BMW 2 Series Active Tourer F46 MPV Workshop Service Repair Manual 2015 Onward 216i 218i 220i 225i 225xe 216d 218d 220d PDF - MBMW2F46OPEK.zip

A full-service workshop and repair guide, complete with electrical wiring diagrams, covering the BMW 2 Series Active Tourer (F46-series) models 216i, 218i, 220i, 225i, 225xe PHEV, 216d, 218d, and 220d. Everything you need to service, troubleshoot, fix, and rebuild these vehicles to the same standard as professional technicians.

This workshop, service, and repair manual for the BMW 2 Series Active Tourer (F46-series) 216i, 218i, 220i, 225i, 225xe PHEV, 216d, 218d, and 220d petrol and diesel engines 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.

BMW 2 Series Active Tourer (Mode F46) MPV Repair Service Manual 2015 & UP.pdf

PRODUCT DETAILS:

Total Pages: 5,571 pages

File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)

Language: English

Petrol engines

Model Years Type/code Power, torque at rpm

216i 2016– 1,499 cc (91.5 cu in) I3 single-scroll turbo (B38B15) 109 PS (80 kW; 108 hp) at 4,100–6,000 rpm, 190 N⋅m (140 lb⋅ft) at 1,250 rpm

218i 2014– 1,499 cc (91.5 cu in) I3 single-scroll turbo (B38A15M0) 136 PS (100 kW; 134 hp) at 4,500–6,000 rpm, 220 N⋅m (162 lb⋅ft) at 1,250 rpm

220i 2014– 1,998 cc (121.9 cu in) I4 twin-scroll turbo (B48B20) 192 PS (141 kW; 189 hp) at 5,000–6,000 rpm, 280 N⋅m (207 lb⋅ft) at 1,350 rpm

225i 2014– 1,998 cc (121.9 cu in) I4 twin-scroll turbo (B48B20) 231 PS (170 kW; 228 hp) at 5,000–6,000 rpm, 350 N⋅m (258 lb⋅ft) at 1,250 rpm

225xe PHEV 2015– 1,499 cc (91.5 cu in) I3 twin-scroll turbo (B38A15M0 Hybrid) + electric motor 136 PS (100 kW; 134 hp) at 4,400–6,000 rpm , 220 N⋅m (162 lb⋅ft) at 1,250–4,300 rpm (Engine)

Diesel engines

Model Years Type/code Power, torque at rpm

216d 2014– 1,496 cc (91.3 cu in) I3 turbo (B37D15) 116 PS (85 kW; 114 hp) at 4,000 rpm, 270 N⋅m (199 lb⋅ft) at 1,750 rpm

218d 2014– 1,995 cc (121.7 cu in) I4 turbo (B47D20) 150 PS (110 kW; 148 hp) at 4,000 rpm, 350 N⋅m (258 lb⋅ft) at 1,750 rpm

220d 2014– 1,995 cc (121.7 cu in) I4 turbo (B47D20) 190 PS (140 kW; 187 hp) at 4,000 rpm, 400 N⋅m (295 lb⋅ft) at 1,750 rpm

MAIN SECTIONS

00 - MAINTENANCE & GENERAL NOTES....3

0 operating fluid overview....7

0000... Brake lines and connections visual inspection for leaks, damage, attachment and correct position....21

0000... CBS reset....22

0000... Check horn, headlight flashers and hazard warning flashers....25

0000... Check windscreen wash _ wipe system....26

0000... Checking coolant level and concentration, correcting if necessary....27

0000... Checking instrument _ inscription lighting, interior _ luggage compartment _ glove box lights and blower....28

0000... Checking lighting system....29

0000... Checking of road safety (test drive)....30

0000... Seat belts Check condition of seat belt strap, check function of automatic reel, seat belt locking reel, seat belt buckle, seat belt clip and, if necessary, seat belt clasp....31

0000... Steering components Check for play, damage and, if nec., tightness....33

0000... Tyres checking and if necessary correcting inflation pressure, checking condition, tread depth and pattern....35

0000... Underbody incl. all visible components Check for damage, correct position, tightness, corrosion....36

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....37

0000... When driving on a race track....41

0000... Windscreen washer system checking fluid level, topping up if necessary....47

0000... Work instruction for removing the protective film....48

0000009 Pre-delivery check....50

0000105 Standard scope of service....55

0000602 Service - air filter element....57

0000610 Service - engine oil....58

0000612 Service - front brakes....60

0000614 Service - rear brakes....62

0000616 Service - microfilter....64

0000618 Service - brake fluid....65

0000622 Service - spark plugs....66

0000624 Service - vehicle check....67

0000685 Service coil springs (only for SA13A load police open or SA13B load emergency physician)....69

0001... Symbols used and information in repair instructions....70

0011276 Oil change in the twin-clutch gearbox (DKG) (7DTC300)....75

0011277 Checking _ topping up oil level in twin-clutch gearbox (DKG) (7DTC300)....81

5.1.1 Axles....86

7.1.1 Installation safety of the seat belts _ seat belt buckles....89

7.1.2 Status of the seat belts _ seat belt buckles....93

7.1.3 Belt force limiter....96

7.1.4 Seat belt tensioner....97

7.1.5 Airbag....98

7.1.6 Supplementary restraint systems (SRS)....101

7.11 Odometer (if present)....102

7.12 Driving dynamics control (Electronic Stability Program, ESP) (if installed _ required)....103

Abbreviations....104

Addition to special tools cabinet All model series....108

Arguments pertaining to engine oil consumption....110

BMW maintenance content F45, F46....113

Brake fluid - Operating Fluids Specification....115

Brake fluid service - extension of the first brake fluid interval to 36 months....116

Brake fluid service ? Bonnet gas strut check with active pedestrian impact mitigation?(SA8TF)....118

CBS general - Reset is lost....120

Changed emissions test indicator BMW Condition Based Service....121

Discontinuation of Service Booklet for vehicles with Central?Information?Display?(CID)....122

Emergency Services (BMW _ MINI) from issue September 2009....124

Engine oil - varying colours _ smell after initial filling in the works....125

Engine oil service - countries with higher levels of dust Check the air filter element for contamination....126

Engine oil service - new scope of maintenance work Replace the battery of the radio remote control....127

Engine oil service _ vehicle check service - procedure for resetting the service interval indicator....129

Extract from BMW Group Standard?GS?90003-2....130

FEB-FEB-NED-TESTMODULE-AKTUELL....132

General and legal information on performing the periodic exhaust-gas (emissions) test in EU countries....133

Handling fault messages _ Check Control messages for Run Flat Indicator?RDC (SA2VB)....139

Handling the acoustic camera....142

IMIB_Next....144

Ignition key data tapping on CBS vehicles....147

Inflation pressure measurement in vehicles with tyre pressure display?RDC?(SA2VB)....153

List of contents....155

M10 and M10 x 1 - maximum tightening torques acc. to BMW GS 90003-2....157

M12 and M12x1.5 - maximum tightening torques acc. to BMW GS 90003-2....158

M14 and M14x1.5 - maximum tightening torques acc. to BMW GS 90003-2....159

M16 and M16x1.5 - maximum tightening torques acc. to BMW GS 90003-2....160

M18 and M18x1.5 - maximum tightening torques acc. to BMW GS 90003-2....161

M4 and M5 - maximum tightening torques acc. to BMW GS 90003-2....162

M6 and M7 - maximum tightening torques acc. to BMW GS 90003-2....163

M8 and M8 x 1 - maximum tightening torques acc. to BMW GS 90003-2....164

Main group 00....165

Maintenance contents F46 public sector vehicles (SA13A vehicle load police open, SA13B vehicle load emergency doctor)....166

New Maintenance Records service booklet and maintenance documentation All models....168

Parking brake function check - new procedure in the standard service scope _ rear brake service....170

Service Sheets - Condition-based Service _ Pre-delivery Check (ISTA, ISPA, Commercial Service Data)....172

Service intervals for countries with low fuel grade (SA988 _ SA8KE, SA8KM, SA984, SA8KK, SA8KL, SA8KH, SA8KP)....174

Standard work scope - expansion of work scope (with slide _ tilt sunroof and panorama glass roof)....180

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....182

Test instructions for the exhaust gas test (AU) on BMW vehicles with diesel engines from European emission classification EURO 6....186

Test instructions for the exhaust gas test (AU) on BMW vehicles with petrol engines from European emission classification EURO 6....199

Workshop Equipment - Planning Documentation....212

Workshop equipment sales....213

11 - ENGINE ....214

11 operating fluid overview....220

11. . . . . Equipment recoding special tool number of the transverse member for fixing the engine in the installation location....222

1100 Overview of Technical Data....224

1100 Overview of tightening torques....234

1100... Engine oil change (B48A)....238

1100... Engine oil consumption measurement....244

1100... Overview of consumables (Electronic Parts Catalogue)....245

1100010 Draining and adding engine oil _ PREMIUM....251

1100039 Checking compression of all cylinders (B48A)....261

1100039 Checking compression of all cylinders (B48A, B46A)....264

1100050 Removing and installing engine with transmission (B48A)....267

1100300 Engine oil consumption measurement....290

1100670 Securing engine in installation position....298

1111 Overview of Technical Data....305

1111 Overview of tightening torques....307

1112 Overview of Technical Data....313

1112 Overview of tightening torques....316

1112000 Removing and installing _ sealing cylinder head cover (B48A)....330

1112100 Removing and installing cylinder head (B48A)....337

1112101 Replacing cylinder head gasket (B48A)....347

1112719 Grinding cylinder head lower face (B48A)....349

1112729 Checking cylinder head on watertightness (B48A)....351

1113 Overview of tightening torques....354

1113000 Removing and installing, sealing or replacing oil sump (B48A)....361

1114 Overview of tightening torques....369

1114005 Replacing front crankshaft seal (B48A)....374

1114110 Removing and installing, sealing _ replacing the rear timing case cover (B48A )....377

1114151 Replacing the crankshaft seal (transmission side) (B48A)....387

1115510 Measuring the internal engine pressure (B48A)....392

1116550 Removing and installing alternator bracket (B48A)....394

1121 Overview of Technical Data....400

1121... Replace lower crankshaft guide bearing shells (B48)....405

1121001 Replacing crankshaft (B48A)....409

1121140 Replace crankshaft guide bearing shells (B48)....421

1121531 Replacing all crankshaft main bearing shells (B48A)....426

1122 Overview of tightening torques....431

1122000 Removing and installing _ replacing flywheel (B48A)....433

1123 Overview of tightening torques....436

1123010 Removing and installing _ replacing vibration damper (B48A)....438

1124 Overview of tightening torques....441

1124571 Replace all connecting rod bearings (B48A)....445

1125 Overview of Technical Data....446

1125000 Removing and installing or replacing all pistons (B48A)....457

1125671 Replacing piston rings on all pistons (B48A)....469

1127 Overview of tightening torques....473

1127030 Removing and refitting _ replacing balancer shafts (B48A)....475

1128 Overview of tightening torques....486

1128... Tensioning _ releasing of drive belt for alternator (B48A)....489

1128010 Replace drive belt for alternator ()....495

1128020 Replacing tensioning device for alternator drive belt (B48A)....499

1128025 Removing and installing _ replacing deflecting element for drive belt (B48A, B46A)....501

1130 Overview of tightening torques....508

1131 Overview of tightening torques....509

1131... Notes for checking and adjusting the timings (B37, B38, B47, B48)....521

1131... Notes on checking and adjusting the timing (B36, B37, B38, B46, B47, B48)....524

1131005 Checking camshaft timing (B48AO0)....527

1131025 Removing and installing _ replacing intake camshaft (B48A)....534

1131028 Removing and installing _ replacing exhaust camshaft (B48A)....538

1131052 Replacing both timing chains (B48A)....544

1131090 Removing and installing _ replacing chain tensioner (B48A)....550

1131505 Adjusting timing of camshaft(s) (B48A)....552

1133050 Removing and installing _ replacing all rocker arms (B48A)....559

1133062 Replacing all hydraulic valve clearance compensating elements (B48A)....562

1134055 Replacing all valve springs (B48A)....564

1134552 Removing and installing or replacing all valves (B48A)....570

1134560 Replacing all valve stem seals (B48A)....572

1136 Overview of tightening torques....575

1136042 Removing and installing _ replacing intake adjuster (B48A)....579

1136044 Removing and installing _ replacing exhaust camshaft adjuster (B48A)....587

1136046 Removing and installing or replacing intake and exhaust camshaft adjusters (B48A)....595

1136125 Removing and installing _ replacing VANOS central valve on the intake side (B48A)....606

1136126 Removing and installing _ replacing exhaust side VANOS central valve (B48A)....613

1136127 Removing and installing _ replacing both VANOS central valves (B48A)....620

1136658 Removing and installing _ replacing both actuators (B48A )....628

1137 Overview of tightening torques....632

1137005 Removing and installing _ replacing eccentric shaft (B48A)....635

1137010 Removing and installing _ replacing intermediate levers (B48A)....639

1137020 Removing and installing _ replacing servomotor for eccentric shaft (B48A)....653

1140000 Checking engine oil pressure (B48A)....657

1141 Overview of tightening torques....662

1141000 Removing and installing or replacing oil pump (B48A)....669

1141115 Removing and installing _ replacing hydraulic valve (B48A)....673

1142 Overview of tightening torques....676

1142020 Removing and installing _ replacing full-flow oil filter (B48A)....689

1142200 Removing and installing _ sealing or replacing oil feed line for exhaust turbocharger (B48A)....696

1142210 Removing and installing _ sealing or replacing oil return line for exhaust turbocharger (B48A)....698

1144000 Removing and installing _ replacing oil-to-water heat exchanger (B48AO0)....702

1151 Overview of tightening torques....705

1151000 Removing and installing _ replacing coolant pump (B48A)....709

1153 Overview of tightening torques....712

1153000 Removing and installing _ replacing coolant thermostat (B48A)....719

1153086 Removing and installing _ replacing coolant feed line for exhaust turbocharger (B48A)....720

1153086 Removing and installing _ replacing coolant return line for exhaust turbocharger (B48A)....724

1153590 Removing and installing _ replacing the auxiliary water pump (B48A)....727

1161 Overview of tightening torques....731

1161050 Removing and installing intake system (B48A)....739

1161362 Removing and installing _ replacing right charge-air duct (B48A)....743

1161365 Removing and installing _ replacing left-hand charge air duct (B48A )....752

1161730 BMW leakage test for differentiated intake system....757

1162 Overview of tightening torques....761

1165 Overview of tightening torques....763

1165020 Removing and installing _ replacing exhaust turbocharger (B48A)....776

1165300 Removing and installing _ replacing wastegate valve actuator (B48) (from 02 _ 2016)....788

1165300 Removing and installing _ replacing wastegate valve actuator (B48) (until 01 _ 2016)....801

1166000 Removing and installing or replacing vacuum pump (B48A)....813

1174559 Replace electric valve for vacuum control of water pump (B48A)....817

1178 Overview of tightening torques....820

1178510 Remove and install _ replace front oxygen sensor (B48A)....822

1178610 Remove and install _ replace monitoring oxygen sensor (B48A)....826

6.1.9 Engine performance....830

9.0 BMW Longlife-17 FE+....831

BMW Quality Longlife-04 All....833

Camshaft....834

Case Covers....835

Chain tensioner....836

Cleaning the cylinder head intake ports and the combustion chamber with the walnut blaster....837

Connecting rod with connecting rod bearing....838

Coolant pump....839

Crankshaft and Bearings....840

Cylinder head with cylinder head cover....841

Drive belt with belt tensioner and deflecting element....842

Dual-mass balance....843

Emissions control, control sensor _ monitoring sensor....844

Emissions-control, Lambda oxygen sensor....845

Engine block....846

Engine identification....847

Exhaust turbocharger with control....857

Fan....858

Flywheel....859

Intake manifold....860

Intake plenum....861

Leak-testing the air-intake system....862

Main group 11....865

Mounting engine on assembly stand (B48A)....866

Oil filter with line....870

Oil pump with strainer and motor....871

Oil sump....872

Oil supply, B48, B46....873

Repair notes to renew the cylinder head....874

Repair notes to renew the engine....877

Replacing guide bearing....879

Standard screw connection....882

Thermostat and coolant lines....883

VANOS....884

Vacuum pump....885

Vacuum supply All models....886

Variable valve gear....890

Vibration damper....891

12 - ENGINE ELECTRICAL SYSTEM....892

1200... Instructions for removal and replacement of control units....894

1212 Overview of tightening torques....896

1212011 Remove and install _ replace all spark plugs (B38, B46, B48)....897

1213511 Replacing ignition coils (B38, B46, B48)....901

1214 Overview of tightening torques....904

1214521 Replacing the pulse sensor on the crankshaft (B38, B48, B46)....907

1214523 Replacing pulse sensor on intake camshaft (B46, B48)....909

1214524 Replace pulse sensor on exhaust camshaft (B46, B48)....911

1214550 Replacing control unit (DME)....914

1214602 Replacing the knock sensor (cylinder 1. and 2.) (B46, B48)....921

1214604 Replacing knock sensor (cylinder 3. and 4.) (B46, B48)....923

1214705 Programming the control unit (DME _ DDE)....925

1231020 Removing and installing or replacing alternator (B46, B48)....926

1241 Overview of Technical Data....932

1241 Overview of tightening torques....933

1241020 Removing and installing _ replacing starter motor....936

1241041 Replacing the engagement solenoid switch....939

1242 Overview of tightening torques....941

1242500 Replacing positive battery cable from vehicle battery to starter motor (B48)....944

1242540 Replacing safety battery terminal (SBK)....950

1251210 Replacing the wiring harness section for the injectors and ignition coils (B46, B48)....957

1251215 Replacing wiring harness section for Valvetronic servomotor (B46, B48)....963

1251235 Replacing the engine sensor system module 1 wiring harness section (B46, B48)....970

1251240 Replacing the engine sensor system module 2 wiring harness section (B46, B48)....978

1251306 Removing and installing the wiring harness - section for the supply unit module (B46, B48)....986

1252 Overview of tightening torques....992

1261 Overview of tightening torques....996

1261280 Removing and installing _ replacing the oil pressure switch (B38, B46, B48)....999

1261285 Removing and installing _ replacing oil level sensor for engine oil....1001

1261285 Replacing engine oil level sensor....1004

1263586 Replacing power distribution box....1014

1290 Overview of tightening torques....1017

Alternator with mounting....1019

Battery tray....1020

Electronics box....1022

Oil pressure, oil level indicator....1024

Plug Connectors, Terminals....1025