BMW Motorsport Preparations for PWC -mandatory-

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1 Preparations for PWC -mandatory- Required parts: Quantity Partnumber Description Fire extinguisher 1 No additional parts required Triangle net Triangle net Schroth Racing Battery cover Battery cover Rivet nut Oval-head screw Boost pressure sensor Adapter for boost sensor O-Ring 9.5x Oval head screw M6x14 Torque control logging GWS cable 1

2 31 10 Tension struts uniball beared -mandatory- Required parts: Quantity Partnumber Description Tension Strut FA left Joint bearings Support ring Tension Strut FA right Joint bearings Support ring 2

3 32 10 Steering gear -mandatory- Required parts: Quantity Part Number Description EPS Sportlenkung (Steering gear) ThyssenKrupp Steering stop ThyssenKrupp 3

33 10 Rear Suspension -mandatory- Required parts: Quantity Partnumber Description Guiding links 2 33 30 8417242 Guiding suspension link 2 33 30 8417241 Joint bearings RH 2 33 30 8310772 Joint

4 33 10 Rear Suspension -mandatory- Required parts: Quantity Partnumber Description Guiding links Guiding suspension link Joint bearings RH Joint bearings LH Nut M16x1,5 10 RH Nut M16x1,5 10 LH Wishbone Wishbone Joint bearings RH Joint bearings LH Nut M16x1,5 10 RH Nut M16x1,5 10 LH 4

5 33 10 Rear Suspension -mandatory- Required parts: Quantity Partnumber Description Trailing arm Trailing arm Joint bearings RH Joint bearings LH Nut M16x1,5 10 RH Nut M16x1,5 10 LH Camber control arm Camber control arm Joint bearings LH Nut M16x1,5 10 LH Track link Track link Joint bearings RH Joint bearings LH Nut M16x1,5 10 RH Nut M16x1,5 10 LH For installation of the track link use following screw Screw M12X1,5X Nut M12 5

6 51 62 Rear Wing -mandatory- Required parts: Quantity Partnumber Description Rear wing Side plates Oval head screws Bracket Bracket LH Bracket RH Rear wing to bracket Oval head screws Bracket to the trunk Cylinder screw M8x Washer M8 Trunk Trunk with bore for the rear wing 6

7 Preparations for PWC -mandatory- Required parts: Quantity Partnumber Description Cooling liquid Screw locking 7

8 18 11 Exhaust without catalytic converter - option - Required parts: Quantitiy Part Number Description ZB exhaust w/o cats Clamp 8

51 XX Frontsplitter Reinforcement - option - Required parts: Quantity Partnumber Description 1 5175 8417286 Splitter

9 51 XX Frontsplitter Reinforcement - option - Required parts: Quantity Partnumber Description Splitter Reinforcement Screw M6x Washer M Kaynut M Screw C-Clip 9

10 17 XX Engine Cooling - option - Please note: Hot weather cooling package is in development. Estimated Release mid Required parts: Quantity Part number Description Gearbox oil radiator Oil pipes coupling radiator Oil pipes thermostat coupling Oil pipes thermostat coupling (return flow) Thermostat Pipes Gearbox Thermostat O-Ring 13,94X2,62 Pipe cover Pipe Cover cooling hose Thermostat Fixation Bracket Thermostat Hexa screw M6X Nut M5 Oil pipe fixation Double clip Bracket pipes Distance bush Hexa screwm6x Plastic bracket gearbox pipes Connector Gearbox radiator 10

11 17 XX Engine Cooling - option - Required parts: Quantity Part number Description Cylinder screw M6X Hexagon Screw M6X Hexagon Screw M6X Clamp shell Clamp shell Compensation bracket Bowden cable Washer Special tools for bleeding Tool for bleeding O-Ring

Preparations for PWC Fire extinguisher: (Nozzle to firewall) 1.

Bend the still installed line down to the air-intake manifold

The freed line and T-piece will be installed at the fire wall. 3.

12 Preparations for PWC Fire extinguisher: (Nozzle to firewall) 1. Remove red marked lines including T- piece. 2. Bend the still installed line down to the air-intake manifold (throttle). The freed line and T-piece will be installed at the fire wall. 3. Please cut the line at b-colomn near to the firewall and insert the t-piece. Place the freed nozzle of the engine compartment to the firewall. 12

Preparations for PWC Additional triangle net: 7211 8424776 Zoom

operating device by removing also the fresh air grille 1.

13 Preparations for PWC Additional triangle net: Zoom Necessary preliminary tasks: - Remove radio cover - Remove IHKA operating device by removing also the fresh air grille 1. Please connect the tensioner of the triangle net to the supporting tube, instrument panel. 2. Cut the centre grille in the shown area and install the grille. 3. Installation note: The upper part of the triangle net has to be inside the drivers seat. 13

Connect the upper belt of the triangle net to

14 Preparations for PWC Additional triangle net: Connect the upper belt of the triangle net to the left C-Column of the roll cage. Picture 5. Please connect the middle belt to the B-column of the roll cage near to the defuel switch. Picture 6. Please connect the lower belt to the c-column of the roll cage near to the screwing plate (trunk). Picture 14

Preparations for PWC Battery cover: 8417310 (1), 7742891 (4), 7742139 (4) 1. Place battery cover 8417310 fitting to the bore (circle left picture).

15 Preparations for PWC Battery cover: (1), (4), (4) 1. Place battery cover fitting to the bore (circle left picture). Tag the four bore holes and drill them with 7,8 mm diameter. 2. Insert rivet nuts Install the battery cover with screws Cooling liquid: For PWC, please change cooling liquid to water. Note: Don t use distilled water BMW Motorsport has not tested without cooling liquid. To drive with water as cooling liquid is on your own risk. Refill cooling liquid after PWC races for engine protection. 15

31 10 Tension struts uniball beared 1. Remove tension strut old spec. 2. Complete tension strut left and right. Insert joint ball 8416802 (2) to tension strut 8417235 (1,7) and 8417236.

16 31 10 Tension struts uniball beared 1. Remove tension strut old spec. 2. Complete tension strut left and right. Insert joint ball (2) to tension strut (1,7) and Secure joint ball with support ring (3). Check right directions of the distance bushes. (5,6) 3. Install the new tension struts left and right. Fasten the tension strut to the front axle support in design attitude. Tightening torques, tension strut to: Wheel carrier: 175 Nm Front axle support: 100 Nm + 90 Use Loctite 270 for both screwing points. 16

32 10 Steering gear Necessary preliminary tasks: Disconnect battery earth lead Remove front wheel left and

Release clamping bolt (1) of steering shaft from steering gear and pull off.

Replace clamping bolt. 32 30 6 778 609 Tightening torque: 24 Nm 2.

17 32 10 Steering gear Necessary preliminary tasks: Disconnect battery earth lead Remove front wheel left and right Remove front underbody protection Remove stiffening plate Release left and right track rod end 1. Release clamping bolt (1) of steering shaft from steering gear and pull off. Installation notes: Clean screw threads to remove all remnants of screw locking adhesive. Replace clamping bolt Tightening torque: 24 Nm 2. Unlock plug connections (1) and disconnect. Unfasten screws (2). Installation notes: Replace the screws (2) and nuts. Replace screws and nuts. Tightening torque: 56 Nm 3. Install steering gear

32 10 Steering gear Tools required: -323160 4.

Undo the joint (1) using special tools 323160 at the steering box rack.

steering gear and fasten with special tool 323160.

18 32 10 Steering gear Tools required: Remove gaiter from steering gear and slide back. 5. Undo the joint (1) using special tools at the steering box rack. 6. Insert steering stop between the tie rod head and the steering gear and fasten with special tool Tightening torque: 105 Nm 7. Complete steering gear. Note: The steering stop of Spec. 2014/15 to Spec ZF is different and has to be replaced.. 18

19 32 10 Steering gear After installation: Steering gear has to be initialized by BMW Motorsport flashing tool. Adjust to basic setup. 19

rims to wheel arch. Note the measurements. 2.

(For easier handling) 3. Disconnect rear wheel speed sensors.

2016 possible Note: BMW Motorsport recommends to change every

The following instructions are guilty for track link, trailing

20 33 10 Rear Suspension 1. Measure the height of the car front and rear from lower edge of rims to wheel arch. Note the measurements. 2. Lift the car and remove tires. Loosen the differential radiator. (For easier handling) 3. Disconnect rear wheel speed sensors. Note: Relocation with rear wheel arch cover spec possible Note: BMW Motorsport recommends to change every link separately. The following instructions are guilty for track link, trailing arm, wishbones, guide links. 4. Dismount the wishbone. Adjust position and length. 5. Put the old and new link on each other. Use the screw to adjust the length. The contact area has to be parallel. 20

The round washes of guide arm and wishbone are no

Regard the washers! Use loctite for the screws.

21 33 10 Rear Suspension 6. Use the screws and old link to lock the screw connection. Tightening Torque: 200 Nm ±50 Nm Use Loctite The round washes of guide arm and wishbone are no longer in use. 8. Install the new links. Regard the washers! Use loctite for the screws. Please check the correct tightening torque for the wheel carrier and rear axle support. Camber control arm 9. Dismount camber control arm. The length of the camber control arm has to be measured. Adjust the new camber control arm to the measured length. 21

33 10 Rear Suspension 10.Remove the old bushes.

Note: The slope has to be on the lower side. 12.

fasten all screws with tightening torque.

22 33 10 Rear Suspension 10.Remove the old bushes. 11.Install the new camber control arm. Note: The slope has to be on the lower side. 12.Adjust the vehicle to the noted height. All bearings have to be free. 13.Tune in standard setup of the BMW M235i Racing, fasten all screws with tightening torque. Use Loctite Tag fasten screws with special color. 15.Install differential radiator. 22

23 33 10 Rear Suspension Assemble advice Wishbones RA 289mm (+/- 2) mm Trailing arm RA 330mm (+/- 2) mm 23

24 33 10 Rear Suspension Assemble advice Chamber link RA 416 (+/- 2) mm Trailing arm RA 245mm (+/- 2) mm 174,5 24

25 33 10 Rear Suspension Assemble advice Tack rod

26 33 10 Rear Suspension Mandatory length of the links Chamber link RA 416 (+/- 2) mm Trailing arm RA 245mm (+/- 2) mm Wishbones RA 289mm (+/- 2) mm Trailing arm RA 330mm (+/- 2) mm 26

27 Vehicle Setup Setup sheet Spec Preparations Fuel filling [liter] [gal] Load [kg] [lbs] seat / foot well Tire pressure [bar] Front / Rear [psi] Reference / Recommended Tire by Dunlop 60 15,85 60 / / 44 2,4 / 2,3 34,8 / 33,4 265/ FL Item Tire fillings [bar] [psi] Target 2,40 34,8 Rebound [Klicks] 11 Bump [Klicks] 9 Height [mm] 110 Toe [`] -7 Camber [ ] -2,9 Anti Roll bar Front hole FR Item Tire fillings [bar] [psi] Target 2,40 34,8 Rebound [Klicks] 11 Bump [Klicks] 9 Height [mm] 110 Toe [`] -7 Camber [ ] -2,9 Anti Roll bar Front hole RR Item Tire fillings [bar] [psi] Target 2,35 34,1 Rebound [Klicks] 10 Bump [Klicks] 9 Height [mm] 126 Toe [`] +18 Camber [ ] -2,5 Rear wing low RL Item Tire fillings [bar] [psi] Target 2,35 34,1 Rebound [Klicks] 10 Bump [Klicks] 9 Height [mm] 126 Toe [`] +18 Camber [ ] -2,5 Rear wing low

28 33 XX Rear axle Description Thread Regulation Torque Shock absorber on guide support Loctite Nm Shock absorber on roll-over strut Loctite 270 Norm position Roll over strut on carrier Loctite 270 Norm position Roll over strut on rear axle carrier Loctite 270 Norm position Wishbone on carrier Loctite 270 Norm position Wishbone on rear axle support Loctite 270 Norm position Track strut on carrier Loctite 270 Norm position Track strut on rear axle support Loctite 270 Norm position Guiding arm on carrier Loctite 270 Norm position Guiding arm on rear axle support Loctite 270 Norm position Trailing arm on carrier Loctite 270 Norm position Trailing arm on rear axle support Loctite 270 Norm position 100Nm Nm 165Nm 100Nm Nm 100Nm Nm 100Nm Nm 100Nm 100Nm Uniball to link (nut) + / - 50Nm Loctite Nm Differential on rear axle support front Loctite Nm Differential on rear axle support rear Loctite 270 Renew the nuts Drive shaft on differential Jointing torque Angle of rotation 165Nm 50Nm 135Nm Drive shaft on carrier M24 Renew the nuts 145Nm 45 Rear axle support on body 120Nm 28

51 62 Rear Wing 1. Dismount the trunk. If air jacks are installed.

Cut the new trunk by using the template.

pdf Check correctness of the scale 1:1 Re -adhere or rivet the

Transfer the hooks to the new trunk 8417227. 4.

Adjust to the old screwing points and fasten the trunk. 5.

29 51 62 Rear Wing 1. Dismount the trunk. If air jacks are installed. 2. Dismount the cover in the trunk. Cut the new trunk by using the template. F22_M235i_2016_51xx_Template_trunk_eng_1.pdf Check correctness of the scale 1:1 Re -adhere or rivet the cover to the trunk. 3. Transfer the hooks to the new trunk Install the trunk Install with almost two persons. Adjust to the old screwing points and fasten the trunk. 5. Install the brackets, left and right, of the rear wing to the trunk by using the screws and washer Tightening Torque: 50 Nm Secure with Loctite and check Screwing after the first 100km 29

Screwing after the first 100km Note: The rear wing is adjustable in

Install the end plates in context to the rear wing position.

middle position Use hole 3 (low) for the lowest position The upper

30 51 62 Rear Wing 7. Fasten the rear wing with the screws to the brackets. Tightening Torque: 12 +/- 2 Nm Secure with Loctite and check Screwing after the first 100km Note: The rear wing is adjustable in 3 positions. Install the end plates in context to the rear wing position. Use hole 1 (up) for the highest position Use hole 2 (middle) for middle position Use hole 3 (low) for the lowest position The upper edge of the plate should be horizontal parallel. 8. The side plates are bolted with the screws to the rear wing, like shown in the drawing. Tightening Torque: 7 +/- 1 Nm Secure with Loctite and check Screwing after the first 100km 30

31 00 17 Coolant Change Required parts: Quantity Partnumber Description Coolant liquid (not for PWC) Vent screw Special tools Befüllgerät Adapter 31

00 17 Coolant Change Notice: Risk of burning! Attention: In case of contamination by engine oil, for example, the cooling system must be cleaned thoroughly. 2 1 Draining the coolant: 1.

32 00 17 Coolant Change Notice: Risk of burning! Attention: In case of contamination by engine oil, for example, the cooling system must be cleaned thoroughly. 2 1 Draining the coolant: 1. Open the cap on the compensating reservoir 2. Remove the shear panel. 3. Loosen hose clamps (1) and (2). Remove the coolant hoses from the coolant pump and drain the coolant. 4. Notice: Observe the installation position of the hose clamps. Fill the cooling system. 1. Filling with 50% cooling agent and 50% distilled water. (not for PWC) 2. Fill slowly. 3. Fill coolant up to the maximum level. 32

33 00 17 Coolant Change Notice: Risk of burning! Attention: In case of contamination by engine oil, for example, the cooling system must be cleaned thoroughly. Fill the cooling system. 4. Close the compensating coolant reservoir. 5. Notice: Close the cap until the arrow markings are aligned. Refill the cooling system. 1 Notice: The following venting procedure is necessary after, e.g., replacing parts in the cooling system or when refilling the cooling system. 1. Fill the cooling system with a vacuum filling device. Vent the cooling system. Boundary conditions: The cap stays open Connect the battery charger Switch-on the ignition Switch-on the dimmed headlights Turn the heater to maximum Turn fan to minimum 33

34 00 17 Coolant Change Notice: Risk of burning! Attention: In case of contamination by engine oil, for example, the cooling system must be cleaned thoroughly. Vent the cooling system. 1. Press the accelerator pedal all the way down for 10 seconds, the engine must not be started. 2. The venting procedure is started and takes about 12 min. The electronic water pump switches off automatically. 3. At the end, fill the coolant level as described on page Check the cooling system for leaks with suitable tool. 5. If the procedure must be performed again, start with step 1 after first turning off the ignition for about 3 minutes, until the DME voltage is complete drained. 34

Preparations for PWC Boost pressure sensor: 8430122 (1), 8430123 (1), 8421746 (2) 1.

Remove series productions pressure sensor from the air intake manifold. 4.

Install the adapter 8430122 to air intake manifold with screws 8421746. 7.

35 Preparations for PWC Boost pressure sensor: (1), (1), (2) 1. Install O-Ring to the adapter Remove engine cover. 3. Remove series productions pressure sensor from the air intake manifold. 4. Install pressor sensor to the adapter Cut bracket as shown. Picture 6. Install the adapter to air intake manifold with screws Place cable loom for the pressure sensor from the passenger foot area to the engine compartment. 8. Install the sensor, spent by PWC to the adapter Cut the engine cover as required. Note: Take care that the cables do not scrub on sharp edges. 35

Preparations for PWC Torque control logging: 8327321 Please note, Pirelli World Challenge will log the requested torque. Therefore please install GWS Y-Cable 8327321. 1. Remove Gear selector (GWS).

36 Preparations for PWC Torque control logging: Please note, Pirelli World Challenge will log the requested torque. Therefore please install GWS Y-Cable Remove Gear selector (GWS). loosen center console loosen GWS cover Remove GWS from bracket (4 screws) 2. Disconnect GWS and connect Install GWS to bracket and tighten c enter console and GWS cover. 4. Contact PWC for wiring to Motec Logger. 36

37 Preparations for PWC Screw locking: Screws for drain and filling plugs of the cooling system, engine, gear box and differential have to be locked. See following pictures how to lock. Differential and radiator: 37

38 Preparations for PWC Screw locking: Screws for drain and filling plugs of the cooling system, engine, gear box and differential have to be locked. See following pictures how to lock. Engine: Gearbox: 38

39 Options Installation 39

17 XX Engine Cooling Warning! Risk of Scalding! Only perform this repair work after engine has cooled down. Important!

Catch and dispose of escaping coolant in a suitable container. Observe country-specific waste disposal regulations. 1.

Remove front additional radiator, gearbox heat exchanger and coolant lines.

40 17 XX Engine Cooling Warning! Risk of Scalding! Only perform this repair work after engine has cooled down. Important! Recycling! Wear safety gloves and safety goggles! Coolant emerges when coolant lines are detached. Catch and dispose of escaping coolant in a suitable container. Observe country-specific waste disposal regulations. 1. Remove front bumper. ISTA manual Remove underfloor cover. 3. Remove front central air duct. 4. Remove front additional radiator, gearbox heat exchanger and coolant lines. (Dispose green painted parts) Catch and dispose escaping coolant. Drain cooling system for easier handling. Refill manual 00 XX Service 5. Close free connection with part Use series production hose clamp to secure. 40

The lower line is closed on its exit for

Remove the cap and close thermostat like

Remove series production gearbox oil lines.

Install gearbox oil radiator 2409076 to the

41 17 XX Engine Cooling 6. Remove black painted lines. The lower line is closed on its exit for interior heating with the cap Remove the cap and close thermostat like shown in the drawing. 7. Remove series production gearbox oil lines. (green) 8. Install gearbox oil radiator to the cooling package. Install lines to the cooling package. 9. Drain and catch engine oil. Remove upper part of the oil dipstick holder. 41

17 XX Engine Cooling 10. Trim flexible hose by 30mm. Install upper part with hose clamp.

Install gearbox oil lines 8417320 to the gearbox. 11. Fix lines to the gearbox clamp shell 8417326.

(picture) K G 12. Install bracket for thermostat 7850363 to the engine by using screw M6X16 9904524. 13.

Install gearbox oil lines 8417320 to the thermostat by using clamp shell 8417325. Fasten clamp shell with screw 9905871.

42 17 XX Engine Cooling 10. Trim flexible hose by 30mm. Install upper part with hose clamp. Note: Measurement indicator of engine oil changed. 10. Install O-Ring to the oil lines Install gearbox oil lines to the gearbox. 11. Fix lines to the gearbox clamp shell Use screw from removed lines. Install compensation bracket between shell and parking lock Bowden cable bracket. (picture) K G 12. Install bracket for thermostat to the engine by using screw M6X Install thermostat to the engine. Fix with nuts Install gearbox oil lines to the thermostat by using clamp shell Fasten clamp shell with screw Note direction of the Thermostat. G = Getriebe, Gearbox K = Kühler, Radiator 15. Install oil return line to the upper side of the thermostat. 16. Intstall oil flow line to the lower side of the thermostat. Fasten both lines with screw

17 XX Engine Cooling 18. Install bracket 7853590 by using spacer pin 785358. Located underneath the alternator. Fasten with screw M6X95. Install dual clip 8608773 to the bracket.

43 17 XX Engine Cooling 18. Install bracket by using spacer pin Located underneath the alternator. Fasten with screw M6X95. Install dual clip to the bracket. Fix return and flow line to dual clip. Bundle both lines between bracket and thermostat with plastic clip and screw Install bracket with screw Install front bumper and connect cooling package to gearbox flow and return lines. 21. Check coolant level. 43

44 17 XX Drawings 44

45 17 XX Drawings 45

46 17 XX Topping up oil level. Special tools required: Important! Do not let skin come in contact with transmission oil and do not inhale fuel vapours Wear protective gloves Ensure adequate ventilation Important! Use only ATF3 transmission oil. Conditions for oil adjustment: Initial condition: Transmission oil temperature 30 C to 40 C Final condition: Transmission oil temperature 40 C to 50 C 1. Open Thermostat by removing circlip and cap. 2. Install spacer and close the thermostat with circlip. (Cap is replaced by the spacer) This step is necessary to keep the Thermostat in a open position for bleeding. 3. Continue with standard Service procedure. 00 XX Service (gearbox) Note: Fill system directly with running engine as lines and radiator are empty. 46

47 00 24 Transmission Oil Change Required parts: Quantity Partnumber Description ATF 3 1l 47

00 24 Transmission Oil Change Notice: Risk of burning Avoid skin contact with transmission oil Ventilate the room sufficiently Drain transmission oil: 1. Lift vehicle and make sure it is leveled. 2. Open the transmission oil drain plug and catch oil with a suitable container.

48 00 24 Transmission Oil Change Notice: Risk of burning Avoid skin contact with transmission oil Ventilate the room sufficiently Drain transmission oil: 1. Lift vehicle and make sure it is leveled. 2. Open the transmission oil drain plug and catch oil with a suitable container. Tightening torque 8 Nm 3. Wait for about 5 minutes. (Fill oil during the change, start the engine briefly and repeat the process several times to purge the system.) Fill transmission oil Heat up gearbox in position P with running engine to operating temperature. 48

00 24 Transmission Oil Change Notice: Risk of burning Avoid skin contact with transmission oil Ventilate the room sufficiently Topping transmission oil.

49 00 24 Transmission Oil Change Notice: Risk of burning Avoid skin contact with transmission oil Ventilate the room sufficiently Topping transmission oil. Display the transmission temperature on the steering wheel: Conditions to start: Transmission oil temperature 30 C to 40 C Conditions to finish: Transmission oil temperature 40 C to 50 C Open filler plug with running engine and gear in position P. A: Oil is emerging from the hole in a thin string => Oil level is correct B: Oil is emerging in large quantities => Wait until a thin string emerges C: No oil emerges => Add prescribed transmission oil until the oil emerges as a thin string Fasten the transmission filler screw. Tightening torque 35Nm 49

17 XX Topping up oil level. Special tools required: 2 405 614 7417329 + 7836178 Important!

50 17 XX Topping up oil level. Special tools required: Important! Do not let skin come in contact with transmission oil and do not inhale fuel vapours Wear protective gloves Ensure adequate ventilation Important! Use only ATF3 transmission oil. Conditions for oil adjustment: Initial condition: Transmission oil temperature 30 C to 40 C Final condition: Transmission oil temperature 40 C to 50 C 4. Wait until gearbox temperature is below 25 C. 5. Open Thermostat by removing circlip and cap. 6. Remove spacer. 7. Close Thermostat. 8. Check system for leaks. 50

51 18 11 Exhaust 1. Remove standard exhaust system. 2. Install Exhaust Tighten with clamp

7060601 and screw 7769457 to fix reinforcement 8417286. 2.

52 51 XX Frontsplitter Reinforcement 1. Leave structural reinforcement panel (1) and extension (2) installed to the car. 1 2 Replace screw and nut with C-Clip and screw to fix reinforcement Place reinforcement and drill holes to the front splitter. Fix with screw , washer and nut

Installation instructions, accessories - Fuel driven heater 912-D

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