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Page 1 of 12 REP-REP-RAE70M57T2-1112800 Cleaning cylinder heat intake channels and intake plenum (E70US, M57T2) VIN: Vehicle: X'

51 11 12 800 Cleaning cylinder heat intake channels and intake plenum (E70US, M57T2) Special tools required: 11 6 080 2 356 969

Lever out expanding rivets. Press lock and raise intake port. Detach intake port from air filter housing and remove.

1 Page 1 of 12 REP-REP-RAE70M57T Cleaning cylinder heat intake channels and intake plenum (E70US, M57T2) VIN: Vehicle: X' / E70 / off-road vehicle / X5 35d x / M57 / USA / left-hand drive / AUT / - / - System version: Data version: Cleaning cylinder heat intake channels and intake plenum (E70US, M57T2) Special tools required: Raise acoustic cover and remove in direction of arrow. Lever out expanding rivets. Press lock and raise intake port. Detach intake port from air filter housing and remove. Clamp off battery. Unlock and disconnect the connector (1). Release clamp (2) and detach air intake hose. Open clamps and remove upper part of intake silencer housing.

2 Page 2 of 12 Pull off intake silencer housing from mounting points. Release screws (1). Tightening torque AZ. Take off acoustic cover (2). Unclip Bowden cable for hood/bonnet release from transverse reinforcement (1). Release screws on left and right. Tightening torque AZ. Remove transverse reinforcement (1). Unfasten plug connection (1) and disconnect. Release bolt (1) from fan cowl.

Page 3 of 12 Press out clamp (1) from charge air hose (2) in

Unfasten plug connection (3) and disconnect.

charge air hose with slip paste and correctly connect hose.

Lay charge air hose (1) over alternator as illustrated.

Press hose (1) out of holder. Press lock (1).

3 Page 3 of 12 Press out clamp (1) from charge air hose (2) in direction of arrow. Unfasten plug connection (3) and disconnect. Pull down charge air hose in direction of arrow. Lubricate connection for charge air hose with slip paste and correctly connect hose. Clamp must audibly snap into place. Lay charge air hose (1) over alternator as illustrated. Press hose (1) out of holder (2). Press hose (1) out of holder. Press lock (1). Raise fan cowl (2) until holder (3) can be folded into centre of vehicle. For reasons of clarity, graphic and text show coolant hose removed. Do not raise fan cowl by fan wheel.

Page 4 of 12 Press lock (1). Feed out fan cowl (2) towards top and remove.

Carry out repair work on the left side in the same way as for the right side

Make sure water gutter (1) is correctly seated in guide (2).

4 Page 4 of 12 Press lock (1). Feed out fan cowl (2) towards top and remove. Insert retaining tab (1) at bottom on module carrier. Release gasket (1) in working area. Unlock screw caps (2) and remove microfilter housing cover (3). Carry out repair work on the left side in the same way as for the right side illustrated here. Make sure water gutter (1) is correctly seated in guide (2). Make sure flap (3) moves freely; if necessary, clean to remove major dirt. Remove gasket (1) for engine compartment lid. Release screws (2 and 4). Remove partition wall (3). Make sure partition wall (3) is correctly positioned.

Page 5 of 12 Release expansion rivet (1). Release screws (2 and 4).

Replace damaged expanding rivet. Make sure partition wall is correctly positioned.

Picture shows right tension strut Release screws (1) on left tension strut.

To ensure a correct ground connection, use only Original BMW replacement part.

5 Page 5 of 12 Release expansion rivet (1). Release screws (2 and 4). Left only: Unclip connecting line (3). Remove left partition wall (5). Replace damaged expanding rivet. Make sure partition wall is correctly positioned. Make sure screws are installed in correct positions. Picture shows right tension strut Release screws (1) on left tension strut. Remove left tension strut (2). To ensure a correct ground connection, use only Original BMW replacement part. Thread repairs on bulkhead console are not permitted. Replace screws. Tightening torque AZ. Disconnect plug connection (1) on swirl-flap actuator. Release screw (2) on dipstick. Unlock and disconnect plug connection (3) on pressure sensor. Unclip vacuum line (4) from holder. Unlock and disconnect plug connection (1) on pressure pipe.

Unlock and disconnect plug connection (3) on electromotive throttle actuator.

Release injector wiring harness from valve cover. Replace all gaskets.

6 Page 6 of 12 Open cable clips (1). Unlock and disconnect plug connection (2) on exhaust-gas recirculation valve. Unlock and disconnect plug connection (3) on electromotive throttle actuator. Picture shows M57T2 Europe. Unlock and detach charge air hose (1). Release profile clamp (2) on exhaust-gas recirculation line. Release screw connection along lines (3). Remove plenum. Release injector wiring harness from valve cover. Replace all gaskets. Dismantle intake plenum: Picture shows M57T2 Europe. Release screws (1). Remove throttle valve from exhaust-gas recirculation valve. Remove exhaust-gas recirculation valve. Picture shows M57T2 Europe.

Page 7 of 12 Clean sealing surfaces. Replace gasket (1).

Remove charging pressure sensor (2) in direction of arrow.

(2). Factory setting of swirl-flap controller (1) may be

7 Page 7 of 12 Clean sealing surfaces. Replace gasket (1). Unfasten plug connection (1) and disconnect. Remove charging pressure sensor (2) in direction of arrow. Replace sealing ring (1) of the charging pressure sensor (2). Factory setting of swirl-flap controller (1) may be lost. Electrical swirl-flap controller (1) must not be removed from intake plenum. Cleaning intake plenum: Wear safety goggles and protective gloves. Never place electrical components in cleaning bath!

Page 8 of 12 Place the intake plenum in the cleaning bath so that the electric swirl-flap controller is not lying in the bath.

Leave to soak for at least 1 hour. Crank engine to cylinder no. 1 TDC setting: Unfasten plug connection (1) and disconnect. Release screw.

Illustration shows valve cover removed for greater clarity. Do not crank engine in reverse direction. Visual inspection via camshaft sensor opening.

8 Page 8 of 12 Place the intake plenum in the cleaning bath so that the electric swirl-flap controller is not lying in the bath. Prepare cleaning bath with 1 part BMW universal cleaner (see Section 3.2) and 2 parts water. Place intake plenum in cleaning bath. Leave to soak for at least 1 hour. Crank engine to cylinder no. 1 TDC setting: Unfasten plug connection (1) and disconnect. Release screw. Tightening torque AZ. Remove pulse sensor (2). Check sealing ring (1) for damage and replace if necessary. Illustration shows valve cover removed for greater clarity. Do not crank engine in reverse direction. Visual inspection via camshaft sensor opening. Crank engine at central bolt. In the TDC setting, cams (1) on camshafts (2) of the 1st cylinder point in the direction of travel to the right. Remove protective cap in direction of arrow. Reinstall protective cap with some grease.

Page 9 of 12 Crank engine at central bolt in direction of rotation until piston of 1st cylinder is in TDC

Special tool 11 6 080 must be removed before starting the engine.

The intake valves of the corresponding cylinder must be closed when cleaning the intake ports.

The following are required: - Blasting tool 81 29 2 208 034 - Walnut shell granulate - Vacuum cleaner Front

9 Page 9 of 12 Crank engine at central bolt in direction of rotation until piston of 1st cylinder is in TDC setting. Secure the crankshaft in the TDC setting with special tool Do not turn the engine back. Special tool must be removed before starting the engine. Cleaning intake ports: Risk of engine damage! The intake valves of the corresponding cylinder must be closed when cleaning the intake ports. Start with the 1st cylinder when cleaning the intake ports. The following are required: - Blasting tool Walnut shell granulate - Vacuum cleaner Front area of sensors is marked with two notches. These can additionally be highlighted in colour. During the blasting process, only pull the wands out of the vacuum adapter until the mark becomes visible. Blasting wand for tangential swirl port: Blasting wands for swirl port:

Page 10 of 12-2 356 970 with straight outlet - 2 356 968 with lateral outlet Vacuum adapter for

per cleaning operation; this corresponds to a blasting duration of approx. 20 seconds.

Operating pressure 6-8 bar. Close main valve (1) on blasting tool (2). Connect compressed air (3).

actuator (2). Actuator (3) has two stages!

10 Page 10 of with straight outlet with lateral outlet Vacuum adapter for tangential swirl port: Vacuum adapter for swirl port: Use 2 litres of granulate per cleaning operation; this corresponds to a blasting duration of approx. 20 seconds. Open blasting tool (1) and pour in 2 litres of granulate (2). Close the device again. Operating pressure 6-8 bar. Close main valve (1) on blasting tool (2). Connect compressed air (3). Cleaning the tangential swirl port of 1st cylinder: Screw together blasting wand (1) and actuator (2). Actuator (3) has two stages! In stage one, only compressed air flows through the blasting wand. In stage two (operation is fully pressed), granulate is added (blasting process). Danger of injury! Risk of damage! Second person required to assist.

Page 11 of 12 Blasting wand may only be pulled out far enough until the mark becomes visible! Wear safety goggles.

Open the main valve on the blasting tool and switch the vacuum cleaner on. Insert blasting wand (3) into the adapter (2). Open the actuator valve (4).

Fully operate valve (3) at stage two; walnut shell granulate is now injected. Clean intake port, rotating the blasting wand and moving it vertically up and down.

When you notice that the container is becoming empty, continue operation for at least 10 seconds at stage one in order to swirl up and draw off the remaining granulate.

11 Page 11 of 12 Blasting wand may only be pulled out far enough until the mark becomes visible! Wear safety goggles. Connect vacuum cleaner (1) to the vacuum adapter (2) and direct towards the tangential swirl port of the 1st cylinder. Open the main valve on the blasting tool and switch the vacuum cleaner on. Insert blasting wand (3) into the adapter (2). Open the actuator valve (4). Slide locking lever (1) to the front in direction of arrow. Operate compressed-air valve (2) at stage one; compressed air can now flow in. Fully operate valve (3) at stage two; walnut shell granulate is now injected. Clean intake port, rotating the blasting wand and moving it vertically up and down. Blasting wand may only be pulled out far enough until the mark becomes visible! When you notice that the container is becoming empty, continue operation for at least 10 seconds at stage one in order to swirl up and draw off the remaining granulate. Close main valve, check pressure drop at the pressure gauge. If necessary, evaluate the result (recommendation: endoscope or similar device). If necessary, repeat procedure. Cleaning the swirl port of 1st cylinder: Risk of damage! Plastic section (1) of the swirl port must not be blasted. Before blast-cleaning, clean the plastic section of the swirl port (1) in the cylinder head cover mechanically (e. g. using a plastic scraper, brushes or similar tools). Two blasting wands must be used for the swirl port. This means that two individual cleaning operations are necessary. Use 2 litres of granulate per cleaning operation; this corresponds to a blasting duration of approx. 20 seconds. Danger of injury! Risk of damage! Second person required to assist. Blasting wand may only be pulled out far enough until the mark becomes visible!

Page 12 of 12 Wear safety goggles. Swap over vacuum adapter 2 356 966 (1) and blasting wands (2).

To prevent damage to the valve cover, blasting wand may only be pulled out until the mark becomes visible! Close main valve, check pressure drop at the pressure gauge.

12 Page 12 of 12 Wear safety goggles. Swap over vacuum adapter (1) and blasting wands (2). Carry out one complete cleaning operation (identical to that for cleaning the tangential swirl port) with blasting wand and then one complete cleaning operation with blasting wand To prevent damage to the valve cover, blasting wand may only be pulled out until the mark becomes visible! Close main valve, check pressure drop at the pressure gauge. If necessary, evaluate the result (recommendation: endoscope or similar device). If necessary, repeat procedure. Check that there is no granulate residue in both intake ports; if necessary, blow out/draw off. Cleaning the other cylinders: Do not crank engine in reverse direction. Remove special tool for securing the crankshaft. Clean the tangential swirl ports and swirl ports of the other cylinders as described above, observing the firing order As you do this, use special tool and to crank the engine at the central bolt by 120 in each case. Cleaning intake plenum: Wear safety goggles and protective gloves. Remove plenum from cleaning bath. Clean plenum openings and swirl flaps with brush set (1) part number: Clean throttle valve, exhaust-gas recirculation valve and mounted parts with brush set. Do not clean electrical components with a component washing machine or high pressure cleaner. Protect electrical swirl-flap controller against splash water. Cover electrical swirl-flap controller accordingly. Then clean the plenum with a parts washer or a high-pressure cleaner. Observe country-specific waste disposal regulations! Crank motor at central bolt at least twice. Assemble engine. Check function of DDE.

See the PDF attachment B Preliminary Work.pdf for removal of the intake manifold and valve cover.

See the PDF attachment B Preliminary Work.pdf for removal of the intake manifold and valve cover. SI B11 03 14 Engine April 2014 Technical Service SUBJECT Diesel Intake Carbon Cleaning MODEL E90 (3 Series Sedan) With M57Y engine (335d) SITUATION The Service Engine Soon light is on and the engine may