5 - 8:
The previously described procedure applies to adjusting/setting throttle valve assemblies 1 - 4 and 5 - 8.
Adjust throttle valve assemblies 1 - 4 and 5 - 8 in sequence.
After successfully completing throttle valve basic setting and checking, tighten down all screw connections of
throttle valve levers to specified torque. See 13 54 1AZ in 13 54 THROTTLE VALVE ACTUATION (S65) .
Fig. 16: Identifying Throttle Valve Assemblies 1 - 4 And 5 - 8 In Sequence

NOTE: After completing adjustment, it is necessary to check the throttle valve basic
setting!
If during the checking of one or more throttle valve assemblies excessively
large or small play is ascertained, it will be necessary to perform the throttle
valve basic setting again!
Function selection:
Complete vehicle
Drive
Engine electronics
Air supply
Throttle valves
2010 BMW M3

Then clear fault memory.
13 54 045 REMOVING AND INSTALLING/SEALING A THROTTLE VALVE ASSEMBLY (S65)

Switch off ignition
Follow instructions on connecting and disconnecting battery . See 12 00 ... INSTRUCTIONS FOR
DISCONNECTING AND CONNECTING BATTERY .
MANIFOLD (S65) .
Remove all injectors
Release and raise cable duct for engine wiring harness; to do so, partially remove engine wiring harness.
See 12 51 001 REPLACING WIRING HARNESS SECTION FOR ENGINE (S65) .
Disengage pull rods of throttle valve actuating motor.
Release all nuts of throttle valve flanges.
Release idle air hose connection.
Lift out throttle valve bank.
Fig. 17: Locating Throttle Valve Flanges Nuts

Release idle air duct on throttle valve bank.

2010 BMW M3
Fig. 18: Identifying Idle Air Duct And Throttle Valve Bank
Release all screw connections on shaft (1).
Grip screws, release nuts only. Replace screws and nuts (3).
Installation:
Actuating lever (2) of throttle valve actuating motor is offset by 180 to throttle valve actuating levers.
Fig. 19: Identifying Actuating Shaft, Actuating Lever And Screw Connections
Mounting sequence of actuating levers, bank 1
1. Levers for throttle valves

2. Lever from actuator motor
2010 BMW M3
Fig. 20: Identifying Throttle Valves And Actuator Motor

Installation:
Clean sealing surfaces on cylinder head.
Replace O-rings (1) on cylinder head.
Check adapter sleeves on throttle valves.
Fig. 21: Identifying Cylinder Head O-Rings


Perform basic throttle valve setting

2010 BMW M3

Switch off ignition
MANIFOLD (S65) .
Installation:
Fig. 22: Identifying Left Hall Sensor

Function selection:
Complete vehicle
Drive
Engine electronics
Air supply
Throttle valves

Clear fault memory
2010 BMW M3

Switch off ignition
MANIFOLD (S65) .
Release and raise cable duct for engine wiring harness; for information, refer to12 51 001 REPLACING
WIRING HARNESS SECTION FOR ENGINE (S65) .
Installation:
Assemble engine.
Fig. 23: Identifying Right Hall Sensor

Function selection:
Complete vehicle
2010 BMW M3
Drive
Engine electronics
Air supply
Throttle valves

Clear fault memory
SENSOR FOR CONTROL UNIT

Switch off ignition

MANIFOLD (S65) .
Installation:
Tightening torque, 13 62 2AZ . See 13 62 SENSORS (S65)
Fig. 24: Locating Oil Pressure Switch


2010 BMW M3

Switch off ignition
MANIFOLD (S65) .
Release cable duct for engine wiring harness; for information, refer to 12 51 001 REPLACING
WIRING HARNESS SECTION FOR ENGINE (S65) .
Tightening torque 13 41 1AZ . See 13 41 PRESSURE SENSORS (S65) .

Installation:

2010 BMW M3


13 62 511 REPLACING INTAKE AIR TEMPERATURE SENSOR (S65)
Switch off ignition
Intake air temperature sensor (1) without retaining clip.
Intake air temperature sensor (2) with large ribs for retaining clip (3).
Fig. 27: Identifying Air Temperature Sensor And Retaining Clip

2010 BMW M3
Version 1:
Fig. 28: Locating Temperature Sensor

Version 2:
Unlock plug and remove.
Pull off retaining clip (1).
Fig. 29: Identifying Retaining Clip

2010 BMW M3

13 62 531 REPLACING COOLANT TEMPERATURE SENSOR (S65)
Switch off ignition
MANIFOLD (S65) .
Remove temperature sensor.
Installation:
Fig. 30: Locating Temperature Sensor

13 62 540 REMOVING AND INSTALLING/REPLACING THROTTLE VALVE ACTUATING

MOTOR (S65)
Switch off ignition
2010 BMW M3
MANIFOLD (S65) .
Partially remove engine wiring harness . See 12 51 001 REPLACING WIRING HARNESS
SECTION FOR ENGINE (S65) .
NOTE: Illustration shows and description refers to the left throttle valve servomotor.
The procedure is identical for the right intake duct.
Remove thrust rod (1).
Release screws.
Remove throttle valve servomotor (2).
Fig. 31: Identifying Thrust Rod And Throttle Valve Servomotor

Function selection:
Complete vehicle
Drive
Engine electronics
Air supply
Throttle valves

2010 BMW M3
Switch off ignition
Remove intake filter housing
Release screw.
Installation:

2010 BMW M3
Switch off ignition
Release screw.
Installation:

Switch off ignition
2010 BMW M3
Remove intake filter housing

Release screw.
Installation:

Switch off ignition
2010 BMW M3
Release screw.
Installation:

Switch off ignition
FRONT UNDERBODY PROTECTION and 51 47 491 REMOVING AND
regulations.
2010 BMW M3
Release screw (1).

NOTE: Top up transmission fluid.

Switch off ignition
FRONT UNDERBODY PROTECTION and 51 47 491 REMOVING AND
Remove reinforcement plate . See 31 10 010 REMOVING AND INSTALLING/REPLACING
REINFORCEMENT PLATE (M3) .
Release screws (1).
Remove cover.
2010 BMW M3

Release screw (1).
Fig. 38: Identifying Pulse Generator Connector Screw


START VALVES
13 64 541 REPLACING ALL FUEL INJECTORS
This work step is described in Removing complete injection pipe .

2010 BMW M3
INTAKE SILENCER
13 71 000 REMOVING AND INSTALLING/REPLACING INTAKE FILTER HOUSING (S65)
Remove intake filter element
Release screws.
Raise intake filter housing, pull out of intake duct and remove in upward direction.
Installation:
Pay attention to position of spacer buffers during installation.
Fig. 39: Pulling Out Of Intake Duct

AIR CLEANER
13 72 001 REPLACING AIR FILTER ELEMENT (S65)
Release screws.
Remove top section (1) of intake filter housing.

2010 BMW M3
Fig. 40: Locating Intake Filter Housing Screws

Release clamp (1) for intermediate flange.
Press air filter element outwards against spring force and remove.
Assemble engine.
Fig. 41: Releasing Clamp For Intermediate Flange

CARBON CANISTER VENTILATION

13 90 500 REPLACING TANK VENTING VALVE (S65)
Switch off ignition
2010 BMW M3
Remove intake air manifold. See 11 61 050 REMOVING AND INSTALLING AIR INTAKE
MANIFOLD (S65) .
NOTE: The tank venting valve is fitted under the intake air manifold.
Unlock hose on tank venting valve and disconnect.
Release clamp, detach hose.
Release bolt on bracket.
Remove tank venting valve.
Fig. 42: Locating Bracket Bolt


2010 BMW M3
ENGINE Fuel Supply System - Repair
ENGINE
Fuel Supply System - Repair
DRAWING OFF OF FUEL, SYSTEM CLEANING

16 00 100 CHECKING FUEL TANK AND TANK VENTILATION SYSTEM FOR LEAKS
Remove COVER FOR CARBON CANISTER
The following procedure is only applicable to vehicles without the tank leak diagnosis module.
Comply with the following conditions in order to obtain plausible test results:
Content of fuel tank:

1. Maximum 90 %
2. Minimum 13 % (reserve telltale must not light up).
Put vehicle into workshop for at least 2 hours such that the fuel temperature corresponds to the workshop
temperature. (Ideal fuel temperature approx. 10...20C)
Disconnect line to evaporation strainer (1) from carbon canister.
IMPORTANT: Risk of breakage!
Carefully remove evaporation strainer from carbon canister.
seal opening (2) for evaporation strainer on carbon canister with special tool 16 1 070 PLUG .
Fig. 1: Identifying Evaporation Strainer And Seal Opening With Special Tool (16 1 070)
2010 BMW M3
Remove fuel filler cap and connect special tool 16 1 174 to fuel filler neck.
Using thumbwheel (1), clamp special tool 16 1 174 to fuel filler neck.
Fig. 2: Clamping Special Tool (16 1 174) On Fuel Filler Neck Adjusting Wheel
IMPORTANT: Turn pressure regulator on special tool 16 1 171 counter-clockwise as far as

the stop.
Using compressed air line (1), connect special tool 16 1 171 to workshop compressed air system (8... 10 bar).
Connect pressure sensor (2) from Diagnosis and Information System with a measuring range of 0... 25 bar.
IMPORTANT: Do not connect quick-release coupling (3) of special tool 16 1 171 as yet.
Fig. 3: Connecting Special Tool (16 1 171) To Garage Compressed Air System Using Compressed Air
Line
2010 BMW M3
1. Select "Measurement" function on Diagnosis and Information System (DIS).

2. Using pressure regulator on special tool 16 1 171, increase pressure by 0.20 bar.
3. Connect special tool 16 1 174 to quick-release coupling of special tool 16 1 171.
4. Wait until the value at the Diagnosis and Information System has levelled out.
5. Using pressure regulator on special tool 16 1 171, reset pressure in fuel tank to 0.20 bar above
atmospheric.
IMPORTANT: Do not under any circumstances increase pressure by more than 0.30 bar as
this would result in damage to the fuel tank and venting system.
Using special tool 13 3 010 TERMINAL , disconnect feed line from special tool 16 1 171 to fuel filler neck.
Allow a rest period of approx. 20 sec.
Read off and note down starting pressure value.
Wait approx. 120 sec.
Read off final pressure value and compare with starting pressure value.
Fig. 4: Disconnecting Delivery Line From Fuel Filler Neck Using Special Tool (16 1 171)
Measurement evaluation
Pressure drop up to 0.01 bar: System OK

Pressure drop over 0.02 bar: System leaking beyond permitted levels
If the system is leaking, a leak test must be carried out and the defective components replaced.
16 00 102 CHECKING FUEL TANK AND TANK VENTING SYSTEM FOR LEAKS WITH TANK
2010 BMW M3
LEAKAGE DIAGNOSIS MODULE (DMTL)
NOTE: An OBD fault is indicated by the "Check Engine" indicator lamp in the
instrument cluster lighting up.
This may indicate a leak in the tank venting system.
Information on this is provided by the fault memory of the DME control unit.
Read out fault memory of DME control unit and carry out a diagnosis in accordance with faults stored.
A leak test of the DMTL module is then carried out if:
The components of the DMTL module are OK.
A fault is stored in the DME fault memory (tank leak detected).
Adhere to following conditions in order to carry out a correct leak test:
Content of fuel tank < 90 %

Reserve indicator lamp "off"
Put vehicle into workshop for at least 2 hours such that the fuel temperature corresponds to the workshop
temperature. (Ideal fuel temperature approx. 10...20C)
Never freshly refuel the vehicle. (Severe gas emissions from fresh fuel)
Check that tank cap is correctly seated.
WARNING: During the leak test, under no circumstances apply external

pressurization through the fuel filler neck as this may cause incorrect
readings.
In the Diagnosis and Information System (DIS), go to the "Function and component selection" page.
Work through tank leakage diagnosis module. Leakage test is carried out.
If fault is recorded again in DME fault memory (tank leak detected), CARRY OUT LEAK TEST .
16 00 510 CONDUCTING LEAK TEST ON FUEL TANK AND TANK VENTING SYSTEM
IMPORTANT: On vehicles with tank leak diagnosis modules (DMTL), do not work with
external pressurization as the tank ventilation system will leak under this
condition.
On account of emerging fuel vapors, carry out all work in well ventilated rooms.
Or use a suitable extractor system.
Observe country-specific accident prevention and occupational safety
regulations.
NOTE: The following procedure is only applicable to vehicles with the tank leak
2010 BMW M3
diagnosis module (DMTL).

For vehicles without tank leak diagnosis module:
PRESSURIZE FUEL TANK AND TANK VENTING SYSTEM.
During the leak test with a leak detector, be sure to follow the operating
instructions of the equipment manufacturer.
NOTE: Select "Tank leak diagnosis module (DMTL)" on Diagnosis and Information
System (DIS).
The leak diagnosis pump pressurizes the fuel tank and tank ventilation system for 30 sec.
If pressure is needed for longer than 30 sec., press "Activate" button again after 30 sec.
The leak test can be carried out with a leak detector.
Possible causes may be:
- Tank cap leaking (CHECK TANK CAP PRESSURE RELIEF VALVE) .

- Tank venting lines leaking (fuel tank - carbon canister - tank venting valve).
- Tank vent line leaking (engine compartment).
- Fuel level sensor flange on tank leaking.
Fig. 5: Identifying Leak Test Detector

16 00 005 DRAINING AND FILLING FUEL TANK
Recycling
Fuel escapes when fuel lines are detached. Have a suitable collecting container ready.
Catch and dispose of escaping fuel.

2010 BMW M3
IMPORTANT: Ensure adequate ventilation in the place of work!

Avoid skin contact (wear gloves)!
Connect the exhaust and extraction systems to the exhaust tailpipe.
The electric fuel pump must not operate without fuel! After completing repairs but before starting the engine for
the first time, fill the fuel tank with min. 5 l fuel through the fuel filler pipe.
Do not damage non-return flap when pulling out extraction hose.
Diesel vehicles
NOTE: Before starting the engine for the first time, if the tank has been run dry or
drawn off, fill with diesel fuel and turn on ignition for approx. 1 minute. The fuel
circuit is thus filled and vented, which results in the engine firing more quickly.
Drawing off fuel
Start engine and allow to run.
NOTE: The electric fuel pump runs.
In this way, the fuel is repumped through the suction jet pump from the left to the right side of the fuel tank.
Fuel can be drawn out of left and right sides of tank through filler neck, leaving only a small residue. The
residual quantity is drawn off through the service opening (on right/left).
Insert special tool 16 1 080 HOSE into filler neck.
Special tool 16 1 080 HOSE has two different diameters for gasoline and diesel vehicles!
Slide extraction hose of extractor unit, refer to BMW Service Workshop Equipment and Planning
Documentation, through special tool 16 1 080 HOSE into the fuel filler pipe, turning in the process if
necessary.
Insertion length approx. 120 cm.
IMPORTANT: Comply with the following instruction if the extraction hose can only be
inserted approx. 100 cm before meeting resistance.
2010 BMW M3

Draw off fuel as much as possible with extractor unit, refer to BMW Service Workshop Equipment and
Planning Documentation.
Follow drawing off of fuel on fuel gauge in instrument cluster.
NOTE: If the extraction hose meets resistance at an insertion length of approx. 100 cm,
a second person must press gently against the rubber hose of the filler pipe.
Only for US cars with N51 engines (metal filler pipe)!
The extraction hose is correctly positioned in the tank at an insertion length of approx. 120 cm.
IMPORTANT: Watch out for escaping fuel when withdrawing the extraction hose from the
filler pipe.
Fig. 7: Pressing Filler Pipe Rubber Hose

2010 BMW M3
Drawing off residual fuel quantity
Drawing off residual fuel amount is not included in the time value of this operation.
IMPORTANT: Ensure car interior is adequately ventilated.

Catch dripping fuel in a suitable container.
Remove left sensor unit See 1612001 REMOVING AND INSTALLING OR REPLACING FUEL
GAUGE SENSOR (GASOLINE, LEFT) or 1614016 REMOVING AND INSTALLING/REPLACING
FUEL FILTER WITH PRESSURE REGULATOR.
Remove RIGHT SENSOR UNIT .
Draw off residual fuel quantity through service openings.
NOTE: Only for US cars with N51 engines!
Fuel filling
Insert special tool 16 1 080 HOSE into filler neck.
Special tool 16 1 080 HOSE has two different diameters for gasoline and diesel vehicles!
Documentation, approx. 40 cm into fuel filler pipe.
Fill fuel from suction extractor unit.

2010 BMW M3
Drawing off after fault in suction jet pump
Draw off right half of tank completely through fuel filler pipe.
Remove cap from left service opening.
Insert extraction hose through service opening in tank, fuel (also residual quantity) can be drawn off.
Fig. 9: Inserting Extraction Hose Through Service Opening In Tank

16 00... FUEL SUPPLY SYSTEM (GASOLINE)
1. General
GENERAL FUNCTION DESCRIPTION OF FUEL SYSTEM .
2. Part designation
Schematic drawings of fuel supply systems

2010 BMW M3
Fig. 10: Identifying Fuel Supply System Components (ECE/Japan)

Fuel supply system (ECE/Japan)

2010 BMW M3
Fig. 11: Identifying Fuel Supply System Components (US Version)

Fuel supply system (US version)
FUEL SUPPLY SYSTEM REFERENCE CHART

1. Fuel level sensor, left 9. Purge air line to tank venting valve
2. Suction jet pump, left 10. Fuel line to engine
3. Fuel level sensor, right 11. Rollover valve
2010 BMW M3
4. Suction jet pump, right 12. Service vent valve

5. Surge chamber 13. Filler vent valve
6. Electric fuel pump 14. Dust filter
7. Fuel filter with pressure regulator 15. To atmosphere
8. Tank leak diagnosis module
8. Evaporator strainer
3. Functional description (see also graphic)
Fuel system
The saddle-shaped fuel tank contains the surge chamber with integrated electric fuel pump on its right side.
The surge chamber ensures that the fuel pump is properly supplied in all vehicle operating states.
The fuel is pumped from the right side of the fuel tank into the surge chamber via the suction jet pump
integrated in the surge chamber.
The suction jet pump in the left fuel tank half pumps the fuel through the tank expansion line to the right side of
the fuel tank.
The suction jet pump is operated via the fuel feed line.
Return line, pressure regulator and fuel filter are located in the tank.
Fuel supply to engine:
The fuel is routed from the electric fuel pump via the fuel feed line and the fuel filter/pressure regulator unit to
the fuel rail.
Pressure regulator and fuel filter are incorporated in a single unit in the tank. There is thus no need for a fuel
return line.
The fuel passes through the pressure regulator into the left side of the fuel tank and thereby drives a suction jet
pump. This pump repumps the fuel from the left side of the tank to the right side.
The fuel rail is return-free.
Tank safety valve (US version):
The fuel tank is vented during refuelling via the refuelling vent line.
Because of its large cross-section, the refuelling vent line directs the displaced volume (fuel vapors) at high
speed through the expansion volume to the carbon canister.
The activated carbon retains the fuel contained in the fuel vapors. The cleaned air is discharged to atmosphere
2010 BMW M3
via the evaporation line, the tank leak diagnosis module and the dust filter.
During driving, the system tank is vented in the same way via the vent line.
The condensed constituents of the fuel vapors remain in the tank because the tank has an integrated
compensating volume.
The refuelling shutoff valve in the fuel tank is closed by the rising fuel if the fuel tank is overfilled. The
ventilation function is maintained by a second float valve.
Al three valves are designed as rollover valves. This prevents fuel from escaping from the fuel tank in extreme
vehicle positions (overturning, inclined position).
The carbon canister is regenerated by purging with fresh air.
The DME control unit opens the tank vent valve. Thus the vacuum pressure of the engine intake manifold is
applied at the purge air line. The carbon canister is purged in this way. The fresh air needed for this purpose is
supplied via the tank leak diagnosis module and the dust filter. The fuel constituents bound by the activated
carbon are flushed out by the supplied air and directed via the purge line to the engine for combustion.
This operation is only possible while the engine is running.
Tank safety valve (worldwide):
Refer to Tank venting system (US version) with following differences:
1. Carbon canister has a smaller capacity.

2. No tank leak diagnosis module or dust filter.
Leak diagnosis for tank safety valve (US version):
The tank leak diagnosis module (see drawing 5.2) serves to diagnose leakages for the tank venting system
within the on-board diagnosis laid down by legislation.
The tank venting system is pressurized and the pressure loss is detected in the event of a leak.
The tank leak diagnosis module is activated by the DME control unit and detects the pressure loss by way of the
power consumption of the integrated pump. The air required for this purpose is supplied via the dust filter.
The pressure test line establishes the connection between fuel tank and fuel filler neck. This enables a leak to be
detected in the fuel filler pipe - fuel tank cap area.
Determining fill level in fuel tank:
The fuel level is measured by means of lever sensors on both sides of the fuel tank. The combination of the
determined ohm values from the right and left lever-type sensors produces the actual level in the fuel tank.
2010 BMW M3
4. Operating data, fuel system
FUEL PUMP OPERATING PRESSURE .
16 00 FUNCTIONAL DESCRIPTION FOR GENERAL FUEL SUPPLY SYSTEMS
Gasoline engine fuel supply systems
Fuel system
The fuel pump in the fuel tank generates pressure in the fuel system, which is set by the electronic pressure
control valve to a certain level.
Tank-venting system
The tank safety valve is a closed system that is bled via a carbon canister. The carbon in the canister is stored as
granules. The large surface of the granules traps the fuel vapor, that occurs in the fuel tank. The carbon canister
needs to be refreshed regularly in order to be able to continue to store fuel vapor. This is done by flushing it
with fresh air from the intake pipe. This process is controlled by the engine control unit.
Diesel engine fuel supply system
Fuel system
The fuel pump in the fuel tank supplies the engine with fuel. Two types of high pressure pump are used for
direct injection.
1. The distributor-type injection pump. This supplies each cylinder directly with fuel via individual injector
nozzles.
2. The high pressure pump for the common rail systems. This generates the required pressure in the injector
pipe for all injector nozzles.
With common rail systems another pump (inline pump, M57/geared pump, M67) is connected between
the high pressure pump and the fuel pump. This pump aids the fuel pump in the fuel tank during times of
high fuel requirement.
Tank-venting system
Diesel fuel is slow-evaporating, therefore no carbon canister is required. The fuel tank is bled directly into the
atmosphere.
FUEL TANK WITH MOUNTING

16 11 130 CHECKING FILLER CAP PRESSURE RELIEF VALVE
Set pressure regulator on special tool 16 1 171 fully in "-" direction.

2010 BMW M3
Connect special tool 16 1 171 using compressed air line (1) to workshop compressed air system (8... 10 bar).
Connect pressure sensor (2) from Diagnosis and Information System.
Fig. 12: Connecting Special Tool (16 1 171) To Garage Compressed Air System Using Compressed Air
Line
Connect special tool 16 1 172 to quick-release coupling of special tool 16 1 171.
Install fuel filler cap on special tool 16 1 172 (3).
Fig. 13: Identifying Fuel Filler Cap With Special Tool (16 1 172)
NOTE: Only the absolute pressure is indicated in the display of the Diagnosis and
Information System (DIS). The current ambient air pressure is already displayed
without additional pressurization.
2010 BMW M3
Check testing equipment for leaks!
Select "Measurement/Pressure" function on Diagnosis and Information System (DIS).
Using pressure regulator on special tool 16 1 171, increase pressure by 0.2 bar.
Using special tool 13 3 010 TERMINAL clamp off feed line from special tool 16 1 171.
Read off and note down pressure.
Wait 60 secs.
Read off pressure again and compare with starting pressure value.
Measurement evaluation:
PRESSURE MEASUREMENT EVALUATION CHART

Pressure drop > Testing equipment leaking.
0.012 bar Check connection points for leaks.
Check fuel filler cap pressure relief valve!
Select "Measurement/Pressure" function on Diagnosis and Information System (DIS).
Using pressure regulator on special tool 16 1 171, increase pressure by 0.3 bar.
Using special tool 13 3 010 TERMINAL clamp off feed line from special tool 16 1 171.
Wait 60 secs.
Read off pressure value again and compare with starting pressure value.
PRESSURE MEASUREMENT EVALUATION CHART

Pressure drop > Filler cap pressure relief valve faulty.
0.012 bar Replace fuel tank cap.
16 11 060 REMOVING AND INSTALLING OR REPLACING FUEL FILLER PIPE
Recycling
2010 BMW M3

After installation of fuel tank/prior to first engine start-up:
Fill fuel tank with at least 5 liters of fuel.

Check ground connection at fuel filler neck to body for continuity. If necessary, clean contact surface
between body and fuel filler pipe screw connection.
DRAW OFF FUEL FROM FUEL TANK

Remove REAR RIGHT WHEEL ARCH TRIM
Lower REAR AXLE
Unhook retaining strap (1) from tank flap.
Open cap and set to one side.
Fig. 14: Identifying Retaining Strap

IMPORTANT: There may still be residual amounts of fuel in the tank.

Detach fuel filler hose from fuel filler pipe.

2010 BMW M3
Installation:
Replace hose clip.
Fig. 15: Identifying Hose Clip

Unlock quick-release fastener (1) and detach vent hose (2).
Unscrew nut (3).
Fig. 16: Identifying Nuts, Fastener And Vent Hose

Unscrew nuts (1).
Installation:

2010 BMW M3
Withdraw fuel filler pipe (2) completely out of rubber gaiter at wheel arch and feed out.
Installation:
Make sure rubber cup fits correctly.

Installation:
Clean contact surface on body and earth cable on fuel filler pipe.
16 11 030 REMOVING AND INSTALLING OR REPLACING FUEL TANK (GASOLINE)
Recycling


2010 BMW M3
Check TRANSFER FUNCTION OF SUCTION JET PUMP .

Remove REAR SEAT BENCH
Remove GUIDE TUBE FOR HANDBRAKE CABLES
Remove right WHEEL ARCH TRIM
Remove REAR LEFT AND RIGHT UNDERBODY PANELLING
Remove left and right UNDERBODY COVER
Release screws (1) and remove cover (2) from left and right sides of fuel tank.
Fig. 18: Identifying Fuel Tank Cover And Screws

Left sensor unit:
Press grey ring (2) towards sensor unit and pull out fuel feed line (3).
2010 BMW M3

USA national version:
Unlock and detach vent lines (2).
If necessary, remove fuel line for independent heating.
Fig. 20: Identifying Plug Connection And Vent Lines (USA National Version)
ECE national-market version:
Right sensor unit:
Unlock quick-release fastener and detach vent line (2).

2010 BMW M3
Installation:
Make sure quick-release fasteners engage correctly.
Fig. 21: Identifying Plug Connection And Vent Line


Release hose clamp (1) and detach fuel filler hose from fuel filler pipe.
If necessary, draw off residual amount of fuel via filler hose.
Installation:

2010 BMW M3
Unlock quick-release fastener (1) and detach vent line (2).
Detach vent line (2) from holder (3).
Fig. 23: Identifying Quick Release Fastener, Vent Line And Holder
Heavily support the fuel tank.
Fig. 24: Identifying Fuel Tank With Support

Unfasten nut.
Installation:

2010 BMW M3
Fig. 25: Replacing Self Locking Nut

Release screws for tightening straps on left and right and remove tightening straps.
Carefully lower fuel tank.
IMPORTANT: Carefully feed the vent line through the body when lowering the fuel tank.
Installation:
Fig. 26: Removing Screws And Tightening Straps

Installation
Note rubber mount with spacer bush.

2010 BMW M3
Wide collar on spacer bush points to screw head.
Fig. 27: Identifying Rubber Mount With Spacer Bush

The following components must be modified when the fuel tank is replaced:
Modify vent line (1)

Modify right sensor unit See 1614010 REMOVING AND INSTALLING OR REPLACING FUEL
PUMP or 1614010 REMOVING AND INSTALLING OR REPLACING FUEL PUMP
(GASOLINE) (2)
Modify left sensor unit See 1612001 REMOVING AND INSTALLING OR REPLACING FUEL
GAUGE SENSOR (GASOLINE, LEFT) or 1614016 REMOVING AND
INSTALLING/REPLACING FUEL FILTER WITH PRESSURE REGULATOR (3)
Fig. 28: Identifying Vent Line And Sensor Units

16 11 350 REPLACING TENSIONING STRAPS FOR FUEL TANK

2010 BMW M3
Partially detach REAR UNDERBODY PANELLING
IMPORTANT: Secure fuel tank against slipping and falling out.
Fig. 29: Identifying Fuel Tank With Support

Release screws (1) and remove clamping band.
Installation:
Fig. 30: Identifying Clamping Band Screws

16 11 071 REPLACING RUBBER SLEEVE BETWEEN FUEL FILLER PIPE AND FUEL TANK
Recycling
2010 BMW M3

Before starting the engine for the first time:

Draw off FUEL FROM FUEL TANK

Detach rubber sleeve first from fuel filler pipe and then from fuel tank.
Installation:

2010 BMW M3
FUEL DELIVERY, SENSOR FOR DISPLAY

16 12... CHECKING REPUMPING FUNCTION OF SUCTION-JET PUMP WITH BMW DIAGNOSIS
SYSTEM

Ensure absolute cleanliness when working on the open fuel tank.
Contaminants in the fuel tank can impair driving operation or may even result
in vehicle breakdown!
Catch escaping fuel in a suitable container.
Fill level must be < or = 28 l

If necessary, DRAW OFF F FROM FUEL TANK
Pour two to three liters of fuel into left tank chamber via the flange opening
Connect diagnosis system
Path:
Brief test KOMBI Instrument cluster
Diagnosis connect unit functions
Diagnosis requests
Tank sensor 1 tank sensor 2
NOTE: Tank sensor 1 = right tank sensor

Tank sensor 2 = left tank sensor
Start engine.
Compare display for left and right tank chambers.
Repumping function OK
If fill level of tank sensor 2 (left chamber) is falling (approx. one liter per minute).
Repumping function not OK
If fill level of tank sensor 2 (left chamber) is stable or rising.
16 14 016 REMOVING AND INSTALLING/REPLACING FUEL FILTER WITH PRESSURE

REGULATOR
Recycling
2010 BMW M3

Remove rear seat bench See 5226005 REMOVING AND INSTALLING/REPLACING REAR
SEAT (THROUGH-LOADING) or 5224005 REMOVING AND INSTALLING OR REPLACING
REAR SEAT
Remove right sensor unit See 1614010 REMOVING AND INSTALLING OR REPLACING FUEL
(GASOLINE)
CHECK REPUMPING FUNCTION OF SUCTION-JET PUMP
Release screws (1) and remove cover (2) from left side of fuel tank.

2010 BMW M3
Press grey ring (1) towards sensor unit and detach fuel feed line (3).
IMPORTANT: Do not use any tools to release the quick-release fasteners.

Release screw cap with special tool 16 8 020 LIFTING GEAR and remove service cap.
Installation:
Fig. 34: Removing Screw Cap Using Special Tool (16 1 020)
IMPORTANT: After tightening to specified torque, notch (1) on screw cap (2) must be in area
2010 BMW M3
(A)!
NOTE: Illustration shows the tank removed.
Fig. 35: Identifying Notch And Screws Cap

Installation:
Service cap can only be installed in one position.
When installing, make sure lug (1) of service cap engages in corresponding opening (2) on fuel tank.
Make sure that the lever sensor moves freely before fitting the service cap.
Clean sealing faces and install new seal.
Fig. 36: Identifying Lug And Opening On Fuel Tank

2010 BMW M3
Attach an auxiliary lead (1) to hose pack (2) through service opening.
The auxiliary lead is pulled through with the hose pack towards the left and facilitates subsequent reinstallation.
Fig. 37: Identifying Auxiliary Lead And Hose Pack

Carefully lift sensor unit (1) out of tank.
In so doing, press tab (2) against spring force in order to make it easier to feed sensor unit out of tank.
Fig. 38: Lifting Sensor Unit

Remove fuel filter (1) and hose pack (2) with auxiliary cable to left.
Installation:
When replacing the fuel filter, modify the end of the auxiliary lead to the new hose pack and carefully pull in
through the tank.
2010 BMW M3
Fig. 39: Removing Fuel Filter And Hose Pack With Auxiliary Cable
16 12 010 REMOVING AND INSTALLING OR REPLACING CARBON CANISTER
Unlock quick-release fasteners (1) and disconnect vent lines.
Release screws (2) and remove carbon canister (3).
Installation:

2010 BMW M3
Fig. 40: Identifying Carbon Canister, Screws And Fasteners

16 12 001 REMOVING AND INSTALLING OR REPLACING FUEL GAUGE SENSOR (GASOLINE,

LEFT)
Recycling

REAR SEAT
Remove RIGHT SENSOR UNIT
2010 BMW M3

Press grey ring (2) towards sensor unit and pull out fuel feed line (3) straight.
IMPORTANT: Do not use any tools to release the fuel feed line.
After installing fuel feed line, carry out tensile test and leak test.
Installation:
Procedure for tightening screw cap, see next work step.

2010 BMW M3
IMPORTANT: Fit screw cap without using a tool and tighten hand-tight.
Then tighten screw cap with special tool 16 8 020 LIFTING GEAR until notch (1) points to marking (2).
Fig. 44: Identifying Notch And Marking On Screw Cap

Installation:
2010 BMW M3

Installation:
Make sure when pulling through the hose pack that the tank ventilation system in the tank tunnel is not
damaged.


2010 BMW M3

Remove sensor unit (1) and hose pack (2) with auxiliary cable to left.
Installation:
When replacing the sensor unit, modify the end of the auxiliary lead to the new hose pack and carefully pull in
through the tank.
Fig. 48: Removing Sensor Unit And Hose Pack With Auxiliary Cable
16 12 000 REMOVING AND INSTALLING OR REPLACING FUEL GAUGE SENSOR (GASOLINE,

RIGHT)
Recycling
2010 BMW M3


Check TRANSFER FUNCTION OF SUCTION JET PUMP
Remove FUEL PUMP
Carefully unlock tabs (1) and pull off fuel level sensor upwards in direction of arrow.
Disengage line (2) from holders.
Unlock plug connection (3) and detach from service cap.
Installation:
Fuel level sensor and connector must audibly snap into place!
Fig. 49: Identifying Plug Connection And Tabs

2010 BMW M3

Carefully feed cable out of cable guide.
Do not kink cable.
16 12 010 REMOVING AND INSTALLING/REPLACING CARBON CANISTER (DMTL)
Installation:
Fig. 50: Identifying Plug Connection, Fasteners And Carbon Canister

Installation:
Lug (1) must be correctly seated in guide (2).

2010 BMW M3
Fig. 51: Identifying Guide And Lug

FUEL DEAERATION
16 13 015 REMOVING AND INSTALLING/REPLACING TANK LEAK DIAGNOSIS MODULE
(GASOLINE CARS WITH US DMTL VERSION)
Remove CARBON CANISTER
Release screws (1).
Disconnect tank leak diagnosis module (2) from carbon canister in direction of arrow.
Installation:

2010 BMW M3
Fig. 52: Identifying Tank Leak Diagnosis Module And Screws

FUEL PUMP
16 14 016 REMOVING AND INSTALLING/REPLACING FUEL FILTER WITH PRESSURE
REGULATOR
Recycling

REAR SEAT
2010 BMW M3
Remove right sensor unit See 1614010 REMOVING AND INSTALLING OR REPLACING FUEL
(GASOLINE)
CHECK REPUMPING FUNCTION OF SUCTION-JET PUMP


2010 BMW M3

Installation:
(A)!
Fig. 56: Identifying Notch And Screws Cap

2010 BMW M3
Installation:


2010 BMW M3

Installation:
through the tank.
Fig. 60: Removing Sensor Unit And Hose Pack With Auxiliary Cable
16 14 500 REMOVING AND INSTALLING OR REPLACING CONTROL UNIT FOR ELECTRIC

FUEL PUMP
2010 BMW M3

E81, E82, E87, E91, E92 and E84:
Remove BACKREST SIDE SECTION for right rear seat
E90:
Remove BACKREST
Release nuts (2) and remove control unit (3).
Installation:
Fig. 61: Identifying Plug Connection, Nuts And Electric Fuel Pump Control Unit
Replacement
16 14 010 REMOVING AND INSTALLING OR REPLACING FUEL PUMP
Recycling

2010 BMW M3

Fill fuel tank with at least 5 liters of fuel

Check TRANSFER FUNCTION OF SUCTION JET PUMP

REAR SEAT
Release screws (1) and remove cover (2) from right side of fuel tank.


2010 BMW M3
ECE national version:
Unlock and detach vent line (2).

Installation:

2010 BMW M3

Carefully raise service cap (1).
Installation:
Clean sealing faces and install new seal (3).

2010 BMW M3
Locating rods (4) must fit correctly in the hole of the delivery unit.
Fig. 67: Identifying Service Cap And Vent Line With Seal
Installation:

Installation:
2010 BMW M3
Connect cable with cable tie (2).
Fig. 69: Connecting Cable With Cable Tie

Unlock quick-connect coupling (1) of fuel feed line and pull off hose pack (2) in upward direction.
Unlock catch (4) and detach corrugated tube (3) towards top.
Draw off remaining fuel from surge chamber.
Carefully remove fuel pump with level sensor from fuel tank. If necessary, turn fuel pump 90 counterclockwise
and tilt towards lever sensor.
Fig. 70: Identifying Quick-Connect Coupling, Corrugated Tube, Hose Pack And Catch
2010 BMW M3
16 14 010 REMOVING AND INSTALLING OR REPLACING FUEL PUMP (GASOLINE)
Recycling

REAR SEAT


2010 BMW M3
ECE national-market version:

Installation:
2010 BMW M3

Installation:
2010 BMW M3
Fig. 76: Identifying Service Cap And Vent Line With Seal
Installation:


2010 BMW M3
Installation:

Unclip black return lines (1) from bracket.
Unlock and disconnect quick-release fastener (2) of fuel line.
Carefully lift fuel pump with fuel level sensor (3) out of fuel tank. If necessary, turn fuel pump 90 counter-
clockwise and tilt towards lever sensor.
Fig. 79: Identifying Black Return Lines, Fuel Level Sensor And Quick-Release Fastener
2010 BMW M3
16 14 060 REMOVING AND INSTALLING/REPLACING DUST FILTER FOR TANK LEAK

DIAGNOSIS MODULE (DMTL)
Remove REAR RIGHT WHEEL ARCH TRIM
Build date up to 09/08:
Unlock and disconnect quick-connect coupling (1).
Release screws (2) and remove dust filter (3).
Installation:
Fig. 80: Identifying Quick-Connect Coupling And Dust Filter

Build date after 09/08:
Press lugs (1) apart in direction of arrow.
Pull out filter cartridge (2) downwards.

2010 BMW M3
Fig. 81: Pulling Out Filter Cartridge Downwards

2010 BMW M3
ENGINE Fuel Supply System - Repair Instructions - M3
ENGINE
Fuel Supply System - Repair Instructions - M3
DRAWING OFF OF FUEL SYSTEM

16 00 GENERAL FUNCTION DESCRIPTION FOR FUEL SUPPLY SYSTEMS
Fuel supply systems, spark-ignition engines
Fuel system
The electric fuel pump in the fuel tank generates the pressure in the fuel system which is set by the pressure
regulator to a specific level.
Tank venting system
The tank venting system is an enclosed system which is vented via a carbon canister. The carbon is incorporated
in the carbon canister as granulate. The large surface of the carbon stores the fuel vapors which occur in the fuel
tank. The carbon canister must be regenerated on a regular basis so as to be able to continue storing fuel vapors.
Regeneration is performed by way of purging with fresh air via the intake manifold. This process is controlled
by the engine control unit.
Fuel supply systems, diesel engines
Fuel system
The electric fuel pump in the fuel tank supplies the engine with fuel. Two types of high-pressure pump are used
for cylinder injection.
1. The distributor injection pump supplies each cylinder directly with fuel via the corresponding injection
nozzle.
2. The high-pressure pump for the common rail systems generates in the fuel rail the necessary pressure for
all the injection nozzles.
In common rail systems, a further pump (inline pump, M57/gear pump, M67) is connected between the high-
pressure pump and the electric fuel pump. This pump supports the fuel pump in the fuel tank in the event of a
high fuel demand.
Tank venting system
Diesel fuel is non-volatile and therefore a carbon canister is not required. The fuel tank is vented directly to
atmosphere.
16 00 ... FUEL SUPPLY SYSTEM (PETROL/GASOLINE)

2010 BMW M3
1. General
General function description of fuel system.
2. Component designation
Schematic drawings of fuel supply systems
Fig. 1: Fuel Supply Systems (ECE/Japan)

Fuel supply system (ECE/Japan)

2010 BMW M3
Fig. 2: Fuel Supply System (US Version)

Fuel supply system (US version)
COMPONENTS REFERENCE
1. Fuel level sensor, left 9. Purge air line to tank venting valve
2. Suction jet pump, left 10. Fuel line to engine
3. Fuel level sensor, right 11. Rollover valve
4. Suction jet pump, right 12. Service vent valve
5. Surge chamber 13. Filler vent valve
6. Electric fuel pump 14. Dust filter
7. Fuel filter with pressure regulator 15. To atmosphere
8. Tank leak diagnosis module (see drawing 5.2)
8. Evaporator strainer (see drawing 5.1)
3. Function description (see also drawing)
Fuel system
The saddle-shaped fuel tank contains the surge chamber with integrated electric fuel pump on its right
2010 BMW M3
side.
The surge chamber ensures that the fuel pump is properly supplied in all vehicle operating states.
The fuel is pumped from the right side of the fuel tank into the surge chamber via the suction jet pump
integrated in the surge chamber.
The suction jet pump in the left fuel tank half pumps the fuel through the tank expansion line to the right
side of the fuel tank.
The suction jet pump is operated via the fuel feed line.
Return line, pressure regulator and fuel filter are located in the tank.
Fuel supply to engine:
The fuel is routed from the electric fuel pump via the fuel feed line and the fuel filter/pressure regulator
unit to the fuel rail.
Pressure regulator and fuel filter are incorporated in a single unit in the tank. There is thus no need for a
fuel return line.
The fuel passes through the pressure regulator into the left side of the fuel tank and thereby drives a
suction jet pump. This pump repumps the fuel from the left side of the tank to the right side.
The fuel rail is return-free.
Tank venting system (US version):
The fuel tank is vented during refuelling via the refuelling vent line.
Because of its large cross-section, the refuelling vent line directs the displaced volume (fuel vapors) at
high speed through the expansion volume to the carbon canister.
The activated carbon retains the fuel contained in the fuel vapors. The cleaned air is discharged to
atmosphere via the evaporation line, the tank leak diagnosis module and the dust filter.
During driving, the system tank is vented in the same way via the vent line.
The condensed constituents of the fuel vapors remain in the tank because the tank has an integrated
compensating volume.
The refuelling shutoff valve in the fuel tank is closed by the rising fuel if the fuel tank is overfilled. The
ventilation function is maintained by a second float valve.
Al three valves are designed as rollover valves. This prevents fuel from escaping from the fuel tank in
extreme vehicle positions (overturning, inclined position).
2010 BMW M3
The carbon canister is regenerated by purging with fresh air.
The DME control unit opens the tank vent valve. Thus the vacuum pressure of the engine intake manifold
is applied at the purge air line. The carbon canister is purged in this way. The fresh air needed for this
purpose is supplied via the tank leak diagnosis module and the dust filter. The fuel constituents bound by
the activated carbon are flushed out by the supplied air and directed via the purge line to the engine for
combustion.
This operation is only possible while the engine is running.
Tank venting system (worldwide):
Refer to Tank venting system (US version) with following differences:
1. Carbon canister has a smaller capacity.

2. No tank leak diagnosis module or dust filter.
Leak diagnosis for tank venting system (US version):
The tank leak diagnosis module (see drawing 5.2) serves to diagnose leakages for the tank venting system
within the onboard diagnosis laid down by legislation.
The tank venting system is pressurized and the pressure loss is detected in the event of a leak.
The tank leak diagnosis module is activated by the DME control unit and detects the pressure loss by way
of the power consumption of the integrated pump. The air required for this purpose is supplied via the
dust filter.
The pressure test line establishes the connection between fuel tank and fuel filler neck. This enables a
leak to be detected in the fuel filler pipe - fuel tank cap area.
Determining fill level in fuel tank:
The fuel level is measured by means of lever-type sensors on both sides of the fuel tank. The combination
of the determined ohm values from the right and left lever-type sensors produces the actual level in the
fuel tank.
4. Service data, fuel system
Fuel pump operating pressure. See FUEL SUPPLY SYSTEM - TECHNICAL DATA .
16 00 005 DRAINING AND FILLING FUEL TANK
16 1 080
2010 BMW M3
See FUEL SUPPLY SYSTEM - SPECIAL TOOLS .
Recycling

Connect the exhaust and extraction systems to the exhaust tailpipe.
The electric fuel pump must not operate without fuel! After completing repairs
but before starting the engine for the first time, fill the fuel tank with min. 5 l
fuel through the fuel filler pipe.
Do not damage non-return flap when pulling out extraction hose.
Diesel vehicles:
NOTE: Before starting the engine for the first time, if the tank has been run dry or
drawn off, fill with diesel fuel and turn on ignition for approx. 1 minute. The fuel
circuit is thus filled and vented, which results in the engine firing more quickly.
Drawing off fuel:
Start engine and allow to run.
NOTE: The electric fuel pump runs.
In this way, the fuel is repumped through the suction jet pump from the left to the right side of the fuel tank.
Fuel can be drawn out of left and right sides of tank through filler neck, leaving only a small residue. The
residual quantity is drawn off through the service opening (on right/left).
Insert special tool 16 1 080 into filler neck.
Special tool 16 1 080 has two different diameters for petrol/gasoline and diesel vehicles!
Documentation, through special tool 16 1 080 into the fuel filler pipe, turning in the process if necessary.
Insertion length approx. 120 cm.

2010 BMW M3

IMPORTANT: Comply with the following instruction if the extraction hose can only be
inserted approx. 100 cm before meeting resistance.
Draw off fuel as much as possible with extractor unit, refer to BMW Service Workshop Equipment and
Planning Documentation.
Follow drawing off of fuel on fuel gauge in instrument cluster.
NOTE: If the extraction hose meets resistance at an insertion length of approx. 100 cm,
a second person must press gently against the rubber hose of the filler pipe.
Only for US cars with N51 engines (metal filler pipe)!
The extraction hose is correctly positioned in the tank at an insertion length of approx. 120 cm.
Fig. 4: Identifying Extraction Hose

2010 BMW M3
IMPORTANT: Watch out for escaping fuel when withdrawing the extraction hose from the
filler pipe.
Drawing off residual fuel quantity:
Drawing off residual fuel amount is not included in the time value of this operation.
IMPORTANT: Ensure car interior is adequately ventilated.

Catch dripping fuel in a suitable container.
Remove left sensor unit.
Remove right sensor unit.
Draw off residual fuel quantity through service openings.
NOTE: Only for US cars with N51 engines!
Fuel filling:
Insert special tool 16 1 080 into filler neck.
Special tool 16 1 080 has two different diameters for petrol/gasoline and diesel vehicles!
Documentation, approx. 40 cm into fuel filler pipe.
Fill fuel from suction extractor unit.

2010 BMW M3
Drawing off after fault in suction jet pump:
Draw off right half of tank completely through fuel filler pipe.
Remove cap from left service opening.
Insert extraction hose through service opening in tank, fuel (also residual quantity) can be drawn off.
Fig. 6: Identifying Extraction Hose

16 00 100 CHECKING FUEL TANK AND TANK VENTILATION SYSTEM FOR LEAKS
13 3 010
16 1 070
16 1 171
16 1 174
Remove cover for carbon canister . See 51 71 ... REMOVING AND INSTALLING/REPLACING
COVER FOR CARBON CANISTER .
The following procedure is only applicable to vehicles without the tank leak diagnosis module.
2010 BMW M3
Comply with the following conditions in order to obtain plausible test results:
Content of fuel tank:

1. Maximum 90 %
2. Minimum 13 % (reserve telltale must not light up).
Park the car in the workshop at least 2 hours before the test so that the fuel temperature is approximately
that of the workshop temperature (ideal fuel temperature approx. 10 ... 20C).
Disconnect line to evaporation strainer (1) from carbon canister.

Carefully remove evaporation strainer from carbon canister.
Using special tool 16 1 070 , seal opening (2) for evaporation strainer on carbon canister.
Fig. 7: Disconnecting Line To Evaporation Strainer From Carbon Canister

Remove fuel filler cap and connect special tool 16 1 174 to fuel filler neck.
Clamp special tool 16 1 174 on fuel filler neck with adjusting wheel (1).
2010 BMW M3
Fig. 8: Identifying Clamping Special Tool (16 1 174) On Fuel Filler Neck With Adjusting Wheel
IMPORTANT: Turn pressure regulator on special tool 16 1 171 counterclockwise up to stop.
Connect special tool 16 1 171 using compressed air line (1) to garage compressed air system (8 ... 10 bar).
Connect pressure sensor (2) from Diagnosis and Information System with a measuring range of 0 ... 25 bar.
IMPORTANT: Do not yet connect fast-release coupling (3) of special tool 16 1 171 .
Fig. 9: Connecting Pressure Sensor From Diagnosis And Information System

1. Select "Measurement" function on Diagnosis and Information System (DIS).

2. Using pressure regulator on special tool 16 1 171 , increase pressure by 0.20 bar.
3. Connect special tool 16 1 174 to fast-release coupling of special tool 16 1 171 .
4. Wait until the value at the Diagnosis and Information System has levelled out.
2010 BMW M3
5. Using pressure regulator on special tool 16 1 171 , reset gauge pressure in fuel tank to 0.20 bar.
IMPORTANT: Do not under any circumstances increase pressure by more than 0.30 bar as
this would result in damage to the fuel tank and venting system.
Using special tool 13 3 010 , disconnect delivery line from special tool 16 1 171 to fuel filler neck.
Allow a rest period of approx. 20 sec.
Read off and note down starting pressure value.
Wait approx. 120 sec.
Read off final pressure value and compare with starting pressure value.
Fig. 10: Disconnecting Delivery Line From Special Tool (16 1 171) To Fuel Filler Neck
Pressure drop up to 0.01 bar:
System OK
Pressure drop over 0.02 bar:
System leaking beyond permitted levels
If the system is leaking, a leak test must be carried out and the defective components replaced.
16 00 102 CHECKING FUEL TANK AND TANK VENTING SYSTEM FOR LEAKS WITH TANK
LEAKAGE DIAGNOSIS MODULE (DMTL)
2010 BMW M3
NOTE: An OBD fault is indicated by the "Check Engine" indicator lamp in the
instrument cluster lighting up.
This may indicate a leak in the tank venting system.
Information on this is provided by the fault memory of the DME control unit.
Read out fault memory of DME control unit and carry out a diagnosis in accordance with faults stored.
A leak test of the DMTL module is then carried out if:
The components of the DMTL module are OK.
A fault is stored in the DME fault memory (tank leak detected).
Adhere to following conditions in order to carry out a correct leak test:
Content of fuel tank < 90 %

Reserve indicator lamp "off"
Leave car in workshop for at least 2 hours so that fuel temperature comes into line with workshop
temperature (ideal fuel temperature approx. 10...20C).
Do not under any circumstances fill up car with fresh fuel (strong exhalation of fresh fuel).
Check that tank cap is correctly seated.
WARNING: During the leak test, under no circumstances apply external

pressurization through the fuel filler neck as this may cause incorrect
readings.
Work through tank leakage diagnosis module. Leakage test is carried out.
If fault is recorded again in DME fault memory (tank leak detected), carry out leak test.
16 00 510 CONDUCTING LEAK TEST ON FUEL TANK AND TANK VENTING SYSTEM
IMPORTANT: On vehicles with tank leak diagnosis modules (DMTL), do not work with
external pressurization as the tank ventilation system will leak under this
condition.
On account of emerging fuel vapors, carry out all work in well ventilated rooms.
Or use a suitable extractor system.
Observe country-specific accident prevention and occupational safety
regulations.
NOTE: The following procedure is only applicable to vehicles with the tank leak
diagnosis module (DMTL).
For vehicles without tank leak diagnosis module:
Pressurize fuel tank and tank venting system.
During the leak test with a leak detector, be sure to follow the operating
2010 BMW M3
instructions of the equipment manufacturer.
NOTE: Select "Tank leak diagnosis module (DMTL)" on Diagnosis and Information
System (DIS).
The leak diagnosis pump pressurizes the fuel tank and tank ventilation
system for 30 sec.
If pressure is needed for longer than 30 sec., press "Activate" button again
after 30 sec.
The leak test can be carried out with a leak detector. Possible causes may be:
Tank cap leaking (check tank cap pressure relief valve).

Tank venting lines leaking (fuel tank - carbon canister - tank venting valve).
Tank vent line leaking (engine compartment).
Fuel level sensor flange on tank leaking.
Fig. 11: Identifying Fuel Tank And Tank Venting System

FUEL TANK WITH MOUNTING

16 11 030 REMOVING AND INSTALLING OR REPLACING FUEL TANK (PETROL/GASOLINE)
Recycling

2010 BMW M3


Check ground connection at fuel filler neck to body for continuity. If
necessary, clean contact surface between body and fuel filler pipe screw
connection.
Check transfer function of suction jet pump.
Draw off fuel from fuel tank

Remove rear seat bench . See 52 24 000 REMOVING AND INSTALLING/REPLACING LEFT OR
RIGHT REAR SEAT (CONV) or 52 24 005 REMOVING AND INSTALLING OR REPLACING
REAR SEAT .
Remove guide tube for handbrake cables . See 34 41 140 REMOVING AND INSTALLING OR
REPLACING GUIDE TUBE FOR HANDBRAKE CABLES .
Remove right wheel arch trim . See 51 71 041 REMOVING AND INSTALLING/REPLACING
Remove rear left and right underbody panelling . See 51 47 ... REMOVING AND
INSTALLING/REPLACING LEFT OR RIGHT UNDERBODY PANELLING .
Remove left and right underbody cover. See 51 75 001 REMOVING AND
INSTALLING/REPLACING LEFT OR RIGHT UNDERBODY COVER .
Release screws (1) and remove cover (2) from left and right sides of fuel tank.

Left sensor unit:

2010 BMW M3
Press grey ring (2) towards sensor unit and pull out fuel feed line (3).

Fig. 14: Identifying Plug Connection And Vent Lines

Right sensor unit:

2010 BMW M3
Unlock quick-release fastener and detach vent line (2).
Installation:
Make sure quick-release fasteners engage correctly.


Release hose clamp (1) and detach fuel filler hose from fuel filler pipe.

2010 BMW M3
Installation:
Tightening torque 16 12 1AZ . See 16 12 FUEL DELIVERY .
Unlock quick-release fastener (1) and detach vent line (2).
Detach vent line (2) from holder (3).
Fig. 17: Identifying Quick-Release Fastener And Vent Line

Fig. 18: Supporting Fuel Tank

Unfasten nut.
Installation:
2010 BMW M3
Tightening torque, 16 11 1AZ . See 16 11 FUEL TANK AND MOUNTING PARTS .
Fig. 19: Locating Self-Locking Nut

Release screws for tightening straps on left and right and remove tightening straps.
Carefully lower fuel tank.
IMPORTANT: Carefully feed the vent line through the body when lowering the fuel tank.
Installation:
Tightening torque 16 11 2AZ . See 16 11 FUEL TANK AND MOUNTING PARTS .
Fig. 20: Locating Fuel Tank Screws

2010 BMW M3
Installation:
Note rubber mount with spacer bush.
Wide collar on spacer bush points to screw head.
Fig. 21: Locating Rubber Mount With Spacer Bush

The following components must be modified when the fuel tank is replaced:
Modify vent line (1)

Modify right sensor unit (2)
Modify left sensor unit and 16 14 016 Removing and installing / replacing fuel filter with pressure
regulator.
Fig. 22: Identifying Right And Left Sensor Unit With Vent Line
16 11 060 REMOVING AND INSTALLING OR REPLACING FUEL FILLER PIPE
Recycling
2010 BMW M3


connection.

Remove rear right wheel arch trim . See 51 71 041 REMOVING AND INSTALLING/REPLACING
Lower rear axle . See 33 31 503 LOWERING/RAISING REAR AXLE CARRIER (M3,
UNIVERSAL LIFTER) .
Unhook retaining strap (1) from tank flap.
Open cap and set to one side.
Fig. 23: Identifying Tank Flap Retaining Strap


2010 BMW M3
Detach fuel filler hose from fuel filler pipe.
Installation:
Replace hose clip.

Unlock quick-release fastener (1) and detach vent hose (2).
Unscrew nut (3).
Fig. 25: Identifying Quick-Release Fastener And Vent Hose

Unscrew nuts (1).

2010 BMW M3
Installation:
Withdraw fuel filler pipe (2) completely out of rubber gaiter at wheel arch and feed out.
Installation:
Make sure rubber gaiter is correctly seated.
Fig. 26: Identifying Fuel Filler Pipe With Nuts

Installation:
16 11 071 REPLACING RUBBER SLEEVE BETWEEN FUEL FILLER PIPE AND FUEL TANK
Recycling

2010 BMW M3

connection.

Detach rubber sleeve first from fuel filler pipe and then from fuel tank.

Installation:
16 11 130 CHECKING FILLER CAP PRESSURE RELIEF VALVE
13 3 010
16 1 171
16 1 172
2010 BMW M3
Set pressure regulator on special tool 16 1 171 fully in "-" direction.
Connect special tool 16 1 171 via compressed air line (1) to workshop/garage compressed air system (8 ... 10
bar).
Connect pressure sensor (2) from Diagnosis and Information System.
Fig. 28: Connecting Pressure Sensor From Diagnosis And Information System
Connect special tool 16 1 172 to fast-release coupling of special tool 16 1 171 .
Install fuel tank cap on special tool 16 1 172 (3).

2010 BMW M3
NOTE: Only the absolute pressure is indicated in the display of the Diagnosis and
Information System (DIS). The current ambient air pressure is already displayed
without additional pressurization.
Check testing equipment for leaks!
Select "Measurement/ Pressure" function on Diagnosis and
Information System (DIS).
Increase pressure by 0.2 bar with pressure regulator on special tool 16 1 171 .
Using special tool 13 3 010 , disconnect supply line from special tool 16 1 171 .
Wait 60 secs.
Read off pressure again and compare with starting pressure value.
CAP PRESSURE SPECIFICATION

Testing equipment leaking.
Pressure drop > 0.012 bar
Check connection points for leaks.
Check filler cap pressure relief!
Select "Measurement/ Pressure" function on Diagnosis and Information System (DIS).
Increase pressure by 0.3 bar with pressure regulator on special tool 16 1 171 .
Using special tool 13 3 010 , disconnect supply line from special tool 16 1 171 .
Wait 60 secs.
Read off pressure value again and compare with starting pressure value.
CAP PRESSURE SPECIFICATION

Filler cap pressure relief valve faulty.
Pressure drop > 0.012 bar
Replace fuel tank cap.
2010 BMW M3
16 11 350 REPLACING CLAMPING BANDS FOR FUEL TANK
Partially detach rear underbody panelling . See 51 47 ... REMOVING AND

INSTALLING/REPLACING LEFT OR RIGHT UNDERBODY PANELLING .
IMPORTANT: Secure fuel tank against slipping and falling out.
Fig. 30: Supporting Fuel Tank

Release screws (1) and remove clamping band.
Installation:
Fig. 31: Identifying Clamping Band Screws

2010 BMW M3
FUEL DELIVERY SENSOR

16 12 ... CHECKING REPUMPING FUNCTION OF SUCTIONJET PUMP WITH BMW DIAGNOSIS
SYSTEM

Contaminants in the fuel tank can impair driving operation or may even result
in vehicle breakdown!
Catch escaping fuel in a suitable container.
Fill level must be < or = 28 L

If necessary, draw off fuel from fuel tank
Pour two to three liters of fuel into the left tank chamber via the flange opening
Path:
Brief test KOMBI Instrument cluster
Diagnosis control unit functions
Diagnosis requests
Tank sensor 1, tank sensor 2
NOTE: Tank sensor 1 = right tank sensor

Tank sensor 2 = left tank sensor
Start engine.
Compare display for left and right tank chambers.
Repumping function OK
If fill level of tank sensor 2 (left chamber) is falling (approx. one liter per minute).
Repumping function not OK
If fill level of tank sensor 2 (left chamber) is stable or rising.
16 12 000 REMOVING AND INSTALLING OR REPLACING FUEL GAUGE SENSOR

(PETROL/GASOLINE, RIGHT)
Recycling
2010 BMW M3


Check transfer function of suction jet pump
Remove fuel pump
Carefully unlock tabs (1) and pull off fuel level sensor upwards in direction of arrow.
Disengage line (2) from holders.
Unlock plug connection (3) and detach from service cap.
Installation:
Fuel level sensor and connector must audibly snap into place!
Fig. 32: Identifying Plug Connection And Unlock Tabs


Carefully feed cable out of cable guide.
2010 BMW M3
Do not kink cable.
16 12 001 REMOVING AND INSTALLING OR REPLACING FUEL GAUGE SENSOR

(PETROL/GASOLINE, LEFT)
16 1 020
Recycling

draw off fuel from fuel tank

REAR SEAT .
Remove right sensor unit
2010 BMW M3

Press grey ring (2) towards sensor unit and pull out fuel feed line (3) straight.
After installing fuel feed line, carry out tensile test and leak test.

Release screw cap with special tool 16 1 020 and remove service cap.
Installation:

2010 BMW M3
Fig. 35: Removing Service Cap

Then tighten screw cap with special tool 16 1 020 until notch (1) points to
marking (2).
Fig. 36: Identifying Notch

Installation:
2010 BMW M3
Fig. 37: Identifying Service Cap Lug With Fuel Tank

Installation:
Make sure when pulling through the hose pack that the tank ventilation system in the tank tunnel is not
damaged.


2010 BMW M3
Fig. 39: Identifying Lifting Sensor Unit

Remove sensor unit (1) and hose pack (2) with auxiliary cable to left.
Installation:
When replacing the sensor unit, modify the end of the auxiliary lead to the new hose pack and carefully pull in
through the tank.
Fig. 40: Identifying Sensor Unit And Hose Pack

16 12 010 REMOVING AND INSTALLING OR REPLACING CARBON CANISTER

2010 BMW M3
Installation:
Tightening torque 16 13 1AZ . See 16 13 TANK VENTILATION .
Fig. 41: Identifying Carbon Canister Screws

16 12 010 REMOVING AND INSTALLING/REPLACING CARBON CANISTER (DMTL)
Installation:

2010 BMW M3
Fig. 42: Identifying Plug Connection And Carbon Canister With Screws
Installation:
Lug (1) must be correctly seated in guide (2).
Fig. 43: Identifying Guide And Lug

FUEL DEAERATION
16 13 015 REMOVING AND INSTALLING/REPLACING TANK LEAK DIAGNOSIS MODULE
(PETROL/GASOLINE CARS WITH US DMTL VERSION)
Remove carbon canister
Release screws (1).

2010 BMW M3
Disconnect tank leak diagnosis module (2) from carbon canister in direction of arrow.
Installation:
Fig. 44: Disconnecting Tank Leak Diagnosis Module From Carbon Canister
FUEL PUMP
16 1 020
Recycling

2010 BMW M3
Fill fuel tank with at least 5 liters of fuel

Check transfer function of suction jet pump

REAR SEAT .


2010 BMW M3
Fig. 46: Identifying Plug Connection And Vent Lines


Installation:

2010 BMW M3

Then tighten screw cap with special tool 16 1 020 until notch (1) points to
marking (2).
Fig. 49: Identifying Notch

Installation:

2010 BMW M3
Fig. 50: Raise Service Cap And Unlock And Detach Vent Line
Installation:
Fig. 51: Identifying Service Cap Lug With Fuel Tank

Installation:
2010 BMW M3

Unlock quick-connect coupling (1) of fuel feed line and pull off hose pack (2) in upward direction.
Unlock catch (4) and detach corrugated tube (3) towards top.
Carefully remove fuel pump with level sensor from fuel tank. If necessary, turn fuel pump 90 counterclockwise
and tilt towards lever sensor.
Fig. 53: Identifying Catch And Tube

2010 BMW M3
16 14 016 REMOVING AND INSTALLING / REPLACING FUEL FILTER WITH PRESSURE

REGULATOR
16 1 020
Recycling


REAR SEAT .
Remove right sensor unit
Check repumping function of suction-jet pump
2010 BMW M3


Installation:
Tightening torque 16 14 1AZ . See 16 14 FUEL PUMP .

2010 BMW M3

(A)!
Fig. 57: Notch (1) On Screw Cap (2) Must Be In Area (A)
Installation:
2010 BMW M3
Fig. 58: Identifying Service Cap Lug On Fuel Tank


2010 BMW M3

Installation:
through the tank.
Fig. 61: Removing Fuel Filter And Hose Pack

16 14 060 REMOVING AND INSTALLING/REPLACING DUST FILTER FOR TANK LEAK

DIAGNOSIS MODULE (DMTL)
Remove rear right wheel arch trim . See 51 71 041 REMOVING AND INSTALLING/REPLACING
REAR LEFT OR RIGHT WHEEL ARCH COVER
2010 BMW M3
Build date up to 09/08:
Unlock and disconnect quick-connect coupling (1).
Release screws (2) and remove dust filter (3).
Installation:
Tightening torque: 16 13 3AZ . See 16 13 TANK VENTILATION .
Fig. 62: Identifying Dust Filter Screws

Build date after 09/08:
Press lugs (1) apart in direction of arrow.
Pull out filter cartridge (2) downwards.
Fig. 63: Pulling Out Filter Cartridge

2010 BMW M3
16 14 500 REMOVING AND INSTALLING OR REPLACING CONTROL UNIT FOR ELECTRIC

FUEL PUMP
protection). See 61 35 ... NOTES ON ESD PROTECTION (ELECTRO STATIC
DISCHARGE) .
E81, E82, E87, E91 and E92:
Remove backrest side section for right rear seat. See 52 24 010 REMOVING AND INSTALLING /
REPLACING BACKREST .
E90:
Remove backrest
Release nuts (2) and remove control unit (3).
Installation:
Tightening torque 16 14 2AZ . See 16 14 FUEL PUMP .
Fig. 64: Identifying Control Unit And Plug Connection With Nuts
Replacement:
Except for M3, carry out programming/coding (M3 is not programming- or coding-relevant)
2010 BMW M3
ELECTRICAL Fuse Assignment Symbol Definitions - BMW
ELECTRICAL
Fuse Assignment Symbol Definitions - BMW
FUSE SYMBOLS
Fuse Assignment Symbol Definitions
System Symbols (Including Variations)
Accessories
Alarm System
Camera System/
(Rear View/Side View)
CD/Radio
CD Changer
2010 BMW M3
Cigarette Lighter/
Accessory Socket
Convertible Top (Down)
Convertible Top (Up)
Display (On-Board Monitor)
Horn
2010 BMW M3
Instrument Cluster
Door Module
Locking System
Memory
(Seat, Mirror, Steering Wheel)
2010 BMW M3
Mirror (Side)
Navigation System
Roller Sun Blind
Seat (Adjust)
Seat (Passenger Adjust)/

Gentleman Function
2010 BMW M3
Seat (Heated)
Seat (Active)
Steering Wheel (Adjust)

2010 BMW M3
Steering Wheel (Heated)
Telephone
Window (Up/Down)
2010 BMW M3
Sunroof (Powered)
Rear Hatch/Trunk
Trailer/Tow
2010 BMW M3
A/C & Heating
Heater
(Heated seats on older models)
Heater (Auxillary/Independent)
Heater (Fuel Burning)
A/C Cooling
2010 BMW M3
A/C-Heater Blower
Window Defroster
Window Defroster (Rear)/

Heated Rear Window
Lighting (Interior/Exterior)
2010 BMW M3
Lighting System
Lighting (Interior)
Lighting (Reading)
Lighting (Instrument)
Exterior Lights
(Adaptive Headlight on Some Models)
2010 BMW M3
Headlight (High Beam)
Headlight (Low Beam)
Headlight (Automatic Control)
Headlight (Cleaning System)
Headlight (Cleaning System)/

Wiper (Rear) (2)
2010 BMW M3
Fog Light
Parking Lights
or Daytime Running Lights
Parking Lights (Roadside)
Engine, Transmission, & Diagnostic
Engine Management
2010 BMW M3
Engine Fan
Fuel Pump
2010 BMW M3
Hybrid Interface Module
Ignition System (Electronic)
Data Link Connector (DLC)/

Diagnostic Socket
Transmission
Steering & Suspension
Steering System/
Active Steering
2010 BMW M3
Suspension System (Electronic)
Electronic Damper Control
Suspension System (Self-Leveling)
Safety & Vehicle Control
ABS
2010 BMW M3
DSC
Active Roll Stabilization
Active Cruise Control/

Cruise Control
Park Distance Control (PDC)

2010 BMW M3
Park Distance Control (PDC)/

Remote Garage Door Opener (2)
Parking Brake
Restraint System (Belts/Air Bag)

2010 BMW M3
Tire Pressure Monitor (TPMS)
Wiper/Washer
Wiper System
Wiper (Front)
Wiper (Rear)
Wiper (Rain Sensor)

2010 BMW M3
Washer System
Washer (Rear Window)
Washer (Heated Jets)
Misc.
(1)
(1) Definition has not been determined.
(2) While the definition of the individual symbols in this combined set is known, the meaning behind the
combination has not been determined.
2010 BMW M3
ELECTRICAL BMW - 3 Series (E90-E93) - 2006-11
ELECTRICAL
BMW - 3 Series (E90-E93) - 2006-11
IDENTIFICATION
WARNING: Vehicles are equipped with air bag supplemental restraint system. Before
attempting any repairs involving steering column, instrument panel or
related components, see DEACTIVATING FRONT PASSENGER AIRBAGS
WITH KEY-OPERATED SWITCH in RESTRAINTS - REPAIR INSTRUCTIONS
article.
CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle. See CODING AND
PROGRAMMING - OVERVIEW - ALL MODELS article in GENERAL
INFORMATION before disconnecting battery.
COMPONENT IDENTIFICATION
ENGINE COMPARTMENT
Engine Electronics Fuse Carriers (A8680 & A8681) are located at the right rear of engine compartment. See
Fig. 1.
2010 BMW M3
Fig. 1: Locating Engine Electronics Fuse Carriers (A8680 & A8681)

Engine Electronics Fuse Carriers (A8680 & A8681) Fuse Assignments

Fuse Number Amperage Circuit(s)
F01 30A Ignition Coils
F02 30A Intake Vanos Valve
F03 20A DISA Controller 2
F04 30A Crankshaft Breather Heating 1
F05 30A Fuel Injectors Relay
F06 10A E-Box Fan
F09 30A Elec. Coolant Pump
F010 5A Engine Breather Heating Relay
2010 BMW M3
PASSENGER COMPARTMENT
The junction box (4010) with the power distributor and junction box electronics (1) is located behind the glove
compartment, see Fig. 2. For fuse assignments, see the Fuse Assignments table.
Fig. 2: Identifying Junction Box (4010) With Power Distributor

NOTE: The fuse assignments below are based on vehicle manufacture dates given by
BMW. Use the vehicle's VIN code to determine the correct set of fuse
assignments.
Fuse Assignments
Model Year Model Mfr. Date See Figure
325i 2006 From 9/05 To 9/06 Fig. 3
From 10/06 To 3/07 Fig. 4
325xi 2006 From 9/05 To 9/06 Fig. 3
From 10/06 To 3/07 Fig. 4
328i 2007 From 10/06 To 3/07 Fig. 4
From 4/07 To 9/07 Fig. 5
2008-11 Fig. 6
2010 BMW M3
328xi 2007 From 10/06 To 3/07 Fig. 4

From 4/07 To 9/07 Fig. 5
2008-11 Fig. 6
330i 2006 From 9/05 To 9/06 Fig. 3
From 10/06 To 3/07 Fig. 4
330xi 2006 From 9/05 To 9/06 Fig. 3
From 10/06 To 3/07 Fig. 4
335d 2009-11 Fig. 6
335i 2007 From 10/06 To 3/07 Fig. 4
From 4/07 To 9/07 Fig. 5
2008-11 Fig. 6
335is 2011 Fig. 6
335xi 2007 Fig. 5
2008-11 Fig. 6
M3 2008-11 Fig. 6
2010 BMW M3
Fig. 3: Identifying Fuses (Vehicles Manufactured Up To 9/06)

2010 BMW M3
Fig. 4: Identifying Fuses (Vehicles Manufactured From 10/06 To 3/07)

2010 BMW M3
Fig. 5: Identifying Fuses (Vehicles Manufactured From 4/07 To 9/07)

2010 BMW M3
Fig. 6: Identifying Fuses (Vehicles Manufactured From 10/07 Onwards)

LUGGAGE COMPARTMENT
2010 BMW M3
NOTE: On models equipped with rear battery.
Rear fuse holder (A46) is located at the right side, next to the battery, see Fig. 7.
Fig. 7: Locating Luggage Compartment Fuse Holder (A46)

Rear Fuse Holder (A46) Fuse Assignments

Fuse Number Amperage Circuit(s) Protected
2006
104 N/A -
108 (Except Ci) 250A Junction Box (Pass.Compartment)
108 (Ci) 200A Junction Box (Pass.Compartment)
2007
104 N/A -
105 100A Elec. Power Steering
108 250A Junction Box (Pass.Compartment)
2008
102 100A Jump Start Terminal Point
104 100A Elec. Auxiliary Heater
105 N/A -
106 50A N/A
2009-10
102 100A Jump Start Terminal Point (Exc.Diesel)
DDE Main Relay (Diesel)
2010 BMW M3

104 100A Elec. Auxiliary Heater (Diesel)
105 N/A -
106 50A Hard Top Drive Unit Relays
2011
102 100A Jump Start Terminal Point (Exc.Diesel)
DDE Main Relay (Diesel)
104 100A Elec. Auxiliary Heater (Diesel)
105 N/A -
106 50A Hard Top Drive Unit Relays
WIRING DIAGRAMS
NOTE: For wiring diagrams, see appropriate SYSTEMS WIRING DIAGRAM article in
ELECTRICAL.
2010 BMW M3
TRANSMISSION Gear Shift Mechanism - Repair
TRANSMISSION
Gear Shift Mechanism - Repair
CENTER SHIFT, MANUAL TRANSMISSION

25 11... OVERVIEW OF GEARSHIFT MECHANISM FOR MANUAL TRANSMISSION
Fig. 1: Overview Of Gearshift Mechanism For Manual Transmission

25 11 000 REMOVING AND INSTALLING SHIFT LEVER M3
REMOVE EXHAUST SYSTEM .

2010 BMW M3
Remove heat shield

Remove KNOB for shift lever
Remove GAITER for shift lever cover.
Remove SHIFT ROD (2).
Installation:
Grease shift rod pin. See GEAR SHIFT MECHANISM - OPERATING FLUIDS
Key:
1. Retainer
2. Shift rod
Fig. 2: Identifying Retainer And Shift Rod

IMPORTANT: New retaining clips fitted as from 04.08.

Retaining clip must interlock captively with retaining web (1) behind shift rod
pin.
Fig. 3: Identifying Retaining Web

2010 BMW M3
Insert special tool 25 1 120 MINIMUM SET: MECHANICAL TOOLS PIN WRENCH MW into mount and
turn 90 counterclockwise.
Press mount upwards out of shift arm.
Fig. 4: Inserting Special Tools (25 1 120) Into Mount

Feed U-gaiter from shift arm and out of body cutout.
Lift out shift lever.
Installation:
Pull U-gaiter from below completely over shift arm receptacle.
Fig. 5: Locating U-Gaiter

Installation:
2010 BMW M3
Pull U-gaiter bead (4) over receptacle on shift arm and pop U-gaiter lips (3) into body cutout.
Make sure the arrow on the upper U-gaiter lip (3) is seated in the direction of travel and crossways to the shift
lever eye (5).
Fig. 6: Identifying Shift Lever Components

Key:
1. Shift lever
2. U-gaiter molded section
3. U-gaiter lips
4. U-gaiter bead
5. Shift lever eye
Installation
Grease shift lever ball. See GEAR SHIFT MECHANISM - OPERATING FLUIDS .
Fit mount on shift arm receptacle.
Align retaining lugs of mount to openings in receptacle (crossways to direction of travel).
Press shift arm with mount
downwards until mount snaps audibly into place (if necessary, use a pressing-in tool).
2010 BMW M3
Fig. 7: Fitting Mount On Shift Arm

25 11 250 REMOVING AND INSTALLING/REPLACING VIBRATION ABSORBER
Remove shift lever cover.

Remove SHIFT LEVER KNOB .
Open clamp (1) on vibration absorber with pliers.
Unlock vibration absorber with screwdriver (2) (there is a locking notch on one side only).
Lift out vibration absorber.
Fig. 8: Opening Clamp On Vibration Absorber

Installation:
In the case of a new vibration absorber which has been attachment to the shift lever, only the retainer (1) still
2010 BMW M3
needs to be unlocked.
Make sure the vibration absorber is correctly engaged in the shift lever.
Fig. 9: Identifying Vibration Damper

25 11... REPLACING U-TYPE BELLOWS
Remove SHIFT LEVER

Remove VIBRATION DAMPER (if fitted).
Detach U-gaiter from shift lever.
If necessary, rub inside of molded section (1) beforehand with Circolight.
Fig. 10: Removing Molded Section

Installation
2010 BMW M3
Degrease shift lever (1)

Coat inside of molded section (2) with Circolight (sourcing reference: BMW Parts Service)
Pull U-gaiter from above over shift lever and align
Arrow on upper lip (3) must point crossways to mount eye (5) in direction of travel
Key:
1. Shift lever
3. U-gaiter lip
4. U-gaiter bead
5. Mount eye
Fig. 11: Identifying Shift Lever Components

25 11 235 REPLACING BEARING BUSHES FOR GEARSHIFT ARM
Remove GEARSHIFT ARM
Press out bearing bush (1).

Coat new bearing bush with Circolight.
Then press into gearshift arm until side surface of bush protrudes uniformly.
NOTE: Graphic shows: gearshift arm simply supported.

2010 BMW M3
Fig. 12: Identifying Bearing Bush

25 11 041 REPLACING BEARING SHELL FOR SHIFT LEVER
Remove shift lever
Detach mount from selector lever.
Installation:
Grease ball joint. See GEAR SHIFT MECHANISM - OPERATING FLUIDS
Fig. 13: Removing Mount From Selector Lever

25 11 001 REPLACING COMPLETE SHIFT LEVER
Remove selector lever.

2010 BMW M3
Remove VIBRATION DAMPER (if fitted).
Installation:
Grease ball joint.
Grease, see GEAR SHIFT MECHANISM - OPERATING FLUIDS .
Fig. 14: Removing Mount From Selector Lever

Detach rubber gaiter from selector lever.
Fig. 15: Removing Rubber Gaiter From Selector Lever

Installation
Degrease selector lever (1).

2010 BMW M3
Coat rubber bellows on inside of shaped section (2) with Circolight.
Pull rubber gaiter from above over selector lever and align. Arrow (3) on rubber gaiter must point in direction of
travel (A).
Fig. 16: Identifying Selector Lever And Rubber Gaiter

25 11 081 REPLACING GAITER (SHIFT LEVER COVER) FOR SHIFT LEVER
IMPORTANT: There are 2 different versions. Removal of shift lever cover is described in
REMOVING SHIFT LEVER KNOB .
Remove SHIFT LEVER KNOB .
Installation
Retaining lugs must not be damaged.

2010 BMW M3
Fig. 17: Locating Retaining Lugs

25 11 071 REPLACING KNOB FOR SHIFT LEVER
WARNING: As from 03/07 there are two different versions. Version 2 can give rise to
damage if incorrectly removed.
Version 1: Shift lever knob and shift lever cover separate.
Version 2: Shift lever knob and shift lever cover are a single part.
Version 1 (shift lever knob and shift lever cover separate)
Press installation frame of gaiter (1) together a little and remove gaiter from center console.
IMPORTANT: Start removing at front left, otherwise the frame may be damaged.
Fig. 18: Removing Gaiter

NOTE: Do not twist shift lever knob during removal as this would cause the turning
lock in the knob to shear off.
Tug firmly to remove knob.
Installation:
Fit shift lever knob on shift lever, align and press on until it snaps noticeably into place.
2010 BMW M3
Fig. 19: Fitting Knob On Shift Lever

Installation
Push gaiter (1) down until groove (2) is fully exposed.
Fig. 20: Pushing Gaiter Down Into Groove

Version 2 (shift lever knob and shift lever one single part)
2010 BMW M3
Fig. 21: Removing Gaiter

NOTE: Do not twist knob during removal as this would cause the turning lock in the
knob to shear off.
Installation:
Fit knob on shift lever, align and press on until it snaps noticeably into place.
Fig. 22: Fitting Knob On Shift Lever

25 11 211 REPLACING SHIFT ARM FOR SHIFT-LEVER MOUNT
Remove SHIFT LEVER

Remove transfer case (AWD)
Lever support bearing (1) out of fixture.

2010 BMW M3
Fig. 23: Removing Support Bearing From Bracket

Installation:
Install support bearing (1) with arrow (2) facing upwards in holder.
Fig. 24: Identifying Support Bearing

Unlock bearing pin (1) in direction of arrow and remove.
Installation:
Grease bearing pin.

2010 BMW M3

Remove shift arm.
Detach support bearing (1) from shift arm.
Installation:
Grease bearing journal.
Attach support bearing (1) with opening (3) towards rear on shift arm.

Replace bearing bush if damaged.

2010 BMW M3
Press out bearing bush.
Coat new bearing bush with Circolight and then press into shift arm until side flanges of bearing bush protrude
uniformly.
Circolight, refer to BMW Parts Service.

25 11 245 REPLACING SHIFT ARM SUPPORT BEARING M3
REMOVE EXHAUST SYSTEM .

Remove front middle heat shield
Lever support bearing (1) with a short screwdriver out of mounting.
Pull support off shift arm.
Fig. 28: Removing Support Bearing From Bracket

2010 BMW M3
Installation
Grease bearing pin of shift arm. See GEAR SHIFT MECHANISM - OPERATING FLUIDS .
Fit support bearing (1) with opening (2) towards top rear onto mounting.

25 12 060 REPLACING SHIFT LEVER KNOB FOR TWIN CLUTCH TRANSMISSION S65
Fig. 30: Removing Gaiter From Centre Console


2010 BMW M3
Installation:
Fig. 31: Fitting Shift Lever Knob On Shift Lever

Installation:
Note installation position of cables.

25 11 101 REPLACING SHIFT ROD

2010 BMW M3
Remove rear assembly underside protection

Remove reinforcement carrier on underbody
REMOVE EXHAUST SYSTEM (M3 only)
Remove heat shields
Remove transmission crossmember . See 22 32 050 REPLACING CROSSMEMBER FOR
TRANSMISSION MOUNTING (S65) .
Remove transmission support block (M3 only)
Detach locking clip.
Fig. 33: Removing Locking Clip

Retaining clip must interlock captively with retaining web (1) behind shift rod pin.

2010 BMW M3
Pull shift rod (1) out of shift rod joint (2).
Installation:
Grease shift rod pin (3). See GEAR SHIFT MECHANISM - OPERATING FLUIDS .
Fig. 35: Pulling Shift Rod From Shift Rod Joint

Remove selector rod (2).
Installation:
Grease selector rod pin. See GEAR SHIFT MECHANISM - OPERATING FLUIDS .
Fig. 36: Identifying Retainer And Shift Rod

25 11 111 REPLACING SHIFT ROD JOINT

2010 BMW M3
Release propeller shaft at transmission and center mount, tie propeller shaft to one side
Tasks are described in REMOVING PROPELLER SHAFT .
Lift off retainer (1).
Disconnect shift rod (2).
Fig. 37: Disconnecting Shift Rod

Installation
Grease shift rod.
Make sure shims (3) are in correct position.

pin.
2010 BMW M3

Lever spring washer (1) out of groove and push a little towards rear.
Press dowel pin (2) upwards/downwards out of shift rod joint and remove shift rod joint.
Installation:
Grease ball of selector shaft.
See GEAR SHIFT MECHANISM - OPERATING FLUIDS .
Replace spring washer (1).
Fig. 39: Pressing Dowel Pin Upwards

Installation
Check rubber ring (1) in shift rod joint (2) and replace if necessary.
2010 BMW M3
Fig. 40: Identifying Rubber Ring And Shift Rod Joint

2010 BMW M3
TRANSMISSION Gear Shift Mechanism - Repair Instructions - M3
TRANSMISSION
Gear Shift Mechanism - Repair Instructions - M3
CENTRE SHIFT MANUAL TRANSMISSION

25 11 ... OVERVIEW OF GEARSHIFT MECHANISM FOR MANUAL TRANSMISSION
Fig. 1: Overview Of Gearshift Mechanism For Manual Transmission

25 11 ... REPLACING U-GAITER

2010 BMW M3
Remove shift lever

Remove vibration damper (if fitted).
Detach U-gaiter from shift lever.
If necessary, rub inside of molded section (1) beforehand with Circolight (sourcing reference: BMW Parts
Service).
Fig. 2: Detaching U-Gaiter From Shift Lever

Installation:
Degrease shift lever (1)

Coat inside of molded section (2) with Circolight (sourcing reference: BMW Parts Service)
Pull U-gaiter from above over shift lever and align
Arrow on upper lip (3) must point crossways to mount eye (5) in direction of travel
Fig. 3: Identifying Shift Lever, U-Gaiter Molded Section And U-Gaiter Lip
2010 BMW M3
Key:
1. Shift lever
3. U-gaiter lip
4. U-gaiter bead
5. Mount eye
25 11 000 REMOVING AND INSTALLING SHIFT LEVER M3
25 1 120
See GEAR SHIFT MECHANISM - SPECIAL TOOLS .
SYSTEM (S65) .
Remove heat shield
Remove knob for shift lever
Remove gaiter for shift lever cover.
Remove shift rod (2).
Installation:
Grease shift rod pin.
Key:
1. Retainer
2. Shift rod
2010 BMW M3
Fig. 4: Identifying Shift Rod With Retainer


pin.

Insert special tool 25 1 120 into mount and turn 90 counterclockwise.
Press mount upwards out of shift arm.

2010 BMW M3
Fig. 6: Inserting Special Tool (25 1 120) Into Mount

Feed U-gaiter from shift arm and out of body cutout.
Lift out shift lever.
Installation:
Pull U-gaiter from below completely over shift arm receptacle.
Fig. 7: Locating U-Gaiter

Installation:
Pull U-gaiter bead (4) over receptacle on shift arm and pop U-gaiter lips (3) into body cutout.
Make sure the arrow on the upper U-gaiter lip (3) is seated in the direction of travel and crossways to the shift
lever eye (5).
Key:
2010 BMW M3
1. Shift lever
3. U-gaiter lips
4. U-gaiter bead
5. Shift lever eye
Fig. 8: Identifying Shift Lever, U-Gaiter Molded Section And U-Gaiter Lip
Installation:
Grease shift lever ball.
Fit mount on shift arm receptacle.
Align retaining lugs of mount to openings in receptacle (crossways to direction of travel).
Press shift arm with mount downwards until mount snaps audibly into place (if necessary, use a pressing-in
tool).
Fig. 9: Aligning Retaining Lugs Of Mount

2010 BMW M3
25 11 001 REPLACING COMPLETE SHIFT LEVER
Remove selector lever.

Remove vibration damper (if fitted).
Installation:
Grease ball joint.
Fig. 10: Detaching Mount From Selector Lever

Detach rubber gaiter from selector lever.
Fig. 11: Detaching Rubber Gaiter From Selector Lever

2010 BMW M3
Installation:
Degrease selector lever (1).
Coat rubber bellows on inside of shaped section (2) with Circolight.
Pull rubber gaiter from above over selector lever and align. Arrow (3) on rubber gaiter must point in direction of
travel (A).
Fig. 12: Degreasing Selector Lever

25 11 041 REPLACING BEARING SHELL FOR SHIFT LEVER
Remove shift lever
Installation:
Grease ball joint.

2010 BMW M3
Fig. 13: Detaching Mount From Selector Lever

25 11 071 REPLACING KNOB FOR SHIFT LEVER
WARNING: As from 03/07 there are two different versions. Version 2 can give rise to
damage if incorrectly removed.
Version 1:Shift lever knob and shift lever cover separate.
Version 2:Shift lever knob and shift lever cover are a single part.
Version 1 (shift lever knob and shift lever cover separate):

2010 BMW M3
Installation:
Fig. 15: Removing Lever Knob

Installation:
Push gaiter (1) down until groove (2) is fully exposed.
Fig. 16: Pushing Gaiter Down Until Groove

Version 2 (shift lever knob and shift lever one single part):
2010 BMW M3

NOTE: Do not twist knob during removal as this would cause the turning lock in the
knob to shear off.
Installation:
Fit knob on shift lever, align and press on until it snaps noticeably into place.
Fig. 18: Removing Lever Knob

25 11 081 REPLACING GAITER (SHIFT LEVER COVER) FOR SHIFT LEVER
IMPORTANT: There are 2 different versions.

Removal of shift lever cover is described in Removing shift lever knob.

2010 BMW M3
Remove shift lever knob.
Installation:
Retaining lugs must not be damaged.
Fig. 19: Locating Retaining Lugs

25 11 101 REPLACING SHIFT ROD
Remove rear assembly underside protection

Remove reinforcement carrier on underbody
Remove exhaust system (M3 only). See 18 00 018 REMOVING AND INSTALLING COMPLETE
EXHAUST SYSTEM (S65) .
Remove heat shields
Remove transmission cross-member. See 22 32 050 REPLACING CROSS-MEMBER FOR
TRANSMISSION MOUNTING (S65) .
Remove transmission support block (M3 only)
Detach locking clip.

2010 BMW M3
Fig. 20: Detaching Locking Clip


pin.

Pull shift rod (1) out of shift rod joint (2).
Installation:
Grease shift rod pin (3).

2010 BMW M3
Fig. 22: Pulling Shift Rod Out Of Shift Rod Joint

Remove selector rod (2).
Installation:
Grease selector rod pin.
Fig. 23: Identifying Shift Rod With Retainer

25 11 111 REPLACING SHIFT ROD JOINT
Release propeller shaft at transmission and center mount, tie propeller shaft to one side
Tasks are described in Removing propeller shaft. See 26 11 000 REMOVING AND INSTALLING
COMPLETE PROPELLER SHAFT (CONSTANT-VELOCITY JOINT) .
2010 BMW M3
Lift off retainer (1).
Disconnect shift rod (2).
Fig. 24: Disconnecting Shift Rod

Installation:
Grease shift rod.
Make sure shims (3) are in correct position.

pin.

Lever spring washer (1) out of groove and push a little towards rear.
Press dowel pin (2) upwards/downwards out of shift rod joint and remove shift rod joint.
2010 BMW M3
Installation:
Grease ball of selector shaft.
Replace spring washer (1).
Fig. 26: Removing Shift Rod Joint

Installation:
Check rubber ring (1) in shift rod joint (2) and replace if necessary.
Fig. 27: Identifying Rubber Ring And Shift Rod Joint

25 11 211 REPLACING SHIFT ARM FOR SHIFT-LEVER MOUNT
Remove shift lever

2010 BMW M3
Lever support bearing (1) out of fixture.
Fig. 28: Levering Support Bearing

Installation:
Install support bearing (1) with arrow (2) facing upwards in holder.
Fig. 29: Installing Support Bearing

Unlock bearing pin (1) in direction of arrow and remove.
Installation:
Grease bearing pin.

2010 BMW M3
Fig. 30: Unlocking Bearing Pin

Remove shift arm.
Detach support bearing (1) from shift arm.
Installation:
Grease bearing journal.
Attach support bearing (1) with opening (3) towards rear on shift arm.
Fig. 31: Identifying Support Bearing With Shift Arm

Replace bearing bush if damaged.
Press out bearing bush.

2010 BMW M3
Coat new bearing bush with Circolight and then press into shift arm until side flanges of bearing bush protrude
uniformly.

25 11 235 REPLACING BEARING BUSHES FOR SHIFT ARM
Remove shift arm
Press out bearing bush (1).

Coat new bearing bush with Circolight (sourcing reference: BMW Parts Service).
Then press into shift arm until side surface of bush protrudes uniformly.

NOTE: Illustration shows: shift arm simply supported.
25 11 245 REPLACING SHIFT ARM SUPPORT BEARING M3

2010 BMW M3
SYSTEM (S65) .
Remove front middle heat shield
Lever support bearing (1) with a short screwdriver out of mounting.
Pull support off shift arm.
Fig. 34: Levering Support Bearing

Installation:
Grease bearing pin of shift arm.
Fit support bearing (1) with opening (2) towards top rear onto mounting.
Fig. 35: Installing Support Bearing

25 11 250 REMOVING AND INSTALLING/REPLACING VIBRATION DAMPER

2010 BMW M3
Remove shift lever cover.

Remove shift lever knob.
Open clamp (1) on vibration damper with pliers.
Unlock vibration damper with screwdriver (2) (there is a locking notch on one side only).
Lift out vibration damper.
Fig. 36: Unlocking Vibration Damper With Screwdriver

Installation:
In the case of a new vibration damper which has been attachment to the shift lever, only the retainer (1) still
needs to be unlocked.
Make sure the vibration damper is correctly engaged in the shift lever.
Fig. 37: Identifying Shift Lever

25 12 060 REPLACING SHIFT LEVER KNOB FOR TWIN CLUTCH TRANSMISSION S65
2010 BMW M3
Fig. 38: Pressing Installation Frame Of Gaiter

Installation:
Fig. 39: Removing Shift Lever Knob

Installation:
2010 BMW M3
Note installation position of cables.

2010 BMW M3
ACCESSORIES AND BODY, CAB General Electrical System - Repair
General Electrical System - Repair
TROUBLESHOOTING
61 00... BATTERY
NOTE: Important notes and instructions for handling batteries in the dealership can be
found in:
DISCONNECTING BATTERY
BATTERY CHARGING
EXTERNAL JUMP-STARTING AID
Battery care and maintenance
In low-maintenance batteries, check the acid level at least once a year. If necessary, top up with distilled water
up to the top marking.
The increasing number of electronic control units in the car reduces the self-discharging time of the battery
(even in standby mode). To maintain the battery service life and to avoid exhaustive discharging, recharge laid-
up vehicles every 6 weeks at the latest. The time for self-discharging depends on vehicle type and equipment
specification.
Battery test
The battery acid density can be used to measure the charge state. However this test produces uncertainty caused
by a design-related range of variation. The acid density e.g. for a charged battery is 1.28 kg/l (in the tropical
version the acid density is 1.23 kg/l).
Another interference factor is the acid lamination immediately after filling with distilled water.
Battery wear with partially sulfated and/or heavily contaminated plates will also lead to incorrect acid density
test results.
2010 BMW M3
Diagnosis system:
Service functions
Body
Voltage supply
Test plan
Programming system:
61 00... DIAGNOSIS FOR CONDITION BASED SERVICE
NOTE: Red symbol for pre-delivery check
The vehicle is coded at the end of the assembly line so that the red symbol for the pre-delivery check is shown
in the Next Service display (same symbol as vehicle check).
2010 BMW M3
The symbol is a reminder to the Service staff that the pre-delivery check has not yet been carried out on this car.
NOTE: Do not carry out a reset.
Do not confuse this function with the "Vehicle check" scope of maintenance work. Do not perform a reset via
the instrument panel.
When performing the pre-delivery check with the service function "Transport mode/pre-delivery check": The
symbol is suppressed automatically after carrying out the service function.
Fig. 1: Service Display Symbol

2010 BMW M3
Fig. 2: Display - Service Functions

CBS DESCRIPTION CHART

Item Description
1 Function and component selection
2 Service functions
3 Maintenance
4 Transport mode/pre-delivery check
5 CBS correction, tester data
6 Reset CBS Condition Based Service
7 CBS vehicle data correction
4 service functions are available in the BMW diagnosis system for maintenance:
Transport mode/pre-delivery check

CBS correction, tester data
Reset CBS
CBS correction of vehicle data
Service Function: Transport Mode/Pre-delivery check

2010 BMW M3
In order to ensure that a vehicle can be handed over to the customer in proper condition, the "Transport
mode/predelivery check" service function must be performed.
The following items are checked during the pre-delivery check:
Deactivation of the transport mode.

To determine the vehicle-specific distance travelled per week an adaptation process is activated.
Transport and standing times before delivery of the vehicle to the customer therefore do not have any
effect on the customer-specific weekly distance travelled.
The weekly mileage/kilometrage is used to control escalation from "green" to "yellow" (approx. 4 weeks
before "red") for maintenance scopes with remaining distances. It is the distance travelled determined
over the last 6 weeks which is taken into account.
Encoding or deletion of the legally-specified intervals for the legally stipulated vehicle inspection and
emissions test.
Inputting the target dates for the legally stipulated vehicle inspection and emissions test (automatically or
manually).
Automatically: By entering the date of the first registration and the interval
Manually: by directly entering the target date
Information on initializing the Tele Service depending on the equipment installed on the vehicle.
Checking and where necessary adjusting the on-board data for the vehicle.
Entry of the date of the first registration of the vehicle.
Delete fault memory.
NOTE: Reduction of input effort.
In order to minimize the input effort for the workshop, standardized data is
saved on the BMW diagnosis system (for repeat use). The standardized data
can be changed with the "CBS Correction Tester Data" service function.
Service Function: CBS Correction Tester Data
During the service function "Pre-delivery check", the data is automatically

stored in the vehicle. With the service function "CBS correction, tester data",
standardized data can be changed.
The following standardized data can be modified:
Phone numbers:
BMW Group Mobile Service
BMW Hotline
2010 BMW M3
Home dealer
The country-specific phone numbers are contained in the BMW diagnosis system as information text (to
be read off when required for input). The phone numbers must be input with the international dialling
code.
Legally stipulated vehicle inspection (country-specific):

Encoding or deletion
Interval for calculating the target date
The target date is calculated on the basis of the date of the first registration.
Legally stipulated emissions test (country-specific):

Encoding or deletion
The target date is calculated on the basis of the date of the first registration.
NOTE: Automation after installation of the BMW diagnosis system.
If the pre-delivery inspection is being carried out for the first time, the standardized data will be defined
automatically. It is therefore not necessary to enter the data separately.
Service Function: Reset CBS Condition Based Service
A maintenance scope can be reset with the "Reset CBS Condition Based Service" service function. Even if
availability is above 80 %. The reset via the BMW diagnosis system has the advantage that the on-board date is
corrected
automatically. The individual maintenance scopes are displayed in the BMW diagnosis system with service
counter and availability.
The service counter is increased by one count on resetting. In new vehicles all service counters are set to
"1".
The service counters are used in the Service Acceptance Module (SAM) to control the additional work for
specific maintenance operations.
On resetting the availability is set at 100%. The percentage availability is the wear reading for the
maintenance operation.
The greater the availability, the further away the next service.
0% means that the maintenance operation must be carried out.

2010 BMW M3
Service Function: CBS vehicle data correction
IMPORTANT: The dates have been exceeded.
After carrying out this service function, it will no longer be possible to restore the previous status.
The service function "CBS vehicle data correction" is available if resetting has been carried out
unintentionally. Thus the availability of a maintenance operation can be corrected to a value which
corresponds more closely to the actual situation.
For this correction a date or kilometer reading is entered. This data is processed internally to give a
percentage availability.
Here, the BMW diagnosis system will only accept a value which is lower that the current status in the
control unit. In addition, the service counter of the scope is automatically reduced by one counter.
The entries in the service booklet are used to determine the actual availability. The most recent
maintenance measure (kilometer reading and date) allows the reconstruction availability for the specific
scope that corresponds more closely to the actual situation. This excludes the correction of availability for
brake pads. The residual values for the brake pads must be measured and input (in millimeters).
NOTE: Reference for distance- and time-dependent maintenance scopes
On correction the availability depends on the distance-dependent and time-dependent calculation.
61 12... GENERAL INFORMATION ON INTELLIGENT BATTERY SENSOR (IBS)
NOTE: Do not connect the charger to the 12 V charging socket
The 12 V charging socket is supplied with voltage by the rear distribution box via relay. This relay drops out
after terminal 15 OFF. This means that a trickle charger connected at the 12 V charging socket will be
disconnected from the battery. Only charge the battery via the jump start terminal point. Only then can the
voltage supply be registered by the vehicle.
WARNING: Danger of destruction in event of mechanical strain
Do not introduce any additional connections at the battery negative terminal.

Do not modify the grounding cable. The grounding cable also serves to dissipate heat.
Do not establish any connection between the IBS and the sensor screw.
Do not use force when disconnecting the pole shoe from the battery terminal:
Do not pull on the grounding cable.
Do not place any tools under the IBS to lever off the pole shoe.
2010 BMW M3
Use a torque wrench and set tightening torque in accordance with repair instructions.
Do not release or tighten down sensor screw (screw with Torx head).
Avoid contact between IBS and ground.
WARNING: Danger of destruction to IBS and cables when battery is replaced
The IBS and the cables can be destroyed by mechanical strain when the battery is replaced. Therefore
avoid mechanical strain.
The size (capacity) of the battery required for the car is coded in the Car Access System (CAS).
Use the battery size (capacity) installed as standard when replacing the battery.
Register battery change via Service Function (Progman or DIS).
Delete fault entries in the Digital Engine Electronics (DME) associated with battery replacement.
Always proceed in accordance with the repair instructions.
NOTE: Battery draining possible in spite of the intelligent battery sensor IBS being
fault-free.
A battery can be drained (e.g. with lights or radio switched on) even when the IBS functions perfectly in
conjunction with power management.
For this reason, only replace the IBS when a corresponding fault entry in the DME or DDE.
61 00... NOTES ON HANDLING OPTICAL FIBRES
IMPORTANT: To avoid damage when handling optical fibres, comply with the following
points:
The minimum permitted bending radius is 25 mm

Do not subject optical fibres to compressive and tensile load
Protect optical fibres against the effects of heat > or = 85C (e.g. during
welding work, drying work with infrared heater or hot air blower)
Fibre-optic cables are permitted to show only one junction point (bridge),
replace fibre-optic cables if necessary
NOTE: The optical fibres are colored differently as follows:

Yellow = ISIS (I ntelligent S afety and I ntegration S ystem) fibre-optic cable
Orange=repair fibre-optic cables
Follow instructions for PROCESSING CABLES AND OPTICAL FIBRES .

2010 BMW M3

Shielded lines
Coaxial line
Shielded RTK031 coaxial lines may only be repaired with special crimping tool.
CVBS lines

HSD lines


2010 BMW M3
FlexRay:
CONNECTORS .
Airbag lines:
Ribbon cables:
Preparation
of injury!
speed.
Operation

2010 BMW M3
compartment.
sparks.
Risk of explosion!
61 13... OPENING PLUG HOUSINGS AND REMOVING CONTACTS OF DIFFERENT PLUG

SYSTEMS

Abbreviations of contacts and what they mean:
ELA Strand seal
D 1.5/2.5/3.5 Round contacts with 1.5 mm, 2.5 mm or 3.5 mm diameter
MDK Miniature double flat spring contact
JPT Junior Power timer
DFK Double flat spring contacts
Elo Electronic contacts
Elo Power Electronic contacts for heavy load
MQS Micro Quadlock system
MPQ Micro Power Quadlock
MLK Mini laminated contact
SLK Sensor laminated contact
Mcon Multi contact
IMPORTANT: The contacts can be changed on ultrasonically welded plugs (1).

Ultrasonically welded plugs (1) must be replaced completely.
Ultrasonic-welded connectors (1) can be identified by the welds (2) on their longitudinal side.
2010 BMW M3
Fig. 3: Identifying Ultrasonic-Welded Connectors And Plugs

NOTE: Special tools referred to in the repair instructions below are contained in the
following special tool kits:
Release and press-out tool 61 1 150 is replaced from 09/2005 by 61 0 300

(BMW) and 61 0 400 (MINI)
Release and press-out tool 61 1 100 (engine)
Repair instructions for opening plug housings and removing contacts of different plug systems
61 20 908 PERFORMING BATTERY "POWER RESET" (FOR PROGRAMMING/CODING

CONTROL UNIT(S))
IMPORTANT: Observe SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY .
The following steps must be carried out for a "power reset":
Switch off and disconnect battery charger

Switch off ignition
Cars with ignition key: Turn ignition key to 0 position
Cars with identification sensor: Remove identification sensor from slot
Cars with comfort access system: Make sure terminal is in 0 position
Disconnect battery negative terminal

Reconnect battery negative terminal (to ensure bus activity)
Waiting time (5-10 seconds)
2010 BMW M3

Waiting time (1 minute)
Connect battery negative terminal and tighten.
Connect and switch on battery charger
Switch ignition on
61 00... REPAIRING AIRBAG CABLES
IMPORTANT: Only repair those cables which show visible signs of damage. In the event of
visible damage, make sure there is only one cable repair in effect after the
repair work. If no visible damage can be identified, the entire cable must be
replaced. When carrying out repairs to the airbag wiring harness, you must use
the spare parts offered in the Electronic Parts Catalogue (EPC).
Safety regulations
Safety regulations for See Recommended Engine Oils For BMW Group Engines See 6100... SAFETY
INSTRUCTIONS FOR HANDLING VEHICLE BATTERY; BATTERY WITH TERMINAL or
SAFETY REGULATIONS FOR HANDLING COMPONENTS WITH GAS GENERATORS .
INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .
Procedure for cable repair
In event of visible damage
Expose cable at damaged areas. Cut through one cable after the other at an appropriate position and insulate
cables no longer required in wiring harness with insulating tape, do not under any circumstances cut through
both cables at the same time. Now, depending on the scope of work, unpin contacts either on airbag control
unit/airbag module or on adapter plug. Cut off unpinned cables. Insulate cables remaining in wiring harness
with insulating tape. Now pin in contacts of repair cable, assignment of repair cables is relevant. Lay repair lead
in car parallel to existing airbag lead up to cutting point. Cut off excess length of repair lead. Twist open cables.
Connect cables with connectors and shrink-fit hoses in Electronic Parts Catalogue (EPC), assignment of repair
cables is relevant. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface (shrink-fit
hoses) with insulating tape to prevent cables from twisting open.
Instructions for cutting off, insulating, crimping cables, installing and removing contacts:
CUTTING OFF AND INSULATING CABLES .
REPAIRING A PLUG CONNECTION USING CONNECTORS .
INSTALLING AND REMOVING CONTACTS .

2010 BMW M3

function is active.


Workshop mode
A = 10 mm
B = 7 mm
2010 BMW M3

61 00... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY
Battery acid is highly corrosive
Do not allow any battery acid to come into contact with the eyes, the skin or clothing. Therefore wear protective
clothing, gloves and goggles.
Do not tilt the battery, acid may emerge from the vent opening.
In event of contact with acid
If acid is splashed into the eyes, rinse them immediately for several minutes with clear water. You must then
consult a doctor without delay.
If acid is splashed onto the skin or clothing, neutralize it immediately with a soapy solution and rinse with lots
of water.
Seek medical attention immediately if battery acid is accidentally swallowed.
Explosion hazard
Strictly no flames, sparks, naked light or smoking!
A highly explosive mixture of electrolytic gas is created when batteries are charged. The rooms where charging
is carried out must therefore always be well ventilated.
Avoid the formation of sparks when handling cables, wiring and electrical devices.
2010 BMW M3
Turn the ignition lock to the 0 position before disconnecting or connecting the battery.
Do not place tools or any similar object on the battery (danger of short-circuiting and explosion!).
61 13... TREATING CABLES AND FIBRE-OPTIC CABLES

Repair range for vehicle electrical system
Crimping set with tool for fibre-optic cables, Micro
Power Quadlock (MPQ), Micro Quadlock System
(MQS) contacts and universal crimping head
Insulation displacement tool for ribbon cable
Subject of repair instructions
SPECIAL TOOLS FOR WIRING HARNESS REPAIRS

CUTTING CABLES TO LENGTH AND STRIP INSULATION
See Recommended Engine Oils For BMW Group Engines See 6113... CRIMPING ANNULAR
CONTACTS; 6113... CRIMPING STOP PARTS; 6113... CRIMPING MICRO QUADLOCK
SYSTEM CONTACTS (MQS) or 6113... CRIMPING MICRO POWER QUADLOCK CONTACTS
(MPQ)
BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION
FAN CONNECTOR FOR RETROFITTING/REPAIRS
Aerial elbow plug on radio receiver
CUTTING TO LENGTH AND STRIPPING INSULATION FROM OPTICAL FIBRES
CRIMPING OPTICAL FIBRES
Insulation displacement connector for REPAIRING RIBBON CABLES
61 13... UNLOCKING AND DISCONNECTING DIFFERENT PLUG CONNECTIONS
NOTE: Examples of unlocking and disconnecting different plug connections.
Press lock and open clip in direction of arrow.

2010 BMW M3


Open clip in direction of arrow and disconnect plug connection in direction of arrow.
2010 BMW M3

Press lock and disconnect plug connection in direction of arrow.


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2010 BMW M3

61 00. VERSION WITH AFS (ACTIVE FRONT STEERING): SETTING STEERING ANGLE (AFTER
RECONNECTING VEHICLE BATTERY)
After RECONNECTING the vehicle battery, carry out the following procedure for setting the steering angle:
Start engine.
Turn steering wheel left to full lock.
Turn steering wheel right to full lock.
Turn steering wheel to central position.
Turn off engine.
Turn on ignition (terminal 15), AFS telltale and Check Control message go out.
NOTE: Entry in the fault memory remains unaffected by this procedure, therefore if
necessary:

Clear fault memory
WIRING HARNESS
61 11... INSTALL THE REPAIR CABLE FOR THE POSITIVE BATTERY CABLE VVT
The repair instructions describe the installation of repair cables for positive battery cable VVT (BMW Parts
Department 9 303 031).
Read and comply with notes on HANDLING WIRING HARNESSES AND WIRING!
Read and comply with notes on CRIMPING STOPS!

2010 BMW M3
Partially remove REAR RIGHT WHEEL ARCH COVER
Remove battery.
NOTE: Work is shown on the E91 by way of example.
There may be differences in detail in the case of other vehicle types and
equipment specifications.
NOTE: Figure shows the following lines (2):
Left: Positive battery cable VVT (thinner cable)

Right side: Positive battery cable (thicker cable)
Remove positive battery cable VVT left only!
Unclip the left cover (1) and loosen the nut beneath it (tightening torque 8 Nm).
Remove the positive battery cable VVT left (2).
Fig. 15: Identifying Cable Lug Mounting From Positive Battery Leads And Cap
Twist tension ring left (1) in direction of arrow and remove.
Installation note:
Ensure that the tension rings (1) are correctly seated.

2010 BMW M3
Fig. 16: Removing Clamping Rings

Release screws (1).
Slightly lower the cover (2) at the point marked with an arrow.

Release screws (1) and cable straps (2) from positive battery cable VVT (3). Lower the cable channel (4) and
remove the positive battery cable VVT (3) from the cable channel (4).
2010 BMW M3
Fig. 18: Identifying Positive Battery Cable VVT, Screws, Cable Straps, And Cable Channel
A. Measure and mark the length (1) = 23 cm on the positive battery cable VVT (2).
B. Disconnect the positive battery cable VVT (2) at the marked point with special tool 2 337 974 (cable
shears).
C. At the end of the positive battery cable VVT (2), measure and mark 1 cm.
D. Strip the insulation off the positive battery cable VVT (2) at the marked point with special tool 2 337 974
(cable shears).
IMPORTANT: Do not damage the strands during stripping!

2010 BMW M3
Fig. 19: Identifying Measuring, Cutting, And Stripping Points

Attach the heat-shrink tubing (2) on the repair positive battery cable VVT (3).
Position the repair positive battery cable VVT (3) as shown with the arrow.
Crimp the positive battery cable VVT on the vehicle (1) and repair positive battery cable VTT (3) with special
tool 61 0 202 .
2010 BMW M3
Fig. 20: Attaching Heat-Shrink Tubing And Crimping Positive Battery Cable VVT On Vehicle And
Repair Positive Battery Cable VTT
A. Centrally measure and mark distance (1) = 7.5 cm as shown.

B. Position the heat-shrink tubing (2) over the crimping location so that mark (3) is must barely visible.
C. Shrink the heat-shrink tubing (2) with hot air blower 0 444 131. Use soldering shrink reflector (5)! (Heat
shrink temperature 400 C)
D. After shrinking, adhesive (4) must emerge from both sides of the heat-shrink tubing (2).
NOTE: If the body has corrosion damage in the area of the transfer support point, it
must be repaired prior to installing the repair positive battery cable VVT
according to the BMW guidelines.
Following the completed repair, the body and positive battery connection point
must be sprayed with cavity preservation in a diameter of 20 cm.
Fig. 21: Identifying Application Of Head Shrink Tubing

61 11... INSTALLING THE REPAIR CABLE FOR THE POSITIVE BATTERY CABLE OF THE
POWER DISTRIBUTION BOX
2010 BMW M3
Read and comply with notes on HANDLING WIRING HARNESSES AND WIRING!
Read and comply with notes on CRIMPING STOPS!
Remove GLOVE BOX
Remove JUNCTION BOX
Work is shown on the E90 by way of example.
There may be differences in detail in the case of other vehicle types and equipment specifications.
Release the wiring harness mounting (2) from the power distribution box (6).
Release screws (3).
Fold the power distribution box (6) forward. Feed positive battery cable (4) out
of holder (5) in the direction of the arrow.
Fig. 22: Identifying Fuse Box Interior And Fuse Box Interior Holder
Disconnect the positive battery cable (2).
Extra plug connections (1) on the back of the power distribution box (3) must not be detached.
2010 BMW M3
Fig. 23: Identifying Fuse Box Interior And Plug Connections

Open retaining straps (1). Pull out positive battery cable (2) as far as possible.
Fig. 24: Identifying Battery Cable And Retaining Straps

Pre-drill both bridges (2) of the power distribution box (1) at the area marked with an arrow with a 2 mm drill.
Then drill through with a 5 mm drill.
2010 BMW M3
Fig. 25: Identifying Power Distribution Box And Bridges

A. Measure a 15 cm length as shown and mark on the positive battery cable (1).
B. Cut off the positive battery cable (1) at the marked location with special tool 2 337 974 (cable shears).
C. At the cut-off end of the positive battery cable (1), measure and mark 2 cm.
D. Carefully strip insulation off of the positive battery cable (1) at the marked location with special tool 2
337 974 (cable shears).
2010 BMW M3
Fig. 26: Identifying Measuring, Cutting, And Stripping Points

CAUTION: Do not damage the strands during stripping!
A. Mount the heat-shrink tubing (1) on the repair positive battery cable. Insert the repair positive battery
cable as shown in the special tool 2 339 646.
(Pliers 2 339 646, die plate 2 339 647)
B. Position the contact (2) as shown.

C. Close special tool. Turn the screw plug (3) anti-clockwise and move it to the position shown.
Fig. 27: Identifying Heat Shrink Tubing, Contact, And Special Tool 2 339 646
Crimp the vehicle-side positive battery cable (2) and the repair positive battery cable (1) using the special tool 2
339 646.
(Pliers 2 339 646, die plate 2 339 647)

2010 BMW M3
After crimping, copper wires of the vehicle-side positive battery cable (2) must be visible in the opening (3).
Fig. 28: Crimping Vehicle-Side Positive Battery Cable And Repair Positive Battery Cable Using Special
Tool 2 339 646
A. Centrally measure and mark distance = 10 cm as shown.

B. Position the heat-shrink tubing (2) over the crimping location so that mark (3) is must barely visible.
C. Shrink the heat-shrink tubing (2) with a hot air blower 0 444 131 at 400 C.
D. After shrinking, adhesive (4) must emerge from both sides of the heat-shrink tubing (2).
2010 BMW M3
Fig. 29: Installing Heat Shrink Tubing Over Crimping Location

It is imperative that you use a heat-shrink tubing reflector (1).
Connect the repair positive battery cable (3) to the power distribution box (1) by pushing down all the way.
Tighten screw (2). Tightening torque: 1, 5 Nm
While tightening the bolt (2), continue pushing down the contact.
Fasten the repair positive battery cable (3) on the power distribution box (1) at the location indicated by the
arrow using a cable strap (4).
2010 BMW M3
Fig. 30: Identifying Repair Positive Battery Cable, Power Distribution Box, Screw, And Cable Strap
Mount the cap (1) flush.

Fasten the positive battery cable (1) at locations (2).

2010 BMW M3
Fig. 32: Fastening Positive Battery Cable


Shielded lines
Coaxial line
Shielded RTK031 coaxial lines may only be repaired with special crimping tool for repairing the coaxial
line.
CVBS lines

HSD lines
2010 BMW M3


FlexRay:
CONNECTORS .
Airbag lines:
Ribbon cables:
AUXILIARY CABLE
2010 BMW M3

Do not modify the grounding cable. The grounding cable also serves to dissipate heat.
Do not use IBS connections as levers.

fault-free.

SYSTEMS

ELA Strand seal
D 1.5/2.5/3.5 Round contacts with 1.5 mm, 2.5 mm or 3.5 mm
diameter
2010 BMW M3

Mcon Multi contact

Ultrasonic-welded connectors (1) can be identified by the welds (2) on their
longitudinal side.

Release and press-out tool 61 1 150 is replaced from 09/2005 by 610300

Release and press-out tool 611100 (engine)
61 12 013 REPLACING BATTERY NEGATIVE LEAD

2010 BMW M3
WARNING: Observe See Recommended Engine Oils For BMW Group Engines See
1200... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING
BATTERY or 6100... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE
BATTERY for handling vehicle battery.
Notes and instructions on INTELLIGENT BATTERY SENSOR IBS .

Remove TOP TRIM FROM TAIL PANEL
Slacken nut (2) on battery negative terminal.
IMPORTANT: Do not under any circumstances use force to pull off pole shoe.
Detach battery negative lead (3) with intelligent battery sensor (IBS) in upward direction.
Release nut (4) and remove cable.
Fig. 34: Identifying Battery Plug Connection, Battery Negative Lead And Nut
Vehicles up to 12/2006 with IBS
NOTE: IBS2004 is replaced by IBS2006.
Remove battery crash element without replacing

2010 BMW M3
Fig. 35: Identifying Battery Crash Element

61 12 002 REPLACING BATTERY POSITIVE LEAD (FROM BATTERY TO LUGGAGE

COMPARTMENT CONNECTOR)
WARNING: Observe SAFETY INSTRUCTIONS for handling vehicle battery.
Remove right LUGGAGE COMPARTMENT TRIM PANEL

Remove DISTRIBUTION BOX
Remove BATTERY
Open cap (1) and release nut underneath.
Remove cable lug mounting from positive battery lead (2).
WARNING: Risk of short circuits!
When installing, ensure:
Correct screw connection

Correct seating of cable lug mounting on positive battery lead (2)
2010 BMW M3
Fig. 36: Identifying Cap And Positive Battery Lead

Replacement with build date up to 03/2006
Connect repair cable for battery terminal (1) to safety battery terminal (2).
Install BATTERY .
Install DISTRIBUTION BOX .
Fig. 37: Identifying Battery Terminal And Safety Battery Terminal

Cut off plug connection (1) and connect to battery terminal repair cable (2).
Follow notes for REPAIRING AIRBAG LEADS .
Secure battery terminal repair cable (2).

2010 BMW M3
Fig. 38: Identifying Battery Terminal Repair Cable With Plug Connection
61 12 004 REPLACING BATTERY POSITIVE LEAD (FROM LUGGAGE COMPARTMENT

CONNECTOR TO ENGINE BULKHEAD CONNECTOR)
IMPORTANT: Read and comply with notes on HANDLING WIRING HARNESSES and cables.
Remove BATTERY
Remove FUEL TANK
Partially remove front right WHEEL ARCH TRIM
Remove COVER FROM ELECTRONICS BOX
Work is shown on the E82 N52N by way of example. There may be differences in detail in the case of other
vehicle models.
Unclip covers (1) and release nuts underneath.
Disconnect battery positive leads (2).

2010 BMW M3
Fig. 39: Identifying Battery Positive Leads With Covers

Turn clamping rings (1) in direction of arrow and remove.
Installation:
Make sure clamping rings (1) are correctly seated.
Fig. 40: Turning Clamping Rings In Direction Of Arrow

Remove battery positive lead (1) from luggage compartment floor (2).
2010 BMW M3
Fig. 41: Identifying Battery Positive Lead And Luggage Compartment Floor
Release bolt (1) and nut (2).
Remove cover (3).
Fig. 42: Identifying Battery Luggage Compartment Bolt, Nut And Cover
Release holder (1) from body.
Feed out battery positive leads (2) and vent line (4) from holder (1).
Release retaining clips (3) and remove vent line (4) from cover (5).
Release all nuts and remove cover (5).

2010 BMW M3
Fig. 43: Locating Battery Nut

Release attachment points for battery positive lead (1) from body.
Fig. 44: Identifying Battery Positive Leads

NOTE: Electronics box shown removed for purposes of clarity.
Unclip cover cap (1).
Release nuts underneath.
Remove positive battery cable.

2010 BMW M3
Fig. 45: Identifying Cover Cap

Release wiring harness holder (1).
Feed out battery positive lead in direction of arrow.
Fig. 46: Removing Out Battery Positive Lead In Direction Of Arrow

61 12 200 REPLACING WIRING HARNESS IN LEFT OR RIGHT FRONT DOOR
Close front side window completely

Remove FRONT ACOUSTIC INSULATION
Unlock plug connection (1) on door lock and disconnect.

2010 BMW M3
Unlock plug connection (4) on power window and disconnect.
Disconnect plug connection (2) on outside door handle light.
Disconnect plug connection (5) on door mirror.
Unclip door wiring harness at points (3).
Fig. 47: Identifying Front Door Plug Connections

Installation:
Make sure door wiring harness is correctly laid.
Release screw (1), fold door wiring harness plug on A-pillar (2) downwards slightly and remove.
Unlock plug connection behind and disconnect.
Pull rubber grommet (3) out of front door.
Feed out door wiring harness towards front to A-pillar and remove.
2010 BMW M3
Fig. 48: Pulling Rubber Grommet Out Of Front Door

61 12 210 REPLACING WIRING HARNESS IN LEFT OR RIGHT REAR DOOR
Close rear side window completely

Remove REAR ACOUSTIC INSULATION
Installation:

2010 BMW M3
Fig. 49: Identifying Door Wiring Harness Points

Release screw (1), fold door wiring harness plug on B-pillar (2) downwards slightly and remove.
Pull rubber grommet (3) out of rear door.
Feed out door wiring harness towards front to B-pillar and remove.


2010 BMW M3
Fig. 51: Pressing Lock And Open Clip


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2010 BMW M3

PLUG CONNECTION, TERMINAL, FUSE BOX

61 13... BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION
IMPORTANT: 1. Identify cause of damage (e.g. sharp-edged body parts, faulty electrical
loads, jammed mechanisms, corrosion caused by ingress of water, etc.).
2. Read out fault memory
3. Eliminate cause of damage.
4. Disconnect battery negative terminal
5. Make sure that no safety-related system according to circuit diagram (e.g.
antilock braking system, active rear-axle kinematics, airbags, etc.) are
influenced. Otherwise replace faulty wiring harness or use repair cable.
6. Carry out function test and read out fault memories again
7. Eliminate new faults if applicable and clear fault memories
NOTE: The repair range IV for vehicle electrical system contained the required special
tools and individual parts for retrofitting and repair work with the aid of fan
connectors.
2010 BMW M3

Choose repair kit.
Example: Repair kit, circular plug system D 2.5.
Fig. 61: Identifying Circular Plug System D 2.5

Remove following parts:
1. Pre-packaged end of cable with requisite wire cross-section

2. Crimp connector for selected wire cross-section
3. Shrink-fit hose
2010 BMW M3
Fig. 62: Identifying Cable With Requisite Wire Cross-Section, Crimp Connector And Shrink-Fit Hose
Open secondary lock on housing.
Mark damaged contact (4) with socket number of housing and press it out of housing using appropriate special
tool contained in special tool kit 610300.
See repair instructions
OPENING PLUG HOUSINGS AND REMOVING CONTACTS of different plug systems
Fig. 63: Identifying Damaged Contacts

IMPORTANT: Check maximum length of repair cable

If more than one wire is to be repaired, the individual interfaces must be
2010 BMW M3
offset so that the wiring harness is not too thick at the repaired point.
Fig. 64: Identifying Hand Plier

Adhere to following procedure:
Cut off wire with faulty contact at point which is easily accessible
Strip insulation from end of wire at wiring harness end
Cut preassembled wire end to length and strip insulation
Refer also to repair instruction:
CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES
Crimp butt connector on preassembled wire end.
CRIMPING ON STOP PARTS
Fig. 65: Identifying Crimp Butt Connector On Preassembled Wire End

2010 BMW M3
Push shrink-fit hose (8) onto free wire end.
Fig. 66: Identifying Shrink-Fit Hose On Free Wire End

Crimp unused wire end to butt connector.
Fig. 67: Identifying Wire End With Butt Connector

Pull shrink-on sleeve over butt connector.

2010 BMW M3
Fig. 68: Identifying Shrink-On Sleeve Over Butt Connector

IMPORTANT: Do not burn shrink-on sleeve.
With hot air blower, shrink the shrink-on sleeve on both sides (9) of shrink-fit hose until glue emerges
uniformly all round.
Insert contact in housing.
Close secondary lock on housing.
Fig. 69: Identifying Shrink-On Sleeve Ends

6113... CONNECTOR HOUSING, LCC CONTACT (LOAD CURRENT CONTACT)
Notes
2010 BMW M3
Socket housing:
Press lock (1) with suitable tool (2) in direction of arrow out of socket housing (3).
Fig. 70: Pressing Lock Using Tool

Pull lock (1) out of socket housing (2).
Fig. 71: Pulling Lock Out Of Socket Housing

Insert special tool 61 0 317 into socket housing (1) and pull out lead with LCC contact (2) in direction of arrow.
2010 BMW M3
Fig. 72: Pulling Out Lead With LCC Contact

Pin housing:
Unlock locking slide (1) of pin housing (2) with suitable tool (3) in direction of arrow.
Fig. 73: Unlocking Locking Slide Of Pin Housing Using Tool

Insert special tool 61 0 317 into pin housing (1) and pull out lead with LCC contact (2) in direction of arrow.
2010 BMW M3

61 13... CRIMPING MICRO POWER QUADLOCK CONTACTS (MPQ)
To crimp MPQ contacts, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 325 (2) from crimping
set 614320.
NOTE: Pliers (1) open automatically as far as they will go when handles are pressed
together.
Fig. 75: Identifying Hand Pliers With Crimping Head (61 4 325)
Open pliers (1).
NOTE: Place contact (2) with utmost care in designated nest (observe cable cross-
section) in crimping head (3). Make sure it is exactly positioned.
2010 BMW M3
Place MPQ contact (2) in crimping head (3).
Close pliers (1) one notch.
Fig. 76: Identifying Hand Pliers With Crimping Head And MPQ Contact
NOTE: Follow procedure for CUTTING AND STRIPPING INSULATION from cables.
Insert stripped cable (2).
Close pliers (1) fully.
Open pliers (1) and remove cable (2).
NOTE: CHECK CONTACT FOR CORRECT CRIMPING .
Fig. 77: Cutting And Stripping Insulation From Cables

2010 BMW M3
61 13... CRIMPING MICRO QUADLOCK SYSTEM CONTACTS (MQS)
set 614320.
together.
Open pliers (1).
Fold up contact carrier (2).
Insert MQS contact (3) in contact carrier (2).
Fold back contact carrier (2).

2010 BMW M3
Fig. 79: Identifying Pliers, MQS Contact And Contact Carrier

Fig. 80: Cutting And Stripping Insulation From Cables

Open pliers (1).
Open contact carrier (2) gently and carefully remove MQS contact.
NOTE: CHECK CONTACT FOR CORRECT CRIMPING .

2010 BMW M3
Fig. 81: Opening Contact Carrier Gently

61 13... CRIMPING ANNULAR CONTACTS
Crimping annular contacts
Special tool 614320
Handling:
61 13... CRIMPING OPTICAL FIBRES
To crimp optical fibres, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 323 (2) from crimping
set 614320.
together.
2010 BMW M3
Move contact guide by means of stop lever (1) into corresponding position (pin contact or jack).
Fig. 83: Identifying Stop Lever On Plier

Open pliers (2).
Place pin contact or jack (1) in crimping head and secure with locking lever (3).
Fig. 84: Placing Pin Contact Or Jack On Crimping Head

NOTE: Follow procedure for CUTTING AND STRIPPING INSULATION FROM OPTICAL
FIBRES .
Insert stripped optical fibre (1) as far as it will go into pin contact or jack (2).
2010 BMW M3
Open pliers (3) and locking lever (4).
Remove optical fibre (1).
Fig. 85: Identifying Optical Fibre And Jack

IMPORTANT: Make sure optical fibre is correctly seated in jack.
Right (A)
End of optical fibre (1) must be flush with tip of pin contact (2).
Wrong (B)
End of optical fibre (1) is not flush with tip of pin contact (2).
2010 BMW M3
Fig. 86: Identifying Optical Fibre And Pin Contact

61 13... CRIMPING STOP PARTS
Spare parts for in-car electronics (housing and contacts)
1. Crimping butt connectors and contact sleeves for fan connectors up to 2.5 mm
2. Crimping butt connectors and contact sleeves for fan connectors larger than 2.5 mm 2
3. Crimping contact sleeves for 4 mm2 fan connectors and ignition cable contacts
Use special tool kit 12 1 080 to attach ignition cable contacts and crimp 4 mm2 contact sleeves for fan
connectors.
12 1 081 (hand pliers)

12 1 083 (nest)
SPECIAL TOOLS FOR WIRING HARNESS REPAIRS.
Fig. 87: Identifying Hand Pliers (12 1 081) And Nest (12 1 083)
Release special tool 12 1 081:
Squeeze grips (1) lightly and push unlocking lever (2) in direction of arrow.
Or:
Compress handles as far as they will go, tool unlocks automatically.

2010 BMW M3
Fig. 88: Pushing Unlocking Lever

Place 4 mm2 contact sleeve in nest with anti-twist safeguard (1) as far as possible.
Fig. 89: Locating Contact Sleeve With Anti-Twist Safeguard

Preload contact by squeezing matrix in crimping tool. Grip contact (1) firmly only, do not crimp.
2010 BMW M3
Fig. 90: Griping Contact

Insert stripped end of wire (7) in the contact. Ensure insulation and stripped wire end are correctly laid in
contact.
Compress crimping tool as far as it will go.
Crimping tool unlocks automatically.
Take contact out of crimping tool.
Fig. 91: Compressing Crimping Tool Over Striped Wire End

2010 BMW M3
4. Checking crimping
Check insulation crimp (8) and wire crimp (9) against following illustrations to ensure crimps are correctly
located.
NOTE: Illustration shows butt connectors and contact sleeves for fan connectors
knocked on one side. The crimping procedure is identical here.
Fig. 92: Identifying Insulation Crimp And Wire Crimp

Correct crimping:
Visible conductor end (10).
Visible insulation end (11).
Fig. 93: Identifying Conductor And Insulator Ends

Incorrect crimping:
Conductor end (10) inserted too far.

2010 BMW M3
Insulation end (11) in wire crimp.
If necessary, repeat crimping with a new contact.
Fig. 94: Identifying Incorrect Crimping Procedure

Incorrect crimping:
Conductor end (10) not visible.
Insulation end (11) not visible.
Fig. 95: Identifying Incorrect Crimping Procedure

61 13... CUTTING OFF, STRIPPING INSULATION AND CUTTING OPTICAL FIBRES TO LENGTH
To cut off, strip insulation and cut optical fibres to length, use pliers 61 4 321 (1) in conjunction with crimping
2010 BMW M3
together.
Cutting optical fibre
Open pliers (1).
Place optical fibre (2) in cutting device (3).
Close pliers (1) and remove optical fibre (2).
Fig. 97: Cutting Optical Fibre

Stripping insulation from optical fibre

2010 BMW M3
Open pliers (1).
Open lever (2) in direction of arrow.
Fig. 98: Opening Lever

Slide optical fibre (1) into stripping device (2) until flush at point (3).
Close clamping lever (5) in direction of arrow.
Open pliers (4) by one tooth notch.
Open clamping lever (5) against direction of arrow again and remove optical fibre (1).
NOTE: A stripping replacement blade set is available under number 61 4 327.

2010 BMW M3
Fig. 99: Closing Clamping Lever

Cutting optical fibre to length
IMPORTANT: The cutting blade must be replaced prior to each cutting of the optical fibre.
Pull pin (1) in direction of arrow.
Fold up blade retaining link (2) in direction of arrow.
Fig. 100: Folding Up Blade Retaining Link

WARNING: Risk of injury when changing the blade.

2010 BMW M3
Remove blade (1) and replace.
Installation:
Make sure blade (1) is correctly seated on locating points (2).
Fig. 101: Identifying Blade And Seated Points

Open pliers (3).
Slide optical fibre (1) into cutting device (2) until insulation of optical fibre (1) butts against clamping device.
Close pliers (3) fully and keep closed.
Fig. 102: Identifying Optical Fibre, Cutting Device And Pliers

2010 BMW M3
61 13... CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES
Stripped length:
WIRE STRIPPED LENGTH REFERENCE CHART

Wire cross-section (mm2 ) Stripped length (mm)
0.35... 0.50 4.0
0.75... 1.00 4.5
1.00... 2.50 5.0
61 13... FUSE HOLDER
Remove appropriate fuse from fuse holder (1).
NOTE: Identify the position when removing fuses.
Pull sliding lock (2) out of fuse holder (1) completely.
Fig. 103: Identifying Sliding Lock And Fuse Holder

With special tool 61 1 136 or 61 1 137 (pressing-off tool), press back retaining hooks (3) of appropriate contact
and pull out cable.
2010 BMW M3
Fig. 104: Pressing Back Retaining Hooks Of Appropriate Contact

61 13... IN-LINE PLUGS, 2-PIN, SYSTEM JPT ELA
Press lock (1) in direction of arrow and slide connector forward.
Fig. 105: Locating Lock

Press lock (1) downward and slide out to one side.

2010 BMW M3
Fig. 106: Locating Lock

With special tool 61 0 316 from kit 61 0 300 , unlock contact and pull out cable (1) with contact towards rear.
Fig. 107: Removing Cable Using Special Tool 61 1 132

61 13... IN-LINE PLUGS, 24- PIN, HYBRID SYSTEM MQS/MPQ
MQS (Micro Quadlock System)

MPQ, width 2.8 mm (Micro Power Quadlock)
Socket housing

2010 BMW M3
NOTE: Detaching the cap releases the secondary locks of the socket contacts.
Fig. 108: Pressing Locks On Cap Upwards On Both Sides

Hold down retaining hook (1) of socket contact in opening of contact carrier with a small screwdriver.
Pull wire with socket contact in direction of arrow as far as secondary lock (2).
Fig. 109: Pulling Wire With Socket Contact In Direction Of Arrow

Hold down retaining hook in secondary lock (1) again and pull cable with socket contact (2) completely out of
contact carrier (3).
2010 BMW M3
Fig. 110: Pulling Cable With Socket Contact Completely From Contact Carrier
Pin housing
Detach cap from housing carrier (3).
contact carriers.
Fig. 111: Detaching Cap From Housing Carrier

Pull contact carrier (1) out of housing carrier (2).
The pin contacts are pulled out of a contact carrier as described under "Socket housing".
2010 BMW M3
Fig. 112: Pulling Contact Carrier From Housing Carrier

61 13... IN-LINE PLUGS, 30- PIN, HYBRID SYSTEM MQS/MPQ

Socket housing
contacts.
Fig. 113: Pushing Contact Carrier From Rear Out Of Housing

2010 BMW M3
Fig. 114: Pulling Wire With Socket Contact

Fig. 115: Pulling Cable With Socket Contact Completely Out Of Contact Carrier
Pin housing
Contacts 1... 13 and 19... 27:

2010 BMW M3
NOTE: Detaching the locking slide releases the secondary locks of the pin contacts.
Fig. 116: Detaching Locking Slide Releases Secondary Locks Of Pin Contacts
Contacts 14... 18 and 28... 30:
Pull slide (1) outwards completely.
Pull contact carrier (3) out of housing.

61 13... IN-LINE PLUGS, 6- TO 50-PIN, SYSTEM ELO

2010 BMW M3
Unlock lock.
Fig. 118: Unlocking Lock

Unfasten cable strap.
Installation:
Cable clip must be reinstalled.
Fig. 119: Locating Cable Strap

Detach catch (1) from plug housing (2).

2010 BMW M3
Fig. 120: Detaching Catch From Plug Housing

Press out contact carrier (3) with wiring harness (4) through opening (5).
Fig. 121: Pressing Out Contact Carrier With Wiring Harness Through Opening
Hold down arrester hook (6) of defective contact and pull cable and contact up to secondary lock (8).
Fig. 122: Pulling Cable And Contact Up To Secondary Lock

2010 BMW M3
Hold down arrester hook once again in secondary lock (8) and pull cable and contact completely out of contact
carrier.
Fig. 123: Pulling Cable And Contact Completely Out Of Contact Carrier
61 13... INLINE PLUGS, 6-, 8- PIN, SYSTEM MQS

2010 BMW M3
Fig. 125: Pressing Locking Hook Downward And Slide Lock Out
Fig. 126: Pulling Out Cable With Contact Towards Rear

61 13... INLINE PLUGS, 8-, 12-PIN, SYSTEM D2.5
Move upper section of connector (1) and lower section of connector (2) against each other in direction of arrow.
2010 BMW M3
Fig. 127: Identifying Upper And Lower Connector Sections

With special tool 61 0 313 from kit 61 0 300 , press back retaining hook (3) of corresponding contact and pull
out cable with contact.
Fig. 128: Identifying Arrester Hook And Special Tool 61 1 132

61 13... INSTALLING COMB CONNECTOR FOR RETROFITTING/REPAIRS
connectors.
Special tools:
Special tool 61 9 040
Choose contact sleeve (up to 4 mm2 ) in accordance with wire cross-section.

2010 BMW M3
Fig. 129: Identifying Special Tools For Vehicle Electrical System Repairing
Fig. 130: Identifying Contact Sleeve

Alternatively:
Choose contact sleeves (up to 2.5 mm2 ) for fan connectors.

2010 BMW M3
Fig. 131: Identifying Contact Sleeves For Fan Connector

Cut through wire loop in wiring harness at established point.
Strip insulation from both wire ends.
Fig. 132: Identifying Crimp Tool

Crimp contact sleeves on both wire ends.
CRIMPING ON STOP PARTS

2010 BMW M3
NOTE: If using repair kit for contact sleeves, refer to repair instruction:
BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION .
Fig. 133: Crimping Contact Sleeves On Both Wire Ends

Crimp connecting cable for retrofitting likewise with contact sleeve.
Fig. 134: Crimping Connecting Cable For Retrofitting

Cut required number of poles to length for fan connectors.

2010 BMW M3
Fig. 135: Identifying Fan Connectors Poles Length

Special tool 61 9 041 (hand crimping tool) in conjunction with 61 9 042 (matrix) are used for pushing contact
sleeves onto fan connectors.
SPECIAL TOOLS FOR WIRING HARNESS REPAIRS .
Fig. 136: Identifying Special Tool 61 9 041 (Hand Crimping Tool)

Unlock special tool 61 9 041:
Or:

2010 BMW M3
Fig. 137: Pushing Unlocking Lever

Insert prepared fan connectors (3) in special tool 61 9 041/61 9 042.
Fig. 138: Inserting Fan Connectors In Special Tool (61 9 041 / 61 9 042)
Attach wire with contact sleeve to fan connector.

2010 BMW M3
Fig. 139: Attaching Wire With Contact Sleeve To Fan Connector

Press crimping tool together and slide contact sleeve firmly home.
Fig. 140: Pressing Crimping Tool Together

IMPORTANT: Once contact sleeves have been pushed on, they should not be detached again
from the fan connector or reused.
Push on further contact sleeves for potential branching.

2010 BMW M3
Fig. 141: Identifying Contact Sleeve On Fan Connector

Installation in wet area (engine compartment, wheel arch)
Apply sealing compound on both sides and press into contacts (1).
Fit shrink-fit hose and heat up with hot air blower (2) (approx. 250C).
NOTE: Ensure that fan connector has sufficient contact surface on mounting point.
Do not heat shrink-fit hose on edges of fan connector too strongly, risk of cracking.
Allow shrink-fit hose to cool down until hand-warm. Then press sealing material again into contacts and onto
edges of fan connector.
If necessary, carefully heat shrink-fit hose again.
Fig. 142: Identifying Fan Connector Contact Surface Mounting Point

2010 BMW M3
Installation in dry area (interior, luggage compartment)
Slide assembled fan connector into insulation housing until it locks into place.
Fig. 143: Sliding Assembled Fan Connector Into Insulation Housing

61 13... MAIN RELAY CONNECTOR FOR DME
Open locking clip (1) for the corresponding cable.
Fig. 144: Opening Locking Clip For Cable

and pull out cable with contact.
2010 BMW M3

61 00... NOTES ON HANDLING OPTICAL FIBRES
IMPORTANT: To avoid damage when handling optical fibres, comply with the following
points:

Do not subject optical fibres to compressive and tensile load
Protect optical fibres against the effects of heat > or =85C (e.g. during
welding work, drying work with infrared heater or hot air blower)
Fibre-optic cables are permitted to show only one junction point (bridge),
NOTE: The optical fibres are colored differently as follows:

Yellow = ISIS (I ntelligent S afety and I ntegration S ystem) fibre-optic cable
Follow instructions for PROCESSING CABLES AND OPTICAL FIBRES .

2010 BMW M3
Shielded lines
Coaxial line
Shielded RTK031 coaxial lines may only be repaired with special crimping tool for repairing the coaxial
line.
CVBS lines

HSD lines


FlexRay:
CONNECTORS .
2010 BMW M3
Airbag lines:
Ribbon cables:

SYSTEMS

ELA Strand seal
D 1.5/2.5/3.5 Round contacts with 1.5 mm, 2.5 mm or 3.5 mm
diameter
Mcon Multi contact

Ultrasonic-welded connectors (1) can be identified by the welds (2) on their longitudinal side.
2010 BMW M3

Release and press-out tool 61 1 150 is replaced from 09/2005 by 610300

Release and press-out tool 611100 (engine)
61 13... PLUG HOUSING, LCC CONTACT (LOAD CURRENT CONTACT)
Socket housing:
Fig. 147: Pressing Lock Using Tool

2010 BMW M3

Insert special tool 610317 into socket housing (1) and pull out lead with LCC contact (2) in direction of arrow.

Pin housing:
2010 BMW M3
Fig. 150: Unlocking Locking Slide Of Pin Housing Using Tool

Insert special tool 610317 into pin housing (1) and pull out lead with LCC contact (2) in direction of arrow.

61 13... RELAY CARRIER
Place special tool 61 1 153 against relay carrier (1) and carefully pull in direction of arrow until the locking tabs
(2) of the relay carrier are raised up.
2010 BMW M3
Fig. 152: Pulling Relay Carrier

Pull relay carrier (2) in direction of arrow into the first catch (3).

Press down arrester hook (4) of corresponding contact and pull out the cable with contact.
With special tool 61 1 136 or 61 1 137 (press out) press out dual spring contacts.
2010 BMW M3
Fig. 154: Pressing Down Arrester Hook

61 13 050 REMOVING AND INSTALLING OR REPLACING FUSE BOX IN PASSENGER

COMPARTMENT (BUILT AFTER 03/2007)
Remove right GLOVEBOX with housing

Remove JUNCTION BOX
Release wiring harness fastener (2) from fuse box interior (6).
Release screws (3).

Carefully fold fuse box interior (6) forwards, feeding battery positive lead (4) in
direction of arrow out of fuse box interior holder (5).
2010 BMW M3
Fig. 155: Feeding Battery Positive Lead Out Of Fuse Box Interior Holder
Disconnect all plug connections (1) on reverse side of fuse box interior (3).
Remove fuse box interior (3).
Installation:
Battery positive lead (2) must not be damaged.
Make sure wiring harnesses are correctly laid and plug connections (1) are correctly engaged.
Fig. 156: Identifying Plug Connections And Fuse Box Interior

Replacement:
If necessary, remove fuses and relays.
61 13... REMOVING AND INSTALLING/REPLACING OBD-II SOCKET

2010 BMW M3
Remove FOOTWELL SIDE TRIM PANEL ON A-PILLAR, LEFT
Release screws (1).
Remove OBD-II socket (2) from holder (3).
Fig. 157: Identifying Screws, OBD-II Socket And Holder

Remove OBD-II socket cover (2) from OBD-II socket (1).
Unlock slide plate (3) with a suitable tool in direction of arrow.
Insert special tool 610315 in OBD-II socket (1) in direction of arrow and press out associated flat spring contact
(4). Press remaining flat spring contacts with special tool 610315 out of OBD-II socket (1).
Installation:
Pay attention to pin assignment of OBD-II socket (1).
Make sure flat spring contacts and slide plate (3) are correctly engaged and seated in OBD-II socket (1).
2010 BMW M3
Fig. 158: Unlocking Slide Plate Using Tool

61 31 134 REMOVING AND INSTALLING/REPLACING USB/AUDIO INTERFACE CONNECTING

SOCKET
Removing and installing/replacing AV CONNECTION SOCKET
Safety regulations
Safety regulations for HANDLING COMPONENTS OF AIRBAG SYSTEM .

2010 BMW M3
61 13... REPAIRING AIRBAG LEADS (BUILD DATE/VERSION AFFECTED 04/2008 TO 07/2008)
modules and pyrotechnical belt pretensioners.
Improper handling can lead to triggering of the pyrotechnical seat belt
pretensioner or side airbag, resulting in injuries.
Switch off ignition!
IMPORTANT: Always use repair cable set for belt tensioner and seat airbag in event of a fault
on driver's and front passenger sides.
Move driver's seat/front passenger seat fully back and upwards.
Disconnect plug (2).
Fig. 159: Identifying Plug Connections And Plug

Release cable tie (1).
Unlock cap (2) on both sides and pull out in direction of arrow.
Installation:
Secure wiring harness for strain relief with cable tie on plug housing.
2010 BMW M3
Fig. 160: Pulling Out Cap

Fig. 161: Identifying Cables Insulation

Strip insulation (1) and disconnect cables in accordance with table.
CABLE DISCONNECTION REFERENCE CHART - DRIVER SEAT

2010 BMW M3
Driver's seat:
Pin 16 Yellow/Red GSF+
Pin 17 Yellow/Brown GSF
Pin 18 Yellow SIAVL+ for LHD
Blue SIAVR+ for RHD
Pin 19 Brown SIAVL/VR
CABLE DISCONNECTION REFERENCE CHART - PASSENGER SEAT

Passenger's seat:
Pin 16 Blue/Red GSBF+
Pin 17 Blue/Brown GsBF
Pin 18 Blue SIAVR+ for LHD
Yellow SIAVL+ for RHD
Pin 19 Brown SIAVR/VL
Cut cable (1) with BMW-recommended cable stripper and strip insulation.
A. Dimension A = 11 cm
Fig. 162: Cutting Cable Using BMW-Recommended Cable Stripper

Cut repair cable (1) with BMW-recommended cable stripper and strip insulation.
Cut repair wiring harness 11 cm.
2010 BMW M3
Fig. 163: Identifying Repair Cable

Connect repair cable (1) with butt connector to vehicle wiring harness.
Universal matrix 61 4 328

Pliers 61 4 321
Fig. 164: Connecting Repair Cable With Butt Connector To Vehicle Wiring Harness
Slide SHRINK-ON HOSES (1) over ignition circuit leads (2).
With hot-air blower, shrink the shrink-on hose on both sides of shrink-on hose until glue emerges uniformly all
round.
2010 BMW M3
Fig. 165: Sliding Shrink-On Hoses Over Ignition Circuit Leads

Connect ignition circuit lead (1) with special tool 610327 in accordance with table.
Fig. 166: Connecting Ignition Circuit Lead Using Special Tool (61 0 327)
61 13... REPAIRING RIBBON CABLES
Place ribbon cables (1) in connector housing (2) and close cover (3).
2010 BMW M3
Fig. 167: Identifying Ribbon Cables On Connector Housing And Cover

Place connector housing (1) in tool (2) 611190.
Close tool (2).
Fig. 168: Placing Connector Housing In Tool (61 1 190)

61 13... SOCKET HOUSING (RADIO PLUG), HYBRID SYSTEM MQS/MPQ

Removing MPQ contacts from radio plug

2010 BMW M3
Press lock (1) in direction of arrow.
Detach secondary lock (2) from radio plug.
Fig. 169: Detaching Secondary Lock From Radio Plug

Fig. 170: Pressing Special Tool (61 1 135)

Removing MQS contacts from contact carrier
Press lock (1) in direction of arrow and pull housing (2) out of radio plug.
2010 BMW M3

Press lock (1) in direction of arrow. Pull contact carrier (2) out of housing (3).
contacts are raised.

NOTE: The illustration shows an 8-pin female connector housing where contact
removal is identical.
2010 BMW M3

Depress retaining hook in secondary lock (1) once again. Remove wire with female contact (2) from contact
carrier (3) completely.
Fig. 174: Pulling Cable With Socket Contact Out Of Contact Carrier
Removing MPQ contacts from contact carrier
Remove contact carrier (1) with MQS contacts from the radio plug.
Raise lock (2) on radio plug.
Remove contact carrier (3) from radio plug.

2010 BMW M3
Fig. 175: Raising Lock On Radio Plug

Pull secondary lock (2) in the direction of the arrow and out of contact carrier (3) completely.
Fig. 176: Pulling Secondary Lock

Press special tool 61 1 135 against inside of contact in contact carrier (2).
Remove wire with female contact (1) from contact carrier (2).
2010 BMW M3
Fig. 177: Pressing Special Tool (61 1 135) Against Inside Of Contact In Contact Carrier
61 13... SOCKET HOUSING 42-, 43-PIN, HYBRID SYSTEM MQS/MPQ
housings:

Press back retaining hook of MPQ contacts (3) with screwdriver or similar tool and pull out cable with contact.
Fig. 178: Pressing Back MPQ Contacts Retaining Hook Using Special Tool (61 1 134)
2010 BMW M3
Installation:
Fig. 179: Identifying Cavity Numbers On Reverse Side Of Socket Housing

61 13... SOCKET HOUSINGS, 2X21-, 2X27-PIN, HYBRID SYSTEMS MQS/MPQ, ELO/ELO-POWER
housings:

housings:
Elo (electronic contact)

Elo-Power 2.8 mm wide (electronic contact for heavy loads)
NOTE: The second contact carrier is pushed out in the same way.
Pushing out the contact carrier releases the secondary locks of the socket
contacts.
2010 BMW M3


2010 BMW M3
Fig. 182: Pulling Cable With Socket Contact Out Of Contact Carrier
61 13... SOCKET OF TAB CONNECTOR HOUSINGS
Unlock hooks (1) with special tool 61 1 360 and push plug housing out of the socket.
Fig. 183: Unlocking Hooks Using Special Tool (61 1 360)

61 13... SPECIAL TOOLS FOR WIRING HARNESS REPAIRS
Special tool 610300

Special tool 61 0 400 (MINI N12/N14)
Handling:
OPENING PLUG HOUSINGS AND REMOVING CONTACTS of different plug systems

2010 BMW M3
Fig. 184: Identifying Special Tools

Handling:
Fig. 185: Identifying Crimp Tool

Crimping stop parts (small contacts)
Special tool 614320

1. Tool without crimping head
2. Crimping head (STRIPPING INSULATION AND CUTTING FIBRE-OPTIC CABLES TO
LENGTH)
2010 BMW M3
3. Crimping head (CRIMPING FIBRE-OPTIC CABLE CONTACTS)

4. Crimping head (CRIMPING MQS CONTACTS)
5. Crimping head (CRIMPING MPQ CONTACTS)
6. Replacement blade (face-cutting fibre-optic cables)
7. Replacement blade with tool (insulation stripping unit)
8. Universal crimping head
Fig. 186: Identifying Crimping Heads

Crimping stop parts (large contacts)
Special tool 610200 (crimping set)

Special tool 610210 (matrix set)
Special tool 610220 (matrix set SLK 2.8)
Special tool 610230 (matrix set MAK 8/DFK4)
Handling:
2010 BMW M3
Fig. 187: Identifying Crimping Stop Parts (Large Contacts)

Crimping antenna elbow plugs
Special tool 61 9 041 (pliers)

Special tool 61 9 044 (matrix)
Handling:
Antenna elbow plug on radio receiver
Fig. 188: Crimping Antenna Elbow Plugs

Repair kit for ignition cables and for crimping fan connector receptacles 4 mm 2

2010 BMW M3
Handling:
CRIMPING STOP PARTS (CONTACTS)
Fig. 189: Identifying Special Tools Kit

Repairing ribbon cables
Special tool 611190
Handling:
REPAIRING RIBBON CABLES
Fig. 190: Identifying Pliers (61 1 190)

61 13... TREATING CABLES AND FIBRE-OPTIC CABLES
2010 BMW M3
SPECIAL TOOL REFERENCE CHART

Crimping set with tool for fibre-optic cables, Micro Power Quadlock (MPQ), Micro Quadlock System
(MQS) contacts and universal crimping head
Insulation displacement tool for ribbon cable
Subject of repair instructions
SPECIAL TOOLS FOR WIRING HARNESS REPAIRS

See Recommended Engine Oils For BMW Group Engines See 6113... CRIMPING ANNULAR
CONTACTS; 6113... CRIMPING STOP PARTS; 6113... CRIMPING MICRO QUADLOCK
SYSTEM CONTACTS (MQS) or 6113... CRIMPING MICRO POWER QUADLOCK CONTACTS
(MPQ)
BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION
FAN CONNECTOR FOR RETROFITTING/REPAIRS
Aerial elbow plug on radio receiver
CUTTING TO LENGTH AND STRIPPING INSULATION FROM OPTICAL FIBRES
CRIMPING OPTICAL FIBRES
Insulation displacement connector for REPAIRING RIBBON CABLES

2010 BMW M3
Fig. 191: Pressing Lock And Opening Clip

Fig. 192: Pressing Lock And Opening Clip

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2010 BMW M3



2010 BMW M3



2010 BMW M3

DISTRIBUTION BOX, POWER SUPPORT POINTS

61 42... REMOVING AND INSTALLING/REPLACING DC/DC CONVERTER
NOTE: DC/DC converter in vehicles with automatic start-stop function.
There are two versions:
Without additional bracket for diesel engine vehicles

With additional bracket for gasoline engine vehicles
Depending on the equipment, one or both versions are installed in the M3
IMPORTANT: Read and comply with INFORMATION ON PROTECTION AGAINST DAMAGE

FROM ELECTROSTATIC DISCHARGE .
Remove lower section of microfilter housing (all except M3)
Remove RIGHT UPPER SECTION OF MICROFILTER HOUSING M3
Remove cover (3).

2010 BMW M3

Diesel engine vehicles (without additional bracket):
Release lugs in direction of arrow. Remove DC/DC converter (1) by pulling upward. Disconnect plug
connection (2).
Fig. 201: Releasing Lugs (Diesel Engine Vehicles)

Gasoline engine vehicles (with additional bracket):
connection (2).
2010 BMW M3
Fig. 202: Releasing Lugs (Gasoline Engine Vehicles)

M3:
Release tabs in direction of arrow and remove DC/DC converter with additional bracket (1) upward. Disconnect
plug connection (2).
Release tabs in direction of arrow and remove DC/DC converter without additional bracket (3) upward.
IMPORTANT: Do not mix up plug connections (2, 4)!
Fig. 203: Releasing Tabs

2010 BMW M3
61 14 010 REMOVING AND INSTALLING/REPLACING DISTRIBUTION BOX (ON BATTERY)
Remove FLAP IN LUGGAGE COMPARTMENT PANEL on right

Release screws (1) and remove bracket (2). Tightening torque 61 14 1AZ .
Fig. 204: Identifying Screws And Bracket

Unlock plug housing (2) and release in direction of arrow.
Fold up covers on nuts (3).
Unscrew nuts (3). Tightening torque 61 21 2AZ .
Disconnect plug connection of IBS cable (5).

2010 BMW M3
Fig. 205: Releasing Plug Housing

Press locking brackets (2) downwards and unclip.
If necessary, using a screwdriver (1), expand locking bracket (2) at lower end and clip out.
Remove power distributor (3) towards top.
Fig. 206: Removing Power Distributor Towards Top

61 14... REMOVING AND INSTALLING/REPLACING ENGINE COMPARTMENT B+ TERMINAL
Remove COVER FROM ELECTRONICS BOX

2010 BMW M3
NOTE: Work is shown on the E82 N52N by way of example. There may be differences in
Unclip covers (1) and release nuts underneath. Tightening torque 61 12 4AZ .
Remove battery positive cables.

Unclip cover (1).
Fig. 208: Identifying Electronics Box Cover

Unscrew nuts (1). Tightening torque 61 12 4AZ .

2010 BMW M3
Release locks (2) and remove frame (3) towards rear from B+ terminal.
Unclip B+ terminal and remove towards front.
Fig. 209: Identifying Engine Compartment B+ Terminal Locks, Frame And Nuts
Installation:
Make sure frame (3) engages correctly in B+ terminal.
BATTERY
61 20... AGM BATTERY
2010 BMW M3
Fig. 210: Identifying AGM Battery

Introduction
In September 2002, the first so-called VRLA batteries, better known as AGM batteries came into use. (VRLA
means V alve R egulated L ead A cid, i.e. lead acid battery with pressure relief valve; AGM stands for A
bsorbent G lass Mat , i.e. absorbent glass-fibre fleece)
AGM batteries are fitted in models with electrical loads/consumers which have a high energy demand.
With the option SA 146 (2nd battery), the AGM battery (70 Ah) is fitted as the 2nd battery.
The constantly increasing energy demand of modern vehicle electrical systems calls for ever more powerful
battery solutions. A modern luxury-class vehicle has some 100 actuator motors that have to be fed with
electrical current. Added to these are safety, environmental and comfort and convenience elements which are
increasingly becoming standard features, such as e.g. Anti-lock Brake System (ABS), Dynamic Stability
Control (DSC), electric steering effort assistance (EPS), heated catalytic converter, electronic chassis and
suspension control, air conditioning and navigation system. Current consumption is considerable even when the
vehicle is not in use.
The somewhat higher price compared with a battery of similar size is fully balanced by the following benefits:
greatly longer service life

improved starting reliability at low temperatures
2010 BMW M3
reliable starting of engines with high starting current requirements, e.g. high-performance diesel engines
100 % freedom from maintenance
low risk in the event of an accident (reduced environmental risk)
Service life of AGM batteries
Fig. 211: Identifying AGM Batteries Service Life Graph

AGM BATTERY CAPACITY

Item Description
1 Available capacity [%]
2 Mileage [thousand km]
3 AGM battery
4 Lead-calcium battery
5 50 % capacity limit
In contrast to conventional lead-calcium batteries, the sulfuric acid in a battery with fleece technology is not
held freely in the battery housing. Rather, 100% of the sulfuric acid is bound into the mats of the glass-fibre
fleece (separators). For this reason, no acid can escape if the battery housing is damaged. In addition, the AGM
battery is sealed to be airtight. This is possible because the gases are converted back into water as a result of the
separator permeability.
2010 BMW M3
Brief component description
An AGM battery can be recognized by its black housing and the lack of a so-called "Magic Eye".
Fig. 212: Identifying AGM Battery Components

AGM BATTERY COMPONENTS DESCRIPTION CHART

Item Description
1 Positive grille with silver alloy
2 Positive plate
3 Negative grille
4 Negative plate
5 Separator made of glass-fibre fleece
6 Set of positive plates
7 Set of negative plates
8 Block of plates
9 Block box with base strips
Construction
2010 BMW M3
larger plates: Larger plates allow a 25% larger power density.

Separators made of glass-fibre fleece: These can cause an up to 3-times higher cycle stability to be
reached. This improves the cold starting capability, the power consumption and service life.
Airtight housing with pressure relief valve:
The inspection plugs are sealed and can not be opened.
Battery acid bound in glass-fibre fleece: Battery acid is not found free in the housing as before, but is
rather bound 100% in the glass-fibre fleece. This gives increased security against the acid escaping and
thus reduces the environmental risk.
How it works
The AGM battery differs from conventional batteries in its non-polluting and substance-retaining behavior
during charging.
When a vehicle battery is charged, the electrolysis process emits the gases oxygen and hydrogen.
In a conventional wet lead calcium battery, the two gases hydrogen and oxygen are dissipated into the
atmosphere.
In an AGM battery, the two gases are converted back into water: The oxygen which is created at the
positive electrode during charging passes through the permeable glass fibre fleece to the negative
electrode. At the negative electrode the oxygen reacts with the arriving hydrogen ions in the electrolyte to
form water (oxygen cycle).
In this manner, the gas, and thus the electrolyte, is not lost.
Only in the event of an excessively heavy build-up of gas, i.e. excessively high pressure build-up (20 to 200
mbar), does the pressure relief valve discharge the gas. In this process, the pressure relief valve does not allow
any oxygen in the air to enter. Because the pressure in the battery is regulated by a valve, the AGM battery is
also known as the VRLA battery (valve-regulated lead acid).
Notes for Service department
It is necessary when handling an AGM battery to observe some particular points pertaining to battery changing
and installation location.
Charging
WARNING: Do not charge the AGM battery with = 15.2 V. Do not use rapid-charging
programs!
When charging removed batteries (so-called stand-alone batteries), do not exceed the maximum charging
voltage of 15.2 V at room temperature. Also, for charging via positive battery connection point the maximum
charging voltage of 15.2 volt at room temperature must not be exceeded. The batter can be damaged even with
2010 BMW M3
short charging of the AGM battery with a charging voltage higher than 15.2 volts. A charging voltage of more
than 15.2 V is usually used in quick-charging routines.
Installation location
WARNING: Do not install the AGM battery in the engine compartment.
The AGM battery must not be installed in the engine compartment on account of the high spatial temperature
differences, otherwise its service life will be significantly shortened.
Housing
WARNING: Do not open AGM batteries.
On no account may AGM batteries be opened, as the ingress of oxygen from the atmosphere would cause the
battery to lose its chemical balance, rendering it unserviceable.
Battery renewal
On principle any conventional lead-calcium battery can be replaced with an AGM battery. No changes result for
the vehicle electrical system by using an AGM battery.
NOTE: AGM batteries are especially recommended for "problem customers".
"Problem customers" have a very high energy throughput through the battery. This high energy throughput is
caused by stationary loads/consumers (TV, independent heating, etc.) and a bad use profile for the battery
("chauffeur operation", short-distance driving, "stop and go"). The use of an AGM battery is recommended for
these problem customers.
61 00... BATTERY
NOTE: Important notes and instructions for handling batteries in the dealership can be
found in:
DISCONNECTING BATTERY
BATTERY CHARGING
EXTERNAL JUMP-STARTING AID
2010 BMW M3
specification.
Battery test
test results.
61 20... BATTERY CHARGE
If a normal or quick charger is used to charge the battery, the battery must be disconnected from the vehicle
electrical system and removed. This prevents damage to paintwork and upholstery.
Ideally, battery charging is performed with BMW-approved charging computers
IMPORTANT: In order to prevent the intelligent battery sensor from malfunctioning, the
charging terminals in the engine compartment must be used without fail in
vehicles from E60 and should be used if possible in other vehicles.
IMPORTANT: Before charging the battery while it is installed, first carry out a CLOSED-
CIRCUIT CURRENT TEST . If here the voltage is 10 V or less, one or more of the
cells may be faulty or the entire battery may already be damaged. In this case,
always remove the battery as escaping gases during charging could damage
the interior equipment and trim. Attempt to regenerate faulty cells with low
charging current.
If necessary, open existing plugs on the individual cells.
61 20... BATTERY OPEN-CIRCUIT CURRENT TEST
NOTE: Observe SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY.

2010 BMW M3
Fig. 213: Identifying Battery Open-Circuit Current Tester

The open-circuit current test is performed using the Diagnosis and Information System (DIS).
2010 BMW M3
Diagnosis system:
Service functions
Body
Voltage supply
Test plan
Programming system:
61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD

Follow INSTRUCTIONS for disconnecting and connecting battery
IMPORTANT: Do not under any circumstances use force to pull/lever off INTELLIGENT
BATTERY SENSOR (IBS) .
REMOVE BATTERY COVER OR OPEN RIGHT LUGGAGE COMPARTMENT TRIM PANEL
Loosen nut (1).

2010 BMW M3
Disconnect battery negative lead (3) and secure at side.
Fig. 214: Identifying Battery Negative Lead And Nut


Do not modify the grounding cable. The grounding cable also serves
dissipate heat.

2010 BMW M3
fault-free.
12 00... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY
Before disconnecting battery
General notes on disconnecting battery

2010 BMW M3
Detach TERMINAL OF BATTERY NEGATIVE lead from car battery and second battery if fitted.
Cover battery negative terminal(s) and secure.
When installing battery terminal: Tightening torque 61 21 1AZ .
After connecting battery
specification.
For example:
Vehicles with AUTOMATIC ENGINE START-STOP FUNCTION (MSA) :

If necessary, carry out ADJUSTMENT FOR ACTIVE FRONT STEERING
If necessary, activate slide/tilt sunroof . See 54 0... NOTES ON GLASS SLIDE/TILT SUNROOF
(INITIALIZATION/NORMAL OF CHARACTERISTIC CURVE) .
If necessary, activate power windows . See 6762... NOTES ON INITIALIZING POWER WINDOW
UNIT IN FRONT DOOR or 6762... NOTES ON INITIALIZING POWER WINDOW UNIT IN
FRONT DOOR .
If necessary, activate MIRROR WITH COMPASS .
Vehicles with a two battery system
Starter and system battery
A two-battery system has a starter battery circuit and a system battery circuit. An auxiliary control unit monitors
both battery circuits. Depending on the situation, the battery circuits are connected to or isolated from the
auxiliary control unit via an cut-off relay.
Two AGM batteries, whose design and properties are described in AGM BATTERIES , are used as a storage
battery.
2010 BMW M3
Receiving/giving starting aid via jump start terminal point
is open.
Charging starter and system batteries via jump start terminal point
voltage at the starter battery is the decisive factor in determining whether the system battery is also included in
the charging operation. The auxiliary control unit automatically detects a charging operation at a charging
voltage at the starter battery of > or = 13.5 V. The cut-off relay is closed and thus the system battery is
connected in parallel. Both batteries are now charged.
Prerequisite:
If terminal 15 becomes "active" during the charging operation, the cut-off relay is opened immediately and
NOTE: When the engine hood is open, the cut-off relay is also opened in normal
operation. The cut-off relay is closed from terminal R in this operating mode.
Trickle charging
The increased standby current consumption can be compensated for via the jump-start connection point with the
aid of the "Acctiva easy" battery trickle charger.
"OFF" on a timed basis (60 mins.), thereby interrupting charging of the system
battery via the cigarette lighter. This is prevented if the battery switch (on the
right side of the luggage compartment behind the panel) is turned on and off
again twice within 2 seconds. (Cigarette lighter battery charging function).
2010 BMW M3
Preparation
of injury!
speed.
Operation

compartment.
sparks.
Risk of explosion!

CONTROL UNIT(S))
2010 BMW M3

Switch off ignition

Connect battery negative terminal and tighten, tightening torque 61 21 1AZ
Switch ignition on
Safety regulations
2010 BMW M3
61 00... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY
Battery acid is highly corrosive
In event of contact with acid
of water.
Explosion hazard
61 20 005 TESTING BATTERY WITH BATTERY TESTER

2010 BMW M3
IMPORTANT: Check is not permissible for AGM batteries!
WARNING: Read and comply with SAFETY INFORMATION pertaining to vehicle

battery.
Remove LUGGAGE COMPARTMENT FLOOR TRIM PANEL .
NOTE: Use BMW-recommended battery tester* to test the battery.
*Sourcing reference BMW Workshop Equipment Catalogue
Procedure:
Turn off ignition and close doors

Connect battery tester directly to battery terminals
Select Battery test and confirm
Enter vehicle identification number
Enter battery data
Carry out battery test
Fig. 215: Identifying BMW-Recommended Battery Tester

61 20... THRESHOLD VALUES FOR BATTERY INSPECTION OF ALL BATTERY (TELEPHONE

EXCEPT FOR TELEPHONE BATTERY)
2010 BMW M3
SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY.
BATTERY CHARGE STATUS - BEFORE CHARGING BATTERY

Test step 1 - before charging the battery
Charge state 1) Starting capability 2) Test result
Not testable Charge
less than 50 % 2) Charge
more than 50 % less than 75 % Charge
more than 50 % more than 75 % 3) Charge
more than 80 % more than 75 % O.K.
BATTERY CHARGE STATUS - AFTER CHARGING BATTERY

Test step 2 - after charging the battery
Charge condition 1) Starting capability 2) Test result
Not testable Defective
less than 50 % less than 75 % Charge
more than 50 % more than 75 % Charge
1. Charge condition and starting power must always be evaluated together

2. When test charging for more than 5 hours, use charger Gossen CG 32 or Siemens/Gossen VB 801
3. Fully charge until charge state is more than 80 %.
NOTE: If battery was checked on the positive terminal in the engine compartment,
repeat check directly on battery for sake of safety.
61 20 503 VEHICLE BATTERY - CLOSED-CIRCUIT CURRENT MONITORING
To access negative lead of battery, perform the necessary preliminary work described in DISCONNECTING
AND CONNECTING BATTERY NEGATIVE LEAD.
Do not disconnect negative lead of battery.
Connect BMW diagnosis system.
Connect clip-on probe to negative lead of battery. The arrow on the current clamp must point towards the
battery.
Measure closed-circuit current.
61 00 VERSION WITH AFS (ACTIVE FRONT STEERING): SETTING STEERING ANGLE (AFTER
RECONNECTING VEHICLE BATTERY)
After RECONNECTING the vehicle battery, carry out the following procedure for setting the steering angle:
2010 BMW M3
Start engine.
Turn steering wheel left to full lock.
Turn steering wheel right to full lock.
Turn steering wheel to central position.
Turn off engine.
Turn on ignition (terminal 15), AFS telltale and Check Control message go out.
NOTE: Entry in the fault memory remains unaffected by this procedure, therefore if
necessary:

Clear fault memory
BATTERY VAPOR SEPARATOR


Follow INSTRUCTIONS for disconnecting and connecting battery
IMPORTANT: Do not under any circumstances use force to pull/lever off INTELLIGENT
BATTERY SENSOR (IBS) .
REMOVE BATTERY COVER OR OPEN RIGHT LUGGAGE COMPARTMENT TRIM PANEL
Loosen nut (1).

2010 BMW M3


CONTROL UNIT(S))

Switch off ignition

Connect battery negative terminal and tighten, tightening torque 61 21 1AZ
Switch ignition on
61 21 010 REMOVING AND INSTALLING OR REPLACING BATTERY

2010 BMW M3
To ensure the correct safety and convenience functions, install only the original battery (battery size and type)
stored in the vehicle order. OBSERVE NOTE ON BATTERY REPLACEMENT .
Remove FLAP in luggage compartment panel on right

Remove DISTRIBUTION BOX
Unlock positive terminal cover (1) and remove.
Fig. 217: Unlocking Positive Terminal Cover

IMPORTANT: Do not under any circumstances pull/lever safety battery terminal off by force.
Battery crash element must be reinstalled!
On vehicles from build date 12/2006 or when IBS is replaced since

12/2006, battery crash element has been removed without replacement
(IBS2006 replaces IBS2004 from 12/2006)
Detach vent (1) in direction of arrow.
Release nut (6) of safety battery terminal (2).
Detach safety battery terminal (2) towards top, lay to one side and secure.
Release threaded pin (5) and remove holder with battery crash element (4).
2010 BMW M3
Fold back both bar fasteners (3) and pull battery towards rear out of associated fixture.
Lift out battery.
Fig. 218: Disconnecting Vent

Installation:
Make sure battery is correctly seated in associated fixture.
Replacement:
Read out fault memory, clear if necessary

On vehicles with IBS (intelligent battery sensor) REGISTER BATTERY REPLACEMENT
SWITCHES, HORN, SMALL DEVICES



2010 BMW M3
Remove cover (3).

connection (2).
2010 BMW M3

connection (2).

M3:
2010 BMW M3

61 30 020 REMOVING AND INSTALLING/REPLACING SWITCH BLOCK (M3)
If necessary, remove socket housing (1) from holder (2).
Unlock catches (3) and feed switch block (4) in direction of arrow out of storage compartment trim (5).
Installation:
Make sure switch block catch (4) engages correctly in storage compartment trim (5).
If necessary, make sure socket housing (1) is correctly seated in holder (2).
2010 BMW M3
Fig. 223: Removing Switch Block From Storage Compartment Trim

61 31 996 CARRYING OUT STEERING ANGLE SENSOR ADJUSTMENT
IMPORTANT: In vehicles with active front steering, steering angle sensor adjustment is
integrated in the service function INITIAL OPERATION/ADJUSTMENT FOR
ACTIVE FRONT STEERING and must not be carried out separately!
NOTE: Steering angle sensor adjustment must be carried out:
Before adjustment work on the front axle/steering

after all mechanical work on the steering system
E46 (all-wheel drive), E53, E83: after disconnecting the battery
after replacement/coding/programming of the following components:
Fixture for switches of steering column/switch cluster/steering angle
sensor
Dynamic Stability Control (DSC) control unit
Control unit active anti-roll stabilization (ARS)
Connect vehicle to BMW diagnosis system or Software Service Station. Select and carry out steering angle
sensor adjustment under Service functions.
61 31... OVERVIEW OF SWITCHES

2010 BMW M3
Fig. 224: Overview Of Switches

61 31 195 REMOVING AND INSTALLING (REPLACING) FRONT CONTROLLER (FROM 09/2008)

2010 BMW M3

Before dismantling it make absolutely sure, whether the controller is installed
with the status before or after Life Cycle Impulse (LCI).
NOTE: The number of buttons and shape of controller can vary depending on vehicle
type.
Before LCI: Controller (1) has buttons on bottom only.
After LCI: Controller (2) has buttons top and bottom.
Fig. 225: Identifying Buttons And Shape Of Controller

NOTE: These repair instructions describe the removal and installation (replacement) of
controller (2)!

The button for the controller must not be removed!
Carefully raise catches (1) on controller holder (3) and remove controller (2) towards top.
Installation:
2010 BMW M3
Make sure controller (2) is correctly engaged in controller holder (3).
Fig. 226: Identifying Catches, Controller Holder And Controller

Replacement
6FOTO1 31 038 REMOVING AND INSTALLING (REPLACING) SWITCH FOR PASSENGER

AIRBAG DEACTIVATION

REMOVE SIDE COVER ON INSTRUMENT PANEL
Unlock catches (1) and feed out switch for passenger airbag deactivation (2) to front of cover.
2010 BMW M3
Fig. 227: Identifying Catches And Switch For Passenger Airbag Deactivation
Installation:
Make sure switch for passenger airbag deactivation (2) is correctly seated in cover.
Installation instructions for replacement only for E63/E64 with production date up to 01/2010:
A groove must be filed in the trim at location (1).
Fig. 228: Identifying Groove In Trim

Replacement:
Remove LOCK CYLINDER FOR PASSENGER AIRBAG DEACTIVATION .

2010 BMW M3
61 31 122 REMOVING AND INSTALLING/REPLACING TOW HITCH SWITCH
Open flap in luggage compartment panel on left
Release screw (1).
Disconnect plug connection underneath and remove tow hitch switch (2).
Fig. 229: Identifying Screw And Tow Hitch Switch

61 31 043 REMOVING AND INSTALLING OR REPLACING ROOF SWITCH CLUSTER
IMPORTANT: Follow instructions for handling light bulbs (INTERIOR LIGHTS) .
PROTECTION).
IMPORTANT: Reflector on interior roof light must not be damaged!
Carefully unclip trim of interior roof light (1) from interior roof light with special tool 00 9 341 in direction of
arrow and remove.
2010 BMW M3
Fig. 230: Opening Ceiling Light Trim

NOTE: Roof switch cluster is secured to frame of headliner (2) with two retaining clips
(1).
Fig. 231: Identifying Headliner And Retaining Clips

IMPORTANT: Reflector (2) and headliner (3) must not be damaged!
Retaining clips (1) are located on centerline of both reading lights.
Position special tool 00 9 341 as illustrated.

2010 BMW M3
Fig. 232: Identifying Retaining Clips, Reflector And Roofliner With Special Tool (00 9 341)
NOTE: Shown from above on a model for clearer illustration.

Retaining clips (1) must not be damaged!
Position special tool 00 9 341 as illustrated.
Fig. 233: Locating Special Tool (00 9 341) Position

Position special tool 00 9 341 as illustrated and release retaining clips (1).
NOTE: Only then can the roof switch cluster be removed without causing damage!
2010 BMW M3
Fig. 234: Positioning Special Tool 00 9 341 And Release Retaining Clips
Lever roof switch cluster (1) out of headliner (2) with special tool 00 9 341 in direction of arrow.
Disconnect plug connections underneath and remove roof switch cluster (1).
NOTE: Disconnecting the plug connection for the hands-free microphone or

emergency call button results in fault memory entries in the telephone control
unit (limitation in the emergency call system).
Fig. 235: Removing Roof Switch Cluster Out Of Headliner Using Special Tool (00 9 341)
Installation note:
2010 BMW M3
Immediately after removal, fit interior roof light cover (1) to roof switch cluster (3):
1. Feed in interior roof light cover (1) at line (2)

2. Press interior roof light cover (1) onto interior roof light in direction of arrow
Make sure interior roof light cover (1) is correctly engaged on interior roof light.
Fig. 236: Pressing Ceiling Light Trim In Ceiling Light

Installation note:
If necessary, initialize SLIDE/TILT SUNROOF .
Replacement:

Initialize SLIDE/TILT SUNROOF ..
If necessary, remove BULBS .
61 31 133 REMOVING AND INSTALLING/REPLACING AV CONNECTION SOCKET
NOTE: Version with rear air conditioning is shown.

2010 BMW M3

Installation:
Catches (1 and 3) and guides (2) must not be damaged.

Lever AV connection socket (1) with a suitable tool (2) upwards out of storage compartment (3).
2010 BMW M3
Fig. 239: Removing AV Connection Socket Using Tool

Remove AV connection socket (2) upwards out of storage compartment (3).
Installation:
Locks (4) must not be damaged.
Make AV connection socket (1) is correctly seated in storage compartment (3).
Fig. 240: Identifying Storage Compartment With AV Connection Socket, Plug Connection And Locks

2010 BMW M3


Remove right upper section of MICROFILTER HOUSING M3
Remove cover (3).

Release lugs in direction of arrow.
Remove DC/DC converter (1) by pulling upward. Disconnect plug connection (2).
2010 BMW M3

Release lugs in direction of arrow.
Remove DC/DC converter (1) by pulling upward. Disconnect plug connection (2).

M3:
2010 BMW M3

61 31 194 REMOVING AND INSTALLING/REPLACING DRIVELOGIC BUTTON (M3)
Unlock catches (1) with a suitable tool.
Remove Drivelogic button (2) in direction of arrow from storage compartment trim (3).
Installation:
Make sure Drivelogic button (2) is correctly seated on storage compartment trim (3).
2010 BMW M3
Fig. 245: Removing Drivelogic Button

61 31 023 REMOVING AND INSTALLING/REPLACING START/STOP SWITCH
Press catches (1) together and unclip Start/Stop switch (2) in direction of arrow.
Fig. 246: Unclipping Start/Stop Switch


SOCKET
Removing and installing/replacing AV CONNECTION SOCKET

2010 BMW M3
61 31 229 REMOVING AND INSTALLING/REPLACING BOTH SWITCHES ON SPORT STEERING

WHEEL
Remove AIRBAG UNIT
NOTE: Illustrations show multifunction steering wheel (4) removed.
Release screws (1).
Detach decorative trim (3) in direction of arrow from holders (2).
Disconnect associated plug connection and remove complete decorative trim (3).
Fig. 247: Detaching Decorative Trim From Holder

Installation:
Make sure electrical leads are correctly routed.
Feed wiring harness (4) out of associated holders.
Release screws (1) and remove both multifunction steering wheel switches (2) from decorative trim (3).
Installation:
Make sure there is a uniform gap between both multifunction steering wheel switches (2) and decorative trim
(3).
2010 BMW M3
Fig. 248: Identifying Screws, Multifunction Steering Wheel Switches And Decorative Trim
61 31 054 REMOVING AND INSTALLING/REPLACING CENTER CONSOLE CONTROL PANEL

(WITH CCC/ASK, CIC)
Avoid subjecting the CIC to vibration/shocks.

Remove CONTROL PANEL FOR HEATING - A/C SYSTEM
Unclip trim (3) at fastening points (1) and (2).
Feed out associated ribbon cable and remove trim (3) complete with center console control panel (4).
2010 BMW M3
Fig. 249: Removing Trim Complete With Centre Console Control Panel
Replacement
Unclip center console control panel (1) at fastening points (2) and (4) and remove.
NOTE: Ribbon cable (3) of center console control panel (1) leads to heating - A/C
system control panel.
Fig. 250: Removing Centre Console Control Panel

Installation note:
Make sure center console control panel (1) engages correctly in upper fastening points (4) and lower fastening
points (2).
Replacement
2010 BMW M3
Assign buttons according to vehicle equipment.
NOTE: LEDs for seat heating must be removed from the center console switch cluster
on vehicles build after 09/2009 with automatic climate control and seat heating!
Refer to information on ESD prevention!
Undo screws (see arrows) and detach cover (1).
Tightening torque: 0.3 Nm
To tighten screws, use special tool 00 9 450 .
Fig. 251: Locating Screws And Cover

IMPORTANT: Wash your hands!
Wear gloves!
(BMW Parts Department 8319 2 159 171)

Do not touch printed circuit board!
Grasp printed circuit board only at the sides!
Remove pc-board together with ribbon cable (1) from casing (2).
2010 BMW M3
Fig. 252: Identifying PC-Board Ribbon Cable And Casing

NOTE: A total of 6 LEDs (1) are removed.
Fig. 253: Identifying PC-Board LEDs

Grip LED (1) with suitable pliers (2) as illustrated. Turn pliers (2) in clockwise direction.
Repeat procedure for remaining LEDs.
Installation note:
Make sure the center console switch cluster is reassembled correctly!

2010 BMW M3
Fig. 254: Turning Pliers In Clockwise Direction

61 31 052 REMOVING AND INSTALLING/REPLACING CENTER CONSOLE SWITCH CLUSTER

(WITHOUT CCC/ASK)
Remove CONTROL PANEL FOR HEATER/AIR CONDITIONING SYSTEM
Replacement
Unclip center console switch cluster (2) at retaining points (4).
Remove center console switch cluster (2) in direction of arrow from trim (3).
Assign buttons according to vehicle equipment.

2010 BMW M3
Fig. 255: Removing Centre Console Switch Cluster From Trim

Replacement note!
Excess length of ribbon cable!
To avoid damage and rattling noise, the ribbon cable must be fitted and secured correctly!
Installation note:
Replacement on vehicles with control panel for automatic climate control:
Install ribbon cable (1) as illustrated and secure over a wide area (A) with adhesive tape (2). Use the entire
length of the side face (B) of the center console switch cluster (3) for this purpose.
IMPORTANT: The customer may notice threads of adhesive tape (see arrow)!
Therefore, cleanly cut off adhesive strips!
2010 BMW M3
Fig. 256: Identifying Ribbon Cable With Adhesive Tape And Centre Console Switch Cluster
Refer to INFORMATION ON SECURING COMPONENTS WITH ADHESIVE TAPE .
Installation note:
Replacement on vehicles with control panel for air conditioning system:
Install ribbon cable (1) as illustrated and secure with two adhesive strips (2).
Cleanly cut off adhesive strips (2).
Refer to INFORMATION ON SECURING COMPONENTS WITH ADHESIVE TAPE .
Fig. 257: Identifying Ribbon Cable And Adhesive Strips

2010 BMW M3
NOTE: LEDs for seat heating must be removed from the center console switch cluster
on vehicles build after 09/2009 with automatic climate control and seat heating!
Refer to information on ESD prevention!
Undo screws (see arrows) and detach cover (1).
Tightening torque: 0.3 Nm
To tighten screws, use special tool 00 9 450 .
Fig. 258: Locating Screws And Cover

IMPORTANT: Wash your hands!

Wear gloves!
(BMW Parts Department 8319 2 159 171)

Do not touch printed circuit board!
Grasp printed circuit board only at the sides!
Remove pc-board together with ribbon cable (1) from casing (2).
2010 BMW M3
Fig. 259: Identifying PC-Board Ribbon Cable And Casing

NOTE: A total of 6 LEDs (1) are removed.
Fig. 260: Identifying PC-Board LEDs

Grip LED (1) with suitable pliers (2) as illustrated. Turn pliers (2) in clockwise direction.
Repeat procedure for remaining LEDs.
Installation note:
Make sure the center console switch cluster is reassembled correctly!

2010 BMW M3
Fig. 261: Turning Pliers In Clockwise Direction

61 31 299 REMOVING AND INSTALLING/REPLACING CLUTCH SWITCH MODULE
NOTE: Clutch master cylinder (2) is removed for purposes of clarity.
Lever out clutch switch module (1) from clutch master cylinder (2) with screwdriver.
Unlock plug (4) and disconnect from housing (3).
Fig. 262: Disconnecting Plug From Housing

2010 BMW M3
Installation:
Clutch switch module is secured against incorrect installation.
Clutch switch module must snap audibly into place.

61 31 006 REMOVING AND INSTALLING/REPLACING FIXTURE FOR STEERING COLUMN

STALK
WARNING: Move wheels into straight-ahead position and do not alter this position
during the repair work.
With steering wheel removed, do not under any circumstances turn/twist
fixture for steering column stalk!
Remove STEERING WHEEL

Remove TOP SECTION OF STEERING COLUMN CASING .
Remove LOWER SECTION OF STEERING COLUMN TRIM
Release screws (1).
Pull back fixture for steering column switch (2) in direction of arrow.
Disconnect plug connections behind and remove fixture for steering column stalk (2).
Installation:
Carry out STEERING ANGLE SENSOR ADJUSTMENT .

2010 BMW M3
On vehicles with active front steering, steering angle sensor adjustment is performed by means of INITIAL
OPERATION /adjustment of active front steering.
Fig. 264: Pulling Back Steering Column Switch Fixture

Replacement:
Remove VOLUTE SPRING CASSETTE

NOTE: If replacement of the steering column switch cluster is initiated via

Progman, the steering column switch cluster is coded indirectly via
the DSC control unit
If coding is cancelled, first adjust the steering angle sensor; this
makes a brand-new steering column switch cluster coding-
compatible again if necessary
Then code the DSC control unit again
NOTE: If steering angle sensor adjustment is cancelled, first code the DSC
control unit
Then adjust the steering angle sensor again
Vehicles with active front steering:

Steering angle sensor adjustment is performed by means of INITIAL
OPERATION/ADJUSTMENT of active front steering
If necessary, proceed in accordance with instructions
2010 BMW M3
61 31 342 REMOVING AND INSTALLING/REPLACING GEAR SELECTOR SWITCH (TWIN

CLUTCH TRANSMISSION)
PROTECTION) .

Remove PARKING LOCK CABLE FROM TRANSMISSION
Replacement:
Remove SHIFT LEVER KNOB FOR TWIN CLUTCH TRANSMISSION (3) .
Fig. 265: Identifying Plug Connections And Shift Lever Knob For Twin Clutch Transmission
Release screws (1). Tightening torque 61 31 6AZ .
Feed gear complete gear selector switch (4) with cable and rubber seal (2) upwards out of center console (5).
2010 BMW M3
Fig. 266: Identifying Gear Selector Switch, Rubber Seal And Centre Console
Installation:
Make sure rubber seal (2) is correctly fitted. Retaining lugs (3) of gear selector switch (4) must be positioned in
associated openings in rubber seal (2). Feed in rubber seal (2) between center console (5) and carpet (6).
Replacement:
61 31 131 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT SHIFT PADDLE FOR

TRANSMISSION (TWIN CLUTCH TRANSMISSION) (M3)
Remove AIRBAG UNIT
Release screw (3).
Feed out wiring harness (2) and remove shift paddle for transmission (5) in direction of arrow from steering
wheel (4).
2010 BMW M3
Fig. 267: Removing Wiring Harness

Installation:
Make sure shift paddle
for transmission (5) is correctly seated on steering wheel (4)
Make sure wiring harness (2) is laid correctly.
61 31 037 REMOVING AND INSTALLING/REPLACING LIGHT CONTROL UNIT
Remove DECORATIVE STRIP ON INSTRUMENT PANEL ON LEFT
Lever out trim of light control unit (2) with special tool 00 9 317 WEDGE at fastening points (1) and pull back
in direction of arrow.
Unlock and disconnect associated plug connection, remove trim of light control unit (2).
2010 BMW M3
Fig. 268: Pulling Back Light Control Unit Trim

Replacement
Unlock catches (1) and unclip light control unit (2) from trim (3).
Fig. 269: Removing Light Control Unit From Trim

61 31... REMOVING AND INSTALLING/REPLACING PARKING LOCK FROM SERIES STATUS

09/2008
PROTECTION) .
Remove gear selector switch

2010 BMW M3
Remove PARKING LOCK CABLE FROM TRANSMISSION
Release screws (1).
Feed rubber seal (2) completely out of gear selector switch (3).
Release parking lock (4) at points (5) and remove in direction of arrow.
Installation:
Make sure parking lock (4) is exactly seated on gear selector switch (3).
Make sure rubber seal (2) is correctly seated.
Fig. 270: Releasing Parking Lock

Install gear selector switch (1).
Install PARKING LOCK CABLE ON TRANSMISSION .
Installation:
Make sure rubber seal is correctly seated.

2010 BMW M3
Fig. 271: Identifying Gear Selector Switch

Release handle (1) from gear selector switch (2).
Withdraw transportation lock (3) from parking lock (4).
US version only:
Transmission emergency release (5) is provided with a grey cap.
Fig. 272: Identifying Transportation Lock, Parking Lock, Gear Selector Switch And Handle
61 31 241 REMOVING AND INSTALLING/REPLACING RIGHT HOOD/BONNET CONTACT

SWITCH (M3)
Lever bonnet/hood contact switch (1) with special tool 641020 out of microfilter housing upper section (2).
Disconnect plug connection (3) and remove bonnet/hood contact switch (1).
2010 BMW M3
Fig. 273: Removing Bonnet/Hood Contact Switch Using Special Tool (64 1 020)
Installation:
Make sure bonnet/hood contact switch (1) is correctly seated in microfilter housing upper section (2).
61 31 008 REMOVING AND INSTALLING/REPLACING STEERING-COLUMN SWITCH CLUSTER
Do not under any circumstances turn the steering column switch cluster
when the steering wheel is removed.
Remove steering wheel

Remove STEERING COLUMN SHROUD LOWER SECTION
If necessary, remove switch for steering column adjustment
WARNING: Do not twist the coil spring cassette (1)!
NOTE: The COIL SPRING CASSETTE (1) may be replaced separately, if necessary!
2010 BMW M3
Fig. 274: Identifying Coil Spring Cassette


Release screws (1).
Remove steering-column switch cluster in direction of arrow.

2010 BMW M3
Fig. 276: Removing Steering-Column Switch Cluster

Installation note:
The steering column switch cluster is installed in reverse sequence.
Carry out steering angle sensor adjustment.
Replacement:
Remove volute spring cassette


makes a brand-new steering-column switch cluster coding-
Carry out steering angle sensor adjustment
control unit
Vehicles with active steering:

Steering angle sensor is adjusted by means of INITIAL OPERATION/ADJUSTMENT of active
front steering
2010 BMW M3
61 31 101 REMOVING AND INSTALLING/REPLACING SWITCH FOR BACKREST WIDTH

ADJUSTMENT
Remove outer cover See REMOVING AND INSTALLING/REPLACING OUTER COVER ON

LEFT OR RIGHT FRONT SEAT BACKREST or REMOVING AND
INSTALLING/REPLACING OUTER COVER ON FRONT LEFT OR RIGHT SEAT (NORMAL)
on front seat
Unlock retaining tab (2) in direction of arrow.
Remove switch for backrest width adjustment (3) in direction of arrow.
Fig. 277: Removing Switch For Backrest Width Adjustment

61 31 079 REMOVING AND INSTALLING/REPLACING SWITCH FOR HAZARD WARNING

FLASHERS/CENTRAL LOCKING
Unclip switch for hazard warning flashers/central locking (1) in direction of arrow from right instrument panel
decorative strip (2).
2010 BMW M3
Fig. 278: Removing Switch For Hazard Warning Flashers/Central Locking

61 31 208 REMOVING AND INSTALLING/REPLACING SWITCH FOR LUMBAR SUPPORT
Remove outer cover See REMOVING AND INSTALLING/REPLACING OUTER COVER ON

on front seat
Unlock catches (1).
Remove switch for lumbar support (2) in direction of arrow.
Fig. 279: Removing Switch For Lumbar Support

2010 BMW M3
61 31 083 REMOVING AND INSTALLING/REPLACING SWITCH FOR UNLOCKING REAR LID
NOTE: To facilitate handling, unclip OBD socket cover (1).
Unclip rear lid unlocking switch (2) in direction of arrow.
Disconnect associated plug connection and remove switch for unlocking rear lid (2).
Fig. 280: Removing Rear Lid Unlocking Switch

61 31 011 REMOVING AND INSTALLING/REPLACING VOLUTE SPRING CASSETTE
Remove FIXTURE FOR STEERING COLUMN STALK
Unlock catches (1).
Press lock (2) and remove volute spring cassette (4) in direction of arrow from fixture for steering column stalk
(3).
2010 BMW M3
Fig. 281: Removing Volute Spring Cassette From Fixture For Steering Column Stalk
IMPORTANT: Do not turn ring (1).

Also turning ring (1) through 360 is not permitted!
Secure ring (1) against unauthorized turning (e.g. with adhesive tape).
Fig. 282: Identifying Notch, Ring And Switch

Installation:
Notch (3) on ring (1) must line up with arrow (4) on switch (2).
IMPORTANT: Fit volute spring cassette (1) so that guide (2) can slide exactly into associated
notch on switch (3).
2010 BMW M3
Fig. 283: Identifying Volute Spring Cassette, Guide And Switch

61 31 009 REPAIRING STEERING COLUMN SWITCH CLUSTER (SZL)

Remove VOLUTE SPRING CASSETTE

Spread antistatic mat
Use antistatic wrist trap with connecting line
Note on ordering:
Workshop equipment
Workshop equipment catalogue
Order number
61 31 9 141 875
IMPORTANT: Extreme cleanliness is required!
NOTE: Installation is described separately.
Removal
Unlock retaining lugs on upper housing section (1) with a suitable tool.
2010 BMW M3
Remove upper housing section.
Fig. 284: Locating Retaining Lugs On Upper Housing Section

Release screws (1) in optical element (2).
IMPORTANT: Touch only the optical element.
NOTE: After removal, render optical element unusable and dispose of it in the
appropriate manner.
Fig. 285: Identifying Optical Element With Screws

2010 BMW M3
Fig. 286: Removing Encoded Disc From Rear Of Steering Column Switch Cluster Using Plastic Tube
Unclip encoded disc (1) from rear of steering column switch cluster with plastic tube (2) supplied for the
purpose.
In this process, hold encoded disc by inserting two fingers in the hole.
2010 BMW M3
Fig. 287: Tilting Encoded Disc Away From Printed Circuit Board When Removing
To prevent damage, tilt encoded disc (1) away from the printed circuit board when removing.
IMPORTANT: It is not permissible to clean the bearing points.
IMPORTANT: Make sure that encoded disc, optical element and printed circuit board do not
come into contact with grease.
Apply grease supplied for the purpose to friction face (1) of bearing race of front of steering column switch
cluster.
2010 BMW M3
Fig. 288: Identifying Bearing Race Friction Face

Installation
IMPORTANT: Thoroughly clean your hands before installation.
Before installing the new parts, put on gloves and hair net included in the
repair kit!
2010 BMW M3
Fig. 289: Precautions For Installing New Parts

IMPORTANT: Not permitted!
Do not touch encoded disc (1) with your fingers!

Do not touch printed circuit board (2)!
Do not apply pressure to encoded disc (3)!
Do not touch sides of encoded disc (4)!
Hold encoded disc (1) by inserting two fingers in the hole.
Position encoded disc centered in fixture and clip it in.
Turn encoded disc to and front to spread the grease over the friction face
2010 BMW M3
Fig. 290: Holding Encoded Disc By Inserting Two Fingers In Hole

Fig. 291: Assembling Optical Element From Individual Parts Included In Repair Kit
Assembly optical element (1) from individual parts included in the repair kit.
2010 BMW M3
Secure optical element (2) with screws (1).

Tightening torque: 0.26 Nm.
Fig. 292: Identifying Optical Element With Screws

Clip upper housing section (1) into place.

After inserting coil spring cassette, affix "CDS" label close to part-number label (2).
Installation note:
Make sure retaining lugs are correctly engaged.
Fig. 293: Identifying Upper Housing Section And Part-Number Label

2010 BMW M3
Installation note:
Mark (1) and mark (2) must point to each other.
Fig. 294: Identifying Alignment Marks

Carry out STEERING ANGLE SENSOR ADJUSTMENT .
61 31 310 REPLACING BRAKE LIGHT SWITCH
Pull brake light switch (2) in direction of arrow out of brake light switch holder (3).
Installation:
Press brake pedal (4) to floor.

Slide brake light switch (2) as far as it will go into brake light switch holder (3).
Grip brake light switch holder (3), slowly return brake pedal (4) to starting position and pull back to stop.
2010 BMW M3
Fig. 295: Pulling Brake Light Switch Out Of Brake Light Switch Holder
NOTE: Removing brake light switch holder (2):
Press brake pedal.
Press catches (1) together and unclip brake light switch holder (2) from bearing block (3).
Fig. 296: Removing Brake Light Switch Holder

61 31 382 REPLACING COOLANT LEVEL SWITCH

Carry out work only after engine has cooled down.
IMPORTANT: Do not damage connected water hoses.

2010 BMW M3
If necessary, release screws for COOLANT EXPANSION TANK and raise coolant expansion tank
slightly
NOTE: Operation is shown by way of example on the E85. There may be differences in
Turn coolant level switch (2) in direction of arrow and feed downwards out of coolant expansion tank (3).
Fig. 297: Turning Coolant Level Switch


slightly
2010 BMW M3


slightly
2010 BMW M3

61 31 492 REPLACING LEVEL SWITCH FOR WINDSCREEN WASHER SYSTEM
Release FLUID RESERVOIR FOR WINDSCREEN WASHER SYSTEM and pull out
Turn level switch for windscreen washer system (2) in direction of arrow and remove towards bottom from
fluid reservoir for windscreen washer system (3).
Fig. 300: Turning Level Switch For Windscreen Washer System

61 31 115 REPLACING ROCKER SWITCH FOR SIDE WINDOW OPERATION (FRONT)
IMPORTANT: Carry out the following operations carefully so as to avoid damaging the door
trim panel and rocker switch.
If necessary, tape off working area.
Driver's side:
Lever rocker switch for side window operation (1) with special tool 00 9 341 at highlighted points (2) out of
armrest (3).
Disconnect associated plug connection and remove rocker switch for side window operation (1).
2010 BMW M3
Fig. 301: Levering Rocker Switch For Side Window Operation Using Special Tool 00 9 341
Installation:
Retaining clips (1) of rocker switch for side window operation (2) must not be damaged or missing.
Make sure rocker switch for side window operation (2) is correctly seated in armrest.
Fig. 302: Identifying Retaining Clips And Rocker Switch For Side Window Operation
Passenger side:
Lever rocker switch for side window operation (1) with special tool 00 9 317 WEDGE in direction of arrow out
of armrest.
2010 BMW M3
Fig. 303: Levering Rocker Switch For Side Window Operation Using Special Tool (00 9 317)
Installation:
Retaining hooks (1) of rocker switch for side window operation (2) must not be damaged.
Fig. 304: Identifying Retaining Hooks And Rocker Switch For Side Window Operation
61 31 116 REPLACING ROCKER SWITCH FOR SIDE WINDOW OPERATION (REAR)
IMPORTANT: Carry out the following operation carefully so as to avoid damaging the door
trim panel and switch.
2010 BMW M3
Fig. 305: Levering Rocker Switch For Side Window Operation Using Special Tool (00 9 317)
Lever rocker switch for side window operation (1) with special tool 00 9 317 WEDGE in direction of arrow out
of armrest.
Installation:
Fig. 306: Identifying Retaining Hooks And Rocker Switch For Side Window Operation
61 31 204 REPLACING SWITCH COMBINATION FOR SEAT ADJUSTMENT

2010 BMW M3
Remove outer cover . See REMOVING AND INSTALLING/REPLACING OUTER COVER ON

on front seat
Unlock retaining tabs (3) in direction of arrow and remove switch combination (1) from cover.
Fig. 307: Unlocking Retaining Tabs

Installation:
Retaining tabs (3) of cover and guide (4) of switch combination (1) must not be damaged.
Make sure switch combination (1) is correctly seated in retaining tabs (3).
61 31 255 REPLACING SWITCH FOR DOOR MIRROR
Replacing ROCKER SWITCH FOR SIDE WINDOW OPERATION
61 31 270 REPLACING SWITCH FOR REVERSING LIGHT
NOTE: The installation location of the reversing light switch can vary, depending on
the transmission model.
If necessary, remove rear underbody protection

2010 BMW M3
Version A:
Release switch for reversing light (2).
Fig. 308: Identifying Plug Connection And Switch For Reversing Light (Version A)
Version B:
Fig. 309: Identifying Plug Connection And Switch For Reversing Light (Version B)
2010 BMW M3
HORN
61 33 060 REMOVING AND INSTALLING/REPLACING BOTH FANFARE HORNS (M3)
Remove FRONT LEFT WHEEL ARCH TRIM
NOTE: Headlight shown removed for purposes of clarity.
Unscrew nuts (2).
Remove fanfare horns (3) from holder (4).
Fig. 310: Identifying Fanfare Horns With Plug Connection, Nuts And Holder
CONTROL UNITS, MODULES

61 35 679 INITIALIZING RAIN/LIGHT (SOLAR) SENSOR
NOTE: Initialization is necessary:
after replacing windscreen

after replacing rain/light (solar) sensor
after replacing optical element on rain/light (solar) sensor
after installing a used rain/light (solar) sensor
NOTE: Connect BMW diagnosis system

2010 BMW M3
Initializing rain/light (solar) sensor
61 35... NOTES ON ESD PROTECTION (ELECTRO STATIC DISCHARGE)

warning symbol.
E -Electro
S -Static
D -Discharge
Statically charged persons can discharge themselves when they touch electrical components.
The danger threshold for electrical components already starts from a level of
approx. 100 V.
Fig. 311: Discharging Charged Person By Touching Electrical Components

Example:

2010 BMW M3

Fig. 313: Caution - Do Not Touch Pins And Multi-Pin Connectors Directly
IMPORTANT: Do not touch pins and multi-pin connectors directly!

2010 BMW M3
IMPORTANT: To avoid damaging or destroying electrical components as a result of

electrostatic discharge, it is absolutely essential to observe the following
instructions:

to be installed
Fig. 314: Identifying Antistatic Shoes

61 35... OVERVIEW OF CONTROL UNITS

2010 BMW M3
Fig. 315: Overview Of Control Units

PROTECTION).

Fold back carpet for passenger compartment at front left in direction of travel
2010 BMW M3
Installation:
Fig. 316: Identifying Seal And USB Hub Protective Socket Cover
Installation:
Fig. 317: Identifying USB Hub And USB Hub Protective Socket Lower Section
61 35 015 REMOVING AND INSTALLING (REPLACING) CONTROL UNIT FOR CAR ACCESS
2010 BMW M3
SYSTEM
PROTECTION) .
NOTE: The comfort access system is a radio-based system and can be interfered with
by radio waves from other systems (e.g. mobile phone).
Remove TRIM FOR PEDAL ASSEMBLY
IMPORTANT: Carefully disconnect plug connection for ribbon cable (1).

INSERT FOR RADIO CONTROL KEY

START/STOP SWITCH
Fig. 318: Identifying Car Access System With Plug Connection And Screw
Release screw (3).
Feed out control unit for Car Access System (4) to left and remove in downward direction.
Installation:
2010 BMW M3
Feed guide (1) of control unit for Car Access System (2) correctly into associated mounting.
Fig. 319: Identifying Control Unit For Car Access System With Guide
Replacement:

Version with independent heating: Initialize Telestart hand transmitter See INITIALIZING
TELESTART HANDHELD TRANSMITTER (T93) (FROM BUILD DATE 03/2007) or
INITIALIZING TELESTART HAND TRANSMITTER (T90) (UP TO BUILD DATE 03/2007) .
61 35 950 REMOVING AND INSTALLING (REPLACING) CONTROL UNIT FOR COMFORT

ACCESS SYSTEM

Remove TRIM FROM REAR APRON

Partially detach insulating mat

2010 BMW M3
Fig. 320: Pulling Back Device Holder

Unlock catch (2) in direction of arrow and remove control unit for comfort access system (3) upwards from
device carrier (4).
Fig. 321: Removing Catch

Replacement
61 35 080 REMOVING AND INSTALLING (REPLACING) CONTROL UNIT FOR LEFT OR RIGHT
SEAT ADJUSTMENT (FRONT SEAT)

2010 BMW M3
NOTE: To facilitate installation/removal of control unit, move seat upwards fully.
Unlock metal lug (1) towards front and remove control unit for seat adjustment (2) towards bottom.
Unlock and disconnect all associated plug connections.
Fig. 322: Removing Control Unit For Seat Adjustment Towards Bottom
Installation:
Make sure control unit for seat adjustment (1) is correctly seated in mounting (2).
Guides (3) and metal lug (4) must not be damaged.
Fig. 323: Identifying Control Unit For Seat Adjustment, Mounting, Guides And Metal Lug
2010 BMW M3
Replacement

ELECTRONICS (HIGH)
PROTECTION) .
Disconnect BATTERY NEGATIVE lead

E91:

Unscrew nuts (1).
2010 BMW M3
Fig. 325: Identifying Wiring Harness Fastener And Guides

E88/E93:
Installation:
Release all nuts.
Remove hands-free charging electronics (3) from holder for telematics control unit/SES (2).
Fig. 326: Identifying Hands-Free Charging Electronics

2010 BMW M3
Replacement:

61 35 177 REMOVING AND INSTALLING (REPLACING) RAIN/LIGHT SENSOR
PROTECTION) .
Version with Autobeam:
Remove INTERIOR REAR-VIEW MIRROR
Detach two-part mirror base cover (1) by pressing from below.
Feed out two-part mirror base cover (1) and remove.
NOTE: Catches of two-part mirror base cover (1) must not be damaged or missing.
Fig. 327: Detaching Two-Part Mirror Base Cover

Release locks (1) in direction of arrow and remove rain/light sensor (2) from optical element.
Installation note:
2010 BMW M3
Do not damage optical element covered by rain/light sensor (2).
Initialize RAIN/LIGHT SENSOR .
Fig. 328: Releasing Locks

61 35 107 REMOVING AND INSTALLING OR REPLACING JUNCTION BOX ELECTRONICS
PROTECTION) .

Remove FOOTWELL SIDE TRIM PANEL on A-pillar, right
Remove TRIM FOR INSTRUMENT PANEL , bottom right
NOTE: Glovebox removed for purposes of clarity.
Release screws (2) and remove junction box electronics (3) from holder.
2010 BMW M3
Fig. 329: Identifying Junction Box Electronics With Plug Connection And Screws
Installation:
Make sure junction box electronics is correctly seated on plug connection (2) of holder.

Replacement:
Delete transport mode.

2010 BMW M3


Remove cover (3).

connection (2).
2010 BMW M3

connection (2).

M3:
2010 BMW M3

61 35 975 REMOVING AND INSTALLING/REPLACING BUMPER ANTENNA FOR COMFORT

ACCESS SYSTEM
Remove REAR BUMPER TRIM
Unlock catches (1) and remove bumper antenna for comfort access system (3) in direction of arrow from holder.
Installation:
Make sure bumper aerial/antenna for comfort access system (3) is correctly seated in holder.
2010 BMW M3
Fig. 335: Removing Bumper Antenna For Comfort Access System From Holder
61 35 115 REMOVING AND INSTALLING/REPLACING FOOTWELL MODULE
PROTECTION) .

Remove FOOTWELL SIDE TRIM PANEL ON A-PILLAR, LEFT
Release nuts (2) and remove footwell module (3).
Fig. 336: Identifying Footwell Module With Nuts And Plug Connection
2010 BMW M3
REPLACEMENT:
61 35 953 REMOVING AND INSTALLING/REPLACING INTERIOR ANTENNA FOR COMFORT

ACCESS SYSTEM
Unlock retaining hook (2) and remove interior antenna for comfort access system (3) in direction of arrow.
Fig. 337: Removing Interior Antenna For Comfort Access System


ACCESS SYSTEM (REAR)
Move with special tool 00 9323 SCRAPER from below behind trim (1) and release catches (2).

2010 BMW M3

Installation:
Guides (2) must not be damaged

Unlock retaining hook (2) and remove luggage compartment antenna for comfort access system (3).
2010 BMW M3
Fig. 340: Identifying Comfort Access System With Plug Connection And Retaining Hook
61 35 970 REMOVING AND INSTALLING/REPLACING REAR LUGGAGE COMPARTMENT

ANTENNA FOR COMFORT ACCESS SYSTEM
Remove LUGGAGE COMPARTMENT FLOOR TRIM PANEL .
Unlock catches (2) and remove luggage compartment antenna for comfort access system (3) in direction of
arrow from holder (4).
Fig. 341: Removing Luggage Compartment Antenna For Comfort Access System From Holder
64 11 970 REPLACING FOGGING SENSOR

2010 BMW M3
WARNING: Make sure rooms are well ventilated when working with adhesive remover
indoors.
IMPORTANT: Do not under any circumstances use paint thinner to clean the bonding
surface.
Expand two-part mirror base cover (1) by pressing from below and detach.

NOTE: If necessary, carefully heat fogging sensor (2) with a hot air blower to approx.
40-60C.
2010 BMW M3
Fig. 343: Identifying Plug Connection And Fogging Sensor

Lift off fogging sensor (2) with special tool 00 9 317 WEDGE and slowly pull off from windshield.
Installation:
Bonding surface must be dry and free of dust and grease.
Clean bonding surface with adhesive remover (sourcing reference: BMW Parts Service).
After cleaning, do not touch bonding surface with bare hands.
Pull off protective film completely from fogging sensor (3).
Place mounting template (1) as pictured on rain sensor (2).
Press fogging sensor (3) in direction of arrow with a contact pressure of > or =15 N/cm2 onto inside of
windshield.
NOTE: Firm thumb pressure attains approx. 30 N/cm2 .
Remove mounting template (1) carefully from fogging sensor (3).
Fig. 344: Pressing Fogging Sensor

61 35 502 REPLACING THE TRAILER MODULE (09/2006 - 03/2009)
NOTE: From 03/2009 trailer module AHM3+ will be replaced by trailer module AHM4R.
Plug connectors and associated pin assignments must be adapted if the old
plug connector AHM3(+) is fitted.
2010 BMW M3
A. Plug connector, new AHM4

B. Plug connector, old AHM3(+)
Fig. 345: Identifying Plug Connectors

Remove trailer module
From build date/version 03/2007 Series E60/61:
Installation:
Cut out device holder up to marking (1).
Cut out indentation in area (2).
Make sure AHM module is exactly seated and wiring harness is correctly routed.
2010 BMW M3
Fig. 346: Identifying Device Holder Cutting Marking And Indentation Cutting Area
NOTE: Positions of plugs and associated pin assignments are set out in the diagnosis
system.
The repair instruction represents the highest vehicle configuration. Pin assignments of plug connections may be
absent if optional equipments are not fitted.
Special tools for disconnecting
Secondary lock:
Special tool 61 0 324 RELEASE TOOL
Primary lock:
Special tool 61 0 316 RELEASE TOOL
Special tool for crimping
Double flat spring contact:
Crimping tool special tool 61 0 202 (crimping tool) with special tool 61 0 230 MATRIX (matrix)
SPECIAL CRIMPING TOOLS DESCRIPTION CHART

(09/2006 - 03/2009)
Previously AHM3(+) New AHM4R
Pin no. Contact (mm2 ) Pin no. Contact (mm2 )
1 2.8 13 2.8
2 2.8 20 2.8
3 0.63 - -
4 0.63 17 0.63
5 0.63 2 0.63
6 0.63 3 0.63
7 0.63 11 0.63
8 0.63 9 0.63
9 0.63 10 0.63
10 0.63 18 2.8
Re-crimp contact from 0.63 mm2 to 2.8 mm2
11 0.63 14 2.8
12 0.63 15 2.8
2010 BMW M3

13 0.63 19 2.8
14 0.63 12 2.8
15 0.63 16 0.63
16 0.63 1 2.8
- - 4-8 0.63
61 00... VEHICLE PROGRAMMING AND ENCODING
NOTE: In order to avoid incorrect programming procedures and error messages,

it is essential when working with the Progman/ISTA/P programming
system always to use the latest Progman version.
Battery voltage must not drop below 13.0 V during programming.
Connect battery charger prior to programming.
IMPORTANT: E72 only:

Before programming the vehicle, it is essential to disconnect the high-voltage
system from the power supply.
Programming sequence via ISTA/P:
Identify vehicle and read out control unit data

Draw up and configure measures plan
Prepare programming, export CBS/CKM data
Carry out repair measures, replace control units if necessary
Identify vehicle again after repair. Update measures plan
Carry out programming
Assess programming afterwards, import CBS/CKM data
Programming successfully completed
Programming sequence via Progman:
Select menu item (1).
Select corresponding procedure from selection list.

2010 BMW M3
For example:
Preparation and subsequent evaluation of vehicle programming

Start a Progman session
Sequence of BMW/MINI vehicle programming and encoding
BMW/MINI Car & Key Memory
BMW/MINI initialization
BMW/MINI service functions in Progman
...
Fig. 347: Display - Vehicle Programming And Encoding

RELAY
61 13... MAIN RELAY CONNECTOR FOR DME
Open locking clip (1) for the corresponding cable.

2010 BMW M3
Fig. 348: Opening Locking Clip

and pull out cable with contact.

61 13... RELAY CARRIER
Place special tool 61 1 153 against relay carrier (1) and carefully pull in direction of arrow until the locking tabs
(2) of the relay carrier are raised up.
2010 BMW M3

Pull relay carrier (2) in direction of arrow into the first catch (3).
Fig. 351: Pulling Relay Carrier Into First Catch

Press down arrester hook (4) of corresponding contact and pull out the cable with contact.
With special tool 61 1 136 or 61 1 137 (press out) press out dual spring contacts.
2010 BMW M3
Fig. 352: Pressing Down Arrester Hook Of Corresponding Contact




Remove cover (3).

2010 BMW M3

Release lugs in direction of arrow. Remove DC/DC converter (1) by pulling upward.

Release lugs in direction of arrow. Remove DC/DC converter (1) by pulling upward.

2010 BMW M3

M3:

2010 BMW M3
WINDSCREEN WIPERS
61 61... ADJUSTING LEFT OR RIGHT WINDSCREEN WIPER
Correctly adjusting the contact angle of the wiper arms on the windscreen increases wiping quality. For
adjustment, refer to the vehicle-specific repair instruction.
Fig. 357: Identifying Contact Angle Between Wiper Blade Centre Plane And Windscreen
A/B = Distance between windscreen wiper blade (2) and trim panel on cowl panel (1)
NOTE: Measurement is taken at the height of the locators (3) for the windscreen wiper
arms
2010 BMW M3
C= Contact angle between wiper blade center plane and windscreen
When adjusting with special tool 61 6 100 MEASURING DEVICE , set the scale value in accordance with the
following table.
For RHD vehicles, change the preceding sign of the scale values.
LHD cars, scale range 0 to -10

RHD cars, scale range 0 to +10
WINDSCREEN WIPER ADJUSTMENT REFERENCE CHART

Contact angle (C) on Scale value (LHD) on Adjustment dimension (A, B) on
windscreen wiper arm special tool windscreen wiper arm
Front Front Front
passenger Driver passenger Driver passenger Driver
Model side side side side side side Rear end
1' E81 85.5 +1.5 - 85.5 -5 -5 473 mm 543 mm
1.0 +1.5 -
1.0
E82 85.5 +1.5 - 85.5 -5 -5 473 mm 543 mm
1.0 +1.5 -
1.0
E87 85.5 +1.5 - 85.5 -5 -5 473 mm 543 mm
1.0 +1.5 -
1.0
E88 85.5 +1.5 - 85.5 -5 -5 473 mm 543 mm
1.0 +1.5 -
1.0
3' E46 85.7 1 85.3 1 -4 -5
E90 86.7 1 86.0 1 -3 -4 883 mm 95 3 mm
E91 86.7 1 86.0 1 -3 -4 883 mm 95 3 mm 353 mm
E92 86.7 1 86.0 1 -3 -4 75 3 mm 84 3
mm
E93 86.7 1 86.0 1 -3 -4 75 3 mm 84 3
mm
5' E39 86.5 1 86.5 1 -4 -4 60.11 mm
E60 86.0 1 86.0 1 -4 -4 69 3 mm 873 mm
E61 86.0 1 86.0 1 -4 -4 69 3 mm 873 mm 30 3 mm
6' E63 86.0 1 86.0 1 -4 -4 69 3 mm 873 mm
E64 86.0 1 86.0 1 -4 -4 69 3 mm 873 mm
7' E38 87.0 1 87.0 1 -3 -3 65 3 mm 58 3 mm
E65 85.5 1 87.0 1 - - 203 mm 483 mm
E66 85.5 1 87.0 1 - - 203 mm 483 mm
E67 85.5 1 87.0 1 - - 203 mm 483 mm
2010 BMW M3
8' E52 85.5 1 85.5 1 -4 -4 38 2 mm 104 2

mm
X E53 85.0 1 85.0 1 -5 -5 543 mm 55 3 mm 32.5 2
mm
E70 85.6 1 85.0 1 -4 -5 1033 mm 903 mm 39 2 mm
E71 85.6 1 85.0 1 -4 -5 1033 mm 903 mm
E83 85.2 1 85.4 1 -5 -5 66 3 mm 61 3 mm 29 1 mm
Z E85/E89 85.5 1 85.5 1 -4 -4 572 mm 52 2 mm
E86 85.5 1 85.5 1 -4 -4 572 52 2 mm
mm
61 61 010 CHECKING/ADJUSTING CONTACT ANGLE OF WINDSCREEN WIPER ARMS ON

WINDSCREEN
NOTE: Wiping quality is increased if the approach angle of the windscreen wiper arms
is precisely adjusted.
Adjusting DIMENSIONS of wiper arms:
Reference points (A, B) are the mountings of the wiper blades on the wiper arms to the sealing lip (1) of the
cowl panel. Contact angle (C) is the angle between wiper blade center plane (2) and windscreen.
Fig. 358: Adjusting Dimensions Of Wiper Arms

Remove wiper blade (1) from wiper arm (2).
Pin (3) is locator for special tool 61 6 100 MEASURING DEVICE .

2010 BMW M3
Fig. 359: Identifying Wiper Blade And Wiper Arm

Slide special tool 61 6 100 MEASURING DEVICE onto pin (1).
Place special tool 61 6 100 MEASURING DEVICE on windscreen (2) and read off value in degrees on scale.
NOTE: LHD vehicles are covered by the scale range of 0 to -10 and RHD vehicles by the
scale range of 0 to +10.
Fig. 360: Sliding Special Tool (61 6 100) Onto Pin

If the specified number in degrees is not correct, the wiper arm (1) must be bent with the special tool 61 6 110
TOOL at the point shown.
2010 BMW M3
Fig. 361: Bending Wiper Arm Using Special Tool (61 6 110)
61 61... OVERVIEW OF WINDSCREEN WIPER AND WASHER SYSTEM

2010 BMW M3
Fig. 362: Overview Of Windscreen Wiper And Washer System

61 61 100 REMOVING AND INSTALLING/REPLACING BOTH WINDSCREEN WIPER ARMS
Take off cap.

2010 BMW M3
Fig. 363: Taking Off Cap

Unfasten nut. Tightening torque 61 61 11AZ .
Fig. 364: Locating Windscreen Wiper Arm Nut


Do not bend windscreen wiper arm when removing.
Detach windshield wiper arm with special tool 616210.

2010 BMW M3
Fig. 365: Detaching Windshield Wiper Arm Using Special (Tool 61 6 210)
Installation:
Windscreen wiper motor must be in its rest position.
Observe ADJUSTMENT DIMENSIONS .
Adjust position of relevant windscreen wiper arm (measured between windscreen wiper blade and trim panel on
cowl panel at height of windscreen wiper arm locator).
Tighten down windscreen wiper arm and check ADJUSTMENT DIMENSIONS of respective windscreen
wiper arm again.
Check and if necessary adjust CONTACT ANGLE .
61 61 270 REMOVING AND INSTALLING/REPLACING BRACKET FOR WINDSCREEN WIPER

SYSTEM COMPLETE WITH MOTOR
Remove BOTH WIPER ARMS

Remove lower section of microfilter housing.
Remove both tension struts from spring strut dome
Release screws (2) from left heater bulkhead (3).
Remove left heater bulkhead (3) towards top.
Unclip cable (1) for wiper motor from holder.

2010 BMW M3
Release screws (5) for wiper bracket (4).
Tightening torque, 61 61 6AZ .
Remove wiper bracket (4) upwards.
Disconnect plug for wiper motor.
Fig. 366: Identifying Screws And Left Heater Bulkhead

Installation:
Rubber mount (1) and rubber guide (3) must not be missing.
Rubber guide (3) must be correctly seated in guide (2).
Fig. 367: Identifying Rubber Mount And Rubber Guide

2010 BMW M3
Installation:
Before fitting the wiper arms, allow the windscreen wiper motor to run into the rest position.
To ensure that the windscreen wiper system functions properly, CHECK/ADJUST the contact angle of the
wiper arms to the windscreen.
61 61 041 REPLACING BOTH WINDSCREEN WIPER BLADES
IMPORTANT: Make sure the wiper arm does not contact the windscreen without its wiper
blade.
Fold wiper arm (3) away from windscreen.
Press lock (1) and remove cover cap (2) in direction of arrow.
Installation:
Make sure cover cap (2) is correctly seated.
Fig. 368: Removing Cover Cap

Turn windscreen wiper blade (1) at an angle of 90 and remove from windscreen wiper arm (2).
2010 BMW M3
Fig. 369: Turning Windscreen Wiper Blade At An Angle Of 90

Installation:
Catches (1) and guide (2) of window cavity cover cap (6) must not be damaged or missing.
Fig. 370: Identifying Window Cavity Cover Cap Catches And Guide
HEADLIGHT WASHER SYSTEM

2010 BMW M3

61 67 083 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT HIGH-PRESSURE

NOZZLE OF HEADLIGHT WASHER SYSTEM
Remove COVER FROM SPRAY NOZZLE

Remove front wheel arch cover
To prevent excessive escape of washer fluid, seal off end of high-pressure line with special tool 13 3 010
2010 BMW M3
TERMINAL .
Catch any escaping washer fluid if necessary.
Fig. 372: Sealing High Pressure Line End With Special Tool (13 3 010)
NOTE: Bumper trim shown removed for purposes of clarity.
Unlock catch (1) in direction of arrow.
Feed high-pressure nozzle (2) towards rear out of headlight arm (3).
Unlock plug connection on high-pressure nozzle (2) and detach high-pressure line from high-pressure nozzle
(2).
2010 BMW M3
Installation:
Keep plug connection for high-pressure nozzle and high-pressure line clean and free from grease.
Ensure guide (2) is correctly seated.
Retaining lugs (1) must snap audibly into place.
Fig. 374: Identifying Guide And Retaining Lugs

Check function.
If necessary, adjustment can be carried out carefully using pointed pliers (tape of front area with adhesive tape
where necessary).
If necessary, top up washer fluid.
61 67 083 REMOVING AND INSTALLING/REPLACING HIGH-PRESSURE NOZZLE OF

HEADLIGHT WASHER SYSTEM ON LEFT OR RIGHT (M3)
Remove FRONT BUMPER TRIM .
To prevent excessive escape of washer fluid, seal off end of high-pressure line with special tool 13 3 010
TERMINAL .

2010 BMW M3

Unlock catches (1) and remove high-pressure nozzle (2) towards rear from headlight arm (3).
Raise retaining clip (4) in direction of arrow and detach high-pressure line (5) from high-pressure nozzle (2).
Fig. 376: Raising High Pressure Line Retaining Clip

Installation:
Keep plug connection for high-pressure nozzle (2) and high-pressure line (5) clean and free from grease.
Make high-pressure line (5) and high-pressure nozzle (2) are correctly seated and engaged on high-pressure
nozzle (2) and headlight arm (3) respectively.
2010 BMW M3
Carry out a function test before fitting bumper trim.
61 67 010 REMOVING AND INSTALLING/REPLACING WASHER PUMP OF HEADLIGHT

WASHER SYSTEM
NOTE: Catch any escaping washer fluid if necessary.
Unlock split pin (3) and detach hose (2) from washer pump of headlight washer system (4).
Fig. 377: Turning Washer Pump Of Headlight Washer System

Turn washer pump of headlight washer system (4) and pull in direction of arrow out of fluid reservoir for
windscreen washer unit (5).
Installation:
Replace strainer for washer pump of headlight washer system.

Coat sealing ring of washer pump for headlight cleaning system with antiseize agent.
Lay hose of washer pump for headlight cleaning system without kinks
Fill fluid reservoir
WINDOW WASHER SYSTEM

2010 BMW M3

61 71 015 REMOVING AND INSTALLING/REPLACING A SPRAY NOZZLE IN WINDSCREEN

WASHER SYSTEM
NOTE: The jet nozzles of the windscreen washer system are preset at the factory and
cannot be readjusted.

2010 BMW M3
Press detent lug (1).
Detach unlocked plug housing (2) in direction of arrow.
Detach hose (3) from spray nozzle.
Fig. 379: Detaching Plug Housing

Release spray nozzle (1) in direction of arrow from cowl panel cover and remove.
Installation:
Make sure spray nozzle (1) is correctly seated.
Fig. 380: Removing Spray Nozzle From Cowl Panel Cover

2010 BMW M3
Installation:
Following parts of spray nozzle (4) must not be damaged or missing:
1 Plug connection
2 Hose connection
3 Detent lug, bottom
5 Detent lug, top
Fig. 381: Identifying Spray Nozzle, Detent Lugs With Plug And Hose Connections
61 71 100 REMOVING AND INSTALLING/REPLACING WINDSCREEN WASHER PUMP
Detach hose from windscreen washer pump (1).
Turn windscreen washer pump (1) and pull in direction of arrow out of fluid reservoir for windscreen washer
unit.
2010 BMW M3
Fig. 382: Turning Windscreen Washer Pump

Installation:
Replace strainer for windscreen washer pump

Coat sealing ring of windscreen washer pump with antiseize agent
Lay hose of windscreen washer pump without kinks
61 71 061 REPLACING WASHER FLUID RESERVOIR FOR WINDSCREEN WASHER SYSTEM
Remove front right side repeater light

Partially remove front right wheel arch cover
Clip cable (1) out of mounting.
Clip hose (5) out of mounting.
Unlock filler hose (2) and detach from fitting on fluid reservoir (3).
Unscrew bolts (4) and (6).
Pull fluid reservoir (3) forwards slightly.

2010 BMW M3
Fig. 383: Pulling Fluid Reservoir Forward

Installation note:
Retaining lug (2) of fluid reservoir (1) must be correctly seated in clip (3).
Fig. 384: Identifying Retaining Lug Of Fluid Reservoir And Clip

Unlock and disconnect all plug connections.
Remove level switch (1) .
Remove WINDSCREEN WASHER PUMP (3) .
If necessary, remove washer pump for rear window washer system (2).
If necessary, remove WASHER PUMP FOR HEADLIGHT WASHER SYSTEM (4) .

2010 BMW M3
Remove washer reservoir.
Fig. 385: Identifying Window Washer System And Windscreen Washer Pump
Installation note:
Replace strainers on washer pumps

Coat sealing rings of washer pumps with lubricant
Lay lines of washer pumps without kinks and clip into holders on fluid tank
Fill fluid tank for windscreen washer system
2010 BMW M3
ACCESSORIES AND BODY, CAB General Electrical System - Repair Instructions - M3
General Electrical System - Repair Instructions - M3
TROUBLESHOOTING
61 00 ... BATTERY
up vehicles every 6 weeks at the latest.
Battery test
test results.
61 00 ... DIAGNOSIS FOR CONDITION BASED SERVICE
NOTE: Red symbol for pre-delivery check
The vehicle is coded at the end of the assembly line so that the red symbol for the pre-delivery check is shown
in the Next Service display (same symbol as vehicle check).
The symbol is a reminder to the Service staff that the predelivery check has not yet been carried out on this car.
NOTE: Do not carry out a reset.
Do not confuse this function with the "Vehicle check" maintenance scope.
Do not carry out a reset via the instrument cluster.
When carrying out the pre-delivery check with the "Transport Mode/Pre-delivery check" service function:
The symbol is automatically removed from the display after the service function has been executed.
2010 BMW M3
Fig. 1: Service Display - Under Body Nut/Bolt Check

Fig. 2: Screen Display - Pre-Delivery Check Service Function

KEY SPECIFICATION CHART

Key Explanation Key Explanation
1 Function and component selection 2 Service functions
3 Maintenance 4 Transport Mode/Pre-delivery check
2010 BMW M3
5 CBS Correction Tester Data 6 Reset CBS Condition Based Service

7 CBS Correction Vehicle Data
4 service functions are available in the BMW diagnosis system for maintenance:
Transport Mode/Pre-delivery check

CBS Correction Tester Data
Reset CBS
CBS Correction Vehicle Data
Service function: Transport Mode/Pre-delivery check
To be able to hand over a vehicle to the customer in proper working order, it is essential to execute the
"Transport Mode/Pre-delivery check" service function.
The following items are worked through during the pre-delivery check:
Deactivation of transport mode.

An adaptation process must be activated in order to determine the vehicle-specific mileage/kilometrage
per week. Transport and immobilization periods before the vehicle is delivered to the customer therefore
have no effect on the customer-specific weekly mileage/kilometrage.
The weekly mileage/kilometrage is used to control escalation from "green" to "yellow" (approx. 4 weeks
before "red") for maintenance scopes with remaining distances. The averaged mileage/kilometrage of the
last 6 weeks is taken into account here.
Coding or blanking out of the legally prescribed intervals for the statutory vehicle inspection and
statutory exhaust emissions test.
Input of the target dates for the statutory vehicle inspection and the statutory exhaust emissions test
(automatic or manual).
Automatic: By input of the date of first registration and of the time interval
Manual: By direct input of the target date
Entry of local, service-related phone numbers, depending on vehicle equipment specification (e.g. BMW
Group Mobile Service, BMW Hotline, customer's home dealer).
The country-specific phone numbers are displayed in the BMW diagnosis system as a reference text. The
phone numbers can simply be read off during the input prompt.
Reference to initialization of TeleService, depending on vehicle equipment specification.

Checking and if necessary setting of the on-board date for the vehicle.
Entry of the date for first registration of the vehicle.
2010 BMW M3
NOTE: Reducing input expenditure.
Standardized data are stored in the BMW diagnosis system (for repeated use) in the interests of minimizing the
time spent on making inputs in the garage/workshop. The standardized data can be changed with the "CBS
Correction Tester Data" service function.
Service function: CBS Correction Tester Data
Data are automatically stored in the vehicle with the "Pre-delivery check" service function.
The standardized data can be changed with the "CBS Correction Tester Data" service function.
The following standardized data can be changed:
Phone numbers:
BMW Group Mobile Service
BMW Hotline
Customer's home dealer
The country-specific phone numbers are contained as reference texts in the BMW diagnosis system (read
off during the input prompt). The phone numbers must be input with the international dialling code.
Legally prescribed vehicle inspection (country-specific):

Coding or blanking out
The target date is calculated on the basis of the date of first registration.
Legally prescribed exhaust emissions test (country-specific):

Coding or blanking out
The target date is calculated on the basis of the date of first registration.
NOTE: Automatic function after installation of the BMW diagnosis system.
The standardized data are automatically established when the pre-delivery check is carried out for the first time.
It is therefore not necessary to input the data separately.
Service function: Reset CBS Condition Based Service
A maintenance scope can be reset with the "Reset CBS Condition Based Service" service function. Even when
2010 BMW M3
availability is over 80 %.
The benefit of reset via the BMW diagnosis system is that the on-board date is corrected automatically.
The individual maintenance scopes are displayed in the BMW diagnosis system with service counter and
availability.
The service counter is reset by one counter on resetting. All service counters are set to "1" on new
vehicles.
The service counters are used in the Service Acceptance/Reception Module (SAM) on a scope-specific
basis for controlling additional work.
Availability is set to 100 % on resetting. Availability in % is the wear value of the maintenance scope.
The greater the availability, the longer it is to the next maintenance scope.
0 % means that the maintenance measure must be carried out.
Service function: CBS Correction Vehicle Data
IMPORTANT: The data are overwritten.
Once this service function has been executed, it is no longer possible to reconstruct the previous status.
The "CBS Correction Vehicle Data" service function is available if a reset has been carried out erroneously. In
this way, the availability of a maintenance scope can be corrected to a realistic value.
A data or a mileage/kilometer reading is entered for correction. These data are converted internally into an
availability in %. In so doing, the BMW diagnosis system only accepts a smaller value as the current reading in
the control unit. In addition, the service counter of the scope is automatically reduced by one counter.
The inputs are used in the Service Booklet to determine the realistic availability. A realistic availability can be
reconstructed on a scope-specific basis by means of the last maintenance measure (with mileage/km reading and
date).
This does not include correcting the availability for brake pads. The brake pad residual thickness must be
measured and input (in millimeters).
NOTE: Reference for distance- and time-dependent maintenance scopes
For a correction, the availability is referred to the distance- and time-dependent calculation.
61 00 ... NOTES ON HANDLING OPTICAL FIBERS
CAUTION: To avoid damage when handling optical fibers, comply with the following
2010 BMW M3
points:

Do not subject optical fibers to compressive and tensile load
Protect optical fibers against the effects of heat > or = 85C (e.g.
during welding work, drying work with infrared heater or hot air
blower)
Optical fibers are permitted to show only one junction point (bridge),
replace optical fibers if necessary
NOTE: The optical fibers are colored differently as follows:
Green=MOST (M edia O riented S ystems T ransport) optical fibers

Yellow=ISIS (I ntelligent S afety and I ntegration S ystem) optical fibers
Orange=repair optical fibers
Follow instructions for processing cables and optical fibers.
61 00 ... NOTES ON HANDLING WIRING HARNESSES AND CABLES
In general:

Ensure non-contacting routing at sharp-edged body parts; use muckets if necessary
Secure additionally laid cables/leads with cable ties
In addition:
Shielded cables (coaxial cables):
IMPORTANT: Shielded cables must not be repaired!
This may lead to indifferences in noise radiation and interference immunity at contact points in the shield
To satisfy the requirements of the type approval, it is essential to replace shielded cables completely
Fibre-optic cables:
NOTE: Fibre-optic cables are colored differently as follows:
Green = MOST (M edia O riented S ystems T ransport) fibreoptic cables

2010 BMW M3
Yellow = ISIS (I ntegrated S ervice I nformation S erver) fibreoptic cables

IMPORTANT: Fibre-optic cables are permitted to show only one junction point (bridge),
Avoid effects of heat > or = 85
Treating cables and fibre-optic cables
FlexRay:
It is possible to repair the FlexRay. In the event of damage, the cables can be joined with conventional butt
connectors.
NOTE: The cable is a twisted cable. If possible, maintain twisted cable after repair.
61 00 ... REPAIRING AIRBAG CABLES
Safety regulations
Safety regulations for handling components of airbag system. See 72 00 ... SAFETY REGULATIONS FOR
HANDLING COMPONENTS WITH GAS GENERATORS .
Instructions for disconnecting and connecting battery.
In event of non-visible damage to wiring harness:
Disconnect plug connection on airbag module or on adapter plug. It is absolutely vital to disconnect the contacts
in succession as there is a risk of them being mixed up! Cut through one cable after the other at an appropriate
position, do not under any circumstances cut through both cables at the same time. Insulate cables remaining in
wiring harness with insulating tape. Now disconnect plug connection on airbag control unit. Unpin contacts. Cut
through one cable after the other at an appropriate position and insulate with insulating tape, do not under any
circumstances cut through both cables at the same time. Pin contacts of repair cable for airbag control unit in
control unit plug, assignment of repair cables is relevant. Lay repair cable in car parallel to existing airbag lead.
Now pin in contacts for airbag control unit or contacts of adapter plug, assignment of repair cables is relevant.
2010 BMW M3
Cut off excess length of repair cable in proximity (visible area) of airbag module or of adapter plug. Twist open
cables. With the connectors and shrink-fit hoses in the Electronic Parts Catalogue (EPC), reconnect the cables
with the same cable colors. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface
(shrink-fit hoses) with insulating tape to prevent cables from twisting open.
61 00 ... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY
Battery acid is highly corrosive:
In event of contact with acid:
of water.
Explosion hazard:
2010 BMW M3
WIRING HARNESS
61 00 ... NOTES ON HANDLING WIRING HARNESSES AND CABLES
In general:

Ensure non-contacting routing at sharp-edged body parts; use muckets if necessary
Secure additionally laid cables/leads with cable ties
In addition:
Shielded cables (coaxial cables):
IMPORTANT: Shielded cables must not be repaired!
This may lead to indifferences in noise radiation and interference immunity at contact points in the shield
To satisfy the requirements of the type approval, it is essential to replace shielded cables completely
Fibre-optic cables:
NOTE: Fibre-optic cables are colored differently as follows:
Green = MOST (M edia O riented S ystems T ransport) fibreoptic cables

Yellow = ISIS (I ntegrated S ervice I nformation S erver) fibreoptic cables
IMPORTANT: Fibre-optic cables are permitted to show only one junction point (bridge),
Avoid effects of heat > or = 85
Treating cables and fibre-optic cables
FlexRay:
It is possible to repair the FlexRay. In the event of damage, the cables can be joined with conventional butt
connectors.
NOTE:
2010 BMW M3
The cable is a twisted cable. If possible, maintain twisted cable after repair.
AUXILIARY CABLE
61 12 ... GENERAL INFORMATION ON INTELLIGENT BATTERY SENSOR (IBS)
NOTE: Do not connect continuous trickle charger to the cigarette lighter.
The cigarette lighter is powered by the rear distribution box via a relay. This relay drops out after terminal 15
OFF. This means that a continuous trickle charger connected to the cigarette lighter is disconnected from the
battery.
Charge the battery via the jump-start connection points. Only then can the power supply be registered by the
vehicle.

Do not modify the grounding cable.
The grounding cable also serves to dissipate heat.

2010 BMW M3
fault-free.
For this reason, only replace the IBS when a corresponding fault is entered in the DME or DDE.

COMPARTMENT CONNECTOR) (COUPE/CONVERTIBLE)
WARNING: Observe safety instructions for handling vehicle battery.
Remove battery
Release screws (1). Remove battery holder (2) from body.
Fig. 3: Removing Battery Holder From Body

Unclip cap (1) and release nut underneath. Tightening torque, see 61 12 1AZ in 61 12 AUXILIARY CABLE .
Release cable ties (2) and disconnect battery positive lead (3).
2010 BMW M3
Fig. 4: Unclip Cap And Release Nut Underneath

During installation, make sure battery positive lead (3) is correctly

screwed and seated on luggage compartment connector.

COMPARTMENT CONNECTOR) (SEDAN)
Remove right luggage compartment trim panel . See 51 47 171 REMOVING AND
INSTALLING/REPLACING FLAP IN LUGGAGE COMPARTMENT TRIM ON RIGHT .
Remove distribution box
Remove battery
Open cap (1) and release nut underneath.
Remove cable lug mounting from positive battery lead (2).
When installing, ensure:

2010 BMW M3
Correct screw connection

Correct seating of cable lug mounting on positive battery lead (2)
Tightening torque, see 61 12 1AZ in 61 12 AUXILIARY CABLE .
Replacement with build date up to 03/2006:
Connect repair cable for battery terminal (1) to safety battery terminal (2).
Install battery.
Install distribution box
Fig. 5: Identifying Cap And Positive Battery Lead
Fig. 6: Identifying Cable For Battery Terminal And Safety Battery Terminal
Cut off plug connection (1) and connect to battery terminal repair cable (2).
2010 BMW M3
Follow notes for repairing airbag leads. See 61 00 ... REPAIRING AIRBAG CABLES .
Secure battery terminal repair cable (2).
Fig. 7: Identifying Plug Connection And Terminal Repair Cable
61 12 004 REPLACING BATTERY POSITIVE LEAD (FROM LUGGAGE COMPARTMENT

CONNECTOR TO ENGINE BULKHEAD CONNECTOR)
IMPORTANT: Read and comply with notes on handling wiring harnesses and cables.
Remove battery
Remove fuel tank . See 16 11 030 REMOVING AND INSTALLING OR REPLACING FUEL
TANK (PETROL/GASOLINE) .
Partially remove front right wheel arch trim . See 51 71 039 REMOVING AND
INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH COVER (REAR
SECTION) .
Remove cover from electronics box . See 12 90 ... REMOVING AND INSTALLING/REPLACING
ELECTRONICS BOX .
Work is shown on the E82 N52N by way of example. There may be differences in detail in the case of other
vehicle models.
Unclip covers (1) and release nuts underneath. Tightening torque, see 61 12 1AZ in 61 12 AUXILIARY
CABLE .
Disconnect battery positive leads (2).

2010 BMW M3
Fig. 8: Identifying Covers And Battery Positive Leads

Turn clamping rings (1) in direction of arrow and remove.
Installation:
Make sure clamping rings (1) are correctly seated.
Fig. 9: Turning Clamping Rings

Remove battery positive lead (1) from luggage compartment floor (2).
2010 BMW M3
Fig. 10: Identifying Battery Positive Lead And Luggage Compartment Floor
Release bolt (1) and nut (2).
Remove cover (3).
Fig. 11: Identifying Bolt, Nut And Cover

Release holder (1) from body.
Feed out battery positive leads (2) and vent line (4) from holder (1).
Release retaining clips (3) and remove vent line (4) from cover (5).
Release all nuts and remove cover (5).

2010 BMW M3
Fig. 12: Identifying Battery Positive Leads, Vent Line, Holder And Cover
Release attachment points for battery positive lead (1) from body.
Fig. 13: Identifying Battery Positive Lead Attachment Points

NOTE: Electronics box shown removed for purposes of clarity.
Unclip cover cap (1).
Release nuts underneath.
Tightening torque, see 61 12 1AZ in 61 12 AUXILIARY CABLE .
Remove positive battery cable.

2010 BMW M3

Release wiring harness holder (1).
Feed out battery positive lead in direction of arrow.
Fig. 15: Identifying Wiring Harness Holder

61 12 013 REPLACING BATTERY NEGATIVE LEAD

Notes and instructions on Intelligent Battery Sensor IBS.
Remove battery cover . See 51 47 ... REMOVING AND INSTALLING/REPLACING BATTERY

COVER .
2010 BMW M3
Slacken nut (2) on battery negative terminal.
Tightening torque, see 61 21 1AZ in 61 21 BATTERY WITH TERMINAL .
IMPORTANT: Do not under any circumstances use force to pull off pole shoe.
Fig. 16: Identifying Plug Connection, Battery Negative Lead And Nuts
Detach battery negative lead (3) with intelligent battery sensor (IBS) in upward direction.
Release nut (4) and remove cable.
61 12 200 REPLACING WIRING HARNESS IN LEFT OR RIGHT FRONT DOOR

(COUPE/CONVERTIBLE)

Remove sound insulation from front door . See 51 48 060 REMOVING AND
INSTALLING/REPLACING SOUND INSULATION IN LEFT OR RIGHT FRONT DOOR .
Remove rearview mirror trim . See 51 16 ... REMOVING AND INSTALLING/REPLACING
TRIM ON LEFT OR RIGHT DOOR MIRROR .
NOTE: Work is shown on the E92 by way of example. There may be differences in
Unlock plug connection for outside door handle light (1).

2010 BMW M3
Disconnect plug connection for Comfort Access System (2).
Disconnect plug connection for door lock (3).
Disconnect plug connection for power window unit (4).
Disconnect plug connection for rearview mirror (5).
Unclip all wiring harness fasteners (6).
Installation:

Release screw (1).
Guide plug connection for door wiring harness (2) in direction of arrow out of A-pillar and disconnect.
Pull rubber grommet (3) out of front door
Feed out door wiring harness towards front to A-pillar.

2010 BMW M3
Fig. 18: Guide Plug Connection For Door Wiring Harness (2) In Direction Of Arrow Out Of A-Pillar
61 12 200 REPLACING WIRING HARNESS IN LEFT OR RIGHT FRONT DOOR (SEDAN)

Remove front door trim panel . See 51 41 001 REPLACING FRONT LEFT OR RIGHT DOOR
TRIM PANEL .
Remove front acoustic insulation.
Disconnect plug connection (5) on door mirror.
Installation:

2010 BMW M3

Release screw (1), fold door wiring harness plug on A-pillar (2) downwards slightly and remove.
Pull rubber grommet (3) out of front door.
Feed out door wiring harness towards front to A-pillar and remove.

61 12 210 REPLACING WIRING HARNESS IN LEFT OR RIGHT REAR DOOR
Close rear side window completely

2010 BMW M3
Remove rear door trim panel . See 51 42 000 REMOVING AND INSTALLING LEFT OR RIGHT
REAR DOOR TRIM PANEL .
Remove rear acoustic insulation . See 51 48 070 REMOVING AND INSTALLING/REPLACING
SOUND INSULATION ON LEFT OR RIGHT REAR DOOR .
Installation:

Release screw (1), fold door wiring harness plug on B-pillar (2) downwards slightly and remove.
Pull rubber grommet (3) out of rear door.
Feed out door wiring harness towards front to B-pillar and remove.
2010 BMW M3

PLUG CONNECTION, TERMINALS

61 13 ... DME MASTER RELAY CONNECTOR
Unlock locking flap (1) of corresponding cable.
Fig. 23: Unlocking Locking Flap Of Corresponding Cable

With special tool 61 1 136 or 61 1 137 (ejector), press back arrester hook (2) of appropriate contact and pull out
cable.
2010 BMW M3
Fig. 24: Pressing Back Arrester Hook

61 13 ... BASE OF TAB CONNECTOR HOUSINGS
Unlock hook (1) with special tool 61 1 360 and slide plug housing downwards out of base.
Fig. 25: Sliding Plug Housing

61 13 ... BUTT CONNECTOR FOR REPAIRING A PLUG CONNECTION
61 0 300
61 9 040
NOTE: See GENERAL ELECTRICAL SYSTEM - SPECIAL TOOLS .
IMPORTANT: 1. Identify cause of damage (e.g. sharp-edged body parts, faulty electrical
2010 BMW M3
loads, jammed mechanisms, corrosion caused by ingress of water, etc.).

2. Read out fault memory
3. Eliminate cause of damage.
4. Disconnect battery negative terminal
5. Make sure that no safety-related system according to connection scheme
(e.g. anti-lock braking system, active rear-axle kinematics, airbags, etc.)
are influenced.
Otherwise replace faulty wiring harness or use repair cable (sourcing

reference: BMW Parts Service)
6. Carry out function test and read out fault memories again
7. Eliminate new faults if applicable and clear fault memories
connectors.
The case can no longer be ordered. Order individual parts for wiring harness repair through BMW Parts
Service.

special tool 61 9 040
Choose repair kit.
Example: Repair kit, circular plug system D 2.5.

2010 BMW M3
Fig. 27: Identifying Circular Plug System D 2.5

Remove following parts:
1. Prepackaged end of cable with requisite wire cross-section

2. Crimp connector for selected wire cross-section
3. Shrink-fit hose
Fig. 28: Identifying Wire, Shrink-Fit Hose And Crimp Connector

Open secondary lock on housing.
Mark damaged contact (4) with socket number of housing and press it out of housing using relevant special tool
contained in special tool kit 61 0 300 .
2010 BMW M3
Fig. 29: Identifying Mark Damaged Contact With Socket Number

IMPORTANT: Check maximum length of repair cable

If more than one wire is to be repaired, the individual interfaces must be
offset so that the wiring harness is not too thick at the repaired point.
Fig. 30: Identifying Special Tool

Observe following procedure:
Cut off wire with faulty contact at point which is easily accessible
Strip insulation from end of wire at wiring harness end
Cut preassembled wire end to length and strip insulation
2010 BMW M3
Fig. 31: Identifying Crimp Butt Connector On Preassembled Wire End

Push shrink-fit hose (8) onto free wire end.
Fig. 32: Identifying Shrink-Fit Hose Onto Free Wire End

Crimp unused wire end to butt connector.

2010 BMW M3
Pull shrink-on sleeve over butt connector.
Fig. 34: Pulling Shrink-On Sleeve

With hot air blower, shrink the shrink-on sleeve on both sides (9) of shrink-fit hose until glue emerges
uniformly all round.
Insert contact in housing.
Close secondary lock on housing.
Fig. 35: Identifying Secondary Lock On Housing

61 13 ... CRIMPING MICRO POWER QUADLOCK CONTACTS (MPQ)

2010 BMW M3
61 4 320
set 61 4 320 .
together.
Fig. 36: Identifying Pliers And Crimping Head

Open pliers (1).
NOTE: Place contact (2) with utmost care in designated nest (observe cable cross-
section) in crimping head (3). Make sure it is exactly positioned.
Place MPQ contact (2) in crimping head (3).

2010 BMW M3
Fig. 37: Identifying MPQ Contact And Crimping Head

NOTE: Follow procedure for cutting and stripping insulation from cables.
Open pliers (1) and remove cable (2).
NOTE: Check contact for correct crimping.
Fig. 38: Identifying Stripped Cable, Cable And Pliers

61 13 ... CRIMPING MICRO QUADLOCK SYSTEM CONTACTS (MQS)

2010 BMW M3
61 4 320
To crimp MQS contacts, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 324 (2) from crimping
set 61 4 320 .
together.
Fig. 39: Identifying Pliers And Crimping Head

Open pliers (1).
Fold up contact carrier (2).
Insert MQS contact (3) in contact carrier (2).
Fold back contact carrier (2).

2010 BMW M3
Fig. 40: Identifying MQS Contact, Contact Carrier And Pliers

Fig. 41: Identifying Stripped Cable And Pliers

Open pliers (1).
Open contact carrier (2) gently and carefully remove MQS contact.
NOTE: Check contact for correct crimping.

2010 BMW M3
Fig. 42: Checking Contact For Correct Crimping

61 13 ... CRIMPING ANNULAR CONTACTS
61 4 320
Crimping annular contacts:
61 13 ... CRIMPING OPTICAL FIBRES
61 4 320
To crimp optical fibres, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 323 (2) from crimping
set 61 4 320 .
together.
2010 BMW M3
Fig. 43: Identifying Crimping Head And Pliers

Move contact guide by means of stop lever (1) into corresponding position (pin contact or jack).
Fig. 44: Identifying Stop Lever

Open pliers (2).
Place pin contact or jack (1) in crimping head and secure with locking lever (3).
2010 BMW M3
Fig. 45: Identifying Jack And Locking Lever

NOTE: Follow procedure for cutting and stripping insulation from optical fibres.
Insert stripped optical fibre (1) as far as it will go into pin contact or jack (2).
Open pliers (3) and locking lever (4).
Fig. 46: Identifying Pliers, Locking Lever And Stripped Optical Fibre
IMPORTANT: Make sure optical fibre is correctly seated in jack.
Right (A)
2010 BMW M3
End of optical fibre (1) must be flush with tip of pin contact (2).
Wrong (B)
End of optical fibre (1) is not flush with tip of pin contact (2).
Fig. 47: Identifying Optical Fibre And Pin Contact

61 13 ... CRIMPING STOP PARTS
12 1 080
12 1 081
12 1 083
NOTE: See ENGINE ELECTRICAL SYSTEM - SPECIAL TOOLS .
Spare parts for in-car electronics (housing and contacts):
1. Crimping butt connectors and contact sleeves for fan connectors up to 2.5 mm2
2. Crimping butt connectors and contact sleeves for fan connectors from 2.5 mm2
3. Crimping contact sleeves for fan connectors 4 mm2 and ignition cable contacts
Special tool kit 12 1 080 is used to fit ignition cable contacts and to crimp 4 mm2 contact sleeves for fan
connectors.
12 1 081 (hand crimping tool)

12 1 083 (matrix)
2010 BMW M3
Fig. 48: Identifying Hand Crimping Tool And Matrix

Or:
Fig. 49: Identifying Squeeze Grips And Unlocking Lever

Insert contact sleeve 4 mm2 in nest with lock (1) as far as it will go.
2010 BMW M3
Fig. 50: Inserting Contact Sleeve With Lock

Preload contact by squeezing matrix in crimping tool. Grip contact (1) firmly only, do not crimp.
Fig. 51: Identifying Grip Contact

Insert stripped end of wire (7) in the contact. Ensure insulation and stripped wire end are correctly laid in
contact.
Compress crimping tool as far as it will go.
Crimping tool unlocks automatically.
Take contact out of crimping tool.

2010 BMW M3
Fig. 52: Inserting Stripped End Of Wire

4. Checking crimping
Check insulation crimp (8) and wire crimp (9) against following illustrations to ensure crimps are
correctly located.
NOTE: Illustration shows butt connectors and contact sleeves for fan connectors
knocked on one side. The crimping procedure is identical here.
Fig. 53: Identifying Insulation Crimp And Wire Crimp

Correct crimping:
Visible conductor end (10).
Visible insulation end (11).

2010 BMW M3
Fig. 54: Identifying Visible Insulation End And Visible Conductor End (Correct Crimping)
Incorrect crimping:
Conductor end (10) inserted too far.
Insulation end (11) in wire crimp.
Fig. 55: Identifying Visible Insulation End And Visible Conductor End (Incorrect Crimping)
Incorrect crimping:
Conductor end (10) not visible.
Insulation end (11) not visible.

2010 BMW M3
Fig. 56: Identifying Conductor End And Insulation End (Not Visible)
61 13 ... CUTTING OFF, STRIPPING INSULATION AND CUTTING OPTICAL FIBRES TO

LENGTH
61 4 320
To cut off, strip insulation and cut optical fibres to length, use pliers 61 4 321 (1) in conjunction with crimping
head 61 4 322 (2) from crimping set 61 4 320 .
together.
Fig. 57: Identifying Crimping Head And Pliers

2010 BMW M3
Cutting optical fibre
Open pliers (1).
Place optical fibre (2) in cutting device (3).
Close pliers (1) and remove optical fibre (2).
Fig. 58: Identifying Cutting Device And Optical Fibre

Stripping insulation from optical fibre
Open pliers (1).
Open lever (2) in direction of arrow.
Fig. 59: Identifying Open Pliers And Open Lever

2010 BMW M3
Slide optical fibre (1) into stripping device (2) until flush at point (3).
Close clamping lever (5) in direction of arrow.
Open pliers (4) by one tooth notch.
Open clamping lever (5) against direction of arrow again and remove optical fibre (1).
NOTE: A stripping replacement blade set is available under number 61 4 327.
Fig. 60: Identifying Clamping Lever And Pliers

Cutting optical fibre to length
IMPORTANT: The cutting blade must be replaced prior to each cutting of the optical fibre.
Pull pin (1) in direction of arrow.
Fold up blade retaining link (2) in direction of arrow.

2010 BMW M3
Fig. 61: Pulling Pin

WARNING: Risk of injury when changing the blade.
Remove blade (1) and replace.
Installation:
Make sure blade (1) is correctly seated on locating points (2).
Fig. 62: Identifying Blade And Locating Points

Open pliers (3).
Slide optical fibre (1) into cutting device (2) until insulation of optical fibre (1) butts against clamping device.
2010 BMW M3
Close pliers (3) fully and keep closed.
Fig. 63: Identifying Optical Fibre And Cutting Device

61 13 ... CUTTING TO LENGTH AND STRIPPING INSULATION FROM CABLES
Stripped length:
STRIPPED LENGTH SPECIFICATION CHART

Wire cross-section (mm2 ) Stripped length (mm)
0.35 ... 0.50 4.0
0.75 ... 1.00 4.5
1.00 ... 2.50 5.0
61 13 ... IN-LINE PLUGS, 24-PIN, HYBRID SYSTEM MQS/MPQ

Socket housing:

2010 BMW M3
NOTE: Detaching the cap releases the secondary locks of the socket contacts.
Fig. 64: Pressing Locks On Cap Upwards

Fig. 65: Holding Retaining Hook Of Socket

2010 BMW M3
Fig. 66: Pulling Cable With Socket Contact

Pin housing:
Detach cap from housing carrier (3).
contact carriers.
Fig. 67: Pressing Locks On Cap Upwards

Pull contact carrier (1) out of housing carrier (2).
2010 BMW M3
Fig. 68: Pulling Contact Carrier Out Of Housing Carrier

61 13 ... IN-LINE PLUGS, 30-PIN, HYBRID SYSTEM MQS/MPQ

Socket housing:
contacts.
Fig. 69: Raising Lock On Housing

2010 BMW M3


Pin housing:
Contacts 1 ... 13 and 19 ... 27:

2010 BMW M3
NOTE: Detaching the locking slide releases the secondary locks of the pin contacts.
Fig. 72: Raising Locking Slide

Contacts 14 ... 18 and 28 ... 30:
Pull slide (1) outwards completely.
Pull contact carrier (3) out of housing.

61 13 ... IN-LINE PLUGS, 6- TO 50-PIN

2010 BMW M3
Unlock lock.
Fig. 74: Unlocking Lock

Unfasten cable clip.
Installation:
Cable clip must be reinstalled.
Fig. 75: Locating Cable Clip

Detach catch (1) from plug housing (2).

2010 BMW M3
Fig. 76: Detaching Catch From Plug Housing

Press out contact carrier (3) with wiring harness (4) through opening (5).
Fig. 77: Pressing Contact Carrier With Wiring Harness

Hold down arrester hook (6) of defective contact and pull cable and contact up to secondary lock (8).
Fig. 78: Identifying Arrester Hook And Secondary Lock

2010 BMW M3
Hold down arrester hook once again in secondary lock (8) and pull cable and contact completely out of contact
carrier.
Fig. 79: Holding Arrester Hook In Secondary Lock

61 13 ... IN-LINE PLUGS, 6-, 8-PIN, SYSTEM MQS
Fig. 80: Pressing Lock Of Slide Plug

2010 BMW M3
Fig. 81: Pressing Locking Hook


61 13 ... INSTALLING FAN CONNECTOR FOR RETROFITTING/REPAIRS
61 9 040
61 9 041
61 9 042
connectors.
2010 BMW M3

Choose contact sleeve (up to 4 mm2 ) in accordance with wire cross-section.
Fig. 84: >Identifying Contact Sleeve In Wire Cross-Section

Alternatively:
Choose contact sleeves (up to 2.5 mm2 ) for fan connectors.

2010 BMW M3
Fig. 85: Identifying Contact Sleeves For Fan Connectors

Cut through wire loop in wiring harness at established point.
Strip insulation from both wire ends.

Crimp contact sleeves on both wire ends.

2010 BMW M3
Fig. 87: Identifying Contact Sleeves On Both Wire Ends

Crimp connecting cable for retrofitting likewise with contact sleeve.
Fig. 88: Crimping Connecting Cable For Retrofitting Likewise

Cut required number of poles to length for fan connectors.

2010 BMW M3
Fig. 89: Identifying Fan Connectors Poles

Special tool 61 9 041 (hand crimping tool) in conjunction with 61 9 042 (matrix) are used for pushing contact
sleeves onto fan connectors.
Fig. 90: Identifying Special Tools For Wiring Harness Repairs

Or:

2010 BMW M3
Fig. 91: Identifying Unlocking Lever And Squeeze Grips

Insert prepared fan connector (3) in special tool 61 9 041 / 61 9 042 .
Fig. 92: Inserting Prepared Fan Connector

Attach wire with contact sleeve to fan connector.

2010 BMW M3
Fig. 93: Attaching Wire With Contact Sleeve To Fan Connector

Press crimping tool together and slide contact sleeve firmly home.
Fig. 94: Pressing Crimping Tool

IMPORTANT: Once contact sleeves have been pushed on, they should not be detached again
from the fan connector or reused.
Push on further contact sleeves for potential branching.

2010 BMW M3
Fig. 95: Identifying Further Contact Sleeves For Potential Branching

Installation in wet area (engine compartment, wheel arch):
Apply sealing compound on both sides and press into contacts (1).
Fit shrink-fit hose and heat up with hot air blower (2) (approx. 250C).
Fig. 96: Fitting Shrink-Fit Hose And Hot Air Blower

NOTE: Ensure that fan connector has sufficient contact surface on mounting point.
Do not heat shrink-fit hose on edges of fan connector too strongly, risk of cracking.
Allow shrink-fit hose to cool down until hand-warm. Then press sealing material again into contacts and onto
edges of fan connector.
If necessary, carefully heat shrink-fit hose again.
Installation in dry area (interior, luggage compartment):

2010 BMW M3
Slide assembled fan connector into insulation housing until it locks into place.
Fig. 97: Sliding Assembled Fan Connector Into Insulation Housing

61 13 ... OPENING PLUG HOUSINGS AND REMOVING CONTACTS OF DIFFERENT PLUG

SYSTEMS
61 0 300
61 0 400
61 1 100
61 1 150
ABBREVIATIONS OF CONTACTS REFERENCE CHART

ELA Strand seal
D 1.5 / 2.5 / 3.5 Round contacts with 1.5 mm, 2.5 mm or 3.5 mm diameter
2010 BMW M3
Mcon Multi contact

Ultrasonic-welded connectors (1) can be identified by the welds (2) on their
longitudinal side.
Fig. 98: Identifying Ultrasonically Welded Plugs And Ultrasonic-Welded Connectors

Release and press-out tool 61 1 150 is replaced from 09/2005 by 61 0 300

Release and press-out tool 61 1 100 (engine)
61 13 ... PLUG HOUSING, LCC CONTACT (LOAD CURRENT CONTACT)
61 0 317
Socket housing:
2010 BMW M3
Fig. 99: Pressing Lock With Suitable Tool


Insert special tool 61 0 317 into socket housing (1) and pull out lead with LCC contact (2) in direction of arrow.
2010 BMW M3

Pin housing:
Fig. 102: Unlocking Locking Slide Of Pin Housing

Insert special tool 61 0 317 into pin housing (1) and pull out lead with LCC contact (2) in direction of arrow.
2010 BMW M3

61 13 ... RELAY CARRIER
Place special tool 61 1 153 on relay carrier (1) and carefully pull in direction of arrow until retaining lugs (2) on
relay carrier are raised.
Fig. 104: Identifying Retaining Lugs

Pull relay carrier (2) in direction of arrow into first catch (3).
2010 BMW M3

Press down arrester hook (4) of appropriate contact and pull out cable with contact.
Press out double flat spring contact with special tool 61 1 136 or 61 1 137 (ejector).

61 13 ... REMOVING AND INSTALLING/REPLACING OBD-II SOCKET
61 0 315
Remove footwell side trim panel on A-pillar, left . See 51 43 070 REMOVING AND
2010 BMW M3
INSTALLING/REPLACING SIDE TRIM PANEL, FOOTWELL, ON A-PILLAR, LEFT

(DRIVER SIDE) .
Release screws (1).
Remove OBD-II socket (2) from holder (3).
Fig. 107: Identifying Screws, OBD-II Socket And Holder

Remove OBD-II socket cover (2) from OBD-II socket (1).
Unlock slide plate (3) with a suitable tool in direction of arrow. Insert special tool 61 0 315 in OBD-II socket
(1) in direction of arrow and press out associated flat spring contact (4). Press remaining flat spring contacts
with special tool 61 0 315 out of OBD-II socket (1).
Installation:
Pay attention to pin assignment of OBD-II socket (1).
Make sure flat spring contacts and slide plate (3) are correctly engaged and seated in OBD-II socket (1).
2010 BMW M3
Fig. 108: Pressing Out Associated Flat Spring Contact

61 13 ... REPAIRING AIRBAG LEADS (BUILD DATE/VERSION AFFECTED 04/2008 TO 07/2008)
61 0 327
61 4 321
61 4 328
WARNING: Read and comply with safety regulations for handling airbag modules and
pyrotechnical belt tensioners. See 72 00 ... SAFETY REGULATIONS FOR
IMPORTANT: Always lead repair cable set for belt tensioner and seat airbag in event of a
fault on driver's and passenger's sides.
Move driver's seat/front passenger seat fully back and upwards.
Disconnect plug (2).

2010 BMW M3
Fig. 109: Identifying Plug Connections And Plug

Release cable tie (1).
Unlock cap (2) on both sides and pull out in direction of arrow.
Installation:
Secure wiring harness for strain relief with cable tie on plug housing.
Fig. 110: Releasing Cable Tie

2010 BMW M3
Fig. 111: Identifying Strip Insulation

Strip insulation (1) and disconnect cables in accordance with table.
PIN COLOR REFERENCE CHART

Driver's seat:
Pin 16 Yellow/Red GSF+
Pin 17 Yellow/Brown GSF-
Pin 18 Yellow SIAVL+ for LHD
Blue SIAVR+ for RHD
Pin 19 Brown SIAVL-/VR-
PIN COLOR REFERENCE CHART

Passenger seat:
Pin 16 Blue/Red GSBF+
Pin 17 Blue/Brown GsBF-
Pin 18 Blue SIAVR+ for LHD
Yellow SIAVL+ for RHD
Pin 19 Brown SIAVR-/VL-
2010 BMW M3
Cut cable (1) with BMW-recommended cable stripper and strip insulation.
Fig. 112: Identifying Cable Dimension

Cut repair cable (1) with BMW-recommended cable stripper and strip insulation.
Cut repair wiring harness 11 cm.
Fig. 113: Identifying Repair Cable

Connect repair cable (1) with butt connector to vehicle wiring harness.
Universal matrix 61 4 328

Pliers 61 4 321
2010 BMW M3
Fig. 114: Connecting Repair Cable

Slide shrink-on hoses (1) over ignition circuit leads (2).
With hot air blower, shrink the shrink-on hose on both sides of shrink-on hose until glue emerges uniformly all
round.
Fig. 115: Sliding Shrink-On Hoses Over Ignition Circuit Leads

Connect ignition circuit lead (1) with special tool 61 0 327 in accordance with table.
2010 BMW M3
Fig. 116: Connecting Ignition Circuit Lead

61 13 ... REPAIRING RIBBON CABLES
61 1 190
Place ribbon cables (1) in connector housing (2) and close cover (3).
Fig. 117: Identifying Ribbon Cables, Connector Housing And Close Cover
Place connector housing (1) in tool (2) 61 1 190 .
Close tool (2).

2010 BMW M3
Fig. 118: Identifying Connector Housing And Close Tool

61 13 ... RETAINING BRACKET
Pull relevant fuse out of fuse block (1).
NOTE: Mark positions when removing fuses.
Pull locking slide (2) out of fuse block (1) as far as it will go.
Fig. 119: Identifying Locking Slide And Fuse Block

cable.
2010 BMW M3

61 13 ... SOCKET HOUSING (RADIO PLUG), HYBRID SYSTEM MQS/MPQ

Removing MPQ contacts from radio plug:
Detach secondary lock (2) from radio plug.
Fig. 121: Detaching Secondary Lock From Radio Plug

2010 BMW M3
Fig. 122: Pulling Wire With Socket Contact Out Of Radio Plug
Removing MQS contacts from contact carrier:
Press lock (1) in direction of arrow and pull housing (2) out of radio plug.

Press lock (1) in direction of arrow. Pull contact carrier (2) out of housing (3).
2010 BMW M3
contacts are raised.

NOTE: The illustration shows an 8-pin socket housing where removal of the contacts is
identical.

Hold down arrester hook in secondary lock (1) again. Pull wire with socket contact (2) out of contact carrier (3).
2010 BMW M3

Removing MPQ contacts from contact carrier:
Remove contact carrier (1) with MQS contacts from radio plug.
Raise lock (2) on radio plug.
Pull contact carrier (3) out of radio plug.
Fig. 127: Pulling Contact Carrier Out Of Radio Plug

Pull secondary lock (2) in direction of arrow completely out of contact carrier (3).
2010 BMW M3
Fig. 128: Pulling Secondary Lock

Press special tool 61 1 135 on inside of contact into contact carrier (2).
Pull wire with socket contact (1) out of contact carrier (2).
Fig. 129: Pulling Wire With Socket Contact Out Of Contact Carrier
61 13 ... SOCKET HOUSING 42-, 43-PIN, HYBRID SYSTEM MQS / MPQ
housings:

2010 BMW M3
Press back retaining hook of MPQ contacts (3) with screwdriver or similar tool and pull out cable with contact.
Fig. 130: Pressing Back Retaining Hook Of MPQ Contacts

Installation:
Fig. 131: Identifying Plug Housing

61 13 ... SOCKET HOUSINGS, 2X21-, 2X27-PIN, HYBRID SYSTEMS MQS/MPQ, ELO/ELO-POWER
housings:

2010 BMW M3
housings:
Elo (electronic contact)

NOTE: The second contact carrier is pushed out in the same way.
Pushing out the contact carrier releases the secondary locks of the socket contacts.

2010 BMW M3


61 13 ... SPECIAL TOOLS FOR WIRING HARNESS REPAIRS
12 1 080
61 0 200
61 0 210
61 0 220
61 0 230
2010 BMW M3
61 0 300
61 0 400
61 1 190
61 4 320
61 9 041
61 9 044
Release and press-out tool:
Fig. 135: Identifying Special Tool Kit

2010 BMW M3

Crimping stop parts (small contacts):

1. Tool without crimping head
2. Crimping head (stripping insulation and cutting fibre-optic cables to length)
Fig. 137: Identifying Crimping Stop Parts (Small Contacts)

3. Crimping head (crimping fibre-optic cable contacts)

4. Crimping head (crimping MQS contacts)
5. Crimping head (crimping MPQ contacts)
6. Replacement blade (face-cutting fibre-optic cables)
7. Replacement blade with tool (insulation stripping unit)
8. Universal crimping head
2010 BMW M3
Crimping stop parts (large contacts):
Special tool 61 0 200 (crimping set)

Special tool 61 0 210 (matrix set LSK 8)
Special tool 61 0 220 (matrix set SLK 2.8)
Special tool 61 0 230 (matrix set MAK 8 / DFK4)
Handling:
Fig. 138: Identifying Crimping Stop Parts (Large Contacts)

Crimping antenna elbow plugs:
Special tool 61 9 041 (hand crimping tool)

Special tool 61 9 044 (matrix)
Handling:
Antenna elbow plug on radio receiver

2010 BMW M3
Fig. 139: Identifying Hand Crimping Tool And Matrix

Repair kit for ignition cables and for crimping fan connector receptacles 4 mm2 :
Handling:
Crimping stop parts (contacts)
Fig. 140: Identifying Special Tool Kit (12 1 080)

Repairing ribbon cables:
Handling:
2010 BMW M3
Repairing ribbon cables

61 13 ... TREATING CABLES AND FIBRE-OPTIC CABLES
61 1 190
61 4 320
SPECIAL TOOL KITS CHART

SI 2 04 07
341
Crimping set with tool for fibre-optic cables, Micro Power Quadlock (MPQ), Micro Quadlock
61 4 320
System (MQS) contacts and universal crimping head
Insulation displacement tool for ribbon cable 61 1 190
61 13 ... UNLOCKING AND DISCONNECTING DIFFERENT PLUG CONNECTIONS

2010 BMW M3


2010 BMW M3

Fig. 145: Pressing Lock And Disconnect Plug Connection


2010 BMW M3



2010 BMW M3



2010 BMW M3

61 13 050 REMOVING AND INSTALLING OR REPLACING FUSE BOX IN PASSENGER

COMPARTMENT (BUILT AFTER 03/2007)
Remove right glovebox with housing. See 51 16 366 REMOVING AND INSTALLING RIGHT
GLOVEBOX WITH HOUSING .
Remove Junction box
Release wiring harness fastener (2) from fuse box interior (6).
Release screws (3).

Carefully fold fuse box interior (6) forwards, feeding battery positive lead (4) in
direction of arrow out of fuse box interior holder (5).
2010 BMW M3
Fig. 151: Identifying Plug Connection, Wiring Harness Fastener, Fuse Box Interior, Screws And Battery
Positive Lead
Disconnect all plug connections (1) on reverse side of fuse box interior (3).
Remove fuse box interior (3).
Installation:
Battery positive lead (2) must not be damaged.
Make sure wiring harnesses are correctly laid and plug connections (1) are correctly engaged.
Fig. 152: Identifying Plug Connections, Fuse Box Interior And Battery Positive Lead
Replacement:
If necessary, remove fuses and relays.
DISTRIBUTION BOX
2010 BMW M3
61 14 ... REMOVING AND INSTALLING/REPLACING ENGINE COMPARTMENT B+ TERMINAL
Remove cover from electronics box . See 12 90 ... REMOVING AND INSTALLING/REPLACING
ELECTRONICS BOX .
NOTE: Work is shown on the E82 N52N by way of example. There may be differences in
Unclip covers (1) and release nuts underneath. Tightening torque, see 61 12 1AZ in 61 12 AUXILIARY
CABLE .

Unclip cover (1).

2010 BMW M3
Fig. 154: Identifying Clip Cover

Unscrew nuts (1). Tightening torque, see 61 12 1AZ in 61 12 AUXILIARY CABLE .
Release locks (2) and remove frame (3) towards rear from B+ terminal.
Unclip B+ terminal and remove towards front.
Installation:
Make sure frame (3) engages correctly in B+ terminal.
Fig. 155: Identifying Nuts, Locks And Frame


2010 BMW M3
(COUPE/CONVERTIBLE)
Release screws (1) and remove bracket (2). Tightening torque, see 61 14 1AZ in 61 14 DISTRIBUTION BOX,
CURRENT TERMINALS .

Disconnect plug connection (1). Fold back cover (3). Slacken nut (2). Tightening torque, see 61 21 2AZ in 61
21 BATTERY WITH TERMINAL . Fold back cover (5). Slacken nut (4)..
Fig. 157: Disconnect Plug Connection (1), Fold Back Cover (3), Slacken Nut (2)
2010 BMW M3
Press locking brackets (1) downwards and unclip. If necessary, using a screwdriver, expand locking bracket (1)
at lower end and clip out. Remove distribution box (2) towards top.
Fig. 158: Press Locking Brackets (1) Downward And Unclip

(SEDAN)
Remove flap in luggage compartment panel on right. See 51 47 171 REMOVING AND
Release screws (1) and remove bracket (2). Tightening torque, see 61 14 1AZ in 61 14 DISTRIBUTION BOX,
CURRENT TERMINALS .
2010 BMW M3

Unlock plug housing (2) and release in direction of arrow.
Fold up covers on nuts (3).
Unscrew nuts (3). Tightening torque, see 61 21 2AZ in 61 21 BATTERY WITH TERMINAL .
Disconnect plug connection of IBS cable (5).
Fig. 160: Identifying Plug Connection, Plug Housing, Nuts And Plug Connection Of IBS Cable
Press locking brackets (2) downwards and unclip.

2010 BMW M3
If necessary, using a screwdriver (1), expand locking bracket (2) at lower end and clip out.
Remove power distributor (3) towards top.
Fig. 161: Removing Power Distributor

BATTERY
12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY
Observe safety instructions for handling vehicle battery.
Before disconnecting battery:
2010 BMW M3
General notes on disconnecting battery:
Detach terminal of battery negative lead from car battery and second battery if fitted. Cover battery
negative terminal(s) and secure.
When installing battery terminal: Tightening torque, see 61 21 1AZ in 61 21 BATTERY WITH
TERMINAL .
After connecting battery:

specification.
Example:
Starter and equipment batteries
A two-battery system has a starter battery circuit and an equipment battery circuit. A supplementary control unit
monitors both battery circuits. Depending on the situation, the battery circuits are connected to or isolated from
the supplementary control unit via an isolating relay.
Two AGM batteries, whose design and properties are described in AGM batteries, are used as a storage
battery.
Receiving/giving starting assistance via jump start terminal
2010 BMW M3
is open.
Charging starter and equipment batteries via jump start terminal
voltage at the starter battery is the decisive factor in determining whether the equipment battery is also included
in the charging operation. The supplementary control unit automatically detects a charging operation at a
charging voltage at the starter battery of > or = 13.5 V. The isolating relay is closed and thus the equipment
battery is connected in parallel. Both batteries are now charged.
Prerequisite:
If terminal 15 becomes "active" during the charging operation, the isolating relay is opened immediately and
NOTE: When the engine hood is open, the isolating relay is also opened in normal
operation. The isolating relay is closed from terminal R in this operating mode.
Trickle charging
The increased closed-circuit current consumption can be compensated for via the jump-start connection point
with the aid of the "Acctiva easy" battery trickle charger (Service Information 2 03 05 205 ).
"OFF" on a timed basis (60 mins.), thereby interrupting charging of the
equipment battery via the cigarette lighter. This is prevented if the battery
master switch (on the right side of the luggage compartment behind the panel)
is turned on and off again twice within 2 seconds. (Cigarette light battery
charging function).
12 00 ... NOTES/INFORMATION ON START ASSISTANCE (JUMP STARTING)

2010 BMW M3
Preparation:
of injury!
speed.
Operation:

compartment.
sparks.
Risk of explosion!
61 00 ... BATTERY
2010 BMW M3
specification.
Battery test
test results.
Safety regulations:
Safety regulations for handling components of airbag system. See 72 00 ... SAFETY REGULATIONS FOR
Instructions for disconnecting and connecting battery.
In event of non-visible damage to wiring harness:
Disconnect plug connection on airbag module or on adapter plug. It is absolutely vital to disconnect the contacts
in succession as there is a risk of them being mixed up! Cut through one cable after the other at an appropriate
position, do not under any circumstances cut through both cables at the same time. Insulate cables remaining in
wiring harness with insulating tape. Now disconnect plug connection on airbag control unit. Unpin contacts. Cut
through one cable after the other at an appropriate position and insulate with insulating tape, do not under any
circumstances cut through both cables at the same time. Pin contacts of repair cable for airbag control unit in
control unit plug, assignment of repair cables is relevant. Lay repair cable in car parallel to existing airbag lead.
Now pin in contacts for airbag control unit or contacts of adapter plug, assignment of repair cables is relevant.
Cut off excess length of repair cable in proximity (visible area) of airbag module or of adapter plug. Twist open
cables. With the connectors and shrink-fit hoses in the Electronic Parts Catalogue (EPC), reconnect the cables
with the same cable colors. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface
(shrink-fit hoses) with insulating tape to prevent cables from twisting open.
2010 BMW M3
In event of visible damage:
61 00 ... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY
Battery acid is highly corrosive:
In event of contact with acid:
of water.
Explosion hazard:
61 12 ... GENERAL INFORMATION ON INTELLIGENT BATTERY SENSOR (IBS)

2010 BMW M3
NOTE: Do not connect continuous trickle charger to the cigarette lighter.
The cigarette lighter is powered by the rear distribution box via a relay. This relay drops out after terminal 15
OFF. This means that a continuous trickle charger connected to the cigarette lighter is disconnected from the
battery.
Charge the battery via the jump-start connection points. Only then can the power supply be registered by the
vehicle.

Do not modify the grounding cable.
The grounding cable also serves to dissipate heat.

fault-free.
2010 BMW M3

For this reason, only replace the IBS when a corresponding fault is entered in the DME or DDE.
61 20 . . . THRESHOLD VALUES FOR BATTERY INSPECTION OF ALL BATTERY (TELEPHONE

EXCEPT FOR TELEPHONE BATTERY)
Test step 1 - before charging the battery
SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY REFERENCE CHART

Charge state 1) Starting capability 2) Test result
Not testable Charge
less than 50 % 2) Charge
more than 50 % less than 75 % Charge
more than 50 % more than 75 % 3) Charge
more than 80 % more than 75 % O.K.
Test step 2 - after charging the battery
SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY REFERENCE CHART

Charge condition 1) Starting capability 2) Test result
Not testable Defective
less than 50 % less than 75 % Charge
more than 50 % more than 75 % Charge
1. Charge condition and starting power must always be evaluated together

2. When test charging for more than 5 hours, use charger Gossen CG 32 or Siemens / Gossen VB 801
3. Fully charge until charge state is more than 80 %.
NOTE: If battery was checked on the positive terminal in the engine compartment,
repeat check directly on battery for sake of safety.
61 20 ... AGM BATTERY

2010 BMW M3
Fig. 162: Identifying AGM Battery

Introduction
In September 2002 so-called VRLA batteries, better known as AGM batteries, were introduced.
(VRLA stands for V alve R egulated L ead A cid, i.e. lead acid battery with pressure relief valve; AGM stands
for A bsorbent G lass Mat, i.e. absorbent glass fibre fleece)
AGM batteries are fitted in models with electrical loads/consumers which have a high energy demand.
With the option SA 146 (2nd battery), the AGM battery (70 Ah) is fitted as the 2nd battery.
The constantly increasing energy demand of modern vehicle electrical systems calls for ever more powerful
battery solutions. Today, up to 100 servomotors, which have to be electrically powered, operate in a modern
luxury-class motor vehicle. Added to these are safety, environmental and comfort and convenience elements
which are increasingly becoming standard features, such as e.g. Anti-lock Brake System (ABS), Dynamic
Stability Control (DSC), electric steering effort assistance (EPS), heated catalytic converter, electronic chassis
and suspension control, air conditioning and navigation system.
The power consumption is considerable even when the vehicle is parked.
The somewhat higher price compared with a battery of similar size is fully balanced by the following benefits:
Significantly longer service life

2010 BMW M3
Increased starting reliability at low temperatures

Safe starting of engines with high starting current demands, e.g. high-performance diesel engines
100 % freedom from maintenance
Low risk in event of an accident (reduced risk to the environment)
Service life of AGM battery
Fig. 163: AGM Battery Service Life Graph


1 Available capacity [%] 2 Kilometres covered [1000 km]
3 AGM battery 4 Lead calcium battery
5 50 % capacity limit
Unlike the previously used lead calcium batteries, the sulphuric acid contained in batteries with fleece
technology is not self-contained in the battery housing.
Instead, the sulphuric acid is 100 % bound up in glass fibre fleece mats (separators). Thus, no acid can escape if
the battery housing is damaged. In addition, the AGM battery is sealed gas-tight. This is possible because the
gases are converted back into water as a result of the separator permeability.
2010 BMW M3
An AGM battery can be recognized by its black housing and the lack of a so-called "Magic Eye".
Fig. 164: Identifying AGM Battery Components


1 Positive grid with silver alloy 2 Positive plate
3 Negative grid 4 Negative plate
5 Separator made of glass fibre fleece 6 Positive plate pack
7 Negative plate pack 8 Plate block
9 Block holder with bottom rails
Design
The AGM battery differs from the conventional lead calcium battery as follows:
Larger plates:
Larger plates provide for a 25 % higher power density.

2010 BMW M3
Separators made of glass fibre fleece:
These provide for up to 3 times higher cycle reliability.
This in turn improves cold starting performance, current consumption and service life.
Gas-tight housing with pressure relief valve (see also mode of operation):
The cell plugs are welded and cannot be opened.
Acid bound up in the glass fibre fleece:
The acid is not as previously self-contained in the housing, but 100 % bound up in the glass fibre fleece.
This provides increased protection against acid leakage and thus represents a reduced risk to the
environment.
Mode of operation
The AGM battery differs from conventional batteries in its non-polluting and substance-retaining behaviour
during charging.
When vehicle batteries are charged, the two gases oxygen and hydrogen are released by electrolysis.
In a conventional wet lead calcium battery, the two gases hydrogen and oxygen are dissipated into the
atmosphere.
In an AGM battery, the two gases are converted back into water: The oxygen which is created at the
positive electrode during charging passes through the permeable glass fibre fleece to the negative
electrode. At the negative electrode the oxygen reacts with the arriving hydrogen ions in the electrolyte to
form water (oxygen cycle).
In this way, the gas and thus also the electrolyte are not lost.
Only in the event of an excessively heavy buildup of gas, i.e. excessively high pressure buildup (20 to 200
mbar), does the pressure relief valve discharge the gas. In this process, the pressure relief valve does not allow
any oxygen in the air to enter. Because a valve regulates the pressure in the battery, the AGM battery is also
known as a VRLA battery (Valve Regulated Lead Acid).
Notes and instructions for service personnel
It is necessary when handling an AGM battery to observe some particular points pertaining to battery changing
and installation location.
Charging
WARNING: Do not charge the AGM battery with > or = 15.2 V. No quick-charging
routines!
2010 BMW M3
When charging removed batteries (so-called stand-alone batteries), do not exceed the maximum charging
voltage of 15.2 V at room temperature. Also when charging via the jump start terminal, do not exceed the
maximum charging voltage of 15.2 V at room temperature.
The AGM battery will be damaged even when it is only briefly charged with a charging voltage of more than
15.2 V. A charging voltage of more than 15.2 V is usually used in quick-charging routines.
Installation location
WARNING: Do not install the AGM battery in the engine compartment.
The AGM battery must not be installed in the engine compartment on account of the high spatial temperature
differences, otherwise its service life will be significantly shortened.
Housing
WARNING: Do not open the AGM battery.
The AGM battery must not be opened under any circumstances as the introduction of oxygen from the air will
cause the battery to lose its chemical equilibrium and be rendered non-operational.
Battery changing
Any conventional lead calcium battery can always be replaced by an AGM battery.
Using an AGM battery does not require any alterations to be made to the vehicle electrical system.
NOTE: The AGM battery is recommended for "problem customers".
"Problem customers" encounter a high energy throughput through their batteries. This high energy throughput is
caused by stationary loads/consumers (TV, independent heating, etc.) and a bad use profile for the battery
("chauffeur operation", short-distance driving, "stop-and-go"). The use of an AGM battery is recommended for
these problem customers.
61 20 ... BATTERY CHARGING
If a normal or quick charger is used to charge the battery, the battery must be disconnected from the vehicle
electrical system and removed. This prevents damage to paintwork and upholstery.
IMPORTANT: In order to prevent the intelligent battery sensor from malfunctioning, the
charging terminals in the engine compartment must be used without fail in
vehicles from E60 and should be used if possible in other vehicles.
2010 BMW M3
IMPORTANT: Before charging the battery while it is installed, first carry out a closed-circuit
current test. If here the voltage is 10 V or less, one or more of the cells may be
faulty or the entire battery may already be damaged. In this case, always
remove the battery as escaping gases during charging could damage the
interior equipment and trim. Attempt to regenerate faulty cells with low
charging current.
If necessary, open existing plugs on the individual cells.
61 20 ... BATTERY OPEN-CIRCUIT CURRENT TEST
NOTE: Observe safety instructions for handling vehicle battery.

Observe Service Information Adapter for open-circuit current measurement.
Fig. 165: Identifying Battery Tester

The open-circuit current test is performed using the Diagnosis and Information System (DIS).

2010 BMW M3
IMPORTANT: Do not under any circumstances use force to pull/lever off Intelligent Battery
Sensor (IBS).
Remove battery cover or open right luggage compartment trim panel . See 51 47 ... REMOVING
AND INSTALLING/REPLACING BATTERY COVER .
Loosen nut (1).


CONTROL UNIT(S))
IMPORTANT: Observe safety instructions for handling vehicle battery.

Switch off ignition

2010 BMW M3

Connect battery negative terminal and tighten, tightening torque, see 61 21 1AZ in 61 21 BATTERY
WITH TERMINAL .
Switch ignition on
BATTERY VAPOR SEPARATOR

61 21 010 REMOVING AND INSTALLING OR REPLACING BATTERY (COUPE/CONVERTIBLE)
WARNING: Observe safety instructions for handling vehicle battery. Notes and
instructions on Intelligent Battery Sensor IBS.
Remove battery cover. See 51 47 ... REMOVING AND INSTALLING/REPLACING BATTERY

COVER .
Disconnect battery negative lead.
Remove Distribution Box (Coupe/Convertible) or Distribution Box (Sedan).
Open positive terminal cover (1) and slacken nut beneath. Tightening torque, see 61 21 1AZ in 61 21
BATTERY WITH TERMINAL .
Detach safety battery terminal (2) towards top, lay to one side and secure. Detach vent (3) in direction of arrow.
Release threaded pin (4) and remove with holder. Lift out battery (5) by handles (6).
2010 BMW M3
Fig. 167: Detach Safety Battery Terminal (2) Towards Top, Lay To One Side And Secure
Installation: Make sure battery is correctly seated in associated fixture.
Replacing version with intelligent battery sensor (IBS):
Read out fault memory, clear if necessary. Register battery replacement.
Battery registration can only be carried out with the BMW diagnosis system. Function selection:
Service functions
Body
Power supply
Battery
61 21 010 REMOVING AND INSTALLING OR REPLACING BATTERY (SEDAN)
WARNING: Observe safety instructions for handling vehicle battery. Notes and
instructions on Intelligent Battery Sensor IBS.
Remove flap in luggage compartment panel on right. See 51 47 171 REMOVING AND
Remove distribution box
Unlock positive terminal cover (1) and remove.

2010 BMW M3
Fig. 168: Unlocking Positive Terminal Cover

Battery crash element must be reinstalled!
On vehicles from build date 12/2006 or when IBS is replaced since

12/2006, battery crash element has been removed without replacement
(IBS2006 replaces IBS2004 from 12/2006 IBS2004)
Detach vent (1) in direction of arrow.
Release nut (6) of safety battery terminal (2).
Detach safety battery terminal (2) towards top, lay to one side and secure.
Release threaded pin (5) and remove holder with battery crash element (4).
Fold back both bar fasteners (3) and pull battery towards rear out of associated fixture.
Lift out battery.

2010 BMW M3
Fig. 169: Identifying Vent, Nut, Safety Battery Terminal, Threaded Pin And Battery Crash Element
Installation:
Make sure battery is correctly seated in associated fixture.
Replacing version with intelligent battery sensor (IBS):

Read out fault memory, clear if necessary
SWITCHES, HORN
61 30 020 REMOVING AND INSTALLING/REPLACING SWITCH BLOCK (M3)
Remove trim for storage tray . See 51 16 212 REMOVING AND INSTALLING TRIM FOR
STORAGE COMPARTMENT .
If necessary, remove socket housing (1) from holder (2).
Unlock catches (3) and feed switch block (4) in direction of arrow out of storage compartment trim (5).
Installation:
Make sure switch block catch (4) engages correctly in storage compartment trim (5).
If necessary, make sure socket housing (1) is correctly seated in holder (2).
2010 BMW M3
Fig. 170: Unlocking Catches

SWITCH
61 31 ... OVERVIEW OF SWITCHES
2010 BMW M3
Fig. 171: Identifying Switches Location

61 31 ... REMOVING AND INSTALLING/REPLACING PARKING LOCK FROM SERIES STATUS

09/2008
protection).
Remove gear selector switch

Remove parking lock cable from transmission
Release screws (1).
Feed rubber seal (2) completely out of gear selector switch (3).
2010 BMW M3
Release parking lock (4) at points (5) and remove in direction of arrow.
Installation:
Make sure parking lock (4) is exactly seated on gear selector switch (3).
Make sure rubber seal (2) is correctly seated.
Fig. 172: Identifying Screws, Rubber Seal, Parking Lock And Gear Selector Switch
Install gear selector switch (1).
Install parking lock cable on transmission.
Installation:
Make sure rubber seal is correctly seated.
Fig. 173: Identifying Gear Selector Switch

2010 BMW M3
Release handle (1) from gear selector switch (2).
Withdraw transportation lock (3) from parking lock (4).
US version only:
Transmission emergency release (5) is provided with a grey cap.
Fig. 174: Identifying Handle, Gear Selector Switch, Transportation Lock, Parking Lock And
Transmission Emergency Release
61 31 006 REMOVING AND INSTALLING/REPLACING FIXTURE FOR STEERING COLUMN

STALK
With steering wheel removed, do not under any circumstances turn/twist
fixture for steering column stalk!
Remove steering wheel . See STEERING WHEEL .

Remove top section of steering column casing. See 32 31 003 REMOVING AND
INSTALLING/REPLACING UPPER SECTION OF STEERING COLUMN TRIM .
Remove lower section of steering column trim . See 32 31 020 REMOVING AND INSTALLING /
REPLACING LOWER SECTION OF STEERING COLUMN TRIM .
Release screws (1).

2010 BMW M3
Disconnect plug connections behind and remove fixture for steering column stalk (2).
Installation:
Carry out steering angle sensor adjustment. See 61 31 996 CARRYING OUT STEERING ANGLE
SENSOR ADJUSTMENT .
On vehicles with active front steering, steering angle sensor adjustment is performed by means of initial
operation / adjustment of active front steering.
Fig. 175: Removing Fixture For Steering Column Stalk

Replacement:
Remove volute spring cassette


makes a brand-new steering column switch cluster coding-
Carry out steering angle sensor adjustment See 61 31 996 CARRYING OUT STEERING ANGLE
SENSOR ADJUSTMENT .
control unit
2010 BMW M3
Vehicles with active front steering:

Steering angle sensor adjustment is performed by means of initial operation / adjustment of
active front steering
61 31 011 REMOVING AND INSTALLING/REPLACING VOLUTE SPRING CASSETTE
Remove fixture for steering column stalk
Unlock catches (1).
Press lock (2) and remove volute spring cassette (4) in direction of arrow from fixture for steering column stalk
(3).
Fig. 176: Unlocking Catches

IMPORTANT: Do not turn ring (1).

Also turning ring (1) through 360 is not permitted!
Secure ring (1) against unauthorized turning (e.g. with adhesive tape).
Installation:
2010 BMW M3
Notch (3) on ring (1) must line up with arrow (4) on switch (2).
Fig. 177: Identifying Ring, Notch And Switch

IMPORTANT: Fit volute spring cassette (1) so that guide (2) can slide exactly into associated
notch on switch (3).
Fig. 178: Identifying Spring Cassette, Guide And Switch

61 31 023 REMOVING AND INSTALLING/REPLACING START/STOP SWITCH
Remove decorative strip on instrument panel on right . See 51 45 263 REMOVING AND
INSTALLING/REPLACING INSTRUMENT PANEL TRIM ON RIGHT .
Press catches (1) together and unclip Start/Stop switch (2) in direction of arrow.
2010 BMW M3
Fig. 179: Uncliping Start/Stop Switch

61 31 037 REMOVING AND INSTALLING/REPLACING LIGHT CONTROL UNIT
00 9 317
NOTE: See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .
Remove decorative strip on instrument panel on left . See 51 45 370 REMOVING AND
INSTALLING (REPLACING) LEFT DECORATIVE STRIP ON INSTRUMENT PANEL .
Lever out trim of light control unit (2) with special tool 00 9 317 at fastening points (1) and pull back in
direction of arrow.
Unlock and disconnect associated plug connection, remove trim of light control unit (2).
2010 BMW M3
Fig. 180: Removing Trim Of Light Control Unit

Replacement:
Unlock catches (1) and unclip light control unit (2) from trim (3).
Fig. 181: Uncliping Light Control Unit From Trim

61 31 038 REMOVING AND INSTALLING (REPLACING) SWITCH FOR PASSENGER AIRBAG

DEACTIVATION
pyrotechnical belt pretensioners. See 72 00 ... SAFETY REGULATIONS
FOR HANDLING COMPONENTS WITH GAS GENERATORS .

2010 BMW M3

Remove side cover on instrument panel . See 51 45 ... REPLACING SIDE COVER ON
INSTRUMENT PANEL .
Unlock catches (1) and feed out switch for passenger airbag deactivation (2) to front of cover.
Installation:
Make sure switch for passenger airbag deactivation (2) is correctly seated in cover.
Fig. 182: Identifying Catches And Airbag Deactivation

Replacement:
Remove lock cylinder for passenger airbag deactivation. .
61 31 043 REMOVING AND INSTALLING OR REPLACING ROOF SWITCH CENTER
00 9 341
IMPORTANT: Follow instructions for handling light bulbs interior lights. See 63 99 ...
INSTRUCTIONS FOR REPLACING LIGHT BULBS (INTERIOR LIGHTS) .
protection).
2010 BMW M3
IMPORTANT: Reflector on ceiling light must not be damaged.
Carefully unclip trim of ceiling light (1) with special tool 00 9 341 in direction of arrow from ceiling light and
remove.
Fig. 183: Uncliping Trim Of Ceiling Light

IMPORTANT: Reflector (2) and roofliner (3) must not be damaged.
Carefully unlock retaining clips (1) with special tool 00 9 341.
Fig. 184: Unlocking Retaining Clips

Lever roof switch center (1) with special tool 00 9 341 in direction of arrow out of roofliner (2).
2010 BMW M3
Disconnect plug connections underneath and remove roof switch center (1).
NOTE: Disconnecting the plug connection for the hands-free microphone or

emergency SOS call button results in fault memory entries in the telephone
control unit (limitation in the emergency SOS call system).
Fig. 185: Removing Roof Switch Centre

Installation:
Assembling roof switch center (3) prior to installation:
1. Feed in ceiling light trim (1) at line (2)

2. Press ceiling light trim (1) in direction of arrow onto ceiling light
Make sure ceiling light trim (1) is correctly engaged on ceiling light.
2010 BMW M3
Fig. 186: Pressing Ceiling Light Trim

Replacement:

Initialize slide/tilt sunroof. See 54 0 ... NOTES ON STEEL AND GLASS SLIDE/TILT SUNROOFS
(INITIALIZATION/NORMALIZATION/LEARNING OF CHARACTERISTIC CURVE) .
If necessary, remove bulbs.

(WITHOUT CCC/ASK)
WITHOUT CCC/ASK) .
Replacement:
Unclip center console switch cluster (2) at retaining points (4).
Remove center console switch cluster (2) in direction of arrow from trim (3).
Fig. 187: Removing Centre Console Switch Cluster


(WITH CCC/ASK)
2010 BMW M3
WITH CCC/ASK) .
Unclip trim (3) at fastening points (1) and (2).
Feed out associated ribbon cable and remove trim (3) complete with center console switch cluster (4).
Fig. 188: Removing Trim Complete With Centre Console Switch Cluster
Replacement:
Unclip center console switch cluster (1) at fastening points (2) and (4) and remove.
NOTE: Ribbon cable (3) of center console switch cluster (1) leads to heater/air
conditioner operator unit.
Installation:
Make sure center console switch cluster (1) engages correctly in upper fastening points (4) and lower fastening
points (2).
2010 BMW M3
Fig. 189: Uncliping Centre Console Switch Cluster

61 31 078 REMOVING AND INSTALLING/REPLACING SWITCH FOR CONVERTIBLE TOP

OPERATION
Necessary preliminary tasks: Remove trim for storage compartment. See 51 16 212 REMOVING AND
INSTALLING TRIM FOR STORAGE COMPARTMENT .
Release screws (1). Remove switch (2) from trim (3).
Fig. 190: Remove Switch (2) From Trim

61 31 079 REMOVING AND INSTALLING/REPLACING SWITCH FOR HAZARD WARNING

FLASHERS/CENTRAL LOCKING
2010 BMW M3
Unclip switch for hazard warning flashers/central locking (1) in direction of arrow from right instrument panel
decorative strip (2).
Fig. 191: Uncliping Switch For Hazard Warning Flashers/Central Locking

61 31 083 REMOVING AND INSTALLING/REPLACING SWITCH FOR UNLOCKING REAR LID
NOTE: To facilitate handling, unclip OBD socket cover (1).
Unclip rear lid unlocking switch (2) in direction of arrow.
Disconnect associated plug connection and remove switch for unlocking rear lid (2).
Fig. 192: Uncliping Rear Lid Unlocking Switch

2010 BMW M3
61 31 101 REMOVING AND INSTALLING/REPLACING SWITCH FOR BACKREST WIDTH

ADJUSTMENT
Remove outer cover on front seat. See SEATS - REPAIR (CONVERTIBLE/COUPE) or SEATS -
REPAIR (SEDAN) .
Unlock retaining tab (2) in direction of arrow.
Remove switch for backrest width adjustment (3) in direction of arrow.
Fig. 193: Removing Switch For Backrest Width Adjustment

61 31 115 REPLACING ROCKER SWITCH FOR SIDE WINDOW OPERATION (FRONT)
00 9 317
00 9 341
IMPORTANT: Carry out the following operations carefully so as to avoid damaging the door
trim panel and rocker switch.
Driver's side:
2010 BMW M3
Lever rocker switch for side window operation (1) with special tool 00 9 341 at highlighted points (2) out of
armrest (3).
Fig. 194: Removing Rocker Switch For Side Window Operation

Installation:
Retaining clips (1) of rocker switch for side window operation (2) must not be damaged or missing.
Fig. 195: Identifying Retaining Clips And Side Window Operation

Passenger side:
2010 BMW M3
Lever rocker switch for side window operation (1) with special tool 00 9 317 in direction of arrow out of
armrest.

Installation:
Fig. 197: Identifying Retaining Hooks And Side Window Operation

61 31 116 REPLACING ROCKER SWITCH FOR SIDE WINDOW OPERATION (REAR)

2010 BMW M3
00 9 317
IMPORTANT: Carry out the following operation carefully so as to avoid damaging the door
trim panel and switch.
Lever rocker switch for side window operation (1) with special tool 00 9 317 in direction of arrow out of
armrest.

Installation:
2010 BMW M3
Fig. 199: Identifying Retaining Hooks And Side Window Operation

61 31 122 REMOVING AND INSTALLING / REPLACING TOW HITCH SWITCH
Open flap in luggage compartment panel on left.
Release screw (1).
Disconnect plug connection underneath and remove tow hitch switch (2).
Fig. 200: Identifying Screw And Tow Hitch Switch

61 31 131 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT SHIFT PADDLE FOR

TRANSMISSION (TWIN CLUTCH TRANSMISSION) (M3)

2010 BMW M3
Remove airbag unit . See 32 34 020 REMOVING AND INSTALLING/REPLACING AIRBAG

UNIT .
Release screw (3).
Feed out wiring harness (2) and remove shift paddle for transmission (5) in direction of arrow from steering
wheel (4).
Installation:
Make sure shift paddle for transmission (5) is correctly seated on steering wheel (4)
Fig. 201: Removing Shift Paddle For Transmission

61 31 133 REMOVING AND INSTALLING/REPLACING AV CONNECTION SOCKET
NOTE: Version with rear air conditioning is shown.

2010 BMW M3
Fig. 202: Identifying Catch And Trim

Installation:
Catches (1 and 3) and guides (2) must not be damaged.

Lever AV connection socket (1) with a suitable tool (2) upwards out of storage compartment (3).
2010 BMW M3
Fig. 204: Identifying Lever AV Connection Socket And Storage Compartment With Suitable Tool
Remove AV connection socket (2) upwards out of storage compartment (3).
Installation:
Locks (4) must not be damaged.
Make AV connection socket (1) is correctly seated in storage compartment (3).
Fig. 205: Identifying Plug Connection, AV Connection Socket, Storage Compartment And Locks

SOCKET

2010 BMW M3
Removing and installing/replacing AV connection socket .
61 31 192 REPLACING KNOB FOR CONTROLLER
00 9 317
Partially fit special tool 00 9 317 as illustrated.
Lever out knob for controller (1) from controller (2) and remove towards top.
Fig. 206: Removing Knob For Controller


Install knob for controller only when controller is installed.
Installation:
Fit knob for controller (1) so that guides (2) are correctly seated in mountings (3).
2010 BMW M3
Fig. 207: Identifying Controller, Guides And Mountings

61 31 194 REMOVING AND INSTALLING/REPLACING DRIVELOGIC BUTTON (M3)
Remove trim for storage compartment . See 51 16 212 REMOVING AND INSTALLING TRIM
FOR STORAGE COMPARTMENT .
Unlock catches (1) with a suitable tool.
Remove Drivelogic button (2) in direction of arrow from storage compartment trim (3).
Installation:
Make sure Drivelogic button (2) is correctly seated on storage compartment trim (3).
Fig. 208: Unlocking Catches With Suitable Tool

2010 BMW M3
61 31 195 REMOVING AND INSTALLING (REPLACING) FRONT CONTROLLER
Replacement only: Remove knob for controller .

Install knob for controller only when controller is installed.
Release screws (1).
Feed controller (2) in direction of arrow out of trim (3) and remove.
Fig. 209: Removing Controller Out Of Trim

Replacement:
Carry out programming/coding.
61 31 195 REMOVING AND INSTALLING (REPLACING) FRONT CONTROLLER (FROM 09/2008)
Carefully raise catches (1) on controller holder (3) and remove controller (2) towards top.
2010 BMW M3
Installation:
Make sure controller (2) is correctly engaged in controller holder (3).
Fig. 210: Identifying Controller, Controller Holder And Catches

Replacement:
61 31 204 REPLACING SWITCH COMBINATION FOR SEAT ADJUSTMENT
REPAIR (SEDAN) .
Unlock retaining tabs (3) in direction of arrow and remove switch combination (1) from cover.
Installation:
Retaining tabs (3) of cover and guide (4) of switch combination (1) must not be damaged.
Make sure switch combination (1) is correctly seated in retaining tabs (3).
2010 BMW M3
Fig. 211: Unlocking Retaining Tabs

61 31 208 REMOVING AND INSTALLING/REPLACING SWITCH FOR LUMBAR SUPPORT
REPAIR (SEDAN) .
Unlock catches (1).
Remove switch for lumbar support (2) in direction of arrow.
Fig. 212: Removing Switch For Lumbar Support

61 31 229 REMOVING AND INSTALLING/REPLACING BOTH SWITCHES ON SPORT STEERING

2010 BMW M3
WHEEL
Remove airbag unit . See 32 34 030 REMOVING AND INSTALLING/REPLACING AIRBAG

UNIT (SPORT STEERING WHEEL) .
NOTE: Illustrations show multifunction steering wheel (4) removed.
Release screws (1).
Detach decorative trim (3) in direction of arrow from holders (2).
Disconnect associated plug connection and remove complete decorative trim (3).
Installation:
Make sure electrical leads are correctly routed.
Fig. 213: Detaching Decorative Trim

Feed wiring harness (4) out of associated holders.
Release screws (1) and remove both multifunction steering wheel switches (2) from decorative trim (3).
Installation:
Make sure there is a uniform gap between both multifunction steering wheel switches (2) and decorative trim
(3).
2010 BMW M3
Fig. 214: Identifying Wiring Harness, Screws, Switches And Decorative Trim
61 31 235 REPLACING MICROSWITCH ON LEFT OR RIGHT FRONT SEAT
Necessary preliminary tasks: Remove carrier of outer cover on front seat. If necessary, partially detach seat
cover.
Remove plug connection (1) from microswitch cover (2) and disconnect. Unclip microswitch cover (2) and
remove in direction of arrow. Installation: Make sure microswitch cover is correctly seated.
Remove screw (1) completely by pulling gently. Note that screw (1) goes through two thread turns. Raise
locking pawl (2) slightly by pulling release handle and remove microswitch (3) in direction of arrow.
Installation: Make sure bushing (1) and guides (2) are correctly seated. Tightening torque, see 52 10 11AZ in 52
10 FRONT SEATS .
Installation: Before fitting microswitch cover (4), carry out function test of microswitch (3) with backrest folded
back: Insert microswitch plug connection. Switch ignition on Locking pawl (1) is at bottom, microswitch (3) is
actuated, belt warning lamp must not light up/flash. Raise locking pawl (1) with release handle, microswitch (3)
is not actuated, belt warning lamp must flash. If necessary, replace microswitch (3). Important! Do not bend
switching spring (2) on microswitch (3).
61 31 241 REMOVING AND INSTALLING/REPLACING RIGHT HOOD/BONNET CONTACT

SWITCH (M3)
64 1 020
NOTE: See HEATING AND AIR CONDITIONING - SPECIAL TOOLS .
Lever bonnet/hood contact switch (1) with special tool 64 1 020 out of microfilter housing upper section (2).
2010 BMW M3
Disconnect plug connection (3) and remove bonnet/hood contact switch (1).
Installation:
Make sure bonnet/hood contact switch (1) is correctly seated in microfilter housing upper section (2).
Fig. 215: Removing Bonnet/Hood Contact Switch

61 31 255 REPLACING SWITCH FOR DOOR MIRROR
Replacing rocker switch for side window operation
61 31 270 REPLACING SWITCH FOR REVERSING LIGHT
NOTE: The installation location of the reversing light switch can vary, depending on
the transmission model.
If necessary, remove rear underbody protection . See 51 75 001 REMOVING AND

INSTALLING/REPLACING LEFT OR RIGHT UNDERBODY COVER .
Version A:
Tightening torque, see 61 31 2AZ in 61 31 SWITCH .

2010 BMW M3
Fig. 216: Identifying Plug Connection And Reversing Light (Version A)

Version B:
Tightening torque, see 61 31 2AZ in 61 31 SWITCH .
Fig. 217: Identifying Plug Connection And Reversing Light (Version B)

61 31 299 REMOVING AND INSTALLING/REPLACING CLUTCH SWITCH MODULE
Remove trim panel for pedal assembly. See 51 45 185 REMOVING AND
2010 BMW M3
NOTE: Clutch master cylinder (2) is removed for purposes of clarity.
Lever out clutch switch module (1) from clutch master cylinder (2) with screwdriver.
Unlock plug (4) and disconnect from housing (3).
Fig. 218: Unlocking Plug

Installation:
Clutch switch module is secured against incorrect installation.
Clutch switch module must snap audibly into place.

61 31 310 REPLACING BRAKE LIGHT SWITCH

2010 BMW M3
Remove trim panel for pedal assembly. See 51 45 185 REMOVING AND
Pull brake light switch (2) in direction of arrow out of brake light switch holder (3).
Installation:
Press brake pedal (4) to floor.

Slide brake light switch (2) as far as it will go into brake light switch holder (3).
Grip brake light switch holder (3), slowly return brake pedal (4) to starting position and pull back to
stop.
Fig. 220: Pulling Brake Light Switch

NOTE: Removing brake light switch holder (2):

Press brake pedal.
Press catches (1) together and unclip brake light switch holder (2) from bearing
block (3).
2010 BMW M3
Fig. 221: Removing Brake Light Switch Holder

61 31 342 REMOVING AND INSTALLING/REPLACING GEAR SELECTOR SWITCH (TWIN

CLUTCH TRANSMISSION)
protection).
Disconnect battery negative lead.

Remove parking lock cable from transmission
Replacement:
Remove shift lever knob for twin clutch transmission (3).

2010 BMW M3
Fig. 222: Identifying Plug Connection And Shift Lever Knob For Twin Clutch Transmission
Release screws (1). Tightening torque, see 61 31 2AZ in 61 31 SWITCH .
Feed gear complete gear selector switch (4) with cable and rubber seal (2) upwards out of center console (5).
Installation:
Make sure rubber seal (2) is correctly fitted. Retaining lugs (3) of gear selector switch (4) must be positioned in
associated openings in rubber seal (2). Feed in rubber seal (2) between center console (5) and carpet (6).
Fig. 223: Identifying Screws, Gear Selector Switch, Rubber End And Center Console
Replacement:
Carry out vehicle programming/coding.

2010 BMW M3

If necessary, release screws for coolant expansion tank and raise coolant expansion tank slightly

61 31 492 REPLACING LEVEL SWITCH FOR WINDSCREEN WASHER SYSTEM
Release fluid reservoir for windscreen washer system and pull out. See .
Turn level switch for windscreen washer system (2) in direction of arrow and remove towards bottom from
fluid reservoir for windscreen washer system (3).
2010 BMW M3
Fig. 225: Turning Level Switch For Windscreen Washer System

61 31 996 CARRYING OUT STEERING ANGLE SENSOR ADJUSTMENT
IMPORTANT: In vehicles with active front steering, steering angle sensor adjustment is
integrated in the service function "Initial operation/adjustment for active front
steering" and must not be carried out separately!. See 61 31 996 CARRYING
OUT STEERING ANGLE SENSOR ADJUSTMENT .
NOTE: Steering angle sensor adjustment must be carried out:
after adjustment work on the front axle/steering

after all mechanical work on the steering system
E46 (AWD), E53, E83: after disconnection of battery
after replacement / coding / programming of the following components:
Fixture for switches of steering column / switch cluster / steering
angle sensor
Dynamic Stability Control (DSC) control unit
Control unit active anti-roll stabilization (ARS)
Connect vehicle to BMW diagnosis system or Software Service Station.
Select and carry out steering angle sensor adjustment under Service functions.
HORN
61 33 060 REMOVING AND INSTALLING/REPLACING BOTH FANFARE HORNS (M3)

2010 BMW M3
Remove front left wheel arch trim . See 51 71 039 REMOVING AND INSTALLING/REPLACING
FRONT LEFT OR RIGHT WHEEL ARCH COVER (REAR SECTION) .
NOTE: Headlight shown removed for purposes of clarity.
Unscrew nuts (2). Tightening torque, see 61 33 1AZ in 61 33 HORN .
Remove fanfare horns (3) from holder (4).
Fig. 226: Identifying Plug Connection, Nuts, Horns And Holder

CONTROL UNITS, MODULES

61 35 ... OVERVIEW OF CONTROL UNITS
2010 BMW M3
Fig. 227: Identifying Control Units Part Location

61 35 ... NOTES ON ESD PROTECTION (ELECTRO STATIC DISCHARGE)
12 7 060

warning symbol.
E -Electro
S -Static
2010 BMW M3
D -Discharge
IMPORTANT: Read and comply without fail with the notes on this subject from Service
Information 2 06 04 128 .
Statically charged persons can discharge by touching electrical components.
The danger threshold for electrical components already starts from a level of approx. 100 V.
Fig. 228: Precaution For Touching Electrical Components

Example:

2010 BMW M3
Fig. 230: Precaution For Do Not Touch Pins Or Multi-Pin Connectors Directly
IMPORTANT: Do not touch pins or multi-pin connectors directly!

IMPORTANT: To prevent electrical components from being damaged or destroyed by

electrostatic discharge, it is absolutely essential to comply with the following
instructions:

to be installed
Read and comply with user information on using the associated special
tool 12 7 060

2010 BMW M3
Fig. 231: Identifying Antistatic Shoes For Safety Purpose

61 35 015 REMOVING AND INSTALLING (REPLACING) CONTROL UNIT FOR CAR ACCESS
SYSTEM
protection).
NOTE: The comfort access system is a radio-based system and can be interfered with
by radio waves from other systems (e.g. mobile phone).
Remove trim for pedal assembly
IMPORTANT: Carefully disconnect plug connection for ribbon cable (1).
Insert for radio control key

Start/Stop switch
2010 BMW M3
Fig. 232: Identifying Plug Connection, Ribbon Cable, Screw And Car Access System
Release screw (3).
Feed out control unit for Car Access System (4) to left and remove in downward direction.
Installation:
Feed guide (1) of control unit for Car Access System (2) correctly into associated mounting.
Fig. 233: Identifying Guide And Car Access System

Replacement:

Version with independent heating:
2010 BMW M3
Initialize Telestart hand transmitter
61 35 080 REMOVING AND INSTALLING (REPLACING) CONTROL UNIT FOR LEFT OR RIGHT
SEAT ADJUSTMENT (FRONT SEAT)
protection).
NOTE: To facilitate installation/removal of control unit, move seat upwards fully.
Unlock metal lug (1) towards front and remove control unit for seat adjustment (2) towards bottom.
Unlock and disconnect all associated plug connections.
Fig. 234: Unlocking Metal Lug

Installation:
Make sure control unit for seat adjustment (1) is correctly seated in mounting (2).
Guides (3) and metal lug (4) must not be damaged.

2010 BMW M3
Fig. 235: Identifying Seat Adjustment, Mounting, Guides And Metal Lug
Replacement:
61 35 107 REMOVING AND INSTALLING OR REPLACING JUNCTION BOX ELECTRONICS
protection).

Remove footwell side trim panel on A-pillar, right. See 41 35 010 REMOVING AND
INSTALLING/REPLACING SIDE PANEL, FRONT LEFT OR RIGHT .
Remove trim for instrument panel, bottom right. See 51 45 181 REMOVING AND
INSTALLING/REPLACING BOTTOM RIGHT TRIM FOR INSTRUMENT PANEL .
NOTE: Glovebox removed for purposes of clarity.
Release screws (2) and remove junction box electronics (3) from holder.
2010 BMW M3
Fig. 236: Identifying Plug Connection, Screws And Junction Box Electronics
Installation:
Make sure junction box electronics is correctly seated on plug connection (2) of holder.

Replacement:
Delete transport mode.
61 35 115 REMOVING AND INSTALLING/REPLACING FOOTWELL MODULE

2010 BMW M3
protection).
Remove footwell side trim panel on A-pillar, left . See 41 35 010 REMOVING AND
INSTALLING/REPLACING SIDE PANEL, FRONT LEFT OR RIGHT .
Release nuts (2) and remove footwell module (3).
Fig. 238: Identifying Plug Connection, Nuts And Footwell Module

Replacement:
61 35 177 REMOVING AND INSTALLING (REPLACING) RAIN/LIGHT SENSOR
protection).
Version with Autobeam:
Remove interior rear-view mirror . See 51 16 060 REMOVING AND INSTALLING/REPLACING

INTERIOR REARVIEW MIRROR (WITH RAIN SENSOR) .
Detach two-part mirror base cover (1) by pressing from below.

2010 BMW M3
NOTE: Catches of two-part mirror base cover (1) must not be damaged or missing.

Release locks (1) in direction of arrow and remove rain/light sensor (2) from optical element.
Installation:
Do not damage optical element covered by rain/light sensor (2).
Initialize rain/light sensor.
Fig. 240: Removing Rain/Light Sensor

2010 BMW M3
Replacement:
61 35 502 REPLACING TRAILER MODULE (09/2006-03/2009)
61 0 202
61 0 230
61 0 316
61 0 324
NOTE: From 03/2009 trailer module AHM3+ will be replaced by trailer module AHM4R.
Plug connectors and associated pin assignments must be adapted if the old plug connector AHM3(+) is fitted.
A. Plug connector, new AHM4

B. Plug connector, old AHM3(+)
Fig. 241: Identifying Plug Connector Models

Remove trailer module
From build date/version 03/2007 Series E60/61:
Installation:
2010 BMW M3
Cut out device holder up to marking (1).
Cut out indentation in area (2).
Make sure AHM module is exactly seated and wiring harness is correctly routed.
Fig. 242: Identifying Marking On Device Holder

NOTE: Positions of plugs and associated pin assignments are set out in the diagnosis
system.
The repair instruction represents the highest vehicle configuration. Pin assignments of plug connections may be
absent if optional equipments are not fitted.
Special tools for disconnecting:
Secondary lock:
Primary lock:
Special tool for crimping:
Double flat spring contact:
Crimping tool special tool 61 0 202 (crimping tool) with special tool 61 0 230 (matrix)
SPECIAL TOOL FOR CRIMPING REFERENCE CHART

(09/2006 - 03/2009)
2010 BMW M3
Previously AHM3(+) New AHM4R

Pin no. Contact (mm2 ) Pin no. Contact (mm2 )
1 2.8 13 2.8
2 2.8 20 2.8
3 0.63 - -
4 0.63 17 0.63
5 0.63 2 0.63
6 0.63 3 0.63
7 0.63 11 0.63
8 0.63 9 0.63
9 0.63 10 0.63
10 0.63 18 2.8
Recrimp contact from 0.63 mm2 to 2.8 mm2
11 0.63 14 2.8
12 0.63 15 2.8
13 0.63 19 2.8
14 0.63 12 2.8
15 0.63 16 0.63
16 0.63 1 2.8
- - 4-8 0.63
61 35 679 INITIALIZING RAIN/LIGHT (SOLAR) SENSOR
NOTE: Initialization is necessary:
after replacing windscreen

after replacing rain/light (solar) sensor
after replacing optical element on rain/light (solar) sensor
after installing a used rain/light (solar) sensor
NOTE: Connect BMW diagnosis system

Initializing rain/light (solar) sensor
2010 BMW M3
61 35 950 REMOVING AND INSTALLING (REPLACING) CONTROL UNIT FOR COMFORT

ACCESS SYSTEM
protection).
Remove right luggage compartment trim panel . See 51 47 220 REMOVING AND
INSTALLING/REPLACING LUGGAGE COMPARTMENT TRIM PANEL ON RIGHT SIDE
PANEL .
Partially detach insulating mat
Fig. 243: Identifying Screws And Device Holder

Unlock catch (2) in direction of arrow and remove control unit for comfort access system (3) upwards from
device carrier (4).
2010 BMW M3
Fig. 244: Unlocking Catch

Replacement:

ACCESS SYSTEM
Remove trim for storage tray . See 51 16 212 REMOVING AND INSTALLING TRIM FOR
STORAGE COMPARTMENT .
Unlock retaining hook (2) and remove interior antenna for comfort access system (3) in direction of arrow.
2010 BMW M3
Fig. 245: Removing Interior Antenna For Comfort Access System


ACCESS SYSTEM (REAR)
00 9 323
Move with special tool 00 9 323 from below behind trim (1) and release catches (2).
Fig. 246: Identifying Catches And Trim

Installation:
Guides (2) must not be damaged

2010 BMW M3

Unlock retaining hook (2) and remove luggage compartment antenna for comfort access system (3).
Fig. 248: Identifying Plug Connection, Retaining Hook And Comfort Access System
61 35 970 REMOVING AND INSTALLING/REPLACING REAR LUGGAGE COMPARTMENT

ANTENNA FOR COMFORT ACCESS SYSTEM
Remove luggage compartment floor trim panel. See 51 47 101 REMOVING AND

2010 BMW M3
Unlock catches (2) and remove luggage compartment antenna for comfort access system (3) in direction of
arrow from holder (4).

61 35 975 REMOVING AND INSTALLING/REPLACING BUMPER ANTENNA FOR COMFORT

ACCESS SYSTEM
Remove rear bumper trim . See 51 12 156 REMOVING AND INSTALLING REAR BUMPER
TRIM .
Unlock catches (1) and remove bumper antenna for comfort access system (3) in direction of arrow from holder.
Installation:
Make sure bumper aerial/antenna for comfort access system (3) is correctly seated in holder.
2010 BMW M3
Fig. 250: Removing Bumper Antenna For Comfort Access System

VEHICLE PROGRAMMING AND CODING
Select menu item (1).
Select corresponding procedure from selection list.
Example:
Preparation and subsequent evaluation of vehicle programming

Start a Progman session
Sequence of BMW/MINI vehicle programming and coding
BMW/MINI Car&Key Memory
BMW/MINI initializations
BMW/MINI service functions in Progman
2010 BMW M3
Fig. 251: Screen Display - Menu Item

NOTE: In order to avoid incorrect programming procedures and error messages, it is

essential when working with the Progman programming system always to use
the latest Progman version.
RELAY
61 13 ... DME MASTER RELAY CONNECTOR
Unlock locking flap (1) of corresponding cable.
Fig. 252: Unlocking Locking Flap Of Corresponding Cable

cable.

2010 BMW M3
61 13 ... RELAY CARRIER
Place special tool 61 1 153 on relay carrier (1) and carefully pull in direction of arrow until retaining lugs (2) on
relay carrier are raised.
Fig. 254: Identifying Retaining Lugs

Pull relay carrier (2) in direction of arrow into first catch (3).

Press down arrester hook (4) of appropriate contact and pull out cable with contact.
Press out double flat spring contact with special tool 61 1 136 or 61 1 137 (ejector).
2010 BMW M3

WINDSCREEN WIPERS
61 61 ... OVERVIEW OF WINDSCREEN WIPER AND WASHER SYSTEM
2010 BMW M3
Fig. 257: Identifying Windscreen Wiper And Washer System Components Location
61 61 ... ADJUSTING LEFT OR RIGHT WINDSCREEN WIPER
61 6 100

2010 BMW M3
Fig. 258: Identifying A/B Distance Between Windscreen Wiper Blade And Trim Panel
A/B = Distance between windscreen wiper blade (2) and trim panel on cowl panel (1)
NOTE: Measurement is taken at the height of the locators (3) for the windscreen wiper
arms
C= Contact angle between wiper blade center plane and windscreen
When adjusting with special tool 61 6 100 , set the scale value in accordance with the following table.
For RHD cars, change the preceding sign of the scale values.
LHD cars, scale range 0 to -10

RHD cars, scale range 0 to +10
SCALE VALUE REFERENCE CHART

Contact angle (C) on Scale value (LHD) on Adjustment dimension (A, B) on
windscreen wiper arm special tool windscreen wiper arm
Model
Passenger Driver Driver
Passenger side Driver side Passenger side Rear end
side side side
2010 BMW M3
85.5 +1.5 - 85.5 +1.5 -

E81 -5 -5 473 mm 543 mm
1.0 1.0
85.5 +1.5 - 85.5 +1.5 -
E82 -5 -5 473 mm 543 mm
1.0 1.0
1'
85.5 +1.5 - 85.5 +1.5 -
E87 -5 -5 473 mm 543 mm
1.0 1.0
85.5 +1.5 - 85.5 +1.5 -
E88 -5 -5 473 mm 543 mm
1.0 1.0
E46 85.7 1 85.3 1 -4 -5
E90 86.71 86.0 1 -3 -4 883 mm 953 mm
3' E91 86.7 1 86.0 1 -3 -4 883 mm 953 mm 353 mm
E92 86.71 86.0 1 -3 -4 753 mm 843 mm
E93 86.71 86.0 1 -3 -4 753 mm 843 mm
60.11
E39 86.5 1 86.5 1 -4 -4
mm
5'
E60 86.0 1 86.0 1 -4 -4 693 mm 873 mm
E61 86.0 1 86.0 1 -4 -4 693 mm 873 mm 303 mm
E63 86.0 1 86.0 1 -4 -4 693 mm 873 mm
6'
E64 86.0 1 86.0 1 -4 -4 693 mm 873 mm
E38 87.0 1 87.0 1 -3 -3 653 mm 583 mm
E65 85.5 1 87.0 1 - - 203 mm 483 mm
7'
E66 85.5 1 87.0 1 - - 203 mm 483 mm
E67 85.5 1 87.0 1 - - 203 mm 483 mm
8' E52 85.5 1 85.5 1 -4 -4 382 mm 1042 mm
32.52
E53 85.0 1 85.0 1 -5 -5 543 mm 553 mm
mm
X E70 85.6 1 85.0 1 -4 -5 1033 mm 903 mm 392 mm
E71 85.6 1 85.0 1 -4 -5 1033 mm 903 mm
E83 85.2 1 85.4 1 -5 -5 663 mm 613 mm 291 mm
E85/E89 85.5 1 85.5 1 -4 -4 572 mm 522 mm
Z
E86 85.5 1 85.5 1 -4 -4 572 mm 522 mm
61 61 010 CHECKING/ADJUSTING CONTACT ANGLE OF WINDSCREEN WIPER ARMS ON

WINDSCREEN
61 6 100
61 6 110

2010 BMW M3
NOTE: Wiping quality is increased if the approach angle of the windscreen wiper arms
is precisely adjusted.
Adjusting dimensions of wiper arms:
Reference points (A, B) are the mountings of the wiper blades on the wiper arms to the sealing lip (1) of the
cowl panel.
Contact angle (C) is the angle between wiper blade center plane (2) and windscreen.
Fig. 259: Identifying Dimensions Of Relevant Wiper Arm

Remove wiper blade (1) from wiper arm (2).
Pin (3) is locator for special tool 61 6 100 .
Fig. 260: Identifying Wiper Blade, Wiper Arm And Pin

2010 BMW M3
Slide special tool 61 6 100 onto pin (1).
Place special tool 61 6 100 on windscreen (2) and read off value in degrees on scale.
NOTE: LHD vehicles are covered by the scale range of 0 to -10 and RHD vehicles by the
scale range of 0 to +10.
Fig. 261: Placing Special Tool On Windscreen

If the specified number in degrees is not correct, the wiper arm (1) must be bent with the special tool 61 6 110 at
the point shown.
Fig. 262: Betting Wiper Arm With Special Tool

61 61 041 REPLACING BOTH WINDSCREEN WIPER BLADES
IMPORTANT: Make sure the wiper arm does not contact the windscreen without its wiper
2010 BMW M3
blade.
Fold wiper arm (3) away from windscreen.
Press lock (1) and remove cover cap (2) in direction of arrow.
Installation:
Make sure cover cap (2) is correctly seated.

Turn windscreen wiper blade (1) at an angle of 90 and remove from windscreen wiper arm (2).
Fig. 264: Turning Windscreen Wiper Blade

Installation:
2010 BMW M3
Catches (1) and guide (2) of window cavity cover cap (6) must not be damaged or missing.
Fig. 265: Identifying Catches, Guide And Window Cavity Cover Cap
61 61 100 REMOVING AND INSTALLING/REPLACING BOTH WINDSCREEN WIPER ARMS
61 6 210
Take off cap.
Fig. 266: Removing Windscreen Wiper Arms Cap

Unfasten nut. Tightening torque, see 61 61 11AZ in 61 61 WINDSCREEN WIPERS .

2010 BMW M3
Fig. 267: Locating Windscreen Wiper Arms Nut


Do not bend windscreen wiper arm when removing.
Detach windshield wiper arm with special tool 61 6 210 .
Fig. 268: Identifying Special Tool On Windshield Wiper Arm

Installation:
Windscreen wiper motor must be in its rest position.
Observe adjustment dimensions.
Adjust position of relevant windscreen wiper arm (measured between windscreen wiper blade and trim panel on
cowl panel at height of windscreen wiper arm locator).
2010 BMW M3
Tighten down windscreen wiper arm and check adjustment dimensions of respective windscreen wiper arm
again.
Check and if necessary adjust contact angle.
61 61 270 REMOVING AND INSTALLING/REPLACING BRACKET FOR WINDSCREEN WIPER

SYSTEM COMPLETE WITH MOTOR
Remove both wiper arms

Remove lower section of microfilter housing . See 64 31 062 REMOVING AND
INSTALLING/REPLACING LEFT LOWER MICROFILTER HOUSING SECTION and 64 31
063 REMOVING AND INSTALLING/REPLACING RIGHT LOWER MICROFILTER
HOUSING SECTION .
Remove cowl panel cover .
Remove both tension struts from spring strut dome.
Release screws (2) from left heater bulkhead (3).
Remove left heater bulkhead (3) towards top.
Unclip cable (1) for wiper motor from holder.
Release screws (5) for wiper bracket (4).
Tightening torque, see 61 61 11AZ in 61 61 WINDSCREEN WIPERS .
Remove wiper bracket (4) upwards.
Disconnect plug for wiper motor.

2010 BMW M3
Fig. 269: Identifying Screws, Heater Bulkhead, Cable And Wiper Bracket
Installation:
Rubber mount (1) and rubber guide (3) must not be missing.
Rubber guide (3) must be correctly seated in guide (2).
Fig. 270: Identifying Rubber Mount And Rubber Guide

Installation:
Before fitting the wiper arms, allow the windscreen wiper motor to run into the rest position.
To ensure that the windscreen wiper system functions properly, check/adjust the contact angle of the wiper
arms to the windscreen.
HEADLIGHT WASHER SYSTEM

61 67 010 REMOVING AND INSTALLING/REPLACING WASHER PUMP OF HEADLIGHT
WASHER SYSTEM
Release fluid reservoir for windscreen washer system and pull out.

2010 BMW M3
Unlock split pin (3) and detach hose (2) from washer pump of headlight washer system (4).
Turn washer pump of headlight washer system (4) and pull in direction of arrow out of fluid reservoir for
windscreen washer unit (5).
Fig. 271: Turning Washer Pump Of Headlight Washer System

Installation:
Replace strainer for washer pump of headlight washer system.

Coat sealing ring of washer pump for headlight cleaning system with antiseize agent.
Lay hose of washer pump for headlight cleaning system without kinks
61 67 083 REMOVING AND INSTALLING/REPLACING HIGH-PRESSURE NOZZLE OF

HEADLIGHT WASHER SYSTEM ON LEFT OR RIGHT (M3)
13 3 010
NOTE: See FUEL SYSTEM - SPECIAL TOOLS .
Remove front bumper trim. See 51 11 156 REMOVING AND INSTALLING FRONT BUMPER
TRIM.
To prevent excessive escape of washer fluid, seal off end of high-pressure line with special tool 13 3 010 .

2010 BMW M3
Fig. 272: Identifying Special Tool On High-Pressure Line

Unlock catches (1) and remove high-pressure nozzle (2) towards rear from headlight arm (3).
Raise retaining clip (4) in direction of arrow and detach high-pressure line (5) from high-pressure nozzle (2).
Installation:
Keep plug connection for high-pressure nozzle (2) and high-pressure line (5) clean and free from grease.
Make high-pressure line (5) and high-pressure nozzle (2) are correctly seated and engaged on high-pressure
nozzle (2) and headlight arm (3) respectively.
Carry out a function test before fitting bumper trim.
Fig. 273: Raising Retaining Clip

2010 BMW M3
WINDOW WASHER SYSTEM

61 71 015 REMOVING AND INSTALLING/REPLACING A SPRAY NOZZLE IN WINDSCREEN
WASHER SYSTEM
NOTE: The jet nozzles of the windscreen washer system are preset at the factory and
cannot be readjusted.
Remove lower section of microfilter housing . See 64 31 062 REMOVING AND

INSTALLING/REPLACING LEFT LOWER MICROFILTER HOUSING SECTION and 64 31
063 REMOVING AND INSTALLING/REPLACING RIGHT LOWER MICROFILTER
HOUSING SECTION .
Press detent lug (1).
Detach unlocked plug housing (2) in direction of arrow.
Detach hose (3) from spray nozzle.
Fig. 274: Detaching Unlocked Plug Housing

Release spray nozzle (1) in direction of arrow from cowl panel cover and remove.
Installation:
Make sure spray nozzle (1) is correctly seated.

2010 BMW M3
Fig. 275: Releasing Spray Nozzle

Installation:
Following parts of spray nozzle (4) must not be damaged or missing:
Plug connection
Hose connection
Detent lug, bottom
Detent lug, top
Fig. 276: Identifying Spray Nozzle, Plug Connection, Hose Connection, Detent Lug, Bottom And Top
61 71 061 REPLACING FLUID RESERVOIR FOR WINDSCREEN WASHER SYSTEM
Remove front right auxiliary turn indicator light . See 63 13 200 REMOVING AND
INSTALLING/REPLACING FRONT LEFT OR RIGHT AUXILIARY DIRECTION
2010 BMW M3
INDICATOR (M3) .
Remove right wheel arch cover
Clip cable (1) out of mounting.
Clip hose (5) out of mounting.
Unlock filler hose (2) and detach from fitting on fluid reservoir (3).
Unscrew screws (4) and (6).
Pull fluid reservoir (3) forwards slightly.
Fig. 277: Identifying Clip Cable, Hose, Filler Hose, Fluid Reservoir And Screws
Installation:
Retaining lug (2) of fluid reservoir (1) must be correctly seated in clip (3).
2010 BMW M3
Fig. 278: Identifying Lug, Fluid Reservoir And Clip

Unlock and disconnect all plug connections.
Remove level switch (1).
Remove windscreen washer pump (3).
If necessary, remove washer pump for rear window washer system (2).
If necessary, remove washer pump for headlight washer system (4).
Remove washer reservoir.
Fig. 279: Identifying Level Switch, Windscreen Washer Pump And Washer Pump For Rear Window
Washer System
Installation:
2010 BMW M3
Replace strainers on washer pumps

Coat sealing rings of washer pumps with antiseize agent
Lay lines of washer pumps without kinks and clip into holders on fluid tank
Fill fluid tank for windscreen washer system
61 71 100 REMOVING AND INSTALLING/REPLACING WINDSCREEN WASHER PUMP
Release fluid reservoir for windscreen washer system and pull out
Detach hose from windscreen washer pump (1).
Turn windscreen washer pump (1) and pull in direction of arrow out of fluid reservoir for windscreen washer
unit.
Fig. 280: Turning Windscreen Washer Pump

Installation:
Replace strainer for windscreen washer pump

Coat sealing ring of windscreen washer pump with antiseize agent
Lay hose of windscreen washer pump without kinks
2010 BMW M3
HVAC Heating and Air Conditioning - Repair
HVAC
Heating and Air Conditioning - Repair
GENERAL
EQUIPMENT)
reactions!

of ignition.
sunlight.
month).


directly.
2010 BMW M3
First Aid:
doctor.
Recycling


function is active.

2010 BMW M3

Workshop mode
A = 10 mm
B = 7 mm

HEATER WITH OPERATION

64 53... OVERVIEW OF A/C CIRCUIT COMPONENTS
2010 BMW M3
Fig. 3: Overview Of A/C Circuit Components

64 11.. OVERVIEW OF ACTUATOR DRIVES ON HEATER/AIR CONDITIONER

2010 BMW M3
Fig. 4: Overview Of Actuator Drives On Heater/Air Conditioner

64 11 856 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR CENTRAL

KINEMATICS (A/C CONTROL)
IMPORTANT: Servomotors must be re-addressed in the event of replacement!

Addressing can only be carried out with the BMW diagnosis system.
2010 BMW M3
Service functions:
Body
Heating and A/C function
Flap motors
Re-address flap motors
Detach right footwell heating duct (1) in area (2) in direction of arrow.
Detach right footwell heating duct (1) with adapter (3) from heater/air conditioner and remove in direction of
arrow from right rear compartment heating duct (4).
Fig. 5: Disconnecting Footwell Heating Duct

Release screws (2).
Detach servodrive for central kinematics (3) in direction of arrow from heater/air conditioner (4).
Installation:
Place servodrive for central kinematics (3) over guide pin (5).
2010 BMW M3
Fig. 6: Identifying Heater/Air Conditioner, Plug Connection With Screws

64 11 206 REMOVING AND INSTALLING/RENEWING HEATING UNIT

Refrigerant circuit is under high pressure!
Avoid contact with refrigerant and refrigerant oil.
Follow safety instructions for handling R 134a refrigerant See 6450...

SAFETY INSTRUCTIONS FOR HANDLING R134A REFRIGERANT or
6450... INSTRUCTIONS FOR HANDLING REFRIGERANT R 134A.
Follow safety instructions for HANDLING REFRIGERANT OIL .
FOLLOW INSTRUCTIONS FOR WORKING ON COOLING SYSTEM .

Restart engine only when air conditioning system has been correctly filled.
Follow INSTRUCTIONS for opening and replacing parts in refrigerant circuit.
If air conditioning system is opened for more than 24 hours:REPLACE
DESICCANT INSERT FOR A/C SYSTEM
Draw off REFRIGERANT FROM A/C SYSTEM

Remove LOWER SECTION OF STEERING SPINDLE
Remove LEFT (OR RIGHT) SUSPENSION CROSSBRACE
Remove EXPANSION VALVE
2010 BMW M3
Remove COMPLETE STEERING COLUMN

Remove AIR DUCTS
Remove CARRIER FOR INSTRUMENT PANEL
Release cap (1) on bulkhead and release screw underneath.
Fig. 7: Identifying Cap On Bulkhead

Unclip refrigerant lines (2).
Unscrew nuts (2).
Feed out media passage sealing plate (3) and associated rubber grommet.
Installation:
Makes sure media passage sealing plate and associated rubber grommet are correctly seated.
IMPORTANT: Carefully blow through aluminum double pipe to remove remaining coolant
from heat exchanger for heating system.
2010 BMW M3
Fig. 8: Identifying Sealing Plate, Refrigerant Lines With Nuts

IMPORTANT: Protect working area (1) against escaping coolant.
Remove heater (2) with a second person helping from vehicle.
Fig. 9: Identifying Working Area Of Coolant And Heater

Installation:
Make sure heater is correctly seated.
Make sure condensate drain (2) is correctly seated in grommet (1).

2010 BMW M3
Fig. 10: Identifying Condensate Drain And Grommet

After installation
VENT COOLING SYSTEM AND CHECK FOR WATER LEAKS

EVACUATE AND FILL A/C SYSTEM
Replacement
Effective 09/2009, vehicles with SA 606 (Navigation Business) or SA 609 (Navigation Professional) will no
longer have ventilation hose (1) on heater (2). In addition, vehicles manufactured up to 09/2009 will no longer
require ventilation hose (1) for parts replacement.
Fig. 11: Identifying Ventilation Hose On Heater

2010 BMW M3
64 11 262 REMOVING AND INSTALLING/REPLACING AUXILIARY WATER PUMP (S65)

Follow INSTRUCTIONS FOR WORKING ON COOLING SYSTEM .
Recycling
Coolant emerges when coolant lines are detached. Have a suitable collecting container ready.
Catch and dispose of emerging coolant.
Remove SUCTION FILTER HOUSING
Disconnect plug connection (1) and remove auxiliary water pump (2) towards top.
Fig. 12: Identifying Plug Connection And Water Pump

Installation:
Observe direction of flow.
Mark position of water hoses (1) prior to removal.

2010 BMW M3
Fig. 13: Identifying Water Hoses And Water Pump

Disconnect water hoses (1) and remove auxiliary water pump (2).
Installation:
Install auxiliary water pump (1) in front engine bracket so that rubber mounts (2) slide exactly in associated
locators (3).
Fig. 14: Identifying Water Pump Of Front Engine Bracket, Rubber Mounts And Locators
After installation
Fill and vent cooling system and check for leaks See 1700005 DRAINING AND ADDING COOLANT
(S65) ; 1700039 VENTING COOLING SYSTEM AND CHECKING FOR WATER LEAKS (S65) or
1700009 CHECKING COOLING SYSTEM FOR LEAKS (S65)
64 11 908 REMOVING AND INSTALLING/REPLACING FOOTWELL TEMPERATURE SENSOR

2010 BMW M3
NOTE: For purposes of clarity, the following graphic shows the heater/air conditioner
removed.
Remove air routing duct (1) and unscrew temperature sensor (2).
Fig. 15: Identifying Air Routing Duct And Temperature Sensor

64 11 212 REMOVING AND INSTALLING/REPLACING HEATER/AIR CONDITIONER FAN

Partially release air duct at side

2010 BMW M3

Carefully raise lug (1) and feed out housing (2) by turning clockwise.
Installation:
Lug (1) must not be damaged and must snap audibly into place.
Fig. 17: Turning Lug And Housing

Replacement
Replace CONTROLLER FOR HEATER/AIR CONDITIONER FAN
64 11 377 REMOVING AND INSTALLING/REPLACING HEATER/AIR CONDITIONER

OPERATOR UNIT (VERSION WITHOUT CCC/ASK)
2010 BMW M3

DAMAGE (ESD PROTECTION) !
NOTE: Car Communication Computer (CCC) Audio System Kontroller/Controller (ASK)
Lever out heater/air conditioner operator unit (1) with special tool 00 9 340 and pull.
Fig. 18: Removing Heater/Air Conditioner Operator Unit With Centre Console Switch Cluster And Trim
Disconnect associated plug connections.
Remove heater/air conditioner operator unit (1) complete with center console switch cluster (2) and trim (3).
Replacement
Carefully unclip operator unit trim (1) at inner retaining points (2) only.
IMPORTANT: Risk of damage to operator unit (3)!

2010 BMW M3
Fig. 19: Identifying Clip Operator Unit Trim And Inner Retaining Points
Carefully unclip operator unit trim (1) at outer retaining points (2) only.
Remove trim (1) from operator unit (3).
Fig. 20: Identifying Clip Operator Unit Trim And Outer Retaining Points
Replacement
Carry out Vehicle programming and encoding.
64 11 378 REMOVING AND INSTALLING/REPLACING HEATING - A/C SYSTEM CONTROL

PANEL (VERSION WITH CCC/ASK AND CIC)

2010 BMW M3
Avoid subjecting the CIC to shaking/shocks.
PROTECTION) .
Abbreviations:
Central Information Computer (CIC)
Car Communication Computer (CCC)
Audio System Controller (ASK)
Remove RIGHT DECORATIVE TRIM ON INSTRUMENT PANEL
NOTE: Unclip the heater/air conditioner operator unit (2) by simultaneously
levering out using special tool using 00 9 340.

pulling on the relevant control button (3).
Fit special tool 00 9 340 on either side as illustrated.
Fig. 21: Identifying Heater/Air Conditioner Operator Unit With Trim

Unclip heater/air conditioner operator unit (2) complete with trim (1) at fastening points (4) and pull back.
2010 BMW M3
Remove heater/air conditioner operator unit (2) complete with trim (1).
Replacement
IMPORTANT: Risk of damage to control panel!
Fig. 22: Identifying Clip Operator Unit Trim And Inner Retaining Points
Remove trim (1) from control panel (3).
IMPORTANT: Risk of damage to control panel (3)!

2010 BMW M3
Fig. 23: Identifying Trim And Control Panel

Replacement:
Carry out Vehicle programming and encoding.
64 11 991 REMOVING AND INSTALLING/REPLACING SENSOR FOR AUTOMATIC

RECIRCULATED AIR CONTROL
Turn sensor for automatic recirculated air control (2) upwards and in direction of arrow and remove from
mounting (3).
Installation:
Make sure sensor for automatic recirculated air control (2) is correctly seated in mounting (3).
Fig. 24: Removing Automatic Recirculated Air Control Sensor

64 11 871 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR BLENDING FLAP

(LEFT)
REMOVE TRIM FOR INSTRUMENT PANEL AT BOTTOM LEFT

E84/E90/E91/E92/E93:
Remove PANEL FOR PEDAL ASSEMBLY
NOTE: Lower instrument panel trim partially shown transparent.

2010 BMW M3
Detach left footwell heating duct (1) in area (2) in direction of arrow.
Detach left footwell heating duct (1) with adapter (3) from heater/air conditioner and remove in direction of
arrow from left rear compartment heating duct (4).
Fig. 25: Removing Footwell Heating Duct

Installation:
Make sure retainer (2) is correctly seated on left footwell heating duct (1).
Insert left footwell heating duct (1) with adapter (3) in left rear compartment heating duct (4).
Attach left footwell heating duct (1) in area (4) to heater/air conditioner. Make sure assembly is locked exactly
at point (5).
Fig. 26: Identifying Footwell Heating Duct, Adapter And Retainer

2010 BMW M3
Detach servodrive for blending flap (3) in direction of arrow from heater/air conditioner (4).
Fig. 27: Removing Blending Flap Servodrive And Guide Pin

Installation:
Place servodrive for blending flap (3) over guide pin (5).
Service functions:
Body
Flap motors

(LEFT)

Service functions:
Body
2010 BMW M3

Flap motors
NOTE: For purposes of clarity, the following graphics show the heater/air conditioner
removed.
Release screws (2).
Remove servodrive at side.
Installation:
Do not twist teeth of servodrive.
Fig. 28: Identifying Plug Connection With Screws


(RIGHT)

E87 only:
2010 BMW M3
Remove center console

Installation:
Make sure retainer (2) is correctly seated on right footwell heating duct (1).
Insert right footwell heating duct (1) with adapter (3) in right rear compartment heating duct (4).
Attach right footwell heating duct (1) in area (4) to heater/air conditioner. Make sure assembly is locked exactly
at point (5).
2010 BMW M3

Fig. 31: Detaching Servodrive For Blending Flap

Installation:
Servomotors must be re-addressed in the event of replacement!
Service functions:
Body
Flap motors
64 11 868 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR DEFROSTING FLAP

(RIGHT)

2010 BMW M3
Service functions:
Body
Flap motors
Remove GLOVEBOX WITH HOUSING
removed.
Release screws (2).
Installation:

64 11 806 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR FRESH-

/RECIRCULATED-AIR FLAP

2010 BMW M3
Service functions:
Body
Flap motors
Release screws (2).
Detach servodrive for fresh-/recirculated-air flap (3) in direction of arrow from heater/air conditioner.
Fig. 33: Identifying Air Flap And Plug Connection With Screws
Installation:
Place servodrive for fresh-/recirculatedair flap (3) exactly on associated gear teeth.
64 11 992 REMOVING AND INSTALLING/REPLACING SOLAR SENSOR
Lever out solar sensor (1) with special tool 00 9 340 REMOVAL AID in direction of arrow.
NOTE: Secure disconnected wiring harness of solar sensor (1) against falling out
below instrument panel trim (2).
2010 BMW M3
Fig. 34: Removing Solar Sensor From Instrument Panel Trim Using Special Tool (00 9 340)
Disconnect associated plug connection and remove solar sensor (1) from instrument panel trim (2).
64 11 905 REMOVING AND INSTALLING/REPLACING VENTILATION TEMPERATURE SENSOR
REMOVE DECORATIVE STRIP ON INSTRUMENT PANEL ON RIGHT
Pull temperature sensor (1) out of retaining lug (2).
Installation:
Make sure rubber ring is correctly seated.
Fig. 35: Identifying Temperature Sensor And Retaining Lug

2010 BMW M3
Disconnect plug connection (1) and remove temperature sensor (2).
Fig. 36: Identifying Plug Connection And Temperature Sensor

64 11 829 REPLACING ACTUATOR DRIVE OF VENTILATION FLAPS
Detach servodrive for ventilation flaps (3) in direction of arrow from heater/air conditioner (4).
Installation:
Place servodrive for ventilation flaps (3) over guide pin (5).
2010 BMW M3
Fig. 37: Removing Ventilation Flaps Servodrive And Guide Pin

Replacement:
Service functions:
Body
Flap motors
64 11 224 REPLACING CONTROLLER FOR HEATER/AIR CONDITIONER FAN
Remove FAN for heater/air conditioner
Release screws (2) and remove controller.

2010 BMW M3

64 11 942 REPLACING EVAPORATOR TEMPERATURE SENSOR
Remove LOWER INSTRUMENT PANEL TRIM
Withdraw temperature sensor (2).
Installation:
Ensure temperature sensor (2) is correctly seated.

2010 BMW M3
indoors.
surface.
Fig. 40: Removing Two-Part Mirror Base Cover

40-60C.
2010 BMW M3
Fig. 41: Identifying Plug Connection And Fogging Sensor

Lift off fogging sensor (2) with special tool 00 9 317 and slowly pull off from windshield.
Installation:
Press fogging sensor (3) in direction of arrow with a contact pressure of > or = 15 N/cm2 onto inside of
windshield.

2010 BMW M3
Fig. 42: Pressing Fogging Sensor

64 11 208 REPLACING HEAT EXCHANGER
IMPORTANT: Determine manufacturer of installed heat exchanger (Denso or Behr) before

ordering spare parts!
Fig. 43: Identifying Heat Exchanger

Installation:
Up to 12/2009 pipes must be replaced as well!
From 01/2010 pipes are automatically integral parts of the repair kit!
2010 BMW M3
Refer to Electronic Parts Catalogue.
64 11 869 REPLACING SERVODRIVE FOR BLENDING FLAP
Fig. 44: Removing Blending Flap Servodrive From Heater/Air Conditioner

Installation:
Service functions:
Body
Flap motors
2010 BMW M3
64 11 839 REPLACING SERVODRIVE FOR FOOTWELL FLAP (AUTOMATIC A/C)

Service functions:
Body
Flap motors
Fig. 45: Disconnecting Footwell Heating Duct With Adapter From Heater/Air Conditioner
Detach bracket (4) complete with servodrives from heater/air conditioner (5).
Installation:
Make sure bracket (4) is correctly seated on heater/air conditioner (5).

2010 BMW M3
Fig. 46: Removing Bracket With Servodrives From Heater/Air Conditioner

Release screws (1).
Remove servodrive for footwell flap (2) from bracket (3).
Installation:
Place servodrive for footwell flap (2) over guide pin (4).
Fig. 47: Identifying Footwell Flap, Bracket And Guide Pin

64 11 850 REPLACING SERVODRIVE FOR REAR COMPARTMENT FLAP

Service functions:
2010 BMW M3
Body
Flap motors
Release screws (2).
Detach servodrive for rear compartment flap (3) in direction of arrow from heater/air conditioner (4).
Installation:
Place servodrive for rear compartment flap (3) exactly onto heater/air conditioner (4).
Fig. 48: Removing Rear Compartment Flap Servodrive From Heater/Air Conditioner
AUXILIARY HEATER WITH CONTROL ELEMENTS

64 12... INITIALIZING TELESTART HANDHELD TRANSMITTER (T93) (FROM BUILD DATE
03/2007)
NOTE: The Telestart hand-held transmitter must be initialized when:
Hand-held transmitter is replaced

Car Access System control unit is replaced
2010 BMW M3
The auxiliary heater is switched on when ambient temperature is approx. 15C with the hand-held transmitter
and at a preselected switch-on time.
Direct activation is possible at any ambient temperature via the "Climate" menu item in the i-Drive, but not in
driving mode.
To initialize a new hand-held transmitter, perform the following operations from inside the vehicle:
Close all doors on vehicle (vehicle must be unlocked!)

Within 5 seconds: Turn ignition lock from terminal "0" to terminal "R" and then back to terminal "0" (by
inserting and removing key, insertion duration: 1 to 5 secs.)
Within 5 seconds: simultaneously press both buttons (1, 2) on hand-held transmitter until LED (3) lights
up orange.
Release both buttons. Briefly press ON button (1) three times within 10 seconds; LED (3) flashes orange
as confirmation.
Fig. 49: Identifying Telestart Handheld Transmitter (T93) ON And OFF Button With LED
NOTE: The vehicle's central locking closes and opens automatically on successful
initialization.
The initialization process must be repeated if there is no feedback signal from the central locking system.
2010 BMW M3
64 12... INITIALIZING TELESTART HAND TRANSMITTER (T90) (UP TO BUILD DATE 03/2007)
NOTE: The Telestart hand transmitter must be initialized when:
Hand transmitter is replaced

The independent heating is switched on under an outside temperature of approx. 15C with the hand transmitter
Direct activation is possible at any outside temperature via the "Climate" menu item in the i-Drive, but not in
driving mode.
To initialize a new hand transmitter, perform the following operations from inside the vehicle:
Close all vehicle doors

Within 5 seconds: Switch ignition lock from terminal "0" to terminal "R" and then back to terminal "0"
Fig. 50: Identifying Telestart Handheld Transmitter (T93) ON And OFF Button With LED
Within 5 seconds: Press OFF button (1) on hand transmitter and with OFF button (1) held down press ON
button (2) three times quickly
Release both buttons. LED (3) on hand transmitter flashes
initialization.
The initialization process must be repeated if there is no checkback signal from the central locking system.
2010 BMW M3
64 12 160 REMOVING AND INSTALLING OR REPLACING COMPLETE INDEPENDENT HEATER

WITH BRACKET

Work on independent heating may only be carried out when it has cooled
down.
Recycling
Drain coolant from radiator

Remove front left wheel arch trim
NOTE: For purposes of clarity, graphic shows front bumper removed.

Disconnect coolant hoses (1) and catch coolant in a suitable container.
Release screw (2).

2010 BMW M3
Release fuel line (3) and catch escaping fuel in a suitable container.
Release nuts (4) and remove complete independent heater bracket.
Fig. 52: Identifying Coolant Hoses, Fuel Line With Screw And Nuts
When replacing independent heater without bracket
Unclip retainer of intake silencer.
Turn metal tube (1) clockwise and remove intake silencer.
Release screws (2) and remove silencer (3).
Install fuel intake line with filter.

2010 BMW M3
Fig. 53: Identifying Metal Tube And Intake Silencer With Screws
Remove coolant hoses (1) and feed out of bracket.
Installation:
Risk of damage!
Make sure abrasion guard (2) is correctly seated.
Fig. 54: Identifying Coolant Hoses And Abrasion Guard

Release screws (2) and remove independent heater from bracket (3).

2010 BMW M3
Fig. 55: Identifying Plug Connection And Bracket Screws

WARNING: Diesel vehicles only:
Independent heaters many only be operated with the associated fuel pump.
In the event of incorrect installation, fuel can escape and black smoke can be issued when the independent
heater is started.
Because of different build dates, installed fuel pumps must be checked.
Read out the heater number via the BMW DIS system and use this number to determine the associated fuel
pump from the table below.
Determine fitted fuel pump model and if necessary install new FUEL PUMP .
Component allocation:
FUEL PUMP COMPONENTS REFERENCE CHART

Build date up to 09/2006 Build date from 09/2006
Heater number: 6 974 470 9 112 792
DP40: 6 951 678 DP41: 6 979 466
Fuel pump:
(black housing) (grey housing + yellow warning sticker)
After installation
Vent cooling system

2010 BMW M3
Diesel only
WARNING: Bear in mind the heater number when replacing the fuel pump
(independent heating metering pump).
For this purpose, read out the heater number via the BMW DIS system
and use this number to select the associated fuel pump from the table
below.
In the event of incorrect installation, fuel can escape and black smoke can
be issued when the independent heater is started.
NOTE: FUEL PUMP REFERENCE CHART

Build date up to Build date from 09/2006
09/2006
Heater 6 974 470 9 112 792
number:
Fuel pump: DP40: 6 951 678 DP41: 6 979 466
(black housing) (grey housing + yellow warning
sticker)
Remove LEFT UNDERBODY PANELLING
Seal off water hoses at fuel pump with special tool 13 3 010 TERMINAL .

Recycling
2010 BMW M3
Release screw (1).
Fig. 57: Identifying Fuel Line Screw

Release hose clamps (2) and detach fuel hoses.
Disengage rubber retainers (3).
NOTE: Secure fuel pump (4) against falling out.
Fig. 58: Identifying Fuel Pump, Rubber Retainers, Plug Connection And Hose Clamps
2010 BMW M3
Installation:
Observe direction of flow of fuel pump (4).
64 12 089 REMOVING AND INSTALLING OR REPLACING MUFFLER/SILENCER

down.
Release screws (1, 2) and remove muffler/silencer (3).
Fig. 59: Identifying Muffler/Silencer With Screws

64 12 120 REMOVING AND INSTALLING/REPLACING INTAKE MUFFLER FOR

INDEPENDENT/AUXILIARY HEATER

down.

2010 BMW M3
Release retainer (1) and unscrew muffler (2) from connecting hose (3) in direction of arrow.
Installation:
Intake muffler (2) must be replaced if retainer (1) is damaged.
Fig. 60: Removing Intake Muffler Retainer And Connecting Hose

NOZZLES AND OUTLETS

64 22... REMOVING AIR DUCTS

2010 BMW M3
NOTE: Lower instrument panel trim partially shown.
Fig. 62: Removing Left Footwell Heating Duct With Adapter

Installation:
Make sure retainer (2) is correctly seated on left/right footwell heating duct (1).
Insert footwell heating duct (1) with adapter (3) in rear compartment heating duct (4).
Attach footwell heating duct (1) in area (4) to heater/air conditioner. Make sure assembly is locked exactly at
point (5).
2010 BMW M3

64 22 162 REMOVING AND INSTALLING/REPLACING CENTER FRESH-AIR GRILL
Release nuts (1) and remove center fresh-air grill (2) from decorative strip on instrument panel on right (3).
Fig. 64: Removing Center Fresh-Air Grill And Nuts

64 22 137 REMOVING AND INSTALLING/REPLACING LEFT FRESH-AIR GRILL
Removing DECORATIVE STRIP ON INSTRUMENT PANEL ON LEFT (REPLACEMENT) .

2010 BMW M3
64 22 191 REMOVING AND INSTALLING/REPLACING REAR COMPARTMENT FRESH-AIR

GRILLE
Lever out rear compartment fresh air grille (1) with special tool 00 9 341 at retaining points (2).
Disconnect associated plug connection and remove rear compartment fresh-air grille (1).
Fig. 65: Removing Rear Compartment Fresh Air Grille Using Special Tool (00 9 341)
64 22 138 REMOVING AND INSTALLING/REPLACING RIGHT FRESH-AIR GRILL
Lever out catches (2) and unclip right fresh-air grill (1) from right decorative strip on instrument panel (3).
Fig. 66: Removing Catches And Right Fresh-Air Grill

2010 BMW M3
MICROFILTER
64 31 062 REMOVING AND INSTALLING/REPLACING LEFT LOWER MICROFILTER HOUSING
SECTION
Release screws (1).
Installation:
Fig. 67: Identifying Rubber Tab, Microfilter Housing Section And Cover With Screws
Installation:

2010 BMW M3

64 31 072 REMOVING AND INSTALLING/REPLACING LEFT UPPER MICROFILTER HOUSING

SECTION
Release screws (1).
contact switch (3).
Installation:
Fig. 69: Identifying Bonnet/Hood Contact Switch And Microfilter Housing Section With Screws
2010 BMW M3
Replacement
Modify HOOD/BONNET CONTACT SWITCH

Modify MICROFILTER FOR INTERIOR VENTILATION
6431092 REMOVING AND INSTALLING/REPLACING MICROFILTER HOUSING (LOWER

SECTION)
Release holder (1).
Remove right cover (2).
Installation note:
Make sure right cover (2) is correctly seated.
Fig. 70: Identifying Right Cover, Holder And Catches

Left cover (4) is removed in same way as right cover.
Also for E90:
Release cable holder (2) and remove hose (1) from cover (4).
Installation note:
2010 BMW M3
Make sure cable holder (2) and hose (1) are correctly seated in opening (3).
Fig. 71: Identifying Left Cover, Cable Holder And Hose

E8x:
Unclip cable from guides (2).

Unclamp cable from guides (2).

2010 BMW M3
Fig. 73: Identifying Connector And Cable Guides

E81, E82, E87, E88:
Open hose clamps (2) on hose (1).

Press detent lugs (3).
Release cable strip (1) in direction of arrow from lower section of microfilter housing (2).
Installation note:
Retaining lugs (3) must not be damaged or missing.
Make sure cable strip is correctly seated.

2010 BMW M3
Fig. 75: Pressing Detent Lugs

Release holder (2) on both sides.
Release screw (1) on both sides on lower section of microfilter housing (3).
Fig. 76: Identifying Microfilter Housing Lower Section, Holder And Screw
Feed out microfilter housing lower section (1) in direction of arrow and remove.
Installation note:
Make sure microfilter housing lower section (1) is correctly seated.

2010 BMW M3
Fig. 77: Installing Microfilter Housing Lower Section

Installation note:
Seal (2) of microfilter housing lower section (1) must not be damaged or missing.
Fig. 78: Identifying Seal Of Microfilter Housing Lower Section

6431081 REMOVING AND INSTALLING/REPLACING MICROFILTER HOUSING (UPPER

SECTION)
NOTE: Example shown on E87:

Release screws (1).
Remove upper section of microfilter housing (4).
Installation:
2010 BMW M3
Make sure upper section of microfilter housing (4) is correctly seated.
Fig. 79: Identifying Microfilter Housing Upper Section And Screws

Replacement
Release microfilter (2) in direction of arrow from upper section of housing (3).
Installation:
Make sure microfilter (2) is correctly seated.
Fig. 80: Identifying Microfilter, Upper Section Of Housing And Catches

64 31 063 REMOVING AND INSTALLING/REPLACING RIGHT LOWER MICROFILTER

HOUSING SECTION
2010 BMW M3
Remove RIGHT UPPER MICROFILTER HOUSING SECTION
Release screw (1).
Installation:
Fig. 81: Identifying AUC Sensor, Rubber Tabs With Screws

Installation:

2010 BMW M3

64 31 074 REMOVING AND INSTALLING/REPLACING RIGHT UPPER MICROFILTER HOUSING

SECTION
Installation:
Fig. 83: Identifying Microfilter Housing Section With Screws

Replacement
Replace MICROFILTER FOR INTERIOR VENTILATION .
64 31 011 REPLACING MICROFILTER FOR INTERIOR VENTILATION

2010 BMW M3

Note on cleaning:
Spray microfilter housing from inside with BMW pollen filter housing cleaner* (observe instructions for use).
Comply WITH NOTES AND INSTRUCTIONS ON HANDLING CLEANING AGENTS !
Wipe away excess liquid.
*BMW part number: 0 447 913
Remove upper microfilter housing section See 6431074 REMOVING AND

INSTALLING/REPLACING RIGHT UPPER MICROFILTER HOUSING SECTION or 6431072
REMOVING AND INSTALLING/REPLACING LEFT UPPER MICROFILTER HOUSING
SECTION on left and right
Installation note:
Fig. 84: Identifying Microfilter

2010 BMW M3
AIR CONDITIONING SYSTEM

64 50... A/C PERFORMANCE TEST (R 134A)
Before A/C performance test, some conditions must be met
1. Provision of a BMW diagnostic system. Safeguard electrical system integrity by checking the fault
memory (no faults in the fault memory).
2. Provide a thermometer with separate gauge.
3. Perform the test in a suitable workshop area with an ambient temperature between 20C and 30C.
Re 1:
Connect BMW diagnostic system to vehicle and display evaporator temperature.
Re 2:
Position a thermometer with a separate gauge approx. 5 cm below the roof liner at the height of the B-pillar.
Lay gauge outwards out of vehicle interior.
Re 3:
Heating up the passenger compartment
A/C button is not activated when heating up.

Close all windows and doors.
Set air recirculation function.
Select air distribution mode for footwell and defrosting.
Maximum temperature setting
Maximum blower speed
Run engine at approx. 2000 RPM until operating temperature is reached, then idle speed.
Air-conditioning performance test
Turn on A/C compressor at a vehicle interior temperature of 50C.
After 3 to 4 minutes, the evaporator sensor temperature must be < or = 15C.
DRAW OFF AIR CONDITIONING if this temperature is not reached. Measure amount of refrigerant drawn
off.
If drawn-off quantity does not correspond to SPECIFIED FILL QUANTITY : supplement refrigerant and
repeat test.
2010 BMW M3
If fill quantity is correct, continue troubleshooting by pressure measurement.
NOTE: Air conditioning with uncontrolled compressors only:

If necessary, then continue troubleshooting by pressure measurement.
64 50 009 DRAWING OFF, EVACUATING AND FILLING HEATING AND AIR CONDITIONING
SYSTEM (R 134A)
IMPORTANT: The suction-side filling line of the refrigerant circuit is omitted from the engine
versions of model series E9x and E8x.
This is replaced by a direction connection on the expansion valve.
Changeover time frame:
From 07/09 - N54

From 08/09 - N43
Until end of 2009 - all other engine versions except N45/N46 and S65
Shown on N54 engine by way of example.
Direct connection of filling adapter (1) on the expansion valve is shown.
NOTE: Make sure filler connection line (1) is laid without kinks.
Fig. 85: Identifying Filler Connection Line

NOTE: N52 engine only:
On vehicles with hydraulic steering (e.g. AFS) oil reservoir (1) must be
2010 BMW M3
detached.
Refer to: Remove oil reservoir for hydraulic steering
Fig. 86: Identifying Fluid Reservoir

WARNING: Only persons in possession of a professional certificate of competence

for the maintenance and repair of heating and air conditioning systems
are authorized to carry out repair work on the refrigerant circuit. This
certificate must be presented by 04/07/2010 at the latest. (applies only to
EU countries; follow country-specific regulations in non-EU countries)
If the protective caps on the filling valves are difficult to open, there
is a danger of injury from leaking valve inserts.
Repair work may only be carried out on a depressurized refrigerant

circuit!
Before conducting repairs, check the actual pressure drop on the

pressure gauge of the A/C service station.
Avoid contact with refrigerant and refrigerant fluid.
Follow safety information for handling refrigerant tetrafluorethane R

134a See 6450... SAFETY INSTRUCTIONS FOR HANDLING R134A
REFRIGERANT or 6450... INSTRUCTIONS FOR HANDLING
2010 BMW M3
REFRIGERANT R 134A.
Follow safety information for HANDLING REFRIGERANT FLUID .
Only BMW-approved tetraflourethane R134a refrigerant may be used
Carefully move the climate service station!
Comply with the operating instructions and maintenance intervals of the service station!
Highly sensitive components, such as scales, are installed in the climate service station. These components may
be damaged by improper handling, such as fast driving over bumps. This will significantly reduce the
measuring accuracy when drawing off and filling.
IMPORTANT: The vehicle must be parked on the ground during the entire draw-off,
evacuation and filling procedure!
Filling a raised vehicle will lead to insufficient filling levels.
NOTE: In case of complaints, carry out a heating and air conditioning performance
test!
If the system fails the test, draw off, evacuate and fill the heating and air conditioning system in accordance
with the operating instructions of the relevant service station.
It is essential to adhere to the service station service intervals.
E60 only:
If necessary, to connect service station, use manufacturer's adapter for high-pressure connection (red).
Notes for drawing off heating and air conditioning system:
To help separation of refrigerant and refrigerant fluid, run engine at low speed (800-1200 RPM) and with
heating and air conditioning system turned on for a few minutes.
The limits the entrainment of refrigerant fluid while it is drawn off.
Drawn-off refrigerant fluid must be changed and reintroduced via the service station.
Recycling
2010 BMW M3
Dispose of drawn-off refrigerant fluid as hazardous waste.
IMPORTANT: E72 only:

Vehicle must be evacuated from both sides!
Notes for evacuating off heating and air conditioning system:
Before each filling, evacuate the refrigerant system.
Observe an evacuation time of at least 30 minutes.
The evacuation procedure removes all traces of ambient air, water vapor and any other gases present from the
heating and air conditioning system. This enables subsequent system filling with refrigerant.
If the vacuum does not remain stable when the system is off, run the procedure for leaks in the refrigerant
circuit.
Notes for filling heating and air conditioning system:
Before filling with refrigerant, replace the refrigerant fluid entrained during drawing off.
Also top up any lost fluid as indicated in the table:
Loss of R134a refrigerant
Table 1 indicates the amount of coolant loss approved after a specific period of time. There is no leak.
Refrigerant fluid may not be topped up.
Table 2 indicates how much refrigerant fluid must be topped up in the event of an unapproved coolant loss due
to a leak after a specific period of time.
Different cases:
a. Loss of refrigerant per Table 1 is not exceeded

Top up lost R134a refrigerant
It is not permitted to top up the refrigerant fluid
b. Loss of refrigerant per Table 1 is exceeded

Top up lost R134a refrigerant
Refrigerant fluid must be topped up additionally per Table 2
REFRIGERANT FLUID REFERENCE CHART

Table 1:
0-1 1-2 2-3 3-4 4-5
Number of years since last filling
2010 BMW M3
Permissible loss [g] --> no need to top up refrigerant < or = < or = < or = < or = < or =
fluid 30 60 90 120 150
REFRIGERANT FLUID REFERENCE CHART

Table 2:
R134a Coolant Loss [g] Top up quantity refrigerant fluid
Number of years since last filling
- <120 0
0 -1 120 - 150 10
>150 20
- <180 0
1-2 180 - 210 10
>210 20
- <240 0
2-3 240 - 270 10
>270 20
- <300 0
3-4 300 - 330 10
<330 20
- <360 10
4-5
>360 20
Depending on the type of component replaced on the heating and air conditioning system, it may be necessary
to top up the refrigerant fluid, even if no measurable losses have occurred during drawing off. Follow the notes
provided by the heating and air conditioning system manufacturer, taking account of the tolerances (and
inaccuracies) indicated in the operating instructions of the relevant service station.
Fig. 87: Identifying Engine Compartment Plate

Information on the required refrigerant capacity for the entire heating and air conditioning system is contained
on the type plate (1) in the engine compartment.
2010 BMW M3
Installation note:
Reseal refrigerant filler necks on vehicle with sealing caps.
64 50... INSTALL THE RETROFIT ABSORBER FOR THE AIR CONDITIONING SUCTION LINE
The retrofit kit may be used for vehicles with a production date from 09/2008.
IMPORTANT: The retrofit kit with part number 6 987 991 may no longer be used!
Remove rear underbody protection
Unscrew nuts (1).
Remove the protective plate (2).
NOTE: Figure All-wheel drive vehicle
Fig. 88: Identifying Protective Plate And Nuts

Lay the steel measuring tape (2) onto the intake pipe (1).
IMPORTANT: The steel measuring tape (2) must be flush with the bottom of the rubber ring
(3)!
Mark distance A =11 cm.

2010 BMW M3
Fig. 89: Identifying Measuring Tape Onto Intake Pipe And Rubber Ring
Attach the lower edge of the vibration absorber (1) at the marked position and screw it to the intake pipe (2).
Fig. 90: Connecting Lower Edge Of Vibration Absorber And Screw To Intake Pipe
64 50... INSTRUCTIONS FOR HANDLING REFRIGERANT R 134A
WARNING: Although R 134a at normal temperature is non-toxic, non-flammable and

not explosive in air in any mixture ratio, it is still essential to follow
2010 BMW M3
various safety precautions.
The filled refrigerant circuit of the A/C system is subject to gauge pressure. When carrying out repairs on the
A/C system, it is absolutely essential to draw off the refrigerant.
Do not weld or solder on to filled A/C systems or in rooms into which R 134a may have leaked. Exposure to
flames or high temperatures (= 50C) may give rise to toxic decomposition products (fluorine gas). For this
reason, do not smoke either.
R 134a must be drawn off, cleaned and returned to the A/C system with a service station following the relevant
operating instructions.
Avoid all contact with liquid or gaseous R 134a. Wear protective goggles and gloves when working on the
refrigerant circuit. R 134a acting on the skin can cause frostbite. Rinse affected body parts thoroughly with cold
water. If R 134a gets into your eyes, likewise rinse with plenty of water and, if necessary, remove contact lenses
if worn. Then seek immediate medical attention. Likewise seek immediate medical attention if you experience
problems after inhaling R 134a fumes.
As a gas, R 134a is colorless, odorless and heavier than air. If it enters the atmosphere, this may result in an
imperceptible danger of asphyxiation or in cardiac palpitations, especially in workshop pits. Ventilate rooms
adequately; if necessary, turn on installed extractor systems.
For a properly functioning A/C system, it is essential to have the greatest possible levels of cleanliness when
working on the A/C system and the best possible evacuation (at least 30 minutes dehumidification from
refrigerant circuit) before each filling of the A/C system.
R 134a absorbs moisture very easily. Therefore, seal off opened pipes, condenser, evaporator, compressor and
drier bottle immediately with plugs.
With replacement parts, the plugs may only be removed immediately before the lines are connected.
In the event of warranty claims, the old parts must be provided with plugs to be able to determine the cause of
the damage.
If an A/C system has been completely drained by leakage, accident or repair, the DRIER ELEMENT must be
replace as excessive moisture may have entered the system.
Store filled pressurized refrigerant bottles in such a way that they are not exposed to direct sunlight or other heat
sources (max. 45C). Also avoid exposing them to mechanical stress (e.g. by dropping).
In the event of fire, carbon dioxide (CO2), extinguishing powder and a sprayed water jet are deemed to be
suitable extinguishing agents. Cool reservoirs at risk with a sprayed water jet (risk of bursting!).
IMPORTANT: After each refill of an A/C system, check that protective caps of filling valves
are hand-tight. They serve as additional seals.
2010 BMW M3
64 50... INSTRUCTIONS FOR HANDLING REFRIGERANT OIL (FOR REFRIGERANT R 134A)
WARNING: Observe the following points when handling refrigerant oil:
Wear protective goggles.

Wear gloves made from impermeable plastic.
Do not swallow.
Do not inhale.
Action to be taken after contact with refrigerant oil
After contact with eyes, rinse thoroughly with plenty of water and take out contact lenses (if worn). Then
seek immediate medical attention.
After contact with the skin, wash body parts affected with plenty of soap and water.
Do not induce vomiting if oil is swallowed, seek immediate medical attention.
If inhaled, introduce the person affected to fresh air. Seek medical attention if problems persist.
WARNING: Refrigerant oil is non-combustible and non-explosive at normal

temperatures. In spite of this, the following precautions must be
observed:
Do not store in the vicinity of flames, heat sources or strongly

oxidizing materials.
Suitable extinguishants: Carbon dioxide (CO2 ), dry extinguishant,
foam.
IMPORTANT: Refrigerant oil is hygroscopic and must therefore be stored in suitable

containers that are sealed airtight!
Recycling
Dispose of drawn-off refrigerant oil as hazardous waste.
Absorb escaping refrigerant oil with fluid-binding material.
Notify the relevant authorities if larger amounts of refrigerant oil are discharged into aboveground water
supplies, drainage systems or subsoil.
64 52... INSTRUCTIONS FOR OPENING AND REPLACING PARTS IN REFRIGERANT CIRCUIT
WARNING: Avoid contact with refrigerant and refrigerant fluid

2010 BMW M3
Follow safety information for handling R134a refrigerant See 6450...

6450... INSTRUCTIONS FOR HANDLING REFRIGERANT R 134A
Follow safety information for HANDLING REFRIGERANT FLUID
IMPORTANT: Always use new O-rings each time A/C connections are opened (refer to
Electronic Parts Catalogue)
They must not be coated.
Use special tool 00 9 030 WEDGE to install sealing rings without

damaging them.
Open the refrigerant circuit for as short of a period as possible.

Close all components and lines in the refrigerant circuit and return parts
immediately following the removals at openings with special tool 32 1 270
PLUG to prevent penetration of moisture or foreign objects.
If the refrigerant circuit was closed at the openings with special tool 32 1
270 PLUG but it remains open for more than 24 hours, the dryer insert for
the air conditioning must be replaced.
I. Part replacement as preliminary work fur further repair work and based on gradual leakage
(minor leak, e.g. hairline crack)
Procedure:
DRAW OFF A/C system, then determine drawn-off refrigerant oil quantity
Carry out part replacement
Replace removed refrigerant fluid and additionally top up with new refrigerant fluid according to
components replaced:
Compressor: refer to NOTES ON REPLACING COMPRESSOR
Evaporator: 10 ml
Capacitor: 20 ml
Desiccant insert/dryer flask: 20 ml
Each replaced refrigerant line: 10 ml
Capacitor with integrated dryer: 40 ml
Safety pressure switch and seals: no additional refrigerant fluid
EVACUATE AND FILL A/C system
II. Part replacement due to sudden leak

2010 BMW M3
(major leak, e.g. pipe break due to accident)
Procedure:
Replace removed refrigerant fluid and additionally replace with new refrigerant fluid according to parts
replaced:
Evaporator: 35 ml
Capacitor: 35 ml

RADIATOR/COOLERS
IMPORTANT: Even when they are correctly installed or due to normal driving, coolers (oil
cooler, radiator, charge air cooler) or air conditioning capacitors may show
slight impressions or deformations on their discs (picture).
This is not damage.
Radiators, cooler or capacitors are not to be replaced in this case.
NOTE: The deformations shown in illustration "1" (see Fig. 91) can be bent back with a
standard fin comb.
Damage to lines carrying media or on the flat pipe require replacement of the radiator/ or air conditioning
condenser. Examples of such damage are shown in illustrations "2", "3", "4", "5", and "6" (see Fig. 91).
2010 BMW M3
Fig. 91: Identifying Damage And Deformations

64 50... LEAK DETECTION WITH ULTRAVIOLET ADDITIVES (UV ADDITIVES) (BMW LEAK-
TESTING CASE)
IMPORTANT: UV leak detection is prohibited in EU countries.

In all other countries, follow the country-specific regulations.
IMPORTANT: It is absolutely essential to read and comply with the equipment manufacturer's
operating instructions use provided in the equipment case!
Read and comply with the instructions for use provided with the special tool
particularly with regard to accident prevention, health protection and
environmental protection.
Use only BMW-approved UV additives (e.g. TRACER).
Only the basic procedure is described in the following!
WARNING: Avoid contact with refrigerant.

FOLLOW SAFETY PRECAUTIONS WHEN HANDLING REFRIGERANT .
2010 BMW M3
IMPORTANT: Ultraviolet lamp gets very hot in the radiation area!

Do not use the ultraviolet lamp without the filter glass.
Eyes and skin will suffer damage if the ultraviolet lamp is used without the filter
glass.
When using the UV lamp, wear the safety goggles provided in the case.
NOTE: Fill the hose system of the hand pump completely with UV additive PRIOR
to use
Use the UV additive exclusively for BMW-approved refrigerant fluids
Do not operate the air conditioning system while the hand pump is
connected or in use
The air conditioning system must always be filled with an adequate
amount of refrigerant to enable the leak-detecting agent to be properly
distributed
Before actually testing for leaks, check the entire refrigerant circuit using the UV leak detection lamp to ensure
that no UV additive is already in the area of the refrigerant circuit.
If already illuminated areas are found, carefully clean the area in question with the cleaning agent contained in
the case.
On initial use:
Connect hand pump (1) to additive cartridge (2) and hose piece (3).
Fig. 92: Identifying Hand Pump To Additive Cartridge And Hose Piece
On initial use:
2010 BMW M3
Attach vent valve (1) to quick-release coupling (2).
Turn handle (3) on hand pump to advance the plunger until a small amount of UV additive emerges. This vents
the hose system.
Fig. 93: Connecting Vent Valve To Quick-Release Coupling

IMPORTANT: The entire hand pump with hose system must not be disassembled again once
the filling work has been completed.
Attach quick-release coupling (1) to low-pressure connection (2) of air conditioning system.
Turn handle on hand pump (3) until the required amount of UV additive is added.
Fig. 94: Identifying Quick-Release Coupling To Low-Pressure Connection

The quantity of UV additive to be added is dependent on the AMOUNT OF REFRIGERANT IN THE

2010 BMW M3
REFRIGERANT CIRCUIT :
Air conditioning systems with refrigerant filling up to 900 g: one graduation mark (4) on additive
cartridge
Air conditioning systems with refrigerant filling in excess of 900 g: two graduation marks (4) on additive
cartridge
NOTE: After filling, remove quick-release coupling (1) and if necessary use the
cleaning agent contained in the special tool case to clean up the UV additive.
Further tasks:
Start engine
Run air conditioning system at highest setting for 5 - 10 minutes in order to ensure adequate distribution
of dye in the system
Turn off engine.
Check all air conditioning system components for possible leaks
Possible leaks show up in luminous green
Complete accompanying information label (1) with the relevant data and attach in an easily visible position next
to the filling capacity information label (2).
Fig. 95: Identifying Information Label And Filling Capacity Information Label
64 50... SAFETY INSTRUCTIONS FOR HANDLING R134A REFRIGERANT

Refrigerant circuit is under high pressure! Work on the refrigerant circuit
may only be carried out by experts!
Draw off refrigerant without fail BEFORE all repair work on the refrigerant
2010 BMW M3
circuit.
The refrigerant circuit is depressurized AFTER drawing off!
It is absolutely essential to read and observe the relevant operating
instructions for the A/C service unit used!
Wear safety goggles

Do not smoke!
Observe country-specific safety regulations.
First aid measures
Eye contact: In the event of contact with the eyes, rinse immediately with plenty of running water and
consult an opthalmologist.
Skin contact: In the event of contact with skin, remove affected clothing immediately and rinse with
plenty of water.
After inhalation: If refrigerant vapors are inhaled in greater concentrations, remove the person affected
to an area of fresh air and keep them under supervision. Consult a doctor. If breathing problems are
experienced, breathe additional oxygen. If the person affected is breathing with difficulty or has stopped
breathing, incline the person's head at the neck and administer the kiss of life.
64 50... SAFETY INSTRUCTIONS FOR HANDLING REFRIGERANT OIL

circuit.
Wear safety goggles

Do not smoke!
First aid measures
If swallowed: Do NOT induce vomiting, unless expressly instructed to do so by medical personnel. Do

2010 BMW M3
not administer anything to an unconscious person through their mouth. Consult a doctor immediately if
larger quantities of this substance are swallowed. Loosen tight-fitting items of clothing (e.g. collar, tie,
belt or similar).
Eye contact: Remove contact lenses if worn. In the event of eye contact, rinse eyes for at least 15
minutes with plenty of water. It is essential to use WARM WATER. Consult a doctor.
Skin contact: In the event of skin contact, rinse immediately with plenty of water. Remove contaminated
clothes and shoes. Wash affected clothes before wearing again. Clean shoes thoroughly before reusing.
Call for a doctor.
After inhalation: If inhaled, take the person affected outside into fresh air immediately and keep them
under supervision. Call for a doctor. If breathing difficulties are experienced, administer additional
oxygen. If the person affected stops breathing, administer the kiss of life.
Recycling
Catch and dispose of emerging refrigerant oil.
AC HOUSING, EVAPORATOR, SWITCHING ELEMENTS

64 51 001 CLEANING EVAPORATOR
WARNING: When handling cleaning agent, observe following protection measures:

Wear protective rubber gloves and protective goggles.
If cleaning agent comes into contact with eyes or skin, wash immediately
with lots of water.
IMPORTANT: To avoid dirtying vehicle interior:
Close all air vents.

Switch heating - A/C system to recirculated-air mode.
Cover carpet in work area.
Recycling
Carry out the cleaning operation in a suitable washing bay as the emerging cleaning agent escapes through the
drain openings in the transmission tunnel.
After completing cleaning, allow car to drip-dry for approx. 5 minutes.

Remove HEATER/AIR CONDITIONER FAN
2010 BMW M3
IMPORTANT: Use special tool 64 1 270 SPRAYER on right hand drive models.
Connect special tool 64 1 260 SPRAYER (spray lance) to spray gun (2).
Insert spray lance 64 1 260 SPRAYER through opening (1) into fresh air duct.
Fig. 96: Connecting Special Tool 64 1 260 To Spray Gun

By moving spray lance (1) back and forth, spray a uniform amount of cleaning agent onto evaporator.
Spray lance 64 1 260 SPRAYER shown on removed and cut-open heater/air conditioner:
Spray lance 64 1 260 SPRAYER in upper end position (1)

Spray lance 64 1 260 SPRAYER in lower end position (2)
Fig. 97: Moving Spray Lance Back And Forth

2010 BMW M3
By moving spray lance back and forth, spray a uniform amount of cleaning agent onto evaporator.
NOTE: Set heating - A/C system to footwell ventilation and fresh-air mode. Open
windows/doors.
Start car and run heating - A/C system at maximum fan power for approx. 5 minutes in order to dry evaporator.
In order to eliminate the last remnants of cleaning agent, repeat this procedure shortly before handover to the
customer.

Follow safety information for handling R134a refrigerant See 6450...

damaging them.

Procedure:
2010 BMW M3

Evaporator: 10 ml
Capacitor: 20 ml
Procedure:
replaced:
Evaporator: 35 ml
Capacitor: 35 ml
64 51... LEAK-TESTING CONDENSER

Follow safety instructions for HANDLING REFRIGERANT
Comply with the standard national safety instructions and precautions on
handling nitrogen.
Ensure that employees are advised of how to handle pressurized vessels
and nitrogen correctly (danger of asphyxiation).
For this purpose, follow the notes and instructions in the technical safety
specifications available from the gas supplier.

2010 BMW M3
Drain off AIR CONDITIONING SYSTEM

Detach refrigerant lines from condenser
E70 only:
Tightening torque 64 53 3AZ, see 64 53 REFRIGERANT LINES AND EXPANSION VALVE .

Special tool 64 5 122 and special tool 64 5 123 have different diameters (A, B) at
the seal plugs!
Ensure correct connection assignment on condenser.
Fig. 98: Identifying Seal Plugs And Special Tools (64 5 122 And 64 5 123)
Fit and secure sealing adapter to connection of low-pressure line.
Fit and secure test adapter 64 5 122 to connection of high-pressure line.
E70 only:
Tightening torque 64 53 3AZ, see 64 53 REFRIGERANT LINES AND EXPANSION VALVE

2010 BMW M3
Fig. 99: Identifying Adapters (64 5 123 And 64 5 121)

Connect special tool 64 5 122 to special tool 64 5 121 HOSE .
Fig. 100: Connecting Special Tool 64 5 122 To Special Tool 64 5 121

IMPORTANT: Risk of damage: Use only nitrogen pressure bottles with pressure reducers for
leak-testing.
Pressurize condenser to 10 bar slowly only. Excessively fast pressurization
and pressures in excess of 20 bar may cause damage to the condenser.
Connect nitrogen pressure bottle with pressure reducer to pressure gauge and then connect to special tool 64 5
121 HOSE (connecting hose).
NOTE: Testing apparatus must be leakproof.

Ambient temperature and temperature of vehicle must not change during
the test procedure.
Do not move the vehicle during this period
2010 BMW M3
Apply test pressure of 10 bar slowly and close nitrogen pressure bottle.
Check leak-tightness of testing apparatus and of connection to refrigerant line.
Set test pressure of 10 bar is only permitted to drop by 2 bar to 8.5 bar over a test period of 1.5 hours.
If the pressure loss is greater than 1.5 bar, this indicates that there is a leak in the condenser unit.
WARNING: After leak-testing, unscrew special tool 64 5 121 HOSE slowly from
special tool 64 5 122 to reduce pressure.
After leak-testing
Replace sealing rings. Use special tool 00 9 030 WEDGE to mount sealing rings without damaging them.
Assemble A/C system
Evacuate and fill A/C system
64 51... LEAK-TESTING EVAPORATOR
WARNING: It is essential, when handling nitrogen, to observe the standard national

safety regulations.
and nitrogen correctly (danger of asphyxiation). For this purpose, follow
the notes and instructions in the technical safety specifications available
from the gas supplier.
Remove EXPANSION VALVE
Replace sealing rings (1) and coat with refrigerant oil

2010 BMW M3

Screw special tool 64 5 124 together with retaining clip (1).
Fig. 102: Identifying Retaining Clip With Special Tool 64 5 124


2010 BMW M3
leak-testing.
Pressurize evaporator to 10 bar slowly only. Excessively fast pressurization
and pressures in excess of 20 bar may cause damage to the evaporator.
Connect pressurized nitrogen cylinder with pressure reducing valve to pressure gauge and then connect to
special tool 64 5 121 HOSE (connecting hose).

the test procedure.
If the pressure loss is greater than 1.5 bar, this indicates that there is a leak in the evaporator unit.
special tool 64 5 124 to release pressure.
After leak-testing
Assemble A/C system
64 51 525 REMOVING AND INSTALLING OR REPLACING EXPANSION VALVE

Follow safety instructions for HANDLING R134A REFRIGERANT .

Restart engine only when A/C system has been correctly filled.
If A/C system is opened for more than 24 hours: REPLACE DESICCANT INSERT FOR A/C SYSTEM
2010 BMW M3
DRAWING OFF, EVACUATING AND FILLING THE A/C SYSTEM are not included in the time
value given for this work operation
Remove LOWER SECTION OF MICROFILTER HOUSING
Remove left (OR RIGHT) SUSPENSION CROSSBRACE
NOTE: Work described on the E90 by way of example, deviations in detail are possible
in other vehicles.
Release screws (1, 2), disconnect refrigerant lines and lay to one side.
Fig. 104: Identifying Refrigerant Lines Screws

Installation:
Use special tool 00 9 030 WEDGE to mount sealing rings without damaging them.
Release screws (1) and remove expansion valve (2).
Installation:
2010 BMW M3
Fig. 105: Identifying Expansion Valve With Screws

Installation:
Place expansion valve (1) exactly on refrigerant lines (2) and (3).
Fit screws of expansion valve (1) and make sure retainer (4) is correctly positioned.
Fig. 106: Identifying Expansion Valve On Refrigerant Lines

After installation
COMPRESSOR
64 52... INSTRUCTIONS FOR COMPRESSOR REPLACEMENT
2010 BMW M3
IMPORTANT: Compressors with plastic belt pulleys:
Avoid impacts/knocks to plastic belt pulley (caused by tools, contact with

base).
Return faulty compressors in their original packaging only.
IMPORTANT: When starting up a new compressor for the first time, it is absolutely essential
to carry out the following initial operation (breaking-in) procedure:
Switch on Air conditioning system

Set all air vents in instrument panel to "OPEN"
Start engine and let it stabilize at idle speed
Set blower output to min. 75% of max. blower output
Switch on Air conditioning system and run for at least 2 minutes at idle
speed (risk of damage at increased engine speed!)
When evacuating the air-conditioning system, refrigerant fluid is also extracted and collected in the oil separator
of the service station.
Fig. 107: Connecting Special Tools To Evacuating Air Conditioning System

After evacuation, the refrigerant must be filtered in the service station as the oil separator could still contain a
liquid refrigerant/oil mixture. The filtering process gasifies the refrigerant completely and only the previously
bound refrigerant fluid remains in the oil separator. Measure and note down this quantity of refrigerant fluid,
REFER TO EVACUATING A/C SYSTEM .
Transfer the refrigerant fluid remaining in the previous compressor via the filler plug completely into a
measuring cup.
2010 BMW M3
Fig. 108: Draining Refrigerant Fluid

Measure the amount of refrigerant fluid collected from the previous compressor.
Fig. 109: Measuring Amount Of Refrigerant Fluid Collected From Previous Compressor
The new compressor is filled at the factory with refrigerant fluid. Open filler plug and pour entire contents of
compressor into a clean collecting vessel.
Installation note:

2010 BMW M3
Fig. 110: Filling Refrigerant Fluid And A/C Compressor

Observe Tightening Torque, 64 52 2AZ. See AIR CONDITIONING COMPRESSOR or A/C

COMPRESSOR
From the new compressor, pour the same amount of refrigerant fluid (as drained from the previous compressor)
+ 10 g extra into a clean measuring cup and pour again into the new compressor.
Remaining refrigerant fluid can be poured into service station tank, REFER TO EVACUATING A/C
SYSTEM .
Otherwise the excess refrigerant fluid must be disposed of correctly.
On account of its hygroscopic properties, refrigerant fluid must not be stored in open containers.
Fig. 111: Identifying Amount Of Refrigerant Fluid

2010 BMW M3
The refrigerant fluid drawn off from the oil separator of the service station and from the previous compressor
must not be reused and must be correctly disposed of.
Fig. 112: Disposing Refrigerant Fluid

After installing the new compressor, it is essential before filling the A/C system to pour the same amount of the
previously drawn off refrigerant fluid into the system again,
REFER TO EVACUATING A/C SYSTEM .
Fig. 113: Connecting Special Tools To Evacuating Air Conditioning System

Installation note:
If air conditioning system is opened for more than 24 hours: REPLACE DRYER FLASK/DESICCANT
INSERT .

2010 BMW M3

Follow safety information for Handling R134A Refrigerant See 6450...

damaging them.

Procedure:
Evaporator: 10 ml
Capacitor: 20 ml

2010 BMW M3
Procedure:
replaced:
Evaporator: 35 ml
Capacitor: 35 ml
64 52 521 REPLACING A/C SYSTEM COMPRESSOR (S65)

Work on the cooling system may only be carried out when it has cooled
down.

Follow safety instructions for Handling R 134A Refrigerant See 6450...
SAFETY INSTRUCTIONS FOR HANDLING R134A REFRIGERANT or 6450...
INSTRUCTIONS FOR HANDLING REFRIGERANT R 134A.

Read and comply with NOTES on replacing compressor.
If air conditioning system is opened for more than 24 hours:
Replace DESICCANT INSERT for A/C system.
DRAIN OFF AIR CONDITIONING SYSTEM

Remove A/C compressor DRIVE BELT
Drain COOLANT from radiator
2010 BMW M3
Remove coolant hose from radiator at bottom
Clamp off overflow hoses (1) and lay to one side.
Raise coolant tank (3) and disconnect associated plug connection.
Place coolant tank (3) to one side.
Fig. 114: Identifying Hoses And Coolant Tank Screws

Release screws (2) and remove refrigerant lines.
Installation:
2010 BMW M3
Fig. 115: Identifying Refrigerant Lines With Screws

IMPORTANT: Close openings or line to compressor with special tool 32 1 270 PLUG to avoid
media leak and dirt contamination.
Release screws (1, 2) and remove holder (3).
IMPORTANT: Secure compressor (5) against falling off/down.
Release screw (4) and feed out compressor (5) towards top.
Fig. 116: Identifying Compressor And Holder With Screws

Installation:
If necessary, replace damaged adapter sleeves (1).

2010 BMW M3
Fig. 117: Identifying Adapter Sleeves

After installation
FILL AND VENT cooling system

Evacuate and fill A/C SYSTEM
CONDENSER AND DRYER WITH LINES


Follow safety information for Handling R134A Refrigerant See 6450...

damaging them.

2010 BMW M3
Procedure:
Evaporator: 10 ml
Capacitor: 20 ml
Procedure:
replaced:
Evaporator: 35 ml
Capacitor: 35 ml

2010 BMW M3

RADIATOR/COOLERS

RADIATOR/COOLERS.
64 51... LEAK-TESTING CONDENSER

Follow safety instructions for HANDLING REFRIGERANT
handling nitrogen.
Drain off AIR CONDITIONING SYSTEM

E70 only:

the seal plugs!
2010 BMW M3
Fig. 118: Identifying Seal Plugs And Special Tools (64 5 122 And 64 5 123)
Fit and secure sealing adapter to connection of low-pressure line.
Fit and secure test adapter 64 5 122 to connection of high-pressure line.
E70 only:
Fig. 119: Identifying Adapters (64 5 123 And 64 5 121)


2010 BMW M3
leak-testing.
121 HOSE (connecting hose).

the test procedure.
special tool 64 5 122 to reduce pressure.
After leak-testing
Assemble A/C system
64 53... NOTES ON REPLACING DRYER FLASK OR DESICCANT INSERT
Note for all E8x and all E9x vehicles:
Replacement of desiccant insert is only possible until 12/08.
Beginning in 12/08, the air conditioning capacitor must be replaced.
The dryer flask or desiccant insert does not have to be replaced at regular inspection intervals in a functioning,
leak proof A/C system.
However, the dryer flask or desiccant insert must absolutely be replaced in the event of:
contamination of the refrigerant with debris (e.g. when the compressor is clamped).
a leaking A/C system or loss of refrigerant
2010 BMW M3
the refrigerant circuit being open for a period exceeding 24 hours, e.g. during a repair.
64 53... OVERVIEW OF A/C CIRCUIT COMPONENTS
Fig. 121: Overview Of A/C Circuit Components

64 53 550 REMOVING AND INSTALLING OR REPLACING CAPACITOR FOR HEATING AND


2010 BMW M3

Read and comply with safety information:
Handling R 134a tetrafluorethane refrigerant See 6450... SAFETY

INSTRUCTIONS FOR HANDLING R134A REFRIGERANT or 6450...
INSTRUCTIONS FOR HANDLING REFRIGERANT R 134A
HANDLING REFRIGERANT FLUID

Restart engine only when heating and air conditioning system has been
correctly filled.
NOTE: Follow NOTES for opening and replacing parts in refrigerant circuit.
If Air conditioning system is opened for more than 24 hours:
REPLACE DESICCANT INSERT FOR HEATING AND AIR CONDITIONING
SYSTEM
IMPORTANT: The desiccant insert can only be replaced in vehicles up to 12/08!

In vehicles after 12/08, the air conditioning capacitor must be replaced!
DRAWING OFF, EVACUATING AND FILLING THE HEATING AND AIR CONDITIONING
SYSTEM are not included in the time value given for this job item
Remove RADIATOR
Release screws (1).
Disconnect suction and pressure lines and lay to one side.
Installation note:
Use special tool 00 9 030 WEDGE to install sealing rings without damaging them.
2010 BMW M3
Fig. 122: Identifying Refrigerant Lines And Expansion Valve Screws

Release screw (1).
Lever out clamp (2).
Remove capacitor (3) towards rear.
Installation note:
Make sure retaining clips are correctly seated in area (4).
Fig. 123: Identifying Lever Clamp, Capacitor, Retaining Clips Seated On Area And Screw
Installation note:
Make sure capacitor (1) is securely seated in area (2).

2010 BMW M3
Fig. 124: Identifying Capacitor Seated On Area

After installation
EVACUATE AND FILL HEATING AND AIR CONDITIONING SYSTEM

Fill cooling system
64 53 515 REPLACING DESICCANT INSERT FOR AIR CONDITIONING SYSTEM

Follow safety instructions for handling R 134a (tetrafluorethane)
refrigerant See 6450... SAFETY INSTRUCTIONS FOR HANDLING R134A
REFRIGERANT or 6450... INSTRUCTIONS FOR HANDLING REFRIGERANT
R 134A.
Follow safety instructions for HANDLING REFRIGERANT FLUID .

NOTE: Follow NOTES for opening and replacing parts in refrigerant circuit.
Follow INSTRUCTIONS ON REPLACING DESICCANT INSERT .
IMPORTANT: The desiccant insert can only be replaced in vehicles with production dates up
to 12/08!
In vehicles after 12/08, the heating and air conditioning system capacitor must
be replaced!
2010 BMW M3
DRAWING OFF, EVACUATING AND FILLING THE HEATING AND AIR CONDITIONING
SYSTEM are not included in the time value given for this job item
Remove CAPACITOR
If necessary, pierce label over sealing cap (1).
Remove cap (1) from capacitor (2).
Installation note:
Tightening torque 64 53 12AZ See REFRIGERANT LINES AND EXPANSION VALVE or AIR
CONDITIONING COMPRESSOR .
Fig. 125: Identifying Capacitor And Sealing Cap

Remove Seeger circlip ring (1) with suitable pliers.

2010 BMW M3
Fig. 126: Identifying Seeger Circlip Ring

With assistance of a screwed-in screw (1), pull the desiccant insert (2) out of the capacitor (3).
Fig. 127: Pulling Desiccant Insert From Capacitor

After installation
Top up and bleed the cooling system and check for watertightness
EVACUATE AND FILL HEATING AND AIR CONDITIONING SYSTEM
64 53 642 REPLACING LINE FROM COMPRESSOR TO CONDENSER (S65)

2010 BMW M3


REPLACE DESICCANT INSERT FOR A/C SYSTEM
Release coolant tank and place to one side
Release screw (1).
Release screw (2) and remove refrigerant line.
Installation:
Fig. 128: Identifying Refrigerant Line With Screw

2010 BMW M3
After installation
64 53 670 REPLACING LINE FROM COMPRESSOR TO EVAPORATOR (S85)

Follow safety information for handling R 134a tetrafluorethane refrigerant
See 6450... SAFETY INSTRUCTIONS FOR HANDLING R134A
REFRIGERANT or 6450... INSTRUCTIONS FOR HANDLING REFRIGERANT
R 134A.
Follow safety information for HANDLING REFRIGERANT FLUID .

Follow NOTES for opening and replacing parts in refrigerant circuit.
REPLACE DESICCANT INSERT FOR HEATING AND AIR CONDITIONING
SYSTEM
DRAIN OFF AIR CONDITIONING SYSTEM

Remove INTAKE SILENCER HOUSING
Remove AIR MANIFOLD
Remove both LEFT (OR RIGHT) SUSPENSION CROSSBRACE
Release refrigerant tank and place to one side
Installation note:
Use special tool 00 9 030 WEDGE to install sealing rings without damaging them.
2010 BMW M3
Fig. 129: Identifying Refrigerant Line Screw

Expose refrigerant line up to evaporator connection.
Installation note:

After installation
Evacuate and fill A/C SYSTEM (R 134a)

2010 BMW M3
64 53 660 REPLACING LINE FROM CONDENSER TO EVAPORATOR (S65)


REPLACE DESICCANT INSERT FOR A/C SYSTEM
Installation:
2010 BMW M3

Installation:

Replacement
2010 BMW M3
Modify SAFETY PRESSURE SWITCH .
After installation
64 53 520 REPLACING SAFETY PRESSURE SWITCH

Follow safety instructions for HANDLING R 134A REFRIGERANT .

Follow INSTRUCTIONS for opening and replacing parts in refrigerant circuit!
NOTE: If A/C system is opened for more than 24 hours:REPLACE DESICCANT INSERT
FOR A/C SYSTEM
value given for this work operation!
Disconnect plug connection (1) and release safety pressure switch (2).
Fig. 133: Identifying Plug Connection And Pressure Switch

2010 BMW M3
After installation
64 53... REPLACING VALVE INSERT FOR REFRIGERANT LINE

Follow safety instructions for HANDLING R 134A REFRIGERANT .

Follow INSTRUCTIONS for opening and replacing parts in refrigerant circuit!
If A/C system is opened for more than 24 hours:REPLACE DESICCANT INSERT FOR A/C SYSTEM
NOTE: The special tool is available under BMW order number: 81 34 0 427 679 from the
BMW workshop equipment catalogue.
Twist valve insert out of filler neck (2) with remover (1).
Installation:
Screw in valve insert hand-tight only.

2010 BMW M3
Fig. 134: Identifying Filler Neck With Remover

After installation

Check leak-tightness of valve insert with soapy solution
In event of leakage:
EVACUATE A/C system

Check sealing faces on line and valve insert for damage, replace line or valve insert if necessary
If necessary, carry out LEAK DETECTION
2010 BMW M3
HVAC Heating and Air Conditioning - Repair - M3
HVAC
Heating and Air Conditioning - Repair - M3
HEATER WITH OPERATION

64 11 ... OVERVIEW OF SERVODRIVES ON HEATER/AIR CONDITIONER
Fig. 1: Identifying Heater And Air Conditioner Components

64 11 206 REMOVING AND INSTALLING/REPLACING HEATER

2010 BMW M3
Follow safety instructions for handling R 134a refrigerant .

Follow safety instructions for handling refrigerant oil .
Follow instructions for working on cooling system . See 17 00 ...

INSTRUCTIONS FOR WORKING ON COOLING SYSTEM .

Follow instructions for opening and replacing parts in refrigerant circuit.
If A/C system is opened for more than 24 hours: Replacing drier insert for A/C
system
Draw off refrigerant from A/C system

MANIFOLD (S65) .
Remove lower section of steering spindle . See 32 31 070 REMOVING AND INSTALLING /
REPLACING LOWER SECTION OF STEERING SPINDLE .
Remove right suspension cross-brace . See 51 71 345 REMOVING AND
Remove expansion valve
Remove instrument panel trim . See 51 45 030 REMOVING AND INSTALLING INSTRUMENT
PANEL TRIM .
Remove complete steering column . See 32 31 090 REMOVING AND INSTALLING/REPLACING
STEERING COLUMN .
Remove air ducts.
Remove carrier for instrument panel . See 51 45 ... REMOVING AND INSTALLING CARRIER
FOR INSTRUMENT PANEL .
Release cap (1) on bulkhead and release screw underneath.
Tightening torque 64 11 1AZ , see HEATER WITH OPERATION .

2010 BMW M3
Fig. 2: Identifying Cap On Bulkhead

Unclip refrigerant lines (2).
Unscrew nuts (2).
Feed out media passage sealing plate (3) and associated rubber grommet.
Installation:
Makes sure media passage sealing plate and associated rubber grommet are correctly seated.
IMPORTANT: Carefully blow through aluminum double pipe to remove remaining coolant
from heat exchanger for heating system.
Fig. 3: Identifying Passage Sealing Plate And Associated Rubber Grommet

IMPORTANT: Protect working area (1) against escaping coolant.

2010 BMW M3
Remove heater (2) with a 2nd person helping from vehicle.
Fig. 4: Removing Heater

Installation:
Make sure heater is correctly seated.
Make sure condensate drain (2) is correctly seated in grommet (1).
Fig. 5: Drain Correctly Seated In Grommet

After installation:
Vent cooling system and check for water leaks . See 17 00 009 CHECKING COOLING SYSTEM
FOR LEAKS (S65) .
2010 BMW M3
64 11 208 REPLACING HEATER CORE
IMPORTANT: Determine manufacturer of installed heater (Denso or Behr) before ordering

spare parts!
Fig. 6: Locating Heater Core

Remove heater/air conditioner
Release screws (1).
Slide rubber grommet (1) with foam seal forward slightly.
Carefully feed pipe holder (3) with pipes (4) past rubber grommet (2).
Installation:
If necessary, replace rubber grommet (1) and/or foam seal.
Make sure rubber grommet (1) is correctly seated on pipe holder (3).
2010 BMW M3
Fig. 7: Identifying Feed Pipe Holder, Pipes And Past Rubber Grommet
If necessary, remove coolant hose (2).
Release screws (3) and remove cover.
NOTE: Diesel version only:

Withdraw electric auxiliary heater (4) in direction of arrow.
Remove heater (5) from heater/air conditioner (6).
Fig. 8: Removing Heater And Air Conditioner

Release screws (1) and slide screw clamps (2) forwards slightly.
Remove pipes (3) from heater core (4).

2010 BMW M3
Installation:
Coat sealing rings with antiseize agent.
Make sure sealing rings are correctly seated.
Fig. 9: Removing Pipes From Heater Core

IMPORTANT: Inflow connection (3) may only be positioned at the bottom.

When installing, make sure that the return-flow connection (2) (larger opening)
marked with a black dot (1) is positioned at the top.
Inflow connection (3) accordingly may only be positioned at the bottom.
Fig. 10: Identifying Return Flow Connection

2010 BMW M3
64 11 212 REMOVING AND INSTALLING/REPLACING HEATER/AIR CONDITIONER FAN
Remove trim for instrument panel , bottom right. See 51 45 181 REMOVING AND
Partially release air duct at side

Carefully raise lug (1) and feed out housing (2) by turning clockwise.
Installation:
Lug (1) must not be damaged and must snap audibly into place.
2010 BMW M3
Fig. 12: Identifying Lug And Housing

Replacement:
Replace controller for heater/air conditioner fan
64 11 224 REPLACING CONTROLLER FOR HEATER/AIR CONDITIONER FAN
Remove fan for heater/air conditioner
Release screws (2) and remove controller.
Fig. 13: Identifying Controller And Plug Connection

64 11 262 REMOVING AND INSTALLING/REPLACING AUXILIARY WATER PUMP (S65)

Follow instructions for working on cooling system . See 17 00 ...
INSTRUCTIONS FOR WORKING ON COOLING SYSTEM .
Recycling
Coolant emerges when coolant lines are detached. Have a suitable collecting container ready.
Catch and dispose of emerging coolant.

2010 BMW M3
Remove suction filter housing . See 13 71 000 REMOVING AND INSTALLING/REPLACING

Disconnect plug connection (1) and remove auxiliary water pump (2) towards top.
Fig. 14: Identifying Plug Connection And Auxiliary Water Pump

Installation:
Observe direction of flow.
Mark position of water hoses (1) prior to removal.
Disconnect water hoses (1) and remove auxiliary water pump (2).
2010 BMW M3
Fig. 15: Identifying Water Hoses And Auxiliary Water Pump

Installation:
Install auxiliary water pump (1) in front engine bracket so that rubber mounts (2) slide exactly in associated
locators (3).
Fig. 16: Identifying Auxiliary Water Pump And Rubber Mounts

After installation:
Fill and vent cooling system and check for leaks . See 17 00 009 CHECKING COOLING SYSTEM FOR
LEAKS (S65) .

OPERATOR UNIT (VERSION WITHOUT CCC/ASK)
00 9 340
protection) ! See 61 35 ... NOTES ON ESD PROTECTION (ELECTRO STATIC
DISCHARGE) .
NOTE: Car Communication Computer (CCC)

Audio System Kontroller / Controller (ASK)
Lever out heater/air conditioner operator unit (1) with special tool 00 9 340 and pull.
2010 BMW M3
Disconnect associated plug connections.
Remove heater/air conditioner operator unit (1) complete with center console switch cluster (2) and trim (3).
Fig. 17: Removing Heater And Air Conditioner Operator Unit

Replacement:
Fig. 18: Identifying Operator Unit


2010 BMW M3
Fig. 19: Identifying Trim And Operator Unit

Replacement:
Carry out programming/coding using scan tool.

OPERATOR UNIT (VERSION WITH CCC/ASK)
00 9 340
protection) ! See 61 35 ... NOTES ON ESD PROTECTION (ELECTRO STATIC
DISCHARGE) .
Car Communication Computer (CCC)
Audio System Kontroller / Controller (ASK)
Remove right decorative trim on instrument panel . See 51 45 181 REMOVING AND
NOTE: Unclip the heater/air conditioner operator unit (2) by simultaneously
levering out using special tool 00 9 340

2010 BMW M3
pulling on the relevant control button (3).
Fit special tool 00 9 340 on either side as illustrated.
Unclip heater/air conditioner operator unit (2) complete with trim (1) at fastening points (4) and pull back.
Remove heater/air conditioner operator unit (2) complete with trim (1).
Fig. 20: Identifying Heater And Air Conditioner Operator Unit

Replacement:
IMPORTANT: Risk of damage to operator unit!

2010 BMW M3
Fig. 21: Identifying Unit Trim

Fig. 22: Identifying Trim And Operator Unit

Replacement:
64 11 806 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR FRESH-

/RECIRCULATED-AIR FLAP

Service functions:
Body
Flap motors
Remove right glovebox with housing . See 51 16 366 REMOVING AND INSTALLING RIGHT
2010 BMW M3
Release screws (2).
Detach servodrive for fresh-/recirculated-air flap (3) in direction of arrow from heater/air conditioner.
Installation:
Place servodrive for fresh-/recirculated-air flap (3) exactly on associated gear teeth.

64 11 829 REPLACING SERVODRIVE FOR VENTILATION FLAPS (AUTOMATIC A/C)

Service functions:
Body
Flap motors
Release screws (2).

2010 BMW M3
Detach servodrive for ventilation flaps (3) in direction of arrow from heater/air conditioner (4).
Installation:
Place servodrive for ventilation flaps (3) over guide pin (5).
Fig. 24: Identifying Ventilation Flaps And Guide Pin

64 11 839 REPLACING SERVODRIVE FOR FOOTWELL FLAP (AUTOMATIC A/C)

Service functions:
Body
Flap motors
2010 BMW M3
Fig. 25: Identifying Footwell Heating Duct

Detach bracket (4) complete with servodrives from heater/air conditioner (5).
Installation:
Make sure bracket (4) is correctly seated on heater/air conditioner (5).
Fig. 26: Identifying Bracket And Screw

Release screws (1).
Remove servodrive for footwell flap (2) from bracket (3).

2010 BMW M3
Installation:
Place servodrive for footwell flap (2) over guide pin (4).
Fig. 27: Identifying Footwell Flap And Guide Pin

64 11 850 REPLACING SERVODRIVE FOR REAR COMPARTMENT FLAP

Service functions:
Body
Flap motors
Remove trim for instrument panel , bottom right. See 51 45 181 REMOVING AND
Release screws (2).
Detach servodrive for rear compartment flap (3) in direction of arrow from heater/air conditioner (4).
Installation:
Place servodrive for rear compartment flap (3) exactly onto heater/air conditioner (4).
2010 BMW M3
Fig. 28: Identifying Rear Compartment Flap And Air Conditioner

64 11 856 REMOVING AND INSTALLING / REPLACING SERVODRIVE FOR CENTRAL

KINEMATICS (A / C CONTROL)

Service functions:
Body
Flap motors
2010 BMW M3
Fig. 29: Identifying Right Rear Compartment Heating Duct

Release screws (2).
Detach servodrive for central kinematics (3) in direction of arrow from heater/air conditioner (4).
Installation:
Place servodrive for central kinematics (3) over guide pin (5).
Fig. 30: Identifying Central Kinematics And Air Conditioner


(LEFT)
2010 BMW M3

Service functions:
Body
Flap motors
removed.
Release screws (2).
Installation:

64 11 868 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR DEFROSTING FLAP

(RIGHT)
2010 BMW M3

Service functions:
Body
Flap motors
Remove glovebox with housing . See 51 16 366 REMOVING AND INSTALLING RIGHT
removed.
Release screws (2).
Installation:

64 11 869 REPLACING SERVODRIVE FOR BLENDING FLAP

2010 BMW M3

Service functions:
Body
Flap motors
Release screws (2).
Installation:
Fig. 33: Identifying Blending Flap And Guide Pin


(LEFT)

2010 BMW M3
Service functions:
Body
Flap motors
Remove trim for instrument panel at bottom left. See 51 45 185 REMOVING AND
E90/E91/E92/E93:
Remove panel for pedal assembly . See 51 45 185 REMOVING AND
NOTE: Lower instrument panel trim partially shown transparent.
Fig. 34: Detaching Left Footwell Heating Duct

Installation:
Make sure retainer (2) is correctly seated on left footwell heating duct (1).
Insert left footwell heating duct (1) with adapter (3) in left rear compartment heating duct (4).
2010 BMW M3
Attach left footwell heating duct (1) in area (4) to heater/air conditioner. Make sure assembly is locked exactly
at point (5).
Fig. 35: Identifying Footwell Heating Duct And Adapter

Release screws (2).
Installation:
Fig. 36: Identifying Blending Flap And Air Conditioner


2010 BMW M3
(RIGHT, AUTOMATIC A/C)

Service functions:
Body
Flap motors
Fig. 37: Detaching Right Footwell Heating Duct

Installation:
Make sure retainer (2) is correctly seated on right footwell heating duct (1).
Insert right footwell heating duct (1) with adapter (3) in right rear compartment heating duct (4).
Attach right footwell heating duct (1) in area (4) to heater/air conditioner. Make sure assembly is locked exactly
at point (5).
2010 BMW M3
Fig. 38: Identifying Right Footwell Heating Duct And Adapter

Release screws (2).
Installation:
Fig. 39: Identifying Blending Flap And Guide Pin

64 11 905 REMOVING AND INSTALLING/REPLACING VENTILATION TEMPERATURE SENSOR

2010 BMW M3
Remove decorative strip on instrument panel on right. See 51 45 380 REMOVING AND
INSTALLING (REPLACING) RIGHT DECORATIVE STRIP ON INSTRUMENT PANEL .
removed.
Pull temperature sensor (1) out of retaining lug (2).
Installation:
Make sure rubber ring is correctly seated.
Fig. 40: Pulling Temperature Sensor (1) Out Of Retaining Lug (2)
Disconnect plug connection (1) and remove temperature sensor (2).
Fig. 41: Identifying Temperature Sensor And Retaining Lug

64 11 908 REMOVING AND INSTALLING/REPLACING FOOTWELL TEMPERATURE SENSOR

2010 BMW M3
NOTE: For purposes of clarity, the following graphic shows the heater/air conditioner
removed.
Remove air routing duct (1) and unscrew temperature sensor (2).
Fig. 42: Identifying Air Routing Duct And Temperature Sensor

64 11 942 REPLACING EVAPORATOR TEMPERATURE SENSOR
Remove lower instrument panel trim . See 51 45 181 REMOVING AND

Withdraw temperature sensor (2).
Installation:
Ensure temperature sensor (2) is correctly seated.

2010 BMW M3

00 9 317
indoors.
surface.

2010 BMW M3
Fig. 44: Identifying Two-Part Mirror Base Cover

40-60C.
Lift off fogging sensor (2) with special tool 00 9 317 and slowly pull off from windshield.
Installation:
Fig. 45: Identifying Fogging Sensor With Special Tool

2010 BMW M3
Press fogging sensor (3) in direction of arrow with a contact pressure of > or = 15 N/cm2 onto inside of
windshield.
Fig. 46: Pulling Protective Film From Fogging Sensor

64 11 991 REMOVING AND INSTALLING/REPLACING SENSOR FOR AUTOMATIC

RECIRCULATED AIR CONTROL
Turn sensor for automatic recirculated air control (2) upwards and in direction of arrow and remove from
mounting (3).
Installation:
Make sure sensor for automatic recirculated air control (2) is correctly seated in mounting (3).
2010 BMW M3
Fig. 47: Identifying Automatic Recirculated Air Control And Mounting

64 11 992 REMOVING AND INSTALLING/REPLACING SOLAR SENSOR
00 9 340
Lever out solar sensor (1) with special tool 00 9 340 in direction of arrow.
NOTE: Secure disconnected wiring harness of solar sensor (1) against falling out
below instrument panel trim (2).
Disconnect associated plug connection and remove solar sensor (1) from instrument panel trim (2).
Fig. 48: Identifying Solar Sensor And Instrument Panel Trim

2010 BMW M3
AUXILIARY HEATER WITH CONTROL ELEMENTS

64 12 ... INITIALIZING TELESTART HAND TRANSMITTER (T90) (UP TO BUILD DATE 03/2007)

driving mode.
Close all vehicle doors

Within 5 seconds: Switch ignition lock from terminal "0" to terminal "R" and then back to terminal "0"
Within 5 seconds: Press OFF button (1) on hand transmitter and with OFF button (1) held down press ON
button (2) three times quickly
Release both buttons. LED (3) on hand transmitter flashes
Fig. 49: Identifying Hand Transmitter ON/OFF Button

initialization.
The initialization process must be repeated if there is no checkback signal from
2010 BMW M3
the central locking system.
64 12 ... INITIALIZING TELESTART HAND TRANSMITTER (T93) (FROM BUILD DATE 03/2007)

driving mode.
Close all doors on vehicle (vehicle must be unlocked!)

Within 5 seconds: Turn ignition lock from terminal "0" to terminal "R" and then back to terminal "0" (by
inserting and removing key, insertion duration: 1 to 5 secs.)
Within 5 seconds: Simultaneously press both buttons (1, 2) on hand transmitter until LED (3) lights up
orange.
Release both buttons. Briefly press ON button (1) three times within 10 seconds; LED (3) flashes orange
as confirmation.
2010 BMW M3
Fig. 50: Identifying Hand Transmitter ON/OFF Button

initialization.
The initialization process must be repeated if there is no checkback signal from
the central locking system.
64 12 089 REMOVING AND INSTALLING OR REPLACING MUFFLER/SILENCER

down.
Release screws (1, 2) and remove muffler/silencer (3).
Tightening torque 64 12 1AZ , see AUXILIARY HEATER .

2010 BMW M3
Fig. 51: Identifying Muffler Screws

64 12 120 REMOVING AND INSTALLING/REPLACING INTAKE MUFFLER FOR

INDEPENDENT/AUXILIARY HEATER

down.
Release retainer (1) and unscrew muffler (2) from connecting hose (3) in direction of arrow.
Installation:
Intake muffler (2) must be replaced if retainer (1) is damaged.

2010 BMW M3
Fig. 52: Releasing Retainer And Unscrew Muffler

NOZZLES AND OUTLETS

64 22 ... REMOVING AIR DUCTS
Fig. 53: Detaching Right Footwell Heating Duct With Adapter

NOTE: Lower instrument panel trim partially shown.
2010 BMW M3
Fig. 54: Detaching Left Footwell Heating Duct

Installation:
Make sure retainer (2) is correctly seated on left/right footwell heating duct (1).
Insert footwell heating duct (1) with adapter (3) in rear compartment heating duct (4).
Attach footwell heating duct (1) in area (4) to heater/air conditioner. Make sure assembly is locked exactly at
point (5).
Fig. 55: Identifying Footwell Heating Duct, Adapter And Rear Compartment Heating Duct
64 22 137 REMOVING AND INSTALLING/REPLACING LEFT FRESH-AIR GRILL

2010 BMW M3
Removing decorative strip on instrument panel on left (replacement) . See 51 45 370 REMOVING
AND INSTALLING (REPLACING) LEFT DECORATIVE STRIP ON INSTRUMENT PANEL .
64 22 138 REMOVING AND INSTALLING/REPLACING RIGHT FRESH-AIR GRILL
Lever out catches (2) and unclip right fresh-air grill (1) from right decorative strip on instrument panel (3).
Fig. 56: Identifying Right Fresh-Air Grill , Catches And Instrument Panel Decorative Strip
64 22 162 REMOVING AND INSTALLING/REPLACING CENTER FRESH-AIR GRILL
Release nuts (1) and remove center fresh-air grill (2) from decorative strip on instrument panel on right (3).
2010 BMW M3
Fig. 57: Identifying Instrument Panel And Nuts

64 22 191 REMOVING AND INSTALLING/REPLACING REAR COMPARTMENT FRESH-AIR

GRILLE
00 9 341
Lever out rear compartment fresh-air grille (1) with special tool 00 9 341 at retaining points (2).
Disconnect associated plug connection and remove rear compartment fresh-air grille (1).
Fig. 58: Identifying Rear Compartment Fresh-Air Grille

2010 BMW M3
MICROFILTER
Important! Risk of damage! A/C system must not be operated without the prescribed filter element.
Note on cleaning: Spray microfilter housing from inside with BMW pollen filter housing cleaner. Comply with
notes and instructions on handling cleaning agents ! Wipe away excess liquid. This kills off germs, bacteria and
fungi that cause smells. The smell that results on the plastic parts of the microfilter housing is eliminated.
(BMW part number: 0 447 913).
Remove sealing lips at marked points. Unclip line and water hose (1) from cover (3). Release retaining lug (2).
Feed out cover (3).
Fig. 59: Unclip Line And Water Hose From Cover

Cover tabs (1) must snap in correctly under cowl panel.
Fig. 60: Cover Tabs (1) Must Snap In Correctly Under Cowl Panel
2010 BMW M3
Remove filter cover (1) in direction of arrow.
Fig. 61: Remove Filter Cover (1) In Direction Of Arrow

Remove upper microfilter (1) in direction of arrow.
Fig. 62: Remove Upper Microfilter (1) In Direction Of Arrow

Unclip filter frame (1) at the marked points and detach. Remove lower microfilter (2) in direction of arrow.
2010 BMW M3
Fig. 63: Remove Lower Microfilter (2) In Direction Of Arrow

Installation note: Make sure upper microfilter (1) and lower microfilter (2) are installed in the correct position.
The arrows mark the direction of the air intake.
Fig. 64: Arrows Mark The Direction Of The Air Intake


Note on cleaning:
Spray microfilter housing from inside with BMW pollen filter housing cleaner (BMW part number: 0 447 913).
2010 BMW M3
Remove upper microfilter housing section on left and right.
Installation:
Fig. 65: Removing Microfilter

64 31 062 REMOVING AND INSTALLING/REPLACING LEFT LOWER MICROFILTER HOUSING

SECTION
Remove upper section of microfilter housing
Release screws (1).
Installation:

2010 BMW M3
Fig. 66: Identifying Rubber Tab And Cover

Installation:
Fig. 67: Identifying Lugs And Cowl Panel

64 31 063 REMOVING AND INSTALLING/REPLACING RIGHT LOWER MICROFILTER

HOUSING SECTION
Remove right upper microfilter housing section
Release screw (1).

2010 BMW M3
Installation:
Fig. 68: Identifying Rubber Tabs And Cover

Installation:
Fig. 69: Identifying Lugs And Cowl Panel

64 31 072 REMOVING AND INSTALLING/REPLACING LEFT UPPER MICROFILTER HOUSING

SECTION
Release screws (1).

2010 BMW M3
contact switch (3).
Installation:
Fig. 70: Identifying Upper Microfilter Housing Section And Hood Contact Switch
Replacement:
Modify hood/bonnet contact switch . See 61 31 241 REMOVING AND

INSTALLING/REPLACING RIGHT HOOD/BONNET CONTACT SWITCH (M3) .
Modify microfilter for interior ventilation.
64 31 074 REMOVING AND INSTALLING/REPLACING RIGHT UPPER MICROFILTER HOUSING

SECTION
Installation:

2010 BMW M3
Fig. 71: Identifying Upper Microfilter Housing Section And Screw

Replacement:
Replace microfilter for interior ventilation .

64 50 ... AIR CONDITIONER TEST (R 134A)
Before A/C efficiency test, satisfy following conditions:
1. Provide a MoDiC or DIS. Safeguard electrical system integrity by checking the fault memory (no faults
in the fault memory).
2. Provide a thermometer with separate gauge.
3. Perform the test in a suitable work bay with an ambient temperature between 20C and 30C.
Re 1:
Connect MoDiC or DIS to car and display evaporator temperature.
Re 2:
Position a thermometer with a separate gauge approx. 5 cm below the roof liner at the height of the B-pillar.
Lay gauge outwards out of vehicle interior.
Re 3:
Heating up vehicle interior:
A/C button is not activated during heating up.

2010 BMW M3
Close all windows and doors.

Set recirculated air mode.
Select air distribution mode for footwell and defrosting.
Maximum temperature setting.
Maximum fan stage.
Run engine at approx. 2000 RPM until operating temperature is reached, then idle speed.
A/C efficiency test:
Turn on A/C compressor at a vehicle interior temperature of 50C.
After 3-4 minutes, the evaporator sensor temperature must be > or = 15C.
Draw off A/C system if this temperature is not reached. Measure amount of refrigerant drawn off.
If drawn-off quantity does not correspond to specified fill quantity: supplement refrigerant and repeat test.
If fill quantity is correct, continue troubleshooting by pressure measurement .
NOTE: A/C systems with uncontrolled compressors only:

If necessary, then continue troubleshooting by pressure measurement .
64 50 ... INSTRUCTIONS FOR HANDLING REFRIGERANT R 134A
WARNING: Although R 134a at normal temperature is non-toxic, non-flammable and

not explosive in air in any mixture ratio, it is still essential to follow
various safety precautions.
The filled refrigerant circuit of the A/C system is subject to gauge pressure. When carrying out repairs on the
A/C system, it is absolutely essential to draw off the refrigerant.
Do not weld or solder on filled A/C systems or in rooms into which R 134a may have leaked. Exposure to
flames or high temperatures (> or = 50C) may give rise to toxic decomposition products (fluorine gas). For this
reason, do not smoke either.
R 134a must be drawn off, cleaned and returned to the A/C system with a service station following the relevant
Avoid all contact with liquid or gaseous R 134a. Wear protective goggles and gloves when working on the
refrigerant circuit. R 134a acting on the skin can cause frostbite. Rinse affected body parts thoroughly with cold
water. If R 134a gets into your eyes, likewise rinse with plenty of water and, if necessary, remove contact lenses
if worn. Then seek immediate medical attention. Likewise seek immediate medical attention if you experience
problems after inhaling R 134a fumes.
2010 BMW M3
especially in workshop pits in an imperceptible danger of asphyxiation or in cardiac palpitations. Ventilate

rooms adequately; if necessary, turn on installed extractor systems.
For a properly functioning A/C system, it is essential to have the greatest possible levels of cleanliness when
working on the A/C system and the best possible evacuation (at least 30 minutes dehumidification from
refrigerant circuit) before each filling of the A/C system.
R 134a absorbs moisture very easily. Therefore seal off opened pipes, condenser, evaporator, compressor and
drier bottle immediately with plugs.
With replacement parts, the plugs may only be removed immediately before the lines are connected.
In the event of warranty claims, the old parts must be provided with plugs to be able to determine the cause of
the damage.
If an A/C system has been completely drained by leakage, accident or repair, the drier element must be replace
as excessive moisture may have entered the system.
Store filled pressurized refrigerant bottles in such a way that they are not exposed to direct sunlight or other heat
sources (max. 45C). Also avoid exposing them to mechanical stress (e.g. by dropping).
In the event of fire, carbon dioxide (CO2), extinguishant powder and a sprayed water jet are deemed to be
suitable extinguishants. Cool reservoirs at risk with a sprayed water jet (risk of bursting!).
IMPORTANT: After each refill of an A/C system, check that protective caps of filling valves
are hand-tight. They serve as additional seals.
64 50 ... INSTRUCTIONS FOR HANDLING REFRIGERANT OIL (FOR REFRIGERANT R 134A)
WARNING: Observe the following points when handling refrigerant oil:
Wear protective goggles.

Wear gloves made from impermeable plastic.
Do not swallow.
Do not inhale.
Action to be taken after contact with refrigerant oil:
After contact with eyes, rinse thoroughly with plenty of water and
take out contact lenses (if worn). Then seek immediate medical
attention.
After contact with the skin, wash body parts affected with plenty of
soap and water.
Do not induce vomiting if oil is swallowed, seek immediate medical
2010 BMW M3
attention.
If inhaled, introduce the person affected to fresh air. Seek medical
attention if problems persist.
WARNING: Refrigerant oil is non-combustible and non-explosive at normal

temperatures. In spite of this, the following precautions must be
observed:
Do not store in the vicinity of flames, heat sources or strongly

oxidizing materials.
Suitable extinguishants: carbon dioxide (CO2), dry extinguishant,
foam.
IMPORTANT: Refrigerant oil is hygroscopic and must therefore be stored in suitable

containers that are sealed airtight!
Recycling:
Absorb escaping refrigerant oil with fluid-binding material.
Notify the relevant authorities if larger amounts of refrigerant oil are discharged into above-ground water
supplies, drainage systems or subsoil.
64 50 ... LEAK TESTING WITH ULTRAVIOLET ADDITIVES (UV ADDITIVES) (BMW LEAK-
TESTING CASE)
IMPORTANT: It is absolutely essential to read and comply with the equipment manufacturer's
instructions for use provided in the equipment case!
Read and comply with the instructions for use provided with the special tool
particularly with regard to accident prevention, health protection and
environmental protection.
Use only BMW-approved UV-additives (e.g. TRACER).
Only the basic procedure is described in the following!
WARNING: Avoid contact with refrigerant.

Follow safety precautions when handling refrigerant .
IMPORTANT: UV lamp gets very hot in the radiation area!

Do not use the UV lamp without the filter glass.
Eyes and skin will suffer damage if the UV lamp is used without the filter glass.
2010 BMW M3
When using the UV lamp, wear the protective goggles provided in the case.
NOTE: Fill the hose system of the hand pump completely with UV additive PRIOR
to use
Use the UV additive exclusively for BMW-approved refrigerant oils
Do not operate the A/C system while the hand pump is connected or in use
The A/C system must always be filled with an adequate amount of
refrigerant to enable the leak-detecting agent to be properly distributed
Before actually testing for leaks, check the entire refrigerant circuit using the UV leak-detecting lamp to ensure
that no AV additive is already in the area of the refrigerant circuit.
If already illuminated areas are found, carefully clean the area in question with the cleaning agent contained in
the case.
On initial use:
Connect hand pump (1) to additive cartridge (2) and hose piece (3).
Fig. 72: Identifying Hand Pump And Additive Cartridge

On initial use:
Attach vent valve (1) to quick-connect coupling (2).
Turn handle (3) on hand pump to advance the plunger until a small amount of UV additive emerges. This vents
the hose system.
2010 BMW M3
IMPORTANT: The entire hand pump with hose system must not be disassembled again once
the filling work has been completed.
Fig. 73: Attaching Vent Valve To Quick-Connect Coupling

Attach quick-connect coupling (1) to low-pressure connection (2) of A/C system.
Turn handle on hand pump (3) until the required amount of UV additive is added.
The quantity of UV additive to be added is dependent on the amount of refrigerant in the refrigerant circuit:
A/C systems with refrigerant filling up to 900 g: one graduation mark (4) on additive cartridge
A/C systems with refrigerant filling in excess of 900 g: two graduation marks (4) on additive cartridge
Fig. 74: Identifying Graduation Marks On Additive Cartridge

NOTE: After filling, remove quick-connect coupling (1) and if necessary use the
2010 BMW M3
cleaning agent contained in the special tool case to clean up the UV additive.
Further tasks:
Start engine.
Run A/C system at highest setting for 5-10 minutes in order to ensure adequate distribution of dye in the
system
Switch off engine
Check all A/C system components for possible leaks
Possible leaks show up in luminous green
Complete accompanying information label (1) with the relevant data and attach in an easily visible position next
to the filling capacity information label (2).
Fig. 75: Identifying Information Label

64 50 ... SAFETY INSTRUCTIONS FOR HANDLING REFRIGERANT R134A

circuit.

2010 BMW M3

Do not smoke!
First aid measures:
Eye contact: In the event of contact with the eyes, rinse immediately with plenty of running water and
consult an opthalmologist.
Skin contact: In the event of contact with skin, remove affected clothing immediately and rinse with
plenty of water.
After inhalation: If refrigerant vapors are inhaled in greater concentrations, remove the person affected
to an area of fresh air and keep them under supervision. Consult a doctor. If breathing problems are
experienced, breathe additional oxygen. If the person affected is breathing with difficulty or has stopped
breathing, incline the person's head at the neck and administer the kiss of life.
64 50 ... SAFETY INSTRUCTIONS FOR HANDLING REFRIGERANT OIL

circuit.

Do not smoke!
First aid measures:
If swallowed: Do NOT induce vomiting, unless expressly instructed to do so by medical personnel. Do

not administer anything to an unconscious person through their mouth. Consult a doctor immediately if
larger quantities of this substance are swallowed. Loosen tight-fitting items of clothing (e.g. collar, tie,
belt or similar).
Eye contact: Remove contact lenses if worn. In the event of eye contact, rinse eyes for at least 15
minutes with plenty of water. It is essential to use WARM WATER. Consult a doctor .
Skin contact: In the event of skin contact, rinse immediately with plenty of water. Remove contaminated
clothes and shoes. Wash affected clothes before wearing again. Clean shoes thoroughly before reusing.
Call for a doctor.
2010 BMW M3
After inhalation: If inhaled, take the person affected outside into fresh air immediately and keep them
under supervision. Call for a doctor. If breathing difficulties are experienced, administer additional
oxygen. If the person affected stops breathing, administer the kiss of life.
Recycling
Catch and dispose of emerging refrigerant oil.
64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A)
WARNING: Refrigerant circuit is under high pressure!

Repair work may only be carried out on a DEPRESSURIZED refrigerant
circuit!
Follow safety instructions for handling refrigerant R 134a .

Only BMW-approved R134a refrigerant may be used.
NOTE: Draw off, evacuate and fill the A/C system in accordance with the operating
instructions of the relevant service station.
E60 only:
If necessary, to connect service station, use manufacturer's adapter for high-
pressure connection (red).
Instructions for drawing off A/C system:
To help separation of refrigerant and refrigerant oil, run engine at low speed (800-1200 RPM) and with A/C
system turned on for a few minutes.
The limits the entrainment of refrigerant oil while it is drawn off.
Drawn-off refrigerant oil must be changed and reintroduced via the service station.
If at the end of the drawing-off procedure the service station moisture indicator shows that the drawn-off
refrigerant is excessively moist, clean the refrigerant in accordance with the service station operating
instructions.
Recycling:

2010 BMW M3
Instructions for evacuating off A/C system:
The evacuation procedure removes all traces of ambient air, water vapor and any other gases present from the
A/C system. This enables subsequent system filling with refrigerant.
A decrease in the vacuum level indicates a leak in the refrigerant circuit .
Instructions for filling A/C system:
Before filling with refrigerant, top up the refrigerant oil entrained during drawing off.
Follow instructions for opening and replacing parts in refrigerant circuit!
Depending on the type of component replaced on the A/C system, it may be necessary to top up the refrigerant
oil, even if no measurable losses have occurred during drawing off. Read and comply with the A/C system
manufacturer's notes in this regard and the operating instructions of the relevant service station.
Fig. 76: Identifying Rating Plate

Information on the required refrigerant fill quantity for the entire A/C system is contained on the rating plate (1)
in the engine compartment.
If necessary, refer to HEATING AND AIR CONDITIONING - TECHNICAL DATA fill quantities .
Installation:
Reseal refrigerant filler necks on vehicle with sealing caps.
AC HOUSING EVAPORATOR, SWITCHING ELEMENTS

2010 BMW M3
64 51 ... LEAK-TESTING CONDENSER
64 5 121
64 5 122
64 5 123

Follow safety instructions for handling refrigerant
handling nitrogen.
Drain off air conditioner

Tightening torque 64 53 6AZ , see 64 53 REFRIGERANT LINES AND EXPANSION VALVE .

the seal plugs!
Replace sealing rings (1) prior to each use.

2010 BMW M3

Fit and secure sealing adapter 64 5 123 to connection of low-pressure line.
Fit and secure test adapter 64 5 122 to connection of low-pressure line.
Fig. 78: Identifying Adapter With Special Tool

Connect special tool 64 5 122 to special tool 64 5 121 .

2010 BMW M3
Fig. 79: Connecting Adapter To Special Tool

leak-testing.
121 (connecting hose).

the test procedure.
WARNING: After leak-testing, unscrew special tool 64 5 121 slowly from special tool
64 5 122 to reduce pressure.
After leak-testing:
Replace all sealing rings and moisten with refrigerant oil

Assemble A/C system
2010 BMW M3
64 51 ... LEAK-TESTING EVAPORATOR
64 5 121
64 5 124
WARNING: It is essential, when handling nitrogen, to observe the standard national

safety regulations.
Remove expansion valve
Replace sealing rings (1) and coat with refrigerant oil

Screw down special tool 64 5 124 with retaining clip (1).

2010 BMW M3
Fig. 81: Identifying Retaining Clip

Connect special tool 64 5 124 to special tool 64 5 121 .
Fig. 82: Connecting Special Tool (64 5 124)

leak-testing.
Pressurize evaporator to 10 bar slowly only. Excessively fast pressurization
and pressures in excess of 20 bar may cause damage to the evaporator.
121 (connecting hose).

2010 BMW M3
the test procedure.

If the pressure loss is greater than 1.5 bar, this indicates that there is a leak in the evaporator unit.
WARNING: After leak-testing, unscrew special tool 64 5 121 slowly from special tool
64 5 124 to reduce pressure.
After leak-testing:
Replace all sealing rings and moisten with refrigerant oil
64 51 001 CLEANING EVAPORATOR
64 1 260
64 1 270
WARNING: When handling cleaning agent, observe following protection measures:

Wear protective rubber gloves and protective goggles.
If cleaning agent comes into contact with eyes or skin, wash immediately
with lots of water.
IMPORTANT: To avoid dirtying vehicle interior:
Close all air vents.

Switch heating - A/C system to recirculated-air mode.
Cover carpet in work area.
Recycling:
Carry out the cleaning operation in a suitable washing bay as the emerging cleaning agent escapes through the
drain openings in the transmission tunnel.
After completing cleaning, allow car to drip-dry for approx. 5 minutes.

2010 BMW M3

Remove heater/air conditioner fan.
IMPORTANT: Use special tool 64 1 270 on right hand drive models.
Connect special tool 64 1 260 (spray lance) to spray gun (2).
Insert spray lance 64 1 260 through opening (1) into fresh air duct.
By moving spray lance (1) back and forth, spray a uniform amount of cleaning agent onto evaporator.
Fig. 83: Inserting Spray Lance Into Fresh Air Duct

Spray lance 64 1 260 shown on removed and cut-open heater/air conditioner:
Spray lance 64 1 260 in upper end position (1)

Spray lance 64 1 260 in lower end position (2)
By moving spray lance back and forth, spray a uniform amount of cleaning agent onto evaporator.
2010 BMW M3
Fig. 84: Identifying Spray Lance In Upper/Lower End Position

NOTE: Set heating - A/C system to footwell ventilation and fresh-air mode. Open
windows/doors.
Start car and run heating - A/C system at maximum fan power for approx. 5
minutes in order to dry evaporator.
In order to eliminate the last remnants of cleaning agent, repeat this procedure
shortly before handover to the customer.
64 51 525 REMOVING AND INSTALLING OR REPLACING EXPANSION VALVE

Follow safety instructions for handling R134a refrigerant .

If A/C system is opened for more than 24 hours: Replace desiccant insert for
A/C system
Drawing off, evacuating and filling the A/C system are not included in the time value given for this
work operation
Remove left suspension cross-brace . See 51 71 345 REMOVING AND
2010 BMW M3
NOTE: Work described on the E90 by way of example, deviations in detail are possible
in other vehicles.
Release screws (1, 2), disconnect refrigerant lines and lay to one side.
Installation:
Replace all sealing rings and moisten with refrigerant oil.
Fig. 85: Identifying Expansion Valve And Screws

Release screws (1) and remove expansion valve (2).
Installation:

2010 BMW M3
Fig. 86: Identifying Expansion Valve And Screws

Installation:
Place expansion valve (1) exactly on refrigerant lines (2) and (3).
Fit screws of expansion valve (1) and make sure retainer (4) is correctly positioned.
Fig. 87: Identifying Retainer And Expansion Valve

After installation:
COMPRESSOR
64 52 ... INSTRUCTIONS FOR COMPRESSOR REPLACEMENT
2010 BMW M3
IMPORTANT: Compressors with plastic belt pulleys:
Avoid impacts/knocks to plastic belt pulley (caused by tools, contact with

base).
Return faulty compressors in their original packaging only.
IMPORTANT: When starting up a new compressor for the first time, it is absolutely essential
to carry out the following breaking-in procedure:
Switch on A/C system

Set all air vents in instrument cluster to "OPEN"
Start engine and let it stabilize at idle speed
Set blower output to min. 75 % of max. blower output
Switch on A/C system and run for at least 2 minutes at idle speed (risk of
damage at higher speed!)
When evacuating the air-conditioning system, refrigerant oil is also extracted and collected in the oil separator
of the service station.
After evacuation, the refrigerant must be filtered in the service station as the oil separator could still contain a
liquid refrigerant/oil mixture. The filtering process gasifies the refrigerant completely and only the previously
bound refrigerant oil remains in the oil separator. Measure and note down this quantity of refrigerant oil,
refer to EVACUATING A/C SYSTEM.
Fig. 88: Measuring Quantity Of Refrigerant Oil,

Transfer the refrigerant oil remaining in the previous compressor via the filler plug completely into a measuring
container.
2010 BMW M3
Fig. 89: Refilling Refrigerant Oil

Measure the amount of refrigerant oil collected from the previous compressor.
Fig. 90: Measuring Amount Of Refrigerant Oil Collected From Previous Compressor
The new compressor is filled at the factory with refrigerant oil. Open filler plug and pour entire contents of
compressor into a clean container.
Installation:
Replace sealing ring and moisten with refrigerant oil.
Observe tightening torque, 64 52 2AZ , see COMPRESSOR .
From the new compressor, pour the same amount of refrigerant oil (as drained from the previous compressor) +
10 g extra into a clean measuring container and pour again into the new compressor.
2010 BMW M3
Remaining refrigerant oil can be poured into service station tank,
Otherwise the excess refrigerant oil must be disposed of correctly.
On account of its hygroscopic properties, refrigerant oil must not be stored in open containers.
Fig. 91: Measuring Oil In Container

The refrigerant oil drawn off from the oil separator of the service station and from the previous compressor
must not be reused and must be correctly disposed of.
After installing the new compressor, it is essential before filling the A/C system to pour the same amount of the
previously drawn off refrigerant oil into the system again,
Installation:
If A/C system is opened for more than 24 hours: Replace drier bottle/drier insert .
64 52 ... INSTRUCTIONS FOR OPENING AND REPLACING PARTS IN REFRIGERANT CIRCUIT
WARNING: Avoid contact with refrigerant and refrigerant oil

Follow safety instructions for handling R134a refrigerant
Follow safety instructions for handling refrigerant oil
CAUTION: Always use new O-rings each time A/C connections are opened.
Moisten O-rings with refrigerant oil prior to fitting
2010 BMW M3
Seal all parts to be returned at openings to prevent ingress of

moisture or foreign bodies
I. Opening refrigerant circuit
without part replacement, as preliminary work to further work
(e.g. engine removal):
Work sequence:
Draw off A/C system, then determine drawn-off refrigerant oil quantity
Carry out main work
Replace removed refrigerant oil with new refrigerant oil
II. Part replacement and part replacement on account of insidious leak
Work sequence:
Additionally replenish new refrigerant oil in accordance with replaced parts:
Compressor: refer to Notes on replacing compressor
Evaporator: 10 ml
Condenser: 10 ml
Desiccant insert / desiccant bottle: 30 ml
Condenser with integrated dryer: 30 ml
Safety pressure switch and seals: no additional refrigerant oil
III. Part replacement on account of sudden leak
Work sequence:
2010 BMW M3

Additionally replenish 25 ml new refrigerant oil and new refrigerant oil in accordance with
replaced parts:
Compressor: refer to Notes on replacing compressor
Evaporator: 10 ml
Condenser: 10 ml
Desiccant insert / desiccant bottle: 30 ml
Condenser with integrated dryer: 30 ml
Safety pressure switch and seals: no additional refrigerant oil
64 52 521 REPLACING A/C SYSTEM COMPRESSOR (S65)
32 1 270
See STEERING AND WHEEL ALIGNMENT - SPECIAL TOOLS .

Work on the cooling system may only be carried out when it has cooled
down.

Follow safety instructions for handling R 134a refrigerant.

Read and comply with notes on replacing compressor.
If A/C system is opened for more than 24 hours:
Replace desiccant insert for A/C system.
Drawing off , evacuating and filling the A/C system is not included in the time value given for this work
operation
Remove A/C compressor drive belt
Drain coolant from radiator. See 17 00 005 DRAINING AND ADDING COOLANT (S65) .
2010 BMW M3
Remove coolant hose from radiator at bottom
Clamp off overflow hoses (1) and lay to one side.
Release screws (2).
Raise coolant tank (3) and disconnect associated plug connection.
Place coolant tank (3) to one side.
Fig. 92: Identifying Coolant Tank And Hoses

Release screws (2) and remove refrigerant lines.
Installation:
Tightening torque 64 52 1AZ , see COMPRESSOR .

2010 BMW M3

IMPORTANT: Seal openings or lines on compressor with special tool 32 1 270 to prevent
escape of media and fouling.
Release screws (1, 2) and remove holder (3).
IMPORTANT: Secure compressor (5) against falling off/down.
Release screw (4) and feed out compressor (5) towards top.
Fig. 94: Identifying Holder And Screw

Installation:
If necessary, replace damaged adapter sleeves (1).

2010 BMW M3
Fig. 95: Identifying Adapter Sleeves

After installation:
Fill and vent cooling system. See 17 00 ... INSTRUCTIONS FOR WORKING ON COOLING
SYSTEM .
CONDENSER AND DRYER WITH LINES

64 53 ... OVERVIEW OF A/C CIRCUIT COMPONENTS
2010 BMW M3
Fig. 96: Identifying Condenser, Evaporator And Expansion Valve

64 53 ... NOTES ON REPLACING DRIER BOTTLE OR DRIER INSERT
The drier bottle or drier insert does not have to be replaced at regular service intervals in a functioning,
leakproof A/C system.
However, the drier bottle or drier insert must be replaced without fail in the event of:
fouling of the refrigerant by filings/shavings (e.g. when the compressor is clamped)

a leaking A/C system or loss of refrigerant
the refrigerant circuit being opened for a period exceeding 24 hours, e.g. during repair work.
64 53 ... REPLACING VALVE INSERT FOR REFRIGERANT LINE

2010 BMW M3


If A/C system is opened for more than 24 hours: Replace desiccant insert for
A/C system
NOTE: The special tool is available under BMW order number: 81 34 0 427 679 from the
BMW workshop equipment catalogue.
work operation
Twist valve insert out of filler neck (2) with remover (1).
Installation:
Screw in valve insert hand-tight only.
Fig. 97: Identifying Filler Neck And Remover

After installation:

Check leak-tightness of valve insert with soapy solution
2010 BMW M3
In event of leakage:
Evacuate A/C system

Check sealing faces on line and valve insert for damage, replace line or valve insert if necessary
If necessary, carry out leak detection
64 53 515 REPLACING DESICCANT INSERT FOR A/C SYSTEM


Read and comply with Notes on replacing compressor .
Replace desiccant insert for A/C system
work operation
Remove condenser
If necessary, pierce sticker over sealing cap (1).
Remove cap (1) from condenser (2).
Installation:

2010 BMW M3
Fig. 98: Identifying Cap From Condenser

Remove Seeger circlip ring (1) with suitable pliers.
Fig. 99: Identifying Seeger Circlip Ring

With assistance of a screwed-in screw (1), withdraw desiccant insert (2) from condenser (3).
2010 BMW M3
Fig. 100: Removing Condenser Bolt

After installation:
Fill and vent cooling system and check for leaks. See 17 00 ... INSTRUCTIONS FOR WORKING ON
COOLING SYSTEM .
64 53 520 REPLACING SAFETY PRESSURE SWITCH


NOTE: If A/C system is opened for more than 24 hours: Replace desiccant insert for
A/C system
work operation!
Disconnect plug connection (1) and release safety pressure switch (2).
Tightening torque 64 53 14AZ , see 64 53 REFRIGERANT LINES AND EXPANSION VALVE ..

2010 BMW M3
Fig. 101: Releasing Safety Pressure Switch And Plug Connection

After installation:
64 53 550 REMOVING AND INSTALLING OR REPLACING CONDENSER FOR A/C SYSTEM


work operation
Remove radiator . See 17 11 000 REMOVING AND INSTALLING RADIATOR .
Release screws (1).
Disconnect suction and pressure lines and lay to one side.
Installation:
2010 BMW M3
Tightening torque 64 53 1AZ , see 64 53 REFRIGERANT LINES AND EXPANSION VALVE ..
Fig. 102: Identifying Pressure Lines Screws

Release screw (1).
Lever out retainer (2).
Remove condenser (3) towards rear.
Installation:
Make sure retaining clips are correctly seated in area (4).
Fig. 103: Identifying Condenser And Screw

2010 BMW M3
Installation:
Make sure condenser (1) is securely seated in area (2).
Fig. 104: Identifying Condenser

After installation:

Fill and vent cooling system and check for leaks. See 17 00 ... INSTRUCTIONS FOR WORKING ON
COOLING SYSTEM .
64 53 642 REPLACING LINE FROM COMPRESSOR TO CONDENSER (S65)


work operation
2010 BMW M3
Release screw (1).
Tightening torque 64 52 1AZ , see COMPRESSOR .
Installation:
Replace sealing rings and moisten with refrigerant oil.
Fig. 105: Identifying Refrigerant Line And Screw

After installation:
Evacuate and fill A/C system.
64 53 660 REPLACING LINE FROM CONDENSER TO EVAPORATOR (S65)


2010 BMW M3
work operation
Installation:

Installation:

2010 BMW M3

Replacement:
Modify safety pressure switch .
After installation:
64 53 670 REPLACING LINE FROM COMPRESSOR TO EVAPORATOR (S85)


work operation
Remove air manifold . See 11 61 050 REMOVING AND INSTALLING AIR INTAKE MANIFOLD
2010 BMW M3
(S65) .
Remove both suspension cross-braces . See 51 71 345 REMOVING AND
Release refrigerant tank and place to one side
Installation:
Replace sealing rings and moisten with refrigerant oil.

Installation:

2010 BMW M3
Fig. 109: Identifying Refrigerant Oil And Screw

After installation:

2010 BMW M3
ACCESSORIES AND BODY, CAB Instruments - Repair
Instruments - Repair
INSTRUMENT CLUSTER
62 11 280 REMOVING AND INSTALLING (REPLACING) INSTRUMENT CLUSTER
PROTECTION) .

Carry out this operation carefully so as to avoid damaging the instrument
panel.
Extend steering wheel completely and lower.
Pull instrument cluster (2) forward slightly in direction of arrow.
If necessary, feed out/unclip associated wiring harness.
Remove instrument cluster (2).
Fig. 1: Removing Instrument Cluster

Replacement:
2010 BMW M3
ACCESSORIES AND BODY, CAB Instruments - Repair
Check values for Condition Based Service (CBS) and correct if necessary.
2010 BMW M3
ACCESSORIES AND BODY, CAB Instruments - Repair Instructions - M3
Instruments - Repair Instructions - M3
INSTRUMENT CLUSTER
62 11 280 REMOVING AND INSTALLING (REPLACING) INSTRUMENT CLUSTER
protection) .

Carry out this operation carefully so as to avoid damaging the instrument
panel.
Extend steering wheel completely and lower.
Release screws (1). Tightening torque 1.5 Nm .
Pull instrument cluster (2) forward slightly in direction of arrow.
If necessary, feed out/unclip associated wiring harness.
Remove instrument cluster (2).
Fig. 1: Pull Instrument Cluster (2) Forward Slightly In Direction Of Arrow

Replacement:
2010 BMW M3
ACCESSORIES AND BODY, CAB Instruments - Repair Instructions - M3
Carry out vehicle programming/coding .
Check values for Condition Based Service (CBS) and correct if necessary.
2010 BMW M3
SUSPENSION Integrated Suspension Systems - Repair
SUSPENSION
Integrated Suspension Systems - Repair
GENERAL
Headaches
Dizziness
Stomach aches
Vomiting
Diarrhoea
Cramps/fits
Unconsciousness

First aid measures

EQUIPMENT)
2010 BMW M3
reactions!

of ignition.
sunlight.
month).


directly.
First Aid:
2010 BMW M3
doctor.
Recycling
37... OVERVIEW OF 2-AXLE RIDE-HEIGHT CONTROL

2010 BMW M3
2010 BMW M3
Fig. 1: Overview Of 2-Axle Ride-Height Control

37.... OVERVIEW OF ELECTRONIC DAMPER CONTROL (EDC)
Fig. 2: Overview Of Electronic Damper Control (EDC)

2010 BMW M3
Danger of injury!
Impaired sight

First aid measures


the information "switch closed" is output. The automatic engine start -
stop function is active.

2010 BMW M3

Workshop mode
A = 10 mm
B = 7 mm


2010 BMW M3
Recycling
REAR CONTROL AND SUSPENSION ELEMENTS

37 12 001 CHECKING FUNCTION OF SELF-LEVELLING SUSPENSION SYSTEM
Carry out error search with BMW diagnosis system.
ELECTRICAL COMPONENTS
37 14 017 REMOVING AND INSTALLING/REPLACING FRONT MOUNTED ACCELERATION
SENSOR (M3)

Remove FRONT WHEEL ARCH COVER (REAR SECTION)
Release screws (2) and remove mounted acceleration sensor (3).

2010 BMW M3
Fig. 5: Identifying Plug Connection And Acceleration Sensor

37 14 027 REMOVING AND INSTALLING/REPLACING REAR MOUNTED ACCELERATION

SENSOR (M3)

Remove HOLDER FOR REAR RIGHT BUMPER
Release nuts (2) and remove mounted acceleration sensor (3).
Fig. 6: Identifying Acceleration Sensor

2010 BMW M3
37 14 511 REPLACING FRONT RIDE-HEIGHT SENSOR

Release nut (1) and disconnect jointed rod (2).
Installation:
Fig. 7: Identifying Plug Connection, Jointed Rod With Screws

Release screws (4).
Remove ride-height sensor and disconnect plug connection (3).
Installation:
After installation
Check headlight adjustment . See 6310004 ADJUSTING HEADLIGHTS or 6310004 ADJUSTING

HEADLIGHTS , correct if necessary
37 14 512 REPLACING REAR RIDE-HEIGHT SENSOR (M3)

2010 BMW M3
Release nut (1) and disengage jointed rod (2) on ride-height sensor.
Installation:
Sensor lever (3) must point starting from ride-height sensor to left rear wheel.
Fig. 8: Identifying Lever, Ride-Height Sensor And Jointed Rod

Release bolt (4) and remove ride-height sensor with holder from rear axle carrier.
Installation:
Align holder to corresponding bore in rear axle carrier.
Release screws (3) and remove ride-height sensor from bracket (2).
Installation:

2010 BMW M3
Fig. 9: Identifying Plug Connection And Ride-Height Sensor

After installation
Check HEADLIGHT ADJUSTMENT , correct if necessary
ELECTRONIC DAMPING FORCE ADJUSTMENT

37 15 055 REMOVING AND INSTALLING (REPLACING) EDC CONTROL UNIT (M3)

Remove right luggage compartment wheel arch trim
Remove cable ties (1) from body.
Feed cable (2) out of insulating mat (3) and lay insulating mat to one side.
2010 BMW M3
Fig. 10: Identifying Cable Of Insulating Mat And Cable Ties

Release screws (1) and remove equipment carrier (2).
Fig. 11: Identifying Equipment Carrier With Screws

Unlock catch (2) and lift control unit (3) out of equipment carrier.
2010 BMW M3
Fig. 12: Identifying Plug Connection, Catch And Control Unit Of Equipment Carrier
After installation
Replacement only: Carry out Vehicle programming and encoding

2010 BMW M3
SUSPENSION Integrated Suspension Systems - Repair Instructions - M3
SUSPENSION
Integrated Suspension Systems - Repair Instructions - M3
GENERAL
Headaches
Dizziness
Stomach aches
Vomiting
Diarrhoea
Cramps/fits
Unconsciousness

First aid measures:
Danger of injury!

2010 BMW M3
Impaired sight

First aid measures:

Recycling:
37 ... . OVERVIEW OF ELECTRONIC DAMPER CONTROL (EDC)

2010 BMW M3
Fig. 1: Identifying Electronic Damper Control (EDC) Components

Safety instructions
ELECTRICAL COMPONENTS
37 14 017 REMOVING AND INSTALLING/REPLACING FRONT MOUNTED ACCELERATION
SENSOR (M3)
DISCHARGE) .
Remove front wheel arch cover (rear section) . See 51 71 039 REMOVING AND
INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH COVER (REAR
SECTION) .
Release screws (2) and remove mounted acceleration sensor (3).

2010 BMW M3
Fig. 2: Identifying Screws, Plug Connection And Mounted Acceleration Sensor

37 14 027 REMOVING AND INSTALLING/REPLACING REAR MOUNTED ACCELERATION

SENSOR (M3)
DISCHARGE) .
Remove holder for rear right bumper . See 51 12 801 REMOVING AND
INSTALLING/REPLACING HOLDER FOR REAR LEFT OR RIGHT BUMPER .
Release nuts (2) and remove mounted acceleration sensor (3).
Fig. 3: Identifying Nuts, Plug Connection And Mounted Acceleration Sensor

2010 BMW M3
37 14 511 REPLACING FRONT RIDE-HEIGHT SENSOR
DISCHARGE) .
Release nut (1) and disconnect jointed rod (2).
Installation:
Tightening torque, see 37 14 3AZ in 14 ELECTRICAL COMPONENTS .
Release screws (4).
Remove ride-height sensor and disconnect plug connection (3).
Installation:
Tightening torque, see 37 14 1AZ in 14 ELECTRICAL COMPONENTS ..
Fig. 4: Identifying Plug Connection, Sensor Lever, Nut And Jointed Rod
After installation:
Check headlight adjustment , correct if necessary. See 63 10 004 ADJUSTING HEADLIGHTS .
37 14 512 REPLACING REAR RIDE-HEIGHT SENSOR (M3)

2010 BMW M3
DISCHARGE) .
Release nut (1) and disengage jointed rod (2) on ride-height sensor.
Installation:
Release bolt (4) and remove ride-height sensor with holder from rear axle carrier.
Fig. 5: Identifying Nut, Jointed Rod, Bolt And Lever

Installation:
Align holder to corresponding bore in rear axle carrier.
Release screws (3) and remove ride-height sensor from bracket (2).
Installation:

2010 BMW M3
Fig. 6: Identifying Screws, Bracket And Plug Connection

After installation:
ELECTRONIC DAMPING
37 15 055 REMOVING AND INSTALLING (REPLACING) EDC CONTROL UNIT (M3)
DISCHARGE) .
Remove right luggage compartment wheel arch trim . See 51 47 161 REMOVING AND
INSTALLING / REPLACING RIGHT LUGGAGE COMPARTMENT WHEEL ARCH TRIM .
Remove cable ties (1) from body.
Feed cable (2) out of insulating mat (3) and lay insulating mat to one side.
2010 BMW M3
Fig. 7: Identifying Cable Ties, Cable And Insulating Mat

Release screws (1) and remove equipment carrier (2).
Fig. 8: Identifying Screws And Equipment Carrier

Unlock catch (2) and lift control unit (3) out of equipment carrier.
2010 BMW M3
Fig. 9: Identifying Plug Connection, Catch And Control Unit

After installation:
Replacement only: Carry out programming/coding

2010 BMW M3
ACCESSORIES & EQUIPMENT Vehicle Lighting - Product Information
ACCESSORIES & EQUIPMENT
Vehicle Lighting - Product Information
ADAPTIVE HEADLIGHTS E60, E61, E63, E64, E65, E66, E70, E81, E87, E90,
E91, E92, E93
Fig. 1: Identifying Headlights Focusing Angle

INTRODUCTION
Adaptive headlights turns the bi-xenon headlights towards the inside of a bend when cornering. This improves
illumination of the curve of the road. Visibility is therefore improved.
When cornering, the driver is not looking into a "black hole" - instead, the adaptive headlights allow the driver
to see the curve of the road.
This service information describes the adaptive headlights for the following model series:
> E60, E61, E63, E64 up to 03/2005:
See SYSTEM OVERVIEW OF ADAPTIVE HEADLIGHTS (E60, E61, E63, E64, E65, E66 UP TO
2010 BMW M3
The system overview applies accordingly for the E65 and E66 up to 03/2005.
> E60, E61, E63, E64 from 03/2005 until 09/2005
See SYSTEM OVERVIEW OF ADAPTIVE HEADLIGHTS (E60, E61, E63, E64, E65, E66 FROM
03/2005)
The system overview applies accordingly for the E65 and E66 from 03/2005.
NOTE: AHL control unit discontinued from 03/2005.
From 03/2005, the AHL control unit software is integrated into the light module
on the E60, E61, E63, E64, E65 and E66. The AHL control unit is no longer fitted.
> E60, E61, E63, E64 from 09/2005
The vehicle electrical system was changed from 09/2005.
As a result of the change, several control units were discontinued and some control unit functions were
integrated into new control units.
> E70
The turning lights function is new on the E70 from the start of series production.
The turning lights give the area next to the carriage way additional illumination when you are turning or
cornering (driving in tight bends). They are also active when you park the vehicle.
Depending on the country concerned, the turning lights are activated when cornering.
> E81, E87, E90, E91, E92, E93
For the E81, E92, E93 from start of series production and for the E87 from 03/2007, the turning light
function is new.
NOTE: Turning lights on E70, E81, E87, E92, E93 only in conjunction with option 524
Turning lights are a subfunction of option 524 "Adaptive headlights".
Bi-xenon headlights are standard equipment on the E92, E93.
Option 524 is standard on the US version.
NOTE: AHL components on E46, E53 and E83
There is a separate system description for the adaptive headlights on the E46,
2010 BMW M3
E53, E83.
NOTE: AHL components on the E63, E64
The E63, E64 has a zero-position sensor.

Otherwise, the E63 and E64 are the same as the other 5-Series models.
NOTE: Components for adaptive headlight on E70, E81, E87, E90, E91, E92, E93
On the E81, E87, E90, E91, E92, E93, the adaptive headlights largely correspond
to those on the E60, E61, E63, E64, E65 and E66:
E70, E81, E87, E90, E91, E92, E93 vehicles are equipped with a zero-
position sensor.
On the E70, E81, E87, E90, E91, E92, E93, the FRM (footwell module) acts
as control unit for exterior lighting. The footwell module contains the
functions of the light module, AHL control unit and the general module (or
body general module).
BRIEF DESCRIPTION OF COMPONENTS
The following components and control units provide signals for the adaptive headlight system:
CAS: Car Access System
The Car Access System supplies signals for the terminal management (e.g. terminal 15 ON).
The adaptive headlights control unit is activated when terminal 15 is switched ON.
Light Switch
The rotary switch for the side lights and dipped headlights differs depending on the vehicle equipment level
(adaptive headlights, automatic driving lights control, automatic or manual headlight-range adjustment). For the
adaptive headlights function to operate, the light switch must be set to position "A" ("A" = "automatic driving
lights control" and "adaptive headlights").
See LIGHT SWITCH
Turn-Signal/Main-Beam Switch
The main-beam headlights are switched on and off with the turn-signal/main-beam switch (by pressing or
pulling the switch). The adaptive headlights function operates with both dipped and main-beam headlights.
See DIRECTION INDICATOR/MAIN-BEAM SWITCH
SZL: Steering Column Switch

2010 BMW M3
The SZL control unit forwards the signals from the turn-signal/main-beam switch to the adaptive headlights
control unit.
E60, E61, E63, E64, E65 and E66
See SZL: STEERING COLUMN SWITCH CLUSTER
E70, E81, E87, E90, E91, E92, E93
The steering column switch cluster forwards the signals from the turn-signal/main-beam switch to the
footwell module (FRM).
Ride-Height Sensors
If the special equipment "Adaptive headlights" is fitted, the adaptive headlights control unit evaluates the
signals from the ride-height sensors. This is because: the adaptive headlights control unit also controls the
automatic headlight-range adjustment.
The automatic headlight - range adjustment feature adjusts the vertical aim of the headlights to compensate for
variations in the vehicle tilt angle (e.g. when the vehicle is laden, and under braking and acceleration in
dynamic driving situations).
See E60, E61, E63, E64, E65, E66, E90 - RIDE-HEIGHT SENSORS
Brake Light Switch
If the special equipment "Adaptive headlights" is fitted, the signals from the brake light switch are read by the
adaptive headlights control unit.
In addition, the brake light switch signal is also a signal for automatic headlight-range adjustment, see RIDE-
HEIGHT SENSORS above.
Position Sensor
E60, E61
E65, E66
Hella headlights have a position sensor.
The position sensor in the positioner module for the bi-xenon headlights supplies a signal for the horizontal
movement of the headlights.
See POSITION SENSOR
Zero-Position Sensor
> E63, E64

2010 BMW M3
> E70, E81, E87, E90, E91, E92, E93
Automotive Lighting headlights, previously Bosch, have a zero-position sensor.
The zero-position sensor registers the horizontal movement of the headlight.
See ZERO-POSITION SENSOR
EGS Control Unit or Reversing Light Switch
When reverse gear is engaged, the headlights are moved to the straight - ahead position.
On vehicles with automatic transmission, the EGS control unit provides the "Reverse gear engaged"
signal. (EGS: electronic transmission control).
On vehicles with manual transmission, the signal is supplied by the reversing light switch.
Rain-Light Sensor For Automatic Driving Lights Control
The rain - light sensor measures the ambient brightness outside the vehicle.
In twilight conditions, the rain - light sensor transmits the message "Twilight" so that the automatic
headlight - range adjustment can activate dipped headlights. The headlights are tilted up and down as
required, but they are not yet moved towards the bend in the road.
In darkness, the rain-light sensor sends the message "Darkness". The adaptive headlights are then
activated when the vehicle is cornering. The headlights are moved to the left or right:
See RAIN-LIGHT SENSOR FOR AUTOMATIC DRIVING LIGHTS CONTROL
Steering-Angle Sensor and DSC Sensor
The steering angle sensor and DSC sensor (DSC = Dynamic Stability Control) supply signals for the adaptive
headlights to the adaptive headlights control unit. These signals are evaluated as follows, depending on the
vehicle's speed:
Vehicle speeds up to 30 km/h:
The adaptive headlights function is controlled using the information from the steering angle sensor (in the
steering column switch cluster).
Vehicle speeds between 30 km/h and 50 km/h:
In the 30 to 50 km/h speed range, there is a continuous transition in signal evaluation: from the evaluation
of signals sent by the steering angle sensor to evaluation of the signals sent by the yaw-rate sensor (in the
DSC sensor).
In extreme dynamic driving situations , e.g. if the vehicle starts to skid or fishtail, even at speeds less
2010 BMW M3
than 50 km/h , the signals from the yaw-rate-sensor are considered.
If the vehicle starts to skid or fishtail, the headlights will move to the straight - ahead position. The
headlights are not moved until the vehicle has stabilized.
Vehicle speeds over 50 km/h:
At speeds upwards of 50 km/h, the signals from the yaw-rate sensor (in the DSC sensor) form the
primary basis for control of the adaptive headlights function.
Reason: For a constant cornering radius, the steering angle required increases disproportionately with
speed. In addition, the steering angle required also depends on the coefficient of friction of the road
surface.
Yaw rate is directly proportional to speed. For this reason, the yaw rate is always the most suitable
measure for controlling the adaptive headlights at high speeds.
Even at high speeds, however, the steering angle sensor signal is used to detect (predict) the driver's
commands in advance. This prediction is important: The yaw rate signal is not supplied until the vehicle
has responded to the steering wheel movement.
The steering-angle sensor signal is disabled so that rapid, momentary steering adjustments do not affect
the adaptive headlights function.
A number of control units are involved in the adaptive headlights system (see above: CAS: CAR ACCESS
SYSTEM, EGS CONTROL UNIT OR REVERSING LIGHT SWITCH and SZL: STEERING COLUMN
SWITCH). Depending on the model series and model version concerned, the adaptive headlights are actuated
by the following control units:
AHL: Adaptive Headlights
> E60, E61, E63, E64, E65, E66 up to 03/2005
The AHL control unit actuates the adaptive headlights.
For safety reasons, the AHL control unit is also responsible for the automatic headlight-range adjustment. This
is because: Oncoming traffic must not be dazzled by the adaptive headlights. If a headlight sticks in an
unfavorable position, the AHL control unit will attempt to move this headlight down (using the stepper motors
in the automatic headlight-range adjustment).
The AHL control unit is connected to the PT-CAN.
See AHL: ADAPTIVE HEADLIGHTS
LM: Light Module
E60, E61, E63, E64, E65, E66 from 03/2005

2010 BMW M3
From 03/2005, the AHL control unit is integrated in the light module.
The light module (LM) controls and monitors all vehicle lights. Information is transmitted and received via the
K-CAN data bus.
The light module actuates the indicator light for the adaptive headlights (on the light switch).
See E60, E61, E63, E64 FROM 03/2005 and/or E65, E66 (FROM 03/2005)
FRM: Footwell Module
> E70, E81, E87, E90, E91, E92, E93
The footwell module controls the exterior lighting and the adaptive headlights.
The footwell module thus takes the place of the light module and the AHL control unit.
The footwell module actuates the indicator light for the adaptive headlights (on the light switch).
See FRM: FOOTWELL MODULE
The footwell module has its own system description.
SMC: Stepper Motor Controllers
The stepper motor controllers control the stepper motors in the headlights (for the automatic headlight - range
adjustment and for the adaptive headlights). The stepper motor controllers are not capable of self - diagnosis.
The stepper motor controllers are diagnosed and encoded via the control unit for adaptive headlights.
See SMC: STEPPER MOTOR CONTROLLERS
SGM: Safety and Gateway Module
E60, E61, E63, E64 until 09/2005 and E65, E66
The safety and gateway module (SGM) is the interface between the two data buses K-CAN and PT-CAN. Thus,
all information exchanged between the light module and the AHL control unit passes through the SGM.
Information from the yaw-rate sensor (in the DSC sensor) is also fed through the SGM to the AHL control unit.
KGM: Body Gateway Module
E60, E61, E63, E64 from 09/2005
The vehicle electrical system was changed from 09/2005.
As a result of the change, several control units were discontinued and some control unit functions were
integrated into new control units.
2010 BMW M3
The new body gateway module (KGM) supersedes the safety and gateway module (SGM) previously fitted, the
door modules and the micro - power module.
Xenon-Headlight Control Unit
The xenon-headlight control unit actuates the bulb in the bi-xenon headlights.
The xenon-headlight control unit is not capable of self-diagnosis. The xenon control unit is monitored by the
light module (E70, E81, E87, E90, E91, E92, E93: footwell module).
See E60, E61, E63, E64, E65, E66, E90 - BI-XENON HEADLIGHTS
Headlights
Option 524 "Adaptive headlights" is only available in conjunction with option 522 "Xenon dipped and main-
beam headlights". This means that bi-xenon headlights are employed.
See E60, E61, E63, E64, E65, E66, E90 - BI-XENON HEADLIGHTS
Stepper Motors For the Adaptive Headlights
The stepper motors turn the positioner modules in the bi-xenon headlights.
The stepper motors move the headlights vertically and horizontally (vertically = up and down for automatic
headlight range adjustment;
horizontally = left and right for the adaptive headlights function).
The positioner modules execute the movement.
See POSITIONER MODULES
Indicator Light On the Light Switch
The indicator light (green LED) next to the "A" (= "automatic driving lights control" and "adaptive headlights")
has 2 display functions:
The indicator light lights up permanently when the automatic driving lights control or adaptive
headlights function is switched on (= light switch in position "A").
The indicator light flashes if a fault develops in the adaptive headlight system.
E60, E61, E63, E64, E65 and E66:
The indicator light is actuated by the light module.
E70, E81, E87, E90, E91, E92, E93:

2010 BMW M3
The indicator light is actuated by the footwell module.
SYSTEM FUNCTIONS
The adaptive headlights system moves headlights horizontal (i.e. from left to right) in order to illuminate the
inside of a bend when cornering.
The following functions of the adaptive headlights system are described below:
System activation and automatic calibration

Activation of stepper motor controllers
Speed-dependent analysis of signals
Adjustment of headlight horizontal aim
Deactivation of adaptive headlights function under extreme handling conditions
Deactivation of adaptive headlights function in response to system faults
Setting headlights to parked position
Automatic headlight-range adjustment
Adaptive headlights for automatic driving lights control
Turning light
NOTE: Different control units for adaptive headlights.
E60, E61, E63, E64, E65, E66 up to 03/2005: The adaptive headlights are
actuated by the AHL control unit.
E60, E61, E63, E64, E65, E66 from 03/2005: The adaptive headlights are
actuated by the light module (LM).
E70, E81, E87, E90, E91, E92, E93: The adaptive headlights are actuated by
the footwell module (FRM).
System Activation and Automatic Calibration
When terminal 15 is switched ON, the headlights always perform a calibration sequence, even if the dipped
headlights are not switched on. The control unit for adaptive headlights sends the "perform calibration
sequence" request to the stepper motor controllers (SMCs, control units for the headlight stepper motors). The
stepper motor controllers actuate the stepper motors in the headlights. The calibration sequence is performed. In
the calibration sequence, the headlights move as follows:
1. The headlights move to the right and left (= calibration sequence for adaptive headlights).
2. The headlights move up and down (= calibration sequence for automatic headlight - range adjustment).
3. At the end of the calibration sequence, the headlights are in the straight-ahead position.
Following the calibration sequence, the system is ready for operation.

2010 BMW M3
When reverse gear is engaged, the headlights are moved to the straight-ahead position.
NOTE: The calibration sequence is performed only after terminal 15 has been switched
OFF for at least 15 seconds.
> E66, E61, E63, E64, E65, E66 until 09/2006

> E87, E90, E91, E92, E93 until 03/2007
If terminal 15 is repeatedly switched on and off (e.g. for demonstration

purposes), the calibration sequence will not be executed every time terminal 15
is switched on.
Terminal 15 must have been switched off for at least 15 seconds before it is
switched on again. Only then is a calibration sequence performed when
terminal 15 is switched on.
NOTE: Calibration sequence always after terminal 15 ON and dipped - beam headlights
ON.
> E66, E61, E63, E64, E65, E66 from 09/2006

> E70 from start of series production
> E81, E87, E90, E91, E92, E93 from 03/2007
If terminal 15 is repeatedly switched on and off (e.g. for demonstration

purposes), the calibration sequence will not be executed every time terminal 15
and the dipped-bead headlights are switched ON.
NOTE: Calibration sequence with enlarged range of movement.
> not E65, E66
From 09/2007, starting with the E60, E61, E63, E64, a calibration sequence with
larger range of movement will be introduced.
The calibration sequence with larger range of movement will then gradually be
introduced on other model series.
Activation of Stepper Motor Controllers
The control unit for adaptive headlights sends the stepper motor controllers (SMC) the nominal values for the
positioner modules (position of positioner modules and speed of movement).
The control unit for adaptive headlights calculates the nominal values using the following signals:
Vehicle road speed

2010 BMW M3
Steering angle (at speeds up to 50 km/h, dependent on encoding)

Yaw rate (50 km/h upwards, see STEERING-ANGLE SENSOR AND DSC SENSOR above)
Speed-Dependent Analysis of Signals
Depending on the road speed, the adaptive headlights are controlled using the following signals: Signals from
the steering angle sensor and signals from yaw - rate sensor (in the DSC sensor).
The encoding (at the end of the production line) determines the priority assigned to sensor signals above which
speed threshold.
Adjustment of Headlight Horizontal Aim
The stepper motor controllers move the headlights to the right or left when the vehicle corners.
Horizontal range of movement of headlights:
Inwards, i.e. towards center of vehicle: up to max. 8

Outwards: up to max. 15
Example: Right - hand bend:
The right-hand headlight turns by up to 15 (the right-hand headlight is the "inside" headlight on a right-hand
bend).
Viewed from the vehicle, the right-hand headlight moves "outwards".
The left-hand headlight moves up to 8 (the left-hand headlight moves towards the middle of the vehicle, i.e.
"inwards" as viewed from the vehicle).
The headlight on the outside of the bend has to reach its end position at the same time as the headlight on the
inside of the bend so that the carriage way remains smoothly and evenly illuminated.
On a right-hand bend, the left-hand headlight is on the outside of the bend. The right-hand headlight is on the
inside of the bend.
Deactivation of Adaptive Headlights Function Under Extreme Handling Conditions
If the vehicle drifts, skids and loses sideways grip, the adaptive headlights function is deactivated as follows:
The headlights are returned to the straight-ahead position. The headlights are no longer turned.
The dipped headlights remain on.
Deactivation of Adaptive Headlights Function In Response To System Faults
Until 09/2007, a system fault will be indicated by the indicator lamp on the light switch flashing.
2010 BMW M3
From 09/2007 system fault will be indicated by a Check-Control message in the instrument cluster.
Dazzling of oncoming traffic must be prevented in the event of a system fault.
For this reason, the adaptive headlights function is deactivated as follows:
If the stepper motors are still functional, the headlights are returned to the straight-ahead position. The
headlights are no longer moved towards bends in the road.
If it is no longer possible for a headlight to be moved back to the straight-ahead position, the headlight is
tilted downwards (by the stepped motors for automatic headlight-range adjustment). This prevents
dazzling of oncoming traffic.
Vehicles up to 09/2007
If the headlight cannot be tilted downwards, the bi-xenon bulb in this headlight is disabled as follows:
When the vehicle is parked up, the control unit registers sleep mode for the adaptive headlights, as
follows: Vehicle standstill and terminal R OFF for several minutes.
The next time the vehicle is restarted, the bi-xenon light of the defective headlight is not switched on.
The front foglights are switched on in order to ensure a minimum level of illumination.
The dipped beam headlights are not switched off while the vehicle is in motion.
NOTE: From 09/2007, the dipped - beam headlights will not be switched off in the event
of a system fault.
If a system fault develops in the adaptive headlights, the dipped-beam

headlights for the affected headlight will not be switched off.
Setting Headlights To Parked Position
When terminal R is switched off, the headlights move to the parked position. The parked position is important
for the headlights' next calibration sequence: From the parked position, the headlights are run through a
calibration sequence in the pre-drive-check. During each calibration sequence, the control unit for adaptive
headlights relearns the straight - ahead position for the headlights.
When the headlights have reached the parked position, the stepper motor controllers SMCs inform the control
unit for adaptive headlights ("verification").
The control unit for adaptive headlights deactivates the stepper motor controllers.
The run-down period lasts approx. 10 seconds.
Automatic Headlight-Range Adjustment

2010 BMW M3
If the special equipment "Adaptive headlights" is fitted, the control unit for adaptive headlights also controls the
automatic headlight-range adjustment.
The automatic headlight - range adjustment adapts the headlight range for different operating conditions.
Variations in the vehicle tilt angle are produced by vehicle loads and braking or acceleration in extreme driving
situations. The automatic headlight-range adjustment moves the headlights up and down as required.
The control unit for adaptive headlights also controls the automatic headlight-range adjustment as follows:
1. The ride-height sensors and the brake light switch supply the signals for the automatic headlight-range
adjustment.
2. The control unit for adaptive headlights computes the vehicle inclination (longitudinally to the roadway)
from the signals.
3. The stepper motors for the automatic headlight-range adjustment automatically and dynamically control
the headlight range.
The headlight range is adjusted so that the actual headlight range conforms to the legally required
headlight range as follows:
If vehicle rear is lower than front:
The actual headlight range will be longer than the legally stipulated range. The headlight beam
height is lowered to reduce the headlight range to match the legal requirement.
If the vehicle is horizontal:
The actual headlight range will be the same as the legally stipulated range.
If vehicle front is lower than rear:
The actual headlight range will be shorter than the legally stipulated range. The headlight beam
height is raised to increase the headlight range to match the legal requirement.
Adaptive Headlights For Automatic Driving Lights Control
The automatic driving lights control feature (option in conjunction with the rain-light sensor) automatically
switches the side lights and dipped headlights on or off.
Switch-on conditions:
The automatic driving lights control must be encoded (in the light module on the E60, E61, E63, E64,
E65, E66, in the footwell module on the E70, E81, E87, E90, E91, E92, E93).
The light switch must be in position "A" ("A" for automatic driving lights control and adaptive
headlights).
The rain-light sensor must be installed and operational.
2010 BMW M3
The rain-light sensor detects the brightness of the ambient light.
The rain-light sensor sends the following prompts to the light module (on the E70, E81, E87, E90, E91,
E92, E93: footwell module):
Ambient brightness low: In twilight, darkness, in an underground garage or tunnel.
"Switch on dipped headlights" request
Ambient brightness sufficient.
"Switch off dipped headlights" request
If only the side lights are to be switched on, the light switch must be set to side lights (switch position 1).
When the light switch is set to position "A", the control unit for adaptive headlights is also activated:
When the automatic driving lights control function switches on the dipped headlights (e.g. at dawn/dusk),
the adaptive headlights function is notified at the same time.
The control unit for adaptive headlights thus assumes control of the automatic headlight - range
adjustment.
In addition, signals from the rain - light sensor are evaluated (E60, E61, E63, E64, E65, E66: by the light
module; E90, E91, E92, E93: by the footwell module).
The headlights are not turned when the vehicle is cornering until total darkness sets in.
The message "dipped headlights on" is given individually for each headlight.
If a headlight fails, the adaptive headlights are switched off.
The front foglights are switched on in order to ensure a minimum level of illumination.
Turning Lights
The turning lights are coupled to the adaptive headlights (option 524).
The footwell module (FRM) uses the following signals to adjust the turning lights:
Steering angle
Yaw rate
Status of reverse gear
> E81, E92, E93 with start of series production and E87 from 03/2007
2010 BMW M3
Instead of the main-beam headlight (H7), the main headlight with turning light has a fixed additional
reflector with an H3 bulb. The special shape of the lens prevents dazzle to the front.
The Fig. 2 shows the main headlight with turning light on the E81, E87, E92, E93
1. Bi-xenon light
2. H8 bulb for side lights and daytime driving lights
3. H3 bulb for turning lights
4. Reflector for turning lights
Fig. 2: Identifying Headlight Reflector For Turning Lights

The Fig. 3 shows the turning light on the E81, E87, E92, E93
1. Left turn
2. Right turn
Fig. 3: Identifying Turning Light Turn

The following conditions must be satisfied for the turning lights to be switched on:
2010 BMW M3
Terminal 15 ON
Light switch in position "A" ("A" stands for automatic driving lights control)
Rain-light sensor detects twilight or darkness (threshold exceeded)
The turning lights are not activated at speeds greater than 70 km/h.
> Europe version:
For legal reasons, the turning lights on the Europe version can only be activated via the turn signal
indicator at speeds up to 40 km/h.
When reversing, the footwell module (FRM) activates the turning lights as follows in the speed range 0 km/h to
35 km/h:
US version: both sides

Other countries: outside of turn only
When the turn signal indicator is switched on:
If the vehicle is stationary, the turning lights will automatically be deactivated after approx. 4 seconds, e.g.
when waiting at traffic lights. However, the turning lights can be activated again with the turn-signal/mainbeam
switch (up to 3 times) until the reflector has reached a certain temperature.
A temperature model protects the headlights from excessive thermal stress.
The switching-off conditions for the turning light depend on the country concerned.
NOTE: Temperature monitoring by temperature model
A temperature model in the footwell module calculates the temperature of the

reflector. The temperature of the reflector must not exceed a certain value. If a
critical temperature is reached, the footwell module (FRM) will deactivate the
turning lights. The turning lights can be activated again after a cooling-off
phase.
> E70 with start of series production
The turning lights are realized using the front foglights. (Reason: The installation location of the
headlights is too high for the turning lights. This prevents legal stipulations from being adhered to.)
Depending on actuation, the right - hand and/or left-hand front foglight is switched on. The turning lights
are actuated by the light module (LM).
The front foglights have an additional reflector to illuminate the areas to the sides better.
2010 BMW M3
When turning, the front foglight on the inside of the turn is automatically activated. The additional
reflector for the turning light reflects the light beam towards the turning area.
The turning light are not switched on suddenly but rather faded according to special time parameters.
Depending on the country concerned, the turning lights are switched on when cornering.
The Fig. 4 shows the front foglight on the E70
1. Additional reflector for the turning light

2. Reflector for the front foglights
3. Bulb
Fig. 4: Identifying Turning Light Reflector

The following conditions must be satisfied for the turning lights to be switched on:
Terminal 15 ON
Light switch in position "A" ("A" stands for automatic driving lights control)
Rain-light sensor detects twilight or darkness (threshold exceeded)
and
Turn signal indicator ON (not one-touch turn signal)

Speed range (forwards):
Europe and Japan version from 0 km/h to 35 km/h
US version from 0 km/h to 65 km/h
Swivel angle (theoretical):

when stationary > or = 77
when driving > or = 10
Alternatively
2010 BMW M3
Speed range (reverse):

0 km/h to 35 km/h

when stationary or driving > or = 70
If the vehicle is stationary, the turning lights will automatically be deactivated after a certain time, e.g. when
waiting at traffic lights. However, the turning lights can be activated again with the turn-signal/main-beam
switch.
The following conditions must be satisfied for the turning lights to be switched off:
Light switch not in position "A" ("A" stands for automatic driving lights control)
Rain-light sensor does not detect twilight or darkness (lower threshold exceeded)
Alternatively
Turn signal indicator OFF

Speed range (forwards):
Europe and Japan versions > or = 40 km/h
US version > or = 70 km/h

when stationary 77
when driving 10
Alternatively
Speed range (reverse): > or = 40 km/h

Swivel angle (theoretical): when stationary and when driving below a certain value
Alternatively
Vehicle skids and swings out.
Alternatively
Front foglights are switched on with the front foglights switch.
PRECONDITIONS FOR ACTIVATION
The control unit for adaptive headlights is "awake" from terminal 15 ON.
The movement of the lights is subject to the following conditions:

2010 BMW M3
The system is free of faults (indicator lamp not flashing and no Check-Control message)
The bulbs for the bi-xenon lights are OK in both headlights.
The vehicle must not be skidding or fishtailing.
The rain - light sensor must detect darkness.
Additional precondition for activation: automatic driving lights control is active (light switch in position
"A", see above).
Notes for service staff
CAUTION: Exercise caution when working on bi-xenon headlights
Whenever inspecting or working on the headlights, always observe the

safety precautions and accident prevention rules. The headlight system
has dangerously high voltage.
General note: See E60, E61, E63, E64, E65, E66, E90 - ADAPTIVE HEADLIGHTS, GENERAL
INFORMATION FOR SERVICE STAFF
Diagnosis: See E60, E61, E63, E64, E65, E66, E90 - ADAPTIVE HEADLIGHTS DIAGNOSIS
Encoding/programming: See E60, E61, E63, E64, E65, E66, E90 - ENCODING/PROGRAMMING
ADAPTIVE HEADLIGHTS
Car and Key Memory:
> E60, E61, E63, E64, E65, E66
The sensitivity of the driving light sensor can be set to one of 2 settings with the Car and Key Memory.
> E70, E81, E87, E90, E91, E92, E93
All Car and Key Memory functions are programmed inside the vehicle itself.
(Please refer to the "Personal profile" section of the Owner's Handbook: Personal settings for a maximum
of 3 remote control units via the display in the instrument cluster or via the Central Information Display.)
NATIONAL VERSIONS
The options "Daytime driving lights" and "Manual headlight - range adjustment" are available in certain
countries. Vehicles with manual headlight-range adjustment do not have adaptive headlights. This is because
vehicles with manual headlight - range adjustment have halogen dipped headlights. Adaptive headlights (option
524) are only available in conjunction with option 522 "Xenon dipped and main - beam headlights".
Switching on adaptive headlights in conjunction with daytime driving lights function
The "Daytime lights" option (Northern Europe and Canada) means that dipped-beam headlights and side lights
(E70, E92, E93: daytime driving lights) are always switched on:
2010 BMW M3
Light switch in position "2"

Terminal 15 ON
The automatic headlight - range adjustment is active (actuated by the control unit for adaptive headlights).
If terminal 15 is switched off, the dipped headlights and the side lights are automatically switched off as well.
The light switch must also be set to position "A" with the "Daytime driving lights" option. The control unit for
adaptive headlights is then in standby.
System functions for "Daytime lights" option when the light switch is set to position "A":
If the vehicle is encoded with the "Daytime driving lights" option (end of production line), the light
switch can remain in position "A" at all times.
When terminal R is switched on, the side lights, parking lights and licence plate lighting are switched on.
As soon as terminal 15 is switched on, the dipped headlights are also switched on.
When the dipped headlights are switched on, the control unit for adaptive headlights is activated (for
automatic headlight-range adjustment).
The indicator lamp on the light switch lights up and indicates that the system is functional.
The adaptive headlights turn when the vehicle is stationary if the steering wheel is turned (to the right
only).
The headlights are moved when the vehicle corners if the rain - light sensor registers darkness.
The switch-on conditions for the adaptive headlights in conjunction with special equipment "Daytime driving
lights" are as follows:
The vehicle must be encoded with the "Daytime driving lights" option (end of production line)
The light switch must be in position "A"
Terminal 15 must be switched on and reverse gear must not be engaged
Rain-light sensor must detect darkness
Subject to change.
MAIN-BEAM ASSISTANT E60, E61, E63, E64, E65, E66, E70, E90, E91, E92,
E93
2010 BMW M3
Fig. 5: Identifying Main-Beam Assistant

INTRODUCTION
The main-beam assistant assists the driver to operate the main-beam headlights. The main-beam assistant
automatically switches the main-beam headlights on and off as the traffic situation changes.
The main-beam assistant detects vehicles travelling ahead of the car and oncoming traffic, and it also detects
lighted stretches of roadway. By automatically switching off the main-beam headlights in good time, the main -
beam assistant ensures that the occupants of oncoming vehicles, for example, are not dazzled by the headlights.
Advantages:
Drivers do not have to concern themselves with the job of operating the main - beam headlights. This enhances
the level of convenience for drivers. The main - beam headlights are switched on more frequently by the main-
beam assistant than is the case with manually operated main-beam headlights. The driver's field of vision is
optimally illuminated. Driving in the dark, therefore, is rendered safer.
IMPORTANT: The driver retains full responsibility for all his/her actions, despite the
assistance of the main - beam assistant.
The main-beam assistant merely assists the driver in the task of operating the
main-beam headlights.
2010 BMW M3
Responsibility for switching the main-beam headlights on and off in

accordance with the dictates of the traffic situation rests with the drivers.
The main-beam assistant can be deactivated at any time with the turn-
signal/main-beam switch.
Option 5AC "Main-beam assistant" is available for the BMW 3, 5, 6 and 7-Series.
> E60, E61, E63, E64, E65, E66 - See SYSTEM OVERVIEW FOR THE MAIN-BEAM
ASSISTANT: E60, E61, E63, E64, E65, E66
NOTE: Only the main beam of the bi-xenon headlights are switched on.
If a main-beam assistant is fitted, only the main beam of the bi-xenon headlights
are switched on.
The halogen headlights are switched on only when the headlight flasher is
actuated. In countries in which daytime driving lights are required by law, the
halogen headlights are used for the daytime driving lights.
BRIEF DESCRIPTION OF COMPONENTS
The following components and control units provide input signals for the main - beam assistant:
Light switch
The main-beam assistant can be activated only when the light switch is in position "A".
"A" stands for "automatic headlight control".
Turn-signal/main-beam switch
The main-beam assistant is activated and deactivated by mans of the turn-signal/main-beam switch.
See the section entitled OPERATION below.
Rain-light sensor
The rain - light sensor measures the brightness of the ambient light. The light module switches the dipped
headlights on when daylight fails.
The main-beam assistant can be activated only when the dipped headlights are on. The precondition is
that the light switch must be in the "A" position.
Wheel-speed sensors
2010 BMW M3
Each of the wheel-speed sensors measures the circumferential speed of an individual wheel. The DSC
control unit (DSC: Dynamic Stability Control) uses these input signals to calculate the car's road speed.
The main-beam headlights are switched on when the car's road speed is above 50 km/h.
The main-beam headlights are switched off when the car's road speed is below 38 km/h.
DSC sensor
The DSC sensor registers lateral acceleration and calculates the yaw rate.
("Yaw" is the movement of the vehicle about the vertical axis, e.g. when the car is cornering).
The main-beam assistant uses the yaw rate to improve evaluation when the car corners. The DSC sensor
is underneath the driver's seat. For safety reasons, cars with active front steering have a second DSC
sensor underneath the front passenger's seat.
Image sensor
The image sensor is a special camera for detecting light sources.
The image sensor transmits images to the control unit for the main - beam assistant.
The images are carried by an LVDS data line (LVDS: Low Voltage Differential Signalling).
The control unit for the main-beam assistant analyses the images.
The image sensor and the control unit are installed in a common housing and can only be supplied as a
unit.
See IMAGE SENSOR FOR THE MAIN-BEAM ASSISTANT: E60, E61, E63, E64, E65, E66
Reverse gear switch
The main-beam headlights are not switched on if reverse gear is engaged.
In a manual-shift car, the reverse gear switch supplies the "reverse gear engaged" information.
The reverse gear switch sends this information to the light module.
Selector lever position switch
In a car fitted with electronic transmission control (EGS), the selector lever position switch supplies the
"reverse gear engaged" information. The selector lever position switch sends this information to the EGS
control unit.
2010 BMW M3
The EGS control unit sends this information to the light module or footwell module.
Selector angle sensor and shift travel sensor

> E60, E61, E63, E64, E65, E66
In a car fitted with sequential manual transmission (SMG), the selector angle sensor and the shift travel
sensor supply the "reverse gear engaged" information. The selector angle sensor and the shift travel
sensor send the information to the SMG control unit. The SMG control unit sends the information to the
light module.
The following control units are involved in the main-beam assistant system:
FLA: Main-beam assistant
The FLA control unit analyses the images from the image sensor. The FLA control unit receives
information on road speed and yaw rate from the DSC control unit.
The FLA control unit sends a switch-on recommendation or a switch-off recommendation for the main-
beam headlights to the light module. The recommendation depends on the traffic situation, the ambient
light, and the car's road speed.
The FLA control unit is connected to the K-CAN.
See FLA CONTROL UNIT FOR THE MAIN-BEAM ASSISTANT: E60, E61, E63, E64, E65, E66
LM: Light module

> E60, E61, E63, E64, E65, E66
The light module receives various input variables for the main-beam headlights:
Switch-on or switch-off recommendation from the FLA control unit

Switch position of the light switch
Switch position of the direction indicator/mean - beam switch
Information from the reverse gear switch or the selector lever position switch or the selection angle
and shift travel sensor
Information from the rain-light sensor, as to whether the dipped headlights have to be switched on
On the basis of the input variables, the light module decides whether the main-beam headlights should be
switched on or off.
The light module actuates the bi-xenon headlights.

The light module actuates the FLA indicator light in the instrument cluster.
2010 BMW M3
A Check-Control symbol appears if the main - beam assistant fails.
The light module is connected to the K-CAN.

> E90, E91, E92, E93, E70
The footwell module receives various input variables for the main - beam headlights:
Switch-on or switch-off recommendation from the FLA control unit

Switch position of the light switch
Switch position of the direction indicator/mean-beam switch
Information from the reverse gear switch or selector lever position switch
Information from the rain-light sensor, as to whether the dipped headlights have to be switched on
On the basis of the input variables, the footwell module decides whether the main-beam headlights should
be switched on or off.
The footwell module actuates the bi-xenon headlights.

The footwell module actuates the FLA indicator light in the instrument cluster.
A Check-Control symbol appears if the main-beam assistant fails.
The footwell module is connected to the K-CAN.
The DSC control unit calculates the car's road speed using the signals from the wheel-speed sensors. The
DSC control unit sends the information on road speed to the main - beam assistant.
The DSC control unit also sends the information from the yaw-rate sensor in the DSC sensor to the main-
beam assistant.
EGS or SMG: Electronic gearbox control or sequential manual transmission
The EGS control unit receives the "Reverse gear engaged" information from the selector lever position
switch.
The EGS control unit is connected to the PT-CAN.
The SMG control unit receives the "Reverse gear engaged" information from the selector angle sensor
and the shift travel sensor. The SMG control unit is connected to the PT-CAN.
SZL: Steering Column Switch

2010 BMW M3
The switch signals from the turn - signal/main-beam switch are picked up and evaluated by the SZL
control unit.
The SZL control unit sends the position of the turn-signal/main-beam switch to the light module (E60,
E61, E63, E64, E65, E66) or footwell module (E90, E91, E92, E93, E70)
The following components are controlled:
Bi-xenon headlights
The bi-xenon headlights are actuated by the light module.
NOTE: Only the main beam of the bi-xenon headlights are switched on.
If a main-beam assistant is fitted, only the main beam of the bi-xenon headlights
are switched on. The halogen headlights are switched on only when the
headlight flasher is actuated. In countries in which daytime driving lights are
required by law, the halogen headlights are used for the daytime driving lights.
Instrument cluster
The indicators in the instrument cluster are as follows:
Main-beam indicator lamp (legally stipulated, blue)

FLA indicator light
Orange on BMW 3, 5 and 6-Series and on X5
Blue on BMW 7-Series
Check-Control symbol for failure of the main-beam assistant (yellow)
See the section entitled SYSTEM FUNCTIONS below.
The following components provide the power supply for the main - beam assistant:
PM: Power module

> E65, E66
In the BMW 7-Series, the power module supplies power to the main - beam assistant.
Rear power distributor

> E60, E61, E63, E64
In the BMW 5-Series and 6-Series, the rear power distributor supplies power to the main-beam assistant.
Power distributor in junction box

2010 BMW M3
On the BMW 3-Series, the power distributor in the junction box supplies voltage to the main - beam
assistant.
Rear power distributor

> E70
On the BMW X5, the rear power distributor provides power to the main - beam assistant.
SYSTEM FUNCTIONS
In accordance with the traffic situation, the FLA control unit sends a switch - on recommendation or a switch -
off recommendation for the main - beam headlights to the light module or footwell module. On the basis of this
recommendation and various other the input variables, the light module or footwell module decides whether the
main-beam headlights should be switched on or off.
The following system functions of the main - beam assistant are described:
Automatic main-beam headlight switch - off when oncoming traffic is detected

Automatic main-beam headlight switch - off when vehicle detected ahead of the car
Automatic main-beam headlight switch - off when adequate ambient lighting is detected
Automatic main-beam headlight switch - on
Indicators in the instrument cluster
Function limitations of the main - beam assistant
Automatic alignment of the main - beam assistant
Automatic Main - Beam Headlight Switch-Off When Oncoming Traffic Is Detected
The light cone of the main - beam headlights has a range of about 400 m. The image sensor can detect other
light sources within a range of about 1000 m. This ensures that the image sensor detects oncoming vehicles
before their drivers can be dazzled by the light cone of the main - beam headlights.
When the image sensor detects an oncoming vehicle, the FLA control unit sends a switch - off recommendation
to the light module or footwell module. The light module or footwell module switches the main - beam
headlights off.
Automatic Main - Beam Headlight Switch-Off When Vehicle Detected Ahead Of The Car
When the image sensor detects a vehicle ahead, the FLA control unit sends a switch - off recommendation to
the light module or footwell module. The light module or footwell module switches the main - beam headlights
off.
Automatic Main - Beam Headlight Switch-Off When Adequate Ambient Lighting Is Detected
When the image sensor detects an environment in which ambient lighting is adequate, the FLA control unit
sends a switch-off recommendation to the light module or footwell module. The light module or footwell
2010 BMW M3
module switches the main-beam headlights off.
Adequate ambient lighting means:
Daylight
Twilight
Street lighting (e. g. in illuminated towns)
Automatic Main-Beam Headlight Switch-On
If there is no reason for the lights to be dipped, the light module or footwell module switches the main-beam
headlights on. The bi-xenon headlights are switched to full beam.
Displays In The Instrument Cluster
The FLA indicator light lights up in the instrument cluster as soon as the main-beam assistant is activated (blue
on the BMW 7-Series, orange on the BMW 3, 5, and 6-Series and on the X5).
The main-beam indicator light also lights up (blue) in the usual way as soon as the main-beam headlights are
switched on.
A Check-Control symbol appears (yellow) if the FLA control unit detects a system failure.
See INDICATORS FOR THE MAIN-BEAM ASSISTANT AND THE MAIN-BEAM HEADLIGHTS:
E60, E61, E63, E64, E65, E66
Function Limitations Of The Main-Beam Assistant
The main-beam assistant can be subject to function limitations under the following circumstances:
Inclement weather conditions (e.g. fog)

Poorly lighted road users (e.g. cyclists, pedestrians)
Certain road signs (e.g. the warning sign for a tight bend): Reflections from traffic signs may be
incorrectly interpreted by the main - beam assistant as a vehicle driving ahead or as oncoming traffic.
See FUNCTION LIMITATIONS OF THE MAIN-BEAM ASSISTANT
Driving over crests and through dips
See FUNCTION LIMITATIONS OF THE MAIN-BEAM ASSISTANT
Certain traffic situations (e.g. tight bends, vehicles approaching from the side)
Image sensor's field of view obstructed (e.g. by snow)
Automatic Alignment Of The Main-Beam Assistant

2010 BMW M3
In order to operate correctly, the image sensor must be aligned parallel with the vehicle's centerline. When the
car is driven at night, the main - beam assistant can automatically correct alignment up to 3 to the left or 3 to
the right. This correction compensates for minor deviations from the centerline.
Driving conditions for automatic directional orientation of the main - beam assistant are:
Straight ahead for a distance of approx. 50 km: A relatively straight stretch accelerates the directional
orientation.
Road marking must be clearly visible.
See IMAGE SENSOR FOR THE MAIN-BEAM ASSISTANT: E60, E61, E63, E64, E65, E66
OPERATION
Operation of the main-beam assistant is described in a separate section.
The following controls of the main - beam assistant are described:
Switching on automatic headlight control

Activating the main - beam assistant
Deactivating the main-beam assistant
Reactivating the main-beam assistant
Switching on the headlight flasher
See OPERATION
PRECONDITIONS FOR ACTIVATION
For technical reasons, distinctions are drawn between the following conditions required for switch - on:
Conditions required for switch-on for the FLA control unit

Conditions required for switch-on for the main-beam assistant
Conditions required for switch-on for the main-beam headlights
Conditions Required For Switch - On For The FLA Control Unit
The FLA control unit is active as of terminal 15 ON.
Conditions Required For Switch - On For The Main-Beam Assistant
Light switch set to position "A"

Dipped headlights switched on.
When the switch is in position "A", the dipped headlights are switched on by the automatic headlight
control.
2010 BMW M3
Turn-signal/main-beam switch pressed forward (in forward direction of travel).
Conditions Required For Switch - On For The Main-Beam Headlights
Road speed greater than 50 km/h.

Reverse gear must not be engaged.
Image sensor does not detect an oncoming vehicle or a vehicle ahead.
Image sensor detects adequate darkness.
Notes for service staff
The following information is available for service staff:
General note: See MAIN-BEAM ASSISTANT, GENERAL INFORMATION FOR SERVICE

STAFF: E60, E61, E63, E64, E65, E66
Diagnosis: See MAIN-BEAM ASSISTANT DIAGNOSIS: E60, E61, E63, E64, E65, E66
Encoding/programming: -
2010 BMW M3
ACCESSORIES AND BODY, CAB Lights - Repair
Lights - Repair
LAMP SETTINGS
63 10... ADJUST THE FOG LIGHTS (WITH ELECTRONIC HEADLIGHT ADJUSTMENT DEVICE
MAHA LITE 3)
IMPORTANT: Comply with TEST PREREQUISITES FOR HEADLIGHT ADJUSTMENT!
Refer to the manufacturer's operating instructions for the headlight adjustment

device!
Switch on the headlight adjustment device by pressing any button.
Press F1 button. The shown display screen appears.
Perform the following settings:
1. The passenger car must be selected.

2. Enter the setting dimension for the headlight with buttons F1/F2: - 2, 0 %
3. The right / left-hand traffic must be selected according to the country.
4. Select the fog light type with the F3 button:
EC : for halogen fog lights
EC LED : for LED fog lights
The adjusted values are adopted for future measurements.
Fig. 1: Identifying Setting Icons On Display Screen

2010 BMW M3
Press the button for the applicable side of the vehicle (1) briefly . The measured values are shown in the
display. Symbol (2) will be displayed.
When the fog light has been adjusted correctly, "OK" will be displayed:
OK (3): The setting is correct. However, a more accurate adjustment is possible.

OK (4): The setting is absolutely correct. A more accurate adjustment is no longer possible.
When a fog light adjustment is incorrect, arrows (5) will be displayed. Use the arrows (5) to adjust the fog light.
Fig. 2: Identifying Buttons On Display Screen For Fog Light Adjustment

63 10 004 ADJUSTING HEADLIGHTS
NOTE: Comply with TEST PRECONDITIONS FOR HEADLIGHT ADJUSTMENT.
Adjust headlights at adjusting screws (1) and (2).
A definite allocation of adjusting screws is not possible.
1. Adjustment screw primarily for vertical adjustment

2. Adjustment screw primarily for lateral adjustment
2010 BMW M3
Fig. 3: Identifying Headlight Adjusting Screws - Version 1

Fig. 4: Identifying Headlight Adjusting Screws - Version 2

High-beam and low-beam headlights may be adjusted using device "MAHA Lite 3". See device manufacturer's
63 10... TEST REQUIREMENTS FOR HEADLIGHTS VERTICAL AIM ADJUSTMENT
Car parked on level ground.

Replace faulty glass and mirrors and blackened light bulbs.
Check tire pressure and correct if necessary.
Apply load equivalent to one person on driver's seat (approx. 75 kg).
Vehicle with full fuel tank or appropriate additional weight in luggage compartment.
Correct adjustment of headlights in relation to engine hood (gap dimensions).
Manual headlight vertical aim control: Turn handwheel to 0 position.
Automatic headlight vertical aim control: Wait approx. 30 seconds after switching on lights.
2010 BMW M3
Version with xenon headlights:
Wait 80 seconds after switching on lights. During this time, do not move the vehicle and avoid vibrations.
Align headlight aimer with vehicle longitudinal axis and parallel to parking surface. Set marking line (M)
on aimer to distance (e). Scale graduations on aimer are equal to a gradient in cm at a distance of 10
meters.
Fig. 5: Checking Headlight Vertical Aim

Light/dark boundary of headlights in headlight aimer
e Adjustment dimension, headlights:
as per type plate on headlight housing in % (e.g.: 1.0 % = 10 cm/10 m = 10 on headlight aimer).
Adjustment dimension, fog lights:
all vehicles 2.0 % = 20 cm/10 m = 20 on headlight aimer.
H Height of center of headlight above parking surface.
h H - e = height of marking line above parking surface
+ Central mark = center point of high-beam headlight.
M Marking line of headlamp aimer
S Parking surface of vehicle and headlight aimer

2010 BMW M3
Adjustment dimension (e) is only valid for EUR. Observe differing national regulations.
FRONT LIGHTS
6311... INSTALLING HEADLIGHT REPAIR KIT
Remove headlight. See XENON HEADLIGHT or ADAPTIVE HEADLIGHT.
NOTE: Damaged retaining tabs (1) can be replaced with the repair kit.
Replacement of headlight is not required !
Remove damaged retaining tabs (1) up to line marked with arrows.
Mount retaining tab from repair kit (3) as shown and tighten screw (2).
Fig. 6: Identifying Retaining Tabs And Screw

After installation:
2010 BMW M3
Adjust headlights. See ADJUSTING HEADLIGHTS.
HEADLIGHTS
6312... HEADLIGHT FOGGING FAULT PATTERN
NOTE: Certain weather conditions can lead to fogging on the inside of the headlight
lens.
This is not necessarily a fault that requires replacement of the headlight.
(A): Permissible fogging. Headlight does not need to be replaced.
(B): Impermissible fogging. Replace the headlight.
Fig. 7: Identifying Permissible And Impermissible Fogging

63 12... INSTALLING ADDITIONAL BRACKET FOR LEFT OR RIGHT XENON HEADLIGHT
NOTE: An additional bracket is installed on some models as standard to protect the

xenon headlights against vibrations.
2010 BMW M3
It is installed on vehicles without a standard additional bracket in the event of a

customer complaint that the "xenon headlight is vibrating".
Remove front bumper panel. See FRONT BUMPER TRIM (UP TO 09/08) or FRONT BUMPER TRIM
(FROM 09/08) .
Slacken nuts (1).

1. Install additional bracket (2) as shown.

2. Tighten nut (1) hand-tight.
3. Screw on additional bracket (2) with holder (4).
Tightening torque: see 2AZ in 63 12 HEADLIGHTS
4. Tighten nut (1).
Tightening torque: see 1AZ in 63 12 HEADLIGHTS

2010 BMW M3
Fig. 9: Identifying Holder, Bracket, And Nuts

63 99... NOTES FOR REPLACING THE PROTECTIVE CAP OF THE HEADLIGHT

Damaged seals on the protective caps will lead to moisture penetration into the
headlight.
This will in turn cause porous cable insulations and malfunctioning of the
headlight.
When working on the headlight system, check the protective cap seals.
Replace the protective cap in the event of damage!
Example: screwed protective cap
Seal (1) on protective cap (2).

2010 BMW M3
Fig. 10: Identifying Seal On Protected Cap

Example: latchable protective cap
Fig. 11: Identifying Seal On Protective Cap

63 12 015 REMOVING AND INSTALLING OR REPLACING LEFT HEADLIGHT (ADAPTIVE

HEADLIGHT)
2010 BMW M3
Therefore, before removing, disconnect all components from the power

supply (lighting system and ignition off).
bulb) may only be carried out by specialist personnel.
Follow instructions for handling light bulbs (EXTERIOR LIGHTS) .
PROTECTION) .
Remove front bumper trim . See 5111156 REMOVING AND INSTALLING FRONT BUMPER
TRIM or 5111156 REMOVING AND INSTALLING FRONT BUMPER TRIM (UP TO 09/08)
Remove high-pressure nozzle . See 6167083 REMOVING AND INSTALLING/REPLACING LEFT
OR RIGHT HIGH-PRESSURE NOZZLE OF HEADLIGHT or 6167083 REMOVING AND
INSTALLING/REPLACING HIGH-PRESSURE NOZZLE OF HEADLIGHT WASHER
SYSTEM ON LEFT OR RIGHT (M3) of headlight washer system
Release screw (1) on headlight arm (2) (from wheel arch side). Tightening torque 63 12 1AZ .
Fig. 12: Identifying Screw On Headlight Arm

Release bolts (1). Tightening torque 63 12 3AZ .
M3:
Release screw (2). Tightening torque 63 12 7AZ .
Release wiring harness fastener (3) on headlight arm.
Remove high-pressure line and wiring harness from headlight arm.

2010 BMW M3
Pull out headlight (4) slightly and disconnect associated plug connection.
Remove headlight (4) in direction of arrow.
Fig. 13: Removing Headlight With Bolts And Screws

Installation:
Observe GAP DIMENSIONS

Adjust headlights See 6310004 ADJUSTING HEADLIGHTS or 6310004 ADJUSTING
HEADLIGHTS
Replacement up to 09/2008:
Release screws (1) (tightening torque 63 12 2AZ ) and remove headlight arm (2) from headlight
Remove ignition unit/bulb for xenon headlight . See 6312871 REPLACING IGNITION UNIT FOR
RIGHT XENON HEADLIGHT (WITH XENON BULB) or 6312870 REPLACING IGNITION
UNIT FOR LEFT XENON HEADLIGHT (WITH XENON BULB)
Remove control unit for xenon headlights . See 6312861 REPLACING CONTROL UNIT FOR
RIGHT XENON HEADLIGHT or 6312860 REPLACING CONTROL UNIT FOR LEFT XENON
HEADLIGHT
Remove drive/electronics box for adaptive headlight . See 6312895 REPLACING
DRIVE/ELECTRONICS BOX FOR LEFT ADAPTIVE HEADLIGHT or 6312896 REPLACING
DRIVE/ELECTRONICS BOX FOR RIGHT ADAPTIVE HEADLIGHT
If necessary, remove bulbs . See 6399273 REPLACING BULB FOR LEFT (OR RIGHT) FRONT
TURN INDICATOR; 6399160 REPLACING BULB FOR FRONT LEFT (OR RIGHT) TURNING
LIGHTS; 6399145 REPLACING BULB FOR FRONT LEFT (OR RIGHT) SIDE LIGHTS or
6312870 REPLACING IGNITION UNIT FOR LEFT XENON HEADLIGHT (WITH XENON
BULB).
Replacement as from 09/2008:

2010 BMW M3
Remove DIRECTION INDICATOR INSERT

Remove drive/electronics box for adaptive headlight
Fig. 14: Identifying Headlight Arm And Screws

63 12 010 REMOVING AND INSTALLING OR REPLACING LEFT HEADLIGHT (XENON

HEADLIGHT)
PROTECTION) .
Remove BUMPER TRIM

Remove high-pressure nozzle See 6167083 REMOVING AND INSTALLING/REPLACING LEFT
OR RIGHT HIGH-PRESSURE NOZZLE OF HEADLIGHT or 6167083 REMOVING AND
SYSTEM ON LEFT OR RIGHT (M3) of headlight washer system
Release screw (1) on headlight arm (2) (from wheel arch side). Tightening torque 63 12 1AZ .
2010 BMW M3
Fig. 15: Identifying Screw On Head Light Arm

M3:
Remove headlamp (4) in direction of arrow.
Fig. 16: Removing Headlight With Bolts And Screws

2010 BMW M3
Installation:
Observe GAP DIMENSIONS

Adjust HEADLIGHTS
Replacement:
Release screws (1) (tightening torque 63 12 2AZ ) and remove headlight arm (2) from headlight
Remove ignition unit/bulb for xenon headlight See 6312871 REPLACING IGNITION UNIT FOR
RIGHT XENON HEADLIGHT (WITH XENON BULB) or 6312870 REPLACING IGNITION
UNIT FOR LEFT XENON HEADLIGHT (WITH XENON BULB)
Remove control unit for xenon headlights See 6312861 REPLACING CONTROL UNIT FOR
RIGHT XENON HEADLIGHT or 6312860 REPLACING CONTROL UNIT FOR LEFT XENON
HEADLIGHT
If necessary, remove bulbs See 6399273 REPLACING BULB FOR LEFT (OR RIGHT) FRONT
TURN INDICATOR or 6399145 REPLACING BULB FOR FRONT LEFT (OR RIGHT) SIDE
LIGHTS.
Fig. 17: Identifying Headlight Arm And Screws


(XENON HEADLIGHT)
Remove WHEEL ARCH COVER FRONT SECTION at front

2010 BMW M3

Release screws (1).
Fig. 19: Identifying Vertical Aim Adjuster Screws

2010 BMW M3

Installation:
Fig. 21: Feeding Ball Head Of Vertical Aim Adjuster Into Mounting
After installation
ADJUST HEADLIGHTS
63 12 012 REMOVING AND INSTALLING RIGHT HEADLIGHT (XENON HEADLIGHT)
Removing and installing LEFT HEADLIGHT
63 12 017 REMOVING AND INSTALLING/REPLACING RIGHT HEADLIGHT (ADAPTIVE

2010 BMW M3
HEADLIGHT)
Removing and installing LEFT HEADLIGHT

ADJUSTER
REMOVING AND INSTALLING/REPLACING LEFT HEADLIGHT VERTICAL AIM ADJUSTER
63 12 860 REPLACING CONTROL UNIT FOR LEFT XENON HEADLIGHT
PROTECTION) .
Remove front left wheel arch trim
S65:
Remove left HEADLIGHT
NOTE: Headlight removed for purposes of clarity.
Lift control unit (2) off headlight.

2010 BMW M3
Fig. 22: Identifying Control Unit And Screws

Installation:
Make sure sealing sleeve (3) is correctly seated.
Fig. 23: Identifying Plug Connection, Control Unit And Sealing Sleeve
63 12 861 REPLACING CONTROL UNIT FOR RIGHT XENON HEADLIGHT
2010 BMW M3
PROTECTION) .
Remove front right wheel arch trim
N54/S65:
Remove RIGHT HEADLIGHT
Fig. 24: Identifying Control Unit And Screws

Installation:

2010 BMW M3
Fig. 25: Identifying Plug Connection, Control Unit And Sealing Sleeve
63 12 895 REPLACING ELECTRONICS BOX/CONTROL UNIT FOR LEFT ADAPTIVE

HEADLIGHT
Work on the entire xenon lighting system (ignition unit, control unit and
PROTECTION) .
Remove LEFT HEADLIGHT
NOTE: Operation is shown by way of example on the E70.
Remove drive/electronics box for adaptive headlight (2) from headlight.
Installation:
Make sure seal is correctly positioned on drive/electronics box for adaptive headlight (2).
Fit drive/electronics box for adaptive headlight (2) exactly on headlight.

2010 BMW M3
Fig. 26: Identifying Adaptive Headlight And Screws

Make sure pin housing (3) is correctly seated in plug housing (4).
63 12 896 REPLACING ELECTRONICS BOX/CONTROL UNIT FOR RIGHT ADAPTIVE

HEADLIGHT
Replacing DRIVE/ELECTRONICS BOX FOR LEFT ADAPTIVE HEADLIGHT
63 12 870 REPLACING IGNITION UNIT FOR LEFT XENON HEADLIGHT (WITH XENON BULB)
Therefore, before removing, disconnect all components from the voltage
bulb) may only be carried out by qualified personnel.
IMPORTANT: Ignition unit and xenon bulb are viewed as a single component and must not be
separated.
REMOVE FRONT LEFT WHEEL ARCH TRIM
Release screws (1) and remove cover cap (2) from headlight. Tightening torque 63 12 6AZ .
2010 BMW M3
Installation note:
Protective cap (2) must be correctly engaged.
Check seal.
Replace protective cap (2) if necessary.
Comply with INSTRUCTIONS FOR REPLACING THE PROTECTIVE CAP .

Unlock spring wire clips (2).
Remove ignition unit for xenon headlight (3) from headlight.
Installation note:
Make sure ignition unit for xenon headlight (3) is exactly seated on headlight.
2010 BMW M3
Fig. 28: Identifying Plug Connection And Spring Wire Clips

63 12 871 REPLACING IGNITION UNIT FOR RIGHT XENON HEADLIGHT (WITH XENON BULB)
separated.
Remove FRONT RIGHT WHEEL ARCH TRIM
Release screws (1) and remove cover cap (2) from headlight. Tightening torque 63 12 6AZ .
Installation:
Make sure cover cap (2) is correctly seated on headlight (otherwise headlight subject to leaks).
2010 BMW M3

Installation:
Fig. 30: Identifying Plug Connection And Spring Wire Clips

TURN SIGNAL INDICATOR LIGHTS

63 13 200 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT AUXILIARY
DIRECTION INDICATOR (M3)
2010 BMW M3
WARNING: Follow instructions for handling light bulbs (EXTERIOR LIGHTS) .
PROTECTION) .

Carry out the following operations carefully so as to avoid damaging the side
panel and auxiliary direction indicator.
Feed cable tie (1) into trim grille (6).
Unlock retaining lugs (2) of trim grille (6) with special tool 00 9 340 REMOVAL AID in direction of arrow.
This operation must release the catch (3) of the auxiliary direction indicator chrome bar (4) from the front side
panel.
Unlock retaining lug (5) of trim grille (6) with special tool 00 9 340 REMOVAL AID , pulling trim grille (6)
with cable tie (1) in direction of arrow.
Feed trim grille (6) with auxiliary direction indicator chrome bar (4) out of front side panel.
Disconnect associated plug connection and remove trim grille (6) with auxiliary direction indicator chrome bar
(4).
Fig. 31: Feeding Cable Tie Into Trim Grille

Installation:
Trim grille (6) and retaining lugs (2, 5) must not be damaged. If necessary, replace trim grille.
Make sure trim grille (6) with auxiliary direction indicator chrome bar (4) is correctly seated on front side panel.
2010 BMW M3
Unlock all retaining lugs of auxiliary direction indicator chrome bar (1) with a suitable tool.
Remove trim grille (2) from auxiliary direction indicator chrome bar (1).
Installation:
Make sure trim grille (2) is correctly engaged on auxiliary direction indicator chrome bar (1).
Fig. 32: Locating Trim Grille On Auxiliary Direction Indicator Chrome Bar
Remove auxiliary direction indicator (2) in direction of arrow from auxiliary direction indicator chrome bar (3).
Installation:
Journal (4) of auxiliary direction indicator (2) must first be fed into auxiliary direction indicator chrome bar (3).
Fig. 33: Removing Auxiliary Direction Indicator

2010 BMW M3
63 13 080 REMOVING AND INSTALLING/REPLACING LEFT DIRECTION INDICATOR INSERT

FROM SERIES STATUS 09/2008
Remove LEFT HEADLIGHT
Release screws (1).
Remove direction indicator insert (2) from headlight (3).
Fig. 34: Identifying Headlight And Screws


2010 BMW M3
Fig. 35: Identifying Headlight And Plug Connection

CLEARANCE AND SIDE MARKER LAMPS

63 14 060 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT SIDE MARKER
(M3/US)

Carry out the following operation carefully so as to avoid damaging the bumper
trim and side marker.
Press side marker (1) upwards with special tool 64 1 020 HOOK and feed in direction of arrow out of bumper
trim (2).
Installation:
Retaining spring of side marker (1) must not be damaged or missing.
Make sure side marker (1) is correctly seated in bumper trim (2).
2010 BMW M3
Fig. 36: Pressing Side Marker Upwards Using Special Tool (64 1 020)
REAR LIGHT CLUSTER

63 21 180 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT REAR LIGHT (IN SIDE
PANEL)
PROTECTION) .
Remove cover (1) in direction of arrow from luggage compartment wheel arch trim (2).
Fig. 37: Removing Cover From Luggage Compartment Wheel Arch Trim
Unlock locking clip (2) in direction of arrow and remove socket housing (3) from rear light (4).
2010 BMW M3
Fig. 38: Removing Socket Housing From Rear Light

Release nuts (1), tightening torque 63 21 1AZ .
Remove rear light (2) in outwards direction from side panel (3).
Installation:
Make sure gap is uniform all round between rear light (2) and side panel (3).
Fig. 39: Identifying Rear Light, Side Panel And Nuts

Installation:
Make sure seal (1) is correctly seated on rear light (2).

2010 BMW M3
Fig. 40: Identifying Seal On Rear Light

63 21 183 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT TAIL LIGHT (ON REAR
LID)
PROTECTION) .
Partially remove TRIM PANEL FOR REAR LID

2010 BMW M3
Slacken nut (1) until clamping jaw (2) on rear lid (3) can be unlatched.
Installation:
Make sure clamping jaw (2) is correctly seated on rear lid (3).
Fold rear light (4) outwards out of rear lid (3).
Remove rear light (4).
Installation:
Position lugs (5) of rear light (4) exactly over side edge of rear lid (3).
Fig. 42: Identifying Slacken Nut, Clamping Jaw And Rear Lid
Installation:

2010 BMW M3

63 21 057 REPLACING A SOCKET HOUSING FOR LEFT OR RIGHT REAR LIGHT (REAR LID)
Partially remove TRIM PANEL FOR REAR LID
WARNING: Follow instructions for HANDLING LIGHT BULBS (EXTERIOR LIGHTS) .
Unlock locking clip (2) in direction of arrow and remove socket housing for rear light (3) from rear light (4).
NOTE: Convert bulbs, replace if necessary.

See TYPE OF BULB .
2010 BMW M3

63 21 055 REPLACING A SOCKET HOUSING FOR LEFT OR RIGHT REAR LIGHT (SIDE PANEL)

Note TYPE OF BULB .
2010 BMW M3

63 21 104 REPLACING SEALING FRAME FOR LEFT OR RIGHT REAR LIGHT (ON REAR LID)
Remove REAR LIGHT
Detach sealing frame for rear light (1) completely from rear light (2).
Clean bonding surface and allow to dry.
Installation:
Make sure sealing frame for rear light (1) is correctly bonded all round on rear light (2).

2010 BMW M3
63 21 101 REPLACING SEALING FRAME FOR LEFT OR RIGHT REAR LIGHT (ON SIDE PANEL)
Remove REAR LIGHT
Installation:
Fig. 48: Identifying Sealing Frame On Rear Light

BRAKE LIGHTS
63 25 000 REMOVING AND INSTALLING/REPLACING AUXILIARY BRAKE LIGHT
Unclip auxiliary brake light cover (1) at retaining points (3).
Remove auxiliary brake light cover (1) in direction of arrow from roofliner (2).
2010 BMW M3
Fig. 49: Removing Auxiliary Brake Light Cover And Roofliner

Installation:
Retaining hooks (3) and guides (2) of auxiliary brake light cover (1) must not be damaged.
Make sure cover for auxiliary brake light (1) is correctly seated.
Fig. 50: Identifying Retaining Hooks, Guides And Auxiliary Brake Light Cover
Unlock slide (2) in direction of arrow and remove auxiliary brake light (4) from rear window (3).
Installation:
Make sure auxiliary brake light (4) is correctly positioned on rear window (3).
2010 BMW M3
Fig. 51: Removing Auxiliary Brake Light From Rear Window

LICENCE PLATE LIGHTS

63 26 000 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT NUMBER/LICENSE
PLATE LIGHT
WARNING: Follow instructions for handling light bulbs (EXTERIOR LIGHTS) .
Lever number/license plate light (1) 64 1 020 HOOK with special tool in direction of arrow out of tailgate.
Remove number plate light (1).
Replacement:
If necessary, remove bulb.

Note bulb type
2010 BMW M3
Fig. 52: Removing Number Plate Light Using Special Tool (64 1 020)
INTERIOR LIGHTS
63 31... OVERVIEW OF INTERIOR LIGHTS
2010 BMW M3
Fig. 53: Overview Of Interior Lights

63 31 004 REMOVING AND INSTALLING OR REPLACING COMPLETE CEILING LIGHT (REAR,

WITH MODULE FOR PASSENGER COMPARTMENT PROTECTION)
remove.
2010 BMW M3
Fig. 54: Removing Trim Of Ceiling Light Using Special Tool (00 9 341)
Version with reading lights:
NOTE: Operation is shown by way of example on the roof switch center.
Fig. 55: Removing Retaining Clips Using Special Tool (00 9 341)
Version without reading lights:

2010 BMW M3
Retaining clips (1) are located at distance (A) from outer edges of ceiling light.
(A) = 35 mm
Fig. 56: Removing Retaining Clips Using Special Tool (00 9 341)
Lever ceiling light (1) with special tool 00 9 341 in direction of arrow out of roofliner (2).
Disconnect plug connection underneath and remove ceiling light (1).
Fig. 57: Removing Lever Ceiling Light Using Special Tool (00 9 341)
Installation:
2010 BMW M3
Assemble ceiling light prior to installation:
Feed in ceiling light trim (1) at line (2)

Press ceiling light trim (1) in direction of arrow onto ceiling light (3)
Make sure ceiling light trim (1) is correctly engaged on ceiling light (3).
Fig. 58: Pressing Ceiling Light Trim In Ceiling Light

Replacement:
Remove MODULE FOR INTERIOR MOVEMENT DETECTOR

63 31 000 REMOVING AND INSTALLING OR REPLACING COMPLETE ROOF LIGHT (FRONT)
Version with roof switch cluster:
Removing and installing (replacing) ROOF SWITCH CENTRE
Version without roof switch cluster:
IMPORTANT: Ceiling light (1) and roofliner (2) must not be damaged.
Lever ceiling light (1) with special tool 00 9 341 out of roofliner (2).
Disconnect associated plug connection and remove roof light (1).

2010 BMW M3
Replacement:
Fig. 59: Removing Ceiling Light From Roofliner Using Special Tool (00 9 341)
63 31 170 REMOVING AND INSTALLING/REPLACING DOOR HANDLE LIGHT ON LEFT OR

RIGHT FRONT DOOR
Remove SOUND INSULATION FROM FRONT DOOR

Remove cover on front outside handle See 5121180 REMOVING AND
INSTALLING/REPLACING COVER ON OUTSIDE DOOR HANDLE or 5121181 REMOVING
AND INSTALLING/RENEWING COVER ON OUTSIDE HANDLE WITH LOCK CYLINDER
Remove DOOR LOCK ON FRONT DOOR
NOTE: Inner door panel partially shown transparent.
Unclip wiring harness (2) from carrier for outside door handle (3).
Raise outside door handle (4) slightly and remove.

2010 BMW M3
Fig. 60: Removing Outside Door Handle

Installation:
Guides (3) of door handle light (1) must be seated in carrier for outside door handle (4).
Fig. 61: Identifying Door Handle Light, Outside Door Handle And Guides
Installation:
Wiring harness holders (2) must not be damaged.
Replacement
2010 BMW M3
Undo loop (3) to obtain the required cable length.
Fig. 62: Identifying Loop, Wiring Harness And Wiring Harness Holders

RIGHT REAR DOOR
Remove COVER ON OUTSIDE HANDLE

E71/E87/E90/E91:
Remove DOOR LOCK ON REAR DOOR
Release all attachment points of wiring harness (2).
Raise door handle light (4) slightly and remove in outward direction from carrier for outside door handle (3).
2010 BMW M3
Fig. 63: Removing Door Handle Light From Carrier

Installation:
Fig. 64: Identifying Door Handle Light, Outside Door Handle And Guides
Installation:
Wiring harness holders (2) of wiring harness (1) must not be damaged or missing.
Replacement:
If necessary, undo loop (3) to obtain the required cable length.

2010 BMW M3
Fig. 65: Identifying Loop, Wiring Harness And Wiring Harness Holders
63 31 020 REMOVING AND INSTALLING/REPLACING FOOTWELL LIGHT (DOOR)
IMPORTANT: Follow instructions for HANDLING LIGHT BULBS (INTERIOR LIGHTS) .
Lever footwell light (1) in direction of arrow out of door trim (2).
Disconnect associated plug connection and remove footwell light (1).
Replacement
If necessary, remove BULB .

Note BULB TYPE .
Fig. 66: Removing Footwell Light Of Door Trim

2010 BMW M3
63 31 020 REMOVING AND INSTALLING/REPLACING FOOTWELL LIGHT (FOOTWELL)
Lever footwell light (1) 64 1 020 HOOK with special tool in direction of arrow out of bottom right instrument
panel trim.
Replacement:
Fig. 67: Removing Footwell Light Using Special Tool (64 1 020)
63 31 150 REMOVING AND INSTALLING/REPLACING GLOVEBOX LIGHT
IMPORTANT: Follow instructions for handling light bulbs (Interior Lights) See 6399461
REPLACING BULB FOR GLOVEBOX LIGHT or 6399... INSTRUCTIONS FOR
REPLACING LIGHT BULBS (INTERIOR LIGHTS).
Lever glovebox light (1) with special tool 64 1 020 HOOK out of glovebox.
Disconnect associated plug connection and remove glovebox light (1).
Replacement:
2010 BMW M3
Fig. 68: Identifying Glovebox Light

63 31 080 REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT LIGHT
IMPORTANT: Follow instructions for HANDLING LIGHT BULBS (INTERIOR LIGHTS) .
Lever out luggage compartment light (1) in direction of arrow.
Disconnect associated plug connection and remove luggage compartment light (1).
Fig. 69: Removing Luggage Compartment Light

Replacement
If necessary, convert bulbs.

Note BULB TYPE .
2010 BMW M3
63 31 050 REMOVING AND INSTALLING/REPLACING MIRROR LIGHT
Lever off make-up mirror light (1) from roofliner (2) in direction of arrow with special tool 00 9 341.
Disconnect plug connection underneath and remove mirror plate light (1).
Replacement:
Fig. 70: Removing Mirror Light From Roofliner Using Special Tool (00 9 341)
LIGHT BULBS
63 99... INSTRUCTIONS FOR HANDLING LIGHT BULBS (EXTERIOR LIGHTS)
WARNING: Xenon headlights: Danger to life due to high voltage!

WARNING: Halogen lamps are under pressure:

To avoid injury, wear protective goggles and gloves.
IMPORTANT: To avoid short circuits, disconnect bulbs from the power supply before
replacing them (lighting system and ignition off).
Do not touch the glass bulbs in new lights bulbs as even the slightest contamination will burn in and reduce bulb
service life.
2010 BMW M3
Only touch light bulbs with clean gloves or a clean cloth.
Do not expose light bulbs to mechanical vibrations.
Use only recommended light bulbs.
Follow the light bulb manufacturer's instructions without fail.
63 99... INSTRUCTIONS FOR REPLACING LIGHT BULBS (INTERIOR LIGHTS)
service life.
63 99... NOTES FOR REPLACING THE PROTECTIVE CAP OF THE HEADLIGHT

Damaged seals on the protective caps will lead to moisture penetration into the
headlight.
This will in turn cause porous cable insulations and malfunctioning of the
headlight.
When working on the headlight system, check the protective cap seals.
Replace the protective cap in the event of damage!
Example: screwed protective cap

2010 BMW M3
Fig. 71: Identifying Seal On Protected Cap

Example: latchable protective cap
Fig. 72: Identifying Seal On Protective Cap

63 99 437 REPLACING BULB FOR FOOTWELL LIGHT (IN DOOR)
WARNING: Follow instructions for HANDLING LIGHT BULBS (INTERIOR LIGHTS) .

2010 BMW M3
Remove FOOTWELL LIGHT in door
Unlock catch (1) on footwell light (2).
Open cover cap (3) in direction of arrow.
Remove bulb.
Installation:
Note BULB TYPE .

63 99 431 REPLACING BULB FOR FRONT CEILING LIGHT
WARNING: Follow instructions for handling light bulbs (INTERIOR LIGHTS)
Remove front ceiling light . See 6331000 REMOVING AND INSTALLING OR REPLACING
COMPLETE ROOF LIGHT (FRONT) or 6131043 REMOVING AND INSTALLING OR
REPLACING ROOF SWITCH CLUSTER
Turn bulb holder in direction of arrow and remove.

2010 BMW M3
Fig. 74: Turning Bulb Holder

Pull bulb (1) out of bulb holder (2).
Fig. 75: Pulling Bulb Of Bulb Holder

Installation:
Make sure bulb holder is correctly seated and engaged in ceiling light
Note BULB TYPE
63 99 145 REPLACING BULB FOR FRONT LEFT (OR RIGHT) SIDE LIGHTS
2010 BMW M3
Follow instructions for handling light bulbs. See (EXTERIOR LIGHTS) .
Unlock catches (1) and remove cover (2) in direction of arrow from headlight.
Installation:
Make sure cover (2) is correctly seated on headlight.
Fig. 76: Removing Headlight Cover

Grip bulb for side lights (2) on both sides, turn in direction of arrow and pull out of headlight.
Installation:
Make sure bulb for side lights (2) is exactly seated in headlight.
Note TYPE OF BULB .

2010 BMW M3

63 99 160 REPLACING BULB FOR FRONT LEFT (OR RIGHT) TURNING LIGHTS
Therefore, before removing, disconnect all components from the voltage
bulb) may only be carried out by qualified personnel.
Installation note:
Cover (2) must be correctly engaged.
Check seal.
Replace cover (2), if applicable.
Observe NOTES REGARDING REPLACEMENT OF THE PROTECTIVE CAP .

2010 BMW M3
Fig. 78: Removing Headlight Cover

Disconnect locking clip (2) and fold upwards.
Remove bulb for turning lights (3) from headlight.
Installation note:
Note BULB TYPE .
Fig. 79: Removing Bulb For Turning Lights From Headlight

63 99 461 REPLACING BULB FOR GLOVEBOX LIGHT

2010 BMW M3
WARNING: Follow instructions for HANDLING LIGHT BULBS (INTERIOR LIGHTS) .
Remove GLOVEBOX LIGHT
Spread bow contacts (1) and remove bulb.
Installation:
Note BULB TYPE .
Fig. 80: Removing Bulb

63 99 273 REPLACING BULB FOR LEFT (OR RIGHT) FRONT TURN INDICATOR
Follow instructions for handling light bulbs. See (EXTERIOR LIGHTS) .
If necessary, remove FRONT WHEEL ARCH COVER
Turn locks (1) counterclockwise through 180.
Remove repair cover (2) from wheel arch cover (3).

2010 BMW M3
Installation:
Make sure guides (4) of repair cover (2) are correctly seated in wheel arch cover (3).
Fig. 81: Identifying Locks And Wheel Arch Cover

Turn direction indicator bulb holder (1) in direction of arrow and pull out of headlight.
Fig. 82: Identifying Indicator Bulb Holder

Twist bulb for front direction indicator (1) in direction of arrow and remove from direction indicator bulb
holder (2).
Installation:
Make sure bulb for front direction indicator (1) and sealing ring (3) are correctly seated on direction indicator
bulb holder (2).
2010 BMW M3
Note type of bulb See DIRECTION INDICATORS or DIRECTION INDICATORS .
Fig. 83: Turning Bulb For Front Direction Indicator

63 99 076 REPLACING BULB FOR LEFT (OR RIGHT) XENON HEADLIGHT (WITH IGNITION
UNIT)
Replacing IGNITION UNIT FOR LEFT XENON HEADLIGHT
63 99 432 REPLACING BULB FOR REAR CEILING LIGHT
WARNING: Follow instructions for handling light bulbs (INTERIOR LIGHTS)
Remove REAR CEILING LIGHT

2010 BMW M3

Fig. 85: Pulling Bulb Of Bulb Holder

Installation:
Note BULB TYPE
63 99 445 REPLACING BULB(S) FOR MIRROR LIGHT
WARNING: Follow instructions for handling light bulbs (INTERIOR LIGHTS) .

2010 BMW M3
Remove MIRROR LIGHT
Expand bow contacts (1) and remove bulb for mirror light.
Installation:
Note BULB TYPE .
Fig. 86: Removing Bulb For Mirror Light

63 99 072 REPLACING HALOGEN BULB FOR LEFT OR RIGHT HEADLIGHT (FROM VERSION
9/2008)
WARNING: Follow instructions for HANDLING LIGHT BULBS (EXTERIOR LIGHTS).
Unlock and remove cover (1).

2010 BMW M3
Fig. 87: Unlocking And Removing Cover

Turn protective cap (1) counterclockwise and remove.
IMPORTANT: Risk of damage due to moisture penetration!
Installation note:
Check seal. Replace protective cap (1) if necessary.
Comply with INSTRUCTIONS FOR REPLACING THE PROTECTIVE CAP.
Protective cap (1) must lock correctly!
Turn the protective cap (1) clockwise to end stop (A)!
Fig. 88: Turning Protective Cap Clockwise To End Stop

Turn bulb holder (1) in direction of arrow and pull out towards rear.
Installation note:
Make sure retaining tabs (2) in headlight are correctly seated.

2010 BMW M3
Fig. 89: Identifying Bulb Holder And Retaining Tabs

Detach bulb (1) from bulb holder (2).
Installation note:
Note bulb type.
Fig. 90: Detaching Bulb From Bulb Holder

63 99 451 REPLACING LIGHT BULB FOR LUGGAGE COMPARTMENT LIGHTING
WARNING: Follow instructions for handling light bulbs (INTERIOR LIGHTS) .

2010 BMW M3
Remove LUGGAGE COMPARTMENT LIGHT
Move lens cover (1) in direction of arrow and remove.
Remove festoon (2) underneath.
Installation:
Note TYPE OF BULB .
Fig. 91: Removing Lens Cover

63 99 315 REPLACING LIGHT BULB(S) FOR LEFT OR RIGHT REAR LIGHT
Remove socket housing for rear light See 6321055 REPLACING A SOCKET HOUSING FOR
LEFT OR RIGHT REAR LIGHT (SIDE PANEL) or 6321057 REPLACING A SOCKET
HOUSING FOR LEFT OR RIGHT REAR LIGHT (REAR LID)
Rear light in side panel
Turn faulty bulb and pull out of socket housing for rear light (5).
NOTE: 1. Bulb, turn indicator light

2. Bulb, rear light
3. Bulb, brake light
2010 BMW M3
4. Bulb, adaptive brake light
Fig. 92: Identifying Rear Light, Indicator Light, Brake Light And Adaptive Brake Light
Rear light in rear lid
NOTE: 1. Bulb, rear fog light

2. Bulb, rear light
3. Bulb, reversing light
Fig. 93: Identifying Rear Fog Light, Rear Light And Reversing Light
Installation:
2010 BMW M3
Note BULB TYPE .

2010 BMW M3
ACCESSORIES AND BODY, CAB Lights - Repair - M3
Lights - Repair - M3
LAMP SETTINGS
63 10 ... TEST REQUIREMENTS FOR HEADLIGHT VERTICAL AIM ADJUSTMENT
Car parked on level ground.

Replace faulty glass and mirrors and blackened light bulbs.
Check tire pressure and correct if necessary.
Apply load equivalent to one person on driver's seat (approx. 75 kg).
Vehicle with full fuel tank or appropriate additional weight in luggage compartment.
Correct adjustment of headlights in relation to engine hood (gap dimensions).
Manual headlight vertical aim control: Turn handwheel to 0 position.
Automatic headlight vertical aim control: Wait approx. 30 seconds after switching on lights.
Version with xenon headlights: Wait 80 seconds after switching on lights. During this time, do not move
the vehicle and avoid vibrations.
Align headlight aimer with vehicle longitudinal axis and parallel to parking surface. Set marking line (M)
on aimer to distance (e). Scale graduations on aimer are equal to a gradient in cm at a distance of 10
meters.
Fig. 1: Identifying Headlight Vertical Aim Adjustment Distance

Light/dark limit of headlights in headlight aimer

2010 BMW M3
e Adjustment dimension, headlights:
as per type plate on headlight housing in % (e.g.: 1.0 % = 10 cm / 10 m = 10 on headlight aimer).
Adjustment dimension, fog lights:
all vehicles 2.0 % = 20 cm / 10 m = 20 on headlight aimer.
H Height of center of headlight above parking surface.
h H - e = height of marking line above parking surface
+ Central mark = center point of high-beam headlight.
M Marking line of headlamp aimer
S Parking surface of vehicle and headlight aimer
Adjustment dimension (e) is only valid for EUR. Observe differing national regulations.
NOTE: Comply with test preconditions for headlight adjustment .

Fig. 2: Identifying Headlights Adjusting Screws

2010 BMW M3
NOTE: Comply with test preconditions for headlight adjustment .

Fig. 3: Identifying Headlights Adjusting Screws

HEADLIGHTS
63 12 010 REMOVING AND INSTALLING OR REPLACING LEFT HEADLIGHT (XENON
HEADLIGHT)
Follow instructions for handling light bulbs (exterior lights ).
protection ). See 61 35 ... NOTES ON ESD PROTECTION (ELECTRO STATIC
DISCHARGE) .

2010 BMW M3
Remove bumper trim . See 51 11 156 REMOVING AND INSTALLING FRONT BUMPER TRIM .
Remove high-pressure nozzle of headlight washer system. See 61 67 083 REMOVING AND
SYSTEM ON LEFT OR RIGHT (M3) .
Release screw (1) on headlight arm (2) (from wheel arch side).
Tightening torque 63 12 1AZ , see 63 12 HEADLIGHTS .
Fig. 4: Identifying Headlight Arm And Screw

Release screws (1). Tightening torque 63 12 3AZ , see 63 12 HEADLIGHTS .
M3:
Release screw (2). Tightening torque 63 12 7AZ , see 63 12 HEADLIGHTS .
Remove headlamp (4) in direction of arrow.
Installation:
Observe gap dimensions . See 41 00 ... GAP DIMENSIONS, BODY .

Adjust headlights
2010 BMW M3
Fig. 5: Identifying Wiring Harness Fastener, Headlight And Headlamp

Replacement:
Release screws (1) (tightening torque 63 12 2AZ , see 63 12 HEADLIGHTS ) and remove headlight arm
(2) from headlight
Remove ignition unit/bulb for xenon headlight (left) or 63 12 871 Replacing ignition unit for right
xenon headlight (with xenon bulb).
Remove control unit for xenon headlights (left) or 63 12 861 Replacing control unit for right xenon
headlight.
If necessary, remove bulbs . See 63 99 145 Replacing bulb for front left (or right) side lights or 63 99
273 Replacing bulb for left (or right) front turn indicator.

63 12 012 REMOVING AND INSTALLING RIGHT HEADLIGHT (XENON HEADLIGHT)

2010 BMW M3
Removing and installing left headlight
63 12 015 REMOVING AND INSTALLING OR REPLACING LEFT HEADLIGHT (ADAPTIVE

HEADLIGHT)
DISCHARGE) .
TRIM .
Remove high-pressure nozzle of headlight washer system. See 61 67 083 REMOVING AND
SYSTEM ON LEFT OR RIGHT (M3) .
Release screw (1) on headlight arm (2) (from wheel arch side).

2010 BMW M3
Release bolts (1). Tightening torque 63 12 3AZ , see 63 12 HEADLIGHTS .
M3:
Release screw (2). Tightening torque 63 12 7AZ , see 63 12 HEADLIGHTS .
Remove headlight (4) in direction of arrow.
Installation:
Observe gap dimensions . See 41 00 ... GAP DIMENSIONS, BODY .

Adjust headlights
Fig. 8: Identifying Wiring Harness Fastener, Headlight And Headlamp

Replacement up to 09/2008:
Release screws (1) (tightening torque 63 12 2AZ , see 63 12 HEADLIGHTS ) and remove headlight arm
(2) from headlight
Remove ignition unit/bulb for xenon headlight (left) or 63 12 871 Replacing ignition unit for right
xenon headlight (with xenon bulb).
Remove control unit for xenon headlights (left) or 63 12 861 Replacing control unit for right xenon
headlight.
Remove drive/electronics box for adaptive headlight . See 63 12 895 Replacing drive/electronics box
for left adaptive headlight or 63 12 896 Replacing drive/electronics box for right adaptive headlight.
2010 BMW M3
If necessary, remove bulbs .
Replacement as from 09/2008:
Remove direction indicator insert

Remove drive/electronics box for adaptive headlight . See 63 12 895 Replacing drive/electronics box
for left adaptive headlight or 63 12 896 Replacing drive/electronics box for right adaptive headlight.

63 12 017 REMOVING AND INSTALLING/REPLACING RIGHT HEADLIGHT (ADAPTIVE

HEADLIGHT)
Removing and installing left headlight.
63 12 860 REPLACING CONTROL UNIT FOR LEFT XENON HEADLIGHT
DISCHARGE) .

2010 BMW M3
Remove front left wheel arch trim .
S65:
Remove left headlight
Fig. 10: Identifying Control Unit And Screw

Installation:

2010 BMW M3
Fig. 11: Identifying Sealing Sleeve, Control Unit And Plug Connection
63 12 861 REPLACING CONTROL UNIT FOR RIGHT XENON HEADLIGHT
DISCHARGE) .
Remove front right wheel arch trim
N54 / S65:
Remove right headlight

2010 BMW M3
Fig. 12: Identifying Control Unit And Screw

Installation:
Fig. 13: Identifying Sealing Sleeve And Plug Connection

63 12 870 REPLACING IGNITION UNIT FOR LEFT XENON HEADLIGHT (WITH XENON BULB)
2010 BMW M3
separated.
Remove front left wheel arch trim . See 51 71 038 REMOVING AND INSTALLING/REPLACING
FRONT LEFT OR RIGHT WHEEL ARCH COVER (FRONT SECTION) .
Release screws (1) and remove cover cap (2) from headlight.
Installation:
Fig. 14: Identifying Cover Cap And Screw

Installation:
2010 BMW M3
Fig. 15: Identifying Ignition Unit For Xenon Headlight

63 12 871 REPLACING IGNITION UNIT FOR RIGHT XENON HEADLIGHT (WITH XENON BULB)
separated.
Remove front right wheel arch trim . See 51 71 038 REMOVING AND
SECTION) .
Release screws (1) and remove cover cap (2) from headlight.
Installation:
2010 BMW M3
Fig. 16: Identifying Cover Cap And Screw

Installation:
Fig. 17: Identifying Ignition Unit For Xenon Headlight

63 12 895 REPLACING DRIVE/ELECTRONICS BOX FOR LEFT ADAPTIVE HEADLIGHT
2010 BMW M3
DISCHARGE) .
NOTE: Operation is shown by way of example on the E70.

Remove drive/electronics box for adaptive headlight (2) from headlight.
Installation:
Make sure seal is correctly positioned on drive/electronics box for adaptive headlight (2).
Fit drive/electronics box for adaptive headlight (2) exactly on headlight.
Make sure pin housing (3) is correctly seated in plug housing (4).
Fig. 18: Identifying Pin Housing And Adaptive Headlight

Carry out vehicle programming/coding .
63 12 896 REPLACING DRIVE/ELECTRONICS BOX FOR RIGHT ADAPTIVE HEADLIGHT
Replacing drive/electronics box for left adaptive headlight

2010 BMW M3

(XENON HEADLIGHT)
See 67 16 011 REMOVING AND INSTALLING/REPLACING LEFT VERTICAL AIM ADJUSTER

(XENON HEADLIGHT) .

ADJUSTER
Removing and installing / replacing left headlight vertical aim adjuster . See 67 16 011 REMOVING
AND INSTALLING/REPLACING LEFT VERTICAL AIM ADJUSTER (XENON HEADLIGHT) .
TURN SIGNAL INDICATOR

63 13 080 REMOVING AND INSTALLING/REPLACING LEFT DIRECTION INDICATOR INSERT
FROM SERIES STATUS 09/2008
Release screws (1).
Fig. 19: Identifying Indicator, Headlight And Screw


2010 BMW M3
Fig. 20: Identifying Headlight And Plug Connection

63 13 200 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT AUXILIARY

DIRECTION INDICATOR (M3)
00 9 340
WARNING: Follow instructions for handling light bulbs (exterior lights ).
DISCHARGE) .

Carry out the following operations carefully so as to avoid damaging the side
panel and auxiliary direction indicator.
Feed cable tie (1) into trim grille (6).
Unlock retaining lugs (2) of trim grille (6) with special tool 00 9 340 in direction of arrow. This operation must
release the catch (3) of the auxiliary direction indicator chrome bar (4) from the front side panel.
Unlock retaining lug (5) of trim grille (6) with special tool 00 9 340 , pulling trim grille (6) with cable tie (1) in
direction of arrow.
2010 BMW M3
Feed trim grille (6) with auxiliary direction indicator chrome bar (4) out of front side panel.
Disconnect associated plug connection and remove trim grille (6) with auxiliary direction indicator chrome bar
(4).
Fig. 21: Pulling Trim Grille With Cable Tie

Installation:
Trim grille (6) and retaining lugs (2, 5) must not be damaged. If necessary, replace trim grille.
Make sure trim grille (6) with auxiliary direction indicator chrome bar (4) is correctly seated on front side panel.
Unlock all retaining lugs of auxiliary direction indicator chrome bar (1) with a suitable tool.
Remove trim grille (2) from auxiliary direction indicator chrome bar (1).
Installation:
Make sure trim grille (2) is correctly engaged on auxiliary direction indicator chrome bar (1).
2010 BMW M3
Fig. 22: Removing Trim Grille From Indicator Chrome Bar

Release screw (1). Tightening torque 63 13 1AZ , see 63 13 TURN SIGNAL .
Remove auxiliary direction indicator (2) in direction of arrow from auxiliary direction indicator chrome bar (3).
Installation:
Journal (4) of auxiliary direction indicator (2) must first be fed into auxiliary direction indicator chrome bar (3).
Fig. 23: Removing Indicator Of Chrome Bar

CLEARANCE AND SIDE MARKER

63 14 060 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT SIDE MARKER
(M3/US)

2010 BMW M3
64 1 020

Carry out the following operation carefully so as to avoid damaging the bumper
trim and side marker.
Press side marker (1) upwards with special tool 64 1 020 and feed in direction of arrow out of bumper trim (2).
Installation:
Retaining spring of side marker (1) must not be damaged or missing.
Make sure side marker (1) is correctly seated in bumper trim (2).
Fig. 24: Retaining Spring Of Side Marker

REAR LIGHT CLUSTER

63 21 055 REPLACING A SOCKET HOUSING FOR LEFT OR RIGHT REAR LIGHT (SIDE PANEL)
2010 BMW M3

Note type of bulb .
Fig. 26: Removing Socket Housing For Rear Light

63 21 057 REPLACING A SOCKET HOUSING FOR LEFT OR RIGHT REAR LIGHT (REAR LID)
Partially remove trim panel for rear lid . See 51 49 000 REMOVING AND
INSTALLING/REPLACING PANEL FOR REAR LID .
2010 BMW M3

Note type of bulb .
Fig. 27: Identifying Unfasten Plug Connection And Rear Light

63 21 101 REPLACING SEALING FRAME FOR LEFT OR RIGHT REAR LIGHT (ON SIDE PANEL)
Remove rear light
Installation:
2010 BMW M3
Fig. 28: Detaching Sealing Frame For Rear Light

63 21 104 REPLACING SEALING FRAME FOR LEFT OR RIGHT REAR LIGHT (ON REAR LID)
Remove rear light
Installation:
Fig. 29: Detaching Sealing Frame For Rear Light

2010 BMW M3
63 21 180 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT REAR LIGHT (IN SIDE
PANEL)
DISCHARGE) .
Fig. 30: Identifying Luggage Compartment Wheel Arch Trim And Cover

2010 BMW M3
Release nuts (1), tightening torque 63 21 1AZ , see 63 21 REAR LIGHT UNIT .
Remove rear light (2) in outwards direction from side panel (3).
Installation:
Make sure gap is uniform all round between rear light (2) and side panel (3).
Fig. 32: Identifying Rear Light And Side Panel

Installation:

63 21 183 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT TAIL LIGHT (ON REAR
LID)
2010 BMW M3
DISCHARGE) .
Partially remove trim panel for rear lid . See 51 49 000 REMOVING AND
INSTALLING/REPLACING PANEL FOR REAR LID .

Slacken nut (1) until clamping jaw (2) on rear lid (3) can be unlatched.
Tightening torque 63 21 1AZ , see 63 21 REAR LIGHT UNIT .
Installation:
Make sure clamping jaw (2) is correctly seated on rear lid (3).
Fold rear light (4) outwards out of rear lid (3).
Remove rear light (4).
Installation:
Position lugs (5) of rear light (4) exactly over side edge of rear lid (3).
2010 BMW M3
Fig. 35: Identifying Slacken Nut, Clamping Jaw And Rear Lid
Installation:

BRAKE LIGHTS
63 25 000 REMOVING AND INSTALLING/REPLACING AUXILIARY BRAKE LIGHT
Unclip auxiliary brake light cover (1) at retaining points (3).
Remove auxiliary brake light cover (1) in direction of arrow from roofliner (2).
2010 BMW M3
Fig. 37: Identifying Auxiliary Brake Light Cover And Roofliner

Installation:
Retaining hooks (3) and guides (2) of auxiliary brake light cover (1) must not be damaged.
Make sure cover for auxiliary brake light (1) is correctly seated.
Fig. 38: Identifying Hooks, Guides And Auxiliary Brake Light Cover
Unlock slide (2) in direction of arrow and remove auxiliary brake light (4) from rear window (3).
Installation:
Make sure auxiliary brake light (4) is correctly positioned on rear window (3).
2010 BMW M3
Fig. 39: Identifying Auxiliary Brake Light And Rear Window

LICENCE PLATE LIGHTS

63 26 000 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT NUMBER/LICENSE
PLATE LIGHT
64 1 020
Lever number/license plate light (1) with special tool 64 1 020 in direction of arrow out of rear lid.
Remove license plate light (1).
Replacement:
If necessary, remove bulb .

Note bulb type .
2010 BMW M3
Fig. 40: Removing License Plate Light

INTERIOR LIGHTS
63 31 ... OVERVIEW OF INTERIOR LIGHTS
2010 BMW M3
Fig. 41: Identifying Interior Lights Parts Location

63 31 000 REMOVING AND INSTALLING OR REPLACING COMPLETE ROOF LIGHT (FRONT)
00 9 341
IMPORTANT: Follow instructions for handling light bulbs (interior lights ).
Version with roof switch cluster:
Removing and installing (replacing) roof switch center . See 61 31 043 REMOVING AND
INSTALLING OR REPLACING ROOF SWITCH CENTRE .
2010 BMW M3
Version without roof switch cluster:
IMPORTANT: Ceiling light (1) and roofliner (2) must not be damaged.
Lever ceiling light (1) with special tool 00 9 341 out of roofliner (2).
Disconnect associated plug connection and remove roof light (1).
Replacement:
Fig. 42: Identifying Ceiling Light And Roofliner

63 31 004 REMOVING AND INSTALLING OR REPLACING COMPLETE CEILING LIGHT (REAR,

WITH MODULE FOR PASSENGER COMPARTMENT PROTECTION)
00 9 341
remove.
2010 BMW M3
Fig. 43: Removing Ceiling Light Using Special Tool

Version with reading lights:
NOTE: Operation is shown by way of example on the roof switch center.
Carefully unlock retaining clips (1) with special tool 00 9 341 .
Fig. 44: Identifying Reflector And Roofliner

Version without reading lights:

2010 BMW M3
Retaining clips (1) are located at distance (A) from outer edges of ceiling light.
A. 35 mm
Carefully unlock retaining clips (1) with special tool 00 9 341 .
Fig. 45: Identifying Reflector And Roofliner

Lever ceiling light (1) with special tool 00 9 341 in direction of arrow out of roofliner (2).
Disconnect plug connection underneath and remove ceiling light (1).
Fig. 46: Identifying Lever Ceiling Light And Roofliner

2010 BMW M3
Installation:
Assemble ceiling light prior to installation:
Feed in ceiling light trim (1) at line (2)

Press ceiling light trim (1) in direction of arrow onto ceiling light (3)
Make sure ceiling light trim (1) is correctly engaged on ceiling light (3).
Fig. 47: Identifying Ceiling Light Trim And Ceiling Light

Replacement:
Remove module for interior movement detector . See 65 75 071 REMOVING AND INSTALLING
(REPLACING) MODULE FOR PASSENGER COMPARTMENT SENSOR .
63 31 020 REMOVING AND INSTALLING/REPLACING FOOTWELL LIGHT (DOOR)
Lever footwell light (1) in direction of arrow out of door trim (2).
Replacement:

Note bulb type .
2010 BMW M3
Fig. 48: Removing Footwell Light

63 31 020 REMOVING AND INSTALLING/REPLACING FOOTWELL LIGHT (FOOTWELL)
64 1 020
Lever footwell light (1) with special tool 64 1 020 in direction of arrow out of bottom right instrument panel
trim.
Replacement:

2010 BMW M3
Fig. 49: Removing Footwell Light

63 31 023 REMOVING AND INSTALLING/REPLACING FOOTWELL LIGHT (ON STORAGE

COMPARTMENT AT REAR)
00 9 340
Lever out footwell light (1) with special tool 00 9 340 in direction of arrow. Disconnect plug connection and
remove footwell light (1).
Fig. 50: Identifying Footwell Light With Special Tool (00 9 340)
2010 BMW M3
63 31 050 REMOVING AND INSTALLING/REPLACING MIRROR LIGHT
00 9 341
Lever mirror light (1) with special tool 00 9 341 in direction of arrow out of roofliner (2).
Disconnect plug connection underneath and remove mirror plate light (1).
Replacement:
Fig. 51: Identifying Lever Mirror Light And Roofliner

2010 BMW M3

Replacement:

Note bulb type .

(REAR LID)

2010 BMW M3
Replacement:

Note bulb type .
63 31 150 REMOVING AND INSTALLING/REPLACING GLOVEBOX LIGHT
64 1 020
Lever glovebox light (1) with special tool 64 1 020 out of glovebox.
Disconnect associated plug connection and remove glovebox light (1).
Replacement:
Fig. 54: Removing Glovebox Light


RIGHT FRONT DOOR
Remove sound insulation from front door . See 51 48 060 REMOVING AND
2010 BMW M3
Remove cover on front outside handle . See 51 21 180 REMOVING AND

INSTALLING/REPLACING COVER ON OUTSIDE HANDLE or 51 21 181 REMOVING AND
INSTALLING/REPLACING COVER ON OUTSIDE HANDLE WITH LOCK CYLINDER .
Remove door lock on front door . See 51 21 090 REMOVING AND INSTALLING/REPLACING
DOOR LOCK IN LEFT OR RIGHT FRONT DOOR .
Unclip wiring harness (2) from carrier for outside door handle (3).
Raise outside door handle (4) slightly and remove.
Fig. 55: Identifying Wiring Harness For Outside Door Handle

Installation:
2010 BMW M3
Fig. 56: Identifying Guides Of Door Handle Light

Installation:
Wiring harness holders (2) must not be damaged.
Replacement:
Undo loop (3) to obtain the required cable length.
Fig. 57: Identifying Wiring Harness And Wiring Harness Holders


RIGHT REAR DOOR
2010 BMW M3
Remove cover on outside handle . See 51 22 180 REMOVING AND INSTALLING/REPLACING

COVER ON OUTSIDE HANDLE, LEFT OR RIGHT .
E71/E87/E90/E91:
Remove door lock on rear door . See 51 22 090 REMOVING AND INSTALLING/REPLACING
DOOR LOCK IN LEFT OR RIGHT REAR DOOR .
Release all attachment points of wiring harness (2).
Raise door handle light (4) slightly and remove in outward direction from carrier for outside door handle (3).
Fig. 58: Identifying Outside Door Handle And Door Handle Light
Installation:
2010 BMW M3
Fig. 59: Identifying Door Handle Light And Outside Door Handle
Installation:
Wiring harness holders (2) of wiring harness (1) must not be damaged or missing.
Replacement:
If necessary, undo loop (3) to obtain the required cable length.
Fig. 60: Identifying Wiring Harness Holders Of Wiring Harness

63 31 180 REPLACING LED FOR FRONT DOOR TRIM PANEL LIGHT
Remove front door trim panel . See 51 41 000 REMOVING AND INSTALLING LEFT OR RIGHT
2010 BMW M3
Unlock LED (1) at catch (2) and detach in direction of arrow from fibre-optic waveguide (3).
Fig. 61: Identifying LED And Catch

Installation: LED (1) must snap noticeably into fibre-optic waveguide (2).
63 31 185 REPLACING LED FOR SIDE TRIM PANEL LIGHT
Remove rear side trim panel . See 51 43 034 REMOVING AND INSTALLING/REPLACING
Pull off LED (1) in direction of arrow from fibre-optic waveguide (2).
Fig. 62: Detaching LED For Side Trim Panel Light In Direction Of Arrow
Installation: LED (1) must snap noticeably into fibre-optic waveguide (2).
LIGHT BULBS
2010 BMW M3
63 99 ... INSTRUCTIONS FOR HANDLING LIGHT BULBS (EXTERIOR LIGHTS)
WARNING: Xenon headlights: Danger to life due to high voltage!

WARNING: Halogen lamps are under pressure:

To avoid injury, wear protective goggles and gloves.
service life.
63 99 ... INSTRUCTIONS FOR REPLACING LIGHT BULBS (INTERIOR LIGHTS)
service life.
63 99 076 REPLACING BULB FOR LEFT (OR RIGHT) XENON HEADLIGHT (WITH IGNITION
UNIT)
Replacing ignition unit for left xenon headlight

2010 BMW M3
63 99 145 REPLACING BULB FOR FRONT LEFT (OR RIGHT) SIDE LIGHTS
Installation:
Fig. 63: Removing Cover From Headlight

Grip bulb for side lights (2) on both sides, turn in direction of arrow and pull out of headlight.
Installation:
Make sure bulb for side lights (2) is exactly seated in headlight.
Note type of bulb .

2010 BMW M3
Fig. 64: Identifying Plug Connection And Side Light

63 99 160 REPLACING BULB FOR FRONT LEFT (OR RIGHT) TURNING LIGHTS
Installation:
Fig. 65: Removing Cover From Headlight

2010 BMW M3
Disconnect locking clip (2) and fold upwards.
Remove bulb for turning lights (3) from headlight.
Installation:
Note type of bulb .
Fig. 66: Removing Turning Lights From Headlight

63 99 273 REPLACING BULB FOR LEFT (OR RIGHT) FRONT TURN INDICATOR
If necessary, remove front wheel arch cover . See 51 71 038 REMOVING AND
SECTION) .
Turn locks (1) counterclockwise through 180.
Remove repair cover (2) from wheel arch cover (3).

2010 BMW M3
Installation:
Make sure guides (4) of repair cover (2) are correctly seated in wheel arch cover (3).
Fig. 67: Removing Repair Cover From Wheel Arch Cover

Turn direction indicator bulb holder (1) in direction of arrow and pull out of headlight.
Fig. 68: Turning Indicator Bulb Holder

Twist bulb for front direction indicator (1) in direction of arrow and remove from direction indicator bulb
holder (2).
Installation:
Make sure bulb for front direction indicator (1) and sealing ring (3) are correctly seated on direction indicator
bulb holder (2).
2010 BMW M3
Note type of bulb .
Fig. 69: Identifying Sealing Ring On Indicator Bulb Holder

63 99 315 REPLACING LIGHT BULB(S) FOR LEFT OR RIGHT REAR LIGHT

(CONVERTIBLE/COUPE)
Rear light in side panel: Release rotary clip (1) and remove cover (2).
Fig. 70: Identifying Trunk Trim Panel Cover And Clip

Turn socket housing and pull out of rear light.
Turn bulb and pull out of socket housing. Note type of bulb.
2010 BMW M3
Rear light in rear lid: Remove trim on rear lid. Turn bulb holder (1) in direction of arrow and pull out of rear
light (2).
Fig. 71: Turning Bulb Holder In Direction Of Arrow

Turn bulb and pull out of bulb holder.
Installation: Note type of bulb.
63 99 315 REPLACING LIGHT BULB(S) FOR LEFT OR RIGHT REAR LIGHT (SEDAN)
Remove socket housing for rear light . See 63 21 055 Replacing a socket housing for left or right
rear light (side panel) or 63 21 057 Replacing a socket housing for left or right rear light (rear lid).
Rear light in side panel:
NOTE: 1. Bulb, turn indicator light

2. Bulb, rear light
3. Bulb, brake light
4. Bulb, adaptive brake light
2010 BMW M3
Fig. 72: Identifying Adaptive Brake Light Bulb, Brake Light Bulb And Rear Light Bulb
Rear light in rear lid:
NOTE: 1. Bulb, rear fog light

2. Bulb, rear light
3. Bulb, reversing light
Fig. 73: Identifying Fog Light Bulb, Rear Light Bulb And Reversing Light Bulb
Installation:
Note bulb type .

2010 BMW M3
63 99 431 REPLACING BULB(S) FOR CEILING LIGHT (ROOF SWITCH CENTER)
WARNING: Follow instructions for handling light bulbs (interior lights )
Turn bulb holders in direction of arrow and pull out of roof switch center.
Fig. 74: Turning Bulb Holders

Installation: Make sure bulb holders are correctly seated and engaged in roof switch center.
Pull bulb (1) out of bulb holder (2). Installation: Note type of bulb.
63 99 431 REPLACING BULB FOR FRONT CEILING LIGHT
Remove front ceiling light

2010 BMW M3

Fig. 76: Pulling Bulb Out Of Bulb Holder

Installation:
Note bulb type
63 99 432 REPLACING BULB FOR REAR CEILING LIGHT

2010 BMW M3
Remove rear ceiling light

Fig. 78: Pulling Bulb Out Of Bulb Holder

Installation:
Note bulb type
63 99 437 REPLACING BULB FOR FOOTWELL LIGHT (IN DOOR)
WARNING: Follow instructions for handling light bulbs (interior lights ).

2010 BMW M3
Remove appropriate footwell light in door. See 63 31 020 Removing and installing/replacing footwell
light (door), 63 31 020 Removing and installing/replacing footwell light (footwell) or 63 31 023
Removing and installing/replacing footwell light (on storage compartment at rear).
Unlock catch (1) on footwell light (2).
Open cover cap (3) in direction of arrow.
Remove bulb.
Installation:
Note bulb type .
Fig. 79: Identifying Catch On Footwell Light

63 99 445 REPLACING BULB(S) FOR MIRROR LIGHT
Remove mirror light
Expand bow contacts (1) and remove bulb for mirror light.
2010 BMW M3
Installation:
Note type of bulb .
Fig. 80: Removing Bulb For Mirror Light

63 99 451 REPLACING LIGHT BULB FOR LUGGAGE COMPARTMENT LIGHTING
Remove luggage compartment light
Move lens cover (1) in direction of arrow and remove.
Remove festoon (2) underneath.
Installation:
Note type of bulb .

2010 BMW M3
Fig. 81: Removing Lens Cover

63 99 452 REPLACING LIGHT BULB FOR LUGGAGE COMPARTMENT LIGHT (ON REAR LID)
Remove luggage compartment light (on rear lid)
Turn bulb holder (1) in direction of arrow and pull out of luggage compartment light (2).
Fig. 82: Identifying Bulb Holder And Luggage Compartment Light

Pull bulb out of bulb holder. Note bulb type.
63 99 461 REPLACING BULB FOR GLOVEBOX LIGHT

2010 BMW M3
Remove glovebox light
Spread bow contacts (1) and remove bulb.
Installation:
Note bulb type .
Fig. 83: Removing Bulb

2010 BMW M3
GENERAL INFORMATION BMW - 1982-13
GENERAL INFORMATION
BMW - 1982-13
BRAKE PAD WARNING LIGHT
NOTE: Most vehicles are equipped with a Malfunction Indicator Light (MIL) or check
engine light. If light comes on and remains on while driving, the vehicle requires
some type of repair. See appropriate service and repair information. After
repairing fault(s) and clearing fault code(s), the Malfunction Indicator Light (MIL)
or check engine light should go out. Some models may use a dual-function
indicator light, which is also used to indicate emission component service is
due. After performing required service, reset indicator light.
NOTE: Brake pad warning light should go out after replacement of brake pad thickness
sensor. If warning light does not go out, turn ignition on, engine off, for 30-45
seconds. Warning light should go out. If the above procedure is not successful,
connect vehicle to DIS tester, access Instrument Cluster/IKE, then "clear fault
memory".
NOTE: The base instrument cluster OIL SERVICE INSPECTION display is located on
the bottom of the cluster, to the right of center. The base cluster is also
equipped with a graphic display of the car that shows if a door or the trunk lid is
open. The high instrument cluster OIL SERVICE INSPECTION display is located
on the bottom of the cluster, to the left of center.
NOTE: To determine the appropriate reset procedure, refer to BRAKE PAD WARNING
LIGHT RESET INDEX. Only vehicles listed in this index have a specific brake
pad warning light reset procedure. For other vehicles, perform PROCEDURE 1
first. If light does not reset, perform PROCEDURE 2. If the above procedures are
not successful, connect vehicle to DIS tester, access Instrument Cluster/IKE,
then "clear fault memory".
BRAKE PAD WARNING LIGHT RESET INDEX

Model & Year Reset Procedure
5-Series
1997-00 Brake Pad Warning Light Reset - Procedure 1
(w/High Instrument Cluster)
(w/Base Instrument Cluster)
7-Series
BRAKE PAD WARNING LIGHT RESET - PROCEDURE 1

2010 BMW M3
To reset light after replacing brake pads, turn ignition on with engine off. Wait 30 seconds. Brake pad warning
indicator light will switch off.
BRAKE PAD WARNING LIGHT RESET - PROCEDURE 2
Start engine. Brake pad warning indicator will switch off.
OXYGEN SENSOR WARNING LIGHT
NOTE: To determine the appropriate reset procedure, refer to OXYGEN SENSOR

WARNING LIGHT RESET INDEX. Only vehicles listed in this index have an
oxygen sensor warning light.
OXYGEN SENSOR WARNING LIGHT RESET INDEX

All Models
1983 & Earlier Oxygen Sensor Warning Light Reset - Procedure 1
1984 & Later Oxygen Sensor Warning Light Reset - Procedure 2
OXYGEN SENSOR WARNING LIGHT RESET - PROCEDURE 1
1. Every 30,000 miles (25,000 miles on 528i) the OXYGEN light in dash will come on as a reminder to
replace the oxygen sensor.
NOTE: On 528e models, pull the protective metal plate off before removing
oxygen sensor.
2. On 528e models, no interval reset switch is provided. After replacing sensor, remove instrument panel.
Remove and discard bulb for OXYGEN sensor light.
3. On all other models, trace speedometer cable to interval switch (in-line with cable, mounted on frame rail
left of transmission). Press White reset button. See Fig. 1. Ensure warning light is out.
2010 BMW M3
Fig. 1: Locating Oxygen Sensor Warning Light Reset Switch (All BMW Models Before 1983)
OXYGEN SENSOR WARNING LIGHT RESET - PROCEDURE 2
NOTE: Some late production (February 1985 and later) BMW models have a reset
button on rear of the light control assembly located near pedal assembly. Press
button to reset light after servicing oxygen sensor.
No reset switch is provided. When oxygen sensor light comes on, service oxygen sensor. Remove and discard
bulb from indicator.
SERVICE INTERVAL REMINDER LIGHTS
NOTE: This is sometimes referred to as the "Oil Change Light" or "Oil Service Light".
NOTE: The service indicator can only be reset using the reset mode in the instrument
cluster or by using BMW hardware. This procedure applies to 3-Series from
production date 9/99, and 5-Series and 7-Series from production date 9/00
(except 2002-05 7-Series and 2004-05 5-Series) without an engine compartment
diagnostic connector.
On models that still use the round diagnostic connector in engine

2010 BMW M3
compartment, use SIA reset tool to reset service lights. See SERVICE
INTERVAL LIGHT RESET - PROCEDURE 1.
On models without the round diagnostic connector in the engine
compartment, the use of the SIA reset tool is not possible. See SERVICE
INTERVAL LIGHT RESET - PROCEDURE 2.
For 2002-up models with condition based service (CBS) interval system
reset procedure, see SERVICE INTERVAL LIGHT RESET - PROCEDURE 3.
NOTE: To determine the appropriate reset procedure, refer to SERVICE INTERVAL

REMINDER LIGHT RESET INDEX. Only vehicles listed in this index have a
service interval reminder.
SERVICE INTERVAL REMINDER LIGHT RESET INDEX

Models With Engine Compartment Diagnostic Connector
1983-05 Service Interval Light Reset - Procedure 1
Models Without Engine Compartment Diagnostic Connector
Models Without Condition Based Service (CBS) Interval System
Models With Condition Based Service (CBS) Interval System
DESCRIPTION & OPERATION
Starting in 1983 and ending on some models in 1999, service indicator on instrument panel consists of 5 Green,
3 Red and one Yellow Light Emitting Diodes (LED) and the inscriptions OIL SERVICE and INSPECTION.
When ignition is on, as many as 5 Green LEDs will light up. The Green LEDs go out when the engine is started.
If the Yellow LED glows and one of the inscriptions comes on and remains on when the engine is started,
maintenance service is due immediately. When maintenance interval has been exceeded (after approximately
1000 miles) the Red LED's will come on in addition to the Yellow LED as a reminder for servicing.
Beginning on some models in 1999, a new method for displaying the service interval is used. Colored LEDs are
no longer used to display the amount of time until the next service or inspection is due. The actual mileage
remaining until the next service will be displayed for five seconds when the ignition is first switched on. The
text OIL SERVICE or INSPECTION will also illuminate to show which service is due. A minus symbol (-)
before the mileage display indicates that a service is past due.
The 2002-12 models with condition based service (CBS) interval system uses an entirely different service
interval system. See SERVICE INTERVAL LIGHT RESET - PROCEDURE 3.
SERVICE INTERVAL LIGHT RESET - PROCEDURE 1

2010 BMW M3
1. To reset instrument cluster SIA OIL SERVICE indicator, turn ignition switch to ON position. Connect
Service Indicator Resetter (62 1 110) to diagnosis connector in engine compartment. See Fig. 2.
2. Press Yellow OIL SERVICE button. Green LED will illuminate. Wait until Yellow LED illuminates and
then goes out again. Ensure that OIL SERVICE indicator has been reset.
3. To reset SERVICE INTERVAL indicator, press Red INSPECTION service button for inspection. Green
LED illuminates. Wait until Red LED illuminates and then goes out again. Turn ignition switch to OFF
position, wait 20 seconds and repeat procedure in order to adapt interval of annual inspection to
inspection. Ensure that SERVICE INTERVAL indicator has been reset.
2010 BMW M3
Fig. 2: Identifying BMW Service Interval Reset Tool

2010 BMW M3
Reset service light by performing the following:
1. Ignition key must be in OFF position.

2. Press and hold trip odometer reset button in the instrument cluster (left button), and turn ignition key to
first position.
3. Keep the button pressed for approximately 5 seconds until one of the following words appear in the
display: "OIL SERVICE", or "INSPECTION", with "RESET".
4. Release reset button and press it again until "RESET" begins to flash in the display. See Fig. 3 and Fig.
4.
5. Service due is shown with "RESET" if coded minimum consumption limit has been reached and resetting
is possible. If "RESET" is not shown, minimum limit has not been reached and resetting is not possible.
6. While "RESET" is flashing, press left button briefly to reset service interval. After display has shown new
interval, following will appear: "END SIA".
7. System can only be reset again after 2.5 gallons of fuel have been consumed.
2010 BMW M3
Fig. 3: Resetting Service Interval Light (E46)

2010 BMW M3
Fig. 4: Resetting Service Interval Light (E39)

The BMW maintenance system SIA IV (service interval indicator) is used on X3 models (E83). The service
interval indicator is a system subject to constant development which in its development stages has been
integrated in various model series such as E85 (Z4) and E46 (3 and M3-Series).
The service indicator appears in the LC display in the instrument cluster's speedometer. The indicator is shown
for 5 seconds in the LC display after terminal R is "ON". See Fig. 5.
2010 BMW M3
Fig. 5: Identifying Service Interval Indicator

Resetting Service Interval Indicator
Resetting the service interval indicator for the oil service and inspection procedures can only be done by
pressing the left button in the instrument cluster. See Fig. 6.
2010 BMW M3
Fig. 6: Identifying Service Interval Indicator Reset Button

Models using a Condition Based Service (CBS) service interval system, which displays a Service Need Display
(SND). When ignition is on, Service Need Display appears under the speedometer in the instrument cluster for
10 seconds in the place where the fuel tank level is normally displayed. The first line corresponds to the mileage
dependent service items. It specifies the mileage when the next service is due.
If the mileage is exceeded (service overdue), it appears with a minus sign. The second line corresponds to the
time dependent service items and is displayed by a clock symbol. It specifies the weeks/months/years when the
next service is due. If the service is overdue, it appears with a minus sign. The actual service item (with
additional information) can be viewed in the control display.
NOTE: On some models an appropriate scan tool may be used to reset CBS service
schedules. By using suitable diagnostic equipment connected to the vehicle
diagnostic connector it is possible to reset CBS service schedules at any time.
By selecting the `CBS' option, the diagnostic equipment will gather information
regarding the current state of CBS items from their relevant modules on the
CAN network.
Service reset is accomplished using instrument cluster:
1. Insert key into ignition.

2. Press ignition start/stop button without depressing the clutch or brake, and wait for the service reminder
to dissapear.
3. Immediately after the service reminder indicator goes out, press and hold the odometer reset button or
stalk. After 3 secs a warning triangle will appear, keep the odometer button pressed and after another 2-3
secs an oil can will appear.
NOTE: If the odometer button is pressed too long (10 secs in total), German
writing will appear (giving the software level/ can bus etc. of the vehicle).
This indicates that you've overshot the reset procedure and you need to
re-start from the beginning.
4. The service menu should now be displayed. Use the button (twist if the switch is a stalk - or if a button,
tap repeatedly) to scroll up/down through the various service items.
NOTE: On newer models, it may be the rocker/toggle switch on the turn indicator
lever that is used to scroll up/down through the various service items. See
Fig. 9.
5. When the item to be reset is showing, press the BC button on end of turn indicator lever. "Reset" should
now appear in the display. Press in and hold the BC button for 2-3 secs and a whirling clock icon will be
2010 BMW M3
displayed. The reset procedure for the selected service item is done.
6. Scroll up/down to select another item (as in step 4), or press the ignition start/stop button to exit.
NOTE: Residual wear or remaining time are specified (possibly with a minus sign). The
"1" symbol means that you can reset service operation (early production
vehicles may show an "F"), while a "0" indicates it is not resettable (the first 20
percent of the service interval is also protected against accidental reset). For
additional information about Condition Based Service (CBS), see RESETTING
AND CORRECTING CONDITION BASED SERVICE under PROGRAMMING in
SELF-DIAGNOSIS - 7-SERIES article.
Fig. 7: Identifying Condition Based Service (CBS) Instrument Panel Controls (Typical)
2010 BMW M3
CBS Reset Using BMW Diagnosis System
IMPORTANT: Although the CBS maintenance jobs can be reset using in-car controls, it is
recommended that the reset procedure be done via the diagnosis system. It is
only possible to code the statutory intervals specific to individual countries
with the diagnosis system.
IMPORTANT: To be able to check and/or correct the car's on-board date properly, the
diagnosis system requires the correctly set tester system date.
The jobs may only be reset after the service measure has been completed.
The brake pads can only be reset with a new brake pad wear sensor.
The CBS jobs can be reset via the diagnosis system on the following path:
Start diagnosis
Carry out vehicle identification
Function selection
2010 BMW M3
Service functions
Maintenance
CBS reset
CBS Reset Using In-Car Controls
On-the-vehicle service operations can be reset at the instrument panel.
NOTE: A reset is only possible in the car if:
There is no Check Control message

Availability of the service job is under 90%
On-board date must be correctly set
NOTE: Resetting of a service job must always be carried out after a maintenance
measure has been completed.
IMPORTANT: If engine oil and vehicle check are reset at the same time, always reset engine
oil first.
1. Switch the ignition on.

2. Press the odometer reset button (1) for approx. 10 seconds, until the 1st service job appears in the display
(2). See Fig. 10.
3. Bring up the next item by briefly pressing the button again.
4. Select the desired service job.
5. If a reset is possible, this is displayed in the instrument panel as "Reset executable".
6. Start the reset by pressing the button for 3 seconds.
7. Confirm text message "Execute reset?" by pressing the button for 3 seconds again.
8. The status of the reset is indicated in the display by a progress bar and in text as "Reset running".
9. The reset is confirmed after completion as "Reset successful".
2010 BMW M3
Fig. 10: Identifying Condition Based Service (CBS) Instrument Panel Controls & Display (Typical)
TIRE PRESSURE MONITOR SYSTEM (TPMS)
NOTE: If a tire pressure has been adjusted, or a wheel or tire has been changed or
replaced, or repairs have been made to air spring suspension, the TPM system
must be reinitialized. System must be reinitialized both before and after pulling
a trailer.
CAUTION: When driving with snow chains or a space-saver spare tire, DO NOT
initialize the system.
NOTE: To determine the appropriate reset procedure, refer to TPMS RESET INDEX.
Only vehicles listed in this index have a TPMS reset.
TPMS RESET INDEX

1-Series (128i & 135i)
2008 TPMS Reset - Procedure 6
2009-13 TPMS Reset - Procedure 7
3-Series
2010 BMW M3

5-Series
6-Series
7-Series
ActiveHybrid Series
Alpina
M3
M5
M6
M-Coupe & M-Roadster
X3
X5 & X5 M
X6 & X6 M
2010 BMW M3

Z4
Z8
TPMS RESET - PROCEDURE 1
1. Set the tire pressure on all wheels to specification.

2. Turn ignition switch to ON position, with engine off.
3. Press reset button (for no longer than 10 seconds) until tire pressure warning light illuminates Yellow for
a few seconds. See Fig. 11, Fig. 12, Fig. 13 or Fig. 14 .
NOTE: On some X5 models, the reset button is marked "RDC".
4. Drive vehicle. Initialization is automatically completed during the drive, without any feedback issued.
Fig. 11: Locating TPM System Reset Button (5-Series)

2010 BMW M3
Fig. 12: Locating TPM System Reset Button (3-Series & X5 - Typical)
Fig. 13: Locating TPM System Reset Button (Z4)

2010 BMW M3

NOTE: The initialization finishes during driving, which can be interrupted at any time.
When driving resumes, the initialization is continued automatically.
1. Set the tire pressure of all wheels to specification.

2. Start engine, but do not start driving.
3. On Control Center, select "RPA" from the "SETTINGS" menu and confirm selection. The initialization
menu will appear. See Fig. 15.
4. Select "SET" and confirm selection.
5. Drive vehicle. The message "FTM IS BEING INITIALIZED" will be displayed. See Fig. 16.
NOTE: It takes at least 10 minutes before the TPM system can detect and report a
flat tire.
6. Select counterclockwise left arrow button and confirm to exit from menu.
2010 BMW M3
Fig. 15: Identifying TPM System Reinitialization Messages (1 Of 2)

Fig. 16: Identifying TPM System Reinitialization Messages (2 Of 2)


2. Start the engine.
3. Press iDrive knob down once to enter Vehicle Info.
4. Select Settings.
5. Select Vehicle Tires.
6. Select TPM.
7. Select Reset.
8. Scroll to Yes.
9. Select "YES" and press the controller.
10. After selecting Yes, drive vehicle until tires on iDrive screen turn green.
2010 BMW M3

2. Press "MENU" button to open start menu.
3. Open the i-menu of the Control Center.
4. Select "SETTINGS" and press the controller.
5. Select "VEHICLE" and press the controller. See Fig. 17.
6. Select "TIRES: TPM" and press controller.
8. Select "RESET" and press the controller.
9. Select "YES" and press the controller.
10. Drive vehicle. The message "RESETTING TPM...." will be displayed. Initialization is automatically
completed during the drive. When initialization is complete, "STATUS: TPM ACTIVE" message will be
displayed.
Fig. 17: Identifying TPM System Reinitialization Messages

CAUTION: When driving with snow chains or a space-saver spare tire, DO NOT
initialize the system.
2010 BMW M3

3. Press reset button (for no longer than 10 seconds) until tire pressure warning light illuminates Yellow for
a few seconds. See Fig. 18, Fig. 19, Fig. 20 or Fig. 21 .
Fig. 18: Locating TPM System Reset Button (M-Coupe & Roadster)
Fig. 19: Locating TPM System Reset Button (X3)

2010 BMW M3
Fig. 20: Locating TPM System Reset Button (X5)


Resetting TPM With iDrive

2010 BMW M3

2. Turn ignition switch ON.
3. Press controller to call up I menu. See Fig. 22.
4. Select SETTINGS and press controller.
5. Select CAR/TIRES and press controller.
6. If necessary, switch to top field and select TIRES/RDC and press controller.
7. Start engine.
8. Select CONFIRM TIRE PRESSURE and press controller.
Fig. 22: Locating TPM System Reset Button (With iDrive)

Resetting TPM Without iDrive

2. Start engine.
3. Move turn signal lever up or down until TPM warning symbol and RESET appears. See Fig. 23.
4. Press BC button on end of turn signal lever to confirm selection.
5. Press and hold BC button for approximately 5 seconds until a CHECK/TICK appears after RESET.
2010 BMW M3
Fig. 23: Locating TPM System Reset Button (Without iDrive)

With iDrive
Indirect System (Flat Tire Monitor)
CAUTION: Do not initialize the system while snow chains are attached.
NOTE: Each time a tire inflation pressure has been corrected or a wheel or tire has
been changed, reset the system.
Initialization:
1. Using the iDrive MENU button, choose:

2. "Vehicle Info"
3. "Vehicle status"
4. "Reset"
6. Start the initialization using "Reset". See Fig. 24.
7. Start to drive.
The initialization is completed during driving, which can be interrupted at any time. When driving resumes, the
initialization is continued automatically.
2010 BMW M3
Fig. 24: iDrive Showing "Reset" Display

Checking FTM Status:

2. "Vehicle Info"
3. "Vehicle status"
4. "Flat Tire Monitor"
5. The status will be diplayed. See Fig. 25.
Fig. 25: iDrive Showing Tire Monitor Status

Direct System (Tire Pressure Monitor)
TPMS Status indicator on the Control Display:
The color of the tires represents the status of the tires and the system. TPM takes into account that tire pressures
change while the vehicle is being driven. The tire pressures do not need to be corrected unless the TPM instructs
you to do so by means of color indicators.
Green: The tire inflation pressure corresponds to the established target value. "TPM active" appears on
the Control Display.
2010 BMW M3
One Wheel Yellow: There is a flat tire or substantial loss of tire pressure in the indicated tire. A message
appears on the Control Display.
All Wheels Yellow: There is a flat tire or substantial loss of tire pressure in several tires. A message
appears on the Control Display.
Gray: The system cannot detect a puncture. Possible reasons for this:
TPM is being reset.
Temporary malfunction caused by systems or devices using the same radio frequency.
Malfunction.
Reset Procedure:

2. "Vehicle Info"
3. "Vehicle status"
4. "Reset"
5. Start the engine. Do not begin driving.
6. Start the reset using "Reset". See Fig. 24.
7. Start to drive.
8. The tires are shown in gray and "Resetting TPM..." is displayed.
After driving a few minutes, the set inflation pressures in the tires are accepted as the target values to be
monitored. The system reset is completed during your drive, and can be interrupted at any time. When driving
resumes, the reset is continued automatically. On the Control Display, the tires are shown in green and "TPM
active" is displayed again.
IMPORTANT: If a flat tire is detected while the system is resetting and determining the
inflation pressures, all tires on the Control Display are displayed in yellow. The
message "Low tire!" is shown.
System Reset Failure:
Message For Unsuccessful System Reset: The warning lamp lights up yellow. A message will appear on
the Control Display. Check the tire inflation pressure and reset the system.
Malfunction: The small warning lamp flashes in yellow and then lights up continuously; the larger
warning lamp comes on in yellow. On the Control Display, the tires are shown in gray and a message
appears. No punctures can be detected. This type of message is shown in the following situations:
If there is a malfunction. Have the system checked.
If a wheel without TPM electronics has been mounted.
If TPM is temporarily malfunctioning due to other systems or devices using the same radio
frequency.
Without iDrive
2010 BMW M3
Indirect System (Flat Tire Monitor)
Reset:

2. Lightly push button 1 on the turn indicator. See Fig. 26.
3. Lever the turn indicator up or down repeatedly until the tire monitor symbol appears in the display,
accompanied by the word "RESET". See Fig. 26.
4. Press button 2 to confirm your choice of the Flat Tire Monitor.
5. Press button 2 for approx. 5 seconds until the a check mark is shown next to the "RESET" display.
6. Drive the vehicle.
The initialization is completed during driving, which can be interrupted at any time. When driving resumes, the
initialization is continued automatically.
Fig. 26: Flat Tire Monitor Status Display

2010 BMW M3
Direct System (Tire Pressure Monitor)
IMPORTANT: The system does not work correctly if it has not been reset; for example, a flat
tire may be indicated even though the tire inflation pressures are correct. The
system is inactive and cannot indicate a flat tire if a wheel without TPM
electronics, such as a compact spare wheel, has been mounted, or if TPM is
temporarily malfunctioning due to other systems or devices using the same
radio frequency.
Reset:

2. Lightly push button 1 on the turn indicator. See Fig. 27.
3. Lever the turn indicator up or down repeatedly until the tire monitor symbol appears in the display,
accompanied by the word "RESET". See Fig. 27.
4. Press button 2 to confirm your choice of the Tire Pressure Monitor. In the display, "ACTIVE" will appear
above "RESET". See Fig. 27.
5. Press button 2 for approx. 5 seconds. In the display, "RESETTING" will now appear above "RESET".
See Fig. 27.
6. Drive the vehicle.
After driving a few minutes, the set inflation pressures in the tires are accepted as the target values to be
monitored. The system reset is completed during your drive, and can be interrupted at any time. When driving
resumes, the reset is continued automatically. The indicator lamp goes out after the system reset is completed.
2010 BMW M3
Fig. 27: Tire Pressure Monitor Status Display

System Reset Failure:
Message For Unsuccessful System Reset: The warning lamp lights up yellow. The system was not reset.
Check the tire inflation pressure and reset the system.
Malfunction: The small warning lamp flashes in yellow and then lights up continuously; the larger
warning lamp comes on in yellow. On the Control Display, the tires are shown in gray and a message
appears. No punctures can be detected. This type of message is shown in the following situations:
If there is a malfunction. Have the system checked.
If a wheel without TPM electronics has been mounted.
If TPM is temporarily malfunctioning due to other systems or devices using the same radio
2010 BMW M3
frequency.
2010 BMW M3
ACCESSORIES AND BODY, CAB Paintwork - Repair
Paintwork - Repair
PAINTWORK
99 00... GENERAL INSTRUCTIONS ON PAINTWORK
General instructions and classification of paint stages are described on the KSD-CD (notes-general information
on flat rate unit data, passenger car explanation for FR specifications for painting).
For further information, please refer to BMW Painting Handbook.
The marked area serves as the starting point for painting. This area may differ from the illustration for technical
painting reasons.
Touching-up areas are taken into account.
41 00... INFORMATION/WARNING LABELS
Missing or damaged information/warning labels (e.g. tire inflation pressure) must be replaced.
Overview of INSTALLATION LOCATIONS

EQUIPMENT)
reactions!

of ignition.
sunlight.
month).

2010 BMW M3
ACCESSORIES AND BODY, CAB Paintwork - Repair


directly.
First Aid:
doctor.
Recycling

2010 BMW M3
BRAKES Pedals - Repair
BRAKES
Pedals - Repair
GENERAL
EQUIPMENT)
reactions!

of ignition.
sunlight.
month).


directly.
2010 BMW M3
First Aid:
doctor.
Recycling
PEDAL MOUNTING BLOCK

35 11 000 REMOVING AND INSTALLING COMPLETE BEARING BLOCK FOR FOOT PEDAL
Remove CLUTCH PEDAL
Release screws (1) and gently press clutch master cylinder (2) to one side.
Installation:
Line remains connected.

2010 BMW M3
Fig. 1: Identifying Clutch Master Cylinder With Screws

Remove locking clip (2) and pull out pin.
Unscrew nut (3).
Release nuts (4) and gently swivel bearing block to left and remove.
Installation:
Tighten nuts (4) before nut (3).

2010 BMW M3
35 21 041 REPLACING SPRING FOR BRAKE PEDAL
Fig. 3: Identifying Brake Pedal Return Spring

35 31 041 REPLACING SPRING FOR CLUTCH PEDAL
Fig. 4: Identifying Clutch Pedal Return Spring

2010 BMW M3
BRAKE PEDAL WITH LINKAGE

Fig. 5: Identifying Brake Pedal Return Spring


2010 BMW M3

CLUTCH PEDAL WITH LINKAGE

35 31 000 REMOVING AND INSTALLING OR REPLACING CLUTCH PEDAL
Remove pedal TRIM .

If necessary, remove OVER-CENTER HELPER SPRING
Press end of pin (2) together with offset pliers and press out pin.
Detach locking clip (3) and pull clutch pedal off bearing block.
Installation:
Replace locking clip (3).
Locking clip (3) must be seated with both legs in the pin groove.
2010 BMW M3
Fig. 7: Identifying Return Spring, Pin And Locking Clips

Installation:
Check bearing bushings (1) and replace if necessary.
Lightly grease bearing bushings (1).
Fig. 8: Identifying Bearing Bushings

35 31 050 REMOVING AND INSTALLING/REPLACING OVER-CENTER HELPER SPRING
Remove PEDAL TRIM .
2010 BMW M3
Fig. 9: Identifying Pin

Push in pin (1) fully in direction of arrow.
Fig. 10: Pushing Pin

Detach retainers (1).
Installation:
Check retainers, replace if necessary.
Retainers must lie with both legs in the groove and snap audibly into place.
Slide out pin (2).
Installation:
Lightly grease pin.
Remove over-center helper spring (3).

2010 BMW M3
Fig. 11: Identifying Over-Centre Helper Spring, Retainers And Pin

(A) Over-center helper spring

(B) Reinforced over-center helper spring
Assembly of over-center helper spring:
Secure black holder (1) to clutch pedal

Smaller coil spacing of spring (2) points to black holder (1)
Secure grey holder (3) to bearing block
Fig. 12: Identifying Black, Grey Holder And Over-Center Helper Springs
Lightly grease holder and spring contact surfaces.
Installation:
Secure over-center helper spring first with black holder to clutch pedal.
2010 BMW M3
Gently press over-center helper spring together and secure with grey holder to bearing block.
Connect clutch pedal to clutch master cylinder.
When replacing reinforced over-center helper spring:
Remove locking clamp (1).
Fig. 13: Identifying Locking Clamp

35 31 011 REPLACING BEARING BUSHES FOR CLUTCH PEDAL
REMOVING AND INSTALLING CLUTCH PEDAL

2010 BMW M3

ACCELERATOR PEDAL ACTUATION

35 40 001 REMOVING AND INSTALLING OR REPLACING ACCELERATOR PEDAL MODULE
Take off cap.
Release screw.
Pull accelerator pedal module upwards out of fixture.
Installation:
Fig. 15: Pulling Accelerator Pedal Module

2010 BMW M3
Remove accelerator pedal module.
Fig. 16: Identifying Accelerator Pedal Module Plug

IMPORTANT: Accelerator pedal module can only be replaced completely with adapter plate.
2010 BMW M3
BRAKES Pedals - Repair - M3
BRAKES
Pedals - Repair - M3
PEDAL MOUNTING BLOCK

35 11 000 REMOVING AND INSTALLING COMPLETE BEARING BLOCK FOR FOOT PEDAL
Remove clutch pedal .
Release screws (1) and gently press clutch master cylinder (2) to one side.
Installation:
Line remains connected.
Tightening torque see.21 52 CLUTCH OPERATION (HYDRAULIC) .
Fig. 1: Identifying Screws And Clutch Master Cylinder

Remove locking clip (2) and pull out pin.
Unscrew nut (3).
Release nuts (4) and gently swivel bearing block to left and remove.
2010 BMW M3
Installation:
Tighten nuts (4) before nut (3).
Tightening torque, see 35 11 PEDAL ASSEMBLY CONSOLE .
Fig. 2: Identifying Plug Connection, Locking Clip And Nuts


2010 BMW M3

BRAKE PEDAL WITH LINKAGE

See 35 21 041 Replacing spring for brake pedal.
See 35 31 041 Replacing spring for clutch pedal.
CLUTCH PEDAL WITH LINK

35 31 000 REMOVING AND INSTALLING OR REPLACING CLUTCH PEDAL
Remove pedal trim . See 51 45 185 REMOVING AND INSTALLING/REPLACING PANEL FOR
PEDALS .
If necessary, remove over-centre helper spring
2010 BMW M3
Detach locking clip (3) and pull clutch pedal off bearing block.
Installation:
Replace locking clip (3).
Locking clip (3) must be seated with both legs in the pin groove.
Fig. 5: Identifying Return Spring, Pin And Locking Clip

Installation:
Check bearing bushings (1) and replace if necessary.
Lightly grease bearing bushings (1).

2010 BMW M3
Fig. 6: Identifying Bearing Bushings

35 31 011 REPLACING BEARING BUSHES FOR CLUTCH PEDAL
Removing and installing clutch pedal

2010 BMW M3
35 31 050 REMOVING AND INSTALLING/REPLACING OVERCENTRE HELPER SPRING
Remove pedal trim . See 51 45 185 REMOVING AND INSTALLING/REPLACING PANEL FOR
PEDALS .

Push in pin (1) fully in direction of arrow.

Detach retainers (1).
Installation:
Check retainers, replace if necessary.

2010 BMW M3
Retainers must lie with both legs in the groove and snap audibly into place.
Slide out pin (2).
Installation:
Lightly grease pin.
Fig. 10: Identifying Retainers And Pin

Remove over-centre helper spring (3).
Over-centre helper spring

Reinforced over-centre helper spring
Assembly of over-centre helper spring:
Secure black holder (1) to clutch pedal

Smaller coil spacing of spring (2) points to black holder (1)
Secure grey holder (3) to bearing block
Lightly grease holder and spring contact surfaces.

2010 BMW M3
Fig. 11: Identifying Holder, Spring And Grey Holder

Installation:
Secure over-centre helper spring first with black holder to clutch pedal.
Gently press over-centre helper spring together and secure with grey holder to bearing block.
Connect clutch pedal to clutch master cylinder.
When replacing reinforced over-centre helper spring:
Remove locking clamp (1).
Fig. 12: Identifying Locking Clamp

ACCELERATOR PEDAL ACTUATOR

35 40 001 REMOVING AND INSTALLING OR REPLACING ACCELERATOR PEDAL MODULE
Take off cap.

2010 BMW M3
Release screw.
Pull accelerator pedal module upwards out of fixture.
Installation:
Tightening torque, see 35 40 PEDALS .
Fig. 13: Identifying Accelerator Pedal Module

Pull off plug (1).
Remove accelerator pedal module.

IMPORTANT: Accelerator pedal module can only be replaced completely with adapter plate.
2010 BMW M3
DRIVELINE/AXLES Propeller Shaft - Repair
DRIVELINE/AXLES
Propeller Shaft - Repair
PROPELLER SHAFT, GENERAL

26 00... PROPELLER SHAFT DEFLECTION ANGLES
IMPORTANT: Specifications on propeller shaft deflection angles

Only possible on request with the vehicle identification number of the problem
vehicle via PuMA.
PROPELLER SHAFT ASSEMBLY

26 11... OVERVIEW OF PROPELLER SHAFT (CONSTANT-VELOCITY JOINT)
2010 BMW M3
Fig. 1: Overview Of Propeller Shaft (Constant-Velocity Joint)

1. Complete propeller shaft

2. Flexible disk
3. Centering mount
4. Centre mount
5. Constant-velocity joint
26 11 000 REMOVING AND INSTALLING COMPLETE PROPELLER SHAFT (CONSTANT-

VELOCITY JOINT)
IMPORTANT: Rear axle differential M3 (S65) is balanced.

Therefore the following points must be observed with the M3.
Non-compliance can lead to humming noises!
NOTE: For all other vehicle types continue with the required preliminary work.
M3 vehicles with marked rear axle final drive on outside of drive flange (color dot) (1):
white dot (1): no measures required

blue dot (1): Measures absolutely required
yellow dot (1): Measures absolutely required
Fig. 2: Identifying Marking On Inner And Outer Side Of Drive Flange

IMPORTANT: If a measure is required, the rear axle final drive must be identified before the
2010 BMW M3
screw connection based on the following instructions.

There are two systems for the screw connection on drive flange of the rear axle
final drive.
System A:
Color coding (2) in interior cone of the drive flange.
System B:
NO color coding (2) in interior cone of drive flange.
The color dots on the exterior of the drive flange are assigned to the respective bolting point and mean that the
corresponding measure must be installed here.
System A:
Yellow mark (1) - install green shiny bolt (2)

Blue mark (1) - install black bolt (2)
Fig. 3: Identifying Bolts And Marking On Propeller Shaft

System B:
Blue mark (1) - black washer (2) between screw head and shim
Yellow mark (1) - silver washer (2) between screw head and shim
Washer
2010 BMW M3
Catalogue MG 26
Fig. 4: Identifying Washer With Marking

IMPORTANT: With four-wheel drive and on renewal only:
according to installation with BMW diagnosis and information system under control unit function
Perform functional check of transfer box (calibration)

Remove complete EXHAUST SYSTEM
Remove heat shields
Release screws.
Installation note:
ZNS bolts and nuts must be replaced.
TIGHTENING TORQUE, 26 11 1AZ .

2010 BMW M3
Fig. 5: Locating ZNS Bolts

Release screws.
Replace screws and shims.
Fig. 6: Locating Propeller Shaft Screws

With a screwdriver, press constant-velocity joint (at the disassembly grooves) off input flange.
2010 BMW M3
Fig. 7: Pressing Constant Velocity Joint Of Drive Flange Using Screwdriver

IMPORTANT: Do not let propeller shaft fall into joints.

Joints and rubber sleeve on constant-velocity joint can be damaged.
Fig. 8: Locating Joints And Rubber Sleeve On Constant-Velocity Joint

Hold down propeller shaft on center mount (1) and release screws.

2010 BMW M3
Fig. 9: Locating Centre Mount Screws

Bend propeller shaft downwards on center bearing.
Remove propeller shaft from transmission output flange and remove constant-velocity joint from rear axle
differential.
Fig. 10: Bending Propeller Shaft On Centre Bearing

Installation note
Pull out constant velocity joint (1), up to limit position.
Install shim.
Attach propeller shaft with constant-velocity joint pulled apart to drive flange of rear axle differential.
Alternately tighten 2 opposing screws to draw constant-velocity joint evenly into the input flange.
Replace ZNS bolts and shims.

2010 BMW M3
Fig. 11: Pulling Constant-Velocity Joint

Installation note
Check centering mount (4).
REPLACE DAMAGED CENTERING MOUNT .
Grease centering mount.
See PROPELLER SHAFT - OPERATING FLUIDS
Fig. 12: Identifying Centering Mount

26 11 090 REMOVING AND INSTALLING/REPLACING FRONT CENTERING MOUNT FOR

2010 BMW M3
PROPELLER SHAFT
REMOVE PROPELLER SHAFT.
Completely fill centering hole (1) with viscous grease.
Drive special tool 11 1 310 MANDREL with a plastic hammer into centering hole.
The centering mount (1) is forced out of the propeller shaft by the pressure on the grease filling.
If necessary, top up grease repeatedly.
NOTE: To drive out the mount, you can also fill the centering bore with water instead of
grease.
Fig. 13: Pushing Special Tool (11 1 310) Into Centering Hole
Installation:
Remove grease/water from mount bore.
Drive in centering mount (1) with special tools 11 2 030 MANDREL and 00 5 500 MANDREL into propeller
shaft (observe protrusion).

2010 BMW M3
Fig. 14: Installing Centering Mount Using Special Tools (11 2 030 And 00 5 500)
See PROPELLER SHAFT - OPERATING FLUIDS .
Installation
Observe protrusion A = 4+2 mm of centering (1).
Fig. 15: Identifying Protrusion Of Centering

26 11 020 REPLACING CENTER MOUNT GAITER
Remove propeller shaft.
NOTE: The propeller shaft is balanced. The front and rear propeller shafts must be
reassembled in the same position.
Detach gaiter (1) from groove (2).
2010 BMW M3
Mark front propeller shaft (3) and rear propeller shaft (4) in one plane.
Fig. 16: Identifying Front And Rear Propeller Shaft With Groove And Gaiter
Pull propeller shaft apart.
Fig. 17: Pulling Propeller Shaft

Installation:
If necessary, insert new clamping ring (1) into front propeller shaft (2).
2010 BMW M3
Fig. 18: Identifying Front Propeller Shaft With Clamping Ring

Release gaiter (1) with screwdriver from groove (2) and pull off over longitudinal splines.
Installation:
Apply an even coating of grease to longitudinal splines on shaft.
Observe markings and force front propeller shaft onto longitudinal splines (markings must be flush).
Fig. 19: Identifying Gaiter And Groove

Push gaiter (1) during installation into groove (2) and make sure it is firmly seated.
26 11 160 REPLACING CONSTANT-VELOCITY JOINT FOR PROPELLER SHAFT

2010 BMW M3
Lever sealing cap (1) with screwdriver (2) out of constant-velocity joint (3).
NOTE: Replace sealing cap (1) with seal.
Fig. 20: Removing Sealing Cap Using Screwdriver

NOTE: Installation sequence:
2. Seal
3. Sealing cap
Fig. 21: Identifying Constant-Velocity Joint, Seal And Sealing Cap

Lift off retainer
Installation:
2010 BMW M3
Replace circlip.
Fig. 22: Locating Circlip

Force cap off constant velocity joint.
Installation:
Insert sealing washer (1) into constant-velocity joint.
Fig. 23: Inserting Sealing Washer Into Constant-Velocity Joint

Detach constant-velocity joint (1) with special tool 26 1 110 WASHER and commercially available special tool
(2).
2010 BMW M3
Fig. 24: Disconnecting Constant-Velocity Joint Using Special Tool (26 1 110)
Release clamp (1) and detach cap with gaiter.
Push on new cap with gaiter.
NOTE: Do not tighten down clamp (1) yet.
Fig. 25: Removing Cap With Gaiter

Mount constant-velocity joint with special tool 23 1 160 MANDREL up to stop.
Align bores of constant velocity joint and cap to each other.
Tighten down clamp on gaiter.
NOTE: Keep toothing free of grease.

Inject new grease into constant velocity joint from rubber gaiter and flange
sides.
2010 BMW M3
Fig. 26: Mounting Constant-Velocity Joint Using Special Tool (23 1 160)
NOTE: Prepare special tools 31 2 102 and 31 2 104.
Fig. 27: Identifying Special Tools (31 2 102 And 31 2 104)

Press sealing cap with special tools 26 1 121, 26 1 122, 31 2 102 and 31 2 104 into constant-velocity joint (1).
NOTE: Align sealing cap and seal to bores of constant-velocity joint with screw.
2010 BMW M3
Fig. 28: Pressing Sealing Cap Into Constant-Velocity Joint Using Special Tools
Push cap (1) onto constant-velocity joint (2).
Fig. 29: Pushing Cap Onto Constant-Velocity Joint

26 11 051 REPLACING FLEXIBLE DISC FOR FRONT PROPELLER SHAFT
Remove PROPELLER SHAFT from transmission and center bearing
NOTE: To protect universal joints, tie back propeller shaft in area of center mount.
Release screws and remove flexible disc (1) from propeller shaft.
IMPORTANT: Replace shiny ZNS bolts and self-locking nuts.
Tightening torque and angle of rotation: 26 11 1AZ .

2010 BMW M3
Installation:
Arrows (3) on circumference of flexible disc must point to flange arms (2).
Grip mounting bolts of flexible disc at propeller shaft flange at nuts and tighten down at bolt heads.
Fig. 30: Locating ZNS Bolts

Installation:
Check centering mount.
Replace damaged CENTERING MOUNT .
Fig. 31: Locating Centering Mount

CENTRE CONSOLE ASSEMBLY

2010 BMW M3

Installation:
2010 BMW M3

Installation:

26 12 001 REPLACING COMPLETE PROPELLER SHAFT CENTER BEARING

2010 BMW M3
Remove PROPELLER SHAFT .
Installation:
Make sure gaiter (1) is securely seated in groove (2).

2010 BMW M3
Installation:

Installation:
Apply a coating of grease to longitudinal splines on shaft.

2010 BMW M3
Install special tool between center mount (1) and universal joint (2).
Fig. 40: Installing Special Tool (00 7 500) Between Centre Mount And Universal Joint
Using a hydraulic press, force center mount (1) off propeller shaft (2).
Fig. 41: Pressing Centre Mount Of Propeller Shaft Using Hydraulic Press
Force new center mount (1) onto propeller shaft. Collar (2) must point in direction of travel towards front
propeller shaft. Drive center mount firmly home with special tool 23 1 160 MANDREL .
2010 BMW M3
Fig. 42: Installing Centre Mount And Collar Onto Propeller Shaft Using Special Tool (23 1 160)
26 12 011 REPLACING GROOVED BALL BEARING IN CENTER MOUNT OF PROPELLER SHAFT
Replace PROPELLER SHAFT CENTRE MOUNT
Press grooved ball bearing using special tool 23 1 160 MANDREL out of center mount (1).
Fig. 43: Pressing Grooved Ball Bearing Using Special Tool (23 1 160)
Coat rubber-coated bearing seat of center mount (2) with Circolight.
Use special tools 33 3 202/33 3 203 to press deep groove ball bearing (1) into center mount (2).

2010 BMW M3
Fig. 44: Pressing Deep Groove Ball Bearing Into Centre Mount Using Special Tools
2010 BMW M3
DRIVELINE/AXLES Propeller Shaft - Repair Instructions - M3
DRIVELINE/AXLES
Propeller Shaft - Repair Instructions - M3
PROPELLER SHAFT
26 00 ... PROPELLER SHAFT DEFLECTION ANGLES
IMPORTANT: Specifications on propeller shaft deflection angles

Only possible on request with the vehicle identification number of the problem
vehicle via PuMA.
PROPELLER SHAFT ASSEMBLY

26 11 ... OVERVIEW OF PROPELLER SHAFT (CONSTANT-VELOCITY JOINT)
Fig. 1: Overview Of Propeller Shaft (Constant-Velocity Joint)

26 11 000 REMOVING AND INSTALLING COMPLETE PROPELLER SHAFT (CONSTANT-

VELOCITY JOINT)
IMPORTANT: Failure to comply with this instruction may give rise to humming noises!
Vehicles with marked rear differential drive flange (colored dot):
The colored dots are applied to the relevant screw threads.
The colored dots are assigned to the respective screw fastening point and
indicate that a corresponding plain washer must be fitted here between the
screw head and shim.
White dot: no plain washer required

Blue dot: black plain washer
Yellow dot: silver plain washer
2010 BMW M3

Remove complete exhaust system . See EXHAUST SYSTEM - REPAIR .
Remove heat shields
Release screws.
Installation:
ZNS bolts and nuts must be replaced.
Tightening torque, 26 11 1AZ , see 26 11 PROPELLER SHAFT COMPLETE .
Fig. 2: Locating Propeller Shaft Bolts

Release bolts and replace.

2010 BMW M3
Fig. 3: Locating Propeller Shaft Bolts

Using a screwdriver, press constant velocity joint off drive flange at disassembly grooves.
Fig. 4: Pressing Constant Velocity Joint Off Drive Flange

IMPORTANT: Do not let propeller shaft fall into joints.

Joints and rubber sleeve can be damaged on constant-velocity joint.
2010 BMW M3
Fig. 5: Identifying Rubber Sleeve Joints Damage Area

Grip propeller shaft at center bearing and release screws.
Fig. 6: Identifying Propeller Shaft Screws

Bend propeller shaft downwards at center bearing.
Remove propeller shaft from transmission output flange and detach constant-velocity joint from rear axle
differential.
2010 BMW M3
Fig. 7: Removing Propeller Shaft From Transmission Output Flange

Installation:
Withdraw constant-velocity joint (1) up to stop.
Fit shims.
Attach propeller shaft with pulled-apart constant-velocity joint to drive flange of rear differential.
Alternately tighten 2 opposing screws to draw constant-velocity joint evenly into the input flange.
Replace ZNS bolts.
Fig. 8: Identifying Constant-Velocity Joint Installation Position

2010 BMW M3
Installation:
Check centering mount (4).
Replace damaged centering mount.
Grease,
refer to PROPELLER SHAFT - OPERATING FLUIDS .
Fig. 9: Identifying Centering Mount

2010 BMW M3
Fig. 10: Aligning Front And Rear Propeller Shaft


Installation:
2010 BMW M3
Fig. 12: Inserting Clamping Ring Into Front Propeller Shaft

Installation:
Grease, refer to PROPELLER SHAFT - OPERATING FLUIDS .
Fig. 13: Pushing Gaiter During Installation Into Groove

26 11 051 REPLACING FLEXIBLE DISK FOR FRONT PROPELLER SHAFT

2010 BMW M3
Remove propeller shaft from transmission and center bearing
NOTE: To protect universal joints, tie back propeller shaft in area of center mount.
Release screws and remove flexible disc (1) from propeller shaft.
IMPORTANT: Replace shiny ZNS bolts and self-locking nuts.
Tightening torque and angle of rotation: 26 11 1AZ , see 26 11 PROPELLER SHAFT COMPLETE .
Installation:
Arrows (3) on circumference of flexible disk must point to flange arms (2).
Grip mounting bolts of flexible disk at propeller shaft flange at nuts and tighten down at bolt heads.
Fig. 14: Identifying Flexible Disc With Screws

Installation:
Check centering mount.
Replace damaged centering mount.

2010 BMW M3
Fig. 15: Locating Grease Area On Centering Mount

26 11 090 REMOVING AND INSTALLING/REPLACING FRONT CENTERING MOUNT FOR

PROPELLER SHAFT
00 5 500
11 1 310
11 2 030
Completely fill centering bore (1) with viscous grease.
Drive special tool 11 1 310 with a plastic hammer into centering bore.
The centering mount (1) is forced out of the propeller shaft by the pressure on the grease filling.
If necessary, top up grease repeatedly.
NOTE: To drive out the mount, you can also fill the centering bore with water instead of
grease.
2010 BMW M3
Fig. 16: Special Tool In Centering Bore

Installation:
Remove grease/water from mount bore.
Drive in centering mount (1) with special tools 11 2 030 and 00 5 500 into propeller shaft (observe protrusion).
Grease: See PROPELLER SHAFT - OPERATING FLUIDS .

Installation:
Observe protrusion A = 4+2 mm of centering (1).

2010 BMW M3
Fig. 18: Identifying Protrusion

26 11 160 REPLACING CONSTANT-VELOCITY JOINT FOR PROPELLER SHAFT
23 1 160
See MANUAL TRANSMISSION - SPECIAL TOOLS .
26 1 110
26 1 121
26 1 122
See PROPELLER SHAFT - SPECIAL TOOLS .
31 2 102
31 2 104
Remove propeller shaft
Lever sealing cap (1) with screwdriver (2) out of constant-velocity joint (3).
NOTE: Replace sealing cap (1) with seal.

2010 BMW M3
Fig. 19: Removing Sealing Cap

NOTE: Installation sequence:
2. Seal
3. Sealing cap
Fig. 20: Identifying Constant-Velocity Joint And Seal With Sealing Cap
Lift off retainer
Installation:
Replace circlip.
2010 BMW M3

Force cap off constant velocity joint.
Installation:
Insert sealing washer (1) into constant-velocity joint.
Fig. 22: Inserting Sealing Washer Into Constant-Velocity Joint

Detach constant-velocity joint (1) with special tool 26 1 110 and commercially available special tool (2).
2010 BMW M3
Fig. 23: Detaching Constant-Velocity Joint With Special Tool

Release clamp (1) and detach cap with gaiter.
Push on new cap with gaiter.
NOTE: Do not tighten down clamp (1) yet.
Fig. 24: Detaching Cap With Gaiter

Mount constant-velocity joint with special tool 23 1 160 up to stop.
Align bores of constant velocity joint and cap to each other.
Tighten down clamp on gaiter.
NOTE: Keep toothing free of grease.

2010 BMW M3
Inject new grease into constant velocity joint from rubber gaiter and flange sides.

NOTE: Prepare special tools 31 2 102 and 31 2 104 .

Press sealing cap with special tools 26 1 121 , 26 1 122 , 31 2 102 and 31 2 104 into constant-velocity joint (1).
NOTE: Align sealing cap and seal to bores of constant-velocity joint with screw.
2010 BMW M3
Fig. 27: Pressing Sealing Cap With Special Tools

Push cap (1) onto constant-velocity joint (2).
Fig. 28: Pushing Cap Onto Constant-Velocity Joint

CENTRE CONSOLE ASSEMBLY

26 12 001 REPLACING COMPLETE PROPELLER SHAFT CENTER MOUNT
00 7 500
23 1 160
2010 BMW M3
Installation:
Make sure gaiter (1) is securely seated in groove (2).
Fig. 29: Aligning Front And Rear Propeller Shaft


2010 BMW M3

Installation:
Fig. 31: Inserting Clamping Ring Into Front Propeller Shaft

Installation:
Apply a coating of grease to longitudinal splines on shaft.
Grease, refer to PROPELLER SHAFT - OPERATING FLUIDS .
2010 BMW M3
Fig. 32: Pushing Gaiter During Installation Into Groove

Install special tool 00 7 500 between center mount (1) and universal joint (2).
Fig. 33: Identifying Special Tool (00 7 500) Between Centre Mount And Universal Joint
Using a hydraulic press, force center mount (1) off propeller shaft (2).
2010 BMW M3
Fig. 34: Pressing Centre Mount Off Propeller Shaft

Force new center mount (1) onto propeller shaft. Collar (2) must point in direction of travel towards front
propeller shaft. Drive center mount firmly home with special tool 23 1 160 .

26 12 011 REPLACING GROOVED BALL BEARING IN CENTER MOUNT OF PROPELLER SHAFT
23 1 160
33 3 202
33 3 203
2010 BMW M3
See REAR AXLE - SPECIAL TOOLS .
Replace propeller shaft center mount
Press grooved ball bearing using special tool 23 1 160 out of center mount (1).
Fig. 36: Pressing Grooved Ball Bearing Out Of Centre Mount

Coat rubber-coated bearing seat of center mount (2) with Circolight.
Using special tools 33 3 202 / 33 3 203 , press new grooved ball bearing (1) into center mount (2).

2010 BMW M3
Fig. 37: Pressing Grooved Ball Bearing Into Centre Mount

2010 BMW M3
SUSPENSION Rear Axle - Repair
SUSPENSION
Rear Axle - Repair
GENERAL
Headaches
Dizziness
Stomach aches
Vomiting
Diarrhoea
Cramps/fits
Unconsciousness

First aid measures
Situation
2010 BMW M3
E32, E34, E38, E39: With the rear spring struts with self-levelling suspension, a slight oil leak usually exists at
the piston rod. These spring struts are permitted to be wet with oil over a maximum of half the shock absorber
length on the outer tube, i.e. they are permitted to "sweat".
Effect
Procedure
Exception: On all M-models, when a limit value is exceeded on one side, it is still necessary always to replace
both shock absorbers on the relevant axle.

EQUIPMENT)
reactions!

of ignition.
sunlight.
2010 BMW M3
month).


directly.
First Aid:
doctor.
Recycling
41 00... INSTALLATION SOLUTION FOR STRAIGHT SHANK/HEXAGON RIVET NUT

2010 BMW M3
Wear safety goggles

Hexagon/straight shank rivet nut (up to thread 8) with hand rivet gun ZS308
Failure to comply with these instructions may result in the drill bit slipping and causing significant paintwork
damage.
Fig. 1: Identifying Bore Position For Installing Hexagon/Straight Shank Rivet Nut

inserted
be used.
2010 BMW M3
Fig. 2: Drilling Bore For Installing Hexagon/Straight Shank Rivet Nut


IMPORTANT: To avoid corrosion, stop chips by means of cavity sealing.

2010 BMW M3



NOTE: According to the manufacturer, the pictured tool is suitable up to an M8 thread.

2010 BMW M3

Set rivet nut with hand rivet gun

thread.
NOTE: Damaged threads in the frame side member may be repaired with Helicoil
thread inserts. Comply with the PROCEDURE described in the example.
Fig. 7: Identifying Damaged Helicoil Thread

2010 BMW M3
31 00... NOTES ON THREADED CHASSIS M3 CTR
The BMW M3 CTR features a threaded chassis with the following range of adjustments:
Vehicle height
Camber on front axle
Rebound/compression stage, shock absorber
This can be used to adjust the chassis to different road profiles and driving styles.
The chassis has two preset setups:
Road setup = factory setting for operation in traffic

Racetrack setup = setting for operation on a racetrack only
IMPORTANT: For operation in traffic, the factory settings (road setup) must be used!
Note the following procedures for setting the various setups:
RIDE HEIGHT
REBOUND AND COMPRESSION STAGE SETTING
Recommended adjustment values (Road Setup) :
Rebound stage Compression stage Ride level

Front Axle 6 clicks open 9 clicks open 613
Rear axle 14 clicks open 6 x 1/4 rotation open 597
Recommended adjustment values (Racetrack Setup) :
Rebound stage Compression stage Ride level

Front Axle 4 clicks open 8 clicks open 613
Rear axle 12 clicks open 5 x 1/4 rotation open 597
33 31... OVERVIEW OF REAR AXLE CARRIER WITH RUBBER MOUNTS

2010 BMW M3
Fig. 8: Overview Of Rear Axle Carrier With Rubber Mounts

1. Rear axle carrier

2. Rubber mount for trailing arm 6 Rear axle carrier rubber mount, front
3. Rear axle carrier rubber mount, rear 7 Rear differential rubber mount, front
4. Rubber mount for camber arm
5. Rear differential rubber mount, rear
6. Rear axle carrier rubber mount, front
7. Rear differential rubber mount, front
33 10.. OVERVIEW OF REAR DIFFERENTIAL/OUTPUT SHAFTS

2010 BMW M3
Fig. 9: Overview Of Rear Differential/Output Shafts

2. Drive flange/radial shaft seal
3. Output shaft (left/right)
4. Cover gasket
2010 BMW M3
6. Output shaft gaiters
33 32... OVERVIEW OF STEERING LINKS
Fig. 10: Overview Of Steering Links

1. Trailing arm
2. Traction strut
3. Camber arm
4. Control arm
5. Toe arm Adjustment work
31... PROCEDURE FOR BASE SUSPENSION SETTING M3 GTS/CTR
IMPORTANT: The suspension setting must always be performed in NORMAL POSITION !

2010 BMW M3
Only perform the ADJUSTMENT OF THE RIDE HEIGHT on the front and rear
axle in rebounded state.
After adjustment of ride height, set vehicle on wheels, move back and forth
approx. 3-5 m. (to release vehicle tension), CHECK RIDE HEIGHT and if
necessary adjust again!
Procedure:
1. Adjust vehicle to ride height "street setup"

Vehicle in normal position
Ride height VA 613 mm/HA 597 mm
2. Check toe and camber values, adjust if necessary

Refer to TECHNICAL DATA
3. Adjust vehicle to ride height "race setup"

Vehicle in normal position
Ride height VA 597 mm/HA 585 mm
4. Sealing "race setup"

Fit new stop ring on spring cup limit position, and tear off bolt (see the following illustrations)
5. Adjust vehicle to ride height "street setup" again (delivery status)

See point 1
Fit C-clips and check ride height (see the following illustrations)
6. Check vehicle suspension settings again (CAMBER/TOE VALUES )

7. Perform damper adjustment (rebound and compression stage) for VA and HA
Front axle:
For point 4:
Turn stop ring (1) to spring cup (2) limit position.
Apply bolt (3), until bolt head breaks off!

2010 BMW M3
Fig. 11: Identifying Stop Ring, Spring Cup, And Bolt

For point 5:
Fit C-clips (1).
Turn spring cup (2) to C-Clip limit position.
Apply set screw to spring cup.
Tightening torque: 1-2 Nm
Fig. 12: Fitting C-Clips And Turning Spring Cup (Front Axle)
Rear axle:
For point 4:
2010 BMW M3
Fit stop ring (3) to spring cup (1) limit position.
Apply shear screw until screw head breaks off.
For point 5:
Fit C-clips (2).
Turn spring cup (1) to C-Clip limit position.
Fig. 13: Fitting C-Clips And Turning Spring Cup (Rear Axle)
00...... RAISING VEHICLE WITH TROLLEY JACK

contact points.
2010 BMW M3
Fig. 14: Identifying Trolley Jack With Rubber Plate


necessary.
points!

Fig. 15: Identifying Car Jacking Points


2010 BMW M3
Fig. 16: Identifying Car Jacking Point On Front Axle Carrier (All-Wheel Drive)
33... REAR AXLE LAYOUT

2010 BMW M3
Fig. 17: Identifying Rear Axle Components

2010 BMW M3
Safety precautions & general information
1. Final drive/output shafts

3. Compression strut/tension strut
4. Arm
5. Wheel bearing/drive flange
6. Shock absorber
7. Stabilizer
8. Coil spring
9. Stabilizer link
10. Wheel carrier
11. Adjustment work
12. Troubleshooting (shock absorber/rear axle)
13. Testing
33 00... REAR AXLE: WHEEL/CHASSIS ALIGNMENT CHECK MUST BE CARRIED OUT AFTER
THE FOLLOWING WORK
Fig. 18: Identifying Rear Axle Carrier Components

2010 BMW M3
A wheel/chassis alignment check See 3200150 KDS CHASSIS/WHEEL ALIGNMENT CHECK WITH
VEHICLE LOAD UP TO DESIGN POSITION or 3200155 KDS CHASSIS/WHEEL ALIGNMENT
CHECK WITH RIDE HEIGHT MEASUREMENT WITHOUT VEHICLE LOAD must be carried out
after the following work:

Camber arm to rear axle carrier/wheel carrier
Trailing arm to rear axle carrier/wheel carrier
Guide arm to rear axle carrier
Toe arm to rear axle carrier/wheel carrier
Control arm to rear axle carrier

2. Camber arm/rubber mount/ball joint
3. Trailing arm/rubber mount
4. Guide arm
5. Wheel carrier/rubber mount/ball joint
6. Toe arm
7. Control arm
31..... REBOUND AND COMPRESSION DAMPING SETTING SHOCK ABSORBER M3 GTS/CTR
NOTE: The setting of the compression stage exerts significant influence on handling
and driveability.
Low rebound forces improves the ride comfort during a slower journey, yet with
according setting reduces the stability and turning precision during faster
journeying!
High rebound forces further improve the handling on the front axle, but
possibly at the expense of the adhesion. The ride comfort will be greatly
reduced.
IMPORTANT: The adjusting spindle operates a precision mechanical valve. The end of the
adjustment range must not, under any circumstance, be exceeded, otherwise
the setting mechanics can become damaged.
Never combine rebound and compression stages in such a way that one axle is
completely hard and the other soft, this leads to adversely affected driving
stability and can thereby lead to accidents!
2010 BMW M3
NOTE: All settings are to be taken based on the closed valve condition. In addition,
turn the adjusting spindle right until the limit position.
Front axle setting:
Adjust rebound:
Remove shock absorber cover

Insert knurled screw (1) into piston rod damper
Adjust rebound (1) by turning knurled screw
See recommended ADJUSTMENT VALUE
Fig. 19: Adjusting Rebound By Turning Knurled Screw

Adjust compression stage:
Adjust compression stage by turning of knurled screw (1) on damper underside.
See recommended ADJUSTMENT VALUE!

2010 BMW M3
Fig. 20: Adjusting Compression Stage By Turning Of Knurled Screw On Damper Underside
Adjust rear axle:
Remove luggage compartment trim panel

Insert knurled screw (1) into piston rod damper and adjust rebound.
Fig. 21: Inserting Knurled Screw Into Piston Rod Damper For Adjusting Rebound
NOTE: Compression stage setting on removed damper described!
Adjust compression stage:
Pull off dust cap (1).

2010 BMW M3
Fig. 22: Pulling Off Dust Cap

Adjust compression stage by turning to left/right with needle-shaped adjusting pen (1) (contained in toolkit).
Fig. 23: Adjusting Compression Stage By Turning To Left/Right With Needle-Shaped Adjusting Pen
41 00... REPAIR SOLUTION FOR STRAIGHT SHANK/HEXAGON RIVET NUT
Wear safety goggles

2010 BMW M3
Fig. 24: Drilling Rivet Head Using Larger Drill Bit

Fig. 25: Knocking Rivet Head Using Chisel


2010 BMW M3
Fig. 26: Identifying Cavity Of Rivet Shank


IMPORTANT: To avoid corrosion, stop chips by means of cavity sealing.
2010 BMW M3


Observe NOTES ON CAVITY FOAM .

IMPORTANT: To avoid corrosion and rattling noises, stop chips and rivet nut shank with
cavity foam.
Remove foam remnants with isohexane (benzine).

2010 BMW M3
Hexagon/straight shank rivet nut (up to thread M8) with hand rivet gun ZS308
NOTE: According to the manufacturer, the pictured tool is suitable up to an M8 thread.



2010 BMW M3

thread.
Danger of injury!
Impaired sight

First aid measures

Recycling
2010 BMW M3
31... SETTING FOR THREADED SUSPENSION M3 GTS/CTR
NOTE: The traffic setup meets the factory setting for the operation in traffic. If the
suspension setting was changed, then you must make sure to change the ride
height to normal position before operation in traffic. See:
FRONT AXLE RIDE HEIGHT

REAR AXLE RIDE HEIGHT
NORMAL POSITION
The ride height adjustment for the street setup is adjusted with C-clips (1). C-clips are installed between the
spring cup and the stop ring (2).
Fig. 32: Identifying Stop Ring And C-Clips

A hook wrench for turning the spring cup is included in the toolkit.
(1) = adjuster for front axle
(2) = adjuster for rear axle

2010 BMW M3
Fig. 33: Identifying Adjuster For Front Axle And Adjuster For Rear Axle
IMPORTANT: After the ride height adjustment (race/street setup) in order for the chassis and
suspension to be optimally adjusted, the damping action, such as compression
stage and rebound settings, must also be adjusted for the ride height.
See REBOUND AND COMPRESSION STAGE SETTING
Front axle setup racetrack setting:
Release set screw (1) in spring cup.
Tightening torque: 1- 2 Nm
Turn spring cup with hook wrench so far to the top until C-clip (2) is loose.
Pull off C-clip (2).
Fig. 34: Identifying C-Clip And Set Screw

2010 BMW M3
The height adjustment for the operation on the racetrack is limited by the stop ring! (1)
Turn spring cup (2) with hook wrench towards bottom until stop ring (1) limit position.
Fig. 35: Identifying Spring Cup And Stop Ring

Rear axle setup racetrack setting:
For the adjustment of the spring cup on the rear axle, the damper on the wheel carrier is to be loosened.
Installation note:
Always renew bolt
Remove spring with adjustable upper spring support
Turn spring cup (1) so far to the left until C-clip (2) is loose.
Pull off C-clip (2).
Turn spring cup (1) towards top until stop ring (3) limit position.
Reinstall spring cup with spring!

2010 BMW M3
Fig. 36: Identifying Spring Cup, C-Clip, And Stop Ring

After the setting to "racetrack setup", the dampening setting / rebound and compression stage is also to be
performed.
After the setting "racetrack setup" no wheel alignment/setting is to be performed. The camber and toe values
result automatically from the height adjustment!
Camber and toe values may only be adjusted in the ride height "road operation".
See:
WHEEL ALIGNMENT TECHNICAL DATA

FRONT AXLE RIDE HEIGHT
REAR AXLE RIDE HEIGHT
FINAL DRIVE
00 11... CHECKING/TOPPING UP OIL LEVEL IN REAR DIFFERENTIAL (M3)

Risk of burning on the exhaust system.

To avoid serious damage to the rear axle differential, it is essential to use only
Hypoid oils for final drive unit with disc-type limited-slip differential (M models).
See REAR AXLE - OPERATING FLUIDS .
Undo oil filler plug (1).
Check oil level.

2010 BMW M3
If necessary, pour in rear differential oil up to lower edge of opening for oil filler plug (1).
Installation:
Replace oil filler plug.
Fig. 37: Identifying Oil Filler Plug

00 11 259 OIL CHANGE IN REAR DIFFERENTIAL INCLUDING USED OIL DISPOSAL
WARNING: Risk of burning if exhaust system is touched!

DANGER OF POISONING if oil is ingested/absorbed through the skin!

To avoid serious damage to the rear differential, it is essential to use only
Hypoid oils for final drive unit with disc-type limited-slip differential (M models).
See REAR AXLE - OPERATING FLUIDS .
NOTE: Only change oil when rear differential is at normal operating temperature.
Recycling
Catch and dispose of emerging differential oil.

2010 BMW M3


Place oil collecting apparatus underneath.
Open plug (1).
Drain and dispose of differential oil.
Replace screw plug.
Open plug (2).
Add differential oil up to lower edge of opening for screw plug (2).
Replace screw plug.
33 10.. OVERVIEW OF REAR DIFFERENTIAL/OUTPUT SHAFTS

2010 BMW M3
Fig. 39: Overview Of Rear Differential/Output Shafts

3. Output shaft (left/right)
4. Cover gasket
2010 BMW M3
6. Output shaft gaiters
33 10... REAR DIFFERENTIAL: ASSIGNMENT TO MODEL SERIES
MODEL SERIES OF ENGINE AND REAR DIFFERENTIAL REFERENCE CHART

Model series Engine Rear differential Remark
E90 N43, N45, N46, N52 168L
(323i)
M47T2, M57T2, N47, 188L/188LW
N51, N52, N53
M57T2 (330d, 335d), N54 215L/215LW
Manual transmission:
M57T2 (325d, 330xd)
E91 N43, N46, N52 (323i) 168L
M47T2, M57T2, N52, 188L/188LW
N53
M57T2 (330d, 335d), N54 215L/215LW
M57T2 (325d, 330xd)
E92 N43, N46, 168L
M57T2, N47, N51, N52, 188L/188LW
N53
M57T2 (330d, 335d), N54 215L/215LW
M57T2 (325d, 330xd)
S65 215 with lock
E93 N43, N46 168L
M57T2, N51, N52, N53 188L/188LW
M57T2 (330d), N54 215L/215LW
L Light-running
LW Light-running, efficiency-optimized
33 10 010 REMOVING AND INSTALLING/REPLACING REAR DIFFERENTIAL (M3)

33 5 206 Rear differential must be lashed with tightening strap to prevent
it falling out when the output shafts are forced off.
IMPORTANT: Rear axle differential M3 (S65) is balanced.

For this reason, the following steps during M3 must observed.
Failure to comply with this instruction may give rise to humming noises!
2010 BMW M3
NOTE: For all other vehicles types, the following required preliminary work applies.
M3 For vehicles with marked rear axle drive, the following colored dots indicate (1):
white dot (1): no action required

blue dot (1): Maaction mandatory
yellow dot (1): Maaction mandatory
Fig. 40: Identifying Dots On Rear Axle Drive And Color Marking Of Drive Flange
IMPORTANT: If an action is mandatory, the rear axle differential must be identified according
the following instruction and prior to fastening all bolts.
There are two methods to bolt the drive flange of the rear axle differential.
Method A:
color marking (2) inside inner cone of drive flange.
Method B:
NO color marking (2) inside inner cone of drive flange.
Colored dots on the outside of the flange are assigned to the respective fastening dot and refer to the specific
method that must be used.
Method A:
blue marking (1) - install shiny green screw (2)

2010 BMW M3
yellow marking (1) - install black screw (2)
Fig. 41: Identifying Marking On Drive Flange With Screw

Method B:
blue marking (1) - place black washer (2) between bolt head and spacer
yellow marking (1) - place silver washer (2) between bolt head and spacer
Fig. 42: Identifying Marking On Drive Flange With Bolt


2010 BMW M3
Remove PROPELLER SHAFT FROM REAR DIFFERENTIAL and tie back

Remove both OUTPUT SHAFTS FROM REAR DIFFERENTIAL and tie back
33 5 200 FIXTURE . Position special tool on workshop jack.
33 5 200 FIXTURE . Support rear differential with special tool.
33 5 206, 33 5 200 FIXTURE . Lash rear differential with tightening strap to special tool.
00 2 030 DEVICE . Slowly lower workshop jack.
Fig. 43: Identifying Workshop Jack Screw

IMPORTANT: Adhere to the following installation sequence in order to prevent distortion of

the rear differential during installation and thereby avoid potential complaints
about noise.
Installation sequence
1. 33 5 200 FIXTURE . Install rear differential with workshop lifter and special tool in rear axle carrier
2. Insert bolts (1) (do not tighten down)
3. Insert bolt (2) from rear and replace nut (do not tighten down)
4. 00 2 030 DEVICE . Lower workshop jack
2010 BMW M3
Fig. 44: Identifying Workshop Jack Bolts

5. Tighten down screws (1)
Tightening torque 33 17 1AZ . .
6. Tighten down screw (2)
After installation
Check REAR DIFFERENTIAL OIL LEVEL , correct if necessary.
FINAL DRIVE WITH COVER

33 11... REPLACING O-RING FOR SIDE COVER ON REAR DIFFERENTIAL ON LEFT OR RIGHT
(M3)
Remove DRIVE FLANGE FROM REAR DIFFERENTIAL
Mark installation position of side cover (2) to housing.
Press cover (2) with two screwdrivers off housing.

2010 BMW M3
Installation:
Markings (3) on cover and housing must match up.
Fig. 45: Identifying Mark Position Of Side Cover To Housing

Tighten screws crosswise.
Raise mount and remove cover (1) with ring (2).
Installation:
Insert cover with ring in housing.
Raise mount and slide in cover as far as it will go.

2010 BMW M3
Fig. 46: Identifying Cover With Ring On Housing

Installation:
Clean contact surface (1) for O-ring all round.
Fig. 47: Identifying Contact Surface Of O-Ring

Replace O-ring (1).
Installation:
2010 BMW M3
Keep drain opening (2) for gear oil clean.
Moisten O-ring with
hypoid oils for final drive unit with disc-type limited-slip differential (M models). See REAR AXLE -
OPERATING FLUIDS ..
Fig. 48: Identifying O-Ring And Drain Opening

After installation
Check REAR DIFFERENTIAL OIL LEVEL , correct if necessary
33 11 091 REPLACING DRIVE FLANGE ON LEFT OR RIGHT OF REAR DIFFERENTIAL (M3)
NOTE: When replacing the drive flange, you must also replace the SHAFT SEAL .
L Drive flange, left
R Drive flange, right

2010 BMW M3
Fig. 49: Identifying Drive Flange Of Rear Differential

Remove OUTPUT SHAFT FROM REAR DIFFERENTIAL and tie back
Press drive flange (1) with suitable screwdrivers off rear differential.
Installation:
Replaced deformed or damaged dust plates.
Insert drive flange and rotate until spline on flange meshes with teeth on differential bevel gear.
Press drive flange in further until circlip locates with an audible click.
2010 BMW M3
Fig. 50: Identifying Drive Flange

IMPORTANT: High installation forces indicate that the spline teeth on the drive
flange/differential bevel gear are damaged/deformed!
Check spline teeth, replaced damaged parts.
Replace circlip (1).
Installation:
twist retaining ring until both ends settle into the groove.
Clean shaft seal race on drive flange thoroughly.
Coat drive flange at contact face of shaft seal with hypoid oils for final drive unit with disc-type limited-slip
differential (M models). See REAR AXLE - OPERATING FLUIDS .
2010 BMW M3

Replacement
Replace SHAFT SEAL .
After installation
Check REAR DIFFERENTIAL OIL LEVEL , correct if necessary
33 11 021 REPLACING RADIAL SHAFT SEAL FOR DRIVE FLANGE ON REAR DIFFERENTIAL
IMPORTANT: Use only hypoid oils for final drive unit with disc-type limited-slip differential (M
models). See REAR AXLE - OPERATING FLUIDS . .
Failure to comply with this instruction will result in serious damage to the rear
differential!
Remove PROPELLER SHAFT FROM REAR DIFFERENTIAL and tie back
Removing drive flange
Lift out retaining plate.
Mark position of collar nut (1) on drive shaft with center punch.
2010 BMW M3
Fig. 52: Locating Collar Nut

Brace drive flange with special tool 23 0 020 HOLDER and release collar nut.
Fig. 53: Removing Collar Nut Using Special Tool 23 0 020

NOTE: Read and comply with document "REAR DIFFERENTIAL: ASSIGNMENT TO

MODEL SERIES ".
215L/215LW/215 with lock:
Pull off drive flange with special tools 31 2 101, 31 2 102, 31 2 103/31 2 104.
2010 BMW M3
Fig. 54: Pulling Drive Flange Using Special Tools

168L/188L/188LW:
Pull off drive flange with special tool 33 1 150 DEVICE .
Fig. 55: Pulling Drive Flange Using Special Tools (33 1 150)
Replacing radial shaft seal
Pull out radial shaft seal with special tool 00 5 010 PULLER .
2010 BMW M3
Fig. 56: Pulling Radial Shaft Seal Using Special Tool (00 5 010)
Drive in new radial shaft seal with following special tools (depending on REAR DIFFERENTIAL ) as far as it
will go.
168L: Use special tools 00 5 500 MANDREL and 33 3 390 MANDREL

188L/188LW: Use special tools 00 5 500 MANDREL and 33 3 470 MANDREL
215L/215LW/215 with lock: Use special tools 00 5 500 MANDREL and 33 3 440 MANDREL
Fig. 57: Installing Shaft Seal Using Special Tools (33 3 390, 33 3 440 And 33 3 470)
Installing drive flange
Coat sealing lips of radial shaft seal and sealing surface of drive flange with differential oil.
Fit drive flange.
Press on drive flange with special tools 23 1 300, 33 1 341 and 23 1 303, and if necessary 23 1 302 until collar
nut can be screwed on.
2010 BMW M3
Fig. 58: Installing Drive Flange Using Special Tools

IMPORTANT: Do not under any circumstances tighten down collar nut beyond marker points
in order to avoid damaging the clamping sleeve.
Tighten down collar nut (1) to point where marker points are aligned.
Fig. 59: Locating Collar Nut

Drive in new retaining plate with following special tools (depending on REAR DIFFERENTIAL ) as far as it
will go.
168L/188L/188LW: Use special tools 00 5 500 MANDREL and 33 3 480 MANDREL

215L/215LW/215 with lock: Use special tools 00 5 500 MANDREL and 33 3 490 MANDREL
2010 BMW M3
Fig. 60: Installing Retaining Plate Using Special Tools

After installation
Correct REAR DIFFERENTIAL FLUID LEVEL
33 11 271 REPLACING REAR COVER GASKET ON REAR DIFFERENTIAL
IMPORTANT: In event of oil loss, always check rear differential for traces of wear and
damage.
Draw off/drain DIFFERENTIAL OIL

Remove rear differential
NOTE: Read and comply with document "REAR DIFFERENTIAL: ASSIGNMENT TO

MODEL SERIES ".
Select rear differential:
168L
188L/188LW
215L/215LW
215 with lock
After installation
Add REAR DIFFERENTIAL OIL
33 11... REPLACING REAR COVER GASKET ON REAR DIFFERENTIAL (168L)

2010 BMW M3
IMPORTANT: To avoid leaks from the rear differential cover, do not use a paper gasket in
cars with liquid gaskets!
To prevent the differential oil from foaming over, make sure that no remnants
of the liquid gasket are pressed into the rear differential housing.
Release screws (1).
Tightening torque (M10x60) 33 11 1AZ .
Unscrew screws (2).
Remove cover.
Fig. 61: Identifying Rear Differential Cover Screws (168L)

If necessary, remove remnants of liquid gasket with scraper.
Clean sealing face on cover and rear differential.
Installation:
If a paper gasket was fitted, a paper or liquid gasket can be used.
33 11... REPLACING REAR COVER GASKET ON REAR DIFFERENTIAL (188L/188LW)
2010 BMW M3
Release screws (1).
Unscrew screws (2).
Remove cover.
Fig. 62: Identifying Rear Differential Case Cover Screws

Installation:
33 11... REPLACING REAR COVER GASKET ON REAR DIFFERENTIAL (215L/215LW)

2010 BMW M3
Remove cover.
Fig. 63: Identifying Rear Differential Case Cover Screws (215L / 215LW)
Installation:
33 11 151 REPLACING SHAFT SEAL FOR DRIVE FLANGE LEFT OR RIGHT
Remove drive flange from rear differential See AZD-AZD-AZDMUC3311-E87_E9X REAR

DIFFERENTIAL CASE WITH COVER or 3311091 REPLACING DRIVE FLANGE ON LEFT
OR RIGHT OF REAR DIFFERENTIAL (M3)
If necessary, press off dust cover
Use special tool 00 5 010 PULLER and 32 1 060 MANDREL /33 1 308 to remove radial shaft seal
2010 BMW M3
Fig. 64: Removing Radial Shaft Seal Using Special Tool 00 5 010 And 32 1 060/33 1 308
Coat housing plate flange and sealing lips of new shaft seal with hypoid oils for final drive unit with disc-type
limited-slip differential (M models). See REAR AXLE - OPERATING FLUIDS .
Drive in new shaft seal as far as it will go with following special tool(s) (depending on REAR
DIFFERENTIAL /outside diameter).
Fig. 65: Installing Radial Shaft Seal Using Special Tools

00 5 500 MANDREL + 33 3 400 MANDREL : 168K/L - 78x44x10
00 5 500 MANDREL + 33 4 240 MANDREL : 188K/L/LW - 90x44x10
00 5 500 MANDREL + 33 4 250 MANDREL : 215K/L/LW, 220K to 230K - 100x50x10
33 5 030 : 210, 215 with lock - 76x50x10

2010 BMW M3
After installation
Correct gearbox oil level/change differential oil See 0011259 OIL CHANGE IN REAR
DIFFERENTIAL INCL. USED OIL DISPOSAL or 0011... CHECKING/TOPPING UP OIL
LEVEL IN REAR DIFFERENTIAL (M3)
FINAL DRIVE MOUNTING

33 17 004 REPLACING ALL FRONT RUBBER MOUNTS FOR REAR DIFFERENTIAL MOUNTING
Remove REAR AXLE FINAL DRIVE
Withdrawing front rubber mount
Remove front rubber mount with special tools 33 3 312, 33 4 161, 33 4 162, 33 4 466 and 33 4 465.
NOTE: The milled recess of special tool 33 4 161 must point upward toward the rear
axle support.
Fig. 66: Removing Front Rubber Mount Using Special Tools

Installing front rubber mount
IMPORTANT: Coat bearing bushing in rear axle carrier and front rubber mount with
Circolight.
2010 BMW M3
Fig. 67: Identifying Front Rubber Mount Aligning Slots

Front rubber mount must be aligned by way of slots (1) to vehicle transversal direction.
Insert front rubber mount in special tool 33 4 311.
Align front rubber mount so that side slots (1) line up with marking (M) on tool.
Fig. 68: Aligning Front Rubber Mount Slots On Marking

Draw in front rubber mount as far as it will go using special tools 33 4 465, 33 4 466, 33 4 166, 33 4 311 and 33
4 312.
2010 BMW M3
Fig. 69: Installing Front Rubber Mount Using Special Tools

33 17 005 REPLACING RUBBER MOUNT FOR REAR DIFFERENTIAL MOUNTING AT REAR

(M3)
Remove REAR DIFFERENTIAL
Withdraw PUR mount with special tools 33 0 101, 33 0 102, 33 0 105, 33 0 106 from rear axle carrier (1).
Fig. 70: Removing PUR Mount Using Special Tools From Rear Axle Carrier
IMPORTANT: Coat bearing bushing in rear axle carrier and new rear PUR mount (2) with
Circolight.
2010 BMW M3
Fig. 71: Removing PUR Mount Using Special Tools

Draw PUR mount (2) in direction of arrow with special tools 33 0 103, 33 0 104, 33 0 105 and 33 0 106 into
rear axle carrier (1).
Installation:
Observe mounting sequence.
Mounting sequence
To avoid damaging the PUR mount (1), draw in the mount in stages.
2010 BMW M3
Fig. 72: Turning Special Tool 33 0 103

Procedure:
Draw PUR mount (1) 5 mm into rear axle carrier

Release special tool 33 0 100 DEVICE .
Turn special tool 33 0 103 in direction of arrow (A) 45
Repeat procedure until PUR mount (1) is pressed in up to stop
OUTPUT SHAFTS
33 21... PRESSING OUTPUT SHAFT OUT OF DRIVE FLANGE AND DRAWING IN (OUTPUT
SHAFT REMOVED FROM REAR AXLE FINAL DRIVE)

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

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

2010 BMW M3
Secure output shaft against falling out.
Screw on special tools 33 2 203, 33 2 207 and 33 2 201 with all wheel bolts to drive flange.
Press output shaft out of drive flange; in so doing, grip basic body 33 2 201 with special tools 33 2 202 and 33 5
070 EXTENSION .
Fig. 74: Pressing Output Shaft Out Of Drive Flange

IMPORTANT: No oil permitted on shaft journal thread!
Lightly oil spline teeth of output shaft.
Insert output shaft into drive flange.
Screw special tool 33 2 205/33 2 206 onto output shaft.

2010 BMW M3
Fig. 75: Positioning Special Tools 33 2 205/33 2 206 Onto Output Shaft
Mount special tool 33 2 201 with three wheel bolts to drive flange.
Draw in output shaft with special tool 33 2 205 up to stop; in so doing, grip basic body 33 2 201 with special
tools 33 2 202 and 33 5 070 EXTENSION .
Fig. 76: Installing Output Shaft Using Special Tool (33 2 205)
Screw on special tools 33 2 111, 33 2 117 and 33 2 116 with all wheel bolts to drive flange.
070 EXTENSION .
2010 BMW M3

Fig. 78: Inserting Output Shaft Into Drive Flange

Screw special tool 33 2 118/33 2 119 onto output shaft.
Mount special tool 33 2 116 with three wheel bolts to drive flange.
Pull in output shaft with special tool 33 2 115 up to stop; in so doing, grip basic body 33 2 116 with special
tools 33 2 202 and 33 5 070 EXTENSION .
2010 BMW M3
Fig. 79: Installing Output Shaft Using Special Tools

33 21 000 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT OUTPUT SHAFT (ON 2-

FLOW EXHAUST SYSTEM)
Remove REAR WHEEL .
IMPORTANT: Expand anti-twist lock sufficiently to avoid damaging thread when releasing
collar nut.
Fig. 80: Identifying Collar Nut

Release collar nut (1), activate handbrake for this purpose.
Installation:
Replace collar nut, oil collar nut/wheel bearing contact surface only and tighten down.
2010 BMW M3
No oil permitted on thread of shaft journal or collar nut.
Secure collar nut by positive peening on flat areas of output shaft.
E91, E93: Remove trailing link (on rear axle).
Except M3: Lower exhaust system in rear area.
M3: REMOVE final muffler.
Release bolts and remove with washers (1).
Press output shaft off drive flange using a suitable tool; if necessary, raise wheel carrier with workshop jack
approx. 20 mm.
Installation:
Fig. 81: Locating Output Shaft Bolts And Washers

Before installing output shaft, make sure that drive flange is fully engaged in rear differential.
Replace bolts and washers (1).
Press OUTPUT SHAFT OUT OF DRIVE FLANGE and remove towards center of vehicle.
After installation
Check that output shaft is correctly seated in rear differential.

2010 BMW M3
Applies to four-wheel drive only:
Replacement only
Control-module functions
Perform functional check of transfer box (calibration)
33 21 071 REPLACING BOTH GAITERS ON LEFT OR RIGHT OUTPUT SHAFT (ON 2-FLOW
EXHAUST SYSTEM)
Remove OUTPUT SHAFT
Removing inner gaiter
Clean output shaft and clamp with a cloth in vice.
Using a suitable tool, force gaiter cap (2) off joint or sealing cover.
Fig. 82: Forcing Gaiter Cap Off Joint Using Suitable Tool
Push back gaiter with cap.

Make sure that joint does not fall apart.
2010 BMW M3
Fig. 83: Forcing Sealing Cover Off Joint Clamp Joint Using Suitable Tool
Clamp joint (1) in vice.
Using a suitable tool, force sealing cover (2) off joint (1).
IMPORTANT: Mark positions in relation to each other of ball hub, ball cage and joint at ends.
NOTE: If the joint falls apart, it can only be reassembled correctly with the aid of the
markings.
Fig. 84: Identifying Marking On Ball Hub, Ball Cage And Joint
Remove circlip (1).

2010 BMW M3
Fig. 85: Identifying Circlip

Grip output shaft.
Using special tool 26 1 110 WASHER and a suitable tool (for hollow shaft 21 2 120 CLUTCH ), press output
shaft out of joint (1).
Clean joint (1) carefully.
NOTE: All traces off old grease must be removed.
Fig. 86: Pressing Output Shaft Out Of Joint Using Special Tool
Detach gaiter from output shaft.
Removing and installing outer gaiter:

2010 BMW M3
Release hose clamps (1, 3) and detach gaiter (2) from output shaft.
Clean joint and output shaft carefully.
Fig. 87: Identifying Hose Clamps And Gaiter On Output Shaft

Check joint for damage; if necessary, replace OUTPUT SHAFT .
Fill joint with propeller shaft grease.
Fit gaiter (2) on bellows and secure with hose clamps (1, 3).
Installing inner gaiter
Push gaiter with cap onto output shaft (1).
Mount special tool 33 2 100 DEVICE with corresponding shell inserts on output shaft (1).
Press joint (2) over bearing inner race onto output shaft.
2010 BMW M3
Fig. 88: Pressing Joint Over Bearing Inner Race Onto Output Shaft Using Special Tool 33 2 100
Install new circlip (1).

IMPORTANT: Keep sealing faces of cap and joint (on both sides) clean and free from grease.
Fill joint at both ends with high-temperature grease.

2010 BMW M3
Fig. 90: Filling High-Temperature Grease Into Both Ends Joints


Do not install gaiter with cap and sealing cover on joint without shims.
Apply a thin coating of sealing compound to sealing faces of sealing cover and cap.
Install sealing cover (1) with two bolts, shims and nuts on joint.
Fig. 91: Identifying Sealing Cover

Install cap (1) with two bolts, shims and nuts on joint.
Fit hose clamp (2).

2010 BMW M3
Fig. 92: Identifying Cap And Hose Clamp

33 21... RIBBED TEETH
IMPORTANT: Bolts with ribbed teeth must be replaced after they have been released!
Fig. 93: Identifying Bolt With Ribbed Teeth

REAR SUB-FRAME
33 31 503 LOWERING/RAISING REAR AXLE SUPPORT (M3, UNIVERSAL LIFTER)

Read and observe the information on permissible load distribution in the lifting platform operating instructions.
2010 BMW M3
Load the luggage compartment with a minimum of 100 kg before lowering/removing the rear axle carrier.

Remove both REAR COIL SPRINGS

Remove REAR MUFFLER

Position an oil sump underneath to catch brake fluid.
Release banjo bolts (1), gripping brake hoses (2) at square head in the process.
Disconnect brake hoses (2) and seal off with plugs.
Installation:
Make sure brake hoses are laid without tension and with sufficient spacing to adjoining components.

2010 BMW M3
Fig. 95: Identifying Brake Hoses And Banjo Bolts

Unclip cables for pulse generator and ride-height sensor/brake pad sensor on rear axle carrier at side.
Slacken nut (1).
Release screws (2) and lay heat shield (3) on exhaust system.
Fig. 96: Identifying Heat Shield On Exhaust System With Nut And Screws
Engage special tool 31 5 250 FIXTURE with a 2nd person helping completely on workshop jack 00 2 030
DEVICE .

2010 BMW M3
Fig. 97: Inserting Special Tools 31 5 255 In Telescopic Supports Of Profile Rail Pair
Align special tools 31 5 255 and 31 5 256 to rear axle carrier.
Support rear axle carrier by operating workshop jack 00 2 030 DEVICE .
Fig. 98: Aligning Special Tools 31 5 255 And 31 5 256 To Rear Axle Carrier
Remove COMPRESSION STRUTS (1).

2010 BMW M3
Release screws (2) and remove stop plate.
Lower rear axle carrier.
Fig. 99: Identifying Compression Struts And Plate Screw

Installation:
First install COMPRESSION STRUTS (1) and then tighten down screws (2).
After installation
3331503 LOWERING/RAISING REAR AXLE SUPPORT (SWZ00-2040)

Read and observe the information on permissible load distribution in the
lifting platform operating instructions.
Load the luggage compartment with a minimum of 100 kg before
lowering/removing the rear axle carrier.

2010 BMW M3


This work may only be carried out on an exhaust system which has
cooled down.

If necessary, remove tension strut (s)
Fig. 100: Pressing Brake Pedal Down

Installation:

2010 BMW M3
Fig. 101: Identifying Brake Hoses And Banjo Bolts

Slacken nut (1).
Turn bracket (2) for exhaust system towards rear.
Release sheet nut and bolts (arrows).
Place heat shield on exhaust system.
Fig. 102: Locating Sheet Nut And Bolts

If necessary, position special tool 00 2 040 with a 2nd person helping on workshop jack 00 2 030 .
Insert special tools 33 4 491 and 33 4 492 into corresponding mountings of special tool 00 2 040 .
2010 BMW M3
Lower special tool 33 3 274.
Fig. 103: Inserting Special Tools 33 4 491 And 33 4 492 Into Special Tool 00 2 040
Support rear axle carrier by operating workshop jack 00 2 030 .
Fig. 104: Identifying Special Tools 33 4 491 And 33 4 492 On Rear Axle Carrier
Remove COMPRESSION STRUTS (1).
Release screws (2) and swivel/remove stop plates to one side.
Installation:
Check threads for damage; if necessary, repair with HELICOIL THREAD INSERTS.
2010 BMW M3
First install COMPRESSION STRUTS (1) and then tighten down screws (2).
Fig. 105: Identifying Rear Axle Carrier Compression Strut With Screws
After installation
33 31... OVERVIEW OF REAR AXLE SUPPORT WITH RUBBER MOUNTS
See OVERVIEW OF REAR AXLE CARRIER WITH RUBBER MOUNTS.
33 32 160 REMOVING AND INSTALLING/REPLACING TENSION STRUT FOR REAR AXLE

SUPPORT

Risk of damage!
Driving without the compression strut is not permitted!
The rear axle support must be supported if it is necessary to replace both
compression struts!
Remove UNDERBODY COVER

Remove rear tension struts
Slacken screws (3) and release screws (4).
Installation:
2010 BMW M3
Fig. 106: Identifying Rear Tension Struts Nuts And Screws

Release screws (1).
Installation:
Fig. 107: Identifying Compression Strut With Screws

2010 BMW M3
Release screw (2) and remove compression strut (3).
Installation:
33 31 000 REMOVING AND INSTALLING COMPLETE REAR AXLE SUPPORT

lifting platform instruction manual.
lowering/removing the rear axle support.

Remove BOTH REAR WHEELS

Remove propeller shaft
If necessary, remove tension strut(s)
Remove both PULSE SENSORS FROM WHEEL CARRIER , unclip line from wishbone and rear
axle support
Disconnect plug connection for BRAKE PAD SENSOR
Disconnect plug connection from ride-height sensor and unclip line from rear axle support
Disengage both HANDBRAKE BOWDEN CABLES FROM EXPANDER LOCK and then remove
from hanging hooks
Remove both shock absorbers from rubber mount/camber arm See 3352000 REMOVING AND
INSTALLING/REPLACING REAR LEFT OR RIGHT SHOCK ABSORBER or 3352010
REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT SHOCK ABSORBER
(M3)
NOTE: The subsequent procedure is described in the document "LOWERING/RAISING

REAR AXLE SUPPORT ".
2010 BMW M3
IMPORTANT: Check sensor head and line from pulse sensor prior to installation for
external damage, replacing if necessary.
After installation

Adjust HANDBRAKE if the setting of the adjustment unit was changed during disengagement and
engagement of the handbrake Bowden cables
33 31 011 REPLACING REAR AXLE SUPPORT


Remove REAR DIFFERENTIAL

Remove COMPLETE REAR AXLE CARRIER
If necessary, remove both BRAKE CALIPERS with brake pad sensor (disconnect brake hose from brake line).
Remove both BRAKE DISCS .
Remove both brake lines from rear axle carrier.

2010 BMW M3
Fig. 108: Identifying Brake Calipers

Remove STABILIZER BAR (remove stabilizer links from wheel carrier).
Remove RIDE-HEIGHT SENSOR WITH HOLDER FROM REAR AXLE CARRIER .
E93 except M3: Remove VIBRATION DAMPER (variant D).
Remove both CAMBER ARMS ON REAR AXLE CARRIER .
Remove both TOE ARMS ON REAR AXLE CARRIER .
Remove both TRAILING ARMS ON REAR AXLE CARRIER .
Fig. 109: Identifying Rear Axle Carrier

Remove both GUIDE ARMS ON REAR AXLE CARRIER .

2010 BMW M3
Remove both CONTROL ARMS ON REAR AXLE CARRIER .
Remove both wheel carriers with output shaft and all arms from rear axle carrier.
If necessary, unclip stoneguard (1) on left and right in marked areas and remove.
Installation:
Replace damaged stoneguard.
Fig. 110: Identifying Stoneguard

After installation

Adjust HANDBRAKE if the setting of the adjustment unit was changed during disengagement and
Perform chassis alignment check See 3200150 KDS CHASSIS/WHEEL ALIGNMENT CHECK
CONTROL ARMS AND STRUTS

33 32... OVERVIEW OF STEERING LINKS
See OVERVIEW OF STEERING LINKS.
33 32 131 REMOVING AND INSTALLING/REPLACING A STEERING KNUCKLE/WHEEL

CARRIER
Remove OUTPUT SHAFT

2010 BMW M3
Remove BRAKE DISC

Replacement only: drive out DRIVE FLANGE FOR REAR AXLE SHAFT
Disconnect HANDBRAKE BOWDEN CABLE FROM EXPANDER LOCK
Remove PULSE GENERATOR FROM WHEEL CARRIER
Remove COIL SPRING
Remove RUBBER MOUNT/SHOCK ABSORBER ON CAMBER ARM
Secure wheel carrier against falling out.
Remove STABILIZER LINK FROM WHEEL CARRIER .
Remove TRAILING ARM FROM WHEEL CARRIER .
Remove GUIDE ARM FROM WHEEL CARRIER .
Remove TOE ARM FROM WHEEL CARRIER .
Remove UPPER CONTROL ARM FROM WHEEL CARRIER .
Remove CAMBER ARM FROM WHEEL CARRIER .
Remove wheel carrier.
Fig. 111: Identifying Wheel Carrier

IMPORTANT: Check sensor head and line from pulse generator prior to installation for
Replacement
2010 BMW M3
Modify or replace HANDBRAKE SHOES

Modify or replace EXPANDER LOCK
Modify or replace BRAKE CARRIER/BRAKE GUARD PLATE
After installation
Adjust HANDBRAKE
33 32 160 REMOVING AND INSTALLING/REPLACING TENSION STRUT FOR REAR AXLE

SUPPORT

Risk of damage!
Driving without the compression strut is not permitted!
The rear axle support must be supported if it is necessary to replace both
compression struts!

Remove rear tension struts
Slacken screws (3) and release screws (4).
Installation:

2010 BMW M3
Fig. 112: Identifying Rear Tension Struts Screws

Release screws (1).
Installation:
Installation:

2010 BMW M3
Fig. 113: Identifying Compression Strut Screws

33 32 190 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT CAMBER ARM (M3)
NOTE: If the camber arm is detached from the rear axle carrier/wheel carrier, it is
necessary after reinstallation to carry out a wheel/chassis alignment check.
Remove COIL SPRING AT REAR

Remove REAR MUFFLER
IMPORTANT: Mark position of eccentric bolt (1) to camber arm (2).

2010 BMW M3
Fig. 114: Identifying Camber Arm With Eccentric Bolt

Slacken nut (1).
Remove jointed rod (2) from camber arm bracket.
Installation:
Fig. 115: Identifying Jointed Rod Of Camber Arm Bracket With Nut
2010 BMW M3
Support wheel carrier with workshop jack.
Release screw (1).
Installation:
Bolt head must point to rear.
Tighten down bolt connection in NORMAL POSITION .
Fig. 116: Identifying Wheel Carrier With Workshop Jack With Nut And Screw
Release nut (3) and remove bolt (2).
Installation:
Release nut (1) and remove eccentric washer (2).
Unscrew eccentric bolt (3) and remove camber arm.
Installation:
2010 BMW M3
Bolt head must point to front.
Fig. 117: Identifying Eccentric Washer Nut And Camber Arm Bolt
Replacement only: Carry over marking from old part to new part.
Install eccentric washer.
Align eccentric screw by means of marking to camber arm.
Replacement
Replace lower spring pad (1).
Installation:
Make sure lower spring pad is correctly seated.

2010 BMW M3
Fig. 118: Identifying Lower Spring Pad And Holder With Screw
Version with xenon lights:
Release nut, remove screw (2) and holder (3).
Installation:
Screw head must point upwards.
After installation
Perform CHASSIS ALIGNMENT CHECK
33 32 180 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT TOE ARM
NOTE: If the toe arm is detached from the rear axle support/wheel carrier, it is
Remove REAR WHEEL
If necessary, open cover (1) on stoneguard (2).
Mark position of eccentric bolt to rear axle support.

2010 BMW M3
Fig. 119: Identifying Cover And Stoneguard

Release bolt.
Installation:
If necessary, turn toe arm by hand.
Fig. 120: Locating Toe Arm Bolt

Unscrew eccentric bolt towards front and remove toe arm (3).
2010 BMW M3
Fig. 121: Removing Toe Arm

Installation:
Bolt head points in direction of travel.
Reinstall eccentric washer.
Align eccentric bolt to rear axle support by means of marking.
After installation

VEHICLE LOAD
other models.
2010 BMW M3
Fig. 122: Identifying Clips And Underbody Cover Screws

Release clips (1).
Release screws (2).
Installation:
33 32 125 REPLACING A BALL JOINT IN LOWER STEERING KNUCKLE/WHEEL CARRIER
NOTE: E90, E91 from 09/2008:

For driving dynamic reasons, both ball joints must be replaced on first
replacement. After replacing the rubber mounts, mark wheel carriers with punch
marks. If the punch marks are provided, the ball joints can be changed again
individually.
Remove COIL SPRING AT REAR

If necessary, remove jointed rod of ride-height sensor from camber arm bracket
Remove rear shock absorber from rubber mount See 3352000 REMOVING AND
INSTALLING/REPLACING REAR LEFT OR RIGHT SHOCK ABSORBER or 3352010
REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT SHOCK ABSORBER
(M3)
Remove CAMBER ARM FROM WHEEL CARRIER
2010 BMW M3
Remove TRAILING ARM FROM WHEEL CARRIER
Pull out and remove ball joint with special tools 33 4 465, 33 4 466, 33 4 475, 33 4 474 and 33 4 482.
Fig. 123: Removing Ball Joint Using Special Tools

Installation:
Push in new ball joint until it stops using special tools 33 4 481, 33 4 474, 33 4 475, 33 4 466 and 33 4 465.
Fig. 124: Installing Ball Joint Using Special Tools

After installation
2010 BMW M3
33 32 091 REPLACING A CONTROL ARM
NOTE: If the control arm is detached from the rear axle support, it is necessary after
Remove REAR WHEEL
Release screw.
Installation note:
If necessary, raise wheel carrier in area of brake caliper by hand.
Replace screw.
Fig. 125: Locating Brake Caliper Screw

IMPORTANT: Make sure during installation that in the connection area to the wheel carrier
the tapered end of the bearing bushing (of the rubber mount) points in the
direction of the wheel carrier.
2010 BMW M3
Fig. 126: Identifying Rubber Mount Position

NOTE: On the M3 a ball joint is fitted in the guide arm.
Fig. 127: Removing Guide Arm

Slacken nut (1).
Unscrew bolt towards rear and remove guide arm (2).
Installation note:

2010 BMW M3
After installation
Perform chassis/wheel alignment check See 3200150 KDS CHASSIS/WHEEL ALIGNMENT

VEHICLE LOAD
33 32 035 REPLACING A RUBBER MOUNT FOR TRAILING ARM IN REAR AXLE CARRIER
Remove TRAILING ARM FROM REAR AXLE CARRIER
Removing rubber mount
Mark installation position of rubber mount by way of slot to rear axle carrier.
Remove rubber mount using special tools 33 4 472, 33 4 474, 33 4 475, 33 4 466 and 33 4 465.
Fig. 128: Removing Rubber Mount Using Special Tools

Installing new rubber mount
If necessary, release knurled screws 33 4 452 and pull off mounting 33 4 455 with spring steel 33 4 456.
2010 BMW M3
Fig. 129: Inserting Rubber Mount In Special Tools

Insert rubber mount in the special tools 33 4 451, 33 4 452, 33 4 454, 33 4 453 with spray points at the top.
IMPORTANT: Clean rubber mount prior to drawing in and moisten with Loctite 638.
Spray-on points of rubber mount must point to rear!
All except for M3:
Align rubber mount by way of slot (1) at an angle to rear axle carrier.
Fig. 130: Identifying Rubber Mount Aligning Slot

M3:
2010 BMW M3

Align rubber mount by way of slot to marking on rear axle carrier.
Using special tools 33 4 471, 33 4 474, 33 4 475, 33 4 466 and 33 4 465 draw rubber mount into the rear axle
support.
Remove special tool 33 4 450 DEVICE .
Apply a thin coating of Loctite 638 to new rubber mount.
Fig. 132: Installing Rubber Mount Using Special Tools

Draw in rubber mount as far as it will go.
After installation
Carry out wheel/chassis alignment check See 3200150 KDS CHASSIS/WHEEL ALIGNMENT
2010 BMW M3

VEHICLE LOAD
33 32 021 REPLACING LEFT OR RIGHT TRAILING ARM
NOTE: If the trailing arm is detached from the rear axle support/wheel carrier, it is
Release nuts (1, 3).
Tightening torque (on rear axle support) 33 32 1AZ .
Tightening torque (on wheel carrier) 33 32 2AZ .
Unscrew bolts.
Remove trailing arm (2) downward.
Fig. 133: Removing Trailing Arm

Installation:
Note insertion direction of bolts.
After installation

VEHICLE LOAD
2010 BMW M3
33 32 071 REPLACING ONE UPPER CONTROL ARM
NOTE: If the control arm is detached from the rear axle carrier, it is necessary after
Remove REAR WHEEL
Release screw (1).
Installation:
If necessary, raise brake disk in drive flange area with workshop jack.
Replace screw.
Fig. 134: Identifying Upper Control Screw

2010 BMW M3
Fig. 135: Identifying Bearing Bushing Position

Release nut (1) and remove screw towards front.
Unclip line holder (3) for pulse generator or brake pad sensor on control arm.
Remove control arm (2).
Fig. 136: Removing Control Arm Nut

Installation:

2010 BMW M3
After installation
33 32 195 REPLACING RUBBER MOUNT FOR CAMBER ARM IN REAR AXLE SUPPORT
WARNING: Risk of burns!

cooled down.
Remove COIL SPRING

Remove CAMBER ARM FROM REAR AXLE SUPPORT
Pull out and remove rubber mount with special tools 33 4 462, 33 4 464, 33 4 463, 33 4 466 and 33 4 465.
Fig. 137: Pulling Rubber Mount Using Special Tools

Pull together rubber mount with special tools 33 4 455, 33 4 456, 33 4 452 and 33 4 451.
2010 BMW M3
Fig. 138: Installing Rubber Mount Using Special Tools

Draw rubber mount into rear axle support so that slot (1), rubber mount center point and notch (2) form a line.
Fig. 139: Identifying Rubber Mount Slot And Notch

Draw rubber mount into rear axle support as far as possible using special tools 33 4 461, 33 4 463, 33 4 466 and
33 4 465.
Remove special tool 33 4 450 DEVICE and draw in rubber mount as far as it will go.
2010 BMW M3
Fig. 140: Installing Rubber Mount Into Rear Axle Support Using Special Tools
After installation

VEHICLE LOAD
33 32 031 REPLACING RUBBER MOUNT FOR TRAILING ARM IN WHEEL CARRIER
NOTE: E90, E91 from 09/2008:

For driving dynamic reasons, both rubber mounts must be replaced on first
marks. If the punch marks are provided, the rubber mounts can be changed
again individually.
Remove TRAILING ARM FROM WHEEL CARRIER
Remove rubber mount with special tool 33 4 465, 33 4 466, 33 4 475, 33 4 474 and 33 4 472.
2010 BMW M3

Insert rubber mount with spray-on points facing upwards in special tool 33 4 451, 33 4 452, 33 4 454, 33 4 453
and pull together.
Insert rubber mount in special tool 33 4 473.
Fig. 142: Installing Rubber Mount In Special Tools

IMPORTANT: Spray-on points of rubber mount must point to rear!
Align rubber mount by way of slot (1) at an angle to wheel carrier.

2010 BMW M3

Pull rubber mount with special tool 33 4 465, 33 4 466, 33 4 475, 33 4 474 and 33 4 473 partially into the wheel
carrier.
Remove special tool 33 4 450 DEVICE and pull in rubber mount as far as it will go.
Fig. 144: Pulling Rubber Mount Using Special Tools

After installation
Carry out wheel/chassis alignment check See 3200150 KDS CHASSIS/WHEEL ALIGNMENT
VEHICLE LOAD
AXLE MOUNTING
2010 BMW M3
33 33 091 REPLACING BOTH RUBBER MOUNTS FOR REAR AXLE CARRIER (M3 FRONT LEFT
AND RIGHT ONLY)
NOTE: On the M3 the front rubber mounts must be drawn from above into the rear axle
carrier.
Remove COMPLETE REAR AXLE CARRIER
If necessary, assemble special tools 33 4 140 DEVICE , 33 4 142 and 33 4 147 as illustrated.
If necessary, position new thrust pieces 33 4 149 with countersunk screws on special tool 33 4 140 DEVICE .
Fig. 145: Assembling Special Tools (33 4 140, 33 4 142 And 33 4 147)
Oil special tool 33 4 436 slightly before use.
Withdraw rubber mount from bearing bushing with special tools 33 4 436, 33 4 437, 33 4 140 DEVICE and 33
4 431.
2010 BMW M3
Fig. 146: Removing Rubber Mount From Bearing Bushing Using Special Tools 33 4 436, 33 4 437
NOTE: Make sure special tool 33 4 140 DEVICE is correctly supported on bearing
bushing of rear axle carrier.
Fit special tool 33 4 431 on rubber mount in such a way that edge of rubber mount disappears in special tool.
IMPORTANT: Arrows (1) must point in direction of longitudinal axis!
Opening (2) on underside must point to left!
Fig. 147: Identifying Rubber Mount Position

2010 BMW M3
Installation:
Coat new rubber mount with Circo Light (sourcing reference: BMW Parts Service).
Fig. 148: Installing Rubber Mount With Special Tools

Draw in new rubber mount with special tools 33 4 432, 33 4 433, 33 4 435 and 33 4 434 as far as it will go.
After installation
33 33 001 REPLACING LEFT OR RIGHT REAR AXLE CARRIER COMPRESSION STRUT

Driving without compression struts is not permitted!
Risk of damage!
The rear axle carrier must be supported at the front is both compression struts have to be replaced!

2010 BMW M3
Release screws (1).
Installation:
Replace screws.
Fig. 149: Identifying Compression Strut With Screws

Installation:
3333101 REPLACING TWO RUBBER MOUNTS (FRONT) FOR REAR AXLE CARRIER
LOWER rear axle support.
If necessary assemble special tools 33 4 140, 33 4 142 and 33 4 147 as illustrated.
If necessary screw new synchronizing keys 33 4 149 onto special tool 33 4 140 with countersunk screws
2010 BMW M3
Fig. 150: Assembling Special Tools 33 4 140, 33 4 142 And 33 4 147

Coat top edge of rubber mount with Circo Light (refer to BMW Parts Service).
Oil special tool 33 4 436 lightly before use.
Align special tool 33 4 140 by way of openings in rubber mount.
NOTE: Ensure it is correctly supported on bearing bushing of rear axle carrier.

Using the special tools 33 4 436, 33 4 437, 33 4 140, and 33 4 431, pull rubber mount out of bearing bush.
Installation:
Coat new rubber mount with Circo Light (refer to BMW Parts Service).
2010 BMW M3
Oil special tool 33 4 434 lightly before use.
If necessary, assemble 33 4 432, 33 4 433, 33 4 435 and 33 4 434 as illustrated.
Align rubber mount by way of arrow to direction of travel.
Fig. 152: Assembling 33 4 432, 33 4 433, 33 4 435 And 33 4 434

After installation
33 33 101 REPLACING TWO RUBBER MOUNTS (REAR) FOR REAR AXLE CARRIER
Lower REAR AXLE SUPPORT
If necessary, assemble special tool 33 4 140 DEVICE , 33 4 142 and 33 4 147 as shown.
If necessary, screw new thrust pieces 33 4 149 with countersunk screws on special tool 33 4 140 DEVICE .
2010 BMW M3
Fig. 153: Assembling Special Tools (33 4 140, 33 4 142 And 33 4 147)
Coat top edge of rubber mount with Circo Light.
Fig. 154: Fitting Special Tool (33 4 441) On Rubber Mount

Align special tool 33 4 140 DEVICE by way of openings in rubber mount.
Pull rubber mount with special tools 33 4 436, 33 4 437, 33 4 140 DEVICE and 33 4 431 out of bearing bush.
Installation:
Coat new rubber mount with Circo Light.

2010 BMW M3
Insert special tool 33 4 444 in opening on rear axle carrier to avoid damaging the rear axle carrier when drawing
in the rubber mount.
If necessary, assemble special tool 33 4 442, 33 4 443, 33 4 435 and 33 4 434 as shown.
Fig. 155: Aligning Rubber Mount Using Special Tools

After installation
WHEEL BEARINGS
33 41... DETACHING WHEEL BEARING INNER RACE FROM DRIVE FLANGE (DRIVE FLANGE
REMOVED)
NOTE: Detach wheel bearing ring with special tool 33 4 400 DEVICE through groove in
wheel bearing inner ring.
Position special tool 33 1 307 on drive flange.
Select one of the following special tools using the wheel bearing inner ring and insert into special tool 33 4 401.
33 4 405 for dia. 45 - 51 mm

2010 BMW M3
33 4 407 for dia. 55 - 61 mm
Fig. 156: Inserting Wheel Bearing Ring Into Special Tool 33 4 400
Screw out special tool 33 4 402 until the tapered attachment of the spindle comes into contact with the special
tool33 4 401.
Position special tool 33 4 401 with the corresponding insert on groove of wheel bearing inner ring.
Compress special tool 33 4 401 with wrenches 33 4 403 and33 4 404 until the special tool can still be turned in
the groove.
Detach wheel bearing inner ring by turning special tool 33 4 402.
Fig. 157: Disconnecting Wheel Bearing Inner Ring Using Special Tool (33 4 402)
2010 BMW M3
33 41 000 REPLACING DRIVE FLANGE ON LEFT OR RIGHT REAR AXLE SHAFT (ON 2-FLOW
EXHAUST SYSTEM)
Remove OUTPUT SHAFT

Remove BRAKE DISK
Remove PULSE GENERATOR
Force drive flange with special tools 33 2 116/33 2 201, 33 2 160 WASHER , 33 4 200 and 5 wheel bolts out of
wheel bearing.
NOTE: Rounded inside edge of special tool 33 2 160 WASHER must point to drive
flange.
Fig. 158: Installing Drive Flange Using Special Tools

IMPORTANT: The wheel bearing is destroyed when the drive flange is removed and cannot
be reused!
Replace WHEEL BEARING .
Installation:
Install OUTPUT SHAFT .
Oil drive flange lightly and attach to splines of output shaft.

2010 BMW M3
Draw DRIVE FLANGE INTO WHEEL BEARING .
After installation
Adjust HANDBRAKE
33 41 151 REPLACING WHEEL BEARING ON LEFT OR RIGHT REAR AXLE SHAFT (ON 2-
Remove DRIVE FLANGE OF REAR AXLE SHAFT
Press retaining ring (1) together using pliers and remove.
Installation:
Install retaining ring (1).
Check seating of retaining ring (1), correct if necessary.

Pull out wheel bearing with special tools 33 3 261, 33 3 263 and 33 3 262.
2010 BMW M3
Fig. 160: Pulling Wheel Bearing Using Special Tools

IMPORTANT: Do not reuse old wheel bearing!

Black-dyed multipole seal (1) must point to center of vehicle!
Fig. 161: Identifying Black-Dyed Multipole Seal

Installation:
Check installation position of wheel bearing (1), correct if necessary.
Draw in wheel bearing (1) with special tools 33 3 261, 33 3 265 and 33 3 264.
2010 BMW M3
Fig. 162: Installing Wheel Bearing Using Special Tools 33 3 261, 33 3 265 And 33 3 264
After installation
Adjust HANDBRAKE
SHOCK ABSORBER
Situation
E32, E34, E38, E39: With the rear spring struts with self-levelling suspension, a slight oil leak usually exists at
the piston rod. These spring struts are permitted to be wet with oil over a maximum of half the shock absorber
length on the outer tube, i.e. they are permitted to "sweat".
Effect
Procedure
2010 BMW M3
33 52 000 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT SHOCK

ABSORBER
IMPORTANT: Installing shock absorbers of different manufacturers on a single axle is not

permitted!
NOTE: Use BMW part number (1) to find the matching shock absorber.
Fig. 163: Identifying BMW Part Number


Car may tilt off lifting platform if the workshop jack is incorrectly handled.
After supporting components, make sure that:

2010 BMW M3
Remove REAR WHEEL

Remove luggage compartment wheel arch trim See 5147161 REMOVING AND
WHEEL ARCH TRIM
NOTE: Read and comply with INFORMATION ON REPLACING SHOCK ABSORBERS .
Release nut; if necessary brace on hex head.
Raise wheel carrier with workshop jack until shock absorber can be removed from rubber mount.
Fig. 164: Locating Self Locking Nut

Press shock absorber together and remove from rubber mount.
Slowly lower wheel carrier until wheel carrier is suspended.
Remove workshop jack underneath car and lower car.
Installation:
Remove protective cap.

2010 BMW M3
Release nut (1); if necessary, grip at hexagon head.
Remove support bearing upper section (2).
Installation:
Replace support bearing upper section (2).
Fig. 165: Identifying Support Bearing Upper Section With Nut

Press shock absorber together and remove from wheel arch.
Installation:
Remove SUPPORT BEARING (LOWER SECTION) , check for damage and if necessary replace.
Check auxiliary damper and protective tube for damage, replace if necessary.
2010 BMW M3
Fig. 166: Identifying Wheel Arch

Replacement
Remove support pot (1) and auxiliary damper (2) with protective tube (3) from rear shock absorber (4)
Fig. 167: Identifying Rear Shock Absorber With Support Pot, Auxiliary Damper And Protective Tube

ABSORBER (M3)

Vehicle may tilt off vehicle hoist if the workshop jack is incorrectly
handled.

the vehicle does not lift off the locating plates on the vehicle hoist.
IMPORTANT: When replacing shock absorber/spring strut, renew auxiliary damper!
Remove REAR WHEEL .

Remove luggage compartment wheel arch trim See 5147161 REMOVING AND
WHEEL ARCH TRIM .

2010 BMW M3
Release screw (1).
Fig. 168: Identifying Wheel Carrier Screw

Installation note:
Tighten down bolt connection in normal position .
Replacement only:
IMPORTANT: Shock absorber and adapter lead (2) must be replaced together!
2010 BMW M3
Fig. 169: Identifying Plug Connection, Shock Absorber And Adapter Lead
Remove REST SIDE SECTION ON REAR SEAT BACK .
Disconnect plug connection (1) and expose adapter lead (2) up to shock absorber.
Installation note:
Make sure adapter lead is correctly routed.
Replacement: Remove adapter lead (2) with protective cap.

2010 BMW M3
Fig. 170: Identifying Plug Connection, Adapter Lead And Support Bearing With Nut
Installation note:
Protective cap is marked "L" for left side and "R" for right side (risk of mixing up).
Installation note:
Remove support bearing (lower section), check for damage and if necessary replace.
2010 BMW M3
Fig. 171: Identifying Shock Absorber

Replacement
Remove support pot (1) and auxiliary damper (2) with protective tube (3) from rear shock absorber (4).
Fig. 172: Identifying Rear Shock Absorber With Support Pot, Auxiliary Damper And Protective Tube
33 52 161 REPLACING SUPPORT BEARING (LOWER SECTION) FOR REAR LEFT OR RIGHT
SPRING STRUT/SHOCK ABSORBER
Remove rear shock absorber See 3352000 REMOVING AND INSTALLING/REPLACING REAR
LEFT OR RIGHT SHOCK ABSORBER or 3352010 REMOVING AND
INSTALLING/REPLACING REAR LEFT OR RIGHT SHOCK ABSORBER (M3).
2010 BMW M3
Press support bearing lower section (1) with seal grommet (2) out of shock absorber mounting.
Installation note:
Clean shock absorber mounting including contact surface (3) all round.
Insert support bearing lower section (1) in sealing grommet (2).
Fig. 173: Identifying Support Bearing Lower Section, Seal Grommet With Shock Absorber Mounting
Contact Surface
Installation note:
Coat sealing grommet as illustrated with Circolight and press into shock absorber mounting.
Fig. 174: Identifying Sealing Grommet Applying Areas

2010 BMW M3
SPRINGS WITH SUSPENSION

33 53... MEASURING RIDE-LEVEL HEIGHT OF VEHICLE
Move vehicle into NORMAL POSITION
Fig. 175: Identifying Actual Ride Height From Lower Edge Of Wheel Arch To Rim Flange
33 53 000 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT COIL SPRING
IMPORTANT: Both coil springs on the relevant axle must be replaced in the event of
corrosion breakage.
The spring pads at the top and bottom must also be renewed when replacing
the coil springs.
Avoid damaging the coil spring coating.
NOTE: The coil spring is allocated in the Electronic Parts Catalogue (EPC) under the
item "Spring table" after the vehicle identification number has been entered and
the optional equipments of the car have been selected.
WARNING: Before using the special tool 33 5 010 SPRING TENSIONER take care to
read through the Owner's Handbook!
All the safety information and instructions contained in the Owner's
2010 BMW M3
6. Impact screwdrivers are prohibited!
Remove REAR WHEEL .
Removal
Insert lower spring cup 33 5 012 centrally into coil spring and turn to lowest winding.
Guide spindle 33 5 013, 33 5 014 THRUST PIECE WITH SPLINED KEY , 33 5 015 from below through
the camber link and the lower spring cup 33 5 012.
Fig. 176: Inserting Lower Spring Plate (33 5 012) Into Coil Spring
Insert top spring cup 33 5 011 sideways into coil spring and turn to the uppermost winding.
IMPORTANT: Make sure spindle (hexagonal) is correctly seated in upper spring cup 33 5 011!
Pull spindle 33 5 013 down.

2010 BMW M3
Fig. 177: Inserting Top Spring Plate (33 5 011) Into Coil Spring

Make sure coil spring is correctly positioned in spring cups.
Fig. 178: Identifying Coil Spring Position

IMPORTANT: Centre special tools 33 5 011, 33 5 012, 33 5 013, 33 5 014 THRUST PIECE WITH
SPLINED KEY , 33 5 015 to achieve the greatest possible contact surface with
the coil spring.
2010 BMW M3

Check installed position of the special tool 33 5 011, 33 5 012 and 33 5 013, 33 5 014 THRUST PIECE WITH
SPLINED KEY , 33 5 015, and correct as needed.
Tighten coil spring using special tools 33 5 016 and 33 5 020 REVERSIBLE RATCHET , gripping the
spindle of the spring tensioner with special tool 33 5 017.
Remove coil spring upwards.
Fig. 180: Tightening Coil Spring Using Special Tools (33 5 016 And 33 5 020)
If necessary, relieve tension on coil spring.
IMPORTANT: Replacement only:

Bottom end of coil spring (1) must be flush with opening of spring cup 33 5 012
(see dotted-dashed line)!
2010 BMW M3
Fig. 181: Identifying Bottom End Of Coil Spring With Opening Of Spring Plate 33 5 012
Installation
Check spring pads (2, 3) for damage.
Remove spring cup (1) and position with upper spring pad (2) on coil spring.
NOTE: Upper spring pad (2) must come into contact with end of coil spring.
Equipment specification with bad-road package: Install adapter as well.
Fig. 182: Identifying Spring Pad With Spring Cup

IMPORTANT: Observe the following when installing and relieving tension on coil spring:
Lower spring pad must be positively seated in the designated receptacle in the camber arm
2010 BMW M3
Fig. 183: Locating Lower Spring Pad Contact With End Of Coil Spring
NOTE: Otherwise there is a risk of the coil spring jumping out sideways.
Lower spring pad must come into contact with end of coil spring (see arrow)
Lower spring pad must rest flush on last coil (see broken line)
Align coil spring by way of spring cup to opening in side member and relieve tension.
Remove special tools 33 5 011, 33 5 012 and 33 5 013, 33 5 014 THRUST PIECE WITH SPLINED KEY ,
33 5 015.

After installation
Check HEADLIGHT ADJUSTMENT , correct if necessary.

2010 BMW M3
STABILIZER BAR
33 55 000 REMOVING AND INSTALLING/REPLACING REAR ANTI-ROLL BAR
IMPORTANT: M3:
When installing the anti-roll bar, make sure the two rubber mount halves are
correctly installed and correctly engaged on both sides (in the retaining
bracket).

Remove LEFT CONTROL ARM ON WHEEL CARRIER
Remove both ANTI-ROLL BAR LINKS FROM ANTI-ROLL BAR
Lower REAR AXLE SUPPORT
NOTE: To simplify the picture, anti-roll bar removal is shown on the removed rear axle.
Release screws (1).
Remove both RUBBER MOUNTS FROM ANTI-ROLL BAR .
Turn anti-roll bar (2) and remove sideways.
Fig. 185: Identifying Anti-Roll Bar With Screws

Installation:
Check both RUBBER MOUNTS FOR DAMAGE and replace if necessary.

2010 BMW M3
After installation
33 55 040 REPLACING ANTI-ROLL BAR LINKS FOR STABILIZER BAR
Remove OUTPUT SHAFT.
Release nut (1), brace with special tool 31 1 140 .
Release screw (2).
Remove anti-roll bar link (3) towards top.
Installation note:
Replace self-locking nut and screw.
Fig. 186: Identifying Anti-Roll Bar Link, Nut, And Screw

33 55 021 REPLACING BOTH RUBBER MOUNTS FOR STABILIZER MOUNTING (M3)
pairs.

2010 BMW M3
Remove STABILIZER FROM REAR AXLE CARRIER
IMPORTANT: When installing the stabilizer, make sure the two rubber mount halves are
correctly installed and correctly engaged on both sides.
NOTE: Insert screwdriver on both sides between retaining bracket (1) and rubber
mount upper section (2)/rubber mount lower section (3).
Remove rubber mount upper section (2) and rubber mount lower section (3).
Fig. 187: Identifying Retaining Bracket, Rubber Mount Upper And Lower Section
Installation:
Keep retaining bracket, rubber mount lower section (1), rubber mount upper section (2) and stabilizer clean and
free from oil and grease.
Mount rubber mount upper section (1) and rubber mount lower section (2) by way of edge (3) as pictured on
stabilizer (observe direction of travel).
2010 BMW M3
Fig. 188: Identifying Rubber Mount Upper And Lower Section

2010 BMW M3
SUSPENSION Rear Axle - Repair Instructions - M3
SUSPENSION
Rear Axle - Repair Instructions - M3
GENERAL
Headaches
Dizziness
Stomach aches
Vomiting
Diarrhoea
Cramps/fits
Unconsciousness

First aid measures:
Danger of injury!

2010 BMW M3
Impaired sight

First aid measures:

Recycling:
00 ... ... RAISING VEHICLE WITH TROLLEY JACK

2010 BMW M3

contact points.
necessary.
Fig. 1: Identifying Trolley Jack

points!

2010 BMW M3
Fig. 2: Identifying Car Jacking Point

Fig. 3: Identifying Car Jacking Point On Front Axle Carrier

33 .. . REAR AXLE LAYOUT

2010 BMW M3

Safety precautions&general information
Facts:
E32, E34, E38, E39: In the case of rear spring struts with ride-height control, there is always a slight oil
spillage on the piston rod. These spring struts are permitted to be wet with oil over a maximum of half the shock
absorber length on the outer tube, i.e. they are permitted to "sweat".
Consequence:
2010 BMW M3
Procedure:
Fig. 5: Identifying Damage Helicoil Thread

NOTE: Damaged threads in the frame side member may be repaired with Helicoil
thread inserts. Comply with the procedure described in the example.
33 00 ... REAR AXLE: WHEEL/CHASSIS ALIGNMENT CHECK MUST BE CARRIED OUT AFTER
THE FOLLOWING WORK
2010 BMW M3

A wheel/chassis alignment check must be carried out after the following work:

Camber arm to rear axle carrier / wheel carrier
Trailing arm to rear axle carrier / wheel carrier
Guide arm to rear axle carrier
Toe arm to rear axle carrier / wheel carrier
Control arm to rear axle carrier

2. Camber arm / rubber mount / ball joint
3. Trailing arm / rubber mount
4. Guide arm
5. Wheel carrier / rubber mount / ball joint
6. Toe arm
7. Control arm
2010 BMW M3
33 10 ... OVERVIEW OF REAR DIFFERENTIAL/OUTPUT SHAFTS
Fig. 7: Identifying Rear Differential/Output Shafts Components

Safety precautions&general information
33 31 ... OVERVIEW OF REAR AXLE CARRIER WITH RUBBER MOUNTS

2010 BMW M3
Fig. 8: Identifying Rear Axle Carrier With Rubber Mounts Components

33 32 ... OVERVIEW OF STEERING LINKS

2010 BMW M3
Fig. 9: Identifying Steering Links Components

41 00 ... INSTALLATION SOLUTION FOR STRAIGHT SHANK/HEXAGON RIVET NUT

Straight shank rivet nut:


2010 BMW M3
Fig. 10: Identifying Bore Mark


inserted
be used.
Fig. 11: Drilling Bore

2010 BMW M3




5. Set straight shank rivet nut with hand rivet gun

2010 BMW M3
thread.
Fig. 14: Setting Straight Shank Rivet Nut With Hand Rivet Gun
Hexagon rivet nut (up to M8 thread):

1. Set hexagon rivet nut with hand rivet gun

thread.
Fig. 15: Setting Hexagon Rivet Nut With Hand Rivet Gun

2010 BMW M3
IMPORTANT: Ensure correct screw length. The complete thread length of the rivet nut must
be used for installation.
Rivet nut is pressed onto the component (screw slowly becomes difficult to move). Procedure is finished with
the fitting of the relevant component and its tightening torque.

41 00 ... REPAIR SOLUTION FOR STRAIGHT SHANK/HEXAGON RIVET NUT


2010 BMW M3
Fig. 17: Drilling Rivet Head With Larger Drill Bit/Countersink

Fig. 18: Removing Rivet Head With Chisel


2010 BMW M3
Fig. 19: Identifying Rivet Shank Into Cavity



Follow instructions on corrosion protection. See 41 00 ... CORROSION
PROTECTION .
2010 BMW M3


Observe notes on cavity foam. See 41 00 ... WORKING WITH 2-
COMPONENT PU CAVITY FOAM .
IMPORTANT: To avoid corrosion and rattling noises, stop chips/swarf and rivet nut
shank with cavity foam.
Remove foam remnants with isohexane (cleaning-grade petroleum spirit).
Fig. 22: Removing Foam Remnants With Isohexane

2010 BMW M3
Hexagon rivet nut (up to M8 thread), straight shank rivet nut:

Fig. 23: Fitting Rivet Nut


thread.
Rivet nut is pressed onto the component (screw slowly becomes difficult to move). Procedure is finished
with the fitting of the relevant component and its tightening torque.
2010 BMW M3

FINAL DRIVE
00 11 ... CHECKING/TOPPING UP OIL LEVEL IN REAR DIFFERENTIAL (M3)


To avoid serious damage to the rear axle differential, it is essential to use only
approved transmission oils in the rear axle differential. See REAR AXLE -
OPERATING FLUIDS .
Undo oil filler plug (1).
Check oil level.
If necessary, pour in rear differential oil up to lower edge of opening for oil filler plug (1).
Installation:
Replace oil filler plug.
Tightening torque 33 11 3AZ . See 33 11 REAR DIFFERENTIAL CASE WITH COVER .

2010 BMW M3
Fig. 25: Identifying Oil Filler Plug

00 11 259 OIL CHANGE IN REAR DIFFERENTIAL INCL. USED OIL DISPOSAL
WARNING: Risk of burning if exhaust system is touched!

Danger of poisoning if oil is ingested/absorbed through the skin!

To avoid serious damage to the rear differential, it is essential to use only
approved transmission oils in the rear differential. See REAR AXLE -
OPERATING FLUIDS .
NOTE: Only change oil when rear differential is at normal operating temperature.
Recycling:
Catch and dispose of emerging differential oil.

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

2010 BMW M3
Open plug (2).
Add differential oil up to lower edge of opening for screw plug (2).
Replace screw plug.

33 10 ... REAR DIFFERENTIAL: ASSIGNMENT TO MODEL SERIES
REAR DIFFERENTIAL REFERENCE

Model series Engine Rear differential Remark
N43, N45, N46, N52 (323i) 168L
M47T2,
M57T2,
188L / 188LW
E90 N47, N51,
N52, N53
M57T2 (330d, 335d), N54
215L / 215LW
Manual transmission: M57T2 (325d, 330xd)
N43, N46, N52 (323i) 168L
M47T2,
M57T2, 188L / 188LW
E91
N52, N53
M57T2 (330d, 335d), N54
215L / 215LW
N43, N46, 168L
M57T2,
2010 BMW M3
N47, N51,
188L / 188LW
N52, N53
E92 M57T2 (330d, 335d), N54
215L / 215LW
S65 215 with lock
N43, N46 168L
M57T2,
E93 N51, N52, 188L / 188LW
N53
M57T2 (330d), N54 215L / 215LW
L Light-running
LW Light-running, efficiency-optimized
33 10 010 REMOVING AND INSTALLING/REPLACING REAR DIFFERENTIAL (M3)
00 2 030
33 5 200
33 5 206

Rear differential must be lashed with tightening strap 33 5 206 to prevent
it falling out when the output shafts are forced off.
Remove propeller shaft from rear differential and tie back. See 26 11 000 REMOVING AND
INSTALLING COMPLETE PROPELLER SHAFT (CONSTANT-VELOCITY JOINT) .
Remove both output shafts from rear differential and tie back.
Position special tool 33 5 200 on workshop jack 00 2 030 .
Support rear differential with special tool 33 5 200 .
Lash rear differential with tightening strap 33 5 206 to special tool 33 5 200 .
Slowly lower workshop jack 00 2 030 .

2010 BMW M3

IMPORTANT: Adhere to the following installation sequence in order to prevent distortion of

the rear differential during installation and thereby avoid potential complaints
about noise.
1. Install rear differential with workshop jack 00 2 030 and special tool 33 5 200 in rear axle carrier
2. Insert bolts (1) (do not tighten down)
3. Insert bolt (2) from rear and replace nut (do not tighten down)
4. Lower workshop jack 00 2 030
5. Tighten down screws (1)
Tightening torque 33 17 1AZ . See 33 17 REAR AXLE DIFFERENTIAL MOUNTINGS .
6. Tighten down screw (2)
Tightening torque 33 17 1AZ . See 33 17 REAR AXLE DIFFERENTIAL MOUNTINGS .

2010 BMW M3

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

33 11 ... REPLACING REAR COVER GASKET ON REAR DIFFERENTIAL (215 WITH LOCK)
cars with liquid sealing compounds! To prevent the differential oil from
foaming over, make sure that no remnants of the liquid sealing compound are
pressed into the rear differential housing.
Release screws (1). Tightening torque (M10x82) 33 11 1AZ . Remove cover (2). If necessary, remove remnants
of liquid sealing compound with scraper. Clean sealing face on cover and rear differential. Installation: If a
paper gasket was fitted, a paper gasket or liquid sealing compound can be used. The liquid sealing compound
can be found in Main Group 33 in the Electronic Parts Catalogue.
2010 BMW M3

33 11 ... REPLACING O-RING FOR SIDE COVER ON REAR DIFFERENTIAL ON LEFT OR RIGHT
(M3)
Remove drive flange from rear differential
Mark installation position of side cover (2) to housing.
Press cover (2) with two screwdrivers off housing.
Installation:
Markings (3) on cover and housing must match up.
Tighten screws crosswise.

2010 BMW M3
Fig. 30: Identifying Side Cover And Markings

Raise mount and remove cover (1) with ring (2).
Installation:
Insert cover with ring in housing.
Raise mount and slide in cover as far as it will go.
Fig. 31: Identifying Cover And Ring

Installation:
Clean contact surface (1) for O-ring all round.

2010 BMW M3
Fig. 32: Identifying Contact Surface For O-Ring

Replace O-ring (1).
Installation:
Keep drain opening (2) for gear oil clean.
Moisten O-ring with approved differential oil.
Fig. 33: Identifying O-Ring And Drain Opening

After installation:
Check rear differential oil level , correct if necessary
33 11 ... REPLACING REAR COVER GASKET ON REAR DIFFERENTIAL (168L)

2010 BMW M3
Release screws (1).
Tightening torque (M10x60) 33 11 1AZ . See 33 11 REAR DIFFERENTIAL CASE WITH COVER .
Unscrew screws (2).
Remove cover.
Installation:
The liquid gasket can be found in Main Group 33 in the Electronic Parts Catalogue.

33 11 ... REPLACING REAR COVER GASKET ON REAR DIFFERENTIAL (188L / 188LW)
2010 BMW M3
Release screws (1).
Unscrew screws (2).
Remove cover.
Installation:

33 11 ... REPLACING REAR COVER GASKET ON REAR DIFFERENTIAL (215L / 215LW)

2010 BMW M3
Remove cover.
Installation:

33 11 021 REPLACING SHAFT SEAL FOR INPUT FLANGE ON REAR DIFFERENTIAL
00 5 010
00 5 500
23 0 020
23 1 300
23 1 302
23 1 303
2010 BMW M3
See MANUAL TRANSMISSION - SPECIAL TOOLS
31 2 101
31 2 102
31 2 103
31 2 104
See FRONT AXLE - SPECIAL TOOLS
33 1 150
33 1 341
33 3 390
33 3 440
33 3 470
33 3 480
33 3 490
IMPORTANT: Use only approved gear oils.

Failure to comply with this instruction will result in serious damage to the rear
differential!
Remove propeller shaft from rear differential and tie back
Removing drive flange:
Lift out retaining plate.
Mark position of collar nut (1) on drive shaft with peening tool.
2010 BMW M3

Brace drive flange with special tool 23 0 020 and release collar nut.
Fig. 38: Releasing Collar Nut

NOTE: Read and comply with document "Rear differential: Assignment to model
series" .
215L / 215LW / 215 with lock:
Remove drive flange with special tools 31 2 101 , 31 2 102 , 31 2 103 / 31 2 104 .
2010 BMW M3
Fig. 39: Removing Drive Flange With Special Tools

168L / 188L / 188LW:
Remove drive flange with special tool 33 1 150 .
Fig. 40: Locating Drive Flange Bolts

Replacing shaft seal:
Withdraw shaft seal with special tool 00 5 010 .

2010 BMW M3
Fig. 41: Removing Shaft Seal

Drive in new shaft seal with following special tools (depending on rear differential ) as far as it will go.
168L: Use special tools 00 5 500 and 33 3 390

188L / 188LW: Use special tools 00 5 500 and 33 3 470
215L / 215LW / 215 with lock: Use special tools 00 5 500 and 33 3 440
Fig. 42: Installing Shaft Seal

Installing drive flange:
Coat sealing lips of shaft seal and sealing surface of drive flange with differential oil.
Fit drive flange.
Press on drive flange with special tools 23 1 300 , 33 1 341 and 23 1 303 , if necessary 23 1 302 until collar nut
can be screwed on.
2010 BMW M3
Fig. 43: Installing Drive Flange

IMPORTANT: Do not under any circumstances tighten down collar nut beyond marker points
in order to avoid damaging the clamping sleeve.
Tighten down collar nut (1) to point where marker points are aligned.

Drive in new retaining plate with following special tools (depending on rear differential ) as far as it will go.
168L / 188L / 188LW: Use special tools 00 5 500 and 33 3 480

215L / 215LW / 215 with lock: Use special tools 00 5 500 and 33 3 490
2010 BMW M3
Fig. 45: Installing Retaining Plate

After installation:
Correct rear differential fluid level . See 00 11 ... CHECKING/TOPPING UP OIL LEVEL IN
REAR DIFFERENTIAL (M3) .
33 11 091 REPLACING DRIVE FLANGE ON LEFT OR RIGHT OF REAR DIFFERENTIAL (M3)
NOTE: When replacing the drive flange, you must also replace the shaft seal .
L Drive flange, left
R Drive flange, right


2010 BMW M3
Remove output shaft from rear differential and tie back
Press drive flange (1) with suitable screwdrivers off rear differential.
Installation:
Replaced deformed or damaged dust plates.
Insert drive flange and rotate until spline on flange meshes with teeth on differential bevel gear.
Press drive flange in further until circlip locates with an audible click.
IMPORTANT: High installation forces indicate that the spline teeth on the drive
flange/differential bevel gear are damaged/deformed!
Check spline teeth, replaced damaged parts.

Replace circlip (1).
Installation:
twist retaining ring until both ends settle into the groove.
Clean shaft seal race on drive flange thoroughly.
Coat drive flange at contact face of shaft seal with approved rear differential oil . See REAR AXLE -
OPERATING FLUIDS .
2010 BMW M3

Replacement:
Replace shaft seal .
After installation:
Check rear differential oil level , correct if necessary. See 00 11 ... CHECKING/TOPPING UP OIL
LEVEL IN REAR DIFFERENTIAL (M3) .
33 11 151 REPLACING SHAFT SEAL FOR DRIVE FLANGE LEFT OR RIGHT
00 5 010
00 5 500
32 1 060
33 1 308
33 3 400
33 4 240
33 4 250
33 5 030

2010 BMW M3
Remove drive flange from rear differential

If necessary, press off dust cover
Withdraw shaft seal with special tools 00 5 010 and 32 1 060 / 33 1 308 .
Fig. 49: Removing Shaft Seal With Special Tools

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

2010 BMW M3
Fig. 50: Installing Shaft Seal With Special Tools

After installation:
Correct gearbox oil level/change differential oil . See REAR AXLE - OPERATING FLUIDS .
33 11 271 REPLACING REAR COVER GASKET ON REAR DIFFERENTIAL
damage.
Draw off/drain differential oil . See 00 11 259 OIL CHANGE IN REAR DIFFERENTIAL INCL.
USED OIL DISPOSAL .
NOTE: Read and comply with Rear differential: Assignment to model series .
Select rear differential:
168L
188L / 188LW
215L / 215LW
215 with lock
After installation:
Add rear differential oil See 00 11 ... CHECKING/TOPPING UP OIL LEVEL IN REAR
DIFFERENTIAL (M3) .
2010 BMW M3
33 11 271 REPLACING COVER GASKET ON REAR DIFFERENTIAL (235L)
damage. To avoid leaks from the rear differential cover, do not use a paper
gasket in cars with liquid sealing compounds! To prevent the differential oil
from foaming over, make sure that no traces of the liquid gasket are pressed
into the housing.
Necessary preliminary tasks: Drain and catch rear differential oil. Remove rear axle final drive.
Fig. 51: Identifying Rear Axle Screws

Release screw (1). Tightening torque (M10x50) 33 11 1AZ, see 33 11 REAR DIFFERENTIAL CASE WITH
COVER . Unfasten screws (2). Tightening torque (M10x25) 33 11 1AZ, see 33 11 REAR DIFFERENTIAL
CASE WITH COVER . Remove cover. If necessary, remove remnants of liquid sealing compound with
scraper. Clean sealing face on cover and rear differential.
Installation note: If a paper gasket was fitted, a paper gasket or liquid sealing compound can be used. After
installation: Add rear differential oil
FINAL DRIVE MOUNTING

33 17 004 REPLACING ALL FRONT RUBBER MOUNTS FOR REAR DIFFERENTIAL MOUNTING
33 3 312
33 4 161
33 4 162
33 4 166
33 4 311
2010 BMW M3
33 4 312
33 4 465
33 4 466
Withdrawing front rubber mount:
Withdraw front rubber mount with special tools 33 3 312 , 33 4 161 , 33 4 162 , 33 4 466 and 33 4 465 .
NOTE: Milled recess of special tool 33 4 161 must point upwards to rear axle carrier.
Fig. 52: Removing Front Rubber Mount With Special Tools

Installing front rubber mount:
IMPORTANT: Coat bearing bushing in rear axle carrier and front rubber mount with
Circolight).
Front rubber mount must be aligned by way of slots (1) to vehicle transversal direction.
2010 BMW M3
Fig. 53: Identifying Front Rubber Mount Slots

Insert front rubber mount in special tool 33 4 311 .
Align front rubber mount so that side slots (1) line up with marking (M) on tool.
Fig. 54: Identifying Front Rubber Mount Side Slots

Draw in front rubber mount with special tools 33 4 465 , 33 4 466 , 33 4 166 , 33 4 311 and 33 4 312 as far as it
will go.
2010 BMW M3
Fig. 55: Installing Front Rubber Mount With Special Tools

33 17 005 REPLACING RUBBER MOUNT FOR REAR DIFFERENTIAL MOUNTING AT REAR

(M3)
33 0 100
33 0 101
33 0 102
33 0 103
33 0 104
33 0 105
33 0 106
Withdraw PUR mount with special tools 33 0 101 , 33 0 102 , 33 0 105 , 33 0 106 from rear axle carrier (1).
2010 BMW M3
Fig. 56: Removing PUR Mount With Special Tools

IMPORTANT: Coat bearing bushing in rear axle carrier and new rear PUR mount (2) with
Circolight.
Draw PUR mount (2) in direction of arrow with special tools 33 0 103 , 33 0 104 , 33 0 105 and 33 0 106 into
rear axle carrier (1).
Installation:
Observe mounting sequence.
Fig. 57: Installing PUR Mount With Special Tools

Mounting sequence:
To avoid damaging the PUR mount (1), draw in the mount in stages.
2010 BMW M3
Procedure:
Draw PUR mount (1) 5 mm into rear axle carrier

Release special tool 33 0 100 .
Turn special tool 33 0 103 in direction of arrow (A) 45
Repeat procedure until PUR mount (1) is pressed in up to stop
Fig. 58: Identifying PUR Mount

OUTPUT SHAFTS
33 21 ... PRESSING OUTPUT SHAFT OUT OF DRIVE FLANGE AND DRAWING IN (OUTPUT
SHAFT REMOVED FROM REAR DIFFERENTIAL)
33 2 111
33 2 115
33 2 116
33 2 117
33 2 118
33 2 119
33 2 160
33 2 201
33 2 202
33 2 203
33 2 205
33 2 206
2010 BMW M3
33 2 207
33 5 070

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

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

Special tool 33 2 200:
Screw on special tool 33 2 203 , 33 2 207 and 33 2 201 with all wheel studs to drive flange.
070 .
2010 BMW M3

Screw special tool 33 2 205 / 33 2 206 onto output shaft.

Mount special tool 33 2 201 with three wheel studs to drive flange.
tools 33 2 202 and 33 5 070 .
2010 BMW M3
Fig. 62: Mounting Special Tool With Three Wheel Studs To Drive Flange
Special tool 33 2 100:
Screw on special tool 33 2 111 , 33 2 117 and 33 2 116 with all wheel studs to drive flange.
070 .
Fig. 63: Securing Output Shaft


2010 BMW M3
Screw special tool 33 2 118 / 33 2 119 onto output shaft.

Mount special tool 33 2 116 with three wheel studs to drive flange.
tools 33 2 202 and 33 5 070 .
Fig. 65: Mounting Special Tool With Three Wheel Studs To Drive Flange
33 21 ... RIBBED TEETH
IMPORTANT: Bolts with ribbed teeth must be replaced after they have been released!
2010 BMW M3
Fig. 66: Identifying Ribbed Teeth

33 21 000 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT OUTPUT SHAFT (ON 2-

Remove rear wheel . See WHEEL AND TIRES - REPAIR .
IMPORTANT: Expand turning lock sufficiently to avoid damaging thread when releasing
collar nut.
Release collar nut (1), activate handbrake for this purpose.
Installation:
Replace collar nut, oil collar nut/wheel bearing contact surface only and tighten down.
No oil permitted on thread of shaft journal or collar nut.
Tightening torque 33 41 1AZ . See 33 41 WHEEL BEARINGS .
Secure collar nut by positive peening on flat areas of output shaft.

2010 BMW M3

E91, E93: Remove tension strut (on rear axle) . See 51 71 482 REMOVING AND
INSTALLING/REPLACING LEFT OR RIGHT TENSION STRUT (ON REAR AXLE)
Except M3: Lower exhaust system in rear area .
M3: Remove final muffler . See 18 12 030 REMOVING AND INSTALLING/REPLACING REAR
MUFFLER (S65) .
Release bolts and remove with washers (1).
Press output shaft off drive flange using a suitable tool; if necessary, raise wheel carrier with workshop jack
approx. 20 mm.
Installation:
Before installing output shaft, make sure that drive flange is fully engaged in rear differential.
Replace bolts and washers (1).
Tightening torque 33 21 1AZ . See 33 21 OUTPUT SHAFT .

2010 BMW M3
Fig. 68: Identifying Bolts And Washers

Press output shaft out of drive flange and remove towards center of vehicle.
After installation:
Check that output shaft is correctly seated in rear differential.
33 21 071 REPLACING BOTH GAITERS ON LEFT OR RIGHT OUTPUT SHAFT (ON 2-FLOW
EXHAUST SYSTEM)
21 2 120
26 1 110
See PROPELLER SHAFT - SPECIAL TOOLS
33 2 100
Remove output shaft
Removing inner gaiter:
Clean output shaft and clamp with a cloth in vice.

2010 BMW M3
Using a suitable tool, force gaiter cap (2) off joint or sealing cover.
Fig. 69: Identifying Hose Clip And Gaiter Cap

Push back gaiter with cap.

Make sure that joint does not fall apart.
Clamp joint (1) in vice.
Using a suitable tool, force sealing cover (2) off joint (1).
Fig. 70: Identifying Clamp Joint And Sealing Cover

IMPORTANT: Mark positions in relation to each other of ball hub, ball cage and joint at ends.
2010 BMW M3
NOTE: If the joint falls apart, it can only be reassembled correctly with the aid of the
markings.
Fig. 71: Identifying Ball Hub And Ball Cage

Remove circlip (1).

Grip output shaft.
Using special tool 26 1 110 and a suitable tool (for hollow shaft 21 2 120 ), press output shaft out of joint (1).
Clean joint (1) carefully.
Detach gaiter from output shaft.

2010 BMW M3
Fig. 73: Identifying Output Shaft Out Of Joint

Removing and installing outer gaiter:
Release hose clamps (1, 3) and detach gaiter (2) from output shaft.
Clean joint and output shaft carefully.
Check joint for damage; if necessary, replace output shaft .
Fill joint with propeller shaft grease.
Fit gaiter (2) on bellows and secure with hose clamps (1, 3).
Fig. 74: Identifying Gaiter And Hose Clamps

2010 BMW M3
Installing inner gaiter:
Push gaiter with cap onto output shaft (1).
Mount special tool 33 2 100 with corresponding shell inserts on output shaft (1).
Press joint (2) over bearing inner race onto output shaft.
Fig. 75: Identifying Output Shaft And Joint

Install new circlip (1).

IMPORTANT: Keep sealing faces of cap and joint (on both sides) clean and free from grease.
Fill joint at both ends with high-temperature grease.

2010 BMW M3
Fig. 77: Identifying Sealing Faces Of Cap And Joint


Do not install gaiter with cap and sealing cover on joint without shims.
Apply a thin coating of sealing compound to sealing faces of sealing cover and cap.
Install sealing cover (1) with two bolts, shims and nuts on joint.
Fig. 78: Identifying Sealing Cover

Install cap (1) with two bolts, shims and nuts on joint.
Fit hose clamp (2).

2010 BMW M3
Fig. 79: Identifying Hose Clamp And Cap

REAR SUB-FRAME
33 31 000 REMOVING AND INSTALLING COMPLETE REAR AXLE CARRIER


Remove both rear wheels . See WHEEL AND TIRES - REPAIR .

Remove propeller shaft . See 26 11 000 REMOVING AND INSTALLING COMPLETE
PROPELLER SHAFT (CONSTANT-VELOCITY JOINT) .
If necessary, remove tension strut(s) . See 51 71 482 REMOVING AND
INSTALLING/REPLACING LEFT OR RIGHT TENSION STRUT (ON REAR AXLE) .
Remove both rear coil springs
Remove both pulse generators from wheel carrier , unclip line from control arm and rear axle carrier.
See 34 52 535 REPLACING A REAR PULSE GENERATOR .
Disconnect plug connection for brake pad sensor . See 34 35 003 REPLACING A BRAKE PAD
SENSOR (REAR)
2010 BMW M3
Disconnect plug connection from ride-height sensor and unclip line from rear axle carrier
Disengage both handbrake Bowden cables from expander lock and then remove from hanging hooks.
See 34 41 120 REMOVING AND INSTALLING OR REPLACING BOTH HANDBRAKE
BOWDEN CABLES .
Remove both shock absorbers from rubber mount/camber arm
NOTE: The subsequent procedure is described in the document Lowering/raising rear

axle carrier .
After installation:
Bleed braking system . See BRAKE TESTING AND BLEEDING .

Adjust handbrake if the setting of the adjustment unit was changed during disengagement and
33 31 011 REPLACING REAR AXLE CARRIER



Remove complete rear axle carrier
If necessary, remove both brake calipers with brake pad sensor (disconnect brake hose from brake line). See
CALLIPER (TEVES) .
Remove both brake discs. See 34 21 320 REMOVING AND INSTALLING OR REPLACING BOTH
REAR BRAKE DISCS .
2010 BMW M3
Remove both brake lines from rear axle carrier.
Remove stabilizer bar (remove stabilizer links from wheel carrier).
Remove ride-height sensor with holder from rear axle carrier. See 37 14 512 REPLACING REAR RIDE-
HEIGHT SENSOR (M3) .
Fig. 80: Identifying Rear Axle Carrier

Remove both camber arms on rear axle carrier.
Remove both toe arms on rear axle carrier.
Remove both trailing arms on rear axle carrier.
Remove both guide arms on rear axle carrier.
Remove both control arms on rear axle carrier.
Remove both wheel carriers with output shaft and all arms from rear axle carrier.
2010 BMW M3
Fig. 81: Identifying Wheel Carriers With Output Shaft

If necessary, unclip stoneguard (1) on left and right in marked areas and remove.
Installation:
Replace damaged stoneguard.
Fig. 82: Identifying Stoneguard

After installation:
Bleed braking system . See 34 00 050 BLEEDING BRAKE SYSTEM WITH DSC .
Adjust handbrake if the setting of the adjustment unit was changed during disengagement and
Perform chassis alignment check .
33 31 503 LOWERING/RAISING REAR AXLE CARRIER (M3, UNIVERSAL LIFTER)

2010 BMW M3
00 2 030
31 5 250
31 5 255
31 5 256
See STEERING AND WHEEL ALIGNMENT - SPECIAL TOOLS .


Remove both rear coil springs.

Remove rear muffler . See 18 12 030 REMOVING AND INSTALLING/REPLACING REAR
MUFFLER (S65) .
2010 BMW M3
Fig. 83: Identifying Clutch Pedal Down To Floor

Installation:
Fig. 84: Identifying Banjo Bolts And Brake Hoses

2010 BMW M3
Slacken nut (1).
Release screws (2) and lay heat shield (3) on exhaust system.
Fig. 85: Identifying Screws, Nut And Heat Shield

Engage special tool 31 5 250 with a 2nd person helping completely on workshop jack 00 2 030 .
Fig. 86: Identifying Special Tools In Telescopic Supports


2010 BMW M3
Support rear axle carrier by operating workshop jack 00 2 030 .
Fig. 87: Supporting Rear Axle Carrier With Workshop Jack

Remove compression struts (1).
Release screws (2) and remove stop plate.
Installation:
First install compression struts (1) and then tighten down screws (2).
Tightening torque 33 33 1AZ . See 33 33 REAR AXLE SUSPENSION .

2010 BMW M3
Fig. 88: Identifying Compression Struts And Screws

After installation:
Bleed braking system. See 34 00 050 BLEEDING BRAKE SYSTEM WITH DSC .
CONTROL ARMS AND STRUT

33 32 021 REPLACING LEFT OR RIGHT TRAILING ARM
NOTE: If the trailing arm is detached from the rear axle carrier/wheel carrier, it is
Release nuts (1, 3).
Unscrew bolts.
Remove trailing arm (2) downwards.
Installation:
Note insertion direction of bolts.
Tightening torque (on rear axle carrier) 33 32 1AZ . See 33 32 CONTROL ARMS AND STRUTS .
Tightening torque (on wheel carrier) 33 32 2AZ . See 33 32 CONTROL ARMS AND STRUTS .
2010 BMW M3
Fig. 89: Identifying Trailing Arm, Nut And Bolts

After installation:
Perform chassis alignment check
33 32 031 REPLACING RUBBER MOUNT FOR TRAILING ARM IN WHEEL CARRIER
33 4 450
33 4 451
33 4 452
33 4 453
33 4 454
33 4 465
33 4 466
33 4 472
33 4 473
33 4 474
33 4 475
NOTE: E90, E91 from 09/2008:

For driving dynamic reasons, both rubber mounts must be replaced on first
marks. If the punch marks are provided, the rubber mounts can be changed
again individually.
2010 BMW M3
Remove trailing arm from wheel carrier
Removing rubber mount:
Pull out rubber mount with special tools 33 4 465 , 33 4 466 , 33 4 475 , 33 4 474 and 33 4 472 .
Fig. 90: Removing Rubber Mount With Special Tools

Installing new rubber mount:
Insert rubber mount with spray-on points facing upwards in special tools 33 4 451 , 33 4 452 , 33 4 454 , 33 4
453 and pull together.
Insert rubber mount in special tool 33 4 473 .
Fig. 91: Inserting Rubber Mount In Special Tool

2010 BMW M3
IMPORTANT: Spray-on points of rubber mount must point to rear!
Align rubber mount by way of slot (1) at an angle to wheel carrier.
Fig. 92: Identifying Rubber Mount Slot

Draw rubber mount with special tools 33 4 465 , 33 4 466 , 33 4 475 , 33 4 474 and 33 4 473 a little into wheel
carrier.
Remove special tool 33 4 450 and draw in rubber mount as far as it will go.

After installation:
Carry out wheel/chassis alignment check
33 32 035 REPLACING A RUBBER MOUNT FOR TRAILING ARM IN REAR AXLE CARRIER
2010 BMW M3
33 4 450
33 4 451
33 4 452
33 4 453
33 4 454
33 4 465
33 4 466
33 4 471
33 4 472
33 4 474
33 4 475
Remove trailing arm from rear axle carrier
Mark installation position of rubber mount by way of slot to rear axle carrier.


2010 BMW M3
If necessary, release knurled screws 33 4 452 and pull off mounting 33 4 455 with spring steel 33 4 456.
Insert rubber mount with spray-on points facing upwards in special tools 33 4 451 , 33 4 452 , 33 4 454 , 33 4
453 and pull together.
Fig. 95: Inserting Rubber Mount With Spray-On Points Facing Upwards In Special Tools
IMPORTANT: Clean rubber mount prior to drawing in and moisten with Loctite 638.
Spray-on points of rubber mount must point to rear!
All models except M3:

M3:
2010 BMW M3

Align rubber mount by way of slot to marking on rear axle carrier.
Draw rubber mount a little into rear axle carrier with special tools 33 4 471 , 33 4 474 , 33 4 475 , 33 4 466 and
33 4 465 .
Apply a thin coating of Loctite 638 to new rubber mount.

After installation:
2010 BMW M3
Carry out wheel/chassis alignment check
33 32 071 REPLACING ONE UPPER CONTROL ARM
NOTE: If the control arm is detached from the rear axle carrier, it is necessary after
Release screw (1).
Installation:
If necessary, raise brake disk in drive flange area with workshop jack.
Replace screw.
Tightening torque 33 32 6AZ . See 33 32 CONTROL ARMS AND STRUTS .

2010 BMW M3
Fig. 100: Identifying Connection Area Of Wheel Carrier

Release nut (1) and remove screw towards front.
Unclip line holder (3) for pulse generator or brake pad sensor on control arm.
Remove control arm (2).
Installation:
Fig. 101: Identifying Control Arm, Line Holder And Nut

2010 BMW M3
After installation:
33 32 091 REPLACING A GUIDE ARM
NOTE: If the guide arm is detached from the rear axle carrier, it is necessary after

Remove both stabilizer links from stabilizer and turn stabilizer in upward direction
Release screw.
Installation:
If necessary, raise wheel carrier in area of brake caliper by hand.
Replace screw.
Fig. 102: Locating Screw

2010 BMW M3
Fig. 103: Identifying Connection Area Of Wheel Carrier

NOTE: On the M3 a ball joint is fitted in the guide arm.
Slacken nut (1).
Unscrew bolt towards rear and remove guide arm (2).
Installation:
Fig. 104: Identifying Guide Arm And Nut

2010 BMW M3
After installation:
33 32 125 REPLACING A BALL JOINT IN LOWER STEERING KNUCKLE/WHEEL CARRIER
33 4 465
33 4 466
33 4 474
33 4 475
33 4 481
33 4 482
NOTE: E90, E91 from 09/2008:

For driving dynamic reasons, both ball joints must be replaced on first
marks. If the punch marks are provided, the ball joints can be changed again
individually.
Remove coil spring at rear

If necessary, remove jointed rod of ride-height sensor from camber arm bracket
Remove rear shock absorber from rubber mount
Remove camber arm from wheel carrier
Remove trailing arm from wheel carrier
Pull out ball joint with special tools 33 4 465 , 33 4 466 , 33 4 475 , 33 4 474 and 33 4 482 .
2010 BMW M3
Fig. 105: Removing Ball Joint With Special Tools

Installation:
Draw in new ball joint with special tools 33 4 481 , 33 4 474 , 33 4 475 , 33 4 466 and 33 4 465 as far as it will
go.
Fig. 106: Installing Ball Joint With Special Tools

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

CARRIER

2010 BMW M3
Remove output shaft

Remove brake disc . See 34 21 320 REMOVING AND INSTALLING OR REPLACING BOTH
REAR BRAKE DISCS .
Replacement only: drive out drive flange for rear axle shaft
Disconnect handbrake Bowden cable from expander lock . See 34 41 120 REMOVING AND
INSTALLING OR REPLACING BOTH HANDBRAKE BOWDEN CABLES .
Remove pulse generator from wheel carrier . See 34 52 535 REPLACING A REAR PULSE
GENERATOR .
Remove coil spring
Remove rubber mount/shock absorber on camber arm
Secure wheel carrier against falling out.
Remove stabilizer link from wheel carrier.
Remove trailing arm from wheel carrier.
Remove guide arm from wheel carrier.
Remove toe arm from wheel carrier.
Remove upper control arm from wheel carrier.
Remove camber arm from wheel carrier.
Remove wheel carrier.
Fig. 107: Identifying Wheel Carrier

2010 BMW M3
Replacement:
Modify or replace handbrake shoes . See 34 41 220 REMOVING AND INSTALLING/REPLACING

ALL HANDBRAKE SHOES .
Modify or replace expander lock . See 34 41 250 REMOVING AND INSTALLING/REPLACING
EXPANDER LOCK FOR HANDBRAKE SHOES .
Modify or replace brake carrier/brake guard plate . See 34 21 173 REPLACING REAR LEFT (OR
RIGHT) BRAKE CARRIER .
After installation:
Adjust handbrake . See 34 10 014 ADJUSTING HANDBRAKE .

33 32 180 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT TOE ARM
NOTE: If the toe arm is detached from the rear axle carrier/wheel carrier, it is necessary
after reinstallation to carry out a wheel/chassis alignment check.
If necessary, open cover (1) on stoneguard (2).
Mark position of eccentric screw to rear axle carrier.
Fig. 108: Identifying Cover And Stoneguard

2010 BMW M3
Release screw.
Installation:
If necessary, turn toe arm by hand.
Fig. 109: Locating Screw

Unscrew eccentric bolt towards front and remove toe arm (3).
Installation:
Reinstall eccentric washer.
Align eccentric screw by means of marking to rear axle carrier.

2010 BMW M3
Fig. 110: Identifying Nut, Toe Arm And Eccentric Washer

After installation:
33 32 190 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT CAMBER ARM (M3)
NOTE: If the camber arm is detached from the rear axle carrier/wheel carrier, it is
Remove coil spring at rear

Remove rear muffler . See 18 12 030 REMOVING AND INSTALLING/REPLACING REAR
MUFFLER (S65) .
IMPORTANT: Mark position of eccentric bolt (1) to camber arm (2).

2010 BMW M3
Fig. 111: Identifying Eccentric Bolt And Camber Arm

Slacken nut (1).
Remove jointed rod (2) from camber arm bracket.
Installation:
Fig. 112: Identifying Jointed Rod, Lever And Nut

Release screw (1).
Installation:
Tighten down bolt connection in normal position. See 32 00 ... MOVING VEHICLE INTO NORMAL
POSITION .
Tightening torque 33 52 4AZ . See 33 52 SHOCK ABSORBERS .
Release nut (3) and remove bolt (2).
Installation:
2010 BMW M3
Fig. 113: Identifying Nut, Screw And Bolt

Unscrew eccentric bolt (3) and remove camber arm.
Installation:
Bolt head must point to front.
Replacement only: Carry over marking from old part to new part.
Install eccentric washer.
Align eccentric screw by means of marking to camber arm.

2010 BMW M3
Fig. 114: Identifying Nut, Eccentric Washer And Eccentric Bolt

Replacement:
Replace lower spring pad (1).
Installation:
Make sure lower spring pad is correctly seated.
Version with xenon lights:
Release nut, remove screw (2) and holder (3).
Installation:
Screw head must point upwards.
After installation:

2010 BMW M3
Fig. 115: Identifying Screw, Lower Spring Pad And Holder

33 32 195 REPLACING RUBBER MOUNT FOR CAMBER ARM IN REAR AXLE CARRIER
33 4 450
33 4 451
33 4 452
33 4 455
33 4 456
33 4 461
33 4 462
33 4 463
33 4 464
33 4 465
33 4 466

cooled down.
Remove coil spring

Remove camber arm from rear axle carrier
2010 BMW M3

Pull rubber mount together with special tools 33 4 455 , 33 4 456 , 33 4 452 and 33 4 451 .
Fig. 117: Identifying Rubber Mount With Special Tools

Draw rubber mount into rear axle carrier so that slot (1), rubber mount center point and notch (2) form a line.
2010 BMW M3

Draw rubber mount as far as possible into rear axle carrier with special tools 33 4 461 , 33 4 463 , 33 4 466 and
33 4 465 .
Remove special tool 33 4 450 and draw in rubber mount as far as it will go.

After installation:
other models.
2010 BMW M3
Release clips (1).
Release screws (2).
Installation:
Fig. 120: Identifying Underbody Cover, Screw And Clips

AXLE MOUNTING
33 33 001 REPLACING LEFT OR RIGHT REAR AXLE CARRIER COMPRESSION STRUT

Driving without compression struts is not permitted!
Risk of damage!
The rear axle carrier must be supported at the front is both compression struts
have to be replaced!
Remove underbody cover . See 51 75 001 REMOVING AND INSTALLING/REPLACING LEFT

OR RIGHT UNDERBODY COVER .
Release screws (1).
Installation:
2010 BMW M3
Replace screws.
Installation:
Fig. 121: Identifying Screw And Compression Strut

33 33 091 REPLACING BOTH RUBBER MOUNTS FOR REAR AXLE CARRIER (M3 FRONT LEFT
AND RIGHT ONLY)
33 4 140
33 4 142
33 4 147
33 4 149
33 4 431
33 4 432
33 4 433
33 4 434
33 4 435
33 4 436
33 4 437
2010 BMW M3
NOTE: On the M3 the front rubber mounts must be drawn from above into the rear axle
carrier.
Remove complete rear axle carrier
If necessary, assemble special tools 33 4 140 , 33 4 142 and 33 4 147 as illustrated.
If necessary, position new thrust pieces 33 4 149 with countersunk screws on special tool 33 4 140 .
Fig. 122: Identifying Countersunk Screws On Special Tool

Withdraw rubber mount from bearing bushing with special tools 33 4 436 , 33 4 437 , 33 4 140 and 33 4 431 .
NOTE: Make sure special tool 33 4 140 is correctly supported on bearing bushing of
rear axle carrier.
Fit special tool 33 4 431 on rubber mount in such a way that edge of rubber
mount disappears in special tool.
2010 BMW M3
Fig. 123: Identifying Special Tool On Rubber Mount

IMPORTANT: Arrows (1) must point in direction of longitudinal axis!

Opening (2) on underside must point to left!
Fig. 124: Identifying Arrows And Opening

Installation:
Coat new rubber mount with Circo Light (sourcing reference: BMW Parts Service).
Draw in new rubber mount with special tools 33 4 432 , 33 4 433 , 33 4 435 and 33 4 434 as far as it will go.
2010 BMW M3

After installation:
33 33 101 REPLACING TWO RUBBER MOUNTS (REAR) FOR REAR AXLE CARRIER
33 4 140
33 4 142
33 4 147
33 4 149
33 4 431
33 4 434
33 4 435
33 4 436
33 4 437
33 4 441
33 4 442
33 4 443
33 4 444
Lower rear axle carrier

2010 BMW M3
If necessary, assemble special tools 33 4 140 , 33 4 142 and 33 4 147 as illustrated.
If necessary, screw new thrust pieces 33 4 149 with countersunk screws on special tool 33 4 140 .
Fig. 126: Identifying Countersunk Screws On Special Tool

Coat top edge of rubber mount with Circo Light.
Align special tool 33 4 140 by way of openings in rubber mount.
Withdraw rubber mount from bearing bushing with special tools 33 4 436 , 33 4 437 , 33 4 140 and 33 4 431 .
Fig. 127: Removing Rubber Mount From Bearing Bushing With Special Tools
2010 BMW M3
Installation:
Coat new rubber mount with Circo Light.
Insert special tool 33 4 444 in opening on rear axle carrier to avoid damaging the rear axle carrier when drawing
in the rubber mount.
Assemble special tools 33 4 442 , 33 4 443 , 33 4 435 and 33 4 434 as illustrated.

After installation:
WHEEL BEARING
33 41 ... DETACHING WHEEL BEARING INNER RACE FROM DRIVE FLANGE (DRIVE FLANGE
REMOVED)
33 1 307
33 4 400
33 1 401
2010 BMW M3
33 1 402
33 1 403
33 1 404
33 1 405
33 1 406
33 1 407
NOTE: Detach wheel bearing ring with special tool 33 4 400 through groove in wheel
bearing inner ring.
Position special tool 33 1 307 on drive flange. Select one of the following special tools using the wheel bearing
inner ring and insert into special tool 33 4 401:
33 4 405 for dia. 45 - 51 mm

33 4 406 for dia 50 - 55 mm
33 4 407 for dia. 55 - 61 mm
Screw out special tool 33 4 402 until the tapered attachment of the spindle comes into contact with the special
tool 33 4 401. Position special tool 33 4 401 with the corresponding insert on groove of wheel bearing inner
ring.
Fig. 129: Position Special Tool 33 1 307 On Drive Flange

Compress special tool 33 4 401 with wrenches 33 4 403 and 33 4 404 until the special tool can still be turned in
the groove. Detach wheel bearing inner ring by turning special tool 33 4 402.
2010 BMW M3
Fig. 130: Compress Special Tool 33 4 401 With Wrenches

33 41 000 REPLACING DRIVE FLANGE ON LEFT OR RIGHT REAR AXLE SHAFT (ON 2-FLOW
EXHAUST SYSTEM)
33 2 116
33 2 160
33 2 201
33 4 200
Remove output shaft

Remove brake disk . See 34 21 320 REMOVING AND INSTALLING OR REPLACING BOTH
REAR BRAKE DISCS .
Remove pulse generator See 34 52 535 REPLACING A REAR PULSE GENERATOR .
Force drive flange with special tools 33 2 116 / 33 2 201 , 33 2 160 , 33 4 200 and 5 wheel bolts out of wheel
bearing.
NOTE: Rounded inside edge of special tool 33 2 160 must point to drive flange.
2010 BMW M3
Fig. 131: Removing Drive Flange With Special Tools

IMPORTANT: The wheel bearing is destroyed when the drive flange is removed and cannot
be reused!
Replace wheel bearing.
Installation:
Install output shaft.
Oil drive flange lightly and attach to splines of output shaft.
Draw drive flange into wheel bearing.
After installation:
33 41 151 REPLACING WHEEL BEARING ON LEFT OR RIGHT REAR AXLE SHAFT (ON 2-
33 3 261
33 3 262
33 3 263
33 3 264
33 3 265

2010 BMW M3
Remove drive flange of rear axle shaft
Press retaining ring (1) together using pliers and remove.
Installation:
Install retaining ring (1).
Check seating of retaining ring (1), correct if necessary.

Pull out wheel bearing with special tools 33 3 261 , 33 3 263 and 33 3 262 .
Fig. 133: Removing Wheel Bearing With Special Tools

2010 BMW M3
IMPORTANT: Do not reuse old wheel bearing!

Black-dyed multipole seal (1) must point to center of vehicle!
Fig. 134: Identifying Black-Dyed Multipole Seal

Installation:
Check installation position of wheel bearing (1), correct if necessary.
Draw in wheel bearing (1) with special tools 33 3 261 , 33 3 265 and 33 3 264 .
Fig. 135: Installing Wheel Bearing With Special Tools

After installation:
SHOCK ABSORBER
2010 BMW M3
Facts:
E32, E34, E38, E39 : In the case of rear spring struts with ride-height control, there is always a slight oil
spillage on the piston rod. These spring struts are permitted to be wet with oil over a maximum of half the shock
absorber length on the outer tube, i.e. they are permitted to "sweat".
Consequence:
Procedure:

ABSORBER (M3)

Car may tilt off lifting platform if the workshop jack is incorrectly handled.

2010 BMW M3
Remove rear wheel. See WHEEL AND TIRES - REPAIR .

Remove luggage compartment wheel arch trim . See SIDE PANELS .
Release screw (1).
Installation:
Tighten down bolt connection in normal position. See 32 00 ... MOVING VEHICLE INTO NORMAL
POSITION .

Replacement only:
IMPORTANT: Shock absorber and adapter lead (2) must be replaced together!
Remove rest side section on rear seat back.
Disconnect plug connection (1) and expose adapter lead (2) up to shock absorber.
2010 BMW M3
Installation:
Make sure adapter lead is correctly routed.
Fig. 137: Identifying Plug Connection And Expose Adapter Lead

Replacement: Remove adapter lead (2) with protective cap.
Installation:
Protective cap is marked "L" for left side and "R" for right side (risk of mixing up).
2010 BMW M3
Fig. 138: Identifying Support Bearing Upper Section, Nut And Adapter Lead
Installation:
Remove support bearing (lower section) , check for damage and if necessary replace.
Fig. 139: Identifying Shock Absorber And Wheel Arch

Replacement:
Remove support pot (1) and auxiliary damper (2) with protective tube (3) from rear shock absorber (4)
2010 BMW M3
Fig. 140: Identifying Support Pot, Auxiliary Damper, Protective Tube And Rear Shock Absorber
33 52 161 REPLACING THRUST BEARING (LOWER SECTION) FOR REAR LEFT OR RIGHT
SPRING STRUT/SHOCK ABSORBER
Remove rear shock absorber
Press support bearing lower section (1) with seal grommet (2) out of shock absorber mounting.
Installation:
Clean shock absorber mounting including contact surface (3) all round.
Insert thrust bearing lower section (1) in sealing grommet (2).
Fig. 141: Identifying Thrust Bearing Lower Section And Sealing Grommet
2010 BMW M3
Installation:
Coat sealing grommet as illustrated with Circolight and press into shock absorber mounting.
Fig. 142: Identifying Sealing Grommet

SPRINGS WITH SUSPENSION

33 53 ... MEASURING RIDE-LEVEL HEIGHT OF VEHICLE
Move vehicle into normal position See 32 00 ... MOVING VEHICLE INTO NORMAL POSITION .
Fig. 143: Identifying Rim Flange And Lower Edge Of Wheel Arch
2010 BMW M3
33 53 000 REMOVING AND INSTALLING / REPLACING REAR LEFT OR RIGHT COIL SPRING
33 5 010
33 5 011
33 5 012
33 5 013
33 5 014
33 5 015
33 5 016
33 5 017
33 5 020
IMPORTANT: Both coil springs on the relevant axle must be replaced only in the event of
corrosion breakage!
Avoid damaging the coil spring coating.
WARNING: Prior to each use of the special tool 33 5 010 , it is essential to read the
associated Owner's Handbook fully!
All the safety precautions and instructions contained in the Owner's
6. Impact screwdrivers are prohibited!

2010 BMW M3
Removal:
Insert lower spring plate 33 5 012 centrally into coil spring and turn to lowest coil.
Guide spindles 33 5 013 , 33 5 014 , 33 5 015 from below through camber arm and lower spring plate 33 5 012 .
Fig. 144: Inserting Lower Spring Plate Centrally Into Coil Spring
Insert upper spring plate 33 5 011 sideways into coil spring and turn to uppermost coil.
IMPORTANT: Make sure spindle (hexagon) is correctly seated in upper spring plate 33 5 011 .
Pull spindle 33 5 013 downwards.
Fig. 145: Inserting Upper Spring Plate Sideways Into Coil Spring

Make sure coil spring is correctly positioned in spring plates.
2010 BMW M3
Fig. 146: Identifying Coil Spring Shaded Area

IMPORTANT: Align special tools 33 5 011 , 33 5 012 , 33 5 013 , 33 5 014 , 33 5 015 centrally to
obtain the biggest possible contact surface on the coil spring.
Check installation position of special tools 33 5 011 , 33 5 012 and 33 5 013 , 33 5 014 , 33 5 015 , correct if
necessary.
Fig. 147: Aligning Special Tools

Tension coil spring using special tools 33 5 016 and 33 5 020 , gripping spindle of spring tensioner with special
tool 33 5 017 in the process.
Remove coil spring upwards.

2010 BMW M3
Fig. 148: Removing Coil Spring Upwards

If necessary, relieve tension on coil spring.
IMPORTANT: Replacement only:

Bottom end of coil spring (1) must be flush with opening of spring plate 33 5
012 (see dotted-dashed line)!
Fig. 149: Identifying Bottom End Of Coil Spring

Installation:
Check spring mounts (2, 3) for damage, replace if necessary.
Remove spring plate (1) and position with upper spring pad (2) on coil spring.
NOTE: Upper spring pad (2) must come into contact with end of coil spring.
Version with rough road package: Install adapter as well.
2010 BMW M3
Fig. 150: Identifying Spring Plate, Upper Spring Pad And Spring Mounts
IMPORTANT: Observe the following when installing and relieving tension on coil spring:
Lower spring pad must be positively seated in the designated receptacle

in the camber arm
NOTE: Otherwise there is a risk of the coil spring jumping out sideways.
Lower spring pad must come into contact with end of coil spring (see
arrow)
Lower spring pad must rest flush on last coil (see broken line)
Fig. 151: Locating Spring Pad

Align coil spring by way of spring plate to opening in side member and relieve tension.
Remove special tools 33 5 011 , 33 5 012 and 33 5 013 , 33 5 014 , 33 5 015 .

2010 BMW M3
Fig. 152: Aligning Coil Spring By Way Of Spring Plate

After installation:
STABILIZER BAR
33 55 000 REMOVING AND INSTALLING/REPLACING REAR STABILIZER
IMPORTANT: M3:
When installing the stabilizer, make sure the two rubber mount halves are
correctly installed and correctly engaged on both sides (in the retaining
bracket).
Remove both rear coil springs

Remove left control arm on wheel carrier
Remove both stabilizer links from stabilizer
Lower rear axle carrier
NOTE: To simplify the picture, stabilizer removal is shown on the removed rear axle.
Release screws (1).
Remove both rubber mounts from stabilizer .
Turn stabilizer (2) and remove sideways.
Installation:
2010 BMW M3
Check both rubber mounts for damage , replace if necessary.
Tightening torque 33 55 1AZ . See 33 55 STABILIZER BAR .
Fig. 153: Identifying Stabilizer And Screws

After installation:
33 55 021 REPLACING BOTH RUBBER MOUNTS FOR STABILIZER MOUNTING (M3)
pairs.
Remove stabilizer from rear axle carrier
IMPORTANT: When installing the stabilizer, make sure the two rubber mount halves are
correctly installed and correctly engaged on both sides.
NOTE: Insert screwdriver on both sides between retaining bracket (1) and rubber
mount upper section (2)/rubber mount lower section (3).
Remove rubber mount upper section (2) and rubber mount lower section (3).
2010 BMW M3
Fig. 154: Identifying Rubber Mount Upper Section And Rubber Mount Lower Section
Installation:
Keep retaining bracket, rubber mount lower section (1), rubber mount upper section (2) and stabilizer clean and
free from oil and grease.
Mount rubber mount upper section (1) and rubber mount lower section (2) by way of edge (3) as pictured on
stabilizer (observe direction of travel).
Fig. 155: Identifying Rubber Mount Upper Section And Rubber Mount Lower Section
33 55 040 REPLACING STABILIZER LINKS FOR STABILIZER
31 1 140
2010 BMW M3
Release nut (1), gripping with special tool 31 1 140 in the process.
Installation:
Release screw (3).
Remove stabilizer link (2) towards top.
Fig. 156: Identifying Stabilizer Link, Nut And Screw

TROUBLESHOOTING
33 90 ... REAR AXLE TROUBLESHOOTING
TROUBLESHOOTING FOR SHOCK ABSORBERS

Fault Cause Remedy
Refer to TROUBLESHOOTING BRAKE SYSTEM
Grinding noise (only when cornering)
Wheel bearings faulty Replace wheel bearings
Check rims , replace if
Radial/lateral rim runout
Vibration (90 - 160 km/h) necessary
Radial tire runout Match or replace tires
Imbalance in output shaft Replace output shaft
2010 BMW M3
Rubber mount on rear axle

Replace rubber mount
differential suspension defective
Drumming
Rubber mount of rear axle
Replace rubber mount
carrier faulty
Refer to TROUBLESHOOTING FOR SHOCK
ABSORBERS .
Check screw connection,
Rattling noise Stabilizer link loose or defective replace stabilizer link if
necessary
Rubber mount of rear axle Check seat, replace rubber
carrier loose or faulty mount if necessary
Poor straight-running stability
(steering wheel inclination)
Refer to BMW diagnosis system "Troubleshooting tree
Unsteady taking of curves due to self-
wheel/chassis alignment check"
steering or poor rear end track stability
Excessive tire wear
33 90 ... TROUBLESHOOTING REAR DIFFERENTIAL
In order to troubleshoot "Noises/leaks on rear differential", it is necessary to work through the fault diagnosis
tree using the BMW Diagnosis and Information System.
See BMW Diagnosis and Information System under:
Fault pattern selection

331001 Noises rear differential
331002 Leaks rear differential
Service functions
Complete vehicle
Drive
Mechanics
Noises/ leaks
33 90 ... TROUBLESHOOTING SHOCK ABSORBER
TROUBLESHOOTING FOR SHOCK ABSORBERS

Fault Cause Remedy
Visually inspect auxiliary dampers
Auxiliary damper faulty for cracking, replace auxiliary
Wheel knocking (bottoming) dampers
Shock absorber mounting loose Tighten shock absorber
Support bearing loose Secure support bearing
2010 BMW M3
Visually inspect for cracking, replace

Support bearing defective (cracked)
support bearing
Visually inspect protective tube for
Protective tube defective/failed
Rattling noise cracking, replace protective tube
Rubber mount/joint eye for lower
Replace rubber mount/joint eye
shock absorber mounting defective
Worn down areas (flattened
areas) on tire profile
Long after-swinging of body Shock absorber leaking (insufficient
Replace shock absorber
after driving over rough road shock absorber effect)
Building-up of body in case Shock absorber leaking (insufficient
of successive uneven surfaces shock absorber effect)
Wheels jumping even on Shock absorber leaking (insufficient
normal road surfaces shock absorber effect)
2010 BMW M3
ACCESSO/RIES AND BODY, CAB Parts + Accessories (Body) - Repair
ACCESSO/RIES AND BODY, CAB
Parts + Accessories (Body) - Repair
GENERAL
EQUIPMENT)
reactions!

of ignition.
sunlight.
month).


directly.
2010 BMW M3
First Aid:
doctor.
Recycling

2010 BMW M3
Fig. 1: Overview Of Airbag Modules, Airbag Control Unit And Belt Tensioners
Overview of sensors for airbag system

2010 BMW M3
72 12... PROCEDURE AFTER AIRBAG TRIGGERING AS RESULT OF AN ACCIDENT
Check and/or replace following components after airbag triggering:
Satellites (control unit + sensor)
Components
Satellite, A-/B-pillar, left/right
Satellite, front door
Satellite, rear seat
Satellite, driver's/front passenger seat
Satellite, vehicle center
Procedure
Inspect visually for mechanical damage
Read fault memory
Disconnect battery and observe waiting period
Rectify faults
Connect battery and observe waiting period (at least 10 seconds)
Delete fault memory
Turn off ignition and wait at least 2 minutes (no consumers may be switched on during this period
such as e.g. inside lights, radio, etc.)
Switch on ignition (wait at least 10 seconds)
Clear fault memory and if necessary rectify faults
Cables and plugs
Components and procedure

Check cables and plugs for damage, replace if necessary.
(e. g. corrosion, correct engagement, bent pin)
Belt system
Components
Retractor mechanism
Seatbelt height adjustment
Anchor fitting tensioner
Procedure
Check components, replace if necessary
2010 BMW M3
Seats
Components
Seat
Airbag module
Active head restraint
Procedure
Check seats (function check of seat mechanism), replace if necessary
Check seat screw/bolt connections
Replace gas generator, active head restraint system
If the severity of the impact has not caused any other damage to the seat, only the triggered gas
generator needs to be replaced.
External feature: The triggered head restraint is folded forwards and engaged.
The repair work can be carried out in the car with the rear panel removed. The entire system can be
pushed back into its original position and the new gas generator installed.
The gas generator can be replaced up to 5 times.
Replace airbag module and, if necessary, seat cover with padding
Driver's airbag
Components
Airbag module
Steering Wheel
Steering column (if damaged)
Procedure
Replace faulty components
Replace steering wheel
Front-passenger airbag
Components
Airbag module
Trim, instrument panel
Supporting tube (if damaged)
Procedure
Check components; replace if necessary
2010 BMW M3
Side airbag, front/rear
Components
Airbag module
Door panel
Door in white
Seat
Procedure
Head airbag
Components
Airbag module
Trim, A-pillar
Roofliner
Trim, B-pillar (if damaged)
Trim, C-pillar (if damaged)
Connection/mounting (on side frame)
Procedure
Knee airbag
Components
Panel (driver's side)
Lower section of glovebox
Active knee protector (driver's and passenger sides)
Procedure
Passive knee protector
Components
Trim panels (driver's side)
Glovebox incl. knee protector (passenger side)
Procedure
Check fastening elements

2010 BMW M3
Notes on safety
SAFETY REGULATIONS for handling airbag modules, airbag components and pyrotechnical seat belt
tensioners
NOTES ON SCRAPPING vehicles with gas generators
DEACTIVATION/ACTIVATION PYROTECHNICAL COMPONENTS
Handling electrical and electronic equipment
UNLOCKING/LOCKING AIRBAG PLUG CONNECTIONS

REPAIRING AIRBAG LINES
HANDLING OPTICAL FIBRES
Check
CHECK SEAT BELT

CHECK LIST FOR SEAT BELT
Airbag system
Functional description and checking, refer to Diagnosis system

DEACTIVATING AIRBAGS
PROCEDURE AFTER AIRBAG DEPLOYMENT .
72 00... SAFETY REGULATIONS FOR HANDLING COMPONENTS WITH GAS GENERATORS
It is essential to comply with the regulations as specified in the law relating to the use of explosives when
working on airbag units and seat belt tensioners.
Airbags, seat belt tensioners etc. are pyrotechnical objects. Pyrotechnical objects are assigned to different
danger classes on the basis of the quantity of propellant that they contain. The assignment can be ascertained
from the identification marking on the product:
IMPORTANT: Failure to comply with the warning notices and repair instructions for gas
generator components can cause accidental deployment and result in injury
and vehicle damage!
This applies in particular to the following components:
Airbag modules (driver's/front passenger airbags, side airbags)

Buckle/belt tensioner
Head airbag
Active knee protection
2010 BMW M3
1. Regulations
The regulations quoted in the following refer to the Federal Republic of Germany.
In all other countries, the relevant legislation and regulations must be observed in each case. Country-specific
legal regulations that go beyond this information or court decisions based thereon must be followed in each case
or given precedence over these regulations.
The following components used by BMW:
Pyrotechnical restraint systems are subject to danger class PT1

Gas generators are pyrotechnical objects belonging to danger class T1.
Handling, transporting and storing non-fired gas generators are subject to the "Explosive Materials Act" (law
relating to the use of explosives dated 13/09/1976).
The relevant trade supervisory authority must be notified at least 2 weeks before pyrotechnical objects are
handled for the first time. Here the relevant authority must be notified in writing of the person responsible (e.g.
dealership owner, holder of general power of attorney or if necessary workshop supervisor). A certificate of
qualification, i.e. specific training, is not required for the person responsible.
2. Disassembly and assembly
Inspection, testing and installation work may only be carried out by expert trained personnel in BMW
Service.
Work on components of the airbag system should only ever be carried out with the battery disconnected,
the negative terminal post covered and the plug connection of the cable leading to the gas generator
disconnected. If only the battery is disconnected, the following prescribed waiting period must be
observed without fail:
30 minutes for vehicles up to 9/93;
1 minute for vehicles from 9/93
In the event of breaks in work, a component with a gas generator that has been removed must be secured
against access by other persons.
Individual components must never be repaired. Instead, always replace them.
Do not treat airbag system components with cleaning agents or grease.
Components of the airbag system must not be exposed to temperatures in excess of 75C.
Airbag system components, including electronic diagnostic components, which have been dropped from
heights in excess of 0.5 m must not be reinstalled in the vehicles.
Before installing, subject components such as housing, connector pins etc. (including electronic
diagnostic components) to a visual inspection for damage and replace if necessary.
Airbag system components may only be electrically tested while they are installed and only with the
BMW ISTA.
2010 BMW M3
Danger of injury: The airbag module may only be set down with the airbag itself facing upwards .
Otherwise the generator will be thrown upwards if it is fired.
Do not point the firing pellet of a gas generator at other persons.
Components with gas generators must not be fired while they are removed. They must be disposed of by
special disposal companies or returned to BMW in the packaging of the new components.
When carrying out straightening and welding work with an electric welder:
Disconnect battery
Cover negative terminal (post)
Avoid all contact with the skin when removing a fired airbag module - wear gloves. Wash with water
after contact with the skin.
3. Transport
Components with gas generators must be sent off in the packaging of the new components.
4. Storage
Observe the regulations of the relevant trade supervisory authority and the applicable national regulations.
SEAT BELTS
72 11... CHECKING AUTOMATIC SAFETY BELT
General considerations when checking seat belts:
The seat belts must be checked after an accident.
For the check, you should start by trying to get information on which seats in the car involved in the accident
were occupied. If this is not possible, check all the seat belts in the car and replace them if necessary.
In the event of deformations on the car, you must subject the components of the restraint system affected in this
area such as e.g.
Seat Belts
Triggering sensors
etc.
to a function check and a visual inspection.
If you are in any doubt as to the unimpaired functional capability of restraint system components, these
2010 BMW M3
components must be replaced in the interests of safety!
If a seat belt has to be replaced following an accident (e.g. in the event of a frontal and/or side impact with
permanently deformed impact dampers/deformation elements or cross-members), the complete seat belt must be
replaced! The complete seat belt comprises:
Top belt
Lower strap
Seat belt buckle (buckle tensioner)
Retaining screws of all components
The following must also be checked and if necessary replaced:
Seatbelt mountings on the car body

Seatbelt mountings on the seat
Seat runners
Seat structure (frame, etc.)
Alignment tests on the seat and the seat runners are not permitted!
The following explanations and the CHECKLIST for the automatic safety belt can provide help.
An unusable seat belt or a seat belt worn in a serious accident should be destroyed immediately after removal to
guarantee that it can not be used again.
Checking automatic reel and seat belt strap:
The automatic reel has two independent activation systems for seat-belt locking.
The first activation system locks the automatic reel when driving quickly around curves, driving in tight curves,
on extreme inclinations (vehicle rolls over) and during sharp braking or impact.
To check, the seat backrest must be placed in the upright position and both hands held in a supporting position
close to the steering wheel. The brakes are then applied fully while driving on a dry surface and at a road speed
equal to twice that of walking speed.
The seat belt must lock.
The second activation system provides additional safety and is controlled by inertia mass.
If the reel locks when the strap is pulled out suddenly, this system is also OK.
In addition, the automatic electric reel (EMA) must eliminate belt slack.
2010 BMW M3
Check whether an attempt was made to eliminate belt slack:
Enter, close doors and latch seat belt buckle contact

EMA eliminates belt slack
If belt slack was not eliminated, the procedure described below must be followed:
Allow vehicle to assume complete sleep mode and repeat the function test.
All doors must be closed!
EMA, left, must be installed and connected correctly.
Work through all fault memory entries before the function test is carried out again.
Replace defective or actuated automatic electric reels.
Automatic reel does not require servicing and must not be opened.
Precondition for complete, problem-free retraction of straps:
the straps must not be twisted!

the straps must not be damaged!
When placed to one side, the straps of the front seats must retract fully.
With the straps in the rear seat bench, a small remaining loop is acceptable due to increased friction between the
strap and the rear seat bench cover if:
this remaining loop is fully retracted when the strap is reguided.
Belt straps should only be cleaned with a lukewarm soap solution or a commercial laundry detergent.
Belt straps must never be cleaned chemically or dyed.
The automatic reel and strap must be replaced in the event of:
1. creases
2. unraveling
3. pinches
4. cracks and tears
5. traces of melting
6. traces of wear on casing of seat belt tongue or on reversing clip.
Checking lower strap (belt buckle tensioner):
To fasten a seat belt, the tongue should insert easily and with a loud click in the lock.
2010 BMW M3
When the "Red button" is pressed, the tongue must be ejected from the lock under spring pressure.
If the lock cover is missing or damaged, the lower strap must be replaced.
Replace the triggered belt buckle tensioner including the complete seat belt with seatbelt height adjustment and
retaining screws and check the

Seat runners
Seat structure
Criteria for a triggered mechanical belt buckle tensioner:
very low position of seatbelt buckle (comparisons with new part).
Criteria for a triggered pyrotechnical belt buckle tensioner:

Airbag warning lamp permanently lit: read out airbag system fault memory.
The belt buckle tensioners can be triggered under certain circumstances even when the seat is not occupied. If it
is definite that the belt system was not used (seat was not occupied), there is no need to replace the after a
check.
upper strap
attachment parts (belt height adjustment, screws)
seatbelt mountings on the car body
Seat runners
Checking anchor fitting tensioner:
Replace the triggered anchor fitting tensioner including the complete seat belt with seatbelt height adjustment,
lower strap and retaining screws and check the

Seat runners
Seat structure
Criteria for a triggered anchor fitting tensioner:
A triggered anchor fitting tensioner can be recognized from the wrapped belt strap around the shaft.
2010 BMW M3
72 11... INSPECTION LIST FOR AUTOMATIC SEAT BELT
Was the automatic seat belt with lower strap NO:

replaced after an accident, e.g. frontal and/or Replace complete automatic seat belt.
oblique collision in which the impact The following must also be checked and replaced, if
absorbers/deformation elements were permanently necessary:
deformed? - seatbelt mounts on the vehicle body
(only while seat belt was fastened) - seatbelt mounts on the seat
- seat rails
.......................................
YES: see next item below
Does seat belt lock when pulled out suddenly? NO:
Replace automatic seat belt (upper seat belt).
.......................................
Does the automatic reel eliminate the belt slack? NO:
Replace automatic seat belt (upper seat belt).
.......................................
Can the seat belt strap be pulled out without NO:
jamming? Automatic reel is loose - tighten reel.
If fault persists:
Return spring broken - replace automatic seat belt
(upper seat belt).
.......................................
Does the strap on the front seat belts retract NO:
automatically? Automatic reel is loose - tighten reel.
Does the strap on the rear seat belts retract Excessive friction in belt guides - replace automatic
automatically? seat belt (upper strap).
(a small remaining loop is acceptable if this Return spring broken - replace automatic seat belt
remaining loop is fully retracted when the seat belt (upper seat belt).
strap is readjusted)
.......................................
Does automatic reel make a squeaking noise when YES:
belt is fastened or unfastened? Excessive friction in belt guides - replace automatic
seat belt (upper strap).
Automatic reel is loose - tighten reel.
Return spring broken - replace automatic seat belt
(upper seat belt).
2010 BMW M3
.......................................
NO: see next item below
Is the plastic casing on the belt tongue free from NO:
damage in the area of the belt opening? Replace complete automatic seat belt
.......................................
Is the fully extended seat belt strap free from: NO:
- pinches? Replace complete automatic seat belt
- burn marks?
- tears and cuts? .......................................
- creasing? YES: see next item below
- unraveling?
When the seat belt is fastened, is the belt tongue NO:
ejected by spring pressure from the buckle when the Replace complete automatic seat belt
"red button" is pressed?
.......................................
Does fastened seat belt lock during emergency NO:
braking on a dry roadway at double walking speed? Replace complete automatic seat belt
.......................................
Is fully pulled-out seat belt strap free of serious dirt NO:
and other marks? If dirt and marks cannot be removed with
commercially available mild detergent, the
automatic seat belt (upper seat belt) must be
replaced.
.......................................
In the case of seat-integrated seat belts, is front NO:
tongue of reclining mechanism or seat rail free of Replace both damaged parts and complete
deformation? automatic-reel seat belt.
The following must also be checked and replaced, if
necessary:
- seatbelt mounts on the vehicle body
- seatbelt mounts on the seat
- seat rails
.......................................
The automatic seat belt is OK!

2010 BMW M3

2010 BMW M3
72 11 041 REMOVING AND INSTALLING OR REPLACING FRONT LEFT OR RIGHT LOWER

BELT FITTING (SEAT BELT PRETENSIONER)
Remove FRONT SEAT
Installation:

Unlock plug connection (3) and pull all plugs out of plug housing (2).
Removing wiring harness.
Installation:
Replace cable tie.

Wires must not be under tension
Plugs are coded and must be reinstalled in the correct sequence in the plug housing
2010 BMW M3
Fig. 3: Pulling Plug Connection

Only in event of replacement for E87 with build date before 09/2004:
New seat belt tensioners are supplied with seat belt buckle contacts which are not required before this build
date.
Disconnect contacts at pin 14 and pin 15

Tie both contacts to rear
NOTE: Clear all fault memories and code car again.
Fig. 4: Disconnecting Contacts At Pin 14 And Pin 15

Release screw (1).

2010 BMW M3
Remove belt pretensioner (3).
Installation:
Replace screw (1).
Belt tensioner (3) is secured through recess (2) to retaining bracket.
Fig. 5: Identifying Belt Tensioner On Recess And Screws

72 11 098 REMOVING AND INSTALLING/REPLACING ALL REAR LOWER BELT FITTINGS
SEAT
Illustration show removal of the left lower belt fitting; proceed in the same way for the right fitting.
Release screw (1).
Remove lower belt fitting (2).
Installation:
2010 BMW M3
Pin (3) determines the installation position and prevents the lower belt fitting (2) from turning.
NOTE: Middle lower belt fitting (4) can only be removed in conjunction with right lower
belt fitting.
Fig. 6: Identifying Middle And Lower Belt Fitting With Screws And Pin
Lower belt fitting with belt tensioner:
Unfasten PLUG CONNECTION (2) and disconnect.
Release screw (1).
Installation:
belt fitting.
2010 BMW M3
Fig. 7: Identifying Middle And Lower Belt Fitting With Screws, Plug Connection And Pin
72 11 033 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT SEAT BELT
Remove panel for door post See 5143150 REMOVING AND INSTALLING OR REPLACING
TRIM FOR LEFT OR RIGHT DOOR PILLAR (BOTTOM) ; 5143148 REMOVING AND
INSTALLING OR REPLACING TRIM ON LEFT OR RIGHT DOOR PILLAR (TOP) or 5143148
REMOVING AND INSTALLING OR REPLACING TRIM ON LEFT OR RIGHT DOOR
PILLAR (TOP) .
Move backrest to full rearward position.
Unclip release tab (2) for belt anchor fitting trim (1) with plastic wedge.
Fig. 8: Removing Release Tab For Belt Anchor Fitting Trim Using Plastic Wedge
2010 BMW M3
Release screw (1).
Remove anchor fitting (2).
Installation note:
Make sure anchor fitting is correctly seated on seat mechanism pin.
Fig. 9: Identifying Anchor Fitting And Screw

Release screws (1).
Remove deflector bar (2).
Release screw (3).
Set down belt deflector with belt (4).

2010 BMW M3
Fig. 10: Identifying Belt With Deflector Bar And Screws

Release screw (1).
Installation note:
Coding (2) of automatic reel must be seated in body opening.
Fig. 11: Removing Automatic Reel

Installation note:
Free spaces of (A) and (B) from the seat belt strap to the guide funnel must be of the same size.
2010 BMW M3
Fig. 12: Identifying Free Spaces Dimension Of Seat Belt Strap

72 11 101 REMOVING AND INSTALLING/REPLACING REAR CENTER SEAT BELT
Remove REAR SEAT

Remove REAR WINDOW SHELF
Unscrew nut (1).
Remove inertia reel unit (2).
Installation:
Pay attention to coding.

2010 BMW M3
Fig. 13: Identifying Inertia Reel Unit With Nut

Release screw (2) on middle seat belt anchor fitting.
Installation:
Pin (3) determines the installation position and prevents the anchor fitting (1) from turning.
Fig. 14: Identifying Anchor Fitting, Screw And Pin

72 11 092 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT SEAT BELTS
Remove REAR WINDOW SHELF

2010 BMW M3
Remove REAR SEAT
Removing left or right inertia reel unit:
Release screw (1) on inertia reel unit (2).
Fig. 15: Identifying Automatic Reel With Screw

Installation:
Push inertia reel unit (1) onto body lug (2).

2010 BMW M3
Fig. 16: Pushing Inertia Reel Unit Onto Body Lug

Release screw (2).
Tightening torques 72 11 22AZ .
Remove seat belt (1).
Installation:
Pin (3) determines the installation position and prevents the anchor fitting from turning.
Fig. 17: Identifying Seat Belt With Screw And Pin

72 SAFETY PRECAUTIONS AND GENERAL INFORMATION
Notes on safety
tensioners

Check
2010 BMW M3
CHECK SEAT BELT

Airbag system

AIRBAG GENERATOR/AIRBAG UNIT FOR PASS

72 12... DEACTIVATING FRONT PASSENGER AIRBAGS WITH KEY-OPERATED SWITCH
WARNING: The responsibility for deactivation/activation rests with the customer.

Depending on the occupation of the front passenger seat, the front
passenger and side airbags must be (de-)activated in accordance with the
Owner's Handbook.
The passenger airbag can only be deactivated in accordance with the following instructions if the vehicle is
equipped with a suitable key-operated switch!
The key-operated switch can be retrofitted if it is missing and has been ordered as an optional extra.
Key-operated switch:
Optional extra SA 5DA for MINI

Optional extra SA 470 for BMW
E83 up to 09/2004 only:
see Deactivation of airbags
E83 from 09/2004 only:
Deactivation via key-operated switch, see following work steps
R50/R53 up to 04/2004 only:
see Deactivation of airbags
R50/R53 from 04/2004 only:
Deactivation via key-operated switch, see following work steps
The following airbags are deactivated simultaneously with the key-operated switch (1):
2010 BMW M3
Passenger airbag
Side airbag (passenger side)
If necessary, knee airbag in US models (passenger side)
The airbags can only be deactivated/reactivated while the vehicle is stationary and with the door open.
IMPORTANT: The head airbag remains active.
Fig. 18: Identifying Key-Operated Switch

Deactivation
1. Turn key-operated switch with ignition key to "OFF" position.
Deactivated airbags on passenger side out of operation.
Head airbag on passenger side remains active.
All airbags on driver side remain active.
Activation
2 Turn key-operated switch with ignition key to "ON" position.
All the airbags in the vehicle are activated and are triggered in appropriate situations.
2010 BMW M3
Fig. 19: Turning Key-Operated Switch

Warning lamp
When the ignition key is turned in the ignition lock, the function of the airbag system is checked and the
warning lamp in the center console lights up for several seconds.
1. The warning lamp is permanently lit when the passenger airbags are deactivated
2. The warning lamp goes out after a few seconds when the passenger airbags are activated
Fig. 20: Identifying Warning Lamps

72 12... NOTES ON SCRAPPING VEHICLES WITH GAS GENERATORS (AIRBAG SYSTEM)
The gas generator is a pyrotechnical component and is for the most part permanently mounted on the following
components:
2010 BMW M3
Airbag module
Side airbag
Head airbag
Knee airbag
Automatic electric reel

Belt end fitting tensioner
With vehicles which are scheduled for scrapping, it is always essential prior to draining and further stripping
work to ensure that all the gas generators in the vehicle are fired. The fired gas generators can then be scrapped
together with the vehicle.
used parts

2010 BMW M3

2010 BMW M3
72 12... PROCEDURE AFTER AIRBAG TRIGGERING AS RESULT OF AN ACCIDENT
Components
Procedure
Inspect visually for mechanical damage
Read fault memory
Disconnect battery and observe waiting period
Rectify faults
Connect battery and observe waiting period (at least 10 seconds)
Delete fault memory
Switch on ignition (wait at least 10 seconds)
Cables and plugs

(e. g. corrosion, correct engagement, bent pin)
Belt system
Components
Retractor mechanism
Procedure
2010 BMW M3
Seats
Components
Seat
Airbag module
Procedure

If the severity of the impact has not caused any other damage to the seat, only the triggered gas generator
needs to be replaced.
Replace airbag module and, if necessary, seat cover with padding
Driver's airbag
Components
Airbag module
Steering Wheel
Steering column (if damaged)
Procedure
Replace steering wheel
Front-passenger airbag
Components
Airbag module
Trim, instrument panel
Procedure
2010 BMW M3
Components
Airbag module
Door panel
Door in white
Seat
Procedure
Head airbag
Components
Airbag module
Trim, A-pillar
Roofliner
Procedure
Knee airbag
Components
Procedure
Components
Trim panels (driver's side)
Procedure

2010 BMW M3
WARNING: Observe SAFETY REGULATIONS for handling airbag modules and

pyrotechnical seat belt tensioners.
Incorrect handling can cause airbags to trigger, resulting in serious
injuries.
IMPORTANT: Operations on pyrotechnical devices may only be carried out by authorized

experts.
Improper, unauthorized operations may result in serious dangers.
Unauthorized persons are strictly prohibited from performing any operations
on this system.

Remove REAR PANEL ON FRONT SEAT
Remove FRONT SEAT
IMPORTANT: Make sure airbag wiring harness is exactly routed when installed.
Cut cable straps.
Release airbag wiring harness (2) from cable holders on seat mechanism.
Raise release clip (3) and pull plug (4) out of plug housing (1).
NOTE: If necessary, release yellow plug housing (1) from holder on seat mechanism.
Fig. 22: Pulling Plug Out Of Plug Housing

Unclip cable holder (1) from seat mechanism (2).

2010 BMW M3
Fig. 23: Identifying Cable Holder

Unscrew nuts (1).
Installation note:
Replace nuts.
Fig. 24: Identifying Seat Nuts

IMPORTANT: Feed the wiring harness carefully through the seat and backrest mechanism as
the edges of the frame can be sharp.
Installation note:
2010 BMW M3
72 12 000 REMOVING AND INSTALLING/REPLACING AIRBAG MODULE ON PASSENGER SIDE
WARNING: Read and comply with safety regulations . See 7200... SAFETY
REGULATIONS FOR HANDLING COMPONENTS WITH GAS
GENERATORS ; 72 SAFETY PRECAUTIONS AND GENERAL
INFORMATION; 7212... NOTES ON SCRAPPING VEHICLES WITH GAS
GENERATORS (AIRBAG SYSTEM) or 7212... PROCEDURE AFTER
AIRBAG TRIGGERING AS RESULT OF AN ACCIDENT for handling airbag

Remove GLOVEBOX
Car and airbag module up to 03/2006
Unlock PLUG CONNECTION (1) and disconnect.
NOTE: Secure airbag module on passenger side (3) against falling out.
Unscrew nuts (2).
Remove airbag module on passenger side (3) towards bottom.
Fig. 25: Identifying Airbag Module On Passenger Side With Plug Connection And Nuts
2010 BMW M3
Car + airbag module from 03/2006
Unlock PLUG CONNECTIONS (1) and disconnect.
NOTE: Secure airbag module against falling out.
Unscrew nuts (2).
Remove airbag module in downwards direction.
Fig. 26: Identifying Airbag Module Nuts And Plug Connections

Replacement in car up to 03/2006 only, with airbag module from 03/2006
NOTE: Before installing the airbag module on the passenger side (2), it is necessary to
fit the accompanying firing cable (4) and secure it with the accompanying foam
sticker pads (5).
Insert plug connections (1) and (3) (pay attention to color coding).
Attach accompanying foam sticker pads (5) as follows:

2010 BMW M3
Fig. 27: Identifying Passenger Side Airbag Module With Firing Cable And Foam Sticker Pads
One foam sticker pad (5) each to both outer edges (A) and (B) of airbag module on passenger side (2)
One foam sticker pad (5) in the middle so as to leave a free length L = 190 10 mm up to cable entry into
the firing cable plug (4)
Clip firing cable plug (4) into installation position in car.
NOTE: Subsequent installation is the same as for the car and airbag module from
03/2006 version.
72 12 004 REMOVING AND INSTALLING/REPLACING KNEE AIRBAG MODULE FOR DRIVER

PROTECTION

Remove LIGHT CONTROL UNIT .
Release screws (1).
Feed out trim panel for pedal mechanism (2) from marked area (3) and set down towards bottom.
Installation note:
Make sure trim panel is correctly fitted (marked area).

2010 BMW M3
Fig. 28: Removing Knee Airbag Module For Driver Protection (1 Of 4)

Release screws (1).

Release screw (1).

2010 BMW M3

Release screw (1).

IMPORTANT: Always replace airbag module for driver protection completely!
Do not carry out any repairs on airbag module!
72 12 006 REMOVING AND INSTALLING/REPLACING KNEE AIRBAG MODULE FOR FRONT

PASSENGER PROTECTION

2010 BMW M3
Removing GLOVE BOX .
72 12 060 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT HEAD AIRBAG
WARNING: Read and comply with safety regulations See 72 SAFETY PRECAUTIONS
AND GENERAL INFORMATION; 7212... NOTES ON SCRAPPING
VEHICLES WITH GAS GENERATORS (AIRBAG SYSTEM) or 7212...
PROCEDURE AFTER AIRBAG TRIGGERING AS RESULT OF AN
ACCIDENT for handling airbag modules and pyrotechnical belt
tensioners.

Follow INSTRUCTIONS for unlocking and locking airbag plug connections
Remove ROOFLINER
Head airbag installation summary:

2010 BMW M3
Fig. 32: Identifying Head Airbag, B-Pillar, Gas Generator, Holder And End Fittings
Release screw (1) on end fitting.
Release screw (2) on folding pack holder.
Folding pack holder (3) is screwed to trim for roof pillar at front.
Installation:
If screws (1...3) slip, coat them with Loctite.
If necessary, lever out clip-mounted holder.

2010 BMW M3
Fig. 33: Identifying End Fitting Screw And Folding Pack Holder Screw
If necessary, slide wiring harness (2) to one side to release screw (1) on folding pack holder.
Release screw (3) from folding pack holders.
Installation:
If screws (1) and (3) slip, coat them with Loctite.
Fig. 34: Identifying Folding Pack Holders Screw And Wiring Harness
2010 BMW M3
Unlock PLUG CONNECTION (4) and disconnect.
Release screws (1) on B-pillar ramp.
Tightening torque 72 1206AZ .
Unscrew bolt (3).
Remove gas generator (5) with head airbag.
Fig. 35: Identifying Gas Generator With Bolt, Plug Connection And Screws
Safety regulations
52 14 385 REPLACING GAS CARTRIDGE (FIRING UNIT) FOR CRASH-ACTIVE HEADREST ON

FRONT SEAT
2010 BMW M3
Incorrect handling may result in activation of the crash-active head
restraint and thereby cause injury.
Switch off the ignition!
IMPORTANT: The firing unit may be replaced up to 4 times.

Triggering frequency is denoted on the label on the head restraint carrier.
Labels are available as spare parts.
Starting situation:
Head restraint is in the crash position after being triggered.
NOTE: Firing unit can only be removed in the triggered state.

The complete crash-active head restraint must be replaced if the event of a
head restraint fault signal and an untriggered firer.
Lever out cover welt in marked area.
Remove cover with padding from head restraint.
Fig. 36: Identifying Cover Belt Removing Areas

Unclip service flap.

2010 BMW M3
Move firing unit (1) forwards and remove towards front.
Fig. 37: Moving Firing Unit

Replace firing unit.
Installation note:
Plug connection (1) must audibly snap into place.
Check firm engagement of plug connection (1) by gently pulling on connector.
Lay cable in side guide.

2010 BMW M3
Press locking spring (1) on left and right through opening and secure with cylindrical pins (or similar).
Head restraint is unlocked.
Fig. 39: Pressing Locking Spring

IMPORTANT: This work requires a great exertion of effort!
Pull head restraint (1) at an angle downwards until it is completely in lowest position and rests on linkage.
Hold head restraint (1) in this position for the following tasks.
Fig. 40: Pulling Head Restraint

Clip firing unit (1) onto linkage (2).
Installation note:
2010 BMW M3
Check that firing unit (1) is firmly seated on linkage.
Press firing unit (1) forwards and clip into place.
IMPORTANT: Firing unit (1) must audibly snap into place.
Fig. 41: Installing Firing Unit

Installation note:
Visually check that firing unit is correctly seated.
Attach label for identification after replacement.
Clip service flap into place.
Fig. 42: Identifying Firing Unit Checking Area

2010 BMW M3
Notes on safety
tensioners

Check
CHECK SEAT BELT

Airbag system

72 00... SAFETY REGULATIONS FOR HANDLING COMPONENTS WITH GAS GENERATORS
and vehicle damage!

Head airbag
2010 BMW M3

1. Regulations
In all other countries, the relevant legislation and regulations must be observed in each case. Country-specific
legal regulations that go beyond this information or court decisions based thereon must be followed in each case
or given precedence over these regulations.

Handling, transporting and storing non-fired gas generators are subject to the "Explosive Materials Act" (law
relating to the use of explosives dated 13/09/1976).
handled for the first time. Here the relevant authority must be notified in writing of the person responsible (e.g.
dealership owner, holder of general power of attorney or if necessary workshop supervisor). A certificate of
qualification, i.e. specific training, is not required for the person responsible.
Inspection, testing and installation work may only be carried out by expert trained personnel in BMW
Service.
Work on components of the airbag system should only ever be carried out with the battery disconnected,
the negative terminal post covered and the plug connection of the cable leading to the gas generator
disconnected. If only the battery is disconnected, the following prescribed waiting period must be
observed without fail:
In the event of breaks in work, a component with a gas generator that has been removed must be secured
against access by other persons.
Airbag system components, including electronic diagnostic components, which have been dropped from
heights in excess of 0.5 m must not be reinstalled in the vehicles.
Before installing, subject components such as housing, connector pins etc. (including electronic
diagnostic components) to a visual inspection for damage and replace if necessary.
2010 BMW M3
Airbag system components may only be electrically tested while they are installed and only with the
BMW ISTA.
Danger of injury: The airbag module may only be set down with the airbag itself facing upwards .
Components with gas generators must not be fired while they are removed. They must be disposed of by
special disposal companies or returned to BMW in the packaging of the new components.
Disconnect battery
Avoid all contact with the skin when removing a fired airbag module - wear gloves. Wash with water
after contact with the skin.
3. Transport
4. Storage
Observe the regulations of the relevant trade supervisory authority and the applicable national regulations.
72 12... UNLOCKING/LOCKING AIRBAG PLUG CONNECTIONS
WARNING: READ AND COMPLY WITH safety regulations for handling airbag modules
and pyrotechnical belt tensioners.
IMPORTANT: An airbag plug connection must be replaced if it is damaged.

Sourcing reference for airbag repair instructions (with plug connection), refer
to BMW Parts Service.
Following versions of plug connections on airbag module/gas generator are possible:
Airbag plug connection on gas generator/airbag module is offset by 90

Airbag plug connection on gas generator/airbag module is straight (3 versions)
Airbag plug connection on gas generator/airbag module offset by 90
There are two ways of unlocking this airbag plug connection on the gas generator/airbag module:
Method 1:
Simultaneously pull cover (1) upwards at lugs on left and right (2).
2010 BMW M3
Fig. 43: Pulling Cover

Method 2:
Insert a narrow screwdriver into recess (1) in housing (2).
Carefully rise cover (3) off (4).
Fig. 44: Pressing Cover Off

Cover (1) is not positioned higher than housing (2).
The airbag plug connection is unlocked and can now be detached from the gas generator/airbag module.
2010 BMW M3
Fig. 45: Identifying Cover And Housing Distance

Installation:
After attaching airbag plug connection to gas generator/airbag module, press cover (1) downwards until it rests
flat on housing.
Check that it catches properly.
Fig. 46: Pressing Cover

Version 1:
Press locking/unlocking plate (1) at edge (4).

2010 BMW M3
Fig. 47: Pressing Locking/Unlocking Plate At Edge

Fig. 48: Identifying Airbag Plug Connection

Installation:
After attaching airbag plug connection to gas generator/airbag module, check whether detent lug (2) is visible in
opening of locking/unlocking plate (1).
Only if the detent lug (2) is visible will the airbag plug connection gas generator/airbag module be correctly
engaged.
2010 BMW M3
Fig. 49: Identifying Detent Lug And Locking/Unlocking Plate

Version 2:
Press locking/unlocking plate (1) on edge (3) and pull plug (2) out of plug housing (4).
Installation:
Only if the detent lug is visible in opening (5) will the gas generator/airbag module plug connection be correctly
engaged.
Fig. 50: Pressing Locking/Unlocking Plate On Edge

Version 3:
Press lock button (1) and pull out plug (2) up to initial engagement position.
2010 BMW M3
Installation:
Insert plug connection in initial engagement position in gas generator/airbag module and engage in final
engagement position.
Fig. 51: Identifying Lock Button And Detent Plug

Illustration of version 3 with gas generator:
A. Initial engagement position

B. Final engagement position
1. Lock button
2. Gas generator
Fig. 52: Identifying Lock Button And Gas Generator

Version 4 - Crash-active head restraint:

2010 BMW M3
Press locking clip at edge and disconnect plug (1).
Installation:
Check for correct engagement.
Fig. 53: Pressing Locking Clip

CHILD SEAT QUICK FASTENING SYSTEM

72 14... REMOVING AND INSTALLING/REPLACING TOP TETHER EYELETS FOR CHILD SEAT
NOTE: Two or three Top Tether eyelets are installed, depending on the model.
Remove Top Tether eyelets (2).

2010 BMW M3
Fig. 54: Identifying Covers With Top Tether Eyelets

IMPORTANT: Ensure Top Tether eyelets (1) are in correct installation position.
It must be possible for Top Tether eyelets (1) to be tilted in the direction of
head restraints (2).
Fig. 55: Identifying Top Tether Eyelets With Head Restraints

2010 BMW M3
ACCESSORIES AND BODY, CAB Restraints & Towing - Repair - M3
Restraints & Towing - Repair - M3
GENERAL
Safety instructions
Safety regulations for handling airbag modules, airbag components and pyrotechnical seat belt
tensioners
Notes on scrapping vehicles with gas generators
Deactivation/activation pyrotechnical components
Unlocking/locking airbag plug connections

Repairing airbag leads . See 61 00 ... REPAIRING AIRBAG CABLES .
Handling optical fibres . See 61 00 ... NOTES ON HANDLING OPTICAL FIBERS .
Check
Check seat belt

Checklist for seat belt
Airbag system
Functional description and checking, refer to DIS (BMW diagnostic system)

Deactivating airbags
Procedure after airbag triggering .
72 00 ... SAFETY REGULATIONS FOR HANDLING COMPONENTS WITH GAS GENERATORS
and vehicle damage!
2010 BMW M3

Head airbag (ITS, AHPS)
Safety battery terminal (SBK)
1. Regulations
In all other countries, the relevant legislation and regulations must be observed in each case. Country-
specific legal regulations that go beyond this information or court decisions based thereon must be
followed in each case or given precedence over these regulations.

Handling, transporting and storing non-fired gas generators are subject to the "Explosive Materials
Act" (law relating to the use of explosives dated 13/09/1976).
handled for the first time. Here the relevant authority must be notified in writing of the person responsible
(e.g. dealership owner, holder of general power of attorney or if necessary workshop supervisor). A
certificate of qualification, i.e. specific training, is not required for the person responsible.

Inspection, testing and installation work may only be carried out by expert trained personnel in
BMW Service.
Work on components of the airbag system should only ever be carried out with the battery
disconnected, the negative terminal post covered and the plug connection of the cable leading to the
gas generator disconnected. If only the battery is disconnected, the following prescribed waiting
period must be observed without fail:
In the event of breaks in work, a component with a gas generator that has been removed must be
secured against access by other persons.

2010 BMW M3
Airbag system components, including electronic diagnostic components, which have been dropped
from heights in excess of 0.5 m must not be reinstalled in the vehicles.
Before installing, subject airbag system components (including electronic diagnostic components)
to a visual inspection for damage and replace if necessary.
Airbag system components may only be electrically tested while they are installed and only with
the BMW diagnostic system / DIS.
Danger of injury: The airbag module may only be set down with the airbag itself facing upwards.
Components with gas generators must not be fired while they are removed. They must be disposed
of by special disposal companies or returned to BMW in the packaging of the new components.
Disconnect battery
Avoid all contact with the skin when removing a fired airbag module - wear gloves. Wash with
water after contact with the skin.
3. Transport
4. Storage
Observe the regulations of the relevant trade supervisory authority and the applicable national
regulations.

2010 BMW M3
SEAT BELTS
72 11 ... CHECKING AUTOMATIC SAFETY BELT
General considerations when checking seat belts:
The seat belts must be checked after an accident.
For the check, you should start by trying to get information on which seats in the car involved in the accident
were occupied. If this is not possible, check all the seat belts in the car and replace them if necessary.
In the event of deformations on the car, you must subject the components of the restraint system affected in this
area such as e.g.
Seat belt
2010 BMW M3

Triggering sensors
etc.
to a function check and a visual inspection.
If you are in any doubt as to the unimpaired functional capability of restraint system components, these
components must be replaced in the interests of safety!
If a seat belt has to be replaced following an accident (e.g. in the event of a frontal and/or side impact with
permanently deformed impact dampers/deformation elements or cross-members), the complete seat belt must be
replaced! The complete seat belt comprises:
Top belt
Lower strap
Seat belt buckle (buckle tensioner)
Retaining screws of all components
The following must also be checked and if necessary replaced:

Seat runners
Seat structure (frame, etc.)
Alignment tests on the seat and the seat runners are not permitted!
The following explanations and the checklist for the automatic safety belt can provide help.
An unusable seat belt or a seat belt worn in a serious accident should be destroyed immediately after removal to
guarantee that it cannot be used again.
Checking automatic reel and seatbelt strap:
The automatic reel has two independent activation systems for seat-belt locking.
The first activation system locks the automatic reel when driving quickly around curves, driving in tight curves,
on extreme inclinations (vehicle rolls over) and during sharp braking or impact.
To check, the seat backrest must be placed in the upright position and both hands held in a supporting position
close to the steering wheel. The brakes are then applied fully while driving on a dry surface and at a road speed
equal to twice that of walking speed.
2010 BMW M3
The seat belt must lock.
The second activation system provides additional safety and is controlled by inertia mass.
If the reel locks when the strap is pulled out suddenly, this system is also OK.
Automatic reel does not require servicing and must not be opened.
Precondition for complete, problem-free retraction of straps:
the straps must not be twisted!

the straps must not be damaged!
When placed to one side, the straps of the front seats must retract fully.
With the straps in the rear seat bench, a small remaining loop is acceptable due to increased friction between the
strap and the rear seat bench cover if:
this remaining loop is fully retracted when the strap is reguided.
Belt straps should only be cleaned with a luke-warm soap solution or a commercial laundry detergent.
Belt straps must never be cleaned chemically or dyed.
The automatic reel and strap must be replaced in the event of:
1. creases
2. unraveling
3. pinches
4. cracks and tears
5. traces of melting
6. traces of wear on casing of seat belt tongue or on reversing clip.
Checking lower strap (belt buckle tensioner):
To fasten a seat belt, the tongue should insert easily and with a loud click in the lock.
When the "Red button" is pressed, the tongue must be ejected from the lock under spring pressure.
If the lock cover is missing or damaged, the lower strap must be replaced.
Replace the triggered belt buckle tensioner including the complete seat belt with seatbelt height adjustment and
retaining screws and check the

2010 BMW M3
seatbelt mountings on the seat

seat runners.
Seat structure.
Criteria for a triggered mechanical belt buckle tensioner:
Criteria for a triggered pyrotechnical belt buckle tensioner:

The belt buckle tensioners can be triggered under certain circumstances even when the seat is not occupied. If it
is definite that the belt system was not used (seat was not occupied), there is no need to replace the
upper strap
attachment parts (belt height adjustment, screws)
seat runners.
after a check.
Checking anchor fitting tensioner:
Replace the triggered anchor fitting tensioner including the complete seat belt with seatbelt height adjustment,
lower strap and retaining screws and check the

Seat runners
Seat structure
Criteria for a triggered anchor fitting tensioner:
A triggered anchor fitting tensioner can be recognized from the wrapped belt strap around the shaft.
72 11 ... INSPECTION LIST FOR AUTOMATIC SEAT BELT
AUTOMATIC SEAT BELT SPECIFICATION
Replace complete automatic seat belt

2010 BMW M3
The following must also be checked and

Was the automatic seat belt with lower strap replaced after
replaced, if necessary:
an accident, e.g. frontal and/or oblique impact in which
No seatbelt mountings on the car body
the impact absorbers/deformation elements were
permanently deformed?
seat runners.
Yes
Does seat belt lock when pulled out suddenly? No Replace automatic seat belt (upper strap).
Yes
Automatic reel is loose - tighten reel.
If fault persists:
Can the strap be pulled out without jamming? No
Return spring broken - replace automatic
Yes
Does the strap on the front seat belts retract automatically? Automatic reel is loose - tighten reel.
Does the strap on the rear seat belts retract automatically, Excessive friction in belt guides - replace
a small remaining loop is acceptable No automatic seat belt (upper strap).
if this remaining loop is fully retracted when the strap is Return spring broken - replace automatic
readjusted. seat belt (upper strap).
Yes
Excessive friction in belt guides - replace
automatic seat belt (upper strap).
Does automatic reel make a squeaking noise when belt is
Yes Reel is loose - tighten reel.
fastened or unfastened?
Return spring broken - replace automatic
No
Is the plastic casing on the latch free from damage in the
No Replace complete automatic seat belt
area of the belt opening?
Yes
Is the fully extended strap free from
pinches,
burn marks,
No Replace complete automatic seat belt
tears and cuts,
folding and
unravelling?
Yes
When the seat belt is fitted, is the latch ejected with spring
pressure from the buckle when the "Red button" is No Replace complete automatic seat belt
pressed?
Yes
Does fastened seat belt lock when stopping vehicle
quickly on a dry road at a road speed twice as fast as No Replace complete automatic seat belt
walking speed?
Yes
If dirt and marks cannot be removed with

2010 BMW M3
commercially available mild-action

Is fully pulled-out belt free of serious dirt and other
No detergent, the automatic seat belt (upper
marks?
strap) must be replaced.
Yes
Replace both damaged parts and
complete automatic-reel seat belt.
The following must also be checked and
In the case of seat-integrated seat belts, is front tongue of
No replaced, if necessary:
reclining mechanism or seat rail free of deformation?
seatbelt mountings on the seat seat
runners.
Yes
The automatic seat belt is O.K.!
72 11 030 REMOVING AND INSTALLING OR REPLACING FRONT SEAT BELT (CONVERTIBLE)
IMPORTANT: Read and comply with safety regulations for handling airbag modules and
pyrotechnical belt pretensioners. Inexpert handling can trigger off the airbag or
the belt pretensioner and thereby cause injuries. If a seat belt which is
damaged due to an accident is exchanged, always check the affected seat for
damage.
Remove front seat. See SEATS - REPAIR (CONVERTIBLE/COUPE) .

Remove and install rear panel on front seat. See SEATS - REPAIR (CONVERTIBLE/COUPE) .
Remove trim cover for outer fitting. See 52 14 ... REMOVING AND INSTALLING OR REPLACING
TRIM COVER FOR OUTER FITTING ON FRONT SEAT .
Remove inner cover on front seat. See 52 14 041 REMOVING AND INSTALLING OR REPLACING
INNER COVER ON LEFT OR RIGHT FRONT SEAT .
Partially detach seat cover. See 52 14 400 REPLACING COVER FOR LEFT OR RIGHT FRONT
SEAT .
Partially detach backrest cover. See 52 14 405 REPLACING BACKREST COVER FOR LEFT OR
RIGHT FRONT SEAT .
IMPORTANT: Do not detach coupling gear from flex shaft. If a new belt system is fitted,
always use a new coupling gear. If a new coupling gear is fitted, always replace
the top belt.
Removing inertia reel with flex shaft and coupling gear: Release screw. Installation: Replace microencapsulated
screw. Tightening torque 72 11 02 AZ, see 72 11 SEAT BELTS . Remove end fitting.
2010 BMW M3

Installation: Plastic washer on end fitting must be fitted! End fitting is coded to prevent incorrect installation.
Fig. 3: End Fitting Is Coded To Prevent Incorrect Installation

Unclip all cables from guides. Release screw (1). Tightening torque: 72 11 09AZ, see 72 11 SEAT BELTS .
Release stud (2). Tightening torque: 72 11 08AZ, see 72 11 SEAT BELTS .
2010 BMW M3
Fig. 4: Release Screw (1) And Stud (2)

Note: Replace driver (1) after removal with a new component as damage cannot be excluded. When removing
driver (1), ensure guide (3) and lever (2) of coupling gear are not damaged. Remove driver (1) from backrest
shaft.
Fig. 5: When Removing Driver (1), Ensure Guide (3) And Lever (2) Of Coupling Gear Are Not Damaged
Installation: Do not fit new driver (1) on backrest shaft yet. Backrest must be in as vertical a position as
possible. Driver (1) and lug are positioned at an angle towards top in direction of travel (arrow).
2010 BMW M3
Fig. 6: Driver (1) And Lug Are Positioned At An Angle Towards Top In Direction Of Travel (Arrow)
Installation: Feed driver (1) into slot (3) in lever (2) of coupling gear. Align lever (2) on coupling gear so that
slot (3) is correctly positioned with respect to driver (1).
Fig. 7: Align Lever (2) On Coupling Gear So That Slot (3) Is Correctly Positioned With Respect To
Driver (1)
Installation: Pin on coupling gear must reach into hole in seat.

2010 BMW M3
Fig. 8: Pin On Coupling Gear Must Reach Into Hole In Seat

Installation: Make sure groove and pin are correctly positioned. Clip flexible shaft (1) into place with coupling
gear (2). Ensure complete engagement by pulling gently on flex shaft. Flexible shaft must not clip out here!
Fig. 9: Clip Flexible Shaft (1) Into Place With Coupling Gear (2)
Unclip flexible shaft (3) from cable tie (2). Unclip cable tie (1) from backrest.
2010 BMW M3
Fig. 10: Unclip Cable Tie (1) From Backrest

Release nut and remove inertia reel with flexible shaft and coupling gear. Replace nut. Tightening torque 72 11
01AZ, see 72 11 SEAT BELTS . Installation: Inertia reel is coded to prevent incorrect installation.
Fig. 11: Inertia Reel Is Coded To Prevent Incorrect Installation

Remove belt guide - build date (version) up to 09/08: Unclip cover (1) with plastic wedge.
2010 BMW M3
Fig. 12: Unclip Cover (1) With Plastic Wedge

Release screw (1). Tightening torque 72 11 03AZ, see 72 11 SEAT BELTS . Remove seat belt guide.
Fig. 13: Release Screw (1) And Remove Seat Belt Guide
Remove belt guide - build date (version) from 09/08:
NOTE: Protect belt guide against damage (scratches). Trims of belt guide at front and
rear (1) are destroyed when removed!
2010 BMW M3
Fig. 14: Trims Of Belt Guide At Front And Rear (1) Are Destroyed When Removed
Installation: Pay particular attention to cutting line between both trims. If the trims are not fully clipped into
place, this will result in grinding noises when the belt is pulled.
Release screw on belt guide. Tightening torque 72 11 03AZ, see 72 11 SEAT BELTS .
Fig. 15: Release Screw On Belt Guide

Release further screw on belt guide and detach belt guide. Remove complete seat belt with belt guide, inertia
reel with flex shaft and coupling gear. Do not kink flex shaft and do not transport inertia reel by flex shaft.
2010 BMW M3
Fig. 16: Remove Complete Seat Belt With Belt Guide, Inertia Reel With Flex Shaft And Coupling Gear
72 11 033 REMOVING AND INSTALLING OR REPLACING FRONT SEAT BELT (COUPE)
Remove panel for door post 51 43 148 REMOVING AND INSTALLING OR REPLACING TRIM
ON LEFT OR RIGHT DOOR PILLAR (TOP)
NOTE: If a seat belt which is damaged due to an accident is exchanged, check the slide
bar for damage (bending) and replace if necessary.
Lever out cap (1). Release screw (2). Tightening torque 72 11 05AZ, see 72 11 SEAT BELTS . Installation:
Check that spacer bushing (3) and rubber ring (4) are in correct position.
Fig. 17: Identifying Spacer Bushing And Rubber Ring

Release screws (1). Tightening torque 72 11 04AZ, see 72 11 SEAT BELTS . Installation: E81 only: If screws
(1) slip, use 6 mm dia. repair screws. Tightening torque 72 11 04AZ, see 72 11 SEAT BELTS . Remove
2010 BMW M3
deflection bracket (2). Release screw (3). Tightening torque 72 11 03AZ, see 72 11 SEAT BELTS . Remove
belt deflection fitting (4).
Fig. 18: Identifying Deflection Bracket

Release screw (1). Tightening torque 72 11 01AZ, see 72 11 SEAT BELTS . Remove automatic reel (2).
Installation: Coding (3) of automatic reel must be seated in body opening.
Fig. 19: Coding Of Automatic Reel Must Be Seated In Body Opening

72 11 033 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT SEAT BELT

(SEDAN)
Remove panel for door post . See 51 43 148 REMOVING AND INSTALLING OR REPLACING
TRIM ON LEFT OR RIGHT DOOR PILLAR (TOP) or 51 43 150 REMOVING AND
INSTALLING OR REPLACING TRIM FOR LEFT OR RIGHT DOOR PILLAR (BOTTOM) .
2010 BMW M3
Move backrest to full rearward position.
Unclip release tab (2) for belt anchor fitting trim (1) with plastic wedge.
Fig. 20: Identifying Belt Anchor Fitting Trim And Plastic Wedge
Release screw (1).
Tightening torque: 72 11 2AZ , see 72 11 SEAT BELTS .
Remove anchor fitting (2).
Installation:
Make sure anchor fitting is correctly seated on seat mechanism pin.
Fig. 21: Identifying Anchor Fitting And Screw

2010 BMW M3
Release screws (1).
Remove deflector bar (2).
Release screw (3).
Set down belt deflector with belt (4).
Fig. 22: Identifying Deflector Bar, Belt Deflector And Screw

Release screw (1).
Installation:
Coding (2) of automatic reel must be seated in body opening.

2010 BMW M3
Fig. 23: Identifying Automatic Reel And Screw

72 11 041 REMOVING AND INSTALLING OR REPLACING FRONT LEFT OR RIGHT LOWER

BELT FITTING (SEAT BELT PRETENSIONER)
Remove front seat . See SEATS - REPAIR (CONVERTIBLE/COUPE) or SEATS - REPAIR

(SEDAN) .
pyrotechnical belt pretensioners.
Installation:

Unlock plug connection (3) and pull all plugs out of plug housing (2).
Removing wiring harness.

2010 BMW M3
Installation:
Replace cable tie.

Wires must not be under tension
Plugs are coded and must be reinstalled in the correct sequence in the plug housing
Fig. 24: Pulling Plugs Out Of Plug Housing

Only in event of replacement for E87 with build date before 09/2004:
New seat belt tensioners are supplied with seat belt buckle contacts which are not required before this build
date.
Disconnect contacts at pin 14 and pin 15

Tie both contacts to rear
NOTE: Clear all fault memories and code car again.

2010 BMW M3
Fig. 25: Disconnecting Contacts Pin 14 And Pin 15

Release screw (1).
Remove belt pretensioner (3).
Installation:
Replace screw (1).
Belt tensioner (3) is secured through recess (2) to retaining bracket.
Fig. 26: Identifying Belt Tensioner And Screw

72 11 080 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT SEAT-BELT

EXTENDER HAND (COUPE)
Extend seat-belt extender

Disconnect battery to prevent seat-belt extender from moving back
Firmly pull seat-belt extender hand (1) in direction of arrow to unclip retaining lug (2) from seat-belt extender.
2010 BMW M3
Fig. 27: Unclip Retaining Lug (2) From Seat-Belt Extender

NOTE: Removal tool for seat-belt extender hand is included in delivery specification.
Insert tool to bridge loss prevention element (1). Pull seat-belt extender hand out of seat-belt extender.
Fig. 28: Insert Tool To Bridge Loss Prevention Element (1)

72 11 092 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT SEAT BELTS
Remove rear window shelf . See 51 46 001 REMOVING AND INSTALLING PANEL FOR REAR
WINDOW SHELF (PARCEL SHELF) .
SEAT .
2010 BMW M3
Removing left or right inertia reel unit:
Release screw (1) on inertia reel unit (2).
Tightening torque 72 11 20AZ , see 72 11 SEAT BELTS .
Fig. 29: Identifying Inertia Reel Unit And Screw

Installation:
Push inertia reel unit (1) onto body lug (2).
Fig. 30: Identifying Inertia Reel Unit And Body Lug

2010 BMW M3
Release screw (2).
Tightening torques 72 11 22AZ , see 72 11 SEAT BELTS .
Remove seat belt (1).
Installation:
Pin (3) determines the installation position and prevents the anchor fitting from turning.
Fig. 31: Removing Seat Belt

72 11 096 REMOVING AND INSTALLING OR REPLACING REAR LEFT OR RIGHT LOWER

BELT FITTING
Remove rear seat. See 52 24 005 REMOVING AND INSTALLING OR REPLACING REAR SEAT .
Illustration show removal of the left lower belt fitting; proceed in the same way for the right fitting. Release
screw (1). Tightening torque 72 11 23AZ, see 72 11 SEAT BELTS . Remove lower belt fitting (2). Installation:
Pin (3) determines the installation position and prevents lower belt (2) from turning.
2010 BMW M3
Fig. 32: Identifying Lower Belt Fitting

72 11 098 REMOVING AND INSTALLING/REPLACING ALL REAR LOWER BELT FITTINGS
pyrotechnical belt tensioners.
SEAT .
Illustration shows removal of the left lower belt fitting; proceed in the same way for the right fitting.
Release screw (1).
Installation:
belt fitting.
2010 BMW M3
Fig. 33: Identifying Lower Belt Fitting And Pin

Lower belt fitting with belt tensioner:
Release screw (1).
Installation:
2010 BMW M3
belt fitting.
72 11 101 REMOVING AND INSTALLING/REPLACING REAR CENTER SEAT BELT
SEAT .
Remove rear window shelf . See 51 46 001 REMOVING AND INSTALLING PANEL FOR REAR
WINDOW SHELF (PARCEL SHELF) .
Unscrew nut (1).
Installation:
Fig. 35: Identifying Inertia Reel Unit And Nut

Release screw (2) on middle seat belt anchor fitting.
Installation:
2010 BMW M3
Pin (3) determines the installation position and prevents the anchor fitting (1) from turning.
Fig. 36: Releasing Screw On Middle Seat Belt Anchor


2010 BMW M3
Fig. 37: Identifying Airbag Modules, Airbag Control Unit, Belt Tensioners
AIRBAG GENERATOR/AIRBAG
See 61 00 ... REPAIRING AIRBAG CABLES .
72 12 ... DEACTIVATING FRONT PASSENGER AIRBAGS WITH KEY-OPERATED SWITCH
WARNING: The responsibility for deactivation/activation rests with the customer.

Depending on the occupation of the front passenger seat, the front
passenger and side airbags must be (de-) activated in accordance with
the Owner's Handbook.
The passenger airbag can only be deactivated in accordance with the following instructions if the vehicle is
equipped with a suitable key-operated switch!
The key-operated switch can be retrofitted if it is missing and has been ordered as an optional extra.
Key-operated switch:
Optional extra SA 5DA for MINI

Optional extra SA 470 for BMW
The airbags can only be deactivated/reactivated while the vehicle is stationary and with the door open.
IMPORTANT: The head airbag remains active.
Fig. 38: Identifying Key-Operated Switch

2010 BMW M3
Deactivation
1. Turn key-operated switch with ignition key to "OFF" position.
Deactivatable airbags on passenger side out of operation.
Head airbag on passenger side remains active.
All airbags on driver side remain active.
Activation
2 Turn key-operated switch with ignition key to "ON" position.
All the airbags in the vehicle are activated and are triggered in appropriate situations.
Fig. 39: Turning Key-Operated Switch With Ignition Key

Warning lamp
When the ignition key is turned in the ignition lock, the function of the airbag system is checked and the
warning lamp in the center console lights up for several seconds.
1. The warning lamp is permanently lit when the passenger airbags are deactivated
2. The warning lamp goes out after a few seconds when the passenger airbags are activated
2010 BMW M3
Fig. 40: Identifying Warning Lamp (Activated And Deactivated) Position

72 12 ... NOTES ON SCRAPPING VEHICLES WITH GAS GENERATORS (AIRBAG SYSTEM)
The gas generator is a pyrotechnical component and is for the most part permanently mounted on the following
components:
Airbag module
Side airbag
Head airbag (e.g. AHPS2)
Knee airbag
Belt tensioner
With vehicles which are scheduled for scrapping, it is always essential prior to draining and further stripping
work to ensure that all the gas generators in the vehicle are fired. The fired gas generators can then be scrapped
together with the vehicle.
Firing failure:
If correct firing is not possible, the relevant components must be removed and disposed of by special waste
2010 BMW M3
disposal companies!
Comply with safety regulations for handling airbag system components.
If a firing operation has failed:
Disconnect the firing device from the battery and

Only approach the vehicle after a few minutes have elapsed
used parts.
Firing:
Firing of the gas generators may only be carried out by expert personnel and under the supervision of a
be observed.
The gas generators must be fired from the outside in this vehicle which has been earmarked for scrapping. In
this process
the doors must be closed

the rear lid must be open
the side windows must be open and
the sunroof must be open
To fire the gas generators, use the firing device with the appropriate cables (follow instructions).
inside the vehicle.
generator!
The burning of solid fuel will heat up the airbag unit - danger of burning
hands!

2010 BMW M3
72 12 ... PROCEDURE AFTER AIRBAG TRIGGERING AS RESULT OF AN ACCIDENT
Components
Procedure
Read out fault memory
Clamp off battery and observe waiting period

2010 BMW M3
Rectify faults
Reconnect battery and observe waiting period
Clear fault memory
Switch ignition on
Cables and plugs

Belt system
Components
Retractor mechanism
Procedure
Seats
Components
Seat
Airbag module
Procedure
If the severity of the impact has not caused any other damage to the seat, only the triggered gas
generator needs to be replaced.

2010 BMW M3
Replace airbag module and seat cover with padding
Driver's airbag
Components
Airbag module
Steering wheel
Steering column
Procedure
Passenger airbag
Components
Airbag module
Instrument panel trim
Procedure
Components
Airbag module
Door trim panel
Door in white
Seat
Procedure
Head airbag (AHPS)
Components
Airbag module
Trim, A-pillar
Roofliner
Procedure
2010 BMW M3
Knee airbag
Components
Procedure
Components
Procedure
72 12 ... UNLOCKING/LOCKING AIRBAG PLUG CONNECTIONS
IMPORTANT: An airbag plug connection must be replaced if it is damaged.
Following versions of plug connections on airbag module/gas generator are possible:
Airbag plug connection on gas generator/airbag module is offset by 90

Airbag plug connection on gas generator/airbag module offset by 90:
There are two ways of unlocking this airbag plug connection on the gas generator/airbag module:
Method 1:
Simultaneously pull cover (1) upwards at lugs on left and right (2).
2010 BMW M3
Fig. 42: Pulling Cover Lugs On Left And Right

Method 2:
Insert a narrow screwdriver into recess (1) in housing (2).
Carefully prise cover (3) off (4).
Fig. 43: Identifying Recess And Housing

Cover (1) is not positioned higher than housing (2).
2010 BMW M3
Fig. 44: Identifying Cover And Housing

Installation:
After attaching airbag plug connection to gas generator/airbag module, press cover (1) downwards until it rests
flat on housing.
Check that it catches properly.
Fig. 45: Identifying Cover And Housing Gap Dimension

Version 1:
Press locking/unlocking plate (1) at edge (4).

2010 BMW M3
Fig. 46: Releasing Detent Lug

Fig. 47: Identifying Airbag Plug Connection

Installation:
After attaching airbag plug connection to gas generator/airbag module, check whether detent lug (2) is visible in
opening of locking/unlocking plate (1).
Only if the detent lug (2) is visible will the airbag plug connection gas generator/airbag module be correctly
engaged.
2010 BMW M3
Fig. 48: Identifying Detent Lug

Version 2:
Press locking/unlocking plate (1) on edge (3) and pull plug (2) out of plug housing (4).
Installation:
Only if the detent lug is visible in opening (5) will the gas generator/airbag module plug connection be correctly
engaged.
Fig. 49: Identifying Edge, Plug And Plug Housing

Version 3:
Press lock button (1) and pull out plug (2) up to initial engagement position.
2010 BMW M3
Installation:
Insert plug connection in initial engagement position in gas generator/airbag module and engage in final
engagement position.
Fig. 50: Identifying Lock Button And Plug

Illustration of version 3 with gas generator:
A. Initial engagement position

B. Final engagement position
1. Lock button
2. Gas generator
Fig. 51: Identifying Lock Button And Gas Generator

Version 4 - Crash-active head restraint:

2010 BMW M3
Press locking clip at edge and disconnect plug (1).
Installation:
Check for correct engagement.
Fig. 52: Pressing Locking Clip And Plug

72 12 000 REMOVING AND INSTALLING/REPLACING AIRBAG MODULE ON PASSENGER SIDE

Remove glovebox . See 51 16 366 REMOVING AND INSTALLING RIGHT GLOVEBOX WITH
HOUSING .
Car and airbag module up to 03/2006:
Unlock plug connection (1) and disconnect.
NOTE: Secure airbag module on passenger side (3) against falling out.
Unscrew nuts (2).
Tightening torque 72 12 01AZ , 72 12 AIRBAG MODULES .
Remove airbag module on passenger side (3) towards bottom.

2010 BMW M3
Fig. 53: Identifying Airbag Module On Passenger Side

Car + airbag module from 03/2006:
NOTE: Secure airbag module against falling out.
Unscrew nuts (2).
Remove airbag module in downwards direction.
Fig. 54: Identifying Airbag Module And Nuts

Replacement in car up to 03/2006 only, with airbag module from 03/2006:

2010 BMW M3
NOTE: Before installing the airbag module on the passenger side (2), it is necessary to
fit the accompanying firing cable (4) and secure it with the accompanying foam
sticker pads (5).
Insert plug connections (1) and (3) (pay attention to color coding).
Attach accompanying foam sticker pads (5) as follows:
One foam sticker pad (5) each to both outer edges (A) and (B) of airbag module on passenger side (2)
One foam sticker pad (5) in the middle so as to leave a free length L = 190 10 mm up to cable entry into
the firing cable plug (4)
Fig. 55: Identifying Foam Sticker Pad And Airbag Module

Clip firing cable plug (4) into installation position in car.
NOTE: Subsequent installation is the same as for the car and airbag module from
03/2006 version.
72 12 050 REMOVING AND INSTALLING SIDE AIRBAG (SPORT SEAT)
WARNING: Observe safety regulations for handling airbag modules and

pyrotechnical seat belt pretensioners.
Incorrect handling can cause airbags to trigger, resulting in serious
injuries.

Remove rear panel on front seat . See 52 13 198 REMOVING AND INSTALLING/REPLACING
2010 BMW M3
REAR PANEL ON LEFT OR RIGHT FRONT SEAT BACKREST .

Remove front seat . See SEATS - REPAIR (CONVERTIBLE/COUPE) or SEATS - REPAIR
(SEDAN) .
IMPORTANT: Make sure airbag wiring harness is exactly routed when installed.
Detach cable tie.
Release airbag wiring harness (2) from cable holders on seat mechanism.
Raise release clip (3) and pull plug (4) out of plug housing (1).
NOTE: If necessary, release yellow plug housing (1) from holder on seat mechanism.
Fig. 56: Identifying Clip, Plug And Plug Housing

Unclip cable holder (1) from seat mechanism (2).

2010 BMW M3
Fig. 57: Unclip Cable Holder From Seat Mechanism

Unscrew nuts (1).
Installation:
Replace nuts.
Tightening torques 72 12 02AZ , 72 12 AIRBAG MODULES .
Fig. 58: Identifying Seat Mechanism Nuts

IMPORTANT: Feed the wiring harness carefully through the seat and backrest mechanism as
the edges of the frame can be sharp.
Installation:
Assemble front seat.
72 12 060 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT HEAD AIRBAG

2010 BMW M3

Follow instructions for unlocking and locking airbag plug connections
Remove roofliner . See 51 44 011 REMOVING AND INSTALLING OR REPLACING
ROOFLINER (WITH SLIDE/TILT SUNROOF) .
Head airbag installation summary:
Fig. 59: Identifying Head Airbag, Holders, Ramp-B-Pillar And Gas Generator
Release screw (1) on end fitting.
Release screw (2) on folding pack holder.
Folding pack holder (3) is screwed to trim for roof pillar at front.
2010 BMW M3
Installation:
If screws (1...3) slip, coat them with Loctite.
Fig. 60: Identifying Pack Holder And Screw

If necessary, slide wiring harness (2) to one side to release screw (1) on folding pack holder.
Release screw (3) from folding pack holders.
Installation:
If screws (1) and (3) slip, coat them with Loctite.

2010 BMW M3
Fig. 61: Sliding Wiring Harness

Unlock plug connection (4) and disconnect.
Release screws (1) on B-pillar ramp.
Tightening torque 72 1206AZ , 72 12 AIRBAG MODULES .
Unscrew bolt (3).
Remove gas generator (5) with head airbag.
Fig. 62: Identifying Gas Generator And Head Airbag

CHILD SEAT QUICK FASTENER

2010 BMW M3
72 14 ... REMOVING AND INSTALLING/REPLACING TOP TETHER EYELETS FOR CHILD SEAT
NOTE: Two or three Top Tether eyelets are installed, depending on the model.
Remove Top Tether eyelets (2).
Fig. 63: Identifying Top Tether Eyelets And Covers

IMPORTANT: Ensure Top Tether eyelets (1) are in correct installation position.
It must be possible for Top Tether eyelets (1) to be tilted in the direction of
head restraints (2).
Fig. 64: Identifying Top Tether Eyelets And Head Restraints

2010 BMW M3
ACCESSORIES AND BODY, CAB Seats - Repair
Seats - Repair
FRONT SEAT, NORMAL, MANUAL

52 14... PERFORMING FUNCTION CHECK WITH ADAPTER CABLE (FOR SEAT REPAIRS)
NOTE: The function check on a repaired driver's or front passenger seat can be
performed outside the vehicle by using adapter cable 61 4 360 ADAPTER
CABLE, 19-PIN (ELECTRIC SEAT) .
Fig. 1: Identifying Adapter Cable (61 4 360)

Use:
Adapter cable 61 4 360 ADAPTER CABLE, 19-PIN (ELECTRIC SEAT) is connected to vehicle wiring
harness (1) and removed seat (2).
2010 BMW M3
Fig. 2: Identifying Adapter Cable (61 4 360), Wiring Harness And Seat
52 13 021 REMOVING AND INSTALLING/REPLACING FLEXMAT ON LEFT OR RIGHT FRONT

SEAT
Remove padding for front seat . See REPLACING SEAT COVER FOR LEFT OR RIGHT FRONT
SEAT (M3 SPORT SEAT) or REPLACING SEAT COVER FOR LEFT OR RIGHT FRONT
SEAT (SPORT/MANUAL)
Cut all cable ties and disengage wiring harnesses from flexmat.
Fig. 3: Locating Cable Ties

Disengage flexmat (1) at front.

2010 BMW M3
Fig. 4: Disengaging Flexmat

Swing flexmat (1) down and disengage from seat frame.
Fig. 5: Swinging Flexmat Down

52 13 041 REMOVING AND INSTALLING/REPLACING INNER COVER ON LEFT OR RIGHT

FRONT SEAT BACKREST (NORMAL/MANUAL)
Remove FRONT SEAT
Release screw (1).
Remove trim (2) from inside of seat.

2010 BMW M3
Fig. 6: Removing Trim From Inside Of Seat

52 13 000 REMOVING AND INSTALLING LEFT OR RIGHT FRONT SEAT (NORMAL/MANUAL)

Remove HEAD RESTRAINT
E90/E91 only from build date 09/08 and F25:
Remove CRASH-ACTIVE HEAD RESTRAINT
IMPORTANT: An airbag module and a pyrotechnical seat belt tensioner are installed in the
front seat.
tensioner or side airbag, resulting in injuries.
Installation note:
Powerlok screws must be replaced and must not be reused

Powerlok screws are mechanical screw locks with trilobular threads
Move seat to upper back position.
Release and dispose of screws (1).

2010 BMW M3
Fig. 7: Identifying Front Seat Screws

Move seat forwards and position flush with seat runners.
Unclip release tab (2) for belt end fitting trim (1) with plastic wedge.
Fig. 8: Releasing Tab For Belt End Fitting Trim Using Plastic Wedge
Release screw (1).
Remove end fitting (2).
Installation note:
Make sure end fitting (2) is correctly seated on seat mechanism pin.
2010 BMW M3
Fig. 9: Identifying End Fitting On Seat Mechanism Pin And Screw

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2007-2013 BMW M3

E90, E92, E93

SERVICE AND REPAIR MANUAL

Commonly Used Abbreviations

* PLEASE READ THIS FIRST *

Air Bag Restraint System

A/C Cycling Switch

Air Charge Temperature Sensor

Air Injection Reactor

Air Injection System

Air Suction Control Solenoid

Air Bag System Diagnostic Module

Air Suction Valve

Automatic Temperature Control

After Top Dead Center

Automatic Transmission Fluid

Air Temperature Sensor

Automatic Transaxle Overdrive (Ford Models Only)

By-Pass Air Control

Barometric Absolute Pressure Sensor

Barrel (Example: 4-Bbl.)

Body Control Module

Barometric and Manifold Absolute Pressure Sensor

Brake On-Off Switch

Barometric Pressure Sensor

Before Top Dead Center

Brake Transmission Shift Interlock

British Thermal Unit

Bimetallic Vacuum Switching Valve

California Air Resources Board

Closed Bowl Distributor

Close Coupled Catalyst

Computer Command Control

Computer Controlled Dwell

Cycling Clutch Orifice Tube

Capacitor Discharge Ignition

Computerized Engine Control

Cubic Inch Displacement

Camshaft Position Sensor

Crankshaft Position Sensor

Coolant Temperature Sensor

Constant Vacuum Control

Check Valve or Constant Velocity

Computer Controlled Coil Ignition

Computer Controlled Catalytic Converter

Direct Current Or Discharge

Dual Diaphragm Distributor

Diagnostic Energy Reserve Module

Digital Fuel Injection

Diagnostic Trouble Code

Driver Information Center

Distributorless Ignition System

Data Link Connector

Diesel Oxidation Catalyst

Double Overhead Cam

Diesel Particulate Filter

Diagnostic Readout Box

Electric Air Control Valve

Electronic Automatic Transaxle

Electronic Brake Control Module

Electronic Back Light

Engine Control Module

Engine Coolant Temperature Sensor