BMW - 4 Series Gran Coupe - Workshop Manual - 2004 - 2004

Original BMW Parts and Accessories. Installation Instructions. M Performance Carbon Exterior Components Retrofit Kit. BMW 4 Series Gran Coupé (G26) BMW i4 (G26 BEV) Retrofit kit number Installation time (h) Number Component designation 51 19 5 A36 851 Carbon front attachment 0.75 51 19 5 A36 997 Carbon rear spoiler 0.50 51 19 2 472 778 Carbon rear diffuser (only with bumper trim) 0.20 51 19 5 A36 853 Black high gloss rear bumper cover MPA* 0.25 51 19 5 A36 855 Black high gloss rear bumper cover MSP** 0.25 51 19 5 A36 857 Black high gloss rear bumper trim BEV 0.25 51 13 5 A59 4E8 Carbon front ornamental grille G26 BEV 1.00 51 13 5 A5C 530 Black high gloss upper interior grille BEV 0.25 51 13 5 A59 640 Black high gloss basic interior grille BEV 0.25 51 13 5 A59 641 Black high gloss interior grille MRR BEV*** 0.25 51 13 5 A59 642 Black high gloss interior grille FRR BEV**** 0.25 51 13 5 A59 4E9 Carbon front ornamental grille G26 ICE 1.00 51 13 5 A5B E69 Black high gloss upper interior grille ICE 0.25 51 13 5 A59 637 Black high gloss basic interior grille ICE 0.25 51 13 5 A59 638 Black high gloss interior grille MRR ICE*** 0.25 51 13 5 A59 639 Black high gloss interior grille FRR ICE**** 0.25 51 44 5 A36 8A4 Aramid antenna cover (see EBA 01 29 5 A5C 9E3 for installation instructions) - * MPA = M Performance Automobile ** MSP = M Sport Package *** MRR = Mid Range Radar **** FRR = Far Range Radar Installation time Installation time, see table. This may vary depending on the condition of the vehicle and the equipment in it. The installation time shown does not include any time spent on programming/coding. The calculation of the total costs for the programming time must be factored into the calculation of retrofitting costs (must not be invoiced under the warranty). © BMW AG, Munich 01 29 5 A45 BF1 01/2022 (V/Z) 2.1 1/19 Important information These installation instructions are primarily designed for use within the BMW dealership organisation and by authorised BMW service companies. These installation instructions are intended for use by qualified specialist staff trained on BMW cars with the relevant expert knowledge. All work must be completed using the latest BMW repair manuals, wiring diagrams, servicing manuals and work instructions, in a logical order, using the prescribed tools (special tools), and observing current health and safety regulations. After the installation of the carbon rear diffuser retrofit set and the carbon front attachment retrofit kit, the retrofit must be programmed/coded via the – Retrofits – path. The front attachment must only be installed with the standard gurney flap or rear spoiler. Furthermore, the rear spoiler may only be installed with the standard front attachment lip or front attachment. If you experience installation or functional problems, restrict troubleshooting to approx. 0.5 hours for mechanical work and 1.0 hours for electrical work. To avoid unnecessary extra work and/or costs, send an inquiry to the technical parts support team. Quote the following information: – VIN, – retrofit kit part number, – a detailed description of the problem, – any work already carried out. Do not archive the printout of these installation instructions. The current version can be found in the EPC (electronic parts catalogue). 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 – All contact/bonding surfaces on the components being installed must be absolutely dry, clean, and free of wax, silicone and grease. These surfaces must be treated with a suitable BMW cleaner or BMW primer (see EPC for details), using the appropriate product application instructions. – If you use adhesive tape, it must be applied using a contact pressure of between 10 N/cm² and 50 N/cm². – Take care not to damage the parts when opening the packaging. – Check that all the parts fit accurately on the car before installing them. – All the components and their bonding surfaces must be at room temperature for installation. The ideal relative humidity is 50%. Different values will change the specified times. – After completing the bonding and installation work, the car must remain stationary at room temperature for at least 12 hours. – If adhesives are used, the car may be driven after 24 hours, and may be taken through a car wash after 48 hours. The car may only be driven at a speed of vmax < 100 km/h for a period of 24 to 48 hours. – The installed parts may become loose and fly off the car if you fail to wait for the full reaction time of the primer/adhesive. Danger of accidents! © BMW AG, Munich 01 29 5 A45 BF1 01/2022 (V/Z) 2.1 2/19 – Some of the installation steps are shown only on one side of the car. Proceed in the same way on the other side of the car. – All illustrations show LHD cars; proceed in the same way on RHD cars. Special tools required – None © BMW AG, Munich 01 29 5 A45 BF1 01/2022 (V/Z) 2.1 3/19 Table of contents Section Page 1. Carbon front attachment parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2. Carbon rear diffuser with black high gloss rear bumper trim parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3. Carbon rear spoiler parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4. Carbon front ornamental grille frame parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 5. Preparatory work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 6. Carbon front attachment installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7. Carbon rear diffuser installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 8. Carbon rear spoiler installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 9. Carbon front ornamental grille frame installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 10. Concluding work and coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 © BMW AG, Munich 01 29 5 A45 BF1 01/2022 (V/Z) 2.1 4/19 1. Carbon front attachment parts list Legend A B C D E F G H Right front attachment Centre front attachment Left front attachment Underbody console Liquid adhesive (included in parts kit No. 83 19 5 A32 6D0) Cleaner (included in parts kit No. 83 19 5 A32 6D0) Primer (included in parts kit No. 83 19 5 A32 6D0) Expanding rivet (8 x, Part No. 51 47 1 911 992) © BMW AG, Munich 01 29 5 A45 BF1 01/2022 (V/Z) 2.1 5/19 2. Carbon rear diffuser with black high gloss rear bumper trim parts list Legend AA AB AC Carbon rear diffuser Black high gloss rear bumper trim (BEV shown, MSP or MPA versions not shown) Expanding rivet (5 x, Part No. 51 46 7 002 606) © BMW AG, Munich 01 29 5 A45 BF1 01/2022 (V/Z) 2.1 6/19 3. Carbon rear spoiler parts list Legend BA BB BC Carbon rear spoiler Liquid adhesive (not included in kit, see EPC for details) Cleaner (not included in kit, see EPC for details) © BMW AG, Munich 01 29 5 A45 BF1 01/2022 (V/Z) 2.1 7/19 4. Carbon front ornamental grille frame parts list Legend CA CB Carbon front ornamental grille frame Fin (18 x) © BMW AG, Munich 01 29 5 A45 BF1 01/2022 (V/Z) 2.1 8/19 5. Preparatory work ISTA/AIR No. The following components must be removed first of all For installing the rear spoiler only The standard rear spoiler may already be installed © BMW AG, Munich 01 29 5 A45 BF1 --- 01/2022 (V/Z) 2.1 9/19 6. Carbon front attachment installation The components/surfaces are only shown in part to make the diagrams clearer. The work must be completed on the entire component/surface. The bonding surfaces must be completely dry, clean, and free from wax or grease. Remove the 12 screws (1) and keep them safe, they will be reused later. Remove the rivets (2) on the left and right and keep them safe, they will be reused later. Clean the surface (3) on the car with cleaner F. Wait for the full drying time to elapse. The thin cavities (approx. 0.4 mm) between the individual thick fins cannot be modified for production reasons but are designed to meet pedestrian safety requirements. Abrade the small surfaces (1) on the underbody console D using suitable tools and clean it with cleaner F. Wait for the full drying time to elapse. Apply the primer G to the backing foils on the adhesive tape (1) on the underbody console D. © BMW AG, Munich 01 29 5 A45 BF1 01/2022 (V/Z) 2.1 10/19 6. Carbon front attachment installation Position the underbody console D and secure it with the six screws (1). Press the underbody console D on to the front attachment to form a positive connection and press the combination onto the car. Then remove the six screws (1) and then the underbody console D. Apply the primer G very accurately as it will cause black discolouration on the bumper trim, which cannot be removed. Apply primer G to the impression on the front apron as shown. Completely remove the backing foils (1) from the adhesive tapes on the underbody console D. Apply dots of liquid adhesive E to the abraded surfaces on the underbody console D. © BMW AG, Munich 01 29 5 A45 BF1 01/2022 (V/Z) 2.1 11/19 6. Carbon front attachment installation Position the underbody console D and secure it with the existing screws (1). Then press all adhesive joints firmly into position. Apply beads of liquid adhesive E to the small abraded surfaces on the underbody console D as shown. Abrade the small surfaces (1) on the carbon centre front attachment B using suitable tools and clean it with cleaner F. Wait for the full drying time to elapse. Remove any excess liquid adhesive immediately using suitable equipment. Slide the carbon centre front attachment B onto the underbody console D from an angle above it. © BMW AG, Munich 01 29 5 A45 BF1 01/2022 (V/Z) 2.1 12/19 6. Carbon front attachment installation Push the four expanding rivets H from below into the oval holes in the carbon centre front attachment B and press them in securely. Abrade the surfaces (1) on the carbon right front attachment A and carbon left front attachment C using suitable tools and clean it with cleaner F. Wait for the full drying time to elapse. Apply beads of liquid adhesive E to both sides. Apply beads of liquid adhesive E to the small abraded surfaces. Remove any excess liquid adhesive immediately using suitable equipment. Slide the carbon right front attachment A onto the underbody console D from an angle above it. Check that it is flush (1) with the wheel arch. Then push in the existing expanding rivet (2) and two expanding rivets H. Install the carbon left front attachment C in the same way. © BMW AG, Munich 01 29 5 A45 BF1 01/2022 (V/Z) 2.1 13/19 6. Carbon front attachment installation Secure the ends of the carbon right front attachment A and the carbon left front attachment C using suitable adhesive tape (1). Remove any excess liquid adhesive immediately using suitable equipment. The gap (1) between the carbon centre front attachment B and the carbon right front attachment A and carbon left front attachment C should be the same at both sides. The front edge (2) should run in a line and not have any overhang. It is possible to adjust the edge (2) to the two front edges of the carbon right front attachment A and carbon left front attachment C by sliding the carbon centre front attachment B. If necessary, the expanding rivet can be released again, corrected and then resecured. Remove any excess liquid adhesive immediately using suitable equipment. Secure the connection surface (1) on the underside between the carbon centre front attachment B and the carbon right front attachment A and carbon left front attachment C using a suitable clamp. As you are securing it, the complete carbon front attachment must not move. Secure the carbon centre front attachment B and the carbon right front attachment A and carbon left front attachment C using suitable adhesive tape (1). © BMW AG, Munich 01 29 5 A45 BF1 01/2022 (V/Z) 2.1 14/19 7. Carbon rear diffuser installation The installation work is described using the BMW i4 as an example. The procedure for the 4 Series Gran Coupé is identical. Keep the screws (1), they will be reused later. Remove the seven screws (1) and take off the standard bumper trim. Take the four C clips (1) from the standard trim and fit them on the black high gloss bumper trim AB. Clip the carbon rear diffuser AA into the black high gloss bumper trim AB. Check on the inside that the lugs (2) have engaged (see magnified diagram). Push the five expanding rivets AC into the boreholes from outside. Install the assembly consisting of the black high gloss bumper trim AB and carbon rear diffuser AA in the same way as the standard trim and screw in the seven existing screws (1) again. © BMW AG, Munich 01 29 5 A45 BF1 01/2022 (V/Z) 2.1 15/19 8. Carbon rear spoiler installation Remove the standard rear spoiler as described in ISTA/AIR if there is one. The components/surfaces are only shown in part to make the diagrams clearer. The work must be completed on the entire component/surface. The bonding surface (1) must be completely clean, dry and free from wax or grease. Clean the complete bonding surface (1) on the boot lid with cleaner BC. Wait for the full drying time to elapse. Ask a second person to help you place the carbon rear spoiler BA on the boot lid and align it at the edges (1). Ensure that the distance x to the left and right is identical and draw a mark (2) on the boot lid on both sides using a water-soluble pen. Pay particular attention to the edge area for tolerances between the carbon rear spoiler BA and boot lid. If you wish to adjust low tolerances, use less adhesive in the next stage in point 3. Remove the carbon rear spoiler BA. Abrade the connection flange around the outside in the outer areas (1), (2) and (3) in full and on all sides on the inside of the carbon rear spoiler BA using suitable tools. Then clean the abraded surfaces (1), (2) and (3) with cleaner BC. Wait for the full drying time to elapse. Then apply as thin a line as possible for liquid adhesive BB to the abraded surface (1). Apply a generous amount of liquid adhesive BB in area (2). In area (3), depending on the checked tolerances, fill the cavity with liquid adhesive BB so that a narrow black joint remains after the cleaning process. © BMW AG, Munich 01 29 5 A45 BF1 01/2022 (V/Z) 2.1 16/19 8. Carbon rear spoiler installation Position the carbon rear spoiler BA using the contour (1) on the boot lid. Recheck the position of the carbon rear spoiler BA to the left and right using the mark (2). Remove any excess liquid adhesive immediately using suitable equipment. Check that the contour (1) of the carbon rear spoiler BA lines up with the contour (2) of the boot lid. It should sit flat on the boot lid, evenly and without a large gap. Secure the carbon rear spoiler BA in at least five places using suitable adhesive tape (1). Apply one piece of adhesive tape right at the outside to ensure the best possible positive connection of the rear spoiler with the boot lid. When it has been secured with the adhesive tape (1), do not adjust the carbon rear spoiler BA any further. Remove any excess liquid adhesive immediately. Do not remove the adhesive tapes (1) for 24 hours, also remove the water-soluble pen on the boot lid and refer to the installation instructions on page 2. If the car does not have an air guide or M Performance front attachment, the air guide must be retrofitted to ensure aerodynamic balance. It should be installed as described in ISTA/AIR No. 5 111 230. © BMW AG, Munich 01 29 5 A45 BF1 01/2022 (V/Z) 2.1 17/19 9. Carbon front ornamental grille frame installation Remove the standard front ornamental grille as described in ISTA/AIR. The interior grille must be removed from the standard trim. To do so, heat the clips with a hot air blower to prevent damage. Insert a suitable tool (for example a screwdriver or installation wedge) between the clip (1) and the detent (2) and push the detent (2) away to the side. It is also possible to push the detent (2) out of the way by inserting a screwdriver through the opening (3) in the clip (1). Insert a fin CB between the clip (1) and detent (2) by holding the detent (2) out of the way with the tool. The standard trim (1) is shown without the interior grille to make it clearer. Repeat the steps described above for all 18 clips (2). As soon as all 18 clips (2) have been released, remove the interior grill from the standard trim (1). The interior grille is made up of two parts. Insert the clips (1) if necessary for this purpose. Clip the interior grille into the carbon front ornamental grille frame CA. Install the assembly on the car as described in ISTA/AIR. © BMW AG, Munich 01 29 5 A45 BF1 01/2022 (V/Z) 2.1 18/19 10. Concluding work and coding The retrofit system requires programming/coding for all cars if the carbon rear diffuser retrofit kit is installed. The retrofit system only requires programming/coding if the carbon front attachment retrofit kit is installed on diesel and petrol cars. This retrofit does not require programming/coding on electric cars. – Connect the battery – Connect the battery charger to the car – Connect the car to the ISTA workshop system – Open the ISTA/P car programming facility – If using ISTA/P, please refer to the instructions provided in the ISTA/P application documentation – Retrofit customer service word for carbon rear diffuser: Select "DSMO" via the – Retrofits – path and work through the action plan – Retrofit customer service word for carbon front attachment: Select M Performance front attachment coding of FGS parameters (MFSG) via the – Retrofits – path and work through the action plan – If necessary, carry out a vehicle test using the ISTA system, and note, or work through, any errors that have been recorded – Conduct a function test – Re-assemble the car © BMW AG, Munich 01 29 5 A45 BF1 01/2022 (V/Z) 2.1 19/19