BMW 2 Series G42 Coupe 218i 220d 220i 230i 230i xDrive M240i M240i xDrive Workshop Repair Service Manual 2021-Present PDF - MBMW2G42OPEK.zip
A full factory-level repair and service guide, complete with Electrical Wiring Diagrams, covering the BMW 2 Series (G42) Coupé in 218i, 220d, 220i, 230i, 230i xDrive, M240i, and M240i xDrive trims — packed with every technical detail you need to service, troubleshoot, fix, and rebuild your car to the same standard as trained technicians.
This BMW 2 Series 218i, 220d, 220i, 230i, 230i xDrive, M240i, M240i xDrive (G42) Coupé workshop service and repair manual contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 15,569 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
000 - MAINTENANCE & GENERAL NOTES.......3
0 operating fluid overview.......8
00 Safety information for working on vehicles with automatic engine start-stop function (MSA).......20
0000... Driving on a race track.......22
0000... Microencapsulated screws.......26
0000... Vehicle care measures for inventory vehicles (new and used vehicles) as well as vehicles to be taken off the road that are in the hands of customers.......27
0000... Work instruction for removing the protective film.......29
0000009 Free pre-delivery check.......30
0000101 Service, Seasonal Check (only for German market).......38
0000105 Standard scope of service.......39
0000252 BMW engine oil service without supplementary service.......46
0000262 BMW rapid inspection.......58
0000602 Service - air filter element.......59
0000606 Servicing particulate filter.......64
0000610 Engine oil service.......77
0000612 Service - front brakes.......91
0000614 Service - rear brakes.......106
0000616 Service - microfilter.......122
0000618 Service - brake fluid.......129
0000622 Service - spark plugs.......136
0000624 Service - vehicle check.......147
0000741 Suspension block delivery inspection.......159
0000742 Pre-delivery check of service and parking brakes with transport and immobilisation periods of 3-6 weeks.......160
0000744 Pre-delivery check of service and electromechanical holding brake for transport and immobilisation periods of more than 6 weeks.......161
0001... Symbols used and information in repair instructions.......162
0002000 Raising vehicle with trolley jack.......165
0002001 Raising the vehicle using a vehicle lift.......170
0011... Information for handling the documents repair instructions, technical data, AZD.......175
0011237 Checking _ topping up oil level in automatic transmission.......177
0011259 Oil change in rear axle final drive incl. used oil disposal.......183
0012200 (Annual) vehicle inspection within framework of DGUV Regulation 70.......189
1100300 Engine oil consumption measurement.......190
5.1.1 Axles.......192
6100... Notes on handling the high pressure cleaner.......195
6112... Information on intelligent battery sensor (IBS).......196
6120... Notes on AGM battery.......197
6400... Information on using cleaning agent _ paints (personal protection equipment).......200
6450... Instructions for handling R1234yf refrigerant.......202
6450... Notes on the refrigerant (R134a, R1234yf) and refrigerant oil.......203
6450... Safety information for handling refrigerant R1234yf.......205
6453... Instructions for desiccant insert replacement.......206
6453... Instructions for replacement of air conditioning capacitors and radiator _ coolers.......207
7.1.1 Installation safety of the seat belts _ seat belt buckles.......208
7.1.2 Status of the seat belts _ seat belt buckles.......212
7.1.3 Belt force limiter.......214
7.1.4 Seat belt tensioner.......218
7.1.5 Airbag.......222
7.1.6 Supplementary restraint systems (SRS).......227
7.11 Odometer (if present).......231
7.12 Driving dynamics control (Electronic Stability Program, ESP) (if installed _ required).......235
Abbreviations.......239
Annual vehicle inspection in compliance with labour protection and accident prevention according to Operating Safety Ordinance BGV D 29 and BBG 916.......241
Arguments pertaining to engine oil consumption.......243
BMW Schnellinspektion.......245
Battery recharging intervals for booth vehicles, battery charging calendars and battery tags (12-V battery, high-voltage battery unit).......246
Brake fluid - Operating Fluids Specification.......248
CBS general - Reset is lost.......249
Changed emissions test indicator BMW Condition Based Service.......250
Check gas pressure spring for bonnet (with active pedestrian protection (SA8TF)).......251
Drawbar load sign omitted All with options 235 and 3AC.......252
Emergency Services (BMW _ MINI) from issue September 2009.......253
Engine oil - varying colours _ smell after initial filling in the works.......254
Engine oil service - countries with higher levels of dust Check the air filter element for contamination.......255
Engine oil service _ vehicle check service - procedure for resetting the service interval indicator.......256
Extract from BMW Group Standard GS 90003-2.......257
FEB-FEB-NED-TESTMODULE-AKTUELL.......258
Final drive oil - new oil quality from 07 _ 2011.......259
Form for equipotential bonding screw connections.......260
General and legal information on performing the periodic exhaust-gas (emissions) test in EU countries.......262
Handling fault messages _ Check Control messages for Run Flat Indicator RDC (SA2VB).......267
Handling the acoustic camera.......270
IMIB_Next.......272
Ignition key data tapping on CBS vehicles.......275
Increasing the oil capacity during engine oil change (EU28+).......280
Inflation pressure measurement in vehicles with tyre pressure display RDC (SA2VB).......281
List of contents.......282
M10 and M10 x 1 - maximum tightening torques acc. to BMW GS 90003-2.......283
M12 and M12x1.5 - maximum tightening torques acc. to BMW GS 90003-2.......284
M14 and M14x1.5 - maximum tightening torques acc. to BMW GS 90003-2.......285
M16 and M16x1.5 - maximum tightening torques acc. to BMW GS 90003-2.......286
M18 and M18x1.5 - maximum tightening torques acc. to BMW GS 90003-2.......287
M4 and M5 - maximum tightening torques acc. to BMW GS 90003-2.......288
M6 and M7 - maximum tightening torques acc. to BMW GS 90003-2.......289
M8 and M8 x 1 - maximum tightening torques acc. to BMW GS 90003-2.......290
Main group 00.......291
New Maintenance Records service booklet and maintenance documentation All models.......292
New repair methods ”Gluing _ Riveting” on steel bodies.......293
Overview of accident-related documents.......295
Parking brake function check - new procedure in the standard service scope _ rear brake service.......301
Repair on the gear selector switch.......302
Service Sheets - Condition-based Service _ Pre-delivery Check (ISTA, ISPA, Commercial Service Data).......303
Service Vorabcheck zur Hauptuntersuchung.......305
Service contents _ contents pre-delivery check BMW 2 Series Coupé (G42).......306
Service intervals for countries with low fuel grade (SA988 _ SA8KE, SA8KM, SA984, SA8KK, SA8KL, SA8KH, SA8KP).......310
Service vehicle check falls due after CBS reset of engine oil service.......315
Standard scope of service - Reduction of the work scope in electrified vehicles.......316
Standard work scope - expansion of work scope (with slide _ tilt sunroof and panorama glass roof).......317
Supplement for target exhaust emissions inspection data of BMW and MINI vehicles from 04 _ 2009. Modified test specifications for petrol lean-mixture engines N43 and N53. Test procedure for hybrid vehicles.......318
Test instructions for the exhaust gas test (AU) on BMW vehicles with diesel engines from European emission classification EURO 6.......321
Test instructions for the exhaust gas test (AU) on BMW vehicles with petrol engines from European emission classification EURO 6.......328
Test instructions for the exhaust-gas (emissions) test on BMW vehicles with petrol engines.......335
Visible corrosion on vehicle add-on parts.......346
Wiring harness repair on exterior mirror.......347
011 - ENGINE .......348
00 Safety information for working on vehicles with automatic engine start-stop function (MSA).......353
0011... Information for handling the documents repair instructions, technical data, AZD.......355
10.0 SAE 10W-60.......357
11 operating fluid overview.......359
11. . . . . Equipment recoding special tool number of the transverse member for fixing the engine in the installation location.......362
1100 Overview of Technical Data.......363
1100 Overview of tightening torques.......379
1100... Engine oil consumption measurement.......384
1100... Handling components after flood damage.......385
1100... Overview of consumables (Electronic Parts Catalogue).......386
1100039 Check compression of all cylinders.......390
1100050 Removing and installing engine.......402
1100300 Engine oil consumption measurement.......520
1100682 Checking pressure loss on all cylinders (after vehicle diagnosis).......522
1100895 Start-up of the oil circuit.......547
1111 Overview of Technical Data.......548
1111 Overview of tightening torques.......552
1112 Overview of Technical Data.......560
1112 Overview of tightening torques.......564
1112000 Removing and installing _ sealing cylinder head cover.......582
1112001 Replace the cylinder head cover.......671
1112070 Remove and install _ replace acoustic cover.......761
1112100 Removing and installing cylinder head.......765
1112154 Disassemble and assemble cylinder head.......912
1112502 Disassemble and assemble cylinder head (cylinder head removed) (without removing the valves).......913
1112670 Cleaning intake ports (after vehicle diagnosis).......991
1112729 Checking cylinder head for watertightness (cylinder head dismantled).......1123
1112800 Clean cylinder head intake channels and intake plenums (after vehicle diagnosis).......1129
1113 Overview of Technical Data.......1199
1113 Overview of tightening torques.......1200
1113000 Remove and install, seal or replace oil sump.......1208
1114 Overview of Technical Data.......1289
1114 Overview of tightening torques.......1290
1114270 Removing and installing _ replacing the rear acoustic cover.......1296
1114290 Removing and installing _ renewing front engine acoustic cover.......1302
1114295 Remove and install _ replace the acoustic cover for the oil sump.......1311
1114300 Remove and install _ replace the acoustic cover for the injectors.......1360
1115 Overview of Technical Data.......1364
1115 Overview of tightening torques.......1365
1115001 Replace engine ventilation line.......1366
1115510 Measuring internal engine pressure (After vehicle diagnosis).......1377
1115510 Measuring internal engine pressure.......1387
1121 Overview of Technical Data.......1394
1121... Table for classifying the guide bearing shells 4 (B58TÜ1).......1400
1121... Table for classifying the main bearing shell 7 (B58TÜ1).......1402
1121... Table for classifying the main bearing shells 1, 2, 3, 5, 6 (B58TÜ1).......1404
1122 Overview of tightening torques.......1406
1123 Overview of tightening torques.......1408
1124 Overview of tightening torques.......1411
1125 Overview of Technical Data.......1416
1125671 Replacing piston rings on all pistons (S55).......1430
1127 Overview of tightening torques.......1432
1128010 Replacing drive belt for alternator.......1435
1128020 Replacing alternator drive belt tensioner.......1445
1130 Overview of tightening torques.......1469
1131 Overview of tightening torques.......1470
1131... Notes on checking and adjusting the timing (B36, B37, B38, B46, B47, B48).......1483
1131005 Check the timing of the camshaft(s).......1485
1131028 Removing and installing _ replacing exhaust camshaft.......1581
1131090 Remove and install _ replace chain tensioner piston.......1683
1131505 Adjusting the timing of the camshaft(s) (for work no. 11 31 005 _ 508).......1721
1133050 Removing and installing _ replacing all rocker arms.......1735
1134552 Removing and installing _ replacing all valves (cylinder head removed).......1844
1134560 Replacing all valve stem seals (cylinder head removed).......1921
1134715 Replace all valve springs (cylinder head removed).......1991
1136 Overview of tightening torques.......2061
1136042 Removing and installing _ replacing intake adjuster.......2066
1136044 Remove and install _ replace the exhaust camshaft adjuster.......2190
1136046 Removing and installing _ replacing the intake and exhaust camshaft adjusters.......2314
1136125 Removing and installing _ replacing intake VANOS central valve.......2440
1136126 Removing and installing _ replacing the Vanos central valve on the exhaust side.......2563
1136127 Removing and installing _ replacing both Vanos central valves (if necessary on the right).......2686
1136658 Removing and installing _ replacing both actuators (after vehicle diagnosis).......2810
1137 Overview of tightening torques.......2830
1137020 Removing and installing _ replacing servomotor for eccentric shaft.......2833
1140000 Checking engine oil pressure.......2847
1141 Overview of tightening torques.......2860
1142 Overview of tightening torques.......2869
1142240 Attaching and detaching _ sealing or replacing the oil return line for the high pressure exhaust turbocharger.......2884
1151 Overview of tightening torques.......2965
1153 Overview of tightening torques.......2971
1153942 Removing and installing (replacing) the connecting branch on the engine block (Draining and topping up coolant, see 17 00 ...).......2980
1161 Overview of Technical Data.......3045
1161 Overview of tightening torques.......3047
1161102 Removing and installing _ replacing engine ventilation line adapter with heating element.......3056
1161730 Leakage test for the intake system.......3083
1162 Overview of tightening torques.......3088
1165 Overview of tightening torques.......3091
1165001 Remove and install both exhaust turbochargers with exhaust manifold.......3108
1165020 Damage on the exhaust turbocharger due to obstructed oil supply lines.......3184
1165803 Replace electrical controller drive for wastegate (after vehicle diagnosis) (cyl. 1-4, if necessary cyl. 1-6).......3186
1171100 Remove and install _ replace the exhaust-gas recirculation cooler.......3204
1178 Overview of tightening torques.......3233
1178510 Replacing oxygen sensor (after vehicle diagnosis).......3236
1178610 Replace monitoring oxygen sensor (after vehicle diagnosis).......3248
4.0 BMW Longlife-01.......3264
5.0 BMW Longlife-01 FE.......3267
6.0 BMW Longlife-04.......3269
6.1.9 Engine performance.......3275
7.0 BMW Longlife-12 FE.......3279
8.0 BMW Longlife-14 FE+.......3281
9.0 BMW Longlife-17 FE+.......3283
Adapter.......3285
Assembly tool.......3286
BMW Quality Longlife-04 All.......3287
Basic body.......3288
Basket.......3289
Blasting material device.......3290
Bush.......3291
Card.......3292
Cartridge gun.......3293
Case.......3294
Chain tensioner.......3295
Cleaning the cylinder head intake ports and the combustion chamber with the walnut blaster.......3296
Crankshaft and Bearings.......3297
Emissions-control, Lambda oxygen sensor.......3298
Engine identification.......3299
Fan.......3305
Intake manifold.......3306
Leak-testing the air-intake system.......3307
Main group 11.......3310
Overview of released engine oils for BMW Group engines.......3311
Repair notes to renew the cylinder head.......3312
Repair notes to renew the engine.......3315
Replacing guide bearing.......3317
Vacuum supply All models.......3320
012 - ENGINE ELECTRICAL SYSTEM.......3323
00 Safety information for working on vehicles with automatic engine start-stop function (MSA).......3325
0011... Information for handling the documents repair instructions, technical data, AZD.......3327
1100... Handling components after flood damage.......3329
12 operating fluid overview.......3330
1200... Instructions for removal and replacement of control units.......3331
1200... Notes _ information on start assistance (jump starting).......3332
1212 Overview of tightening torques.......3333
1212011 Removing and installing _ renewing all spark plugs.......3334
1213 Overview of tightening torques.......3348
1213511 Replacing an ignition coil (after vehicle diagnosis).......3349
1214 Overview of tightening torques.......3358
1214521 Replace crankshaft sensor (after vehicle diagnosis).......3361
1214523 Replacing the camshaft sensor of the intake camshaft (after vehicle diagnosis).......3369
1214524 Replacing the camshaft sensor of the exhaust camshaft (after vehicle diagnosis).......3377
1214550 Replacing the control unit of the Digital Motor Electronics (After vehicle diagnosis) (without programming _ encoding, see 61 00 ...).......3384
1214602 Replacing knock sensor (after vehicle diagnosis) (cylinders 1+3).......3399
1214700 Encoding the control unit (DME _ DDE).......3428
1214705 Programming the control unit (DME _ DDE).......3429
1231 Overview of tightening torques.......3430
1231020 Removing and installing _ replacing alternator.......3434
1232 Overview of tightening torques.......3463
1236 Overview of tightening torques.......3464
1241 Overview of Technical Data.......3469
1241 Overview of tightening torques.......3470
1241041 Replacing the engagement solenoid switch.......3473
1242 Overview of tightening torques.......3474
1242540 Replacing safety battery terminal (SBK).......3478
1251 Overview of tightening torques.......3482
1252 Overview of tightening torques.......3487
1261 Overview of tightening torques.......3492
1261280 Removing and installing _ replacing oil pressure switch.......3495
1263586 Replacing power distribution box (after vehicle diagnosis).......3504
1290 Overview of tightening torques.......3514
6100... Notes for disconnecting and connecting the vehicle battery.......3518
6100... Safety information on handling hybrid cars.......3519
6113... Unlocking and disconnecting various plug connections in electrical and hybrid vehicles.......3521
Form for equipotential bonding screw connections.......3525
Main group 12.......3527
Spark Plugs.......3528
013 - FUEL PREPARATION & CONTROL.......3529
00 Safety information for working on vehicles with automatic engine start-stop function (MSA).......3531
0011... Information for handling the documents repair instructions, technical data, AZD.......3533
1331... Notes regarding the fuel pressure test (reference pressure surrounding area).......3535
1331035 Removing and installing _ replacing the fuel feed line.......3537
1332 Overview of tightening torques.......3556
1351017 Removing and installing high pressure pump.......3557
1353 Overview of tightening torques.......3586
1353... Clean the cylinder heads in the area of injectors to prevent sand _ dust contamination.......3601
1353080 Remove and install _ replace rail at cylinder 1-3.......3603
1353081 Remove and install _ replace rail at cylinder 4-6.......3639
1353082 Remove, install _ replace both rails.......3676
1353180 Replace pressure line (between high pressure pumps and pressure accumulator).......3729
1353301 Remove, install _ replace injector(s) in the injection system at cyl. 1-3.......3746
1353302 Remove, install _ replace injector(s) in the injection system at cyl. 4-6.......3782