Installing the double-clutch transmission (DCT)

CAUTION: Materials harmful to health.
Contact with fluids harmful to health!

Note and follow safety instructions on containers.
Conduct all work in appropriate personal protective equipment only.

NOTE: RISK OF DAMAGE
Damage to the engine block.
Serious damage to the engine block and transmission due to damaged and corroded screws.

It is imperative that protruding threads of the transmission bolts are checked for corrosion and damage prior to removal.
It is imperative that all rust is removed from corroded threads and that they are cleaned prior to removal.
Replace rusted and damaged bolts.

NOTE: RISK OF DAMAGE
Damage to the flywheel and the double-clutch transmission (DCT).
Damage to the flywheel or the double-clutch transmission (DCT) through improper development and installation of the double-clutch transmission.

Orient the double-clutch transmission absolutely levelly during development and installation.

NOTE: TECHNICAL INFORMATION
The transmission oil temperature must be between 20°C and maximum 40°C!
With the diagnostic system, carry out the "Transmission oil adjustment" service function.
In case of exceeding the oil change by more than 3000 km, the double clutch must also be replaced!
Failure to comply with this requirement will result in serious damage to the double clutch transmission (DCT).

NOTE: RISK OF DAMAGE
Missing transmission breather cap. Damage to or leak in the transmission.

It is essential to remove the protective cap and replace it with the transmission breather cap.

Install the protective cap (1) on the transmission and replace through the white transmission breather cap (2).

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Check the fitting sleeves (1) for correct seating and damage and replace if necessary.

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Correct: Insert the double-clutch transmission (DCT/DKG) aligned horizontally in the flywheel.

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Incorrect: Insert the double-clutch transmission (DCT/DKG) without tilting in the flywheel.

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Clean drive shaft gearing (1).
Grease gearing (1) with MI-Setral-43N grease (BMW part number 83 23 2 152 082).
The tooth gaps must be filled with grease up to the height of the teeth.

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Keep double-clutch transmission (DCT) completely level when flange-mounting to engine.
Hand-tighten the screws (arrows).

Tighten screws (arrows).

TIGHTENING TORQUES SPECIFICATION

Transmission to engine
M8	Tightening torque	19 Nm
M12	Tightening torque	66 Nm

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Connect and lock the coolant lines (1).

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Install the connector (2) on the control unit and fold the red lever (1) in the arrow direction up to the stop.
Check the correct seating of the connector (2).

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Install the grounding cable (2) and tighten the screw (1).

TIGHTENING TORQUES SPECIFICATION

Standard screw connection M6
M6	Tightening torque	8 Nm

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Replace screws (1).
Parts: Screws

Tighten down screws (1),

TIGHTENING TORQUES SPECIFICATION

Transmission mounting
M10 Replace screws.	Joining torque	40 Nm
	Angle of rotation	90°

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Screw the ground strap (2) with the screw (1) onto the transmission.

TIGHTENING TORQUES SPECIFICATION

Standard screw connection M8
M8	Tightening torque	19 Nm

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Install battery carrier

Insert and install battery carrier (5).
Hand-tighten the bolt (4).
Hand-tighten the bolts (3).

Tighten down screw (4).

TIGHTENING TORQUES SPECIFICATION

Battery carrier to engine mount
Hexagon screw M8x30	Tightening torque	19 Nm

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Tighten down screws (3).

TIGHTENING TORQUES SPECIFICATION

Battery carrier to engine mount
Hexagon screw M8x30	Tightening torque	19 Nm

Attach coolant line (2) on battery carrier (5).
Attach cable clip (1) on battery carrier (5).
Install E-box

Precondition

Battery ground lead is disconnected.
NOTE:
RISK OF DAMAGE
Improper routing of cables and wiring harnesses.
Trapped, crushed or damaged cables may cause short circuits and malfunctions.
- Route all cables without abrasions, do not trap and crush.
Feed in the E-Box (1) into the guide (2) in the arrow direction and install.

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Ensure that the E-Box (1) is positioned correctly on the cowl (2).

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Tighten down screw (1).
TIGHTENING TORQUES SPECIFICATION

E-box to battery tray

M8x16 15 Nm

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Feed the holder (1) into the E-Box (2) in the arrow direction and install.
Make sure the holder (1) engages audibly.

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Feed in and install the wiring harness section (2) of the engine in the arrow direction.
Ensure that the locking mechanisms (1) engage audibly.

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Feed in and install the wiring harness section (2) of the Valvetronic servomotor in the arrow direction.
Ensure that the locking mechanisms (1) engage audibly.

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Feed in the wiring harness section (3) for the injectors and ignition coils in the arrow direction and install.
Make sure the locking mechanism (2) engages audibly.
Insert and install the positive battery cable (1).

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Connect all connectors (1) and lock.
Ensure that the connectors (1) engage audibly.

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Connect and lock all connectors (1) in the arrow direction.
Ensure that the connectors (1) engage audibly.

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Connect connectors (1) and lock.
Make sure the connector (1) engages audibly.
Feed the connector (1) into the E-Box (2) in the arrow direction and install.

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Feed the cover (2) into the guides (3) in the arrow direction and install.
Ensure that the cover (2) engages audibly into the guides (3).

Tighten down screw (1).

TIGHTENING TORQUES SPECIFICATION

Cover panel to E-box
RF5x26.5	Tightening torque	2.5 Nm

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Insert and install the positive battery cable (2) on the holder (3).
Insert and install the battery positive terminal (1).

Tighten the battery positive terminal (1).

TIGHTENING TORQUES SPECIFICATION

Positive battery terminal to battery
Nut M6	Tightening torque	5 Nm

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Loosening the luggage strap (3).
Remove special tools 0 490 133 (00 2 030) and 0 495 827 (23 4 150).

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Follow-up work

Refer to INSTALLING THE RIGHT RADIAL SHAFT SEAL ON THE DIFFERENTIAL (7DCT300) .
Refer to INSTALLING THE LEFT RADIAL SHAFT SEAL ON THE DIFFERENTIAL (7DCT300) .
Refer to INSTALLING THE LEFT OUTPUT SHAFT AT THE TRANSMISSION END .
Refer to INSTALLING RIGHT OUTPUT SHAFT AT TRANSMISSION END .
Refer to INSTALLING STARTER MOTOR .
Refer to INSTALLING AND SECURING COMPLETE FRONT AXLE .
Refer to SECURING MOUNTED PARTS ON THE FRONT AXLE SUPPORT .
Refer to CONNECTING PURGE AIR LINE .
Refer to CONNECTING CONNECTOR ON STEERING GEAR .
Refer to FASTENING THE RUBBER MOUNT ON THE FRONT AXLE SUPPORT .
Refer to SECURING THE ANTI-ROLL BAR ON THE LEFT AND RIGHT ON THE ANTI-ROLL BAR LINK .
Refer to FASTENING THE CABLE FOR THE RIDE HEIGHT SENSOR .
Refer to INSTALLING WHEEL ARCH COVER AT FRONT LEFT AND RIGHT .
Refer to IF INSTALLED: INSTALLING UNDERBODY PROTECTION AT REAR .
Refer to INSTALLING FRONT UNDERBODY PROTECTION .
Refer to INSTALLING THE FRONT LEFT AND RIGHT WHEELS .
Refer to REMOVING THE MOUNTING FOR THE COOLANT RADIATOR ON THE LEFT AND RIGHT .
Refer to SECURING THE STEERING SHAFT AT THE BOTTOM ON THE STEERING GEAR .
Refer to TAKING ENGINE OUT OF INSTALLATION ORIENTATION .
Refer to INSTALLING THE BATTERY .
Refer to INSTALLING THE BATTERY COVER .
Refer to CHECKING OIL LEVEL/REPLENISH OIL IN DOUBLE-CLUTCH TRANSMISSION (DCT) (7DCT300) .
Refer to INSTALLING ACOUSTIC COVER .
Refer to CONNECTING COOLANT LINE .
Refer to INSTALLING SECOND UPPER BULKHEAD .
Refer to INSTALLING THE RIGHT WINDSHIELD PANEL COVER .
Refer to INSTALLING THE LEFT WINDSHIELD PANEL COVER .
Refer to INSTALLING THE REAR HOOD SEAL .
Refer to INSTALLING LEFT AND RIGHT WIPER ARM .
Refer to INSTALLING FAN COWL WITH ELECTRIC FAN .
Refer to INSTALLING CROSS CONNECTION .
Refer to INSTALLING INTAKE SILENCER HOUSING .
Refer to INSTALLING INTAKE PORT .
Refer to FILLING THE COOLANT CIRCUIT WITH THE VACUUM FILLING EQUIPMENT .
Refer to VENTING THE COOLING CIRCUIT .
Refer to ENCODE/PROGRAM CONTROL UNIT(S) .

E-box to battery tray
M8x16	15 Nm