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  1. 
Start by disconnecting the negative terminal of your battery
    • Start by disconnecting the negative terminal of your battery

    • Unscrew the 6 screws then remove the filter.

  2. 
Unscrew the 4 screws on the engine cover then remove it.
    • Unscrew the 4 screws on the engine cover then remove it.

  3. 
The AUC sensor must be extracted by rotating it 1/4 turn (green square).
    • The AUC sensor must be extracted by rotating it 1/4 turn (green square).

    • Then remove the cable (yellow line) by pulling on it, it is fixed by 3 staples (blue square).

    • We now unscrew the 2 screws (circled in red) which hold the apron.

    • Remove the apron by pulling on it.

  4. 
The seal is removed.
    • The seal is removed.

    • Remove the cover of the upper screw. You need an E18 torx socket for the screw.

    • Remove the other 2 torx screws. You need an E16 torx socket.

    • The 2 anti-rapprochement bars can be removed by pulling on them.

  5. 
We start by removing the screed by unscrewing the 3 screws then we remove it.
    • We start by removing the screed by unscrewing the 3 screws then we remove it.

    • The acoustic cover is removed by unscrewing the 2 screws and then removing it.

  6. 
Disconnect the pressure sensor.
    • Disconnect the pressure sensor.

    • Now you need to remove the pressure converter from the intake manifold. The pressure converter (circled in purple) is attached to the manifold clip (in red). Simply push the small mounting tab (in blue).

    • A small vacuum hose is connected to the pressure converter AND to the collector, it must therefore be extracted at the converter level (in yellow).

    Undoing the converter (purple) was the black point from step 6 for me. To properly unfasten it, you have to lift slightly the fixing lug (blue) on the right. To do this, pass your hand (passenger compartment side) and you can do it with a finger, then push the sensor from the right (passenger compartment side) to the left (bumper side). It will release with a “click”.

    christophe delouis - Reply

    Yes, absolutely. I created an account to post my comments. I would have saved time if I had done it before and had seen your comment!

    hessjee -

  7. 
The vacuum hose is removed.
    • The vacuum hose is removed.

    • We disconnect the connection box.

    • The staple is removed from the electrical sheath.

    • Remove the clip holding the hose and then remove the hose. In the photo, the hose is already unclipped.

    Hello. Don't forget to also unscrew the other metal collar on the EGR valve to remove the intake manifold by the

    hessjee - Reply

  8. 
Unscrew the 12 screws with a 10 socket.
    • Unscrew the 12 screws with a 10 socket.

    • Unscrew the 7 nuts with an 11 socket.

    • The collector is removed.

    Here you must not forget to remove the 10 screw on the oil gauge which is screwed onto the collector on the side otherwise it will be impossible to remove it.

    hessjee - Reply

  9. 
There is one per candle, you have to press on each side of the head of the beam then pull upwards to remove it from the candle.

Then unscrew each spark plug with a long 10mm socket.

Then unscrew each spark plug with a long 10mm socket.
    • There is one per candle, you have to press on each side of the head of the beam then pull upwards to remove it from the candle.

    • Then unscrew each spark plug with a long 10mm socket.

    Here you can change the preheating relay which is located approximately in the middle of the block below the 3rd spark plug and well hidden. Accessible with a 10 socket and an extension. A little difficult to disconnect the two plugs because there is not much space but doable for those who have reached this stage without any problems. I recommend changing it on this model to avoid new problems with the spark plugs.

    hessjee - Reply

    1 small photo error (No. 3) for the screw, it's the inside D of the trunk...

    By the way, while we're at it, given the labor to access it, change the timing box that controls these spark plugs and is below them and above the starter 1 little forward, held by 2 nuts and 2 clipped electrical plugs, because it can generate errors on its own, price 60 Euros, respect the OEM Ref. 1 little WD-40 to unscrew the spark plugs if it gets stuck and shown in photo 1. Great idea these tutorials, thank you.

    Henri BOULET - Reply

    I hadn't seen your comment. I totally agree with you.

    hessjee -

    • To reassemble the spark plugs, you can apply a little copper grease to the threads.

    • Everything else is done in reverse order of disassembly.

Finish Line

11 other people completed this guide.

laurent.immo13003

Member since: 03/03/2016

12,942 Reputation

155 Guides authored

21 Comments

Good morning,

Very well done tutorial that allowed a novice like me to change his glow plugs! Great, thank you.

Pierre

bsc16517 - Reply

Hello, I am stuck at step 5 I can't remove the yoke I unscrewed but then I have to pull hard? Do you have a technique it doesn't come out for me :-(

THANKS

valery kalombo - Reply

In fact, to remove the knob you have to put it in front drive, to put it back, it doesn't matter.

Henri BOULET - Reply

Hello Laurent,

Actually it's just glued on. Just pull it up like you would a big carrot!

With the knob, a 15 cm plastic rod comes with it. It didn't look solid but the installation was no problem.

@+

FYI, I'm going to upgrade from the 525d to the 525xi :)

Christophe

christophe delouis - Reply

Hello Christophe,

I never took the knob apart, sorry.

Sincerely

Laurent

laurent.immo13003 - Reply

Hello Laurent,

For your information, I managed to easily remove the roof lining thanks to the advice of my expert bodybuilder. But in fact the problem did not come from above but from below: the outlets (located in the rear bumper) were blocked by lots of dirt and the pipes in charge were pushing the water back up. All that for that!

Otherwise, something else have you already disassembled the automatic gearbox knob? My trigger is no longer firm and I would like to know why

@+

Christophe

christophe delouis - Reply

You didn't change the preheating box?

Is it mandatory to change it with the spark plugs, if so where can I find it exactly.

Good job, thank you very much in advance

anis elichaoui - Reply

realoem.com? I didn't know it but apparently there is an exploded view of the TO but not of the interior cabins.

christophe delouis - Reply

Hello Christophe,

Sorry I don't have any. Maybe the exploded views on realoem.com would help you.

laurent.immo13003 - Reply

Hello Laurent,

Bmw fixed the passenger compartment of the E61 like that of the E9. So disassembly successful thanks to your image. But unfortunately it is not at this place that the water escapes but in the roof at the level of the notch net of the trunk (just above the headrest ArDt) I am good at disassembling the passenger compartment of the roof. If you have good tips for doing this I am a taker.

Have a nice day

christophe delouis - Reply

Hello Laurent,

Well, good for you, because I can't tell you what a hassle water on the battery is, especially since it doesn't appear immediately after the rain but several days later, making the diagnosis even more difficult.

Well I'm going to try to take the cabin apart to unblock or repair this damn drain pipe. To be continued...

christophe delouis - Reply

Hello Christophe,

Never had this problem since I don't have the TO on my car.

Have a nice day

laurent.immo13003 - Reply

Hello Laurent,

Great idea for the photo. Yes, that's the right amount, and I understand that there are 3 other screws (green arrows) that I hadn't seen.

Thanks for the advice.

Have you ever had this problem with TO evacuation?

Have a good day.

christophe delouis - Reply

Hello Christophe,

I'm not sure what amount you're talking about (the fuse box is confusing me). I added a picture in step 9 where you'll see the right rear pillar mounts on my car.

Sincerely

laurent.immo13003 - Reply

Hello Laurent,

Nothing to do with the spark plugs, one of the 4 drains of my sunroof is causing a problem and not the least the one on the right rear side because the water comes back inside above the fuse box and falls on the battery! I can't remove the passenger compartment from this right rear pillar. Apart from undoing the 2 screws above the fuse box, do you have any advice please?

Thank you and have a nice weekend.

christophe delouis - Reply

Hello to you,

for Bosch spark plugs it is 18 Nm

for the M6 EGR screws it is 10 Nm

for the M7 nuts of the cylinder head it is 15 Nm

for the M6 screws of the cylinder head it is 10 Nm

Please note that some torque wrenches are in Kilo and others in Nm (10 Nm = 1 Kilo!)

Good luck Arnaud…

Christophe

christophe delouis - Reply

No sorry I don't have them.

laurent.immo13003 - Reply

Hello, great tutorial, however for reassembly, do you have the tightening torques???????

Thank you in advance!!!

Arnaud Lapeyre - Reply

Hello Mr Grandin,

Yes, you had to put your hand on the right side to lift it and unfasten it.

It was so good to hear “click” and finally see the converter release “zou”.

Without this clarification I would never have been able to complete the tutorial and therefore the repair.

PS: Of the 6 spark plugs, 2 must have been faulty because they were full of black oil unlike the other 4.

Summary: It restarted very well but with a big cloud of smoke and above all consumption has gone from 7.6 to 6.6 L/100 (AR Larochelle/Angers)!

Mechanically yours, Christophe (525d-E61)

christophe delouis - Reply

It is necessary to raise slightly the fixing lug on the right (passenger compartment side). This fixing is very fragile and risks being broken if you force too much. You can do it either with your finger or with a small screwdriver, then you have to slide the sensor from the right (passenger compartment side) to the left (bumper side).

laurent.immo13003 - Reply

Good evening Mr Grandin,

Your tutorial is really great, that said I'm stuck at step 6: removing the pressure converter from the intake manifold.

Ok but I can't un-fix it from the collector clip (in red). The small fixing tab (in blue), how do you push it please? Up? To the left?

Thank you in advance for your help because I have to finish tomorrow.

Mr Delouis Christophe (La Rochelle)

06.52.12.60.49 or xtophe70@gmail.com

christophe delouis - Reply

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