E90 Powertrain

Initial Print Date: 03/05 Table of Contents Subject Page Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 N52B30 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Engine Power Output (N52B30 - 3.0 Liter) . . . . . . . . . . . . . . . . . . . . . .4 Technical Data (N52B30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Engine Designations and Identification . . . . . . . . . . . . . . . . . . . . . . . . .6 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Engine Management (MSV70) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Processor Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 MSV70 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Manual Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Automatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 External Gearshift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Shiftlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Interlock Without Comfort Access: . . . . . . . . . . . . . . . . . . . . . . . . .14 Interlock with Comfort Access: . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Emergency Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Transmission Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Stationary Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Automatic Transmission Selector Lever - Circuit Diagram . . . . . . . .16 Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Final Drive/Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Output Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 E90 Powertrain Revision Date: 04/05 2 E90 Powertrain E90 Powertrain Model: E90 Production: From Start of Production After completion of this module you will be able to: • Establish an overview of the advancements made with the N52 engine • Identify the N52 engine designations • Establish an overview of the MSV70 Engine Control Module • Establish an overview of E90 transmissions • Identify the components of the driveline • Determine what ratio differential is installed with specific transmission The introduction of the new BMW 3 series (E90) to the U.S. market will again set the standard by which all others will be judged, including its predecessors. The previous M54/M56 engine is being replaced with a new engine variant referred to as the N52, which introduces a number of new technologies with regard to engine development. The objectives in developing the N52 include: • Increased power output and torque • Reduction of fuel consumption • Reduction of overall engine weight • Top position in engine class through efficient dynamics • Utilization of innovations for customer benefit By implementing some of the latest technology into the N52 engine, BMW met the objectives by improving the power to weight ratio, reduced emissions and decreased fuel consumption. 3 E90 Powertrain Engine N52B30 Engine The simplest way of achieving these objectives was to reduce the weight of the engine. By utilizing new engine development technology the N52 variant is 10 Kg (22 lbs) lighter than its predecessor, as a result of: • New composite magnesium-aluminum crankcase • Lightweight exhaust manifold • Magnesium bedplate • Magnesium cylinder head cover. Improvements have also been made with regard to the Valvetronic system (Valvetronic II) along with a new 3 stage DISA intake manifold, electric coolant pump and a new Engine Management (MSV70). The introduction of these improvements provides the N52 with a 12% reduction in fuel consumption and a 10% increase in dynamics, compared to the previous engine (M54/M56). The increases in efficiency allow the N52 to comply with ULEV II standards. For the U.S. Market the N52 engine will be available in the 330i and 325i, both engine variants will be designated N52B30. Engine Power Output (N52B30 - 3.0 Liter) 4 E90 Powertrain Technical Data (N52B30) 5 E90 Powertrain Description Value Engine Type 6 cylinder in-line Displacement (cm3) 2.996 Stroke/bore (mm) 85.0/88.0 Cylinder spacing (mm) 91 Crankshaft main bearing diameter 6 @ 56mm / 1 @ 65mm Crankshaft big-end (rod) bearing diameter 50mm Firing Order 1-5-3-6-2-4 Power output (kW/hp) 190/255 @ engine speed 6,600 Torque 300 @ engine speed 2,500 to 4,000 Maximum rpm (governed cutoff) 7,000 Power to weight ratio 0.84 Power output per liter 63.4 Compression ratio 10.7 Valves per cylinder 4 Intake valve diameter (mm) 34.2 Exhaust valve diameter (mm) 29 Minimum intake valve lift (mm) 0.18 Maximum intake valve lift (mm) 9.9 Exhaust valve lift 9.7 Camshaft opening angle, intake (crankshaft degrees) 255 Camshaft opening angle, exhaust (crankshaft degrees) 263 Camshaft spread, intake (crankshaft degrees) 120-50 Camshaft spread, exhaust (crankshaft degrees) 115-60 Engine weight (kg.) 161 Fuel requirement 91 (98 RON) Engine oil SAE 5W-30 Knock control Yes Intake manifold 3 Stage Resonance Intake Manifold (DISA) Engine Management Siemens MSV70 Valvetrain System Valvetronic II Emissions Certification ULEV 2 Engine Designations and Identification The N52 engine designation is similar to past engines and is broken down as follows: The N52B30 engine in the U.S. will be available on the 330i as “OL” and on the 325i as “UL” versions. The “OL” designation refers to the upper output stage engine and the “UL” designation refers to the lower output stage engine. The engine identification code is located on the side of the engine block, below the intake manifold directly between the knock sensors. The designation: • “AF” in the engine code refers to the upper output stage or “OL” • “AE” in the engine code refers to the lower output stage “UL”. 6 E90 Powertrain Index Explanation Index Explanation 1 N = New Generation Engine 4 30 = 3.0 Liter Displacement 2 52 = Inline 6 Cylinder Engine 5 OL = Upper Output Stage (High Output) UL = Lower Output Stage (Low Output) 3 B = Gasoline N52 B 30 OL 1 2 3 4 5 Components The N52 engine consists of the following components/systems: • 6-cylinder, 4-valve in-line, friction optimized engine • Two-piece crankcase in composite magnesium-aluminum structure • Trapezoidal connecting rods (weight optimized) • Aluminum silicon (Alusil) cylinder head • Timing case integrated in crankcase and cylinder head • Cylinder head gasket with silicon sealing lip • VALVETRONIC II • Weight-optimized double VANOS • Volumetric flow-controlled oil pump • Electrically controlled coolant pump • Crankcase ventilation with integrated heater • 3-stage DISA 7 E90 Powertrain 8 E90 Powertrain Engine Management (MSV70) There are several new innovations introduced with the new MSV70 engine management system. The most obvious innovation is the addition of Valvetronic II to the six-cylinder engine line. This is the first use of Valvetronic on the BMW six-cylinder. The MSV70 engine management system is responsible for the following tasks: • Ignition control • Injection control • VALVETRONIC II control • Control of “Weight Optimized” double VANOS • Engine temperature control (characteristic map control of engine thermostat) • Electric coolant pump control (Heat Management System) • Knock control • Lambda control • Fuel tank ventilation control • Load request to air conditioning control unit for A/C compressor • Activation of 3-stage differentiated intake manifold (DISA) • Electric fuel pump module control (EKP) • Cruise control • Alternator control • Heated crankcase ventilation • Electronic oil condition monitoring and oil level monitoring • Energy management (IBS) • Monitoring of input and output signals • Calculation of substitute signals and failsafe functions • Self-diagnosis The engine management system on the N52 engine complies with OBD regulations and meets the ULEV II requirements for 2006. 9 E90 Powertrain Control Module The new MSV70 control module is manufactured by Siemens/VDO. The “MSV” desig- nation indicates a Siemens control module (Motor Control with Valvetronic). The control module features an all aluminum housing with a new modular connector configuration. The control module has two main connections, one with 4 modular con- nections and the other with 3 for a total of 7 “sub” connectors. This arrangement pro- vides a total of 146 possible pin connections. Processor Power The computing power has been increased to a clock frequency of 60 MHz to accommo- date the extended functions. Index Explanation Index Explanation 1 Connector X60004 to X60007 M4 Connector module 4 (6 pins) 2 Connector X60001 to X60003 M5 Connector module 5 (44 pins) M1 Connector module 1 (26 pins) M6 Connector module 6 (12 pins) M2 Connector module 2 (26 pins) M7 Connector module 7 (26 Pins) M3 Connector module 3 (6 pins) 10 E90 Powertrain MSV70 System Overview PT-CAN t° P DME DMTL IHKA T O 0 4 -4 9 5 3 4 64 63 61 59 57 55 53 50 51 48 46 44 39 38 62 60 58 56 54 52 49 47 45 37 2 1 3 6 8 13 11 5 7 9 10 12 15 17 19 24- 32 34 14 16 18 33 25 35 36 6 x 26 31- 40 42+ 6 x 2 x 41 43+ 2 x 11 E90 Powertrain Legend for MSV70 System Overview Additional information on the N52 engine & MSV70 is provided in ST501 New Engine Technology Index Explanation Index Explanation 1 DME (ECM) 38 Diagnosis connection 2 Integral ambient temperature sensor 39 Valvetronic relay 3 Integral ambient pressure sensor 40 Oxygen Sensor 4 DME (ECM) main relay 41 Oxygen Sensor 5 DM-TL 42 Oxygen Sensor 6 IHKA 43 Oxygen Sensor 7 Electric engine cooling fan 44 Valvetronic motor 8 E-Box fan 45 Knock sensor (cyl 1-3) 9 Characteristic map thermostat 46 Knock sensor (cyl 4-6) 10 Crankcase ventilation heater 47 Eccentric shaft sensor 11 Crankcase ventilation heater relay 48 Hot-film air mass meter (HFM) 12 Secondary air pump 49 Exhaust camshaft sensor 13 Secondary air pump relay 50 Intake camshaft sensor 14 HFM for Secondary air 51 Crankshaft sensor 15 Fuel tank vent valve (TEV) 52 DISA actuator 16 VANOS solenoid valve (Intake cam) 53 DISA Actuator 17 VANOS solenoid valve (Exhaust cam) 54 Electric Throttle Valve (EDK) 18 Electro-magnet for airflap control (not for US) 55 Accelerator Pedal Module (FPM) 19-24 Fuel injectors 56 SPORT button 25 Fuel injector relay 57 Coolant temperature sensor (engine temp) 26-31 Ignition coils 58 Coolant temperature sensor (radiator outlet) 32 Electric coolant pump 59 DSC module 33 Intelligent Battery Sensor (IBS) 60 Brake Light Switch (BLS) 34 Alternator 61 Clutch switch 35 Oil Condition Sensor (OZS) 62 Car Access System (CAS) 36 Ground connection 63 Differential pressure sensor 37 PT-CAN 64 Oil pressure switch On the E90 a six speed manual transmission (GS6-37BZ) will be standard and a six speed automatic transmission with STEPTRONIC (GA6HP19Z) will be optional. Manual Transmission The Manual Transmission (GS6-37BZ) available on the E90 is the same as that used previously on the E46 and currently on the E60 & E85. The transmission has a lifetime oil fill. Automatic Transmission For the first time the 3 series will see a six speed Automatic Transmission (GA6HP19Z) with STEPTRONIC. The transmission is similar to that used in the E60 with the M54 engine. In order to utilize this transmission on the E90 changes were made to: • Outer gearshift mechanism with electrical interlock • New transmission control module • Adapted hole circle diameter at the output flange 12 E90 Powertrain Transmissions 13 E90 Powertrain External Gearshift Mechanism The external gearshift mechanism consists of the selector lever with the following components: • Cable assembly to gearbox • Solenoid valve for shiftlock function • Solenoid valve for interlock function • Microswitch for detecting locked shift lever • Emergency release of interlock function • Switch unit for Steptronic function • Selector lever position switch indicator Cable Assembly The cable assembly is the mechanical connection between the selector lever and the inner gearshift mechanism (mechatronics module). The drive stages are preselected and the parking lock engaged with the aid of the cable assembly. Index Explanation Index Explanation 1 Gearbox Casing 3 Output Flange 2 Selector Lever Unit 4 Cable Assembly 14 E90 Powertrain Shiftlock The shiftlock function prevents the vehicle from inadvertently being placed in gear with the ignition on, unless the brake pedal is depressed. A solenoid is used to lock the shift lever in position P or N once the ignition is swithed off and the lever has been placed into position P or N. The solenoid is activated by a switched ground signal from the Transmission Control Module Interlock The interlock function prevents removal of the remote control “key” when the selector lever is not in position P . The selector lever remains locked in position P if the remote control “key” is not inserted in its slot. For this purpose, the selector lever is locked in position P by two electric magnets once the ignition is switched off. Interlock Without Comfort Access: The selector lever is locked in position P after ignition OFF and the radio remote control “key” can be removed. The microswitch on the selector lever unit monitors the lock state of the selector lever and sends the signal to the CAS to release the radio remote control once the selector lever is in position P. Interlock with Comfort Access: When the vehicle is stationary, the engine or terminal 15 can only be turned off when the selector lever is in position P. Emergency Release In case of an emergency (e.g. failure of the power supply system), the selector lever can be released by operating the emergency release. The emergency release is accessible by removing the selector lever cover. The selector lever is released by pressing on the pawl (1). Index Explanation 1 Emergency Release Pawl for Interlock 15 E90 Powertrain Transmission Control Module The newly developed Transmission Control Module (GS 19.11) is used for the automatic transmission GA6HP19Z (in all models). Compared to its predecessor (GS 19.04) it offers the following advantages: • Flash memory expanded from 512 Kbit to 1 MB • Designed to withstand higher temperatures • Electromagnetic compatibility considerably improved • Reserve for further functions The Transmission Control Module is located on the mechatronics module in the gearbox with the same housing and pin assignments from the previous version. Torque Converter A torque converter (LUK) with a two-layer torque converter lockup clutch is used. Stationary Disconnection The gearbox features a stationary disconnection (uncoupling) function for the torque con- verter. The torque converter is disconnected from the drivetrain instead of running the engine against the torque converter when the vehicle is stationary. By disconnecting the torque converter with the vehicle stationary, the engine is subject to minimum load and fuel consumption is reduced. Disconnection (uncoupling) of the torque converter is achieved as a function of the following signals: • Brake operated • Selector lever position D • Gear oil temperature > 20°C and < 120°C • No trailer signal applied 16 E90 Powertrain Automatic Transmission Selector Lever - Circuit Diagram Index Explanation Index Explanation 1 Electronic Transmission Control Module (TCM) 9 Microswitch for Detecting Locked Shift Lever 2 Engine Control Module (DME/ECM) 10 Switch for S-program and Steptronic 3 Steering Column Switch Cluster (SZL) 11 Position indicator on selector lever 4 Dynamic Stability Control (DSC) 12 Sliding Contact for Background Lighting of Position Indicator on Selector Lever 5 Junction Box (JB) 13 Shiftlock Magnet 6 Car Access System (CAS2) 14 Interlock Magnet 7 Brake- Light Switch 15 Selector Lever Unit 8 Accelerator Pedal Module Drive Shaft The E90 utilizes a two piece steel drive shaft with a deformation element (collapsing tube similar to E60). 17 E90 Powertrain Driveline Index Explanation Index Explanation 1 Flexible Coupling 5 Flexible Coupling 2 Front Drive Shaft Section 6 Right-Hand Output Shaft 3 Universal Joint 7 Final Drive Unit 188L 4 Rear Drive Shaft Section 8 Left Hand Output Shaft 18 E90 Powertrain Final Drive/Differential The differential unit 188 L (L = low friction) is used for the first time on the 3 series. The 188 L differential uses angular-contact ball bearings (1), compared to the linear con- tact of tapered roller bearings, the point contact of the angular-contact ball bearings pro- duces less friction. By reducing friction the temperature of the gearbox is reduced which in turn increases efficiency. The differential utilizes a lifetime fill oil. Output Shafts Solid shafts, torsionally-rigid hollow shafts or torsionally-flexible hollow shafts are used depending on the engine-gearbox combination. The joint size also varies corresponding to the engine-gearbox combination. Series/Model Engine Gearbox Final Drive E90/325i N52B30 UL GS6-37BZ 188 L (i = 3. 23) E90/325iA N52B30 UL GA6HP19Z 188 L (i = 3.73) E90/330i N53B30 OL GS6-37BZ 188 L (i = 3.15) E90/330iA N52B30 OL GA6HP19Z 188 L (i = 3.64) 1. Angular-contact ball bearing Main Menu E90 Complete Vehicle E90 Suspension & Chassis Components E90 Voltage Supply and Bus Systems E90 Powertrain E90 Dynamic Driving Systems E90 General Vehicle Electrical E90 General Vehicle Electrical II E90 Driver Information Systems E90 Entertainment and Communication E90 Climate Control E90 Multiple Restraint System 5 E61 Sport Wagon E65/66 Model Update Glossary