Manual gearbox

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2012 BMW 328xi, 2012 BMW 328i, 2011 BMW 328xi, 2011 BMW 328i, and 2010 BMW 328xi. However, it is still accessible from the selected car via links, so may be relevant.

IMPORTANT: Position crankshaft at TDC.

Remove dual-mass flywheel.

Secure flywheel with special tool 11 9 260 .

Remove VIBRATION DAMPER .

Release flywheel bolts with special tool 11 4 180

Fig 1: Releasing Flywheel Bolt Using Special Tool (11 4 180)

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Fig 2: Identifying Crankcase Bolts

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Release all crankcase bolts (1) along line (2).

Fig 3: Crankcase Bolts Tightening/Loosening Sequence

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Release crankcase bolts M10 in sequence 14 to 1.

Release crankcase lower section (1) from crankcase upper section (2) with suitable tool (3)

Remove crankcase lower section (1) upwards.

IMPORTANT: Do not rotate crankshaft without crankcase lower section (1) (risk of damage).

Fig 4: Releasing Crankcase Lower Section From Crankcase Upper Section Using Tool

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IMPORTANT: Timing chain is pre-tensioned.
Do not raise crankshaft.

Carefully remove radial shaft seal (1).

Catch escaping engine oil with a cloth (2).

Fig 5: Removing Radial Shaft Seal

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Carefully remove radial shaft seal (1) towards front.

Catch escaping engine oil with a cloth (2).

Fig 6: Stopping Engine Oil Using Cloth

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IMPORTANT: Protect crankcase against sealant residues with a cloth (1).

Fig 7: Identifying Cloth For Protecting Crankcase

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Remove sealant residues (1) with special tool 11 4 470 .

Remove injector nozzles (2) for liquid sealing compound on left and right.

Installation:

Replace injector nozzles (2).

Clean all threads with compressed air.

Fig 8: Identifying Injector Nozzle And Sealant Residue

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Position crankcase lower section (1) on crankcase upper section.

Screw in all M10 crankcase bolts.

Joint all M10 crankcase bolts (1) 20 NM from inside outwards.

Fig 9: Tightening M10 Crankcase Bolts

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Identify all M10 crankcase bolts with a colored marking (1) for checking.

Fig 10: Identifying Marking On M10 Crankcase Bolts

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Fig 11: Crankcase Bolts Tightening/Loosening Sequence

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Secure crankcase bolts M10 in sequence 1 to 14 with special tool 00 9 120 .

Tightening torque: 11 11 1AZ.

Fig 12: Identifying Crankcase Bolts

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Insert all crankcase bolts (1).

IMPORTANT: Observe different lengths and sizes of the bolts.
Tightening torque: 11 11 2, 3 AND 4AZ.

Tighten screw (1) for oil pump triangular drive with special tool 11 8 640 .

NOTE: Replace screw.
Tightening torque: 11 41 4 AZ .

Fig 13: Identifying Oil Pump Screw

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Tighten screw plug on front of crankcase.

Tightening torque: 11 11 8 AZ.

Installation:

Replace sealing ring.

Fig 14: Identifying Crankcase Screws Plug

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Prepare radial shaft seal (1) on special tool 11 8 220.

Fig 15: Identifying Radial Shaft Seal On Special Tool (11 8 220)

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Position radial shaft seal (1) with special tool 11 8 220 on the crankshaft.

Fig 16: Positioning Radial Shaft Seal On Crankshaft Using Special Tool (11 8 220)

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Brush radial shaft seal (1) over the special tool 11 8 220.

Move radial shaft seal (1) parallel up against the crankcase.

Fig 17: Moving Radial Shaft Seal

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Screw special tool 11 9 182 with screws (special tool 11 9 184) to crankshaft.

Fig 18: Identifying Special Tools (11 9 182 And 11 9 184)

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Installation:

Prepare special tool 11 9 181 for installation. Connect special tool 11 9 185 onto special tool 11 8 181.

Fig 19: Connecting Special Tool (11 9 185) Onto Special Tool (11 8 181)

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Pull on radial shaft seal with special tool 11 9 181 and 11 9 185 in combination with special tool 11 9 183.

Fig 20: Pulling Radial Shaft Seal Using Special Tool (11 9 181)

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Screw on radial shaft seal with special tool 11 9 183 to limit position.

Fig 21: Tightening Radial Shaft Seal

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Installation:

Clean sealing surface (1) and degrease thoroughly in area of housing partition.

Apply a light coat of oil to running surface (2) of radial seal.

NOTE: Graphic N42.

Fig 22: Identifying Radial Seal Running And Sealing Surfaces

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Push radial shaft seal (1) 11 9 235carefully in direction of arrow on the special tool.

Fig 23: Pushing Radial Shaft Seal

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IMPORTANT: 11 9 235Special tool can only be fastened with
2 opposite bolts.
Determine hole pattern on special tool.

Screw special tool 11 9 235 with special tool 11 9 234 on crankshaft.

Fig 24: Identifying Special Tools (11 9 234 And 11 9 235)

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Align groove (2) of radial shaft seal (1) centered to the housing partition (3.

IMPORTANT: After installation, the grooves must be filled with sealing compound.

Fig 25: Aligning Groove Of Radial Shaft Seal

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Draw in radial seal with special tool 11 9 231 in conjunction with special tool 11 9 233 until flush.

Fig 26: Installing Radial Seal Using Special Tools (11 9 231)

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Drive both injector nozzles (1) on left and right with special tool 11 9 360 into crankcase up to stop.

Fig 27: Installing Nozzles On Crankcase Using Special Tool (11 9 360)

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After fitting both sealing rings, check both sealing ducts for clearance.

Blow compressed air (1) at max. 6 bar into injector nozzle (2).

Compressed air must emerge at both sealing rings on left and right from the outlet bores.

IMPORTANT: If the compressed air does not flow out of all ducts. the crankcase must again be taken apart and cleaned.

Fig 28: Blowing Compressed Air Into Injector Nozzle

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Installation:

Use PRIMER 1.3 AND LIQUID SEAL 1.4 .

Prepare liquid sealing compound (1) in special tool 11 4 370 .

Injector nozzles for injecting sealing compound are not required.

Fig 29: Identifying Injector With Primer Bottle

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Slowly insert liquid sealing compound (1) with special tool 11 4 370 in direction of arrow.

Liquid sealing compound must emerge at radial shaft seals at front and rear.

Fig 30: Inserting Liquid Gasket Using Special Tool (11 4 370)

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Stop (seal off) escaping liquid gasket with primer 1.3.

Fig 31: Sealing Liquid Gasket Using Primer 1.3

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Stop (seal off) escaping liquid gasket with primer 1.3.

Fig 32: Sealing Liquid Gasket Using Primer 1.3

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Assemble engine.