Table of Contents E60 Climate Control Subject Page E60 Automatic Heating and Air Conditioning System.3 Purpose of the System.3 New System Components and Features .3 Additional System Features .4 System Components.6 Components Located in Passenger Compartment.6 Components Located in (or on) IHKA Housing.6 Components Located in Engine Compartment.6 IHKA Control Panel/Module .7 Condensation Sensor.10 Solar Sensor.12 AUC-2 Sensor .12 CID and Controller .12 Components Located on IHKA Housing.13 Stepper Motors .13 Blower Motor with Blower Controller .14 Temperature Sensors .14 Component Layout .16 A/C System Component Layout.17 A/C Compressor.17 Pressure Sensor.18 Water Valves.18 Auxiliary Water Pump (ZWP).18 Microfilter System.19 Workshop Hints.20 AC Housing Installation.20 Compressor Run-in .20 Initial Print Date: 08/03 Revision Date: 09/03 Model: E60 Production: Start of Production MY 2004 Climate Control Objectives: After completion of this module you will be able to: • Identify and locate the components of the E60 Climate Control System • Understand the differences between E39 and E60 IHKA • Understand LIN bus operation • Understand Condensation Sensor Operation • Operate Features of the E60 IHKA System 2 E60 Climate Control E60 Automatic Heating and Air Conditioning System Purpose of the System The E60 IHKA system is designed using the same criteria as the E65. There are techno¬ logical improvements as well as new or modified functions. As with E65, the design objec¬ tives were to meet the requirements of customers worldwide for heating and cooling capacity. New System Components and Features • Condensation Sensor (Mist Sensor) - The Condensation sensor evaluates the humidity level of the windshield area and implements control measures to reduce windshield fogging. • New Bus System - The Local Interconnect Network (LIN Bus) connects all 9 step per motors and the blower controller. • Modified Control Concept (As compared to E39) - Similar to E65, there is a reduc¬ tion in the number of primary controls. The temperature and air volume are contr¬ olled by rotary knobs. Extended air conditioning functions such as air stratification are selected and activated by means of the controller in the CID. 3 E60 Climate Control Additional System Features • Modified Display Concept - The Scope of display elements for the extended AC functions in the CID are similar to those in the E65. The required fan and tempera¬ ture settings are not shown in the CID. The set values for temperature and air vol¬ ume can be read from scale rings on the IHKA panel. Air distribution is set by means of the controller in the CID. • Elimination of LCD Display - The LCD display from the E39 has been eliminated. • No Bowden Cables - All flap positions are set by stepper motors which are con¬ trolled via the LIN bus. • Separate Footwell Flaps for Left and Right • Separate Ventilation Flaps for Left and Right • New Suction Action Blower arrangement - The new blower arrangement allows for a more compact IHKA housing. The blower is arranged behind the evaporator. The heat exchanger for the heating system is positioned at right angles with respect to the evaporator and is arranged over the blower. The blower motor and blower motor housing can be removed without removal of the complete dashboard assembly. • Clutchless A/C Compressor - The clutchless compressor is externally actuated and output regulated. The component and operation are carried over from the E65. • AUC-2 Sensor - The AUC sensor is carried over from the E65. • Solar Sensor - The solar sensor is located in the center of the dashboard and is also carried over from the E65/E66. 4 E60 Climate Control System Overview 1. Mist sensor 2. Mist sensor signal 3. Ambient temperature sensor 4. Face vent temperature sensor 5. IHKA control panel 6. Not shown 7. Evaporator and expansion valve 8. Blower and controller (on LIN bus) 9. Stepper motors (9 on LIN bus) 10. Clutchless AC compressor 5 E60 Climate Control System Components The E60 Climate Control System consists of the following components: Components Located in Passenger Compartment • IHKA Control Panel/Module • Condensation (Mist) Sensor • Solar Sensor • CID and Controller • Face Vent Temperature Sensor Components Located in (or on) IHKA Housing • 9 Stepper Motors (all on LIN Bus) • Blower Motor with Controller (on LIN Bus) • Evaporator Temperature Sensor • 2 Heater Core Temperature Sensors (Left and Right) • Heater Core (Heat Exchanger) • Evaporator • Expansion Valve Components Located in Engine Compartment • A/C Compressor • AUC Sensor • Water Valves • Auxiliary Water Pump • A/C Condenser (with Integrated Receiver/Dryer) • Auxiliary Cooling Fan • A/C Pressure Sensor • Refrigerant Lines • Microfilter System 6 E60 Climate Control IHKA Control Panel/Module The IHKA Control Panel/Module controls the following functions: • Desired Temperature Setting, Left/Right • Air Volume (Automatic and Manual Blower Settings) • A/C On/Off Switch • Recirculation Control (Including AUC) • Rear Window Defogger • MAX A/C • Defrost Function There are additional functions such as air distribution (defrost, face and footwell) and air stratification that are selected and controlled with the controller in the CID. 10 9 8 1. Rotary control for left side temperature setting with MAX AC button. 2. Opening for interior temperature sensor. 3. DEFROST Button 4. Rotary control for blower setting with OFF button. 5. A/C Button US223_Q2256_02 6. AUTO Button (Automatic flap and blower function). 7. Rotary control for right side temperature setting with REST button. 8. AUC recirculating air button 9. Independent Heating Indicator (Not for US Market) 10. Rear window defogger button 7 E60 Climate Control Workshop Exercise - IHKA Control Panel 1.26 Pin plug connection to vehicle electrical system 2. 12 Pin plug connection to heater/air conditioner 3. 2 Pin plug connection to front of power distribution box Remove IHKA panel and connect breakout boxes Record the steps and fasteners (if any) used to remove the IHKA control panel/module: List part numbers of breakout boxes and cables used: List the connector numbers for the following connectors: 26 Pin _ 12 Pin _ 3 Pin 8 E60 Climate Control Workshop Exercise - IHKA Control Panel List the connector and pin #’s of the power supply and ground connections to the IHKA panel: KL15 _ KL30 _ KL31 _ List the Bus interface connections to the IHKA control panel: How does the IHKA panel receive outside temperature information? Can the interior temp sensor fan be replaced as a separate item? Describe the AC compressor control circuit (list connectors, pins, etc.): 9 E60 Climate Control Condensation Sensor The condensation sensor is new to BMW climate control systems. The sensor is used to measure air humidity and temperature in the windshield area. This information is sent to the IHKA control unit via a digital signal with a varying frequency. This information is evaluated by the IHKA control module, which then implements a series of countermeasures to prevent windscreen fogging. The coun¬ termeasures are implemented in the following sequence: Measures Action 1 Defroster flaps opened further 2 Recirculating air/AUC/automatic recirculating air switched to fresh air 3 Partial fresh air in connection with recirculating air/AUC/automatic recirculating air switched to fresh air 4 Minimum evaporator temperature (progressive evap temperature de-activated) 5 Blower air volume increased 6 Footwell share decreased 7 Temperature setpoint increased These measures are implemented one after another until windscreen fogging is eliminated. Further steps are initiated if one measure proves to be ineffective. After successfully eliminating windscreen fogging, the measures are gradually cancelled in steps. The sensor is located beneath the RLS on the wind¬ shield below the cover for the base of the rear view mirror. A special locating tool is used to install the new sensor, this tool is supplied with the replacement sensor. The sensor is affixed to the windscreen with an adhesive. If the sensor needs to be removed from the windshield it must be replaced. 4 3 's' 1. Sensor Electronics 2. 3 Pin Connection 3. Moisture measuring cell 4. Well for laser adjusted resistors E60 Climate Control Workshop Exercises - Condensation Sensor Using the DISPIus or GT-1, record the following information: What type of signal is sent from the condensation sensor to the IHKA module? What is the pin and connector number for the condensation sensor signal at the IHKA con¬ trol panel/module? Measure and record the following signal information from the condensation sensor: Frequency _ Duty Cycle _ Voltage _ What is the observed condensation sensor values on status requests? While observing status requests, place a cup of hot water near the condensation sensor and observe the new signal information. What happens to the value on Status requests? _ What other observation can be made when the mist sensor signal changes? Is there a test plan available for the mist sensor? What is the special tool # used to install the condensation sensor? E60 Climate Control Solar Sensor The solar sensor is located in the center of the dash¬ board to the right of the center speaker grill. The solar sensor operation is identical to the past models such as E65/E66. As on previous models, the solar sensor signals will influence blower output, air stratification and ventila¬ tion flap operation. AUC-2 Sensor The AUC-2 sensor is located on the cooling fan housing at the top. The sensor operation is identical to the E65. The AUC-2 sensor will signal the IHKA to activate recirculation mode when the sensor detects oxidizable gases such as hydrocarbons, carbon monoxide and nitrogen oxides. CID and Controller AUC-2 Sensor The CID and Controller are used for air distribution adjustments, air stratification and for the parked car ventilation features. The air volume for face vent, foot well and defrost can be adjusted independently for the driver and passenger. 1 j 2 3 ozm 02 1. Air volume, defrost 2. Air volume, face vent 3. Air volume, footwell E60 Climate Control Components Located on IHKA Housing 1. Heater Core Temperature Sensor (RH) 2. Stepper Motor, right footwell 3. Stepper Motor, fresh air/recirc air (RH) 4. Stepper Motor, right side ventilation 5. Stepper Motor, air stratification 6. Stepper Motor, rear compartment (center) 7. Stepper Motor, left side ventilation 8. Stepper Motor, fresh air/recirc air (LH) 9. Evaporator Temperature Sensor 10. Stepper Motor, defrost 11. Stepper Motor, left footwell 12. Heater Core Temperature Sensor (LH) Stepper Motors These stepper motors are MUX5 motors (multiplex motor type 5). There are 9 stepper motors used on the E60 IHKA system. All motors are connected to the LIN Bus. The LIN bus circuit consists of three wires, power (B+), ground and the LIN bus signal wire. The stepper motors for the fresh air/recirculating air flaps are designed as high speed motors. vSajKMqjE This system does not use any bowden cables for flap actuation. E60 Climate Control Blower Motor with Blower Controller The blower motor for generating the necessary air volume is fitted in the heater air conditioner. The blower features a symmetrical design and is equipped with two dual suction action radial fan wheels (four flute blower). The blower controller is mounted directly on the housing of the blower motor. The controller features self diagnosis capabilities and is actuated by the con¬ trol unit in the IHKA panel via the LIN bus. It is pos¬ sible to replace the fan motor without the need to dis¬ assemble the instrument panel. Temperature Sensors All temperature sensors used in the E60 IHKA system are NTC type. The E60 IHKA system uses the following temperature sensor inputs: • Interior Temperature Sensor - Located in the IHKA control panel faceplate. The IHKA panel also incorporates a sensor fan which is removable and can be replaced as a separate part. The temperature sensor itself is not replaceable separately. • Ambient (outside) Temperature - The ambient temperature sensor is an NTC sensor which is an input to the instrument cluster. The temperature signal is then sent to the IHKA control module via K-CAN. • Two Heater Core Temperature Sensors - The Heater core temperature sensors can be accessed by removing the CID. The temperature sensors are used to monitor the temperature of the left and right side of the heat exchanger. • Evaporator Temperature Sensor - As on previous models, the evaporator temp sensor is used to prevent evaporator freeze-up. • Face Vent Temperature Sensor - There is one face vent temperature sensor located behind the center face vent. It can be accessed by removing the center face vent, IHKA panel and M-ASK. I 2) 1. Blower controller on blower motor E60 Climate Control Workshop Exercise - LIN Bus List the LIN bus connections (Pin # and connector #) at the IHKA control panel: How many LIN bus connection are there at the IHKA panel? Ground the LIN bus signal wire to the blower controller and record observations: Ground the LIN bus signal wire to the stepper motors and record observations: Notes: E60 Climate Control Component Layout 1. Heater core 2. Evaporator core 3. Blower motor controller 4. Blower motor with housing 5. Expansion Valve E60 Climate Control A/C System Component Layout 1. Radiator 2. A/C Compressor 3. Pressure Sensor 4. Service Connection, 5. IHKA Control Panel 6. Heater/AC Housing 7. Water Valve(s) 8. Auxiliary Water Pump 9. Electric Fan 10. Condenser with Dryer A/C Compressor The A/C compressor in the E60 is identical to the clutchless design introduced on the E65/E66 E60 Climate Control Pressure Sensor The pressure sensor is located in the high side pres¬ sure line between the condenser and the evapora¬ tor near the passenger side strut tower. The sensor sends the IHKA control module an ana¬ log signal between 0.4V and 4.6V as a representa¬ tion of system pressure. The 5V supply is provided by the IHKA control mod¬ ule and the sensor current consumption is < 20mA. Water Valves The water valves on the E60 are of the same design as used on previous models. The valves are nor¬ mally sprung open and are pulse width modulated by the IHKA control unit. The IHKA control unit con¬ trols the valves via the B+ circuit, both valves are grounded at a common location. The valves are powered closed by the IHKA module when full cool¬ ing is needed. They are located on the driver’s side strut tower. Auxiliary Water Pump (ZWP) The auxiliary water pump is mounted on the drivers side frame rail near the alternator. The ZWP enhances hot water flow through the heater core particularly when the engine is idling. E60 Climate Control Microfilter System An activated carbon microfilter is fitted on the E60 IHKA system. Microfilter replacement intervals are based on CBS data. Based on operating time and operating parameters, the “filter condition detection” system determines the load status of the filter without additional sensors. In this way, due dates for filter service are calculated together with other wear¬ registering components. After changing the filter, the CBS system must be reset via the instrument cluster or in the tester (DISplus/GT-1). The following are recorded parameters for determining the filter load status: • Blower Voltage • Road Speed • Outside Temperature • Rain Intensity • Sun Intensity • Day Counter • Mileage Q2Sm_ 02 1. Microfilter Compartment 3. Bulkhead/filtered air duct seal 2. Water Drain 4. Filtered air duct E60 Climate Control Workshop Hints AC Housing Installation Particular care must be taken when mounting the air conditioner on the inner side of the bulkhead to ensure the seals are fitted correctly. The butyl beading on the seal provides a tight seal with the bulkhead. When assembling, make sure the repair instructions are fol¬ lowed precisely. Failure to adhere to the procedure could result in interior water leakage. 1. Bulkhead/filtered air duct seal 2. Aperture for expansion valve 3. Aperture for water connections, heating circuit 4. Aperture for air conditioner and screw mounting points and seals 1. Intake/filter compartment seal 2. Threaded connection, filtered air duct 3. Filtered air duct In the same way as for the seals, particular care must be taken when installing the filtered air duct and the filter compartment covers. Secondary (unfiltered) air may be drawn in from the engine compartment if the seal between the duct components is defective. Initial Operation After Replacing the Refrigerant Compressor (Compressor Run-in) In order to prevent compressor damage after installation, the compressor run-in procedure must be performed. The “Run-in” procedure is identical to E65/E66 and can be found in the service functions menu. E60 Climate Control