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BMW 11 12 2 157 664 Installation Instructions Manual

Performance power kit retrofit for bmw 1 series (e82; e88); bmw 3 series (e90; e91; e92; e93)
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Installation Instructions.

BMW Performance Power Kit Retrofit
BMW 1 Series (E82, E88)
BMW 3 Series (E90, E91, E92, E93)
These installation instructions are only valid for 135i, 335i and 335ix cars.
On US cars only in conjunction with SA 840 (high-speed tuning).
Retrofit kit number
11 12 2 157 664
11 12 2 157 665
11 12 2 184 495
Installation time
The installation time is approx. 4.0 hours. This may vary depending on the condition of the car and the equipment
in it.
The installation time specified does not include the time spent on programming / coding.
The calculation of the total costs for the programming time must be factored into the calculation of retrofitting costs
(no invoicing via warranty).
Important information
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.
If you experience installation or function problems, restrict troubleshooting to approx. 0.5 hours for
mechanical work and 1.0 hour for electrical work.
To avoid unnecessary extra work and/or costs, an inquiry is to be sent straight away to the technical parts support
via the After Sales Assistance Portal (ASAP).
Quote the following information:
- Chassis number,
- Retrofit kit part number,
- A detailed description of the problem,
- Any work already carried out.
Do not archive the hard copy of these installation instructions since daily updates are made via ASAP!
© BMW AG, Munich.
© BMW AG, Munich.
BMW Performance Power Kit with FSC Retrofit Kit
BMW Performance Power Kit with FSC Retrofit Kit
BMW Performance Power Kit with FSC Retrofit Kit
01 29 2 160 471
01 29 2 160 471
2/2011
2/2011
(Z/Z)
(Z/Z)
1

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Summary of Contents for BMW 11 12 2 157 664

  • Page 1: Installation Instructions

    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.
  • Page 2 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. Additional cables/lines that you install must be secured with cable ties.

  • Page 3: Table Of Contents

    Workshop certificate ................35 © BMW AG, Munich.

  • Page 4: Parts List For Retrofit Kit

    Supply hose Engine control unit sticker Service sticker (for cars built before 3/09 only) Relay holder Fan relay Activation code certificate (in red envelope) Thread plate Servo oil tank holder © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)
  • Page 5 Hexagon nut with collar M6 (2x) Sheet metal nut (8 x) Hexagon sheet metal screw (8 x) Expanding rivet (6x) Sealing strips Hexagon nut M6 (2x) Spring washer A6 (2x) BMW Performance emblem © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)
  • Page 6 Rear air guide, for E90/E91 LCI with M bumper (not supplied with the retrofit kit) Rear air guide, for E90/E91 LCI with Performance bumper (not supplied with the retrofit kit) © BMW AG, Munich. 01 29 2 160 471 2/2011...
  • Page 7 Left finisher holding frame for E92/E93 LCI with M bumper without fog light (not supplied with the retrofit kit) Butt connector (cars with N55 engines only, not supplied with the retrofit kit) © BMW AG, Munich. 01 29 2 160 471 2/2011...
  • Page 8 Rubber bearing M6 x 10 mm (2x, only for E82/E88 cars, not supplied with the retrofit kit) Left fog light holder (only for E92/E93 LCI with standard bumper and fog light, not supplied with the retrofit kit) © BMW AG, Munich. 01 29 2 160 471 2/2011...

  • Page 9: Preparatory Work

    51 43 075 Glove box 51 16 366 Only E93/E93 LCI cars Remove the fog lights (no longer required) – – – Finisher holder on front bumper – – – © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)

  • Page 10: Connection Diagram

    Eyelet, diameter 6 mm Terminal 30 To fan relay K X17279 12.0 mm SW 2-pin socket casing To fan relay K X1798 SW 4-pin socket casing To electric fan B X18193 © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)

  • Page 11: Auxiliary Cable Connection Diagram

    To cable of same colour from original fan relay in E-Box Horn extension E82/E88 cars only SW 2-pin socket casing To horn left X3530 SW 2-pin pin housing To original horn connector left X3529 © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)

  • Page 12: Installation And Cabling Diagram For Lhd Cars

    Strut tower earth support point X175 B+ post X2219 E-Box (DME control unit A6020 and original fan relay) Fuse holder front, fuse F92 Glovebox light E42a (only cars built before 3/07) © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)

  • Page 13: Installation And Cabling Diagram For Rhd Cars

    Retrofit wiring harness connector A and RHD auxiliary cable BC E-Box (DME control unit A6020 and original fan relay) Fuse holder front, fuse F92 Glovebox light E42a (only cars built before 3/07) © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)

  • Page 14: Converting The Horn (E82/E88 Cars Only)

    Screw horns (1) using original nuts and washers to retaining bracket BF. Route branch BE1 to the left horn and branch BE2 to the left original horn connector and connect. 082 0121 Z © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)

  • Page 15: Installing The Retrofit Wiring Harness On Lhd Cars

    Disconnect SW/BL cable from PIN 8 of plug X60101 (GR 26-pin) on the DME control unit, insulate it and tie it back. Connect branch A5, SW/BL cable, to PIN 8 of plug X60101. BA1-BA2 090 1489 Z © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)
  • Page 16 AA behind the right headlight. Route branches A7 – A10 along the standard wiring harness to the left-hand side of the car. A7-A10 090 1458 Z © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)
  • Page 17 Route branches A7 – A10 along the front panel. Tie back the original plug of the electric fan in the area of the right headlight. A7-A9 090 1459 Z © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)

  • Page 18: Installing The Retrofit Wiring Harness On Rhd Cars

    Disconnect SW/BL cable from PIN 8 of plug X60101 (GR 26-pin) on the DME control unit, insulate it and tie it back. Connect branch A5, SW/BL cable, to PIN 8 of BA1-BA2 plug X60101. 090 1498 Z © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)
  • Page 19 AA behind the right headlight. Route branches A7 – A10 along the standard wiring harness to the left-hand side of the car. A7-A10 090 1458 Z © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)
  • Page 20 Route branches A7 – A10 along the front panel. Tie back the original plug of the electric fan in the area of the right headlight. A7-A9 090 1459 Z © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)

  • Page 21: Installing The Additional Radiator And Air Guides

    (2) for additional radiator holder D . Insert thread plate M into side member (1), rotate it around 90° and engage it in the centring drill hole (2). 090 1461 Z © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)
  • Page 22 Place front air guide AP on rear air guide AI and secure from the inside using expanding rivets V. Place sealing strip W on bumper trim support (1). 092 0159 Z © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)

  • Page 23: Modifying The Wheel Arch Cover

    9 1467 Z Push sheet metal nuts T onto the wheel arch cover (1). Screw on radiator grille AD using hexagon sheet metal screws U . 090 1468 Z © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)

  • Page 24: Installing Water Tubing

    - E1 and G1 to additional radiator C - E2 and G2 to engine radiator - E3 to engine block - G3 to heating heat exchanger on the bulkhead © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)

  • Page 25: Installing The Fan Relay

    090 1473 Z Connect branches A7–A8 using hexagon nuts X and spring circlips Y to fan relay K. Connect branch A9 to fan relay K. A7-A8 090 1478 Z © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)

  • Page 26: Affixing The Stickers

    Enter the dealership and date on the engine control unit sticker H. 090 1475 Z Stick engine control unit sticker H onto the cylinder head cover. © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)
  • Page 27 14. Affixing the stickers For US cars only Stick ARB EO# label AF onto the hood (1) as shown. 090 1465 Z © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)

  • Page 28: Modifying The Front Bumper Trim

    E90/E91 LCI cars with M bumper only Place left brake air duct (1) against air guide AJ as shown, transfer inner contour (2) and cut out. 090 1479 Z © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)
  • Page 29 E92/E93 LCI cars with M bumper without fog lights only Remove left finisher holder (1) (no longer required) and replace with finishers AX and finisher holder AY. 092 0172 Z © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)

  • Page 30: Concluding Work And Coding

    E92/E93 LCI cars with M bumper and fog light only Disconnect plug X14259 from the footwell module (1) X14259 and open it. Disconnect the yellow/white cable from pin 15, insulate it and tie it back. 087 0786 Z © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)
  • Page 31 - On E92/E93 LCI cars with M bumper and fog light, the NSW function must also be disabled via ISSS. - Re-assemble the car. Workshop certificate Print out the “Workshop certificate” section at the end of the installation instructions, fill it in and give it to the customer. © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)

  • Page 32: Wiring Diagram

    RHD cars with N54 engine only A6020 X2219 X60101 BC4* X175 125 A BC2* BC3* BC1* BC5* BC6* BA1* BA2* BA3* 0,5 BR BA4* 0,5 RT/GN A10* X18336 090 1501 Z E42a © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)
  • Page 33 RHD cars with N55 engine only A6000 X2219 X60001 X175 125 A BC2* BC3* BC4* BC1* BC5* BC6* BA1* BA2* BA3* 0,5 BR BA4* 0,5 RT/GN A10* X18336 E42a 092 0170 Z © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)
  • Page 34 Butt connector on the cable of the original fan relay or on branch BA2* (RHD cars only) BC6* All the designations marked with an asterisk (*) apply only to these installation instructions or this wiring diagram. Cable colours Blue Green Brown Grey Black © BMW AG, Munich. 01 29 2 160 471 2/2011 (Z/Z)

  • Page 35: Workshop Certificate

    Workshop certificate BMW Performance Power Kit This is to confirm that the BMW Performance Power Kit 11 12 2,157,664 or 11 12 2,157,665 or 11 12 2 184 495 has been completely installed on the car identified below. Specifically, the following components have been modified and/or retrofitted: 1.

This manual is also suitable for:

11 12 2 157 66511 12 2 184 495

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