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11 02 20_ENGINE REPLACEMENT AND ENGINE REPAIRS

SIB 11 02 20
ENGINE REPLACEMENT AND ENGINE REPAIRS

2021-06-28

This Service Information Bulletin (Revision 3) replaces SI B11 02 20 dated December 2020.
What’s New (Specific text highlighted):
Reusing or transferring components from the old engine to the new engine
Filling the engine with coolant

MODEL
All

INFORMATION
New and remanufactured replacement engine assemblies are NOT pre-filled with engine oil.
After replacing an engine with a new or remanufactured engine assembly, the engine oil level must
be verified as outlined in the procedure below first, before starting the engine for the first time.
If the new or remanufactured replacement engine is started to determine electronically if the engine is filled
with the appropriate amount of engine oil, damage to the replacement engine can occur immediately.
The engine may have some residual engine oil from assembly, but this is not enough engine oil to properly
lubricate the engine to measure the engine oil level electronically when it is started for the first time.
Furthermore, the electronic engine oil measurement is only operational when the engine is running at its full
operating temperature. Checking the engine oil without the engine running at operating temperature will lead
to an incorrect or incomplete measurement.
After replacing the engine or making engine repairs that require the replacement or removal of the following
components, you must perform a short oil pump and oil supply circuit priming procedure. Refer to the
appropriate section below.

Engine bearings
VANOS gears
Camshafts
Bed plate resealing
Engine oil pump
Engine oil filter housing
Cylinder head
Engine oil cooler
Anything that interrupts the engine oil supply circuit of the engine

Reusing or transferring components from the old engine to the new engine:
Always inspect and clean prior, as needed, when reusing or transferring components.
If required, use a borescope to look inside the components. Contaminated engine parts (metal particles,
fuel, water, antifreeze, etc.) can lead to subsequent engine or component failure and will not be covered by
Warranty.
If the engine is hydro locked due to water ingestion, clean the entire intake track by removing all of the
induction system components from the vehicle and ensuring no water is present before starting the
replacement engine.
If the engine is hydro locked due to a leaking injector, clean the entire intake track by removing all of the
induction system components from the vehicle and ensuring no fuel is present before starting the
replacement engine. Replace the affected injector.

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If the engine failure includes damage to the pistons and valves, for example, a hole in the piston or a broken
valve then inspect and clean the intake track and the exhaust system by removing and reinstalling all of the
components for inspection before starting the replacement engine engine.
If the lubrication circuit is contaminated with metal fragments, then the oil cooler and the oil cooler lines
need to be replaced. Cleaning these components will not be effective.
If necessary, use a bore scope to inspect all of parts if the component cannot be inspected visually, for
example, an induction pipe with multiple direction changes and blind spots.
If repairing the engine always account for all the broken parts, timing chain guides, bolt heads, etc., using a
bore scope in the oil drain plug hole or if necessary, the oil pan may need to be removed if all of the parts
are not accounted for.
All vehicles using two turbos and vacuum operated wastegates:
When disassembling the vacuum supply system always ensure the hoses and components are marked or
labeled so that reassembly is performed correctly. Always refer to the applicable repair instruction to ensure
the vacuum hoses are connected to the correct bank turbocharger wastegate actuator or EPDW.
If the hoses are not connected correctly subsequent engine damage can occur. Engine or component failure
related to incorrectly connected vacuum hoses will not be covered by Warranty.

PROCEDURE
Engine Replacement:
The following procedure applies to all engines equipped with an electronic engine oil level sensor, with or
without an engine oil dipstick.
This procedure is used when the high-pressure fuel system pressure is already depleted from complete
engine replacement.

1. After installation of the replacement engine and before starting the engine for the first time, remove the
engine oil drain plug. Drain any residual engine oil from the crankcase.

2. Reinstall and torque the engine oil drain plug (with a new seal ring) per the applicable repair instruction.
3. Remove the oil filter housing cover and verify the oil filter is present. Reinstall the oil filter housing cover
and torque it to the proper specification noted in the applicable repair instruction.

4. Fill the engine with the proper type and amount of engine oil, as specified in the applicable repair
instruction.

5. Manually rotate the engine 2 revolutions in the clockwise direction with the appropriate wrench or a
ratchet with socket. Never rotate the engine counterclockwise.

6. Connect a battery charger to the vehicle.
7. Remove the electric fuel pump fuse. Refer to the applicable wiring diagram using the VIN of the vehicle
in ISTA.

8. Crank the engine for 10 seconds.
9. After 10 seconds have elapsed, stop the starter, and allow the starter to cool for 20 seconds.

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10. Repeat steps 8 and 9 two additional times.
11. Reinstall the electric fuel pump fuse and start the engine. Verify proper engine operation.
12. After the engine has reached operating temperature, check the engine oil electronically or with the
dipstick, and top up the engine oil as needed.

Cylinder Head Replacement or Valvetrain Repairs:
This procedure is used when the cylinder head is removed and installed or replaced. This also applies to valvetrain
repairs where the valvetrain is disassembled from the cylinder head. This would include-

Camshafts
Eccentric shafts
Intermediate levers
Roller drag levers
Valve springs
Valves

The following procedure applies to all engines equipped with an electronic engine oil level sensor, with or
without an engine oil dipstick.
This procedure is used when the high-pressure fuel system pressure is already depleted from complete
engine replacement.

1. If the engine oil was drained, torque the engine oil drain plug (with new seal ring per the applicable
repair instruction), ensure the proper type and amount of engine oil is used when refilling the engine.

2. If you are unsure, remove the oil filter housing cover and verify the oil filter is present. Reinstall the oil
filter housing cover and torque it to the proper specification noted in the applicable repair instruction.

3. Manually rotate the engine 2 revolutions in the clockwise direction with the appropriate wrench or a
ratchet with socket. Never rotate the engine counterclockwise.

4. Connect a battery charger to the vehicle.
5. Remove the electric fuel pump fuse. Refer to the applicable wiring diagram using the VIN number of the
vehicle in ISTA.

6. Crank the engine for 10 seconds.
7. After 10 seconds have elapsed, stop the starter, and allow the starter to cool for 20 seconds.
8. Repeat steps 6 and 7 two additional times.
9. Reinstall the electric fuel pump fuse and start the engine. Verify proper engine operation.
10. After the engine has reached operating temperature, check the engine oil electronically or with the
dipstick, and top up the engine oil as needed.

Engine Repairs:
This procedure is used when the engine oil supply circuit is interrupted during a repair. This applies to-

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VANOS gears
Timing chain tensioner
Bed plate resealing
Engine oil pump
Engine oil filter housing
Engine oil cooler
Any engine repair that interrupts the engine oil supply circuit of the engine
This procedure is used when the high-pressure fuel system pressure may not be depleted after minor
engine repairs. The fuel injection system needs to be disabled by removing the fuel injector electrical
connectors.

1. If the engine oil was drained, torque the engine oil drain plug (with new seal ring per the applicable
repair instruction), ensure the proper type and amount of engine oil is used when refilling the engine.

2. If you are unsure, remove the oil filter housing cover and verify the oil filter is present. Reinstall the oil
filter housing cover and torque it to the proper specification noted in the applicable repair instruction.

3. Connect a battery charger to the vehicle.
4. Remove all fuel injector electrical connectors to disable fuel injection.
5. Crank the engine for 10 seconds.
6. After 10 seconds have elapsed, stop the starter, and allow the starter to cool for 20 seconds.
7. Repeat steps 5 and 6 two additional times.
8. Reinstall the fuel injector electrical connectors, reassemble the vehicle and verify proper engine
operation.

9. After the engine has reached operating temperature, check the engine oil electronically or with the
dipstick, and top up the engine oil as needed.

Replacement Components Requiring 1,200 Mile Service
Certain BMW vehicles have specific components that require a “running-in” fluid replacement service after
the first 1,200 miles of vehicle operation, refer to SI B00 06 10 for more information.
Cooling Systems
Always ensure the replacement engine is filled with the proper coolant and quantity before starting the
engine. Refer to the applicable repair instructions.

WARRANTY INFORMATION
Claimable in conjunction with an applicable repair that is covered under the terms of a BMW Limited
Warranty or BMW program coverage that applies and is active.
Claim with the defect code that applies to the engine
replacement or component repair that required this
necessary work procedure to be performed

Defect Code:

Refer to AIR

Labor
Operation

Description (Associated work)

Labor Allowance

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11 00 896

11 02 20_ENGINE REPLACEMENT AND ENGINE REPAIRS

Engine oil priming procedure (Performing any of the repair
procedures listed above that includes the engine oil pump
and oil supply circuit priming procedure after engine
replacement, cylinder head replacement or other
applicable engine repairs)

Refer to AIR

Or:
11 99 000

Work time for the engine oil priming procedure (See below)
(Performing any of the repair procedures listed above that
includes the engine oil pump and oil supply circuit priming
procedure after engine replacement, cylinder head
replacement or other applicable engine repairs)

5 FRU

Refer to AIR for the corresponding flat rate unit (FRU) allowance (See below).
Work Time Labor Operation 11 99 000
At the AIR start screen, use the Search for vehicle with vehicle identification number option (enter a
minimum of the last 7 digits of the VIN).
In the AIR application, select Flat Rate Units from the top menu bar, enter flat rate labor operation code
1100896 (without spaces) in the search field, hit enter or the search icon to confirm that labor operation 11
00 896 applies and is available and then obtain the corresponding FRU allowance information.
If flat rate labor operation 11 00 896 is not found, submit and claim for job/repair work time labor operation
11 99 000 for the FRU allowance as described above instead.
If other required work was also performed under labor operation 11 99 000, claim labor operation 11 99 000
one time only for all the job/repair WT FRU that was needed and itemize the total FRU amount claimed on
the repair order and in claim comment section.
As applicable to your center, please refer to SI B01 01 20 or B01 07 20 for claiming your diagnosis work
time, job/repair work time (WT), RO/Claim WT and/or repair explanation procedures.

QUESTIONS REGARDING THIS BULLETIN
Technical inquiries
Warranty inquiries
Parts inquiries

Submit feedback at the top of this bulletin
Submit an IDS ticket to the Warranty Department or use the chat
available in the Warranty Documentation Portal
Submit an IDS ticket to the Parts Department

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