2014-2015 BMW I3 Service & Repair Manual

Technical training. Product information. BMW Service I01 Product Presentation

General information Symbols used The following symbol is used in this document to facilitate better comprehension or to draw attention to very important information: Contains important safety information and information that needs to be observed strictly in order to guarantee the smooth operation of the system. Information status and national-market versions BMW Group vehicles meet the requirements of the highest safety and quality standards. Changes in requirements for environmental protection, customer benefits and design render necessary continuous development of systems and components. Consequently, there may be discrepancies between the contents of this document and the vehicles available in the training course. This document basically relates to the European version of left hand drive vehicles. Some operating elements or components are arranged differently in right-hand drive vehicles than shown in the graphics in this document. Further differences may arise as the result of the equipment specification in specific markets or countries. Additional sources of information Further information on the individual topics can be found in the following: • Owner's Handbook • Integrated Service Technical Application. Contact: conceptinfo@bmw.de ©2013 BMW AG, Munich Reprints of this publication or its parts require the written approval of BMW AG, Munich The information contained in this document forms an integral part of the technical training of the BMW Group and is intended for the trainer and participants in the seminar. Refer to the latest relevant information systems of the BMW Group for any changes/additions to the technical data. Information status: August 2013 BV-72/Technical Training

I01 Product Presentation Contents 1. BMW i Brand......................................................................................................................................................................................................................................... 1 1.1. BMW i .................................................................................................................................................................................................................................... 1 1.1.1. Introduction.................................................................................................................................................................................... 1 1.1.2. BMW i3................................................................................................................................................................................................. 2 1.1.3. Development................................................................................................................................................................................ 3 1.1.4. Production........................................................................................................................................................................................5 1.1.5. Usage.......................................................................................................................................................................................................7 1.1.6. Recycling............................................................................................................................................................................................ 7 1.1.7. The BMW i sub-brand..................................................................................................................................................7 1.1.8. 360° ELECTRIC..................................................................................................................................................................... 8 1.1.9. BMW i Technical Training ................................................................................................................................. 12 1.1.10. Repair costs.............................................................................................................................................................................. 13 1.1.11. Mobility services................................................................................................................................................................13 2. Technical Data............................................................................................................................................................................................................................... 15 3. Overview of Body.....................................................................................................................................................................................................................18 3.1. Introduction................................................................................................................................................................................................................. 18 3.2. LifeDrive concept.............................................................................................................................................................................................. 18 3.2.1. Life module................................................................................................................................................................................ 20 3.2.2. Drive module........................................................................................................................................................................... 22 3.3. Outer skin concept......................................................................................................................................................................................... 23 3.4. Door concept........................................................................................................................................................................................................... 27 3.5. Passenger compartment concept.......................................................................................................................................... 28 3.5.1. Luggage compartment........................................................................................................................................... 29 3.5.2. Seats.................................................................................................................................................................................................... 30 3.5.3. Materials......................................................................................................................................................................................... 30 3.6. Equipment specifications..................................................................................................................................................................... 31 3.6.1. Giga World...................................................................................................................................................................................31 3.6.2. Tera World....................................................................................................................................................................................31 3.7. Notes on body damage........................................................................................................................................................................... 32 3.7.1. Notes on body damage..........................................................................................................................................32 4. General Vehicle Electrical........................................................................................................................................................................................ 34 4.1. Vehicle electrical system....................................................................................................................................................................... 34 4.1.1. Bus overview........................................................................................................................................................................... 34 4.1.2. K-CAN................................................................................................................................................................................................ 36 4.1.3. Installation locations of control units................................................................................................ 37 4.1.4. Control units............................................................................................................................................................................ 38 4.2. Voltage supply........................................................................................................................................................................................................ 42 4.2.1. Overview of the 12 V voltage supply................................................................................................ 42

I01 Product Presentation Contents 4.2.2. Components............................................................................................................................................................................ 43 4.2.3. Terminal control................................................................................................................................................................. 51 4.2.4. Emergency charging................................................................................................................................................... 52 4.2.5. Diagnosis and programming.......................................................................................................................... 52 4.3. Exterior lights........................................................................................................................................................................................................... 53 4.3.1. Front lights................................................................................................................................................................................. 53 4.3.2. Rear lights.................................................................................................................................................................................... 54 4.4. Wash/wipe system........................................................................................................................................................................................... 55 4.4.1. System components...................................................................................................................................................56 4.4.2. System components...................................................................................................................................................57 4.5. Heating and air-conditioning system................................................................................................................................. 57 4.5.1. System functions............................................................................................................................................................. 57 5. IKT System Overview....................................................................................................................................................................................................... 68 5.1. System components.................................................................................................................................................................................... 68 5.1.1. Headunits...................................................................................................................................................................................... 68 5.1.2. External devices................................................................................................................................................................. 69 5.1.3. Telephone Systems...................................................................................................................................................... 70 5.1.4. Telematic Communication Box.................................................................................................................. 70 5.1.5. Touch controller................................................................................................................................................................. 71 5.1.6. Speaker Systems............................................................................................................................................................. 71 5.2. Functions........................................................................................................................................................................................................................ 71 5.2.1. Display and operating concept.................................................................................................................. 71 5.2.2. BMW i specific navigation................................................................................................................................. 72 5.2.3. BMW ConnectedDrive............................................................................................................................................. 73 6. Chassis and Suspension Overview........................................................................................................................................................ 74 6.1. Introduction................................................................................................................................................................................................................. 74 6.1.1. Overview of chassis and suspension............................................................................................... 74 6.2. Wheels................................................................................................................................................................................................................................ 75 6.2.1. Wheel sizes................................................................................................................................................................................75 6.3. Tire Pressure Monitoring System (TPMS)................................................................................................................ 77 6.3.1. Wheel electronics teach-in process................................................................................................... 78 6.3.2. Functional prerequisites........................................................................................................................................ 78 6.3.3. Initializing the tire pressure monitoring system (TPMS)..................................... 79 6.3.4. Information in Central Information Display ............................................................................ 79 6.3.5. Information in the instrument cluster (KOMBI)................................................................. 82 6.4. Brake...................................................................................................................................................................................................................................... 83 6.5. Dynamic handling control systems....................................................................................................................................... 84 6.5.1. Dynamic traction control, DTC................................................................................................................... 84

I01 Product Presentation Contents 7. Overview of Electric Motor.................................................................................................................................................................................... 85 7.1. Components of the electric motor........................................................................................................................................ 85 7.1.1. Electrical machine........................................................................................................................................................... 87 7.1.2. Transmission............................................................................................................................................................................87 7.1.3. Electrical machine electronics.................................................................................................................... 88 7.1.4. High-voltage battery....................................................................................................................................................89 7.2. Role and components of the range extender....................................................................................................... 89 7.3. Power transmission........................................................................................................................................................................................ 90 7.4. Operating strategy of the electric motor...................................................................................................................... 92 7.5. Operating strategy of the range extender in the I01.................................................................................. 93 7.5.1. Overview......................................................................................................................................................................................... 93 7.5.2. Automatic engine start/stop function............................................................................................... 94 7.5.3. Automatic service............................................................................................................................................................ 94 7.6. Refueling with range extender...................................................................................................................................................... 95 8. Charging the High-voltage Battery........................................................................................................................................................ 97 8.1. Introduction................................................................................................................................................................................................................. 97 8.2. Charging plug........................................................................................................................................................................................................ 99 8.3. Electric Vehicle Supply Equipment.................................................................................................................................... 99 8.3.1. Mobile solution.............................................................................................................................................................. 100 8.3.2. Fixed charging station........................................................................................................................................101 8.4. Charging status display...................................................................................................................................................................... 103 8.5. Charging in Service mode.............................................................................................................................................................. 105 9. Maintenance.................................................................................................................................................................................................................................. 107 9.1. Service............................................................................................................................................................................................................................ 107 9.2. Maintenance work for range extender......................................................................................................................... 107 10. Assessing the vehicle after an accident...................................................................................................................................108 10.1. Electrical assessment............................................................................................................................................................................ 108 10.2. Visual assessment....................................................................................................................................................................................... 109

I01 Product Presentation 1. BMW i Brand 1 1.1. BMW i 1.1.1. Introduction As the world's most successful manufacturer of premium cars, the BMW Group will also play a leading and pioneering role in the future in the design of individual mobility. The foundations for sustainable mobility solutions were laid with the research and development work carried out since 2007 within the framework of the i project, which takes into consideration the ecological, economical and social change. The BMW Group strikes the necessary balance between individual needs and the global requirements of future mobility with a comprehensive approach, which is portrayed by the new BMW i brand. BMW i represents future-oriented vehicles and mobility services whose premium character is consistently defined using sustainability. Now this vision is becoming a reality. The BMW i3 (development code I01), the first series model of the new brand, allows emissions-free mobility in a premium car. View of the BMW i3 from rear left The BMW i3 is the world's first premium electric vehicle which was designed from scratch for this type of drivetrain. A car which conveys the typical BMW driving pleasure was thus developed - emissions- free and more intensive than ever before in an electrically powered vehicle. As well as the unique vehicle architecture with LifeDrive structure, including the carbon passenger compartment and the aluminium module for the electric motor, high-voltage battery and chassis and suspension, within the framework of BMW eDrive the electrical machine, power electronics and the high-voltage battery are also developed independently by the BMW Group. The Ultimate Driving Machine characteristic also becomes an elementary product feature of the BMW i3. The use of the lightweight, long-life and crash-resistant high-tech carbon material on this scale is unique for the mass production of a vehicle. Thanks to the optimized weight, the BMW i3 is not heavier than a comparable vehicle with a traditional engine and full fuel tank. Its vehicle curb weight i.a.w. German Standardization Institute (DIN) is 1195 kg/2634 lbs, including a high-voltage battery, which enables sporty vehicle performances and day-to-day range.

I01 Product Presentation 1. BMW i Brand 2 An additional range of mobility solutions, which can be used independently of the vehicle, is also an element of BMW i. The holding company BMW i Ventures was founded for this purpose. The New- York-based company My City Way is the first company in which BMW i Ventures is involved. It offers a mobile app for over 40 cities in the USA with information on public transport, available car parks and entertainment. Another 40 cities, including Munich, will be added in the course of the global market introduction. 1.1.2. BMW i3 The BMW i3 with the electric motor is designed vehicle for urban traffic: With a purely electric motor and customized to the requirements of sustainable and emissions-free mobility, it incorporates an intelligent method of mobility in the city or for commuting. The high-voltage battery of the BMW I01 only has to be charged every two to three days when used for the typical commute between the place of residence and work. This corresponds to a range of 130 to 160 km (80 to 100 mi). The BMW I01 is thus ideal for driving requirements in the city and, at the same time, allows comfortable cross-country journeys. The voltage supply of the electric motor and all other vehicle functions is powered via a specially developed high-voltage battery. This sets even more standards in terms of the energy efficiency. The intelligent heating/cooling system of the high- voltage battery ensures that the energy performance (and also the range of the vehicle) is not affected as much by temperature fluctuations as is normally typical with such batteries. Furthermore, during the development of the BMW I01 particular importance was attached to low energy consumption of the electrical components. The standard range can be increased by up to 25 percent by using the different driving modes and the distance travelled using purely electric means can be extended comfortably to 200 km (125 mi). Drive system The electrical machine of the BMW I01 is primarily designed for use in urban traffic and delivers 125 kW/170 bhp at a peak torque of 250 Nm (184 lb-ft). The full torque is already available from standstill, which is typical for electric motors, and does not have to be built up first over the engine speed like in combustion engines. This gives the BMW I01 particularly high agility and delivers impressive acceleration values. The high torque is also available over a very large engine speed range, thus enabling very homogeneous power development. The single-stage transmission ensures optimal power transmission to the rear wheels and accelerates the BMW I01 by means of an electronic control without the loss of power up to 150 km/h (93 mph). The electric motor also offers the option of braking using the accelerator pedal. If the driver takes his foot off the accelerator pedal, the electrical machine assumes the function of an alternator, which returns the current converted from the kinetic energy to the high-voltage battery. A braking torque is generated by this so-called energy recovery, which leads to effective deceleration of the vehicle. This unique "one pedal control", acceleration and braking only using the accelerator pedal, is even more comfortable with freewheeling. If the driver takes his foot off the accelerator pedal, the zero torque control of the electric motor disconnects the transmission as long as the accelerator pedal is in this position. The vehicle then continues to roll without energy consumption and uses its own kinetic energy for the electric motor. In contrast to the MINI E, the BMW I01 has a more pronounced "intermediate setting" of the accelerator pedal. This allows the vehicle "to roll". The vehicle does not recover straight away when the driver releases his foot off the accelerator pedal, but in principle disengages. The electrical

I01 Product Presentation 1. BMW i Brand 3 machine then rotates load-free so that the BMW I01 rolls without energy consumption. Within the framework of a proactive driving style "rolling" offers a very comfortable option to generate a slightly larger range. Range extender As many customers would like an even larger range or a high degree of flexibility, an optional range extender (REX) in the BMW I01 enables the range to be increased by a further 130 km (80 mi) approximately. The range extender (REX) is a small, very smooth-running and quiet gasoline engine, which drives an electrical machine, in order to maintain the state of charge of the high-voltage battery so that the vehicle can continue to drive using electrical energy. 1.1.3. Development The BMW i LifeDrive architecture means less weight and an extended range. Two separate function units, a Drive module made from aluminium and a Life module made from carbon, result in the interaction of an ultralight and stable design. The result: improved energy efficiency, higher range and enhanced safety. LifeDrive architecture in the I01 Index Explanation 1 Life module 2 Drive module The LifeDrive architecture comprises two independent units. The upper module: the passenger compartment made from carbon fibre reinforced plastic – also called CFK or simply carbon. On the one hand, it offers the occupants the best possible protection in the event of accidents thanks to its stability, and, on the other hand, it is still light enough to offset the additional weight of the high-voltage battery.

I01 Product Presentation 1. BMW i Brand 4 The lower module which is made entirely from aluminium has space for the high-voltage battery. The suspension, structure and impact elements, as well as the electric motor, are housed here. With the location of all drive components in the lower module the occupants now have more space because there is no center console dividing the passenger compartment. The LifeDrive architecture is thus an innovation which not only balances the weight of the high-voltage battery, but also lowers the center of gravity of the vehicle and thus lends every BMW i the agility which is expected of a BMW. As the carbon passenger compartment is particularly robust, driving pleasure and comfort go hand and hand with enhanced safety for the occupants. The result: less weight, enhanced safety and spacious and comfortable passenger compartment. First-class aerodynamics is an important element of efficient electric mobility. In the BMW i the fully cladded vehicle underbody prevents recirculation under the vehicle. At the same time, so-called AirCurtains and AeroFlaps improve the aerodynamics at the wheel arches and in the side sill area behind the front wheels. The passenger compartment of the BMW I01 is characterized by its high-quality equipment features made from renewable raw materials such as natural fibers and naturally tanned leather. 25% of the plastic used for the passenger compartment of the BMW I01 and 25% of the thermoplastic parts at the body either come from recycled materials or renewable sources. Carbon era It is a breakthrough achievement and one of the most innovative developments of BMW i: the standard production of passenger compartments made from carbon (CFK). To date, the weight of the high- voltage battery restricted the range of electric vehicles. The larger the high-voltage battery, the heavier the vehicle - and thus the more energy that was required to get from A to B. Thanks to the intensive use of carbon components in the I01 additional weight of the high-voltage battery has now been successfully offset. For a long time it was only possible to use these carbon components in a restricted manner, as they were very expensive (hand-made). BMW i has now rewritten this standard with the first passenger compartment made from carbon originating from standard production. However, carbon components not only revolutionizethe lightweight construction. They also enable new moulds in the design as the plastic reinforced with carbon fibers is just as easy to process when dry as textile material. On the one hand, bodies made from carbon offer more space in the passenger compartment, and, on the other hand, also enable complex styling which is optimized in terms of aerodynamics. Last but not least, carbon is a high-strength material and increases the safety of all occupants of a BMW i. After over ten years of intensive research and experience in production, the BMW Group, together with SGL Automotive, is now developing and producing carbon fibers, as well as carbon fiber boards. Interior The LifeDrive architecture with the carbon passenger compartment also allows greater freedom in the design of the passenger compartment of the BMW i3. Doors which open in the opposite direction and the omission of B-pillars are the basis for the exceptionally high degree of spatial comfort and freedom of movement in relation to the outer dimensions. Thanks to the direct location of the electrical machine at the rear axle and also the omission of the normal center console in conventional vehicles, there is a direct link between the right and left footwell.

2014-2015 BMW I3 Service & Repair Manual

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