Preparations for PWC -mandatory- Required parts: Quantity Partnumber Description Fire extinguisher 1 No additional parts required Triangle net 1 7211 8424776 Triangle net Schroth Racing Battery cover 1 5177 8417310 Battery cover 4 4131 7742891 Rivet nut 4 1100 7742139 Oval-head screw Boost pressure sensor 1 1161 8430122 Adapter for boost sensor 1 1161 8430123 O-Ring 9.5x2 2 4100 8421746 Oval head screw M6x14 Torque control logging 1 8130 8327321 GWS cable 1
31 10 Tension struts uniball beared -mandatory- Required parts: Quantity Partnumber Description 1 31 10 8417235 Tension Strut FA left 1 31 10 8416802 Joint bearings 2 31 10 8416803 Support ring 1 31 10 8417236 Tension Strut FA right 1 31 10 8416802 Joint bearings 2 31 10 8416803 Support ring 2
32 10 Steering gear -mandatory- Required parts: Quantity Part Number Description 1 3210 6886290 EPS Sportlenkung (Steering gear) ThyssenKrupp 2 3210 8417281 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 bearings LH 2 33 30 8332900 Nut M16x1,5 10 RH 2 33 30 8332901 Nut M16x1,5 10 LH Wishbone 2 33 30 8417247 Wishbone 2 33 30 8417241 Joint bearings RH 2 33 30 8310772 Joint bearings LH 2 33 30 8332900 Nut M16x1,5 10 RH 2 33 30 8332901 Nut M16x1,5 10 LH 4
33 10 Rear Suspension -mandatory- Required parts: Quantity Partnumber Description Trailing arm 2 33 30 8417250 Trailing arm 2 33 30 8417241 Joint bearings RH 2 33 30 8310772 Joint bearings LH 2 33 30 8332900 Nut M16x1,5 10 RH 2 33 30 8332901 Nut M16x1,5 10 LH Camber control arm 2 33 30 8417254 Camber control arm 2 33 30 8310772 Joint bearings LH 2 33 30 8332901 Nut M16x1,5 10 LH Track link 2 33 30 8417261 Track link 2 33 30 8417264 Joint bearings RH 2 33 30 8310772 Joint bearings LH 2 33 30 8332900 Nut M16x1,5 10 RH 2 33 30 8332901 Nut M16x1,5 10 LH For installation of the track link use following screw 2 41 00 8427181 Screw M12X1,5X65 10.9 2 41 00 8427203 Nut M12 5
51 62 Rear Wing -mandatory- Required parts: Quantity Partnumber Description 1 51 62 8 065 379 Rear wing 2 51 48 8417322 Side plates 4 41 00 8422038 Oval head screws Bracket 1 51 48 8417323 Bracket LH 1 51 48 8417324 Bracket RH Rear wing to bracket 4 11 12 7730917 Oval head screws Bracket to the trunk 4 41 00 8421771 Cylinder screw M8x18 4 41 00 8427217 Washer M8 Trunk 1 41 62 8417227 Trunk with bore for the rear wing 6
Preparations for PWC -mandatory- Required parts: Quantity Partnumber Description Cooling liquid Screw locking 7
18 11 Exhaust without catalytic converter - option - Required parts: Quantitiy Part Number Description 1 1811 8416477 ZB exhaust w/o cats 1 1800 8416019 Clamp 8
51 XX Frontsplitter Reinforcement - option - Required parts: Quantity Partnumber Description 1 5175 8417286 Splitter Reinforcement 8 4100 8422052 Screw M6x16 5 4100 8427227 Washer M6 5 1100 2190417 Kaynut M6 2 0711 9905184 Screw 3 4135 7060601 C-Clip 9
17 XX Engine Cooling - option - Please note: Hot weather cooling package is in development. Estimated Release mid-2017. Required parts: Quantity Part number Description 1 1721 2409076 Gearbox oil radiator 1 1722 7856727 Oil pipes coupling radiator 1 1722 7853889 Oil pipes thermostat coupling 1 1722 7853890 Oil pipes thermostat coupling (return flow) 1 1722 7592723 Thermostat 2 1711 8417320 Pipes Gearbox Thermostat 4 1722 7613656 O-Ring 13,94X2,62 Pipe cover 1 1711 8417327 Pipe Cover cooling hose Thermostat Fixation 1 1722 7850363 Bracket Thermostat 3 0711 9904524 Hexa screw M6X16 8.8 2 0712 9904381 Nut M5 Oil pipe fixation 1 1712 8608773 Double clip 1 1722 7853590 Bracket pipes 1 1722 7853589 Distance bush 1 0711 9905433 Hexa screwm6x95 1 1722 7519270 Plastic bracket gearbox pipes 1 1722 7853588 Connector Gearbox radiator 10
17 XX Engine Cooling - option - Required parts: Quantity Part number Description 1 0711 9905014 Cylinder screw M6X25 1 0711 9904524 Hexagon Screw M6X16 2 0711 9905871 Hexagon Screw M6X25 1 1711 8417325 Clamp shell 1 1711 8417326 Clamp shell 1 1711 8417328 Compensation bracket Bowden cable 1 3331 1108205 Washer Special tools for bleeding 1 8331 7417329 Tool for bleeding 1 1161 7836178 O-Ring 1 2 405 614 11
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 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
Preparations for PWC Additional triangle net: 7211 8424776 4. 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). Tag the four bore holes and drill them with 7,8 mm diameter. 2. Insert rivet nuts 7742891. 3. Install the battery cover with screws 7742139. 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. Secure joint ball with support ring 8416803 (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 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. 32 30 6 778 609 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 6886290. 17
32 10 Steering gear Tools required: -323160 4. Remove gaiter from steering gear and slide back. 5. Undo the joint (1) using special tools 323160 at the steering box rack. 6. Insert steering stop 8417281 between the tie rod head and the steering gear and fasten with special tool 323160. Tightening torque: 105 Nm 7. Complete steering gear. Note: The steering stop of Spec. 2014/15 to Spec. 2016 ZF is different and has to be replaced.. 18
32 10 Steering gear After installation: Steering gear has to be initialized by BMW Motorsport flashing tool. Adjust to basic setup. 19
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. 2016 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
33 10 Rear Suspension 6. Use the screws and old link to lock the screw connection. Tightening Torque: 200 Nm ±50 Nm Use Loctite 270. 7. 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. 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 270. 14.Tag fasten screws with special color. 15.Install differential radiator. 22
33 10 Rear Suspension Assemble advice. 8417247 Wishbones RA 289mm (+/- 2) mm 219 8417250 Trailing arm RA 330mm (+/- 2) mm 23
33 10 Rear Suspension Assemble advice. 8417254 Chamber link RA 416 (+/- 2) mm 8417242 Trailing arm RA 245mm (+/- 2) mm 174,5 24
33 10 Rear Suspension Assemble advice. 8417261 Tack rod 298 25
33 10 Rear Suspension Mandatory length of the links. 8417254 Chamber link RA 416 (+/- 2) mm 8417242 Trailing arm RA 245mm (+/- 2) mm 8417247 Wishbones RA 289mm (+/- 2) mm 8417250 Trailing arm RA 330mm (+/- 2) mm 26
Vehicle Setup Setup sheet Spec. 2016 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 / 20 132 / 44 2,4 / 2,3 34,8 / 33,4 265/660-18 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
33 XX Rear axle Description Thread Regulation Torque Shock absorber on guide support Loctite 270 50Nm 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 90 165Nm 165Nm 100Nm 90 100Nm 100Nm 90 100Nm 100Nm 90 100Nm 100Nm 100Nm Uniball to link (nut) + / - 50Nm Loctite 270 200Nm Differential on rear axle support front Loctite 270 100Nm 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. 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 8417227. 4. Install the trunk 8417227. Install with almost two persons. Adjust to the old screwing points and fasten the trunk. 5. Install the brackets, 8417323 left and 8417324 right, of the rear wing to the trunk by using the screws 8421771 and washer 8427217. Tightening Torque: 50 Nm Secure with Loctite and check Screwing after the first 100km 29
51 62 Rear Wing 7. Fasten the rear wing 8065379 with the screws 7730917 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 8417278 are bolted with the screws 8433038 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
00 17 Coolant Change Required parts: Quantity Partnumber Description 8 8319 2211191 Coolant liquid (not for PWC) 2 1153 7793373 Vent screw Special tools 1 8839 2152473 Befüllgerät 1 8830 0494642 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. 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
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
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 6. 4. 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. Install O-Ring 8430123 to the adapter 8430122. 2. Remove engine cover. 3. Remove series productions pressure sensor from the air intake manifold. 4. Install pressor sensor to the adapter 8430122. 5. Cut bracket as shown. Picture 6. Install the adapter 8430122 to air intake manifold with screws 8421746. 7. 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 8430122. 9. 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). loosen center console loosen GWS cover Remove GWS from bracket (4 screws) 2. Disconnect GWS and connect 8327321. 3. Install GWS to bracket and tighten c enter console and GWS cover. 4. Contact PWC for wiring to Motec Logger. 36
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
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
Options Installation 39
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 - 51 11 165 2. 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 8417327. Use series production hose clamp to secure. 40
17 XX Engine Cooling 6. Remove black painted lines. The lower line is closed on its exit for interior heating with the cap 7799184. Remove the cap and close thermostat like shown in the drawing. 7. Remove series production gearbox oil lines. (green) 8. Install gearbox oil radiator 2409076 to the cooling package. Install lines 7856727 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. Note: Measurement indicator of engine oil changed. 10. Install O-Ring 7613656 to the oil lines 8417320. Install gearbox oil lines 8417320 to the gearbox. 11. Fix lines to the gearbox clamp shell 8417326. Use screw from removed lines. Install compensation bracket 8417328 between shell and parking lock Bowden cable bracket. (picture) K G 12. Install bracket for thermostat 7850363 to the engine by using screw M6X16 9904524. 13. Install thermostat 7592723 to the engine. Fix with nuts 9904381. 14. Install gearbox oil lines 8417320 to the thermostat by using clamp shell 8417325. Fasten clamp shell with screw 9905871. Note direction of the Thermostat. G = Getriebe, Gearbox K = Kühler, Radiator 15. Install oil return line 7853890 to the upper side of the thermostat. 16. Intstall oil flow line 7853889 to the lower side of the thermostat. Fasten both lines with screw 9905871. 42
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. Fix return and flow line to dual clip. Bundle both lines between bracket and thermostat with plastic clip 7519270 and screw 9905014. 19. Install bracket 7853588 with screw 9904524. 20. Install front bumper and connect cooling package to gearbox flow and return lines. 21. Check coolant level. 43
17 XX Drawings 44
17 XX Drawings 45
17 XX Topping up oil level. Special tools required: 2 405 614 7417329 + 7836178 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 7417329 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
00 24 Transmission Oil Change Required parts: Quantity Partnumber Description 9 8322 2305397 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. 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. 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! 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
18 11 Exhaust 1. Remove standard exhaust system. 2. Install Exhaust 8416477. 3. Tighten with clamp 8416019. 51
51 XX Frontsplitter Reinforcement 1. Leave structural reinforcement panel (1) and extension (2) installed to the car. 1 2 Replace screw 7742139 and nut 1313170 with C-Clip 7060601 and screw 7769457 to fix reinforcement 8417286. 2. Place reinforcement 8417286 and drill holes to the front splitter. Fix 8417286 with screw 8422052, washer 8427227 and nut 2190417. 52