E82 Complete Vehicle - BMW Forum, BMW News And BMW Blog
courtesy of www.1addicts.comTable of ContentsE82 Complete VehicleSubjectPageIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Exterior Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Interior Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Aerodynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Passive Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Bodyshell Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Strut/sill Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12Layout of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Slide/tilt Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Door and Side Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Chassis Dynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Chassis Dynamic Driving Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Double Pivot Spring Strut Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Rear Axle "HA 5" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Dynamic Driving Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19New DSC Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Bus System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23Interface Box (High) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24USB/Audio Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Intelligent Alternator Control (IGR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Special Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Special Features of the 135i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Initial Print Date: 1/08Revision Date:
courtesy of www.1addicts.comComplete VehicleModel: E82Production: From 3/2008After completion of this module you will be able to: Describe the similarities between the E82 and the E9X vehicles Describe the construction of the body-shell of the E82 Identify the features offered in the E822E82 Complete Vehicle
courtesy of www.1addicts.comIntroductionInspired by past 2002 models of the sixties and seventies BMW has designed a vehiclecombining rear-wheel-drive, excellent handling, powerful engines with the stiffest andlightest bodyshell possible along with accommodations for four. The 1 Series Coupé issure to pick up where the 2002 left off.For those of us that where lucky enough toever drive the legendary BMW 2002 theNew 1 Series inspires feelings of nostalgia.With the innovations in automotive technology and safety along with the experiencegathered over the many years of vehicledevelopment, one can only imagine the carthat BMW would build today in honor ofsuch automotive legacy.Efficient Dynamic concepts come to life inthe 1 Series with the use of Brake EnergyRegeneration, light but rigid body construction and sleek aerodynamic underbody.Dynamic Stability Control and DynamicTraction Control have been developed evenfurther for this car to ensure that advancedmanagement systems deliver maximumpower with exceptional handling.BMW 2002There is no doubt that with this New 1Series, BMW succeeded in recreating thelook, feel and performance of the sport sedanwith a race car soul, for new drivers to experience and for enthusiast to enjoy once again.The E82 1 Series Coupe3E82 Complete Vehicle
courtesy of www.1addicts.comThe E82 is being launched in Spring of 2008. The models available are the 128i and135i. The difference between the E92 and E82 is in the area of the side frame. Thedoors and the roof are also different. Similarly, there are differences in the trunk and luggage compartment. There are also noticeable differences in the floor assembly and in theinterior. The front and rear bumpers have also been adapted.The 128i is powered by the N52, 230 horsepower inline 6-cylinder 3.0-liter engine thatgenerates 200 lb-ft of torque, the 128i Coupe will feature Valvetronic, VAVOS and aluminum/magnesium block construction. The 135i Coupe features the N54 twin-turbocharged direct injection 3.0-liter inline six-cylinder engine, that produces 300 horsepower and an incredible 300 lb-ft of torque from as low as 1,400 rpm.Conforming to BMW’s Efficient Dynamics, these vehicles will include the following: Brake Energy Regeneration - The system increases the demand on the chargingsystem under braking thus charging the battery when the vehicle isreducing speed which results in saving fuel. (see page 27) Very light but rigid bodyshell. Aluminum front axle with lightweight components like hollow anti-roll bars. Run Flat Tires as standard eliminates the weight of a spare tire and jack.Exterior Dimensions905751266043604E82 Complete Vehicle949TK07-033914271423976In comparison to the E92, the E82 has become taller.
courtesy of www.1addicts.comThe E82 compared with the current E92:External dimensions (mm)E82E92Vehicle lengthOverall vehicle widthVehicle height, unladenWheelbaseOverhang frontOverhang rearTrack width frontTrack width rear436017481423266075194914861532 rior Dimensions7341357137213981423Note: A convertible version of the 1 Series, the E88 will also be availablein the Spring of 2008.5E82 Complete Vehicle
BodyThe E82 features an intelligent mix of parts. The front end is completely identical to thatof the E90. The doors were adopted from the European 1 Series. The rear end is somewhat shorter than that of the E92. The main differences are to be found in the sideframe. All steel grades in this vehicle were featured in the E90. From the very beginning,the aim has been to achieve the 5-star Euro NCAP rating. The E82 body therefore offersa high level of passive safety.AerodynamicsIn combination with the perfect 50/50 weight distribution and rigid body construction,this produces outstanding driving characteristics and effective dynamics.The aerodynamically favorable design is complemented by various aerodynamic components. These include the front spoiler edge, very smooth underbody pan with speciallydesigned cooling ducts molded into the bodywork.courtesy of www.1addicts.com6E82 Complete Vehicle
Additionally, the underbody allows a defined flow of air to be directed to componentssubjected to greater thermal load. It was also possible to influence flow and pressurecharacteristics by means of targeted improvements to spoiler edges and ram-air lips.Passive SafetyThe basis for the bodyshell's passive safety on the E82 are: High load-bearing carrier structures Optimum utilization of deformation ranges Extremely rigid passenger cell.Maintaining the interior required for protection of occupants even in the most severe ofaccidents places high demands on the structure of the passenger cell and on the deformation zones at the front and rear ends.All external loads acting on the vehicle are countered by specially designed load-bearinggeometries in the floor assembly, in the side frame, on the bulkhead, in the roof and onthe luggage compartment partition.The body structure of the E82 offers occupants maximum safety while optimizing vehicleweight at the same time. The use of high-tensile sheets in large-volume carrier structureswith the deliberate application of reinforcements makes it possible to achieve challengingobjectives in respect of the rigidity and strength of the body.courtesy of www.1addicts.com7E82 Complete Vehicle
In this way, an optimum dissipation of forces is achieved by means of precisely calculatedand tried-and-tested load paths in the event of a frontal collision with maximum or lowoverlap, i.e. a defined distribution of the force of impact onto several body components.The main focus in achieving balance in moderate and severe collisions is on the development of an optimum interaction between front-end deformation and passenger-cell rigidity. Only then can the prerequisites for minimizing the load to which occupants are subjected be achieved.Ideally, this load distribution can channel forces in severe collisions into the side oppositethe impact and it protects the bulkhead area in the footwell through dynamic deformationzones at the front. The energy absorption characteristics achieved form the basis formaintaining the passenger-cell structure and the prerequisite for the successful adaptation of restraint systems by means of a correspondingly low passenger cell deceleration.In the event of side impacts, the deformations and forces must, for the protection ofoccupants, be reduced to such an extent that the loads to which the occupants are subjected remain below the biomechanical limits.In addition, an impact-optimized footrest is fitted. In the event of a frontal collision, thefootrest deforms in the area between the driver's foot and the bodyshell. This significantlyreduces how much force is transmitted to the driver's foot.In addition, the following range of measures works at three levels.The specially arranged floor system causes impact forces to be transmitted to the side ofthe vehicle opposite the impact. In the door area, the doors themselves, the reinforced Bpillar, the seats and the instrument carrier between the A-pillars provide the stability of theside structure in connection with the roof frame. All the measures listed enable the vehicle to remain below significant values, such as the maximum permissible intrusion speed,in the event of a side impact.The rear deformation zone is made up of two longitudinal carrier sections, the luggagecompartment floor, rear trim panel, the rear side panels integrated in the side frame andvarious reinforcements.Here, too, the primary objective is to ensure that the protective function of the passengercell is retained even in the event of asymmetrical accident loads and that the doors canstill be opened despite suffering impact stress.Even if the vehicle overturns, the passenger cell safeguards the occupants' survival spacethanks to the heavily reinforced pillars and cross members.8E82 Complete Vehicle
courtesy of www.1addicts.comBodyshell BD, HC180YD, HX180BD6H400T, HC400TD, HC420LAD2DC01, DC04, DX54D, DX56D7HC600C, HD680C3HC220BD, HC220YD, HX220BD8Plastics4HC300BD, HC306LAD, HC300XD9Other metal materials5HC380LAD9E82 Complete Vehicle
courtesy of www.1addicts.comBodyshell , HC180YD, HX180BD6H400T, HC400TD, HC420LAD2DC01, DC04, DX54D, DX56D7HC600C, HD680C3HC220BD, HC220YD, HX220BD8Plastics4HC300BD, HC306LAD, HC300XD9Other metal materials5HC380LAD10E82 Complete Vehicle
courtesy of www.1addicts.comBodyshell , HC180YD, HX180BD6H400T, HC400TD, HC420LAD2DC01, DC04, DX54D, DX56D7HC600C, HD680C3HC220BD, HC220YD, HX220BD8Plastics4HC300BD, HC306LAD, HC300XD9Other metal materials5HC380LAD11E82 Complete Vehicle
courtesy of www.1addicts.comStrut/sill ConceptIndexExplanation11 Tension strutsLayout of ComponentsIndexExplanationIndexExplanation1TCU3CD changer2Battery12E82 Complete Vehicle
courtesy of www.1addicts.comBumpersIn contrast to the E90, the E82 has new bumper trims of different appearance. Energy isdissipated through carriers with deforming elements. Fulfillment of Institute for Highway Safety (IIHS) low-speed frontal crash at 10 km/h. Fulfillment of Institute for Highway Safety (IIHS) low-speed side crash at 5 km/h andan overlap of 15% vehicle width.The 135i is equipped with a trim weight on the rear bumper. This component contributesto an overall improvement in axle-load distribution.Slide/tilt SunroofThe slide/tilt sunroof is constructed in the same way as in the E90. Only the glass panelis slightly different due to the new roof contour. Removal/installation and adjustment areidentical to the E90.Door and Side PanelsThe door panel is newly designed with an integrated map pocket and a new dooropening handle.SeatsThe front-passenger seat is also equipped with height adjustment as standard.Otherwise, the front seats are identical to those of the E92.The rear bench seat is available as a two seater with or without through-loading facility.The rear seat backs fold down flat to enhance cargo space and for easy loading of thetrunk.13E82 Complete Vehicle
courtesy of www.1addicts.comChassis DynamicsChassis Dynamic Driving SystemsAs another member of the BMW 1 Series, the E82 has many features in common withthe E9X as far as the chassis and dynamic driving systems are concerned. The doublepivot spring strut front axle design has previously been used on all 3, 5, 7 and 8 seriesvehicles and will now be used on the new 1series. For the most part the E82 and E88front and rear suspension are identical to those of the E9X vehicles. With the exceptionof the 135i sport tuned version.Double Pivot Spring Strut Front AxleThe double pivot system establishes a geometrical “axis” that is formed by the suspension links, which in turn create pivot points, one upper and two lower. Two lower pivotpoints (double pivot) established by the control arm and tension strut create a “imaginary” pivot point, that is extended further out on the wheel carrier. This design allowspivot points on the wheel carrier to be selected in order to effectively accommodatelarger brakes.Additional advantages of double pivot system are: Ability to reduce body roll while cornering. Reduces front end dive tendencies during severe braking situations. Utilization of a small positive steering offset, which offers improvedhandling if friction levels while braking is different on both wheels. Improved caster position, improving straight line stability at higherspeeds, plus better steering return after small steering inputs.14E82 Complete Vehicle
courtesy of www.1addicts.comDouble pivot spring strut front axle/determining the lower pivot pointIndexExplanationIndexExplanation1Front Axle Carrier6Tension Strut2Wheel Hub7Stabilizer Bar3Stabilizer Link8Swivel Bearing4Control Arm9Hydro-Mount5Rack-and-Pinion Steering10Spring Strut15E82 Complete Vehicle
courtesy of www.1addicts.comRear Axle "HA 5"The rear axle on the E82/88 is of the development designation "HA 5" and was used forthe first time on the E90. Currently all E9X vehicles are equipped with a version of thisrear axle assembly.It is designed as a multi-link independent rear suspension axle with 5 different link arms.The designation "HA 5" does not refer to the five links but rather represents the consecutive development designation used at BMW.IndexExplanationIndexExplanation1Rear Axle Carrier6Stabilizer Link2Thrust Rod7Toe Link3Traction Strut8Semi-Trailing Arm4Wheel Hub9Camber Link5Control Arm10Wheel Carrier16E82 Complete Vehicle
courtesy of www.1addicts.comThe use of five links enables free selection of the pivot axle for the design layout. Thismeans that the movement of the wheel in interaction with the suspension can be optimized without compromise under braking, acceleration and lateral forces. This largelydetermines all important variables such as toe, camber, brake support (anti-dive) angle,roll center and roll center change rate.HA 5 Rear AxleThe large rear axle carrier is connected directly to the rigid frame side member, allowing itto transmit the applied crash forces more favorably. The semi-trailing arm features crashbeading (in the semi-trailing arm of the HA 5 rear axle) to ensure the fuel tank is not damaged.The braking support (anti-dive) realized on the E82 as on E9X vehicles represents anoptimum compromise between comfort, safety and driving dynamics requirements.The placement of the mounting points considerably lower stress and strain on the bodyand the option of designing the rear axle bearing mounts relatively soft. This arrangementand the double flexible mounting, provide outstanding insulation against road noise andtire rolling noise.Note: For further information on the 1 Series suspension refer to theE90 reference material.17E82 Complete Vehicle
courtesy of www.1addicts.comThe two upper links (blue in the illustration)form a triangle in the top view as do the twolower links (purple in the illustration). The rearlink (orange in the illustration) represents thetoe rod.The rear axle carrier and the links are madefrom high strength steel. The wheel carrier iscast from GGG 40.IndexExplanation1Toe Adjusting Screw2Camber Adjusting ScrewE9X/E82 Rear Axle AdjustmentsMinor differences exist between the HA 5 versions being used on the E9X and E82/88variants. The rear axle of the E82 is fitted with modified wheel hubs. As a result, the reartrack width of the E82 has been widened by 20mm in comparison to the E9X. Theexposed wheel housings combined with the wider track width at the rear to emphasizethis vehicle's rear-wheel drive.Wheel Hub on the Rear Axle, Difference between E82 - E90IndexExplanation1Drive shaft2Wheel bearing3E90 wheel hub4Widening of track width ( 10 mm each side)5E82 wheel hub18E82 Complete Vehicle
The springs and dampers have been specifically adapted to the E82 in terms of engineand car weight. They differ, therefore, from those in the E90. In the interests of weight,the front axle of the E82 is fitted with a tube-type anti-roll bar. Sports suspension tuningis available as an optionThe following steering systems are fitted in E82 vehicles: Conventional rack-and-pinion steering with Servotronic assist hydraulic pump(vane cell pump) this is the standard steering for all 128i and 135i vehicles. Active Steering with hydraulic pump and ECO valve is available as an option.Active Steering in the E82 features the following optimization measures carried overfrom the E70 or E6x LCI: Modified planetary gearing New control module Absence of the cumulative steering-angle sensor on the rack.Note: The new procedure for initializing the Active Steering (as in the E70) nowalso applies to the E82. (because of the absence of the cumulative steering-angle sensor).There will be no electrical steering lock (ELV) in the US variant of the E82. This applies tovehicles with automatic transmission and to vehicles with manual transmission.Dynamic Driving SystemsThe Dynamic Stability Control (DSC) has been newly tuned for the E82. DSC in the E82has undergone the following modifications.These only apply to the Active Steering models.: DSC sensor: two separate units, one with and one without a longitudinal acceleration sensor DSC control unit and hydraulic control unit modified Extended diagnostic capabilities thanks to more precise fault code memory entries.As a special case, it should be noted that, in vehicles with Active Steering, operation ofthe DSC sensor is monitored by both the DSC control unit and the Active Steering control unit.19E82 Complete Vehicle
courtesy of www.1addicts.comNew DSC FunctionAt present only the BMW M models are equipped with
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