2023年宝马1系E87手册最全面精品资料mfptnue87karosseriegesamtf_en.pdf

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1、Participants ManualBody-Complete Vehicle E87BMW Serviceconceptinfobmw.de2004 BMW AGMnchen,Germany.Reprintof this manualor its parts requirethe writtenapprovaloftheBMW AG,Mnchen.VS-12 Aftersales TrainingParticipants ManualBody-Complete Vehicle E87Engine variantsComplete vehicleBodyshellContentsBody-C

2、ompleteVehicleE87Objectives1Purpose of this Participants Manual1Introduction3Engine variants3System overview5Complete vehicle5Bodyshell1917ObjectivesBody-Complete Vehicle E87Purpose of this Participants ManualThe Participants Manual is a documentdesigned to accompanya seminar while at thesame time s

3、erving as a source of reference.This Participants Manual deals with the newfeatures and further developmentsincorporated in the body as well as thecomponent locations.2738IntroductionBody-Complete Vehicle E87Engine variantsThe Regensburg plant will launch the E87 in2004.With this 1 Series BMW is ent

4、ering anew market segment.The 116i,118i and the 120i with 4-cylinderpetrol engines will be available at the start ofseries production.The 118d and 120d with 4-cylinder diesel engines will also be offered.116i with N45 B16118i with N46 B20 UL120i with N46 B20 OL118d with M47 D20 TU2 UL120d with M47 D

5、20 TU2 OLAll E87 vehicles feature a longitudinal enginein the front with rear-wheel drive.1-E87-The 1 Series4859System overviewBody-Complete Vehicle E87Complete vehicleDimensions and weightsWith a length of 4,227 mm,the E87 is 35 mmshorter than the E46/5.The E87 is 1,751 mm wide and therefore justas

6、 wide as the E46/5.At 1,430 mm,its height exceeds that of theE46/5 by 22mm.Depending on themotorization,the E87 weighs between1-Garage dimensions E872-Garage dimensions E87691,280 kg and 1,335kg.It has a possiblepayload of 500kg(E46/5:425kg).Ithas a trailer load of 1,200 kg.Incomparison,the E46/5 ha

7、s a trailer load of 1,300kg.Bonnet,engine compartmentThe bonnet is made from steel and featuressound insulation on the inside.As on the E46,the bonnet can be set inthe servicing positionwith the aid of special tool 512170.In the engine compartment,the vehicleidentification number is punched on the r

8、ight-hand wheel arch and the bodyshell number onthe left-hand wheel arch.The filter for the heating/air conditioningsystem is accessible from the enginecompartment.For the first time,the AUCsensor is now mounted on this filterhousing inthe vicinity of the bulkhead.The DME/DDE control unit is located

9、 in the E-box.The filter housing of the heating/airconditioning system must be removed first inorder to access the E-box.The wiper motor and the wiper linkage are alsoaccessible after removing this housing.3-Engine compartment79Front headlight systemThe E87 is equipped as standard with halogenheadli

10、ghts.Bi-xenon headlights are alsooptionally available.Adaptive headlights arecurrently not planned for the E87.Itis not necessaryto remove the headlights inorder to replace the bulbs.If,for any otherreason itis necessaryto remove the completeheadlight system,the bumper trim panelshould be removed to

11、 prevent it beingdamaged.Two headlight adjusting screws are provided(horizontal/vertical adjustment).Adjustingscrews are also provided to adjust the gapsbetween the complete headlight assemblyand the body.This function not only enhances the visualappearanceof the vehicle but it also serves tominimiz

12、e wind noise.4-Front headlight system89Front bumperA new feature of the E87 bumper system isthe two-piece design of the bumper trimpanel.This feature reduces the costs ofrepairing minor damage.The trim panel can withstand bumps atspeeds of up to 4km/h.The bumper carrierabsorbs forces at speeds betwe

13、en 4 km/h and8 km/h while deformation elements absorb theforces between 8km/h and 15 km/h.Theengine supports are only affected by impactsat speeds in excess of 15km/h.The bumper system therefore consists of atop panel and a bottom panel.The bumpercarrier is located behind these panels,followed by th

14、e deformation elements.Ifapplicable,the PDC sensors and fog lights areaccommodated in the trim panel.5-Front bumper system99Front endAfter removing the bumper trim panel,thecomplete front end,including the bumpercarrier,headlights,air ducts and bonnet lock,can be removed.The bowden cable assembly ca

15、n bedisconnected at its parting point.The screwconnections to the engine support must bereleased and the electrical connectionsto theheadlights unplugged.Front doorThe front door is made from steel.Itfeatures aside impact protection system together withits anchoring.The door handle ispainted intheca

16、r colour and can be removed and installedsimilar to on the E46.A lock that can beoperated with the slide-in key of theidentification transmitter is integrated in thedoor handle on the drivers side.The outside mirror is secured with threescrews to the door.A new feature of theoutside mirror is its ce

17、ntral connector,makingdisassembly and assembly easier.Ifnecessary,the mirror glass and housing of theoutside mirror can be removed individually.6-Outside mirror109The door trim panel is attached to the door bymeans of three mounting screws.A new feature is that there is no airbagintegrated in the do

18、or trim panel.The sideairbag is now incorporated in the seat.A sound insulation mat that also keeps awaymoisture is adhered to the back of the doortrim panel.Another new feature is the clip-mountedwindow that is connectedby means of clips tothe power window regulator.The E87 is equipped with standar

19、d with cable-type power windows at the front.7-Door trim panel/position of mounting screws119Front seatThe E87 is available with basic seats andsports seats.Electrically adjustable versionsare also available.The seats are furtherenhanced by a memory function as well as abackrest width adjustment opt

20、ion(similar toM3 E46).A new feature is that the side airbag is nowintegrated in the front seat.The seat must beremoved in order to dismantle the side airbag.Allcovers and connectorsare then accessibleallowing the side airbag to be removed.8-Exploded view of front seat129Instrument panelThe instrumen

21、t panel is a multi-part unit.Itcanbe dismantled in the vehicle.Completeremoval is also possible without the need toremove the centre console.The fresh airgrilles are clip-mounted while twoscrews secure the instrument cluster to theinstrument panel.The slot for the identificationtransmitter as well a

22、s the starter button areclipped.The radio and airconditioning controlpanel are also clipped into the instrumentpanel.Threaded connections are used tosecure the glove compartment and thefootwell trim panels below the instrumentpanel.The solar sensor isclip-mounted(twist lock).Anumber of control units

23、 are also located in thearea of the instrument panel.The footwell module is located on the left-hand A-pillarunder the left footwell trim panel.The CAS is also positioned under theinstrument panel on the drivers side while thejunction box is arranged on the passengersside behind the glove compartmen

24、t.The control units for CCC,CID as well as thecontrol module for the heating/air conditioningsystem are also mountedin the control panel.9-Instrument panel139Centre consoleNo parts of the instrument panel need to beremoved in order to dismantle the centreconsole.The covers at the rear end of the cen

25、treconsole in the area of the handbrake andselector lever must be removed in order toaccess the screw connections.There are alsotwo mounting screws located in the front areabeneath the instrument panel.The MRS5 control unit and,iffitted,antennasfor the CAS are arranged under the centreconsole.Ifnece

26、ssary,emergencyoperation for the shiftlock system is also accessible via the centreconsole.Inthis case,the cover of the selectorlever must be removed so that the pawl for theshift lock can be operated with the aid of ascrewdriver.Rear seatA plug-in system is used to secure the rearbench seat and the

27、 side rests.The control unitfor the electric fuel pump(EKP)is locatedunder the right-hand backrest on the E87 withdiesel engine.The ISOFIX bracket is accessible afterremoving the bench seat.ISOFIX is installedas standard on the E87 and serves thepurpose of mounting child safety seats in therear comp

28、artment.The seat backrest is split 2/3 to 1/3.Theheadrests plug in.By folding down the seats,the capacity of theluggage compartment can be increased fromthe original 330 litres to 1,150 litres.A ski bagis optionally available.10-Centre console mounting149Roof linerTwo control units are clipped into

29、the roof linerof the E87.The FZD is located inthe front areaand the USIS in the rear.Removal for repairs is made more difficult asthe headliner is installed at the productionplant before the windscreen.To providesufficient space for removal and installationwithout damage being incurred,it isrecommen

30、ded to remove at least one frontseat.Rear doorInprinciple,the rear door is designed similarlyto the front door.However,the rear door isequipped with mechanical window regulatorsas standard.Power windows are available asan option.11-Rear door structure159Slide/tilt sunroofA glass panel slide/tilt sun

31、roof is optionallyavailable for the E87.For servicing purposes,the glass panel can beadjusted or removed and installed by means ofwell-accessible screws.The visor can also bedetached.Itis spring-mountedinthe cassette.The electric motor is held by screws.A new feature is that the control unit is nolo

32、nger located on the motor but rather it isintegrated in the FZD.The wind deflector and water drain channelcan also be detached without having toremove the sunroof cassettefrom the vehicle.The cable assemblies cannot be replaced.Inthis case,the entire sunroof cassette shouldbe replaced.The SHD requir

33、es initialization followingassembly.This is achieved by pressing thepush-button in the tiltposition.The system isinitialized after 20 seconds.12-Slide/tilt sunroof169Antenna locationsThe E87 is equipped with one roof antenna(aerial).This antenna is used for GPS,telephone,AM-FM1.Further antennas are

34、integrated in thewindscreen.They are used for FM2,FM3 anddiversity functions(there is currently no TVfunction for the E87).On the E87,the antenna for the remotecontrol is accommodated in the interior rear-view mirror.Inconnectionwith the comfort access option,antennas can still be found in the front

35、 doorhandles,in the vehicle interior,in the luggagecompartment and on the rear bumper.Theantennas in the vehicle interior are arrangedon the tunnel panel at the level of the ashtrayand centre console armrest.Rear hatchThe rear hatch is a one-piece componentmade from steel.The window is bonded andcan

36、not be opened separately.The BMW badge serves as the push-button toopen the rear hatch.Inan emergency,a cable assembly allows therear hatch to be opened from the inside.The 3rd brake light and antenna amplifier aremounted on the inside of the rear hatch.Thetrim panels must be removed in order toacce

37、ss these components.The lock with integrated actuator is alsoaccessible after removing the inner trimpanels.The rear hatch can be adjusted at the hingesequipped with corresponding slot.The wiper motor for the rear window wiper aswell as the mounting of the push-button foropening the rear hatch are a

38、ccessible from theinner side of the rear hatch.13-Rear hatch179Luggage compartmentSince the E87 is equipped with run-flat tyresas standard,there is no spare wheel in theluggage compartment.Instead of the luggagecompartment well,the battery as well as thecontrol units for PDC,RDC,AHM and atelephoneco

39、ntrol unit are located in this area.In connection with the correspondingequipment,the Top-HiFi amplifier and the CDchanger are additionally arranged on the sidepanel on the left side of the luggagecompartment.Space is additionally providedfor the ball head of the detachable towinghitch.The luggage c

40、ompartment has a capacity of330 litres.By folding down the rear seats,thecapacity can be increased to 1,150litres.As part of the phase-in of the comfort accesssystem,the CA control unit willalso be locatedin the luggage compartment in the vicinity ofthe battery.Rear bumper systemA new feature of the

41、 rear bumper is its two-piece design.The top and bottom sectionscan be replaced separately.The trim panel canalso be removed as a complete unit.It isscrew-mounted from the wheel arch side aswell as from the bottom.Itis only clipped in inthe top section.The steel carrier which features two crashboxes

42、 and is screw-mounted to the body islocated behind the bumper trim panel.Twoversions of the steel bumper carrier areavailable.Apart from the mounting points onthe body,the version for the towing hitchdiffers completely from the version without atowing hitch.The trim panel is designed such that it ca

43、nwithstand small bumps at speeds of up to4 km/h without damage.The bumper carrier14-Rear bumper panel189absorbs forces at speeds between 4-8km/h.The crash boxes deform and absorb impactsat speeds up to about 15km/h.The sheetmetal componentsof the vehicle structure areonly affected by impacts at high

44、er speeds.Furthermore,PDC sensors as well as themount for the number plate are integrated inthe bumper trim panel.Rear light clustersThe rear light clusters of the E87 are equippedwith conventional lamp technology.LEDs arenot used.Four lamp bulbs per rear light cluster serve thebrake light,direction

45、 indicator light,reversinglight,tail light and rear fog light.A flap can be removed in the luggagecompartment trim panel for the purpose ofreplacing the bulbs.The lamp carrier is accessible.Itis clipped intothe rear light cluster and carries all the lampbulbs.To remove the complete rear light cluste

46、r,itisnecessary to release three lock nuts that arealso accessible through the service flap in theluggage compartment trim panel.15-Rear light clusterIndexExplanationIndexExplanation1Tail light/rear fog light3Reversing light2Direction indicator light4Tail light199BodyshellIn order to satisfy the dem

47、anding crashrequirements(5 star Euro NCAP),new steelgrades(polyphase steels)have been used inalarge number of body reinforcements in thefront end,B-pillarand rear end.Consequently,the load bearing capacity has been increasedsubstantially compared to conventional steelgrades.These steel grades still

48、retain theirgood welding properties.The bodyshell is fullygalvanized and equippedwith a safety passenger cell.The static rigidity is approx.16,000Nm/degree(E46/5:14,500Nm/degree).Thedynamic rigidity is 31.6Hz(E46/5:29.2Hz).To relieve the load on the bulkhead,theengine support is designed such that i

49、tbendsin when subject to severe impact.Anextremely sturdy tunnel additionally supportsthe bulkhead.The front axle carrier is a furtherimportant componentin the energy reductionsystem.The vehicle interior is additionallyprotected by the carrier support-bulkheadcross member.This also includes the sill

50、reinforcements and crash reinforcements atthe rear of the engine support.Rigidlongitudinal strut structures and tunnel closing16-Reinforcements of the E87 bodyshellIndexExplanationIndexExplanation1Carrier support Bulkhead5B-pillar2Longitudinal member6Entrance3Tunnel,front and rear7Seat cross member4