Table of Contents E92 Complete Vehicle Workbook Subject Page Introduction.5 Body.6 Walk Around .7 CAS3 EWS4.9 Replacement of Control Units .9 Start Enable .11 Time-based Query .11 Key Memory Expansion in CAS3 .11 Energy Management..13 Advanced Power Management APM.13 Terminal Shut-down Identification .14 Electric load shut-down terminal 30g relay.14 Electric load shut-down terminal 30g_f relay .14 Control Units Connected to Terminal 30 .15 Control units connected to terminal R and 15 .15 Seat Belt Extender .19 System Function .19 System Components .20 Seat Belt Extender Controller.20 Initial Print Date: 10/06 Revision Date: 12/06 Table of Contents Subject Page Seat Belt Extender Motor.20 Blocking Detection.22 Diagnosis .25 Coding .25 Exterior Lighting .29 Welcome Lights.29 Daytime Running Lights.29 Light distribution in headlight for daytime runninglight function .30 Deactivating the daytime running lights function .30 Cornering Lights .31 Switch-on conditions forthe cornering lights .34 Switch-off conditions forthe cornering lights .34 Bus Systems .37 Changes in PT-CAN .37 Changes in MOST.37 Changes in K-CAN .37 Changes in LIN-bus .37 E92 Bus System Overview .38 Table of Contents Subject Page 4 E92 Complete Vehicle Workbook Complete Vehicle Workbook Model: E92 Production: From Start of Production OBJECTIVES After completion of this module you will be able to: • Identify the E92 coupe body styling cues and fabrication techniques. • Describe the operation of the new EWS4 Immobilizer system. • Identify the changes made to the vehicle energy management system. • Describe the operation of the E92 Seat Belt Extender System. • Describe the different lighting functions found on the E92 Coupe. • Identify the additional systems/modules in the vehicle Bus System. Introduction The third generation of the 3 Series Coupes is here, developed on the basis of the E90 and honoring the long line of BMW coupes of the past with its sporty new 2 door body styling. The use of lighter and stronger body components, more powerful engines and enhanced features make this coupe stand out among its competi¬ tion. The 335i will replace the 330i and it gets the new N54 twin turbo, direct injected engine with 300hp and 300ft/lb. The 328i will replace the 325i and will come with a further developed N52 engine with increased horse powerto 230hp and torque to 200ft/lb.There is also a N51 SULEV engine that will be available only with automatic transmission. •The front fenders and rocker panel covers are fabricated from Thermo-Plastic material to promote weight distribution. • Upgraded brakes on 335i: front disc diameter increased from 13.0 (330i)to 13.7 in. • New lighting features like Bi-Xenon headlamp standard the addition of Welcome lights (a BMW first) that greet the driver as the vehicle is opened. Adaptive headlights with Cornering lights help illuminate around the dark corners as well as Daytime running lights with corona rings promote daytime vehicle visibility. • Vehicle security is enhance with the use of EWS4 immobilizer. •The use of a Seat Belt Extender and the Easy-Entry (rear com¬ partment) functions promote occupant comfort. •TheTire Pressure Monitoring System Has been updated to comply with the most recent US regulations. • IBOC (In Band on Channel) digital radio has been added. E92 Complete Vehicle Workbook 5 6 E92 Complete Vehicle Workbook Body Index Explanation Index Explanation 1 DX54, DX56 Steel 6 HC600,HD680 Steel 2 HC 180,HX180 Steel 7 Docol 1000,22Mn B5 Steel 3 HC220,HX220 Steel 8 Plastic 4 HC300, HX 300 Steel 9 Other metals materials 5 HC 400 Steel External dimensions (mm) E92 E46/2 Vehicle length 4580 4448 Overall vehicle width 1782 1757 Vehicle height, unladen 1395 1369 Wheelbase 2760 2725 Overhang front 771 774 Overhang rear 1049 1049 Track width front 1500 1474 Track width rear 1513 1486 Wheels /tires 225/45 R17 205/55 R16 Walk Around E92 Exterior Lets walk around the E92 and try to identify the visible features that BMW has implemented here that differ from the E90 and from past 3 Series coupes. E92 Complete Vehicle Workbook 7 8 E92 Complete Vehicle Workbook Workshop Exercise - Walk Around Body Let's walk around the E92 and try to identify the visible features that BMW has implemented here that differ from the E 90 and from past 3 Series coupes. What distinctive features do you notice in the interior? What body styling features are noticed immediately? Why did BMW incorporate a seat belt extender in the design of the E92 interior? Which body components are made from Thermo-plastic? How is the exhaust different from the E90? What is the difference between the normal seat adjustment speed and the Easy-Entry seat adjustment speed? Open the door and inspect the interior. How many passengers does the E92 accommodate? CAS3 EWS4 With the launch of the E92, we have a new electronic vehicle immobilizer. The Car Access System 3 with the new generation of electronic vehicle immobilizer EWS4 was introduced in E92 vehicles with the N52/N54 gasoline engine. The vehicle immobilizer consists of the ID transmitter which is identical forthe vehicle and therefore to CAS3. CAS3 exchanges data with the DM E via the CAS-bus and cancels the vehicle immobilization function. The EWS4 is a new development and uses a new, modern encryption method. A 128 bit long secret key is assigned to each vehicle and stored in the BMW database. This secret key is known only to BMW.The secret key is pro¬ grammed and locked in the CAS and in the DM E control unit. Once entered in the control unit, the secret key can no longer be changed or deleted. This therefore means that each control unit is assigned to a specific vehicle. One control unit in the system sends an encrypted code to anoth¬ er control unit forthe purpose of checking the authorization. In turn, this control unit sends back a corresponding code. Replacement of Control Units The procedure described below must be followed in orderto replace a defective control unit (CAS/DM E).The required control unit is ordered together with the necessary vehicle data (VIN) from the Parts Department. A new "blank" control unit is programmed with the corresponding program data forthe vehicle and the secret key from the BMW database, locked and sent to the dealer. Note: No alignment procedure is necessary as in earlier E WS systems. S ince the control units are assigned to the specific vehicle, replacement with a unit from anothervehicle is not possible. The electronic vehicle immobilizer consists of several compo¬ nents. In the E92 these components are the CAS3 and the DM E M SV80/M SD80. The CAS3 contains the software forthe EWS4 and, with corre¬ sponding identification of the ID transmitter, the enable of terminal R, 15 and 50 forthe starter. The enable forthe ignition and fuel injection systems is done by the DME. Both control units are connected by the K-CAN, the junction box serving as the gateway and the PT-CAN. Data is also exchanged on the CAS-bus.The data is always transmitted parallel via both bus systems. The signals that arrive first are used. The DME activates the fuel injection relay for the power supply of the fuel injectors. The DM E features a direct line to the starter relay in the CAS in orderto initiate the start procedure and, if nec¬ essary, to terminate it, in the event of a PT-CAN fault or a faulty signal, like no engine speed signal. The new control unit is installed in the vehicle and started. E92 Complete Vehicle Workbook 9 CAS3 with EWS4 Circuit Diagram 10 E92 Complete Vehicle Workbook 1 ) V J 2 J Kl. 50L CAS Bus A S Start Kl. 15 Wlip Kl. 15 Kl, 15 Kl, 30E Kl. 30q Kl. R Kl. R KI.30L Index Explanation Index Explanation 1 Car access system with EWS4 5 J unction box 2 Starter 6 Battery 3 Injection relay 7 S tart/S top button 4 Digital motor electronics MSV80/MSV80 8 Holder Start Enable The start procedure is enabled by means of a special request and response procedure known as challenge-response.The DME gen¬ erates a random number in a random generator and sends it as the challenge to the CAS .The CAS and the DM E contain the same secret key and both control units use the same calculation algo¬ rithm. The CAS now calculates the result from the received random number, the secret key and the algorithm. The result is sent as the CAS response to the DME. During this time, the DM E now calcu¬ lates the same random number with the secret key and the algo¬ rithm and already knows the result. The response of the CAS is compared with the result of the DME. Start is enabled if the result is identical. Time-based Query As from terminal R orterminal 15 ON, a query (challenge- response) is performed as long as the engine is not yet running. A fault code is entered in the CAS if no DM E response is received approximately 10 seconds afterthe start of the query or if the response deviates. Key Memory Expansion in CAS3 The data memory of the remote key in vehicles equipped with CAS3 is increased from 256 bytes to 512 bytes. The benefit of this key memory expansion forthe customer is that more accurate information on the time and scope of the workshop visit can be provided as part of the service acceptance procedure. The following system network information can be read out from the identification transmitter with the key reader in the service work¬ shop. Data Previous New Remark Mileage reading X Current mileage (km) reading of vehicle Vehicle Identification (VIN) X Key number X N umber of identification transmitter Service- relevant CC message X DTC Information (fault code memory) X As from SAM 25, the DTC data is indicated and linked to possible measures in PUMA NAVI-DVD version X Data status of NAVI-DVD Engine oil X Information on topping up or drain¬ ing the engine oil (overfilling) Battery condition X Change status of the battery in the vehicle Integration stages X l-stage that left the factory, l-stage last programmed and l-stage currently available in the dealership network E92 Complete Vehicle Workbook 11 CAS3 L 12 E92 Complete Vehicle Workbook 123466 637654 lr’TJ Energy Management As in the current models, an energy management system is also used on the BMW 3 Series Coupe to ensure a balanced energy supply in the vehicle. The energy management functions are inte¬ grated in the power management system that is implemented in the form of software in the Engine Control Module (ECM/DME). The power management, the components and the various func¬ tions of the system differ depending on the equipment configura¬ tion of the vehicle. Two energy management control systems are installed: • Basic Power Management BPM • Advanced Power Management APM. On vehicles equipped with advanced power management modifications have been made in the terminal shut-down system through relay 30g and 30g_f. Advanced Power Management APM Advanced power management APM is used on vehicles featuring certain options. The advanced power management has been expanded by the intelligent battery sensor IBS.The IBS provides precise informa¬ tion on the condition of the battery. For example, the battery tem¬ perature is no longer calculated but measured directly by the IBS. In addition to the change in the idle speed and the specified charging voltage target value, the system includes the following functions that differ from the BPM. • Electric load reduction • Electric load shut-down • Systems network diagnosis • Battery diagnosis. Index Explanation 1 Advanced power management 2 Idle speed boost 3 Combustion engine 4 Changing voltage target value 5 Alternator 6 Electric load reduction 7 Electric loads 8 Electric system and battery diagnosis 9 BMW diagnostic system 10 Intelligent battery sensor 11 Battery data E92 Complete Vehicle Workbook 13 14 E92 Complete Vehicle Workbook Terminal Shut-down Identification Note: To provide clear identification of the terminal shut¬ down function, the control units are identified with colored triangles. The identification and assignment to the individual terminals is shown in the illustration on page 18. Electric load shut-down terminal 30g relay Time-dependent shut-down The E92 is equipped with a terminal 30g relay for switching off the power supply to the majority of the control units. Most convenient electric loads such as the radio are switched off after 30 minutes by terminal 30g in orderto maintain the starting capability of the battery. Power to the terminal 30g relay is activated by the car access sys¬ tem for an extra 60 minutes if a telephone or auxiliary heating sys¬ tem is installed in the vehicle. Electric load shut-down terminal 30g_f relay Fault-dependent shut-down The terminal 30g_f relay is installed in the junction box of the E92 only when one of the following equipment options is ordered: • M-Audio system controller(M-ASK) • Car communication computer • Telephone (US vehicles) The terminal 30g_f relay is a bi-stable relay and is always in the ON state under normal conditions. It switches off the connected elec¬ tric loads only in the case of fault. The switching status is retained even when no power is applied. The terminal 30g_f relay is activated by the junction box control unit and switches off the connected electric loads if a fault occurs. The calculations required for activating the terminal 30g f relay take place in the ECM/DM E and in the junction box. The following activities are monitored in the junction box control unit: • Unauthorized wake-ups within the bus system • Sleep mode preventers (control units that constantly keep the bus systems active) Note: The battery values are constantly read out and evaluated in the Engine Control Module (ECM/DME). The relay is also switched off when the starting capa¬ bility limit of the vehicle battery is reached. Control Units Connected to Terminal 30 Reasons for remaining connected to terminal 30. Note: Due to theirfunctionality, some control units can not be switched off. Control unit Explanation J B Because of the master functionality FRM Because of the legally required hazard warning function FZD- Because ofthe connection ofthe DWA components SINE Because ofthe DWA functionality USIS Because ofthe vehicle interior monitoring CAS Because ofthe "Unlock vehicle" function CA Because ofthe "Unlock vehicle" function SMFA Because ofthe power draw ofthe seat heating SMBF Because ofthe high power draw ofthe seat heating SZL Because ofthe steering angle sensor whose data is stored only volatile DME Because ofthe power management KOMBI Because ofthe data saving function (mph reading) Control units connected to terminal R and 15 Control units that have only one functionality connected to terminal R or 15 can be switched off directly. • The M RS control unit is connected to terminal R. • The high beam assistant and park distance control are connected to terminal 15 E92 Complete Vehicle Workbook 15 E92 Bus System Overview - Control Units 16 E92 Complete Vehicle Workbook ASP 2x SBFA ........ • • • • SMC • • • •••# 2x 9 GBFA i GBBF ^FRM 0 ■HP I ^Kombi 0 °3 con k SMFA SINE RLS USIS • •A , V V V.^ZD- wSMBF 1=1 TPMS J o MRS5 ^PDC 0 © 8x (4x) k CAS2 b JB RAD2 ( ccc CDC TPM-SEN 4x TOP-HIFI OC3 •••••••• Pi TCU |HKA . CA l— - 1 • •••# TAGE 2x FS SDARS —S IBOC k KL 30 KL 30g k KL 30g-f k KL R k KL 15 SZL ' DSC LWS DSC-SEN AL I gsg LDM —| ACC I QLT EWP o IBS • ®o • •o 14=1 DME EKP ft GS ^ Classroom Exercise - List the controllers undertheircorrect power source. 1. Which controllers are connected to KL 30? 2. Which controllers are connected to KL 30g? 3. Which controllers are connected to KL 30g_f? 4. Which controllers are connected to KL R? 5. Which controllers are connected to KL 15? E92 Complete Vehicle Workbook 17 18 E92 Complete Vehicle Workbook Legend forE92 Bus System Overview - Control Units Index Explanation Index Explanation ACC Active cruise control J B J unction box AL Active steering system KOMBI Instrument cluster ASP Outside mirror LDM Longitudinal dynamic management CA Comfort access LWS Steering angle sensor CAS Car access system M-ASK Multi-audio system controller CCC Car communication computer MRS Multiple restraint system CDC CD changer OC3 Seat occupancy detection mat C ID Central information display PDC Park distance control CON Controller QLT Quality, level, temp, oil sensor DM E Digital motor electronics RAD Radio 1, radio 2 DSC Dynamic stability control RLS Rain/driving light sensor DSC- Sen DSC Sensor SB FA Driver's door switch cluster DWA Anti-theft alarm system SDARS Satellite tuner DXC Dynamic traction control mm Emergency current siren w/tilt alarm sensor EGS Electronic transmission control unit SMBF Passenger's seat module EKP Electric fuel pump control unit SMC Stepper motor controller ELV Electric steering lock SMFA Driver's seat module EWP Electric water pump TONS Temperature, oil level sensor FRM Footwell module Top-HiFi Top-HiFi amplifier FS Most direct access TPMS Tire pressure monitoring system FZD Rooffunction center TPM-sen TPMS sensorsX4 GBBF Passenger's seat belt extender module ULF Universal charging and hands-free facility GBFA Driver's seat belt extender module USIS U Itrasonic passenger compartment protection IBOC In band on channel (digital radio) VGSG Transfer box control unit IBS Intelligent battery sensor ZH Electric auxiliary heater based on PTC principle IHKA Automatic climate control SZL Steering column switch cluster TCU Telematics control unit TAGE Electric outer door handle module Seat Belt Extender In line with its concept and design, the E92 Coupe features large doors. As a result, the B-pillarwith the reversal point forthe seat belt is located further towards the rear relative to the seat position. This makes the seat belt difficult to reach forthe driver orfront passenger. Forthis reason, an electrically operated seat belt extender is installed on the E92.The seatbelt extender extends and moves the seat belt out of its rest position at the B-pillarby approximately 25 cm in the direction of the driver and front passenger. This makes it considerably easier and more convenient for the driver and front passenger to fasten the seat belt. Note: The side curtain airbags are now riveted, on the E92. Refer to the most current repair procedure information found in TIS. System Function The seatbelt extender system essentially consists of the footwell module with the masterfunctionality and the two seat belt exten¬ der controllers connected via the UN-BUS. The footwell module receives the terminal status from the car access system via the K-CAN. The footwell module receives fur¬ ther important information from the airbag control unit via the K- CAN.The information contains the status of the seat belt contacts and of the seat occupancy detection facility on the front passen¬ ger seat. The footwell module evaluates this information together with the determined status of the door contacts and decides whetherthe seat belt extenders are extended or retracted. The footwell module informs the seat belt controllers of this deci¬ sion via the LIN-bus. The corresponding seat belt controller activates the seat belt extender motor and extends or retracts the toothed rack of the seat belt extender. The seat belt controller evaluates the Hall sig¬ nals forthe speed and end position and informs the footwell mod¬ ule of the position. The functions of the seat belt extender are uniform throughout the world. Only a difference is made between the driver and front pas¬ senger in terms of functionality. The driver and passenger doors must be closed the key in the ignition orthe ignition on forthe seat belt extenders to operate. E92 Complete Vehicle Workbook 19 20 E92 Complete Vehicle Workbook System Components The system consists of the following components: • Controller for driver's seat belt extender GB FA • Controllerfor passenger's seat belt extender GBBF • Driver's seat belt extender - Seatbelt extender motor - Hall sensor - End position sensor • Front passenger's seat belt extender - Seatbelt extender motor - Hall sensor - End position sensor • Footwell module with sensors and LIN-bus connection • J unction boxfor power supply • Airbag control unit for sensor information Seat Belt Extender Controller The universal control unit that is also used in other systems is used as the controller for the seat belt extender. The controller for the seat belt extenders is connected via the LIN-bus to the footwell module.This LIN-bus has a data rate of 19.2 Kbit/s. The controllers for the driver/passenger seat belt extenders are identical and differ in terms of their ground coding. The control unit is connected by means of three plugs. Plug con¬ nector (1) is used forthe power supply and ground coding. This plug connector also features the LIN-bus connection. Plug connector (2) connects the end position sensor. Plug connec¬ tor (3) connects the motor and the speed Hall sensor. (See graphic on the following page.) The controller is located behind the side trim panel along with the seatbelt extender. The controller is constantly monitoring the extension and retraction of the seatbelt extender and it's designed to shutdown in the event of overvoltage (16V) or under voltage (9V) condition. S eat B elt Extender M otor The seat belt extender motor is a DC motor. The motor is connect¬ ed to the toothed rack by means of a step-down gear mechanism. A Hall sensor, mounted on the seat belt extender motor measures motor's speed. A Hall signal is generated for each revolution of the motor. Based on the number of Hall signals, the control unit always knows the exact position of the seat belt extender. The Hall pulses are added as the seat belt extender extends and the motor is switched off on reaching the maximum number of pulses. This represents the "extended" end position. When the seat belt extender is retracted, power is applied to the motor until the magnet in the toothed rack reaches the end posi¬ tion sensor.The system is initialized by reaching the end position. Initialization is performed every time the seat belt is retracted. Seat Belt Extender and Controller 1 ) 2 3.4 v_/ v_/ vy Inde X Explanation Inde X Explanation 1 End position sensor 4 Toothed rack 2 Electric motor 5 Seat belt guide with chrome cover 3 Magnetforend position sensor Note: Only the chrome cover orthe complete seatbelt extender can be replaced for repair purposes. Index Explanation 1 Plug connection to vehicle system network 2 Plug connection to end position switch 3 Plug connection to drive unit E92 Complete Vehicle Workbook 21 22 E92 Complete Vehicle Workbook Blocking Detection If, during extension, the Hall signals are not received for 250ms, this situation is interpreted as blocking of the extender and the motor is switched off. The seat belt extender motor is reversed and the toothed rack retracted. The motor is driven for 1 second if the toothed rack is blocked. This procedure is repeated up to three times. The motor is then no longer activated. A renewed attempt to drive the motor is made only on reactivation of the system (door contact and terminal R). The system must be checked by a BMW dealer workshop if the system is actually blocked mechanically. Extend Conditions Driver's Extender Passenger's Extender Terminal R* x x Terminal 15* x x Seat belt contact open x x Door contact detects closed state x x Seat occupancy** x ID transmitter in the vehicle with comfort access x x * Depending on when the doorwas closed. **The passenger seat belt extender extends at terminal R after 10 seconds regardless of whetherthe seat is occupied or not. Retract C onditions Driver's Extender Passenger's Extender Seat belt contact closed x x Door contact detects opened state x x Driving speeds above 7kph x x Seat belt extender extended longer that 60 sec. x x Seat detected as not occupied x 30 sec. after switching from terminal R x x Mechanical blocking x x E92 Complete Vehicle Workbook 23 24 E92 Complete Vehicle Workbook Seat Belt Extender Circuit Diagram 3 > n o^o Q. fD S < E- £D Q. 5' (2 flj flj n 3- □ fD (Q C 3 Z fD O' o W 3- Ff | to' (D 8 S’ IT fD "O O gj Id g; 2 fD ^ 3" fD flj rt a fD % & a fD i/i i/i rt 17 _ fD ri- C 3 l/l fD n fD O 3 c or' 3 n O a fD a •< Q. ZT 3 2, 9 - § fD fD l/l IL> -5 =■ /"> —' i/i S’ 13 —■ — 3 D) FF fD fD to n fD fD fD fD E92 Complete Vehicle Workbook 25 Seat Belt Extender Circuit Diagram Legend 26 E92 Complete Vehicle Workbook Workshop Exercise - Seat Belt Extender Diagnosis Work Sheet Using an instructor designated vehicle, perform complete short test on vehicle. Proceed with diagnosis based on complaint listed below. Complete worksheet using proper format regarding, "Complaint/Cause and Correction". Vehicle: Chassis #: Production Date: Complaint: Cause: Correction: Workshop Exercise - Seat Belt Extender Diagnosis £ Using an instructor designated vehicle, perform complete short test on vehicle. Proceed with diagnosis based on complaint listed below. Complete worksheet using proper format regarding, "Complaint/Cause and Correction". What relevant faults are there stored after performing the Short What Component Activation Requests are there available under Test? Control M odule Functions? WhatTest Plans are available under Function Selection? Using the Inputs/Processing/Outputs principle fill out the following table. WhatTest Plans are available under Symptoms Path? Inputs Processing Outputs What Status Requests are there available under Control Module What portion of this principle is operating properly? Functions? E92 Complete Vehicle Workbook 27 28 E92 Complete Vehicle Workbook Workshop Exercise - Seat Belt Extender Diagnosis What portion of this principle is notoperating properly? What is the cause of the inoperative seat belt extender? Note: Please fill outthe Diagnosis Work Sheet that outlines the Complaint/Cause/Correction on the previous page. How many punches would be required to complete this work order properly following approved BMW procedure? Exterior Lighting Compared to the E90, several changes have been made in the exterior lighting system of the E92: • The E92 is equipped with standard bi-xenon headlights. • Adaptive headlights with cornering lights are available as an option. • Standard daytime running light function, realized by the parking light corona rings. Welcome Lights The welcome lights are also a new function. The interior lights are activated for 20 sec. when the vehicle is unlocked but also the parking light corona rings, the tail lights, license plate lights,the doorhandle area lights and side markers. Note: The welcome lights operate only in automatic and are not activated when the light switch is in theO position. This provides the customer with the option of deactivating the system if he/she does not wantthis function. Daytime Running Lights The daytime running lights function is realized by the two corona rings in the headlights and activation of the tail lights and license plate lights. The corona rings light brighter during the day to realize the daytime running lights function. The brightness of the coro¬ na rings is reduced to that of the side lights when the low beam headlight is switched on by the rain/light sensor or by switch position 2. Note: Non serviceable LEDs are used for the front headlamp side marker and on the tail lamp, LEDs are integrated to fiberoptic strips to realize the rear parking light. E92 Complete Vehicle Workbook 29 30 E92 Complete Vehicle Workbook The corona rings are always switched on at terminal 15 ON.The corona rings are activated pulse width-modulated. The pulse width modulation ensures the daytime running lights and parking light function can be realized with one lamp bulb. Light distribution in headlight fordaytime running lightfunction The daytime running light uses the same corona rings as the side lights. Both corona rings feature a common H8 bulb.The H8 lamp bulb is activated differently depending on the side light or daytime running light function.The inner ring is illuminated from the rear by reflectors. The outer rings around the headlight are supplied via fiberoptic glass rods.The lightfromthe H8 bulb is directed by mir¬ rors into the fiberoptic glass rods. Deactivating the daytime running lights function The function can be deactivated if required by the customer. On vehicles equipped with a central information display, the function can be deactivated in the "Light settings" menu.The function is deactivated in the instrument cluster on vehicles with no CID. Index Explanation 1 Bi-xenon lamp 2 H8 bulb for side light and daytime running light 3 H3 bulb for cornering light 4 Mirror for cornering light Side View of Headlamp Assembly Cornering Lights Cornering lights will be introduced forthe first time with the launch of the E92.They represent an expansion of the functions of the adaptive headlights. In addition to the adaptive headlight, the cor¬ nering light illuminates the area in front of and to the side the vehi¬ cle. The cornering light is integrated in the headlight where the previ¬ ous high beam lamp was located.The light beam is reflected to the side bythe special shape ofthe deflectorand the position of the H3 bulb. The cornering light cannot be ordered as a separate option as it is an added function of Adaptive Headlights (SA 524) The special arrangement ofthe mirrorsurface in the reflectorand the special shape ofthe lens deflect the light beams to the side while preventing forward dazzle. The cornering lights illuminate when the respective turn signal is operated and orthe steering angle sensor indicates a turn below 40mph. The angle ofthe steering wheel to activate the cornering light dif¬ fers depending on the type of steering system used (power steer¬ ing or active steering), steering gear and steering gear ratio. The steering wheel lock to activate the cornering light when the vehicle is stationary is between approximately 40° and 75° depending on the type of steering. Flash to pass does not affect the cornering light nor does the haz¬ ard function activate it. Note: Both cornering lights come on when the reverse gear is selected to help illuminate the way. E92 Complete Vehicle Workbook 31 32 E92 Complete Vehicle Workbook Bi-xenon Headlamp Diagram Dynamic stability control E92 Complete Vehicle Workbook 33 34 E92 Complete Vehicle Workbook Switch-on conditions forthe cornering lights The corresponding cornering lights will illuminate depending on the following criteria: • The selection of the turn signal below 65kph/40mph • Steering angle input while driving below 65kph/40mph • With vehicle stationary and engine running a steering angle of 40° to 70°, depending on the steering system • With reverse gear engaged both cornering light will illuminate Switch-off conditions forthe cornering lights The cornering lights switches off in the following conditions: • Adaptive headlight off • Direction indicator off • Directional constantly on above 40kph/25mph • Steering angle is reduced (by5°-10° after switch-on condi¬ tion with vehicle stationary) • Steering angle increased while driving above 70kph/43mph • While drifting (Steering lock and yaw rate in opposite direc¬ tions) • While turning at a traffic light there is a 4 sec time out • Headlight temperature too high (headlight protection) • Reverse gear disengaged Workshop Exercise - Headlamp Functions Using an instructor assigned vehicle, Inspect headlamp assemblies and Identify the following functions. Open the vehicle with remote and list all the lights that come on. What do we call this lighting function? Turn the light switch to position 1 (parking lights) and verify operation. Which of the parking lamps cannot be serviced with out replacing the lamp assembly? With the light switch in Automatic position turn on Left side turn signal, then the Right turn signal and describe what happens? With the Engine OFF put the gear selector in the reverse position. Describe what happens at the headlamps. Return the gear selector to the Park/Neutral position and put the headlight switch in the position 2. Describe which lamps come on. Apply the Flash to Pass function. Describe which lights are used to realize the Flash to Pass. Apply the High Beam function. Describe which lights are used to realize the High Beam function. E92 Complete Vehicle Workbook 35 36 E92 Complete Vehicle Workbook Workshop Exercise - Headlamp Functions Fill in the individual lamp/function. Bus Systems With the adoption of the bus systems from the E90 with the junc¬ tion box as the gateway and the footwell module as a further con¬ trol unit with many functions, the system overview of the bus sys¬ tems are, to a large extent identical. The E90/E92 bus systems differ only slightly by the addition of new control units. The following changes have been made in the various bus systems: Changes in PT-CAN The transfer case control unit is installed in vehicles equipped with the xDrive all-wheel drive system option.The DSC is replaced by the DXC.The DXC performs the functions of the DSC and has been expanded to include additional all-wheel drive functions. Changes in MOST IBOC (In-Band On-Channel), a terrestrial digital radio, has been newly added Changes in K-CAN Further exterior lighting functions have been implemented in the footwell module.These functions include : • Daytime driving lights • Welcome light • Cornering light on vehicles with active headlight The tire pressure monitoring system TPM S replaces the tire fail¬ ure indicator RPA to conform to US legal requirements. The EWS 4 has been implemented in the CAS 3 on gasoline engine vehicles. A 4-channel PDC forthe rear is offered in the E92. There is no PDC button in the center console. A new addition is the front passenger seat module SMBF for eval¬ uating the Hall sensor of the seat forward/backward adjustment facility on vehicles with electrically adjustable seats forthe rear compartment easy entry function. Changes in LIN-bus New features in the LIN-bus include the two control units forthe driver and front passenger seat belt extender. Note: There are no changes in the F-C AN system northe Bit-serial Data interface (BSD). E92 Complete Vehicle Workbook 37 38 E92 Complete Vehicle Workbook E92 Bus System Overview ASP 2x SBFA •••oQ •• SMC 2x GBBF FRM CID Kombi H CON • • SMBF GBFA • ••. o SMFA CDC • • SINE • •• • • • • USIS • • • • • RLS • • >fzd - TPMS ....ITPM-SEN 4x TOP-HIFI OC3 MRS5 PDC CAS2 • •••#••••• • 8x (4x) lUl^A ■ ini\M ° CA I TAGE 2x TCU D-Bus K-CAN MOST PT-CAN F-CAN K-Bus (protokoll) BSD LIN-Bus Legend for E92 Bus System Overview Index Explanation Index Explanation ACC Active cruise control J B J unction box AL Active steering system KOMBI Instrument cluster ASP Outside mirror LDM Longitudinal dynamic management CA Comfort access LWS Steering angle sensor CAS Car access system M-ASK M ulti-audio system controller CCC Car communication computer MRS M ultiple restraint system CDC CD changer OC3 Seat occupancy detection mat CID Central information display PDC Park distance control CON Controller QLT Quality, level, temp, oil sensor DM E Digital motor electronics RAD Radio 1, radio 2 DSC Dynamic stability control RLS Rain/driving light sensor DSC-Sen DSC Sensor SB FA Driver's door switch cluster DWA Anti-theft alarm system SDARS Satellite tuner DXC Dynamic traction control SINE Emergency current siren w/tilt alarm sensor EGS Electronic transmission control unit SMBF Passenger's seat module EKP Electric fuel pump control unit SMC Stepper motor controller ELV Electric steering lock SMFA Driver's seat module EWP Electric water pump TONS Temperature, oil level sensor FRM Footwell module Top-HiFi Top-HiFi amplifier FS Most direct access TPMS Tire pressure monitoring system FZD Roof function center TPM-sen TPMS sensorsX4 GBBF Passenger's seat belt extender module ULF Universal charging and hands-free facility GBFA Driver's seat belt extender module USIS Ultrasonic passenger compartment protection IBOC In band on channel (digital radio) VGSG Transfer box control unit IBS Intelligent battery sensor ZH Electric auxiliary heater based on PTC principle IHKA Automatic climate control SZL Steering column switch cluster TCU Telematics control unit TAGE Electric outer door handle module E92 Complete Vehicle Workbook 39 40 E92 Complete Vehicle Workbook C lassroom Exercise - Review Questions 1. What vehicle use the N51 engine? 2. How many bulbs in the headlamp assembly are used to realize the the high beam function on the E92? And why? 3. When should the DM E / CAS alignment be performed? And why? 4. Thermo Plastic used in the fabrication which parts ofthe E92 body? 5. What is special about the new key?