Page 1/6 11.11 INS423 BAVARIAN AUTOSPORT High-Performance Ignition Coil Installation Instructions INPORTANT! Installer must read these instructions prior to coil installation. Late model BMW pencil coils require special attention during installation, to assure proper installation. Failure to follow these steps and notes may result in engine fault codes and/or a no-start situation. SAFETY WARNING: Be sure the engine is cool before beginning the installation. INSTALLATION NOTE: Depending on the mileage of your BMW, you may want to consider having a fresh set of spark plugs and a valve cover gasket set on hand before beginning the installation. These parts are available from Bavarian Autosport. PROCEDURE NOTE: These instructions will assume that the installer is familiar with the standard ignition coil replacement procedures and has access to the appropriate repair manuals for the applicable BMW models. Repair manuals are available from Bavarian Autosport. Accompanying photos show 6 cyl. installation; 8 cyl. and 12 cyl. are similar. 3 series 6 cyl. 03 thru 05 M3 01 thru 06 5 series 6 cyl. 03 thru 05 8 cyl. 04 thru 09 6 series 8 cyl. 04 thru 09 7 series 8 cyl. 02 thru 09 12 cyl. 02 thru 09 Z3 M roadster/coupe 01 thru 02 Z4 thru 09 X3 thru 09 X5 6 cyl. 03 thru 09 8 cyl. 04 thru 09 (except M) PART NUMBERS: 5004 5004 6 5004 8 5004 12 12 13 1 712 219 PROCEDURE (SHOWN ON M54 6 CYL.): 1. Open the engine hood. Watch the installation video at blog.bavauto.com/go/coils2 2. Remove the plastic valve cover trim panel(s) by first removing the oil filler cap and then the plastic plugs which cover the trim panel retaining nuts (Figure 1). Remove the cover retaining nuts and then lift off the trim panel(s) (Figure 2). 3. For each coil, gently pry up the coil harness plug lock clip (Figures 3 & 4) and remove the harness plug from the coil (Figures 5 & 6). Be sure to note the position of each harness plug. 4. Gently pull up on the coil assembly. The spark plug connector boot may be stuck to the spark plug. If so, twist the coil a bit while pulling up. Careful prying with a screwdriver may be required (Figures 7 & 8). Repeat for each coil. 5. a) Inspect the spark plug cavities for evidence of any oil. If there is oil in any of the cavities, the valve cover gasket is leaking and should be replaced. The oil can cause random miss-fires and will contribute to deterioration of the spark plug connector boots. New valve cover gasket sets are available from Bavarian Autosport. b) If you re installing new spark plugs, do so at this point. 6. Carefully install the new high-performance coil assemblies over the spark plugs and push down until the coil is fully seated and against the valve cover (Figure 9). 7. Install the coil harness plugs over the coil plug housings. Firmly push the female harness plug housing onto the coil s male housing. Use your forefinger and thumb to squeeze the female socket fully onto the coil s male housing (Figures 10 & 11). NOTE: If you are having trouble fully seating the female socket onto the coil s male housing, you can carefully use a pair of channel-lock type pliers to pull the socket fully onto the male housing (Figures 12 & 13). NOTE: DO NOT try to secure the female socket by levering the locking clamp down. As the socket is fully seated, the locking clamp will automatically move down over the female socket.
Page 2/6 11.11 INS423 8. Verify that the female socket is fully seated up to the stop flange on the coil s male housing (Figure 14 & 15). 9. Secure the locking clip by pressing down, once the harness socket is verified as being fully seated (See Step 8, Figure 16). NOTE: Reference Figures 14, 15, 17 and 18. Female socket must be flush against coil stop flange (Figures 14 & 15). Sides of locking clip must be flush with side flange on coil (Figures 17 & 18). 10. Install the plastic trim cover(s) and the oil filler cap. Figure 1 Figure 2
Page 3/6 11.11 INS423 Figure 3 Figure 4 Figure 5 Figure 6
Page 4/6 11.11 INS423 Figure 7 Figure 8 Upper boot is flush with alignment flange on valve cover Figure 9
Page 5/6 11.11 INS423 Figure 10 Figure 11 Figure 12 Figure 13
Page 6/6 11.11 INS423 Shown without locking clip in place for clarity. Shown without locking clip in place for clarity. Coil stop flange Coil stop flange No gap Gap CORRECT INCORRECT Figure 14 Figure 15 Sides of locking clip are flush with side flange on coil No gap CORRECT Figure 17 Sides of locking clip are outside side flange on coil Gap INCORRECT Figure 16 Figure 18