Chassis Control Systems

BMW Service Aftersales Training
Participant's Manual
Chassis control systems
The information contained in this Participant's Manual is intended solely for the participants of
this seminar run by BMWAftersales Training.
Refer to the latest relevant "BMW Service" information for any changes/supplements to the
Technical Data.
Information status: October 2004
[email protected]
2004 BMW Group
Aftersales Training, Mnchen, Germany.
Reprints of this manual or its parts require the written approval of BMW Group,
Mnchen.
Participant's Manual
Chassis control systems
Steering systems
Longitudinal dynamics
Transverse dynamics
Ride-height control systems
Damper systems
Tyre inflation pressures
Notes concerning this Participant's Manual
Symbols used
The following symbols are used in this Participant's Manual for clearer
understanding and to emphasize important information:
3 Contains information that provides clearer understanding in relation
to the systems described and their operation.
1 Indicates the end of a note item.
Editorial status of the Participant's Manual
There may be deviations between this Participant's Manual and the
vehicles available in training courses due to ongoing developments in
design and the equipment of BMW vehicles.
Only left-hand-drive vehicles were documented at the time of publication.
The arrangement of some of the operating and control elements on right-
hand-drive vehicles may differ from the arrangement shown in the
illustrations of this Participant's Manual.
Additional sources of information
You find further information about individual vehicle topics in the BMW
diagnostics and repair systems or on the Internet at www.bmw.com.
Contents
Steering systems history
Objectives 1
Useful information for the reader 1
Introduction 3
History/steering 3
1
8
Objectives
General information on steering systems
Useful information for the reader
Steering systems at BMW- this is a field which
is becoming increasingly complex. To
maintain an overview and to be able to deal
with these systems confidently, support and
assistance is provided on the following pages.
You will be able to familiarize yourself with the
most important steering systems at BMW
Group and also find out how they are put
together and how they work.
Afterwards, you will understand their
construction and interaction, which will mean
that you will be equipped with all the
knowledge you need for successful
troubleshooting of steering system faults.
This understanding will enable you to base
your approach on the codes of engineering
practice when working on modern BMW
vehicles.
2
8
3
9
Introduction
General information on steering systems
History/steering
A steering system must be able to convert a
turning motion input by the driver at the
steering wheel into a change of steering angle
at the steered wheels on the vehicle. This is
the essential requirement of a steering system
irrespective of whether it is a simple,
conventional steering system or the latest
modern BMW Group steering system.
Steering systems must have the following
characteristics:
The construction of the steering gearbox in
each case must enable the vehicle to
respond to the slightest steering
adjustments.
When the steering wheel is released, the
wheels must return to the centre position
(straight-ahead travel).
The steering kinematics must follow the
Ackermann rule, i.e. when the left and right
wheels are locked over, the extension of the
wheel axes must intersect the extension of
the rear axle.
The steering systemmust compensate for
unevenness in the road whilst ensuring that
the driver remains in control.
To achieve the best possible handling, the
steering system must have a low
transmission ratio, i.e. number of steering-
wheel turns from lock to lock.
On the whole, two types of steering meet
these requirements - rack-and-pinion steering
and recirculating-ball steering.
Rack-and-pinion steering:
Rack-and-pinion steering essentially consists
of a pinion and toothed rack. The transmission
ratio is determined by the ratio between the
number of pinion revolutions (steering wheel
turn) and the rack travel. The transmission
ratio varies with the rack travel and
corresponding gearing of the rack. Steering
corrections and operating forces are dealt with
by this system.
Recirculating-ball steering:
A low friction endless row of balls transmits
forces between the steering worm and
steering nut. The steering nut exerts a force
on the steering shaft via gear teeth. A variable
ratio is also possible with this steering gear.
An extensive and wide-ranging development
history lies behind the modern steering
systems used nowadays incorporating power
steering assistance.
1 - View of steering system
4
9
However, this development has given rise to
conflicting objectives. Greater assistance is
required during parking whereas less
assistance is required at high road speeds as
high servo assistance in the latter situation
would lead to a loss of desirable road surface
contact. This conflict has been resolved by
power steering systems with speed-
dependent control. The servo assistance
decreases as the driving speed increases. In
this way, the steering conveys the familiar
good contact between the road and wheel.
An additional step also changes the
transmission ratio. A decisive milestone here
was also the introduction by BMW of a
dynamic steering system, which represented
a new level in driving comfort, pleasure and
safety. This new global optional product is
known as active steering. BMW technicians
call this system AL. The abbreviation AL
stands for active steering.
If a vehicle begins to lose grip on the road
surface, the DSC attempts to restore driving
stability by braking wheels individually.
However, it might in fact be more logical to
counter these kind of situations through
steering system intervention. Active Steering
has made this and other things possible. The
variable steering gear transmission ratio has
made driving on winding roads an enjoyable
experience and saves the driver unnecessary
work at the wheel.
Another clear advantage of active steering is
evident when observing the number of
steering wheel turns required when parking.
Considerably less steering effort is required in
this situation compared to vehicles without
active steering.
Contents
Active steering
Introduction 1
Advantages of active steering 1
System overview 3
Mechanical system overview 3
Inputs/outputs on the E60 as an example 4
Bus overview using the E60 as an example 6
Functions 9
Motor position sensor of the actuating unit 9
Cumulative steering angle sensor 10
Steering angle sensor 11
Active Steering control unit 12
Safety and gateway module (SGM) 13
Hydraulic pump 14
Power steering cooler 16
Active Steering actuating unit 17
System safety 25
System components 27
System circuit diagram using the E60 as an
example 27
Service information 29
1
5
Introduction
Active steering
Advantages of active steering
The dynamic steering systemknown as active
steering is nowbeing used at BMWfor the first
time since the E60. In addition to the power
assisted torque provided by the power
steering, the electronically-controlled steering
system also employs a variable steering gear
transmission ratio to assist the driver. During
this process and depending on the vehicle
speed, an electric motor uses a wormdrive to
intervene in a planetary gearbox with override
function. This means that, depending on the
driving situation, the steering system
generates an additional/reduced steering
angle for the front wheels by changing the
transmission ratio of the steering shaft pinion.
In critical situations, the steering system can
selectively change the steering lock when the
wheels are turned by the driver thus stabilizing
the vehicle more quickly than the driver could.
The active steering is networked with the DSC
driving stability programand can intervene and
correct the steering angle via a yaw rate
control at the first sign of instability. This
means that active steering reduces DSC
interventions in the lower response range thus
providing optimum control comfort.
Active steering offers optimum agility,
convenience and active driving safety.
Increased agility
Due to the direct transmission ratio, the
vehicle is perceived as having a greater agility
and handling performance up into the medium
driving speed range (approximately 100 km/h).
The driver also has far greater control when
swerving, for example - this combined with
considerably enhanced steering precision and
reduced steering effort. Direct contact with
the road via the steering wheel is maintained
throughout.
Increased convenience
Some BMW models require more than 3 full
steering-wheel turns to achieve a full wheel
lock from the far left over to far right. Active
Steering reduces this at low speeds to less
than 2 steering-wheel turns from lock to lock.
The benefit: less steering effort is required
when turning in city traffic or manoeuvring in
narrow parking spaces. On twisting roads in
mountainous regions, for example, the
reduced steering angle also ensures that
hands always remain in the optimum position
on the steering wheel, which means that
crossing of hands, or even arms in some
cases, is no longer necessary. The
multifunction buttons on the steering wheel or
the gearshift paddles for the SMG sequential
manual transmission therefore always remain
conveniently within reach in all road situations.
Increased active driving safety
The situation at high speeds is somewhat
different:
A more indirect transmission ratio during high-
speed journeys moderates driving errors as
well as sudden steering wheel movements
arising from fright reactions. Active steering
stabilizes yaw (turning motion of the vehicle
about its vertical axis) at the outset. Yaw
motion occurs for example when changing
lane, when swerving or when a load change
occurs during cornering. Active steering
intervenes electronically at all speeds without
the driver being aware of this. The electronic
stability program - dynamic stability control
(DSC) - therefore does not need to intervene
as frequently or as powerfully.
2
5
Characteristics of active steering
At high speeds, the steering gear transmission
ratio becomes increasingly indirect, reaching,
and even extending beyond the level of
conventional steering systems. The
corresponding increase in steering-wheel
torque level prevents undesirable steering
wheel movements and therefore supports
driving stability.
Undesirable vehicle movements, e.g.
oversteering, are compensated for without
requiring corrective intervention on the part of
the driver.
When parking, only small steering wheel
movements are required to achieve a large
wheel lock: less than 2 revolutions from
steering wheel lock to lock.
3
6
System overview
Active steering
Mechanical system overview
1 - System overview
Index Explanation Index Explanation
1 Hydraulic oil reservoir 4 Hydraulic hose
2 Hydraulic pump with ECO valve 5 Steering gear with actuating unit
3 Power steering cooler for the
hydraulic fluid
4
6
Inputs/outputs on the E60 as an example
2 - Input/Output
5
6
1 Dynamic stability control DSC 16 Motor position sensor
2 Wheel speed sensor, front right 17 Steering angle sensor
3 Wheel speed sensor, rear right 18 Cumulative steering angle
sensor
4 Brake pad wear sensor, front left 19 DSC sensor 2
5 Brake pad wear sensor, rear right 20 DSC sensor
6 Digital motor electronics DME
(or digital diesel electronics DDE)
21 DSC button in the centre
console switch cluster SZM
7 Electromagnetic lock 22 Brake-fluid level switch
8 Actuator motor at the
superimposed gear unit
23 Brake light switch
9 Servotronic valve 24 Wheel speed sensor, rear left
10 Power steering pump with ECO
valve
25 Wheel speed sensor, front left
11 BMW diagnostic system byteflight byteflight
12 Safety and gateway module
SGM
F-CAN Chassis CAN
13 Active steering control unit K-CAN Body CAN
14 Instrument cluster PT-CAN Powertrain CAN
15 Car access system CAS
6
6
Bus overview using the E60 as an example
3 - Bus overview
7
6
CAS Car access system CDC Telephone
SZM Centre console switch cluster CDC CD changer
PDC Park distance control SGM Safety and gateway module
DWA Anti-theft alarm system SBSL B-pillar satellite, left
RLS Rain/driving lights sensor TMFA Door module, driver
AHM Trailer module SFZ Vehicle centre satellite
SMFA Driver's seat module SZL Steering column switch cluster
LM Light module TMBF Door module, passenger
IHKA Integrated automatic heating/air
conditioning
SBSR B-pillar satellite, right
SMBF Passenger's seat module ACC Active cruise control
KBM Body basic module EKP Electric fuel pump
SH Auxiliary heating DSC Dynamic stability control
CDN Controller EGS Electronic transmission control
unit
Kombi Instrument cluster ARS DynamicDrive
CID Central information display AFS (AL) Active steering
SHD Slide/tilt sunroof DME Digital engine electronics
M-ASK Multi-audio system controller DDE Digital diesel electronics
Top-HiFi Top HiFi amplifier
8
6
9
7
Functions
Active steering
Motor position sensor of the actuating unit
The motor position sensor of the actuating
unit is located on the rear of the electric motor
of the active steering actuating unit.
1 - Motor position sensor
1 Motor position sensor 2 Electric motor
10
7
Cumulative steering angle sensor
The vehicle is only equipped with a cumulative
steering angle sensor if it is also equipped with
active steering.
The cumulative steering angle sensor detects
the angle of rotation of the steering pinion and
thus the steering angle of the vehicle.
The cumulative steering angle sensor is
mounted on the actuating unit of the active
steering and cannot be replaced individually.
The cumulative steering angle sensor
operates in accordance with the
magnetoresistive principle.
2 - Steering angle sensor
installation location
Index Explanation
1 Cumulative steering angle sensor
11
7
Steering angle sensor
The steering angle message is forwarded to
the active steering control unit by the steering
column switch cluster SZL.
There is a second processor in the SZL for the
redundant steering angle calculation. The
second processor is only fitted if the vehicle is
equipped with active steering. The second
processor is used for plausibility monitoring of
the signal.
The steering angle sensor is located in the
steering column switch cluster.
12
7
Active Steering control unit
The active steering control unit is located in
the right-hand footwell. The control unit is
bolted to the floor of vehicle.
The active steering control unit is housed to
prevent damage caused by the feet of vehicle
occupants.
The control unit is integrated into the vehicle
electrical system by the PT-CAN and the F-
CAN.
The active steering control unit uses various
input signals to calculate the signals for
controlling the active steering actuating unit.
The active steering control unit is initialized
after the ignition is switched on. The active
steering actuating unit cannot be operated
during initialization. The sensor signals are
checked and calibrated if necessary. If errors
are detected, either the "Error" fault status is
activated immediately or the yaw rate control
is deactivated. The actuating unit cannot be
operated when the "Error" fault status is
active. If initialization is successful, the "Drive"
status is activated.
The active steering control unit sends the
information about the required volumetric flow
of the power steering pump to the SGM.
13
7
Safety and gateway module (SGM)
The SGMcomprises the junction of the same
central gateway module (ZGM) used on the
E65 and the safety and information module
(SIM).
In the SGM housing, there are 2 separate
motherboards linked by CAN connection.
The output stages for controlling the
Servotronic valves and the ECO are
integrated in the SGM.
The SGM is located in the equipment carrier
behind the glove compartment.
The SGM receives the volumetric flow
information for controlling the Servotronic
valve and the ECO from the active steering
control unit. The signal from the SGM for
controlling the Servotronic valve and the ECO
is pulse-width modulated.
The software for controlling the Servotronic
valve and the ECO is installed in the SGM on
vehicles with active steering. The active
steering control unit sends the information
required for controlling the Servotronic valve
and the ECO to the SGM. The information is
sent via the PT-CAN.
The software for controlling the Servotronic
valve is installed in the SGM on vehicles with
active steering. No ECO valve is installed in
vehicles without active steering.
14
7
Hydraulic pump
The hydraulic pump is a vane-type pump and
has an electrically regulated valve for
regulating the volumetric flow of the hydraulic
fluid. The name of this valve is electrically
controlled orifice (ECO).
The active steering systemis able to generate
greater angular velocities of wheels by
comparison with conventional power-assisted
rack and pinion steering. A correspondingly
high level of hydraulic power must be
maintained in the hydraulic system for these
high angular velocities. An adequately
dimensioned, conventional vane pump would
generate a high loss of power. Fuel
consumption would be increased
unnecessarily. A better solution would be
achieved using a controllable hydraulic pump.
The hydraulic pump with the ECOcontrols the
volumetric flow corresponding to
requirements. At the same time, the hydraulic
pump reduces the ram pressure in the
steering system.
3 - Hydraulic pump
Index Explanation
1 Electrical controlled orifice (ECO)
15
7
The low power consumption of the hydraulic
pump reduces fuel consumption and thus the
CO
2
emissions of the vehicle.
When the ECO is supplied with maximum
current, the hydraulic pump delivers a
maximum of 15 litres/minute, depending on
the engine speed.
When the ECOis supplied with no current, the
hydraulic pump delivers a reduced volumetric
flowof approximately 7 litres/minute for power
4 - ECO valve hydraulic circuit diagram
Index Explanation
1 Power-assisted rack and pinion
steering
2 Damping orifice
3 Pressure limiting valve
4 Pressure regulating valve
5 Hydraulic reservoir
6 Hydraulic pump
7 ECO valve
16
7
Power steering cooler
The power steering cooler is located at the
engine cooling module.
The power steering cooler comprises 4 pipes
with a right-angle cross section and soldered
fins.
5 - Power steering cooler
17
7
Active Steering actuating unit
The active steering actuating unit is located in
the steering gear. The active steering
actuating unit is fitted in the divided steering
column between the Servotronic valve and the
rack.
The active steering actuating unit comprises a
brushless DCsynchronous electric motor and
a planetary gear train.
The core component of the active steering
actuating unit is a superimposed gear unit with
2 input shafts and one output shaft.
The input shaft is connected to the lower
steering shaft as with standard Servotronic.
The second input is driven by the electric
motor via a self-locking reduction wormdrive.
The self-locking feature of the worm drive
ensures that the worm is turned only by the
electric motor. The wormdrives a wormwheel
that superimposes the front wheel steering
angle input by the driver at the steering wheel.
6 - Actuating unit with rack
1 Cumulative steering angle
sensor
5 Servotronic valve
2 Rack 6 Steering shaft
3 Planetary gear train housing 7 Electric motor
4 Solenoid lock
18
7
The electric motor is permanently connected
to the wormdrive and engages, free of play, in
the worm wheel. The direction, speed and
duration of motor rotation are monitored by
motor angle sensor to calculate the redundant
steering angle.
The superimposed gear unit essentially
comprises the wormwheel, two planet carriers
and three planet wheels. The permanent
connection forms a compact unit.
The planetary gears form the mechanical
connection between the upper (shaft of the
Servotronic valve) and the lower sun wheel.
The lower sun wheel and the drive pinion are
designed as a single component. Direct drive
to the splines on the rack is ensured through
the Servotronic valve, even in the opposite
direction.
Turning the worm wheel, induced by the
electric motor, causes the planetary gears to
turn around two sun wheels. The two sun
wheels turn at different speeds because the
planetary gears have different numbers of
teeth. The steering wheel and worm
movement meet at the lower sun wheel and
are transferred to the rack by the drive pinion.
The movement of the rack produces an
additional steering angle. This steering angle
is smaller (negative) when the wormwheel and
upper sun wheel move in the same direction.
However, in this case, the effective steering
angle is larger (positive) than defined by the
basic gear ratio.
19
7
7 - Active steering
1 Drive pinion 7 Safety lock
2 Planet gear, ECO valve carrier 8 Worm drive
3 Worm wheel 9 Electric motor
4 Planetary gear 10 Motor position sensor
5 Sun wheel (shaft) 11 Rack
6 Servotronic valve
20
7
A solenoid-operated safety lock is fitted. The
safety lock engages under spring load in the
locking splines of the gear drive when no
voltage is applied.
The safety lock is released when there is a
current of approximately 1.8 A.
8 - Active steering planetary gear
2 Planet wheel carrier 7 Safety lock
3 Worm wheel 8 Worm drive
4 Planetary gear 9 Electric motor
5 Sun wheel (shaft)
21
7
The position of the electric motor's rotor is
detected by the motor position sensor on the
electric motor.
The voltage of the electric motor is supplied
via the 3 phases. The 3 phases are supplied
with current alternately by the electronics of
the active steering control unit.
The shielding is realized by the ground
connection of the electric motor housing to
the body.
9 - Solenoid lock layout
1 Electric motor 3 Solenoid lock
2 Motor position sensor
22
7
The actuating forces for turning the wheels
are not produced by the electric motor,
however, but by the separate power steering
assistance as with conventional steering.
10 - Power supply
1 Active steering control unit 5 Motor stands
2 Processor 6 Motor coils
3 Circuit in the control unit 7 Electric motor
4 Analogue/digital converter
23
7
Functions of the active steering
Variable steering gear ratio
This function adapts the steering gear ratio to
the driving speed and the steering angle
required by the driver. The steering is indirect
at high driving speeds. The steering is direct at
slow driving speeds.
The ease of handling the vehicle at lowspeeds
or when parking is greatly increased by the
active steering actuating unit. It is no longer
necessary to grapple with the steering wheel.
Just two turns of the steering wheel when the
vehicle is stationary are enough to move the
steering wheel from one lock to the other.
At high speeds (> 120 km/h), the active
steeringprovides a more indirect steeringgear
ratioby comparisonwithconventional steering
systems. The actuator motor operates against
the steering wheel angle at high speeds.
Together with the elevated steering torque
level (Servotronic), this has the effect of
improving directional stability.
Yaw rate control
The active steering system supports the
vehicle stabilization functions of DSC.
In critical vehicle dynamics situations, the
active steering specifically changes the
steering lock of the wheels defined by the
driver. The vehicle is stabilized much faster
than possible by the driver.
The intervention thresholds of DSCare higher
than the intervention thresholds of the active
steering. If oversteering is detected, active
steering initially intervenes in an attempt to
stabilize the vehicle. DSConly intervenes if the
steering is unable to stabilize the vehicle on its
own.
11 - Steering gear ratio
1 Active steering design 3 Road speed
2 Conventional design 4 Ratio
24
7
Power steering assistance
Power steering assistance is realized by
conventional hydraulic rack and pinion
steering.
The magnitude and direction of the auxiliary
hydraulic force acting on the rack depend on
the rotational angle of the torsion rod. The
torsion rod is located between the steering
shaft and pinion.
Servotronic, the speed-dependent power
steering assistance, is available as option SA
216.
The electronics and the software for
Servotronic are located in the SGM if the
vehicle is not equipped with active steering.
On vehicles with active steering, the software
for the power steering assistance is installed in
the active steering control unit. The output
stage for activating the Servotronic valve and
the valve in the hydraulic pump (ECO) is
located in the SGM and controls the
volumetric flow in the hydraulic pump such as
to make available only the volumetric flow
required for the power steering. The ECO
therefore controls the power intake of the
hydraulic pump, thus reducing the fuel
consumption and the CO
2
emissions of the
combustion engine.
25
7
System safety
A situation that would critically affect driving
safety would be for the active steering to
initiate steering movements on its own.
The safe system status (fail-safe) is when the
actuator motor of the actuating unit is without
power. Irrespective of whether the safe status
is initiated by loss of power or by specific
system shutdown, the fail-safe system
ensures: the actuating unit does not engage in
the steering. The actuating unit is arrested by
a lock that engages in the worm drive of the
actuating unit. The lock is pretensioned by a
spring and held against this pretension by the
power supply. The actuator unit is inhibited by
a break in the power supply.
The arrested superimposed gear unit ensures
that it is still possible for steering wheel
movements input by the driver to be
transferred along the steering column. The
steering then responds in the same way as
conventional steering. The purely mechanical
transmission between the steering wheel and
the front wheels is retained.
The electric motor of the active steering
actuating unit is connected to 3 phases. A
short circuit to earth will therefore prevent the
electric motor from completing a full turn, the
maximum possible being only 120 (360 : 3).
The Servotronic valve switches under no
electrical load to the fast driving characteristic
curve. The power steering assistance is
reduced accordingly. The volumetric flow
when the ECO is without power is 7 litres/
minute.
If the active steeringcontrol unit does not send
a valid message on the PT-CAN, the SGMwill
operate with a speed-dependent substitute
characteristic curve after 100 ms. The
substitute characteristic curve guarantees
sufficient steering response for the passive
active steering system.
The driver is made aware of faults in the
systemin the formof an indicator lamp symbol
as well as check control messages in the
instrument cluster.
The check control message reads:
Active steering failure! Steer with care.
The following or similar message will appear in
the control display:
Steering behaviour altered! Possible to
continue the journey. Steering wheel may be
at an angle. Have the problemchecked by the
nearest BMW Service.
12 - Indicator lamp
26
7
Activation conditions
The activation conditions for the active
steering system are terminal 15 ON and a
running engine.
After the engine is started, the system
synchronizes the position of the steering
wheel and the wheel lock. This ensures
steering wheel movements are detected
when the system is switched off (passive
state). The steering wheel position and wheel
lock always agree. Steering wheel or wheel
movements may be perceived.
27
8
System components
Active steering
System circuit diagram using the E60 as an example
1 - System circuit diagram
28
8
This overview shows how the vehicle stability
control systems are networked with the
dynamic stability control (DSC). Sensors and
signals used by the DSC are also used by the
active steering control unit. The steering lock
turned by the driver is specifically
counteracted in critical driving situations. This
enables the vehicle to be stabilized more
quickly and more effectively. It is also possible
to compensate for undesirable vehicle
movements, e.g. oversteering, by the active
steering, without the driver having to intervene
with corrective steering. The intervention
thresholds of DSC are higher than the
intervention thresholds of the active steering.
The active steering initially intervenes when
control of the vehicle dynamics is required.
DSC will intervene if intervention by the
steering is not sufficient to stabilize the vehicle
on its own.
1 Dynamic stability control DSC 19 DSC sensor 2
2 Wheel speed sensor, front right 20 DSC sensor
3 Wheel speed sensor, rear right 21 DSC button in the centre
console switch cluster SZM
4 Brake pad wear sensor, front left 22 Brake-fluid level switch
5 Brake pad wear sensor, rear right 23 Brake light switch
6 Digital engine electronics DME
(or digital diesel electronics DDE)
24 Wheel speed sensor, rear left
7 Electromagnetic lock 25 Wheel speed sensor, front left
8 Actuator motor at the
superimposed gear unit
Kl. 15 Terminal 15
9 Servotronic valve Kl. 30 Terminal 30
10 Power steering pump with ECO
valve
Kl. 30 g Terminal 30g
11 BMW diagnostic system Kl. 31 Terminal 31
SGM
Kl. R Radio terminal
13 AFS control unit (active steering) byteflight byteflight
14 Instrument cluster D-Bus Diagnosis bus
15 Car access system (CAS) F-CAN Chassis CAN
16 Motor position sensor K-CAN Body CAN
17 Steering angle sensor PT-CAN Powertrain CAN
18 Cumulative steering angle
sensor
29
9
Service information
Active steering
Service information
Steering angle sensor adjustment
A steering angle sensor adjustment (offset)
must be carried out if the steering column
switch cluster (SZL) or the steering gear and
rack are replaced.
The cumulative steering angle sensor in the
steering gear is calibrated to rack centre by the
steering gear manufacturer.
Radio reception interference
Radio interference may be caused by a broken
connection between the shielding of the
3 phases of the actuating unit to the housing
of the active steering control units.
Diagnostics, coding
For diagnostics purposes, the active steering
can be controlled as a control unit in its own
right. The control unit is an individual
component.
Coding only enters vehicle-specific
configurations.
30
9
Contents
EPS steering systems
Introduction 1
Electromechanical power steering 1
New system features 2
System advantages 3
System overview 5
Vehicle electrical system diagram 5
IN/OUT overview 7
Functions 9
System functions 9
Components 11
Servo unit 14
Steering wheel torque sensor 17
Steering angle sensor 18
EPS control unit 19
Electric motor and worm gear 20
Lower steering shaft 21
Steering gear with rack 23
Notes for service staff 25
Coding and diagnostics 27
1
5
Introduction
Electromechanical power steering
Electromechanical power steering,
abbreviation EPS, is used by BMWfor the first
time in the E85. It offers the same steering
force and steering feel characteristics that are
typical of BMW steering systems. Another
term you may find used for EPS is Electric
Power Steering.
EPS offers very direct, sporty steering that
makes it possible to switch between standard
and sports mode using the Dynamic Driving
Control button.
EPS operates according to road speed and
actively centres the steering.
2
5
New system features
New features by comparison with previous BMW developments
The EPS allows for an extremely high degree
of flexibility in steering tuning as adaptation of
the damping, the active return and of the
steering characteristic takes place by way of
the software.
The EPS is a "dry system". There are no
hydraulic components such as the expansion
tank, pump, cooler, lines and hydraulic oil
(environmental aspect).
A dampened pressure piece is used in the
steering gear.
Electromechanical power steering is used in
vehicles that require less steering force owing
to the vehicle's low weight (e.g. Audi A3, Golf
V, Vauxhall Corsa).
3
5
System advantages
Benefits by comparison with previous BMW developments
Electromechanical power steering offers the
customer, the maintenance service and the
fitter a range of benefits by comparison with
hydraulic power steering. EPS has the
following benefits:
Improved driving dynamics
Enhanced driving comfort
Greater driving safety
Less harmful to the environment
Simplifications for the vehicle manufacturer
Improved driving dynamics
Good steering response due to direct
transfer of steering force
Active centring
Selectable steering characteristics (sports
mode)
Longitudinal dynamics benefit of 1.6 kW
Use of low-weight sports steering wheels
Enhanced driving comfort
Decoupling of axle vibrations with no impact
on the transfer of relevant road surface
information (different road conditions) to
the driver
Better protection from road surface
defects, less jarring
Controlled, speed-dependent steering
force support (e.g. when parking)
Greater driving safety
At high speeds and with low steering force,
EPS reproduces the feel of a direct
connection with the road and directly
transfers road surface information.
Speed-dependent active damping reduces
the movement of the steering wheel.
Less harmful to the environment
Fuel saving of approximately 0.23 l per
100 km
A dry system cannot have leaks
Simplifications for the vehicle
manufacturer
Simplified fitting and testing in works
because delivered as a complete system
Fewer component variants than in hydraulic
systems (pumps, hoses, steering wheels)
Easier tuning of steering force support
through programming
Great future potential: Drive by wire,
networking of systems in the vehicle
(brakes, chassis)
4
5
5
6
System overview
Vehicle electrical system diagram
1 - Bus overview
6
6
CDC CD changer (Compact Disc
Changer)
LWS Steering angle sensor
CID Central information display NAV Navigation computer
CVM Convertible soft top module PDC Park distance control
DME Digital engine electronics RADIO Radio
DSC Dynamic stability control RLS Rain/driving light sensor
EGS Electronic transmission control
unit
SBSL B-pillar satellite, left
EPS Electric power steering SBSR B-pillar satellite, right
EWS Electronic immobilizer SIM Safety and information module
GM5 General module 5 SM Seat module
HiFi Top-HiFi amplifier (DSP) SMG Sequential manual gearbox
IHKA Integrated automatic heating
and air conditioning
SZM Centre console switch cluster
IHKS Integrated heating and air
conditioning control
TEL Telephone control unit
IHS Integrated heating control VM Video module
LSZ Light switch cluster
7
6
IN/OUT overview
2 - System overview
1 FDC button with function
indicator lamp
5 DSC control unit
2 EPS servo unit with control unit,
steering wheel torque and EPS
motor speed sensor
6 MS45.0 engine control
4 Steering angle sensor D-Bus Diagnosis bus
8
6
9
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Functions
System functions
The EPS system has the following functions:
Power steering assistance with Servotronic
Adjustment of steering force
Active steering centring
Check display
Power steering assistance
The system is integrated with Servotronic,
which electronically regulates the speed-
dependent power steering assistance.
The control unit determines the amount of
power steering assistance required from a
range of input variables.
Characteristic maps for assistance and
damping characteristics are stored in the
control unit. The power assistance torque
required is derived fromthe values calculated
fromthe input variables in conjunction with the
characteristic curve. The power assistance
torque is produced by the electric motor and
the transmission.
Important input variables for power steering
assistance:
Road speed
Steering input by the driver
Steering angle speed
Steering angle
FDC button
System temperature
The operating voltage range is 9 V to 16 V.
Adjustment of steering force
The sports-oriented driving function is
selected with the vehicle dynamics control
button (FDC button). The engine
management then sends the corresponding
signal via the PT-CANto the EPS control unit.
The EPS control unit switches to a map for a
sporty driving. The deflection and holding
forces are tuned for a more sporty driving
style.
One of two characteristic curve sets is
selected when the "FDC button ON" CAN
message is sent from the engine control.
Characteristic curve set 1 is the standard
characteristic curve set.
Characteristic curve set 2 is the sports
characteristic curve set.
Active steering centring
Active steering centring is controlled based on
steering angle information from the steering
angle sensor.
Active steering centring ensures that steering
return behaviour is the same across the entire
operating temperature range.
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7
Check display
The vehicle's instrument cluster is equipped
with an indicator lamp for the EPS system.
The indicator lamp informs the driver of a
significant reduction in steering force support
or of a complete power assistance shutdown.
The possible reasons for system shutdown
are:
Fault in the EPS control unit or another
control unit in the system(DSCcontrol unit,
steering angle sensor, engine control unit)
Thermal overload of the EPS
Under/overvoltage
1 - Indicator lamp
11
8
System components
Components
The EPS system can be divided into 3
assemblies:
Upper steering column
Lower steering shaft
Steering gear with rack
1 - EPS assemblies
1 Upper steering column 3 Steering gear with rack
2 Lower steering column
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8
In the after-sales service organization, these
assemblies are replaced individually as a unit if
their components require replacement.
The visible components of the upper steering
column are the EPS control unit, the electric
motor with worm gear and the steering angle
sensor.
The lower steering shaft and the steering gear
with rack are separate assemblies.
2 - Complete EPS system
1 Control unit 4 Steering gear with rack
2 Electric motor with worm gear 5 Steering angle sensor
3 Lower steering shaft
13
8
Upper steering column assembly
The upper steering column is secured to a
bracket by 4 bolts, the bracket itself is welded
to the instrument cluster support pipe.
The bracket for the support pipe is secured to
the body by 4 bolts.
It is possible to distinguish the mechanical
section of the upper steering column
assembly fromthe electrical section: the servo
unit.
The mechanical section of the upper steering
column begins with the steering wheel and
ends with the connection to the lower steering
shaft. The mechanical section of the upper
steering column transfers the entire steering
wheel torque to the lower steering shaft.
The electrical section provides the power
The following components are part of the
upper steering column assembly:
Steering lock with ignition switch
Mechanical steering wheel adjustment
Servo unit: the servo unit comprises the
EPS control unit, the EPS electric motor
with worm gear and internal EPS sensors.
Steering angle sensor: the steering angle
sensor is part of the mechanical section of
the upper steering column.
The steering angle sensor and the steering
lock are the only parts of the upper steering
column that may be replaced individually.
This section describes in detail the individual
main components of the servo unit.
Lower steering column assembly
The lower steering shaft transfers the high
steering forces from the upper steering
column to the steering gear.
Steering gear with rack assembly
The steering gear is purely mechanical.
The following components are part of the
steering gear assembly:
Rack
Track rods
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8
Servo unit
The servo unit is the electrical part of the
upper steering column.
The role of the servo unit is to provide active
steering force support as a function of steering
forces and system conditions.
Installation location
The servo unit is located on the upper steering
column, housed in the vehicle interior.
3 - Servo unit on the steering column
1 EPS control unit 3 Balancing spring
2 Servo unit electric motor 4 Column tube of the upper
steering shaft
15
8
Design
The servo unit comprises the following
components:
Various internal sensors. They serve the
purpose of registering
the speed of the electric motor
the steering torque
the system temperature
the system voltage
Flat spring cassette for the current draw of
the internal steering wheel torque sensor
EPS control unit
Electric motor with mechanical worm gear
4 - Design
1 Magnet wheel 6 Steering angle sensor
2 Steering wheel torque sensor with
flat spring cassette
7 Anti-twist lock
3 EPS control unit 8 Housing for the worm gear and
steering wheel torque sensor
4 Servo unit electric motor 9 Worm gear
5 Worm gear shaft 10 Torque rod
16
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Operating principle
The servo unit makes the required amount of
power steering assistance available.
The servo unit detects the steering input from
the steering wheel by means of steering wheel
torque sensors.
The EPS control unit calculates the required
steering assistance. The electric motor is
actuated. The electric motor in the servo unit
transfers the amount of power steering
assistance required to the worm gear.
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8
Steering wheel torque sensor
The steering wheel torque sensor is fitted in
the servo unit and thus forms part of the upper
steering column assembly.
The steering wheel torque sensor is located in
the wormgear housing of the servo unit on the
upper steering shaft.
Design
The steering wheel torque sensor comprises
the input shaft, torque rod, output shaft and
magnetoresistive element.
The signal transfer, power supply and earth
lines of the steering wheel torque sensor are
routed inside a flat spring cassette.
The flat spring cassette is secured to the
output shaft of the upper steering shaft and is
located in the housing for the worm gear and
the magnetoresistive element.
Operating principle
Operation of the steering wheel torque sensor
is based on the magnetoresistive principle.
The magnetoresistive elements generate
different voltage signals that are forwarded to
the control unit. The control unit calculates the
power assistance torque to be generated by
the electric motor.
As in the case of a hydraulic steering gear, the
input shaft of the upper steering shaft is
connected to the output shaft of the upper
steering shaft by a torque rod.
Notes for service staff
The steering wheel lock must be locked in
zero position when performing all work on the
steering column. The locking device must be
additionally installed to ensure the signal line in
the coil spring package is not broken.
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8
The steering angle sensor (LWS) is part of the
upper steering column assembly.
The steering angle sensor used is the same as
the one on the E46.
With the EPS system, the LWS is only
important for the active steering centring.
The steering angle sensor is located on the
upper steering column in the vehicle interior.
Note for service staff: Steering angle sensor replacement
The steering angle sensor can be replaced as
an individual part. The upper steering column
must be removed to permit replacement of
the steering angle sensor.
After the steering angle sensor has been
refitted, the steering angle must be calibrated
and re-encoded.
5 - Steering angle sensor installation location
Index Explanation
1 Steering angle sensor
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8
EPS control unit
The EPS control unit is fitted in the servo unit
and thus forms part of the upper steering
column assembly.
The EPS control unit is part of the servo unit.
The EPS control unit is permanently
connected to the top of the electric motor.
Operating principle
The EPS control unit calculates the required
steering assistance from the signals of the
steering torque sensor. At the same time, the
EPS control unit actuates the electric motor.
The EPScontrol unit receives the information,
relating to the steering assistance currently
set by the electric motor, from the speed
sensor of the electric motor.
The EPS control unit calculates the steering
angle speed fromthe speed information of the
electric motor. The steering angle speed is
necessary for the active steering reset and
steering damping functions.
6 - Servo unit on the steering column
1 EPS control unit 3 Balancing spring
2 Servo unit electric motor 4 Column tube of the upper
steering shaft
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8
Electric motor and worm gear
The electric motor and worm gear are part of
the servo unit.
Design
The electric motor and worm gear form one
unit.
Operating principle
The electric motor transfers the steering
torque necessary for power steering
assistancetowormgear supportedby resilient
bearings. The worm gear transfers the
steering torque to the steering column at a
ratio of 1:20. The whole mechanical force
transfer of the steering thus begins at the
upper steering column.
The steering forces are transferred from the
upper steering column to the lower steering
shaft and forwarded from the lower steering
shaft to the steering gear.
Noise characteristics
The electric motor and the worm gear of the
servo unit produce a new sound pattern
(acoustics) in the vehicle interior.
The EPS has distinct, system and design-
related noise characteristics.
These system and design-related noise
characteristics can be heard in specific
situations:
When the steering wheel is turned rapidly
When the steering wheel is turned with the
vehicle stationary
When the steering wheel turned in quiet
surroundings (e.g. radio switched off)
These noises do not mean that there is a fault
in the system.
There will be no noises associated with
hydraulic steering (pump modulation, limit
valve).
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8
The lower steering shaft connects the upper
steering column to the steering gear.
The lower steering shaft runs from the
bulkhead inside the engine compartment to
the front axle. At the bulkhead end, the lower
steering shaft is connected to the upper
steering column by a universal joint. A
universal joint at the front axle end connects
the lower steering shaft to the steering gear.
Design
The lower steering shaft is housed in a plastic
sleeve that protects it from corrosion.
The lower steering shaft is formed of two
parts. The lower section, mounted in ball
bearings, slides into the upper section.
The sleeve is manufactured from heat-
resistant plastic because the lower steering
shaft on right-hand-drive vehicles is located
near to the exhaust manifold.
7 - Lower steering shaft
Index Explanation
1 Plastic sleeve
22
8
Operating principle
The lower steering shaft transfers the high
steering torques from the upper steering
column to the steering gear.
The ball bearing for the 2 parts of the lower
steering shaft is necessary for the following
reasons:
Installation length compensation
Compensation for steering wheel height
adjustment
Telescopic feature in the event of an impact
Note for service staff: Plastic sleeve replacement
It is possible to replace the plastic sleeve with
a new one if it is damaged during installation.
Note for service staff: Fitting the lower steering shaft
If the lower steering spindle has been
disconnected, it is essential that the lower
steering spindle be reconnected cleanly.
New bolts must be used.
The threads must be recut.
8 - Cross section of the lower
steering shaft
1 Ball bearing 2 Telescopic chamber
23
8
This steering gear is a purely mechanical
system.
The track rods, the sleeves and the tension
straps have all been adopted from the E46.
The steering gear is located on the front axle.
It is connected to the front axle in the same
way as on the E46.
Design
A new, damped pressure piece has been
integrated into the steering gear. A damper
has been integrated to supplement the spring
common to conventional pressure pieces.
9 - Steering gear
1 Steering gear 3 Damped pressure piece
2 Position indicator
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Function
The steering forces transferred along the
steering column are then transferred to the
rack by a pinion. High deflection forces act on
the rack due to the high steering torque
transmitted by the lower steering shaft. The
deflection forces push the rack away fromthe
pinion. To counter these forces, a new,
damped pressure piece has been integrated
into the steering gear.
The rack may be pushed away by high
deflection forces when the steering wheel is
turned rapidly. The damped pressure piece
reduces design-related knocking noise when
the rack suddenly returns.
Note for service staff: Pressure piece play
It is no longer necessary and also no longer
possible to readjust the play in the pressure
piece.
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Service information
System shutdown
If the systembecomes overloaded, it attempts
to protect itself by reducing the power
steering assistance. The driver notices the
increased steering torque that needs to be
applied. At the same time, the indicator lamp
provides the driver with a visual signal.
Possible reasons for the initiation of protective
measures:
Power steering assistance is reduced if a
fault is detected in one of the control units
that are part of the system (MS45.0, DSC
control unit, steering angle sensor). An
entry is then stored in the fault code
memory.
The indicator lamp in the instrument cluster
lights up when then system is completely
shut down. The indicator lamp goes out
when the fault is no longer present.
Power steering assistance is reduced if the
system temperature rises. If this reduction
is not sufficient for the systemto cool down,
the power steering assistance will be
reduced to zero. An entry is then stored in
the fault code memory.
The indicator lamp in the instrument cluster
lights up. If the system temperature falls,
the power steering assistance will be
restored to the value currently required.
The indicator lamp goes out.
Power steering assistance shuts down
immediately to protect the end stages if
there is an overvoltage greater than 17 V.
An entry is then stored in the fault code
memory. The indicator lamp in the
instrument cluster lights up. If the voltage
drops back below 16 V, the power steering
assistance will be restored to the value
currently required within 2 seconds. The
indicator lamp goes out.
If an undervoltage of less than 9 V is
detected, the power steeringassistance will
immediately be reduced to zero. An entry is
then stored in the fault code memory. The
indicator lamp in the instrument cluster
lights up when the system is completely
shut down. If the voltage rises back above
10 V, the power steering assistance will be
restored to the value currently required
within 2 seconds. The indicator lamp goes
out.
Steering shaft installation anti-twist lock
The steering wheel lock must be engaged in
the zero position if work is to be carried out on
the steering column.
The anti-twist lock below the servo unit for
retaining the steering shaft in position must
also be secured during repair work.
Engaging the steering wheel lock in the zero
position and applying the anti-twist lock
prevent the steering shaft from turning when
the upper steering column is refitted. Turning
the steering shaft would tear the internal
steering wheel torque sensor connection
cables in the flat spring cassette. The flat
spring cassette is located in the housing of the
worm gear and the steering wheel torque
sensor.
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Position marking and foolproof fitting
If the lower steering shaft is removed fromthe
steering gear, it is essential that the centre
marking on the lower steering shaft be located
opposite the steering gear when the spindle is
refitted.
There are plastic indicators on the upper
steering shaft and steering gear that indicate
whether the lower steering shaft has been
fitted correctly.
These plastic indicators also ensure that the
parts are fitted into each other far enough
before the lower spindle can be bolted to the
upper steering shaft and the steering gear.
The connecting bolts must pass through the
hole in the indicator.
Maintenance
The balancing spring should be detached
before work is carried out on the upper
steering column.
The pretensioning force of the balancing
spring is sufficient to bend the retainers.
The following replacement parts are only
available as complete assemblies:
Upper steering column
The only mechanical components of the
upper steering column that may be replaced
individually are the ignition switch, the lock
cylinder and the steering angle sensor. If
replaced, the steering angle sensor must be
recalibrated.
The only parts of the steering gear with rack
that may be replaced individually are the track
rods.
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Coding and diagnostics
EPS control unit
The EPS control unit must be recoded if the
EPS is replaced. The coding procedure is the
same regardless of whether or not there is an
FDC button.
The steering angle sensor must also be
recoded if replaced.
Diagnosis
EPS systemdiagnosis is fully compatible with
the application program of all diagnosis
queries.
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Contents
Servotronic
Introduction 1
Servotronic 1
System overview 3
General overview E83 3
Functions 5
Control units 5
System functions 6
E83 Servotronic control unit (SVT) 8
E83 Servotronic valve 9
E83 general information for service staff
concerning 10
1
7
Introduction
Servotronic
Servotronic
The following component and function
descriptions are based on the BMWX3 (E83)
as an example. Servotronic is available as an
option (SA 216).
Servotronic steering is based on the proven
power-assisted rack and pinion steering.
The special feature of Servotronic is the
control of steering force support as a function
of road speed and not engine speed, as is the
case with conventional systems. This is made
possible by an electrohydraulic pressure
converter (Servotronic valve). Servotronic
regulates the hydraulic pressure in the power
steering pump. The adjustment of hydraulic
pressure in relation to road speed has the
following effects:
high steering force support at low road
speeds
minimal steering force support at high road
speeds
This means that only minimal effort is required
to steer at low speeds. Steering force support
is continuously reduced with increasing road
speed. Steering feedback is more direct and
more precise. The result is a marriage
between high levels of comfort and maximum
manoeuvrability, e.g. when parking.
1 - Servotronic steering diagram
2
7
3
8
System overview
Servotronic
General overview E83
1 - Hydraulic circuit diagram general overview
4
8
The torque bar's main priority is to generate
the return forces for the steering.
There is a centring unit integrated into the
steering gear.
The centring unit assists the steering in
restoring the steering wheel centre position.
The behaviour of the centring unit is another
variable in the design of the steering.
E83 inputs/outputs
1 Dynamic stability control (DSC) 8 Piston on the rack
2 Servotronic (SVT) 9 Steering gear
3 Power steering pump 10 Centring unit
4 Servotronic valve 11 Spring for the centring unit
5 Rotary slide in the steering gear 12 Torque rod
6 Throttle 13 Steering wheel
7 Expansion tank
2 - CAN with components
1 Servotronic (SVT) 5 Dynamic stability control (DSC)
2 Servotronic valve 6 Digital engine electronics
3 Connection to body bus K-Bus Body bus
5
9
Functions
Servotronic
Control units
The following control units are part of the
Servotronic system:
Servotronic control unit (SVT)
DSC control unit
Digital motor electronics or digital diesel
electronics (DME or DDE)
Instrument cluster (KOMBI)
Servotronic control unit (SVT)
The SVT control unit issues the reference
values for controlling the Servotronic valve
(hydraulic pressure). The SVT control unit is
connected to the PT-CAN (Powertrain CAN)
and the K bus (body bus).
Servotronic does not shut down if the mileage
signal fails (no function restriction). The
"Mileage 0000" entry is stored in the fault
code memory. The SVT control unit enters
idle status (sleep mode) within 30 seconds of
terminal 15 OFF.
The SVT control unit is woken again when
terminal 15 is switched ON.
DSC control unit (dynamic stability control)
The DSC control unit sends the signal for the
roadspeed. The DSCcontrol unit and the SVT
control unit are connected by the PT-CAN.
Digital motor electronics anddigital diesel electronics (DMEand
DDE)
The DME or DDE sends the signal indicating
whether the engine running to Servotronic on
the PT-CAN. Servotronic only controls the
Servotronic valve when the engine is running
and terminal 15 is switched ON.
Instrument cluster (KOMBI)
With the aid of the K-bus, the instrument
cluster makes available the terminal status
(e.g. terminal 15 ON) and the kilometre
reading.
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9
System functions
Servotronic operation requires following
system functions/conditions:
Initialization of Servotronic
Detection of road speed
Current supplied to the Servotronic valve
Undervoltage and overvoltage detection
Initialization of Servotronic
Servotronic is activated when terminal 15 is
switched ON. A brief Servotronic initialization
phase (less than one second) is necessary for
the low-speed characteristic curve to be
achieved as rapidly as possible. A plausibility
check for the supply of current to the
Servotronic valve is carried out during this
initialization phase.
Detection of road speed
The speed signal is calculated by the DSCand
sent on the PT-CAN. Servotronic specifies an
acceleration value for checking the plausibility
of the speed signal. A speed signal is
calculated from this acceleration value.
With low acceleration, the speed signal sent
by the DSC is used.
With high acceleration, the Servotronic control
unit calculates the road speed internally. The
road speed is stored in the Servotronic control
unit.
Current supplied to the Servotronic valve
The Servotronic valve is supplied with current
as a function of road speed. The power
steering assistance characteristics are
represented in a characteristic curve. The
characteristic curve indicates the current in
relation to the road speed.
The characteristic curve is described by 16
reference points.
When the engine switched OFF(via PT-CAN),
the Servotronic valve is no longer supplied
with current. Minimal power steering
assistance is set when the Servotronic valve is
not supplied with current (high speed).
In addition, the Servotronic valve is no longer
supplied with current if an entry is stored in the
fault code memory.
Undervoltage and overvoltage detection
The Servotronic valve stops being supplied
with current under the following conditions:
Supply voltage less than 9 V
Supply voltage greater than 17 V
Voltage dips are detected in ignition faults.
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9
The activation conditions for Servotronic are:
Terminal 15 ON
Engine running.
Servotronic only controls the Servotronic valve
if the engine is running.
Servotronic sets the maximumpower steering
assistance available if no speed signal is
present when the engine is started.
If a plausible speed signal is detected, the
Servotronic valve is controlled according to
the characteristic curve. Minimum power
steering assistance is set if still no speed
signal (or no plausible signal) is detectedwithin
5 seconds of the engine start.
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9
E83 Servotronic control unit (SVT)
Installation location on E83
The SVT is fitted to the equipment carrier
behind the glove compartment.
The installation location is the same on right-
hand-drive and left-hand-drive vehicles, but
the installation position of the Servotronic
control unit within the equipment carrier is
different.
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9
E83 Servotronic valve
The Servotronic valve is an electrohydraulic
converter located in the power steering
hydraulic fluid circuit. The Servotronic valve
throttles the flow of hydraulic oil and thus
reduces the hydraulic pressure.
The Servotronic valve is controlled directly by
the Servotronic control unit in relation to a
characteristic curve and therefore works like
an actuator.
The Servotronic valve is fitted directly to the
steering gear.
Design
The Servotronic valve is an electrohydraulic
converter. Avariable stop is integrated into the
Servotronic valve. The diameter of the variable
stop is between 0.0 and 0.7 millimetres.
1 - Servotronic valve
1 Steering gear 2 Servotronic valve
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9
E83 general information for service staff concerning
Servotronic
3 Do not hold the steering wheel at full lock
for longer than is necessary.
The power steering pump does not have a
limit stop shut down. Holding the steering
wheel at full lock for long periods (more than
1 minute) could damage the power steering
pump. 1
3 Different power steering pump
depending on the engine variant.
Different power steering pumps may be fitted,
depending on the engine variant. On vehicles
with a petrol engine, the expansion tank is not
fitted directly to the power steering pump. The
expansion tank is bolted to the power steering
pump on vehicles with a diesel engine. 1
3 Cooling fins instead of cooling loop.
The power steering cooler on vehicles with a
diesel engine is designed with cooling fins
rather than a
cooling loop (design also planned for vehicles
with a petrol engine). 1
Contents
Traction control and
stability systems
Objectives 1
Introduction 3
History 3
1
8
Objectives
Traction control and stability systems
Development shows that traction control and
stability systems are becoming ever more
complex. In addition to providing basic
information, the following pages describe how
these systems are integrated into dynamic
driving control systems.
You will become familiar with the layout and
operation of the important features of traction
control and stability systems. The notes for
service staff provide useful information with
reference to your daily activities.
Particular emphasis is placed on the new and
latest DSC8.0 and MK60 systems.
You will be able to perform diagnostics and
fault finding on BMW vehicles to a
professional standard.
2
8
3
9
Introduction
Traction control and stability systems
History
In 1978, BMW was the first automobile
manufacturer to introduce ABS systems into
the series production of luxury class vehicles.
ABS was available on the BMW 745i as
standard, otherwise it was available as an
option. There were doubts in the engineering
world at first, however, concerning the
longevity and reliability of the electronics in the
ABS that, as you should appreciate fromyour
work, have long since been maintenance-free.
The high levels of reliability already achieved in
the 1980s changed the outlook completely.
Every automobile manufacturer came to
recognize the benefits of ABS. As the number
of manufactured systems grew into the
millions, their cost fell considerably. Nowadays
even the absence of ABS on a vehicle is
considered to be a shortcoming. BMWset the
course for ongoing development of dynamic
driving control systems in vehicles.
Modern BMWvehicles are equipped with the
most efficient and responsive safety systemin
the world as standard. Today, brake
management is not only responsible for
ensuring high braking efficiency at all times, it
is also a component of dynamic stability
control (DSC) essential to maintaining
directional stability. It plays a role in achieving
the most important aims of driving dynamics,
such as:
Lane handling under braking
Avoidance of the risk of skidding when
cornering
Manoeuvrability despite full braking
Improved pulling away on slippery surfaces
and
Reduction of braking distance in
emergency situations
In short, dynamic driving control systems are
among the most important developments in
active driving safety in recent years. The DSC
system and its modules help the driver to not
only master critical situations but to drive
relaxed in the knowledge that the systemitself
will undertake within a fraction of a second
many of the decisions for which the driver
would otherwise be responsible.
In the context of dynamic driving control
systems, we make distinctions between
translatory movements (lengthwise
movements):
front - back (along the longitudinal axis)
right - left (along the transverse axis)
up - down (along the vertical axis)
and rotary movements (rotational motion)
about the longitudinal axis (rocking, rolling:
suspension more heavily compressed on
one side of the vehicle when cornering)
about the transverse axis (pitching: front
suspension heavily compressed, e.g. under
full braking)
about the vertical axis (yawing: the vehicle
drives through a bend)
No dynamic driving control system is
abletoovercomethelawsof physicsand
take full responsibility away from the
driver.
Drivers remain responsible for
themselves and others at all times and
must adapt their driving style to suit
prevailing road and traffic conditions.
4
9
Contents
ABS - DSC modules
Introduction 1
Brake modules 1
1
9
Introduction
ABS - DSC modules
Brake modules
As previously described, BMW plays a
decisive role in the chassis control topic.
Electronic brake management is not only
responsible for ensuring high braking
efficiency at all times, it is also a component of
dynamic stability control (DSC) essential to
maintaining directional stability.
DSC optimizes:
directional stability when pulling away and
under acceleration and braking
traction
DSC also detects unstable driving conditions
such as under or oversteering. DSC helps to
keep the vehicle on a safe course within
physical limits.
For this to be possible, DSC must know the
following dynamic driving parameters:
the yaw rate as a measure of the rotational
motion of the vehicle about the vertical axis
transverse acceleration as a measure of the
friction coefficient of the road surface
the road speed
Also detected are the steering angle desired
by the driver and the brake pressure exerted
by the driver at the brake pedal. In addition,
wheel speed sensors provide information
about the speed of individual wheels. The
actual status of vehicle movement at a given
time is determined fromthe measured values
available. The actual status is compared with
target values calculated in the DSC control
unit. Where current actual values differ from
the target status, DSCis activated and actively
intervenes in the brake system or the engine
control.
Benefits:
With active engine and brake interventions,
DSC provides outstanding directional stability
and excellent traction in all road situations.
DSCcounteracts all negative, dynamic driving
forces andthus provides, withinphysical limits,
the highest degree of active safety possible.
DSC also enhances driving comfort through
relaxed driving.
DSC, the driving assistance system,
comprises various modules that work together
in a complex data bus.
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9
The most important modules of DSC are:
This list shows the most important DSC
components used in vehicles with Mk60
and DSC 8.0.
1 - DSC components
ABS Anti-lock braking system EBV Electronic brake power
distribution
CBC Cornering brake control ASC Automatic stability control
DTC Dynamic traction control MSR Engine drag torque control
DBC Dynamic braking control ECD Electronically controlled
deceleration (only with ACC)
HDC Hill descent control SDR Overrun differential control
3
9
Dynamic Stability Control DSC Mk60
The system supplier for DSC Mk60 is
Continental Teves.
The E85 is equipped with Dynamic Stability
Control Mk60 as standard. DSC Mk60 was
first used in the E46 from 09/2000, but
without the DTC function (DTC = dynamic
traction control). The DTC function has been
available as part of DSC Mk60 since 09/2001.
Dynamic Stability Control Bosch DSC 8.0
The system supplier for the DSC 8.0 is
Bosch.
The new 5 Series BMW (E60, E61) and the
new 6 Series BMW are equipped with
dynamic stability control DSC 8.0 as standard.
DSC 8.0 is a further development to DSC 5.7
known from the E65.
The essential new features of DSC 8.0 by
comparison with DSC 5.7 are:
very compact DSC unit, approximately
25 % smaller
approximately 30 %lighter (saving of 700 g
in the module, saving of 1.8 kg through
omission of the electric precharging pump)
Connection of the DSC unit to the Chassis
CAN (F-CAN) in addition to the connection
to the Powertrain CAN (PT-CAN)
Control unit memory 768 kB ROM
(previously 256 kB ROM)
Processor computing cycle time 5 to 10 ms
(previously 20 ms)
There is no longer an electric precharging
pump in either of the systems. This has
particular consequences for changing or
topping up the brake fluid. These guidelines
must be observed and are described in the
Notes for service staff section.
Before the DSC Mk60 and 8.0 systems are
described in more detail, there now follows
more general information concerning ABS.
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9
Design and operation of the passive ABS wheel speed sensor
The wheel speed sensors in a simple ABS
systemare passive and operate in accordance
with the induction principle. It states that an
induction voltage is generated in a coil if the
coil is moved through a magnetic field. The
permanent magnet and coil are fixed in the
form of a speed sensor. Therefore the
magnetic field itself must be changed. This is
made possible by an increment wheel.
The wheel speed sensors detect the wheel
speeds through contactless sensing of the
increment wheels and they forward these
values to the brake control unit as sinusoidal
alternating voltage signals. There they are
converted into a measurable square wave
signal.
Passive wheel speed sensors do not require a
power supply because the voltage is
generated by the wheel rotations in the
sensor. The voltage produced in the formof a
sinusoidal signal is also forwarded as a
sinusoidal signal to the control unit.
The wheel speed sensor comprises a
permanent magnet surrounded by a coil. The
cable ends of the coil lead into a connector
housing for a cable connection. The
permanent magnet and the coil are cast
watertight in a plastic housing.
The wheel speed sensor is fitted contact-free
in the wheel carriers.
The wheel speed sensor sends the control
unit decisive information concerning different
wheel peripheral speeds, wheel deceleration,
wheel acceleration and wheel slip. These
signals are used to calculate the control
variables.
Summary
If an electrical conductor is moved inside a
magnetic field or alters the strength of the
magnetic field, the conductor will generate an
electrical voltage. This voltage is known as an
induced voltage.
The level of the induced voltage depends on:
the strength of the magnetic field
the speed with which the field is passed
through
the number of windings in the coil
Disadvantages of passive wheel speed
sensors:
Unable to detect a reversing motion of the
vehicle. This is necessary for the hillholder
function, which brakes the wheels
accordingly to prevent the vehicle from
rolling back when pulling away on uphill
gradients.
Failure to detect reversing motion on
vehicles with a navigation system.
The brake control unit cannot determine
the signal quality on vehicles with passive
wheel speed sensors. Consequently, the
driver is not requested in good time to visit
his/her BMWdealer in response to the first
sign of sensor defects.
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9
Design and operation of the active wheel speed sensor
More and more of today's vehicles are being
equipped with active, or magnetoresistive,
wheel speed sensors.
2 - Wheel speed sensor
Index Explanation
1 Sensor ring/ferromagnetic wheel bearing seal carrier
2 IC sensor with Hall sensor
3 Sensor housing
6
9
This type of sensor operates in accordance
with the Hall principle and has the notable
feature of being able to detect forwards and
reverse motion. Rotation direction detection is
made possible by the internal signal offset of
three appropriately arranged Hall elements in
the sensor. With this type of wheel speed
sensor, magnets assume the same functionas
the teeth of the increment wheel. The
magnets are differentiated by north and south
pole and are arranged alternately on a pole
ring.
Unlike the passive wheel speed sensor, the
active wheel speed sensor is supplied with a
defined voltage and sends a square wave
signal generated in the wheel speed sensor to
the control unit as a data log. This data log is
transferred as a current signal by pulse width
modulation (PWM).
The current signal has levels of 14 mA and
7 mA. The latter provides evaluation
information for the fault code memory. The
14 mA level is an information signal.
The brake control unit is able to derive a range
of information from the width of the square
wave pulse and the interval between pulses.
The wheel speed sensor at a stationary wheel
sends a pulse once every 0.75 seconds.
The following chart shows the important
output signals of the active wheel speed
sensor.
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9
3 - PWM sensor signals
1 Internal signal sensor 6 Installation limit position,
direction of rotation B
2 Air gap reserve too low 7 Stationary signal
3 Direction of rotation A N North pole (magnet)
4 Direction of rotation B S South pole (magnet)
5 Installation limit position,
direction of rotation A
8
9
Main features of the active wheel speed
sensor
1. Installation location detection:
Indicates whether thechange inmagnetic
field strength can be guaranteed for
correct operation with a high degree of
certainty.
This signal is no longer required after
approximately 20 km/h.
2. Stationary detection:
The power supply is switched on if the
wheel is stationary for more than 1
second. Asignal is sent to the control unit
every 740 ms so that the availability of the
sensor can be checked.
3. Speed signal:
This is a frequency-dependent signal for
determining the peripheral wheel speed
4. Rotation direction detection:
Indicates the direction of rotation,
clockwise/anticlockwise
5. Air gap reserve:
Indicates whether the changeinmagnetic
field strength is below the necessary
value for correct operation
A two-wire line is used to transfer the signal.
This two-wire interface is a combined earth
and data line.
The permanent magnet in the wheel speed
sensor generates a magnetic field. The lines of
the magnetic field run perpendicular to the
sensor layer on the sensor element.
The deviation of the fields lines caused by the
increment wheel produces changes in
resistance in the thin ferromagnetic layer of
the sensor element.
operation
1 Increment wheel 4 Permanent magnet
2 Electronic evaluation unit 5 Magnetic field lines
3 Signals from the wheel speed
sensor
6 Sensor element
Contents
DSC 8.0 Bosch
Functions 1
What the DSC function makes possible: 1
Hydraulic schematic 13
1
7
Functions
DSC 8.0 Bosch
What the DSC function makes possible:
System functions
DSC uses sensor signals to calculate the
current driving status.
DSC corrects detected handling instabilities
through active braking interventions and
interventions in engine power output.
If the vehicle oversteers, for example, the front
wheel on the outside of the bend is actively
braked by a stabilizing torque acting in the
opposite direction. In the event of vehicle
understeering, active interventions at the inner
cornering wheels provide a stabilizing counter-
torque.
Vehicle stabilization by the DSC is
implemented in all driving situations, i.e. when
coasting, accelerating and braking.
Dynamic Stability Control DSC
The control unit uses the vehicle speed,
steering angle and transverse acceleration
signals to calculate the setpoint yaw angle of
the vehicle while cornering. The DSC sensor
supplies the actual value. A comparison is
made in the control unit between the
calculated yawvalue and the actual yawvalue.
The DSC initiates control if a deviation is
detected that is above a control threshold
defined in the control unit.
The DSC control responds accordingly to
oversteer or understeer. The control
procedure involves intervening in engine
management in order to reduce the tractive
forces. Braking pressures are built up at the
wheels which serve to stabilize the vehicle
again.
The DSC function can be deactivated by
means of the DSC button.
The system comprises the following
functions:
ABS Anti-lock Braking System
ASC Automatic Stability Control
MSR Engine drag torque control
DBC Dynamic brake control
CBC Cornering brake control
ECD Electronically controlled deceleration
(ACC only)
EBV Electronic brake force distribution
FLR Driving performance control
DTC Dynamic traction control
BTM Brake temperature model
RPA Tyre failure indicator
BBV Brake pad wear indicator
SDR overrun differential control
Anti-lock Braking System ABS
ABS prevents the wheels from locking under
braking.
Benefit: lane handling for the entire braking
distance, the vehicle remains stable.
The braking pressure at all wheels is
controlled in such a way that each wheel turns
in an optimum traction range. Traction is
controlled in such a way that high braking and
cornering forces can be transferred.
2
7
Automatic Stability Control ASC
ASC prevents wheel spin during acceleration
on all types of road surface.
Control takes place at a control threshold
stored in the control unit.Brake interventions
are performed as well as intervention in engine
management for the purpose of reducing the
tractive force.
The ASC function can be deactivated by
pressing and holding the DSC button for
longer (3 s).
Engine drag torque control MSR
The engine drag torque control prevents the
rear end of the vehicle swerving out when the
throttle is reduced abruptly or in the event of
inappropriate downshift to a lower gear.
Significant load changes are realized by
temporary increases in the engine torque.
The engine drag torque control function is
only activated froma driving speed of 15 km/h.
Dynamic Brake Control DBC
The DBC (dynamic brake control) function is
divided into 3 subfunctions:
Dynamic brake support (DBS)
Maximum brake support (MBS)
Fading brake support (FBS)
Dynamic brake support (DBS):
DBS assists the driver in emergency braking
situations.
The DBS function is activated when the brake
pedal is depressed rapidly enough (6 bar per
1/1000 s). The driver exerts a braking
pressure. As a result, the hydraulic pressure
increases to such an extent that ABScontrol is
implemented on the front and rear axle. The
driver can thus achieve full deceleration with
low pedal force. The systemis deactivated as
soon as the driver eases off the brake pedal.
Maximum Brake Support (MBS):
MBS assists the driver in normal, non-
emergency braking situations. When the ABS
control range is reached at the front axle, MBS
increases the pressure at the rear axle until the
ABScontrol limit is reached. Optimumbraking
deceleration is thus achieved as normally the
driver stops pressing the brake in this
situation. The system is deactivated as soon
as the driver eases off the brake pedal.
Fading Brake Support (FBS):
The FBSfunction assists if the driver is unable
to achieve full vehicle deceleration on account
of poor brake pad friction coefficients, e.g. due
to high thermal loads. The requirement is a
high braking pressure with a simultaneously
low vehicle deceleration and high brake disc
temperature.
The FBS function compensates for the brake
force loss through an increase in temperature.
The diminishing braking effect when brakes
are hot requires the driver to press the brake
pedal more firmly. This increase in pressure is
nowassumed by an activation of the hydraulic
pump.
The brake disc temperature is not measured
but rather calculated by means of the following
input variables:
Peripheral wheel speed
Individual wheel brake pressure
Ambient temperature
Braking time
Driving style (cooling phase)
3
7
Cornering Brake Control CBC
CBC (cornering brake control) is an extension
of ABS. It improves directional stability,
particularly under braking when cornering.
The CBC function is activated at medium to
high transverse acceleration.
If a vehicle enters a bend under braking and
threatens to oversteer, an improvement in
stability is achieved by partially releasing or
delaying pressure build-up at the brake at the
rear wheel on the inside of the bend.
In the case of braking on bends, the pressure
in the rear-axle wheel brake cylinders is
individually controlled. Essentially this
prevents the vehicle from oversteering.
If the vehicle decelerates when cornering,
CBC ensures the best possible directional
stability by means of optimum brake force
distribution.
CBC
performs its control function ahead of ABS
or DSC
also functions when DSC is deactivated
is deactivated only in the event of an ABS
failure
Electronically Controlled Deceleration
ECD
ECD (electronically controlled deceleration)
responds to the request of the ACC signals.
DSC executes braking retardation when
deceleration is requested by ACC.
This is realized by way of automatic brake
intervention at the four disc brakes. This
depends on the vehicle speed, the distance
and speed of the preceding vehicle at
maximum 3 m/s
2
deceleration.
On downhill gradients at a preselected driving
speed, ECD maintains the driving speed
continuously at the preset value by way of
automatic brake intervention.
The new brake pressure sensors can
guarantee more uniform braking at the front
and rear axles. This allows longer activation
without compromising on comfort or
overheating of the brakes on one axle.
In the case of automatic braking, the brake
lights are activated in line with legal
requirements.
The light module (LM) only lights the brake
lights from deceleration of 1 m/s
2
. This
prevents the brake lights from coming on
frequently and for brief periods.
Electronic Brake Force Distribution EBV
When the system is intact, the electronic
brake force distribution function prevents
overbraking the rear axle. Rear axle influencing
(HAB) ensures the rear wheels are not
controlled by the ABS before the front wheels
while braking. The control takes place both
while driving straight ahead as well as when
cornering, thus ensuring high vehicle stability.
The EBV emergency operation function
prevents overbraking under the following
conditions:
Effective until the failure of 2 wheel speed
sensors. The failure can occur in any order.
Effective with intact pump motor activation
(pressure-holding function or pressure
decrease meeting requirements at the rear
axle).
Effective even if the admission pressure
sensor fails.
In the event of system malfunctions or
additional sensor faults, the driver is alerted by
the red brake warning lamp in the instrument
cluster.
4
7
Driving performance control FLR
The FLR function protects the brakes from
overload under misuse conditions.
The engine power output is reduced to a
defined boundary when a temperature in
excess of 600 C is reached. This value
depends on the type of vehicle. When the
temperature drops below a lower limit
(typically 500 C), the reduced engine torque
is increased in ramps, time-controlled, to the
maximum torque.
The driving performance control function is
activated as from a speed of 60 km/h.
This reduction of the engine torque is stored
as a fault (driving performance control active).
Should the customer find fault with the lack of
engine power, this can be established by the
garage/workshop and explained as brake
overloading.
This function is stored in the fault code
memory.
Dynamic Traction Control DTC
The DTC function can be activated by means
of the DSC button. The active DTC function
increases the ASC slip thresholds for
improving propulsion up to a speed of
approximately 70 km/h. Basically the
permissible slip is doubled but there is a
programmap in the background. This function
offers advantages when driving on poor roads
and thick fresh snow. Driving is not safety- but
rather traction-orientated. With increasing
transverse dynamics, measured by the yaw
rate sensor, the slip thresholds are reduced
back to the normal mode for stability reasons.
DTC may appear in the instrument cluster if
DTCtraction mode is activated, depending on
the vehicle model concerned (no DTC display
in the E46).
Brake Temperature Model BTM
The BTM function determines the
temperature of all four brake discs by means of
a calculation model integrated by way of the
software in the DSCcontrol unit. This function
uses the following input variables:
Peripheral wheel speed
Individual wheel brake pressure
Ambient temperature
Braking time
Driving style
If the critical brake disc temperature is
exceeded (t > 600 C) at one wheel, DSC
functions may be restricted depending on the
prevailing driving conditions:
Locking interventions are reduced to zero
for each individual wheel.
Symmetrical braking torques on the
corresponding axle are prohibited.
The engine torque is limited temporarily via
an algorithm for driving-performance
control.
The restrictions are cancelled again when the
temperature drops below another threshold (t
< 500 C).
5
7
RPA Tyre failure indicator
The RPA function is integrated in the DSC
control unit.
The system is addressed separately in the
training course.
Brake Pad Wear Indicator BBV
The evaluation of the 2-stage brake pad wear
sensors is integrated in the DSC control unit.
Overrun Differential Control SDR
SDR is a special function of DSC. The SDR
function switches the DSC control
characteristics from understeer to oversteer
and vice versa in response to a sudden change
in the vehicle handling. The sudden change in
vehicle handling, e.g. in connection with a load
change, occurs in a bend. This has the effect
of bypassing the control tendency towards
neutral.
Operation
The DTCand DSCfunctions can be activated
and deactivated using the DSC button in the
centre console switch cluster (SZM).
One brief press of the button activates the
DTC function.
Pressing the button for longer (approximately
3 s) deactivates the DSC function.
However, ABS will remain active.
Activation and deactivation of the DTC and
DSC function is indicated in the instrument
cluster by warning and indicator lamps.
If the DSCbutton is pressed for longer than 10
s, the DSCfunction is activated and cannot be
deactivated until the next time the ignition is
switched ON. This is a safety function to
account for the possibility of an object placed
on the centre console (e.g. a handbag)
pressing the DTC/DSC OFF button.
6
7
Components and their functions
DSC module as a complete component
The DSC module is located in the engine
compartment.
The brake pressure is built up with the aid of
an electric motor during a DSC control
procedure.
The brake pressure is registered by a pressure
sensor integrated in the valve block. The driver
determines the brake pressure by operating
the brake.
1 - DSC module
Index Explanation
1 DSC control unit
2 Valve block
3 Electric motor (pump)
4 Plug connector
7
7
DSC module dismantled
Design
2 - Exploded view of the DSC unit
1 Pump motor 6 Control unit housing
2 Valve block 7 Circuit board
3 Pump element 8 Internal brake pressure sensor
4 Solenoid valves 9 Accumulator chamber
5 Valve coils on the circuit board
8
7
The DSC unit comprises the DSC control unit
and hydraulic control unit. The hydraulic
control unit essentially comprises the valve
block and the pump motor.
The valve block contains:
2 pump elements driven by eccentric discs
(front axle brake circuit and rear axle brake
circuit)
12 solenoid valves
2 intake valves
2 changeover valves
4 inlet valves
4 outlet valves
1 internal brake pressure sensor
2 accumulator chambers
In design terms, the dividing line between the
DSCcontrol unit and the hydraulic control unit
runs through the solenoid valves. The
electrical components of the solenoid valves
(valve coils) are assigned to the DSC control
unit and directly connected to the circuit
board. The mechanical components of the
valve are secured in the hydraulic unit. These
components mainly comprise valve domes
with valve plungers.
9
7
DSC sensor dismantled
The DSC sensor fitted as standard is located
under the driver's seat. For safety reasons
(redundancy), there is a second sensor on
vehicles with active steering in addition to the
standard DSC sensor. The second DSC
sensor is located under the front-passenger
seat.
Design
Each of the DSCsensors is a combination of a
transverse acceleration and yaw rate sensor.
The DSC sensor comprises:
Housing cover
Circuit board with electronic evaluation unit
for signal processing
Sensor electronics. These are formed of
2 piezoelectric acceleration sensors. There
is a spring-mounted mass in the measuring
cell of the acceleration sensors.
Damper to prevent mechanical overloading
Housing with connector
The two DSC sensors are almost identical in
technical terms. However, DSC sensor 2 has
an additional terminating resistor. The two
DSC sensors have different part numbers.
The DSC sensors also have different
identification on the CAN bus. This rules out
the possibility of confusing the DSC sensors.
Operating principle
When the vehicle accelerates, the spring-
mounted mass also accelerates. The force
required to do this generates a mechanical
voltage in the piezoelectric material. This
produces a shift in electrical charge. The shift
in electrical charge is attenuated by electrodes
and processed as an electrical signal. The yaw
rate is derived from the difference between
the two acceleration signals.
The second DSCsensor is used for redundant
signal detection of the transverse acceleration
and yaw rate.
The use of 2 DSC sensors makes plausibility
monitoring possible. Each of the DSCsensors
is triggered (excited) by the DSCcontrol unit in
a 10 millisecond cycle.
The DSC sensors output their signals on the
F-CAN in response.
3 - DSC sensor
Index Explanation
1 Housing cover
2 Circuit board with electronic
evaluation unit
3 Sensor element
4 Mechanical damper
5 Housing with connector
10
7
The steering angle sensor is integrated in the
steering column electronics module or
secured to the bottom of the steering shaft,
depending on the vehicle model. The steering
column electronics module is a component of
the steering column switch cluster (SZL).
Design
The steering angle sensor is a potentiometer
with 2 sliding contacts offset by 90. The use
of 2 sliding contacts makes it possible to
detect the direction of rotation.
4 - Steering angle sensor
1 Steering column electronics
module (lower section of the
steering column switch cluster)
11
7
Operating principle
DSC requires a steering angle value to carry
out control interventions. The steering angles
(2 voltage values) detected by the sliding
contacts cover one full turn of the steering
wheel. The voltage values are repeated after a
360 turn of the steering wheel. The steering
angle sensor is thus able to count the number
of steering wheel turns.
The total steering angle determined by the
steering angle sensor is derived from:
A correction value of the steering angle
sensor
This correction value defines the straight-
ahead position of the steering wheel. The
correction value is defined and stored
during steering angle sensor calibration.
The currently measured steering angle
The number of steering wheel turns
A cumulative steering angle is also
detected by the cumulative steering angle
sensor if the vehicle is equipped with active
steering. The cumulative steering angle is
the steering angle at the output of the
steering gear.
The steering angle and the number of steering
wheel turns must be available when the
ignition is switched ON.
For this reason, the steering column switch
cluster (SZL) and thus the steering angle
sensor are continuously supplied with current
via terminal 30. This means that steering
wheel movements are detected even after
terminal R is switched OFF.
5 - Function of the steering angle sensor
1 Reference voltage 4 Earth
2 Sliding contact 1 voltage 5 Steering angle sensor signal
3 Sliding contact 2 voltage
12
7
Open circuits would lead to the loss of the
steering wheel centre position stored in the
steering angle sensor. For the steering angle
sensor to remain functional following an open
circuit, the DSC control unit must learn the
steering angle by plausibility check
(initialization). The DSC control unit calculates
the steering angle using the wheel speeds
detected at the front axle. By comparing other
sensor signals, the plausibility check detects
whether the vehicle is operating with the
steering angle sensor calibrated incorrectly.
The following measures are initiated if the
initialization process after the vehicle has
pulled away does not reach a speed threshold
of approximately 18 mph (30 km/h):
DSC is shut down
The DSC warning lamp is lit
A fault code entry is stored in the DSC
control unit (not in the steering angle
sensor)
3 Steering angle sensor failure
ABS remains active in the event of a steering
angle sensor failure. 1
Brake pressure sensors on the E60
If the car is equipped with ACC, the left front
axle and rear axle brake lines each incorporate
a brake pressure sensor.
The brake pressure sensor for the front-axle
brake circuit is located on the front right wheel
arch.
The brake pressure sensor for the rear-axle
brake circuit is located on the left side of the
engine compartment at the rear.
13
8
System components
DSC 8.0 Bosch
Hydraulic schematic
1 - Hydraulic schematic
14
8
1 Tandem master brake cylinder 10 Non-return valve
2 Internal brake pressure sensor 2 11 Accumulator chamber
3 Fine filter 12 Exhaust valve
4 Intake valve (high-pressure
switch valve)
13 Rear axle brake circuit brake
pressure sensor (only with active
cruise control ACC)
5 Changeover valve 14 Front axle brake circuit brake
pressure sensor (only with active
cruise control ACC)
6 Pump element (rear axle brake
circuit)
15 Wheel brake, rear left
7 Pump motor with return pump
with automatic intake
16 Wheel brake, rear right
8 Pump element (front axle brake
circuit)
17 Wheel brake, front left
9 Inlet valve 18 Wheel brake, front right
15
9
Service information
DSC 8.0 Bosch
Service information
An open circuit to the rotation rate sensor is
not detected.
The steering angle sensor has to relearn its
offset after the battery has been
disconnected.
The DSC control unit does not learn the
steering angle until the vehicle has pulled
away. The DSC indicator and warning lamp in
the instrument cluster lights up if the DSC
control unit is not taught the offset steering
angle before the vehicle has reached a speed
of 15 mph (25 km/h).
Adifferent DSCcontrol unit is used in vehicles
equipped with active steering. The control
units for vehicles with active steering and
without active steering differ in the matching
resistors they use.
New features
There is a new brake fluid specification.
All vehicles with DSC without a precharging
pump (currently DSC8.0 and MK 60) must be
filled with a new low-viscosity DOT 4 brake
fluid.
All other vehicles may be filled with the new
low-viscosity DOT 4 brake fluid mixed with
DOT 4. Containers marked DOT 4 brake fluid,
container size 0.25 - 0.5 litres: Cap coloured
red. Containers marked DOT 4 low-viscosity
brake fluid, container size 0.25 - 0.5 litres: Cap
coloured black.
Diagnosis
Diagnosis is performed by means of the PT-
CAN.
Programming
Flash programming of the control unit is
possible by means of the PT-CAN.
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9
Coding
The DSC control unit detects automatically
whether the relevant vehicle is fitted with ACC,
DynamicDrive or Active Front Steering.
Important:
Do not code the steering angle sensor on
vehicles with DSC 8.0. The coding as carried
out on the E65 is not necessary. As a
component of the steering column switch
cluster, the steering angle sensor is uniquely
assigned to the vehicle model.
Steering angle sensor calibration
Calibration is required after the following work:
Replacement of the steering column switch
cluster (SZL)
Programmingof the steeringcolumnswitch
cluster (SZL)
Replacement of the steering gear and the
cumulative steering angle sensor (on
vehicles with active steering)
Work on the steering and the front axle
Adjustment work on the steering geometry
During calibration, the current position of the
steering wheel is stored in the steering angle
sensor as the steering wheel straight-ahead
position. The front wheels and the steering
wheel must therefore be brought into the
exact straight-ahead position as part of the
calibration process. Calibration must be
carried out using the BMWdiagnostic system.
3 Note concerning different chassis
numbers
It is not possible to calibrate the steering angle
sensor if the chassis number entered in the
steering column switch cluster differs fromthe
number stored in the instrument cluster. 1
Contents
DSC Mk60
Functions 1
What the DSC function makes possible: 1
Hydraulic schematic 13
1
7
Functions
DSC Mk60 on the E85
What the DSC function makes possible:
A sporty automatic stability control (ASC)
and DSC tuning.
Significantly improved traction
characteristics, particularly on surfaces with
low friction and high slip (gravel, deep
snow).
Greater individual freedom for the driver,
because interventions have higher
thresholds.
DSC Mk60 has the following subfunctions:
Anti-lock Braking System ABS
ABS prevents the wheels from locking under
braking.
Benefit: lane handling for the entire braking
distance, the vehicle remains stable.
The braking pressure at all wheels is
controlled in such a way that each wheel turns
in an optimum traction range. Traction is
controlled in such a way that high braking and
cornering forces can be transferred.
Electronic brake force distribution EBV
EBV is a component of ABS and controls the
distribution of brake force between the front
and rear axle.
Benefit: Optimum braking distances and high
levels of directional stability are achieved
regardless of the vehicle load.
EBV permanently monitors slip values to
prevent overbraking of the rear wheels in
certain situations. EBV controls slip at the rear
axle in relation to the front axle.
Cornering Brake Control CBC
CBC is an enhancement of ABS. CBC
improves directional stability under braking
when cornering.
Benefit: CBC ensures the best possible
directional stability under braking when
cornering through optimum brake force
distribution.
Shifts in wheel loads when cornering (even
under gentle braking) can result in a reduction
in directional stability. Where necessary, CBC
generates a stabilizing counter-torque under
gentle braking outside the ABS intervention
range.
Automatic Stability Control ASC
ASCprevents the wheels fromspinning under
acceleration.
Benefit: More traction and the vehicle remains
stable.
ASC brakes the wheel that is likely to spin if a
situation arises whereby one wheel on the
driven axle moves over a slippery section of
the road surface while the other remains on a
section with adequate grip.
ASC may also intervene in the engine control
(reduction in the ignition timing angle, the
injection amount, the throttle valve position).
2
7
Dynamic traction control DTC
The DTC function is equivalent to DSC but
with a somewhat modified intervention
strategy. DTC can be activated by
deactivating DSC (DSC button). DTC
reproduces the function of a conventional
differential lock by means of brake
intervention.
Benefit: Greater traction available with DTC.
Interventions to stabilize the vehicle (e.g.
reduction in engine output) later than with
DSC. There is therefore an improvement in
traction occasionally at the expense of
directional stability. A compromise between
vehicle stability and traction is required
particularly in connection with coefficient of
friction with increased slip. Such driving
situations can be found when accelerating and
driving uphill on loose ground and in deep
snow. DTC provides improved traction in the
event of occasionally reduced stability and is
therefore only recommended for exceptional
situations (e.g. driving in deep snow).
Engine drag torque control MSR
Engine drag torque control MSRprevents: the
tendency of the drive wheels to lock on
slippery surfaces under downshifts or a
sudden load reversal.
Benefit: The drive wheels retain their lateral
cornering forces even in overrun mode.
MSR uses the wheel speed sensors to detect
the existing lockup tendency. MSR
temporarily reduces engine drag by gently
increasing engine throttle.
Dynamic braking control DBC
DBC assists the driver in emergency braking
situations by automatically boosting the brake
pressure.
Benefit: Shortest possible braking distances in
emergency braking situations through ABS
interventions at all four wheels.
It is often the case that the brake pedal is not
depressed hard enough in emergency braking
situations The result of this is that the ABS
intervention range is not reached.
The return pump brings the brakes to the ABS
intervention range by boosting the brake
pressure:
if the brake pedal is depressed with
insufficient pedal pressure (from the signal
of the brake pressure sensors)
if the brake pedal is depressed slowly and
then a high rate of deceleration is required
(determined fromthe signal fromthe brake
pressure sensors) if a wheel reaches the
ABS intervention threshold.
The wheel that locks first depends on the
load and the road surface friction
characteristics.
These situations are typical:
Traffic conditions demand only gentle braking
at first but then require a short braking
distance.
3
7
Electronically controlled deceleration
ECD
ECD (electronically controlled deceleration)
responds to the request of the ACC signals.
When the ACC requests deceleration, the
DSC brakes the vehicle by way of automatic
brake intervention at the four disc brakes. This
depends on the vehicle speed, the distance
and speed of the preceding vehicle at
maximum
3 m/s
2
deceleration.
On downhill gradients at a preselected driving
speed, ECD maintains the driving speed
continuously at the preset value by way of
automatic brake intervention. The new brake
pressure sensors can guarantee more uniform
braking at the front and rear axles. This allows
longer activation without compromising on
comfort or overheating of the brakes on one
axle.
In the case of automatic braking, the brake
lights are activated in line with legal
requirements.
The light module (LM) only lights the brake
lights from deceleration of > 1 m/s
2
. This
prevents the brake lights from coming on
frequently and for brief periods.
Hill Descent Control HDC
Controls the road speed of the vehicle on
steep mountainous descents by automatically
initiating braking interventions. HDC makes
driving down steep descents safe at all times
even under the most arduous road conditions,
e.g. no reduction in safety on mountain
descents if the downhill gradient sharpens
suddenly.
Overrun Differential Control SDR
SDR is a special function of DSC. The SDR
function switches the DSC control
characteristics from understeer to oversteer
and vice versa in response to a sudden change
in the vehicle handling. The sudden change in
vehicle handling, e.g. in connection with a load
change, occurs in a bend. This has the effect
of bypassing the control tendency towards
neutral.
4
7
The system comprises the following
components:
DSC module (Mk60)
DSC sensor
DSC button
DSC module
Installation location:
The DSCmodule is located on the spring strut
dome to the front of the engine compartment
on the left-hand side.
Design:
The control unit and the valve block formone
unit. However, the DSC unit is formed of
electrical and mechanical components.
The electrical components of the valves (valve
coils) are assigned to the DSCcontrol unit and
directly connected to the circuit board.
The mechanical components of the valve
(essentially the valve cone with valve tappets)
are permanently secured inside the hydraulic
assembly. The valve tappets move as a result
of the magnetic field generated by the valve
coils. The valve tappets close/open hydraulic
connections by means of the valve seat.
The return pump is integrated in the hydraulic
assembly. The return pump has 2 pump
elements (driven by eccentric discs) that
supply the front and rear axle brake circuit.
The return pump is driven by an electric motor
(see also Notes for service staff).
1 - Hydraulic control unit
installation location
1 DSC module 2 Spring strut dome
5
7
DSC sensor
Installation location:
The DSC sensor for detecting transverse
acceleration andyawrate is locatedunder seat
on the right-hand side of the vehicle.
The DSC sensor combines the functions of
the yaw rate sensor and the acceleration
sensor. The DSC sensor comprises:
Housing with connector
Damper to prevent mechanical overloading
Sensor element
Housing cover
The sensor element is formed of
2 piezoelectric acceleration sensors.
There is a spring-mounted mass in the
measuring cell of the acceleration sensors.
The DSC sensor is connected to the DSC
control unit by a separate CAN interface
(private CAN).
Operating principle
When the vehicle accelerates, two spring-
mounted masses also accelerate. The force
required to do this generates a mechanical
voltage in the piezoelectric material. The
resulting shift in electrical charge is attenuated
by metal electrodes and processed as an
electrical signal. The yaw rate is derived from
the difference between the two acceleration
signals.
The DSCsensor thus supplies both a yawrate
and an acceleration signal.
Operating principle:
The DSC sensor is connected to the DSC
module by a separate CAN (private CAN).
DTC button
Installation location shown on the E85:
The DTC button is located next to the RPA
button in the centre console switch cluster
above the ashtray insert.
2 - DSC sensor installation
location
Index Explanation
1 DSC sensor
2 Sill
6
7
3 - Control panel
1 DTC button 3 DTC indicator lamp in
instrument cluster
2 RPA button 4 DSC indicator and warning
lamp in the instrument cluster
7
7
DTC button operation
The DTC button has two different functions
that are selected by pressing the button for
different lengths of time.
1. Deactivating the DSC function
Briefly pressing the DTC button deactivates
the DSC function but the DTC function
remains active. The DTC indicator lamp in the
instrument cluster lights up.
2. Deactivating the DSC and DTC function
The DSC, ASC, DTC and DBC functions are
deactivated by pressing the button
uninterruptedly (longer than 3 s). The DSC
indicator and warning lamp in the instrument
cluster lights up when the DSC functions are
deactivated.
Reactivating DSC:
Pressing the button once more reactivates the
DSCfunction. The DSCindicator and warning
lamp goes out (except in the event of a system
fault).
DSC is automatically reactivated after every
engine start.
The RPA button is required for initializing
(teaching in the tyre pressures) the RPA tyre
failure indicator. The tyre failure indicator is a
function integrated in DSC (albeit with no
dynamic driving function). Reason: The speed
signals fromall 4 wheels are already present in
the DSC.
Button pressed Function Remark
Briefly 3 seconds DTC function activated DTC indicator lamp on
And held 3 seconds DSC function
completely deactivated.
DSC indicator and warning lamp on.
This mode is intended for service
staff. (e.g. on the brake dynamometer)
8
7
E85 steering angle sensor
The steering angle sensor is fitted to the
steering shaft.
Design
The steering angle sensor is a potentiometer
with 2 sliding contacts offset by 90. The use
of 2 sliding contacts makes it possible to
detect the direction of rotation.
Operating principle
DSC requires a steering angle value to carry
out its functions. The steering angles (2
voltage values) detected by the sliding
contacts cover one full turn of the steering
wheel. The voltage values are repeated after a
360 degree turn of the steering wheel. The
steering angle sensor is thus able to count the
number of steering wheel turns. The total
steering angle is thus derived fromthe current
measured steering angle and the number of
steering wheel turns. The signal is converted
into a digital data record (CAN message) by
the steering angle sensor.
4 - Steering angle sensor installation location
Index Explanation
9
7
MK60 wheel speed sensor
1 Increment wheel 6 Permanent magnet
2 Sensor cable with grommet 7 Sensor element
3 Fastener 8 Electronic evaluation unit
4 Contact ring 9 Carrier for the sensor element
5 Sensor housing
10
7
E85 brake pressure sensors
The two brake pressure sensors (1 and 2) are
fitted to the tandem master brake cylinder in
the pressure connection with the front axle
brake circuit and the rear axle brake circuit.
Design
The brake pressure sensors are capacitive
sensors. A plate capacitor acts as a pressure
sensor. One plate of the plate capacitor is
fixed. The other plate is spring-mounted and
moves.
Operating principle
The pressure in the hydraulic circuit exerts
force on the plate capacitor. The plate gap is
modified if the force acting on the moving
plate of the plate capacitor changes. Changes
in the plate gap change the capacitance.
The brake pressure sensor supplies an
analogue signal in the measuring range of 0 to
250 bar.
The following is derived for DSC from the
signal from the brake pressure sensors:
Estimate of variables such as lateral
cornering force and brake force for all
relevant driving conditions (unbraked,
partially braked, ABS intervention range).
Evaluation of the pressure correction
information at a wheel braked by the DSC
but only if the brake is pressed during the
control procedure.
6 - Brake pressure sensor
installation locations
11
7
System functions
Dynamic traction control DTC
The driver is able to activate the DTCfunction
by pressing the DSC button. The engine
thresholds of ASC (slip thresholds) are
increased up to a speed of approximately 90
mph (150 km/h) to improve propulsion.
Driving is not safety- but rather traction-
orientated.
The slip thresholds are reduced again with
increasing levels of transverse dynamics,
measured by the transverse acceleration
sensor, or increasing instability.
The DTC indicator lamp in the instrument
cluster lights up when DTC traction mode is
activated.
This function is beneficial on roads with loose
surfaces (gravel) or deep snow.
12
7
13
8
System components
DSC Mk60 on the E85
Hydraulic schematic
14
8
1 Brake pressure sensor 1 (front
axle brake circuit)
9 Low-pressure accumulator
2 Brake pressure sensor 2 (rear
axle brake circuit)
10 Inlet valve
3 Expansion tank 11 Outlet valve
4 Tandem master brake cylinder 12 Wheel brake, front left
5 DSC hydraulic unit 13 Wheel brake, front right
6 Intake valve 14 Wheel brake, rear left
7 Changeover valve 15 Wheel brake, rear right
8 Return pump (pump element
for the front axle brake circuit
and rear axle brake circuit)
15
9
Service information
DSC Mk60 on the E85
Service information
The sensors must be calibrated if the DSC
control unit is replaced or if sensors that are
part of the DSC system are replaced.
New features
There is a new brake fluid specification.
All vehicles with DSC without a precharging
pump (currently DSC 8.0 and Mk60 ) must be
filled with a new low-viscosity DOT 4 brake
fluid.
All other vehicles may be filled with the new
low-viscosity DOT 4 brake fluid mixed with
DOT 4. Containers marked DOT 4 brake fluid,
container size 0.25 - 0.5 litres: Cap coloured
red. Containers marked DOT 4 low-viscosity
brake fluid, container size 0.25 - 0.5 litres:Cap
coloured black.
Diagnosis
The DSC Mk60 system is fully compatible
with diagnostics.
Coding
DSC control unit
The DSC control unit must be recoded if the
DSC control unit is replaced. The repair
instructions must be observed.
The steering angle sensor must be recoded if
the DSC control unit or the steering angle
sensor itself is replaced.
Calibration of sensors for DSC
Calibration is required after the following work:
Replacement of the DSC control unit
Steering angle sensor replacement
Replacement of a DSC sensor
Replacement of a brake pressure sensor
Adjustment work on the steering geometry
Work on the steering of the front axle
The actual values must be calibrated as part of
the sensor calibration process for DSC.
16
9
Contents
xDrive four-wheel drive
Introduction 1
What is xDrive? 1
System overview 3
xDrive general overview 3
Functions 7
Functional description 7
Components and their functions 8
Limp-home operation 21
1
6
Introduction
What is xDrive?
xDrive is a four-wheel drive system with an
infinitely variable distribution of drive torque
between the front and rear axle. The central
component is an electronically controlled
clutch, the plates of which are pressed
together within milliseconds by an electric
motor. The higher the pressure exerted on the
multi-plate clutch, the more force is
transferred to the front axle. When the clutch is
open, all of the engine power is transmitted to
the rear axle. xDrive is in constant
communication with DSC. xDrive receives the
following information from DSC:
Rotation speeds of the four wheels
Setting of pedal position sensor
Steering angle
Through continuous analysis of this
information, xDrive is permanently able to
detect whether the vehicle can fully respond
to the driver's commands. xDrive will intervene
with corrective measures if the wheels are
likely to spin or if the vehicle is threatening to
under or oversteer. When the vehicle tends to
understeer while cornering, the drive forces
are reduced at the front axle and increased at
the rear axle. If a tendency towards
oversteering is detected (if the rear is
threatening to break out), the distribution of
drive forces is shifted away from the rear axle
to the front axle. xDrive controls the
distribution of drive torque between the two
axles as required.
On roads with varying surface conditions (e.g.
snow, ice, gravel), the drive torque is variably
transferred to the axle with the better traction.
xDrive, the intelligent BMW four-wheel drive
system, is an innovative concept with active
vehicle dynamics control. The following
advantageous features have been created by
the synergy of the new all-wheel drive train
with the DSC system which now includes
longitudinal torque management. Vehicle
stability, driving safety, agility, traction and
comfort have been further improved while at
the same time achieving the best possible
driving performance characteristics at
maximum efficiency.
Acceleration
Flexibility
Top speed
In short, excellent handling in all driving
situations.
2
6
3
7
System overview
xDrive general overview
1 - Overview of mechanical system
4
7
Mechanical layout of transfer case
2 - Overview of transfer case mechanism
1 Connection to the manual
transmission or the automatic
transmission
4 Servomotor
2 Connection to the rear axle 5 E53: Connection to the front axle
3 Classification resistor 6 E83: Connection to the front axle
5
7
Bus overview
3 - Bus overview
6
7
AHL Adaptive headlight NAV Navigation computer
AHM Trailer module OC3 Occupation 3
CDC CD changer PDC Park distance control
CID Central information display RADIO Radio
DME Digital motor electronics RLS Rain/driving light sensor
DSC-SEN Dynamic stability control -
sensor
SES Voice-activated control system
unit
SDARS Satellites
EWS III+ Electronic immobilizer III SM Seat memory
GM5RD General module 5 Redesign SMG Sequential manual gearbox
HI-FI Top-HiFi amplifier (DSP) SVT Servotronic
IHKA Integrated automatic heating
and air conditioning
IHKR Integrated heating and air
conditioning control
TEL Telephone control unit
LSZ Light switch cluster VG-SG Transfer case electronic control
unit
LWS Steering angle sensor VM Video module
MDS Panoramic glass roof XENON Xenon light electronic control
unit
MRS4RD Multiple restraint system 4
Redesign
7
8
Functions
Functional description
xDrive, the dynamic drive control system,
monitors slip behaviour at the front and rear
axle. The role of xDrive is to achieve optimum
traction and to stabilize or maintain the stability
of the vehicle.
The following evaluation criteria are used for
monitoring:
Wheel speeds
Yaw rate
Transverse acceleration
Steering angle
Under normal driving conditions with four-
wheel drive, the drive torque is distributed as
follows:
40 % to the front axle
60 % to the rear axle
The distribution of drive torque is dependent
on the torque that can be supported at each
axle. When the vehicle pulls away in 1st gear,
for example, a higher load is placed on the rear
axle than the front due to dynamic axle load
transfer. The rear axle is thus able to support a
greater drive torque.
If, for example, the front wheels are moving on
a surface with high friction and the rear wheels
move over black ice, almost 100 % of the
available drive torque will be transferred to the
front axle. The rear axle, under hardly any load,
will only be able to support a low drive torque.
A centrifugal force is produced on a bend by
transverse acceleration, which forces the
vehicle to the outside of the bend. The vehicle
loses stability if the centrifugal force is greater
than the maximum possible lateral cornering
forces of the wheels. The phenomenon
whereby the front wheels of the vehicle slide
towards the outside of the bend is known as
understeering. Conversely, oversteering is
where the rear wheel lose their grip. The rear
of the vehicle is forced outwards.
The xDrive minimizes the tendency to
understeer or oversteer. This is realized by
optimum distribution by drive force between
the rear axle and front axle.
8
8
Yaw rate and transverse acceleration sensor
The sensor cluster in the E83 and E53 is
located on the transmission tunnel level with
the rear seat cross member.
1 - Transverse acceleration/yaw rate sensor
x Vehicle longitudinal axis ay Transverse acceleration
y Vehicle transverse axis Yaw rate
z Vehicle vertical axis
9
8
ATC 400/ATC 500 transfer case
The E83 is fitted with the ATC 400 transfer
case, the E53 with the ATC 500. In
connection with the ATC 500, the propeller
shaft leading to the front axle gearbox has a
slide-on fit. In connection with the ATC 400,
the propeller shaft is secured by means of four
bolts to a flange. The multidisc clutch of the
ATC 500 features an additional disc. The
distance between the input shaft and output
shaft to the front axle on the ATC 500 is
19 mm greater than on the ATC 400.
The flange illustration of the ATCtransfer case
is the same for automatic and manual
gearboxes.
2 - Transfer case housing
1 Output to rear axle 5 Chain
2 Plate assembly 6 Output to front axle
3 Control lever 7 Disc cam
4 Drive from the manual
transmission or the automatic
transmission
8 Servomotor
10
8
Power flow
Operating principle
When the multi-disc clutch in the transfer case
is open, no driving torque is transmitted to the
front axle; instead, the entire driving torque is
directed to the rear differential.
When the multi-disc clutch is fully closed, the
front and rear axles turn at the same
speed.Torque distribution is dependent on
the torque that can be supported on each axle.
If, for example, the driver moves off fromtraffic
lights in first gear at full throttle, there is a
higher load placed on the rear axle as a result
of dynamic axle-load transfer. Consequently,
the drive torque support at the rear axle is
greater. This means that the transmittable
drive torque corresponds to the axle-load
distribution when the coefficient of friction is
identical on the front and rear axles.
An exception is made when the front axle is on
a surface with a high friction coefficient and
the rear axle is on black ice, for example. In this
case, almost 100% of the available drive
torque is transmitted to the front axle since
almost no torque can be supported at the rear
axle.
3 - Transfer case operation
1 Drive from the transmission 5 Control lever
2 Multi-plate clutch 6 Output to front axle
3 Output to rear axle 7 Chain
4 Disc cam
11
8
Servomotor with motor position sensor
This actuator motor is a DC motor which also
contains a Hall sensor for registering the
position and swivel speed of the motor shaft.
The motor shaft is arranged proportional to
the closing rate of the multi-disc clutch.
4 - Servomotor
1 Magnetic ring 2 Motor position sensor (Hall
sensor)
12
8
Coding resistor
Because of mechanical tolerances in
production, the characteristic curve of the
multi-plate clutch locking torque can vary
slightly. The actual locking torque is therefore
measured with the aid of the coding resistor.
The measured value represents a reference
for the progression of the locking torque.
Each time the engine is started, the transfer
case control unit measures the resistance
value once and in such a way that the optimum
program map for the transfer case fitted is
selected.
5 - xDrive servomotor
1 Disc cam 3 Classification resistor
2 Servomotor 4 Worm gear
13
8
Control lever
When the servomotor is running, the disc cam
turns and forces the arms of the control lever
apart. As the lever arms are forced apart, an
axial motion is produced by the ball ramps.
This axial motion of the control armforces the
plates in the multi-plate clutch together. The
multi-plate clutch is closed.
6 - Control lever
1 Multi-plate clutch 2 Control lever
14
8
7 - Control lever operation
1 Ball ramp 3 Control lever
2 Disc cam
15
8
Transfer case electronic control unit
The transfer case control unit is installed in the
E83 on the rear floor panel under the luggage
compartment trim. In E53 it is located
underneath the rear bench seat on the left.
Operating principle
The transfer case control unit regulates the
closing torque of the multi-plate clutch in the
transfer case. The control and power
electronics required for this task are integrated
in the transfer case control unit.
The transfer case control unit is sent
information about the currently required
closing torque by the DSC control unit.
This information is translated into a
corresponding turning motion of the
servomotor. The distribution of drive torque to
the front and rear axle is derived from the
closing torque. The closing torque to be
applied is calculated from the driver's input
and from a higher-level traction and dynamic
driving controller.
A reference run is formed every time the
engine is turned off in order to assign a
corresponding clutch closing torque to a
certain angle position of the actuator motor.
This reference run also takes into account the
influences of wear. The clutch is opened and
closed completely during the reference run.
The current intake is measured at the
respectiveanglepositionof theactuator motor
while the clutch is closed and opened. The
start and end of the clutch closing procedure
are determined in this way. The angular
position is determined by means of a Hall
sensor integrated in the servomotor.
8 - Transfer case control unit
Index Explanation
1 9-pin ELO connector (unassigned)
2 6-pin ELO connector
3 18-pin ELO connector
16
8
A clutch and oil wear model is also calculated
in the transfer case control unit. If necessary,
the clutch and oil wear model limits the closing
torque in order to reduce frictional work.
In the event of DSC failure, an emergency
strategy for actuating the transfer case clutch
is integrated as a fall-back level in the transfer
case control unit, ensuring all-wheel drive is
maintained also in this case.
The transfer case clutch is controlled by the
DSC mounted control unit. Nevertheless,
even when DSC is deactivated, DTC remains
active for the purpose of maximum traction
and driving dynamics.
Permanent all-wheel drive is cancelled in only
3 control cases:
during very tight cornering manoeuvres
with little engine torque to permit speed
compensation between the front and rear
axles (e.g. parking)
at speeds in excess 180 km/h
when the vehicle understeers markedly
The control algorithm of transfer case clutch
control can be described in three main
modules:
Pre-control
Traction control / driving-dynamics control
Tyre tolerance logic
Pre-control
The pre-control algorithmreflects the driver's
command and calculates as a function of
accelerator pedal value,
engine torque,
engine speed,
vehicle speed,
gear,
and steering angle
the required closing torque while taking into
account the maximum clutch, transfer case
and axle drive loads.
Under normal driving conditions, the drive
torque is distributed in a proportion of 40 %to
the front axle and 60 % to the rear axle.
The pilot control ensures rapid response of
the system even in the case of different
coefficient of friction at the front and rear axle
(rear axle on sheet of ice). The system is
illustrated in the following graphic.
In contrast to vehicles with an open
longitudinal differential, in this case with
xDrive, no brake intervention is required at the
rear axle as no slip an occur.
17
8
9 - Overhead view of DSC/xDrive on an icy road
Index Explanation
M Drive torque
M VA Drive torque at front axle
t Time
18
8
Traction control / driving-dynamics control
Traction control monitors the slip ratios at the
front and rear axle. The wheel speeds, yaw
rate and transverse acceleration serve as the
input signals here.
The role of traction control/driving-dynamics
control is to achieve optimum traction and to
stabilize or maintain the stability of the vehicle.
As can be seen in the following graphics, in the
event of an oversteer tendency, the transfer
case clutch is completely closed and thus the
maximum supportable driving torque on the
front axle is transmitted.
Drive torque distribution with oversteer
tendency
The drive torque that can be supported on the
front axle is basically determined by the
relationships in Kamm's circle.
10 - Oversteering
19
8
Drivetorquedistributionwithundersteer
tendency
In the event of an understeer tendency, the
clutch can be fully opened if necessary. In this
way, the front axle is separated from the
drivetrain and the drive torque can only be
transmitted to the rear axle.
11 - Drive torque distribution
20
8
Tyre tolerance logic
The tyre tolerance logic detects different tyre-
tread circumferences on the front and rear
axles. The tyre tolerance logic may be active
when:
mixed tyres are used
an inflatable spare tyre is fitted
tyres are used that have been worn down to
markedly different levels
With a normally pre-controlled multi-plate
clutch, tyre circumference deviations result in
drivetrain torque bias. The axle that is turning
at a higher speed is braked and the other axle
is driven at the same speed.
12 - Tyre tolerance logic
Index Explanation
nVA Wheel speed at the front axle
nHA Wheel speed at the rear axle
1 Different rolling circumferences at the front axle
2 Same rolling circumference at the front and rear axle
3 Greater rolling circumference at the front axle than at the rear axle
4 Smaller rolling circumference at the front axle than at the rear axle
21
9
Service information
Limp-home operation
All-wheel drive is maintained for as long as
possible in the event of failure of important
signals or of the DSC control unit. A limp-
home (emergency operation) controller is
integrated in the transfer case control unit for
this purpose.
This controller operates in redundancy to the
transfer case clutch control in the DSCcontrol
unit.
Failed wheel speed signals at the rear axle are
calculated from the drive or engine speed.
The values from the rear axle are used if the
front wheel speed signals fail.
A substitute value can be derived from the
peripheral wheel speeds if no signal is
received from the steering angle sensor.
General information for towing four-wheel-drive vehicles and
notes on correct operation on brake dynamometers
Important: Towing vehicles with xDrive
Always raise both axles when towing vehicles
with xDrive. Do not tow the vehicle with only
one axle raised (either the front or rear axle).
Not one wheel of a vehicle with xDrive is
permitted to make contact with the road
during towing. There is no guarantee that the
clutch will be fully separated, even if the
servomotor is supplied with no power. The
vehicle could move out of the towing device.
The transfer case would be damaged if the
wheels of the raised axle become locked in the
towing device as a result of deformation.
Observe the warning plate on the left-hand B-
pillar and the note in the Owner's Handbook.
Towing vehicles with xDrive is permitted but
with certain restrictions. Even towing on all
wheels is technically permissible, but with the
following restrictions:
Maximum towing speed of 40 mph (70 km/
h)
Towing distance: maximum of 90 miles
(150 km)
Observe the note in the Owner's Handbook.
Important: Driving onto brake
dynamometers
Hill Descent Control (HDC) must be switched
off before the vehicle is driven onto the brake
dynamometer and must remain switched off.
The HDC indicator lamp must not light up.
There is a possibility of the HDC indicator
lamp going out or not lighting up even when
HDC is active. This is because HDC is
temporarily unavailable due to high brake
temperatures.
Vehicles with xDrive and automatic
transmission
Always carry out the brake test with the
selector lever in position "N" (neutral) and do
not accelerate when the rollers begin turning.
This ensures that the multi-plate clutch in the
transfer case remains separated and the
vehicle cannot be moved off the
dynamometer.
After driving onto the brake test rig, the
accelerator must not be pressed in vehicles
with xDrive and manual gearbox. The transfer
case clutch is also not closed. The vehicle
cannot be pushed/pulled out of the brake test
rig.
22
9
Diagnosis
If tyre tolerance logic is active, an entry to this
effect will be stored in the fault code memory.
Programming
The transfer case control unit and the DSC
control unit are programmable.
Indicator and warning lamps
The following table shows the assignment of
warning lamps and audible signals to the
system statuses of xDrive/DSC.
System status Lamp display in the
instrument cluster
Gong
DSC off No
DSC defective (ABS
fallback level)
or
transfer case control unit
defective
Yes
23
9
Total DSC failure
or
total DSC failure and
failure of the
transfer case control unit
Yes
System status Lamp display in the
instrument cluster
Gong
24
9
Contents
Active Cruise Control
(ACC)
Introduction 1
System description 1
Functions 3
Components 13
Paintwork repairs on vehicles with active
cruise control 19
1
6
Introduction
Active cruise control (ACC)
System description
Active cruise control is a convenience
distance and speed control system that
operates by automatic engine management
and braking interventions.
It is a convenience system for relieving the
strain on the driver on country roads and
motorways.
A radar sensor detects the distance, speed
and angle of objects moving in front of your
vehicle.
The driver is able to preselect a desired speed
of between 30 km/h and 180 km/h. The
desired speed is adjustable. Pressing the
steering column lever inwards increases the
desired speed in increments of 1 km/h.
There are two different modes of operation:
Free driving
ACCautomatically adjusts the speed of the
vehicle to the desired speed selected.
Traffic flow driving
The driver is notified that distance-
dependent traffic flow mode is in operation
by an indicator lamp in the instrument
cluster. ACCmaintains a specified distance
from the vehicle in front.
The speed of the driver's own vehicle is
controlled by interventions in the engine
management and brake system.
As soon as the road ahead is clear again, the
indicator lamp goes out and the desired
speed is resumed.
Principle
Active Cruise Control enables the driver to
select a desired speed that will automatically
be maintained by the vehicle, provided the
lane ahead is clear.
Within technically possible limits, the system
automatically modifies the speed of the
vehicle to match the speed of a slower vehicle
in front. There are four levels that may be
selected for maintaining the distance fromthe
vehicle ahead. For safety reasons, the
distance is speed-dependent. To maintain the
distance specified, the system automatically
reduces throttle and may even gently apply
the brakes. The vehicle accelerates if the
vehicle in front begins to pick up speed. As
soon as the lane ahead is clear again, the
systemaccelerates the vehicle back up to the
desired speed.
2
6
3
7
Functions
Operating principle
After being actuated by the driver, the ACC
system processes information from the radar
sensor. As a result, the vehicle speed is
adapted to the preceding vehicles.
To be able to do this, ACC must be able to
support the following:
Detection of vehicles in front (by the ACC1)
up to a distance of approximately 120 m in
a range of 4.
Detection of vehicles in front (by the ACC1)
up to a distance of approximately 120 m in
a range of 8.
Measurement of distance, angle and
relative speed
Prediction of the vehicle's own suspected
lane course
Identification of the relevant object for
distance control
Adjustment of the vehicle's speed to match
the speed of the vehicle in front through:
Acceleration at a rate of up to 1.2 m/s
2
with ACC1 or ACC2.
Deceleration at a rate of up to 2.0 m/s
2
with ACC1.
Deceleration at a rate of up to 2.5 m/s
2
with ACC2.
Limitation of transverse acceleration to a
maximum rate of 3.0 m/s
2
with ACC1 or
ACC2.
ACC operates in the same way as
conventional cruise control when there is no
vehicle in front, i.e. free driving mode. The
speed of the vehicle is controlled to maintain
the desired speed set by the driver.
1 - Operating principle
4
7
ACClights the "object detected" lamp as soon
as a vehicle is detected in the predicted lane.
ACC automatically decelerates the vehicle if
the vehicle in front is moving at a slower
speed. In the majority of cases this is realized
smoothly through engine intervention and
only rarely through brake intervention.
The switch from free driving to traffic flow
mode takes place without the need for driver
intervention.
In trafficflowmode, the ACCvehicle follows
the vehicle in front with a predefined time gap
in between, and no faster than the desired
speed set. The distance to the vehicle ahead
changes with the speed of this vehicle.
2 - Free driving
3 - Distance control
5
7
The driver is able to select one of four different
time gaps (1 s, 1.5 s, 2 s and 2.5 s).
ACCtherefore assists the driver in maintaining
the minimum distance specified by law in
certain countries. Traffic flow mode avoids
distances that may incur fine payments.
Standard cruise control is resumed
automatically as soon as no vehicle is
detected in the predicted course of travel.
Lane prediction
Technicians refer to the task of
predetermining the driving line by way of
calculation as lane prediction.
To identify the correct object for distance
control, ACC must predict the future lane
course of the vehicle. Vehicles are then
deemed relevant for control interventions if
they are moving in the same lane. Lane
prediction is advance determination of the
course of the ACC vehicle, which is almost
always accurate on motorways and major
country roads.
The speed (1) and the yawrate (2) supplied by
DSC are used to predict the course of travel
(3).
4 - ACC selector lever
5 - Lane prediction
6
7
Function limits
The following limits are imposed for safe ACC
operation:
ACC operation only possible between
30 km/h and 180 km/h.
ACC deceleration by brake intervention
A rate of 2.0 m/s
2
with ACC1
A rate of 2.5 m/s
2
with ACC2
Maximum ACC acceleration of 1.2 m/s
2
.
Maximum transverse acceleration of 3.0 m/
s
2
.
ACC reaches its limits in the following
situations:
The monitoring range of the radar sensor
limits detection of vehicles in front and
vehicles on a different course, e.g. on tight
bends.
ACC may respond to a vehicle cutting in
with a delay. For these reasons, ACC
should not be used on winding roads or
where frequent lane changing is required.
It is not possible to compensate for
considerable differences in speed, e.g.
approaching a slow moving truck at high
speed.
ACC cannot be used in stop/start traffic
because it is not able to brake the vehicle to
a halt. The driver is responsible for control
of the vehicle by braking in good time.
Only use ACC in conditions of adequate
visibility.
The time gap between the ACCvehicle and
the vehicle in front is no less than 1 second
in stationary conditions. This time gap may
be temporarily less than 1 second if a
vehicle cuts in just in front, for example.
The "object detected" lamp begins to flash if
the ACC is no longer able to control the
selected distance. An audible signal also
sounds. The driver must then take control.
If the system's function limits are reached in
ACC mode, the system may behave in a
manner that requires further explanation.
These situations are described below.
7
7
Limited range and deceleration
The radar sensor has a limited range of
approximately 120 mon the one hand, on the
other hand DSC only provides ACC with a
maximum deceleration rate of 2.0 m/s
2
or
2.5 m/s
2
.
ACC is thus only able to fully provide
automatic speed control in a limited relative
speed range.
If the system reaches its function limits, the
driver is prompted to take control by a flashing
"object detected" lamp.
Lateral field of view
The preceding vehicle can be lost in bends
due to the limited lateral field of view. The ACC
vehicle is not accelerated to the required
speed for approx. 2 s in a bend. This function
is designed to ensure the ACC vehicle can on
no account drive too close to the preceding
vehicle that is briefly out of view.
6 - Range
7 - Lateral detection range 1
8
7
With straight-ahead travel, there may be a
delayed response if a vehicle cuts in just in
front. This vehicle is only detected when it is
clearly moving in the same lane as the ACC
vehicle.
Unexpected behaviour
The vehicle on the left is being undertaken
by the vehicle on the right (left-hand-drive
vehicles) because the desired speed is
higher than the speed of the vehicle on the
left.
ACC responds differently if vehicle A is
waiting at traffic lights or if it is still moving at
low speed.
Vehicle stationary
No ACC braking intervention, only
acceleration inhibition close to vehicle A.
The "object detected" lamp does not
light up. The driver is not prompted to
take control.
Vehicle moving slowly
The ACCvehicle is braked by DSCdown
to approximately 40 km/h, there is then a
smooth transition to drag torque control.
The "object detected" lamp lights up.
The driver is prompted to take control.
8 - Lateral detection range 2
9 - Unexpected behaviour 1
9
7
On a bend, ACC prevents acceleration to
the desired speed if this would increase
transverse acceleration to over 3 m/s
2
.
ACC accelerates to the desired speed
before a bend.
Special situations
The driver recognizes special situations by the
fact that the "object detected" lamp is not on.
The vehicle, however, remains below the
required speed and is not further accelerated.
For reasons of comfort, the vehicle controls
the speed on tight bends so as to limit
transverse acceleration to a maximum of
3 m/s
2
. This applies in free driving and
traffic flow mode.
The range can be substantially reduced by
rain, fog and snow. ACC can no longer be
used in extreme cases.
Driving up hills and down valleys may cause
the object to be lost.
10 - Vehicle stationary
11 - Cornering:
10
7
Lens heating
The integrated lens heating reduces the risk of
ACC unavailability in wintery conditions. The
lens heating is activated by directly switching
through the vehicle voltage (terminal 30g on
E6x vehicles) from the ACC sensor. The lens
heating is controlled by a pulse-width-
modulated (PWM) signal from the active
cruise control control unit. The heater coil is
integrated in the lens of the ACC sensor (the
lens is made of plastic.)
The lens heating is only switched on within a
specific outside temperature range
(approximately +5 C to -5 C). At
temperatures around freezing the snowis wet.
At much lower temperatures the snow is dry.
The lens heating is switched off below a
specific outside temperature to prevent the
snow fromthawing on the lens and leaving an
artificial lining. The current outside
temperature value is supplied by the
instrument cluster.
Switch-on conditions for the lens
heating
Engine ON
ACC ON
Outside temperature between +5 C and -
5 C
Lens heating safety switch-off
Temperature in the ACC sensor above
50 C (measured by the internal
temperature sensor in the ACC sensor
control unit)
Voltage greater than 16 V.
The safety switch-off only deactivates the
lens heating. Active cruise control is not
deactivated (no entry in fault code memory).
Monitoring of lens heating
The lens heating is monitored for open
circuit and short circuit of the heater coil.
If the watchdog responds, active cruise
control is deactivated (entry in fault code
memory).
12 - Lens heating
11
7
Check control message
The following check control messages may be
displayed in the event of ACC failure or
deactivation:
12
7
Check control message in
the status line of the CID
Additional text
ACC deactivated!
Drive carefully
ACC deactivated
Active cruise control deactivated due to risk of slipping.
Keep your distance and drive carefully!
Reactivate ACC if necessary, driving situation permitting.
ACC deactivated!
Keep your distance
ACC deactivated
Active cruise control deactivated due to a dirty sensor.
Keep your distance!
Wipe the sensor clean, see Owner's Handbook.
ACC failure!
Keep your distance
ACC failure
Active cruise control ACC failure.
Keep your distance!
Have the vehicle checked at the nearest BMW Service
centre.
ACC deactivated!
Parking brake
ACC deactivated
Active cruise control deactivated because parking brake
applied.
Keep your distance!
Reactivate ACC if necessary.
ACC deactivated!
Keep your distance
ACC deactivated
Active cruise control ACC is deactivated below approx.
30 km/h (20 mph).
Keep your distance!
ACC deactivated!
Brake yourself
ACC deactivated
Active cruise control deactivated due to long downhill
driving.
Keep your distance!
Engine speed!
Select a higher gear
Engine speed too high
Select a higher gear, driving situation permitting.
ACC deactivated
Keep your distance
ACC deactivated
Active cruise control ACCdeactivated: selected gear not
suitable for driving situation. Change gear and reactivate
ACC if necessary.
Engine speed!
Change down
Engine speed too low
Select a lower gear, driving situation permitting.
13
8
System components
Components
Radar sensor
The radar sensor (transmission frequency
76-77 GHz) detects objects moving in front of
the vehicle by transmitting radar waves. The
radar pulse is radiated at the speed of light.
The pulses are transmitted for 10 ms every
100 ms.
The aerial detects an echo if the radar beamis
interrupted by a radar-reflective object.
For the period of the signal, ACC is able to
determine the distance to an object.
The Doppler effect makes it possible to
determine the relative speed between the
ACCvehicle and an object. If the object moves
towards the transmitter, the frequency of the
reflected waves increases.
If the object moves away fromthe transmitter,
the frequency of the reflected waves
diminishes.
To determine the angle, the measuring range
of the ACC1 is monitored by three radar
beams. The middle beam is aimed straight
ahead. The other two beams are aimed at an
offset of 2.5 in relation to the middle beam.
The entire horizontal detection range of the
radar sensor is 4.
The ACC2 emits 4 radar beams. These have a
detection range of 8.
1 - ACC sensor installation
location
2 - Radar beam
14
8
How the ACC2 differs:
The ACCsensor continuously monitors the
detection range in front of the vehicle,
extending approx. 2 - 120 metres, using
4 radar beams. The transmission frequency
of the ACC2 is also 76-77 GHz. The
detection range is limited laterally and
vertically by the aperture angle of the ACC
sensor. The horizontal aperture angle is
8. The vertical aperture angle is 4.
Each radar beamis emitted by an aerial in the
control unit that also receives the reflected
radar signal.
3 - Beam diagram
4 - Angle measurement
15
8
Control unit
The ACC control unit is fitted underneath the
bumper at the front of the vehicle. It is secured
to a metal bracket by three studs. The control
unit can only be coded by variant. The aerial
required is integrated in the control unit. It is
not possible to repair the control unit.
The ACCcontrol unit in the systemnetwork is
responsible for controlling the distance,
vehicle speed and acceleration as well as CAN
communication with the partner systems. The
ACC control unit contains all diagnosis and
self-test functions.
The ACC control unit is protected against
short circuit to positive or earth, polarity
reversal and open circuit.
The sensor shuts down if the system voltage
drops to < 10 V or rises to > 17 V. An entry is
then stored in the fault code memory.
Steering column lever with the following functions:
1. To store and increase the desired speed,
the system is activated.
2. To store and reduce the desired speed,
the system is activated.
3. To deactivate the system.
4. With the system deactivated:
press briefly to call up the stored speed
and distance.
With the system activated:
To increase the desired speed by 1 km/h
with each press of the button. The thumb
switch on the lever allows the driver to
select one of four distances from the
vehicle in front.
5 - Control unit on the bracket
6 - ACC selector lever
16
8
17
9
Service information
Deactivation by the driver
There are various ways in which ACC can be
deactivated by the driver:
Pressing the button
Depressing the brake pedal
Moving the selector lever to N
Deactivating DSC using the button
Automatic deactivation
The systemis deactivated automatically in the
following situations and the driver is notified
accordingly:
Subsystem failure --> "ACC inactive"
Sensor obscured --> "Sensor view"
The set speed LEDgoes out if the speed of
the vehicle drops below the minimum of
30 km/h.
ACC is deactivated and the set speed LED
goes out in the event of prolonged ASC or
DSC interventions.
Vehicles with manual transmission
It is possible to use the system, and also
change gear, from2nd gear within the normal
engine speed range. Continuous operation at
very high or very low engine speeds is not
possible. In this event, a gearshift message is
displayed or the system is automatically
deactivated.
Vehicles with SMG
In sequential mode, continuous operation is
not possible at very high engine speeds. In this
event, a gearshift message is displayed or the
system is automatically deactivated.
Lens heating
The lens is heated to reduce the risk of ACC
unavailability in winter or poor weather
conditions. The heater is a resistance heater.
The heating coil is integrated in the plastic lens
body.
The lens heater is switched on after the
engine is started, depending on the outside
temperature T
a
.
It may not be possible to prevent sensor
"blindness" in all conditions despite the use of
a lens heater.
The "Sensor view" message is displayed for
approximately 20 seconds and a gong sounds
if the lens heating is not sufficient to clear the
radar sensor of snow.
To prevent overheating of the lens body, the
lens heating is deactivated if the internal
component temperature rises to more than
50 C. This temperature is measured by the
internal temperature sensor of the ACC
control unit.
The ACCcontrol unit shuts down to protect its
processor if the vehicle voltage rises to > 17 V.
The lens heating is monitored. Any faults
cause ACC to be deactivated and an entry is
stored in the fault code memory.
18
9
Alignment
The radar sensor must be adjusted with the
vehicle unladen.
Correct adjustment is a prerequisite for
reliable system operation.
Horizontal misalignment results in faulty
response to vehicles in an adjacent lane as
well as in delayed response to vehicle in the
own lane.
ACC is able to compensate for minor
horizontal misalignments of up to 1 by
enforcing certain function restrictions. Any
greater deviation will cause ACC to be
deactivated. The "ACC inactive" message is
displayed.
1 - Alignment 1
2 - Alignment 2
19
9
Paintwork repairs on vehicles with active cruise control
Important: The radar sensor must be
protected from prolonged exposure to
heat and to excessive levels of heat
during repairs to paintwork.
The radar sensor is able to withstand exposure
to temperatures of approximately 100 C to
approximately 125 C for a maximum of 1
hour.
The radar sensor must not be active. The
radar sensor must be removed for work
involving higher temperatures or a longer
duration.
20
9
Contents
Electromechanical
parking brake
Introduction 1
What are the special features of the system? 1
Functions 3
Basic functions 3
EMF components and their functions 4
Gearbox with wrap spring 7
Parking brake button on the E65 8
Indicator lamps on the E65 9
System components on the E65 13
Emergency release and restoring normal
operation 15
Summary 19
1
5
Introduction
Electromechanical parking brake
What are the special features of the system?
The task of the systemis to mechanically hold
the vehicle when parked. In addition, the brake
system features an additional independent
brake system as prescribed by law. The
parking brake also offers other convenience
and safety functions.
The E65 was the first model to benefit from
the electromechanical parking brake (EMF) as
standard. The fundamental aimof the parking
brake is to prevent a stationary vehicle from
moving away. It brakes the parked vehicle
securely. The parking brake replaces the
previous handbrake and footbrake. This is an
automated, comfort-oriented parking brake
system, in which the driver can apply and
release the parking brake by the push of a
button. This conversion satisfies typical BMW
requirements:
Elimination of all situations that may have a
detrimental effect on safety
Optimum functionality
Maximum system availability
Best possible convenience
Components of the parking brake system
1 - EMF components
1 EMF actuating unit 3 Drum brake
2 Bowden cable
2
5
3
6
Functions
Basic functions
The parking brake has two different functions,
depending on the operating status of the
vehicle.
1. Independent stationary braking
When the engine is running, the parking
brake acts on the disc brakes at the front
and rear axle with support from the DSC
hydraulics.
When the vehicle is stationary and the
engine is not running, the parking brake
acts on the duo-servo parking brake on the
rear axle. This is realized with the aid of the
electromechanical actuating unit and
bowden cables. The actuating unit, if
activated, always applies a braking force
defined in the control unit.
2. Dynamic emergency braking
Predefined braking interventions are
initiated by the DSC system if the parking
brake button is pressed when the vehicle is
in motion. The braking is monitored by the
ABS control function and remains active
until the button is released.
4
6
EMF components and their functions
Electromechanical actuating unit
The motor of the actuating unit drives the
gearbox, which then turns the spindle. The
spindle moves the balancing arm, which is
required for right-left balancing of the Bowden
cables. Depending on the direction of spindle
rotation, the balancing arm pulls the cable
pulleys connected by a lever. The Bowden
cables connected to the cable pulleys apply or
release the duo-servo parking brake. The
release action is effected by return springs in
the duo-servo parking brake.
1 - Assembled EMF components
Index Index
1 Cable pulleys 4 Balancing arm
2 Attached control unit 5 Gearbox
3 Servomotor 6 Spindle
5
6
If the brake is released again, the spindle is
driven by the gearbox and takes the end of the
wrap spring on the opposite side with it. The
spindle is released fromthe housing by being
drawn inwards and around the spindle. The
balancing arm shifts forwards and turns the
cable pulleys outwards by means of the
connecting lever. This releases the Bowden
cables.
The holding force of the parking brake is
maintained by the wrap spring on the spindle.
After the holding position has been reached,
the power flow of the spindle has the effect of
turning the spindle in the opposite direction
due to the tensile force of the tensioned
cables. This causes the first windings of the
wrap spring to splay outwards. They press
against the surrounding housing and hold the
spindle in position. The parking brake force is
thus supported by the wrap spring and not the
gearbox.
It is also possible to use the gearbox to turn the
spindle using the manual emergency release
and release the spring tension.
2 - Parking brake limit stop
Index Index
1 Servomotor 5 Guide tube for emergency
release
2 Gearbox 6 Cable pulley
3 Balancing arm 7 Control unit
4 Limit stop 8 Bowden cable
6
6
Control unit
The add-on parking brake control unit is
integrated in the EMF actuating unit. It is
connected to the DSC control unit and the
vehicle peripherals (instrument cluster, DME,
gearbox) via the CAN.
The ECD interface (electronically controlled
deceleration) is used in the DSC control unit
for the hydraulic brake control. Pressing the
parking brake button while the engine is
running requests a fixed amount of brake
pressure, which is generated by the hydraulic
unit and forwarded to the parking brakes.
The force acting on the spindle is calculated in
the parking brake control unit.
This is realized, on the one hand, by
determining the power intake of the motor in
connection with the temperature at the motor
coil. On the other hand, the actuating force is
calculated in connection with the speed drop
of the motor. The drop in speed can be
derived from the motor speed against torque
characteristic curve.
There is also a Hall sensor for detecting the
speed and position of the motor.
7
6
Gearbox with wrap spring
The gearbox is a three-stage reduction gear
set comprising a worm gear, spur gear and
spindle. The gearwheels of the gear
mechanism are made from plastic.
For this reason, the entire holding force of the
parking brake is supported by the wrap spring
in the cover of the spindle housing.
3 - Gearbox and wrap spring
1 Spindle 3 Wrap spring
2 Wrap spring cover 4 Emergency release drive
8
6
Parking brake button on the E65
Two separate operating elements are
provided for controlling parking brake
functions:
The basic parking brake functions, i.e.
Apply/Release with vehicle stationary, are
operated by means of a button (1) arranged
to the left of the steering wheel on the
instrument panel. It operates as an ON/OFF
button. In the case of dynamic emergency
braking, the brake is applied for as long as
the button is pressed, irrespective of the
vehicle speed.
The second operating element is an action
field in the menu of the control display. The
menu is controlled and activated using the
controller. This control allows the driver to
select whether the Automatic Hold
convenience parking brake function should
be activated or deactivated. The activation
and deactivation of this convenience
function can also be assigned to the
individually programmable button on the
multifunction steering wheel.
4 - Parking brake button
9
6
Indicator lamps on the E65
The driver is informed at all times of parking
brake system status and availability.
This information is in the form of an indicator
lamp in the instrument cluster and additional
instructions in the control display in the event
of a malfunction. The parking brake control
unit is connected to the instrument cluster and
the control display by CAN. The lamp check is
started after the ignition is turned on.
Technicians call this the pre-drive check.
Display in the instrument cluster
Application of the parking brake is indicated by
a red indicator lamp with the brake symbol P.
PARK lights up in the indicator lamp for the
duration of the actuation process. The P
symbol indicates whether the requested
status, applied or released, has been achieved.
An audible warning also sounds if the parking
brake is operated when the vehicle is in motion
(dynamic emergency braking).
Convenience display (automatic)
The readiness of automatic hold function is
displayed by AUTO-P in green in the lamp.
The parking brake symbol is also displayed if
the Automatic Hold function is active and
holding the vehicle.
The parking brake symbol lights up green in
this event (the hold function is now controlled
by DSC at all 4 wheel brakes).
The green parking brake symbol goes out
following automatic release of the brake when
driving off. The green readiness indication
AUTO-P, however, remains active.
Automatic transition fromthe hydraulics to the
mechanical system takes place when the
engine is turned off. The illuminated indicator
changes from green to red (additional
application of the parking brake and release of
DSC).
10
6
Indicator lamp control
System functions Indicator lamps
Parking brake released
Parking brake activated
Dynamic emergency braking and gong
Automatic Hold ready
Automatic Hold active
System fault
11
6
Check control display
Parking brake malfunctions are indicated by a
yellow lamp in the instrument cluster.
The same symbol is also shown by the
variable indicator lamp and explained by a brief
text message.
In addition to the parking brake, the variable
indicator lamp is also available to other control
units. Corresponding to a defined priority
control, the parking brake control unit can only
partially use the indicator lamp. The variable
indicator lamp is able to display all symbols
and colours of all malfunctions as shown in the
instrument cluster.
Malfunction of the parking brake is indicated
with the aid of the variable indicator lamp in the
instrument cluster. At the same time, the fault
is detailed with supplementary information in
the control display.
5 - Instrument cluster
1 Parking brake indicator lamp 3 Variable display and warning field
2 Check control display
12
6
EMF emergency function
The handbrake function is not the only task of
the electromechanical parking brake. The
EMF additionally conforms to the legal
requirement of providing a second operating
unit for brake operation.
The electromechanical parking brake is the
second operating unit in the E65 in addition to
the foot brake.
The vehicle decelerates at a rate of 3 m/s
2
for
0.8 seconds if the button is pressed when the
vehicle is in motion. Braking deceleration is
then ramped up to 5 m/s
2
for the next 2
seconds. This braking deceleration is
maintained for as long as the button is
pressed.
For safety reasons, the DSC hydraulic system
ensures the dynamic braking function by way
of the active pressure build-up also when the
vehicle is rolling with inclusion of the ABS
function. Rolling situations include traffic
queues while driving downhill, towing. The
brake pressure required is made available as
rapidly as possible.
The braking is always monitored by the ABS
control function. This ensures vehicle stability
under braking. Since all four wheels are braked
hydraulically, there is considerably greater
deceleration with a minimum of operating
effort (button) by comparison with
conventional parking brakes. The controlled
brakes is therefore able contribute to
improving vehicle safety.
For traffic safety reasons, operation of
dynamic emergency brakingis indicatedtothe
road users behind by the brake lights coming
on.
To avoid accidental operation and misuse, the
driver is notified of dynamic emergency
braking operation by the "Release parking
brake" message and a gong.
The vehicle will remain hydraulically braked if
the vehicle is braked to a halt by dynamic
emergency braking alone. The red P lamp
remains on.
The more effective braking solution is used if
the parking brake deceleration request is
overlapped by the brake pedal being
depressed. Which deceleration request to
carry out is decided in the DSC control unit.
This function is intended only for use in an
emergency and must never be used as a
substitute for normal operation of the service
brake.
When is the emergency function cancelled?
The vehicle will remain hydraulically braked
even after the parking brake button has been
released if the vehicle is braked to a halt by
dynamic braking. There is a transition to the
normal DSChydraulics function. The hydraulic
brake is only released when the button is
pressed once more.
If the driver releases the parking brake button
while the vehicle is still in motion, the system
level prevailing before the emergency
dynamic braking was activated is resumed.
If the parking brake is released and the vehicle
is coasting, it is possible to activate
emergency dynamic braking in any situation
(terminal 15, terminal R, terminal 30) by
pressing the button.
13
7
System components
System components on the E65
1 - EMF system diagram
1 DSC module 8 EMF control unit
2 Service brake, front axle 9 Parking brake, rear axle
3 Service brake, rear axle 10 Parking brake servomotor
4 Instrument cluster 11 Parking brake button
5 Controller 12 4 wheel speed sensors
6 Control Display K-CAN Body CAN
7 Safety and gateway module SGM PT-CAN Powertrain CAN
14
7
15
8
Service information
Emergency release and restoring normal operation
The full parking brake effect is released by
intervening directly in the gearbox mechanism.
To release the brake in an emergency, an
extension rod supplied separately in the
vehicle tool kit is inserted through a guide tube
and into the emergency release gearwheel.
The insert tool is intended to be inserted
through a guide tube on the side of the
housing opposite the gearbox.
The turning torque required is achieved using
the open-ended spanner and screwdriver
handle from the vehicle tool kit.
1 - Actuating unit
1 Electric motor 3 Emergency release tool
2 Emergency operation gearwheel
16
8
The brake is released by turning anticlockwise.
A release spring in the release tool prevents
the tool from turning if accidentally left inside.
Note:
After releasing the brake by emergency
release, it may still not be possible to move the
vehicle if there has been a power failure.
The automatic transmission parking lock may
still be engaged.
There is a manual emergency release for the
gearbox in the left-hand footwell. Opening a
cover reveals a lever that can be folded out by
pulling a strap and then engaged. It is then
possible to move the vehicle.
The cover in US vehicles is secured by a lock.
It can only be opened using the ignition key.
Restoring normal operation after an
emergency release
If the power supply is restored after the
emergency release, the parking brake button
must be pressed 3 times.
1st operation
The control unit would like to release the
brake. The motor cannot turn in reverse as the
brake was already released by the emergency
release function. The control unit detects an
implausible condition.
2nd operation
The motor is able to turn forwards. The brake
is applied. The control unit detects the
situation.
3rd operation
The motor is able to turn in reverse. The brake
is released again. Normal operating status is
restored.
This procedure is also described in the
Owner's Handbook.
17
8
Brake shoe adjustment
The brake shoes of the parking brake are
adjusted as before by turning an adjusting
screw with a screwdriver. A threaded hole is
provided in the wheel hub for this purpose.
Removing the Bowden cables
To permit removal of the Bowden cables, it is
necessary to raise the end stop using a tool
(e.g. a screwdriver). The release tool turns
back the balance arm until the cable pulleys
come up against the housing, thus releasing
the Bowden cables from the pulleys.
Initializing the parking brake
The parking brake must be initialized following
replacement of the drum brake pads. This
function can be performed with the aid of the
DIS or MoDIC. The process teaches in the
new free play of the brake cables as detected
by the Hall sensor in the actuating unit. This
makes later detection of cable tearing more
reliable.
Bedding-in the duo-servo brake
If the brake shoes of the duo-servo parking
brake are replaced as part of repair or
maintenance work, it is necessary to bed-in
the brake shoes before a sufficient holding
effect may be achieved. A special bedding-in
routine is stored in the parking brake software
that can be called up using DIS.
The readiness of the bedding-in program is
indicated to workshop personnel by a flashing
red parking brake indicator lamp in the
instrument cluster. The bedding-in procedure
must be performed within 30 minutes after
activating the program. The ignition must not
be turned to OFF otherwise the bedding-in
program will be terminated. The system will
revert to the normal parking brake function.
PBR abbreviation for parking brake
The abbreviation PBR is also used in DIS
when referring to the parking brake.
18
8
19
9
Summary
System benefits
Operating comfort has been enhanced
considerably by comparison with the
conventional mechanical parking brake.
Optimum ergonomics have been achieved
thanks to its space-saving control (button).
Moreover, it has been possible to utilize the
room reclaimed in the centre console
(stowage compartments, telephone, etc.).
The automatic braking of the automatic
hold function relieves some of the stress of
stop and start traffic. It relieves the strain on
the driver by reducing the amount of foot
operation usually required in creeping
traffic.
Similarly, the automated release of the
brake makes pulling away comfortable on
uphill gradients without the risk of the
vehicle rolling backwards.
The intervention of the ABS control
function during dynamic emergency
braking and the deceleration effect boosted
by hydraulic four-wheel braking
interventions have contributed to raising
standards of vehicle safety.
Yet another safety feature is that it is only
possible to release the parking brake when
the ignition is ON (child-safety lock,
electronic immobilizer).
The system is diagnostics compatible and
benefits from wear compensation. No
adjustment work is necessary (Bowden
cable adjustment).
Its diagnostic capabilities inform the driver
of systemcondition and simplify repair and
service work.
A manual emergency release is provided in
case of systemfailure or insufficient power
supply.
There are no distracting brake operation
noises.
20
9
Contents
Transverse dynamics
systems
Objectives 1
Introduction 3
Dynamic Drive 3
System overview 5
E60 Mechanical system 5
Functions 7
Components and their functions 7
System functions 17
Operating states 21
E60 inputs/outputs 25
E60 system circuit diagram 27
1
4
Objectives
Transverse dynamics systems
Dynamic Drive or active roll stabilization - the
BMW transverse dynamics system.
The followingpages contain all the information
you need to understand the system. You will
become acquainted with all system
components and their operation, and
individual functions will be explained in detail.
You will then be in a position to carry out
diagnostics to a professional standard - the
basis for high customer satisfaction.
2
4
3
5
Introduction
Dynamic Drive
DynamicDrive is a suspension control system
that counteracts rolling forces. DynamicDrive
is also known as ARS. This stands for Active
Roll Stabilization. DynamicDrive prevents
vehicle roll (= turning motion around
longitudinal axis during cornering). When a
vehicle is cornering, a centrifugal force acts on
the centre of gravity which builds up a rolling
moment via the vehicle longitudinal axis. This
force tilts the vehicle body towards the wheel
on the outside of the bend and the vehicle
rapidly approaches its dynamic limits.
Stabilizer bars are used to counteract the
varying forces which act on the wheels as a
result of the body angle. During cornering, the
wheel suspension on the outside of the bend
is compressed and the wheel suspension on
the inside of the bend rebounds. This causes
the spine of the stabilizer bar to turn. The
forces occurring at the mounting points of the
stabilizer bar produce a moment. The moment
counteracts the tilt of the body, thus achieving
more effective distribution of the load over
both wheels. DynamicDrive therefore
enhances driving stability. Vertically divided
stabilizer bars on both axles are the basic
elements of this system. Both halves of the
stabilizer bars are connected by a hydraulic
oscillating motor which adapts the suspension
to the road situation within milliseconds.
DynamicDrive also improves driving comfort -
especially ride comfort - when travelling
straight ahead. If potholes are present on one
side of the road, in vehicles with conventional
stabilizer bars this has a negative effect on the
suspension on the other side. Not so with
DynamicDrive.
4
5
5
6
System overview
E60 Mechanical system
1 - Overview of mechanical system
1 Fluid reservoir 6 Control unit
2 Tandem pump 7 Transverse acceleration sensor
3 Hydraulic-fluid cooler 8 Hydraulic lines
4 Front oscillating motor 9 Rear oscillating motor
5 Valve block
6
6
7
7
Functions
Transverse acceleration sensor
The transverse acceleration sensor supplies
the main sensor signal. It measures the
transverse acceleration of the vehicle during
cornering up to a measurement range of
1.1 g. The transverse acceleration sensor is
installed on the base plate under the right front
seat.
Oil level sensor
The oil level sensor detects the fluid supply in
the oil reservoir.
It is installed on the oil reservoir. Short-circuit/
open circuits cannot be detected by the oil
level sensor. A line break is interpreted as a
loss of fluid.
DynamicDrive control unit
The DynamicDrive control unit is located on
the right side of the passenger compartment
in the A-pillar area.
The control unit is supplied with power via
terminal 30 and is protected by a 10 A fuse.
A vehicle authentication process takes place
when the system is started. This compares
the vehicle identification number from CAS
with the vehicle identification number which is
encoded in the DynamicDrive control unit.
Then the control unit's hardware and software
is checked.
All the outputs (valve magnets) are subjected
to a complex check for short circuits and
breaks. If there is a fault, the system switches
the actuators into a safe driving condition.
The control unit switches off if there is
undervoltage or overvoltage.
The control unit learns the "offset" for the
steering angle and the transverse acceleration
during start-up and during driving.
8
7
Active stabilizer bar
The active stabilizer bar consists of the
oscillating motor and the halves of the
stabilizer bar with press-fitted roller bearings
which are mounted on the oscillating motor.
The roller bearings provide the connections to
the axle carrier. The use of roller bearings
ensures optimum comfort thanks to better
response and reduced control forces.
The oscillating motor and the oscillating motor
housing are joined by one half of the stabilizer
bar.
1 - Oscillating motor
1 Oscillating motor shaft 2 Oscillating motor housing
9
7
The oscillating motor of the front-axle
stabilizer bar is fitted with 2 pressure relief
valves.
Pneumatic lines are mounted on the pressure
relief valves (venting valves).
The pneumatic lines lead to a filter element
(conventional fuel filter) which is inserted in the
diagonal strut on the left wheel arch.
2 - Pressure relief valves
1 Oscillating motor 3 Pneumatic lines
2 Pressure relief valves
10
7
The filter element is located in different
positions in the engine compartment,
depending on the mounting position of the
various engines.
The positions for the pressure relief valves are
fitted with screwplugs on the oscillating motor
of the rear-axle stabilizer bar.
Function of pressure relief valves
When the vehicle is driven on poor road
surfaces, the stabilizer bar movements give
rise to brief underpressures (cavitation) in the
oscillating motors which in turn cause rattling
noises.
Pressure relief valves have been fitted on the
front oscillating motor in order to eliminate
these noises. These pressure relief valves
allow filtered air to flow into the oscillating
motor throughtheconnectedpneumatic lines.
This prevents cavitation.
This small quantity of air is absorbed by the
hydraulic fluid (Pentosin) to forman emulsion,
which is discharged during subsequent
activations of the oscillating motor. The air is
separated in the expansion tank.
Since no noises can be heard at the rear axle,
the pressure relief valves have been omitted
from the rear oscillating motor.
3 - Filter element
Index Explanation
1 Filter element
11
7
Operating principle of oscillating motors
The oscillating motor has three functions to
perform:
It guides the torque into the two halves of
the stabilizer bar.
It decouples the two halves of the stabilizer
bar.
In the event of system failure (fail-safe
mode), the front axle stabilizer bar creates
sufficient damping via the hydraulic fluid of
the oscillating motor. It now works like a
conventional stabilizer bar.
Exception: If the oscillating motor chambers
no longer contain any fluid as a result of a
leak, the front axle stabilizer bar can no
longer create damping.
The opposing chambers in the oscillating
motor are connected to one another. The
same pressure exists in both chambers. Two
chambers are supplied with high-pressure
fluid using one connection. The two other
chambers are connected to the tank via the
return line. The forces F
H
(High) or F
L
(Low)
are created as a result of the differences in
pressure. As F
H
is greater than F
L
, a torque M
S
is generated. The shaft turns in the opposite
direction to the housing as a result.
Since one half of the stabilizer bar is
connected to the shaft, and the other with the
housing, the two halves turn in opposite
directions.
This torque M
S
at the stabilizer bar
connections produces the active moment M
A
about the vehicle longitudinal axis. The active
moment counteracts the rolling moment M
while cornering. The body is forced upwards
on the outside of a bend, and dragged down
on the inside of a bend.
The maximum body torque on the front and
rear axle occurs when there is a high degree of
transverse acceleration. The systempressure
is then 180 bar at the front axle and 170 bar at
the rear axle.
4 - Generating torque
12
7
Front-axle stabilizer bar
The stabilizer bar is mounted on the front-axle
carrier.
The stabilizer links are connected to the
"goosenecks" of the swivel bearings.
5 - DynamicDrive front axle
1 Anti-roll bar link connection to
swivel bearing
4 Oscillating motor
2 Anti-roll bar bracket 5 Anti-roll bar links
3 Anti-roll bar
13
7
Rear-axle stabilizer bar
The stabilizer bar is mounted behind the rear-
axle carrier.
The stabilizer links are connected to the rear-
axle swinging arms.
6 - DynamicDrive rear axle
1 Hydraulic lines from valve block 4 Oscillating motor
2 Anti-roll bar links 5 Hydraulic lines
3 Anti-roll bar
14
7
Valve block
The valve block is located on the floor plate
behind the front right wheel-arch trim.
7 - Valve block
1 Rear-axle pressure sensor 8 Directional valve
2 Rear-axle pressure-limiting valve 9 Line 1, rear-axle oscillating motor
3 Front-axle pressure-limiting
valve
10 Line to hydraulic fluid reservoir
4 Line 1, front-axle oscillating
motor
11 Line 2, rear-axle oscillating motor
5 Line 2, front-axle oscillating
motor
12 Switching position recognition
sensor
6 Front-axle pressure sensor 13 Line to tandem pump
7 Fail-safe valve
15
7
Pressure control valves
There is a pressure control valve on both the
front and rear axles. They both adjust the
actuation pressures for the front- and rear-axle
stabilizer bars.
Directional valve
The directional valve is electrically actuated. It
specifies the direction of the high-pressure
fluid (active pressures) and the reservoir fluid
for right-hand and left-hand bends.
Fail-safe valve
The fail-safe valve (safety valve) is electrically
actuated. The fail-safe valve responds in the
event of a power supply failure or if a fault is
detected in the system.
When de-energized, the fail-safe valve locks
the oscillating motor for the front axle. Thus
the active stabilizer bar behaves like a normal
mechanical stabilizer bar and brings about
understeering.
Switching position recognition sensor
The task of this sensor is to detect the specific
position of the directional valve.
2 positions can be detected:
Left-hand control
Right-hand control
Front-axle/rear-axle pressure sensors
The pressure sensors are responsible for
detecting the front and rear axle stabilizer bar
hydraulic pressures. Thesensors aremounted
on the valve block. The pressure sensor offset
values are taught-in by the control unit once,
during commissioning.
8 - Pressure sensor characteristic curve
16
7
Tandem pump
The engine drives the tandem pump via a
ribbed V-belt. The tandempump consists of a
radial piston part for DynamicDrive and a vane
cell part for the power steering.
When idling, the pump speed is approximately
750 rpm.
The pump's minimum fluid flow rate is 4.5 l/
min at approximately 5 bar and 3.3 l/min at 200
bar. This means that sufficient system
dynamics are also guaranteed when the
engine is idling.
The maximum fluid flow rate is limited to 7 l/
min from a pumping speed of approximately
1165 rpm and upwards.
The DynamicDrive and power steering share a
common oil reservoir and power steering
cooler.
Oil reservoir
The oil reservoir is identical on all vehicles,
whether they have the DynamicDrive function
or not. The reservoir incorporates a fluid filter.
An oil level sensor is provided for the minimum
quantity.
Cooler
The cooler ensures a long-term fluid
temperature of < 120 Cand a short-termfluid
temperature of < 135 C in all
hydromechanical components under all
conditions.
17
7
System functions
Transverse acceleration a
q
is exerted on the
vehicle while cornering. The transverse
acceleration is applied at the centre of gravity
of the vehicle body.
The body rolls about the vehicle longitudinal
axis (rolling axis) RA which is defined by the
kinematics of the front and rear axle. The roll
angle is formed (max. 5). This produces a
maximumchange in level at the wheel arch of
10 cm.
In a passive vehicle with conventional
suspension, the rolling moment Mis absorbed
by the stabilizer bars and springs. The springs
on the outside of the curve are compressed.
The springs on the inside of the curve are
elongated. In addition, the stabilizer bars
rotate. A roll angle between the vertical axis
and the body results.
On vehicles with DynamicDrive, the rolling
moment Mis compensated up to a transverse
acceleration a
q
of approx. 3 m/s
2
(0.3 g). The
active stabilizer bars alone are responsible for
this function. A roll angle only builds up once
the rolling moment M has exceeded the
moment actively set M
a
by the stabilizer bar.
The additional rolling moment M is then
absorbed by the passive springs.
9 - Rolling
A Vehicle without DynamicDrive Ma Active body moment
B Vehicle with DynamicDrive SP Centre of gravity
M Rolling moment RA Vehicle longitudinal axis (rolling
axis)
aq Transverse acceleration F
q
Transverse force
Roll angle h Lever arm centre of gravity
height
18
7
The active body moments M
a
at (the front and
rear axle) counter the rolling moment M. Using
this approach, the roll angle is compensated
for in accordance with the characteristic curve
specified in the control unit. The roll angle is
fully compensated for up to a transverse
acceleration of approximately 3 m/s
2
(0.3 g). A
roll angle also builds up with DynamicDrive but
only with a high transverse acceleration. The
roll angle together with an increasing
understeering trend therefore provide the
driver with an indication that the vehicle is
approaching its limit range.
3 Note: The tyre suspension created by the
rolling moment (M) is not compensated for. 1
Roll angle diagram
The roll angle shown is achieved with an
unladen vehicle with the driver in the vehicle.
When a vehicle is fully laden, the greater body
weight effects a greater transverse force on
the vehicle. Depending on the configuration of
the vehicle load (in the vehicle or on the roof),
this also results in a change to the lever arms
h. The vehicle will in this case form a slightly
greater roll angle than specified in the control
curve.
By the same token, however, the fully laden
passive vehicle also forms higher roll angles.
The distribution of the active body torque
between the front and rear axle depends on
the road speed.
10 - Roll angle diagram 1
11 - Roll angle diagram 2
19
7
Affect of the self-steering behaviour
The self-steering behaviour can be decisively
influenced by the distribution of the stabilizing
torque on the axles. The greater the stabilizing
torque on an axle, the lower the transverse
forces transmitted on this axle.
Two cases are described below with different
distribution of stabilizing torque on the axles:
1. Identical stabilizing torque on both
axles
Handling is NEUTRAL.
The front wheels can apply about the same
amount of transverse force on the road as the
rear wheels without drive torque. The handling
conditions are neutral.
The handling of a vehicle with neutral tuning is
very agile and precise. The steering response
is very direct.
Even an inexperienced driver can control a
vehicle which is tuned to neutral handling very
well at low speeds.
2. Greater stabilizing torque on the front
axle
Handling is UNDERSTEERING.
The front axle wheels cannot apply the same
amount of transverse force on the road as the
rear axle wheels. The vehicle suffers
understeer.
A greater steering-wheel angle is required to
be able to follow the desired course.
A vehicle with understeer can generally also
be controlled well by an inexperienced driver
at higher speeds and higher cornering speeds.
This very sensitive handling reduces the
vehicle's agility.
DynamicDrive sets different stabilization
moments at the front and rear axle. This
results in different vehicle response for low
and high speeds.
The passive vehicle is configured as slightly
understeering irrespective of the speed range.
The active vehicle with DynamicDrive is
configured neutrally in the low speed range.
Less steering is required by the driver to drive
round the same bend. The result is optimum
handling and agility.
In the upper speed range, both vehicles
behave almost identically with regard to the
required steering angle on the same bend.
The hydromechanical concept is designed so
that a greater active stabilizing torque cannot
occur on the rear axle than on the front axle.
This means that mechanically and
hydraulically the vehicle with DynamicDrive is
safeguarded such that no oversteering and
therefore for normal customers no critical
handling characteristics can occur under any
circumstances.
20
7
Comparison between the conventional stabilizer bar and the
active stabilizer bar
Active stabilizer bars introduce fewer comfort-
reducing forces into the body than
conventional stabilizer bars. In this case a
differentiation must be made depending on
the frequency with which the forces were
introduced.
Road stimulus Stabilizer bar behaviour
At approximately 1 Hz
(body natural frequency)
At smaller strokes the active stabilizer bar is easier to turn than a
conventional stabilizer bar.Consequently, the forces applied in
the body are lower. The vehicle is more comfortable and body
stability is improved.
From 8 Hz
(wheel natural frequency)
Both stabilizer bars behave in a similar way.The active stabilizer
bar becomes harder because the fluid is not displaced as quickly.
21
7
Operating states
Straight-ahead travel:
When the engine is started, the pump delivers
hydraulic fluid to the system and a back
pressure builds up. The pressure difference
that occurs between the chambers of the
actuator motor has no effect on the stabilizer
bar. The reason for this is that, at approx. 1 bar,
the pressure difference is very low. No power
is applied to the high pressure control valves
for the front axle stabilizer bar and the rear axle
stabilizer bar. The valves are therefore open.
The hydraulic fluid can flow back into the tank
directly. This condition remains unchanged as
long as the vehicle is travelling straight ahead.
The systemfunction is displayed continuously
up to 15 km/h. The full stabilization potential is
available from 15 km/h onwards.
Cornering:
When approaching a bend, signals from the
transverse acceleration sensor are sent to the
DynamicDrive control unit. The control unit
now sends a pulse-width-modulated signal
(PWM) to the high pressure valves for the front
and rear axle stabilizer bars. The stronger the
transverse acceleration, the greater the signal
will be (current). The higher the power applied
to the valves, the more they close. A
correspondingly higher pressure is built up in
the stabilizer bars. The pressure at the
stabilizer bar is registered by the respective
pressure sensor on the front axle and on the
rear axle and sent to the control unit.
The direction valve (RV) is activated by the
control unit to create a pressure build-up
which corresponds with the characteristic of
the bend (left or right-hand bend). A sensor
(SSE) detects the switch position of the
direction valve.
The fail-safe valve is also activated with this
function.
22
7
23
7
SMV Front oscillating motor RV Directional valve
SMH Rear oscillating motor DSH Rear-axle pressure sensor
V1 Front-axle hydraulic circuit 1 DSV Front-axle pressure sensor
V2 Front-axle hydraulic circuit 2 PVV High-pressure control valve,
front axle
H1 Rear-axle hydraulic circuit 1 PVH High-pressure control valve, rear
axle
H2 Rear-axle hydraulic circuit 2 P Tandem pump
FS Fail-safe valve T Fluid reservoir
SSE Switching position recognition
sensor
24
7
25
8
System components
E60 inputs/outputs
1 - System overview
26
8
1 DynamicDrive control unit 9 Transverse acceleration sensor
2 Valve block, DynamicDrive 10 Hydraulic reservoir, fluid level
sensor
3 DSC module 11 Current distributor, front, power
supply
4 Digital motor electronics byteflight byteflight
5 Safety and Gateway Module PT-CAN Powertrain CAN
6 Instrument cluster K-CAN Body CAN
7 Car Access System control unit F-CAN Chassis CAN
27
8
E60 system circuit diagram
2 - DynamicDrive system diagram
1 DynamicDrive control unit 9 Transverse acceleration sensor
2 Valve block, DynamicDrive 10 Hydraulic reservoir, fluid level
sensor
3 DSC module 11 Current distributor, front, power
supply
4 Digital motor electronics byteflight byteflight
5 Safety and Gateway Module PT-CAN Powertrain CAN
6 Instrument cluster K-CAN Body CAN
7 Car Access System control unit F-CAN Chassis CAN
28
8
29
9
Service information
Service information
If the DynamicDrive fails, DSC can no longer
be deactivated or if it is already deactivated it
does not switch back on automatically.
The connections for all the hydraulic
components are designed in different
dimensions and lengths so that they cannot
be transposed.
A disturbing noise may be heard in the vehicle
interior, predominantly caused by assembly
and cable connections.
The cables must not make contact. They must
not be overtightened or loose in the holders.
They are covered by the underbody panelling.
Steering angle sensor adjustment
After work on the steering, it is necessary to
adjust the steering angle sensor with the
steering column switch cluster (SZL) control
unit.
The DynamicDrive system is dependent on
the exact zero balance of the steering angle.
The maximum deviation tolerance is 1.
Precise wheel alignment check and
adjustment is a prerequisite.
The steering angle sensor for ARS 1 must
always be adjusted on a model by model basis
in accordance with BMW specifications.
Adaptive tuning is carried out for ARS 2.
The zero position is lost each time the
DynamicDrive control unit or the SZL is flash
programmed.
Steering angle sensor adjustment is then
required.
DynamicDrive initialization
The initialization procedure must always be
carried out once the systemhas been opened
or a part has been replaced. This also applies
after the transverse acceleration sensor has
been replaced.
The following conditions must be guaranteed
for matching the transverse acceleration
sensor and the two pressure sensor offset
values:
The vehicle must stand level on all four
wheels
The vehicle must be unladen
The engine must be idling
Rest status (doors closed, persons are not
allowed in the vehicle)
No persons may remain within the vicinity of
moving chassis parts during the
commissioning (both in the works and the
workshop). In addition you must ensure that
the basic initialization conditions (temperature
range, constant engine speed etc.) are
observed. The ground clearance must not be
restricted. The doors must be closed. The
arms of the hoist may no longer be situated
beneath the car.
30
9
The initialization procedure is split into five
stages which follow on from each other
automatically:
Bleeding DynamicDrive
A bleeding routine must be carried out using
the BMW diagnostic tester if the
DynamicDrive system was opened
hydraulically.
The bleeding operation must be performed
only using the initialization routine of the BMW
diagnosis system. The bleeding operation
must not be performed at the pressure relief
valves or at the screw plugs of the oscillating
motors!
If the test still detects air in the system, a short
movement trip should be made if necessary.
The initialization routine must then be
repeated after the short trip.
In the event of an extreme leak or suspected
partial function of the pressure relief valves
(noticeable by rattling noises in the front end),
the pressure relief valves and the pneumatic
lines must be replaced with new components.
I: Direction valve test
(from 3 to 3.4 s)
First the direction valve is tested by evaluating the signal of
the switch-position recognition sensor.
II: Low-pressure test (from
3.4 to 4.3 s)
During this phase, the fail-safe and direction valve are not
supplied with current.
Checks are then carried out using de-energized and
energized pressure control valves at the front and rear axle.
This will cause the body to roll. The sides of the vehicle
must be clear.
III: High-pressure test
front axle
(from 4.3 to 9.9 s)
Pressure of 180 bar is applied to the front-axle oscillating
motor. Air in the system, internal leaks and a blocked
oscillating motor are detected.
IV: High-pressure test
rear axle
(from 9.9 to 15 s)
Pressure of 170 bar is applied to the rear-axle oscillating
motor. Air in the system, internal leaks and a blocked
oscillating motor are detected.
V: Pressure control valve
test
(from 15 to 25 s)
The characteristic curves of the front and rear axle are
checked (setpoint/actual value comparison). Faulty
pressure control valves are detected.
31
9
Diagnosis
The following faults can be detected at the
components:
Component Fault type Fault detection via:
Control unit De-energized or faulty No alive counter in the instrument cluster, VIN
not recognized during authentication,
software reset
Pump No pressure Setpoint/actual-value comparison pressures
Directional valve Jammed in "energized"
position (spring break,
swarf)
Directional-valve sensor
Jammed in "de-
energized" position
(line break)
Direction valve sensor and
current monitoring
Pressurecontrol
valve
front axle
Open (de-energized, p =
pRA)
Setpoint/actual-value comparison, pressure at
front axle
current measurement
Closed
(mechanical fault)
(pFA = pmax)
Setpoint/actual-value comparison, pressure,
front axle
Pressurecontrol
valve
rear axle
Open (de-energized) (p =
0)
rear axle
and current measurement
Closed
(mechanical fault)
(pRA and pFA = pmax)
rear axle,
Fail-safe valve Jammed open Predrive check
Jammed closed
(line)
Current measurement
Actuator,
front/
rear axle
Leaking (no torque) Setpoint/actual-value comparison pressure
Blocked Setpoint/actual-value comparison pressure
CAN bus Total failure (line
disconnected)
CAN timeout
Steering angle,
vCar, a
q
,
Implausible or omitted Plausibility monitoring and
CAN bus signal fault detection
32
9
System shutdown (fail-safe status)
Depending on the fault, the system displays
one of the following responses.
The following faults result in system
shutdown, i.e. all output stages are de-
energized:
Fault in the front axle stabilizer bar
Fault at the front-axle pressure sensor
Fault in the pressure build-up (pump,
pressure-limiting valve on the front axle)
Fault in the control unit
VIN is not sent via the CAS / absent /
incorrect
Direction-valve position fault, faulty switch-
position recognition sensor
No PT-CAN signal
The de-energized fail-safe valve shuts off the
chambers of the active stabilizer bar. Fluid
balancing is only carried out through internal
leakage of the oscillating motor and valve
block.
The check valves in the valve block enable
fluid feed to prevent cavitation in the front axle
oscillating motor.
The chambers of the rear axle oscillating
motor must not be shut off.
The handling corresponds virtually to that of a
conventional vehicle. The crossover to the fail-
safe status can also be controlled in the event
of extreme manoeuvring.
Component Fault type Fault detection via:
Sensor a
q
Total failure (line
disconnected)
Voltage monitoring
Incorrect signal Check plausibility via CAN messages
Oil level sensor No signal (line)
Pressure
sensor,
front axle
No signal (line) Voltage monitoring
Incorrect signal Setpoint/actual-value comparison, pressure,
front axle
Pressure
sensor,
rear axle
No signal (line) Voltage monitoring
Incorrect signal Setpoint/actual-value comparison, pressure,
rear axle,
Sensor,
direction valve
no signal Voltage monitoring
Incorrect signal Setpoint/actual-value comparison, direction
valve and
switch-position recognition sensor
33
9
Warning message
Cornering stability! Drive slowly around
bends
Instruction
Driving-stability systemnot functioning, driving
stability restricted. No high cornering speeds.
Continued driving possible, contact BMW
Service immediately.
In the event of a fluid loss in the DynamicDrive hydraulic systemor in the steering circuit, the
oil level sensor in the oil reservoir responds.
The driver is alerted so that damage to the tandem pump caused by continued driving is
avoided.
Warning message
Fluid loss! Pull over carefully, switch off
engine
Instruction
Fluid loss in the chassis and steering systems.
Continued driving not possible, contact BMW
Service immediately.
34
9
Restricted control comfort
A transverse acceleration is calculated from
the road speed and steering wheel angle from
the CAN messages. This signal is faster than
the actual transverse acceleration and
compensates the time delay of the
hydromechanical system. In the event of a
fault in these two signals, the systemresponds
with a delayed roll compensation. This arises
only in the case of extremely quick steering
manoeuvres and is barely noticeable in normal
cornering manoeuvres.
If a transverse acceleration sensor is defective,
the transverse acceleration is calculated. No
impairment of function can be detected by the
customer.
The customer notices that the vehicle roll is
greater if a fault occurs on the rear axle.
The agility decreases at road speeds <
120 km/h.
The system also responds if the fault "Fail-
safe valve stuck open" is detected in the
predrive check.
An electrical fault in the rear-axle pressure
sensor may result in minor failures in roll-angle
compensation. To be on the safe side, slightly
more stabilizing torque is exerted on the front
axle than in normal operation. This can be felt
by the driver.
Warning message
Cornering stability slightly restricted
Instruction
Chassis stabilization slightly restricted around
bends.
Service at next opportunity.
35
9
Restricted system monitoring
DynamicDrive receives the following sensor
signals from DSC and SZL via PT-CAN :
Transverse acceleration
Yaw velocity
Road speed
Steering-wheel angle
These signals are used to check the
transverse acceleration sensor.
Drop-out of the engine-speed signal (DME)
results in restricted control comfort.
In the event of a fault in the transverse
acceleration and yawvelocity CANmessages,
the system is lacking two items of redundant
information. Since this information is used
exclusively for checking the other signals, the
DynamicDrive function is preserved with full
control comfort.
Although no restriction of the DynamicDrive
function exists, the message "Chassis and
suspension-control system comfort
restricted" is displayed for the driver who is
requested to drive to the workshop at the next
opportunity.
A "dynamic" driver will notice the absence of
the steering angle sensor signal.
The warning messages must be
acknowledged by the driver. Each warning
message goes out only after it has been
acknowledged.
Once the cause of the fault has been rectified,
the control unit can be returned to full function.
There are two reset conditions depending on
how fast a fault is to be detected:
All faults which are no longer present are
reset with ignition OFF. It is necessary to
wait until the vehicle has entered sleep
mode before the ignition is switched ON
again.
Sporadic faults which can mostly be traced
back to communication faults in the CAN
bus are then automatically reset while the
vehicle is moving straight ahead or
stationary provided they have only occurred
briefly and rarely. In this case, the customer
cannot detect the activation while the
vehicle is moving or stationary.
The associated faults with important
additional information are stored in the fault
code memory. This additional information
contains the kilometre reading/mileage at
which the fault occurred, whether the fault
is currently present and the frequency with
which the fault in question has occurred.
Thus, when the vehicle is brought into the
garage/workshop, it is possible to carry out
a specific analysis of the currently present
fault and also an analysis of a sporadic fault.
Warning message
Cornering stability slightly restricted
Instruction
Chassis stabilization slightly restricted around
bends.
Service at next opportunity.
36
9
Programming
The DynamicDrive control unit is
programmed.
Coding
The DynamicDrive control unit is encoded.
Contents
Level systems
Objectives 1
Introduction 3
History 3
System overview 5
System structure 5
Functions 7
Functional description (overview) 7
Functioning principle (normal function) 14
1
5
Objectives
The BMWelectronic ride height control, EHC
for short, is an important component for
stability control. This document contains all
the important information about the design of
this system.
The control strategies described here will help
you to understand the function of the EHCand
its associated logic systems. This is an
important prerequisite for performing
diagnostics and troubleshooting on the
system successfully and to a professional
standard.
You can acquire all the knowledge necessary
to do this on the following pages.
Topics relevant to service personnel and
inspection conditions which must be adhered
to when carrying out a wheel alignment check
are also covered.
2
5
3
6
Introduction
History
BMW introduced level control systems in the
7 Series - E23/E32, 6 Series - E24 and 5
Series - E28 as an option and, in some
vehicles, as standard. The entire rear-axle load
was supported by air suspension for the first
time on the E39. The system was controlled
automatically under all operating conditions
and without the driver having to make any
input.
The single-axle air suspension system on the
rear axle of the X5 was transferred from the
E39. The air springs were adapted to the X5.
There is a standard and a sports version.
Ride-height control was offered as standard
with the M62 engine. It was available as an
option with the M57 and M54 engines.
This Participant's Manual deals with the two-
axle air suspension system on the X5.
Why is a new system required?
The new two-axle air suspension system has
off-roading advantages over the single-axle air
suspension.
Lowering the entire body makes it easier to
get into and out of the vehicle, as well as to
load and unload it.
Off-roading capabilities are improved by the
option of increasing the ground clearance of
the body.
The driver has the option of setting three
different heights using a rocker switch,
according to his requirements.
The vehicle still has automatic ride-height
control for load compensation and automatic
lean compensation.
4
6
Market requirements and customer expectations
Market requirements and customer
expectations regarding comfort and
functionality are constantly increasing. Both
these aspects have been taken into
consideration by giving the driver the option of
making settings to the system.
An important comfort feature of off-road
vehicles with a large ground clearance is being
able to get into and out of the vehicle and load
and unload the vehicle easily.
The functionality of the vehicle is expressed in
its off-roading capabilities. This is achieved by
the possibility of increasing the ground
clearance with the two-axle air suspension.
Advantages of the new system
The new system allows active control of the
ride-height control by the driver.
The two-axle air suspension allows the vehicle
to be lowered at both axles by equal amounts
and parallel to each other.
This makes it easier for the occupants to get
into and out of the vehicle and to load and
unload the vehicle.
The air suspension systemis also fitted in the
E61. This is a single-axle air suspension and is
basically the same as the one in the E65.
5
7
System overview
System structure
Overview
1 - Air suspension diagram
1 Air supply unit 4 Pressure accumulator valve unit
2 Rear axle air bellows 5 Front axle air bellows
3 Height sensor 6 Control unit
6
7
7
8
Functions
Functional description (overview)
In addition to the automatic ride-height control
system to compensate for variations in load,
the driver has 3 further different options for
setting the ride height of the vehicle.
Off-road (+25 mm), high ground clearance
Standard (0 mm), normal vehicle height
Access (-35 mm), for getting in and out,
loading and unloading
The different heights are selected using a
rocker switch. LEDs show the current height
setting.
Lowering the height is only possible when
terminal 15 or higher is ON and the doors are
closed. The bonnet and tailgate may be open.
The system also has automatic lean control,
with which you will be familiar fromthe single-
axle air suspension.
Pressure accumulator valve unit
The two-axle air suspension system has a
pressureaccumulator which, together withthe
valves, forms the pressure accumulator valve
unit. The pressure accumulator valve unit is
located under the vehicle floor in the vicinity of
the right-hand sill.
1 - Rocker switch
2 - Installation location of the
air valve unit
8
8
Pressure accumulator
The pressure accumulator allows the very
large differences in height to be achieved
more quickly than with a compressor system.
The internal pressure is measured by a sensor
on the pressure accumulator.
The system pressure is 15.7 0.7 bar.
The minimum pressure is 9 bar.
The theoretical filling capacity of the pressure
accumulator is sufficient for charging the four
spring struts once. This applies from the
access to the standard position and for loading
the unladen vehicle. However, only up to the
permissible gross weight rating at normal
temperatures.
3 - Valve unit
1 Air lines
Yellow = rear right
Black = rear left
4 Pressure sensor
2 Pressure accumulator 5 Valve unit
3 Connection line
9
8
Valve unit
The four bellow valves and the pressure
accumulator valve are controlled in the valve
unit.
The bellow valves and the pressure
accumulator valve are solenoid valves which
are closed by spring force when de-energized.
4 - Sectional viewof the valve
unit
1 Air line connections 2 Pressure accumulator valve
10
8
Air supply unit
The air supply unit is located under the spare
wheel in the luggage compartment, the same
as in vehicles with single-axle air suspension.
The auxiliary reservoir for the rear air-spring
bellows is also located in the luggage
compartment, as in vehicles with single-axle
air suspension.
The air supply unit is designed in a similar way
to the single-axle air supply unit for ride-height
control, fitted as standard on the E39.
The functions are controlled by actuating a
compressor and various valves in the air
supply unit and on the pressure accumulator
valve unit.
The maximumpressure for the air supply unit
is 21 bar.
Pilot valve
The electrically controlled pilot valve acts as a
control function for releasing pressure from
the system in the normal way.
Bleed valve
The pneumatically controlled bleed valve
serves to actually release the pressure. The
small controlled amount of air released from
the pilot valve pushes open the main valve as
a relay function and large amounts of air can
escape quickly.
This combined arrangement of the pilot and
bleed valve means that it is not necessary to
have a solenoid valve with a high power
consumption.
The 21-bar limit valve is integrated in the
bleed valve.
5 - Pneumatics plan 2
1 Sinter filter 5 To the pressure accumulator
valve unit
2 Pneumatic bleed valve 6 Air drier
3 Electric pilot valve 7 Compressor
4 High-pressure vent valve NW Nominal width in mm
11
8
High-pressure vent valve
The high-pressure vent valve acts as a
comfort valve. The high-pressure vent valve
expels the high pressure fromthe line after the
pressure accumulator valve has closed with
the compressor running. The compressor
cannot be stopped without generating noise
until this pressure has been released.
Compressor assembly
The following technical developments have
been implemented:
Fitting a temperature sensor
A temperature sensor which switches off
the compressor at temperatures above 110
C is located on the cylinder head of the
compressor .
Extension of the compressor on period
(180 s)
New air drier design because of quicker
lowering
3 The temperature sensor is not located on
the compressor itself, but is integrated into the
wiring harness. 1
6 - Compressor
1 Pilot valve 4 Installation location of
temperature sensor
2 Bleed valve 5 Compressor
3 Air drier 6 Electric motor
12
8
The principles of air drying
The intake air passes over water-absorbing
filter material. The filter material is integrated in
the air drier in the form of filter granules and
absorbs moisture from the air. As long as the
air contains more moisture than the filter
material, the moisture will be absorbed into the
individual balls and stored. When it flows back,
the air is drier than the filter material. Moisture
is therefore drawn back into the air and
removed to the outside.
A maximum of 30 g of water can be stored in
the filter.
Height sensor
The height sensor provides information about
the height of the vehicle. There is a height
sensor for each wheel. You provide
information to the control unit for ride-height
control.
7 - Height sensor
13
8
Air spring struts
No modifications were made to the rear-axle
air springs. The air springs and dampers are
separate on the rear axle.
On the front axle, the air spring replaces the
steel spring, i.e. the spring bellow is fitted to
the damper. The front air spring strut and the
shock absorber form a complete unit.
8 - Air suspension
9 - Air spring strut
Index Explanation
1 Auxiliary spring
2 Air bellows
3 Damper
14
8
Functioning principle (normal function)
Adjusting procedures for the various heights of the E53
The driver can use the rocker switch to set
three different heights on the E53.
Offroad (+25 mm): high ground clearance,
up to a maximum speed of 50 km/h
Standard (0 mm): normal vehicle height
Access (-35 mm): for getting in and out as
well as loading and unloading, up to a
maximum speed of 35 km/h. Access may
be activated fromstandard mode from< 25
km/h.
All adjusting procedures are performed
without requiring intermediate heights. The
vehicle's pneumatics are designed so that
virtually parallel lowering is possible however
the vehicle is laden. Depending on how the
vehicle is laden, either the front axle or the rear
axle may be slightly quicker.
A height difference between the two axles is
possible in all adjusting procedures due to the
different control speeds. If a set threshold is
exceeded, the quicker axle is briefly halted.
The different heights can be preselected while
the vehicle is in motion. The height of the
vehicle will not change until the speed
threshold determined in the control unit is
reached. The height change is controlled by
the control unit.
The LEDindicating the current level continues
to flash when a newtarget level is defined and
the LED of the target level flashes. The driver
defines a new target level by the push of a
button or a change is initiated automatically
under defined driving conditions. When the
new level is reached, the LED of the last level
goes out and the LED of the newly reached
level lights permanently.
If it is not permissible to select the height, the
LED showing the current vehicle height
flashes for 3 seconds.
An exception is preselecting the access height
while the vehicle is still in motion: the access
LED flashes and the LED for the previous
height lights up constantly. This does not
mean that the vehicle has started to change
height. Control will not take place until the
vehicle is travelling at or belowthe appropriate
speed threshold for the access height.
The following text messages may appear in
the instrument cluster next to the LED display:
TRAILER MODE
A trailer has been detected via the trailer
connector. The vehicle height should not
be changed, otherwise there is a risk of
damage to the trailer and the vehicle. The
vehicle is fixed at the standard height. If the
trailer is hitched when the vehicle is not at
the standard height, the vehicle will not
change to standard height until the button
is pressed. In any case, the change to
standard takes place automatically on
reaching the speed threshold. The vehicle
will then be fixed at the standard height until
the trailer connector is disconnected.
RIDE-HEIGHT CONTROL INACTIVE
There is a fault in the systemor a fault in the
control unit that can only be detected by the
instrument cluster, e.g. control unit
disconnected.
RIDE-HEIGHT CONTROL INACTIVE +
MAX. 60 KM/H
For safety-critical faults (vehicle is too high
or is leaning)
15
8
Adjustment mode
Sleep mode
The vehicle enters sleep mode 16 minutes
after it is switched off. No more height
adjustments are made. A watchdog wakes up
the control unit every 6 hours for a few
minutes (wake-up mode) to rectify any vehicle
lean.
Wake up
In wake-up mode, the control unit is woken up
for a certain amount of time to rectify any
vehicle lean. The vehicle may lean if there are
large variations in temperature or small leaks.
This adjustment to the front and rear axles
ensures that the vehicle is level. The vehicle is
only lowered so that as little power is used as
possible. The target level of the lowest wheel
acts as the level for all the other wheels. The
lowest target level to which the vehicle can be
lowered is the access height (-35 mm).
Exception: if the vehicle was already at the
access height when it was switched off, it can
be lowered to a minimum of -50 mm in wake-
up mode. If a leak occurs in the systemduring
longer parking periods, further loss of air will
no longer result in a change in the ride-height.
In this case, the body is supported by the
auxiliary springs and the residual air pressure.
Pre (lead/run-on mode)
The vehicle is normally woken from sleep
mode into lead/run-on mode by the load-
cutout signal (VA). Because the engine is not
yet running or has already been switched off in
this mode, only limited height adjustments can
be made in order to protect the battery. The
vehicle will only be made level outside a
tolerance range of 20 mm up and 25 mm
down, thus counteracting the reduction in
control frequency.
All adjustments during the lead and run-on
time are made from the accumulator, if this is
available. If the accumulator is empty and the
engine is switched off, then the adjustment is
made directly by the compressor. It is not
possible for the user to change the height or
for the accumulator to be charged.
Terminal 15
As soon as the ignition is switched on (terminal
15), the driver can lower the vehicle to the
required level.
However, it is not yet possible for the vehicle
to be raised or for the accumulator to be
charged.
The vehicle will be made level outside a
smaller tolerance range of 10 mm up and 10
mm down.
Normal (engine on)
When the engine is running, the vehicle can be
made level, the height can be adjusted up and
down and the accumulator can be charged.
The compressor starts up when each
adjustment is made.
The vehicle will continue to be made level
outside the small tolerance range of 10 mm.
As long as the vehicle is stationary, the quickly
filtered height signals are used to detect a
change in load. This means that the system
can react immediately to changes in height.
16
8
Post (subsequent adjustment)
Post mode is used to rectify any vehicle lean
before it enters sleep mode. It is a mode for
subsequent adjustment. Post mode is time-
restricted (currently coded to 1 minute). Post
mode is only entered if the engine has been
running. If the engine has not been running,
sleep mode is entered directly frompre mode.
Adjustments are made with a tolerance range
of 7 mm. The maximumadjustment made is 5
mm. The quick signal filter is used. The
system sets the defined target height levels
when the vehicle is leaning (kerb detection).
Curve (cornering)
Rolling motion has a direct influence on the
measured ride-height levels. Despite the slow
filtering of Drive mode, this would mean
undesirable control response would be
initiated during longer cornering periods with
corresponding rolling angle. This would mean
that the vehicle would be leaning once the
corneringhadbeen completedandthe vehicle
level would have to be adjusted again. Curve
mode prevents this adjustment by stopping
the slow filtering when cornering is detected
and cancelling any adjustment that may have
been started. Cornering is detected by an
incoming transverse acceleration signal of > 2
m/s
2
. Curve mode is ended when there is a
transverse acceleration signal of < 1.5 m/s
2
.
The transverse acceleration signal is sent by
the yaw rate sensor.
Drive
As soon as the vehicle is in motion, the system
switches to the slow filtered height signals.
The system now no longer reacts to
suspension compression caused by
unevenness in the road surface. An average is
calculated over a longer period and the load
only changes due to the emptying of the fuel
tank.
The quick filter is not used again until the
vehicle is stationary again and a door or hatch
is opened. This is because the vehicle cannot
be loaded or unloaded until a door or hatch is
opened.
Lift (workshop platform)
If a height threshold is exceeded at all 4
wheels, the control unit assumes that the
vehicle is being raised on a workshop platform.
There are three options for resetting the
workshop platform recognition:
The height values become less than the
original height settings on all four wheels,
A selection is made by pressing the switch,
The system detects a speed of > 40 km/h
for 3 seconds.
17
8
Vehicle jack
If the system detects that one wheel is
lowering, but not at sufficient speed, it
recognizes that the vehicle is being raised on a
jack. The lowering speed must be less than a
given pre-programmed speed threshold. If a
jack is detected, the height is stored for the
wheel concerned.
The jack recognition is reset when the height
falls belowthe stored height again. In addition,
if the vehicle reaches a road speed of 40 km/h
for at least 3 seconds, the systemwill attempt
to adjust the vehicle height.
The jack recognition is also reset if the switch
is pressed.
Kerb (distortion control/off-road)
The systemmust not attempt to compensate
as soon as there is distortion, e.g. if a wheel is
driven over an earth bank. If the vehicle is
stationary and the front axle height difference
plus the rear axle height difference in the
opposite direction is greater than a given
threshold, the systemrecognizes that there is
"distortion". This leaning mode is exited when
the distortion is smaller than the threshold or
the vehicle is moved.
If the distortion is very large, no adjustments
are permitted because making adjustments
from this level of distortion is not useful,
depending on the vehicle.
18
8
19
9
Service information
General information
Please be aware that the systemis also active
in diagnostic mode. Therefore, assembly line
mode must be activated before carrying out
any work on the system or when making
height adjustments.
Assembly line mode:
The heights are fixed; no level adjustments are
made. When assembly line mode is set, the
function LED is off. The "ride-height control
inactive" message appears in the instrument
cluster.
Transport mode:
If the vehicle is being transported, the level
control is set to transport mode.
To change the vehicle to the height set by the
factory, transport mode must be cancelled in
Service functions. When transport mode is
active, the "Level control inactive" message
appears when terminal 15 is switched on.
Transport mode is available again. When the
ignition is switched on, the "ride-height control
inactive" message appears. Heights are
adjusted up or down according to the position
of the ignition key. For example, lower when
lashed down on a ship or train, higher when
"engine on" and travelling on a vehicle
transporter.
The correct height from the technical data is
set to 5 mm using "control components".
The ride-height level at the right and left of the
rear axle are set separately. Then the setting is
made on the front axle. Here, the right and left
air springs are adjusted together.
The height of the front and rear axles is then
stored using the offset function.
The system must be depressurized before
any components are exchanged. This is done
in diagnosis via control unit functions, control
components, bleed front/rear axle. Repeat this
command 6 times.
If the bellows material is visible, they must be
replaced.
Once the repair work is completed, the air
suspension system of the vehicle on the
workshop platformmust be recharged with air
using diagnostics. The command must also
be repeated 6 times. This prevents incorrect
folding in the bellows.
The vehicle must not be placed on its wheels
when the spring struts are depressurized.
In the same way, a faulty vehicle with a leaking
pneumatic systemshould not be lifted on the
workshop platform when the system is
"open". The bellows would contract due to the
suction and incorrect folds would be formed.
These could lead to subsequent malfunctions.
Possible sources of leaks are the O-ring on the
piston rod and the sealing element mountings
on the piston.
The plug connections for all lines are the same
as the connections on the single-axle air
suspension. 6-mmlines have been used. The
tightening torques in the entire systemare 3 +
1 Nm.
When handling air suspension elements, you
must be particularly careful with plastic parts
which are prone to breaking.
Once the repair work is complete, assembly
line mode must be deactivated again via the
diagnostics. The function LED in the switch
lights up. A text message does not appear in
the instrument cluster. The systemis OK and
operational.
20
9
Notes about wheel alignment checks
1. Simulate normal conditions for the
vehicle
Vehicle and all its equipment for normal
driving:
2 x 68 kg on the front seats (seats in central
position);
1 x 68 kg on the rear seat (centre);
1 x 21 kg in the luggage compartment (centre)
and tank full.
2. Inspection conditions for the wheel
alignment check
Correct wheels and tyres with an even tyre
tread pattern
Correct tyre pressure (see the information
plate on the vehicle)
Correct wheel bearing play
EHC in
Normal position (see above);
For ride-height measurement, see Repair
instructions 31 33 095 in TIS.
Attention: if the vehicle is not at the
specified height, repair the vehicle.
The relevant fuse should be removed when
you are working on the air supply unit so
that no inadvertent adjustments are made.
This is purely for the safety of the mechanic.
Set the correct height for the measurement
= specified value 2 mm by loading or
unloading the vehicle.
The fuse must be replaced in order to set
the height.
Contents
Damping systems
Objectives 1
Introduction 3
Electronic damper control 3
Functions 5
System requirements 8
Power supply 10
Vertical acceleration sensor 11
Electronically controlled vibration damper 12
Infinitely adjustable control valve 13
Diagnosis 15
General information 17
1
6
Objectives
Damping systems
The EDC-K continual damping system in
BMW vehicles provides the customer with a
high degree of comfort.
The following pages contain the most
important information about the design and
the function of this system.
This will enable you to understand how the
system and all its associated components
function, so that you can perform diagnostics
on the system to a professional standard.
2
6
3
7
Introduction
Damping systems
Electronic damper control
A modern chassis must offer the driver
optimumride comfort, a high degree of driving
safety, good agility and simple handling.
Conventional, non-adjustable vibration
dampers can only ever provide a compromise
of these objectives. Manually adjustable
vibration dampers can be set to either sports
or comfort damping.
Electronically adjustable damping systems
have been developed to provide a solution to
these conflicting objectives.
This system is called BMW EDC (Electronic
Damper Control).
The first system was the EDC I, which was
fitted as standard in the E32 in 1987.
This dual-stage, fully-automatic electronic
adjustment system was continually improved
and developed. The result was EDC III and
later EDC-K.
BMW EDC-K is a fully-automatic system
which continually adjusts the damper settings
to the current driving situation. The biggest
change compared to EDC III was the EDC
valves and their control logic system. EDC-K
increases ride comfort without impairing
safety. If the damper settings are too soft or
comfortable on unfavourable road conditions,
the vehicle will quickly begin to vibrate. EDC-K
remains in the soft damper setting for as long
as possible and only changes immediately to
the harder setting when the road situation
requires it.
With the EDC-K system, BMW set a
benchmark for adjustable damping systems.
Electronic Damping Control (EDC) combines
the highest degree of ride comfort with the
best possible driving safety. The system also
guarantees consistently good vibration
characteristics however the vehicle is laden. In
addition, all vehicle movements which have an
effect on vehicle handling are monitored
constantly by sensors. All measurements are
analysed by a microprocessor and appropriate
control commands are transferred to the
shock absorbers. The damping force at the
shock absorber is then adjusted to the
changing road conditions, load status and
handling characteristics by solenoid valves.
Pitching under braking or body movements,
e.g. when driving over bumps, cornering or
accelerating, are significantly reduced. There
is also the option of selecting the "Sport"
program at the press of a button, thereby
setting stiffer damping characteristics.
4
7
5
8
Functions
Damping systems
The EDC-K works with an infinitely variable
valve in the dampers. The dampers have an
infinite number of characteristic curves, thus
the term characteristic map damper. This
makes it possible to adjust the damping force
continually to the low frequency vehicle
structure movements.
The result is significantly improved ride
comfort and further safety benefits.
The following diagrams illustrate the
characteristic curves of the damper settings
according to the piston speed in the damper.
The following diagram is the characteristic
curve for a standard damper in the rebound
phase.
The rebound-phase damper force curve and
its damper force F
D
are a function of the piston
speed V
K
.
1 - Front axle
1 Envelope space coil spring 3 Upper support bearing
2 EDC-K plug connection
6
8
EDCI allowed the driver to manually select the
hard, sporty damping or soft, comfortable
damping while the vehicle was in motion. The
upper characteristic curve represents the hard
damping; the lower characteristic curve
represents the soft damping.
Neither of the characteristic curves could be
too far from the characteristic curve of the
standard damper. The vehicle handling would
otherwise be too uncomfortable, i.e. hard or
unstable, soft.
2 - Standard rebound phase
characteristic curve
3 - EDC1 rebound phase
7
8
EDCIII is a fully-automatic adjustment system
which adapts to the driving situation. Input
parameters, such as road conditions, the load
carried in the vehicle and the driving style are
all detected by system's sensors. The system
automatically activates one of the three
characteristic curves (hard, medium or soft).
The driver also has the option of selecting a
comfort or sport program.
EDC-K enables fully-automatic damper
adjustment over the entire characteristic map.
The characteristic map is made up of an
infinite number of characteristic curves. The
dampers are able to adjust continually and to
varying degrees because a damper force F
D
can be set for every piston speed V
K
.
The driver also has the option of selecting a
comfort or sports setting using the controller.
4 - EDC3 rebound phase
5 - EDC-K rebound phase
8
8
System requirements
As part of the chassis, the EDC-K is
responsible for compensating for dynamic
forces acting on the vehicle when it is in
motion.
The following forces occur:
Vertical forces (e.g. through road
unevenness)
Transverse forces (centrifugal forces,
crosswind)
Longitudinal forces (acceleration, braking)
The following vehicle structure movements
can occur as a result of these forces:
About the transverse axis: Pitching
About the longitudinal axis: Rolling
About the vertical axis: Yawing
The task of the chassis is to absorb the effects
of these forces. The continual adjusting
dampers play a large part in this task.
The primary task of the EDC-K is to increase
ride comfort while maintaining a high degree
of driving safety.
The objective of the EDC-K is for the vehicle
to be set to the comfortable, soft damper
settings for as long as possible. To increase
safety and because the degree of comfort
which will now be lost is reduced, a harder
damper setting is activated to prevent large
vehicle body movements.
The damper hardness is not set to fixed levels,
but to many control options via a variable EDC
valve.
The EDC-K is a microprocessor-controlled
mechatronics adjustment system.
The system consists of:
mechanical,
hydraulic,
electrical and
electronic subsystems
The driving conditions and prevailing road
conditions are detected by sensors.
The control unit receives the incoming signals,
checks their plausibility and evaluates them
dependent on frequency. The control unit
then links the various sensor signals and the
system logic activates the valves
corresponding to defined characteristic maps.
Vehicle body andwheel vibrations are damped
at required.
The driver can also set a comfort or sport
program using the controller if he wishes.
The system is fully compatible with
diagnostics.
If the sensors are faulty, the system is made
safe by a fixed current feed to the EDC valves.
The damping characteristic curve is similar to
the curve for a standard damper. If the system
should fail (no power), the dampers
automatically adjust to the hardest damper
setting.
9
8
The EDC-K can be divided into 3 functional
blocks:
The control unit
The sensors and the program selection
function
The actuators, 4 electronically adjustable
vibration dampers
The input signals for the systemare generated
by:
Sensor/switch Signal Calculated size Installation
location
Acceleration sensors,
front axleandrear axle
Vertical
acceleration,
front and rear
Vertical speed,
compression and rebound
travel
Spring strut dome
front right, front left,
rear right
Steering angle sensor Steering angle Steering angle speed Switch cluster,
steering column
Wheel speed sensor,
front left/front right
Wheel speed Road speed,
acceleration/braking
Wheel hub front left/
front right
Program selection Comfort/sport
program
Controller
10
8
Power supply
A low current at the valves has the effect of
hard damping. A high current results in soft
damping.
The specified values for the output voltage are
transmitted from the microprocessor in the
form of a pulse-width-modulated (PWM)
signal.
The current is limited by an excess current
cutout in the hardware.
All analogue inputs are protected against
positive and negative overvoltage by diodes.
The following analogue signals from the
control unit are processed by the
microprocessor:
Power supply from the vehicle
Output voltage from the switching
controller
Voltage and current to the valves
Valve control/output stage switching
The actuators are powered by the control unit
on the negative side.
The solenoid valves in the dampers have a
relatively small ohmic resistance
(approximately 2.2 Ohms per valve at room
temperature). The current to be set
corresponding to the required damping force
is in the range from 0 to 2 A. A relatively high
current is required at low voltage. The target
value must not exceed 2 Aotherwise the valve
will be damaged. The solenoid valves are
connected in series on the axle side. The
output current is a direct current.
The adjusting dampers are activated in series
on the axle side.
6 - Valve switching, rear axle
1 Microcontroller 2 EDC valve, rear right
PWM Pulse width modulation 3 EDC valve, rear left
11
8
Vertical acceleration sensor
The three vertical acceleration sensors have a
measuring range of 2.5 g. They are fitted to
the right and left spring strut domes and to the
right rear axle dome in the wheel arch. All three
sensors are of the same design. They differ
only in terms of their mounting arrangement in
the wheel arches. The front two sensors (1)
are fitted to the top of the wheel arch; the rear
sensor (2) is fitted to the side of the wheel
arch.
The plug connection to the control unit points
downwards on all sensors.
7 - Vertical acceleration sensor, front axle/rear axle
1 Acceleration sensor, front 2 Acceleration sensor, rear
12
8
Electronically controlled vibration damper
Twin tube gas-pressure dampers are fitted to
the front and rear axles.
These dampers are designed as characteristic
map dampers. This means there are no fixed
settings as in the EDC III.
A controllable proportional valve is integrated
into the piston of each valve. Alternate sides of
this valve are supplied with shock absorber
fluid during compression and rebound travel.
The control valve generates a lower pressure
above and belowthe piston depending on the
volume of fluid which enters.
The electric supply line for the integrated
control valve is routed through the hollow
piston rod.
A base valve is connected axially in parallel
next to the control valve. Its primary task is to
guarantee the minimum pressure level of the
characteristic curve.
The minimum rebound phase characteristic
curve is generated primarily by a conventional
piston valve connected in series to the control
valve.
The two valves are controlled separately to
ensure that there are optimum vehicle body
vibration characteristics in all driving situations.
If the control unit fails and when the ignition is
off, the valves are not powered. The dampers
are automatically set to the hardest damper
setting.
There are differences in the valve
configuration at the spring struts of the front
and rear axles on vehicles with DynamicDrive.
8 - Cross section of a damper
1 Screw 5 Floating valve seat ring
2 Solenoid coil 6 Valve spring
3 Main damper valve 7 Armature
4 Auxiliary valve
13
8
Infinitely adjustable control valve
When the system is without power, the
highest hydraulic resistance is set by the
manufacturer. This is achieved by screw (1)
which pretensions valve spring (6). This is the
hardest damper setting - also known as the
safety setting.
The valve spring pushes on armature (7) with
maximumforce, which in turn pushes on main
damper valve (3). The main damper valve
pushes on the floating valve seat ring (5),
which then rests on the housing and creates a
resistance to the flow of fluid.
When power is supplied to solenoid valve (2),
the armature moves upwards against the valve
spring pretension (F
F
). Supplying power to the
solenoid coil counteracts the valve spring
tension (F
M
), so that the armature exerts less
pressure on the main damper valve (F
r
). The
smaller F
r
, the more loosely the floating valve
seat ring fits against the housing. The
volumetric flow of oil increases. Damping
becomes softer. The maximum power of 2 A
supplied to the solenoid coil results in the
loosest fit of the valve seat ring and the most
comfortable damping setting.
Auxiliary valve (4) generates the softest
pressure damping together with the base
valve (not illustrated).
9 - Forces in the valve
14
8
Rebound phase operating principle
The piston is pulled upwards. The oil flows in
the direction indicated by the arrows. The
floating valve seat ring pushes the main
damper valve upwards due to the hydraulic
ratios.
Compression phase operating principle
The piston rod is pushed downwards. The oil
flows in the direction indicated by the arrow.
The main damper valve is pushed upwards
due to the hydraulic ratios. The floating valve
seat ring sits on the bottom.
10 - Oil flow in rebound phase
11 - Oil flow in compression phase
15
8
Diagnosis
System monitoring and plausibility
For safety reasons, faults in one valve cause
the power to be cut to all valves immediately.
Faults are detected for each axle separately.
The DIS is used for the purpose of locating a
fault in a defective valve. Alternatively, the
resistance of the individual valves is measured
and compared. An operational valve will have a
resistance of 2.2 Ohms 10 % at room
temperature (20 C). The measured
resistance is dependent on temperature.
Acceleration sensors
The EDC-K control unit does not differentiate
between faulty behaviour and real operating
conditions.
The three sensors are connected in parallel in
the control unit without isolation. A short
circuit in the power supply of one of these
consumers will therefore also affect the power
supply to the other sensors.
A maximum of seven different faults can be
stored.
16
8
17
9
Service information
Damping systems
General information
After removing the steering angle sensor, it is
necessary to manually reset the steering
wheel in the straight ahead position. This
position must be reinitialized in the control
unit. The steering angle sensor is in the
steering column switch cluster.
The straight-ahead position (zero balance) is
reset for the first time on the assembly line
(steering wheel in the straight-ahead position).
The control unit has a learning feature for the
straight-ahead position.
While the vehicle is in motion, the steering-
wheel straight-ahead position is constantly
monitored and corrected if necessary.
The EDC diagnostics recognize electronic
damper faults for each axle. A mechanical
check of individual dampers can be carried out
on the shock-absorber tester.
The dampers will become weaker over time
due to mechanical wear during use. Arunning-
time memory is used to offset the damper
characteristic curves with a harder setting.
Faulty dampers are usually only replaced on
one axle at a time. If a replacement has been
made, running-time memory must be reset for
the front or rear axle using the DIS (life time
reset).
18
9
Contents
Tyre failure indicator
Objectives 1
Introduction 3
System overview 5
Different control units for the tyre failure
indicator 5
Functions 7
Components 7
Input/outputs, RPA with RPA control unit 11
System circuit diagram for RPA with RPA
control unit 12
System circuit diagram for DSC control unit
with additional 13
System circuit diagram for RPA with Chassis
Integration 14
General information 15
Special information on the RPA for E60
models 17
1
4
Objectives
The tyre failure indicator (RPA) offers the
customer a considerable improvement in
driving safety.
This document provides a comprehensive
overview of this system, and how it is
integrated in BMW vehicles.
This documentation provides important
information on the design and function of the
system. Once you have read this document,
you will be able to understand howthe system
operates, andidentify thedifferences between
this and the familiar tyre pressure control
system (RDC).
You will be able to performdiagnostics on the
tyre failure indicator to a professional standard.
2
4
3
5
Introduction
Introduction to the tyre failure indicator (RPA) and tyre
pressure control (RDC)
Froma purely statistical point of view, a driver
suffers a puncture once in every five to seven
years, or 100,000 to 150,000 kilometres into
their service life. Approximately 80%of all tyre
defects are caused by small holes (e.g. caused
by nails). These holes lead to a gradual loss of
tyre air pressure. Many "tyre blow-outs" can
be traced back to preliminary damage from a
slow loss in tyre air pressure.
The actual event can be most inconvenient for
the individual driver, quite apart fromhaving to
stop by the side of the road at night, in rain or
in the cold. Driving safety is also no longer
guaranteed, as a loss of air pressure in the tyre
causes a risk of skidding, or the vehicle may
become difficult to steer. The BMW Group
offers a warning systemthat notifies the driver
of loss of air pressure in a tyre at an early stage.
The RPA (tyre failure indicator) has been in
use since 2001. RDC was still available to
order until model year 2004.
The RDC systemmonitors tyre pressure both
when the vehicle is in motion, and when
stationary. An electronic module mounted
inside the tyre measures the tyre pressure and
temperature at regular intervals. The
measured values are sent to a central control
unit.
These components are discontinued in the
RPA. In contrast, the RPAidentifies a loss of air
pressure based on an increased number of
revolutions of the wheel. Air escaping from a
tyre alters the tyre circumference and the
rolling radius of the tyre. The peripheral wheel
speed therefore increases. The wheel speeds
are monitored continuously with the aid of
wheel speed sensors. The system compares
the wheels aligned diagonally to each other,
and their average number of revolutions. The
RPA detects whether the wheel speed has
fallen below the initial value by approximately
30 % 10 %, and informs the driver. The
systemprovides information after only a short
distance, usually within a few minutes or after
the driver reaches a certain minimum speed.
4
5
5
6
System overview
Different control units for the tyre failure indicator
Series E ... Date of
introduction
of RPA
RPA design Initialized by:
RPA button CID and
controller
3 Series E46 SA
as from 09/0
RPA
integrated
in DSC
X ---
E46 Four
wheel drive
SA
as from 09/01
RPA control
unit
X ---
5 Series E60 Standard RPA
integrated
in the DSC
--- X
E61 Standard RPA
integrated
in the DSC
--- X
6 Series E63 Standard RPA
integrated
in the DSC
--- X
E64 Standard RPA
integrated
in the DSC
--- X
7 Series E65 SA from 09/
02
to 12/03,
Standard
as from 12/03
RPA
integrated
in CIM
--- X
E66 SA from 09/
02
to 12/03,
Standard
as from 12/03
RPA
integrated
in CIM
--- X
Z-models E85 Standard RPA
integrated
in the DSC
X ---
X-models E53 Standard
as from 04/04
RPA
integrated
in the DSC
X ---
E83 Standard RPA
integrated
in the DSC
X ---
CID = Central Information Display
CIM = Chassis Integration Module
DSC = Dynamic Stability Control
RPA = Tyre failure indicator
SA = Option
E = Development series
6
6
7
7
Functions
Components
The systems consist of the following major
components:
4 wheel speed sensors
The wheel speed sensors of the Dynamic
Stability Control system (DSC) detect the
rotation speeds of the individual wheels.
RPA button
(E46, E85, E83, E53 from 04/04)
The RPA button is only required for
initialization. In vehicles without an RPA
button, the systemis initialized via the Central
Information Display (CID) using the controller.
Depending on the series, the software for the
RPA is contained in the following control units:
DSC control unit with additional
software for tyre failure indicator
(E85, E83, E53 from 04/04, E60, E61,
E63, E64)
In connection with the DSC Mk60 and the
DSC 8, the RPA is integrated by way of
additional software in the DSC control unit.
or
Chassis Integration Module 2
(E65, E66)
The chassis integration module (CIM) controls
Servotronic, steering column adjustment and
the tyre failure indicator (RPA).
As of 12/03, the software for the RPA is now
integrated in the CIM(a separate processor in
the CIM is no longer required).
or
RPA control unit
(E46 four-wheel drive)
The E46 four-wheel drive has a separate RPA
control unit. The wheel speeds are detected
by the 4 wheel speed sensors. The DSC
control unit sends the signals to the RPA
control unit by four direct leads.
The following control units participate in the
functions of the tyre failure indicator:
SafetyandGatewayModule(frommodel
03/04 e.g. E60/61 E65/66)
The safety and gateway module (SGM) forms
the connection between the body controller
area network (K-CAN) and the powertrain
controller area network (PT-CAN).
Central gatewaymodule(uptomodel 02/
04 e.g. E65/66)
The central gateway module (ZGM) forms the
connection between K-CAN and PT-CAN.
Car access system
The CAS control unit informs the RPA of the
terminal status (e.g. terminal 15 ON).
Multi-Audiosystem Controller or Car
Communication Computer
The multi-audio systemcontroller (M-ASK) or
the car communication computer (CCC) emits
an audible warning if the tyre pressure has
dropped.
8
7
Indicator and warning lamps and the
central information display
A fault in the RPA or a loss of tyre pressure is
displayed by the permanent RPAindicator and
warning lamp in the instrument cluster. At the
same time, a check control message is
displayed with a variable check control symbol
(only on LC display that shows variable check
control symbol).
A fault status in the RPA is displayed by the
RPA indicator and warning lamp as follows:
The indicator and warning lamp can have
the following status:
Red and audible signal:
Loss of tyre pressure of more than
approximately 30 % 10 %, and driving
safety is no longer guaranteed.
Yellow:
The RPA is malfunctioning defective.
The detailed text of the Check Control
message can be called up in the Central
Information Display (E65, E66, E60, E61,
E63, E64).
System functions
The tyre failure indicator (RPA) includes the
following functions:
Self-test
Initialization
Measure loss in tyre air pressure
Visual and audible warning
Self-test
The RPA performs a self-test at terminal 15
ON. Any fault in the systemis displayed by the
RPA indicator and warning lamp and a check
control message.
Initialization
Initialization is a fully automatic learning
process.
The RPA is calibrated or initialized to the
specific set of tyres with the current tyre
pressure.
Once the journey has started, the control unit
begins the adaptation phase. This means that
the tyre circumference of the individual wheels
is measured and evaluated. During the
adaptation phase, the system warns of large
losses in tyre pressure.
After approximately 10 minutes, losses in tyre
pressure of around 50%of the initial value can
be detected.
The end of the adaptation phase is not
indicated. As initialization continues, the
detection of a loss in tyre pressure increases
incrementally to 30% 10%.
In order to take into account changes in tyre
circumference at different road speeds, the
system uses different road speed ranges.
These road speed ranges each need to be
initialized individually. The driving time
required for initialization depends on the
model. Below a certain minimum speed, no
warning is issued by the system.
9
7
Example:
Each of these road speed ranges has its own
warning threshold value. The warning
threshold value is only reached after a specific
driving time within this road speed range, after
initialization.
This driving time is not a fixed length of time.
The driving time depends greatly on the
driving style and the driving conditions. The
driving time is reached when, for example, a
total of 15 or 5 minutes' worth of useful wheel
rotation speed signals is available. When
accelerating or braking sharply, or when
driving around bends, the wheel speed signal
cannot be used.
For example, a vehicle is travelling in the road
speed range 110 km/h to 140 km/h for at least
10 minutes. If there is a loss in tyre pressure
within this range, a warning is issued.
The RPA detects the wheel speed via the
wheel speed sensors of the dynamic stability
control system(DSC). The RPAcompares the
individual wheels with each other and
calculates the average speed for the purpose
of detecting a loss in tyre pressure.
Visual and audible warning
Adrop in air pressure in a tyre of approximately
30% 10% of the initial value is indicated by
the RPA indicator and warning lamps. An
audible signal additionally sounds.
The signal output depends on the specific
model. Either via the instrument cluster or the
mulit-audio system controller (M-ASK) or car
communication computer (CCC).
Road speed ranges Drivingtimeinroadspeedrange/ model-
dependent
0 km/h to specific minimum speed (e.g.
25 km/h)
---
25 km/h to 110 km/h 15 minutes
Over 200 km/h 5 minutes
10
7
11
8
System components
Input/outputs, RPA with RPA control unit
Example: E46 four-wheel drive
1 - Four-wheel drive inputs/outputs
1 Wheel speed sensors 5 RPA button
2 DSC control unit
(Dynamic stability control)
D-Bus Diagnosis cable
3 RPA control unit
(tyre failure indicator)
K-Bus Body bus
4 Instrument cluster PT-CAN Powertrain CAN (Powertrain
Controller Area Network)
12
8
System circuit diagram for RPA with RPA control unit
Example: E46 four-wheel drive
2 - System circuit diagram
1 Wheel speed sensors D-bus Diagnosis cable
2 DSC control unit
K-bus Body bus
3 RPA control unit
(tyre failure indicator)
Terminal
58g
Locator lamp of the RPA button
4 Instrument cluster PT-CAN Powertrain-CAN (Powertrain
Controller area network)
5 RPA button
13
8
System circuit diagram for DSC control unit with additional
software for the RPA
Example: E60
3 - System circuit diagram for E60 tyre failure indicator
1 Wheel speed sensors 6 Instrument cluster
2 DSC control unit
(SGM)
3 Car access system (CAS) D-bus Diagnosis cable
4 Central information display (CID) K-CAN Body CAN (body controller area
network)
5 Controller (CON) PT-CAN Powertrain CAN (Powertrain
14
8
System circuit diagram for RPA with Chassis Integration
Module (CIM)
Example: E65
4 - System circuit diagram E65
1 Chassis Integration Module
(CIM)
8 Wheel speed sensors
2 Multi-Audiosystem Controller
(M-ASK)
9 DSC control unit
3 Instrument cluster D-bus Diagnosis cable
4 Central information display (CID) K-CAN Body CAN (body controller area
network)
5 Controller (CON) MOST MOST bus (Media Oriented
System Transport Bus)
6 Car access system (CAS) PT-CAN Powertrain CAN (Powertrain
(SGM)
15
9
Service information
General information
The following general information is provided for servicing the
RPA:
Wheel speed sensor failure
If a signal is not received fromone of the wheel
speed sensors, the RPA assumes the status
"inactive" after approximately 2 minutes. The
RPA indicator and warning lamp turns yellow.
The fault is also displayed in a Check Control
message. A fault is entered in the fault code
memory.
When the signal returns, the RPA is
reactivated after approximately 30 minutes of
driving time, and the fault remains recorded in
the fault code memory.
Driver's responsibility
Check the tyre pressure regularly (at least
twice a month), and always before starting a
long journey. The set tyre pressure is adopted
as the output value.
The RPA does not monitor the natural escape
of air (diffusion) in all 4 tyres.
If all 4 tyres have the same loss in tyre
pressure, all the wheel speeds change at an
equal rate. The RPA cannot detect an equal
loss of tyre pressure.
Problematic factors for system function
The following driving conditions can lead to a
delayed or incorrect warning of a loss in tyre
pressure:
Sharp braking
Powerful acceleration
High transverse acceleration
Driving around a narrow bend radius
Driving below a minimum speed (the RPA
only responds above a certain minimum
speed)
Large differences in slip (axle and/or vehicle
side)
Incomplete initialization in the current road
speed range (see Operation)
Winter driving conditions
The following operating conditions can lead to
a delayed warning of a loss in tyre pressure:
Use of snow chains
The RPA cannot be guaranteed to function
accurately when snow chains are used.
3 If using snow chains, do not perform
initialization.
The system should not be initialized when
using snow chains, because this leads to
incorrect adaptation values.
After the snow chains are removed, the
system function returns to normal after a few
minutes driving time. 1
16
9
Towing
If towing a trailer load of more than
approximately 300 kg, re-initialization is
necessary.
After unhooking or unloading the trailer,
perform initialization once more.
Old/new tyres
Avoid fitting tyres with large differences in
tread depth (more than approx. 2 mm) on
one axle.
The systemdoes not issue a warning, despite
a loss of tyre pressure, in the following cases:
If two or more tyres lose air pressure to the
same extent
Loss of tyre pressure caused by natural
diffusion and that affects all 4 tyres equally
Tyre damage with immediate great loss of
tyre pressure (tyre blow-out, the warning is
too late)
Operation
The tyre failure indicator (RPA) is initialized
using the following operating elements:
RPA button
With iDrive, in the central information
display (CID) using the controller
3 Always perform initialization immediately
after correcting the tyre pressure, changing or
interchanging tyres. Always set the tyre
pressure for cold tyres.
The correct tyre pressure must be set before
initialization. During initialization, the set tyre
pressure is used as the initial value for the
current set of tyres.
The tyre pressures must always be set as for
coldtyres to avoiderroneous values causedby
changes in temperature. 1
The tyre failure indicator cannot be
guaranteed to function correctly if using
an emergency wheel.
When an emergency wheel is used, the
software of the RPA can no longer
compensate for the different wheel diameters.
Initialization cannot be completed.
Initialization must be performed:
when changing the tyre pressure
(tyre pressure is corrected or a new
pressure is set)
if the position of the wheels is altered, even
if the tyre pressure has not been changed
when changing or interchanging tyres
(e.g. when changing old tyres for newtyres,
summer tyres for winter tyres, etc.)
To perform initialization, proceed as follows:
Terminal 15 ON
Vehicles with an RPA button
Hold the RPA down until the RPA
indicator and warning lamp is lit up in
yellow for a few seconds
Vehicles without RPA button
Initialization is performed via the Central
Information Display (CID) using the
controller
Select "RPA" in the "Settings" menu,
and confirm
Select "Set", and confirm
Start driving
The end of the adaptation phase is not
indicated.
The tyre pressure indicator (RPA) is
automatically activated when terminal 15 is
ON. The RPA cannot be switched off
manually.
17
9
Special information on the RPA for E60 models
The following illustration shows the variable
check control symbol.
(Example of E60 instrument cluster)
There are two variable check control symbols
for the RPA, with 2 corresponding check
control messages, which are displayed in the
instrument cluster:
"Flat tyre!" reports a loss of pressure in a
tyre of more than 30%. This is
accompanied by a gong.
"Tyre failure indicator failure!" reports that
the system is inactive due to a fault and
cannot detect a flat tyre.
1 - Instrument cluster
1 Variable check control symbol
together with a check control
message (yellow or red indicator
lamp)
3 Check control message in the
central
information display
2 "BMW Service" menu in the
central
information display
18
9
Additional information for each check control
message is displayed in the CID.
The RPA submenu in the CID also contains a
status line that indicates the current status of
the RPA.
'Adaptation phase': The system is being
calibrated. The adaptation phase is
displayed until the RPAfirst becomes ready
for operation after the start of calibration.
"Inactive": There is a fault in the systemand
therefore no flat tyres can be detected.
"Active": The system is capable of
detecting a puncture.
Diagnosis
The diagnosis for the RPA function is
performed in the DSC control unit.
Fault codes
There is a range of different fault codes. If a
fault code is displayed, the RPA assumes
"inactive" status.
If there are errors in the coding data:
The system needs to be recoded. If faults
recur regularly in the vehicle, the control
unit needs to be replaced.
If there are errors in the standardization
data:
The system needs to be restandardized. If
faults recur regularly in the vehicle, the
control unit needs to be replaced.
Failure of a wheel speed sensor is stored in
the fault code memory by the DSCfunction.
Variable check control symbols Information in the CID
Flat tyre
Reduce speed, see the Owner's Handbook.
Safety tyres:
Maximum possible driving speed is 80 km/h.
Distance is limited, see the Owner's
Handbook. Have the problemchecked by the
nearest BMW Service.
failure
Flat tyres are not indicated.
Have the problem checked as soon as
possible by the nearest BMW Service.
19
9
Programming
The RPA is automatically flash programmed
using the DSC software.
Coding
The RPA is encoded by means of a coding
description file. This enters different
parameters into the control unit that take into
account the differences between the different
vehicle models.
Note for the E60
Depending on the equipment specification, a
space-saver wheel may be supplied. This
wheel has the designation T-135/80-17(the T
stands for: "Temporary spare").
Important: The space-saver spare wheel has a
pressure of 4.2 bar!
20
9
Abbreviations
ABS Anti-lock braking system
ACC Active cruise control
AHM Trailer module
AL Low beam
Active steering
ARS Dynamic drive
ASC Automatic stability control
CAN Controller area network
CAS Car access system
CBC Cornering brake control
CCC Car communication computer
CDC CD changer
CID Central information display
CIM Chassis integration module
CON Controller
CVM Convertible top module
DBC Dynamic braking control
DDE Digital diesel electronics
DME Digital motor electronics
DSC Dynamic stability control
DSC-SEN Dynamic stability control - sensor
DWA Antitheft alarm system
EBV Electronic brake power distribution
ECD Electronically controlled deceleration
ECO Electronically controlled orifice
EDC Electronic damper control
EHC Electronic ride-height control (level control)
EKP Electric fuel pump
EMF Electromechanical parking brake
EPS Electromechanical power steering
EWS Electronic immobilizer
F-CAN Chassis CAN
FLR Driving performance control
GM Base module
IHKA Integrated automatic heating/air conditioning
K-CAN Body Controller Area Network
KBM Body basic module
LED Light-emitting diode
LM Light module
LSZ Light switch cluster
LWS Steering angle sensor
M-ASK Multi-audio system controller
MDS Panoramic glass roof
MRS Multiple restraint system
MSR Engine drag torque control
NAV Navigation
PDC Park distance control
PT-CAN Power Train Controller Area Network
PWM Pulse width modulation
RLS Rain/driving light sensor
RPA Tyre puncture warning
SA Option
SBSL B-pillar satellite, left
SBSR B-pillar satellite, right
SDARS Satellite Digital Audio Radio Service
SDR Short distance radar
Overrun differential control
SES Voice recognition system
SFZ Vehicle centre satellite
SH Auxiliary heating
SHD Slide/tilt sunroof
SIM Safety and information module
Subscriber identification module
SM Seat module
SMBF Passenger's seat module
SMFA Driver's seat module
SMG Sequential manual transmission
Sequential M transmission
SZL Steering column switch cluster
VM Video module
ZGM Central gateway module
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BMW Service
Aftersales Training
80788 Mnchen
Fax. +49 89 382-34450
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