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This article gives detailed instructions on replacing the air pump control valves in a BMW vehicle with the 8 cylinder N62 engine. Even though we used a 2005 645ci to perform this repair, this article can be applied to any vehicle with the BMW N62 8 cylinder engine including 5,6,7 and X5 models with minor modifications to the repair steps.
The BMW N62 air pump control valves are a known source of failure in the V8's emissions system.
One of the more overlooked (and misunderstood) systems in our BMW vehicles is that of emissions control. Emissions control is the process of reducing the hazardous air pollutants that are emitted from a vehicle as a byproduct of fuel combustion. These hazardous pollutants include hydrocarbons, carbon monoxide (CO), and other volatile compounds that are considered dangerous to human health and the environment.
One of the critical components in reducing hydrocarbon and CO emissions in our BMWs is the secondary air injection system - a method of injecting outside air into the exhaust manifold during a cold engine start. Injecting fresh outside air into cold engine exhaust gases helps the catalytic converter reach its operating temperature faster, reducing the number of unburned hydrocarbons emitted from the vehicle. The secondary air injection system relies on an electric air pump which directs outside air into the exhaust manifold through a network of pipes, and two non-return valves. These non-return valves, also known as air pump control valves, basically check valves located on each of the V8's two exhaust manifolds. They allow the fresh outside air from the secondary pump to flow into the exhaust manifolds without allowing dangerous gases to flow back in the opposite direction into the pump. Without the air pump control valves, dangerous gases would flow back into the engine when the secondary air pump shuts off.
Unfortunately, age and general wear and tear take their toll on the BMW N62 air pump control valves, causing them to malfunction. Dirt, debris, and mechanical malfunction can cause the valves to stick open or closed triggering the dreaded "service engine" light in the instrument cluster as well as displaying emission system warning messages on the iDrive display. BMW N62 air pump control valve failure will also produce error codes including P0491 and P0492.
Replacing the air pump control valves on the N62 eight-cylinder engine is unfortunately not a simple process. The valves and the pipes that connect them to the secondary air pump are located underneath the intake manifold. The intake manifold must be removed to replace the air pump control valves in the N62 engine...it is impossible to access them any other way.
When performing an air pump control valve replacement on your BMW N62 engine, we strongly recommend replacing the pressure hose assembly that supplies the air from the secondary pump. The pressure hose assembly is made of plastic and is notorious for becoming brittle and cracking with age. We cannot stress enough spending a few extra dollars and replacing this pipe while you have the engine disassembled.
N62 Engine - All Models
5 Series E60 (02/2002 - 02/2007)
5 Series E60 LCI (11/2005 - 12/2009)
5 Series E61 (11/2002 - 02/2007)
5 Series E61 LCI (11/2005 - 03/2010)
6 Series E63 (05/2002 - 07/2007)
6 Series E63 LCI (04/2006 - 07/2010)
6 Series E64 (09/2002 - 07/2007)
6 Series E64 LCI (04/2006 - 07/2010)
7 Series E65 (02/2000 - 07/2008)
7 Series E66 (06/2000 - 07/2008)
7 Series E67 (10/2002 - 06/2008)
X5 E53 (01/2003 - 09/2006)
X5 E70 (02/2006 - 03/2010)
View the detailed parts diagram for this repair.
Includes detailed part diagrams, part numbers and links to purchase all of the required components needed to complete this repair.
Before starting this repair, you must have the following required parts.
BMW N62 V8 Engine
This is the same factory air pump control valve that would be installed at the BMW dealership.
BMW N62 V8 Engine
These gaskets should be replaced each time the intake manifold is removed.
In order to gain access to the BMW N62 air pump control valves, the intake manifold must be removed. You cannot remove the air control valves with the intake manifold in the vehicle. This is because the pressure hose assembly that connects the air pump to the valves is underneath the intake manifold...it is not possible to reach its connections otherwise.
Section 2 - Replacing the BMW N62 Air Pump Control Valves
Once the intake manifold is removed, replacing the control valves is a simple procedure. They are simply attached to the top of each exhaust manifold with two bolts. There is a very good probability that you will break the plastic pressure hose assembly while removing the valves. DO NOT get discouraged...this is a very normal occurrence. The pressure hose assembly becomes very brittle with age and in older vehicles, it is nearly impossible to remove without it falling apart in your hands. If you break yours, please see our parts block above to reorder or click here to purchase a replacement.
Locate the two air pump control valves. They are located at the rear of the engine.
Starting with the right control valve, squeeze the pressure hose assembly fitting and pull it free from the valve. Repeat on the left valve.
The air pump control valves are anchored to the exhaust manifold with two bolts. Use a 10mm socket wrench with a long extension to reach them.
Grasp the valve and remove it from the engine. Make sure to remove the old sealing gasket with it.
When reinstalling the new air valves, make sure to use a fresh sealing gasket. Their should be new ones included with your new valves.
Section 3 - Reassembling the Vehicle
Reassembling the vehicle is very straightforward with no special procedures. We have provided a handy checklist below for your convenience to help with reassembly.
BMW N62 Air Pump Control Valve Reassembly Checklist
***The following steps were performed on a 2005 645ci...other models may vary.
Install the new control valves. make sure the new sealing gaskets are properly aligned with the mounting holes. We suggest using a little spray adhesive to keep the gaskets from sliding out of position.
Install the mounting bolts and torque them to 10.5 Nm (7.75 ft-lb).
Reinstall the pressure hose assembly to the control vales. make sure they snap securely in place.
Part # 11-72-7-508-270 - Do you have a check engine light for an emissions leak? Check this hose - they break down over time and can start to leak. Replace your worn-out hoses with new parts from ECS tuning to keep your BMW running at its best. Fits: BMW E60 545i, BMW E63 645Ci, BMW E64 645Ci, BMW E65 745i, BMW E66 745Li
Goes between the valve and intake tube Fits: BMW E60 545i, BMW E63 645Ci, BMW E64 645Ci, BMW E65 745i, BMW E90 325i, BMW E90 328i, BMW E90 325xi, BMW E90 330i, BMW E90 330xi, BMW E90 328xi, BMW E91 328i, BMW E91 325xi, BMW E91 328xi, BMW E92 328i, BMW E92 328xi, BMW E93 328i
Part # 11-72-7-553-101 - A critical component of the emissions system, this valve regulates the function of the secondary air pump. In the event of valve failure, the pump is unable to push air to the intake manifold, and will accelerate pump failure. Fits: BMW E60 545i, BMW E63 645Ci, BMW E64 645Ci, BMW E65 745i, BMW E65 B7 Alpina, BMW E66 745Li
Part # 11-72-1-438-814 - This unit monitors air flow going into the EVAP pump. Fits: BMW E46 325i M54 2.5L, BMW E46 325Ci M54 2.5L, BMW E46 325xi M54 2.5L, BMW E46 330Ci M54 3.0L, BMW E46 330i M54 3.0L, BMW E46 330xi M54 3.0L, BMW E53 X5 M54 3.0L, BMW E60 530i M54 3.0L, BMW E60 M5 S85 5.0L, BMW E60 525i M54 2.5L, BMW E63 M6 S85 5.0L, BMW E64 M6 S85 5.0L, BMW E83 X3 M54 2.5L, BMW E83 X3 M54 3.0L
Part # 07-11-9-901-511 - This o-ring is used on each side of the secondary air line to seal the line to the air pump and the EGR control valve. Fits: BMW E38 740i M62 4.4L, BMW E39 M5 S62 5.0L, BMW E39 540i M62 4.4L, BMW E52 Z8 S62 5.0L, BMW E53 X5 M62 4.4L, BMW E53 X5 M62 4.6L, BMW E53 X5 N62 4.4L, BMW E60 545i N62 4.4L, BMW E63 645Ci N62 4.4L, BMW E64 645Ci N62 4.4L, BMW E65 745i N62 4.4L, BMW E66 745Li N62 4.4L
Part # 11-72-7-534-722 - Small air filter used in the air pump system, connects to air intake hose on the air pump. Fits: BMW E53 X5 M54 3.0L, BMW E53 X5 N62 4.4L, BMW E60 530i M54 3.0L, BMW E60 525i M54 2.5L, BMW E60 545i N62 4.4L, BMW E63 645Ci N62 4.4L, BMW E64 645Ci N62 4.4L, BMW E83 X3 M54 2.5L, BMW E83 X3 M54 3.0L
Part # 11-72-7-839-125 - Keep your air pump secured safely in your engine bay and replace your bent or corroded bracket. The bracket provides secure mounting underneath the hood to keep your secondary air pump from moving freely and becoming damaged. Fits: BMW E60 M5 S85 5.0L, BMW E63 M6 S85 5.0L, BMW E64 M6 S85 5.0L
This rubber mount is found between the air pump and mounting bracket. Fits: BMW E46 325i, BMW E46 325Ci, BMW E46 325xi, BMW E46 330Ci, BMW E46 330i, BMW E46 330xi, BMW E60 530i, BMW E60 M5, BMW E60 525i, BMW E60 545i, BMW E63 M6, BMW E63 645Ci, BMW E64 M6, BMW E64 645Ci, BMW E65 745i, BMW E65 760i, BMW E65 760Li, BMW E65 B7 Alpina, BMW E66 760Li, BMW E66 745Li, BMW E83 M54 3.0L, BMW Z4 2.5i M54 2.5L, BMW Z4 3.0i M54 3.0L, BMW Z4 M Coupe S54 3.2L, BMW Z4 M Roadster S54 3.2L
Part # 11-72-7-571-589 - Secondary air pump for BMW vehicles. A failed secondary air pump can lead to a list of emission related issues. Driving around with a bad air pump for long periods of time can lead to oxygen sensor, catalytic converter and mass air flow sensor damage, resulting in a lengthy and costly repair bill. A bad air pump will throw a check engine light and can cause a vehicle to fail emission's related testing. Fits: BMW E46 325i, BMW E46 325Ci, BMW E46 325xi, BMW E46 330Ci, BMW E46 330i, BMW E46 330xi, BMW E53 X5 M54 3.0L, BMW E60 530i, BMW E60 M5, BMW E60 525i, BMW E60 545i, BMW E63 M6, BMW E63 645Ci, BMW E64 M6, BMW E64 645Ci, BMW E83 X3 M54 3.0L
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