BMW 1 Series User manual

Technical Training
E82 / E88
COMPLETE VEHICLE
Reference Manual
The information contained in this manual is not to be resold, bartered, copied or transferred
without the express written consent of BMW of North America, LLC ("BMW NA").

Initial Print Date: 1/08
Table of Contents
Subject Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Exterior Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Interior Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Aerodynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Passive Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Bodyshell Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Undercar View of Strut/sill Concept . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Layout of Components in Luggage Compartment . . . . . . . . . . . . . . . . .12
Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Slide/tilt Moonroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Door and Side Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Chassis Dynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Chassis Dynamic Driving Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Double Pivot Spring Strut Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Rear Axle "HA 5" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Dynamic Driving Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
New DSC Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Bus System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Interface Box (High) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
USB/Audio Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Special Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Special Features of the 135i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
E82 Complete Vehicle
Revision Date: 4/08

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E82 Complete Vehicle
Complete Vehicle
Model: E82
Production: 3/2008
After completion of this module you will be able to:
• Describe the similarities between the E82 and the E9X vehicles
• Describe the construction of the body-shell of the E82
•Identify the features offered in the E82

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E82 Complete Vehicle
Inspired by past 2002 models of the sixties and seventies BMW has designed a vehicle
combining rear-wheel-drive, excellent handling and powerful engines with the stiffest and
lightest bodyshell possible along with accommodations for four. The 1 Series Coupe is
sure to pick up where the 2002 left off.
For those of us that where lucky enough to
ever drive the legendary BMW 2002, the 1
Series inspires feelings of nostalgia. With the
innovations in automotive technology and
safety along with the experience gathered
over the many years of vehicle development,
one can only imagine the car that BMW
would build today in honor of such automo-
tive legacy.
Efficient Dynamic concepts come to life in
the 1 Series with the use of light but rigid
body construction and a sleek aerodynamic
underbody. Dynamic Stability Control and
Dynamic Traction Control have been devel-
oped even further for this car to ensure that
advanced management systems deliver max-
imum power with exceptional handling.
There is no doubt that with this 1 Series,
BMW succeeded in recreating the look, feel
and performance of the sport sedan with a
race car soul, for new drivers to experience
and for enthusiasts to enjoy once again.
Introduction
BMW 2002
The E82 1 Series Coupe

The E82 is being launched in Spring of 2008. The models available are the 128i and
135i. The main difference between the E92 and E82 is in the area of the side sills or
rockers panels. The doors, roof and luggage compartment also differ from the E82, with
noticeable changes in the floor assembly and in the vehicle interior. The front and rear
bumpers have been newly designed for this vehicle.
The 128i will be powered by an N51 Sulev engine or the N52, 230 horsepower inline
6-cylinder 3.0-liter engine that generates 200 lb-ft of torque, the 128i Coupe will feature
Valvetronic, VANOS and aluminum/magnesium block construction.
The 135i Coupe features the N54 twin-turbocharged direct injection 3.0-liter inline six-
cylinder engine, that produces 300 horsepower and an incredible 300 lb-ft of torque from
as low as 1,400 rpm.
Conforming to BMW’s Efficient Dynamics, these vehicles will include the following:
• Light weight but rigid bodyshell.
• Aluminum front axle with lightweight components like hollow anti-roll bars.
• Run Flat Tires as standard equipment.
Exterior Dimensions
In comparison to the E92, the E82 is taller.
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E82 Complete Vehicle
TK07-0339
1423
1427
2660
751
4360
949
976
905

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E82 Complete Vehicle
The E82 compared with the current E92:
Interior Dimensions
Note: A convertible version of the 1 Series, the E88, is also available.
976
905
734
1372
1423
253
1398
1357
External dimensions (mm) E82 E92
Vehicle length 4360 4580
Overall vehicle width 1748 1782
Vehicle height, unladen 1423 1395
Wheelbase 2660 2760
Overhang front 751 771
Overhang rear 949 1049
Track width front 1486 1500
Track width rear 1532 (135i) 1513

The E82 features an intelligent mix of components.
The front body work was inspired by the E9x design and re designed to complement the
E82 styling. The doors were adopted from the European 1 Series. The luggage com-
partment is somewhat shorter than that of the E92. The main differences are to be found
in the side view and silhouette of the vehicles.
All of the steel grades used in this vehicle were featured in the E90 with the aim on
achieving comparable crash results. In addition, the E82 body offers a high level of pas-
sive safety protection.
Aerodynamics
Aerodynamics in combination with 50/50 weight distribution and a rigid body construc-
tion, contributes to outstanding driving characteristics and effective dynamics. The aero-
dynamic styling is complemented by various design components. These include the
front spoiler edge, very smooth underbody pan with specially designed cooling ducts
molded into the bodywork.
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E82 Complete Vehicle
Body
E82 Underbody Pan (front bumper and spoiler view)

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E82 Complete Vehicle
Additionally, the underbody allows a defined flow of air to be directed to components
subjected to greater thermal load with the use of spoiler edges and ram-air ducts.
Passive Safety
The basics for the E82’s bodyshell passive safety are:
• High load-bearing carrier body reinforcements
• Optimum utilization of deformation zones
•Extremely rigid passenger compartment.
The protection of occupants even in the most severe of accidents places high demands
on the structure of the passenger compartment and on the deformation zones at the
front and rear sections of the vehicle.
All external loads acting on the vehicle are absorbed by specially designed load-bearing
reinforcements in the floor assembly, side frame, bulkhead, roof and on luggage compart-
ment partition.
The body structure of the E82 offers occupants maximum safety while optimizing vehicle
weight. The use of high tensile strength steel in large panels complemented by well cal-
culated reinforcements results in a light but rigid and strong bodyshell.
E82 Front Brake Cooling

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E82 Complete Vehicle
In the event of a strong frontal collision, optimum dissipation of forces is achieved by
means of precisely calculated and tested load paths which absorb and distribute the
force of impact onto several of the body components.
The main focus is the development of an optimum balance between front-end deforma-
tion and passenger compartment rigidity, minimizing the forces to the vehicle occupants.
Ideally, in severe collisions this load distribution can channel forces towards the side
opposite the impact, protecting the bulkhead area and the footwell through dynamic
deformation zones at the front. The energy absorption characteristics form the basis for
maintaining the passenger compartment structure and the prerequisite for the successful
adaptation of restraint systems by means of a correspondingly low passenger compart-
ment deceleration.
In addition, an impact-optimized footrest is fitted. In the event of a frontal collision, the
footrest deforms in the area between the driver's foot and the bodyshell. This significantly
reduces how much force is transmitted to the driver's foot.
There are three additional design elements:
• Specially arranged floor components cause impact forces to be transmitted to the
side of the vehicle opposite the impact.
• The doors themselves, a reinforced B-pillar, the seats and the instrument panel
between the A-pillars provide the stability and side structure in combination with
the roof frame.
• The rear deformation zone is made up of two longitudinal sections, the luggage
compartment floor, rear trim panel, the quarter panels integrated in the side frame
and various reinforcements.
Here too, the primary objective is to maintain the protection of the passenger compart-
ment so that even in the event of an offset impacts the doors can still be opened
afterwards.
Even if the vehicle overturns, the passenger compartment safeguards the occupant
space thanks to the heavily reinforced pillars and cross members.

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E82 Complete Vehicle
Bodyshell Construction
IndexExplanation IndexExplanation
1HC180BD, HC180YD, HX180BD 6H400T, HC400TD, HC420LAD
2DC01, DC04, DX54D, DX56D 7HC600C, HD680C
3HC220BD, HC220YD, HX220BD 8Plastics
4HC300BD, HC306LAD, HC300XD 9Other metal materials
5HC380LAD

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E82 Complete Vehicle
Bodyshell Components
IndexExplanation IndexExplanation
1HC180BD, HC180YD, HX180BD 6H400T, HC400TD, HC420LAD
2DC01,DC04, DX54D, DX56D 7HC600C, HD680C
3HC220BD, HC220YD, HX220BD 8Plastics
4HC300BD, HC306LAD, HC300XD 9Other metal materials
5HC380LAD

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E82 Complete Vehicle
Bodyshell Components
IndexExplanation IndexExplanation
1HC180BD, HC180YD, HX180BD 6H400T
,HC400TD, HC420LAD
2DC01, DC04, DX54D, DX56D 7HC600C, HD680C
3HC220BD, HC220YD, HX220BD 8Plastics
4HC300BD, HC306LAD, HC300XD 9Other metal materials
5HC380LAD

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E82 Complete Vehicle
Layout of Components in Luggage Compartment
Index Explanation
11Tension struts
IndexExplanation IndexExplanation
1TCU 3CD changer
2Battery
Undercar View of Strut/sill Concept

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E82 Complete Vehicle
Bumpers
In contrast to the E90, the E82 has new bumper trims of different appearance.
Energy is dissipated through carriers with deforming elements.
• Fulfillment of Institute for Highway Safety (IIHS) low-speed frontal crash at
10 km/h (6 mph).
• Fulfillment of Institute for Highway Safety (IIHS) low-speed side crash at
5 km/h (3 mph) @ a 15% offset.
The 135i is equipped with a trim weight on the rear bumper. This component
contributes to an overall improvement in the overall weight distribution.
Slide/tilt Moonroof
The standard equipment slide/tilt moonroof is constructed in the same way as in the E90.
Only the glass panel is slightly different due to the new roof contour. Removal/installation
and adjustment are identical to the E90.
Door and Side Panels
The inner door panels are newly designed with an integrated map pocket and a new door
opening handle.
Seats
The rear bench seat accommodates two passengers with through-loading system.
The rear seat backs fold down flat to enhance cargo space and for easy loading of the
luggage compartment.

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E82 Complete Vehicle
Chassis Dynamic Driving Systems
The E82 has many features in common with the E9X as far as the chassis and dynamic
driving systems. The double pivot spring strut front axle design of the 3, 5, 7 and 8
Series vehicles will now be used on the 1 Series. With the exception of the 135i sport
tuned version the front and rear suspensions are inspired by the E90 design.
Double Pivot Spring Strut Front Axle
The double pivot system establishes a geometrical “axis” formed by the suspension
links, creating one upper and two lower pivot points. Two lower pivot points (double
pivot) established by the control arm and tension strut create an “imaginary” pivot point,
that is extended further out on the wheel carrier. This design allows pivot points on the
wheel carrier to be selected in order to effectively accommodate larger brakes.
Additional advantages of double pivot system are:
• Ability to reduce body roll while cornering.
• Reduces front nose dive tendencies during severe braking situations.
• Utilization of a small positive steering offset, which offers improved handling
if friction levels while braking is different on both wheels.
• Enhanced caster position, improves straight line stability at higher speeds,
plus better steering return after small steering inputs.
Chassis Dynamics

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E82 Complete Vehicle
Double pivot spring strut front axle components
Index Explanation Index Explanation
1Front Axle Carrier 6Tension Strut
2Wheel Hub 7Stabilizer Bar
3Stabilizer Link 8Swivel Bearing
4Control Arm 9Hydro-Mount
5Rack-and-Pinion Steering 10 Spring Strut

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E82 Complete Vehicle
Rear Axle "HA 5"
The rear axle on the E82 is of the development designation "HA 5" and was used for the
first time on the E90. Currently all E9X vehicles are equipped with a version of this rear
axle assembly.
It is designed as a multi-link independent rear suspension axle with 5 different link arms.
The designation "HA 5" does not refer to the five links but represents the consecutive
development designation used at BMW.
Index Explanation Index Explanation
1Rear Axle Carrier 6Stabilizer Link
2Thrust Rod 7Toe Link
3Traction Strut 8Semi-Trailing Arm
4Wheel Hub 9Camber Link
5Control Arm 10 Wheel Carrier
Rear Axle “HA 5” Components

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E82 Complete Vehicle
The use of five links enables free selection of the pivot axle for the design layout. This
means that the movement of the wheel interacting with the suspension can be optimized
without compromise under braking, acceleration and lateral forces. This mostly deter-
mines all important variables such as toe, camber, brake support (anti-dive) angle, roll
center and roll center change rate.
The large rear axle carrier is connected directly to the rigid frame side member, allowing it
to transmit impact forces more favorably. The semi-trailing arm is a crash collapsible com-
ponent (in the semi-trailing arm of the HA 5 rear axle) to ensure the fuel tank is not dam-
aged.
The braking support (anti-dive characteristic) on the E82 and on E9X vehicles represents
an optimum compromise between comfort, safety and driving dynamics requirements.
The placement of the axle carrier mounting points considerably lower stress and strain on
the body with the use of relatively soft rear axle bearing mounts. Together with the double
flexible mounting, this provides outstanding insulation against road noise and tire rolling
noise.
Note: For further information on the 1 Series front or rear suspension
refer to the E90 reference material.
HA5Rear Axle
(inner side of wheel view)
Index Explanation Index Explanation
1Semi-Trailing Arm 4Toe Link
2Traction Strut 5Camber Link
3Control Arm
×
Front of
Vehicle

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E82 Complete Vehicle
The two upper links (blue in the illustration)
form a triangle in the top view as do the two
lower links (purple in the illustration). The rear
link (orange in the illustration) represents the
toe rod.
The rear axle carrier and the links are made
from high strength steel. The wheel carrier is
cast from aluminum alloy.
Minor differences exist between the HA 5 versions being used on the E9X and E82 vari-
ants. The rear axle of the E82 is fitted with modified wheel hubs. As a result, the rear track
width of the E82 has been widened by 20mm in comparison to the E9X. The extended
rear wheel arches, combined with the wider rear track width emphasizes this vehicle's
rear-wheel drive characteristics.
Index Explanation
1Drive shaft
2Wheel bearing
3E90 wheel hub
4Widening of track width (+10 mm each side)
5E82 wheel hub
Index Explanation
1Toe Adjusting Screw
2Camber Adjusting Screw
Wheel Hub on the Rear Axle,
Difference between E82 - E90
E9X/E82 Rear Axle Adjustments
(rear view of left rear)

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E82 Complete Vehicle
The springs and dampers differ from those in the E90 in that they have been adapted to
the E82’s vehicle weight. The front axle of the E82 is fitted with a hollow-type anti-roll bar
for weight reduction and a sport tuned suspension is available as an option on the 128i
(standard equipment on 135i).
The following steering systems are fitted in E82 vehicles:
• Conventional rack-and-pinion steering with Servotronic assist hydraulic pump
(vane cell pump) as standard equipment for all 128i and 135i vehicles.
• Active Steering with hydraulic pump and ECO valve is available as an option.
Active Steering in the E82 features the following optimization measures carried over
from the E70 or E6x LCI:
• Modified planetary gearing
• New control module
• Absence of the cumulative steering-angle sensor on the rack.
Note: The new procedure for initializing the Active Steering (as in the E70) now
also applies to the E82 (because of the absence of the cumulative steer-
ing-angle sensor).
Note: There is no electrical steering lock (ELV) for E82 US vehicles, regardless
of the transmission type.
Dynamic Driving Systems
The Dynamic Stability Control (DSC) has been newly tuned for the E82, containing the
following modifications.
These only apply to the Active Steering models:
• DSC sensor: two separate units, one with and one without a longitudinal accelera-
tion sensor.
• DSC control unit and hydraulic control unit modified.
• Extended diagnostic capabilities due to more precise fault code memory entries.
Note: Vehicles with Active Steering; the operation of the DSC sensor is moni-
tored by both the DSC control unit and the Active Steering control unit.