Original BMW Accessories. Installation Instructions.

Transcription

1 Original BMW Accessories. Installation Instructions. BMW Performance Retrofit/M Performance Power Kit BMW Series (E8, E82, E87, E88) built after 03/07 BMW 3 Series (E90, E9, E92, E93) from 03/07 to 03/0 for 30 kw, from 03/0 for 35 kw BMW 5 Series (F0, F) from 06/0 Retrofit kit No.: BMW Performance Power Kit BMW Performance Power Kit BMW Performance Power Kit BMW Performance Power Kit BMW Performance Power Kit BMW Performance Power Kit BMW Performance Power Kit BMW Performance Power Kit BMW Performance Power Kit BMW Performance Power Kit M Performance Power Kit M Performance Power Kit M Performance Power Kit M Performance Power Kit M Performance Power Kit Installation time The installation time on E8, E82 and E87 cars is.75 hours without SA 205 and 5.25 hours with SA 205, on E88, E90, E9, E92 and E93 cars it is.25 hours without SA 205 and 4.75 hours with SA 205 (30 kw only), on E9x cars with 35 kw.25 hours, and on F0 and F cars hour. F0, F LCI (built after 07/203) with rear-wheel drive and SA 205 or SA 2TE 4.50 hours. This may vary depending on the condition of the car and the equipment in it. The installation time does not include any time for programming/encoding, as this depends on the age of the car and the equipment in it. Important information Use at least ISTA/P Version ! These installation instructions are primarily designed for use within the BMW dealership organisation and by authorised BMW service companies. In any event, the target group for these installation instructions is specialist personnel trained on BMW cars with the appropriate specialist knowledge. All work must be completed using the latest BMW repair manuals, wiring diagrams, servicing manuals and work instructions, in a rational order, using the prescribed tools (special tools) and observing current health and safety regulations. BMW AG, Munich /205 (T/Z)

2 If you experience installation or function problems, limit troubleshooting to approx. 0.5 hours for mechanical or.0 hour for electrical work. In order to reduce costs and avoid any additional expense, send a query immediately to the Technical Parts Support via the Aftersales Assistance Portal (ASAP). Specify the following information: - Chassis number, - Part number of the retrofit kit, - A precise description of the problem, - Work steps already carried out. Do not archive the hard copy of these installation instructions since daily updates are made via ASAP! Pictograms Denotes instructions that draw your attention to dangers.! Denotes instructions that draw your attention to special features. Denotes the end of the instruction or other text. Installation information Ensure that the cables and/or lines are not kinked or damaged as you install them in the car. Costs arising from this will not be reimbursed by BMW AG. All pictures show LHD cars; proceed accordingly on RHD cars. Before exchanging the control units, transfer the IMA (integrated quantity compensation) values from the injectors. After installation, the retrofit must be programmed / coded using ISSS (Integrated Software Service Station) via the Retrofit path. On E9 cars (320d Touring and 320xd Touring) with only 30 kw, a V-max increase is possible by 0 km/h. This must be activated immediately via a second password when the increase in performance is uploaded. If the customer wishes the optional V-max increase by 0 km/h, an entry of the tyres with speed index W (up to 270 km/h) or higher is invariably required in the vehicle s paperwork (see parts reports). If the car in question is not equipped with suitable tyres, these must be replaced (see ordering information). Ordering instructions for E9 cars (320d Touring and 320xd Touring) only 30 kw With the optional V-max increase by 0 km/h, the tyres must be changed with speed index W (up to 270 km/h) or higher (for part numbers and instructions, see EPC). F0/F: M Performance lettering for side skirts, see installation instructions Workshop certificate Print out the Workshop certificate at the end of the installation instructions, fill it in and give it to the customer. Parts reports (for German-speaking countries only) Print out the Parts reports P45 or P47 section at the end of the installation instructions and give it to the customer. List of special equipment The following special equipment must be taken into consideration when installing the retrofit kit: SA 205 SA 205, SA 2TE (only 520d LCI built after 07/203 and rear-wheel drive) Special tools required , Installation wedges Automatic gears (30 kw only) automatic transmission, automatic transmission with rocker switches BMW AG, Munich /205 (T/Z) 2

3 Table of contents Section Page. Parts list Preparatory work Installing the charge air cooler Installing the fan frame with electric fan Adjusting the charge air cooler and fan frame with electric fan (E8, E82, E87 cars only) Exchanging the engine control unit Attaching the badge Concluding work and coding BMW AG, Munich /205 (T/Z) 3

4 . Parts list A B C D E F G H I J K L BMW Performance Power Kit M N O P Q R Z Legend A Charge air cooler with aluminium coarse stud bolts (E8, E82, E87 cars only) B Charge air cooler without aluminium coarse stud bolts (E88, E90, E9, E92, E93, F0, F cars only) C Fan frame with electric fan (only for E8x, E9x cars and F0, F cars with manual gearbox and trailer tow hitch) D Seal (E8, E82, E87 cars only) E Sealing tape (2x, E8, E82, E87 cars only) F Shims (8x, E8, E82, E87 cars only) G Engine control unit H Seal (E88, E90, E9, E92, E93, F0, F cars only) I Charge air pipe (E88, E90, E9, E92, E93 cars only) with basic 30 kw J Plastic nut (3x, E8, E82, E87 cars only) K Badge (E8x, E9x BMW Performance and F0, F BMW M Performance) L Socket casing (SW 4-pin) M Socket contact (SLK 2.8) N Socket contact (2x, LSK8) O Single conductor seal P Single conductor seal (2x, 4 mm) Q Maxi blue 60 A fuse (only for E8x and E9x cars) R Torque converter (cars with SA 205 only) based on 30 kw Torque converter (only cars with rear-wheel drive and SA 205 or SA 2TE, 520d LCI built after 07/203) BMW AG, Munich /205 (T/Z) 4

5 2. Preparatory work ISTA No. Conduct a brief test --- Disconnect the negative pole of the battery The following components must be removed first of all Power unit bottom guard, front Front bumper trim (E8, E82, E87 cars only) 5 56 Fan frame with electric fan (no longer required) Release the front panel (E8, E82, E87 cars only) Release the module carrier (E8, E82, E87 cars only) Charge air cooler (no longer required) Microfilter housing (bottom section) Engine control unit (no longer required) E88, E90, E9, E92, E93 cars only - only 30 kw! Right charge air hose (no longer required) Cars with SA 205 only Replace the torque converter (it is no longer required) only 30 kw Only 520d LCI cars built after 07/203 with rear-wheel drive and SA 205 or SA 2TE Replace the torque converter (it is no longer required) BMW AG, Munich /205 (T/Z) 5

6 3. Installing the charge air cooler E E8, E82, E87 cars only Cut sealing tape E and slide it onto the edges () of charge air cooler A. The middle section of sealing tape E is no longer required. A Z Pull the front panel () forwards and fit charge air cooler A, securing it in place with the existing screws (2) (see ISTA ). Insert the existing frame holder (3). 2 A Z Clean the surface to be glued with a suitable cleaner to ensure it is free from grease. Remove the protective adhesive film (), press seal D onto the fixing strips and secure with plastic nut J using a maximum torque of 2.3 Nm (± 0.2 Nm). D J Z # E88, E90, E9, E92, E93, F0, F cars only Install charge air cooler B (see ISTA ) and insert existing frame holder (). B Z BMW AG, Munich /205 (T/Z) 6

7 3. Installing the charge air cooler Install seal H and secure the fastenings (). H Z Install charge air hose (30 kw only!) I (see ISTA ). I Z BMW AG, Munich /205 (T/Z) 7

8 , 4. Installing the fan frame with electric fan C E E8, E82, E87 cars only Cut sealing tape E and slide it onto the edge () of fan frame with electric fan C Z C For E8, E82, E87 cars, consult section 5 Adjusting the charge air cooler and fan frame with electric fan. All cars Install the fan frame with electric fan C (see ISTA 7 035). N L M O P Z Z Changes to plug connections must be made as per ISTA Disconnect the cables from plug X893 and convert as follows: - Disconnect the socket contacts - BR cable, slide on single conductor seal P, crimp socket contact N and connect to PIN of socket casing L - RT/BL cable, slide on single conductor seal P, crimp socket contact N and connect to PIN 2 of socket casing L - SW/BL cable, slide on single conductor seal O, crimp socket contact M and connect to PIN 4 of socket casing L Connect socket casing K to the electric fan. BMW AG, Munich /205 (T/Z) 8

9 , 5. Adjusting the charge air cooler and fan frame with electric fan (E8, E82, E87 cars only) A Ensure that you do not damage the retrofitted parts. 5mm 2 5mm F The connecting lug () of charge air cooler A must not lie on front axle support (2); the minimum distance is 5 mm. If the connecting lug of charge air cooler A lies on the front axle support, four shims F must be placed inbetween in the next-but-one step of the installation process Z B M W F Ensure that you do not damage the retrofitted parts. When installed, the fan frame must not lie on the weld seams () of the front axle support. If the fan frame with electric fan lies on the weld seams, four shims F must placed inbetween in the next step of the installation process Z F Place three or four shims F in the bottom cooler holder () and secure the module carrier (see ISTA 7 046). F Z BMW AG, Munich /205 (T/Z) 9

10 6. Replacing the engine control unit Replace engine control unit G (see ISTA ). Before exchanging the control units, transfer the IMA (integrated quantity compensation) values from the injectors. G Z BMW AG, Munich /205 (T/Z) 0

11 7. Attaching the badge B M W BMW Performance K Clean the surface to be glued to ensure it is free from grease. Stick badge K as shown on air guide (). For 20d and 320d Power Kit K Z Clean the surface to be glued to ensure it is free from grease. Stick badge K as shown on air guide (). 520d only F0 056 Z BMW AG, Munich /205 (T/Z)

12 8. Concluding work and coding Remove fuse F92 from the fuse slot in the front fuse holder () and replace with fuse Q. F92 Q Z The retrofit system requires programming / coding. - Connect the battery - Carry out a vehicle test using the ISTA system and note or work through any entered error memory. - Change in the ISTA/P car programming - Select the "Diesel Performance" retrofit via the Conversion path and work through the created action plan - If using ISTA/P, please note the instructions in the ISTA/P application documentation - Re-fit the car components as required E9 cars only (320d Touring and 320xd Touring) only 30 kw If the customer wishes the V-max increase by 0 km/h, this must be activated with the corresponding retrofit (increased performance and V-max increase). Tyres with speed index W (up to 270 km/h) or higher are absolutely essential for this. Diesel Performance retrofit / Diesel Performance with increase in maximum speed retrofit (E9 only), only 30 kw BMW AG, Munich /205 (T/Z) 2

13 Workshop certificate BMW Performance/ M Performance Diesel Power Kit This confirms that the BMW Performance/M Performance Diesel Power Kit has been fully installed in the vehicle below (delete the non-applicable Power Kits). Specifically, the following components have been modified and/or retrofitted:. Charge air cooler 2. Fan frame with electric fan with modified electrical connection (socket casing) and 60A fuse 3. Engine control unit 4. Charge air hose (E88, E90, E9, E92, E93 cars only) 5. Air guide seal 6. Torque converter (only on cars with SA 205 and 30 kw) or torque converter (only on cars with rear-wheel drive and SA 205 or SA 2TE, 520d LCI built after 07/203) 7. With optional V-max increase, tyres with speed index W or higher (E9 cars only (320d Touring and 320xd Touring) and 30 kw) Car type: BMW 20d (E8/E82/E87/E88) BMW 320d/320xd (E90/E9/E92/E93) BMW 520d, 520xd (F0/F) Vehicle identification no.:... Vehicle owner Name and address: Place, date... Signature of person responsible Dealership (company name / stamp) BMW AG, Munich /205 (T/Z) 3