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BMW Series 3 G20 Workshop Service Manual
Brand: BMWFile Size: 446 MB
Format: PDF
Language: English
Machine Type: Automotive
Manual Type: Workshop Manual, Service Manual
Model: BMW Series 3 G20
Number of Pages: 7753 Pages
List of Files:
Repair Instructions
00 Maintenance and general note
00 Maintenance
Additional work: mounting the number plate baseplate/number plate
BMW engine oil service without supplementary service
BMW rapid inspection
Engine oil consumption measurement
Engine oil service
Free pre-delivery check
Pre-delivery check of service and electromechanical holding brake for transport and
immobilisation periods of more than 6 weeks
Pre-delivery check of service and parking brakes with transport and immobilisation
periods of 3-6 weeks
Service - brake fluid
Service - front brakes
Service - microfilter
Service - rear brakes
Service - spark plugs
Service - vehicle check
Standard scope of service
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
When driving on a race track
Work instruction for removing the protective film
01 Safety information, note regarding the handling of the repair instructions
Information on using cleaning agent/paints (personal protection equipment)
Instructions for desiccant insert replacement
Notes on handling the high pressure cleaner
Safety information for working on vehicles with automatic engine start-stop function (MSA)
Symbols used and information in repair instructions
02 Raise vehicle and tow away
Raising the vehicle using a vehicle lift
03 Tightening specifications
Microencapsulated screws
04 12 V vehicle electrical system
Information on intelligent battery sensor (IBS)
Notes on AGM battery
Notes on handling optical fibres
Notes on handling wiring harnesses and cables
06 Vehicle-specific notes
Instructions for opening and part exchange in refrigerant circuit
Instructions for replacement of air conditioning capacitors and radiator/coolers
07 Operating fluids
Instructions for handling R1234yf refrigerant
Notes on the refrigerant (R134a, R1234yf) and refrigerant oil
Safety information for handling refrigerant R1234yf
Safety informations for handling tetrafluorethane refrigerant R134a
10 Heating/air conditioning system
Instructions for desiccant insert replacement
Instructions for handling R1234yf refrigerant
Instructions for opening and part exchange in refrigerant circuit
Instructions for replacement of air conditioning capacitors and radiator/coolers
Notes on the refrigerant (R134a, R1234yf) and refrigerant oil
Safety information for handling refrigerant R1234yf
Safety informations for handling tetrafluorethane refrigerant R134a
11 General maintenance
Checking/topping up the oil level in the transfer box
Oil change in the front axle transmission including used oil disposal
Oil change in transfer box including used oil disposal
11 Engine
00 Engine
Engine identification
Engine oil consumption measurement
Equipment recoding special tool number of the transverse member for fixing the engine in the installation location
Handling components after flood damage
Overview of consumables (Electronic Parts Catalogue)
Safety information for working on vehicles with automatic engine start-stop function (MSA)
31 Camshaft
Notes on checking and adjusting the timing (B36, B37, B38, B46, B47, B48)
61 Intake manifold
Leakage test for the intake system
Engine
Equipment recoding special tool number of the transverse member for fixing the engine in the installation location
Parking-residing-driving
12 Engine electrical system
00 Engine electrical system
Handling components after flood damage
Information on removing, connecting and changing the battery
Instructions for removal and replacement of control units
Instructions for working on the ignition system
Notes on handling wiring harnesses and cables
Notes/information on start assistance (jump starting)
Safety information for working on vehicles with automatic engine start-stop function (MSA)
Safety information on handling hybrid cars
Unlocking and disconnecting various plug connections in electrical and hybrid vehicles
14 Electronic Shift Units or Control Units
Encoding the control unit (DME/DDE)
Programming the control unit (DME/DDE)
41 Starter motor with mounting
Handling components after flood damage
Replacing the engagement solenoid switch
42 Starter line
Replacing safety battery terminal (SBK)
51 Engine wiring harness
Safety information on handling hybrid cars
Engine electrical system
Parking-residing-driving
13 Fuel preparation and control
00 Fuel preparation, check
Safety information for working on vehicles with automatic engine start-stop function (MSA)
31 Fuel pump with drive and line
Notes regarding the fuel pressure test (reference pressure: surrounding area)
53 Fuel Injector Nozzles and Lines
Clean the cylinder heads in the area of injectors to prevent sand/dust contamination.
62 Senders for Control Unit
Remove and install/replace hot film air mass meter
71 Intake silencer
Remove and install intake silencer housing
16 Fuel supply
00 Fuel supply
Draining and filling fuel tank
11 Fuel tank with fuel filler pipe
Removing and installing fuel tank
12 Lines
Removing and installing or replacing carbon canister
Removing and installing/replacing the external fuel filter
13 Crankcase ventilation, emission monitoring
None
14 Delivery, preparation and content measurement, control units, electric fuel pump
Removing and installing or replacing control unit for electric fuel pump
Removing and installing/replacing delivery unit
None
Fuel supply
Information on using cleaning agent/paints (personal protection equipment)
17 Cooling
00 Cooling, check
Instructions for working on cooling system
Safety information for working on vehicles with automatic engine start-stop function (MSA)
10 Radiator, expansion tank, lines
Instructions for replacement of air conditioning capacitors and radiator/coolers
11 Engine oil cooler and mounting parts
Instructions for replacement of air conditioning capacitors and radiator/coolers
Removing and installing/replacing fan cowl with electric fan
21 Oil cooler
Instructions for replacement of air conditioning capacitors and radiator/coolers
51 Charge air cooler with mounting
Instructions for replacement of air conditioning capacitors and radiator/coolers
Cooling
Instructions for working on cooling system
18 Exhaust system
10 Rear and front silencer, diesel fuel
Replacing all exhaust covers
12 Silencer
Replacing the controller drive for exhaust flap
22 Engine and transmission mounting
11 Engine mounting
Replacing left engine mount
Replacing left engine support bracket
Replacing right engine mount
Replacing right engine mounting bracket
32 Transmission mounting, automatic transmission
Replacing cross member for transmission mounting
23 Manual gearbox
00 Manual gearbox
Transmission designations
Universal BMW transmission take-up
Universal transmission retaining bridge
Manual gearbox
Transmission designations
Universal BMW transmission take-up
Universal transmission retaining bridge
24 Automatic transmission
00 Automatic transmission
Installing exchange transmission
Remove and install automatic transmission
Transmission designations
Universal BMW transmission take-up
Universal transmission retaining bridge
11 Transmission Case, Oil Sump
Removing and installing/sealing or replacing transmission oil sump
13 Transmission Extension, Bearings, Sealing Ring
Replacing radial shaft seal for output flange
30 Electro-hydraulic control parts and elements
Removing and installing/replacing the hydraulic impulse storage
31 Oil pump
Replacing the radial shaft seal for the torque converter
34 Shift valves, parking lock
Removing and installing/replacing the parking lock
Replace mechatronics
Replacing the sealing sleeve for the transmission housing
40 Torque converter
None
26 Propeller shaft
00 Propeller shaft, general
Additional work on all-wheel drive vehicles after driving with faulty (non-engaging) drive
11 Single or multiple part propeller shaft
Removing and installing complete propeller shaft
Replacing centre mount gaiter
Replacing centring for propeller shaft
Replacing flexible disc for propeller shaft
Replacing flexible disc for rear propeller shaft
12 Centre console assembly
Replacing complete propeller shaft centre bearing
Replacing grooved ball bearing in propeller shaft centre bearing
20 Front propshaft
Removing and installing the front propeller shaft
27 Transfer box
00 Transfer box
Oil change in transfer box including used oil disposal
10 Transfer box
Install the exchange transfer box
Removing and installing the transfer box
Replacing gaiter or centrifugal disc at transfer box
Replacing the output flange on the transfer box at the rear
None
21 Bearing, radial shaft seals, drive shaft
Replacing the radial shaft seal for the actuator shaft
Replacing the radial shaft seal for the drive shaft
31 Front axle, front suspension
00 Front axle in general
Information on replacing shock absorbers
Mobile table lift
Notes on wheel bearing replacement following accident damage
Raising the vehicle using a vehicle lift
Safety information for working on vehicles with automatic engine start-stop function (MSA)
10 Front Axle Suspension
Removing and installing complete front axle
11 Front axle support
Lowering/raising front axle support
Removing and installing/replacing stiffening plate
12 Wishbones and struts including rubber mounts
Removing and installing/replacing left or right tension strut
31 Spring Struts
Information on replacing shock absorbers
Removing and installing complete front left or right spring strut shock absorber
35 Anti-roll bar
Removing and installing / replacing anti-roll bar link, left
Removing and installing / replacing anti-roll bar link, right
50 Front axle differential
Removing and installing front axle differential
Replace front axle differential
51 Front axle/sealing
Replacing O-ring for bearing block
Replacing O-ring for front axle differential on right
53 Differential with bearings
Replace the bearing support for the right output shaft
60 Output shaft
Notes on removing and installing Low Profile band clamps
Removing and installing/replacing left output shaft
Removing and installing/replacing right output shaft
Front axle, front suspension
Microencapsulated screws
32 Steering and Wheel Alignment
00 Steering, measurement
Adjusting toe-in on front axle
Carry out Kinematics Diagnosis System wheel alignment with vehicle load up to design
position
General chassis and suspension definitions
General information and definitions
KDS data statuses
Kinematics Diagnosis System wheel alignment with ride height measurement without loading
the vehicle
Notes on replacement of steering gear/steering column/steering shaft following accident damage
Safety information for working on vehicles with automatic engine start-stop function (MSA)
Troubleshooting chassis mechanics
11 Mechanical steering gear
Notes on replacement of steering gear/steering column/steering shaft following accident damage
13 Steering gear with power steering unit
None
Notes on replacement of steering gear/steering column/steering shaft following accident damage
21 Steering column stalk, track rod, steering damper
Replacing left or right track rod end
31 Steering column
Removing and installing/replacing double pivot for bottom steering shaft
Removing and installing/replacing lower section of steering column shroud
Removing and installing/replacing steering column shroud upper section
Replacing steering shaft collar
Replacing the steering column
33 Steering Wheel
Removing and installing the sports steering wheel
Replacing the M sports steering wheel
34 Airbag and airbag steering wheel
Procedure after airbag deployment as result of an accident
Removing and installing/replacing airbag unit
Removing and installing/replacing airbag unit
Safety regulations for handling components with gas generators
Steering and Wheel Alignment
Microencapsulated screws
33 Rear axle, rear-wheel drive, guide
00 Rear axle, rear-wheel drive, guide
Notes on wheel bearing replacement following accident damage
Raising the vehicle using a vehicle lift
10 Rear axle final drive
Removing and installing/replacing temperature sensor
11 Transmission housing with lid
Replacing rear cover gasket on rear axle final drive
Replacing the rear axle differential M sport differential cover gasket
31 Rear axle support
Remove and install/replace the vibration absorber on the rear axle differential
Removing and installing/replacing the vibration absorber on the rear axle support
32 Trailing arms and struts
Removing and installing/replacing left or right camber control arm cover
Removing and installing/replacing left or right track control arm
Replacing left or right trailing arm
Replacing one upper wishbone
33 Rear Axle Suspension
Replacing left or right rear axle support compression strut
Replacing rear left or right compression strut for rear axle support
52 Shock Absorbers
Removing and installing rear left or right shock absorber
Replacing rear left or right side shock absorber
Replacing rear left or right support bearing for spring strut/shock absorber
53 Springs with suspension
Removing and installing / replacing rear left or right coil spring
55 Anti-roll bar
Replacing left or right anti-roll bar link
Rear axle, rear-wheel drive, guide
Microencapsulated screws
34 Brakes
00 Braking, check, ventilation
Guideline for applying brake pad paste on brake pads and caliper carrier
Replacing fluid in brake system
Safety information for working on vehicles with automatic engine start-stop function (MSA)
11 Front Wheel Brakes
Reconditioning front left or right brake caliper
Removing and installing/renewing brake pads on both front disc brakes
Removing and installing/replacing both front brake discs
Removing and installing/replacing left or right front brake caliper
Replacing front left or right caliper carrier/guard plate
21 Rear Wheel Brakes:
Guideline for applying brake pad paste on brake pads and caliper carrier
Remove and install/replace rear right protective plate
Removing and installing/renewing both brake discs
Removing and installing/replacing both rear brake pads of disc brake
Removing and installing/replacing rear left protective plate
Replacing rear right brake pad
31 Foot and tandem brake master cylinder
Removing and installing/replacing tandem brake master cylinder
Replacing brake fluid level switch
Replacing expansion tank for hydraulic brake actuation
32 Brake Lines
Replacing front left or right brake hose
Replacing rear left or right brake hose
33 Brake servo
Removing and installing/replacing brake booster
35 Electrical components / wear indicator
Replacing one brake pad wear sensor
41 Parking brake
EMF parking brake - use emergency release
Replacing the control unit for parking brake
51 Mechanical hydraulic components
Removing and installing the hydraulic unit
Replacing the hydraulic unit
52 Electronic components
Removing and installing/replacing EMF actuator
Replacing DSC control unit
Brakes
Information on using cleaning agent/paints (personal protection equipment)
Microencapsulated screws
35 Pedals
40 Accelerator pedal activation
Removing and installing or replacing accelerator pedal module
36 Wheels with tyres
10 Wheels
Notes and specifications for tyre / wheel exchange
Remove or install front or rear wheel
11 Disc wheels (rims)
None
Replacing the RDC control unit
12 Tyres
Notes and specifications for tyre / wheel exchange
Replacing a tyre
Wheels with tyres
Notes and specifications for tyre / wheel exchange
37 Integrated Suspension Systems
00 Integrated suspension system in general
Safety information for working on vehicles with automatic engine start-stop function (MSA)
11 Control and suspension elements, front
Removing and installing front left or right spring strut
Replacing front left or right spring strut
12 Control and suspension elements, rear
Carrying out ride height adjustment
Removing and installing rear left or right shock absorber
Replacing rear left or right side shock absorber
14 Electric components
Replacing front left or right vertical acceleration sensor
Replacing front ride height sensor
Replacing rear ride height sensor
None
41 Body
00 Body
0 Notes on the repair technique used in the main group 41
Blind rivet
BMW/MINI bonding instructions
Checklist for front seat
Corrosion protection
EMC screws
Fix bolts on the new part
General instructions on paintwork
General notes for labelling with adhesive films
Grinding aluminium components
Grinding steel parts
Handling airbags and restraint systems
Handling components after flood damage
Handling electrical system and electronics
Information on hazards
Information on metal filler
Information on using cleaning agent/paints (personal protection equipment)
Information on vehicle protection
Information/warning labels
Installation solution for straight shank/hexagon rivet nut
Installing a cavity sealing with 2-component PU cavity foam
Installing cavity sealing (expanded)
Installing cavity sealing (not expanded)
Materials science
Notes on adhesive K1
Notes on adhesive K2
Notes on adhesive K3
Notes on adhesive K4
Notes on adhesive K5
Notes on adhesive K6
Notes on cleaning agent R1
Notes on handling the high pressure cleaner
Notes on the water drain hose of the slide/tilt sunroof
Notes on using temperature-controlled infra-red radiators
Opening bonded connections
Opening brazed connections
Opening rivet connections
Opening welded connections
Overview of additional work for the removal and installation or replacement of electronic components in the body area/windscreen
Overview of adhesive cartridge guns
Overview of consumables (Electronic Parts Catalogue)
Punch rivets
Quality standard
Reinforcement plate with stud bolt (bonded or welded)
Releasing bonded folded seam connections
Repair methods, repair stages 1
Repair solution for straight shank/hexagon rivet nut
Repair techniques, repair stage 2
Repair techniques, repair stage 3
Repairing headlights
Repairing plastic components
Replacing blind rivets
Safety at work
Safety information for working on vehicles with automatic engine start-stop function (MSA)
Safety instructions for handling magnets
Separating cut determination with a template
Setting blind rivet nuts and bolts
Soldering steel components
Spot-weld bonding steel components
Spray gun for cavity sealant
Straightening aluminium component on the outer skin
Straightening aluminium components in structure
Straightening steel components in the structure
Straightening steel components on the outer skin
Touching up paintwork damage
Welding in reinforcement plate (sheet steel)
Welding steel components
Working with 2-component PU cavity foam
Workshop equipment (BMW and MINI vehicles)
11 Support
0 Notes on the repair technique used in the main group 41
Completely replacing the left carrier support
Replacing engine support in front of bulkhead, left
Replacing engine support with left wheel arch in front of bulkhead
Replacing entrance for door front left
12 Floor panels
0 Notes on the repair technique used in the main group 41
Replace luggage compartment floor, middle section
Replacing left luggage compartment base
Replacing left luggage compartment base
None
Replacing the left luggage compartment floor and side member
Replacing the luggage compartment floor and right-hand side member
Replacing the right luggage compartment floor
Replacing the right luggage compartment floor
14 Wheel arches
0 Notes on the repair technique used in the main group 41
Replace rear outer wheel arch section with left reinforcement
Replace the rear left outer wheel arch section
Replace the rear right outer wheel arch section
Replacing engine support side frame connection, front left
Replacing engine support/front left side frame connection
Replacing front left wheel arch
Replacing rear outer wheel arch section with right reinforcement
21 Side frames and pillars
0 Notes on the repair technique used in the main group 41
Replace outer left B-pillar.
Replacing A-pillar with reinforcement on left
Replacing B-pillar with reinforcement on left
Replacing left outer A-pillar
Replacing reinforcement for roof frame at rear left
22 Roof frame
0 Notes on the repair technique used in the main group 41
31 Roof
0 Notes on the repair technique used in the main group 41
Replace roof outer skin
Replace roof outer skin with slide/tilt sunroof
32 Front and rear window frame
0 Notes on the repair technique used in the main group 41
33 Front trim panel
0 Notes on the repair technique used in the main group 41
Replacing front left or right side wall holder
34 Rear trim panel
0 Notes on the repair technique used in the main group 41
Replacing outer tail panel section
Replacing tail panel
35 Side Panels
0 Notes on the repair technique used in the main group 41
Reinforcement plate with stud bolt (bonded or welded)
Replace a holder for the front side panel
Replace right front side panel
Replace three holders for the front side panel
Replacing front left or right side wall holder
Replacing left front side panel
Replacing rear left side panel
Replacing rear right side panel
51 Front doors
Adjusting front left or right door
Notes on replacing the door
Removing and installing left or right front door
Replace front left or right door
52 Rear doors
Notes on replacing the door
62 Tailgate
Adjusting tailgate
Removing and installing rear lid
Replacing tailgate
Body
0 Notes on the repair technique used in the main group 41
Information on using cleaning agent/paints (personal protection equipment)
51 Body equipment
00 General body equipment
Fix bolts on the new part
Notes on component bonding with adhesive tape
Overview of additional work for the removal and installation or replacement of electronic components in the body area/windscreen
Overview of consumables (Electronic Parts Catalogue)
Replacing blind rivets
Safety information for working on vehicles with automatic engine start-stop function (MSA)
Safety instructions for working on cars with airbag systems
11 Front Bumper
Additional work: mounting the number plate baseplate/number plate
Remove and install front bumper panel
Removing and installing/replacing support for front bumper panel
Removing and installing/replacing support for front lower bumper panel
Removing and installing/replacing the ornamental grille in the front bumper panel
Replace bumper panel, front
Replacing the number plate baseplate for the number plate
12 Rear bumper
Overview of consumables (Electronic Parts Catalogue)
Removing and installing rear bumper panel
Removing and installing/replacing cover on rear bumper panel
Removing and installing/replacing rear centre bumper guide
Removing and installing/replacing rear diffuser
Removing and installing/replacing rear left or right bumper guide
Removing and installing/replacing support for rear bumper panel
Replace rear bumper panel
None
13 Trim Parts, Covers, Handle Strip
Remove and install cowl panel cover
Removing and installing left or right roof trim strip
Removing and installing/replacing front grill centre section
Removing and installing/replacing the trim on the rear left or right side panel
14 Badges, labels, adhesive strips
General notes for labelling with adhesive films
Removing and installing/replacing front BMW badge
Removing and installing/replacing rear BMW badge
Replacing model name plate, rear
Replacing the model inscription, rear
16 Mirrors, Finishers, Ashtrays, Consoles
Remove and install the front storage compartment
Remove and install the rear centre console trim
Remove and install/replace lock barrel for glove box
Remove and install/replace the interior mirror
Removing and installing center console trim
Removing and installing complete centre console
Removing and installing glove box lid
Removing and installing or replacing front grab handle
Removing and installing or replacing retaining ring on left or right exterior mirror
Removing and installing or replacing sun visor and left or right counter support
Removing and installing the centre armrest storage compartment
Removing and installing the exterior mirror on left or right front door
Removing and installing/replacing both sun visors and counter supports
Removing and installing/replacing centre armrest
Removing and installing/replacing cover cap on left or right exterior mirror
Removing and installing/replacing damper for glove box
Removing and installing/replacing decorative trim on centre console on left or right
Removing and installing/replacing driver's side fold-down compartment
Removing and installing/replacing front cup holder
Removing and installing/replacing housing on left or right exterior mirror
Removing and installing/replacing rear left/right grab handle
Replace centre console trim to the rear inside
Replace front storage compartment
Replace the rear centre console trim
Replacing centre console
Replacing glove box lid
Replacing mirror glass for exterior mirror
Replacing storage compartment trim
Replacing storage compartment trim
Replacing the exterior rearview mirror on the front door on the left or right
21 Door locks, handles, fittings, front
Adjusting front left or right lock striker
Remove and install/replace door stop of the front left or front right door
Removing and installing/replacing the Bowden cable for the inside door opener on the
left or right front door
Removing and installing/replacing the Bowden cable of the outside door handle at the
front left or right
Removing and installing/replacing the complete lock barrel on the left or right front
door
Removing and installing/replacing the door lock of the driver's door
Removing and installing/replacing the door lock of the front passenger door
Removing and installing/replacing the inner door opener on the left or right front
door
Removing and installing/replacing the outside door handle at the front left or right
Removing and installing/replacing the outside door handle support including lock barrel,
left or right
Removing and installing/replacing the outside door handle support without lock barrel,
left or right
Removing and installing/replacing the weather strip on the inside of the front door
Removing and installing/replacing weather strip on outside of front door
Replacing front left or right lock striker
Teach in radio remote control/radio remote control with display (BMW display key)
22 Door locks, handles, fittings, rear
Adjusting rear left or right lock striker
Remove and install/replace the door lock on the left or right rear doors
Removing and installing/replacing the Bowden cable for the inside door opener on the
left or right rear door
Removing and installing/replacing the Bowden cable for the outside door handle at
the rear left or right
Removing and installing/replacing the door brake on the left or right rear door
Removing and installing/replacing the inner door opener on the left or right rear
door
Removing and installing/replacing the outside door handle at the rear left or right
Removing and installing/replacing the outside door handle support in the left or right
rear door
Removing and installing/replacing the weather strip on the inside of the rear door
Removing and installing/replacing the weather strip on the outside left or right rear
door
Replacing the rear left or right lock striker
23 Bonnet catch, locks
Adjusting left or right striker on engine compartment lid
None
Adjusting/replacing bump stops
Removing and installing/replacing Bowden cable for front bonnet locks
Removing and installing/replacing left engine compartment lid lock
Removing and installing/replacing left or right gas pressure spring for engine compartment
lid
Removing and installing/replacing right engine compartment lid lock
Removing and installing/replacing the left or right actuator
Removing/installing ball sockets with clip
24 Tailgate catch, locks
None
Adjusting/replacing bump stops
Removing and installing/replacing drive for Automatic Soft Close drive on tailgate
Removing and installing/replacing gas pressure spring for tailgate
Removing and installing/replacing left tension spring for tailgate
Removing and installing/replacing right electrical spindle drive for tailgate
Removing and installing/replacing right tension spring for tailgate
Removing and installing/replacing striker for tailgate lock
Removing and installing/replacing tailgate lock
Removing/installing ball sockets with clip
Replace button for tailgate activation
31 Front and rear window
General procedure for the disassembly and installation of bonded window glass
Materials for bonding window
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