2005 BMW Z4

2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

2003-05 ENGINE

Exhaust Systems - Repair Instructions - Z4/E85

EXHAUST SYSTEM COMPLETE

18 00 020 REMOVING AND INSTALLING COMPLETE EXHAUST SYSTEM (M54)

Special tools required:

z 31 2 220

WARNING: Scalding hazard!

Only perform this work after engine has cooled down.

Support exhaust system with jack and special tool 31 2 220 and secure against falling out.

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 2005 BMW Z4
2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

Fig. 1: Supporting Exhaust System With Jack And Special Tool

Courtesy of BMW OF NORTH AMERICA, INC.

Lift out expansion rivet (1).

Release screws and remove heat shield (2).

Fig. 2: Removing Heat Shield

Courtesy of BMW OF NORTH AMERICA, INC.

Release nuts (1) and remove connecting plate (2).

Installation:

Replace self-locking nuts.

Coat threads with copper paste.

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 2005 BMW Z4
2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

Fig. 3: Removing Connecting Plate

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Replace both seals (1).

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 2005 BMW Z4
2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

Fig. 4: Replacing Seals

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Removal of exhaust system must be carried out with assistance of a second
person.

NOTE: The reinforcement plate (1) is connected via rubber mounts to the exhaust
system and can remain on the exhaust system during removal.

Release screws on reinforcement plate (1). See 51 71 390 REMOVING AND INSTALLING/REPLACING
REINFORCEMENT PLATE .

Release screws and remove body reinforcement strut (2). See 51 71 482 REMOVING AND
INSTALLING/REPLACING LEFT OR RIGHT TENSION STRUT .

Release nuts on rubber mount of rear muffler (3) on left and right.

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 2005 BMW Z4
2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

Lower exhaust system with lifter and remove.

Fig. 5: Releasing Rear Muffler Rubber Mount Nuts

Courtesy of BMW OF NORTH AMERICA, INC.

MUFFLERS
18 12 030 REPLACING FINAL MUFFLER

Special tools required:

z 00 2 210

WARNING: Scalding hazard!

These tasks should only be carried out on an exhaust system that has
cooled down!

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 2005 BMW Z4
2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

NOTE: Illustration shows exhaust system removed.

Determining cutting line:

Carry over pipe length of new rear muffler to installed rear muffler (1).

Marking cutting line.

Fig. 6: Identifying Rear Muffler (Final Mufflers)

Courtesy of BMW OF NORTH AMERICA, INC.

Cut exhaust pipes with special tool 00 2 210 at marked points and deburr.

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 2005 BMW Z4
2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

Fig. 7: Cutting Exhaust Pipes With Special Tool At Marked Points (Final Mufflers)
Courtesy of BMW OF NORTH AMERICA, INC.

Release screws and nuts, remove reinforcement plate (1). See 51 71 390 REMOVING AND
INSTALLING/REPLACING REINFORCEMENT PLATE .

Release screws and remove body reinforcement strut (2). See 51 71 482 REMOVING AND
INSTALLING/REPLACING LEFT OR RIGHT TENSION STRUT .

Release nuts on rubber mount of rear muffler (3) on left and right and remove rear muffler (3).

Installation:

Fit rubber mount of rear muffler on new rear muffler.

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 2005 BMW Z4
2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

Fig. 8: Releasing Rear Muffler Rubber Mount Nuts (Final Mufflers)

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Connect new rear muffler and front muffler by means of clamping sleeves.

Cutting point is in middle of clamping sleeve.

Align exhaust system and clamping sleeves so that there is sufficient distance to the adjoining components.

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 2005 BMW Z4
2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

Fig. 9: Connecting Rear Muffler And Front Muffler (Final Mufflers)

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Check position of tailpipes (1) to body cutout.

Tighten down screws of clamping sleeves.

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 2005 BMW Z4
2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

Fig. 10: Identifying Tailpipes Position (Final Mufflers)

Courtesy of BMW OF NORTH AMERICA, INC.

18 12 040 REMOVING AND INSTALLING/REPLACING FRONT MUFFLER (M54)

Special tools required:

z 00 2 210

WARNING: Scalding hazard!

These tasks should only be carried out on an exhaust system that has
cooled down!

NOTE: Illustration shows exhaust system removed.

Determining cutting line:

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 2005 BMW Z4
2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

Carry over pipe length of new front muffler to installed front muffler (1).

Marking cutting line.

Fig. 11: Identifying Front Muffler (Front)

Courtesy of BMW OF NORTH AMERICA, INC.

Cut exhaust pipes with special tool 00 2 210 at marked points and deburr.

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 2005 BMW Z4
2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

Fig. 12: Cutting Exhaust Pipes With Special Tool At Marked Points (Front)
Courtesy of BMW OF NORTH AMERICA, INC.

Release nuts (1) and remove connecting plate (2).

Installation:

Replace self-locking nuts.

Coat thread with copper paste.

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 2005 BMW Z4
2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

Fig. 13: Removing Connecting Plate (Front)

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Replace both seals (1).

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 2005 BMW Z4
2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

Fig. 14: Replacing Seals (Front)

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Connect new front muffler and rear muffler by means of clamping sleeves.

Cutting point is in middle of clamping sleeve.

Align exhaust system and clamping sleeves so that there is sufficient distance to the adjoining components.

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 2005 BMW Z4
2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

Fig. 15: Connecting Rear Muffler And Front Muffler (Front)

Courtesy of BMW OF NORTH AMERICA, INC.

EXHAUST MANIFOLD
18 40 030 REMOVING AND INSTALLING/REPLACING BOTH EXHAUST MANIFOLDS (M54)

Necessary preliminary tasks:

z Secure engine in installation position . See 11 00 050 REMOVING AND INSTALLING ENGINE
(M54) .
z Remove front engine underguard
z Remove reinforcement plate . See 51 71 390 REMOVING AND INSTALLING/REPLACING
REINFORCEMENT PLATE .
z Remove entire exhaust system . See 18 00 020 Removing And Installing Complete Exhaust System
(M54) .
z Remove bracket between exhaust manifold and transmission
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 2005 BMW Z4
2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

z Detach grounding cable from body

z Remove right engine support arm with engine mount.
z Release nuts on heat shield at bottom
z Remove right tension strut . See 51 71 371 REMOVING AND INSTALLING/REPLACING
TENSION STRUT ON LEFT OR RIGHT .
z Remove air pump . See 11 72 000 REMOVING AND INSTALLING/REPLACING AIR PUMP .
z Release heat shield at top and remove

NOTE: The oxygen sensors are in danger of being damaged when the exhaust
manifolds are removed and installed.

Remove oxygen control sensors. See 11 78 513 REPLACING BOTH OXYGEN CONTROL SENSORS .

Remove cover from injection valves.

NOTE: Do not mix up oxygen monitor sensors for cylinders 1 to 3 and 4 to 6 at plug
connection to wiring harness.

Mark plug connections.

Unclip the cable from the retainer. Disconnect plug connection. Unclip cable on rear side of engine from cable
guide.

Remove oxygen monitor sensor from cylinders 1 to 3 from above. See 11 78 611 REPLACING OXYGEN
MONITOR SENSOR .

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 2005 BMW Z4
2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

Fig. 16: Removing Cover From Injection Valves

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Rear exhaust manifold with catalytic converter can only be removed after front
exhaust manifold with catalytic converter has first been removed.

Remove front exhaust manifold with catalytic converter. See 18 40 050 Removing And Installing/Replacing
Front Exhaust Manifold (M54) .

Remove oxygen monitor sensor from cylinders 4 to 6. See 11 78 612 REPLACING OXYGEN MONITOR
SENSOR .

Unscrew nuts.

Remove exhaust manifold (1).

Installation:

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 2005 BMW Z4
2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

Clean sealing faces, replace gaskets.

Coat threads with copper paste.

Replace nuts.

Tightening torque, see 11 62 1AZ in ENGINE - TIGHTENING TORQUES .

Fig. 17: Removing Exhaust Manifold

Courtesy of BMW OF NORTH AMERICA, INC.

18 40 050 REMOVING AND INSTALLING/REPLACING FRONT EXHAUST MANIFOLD (M54)

Necessary preliminary tasks:

z Secure engine in installation position. See 11 00 050 REMOVING AND INSTALLING ENGINE
(M54) .
z Remove front splash guard.
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 2005 BMW Z4
2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

z Remove reinforcement plate. See 51 71 390 REMOVING AND INSTALLING/REPLACING

REINFORCEMENT PLATE .
z Remove complete exhaust system. See 18 00 020 Removing And Installing Complete Exhaust System
(M54) .
z Remove bracket between exhaust manifold and transmission.
z Detach grounding cable from body.
z Remove right engine support arm with engine mount.
z Release nuts on heat shield at bottom.
z Remove right tension strut. See 51 71 371 REMOVING AND INSTALLING/REPLACING
TENSION STRUT ON LEFT OR RIGHT .
z Remove air pump. See 11 72 000 REMOVING AND INSTALLING/REPLACING AIR PUMP .
z Release heat shield at top and remove.

NOTE: The oxygen sensors are in danger of being damaged when the exhaust
manifolds are removed and installed.

Remove front oxygen control sensor. See 11 78 513 REPLACING BOTH OXYGEN CONTROL
SENSORS .

Remove cover from injection valves.

NOTE: Do not mix up oxygen monitor sensors for cylinders 1 to 3 and 4 to 6 at plug
connection to wiring harness.

Mark plug connections.

Unclip the cable from the retainer. Disconnect plug connection. Unclip cable on rear side of engine from cable
guide.

Remove oxygen monitor sensor from cylinders 1 to 3 from above. See 11 78 611 REPLACING OXYGEN
MONITOR SENSOR .

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 2005 BMW Z4
2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

Fig. 18: Removing Cover From Injection Valves (Front Exhaust Manifold)
Courtesy of BMW OF NORTH AMERICA, INC.

Unscrew nuts.

Remove exhaust manifold (1).

Installation:

Clean sealing faces, replace gaskets.

Coat threads with copper paste.

Replace nuts.

Tightening torque, see 11 62 1AZ in ENGINE - TIGHTENING TORQUES .

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2003-05 ENGINE Exhaust Systems - Repair Instructions - Z4/E85

Fig. 19: Removing Exhaust Manifold (Front Exhaust Manifold)

Courtesy of BMW OF NORTH AMERICA, INC.

18 40 060 REMOVING AND INSTALLING/REPLACING REAR EXHAUST MANIFOLD (M54)

Rear exhaust manifold with catalytic converter can only be removed after front exhaust manifold with catalytic
converter has first been removed.

Procedure is described in 18 40 030 Removing And Installing/Replacing Both Exhaust Manifolds (M54) .

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