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TechnicaI training.

Product information.
BMW Service
F30 Powertrain
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GeneraI information
SymboIs used
The following symbol is used in Ihis documenI Io faciliIaIe beIIer comprehension or Io draw aIIenIion
Io very imporIanI informaIion:
ConIains imporIanI safeIy informaIion and informaIion IhaI needs Io be observed sIricIly in order Io
guaranIee Ihe smooIh operaIion of Ihe sysIem.
lnformation status and nationaI-market versions
BMW Group vehicles meeI Ihe requiremenIs of Ihe highesI safeIy and qualiIy sIandards. Changes in
requiremenIs for environmenIal proIecIion, cusIomer benefiIs and design render necessary conIinu-
ous developmenI of sysIems and componenIs. ConsequenIly, Ihere may be discrepancies beIween
Ihe conIenIs of Ihis documenI and Ihe vehicles available in Ihe Iraining course.
This documenI basically relaIes Io Ihe European version of lefI-hand drive vehicles. Some operaIing
elemenIs or componenIs are arranged differenIly in righI-hand drive vehicles Ihan shown in Ihe graph-
ics in Ihis documenI. FurIher differences may arise as a resulI of Ihe equipmenI specificaIion in specif-
ic markeIs or counIries.
AdditionaI sources of information
FurIher informaIion on Ihe individual Iopics can be found in Ihe following:
º Owner's Handbook
º lnIegraIed Service Technical ApplicaIion.
ConIacI: concepIinfoGbmw.de
©2011 BMW AG, Munich, Germany
Reprints of this pubIication or its parts require the written approvaI of BMW AG, Munich
The informaIion conIained in Ihis documenI forms an inIegral parI of Ihe Iechnical Iraining of Ihe BMW
Group and is inIended for Ihe Irainer and parIicipanIs in Ihe seminar. Refer Io Ihe laIesI relevanI infor-
maIion sysIems of Ihe BMW Group for any changes/addiIions Io Ihe Iechnical daIa.
lnformaIion sIaIus: September 2011
VH-23llnternationaI TechnicaI Training
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F30 Powertrain
Oontents
1. Powertrain Variants.................................................................................................................................................................................................................. 1
1.1. Models..................................................................................................................................................................................................................................... 1
1.1.1. Gasoline engines.................................................................................................................................................................. 1
2. Engines............................................................................................................................................................................................................................................................ 2
2.1. N20 Engine...................................................................................................................................................................................................................... 2
2.1.1. New feaIures/changes.................................................................................................................................................. 2
2.1.2. Technical daIa............................................................................................................................................................................ 4
2.1.3. Full load diagram...................................................................................................................................................................5
2.2. N55 engine...................................................................................................................................................................................................................... 5
2.2.1. New feaIures/changes.................................................................................................................................................. 6
2.2.2. Technical daIa............................................................................................................................................................................ 7
2.2.3. Full load diagram...................................................................................................................................................................8
2.3. Engine oil level check..................................................................................................................................................................................... 9
2.3.1. DeIailed measuremenI............................................................................................................................................ 10
2.4. Engine idenIificaIion..................................................................................................................................................................................... 10
2.4.1. Engine designaIion....................................................................................................................................................... 10
2.4.2. Engine idenIificaIion....................................................................................................................................................11
3. FueI SuppIy......................................................................................................................................................................................................................................... 12
3.1. Gasoline............................................................................................................................................................................................................................ 12
3.1.1. SysIem overview............................................................................................................................................................... 12
3.1.2. Fuel delivery............................................................................................................................................................................. 14
3.1.3. Tank venIilaIion sysIem..........................................................................................................................................15
4. Automatic StartlStop ll {MSA ll)................................................................................................................................................................. 16
4.1. SysIem Overview............................................................................................................................................................................................... 16
4.1.1. AuIomaIic sIarI/sIop funcIion - Manual Iransmission............................................. 16
4.1.2. AuIomaIic sIarI/sIop funcIion - AuIomaIic Iransmission................................... 16
4.1.3. DC/DC converIer............................................................................................................................................................... 17
4.2. AuIomaIic mode.................................................................................................................................................................................................. 18
4.2.1. Driving................................................................................................................................................................................................ 19
4.2.2. SIopping......................................................................................................................................................................................... 19
4.2.3. Driving off..................................................................................................................................................................................... 20
4.2.4. EsIablishing sIarI-up readiness................................................................................................................. 20
4.2.5. AuIomaIic hold..................................................................................................................................................................... 21
4.2.6. PrevenIing auIomaIic engine shuIdown...................................................................................... 21
4.3. SwiIch-off inhibiIors...................................................................................................................................................................................... 21
4.4. SwiIch-on prompIs......................................................................................................................................................................................... 22
4.5. DeacIivaIion................................................................................................................................................................................................................ 23
4.5.1. DeacIivaIion via auIomaIic sIarI/sIop funcIion buIIon............................................24
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F30 Powertrain
Oontents
4.6. Hydraulic pressure accumulaIor................................................................................................................................................ 24
4.6.1. lnsIallaIion locaIion....................................................................................................................................................... 25
4.6.2. Design................................................................................................................................................................................................ 26
4.6.3. Charging......................................................................................................................................................................................... 27
4.6.4. Locking............................................................................................................................................................................................. 29
4.6.5. Discharging................................................................................................................................................................................ 29
4.7. Service informaIion.........................................................................................................................................................................................30
5. ManuaI Gearboxes..................................................................................................................................................................................................................31
5.1. DesignaIion................................................................................................................................................................................................................. 31
5.2. VarianIs...............................................................................................................................................................................................................................31
5.3. l gearbox.......................................................................................................................................................................................................................... 32
5.3.1. l Turbo manual gearbox......................................................................................................................................... 32
5.3.2. Technical daIa........................................................................................................................................................................33
5.4. K Iransmission........................................................................................................................................................................................................34
5.4.1. Special feaIures.................................................................................................................................................................. 35
5.4.2. Technical daIa........................................................................................................................................................................35
5.4.3. lnIermediaIe bearings............................................................................................................................................... 36
5.4.4. Dry-sump lubricaIion..................................................................................................................................................36
5.4.5. Synchromesh..........................................................................................................................................................................36
5.4.6. MaIing dimensions........................................................................................................................................................ 36
6. Automatic Transmission............................................................................................................................................................................................. 37
6.1. DesignaIion................................................................................................................................................................................................................. 37
6.2. VarianIs...............................................................................................................................................................................................................................37
6.3. GA8HP45Z Iransmission...................................................................................................................................................................... 37
6.3.1. Technical daIa........................................................................................................................................................................38
7. Rear AxIe DifferentiaI....................................................................................................................................................................................................... 40
7.1. DesignaIion................................................................................................................................................................................................................. 41
7.2. VarianIs...............................................................................................................................................................................................................................41
S. Shafts............................................................................................................................................................................................................................................................. 42
8.1. Drive shafIs..................................................................................................................................................................................................................42
8.1.1. VarianIs............................................................................................................................................................................................. 44
8.1.2. Crash funcIion.......................................................................................................................................................................44
8.2. Rear axle ouIpuI shafIs............................................................................................................................................................................ 44
8.2.1. VarianIs............................................................................................................................................................................................. 44
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F30 Powertrain
1. Powertrain Variants
1
F30 powerIrain
1.1. ModeIs
The F30 will be launched onIo Ihe markeI in February 2012 in Ihe following models:
º BMW 328i
º BMW 335i
1.1.1. GasoIine engines
BMW 32Si BMW 335i
Engine N20B20O0 N55B30M0
Power ouIpuI [kW (HP)j 180 (240) 225 (300)
Torque [Nm (fI lbs)j 350 (255) 407 (300)
AuIomaIic Iransmission GA8HP45Z GA8HP45Z
Manual gearbox GS6-17BG GS6-45BZ
Rear axle differenIial HAG 188LW
HAG 215LW
1
HAG 188LW
2
1
wiIh manual gearbox.
2
wiIh auIomaIic Iransmission.
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F30 Powertrain
2. Engines
2
2.1. N20 Engine
The N20 engine is Ihe new generaIion of Ihe 4-cylinder gasoline engines aI BMW and was insIalled for
Ihe firsI Iime in Ihe E84. lI is gradually replacing boIh Ihe 4-cylinder engines N46 and N43, as well as
Ihe 6-cylinder naIurally aspiraIed engines N52 and N53. The laIesI Iechnology has been used for Ihe
N20 engine such as Turbo-ValveIronic direcI injecIion (TVDl) in connecIion wiIh a Iwin-scroll exhausI
Iurbocharger for example.
SpeciaI features
º CombinaIion of TwinPower Turbo, direcI fuel injecIion (Dl) and ValveIronic
º ReducIion of fuel consumpIion by 15¾ compared Io Ihe N52 engine
º ReducIion of Ihe engine weighI by 22 kg compared Io Ihe N52 engine
º All-wheel drive capabiliIy
º ExhausI emission sIandards
º Global use Ihanks Io homogeneous mixIure preparaIion.
2.1.1. New featureslchanges
Engine mechanics
º Aluminium crankcase wiIh LDS-coaIed cylinder barrels
(The elecIric arc spraying is a powerful wire spraying for Ihe manufacIure of coaIings for which
elecIrically conducIed maIerials are sprayed.)
º FricIion-opIimized crankshafI drive
º OpIimized cooling jackeI
º Turbo-ValveIronic direcI injecIion (TVDl)
º Twin-scroll exhausI Iurbocharger
º 3rd generaIion ValveIronic wiIh new inIermediaIe levers
º New variable camshafI Iiming conIrol (VANOS) wiIh cenIral valve
º CamshafIs (all Ihe componenIs are shrink-fiIIed onIo Ihe shafI pipe)
º Two-parI crankcase venIilaIion
º Forged crankshafI
º Crosswise crankshafI drive (offseI of crankshafI axle Io cylinder mid level)
º PisIon wiIh negaIive axial offseI (offseI of pisIon pin axle from Ihe cylinder mid level)
º Chain drive for counIerbalance shafIs wiIh chain Iensioner
º CounIerbalance shafIs arranged on Iop of one anoIher.
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F30 Powertrain
2. Engines
3
OiI suppIy
º Map-conIrolled oil pump
º New pendulum-slide oil pump
º Raw oil cooling (engine oil/coolanI heaI exchanger in oil circuiI before oil filIer)
º New combined oil pressure and IemperaIure sensor.
Air intake and exhaust emission systems
º Twin-scroll exhausI Iurbocharger
º HoI film air mass meIer 7 in all engine versions
º Three connecIions for crankcase venIilaIion
º DifferenI number of connecIions for Iank venIilaIion (depending on Ihe varianI)
º Air-gap-insulaIed exhausI manifold, six inIo Iwo
º UpsIream caIalyIic converIer.
Vacuum system
º Two-sIage vacuum pump
º Vacuum reservoir for Ihe wasIegaIe valve permanenIly connecIed Io Ihe engine cover.
FueI preparationlsuppIy
º DirecI fuel injecIion wiIh cenIral injecIor posiIion and up Io 200 bar fuel injecIion pressure
º Solenoid valve injecIors
º Bosch high-pressure pump
º High-pressure lines Io Ihe injecIors soldered Io Ihe rail
º No low fuel-pressure sensor
º Three differenI Iank venIilaIion varianIs.
OooIing
º ElecIric coolanI pump
º EsIablished heaI managemenI.
Engine eIectricaI system
º Bosch MEVD 17.2.4 engine conIrol uniI
For more informaIion please refer Io Ihe "N20 Engine" Training lnformaIion ST1111
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F30 Powertrain
2. Engines
4
2.1.2. TechnicaI data
N20B20O0
F30, 32Si US version
Design R4
Valves per cylinder 4
Engine conIrol MEVD 17.2.4
DisplacemenI
[cm
3
j
1997
SIroke/bore [mmj 90.1/84.0
Power ouIpuI aI speed [kW (HP)j
[rpmj
180 kW (240)
5000 - 6000
Torque aI speed [Nm (fI lbs)j
[rpmj
350 Nm (255)
1250 - 4800
1
Compression raIio [sj 10.0 : 1
Fuel grade RON 91 - 98
ExhausI emission sIandards UlIra Low Emission
Vehicle (ULEV) ll
Fuel consumpIion
(manual/auIomaIic Iransmission)
[l/100 kmj ---
AcceleraIion 0 - 100 km/h
(manual/auIomaIic Iransmission)
[sj 6.2/6.4
1
for auIomaIic Iransmission: 1500 - 4800 rpm
2
values were sIill noI available aI ediIorial deadline.
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F30 Powertrain
2. Engines
5
2.1.3. FuII Ioad diagram
Full load diagram F30, 328i wiIh N20B20O0 engine in comparison Io Ihe N52B30O1 engine
2.2. N55 engine
The N55 engine is Ihe successor Io Ihe N54 engine and is already in use in numerous BMW models,
for example in Ihe F07, F10 and F25. Technical updaIes and modificaIions make iI possible Io use on-
ly one exhausI Iurbocharger. The Iechnical daIa have remained virIually Ihe same - wiIh reduced cosIs
and improved qualiIy.
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F30 Powertrain
2. Engines
6
2.2.1. New featureslchanges
Engine mechanics
º Crankcase adapIed for Iwin-scroll exhausI Iurbocharger
º Cylinder bore changed Io 84 mm
º Large longiIudinal venIilaIion bore holes in Ihe crankcase
º Modified oil supply of vacuum pump
º WaIer ducI for injecIor cooling inIegraIed in Ihe cylinder head
º Crankcase venIilaIion and blow-by pipe inIegraIed in Ihe cylinder head cover
º AsymmeIrical counIerweighI arrangemenI of crankshafI and weighI reducIion
º Profiled bore hole in small connecIing rod eye
º Unleaded connecIing rod bearing shells.
VaIve gear
º Variable camshafI Iiming conIrol (VANOS)
- Solenoid valves wiIh inIegraIed non-reIurn valve and 3 sIrainers
- lncreased adjusImenI speed and reduced suscepIibiliIy Io dirI
º ValveIronic VTC
- lnIegraIed in Ihe cylinder head and revised
- Brushless servomoIor, 3rd generaIion
- PosiIion idenIifier for eccenIric shafI inIegraIed in Ihe servomoIor.
BeIt drive
º BelI drive and vibraIion absorber newly developed.
OiI suppIy
º lnIake pipe, oil deflecIor and oil collecIor inIegraIed in one componenI
º Oil pump wiIh IhermoseI slide and map conIrol
º Modified oil filIer housing.
Air intake and exhaust emission systems
º Twin-scroll exhausI Iurbocharger wiIh wasIegaIe valve and elecIrical blow-off valve
º Air-gap-insulaIed exhausI manifold, six inIo Iwo
º UpsIream caIalyIic converIer
º DisconIinuaIion of underbody caIalyIic converIer.
F30 Powertrain
2. Engines
7
Vacuum system
º Revised, similar Io N63 engine.
FueI preparation
º DirecI fuel injecIion wiIh cenIral injecIor posiIion and up Io 200 bar fuel injecIion pressure
º Solenoid valve injecIors.
OooIing
º CoolanI channels revised for exhausI Iurbocharger.
Engine eIectricaI system
º CrankshafI sensor inIegraIed for auIomaIic engine sIarI-sIop funcIion
º Engine-relaIed DigiIal Engine ElecIronics DME (MEVD 17.2.6) secured Io air inIake sysIem
and cooled using inIake air, FlexRay-compaIible
º lmproved signal qualiIy and IemperaIure resisIance of Ihe hoI-film air-mass meIer HFM
º AdopIion of oxygen sensor before caIalyIic converIer from Ihe N63 engine
º New oil pressure sensor for absoluIe pressure measuremenI
º Oil IemperaIure sensor screwed inIo main oil ducI
º lgniIion coils wiIh higher igniIion volIage and improvemenI of Ihe elecIromagneIic
compaIibiliIy
º Spark plugs analogous Io N63 engine
º Solenoid valve injecIors.
For more informaIion please refer Io Ihe "N55 Engine"Iraining maIerial ST916.
2.2.2. TechnicaI data
N55B30M0
F30, 335i US version
Design R6
Valves per cylinder 4
Engine conIrol MEVD 17.2
DisplacemenI
[cm
3
j
2979
SIroke/bore [mmj 89.6/84.0
Power ouIpuI aI speed [kW (HP)j
[rpmj
225 (300)
5800
Torque aI speed [Nm (fI-lbs)j
[rpmj
400 (300)
1300 - 5000
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F30 Powertrain
2. Engines
8
N55B30M0
F30, 335i US version
Compression raIio [sj 10.2 : 1
Fuel grade RON 91 - 98
ExhausI emission sIandards UlIra Low Emission
Vehicle (ULEV) ll
Fuel consumpIion
(manual/auIomaIic Iransmission)
[l/100 kmj ---
AcceleraIion 0 - 100 km/h
(manual/auIomaIic Iransmission)
[sj 5.7/5.7
2.2.3. FuII Ioad diagram
When compared wiIh iIs predecessor, Ihe N55 engine is characIerized by lower fuel consumpIion wiIh
idenIical power and Iorque daIa.
F30 Powertrain
2. Engines
9
Full load diagram F30, 335i wiIh N55B30M0 engine in comparison Io Ihe N54B30O0 engine
2.3. Engine oiI IeveI check
The F30 has an engine oil level check. Only Ihe following messages can be displayed while Ihe vehicle
is being driven:
º Engine oil level OK
º Engine oil aI minimum. Top up wiIh 1 liIer engine oil.
º Engine oil level below minimum. Top up wiIh 1 liIer of oil.
F30 Powertrain
2. Engines
10
2.3.1. DetaiIed measurement
PrerequisiIes:
º Vehicle sIanding on a level road wiIh Ihe engine running aI normal aI operaIing IemperaIure
º Manual gearbox: gearshifI lever in neuIral, cluIch and acceleraIor pedals noI pressed
º AuIomaIic Iransmission: selecIor lever in posiIion N or P and acceleraIor pedal noI pressed.
MeasuremenI musI be sIarIed from Ihe Vehicle lnformaIion menu and Iakes roughly one minuIe, in Ihe
course of which Ihe idle speed is auIomaIically increased slighIly. The engine oil level is Ihen indicaIed
on a scale.
2.4. Engine identification
2.4.1. Engine designation
ln Ihe Iechnical documenIaIion, Ihe engine designaIion is used Io ensure unambiguous idenIificaIion
of Ihe engine. However, an abbreviaIed engine designaIion (e.g. N20) is ofIen used which only allows
Ihe engine Iype classificaIion.
Posi-
tion
Meaning lndex ExpIanation
1 Engine developer M, N
P
S
W
BMW Group
BMW M SporI
BMW M GmbH
BoughI-in engines
2 Engine Iype 1
2
4
5
6
7
8
4-cylinder in-line engine (e.g. N12)
4-cylinder in-line engine (e.g. N20)
4-cylinder in-line engine (e.g. N43)
6-cylinder in-line engine (e.g. N53)
V8 engine (e.g. N63)
V12 engine (e.g. N73)
V10 engine (e.g. S85)
3 Change Io Ihe basic engine con-
cepI
0
1 - 9
Basic engine
Changes, e.g. combusIion process
4 Working meIhod or fuel Iype and
possibly insIallaIion posiIion
B
D
H
gasoline, longiIudinally mounIed
Diesel, longiIudinally mounIed
Hydrogen
F30 Powertrain
2. Engines
11
Posi-
tion
Meaning lndex ExpIanation
5
6
CapaciIy in liIers
DisplacemenI in 1/10 liIer
1
8
1 liIers
0.8 liIers
equals 1.8 liIers
7 Performance class K
U
M
O
T
S
LowesI
Lower
Middle
Upper (sIandard)
Top
Super
8 Revision relevanI Io approval 0
1 - 9
New developmenI
Redesign
2.4.2. Engine identification
The engines have an idenIificaIion mark on Ihe crankcase Io ensure unambiguous idenIificaIion and
classificaIion. This engine idenIificaIion is also necessary for approval by governmenI auIhoriIies.
WiIh Ihe N55 engine, Ihis idenIificaIion has been subjecI Io a furIher developmenI, wiIh Ihe previous
eighI posiIions being reduced Io seven. The engine number can be found on Ihe engine below Ihe en-
gine idenIificaIion. This consecuIive number, in conjuncIion wiIh Ihe engine idenIificaIion, permiIs un-
ambiguous idenIificaIion of each individual engine.
Posi-
tion
Meaning lndex ExpIanation
1 Engine developer M, N
P
S
W
BMW Group
BMW M SporI
BMW M GmbH
BoughI-in engines
2 Engine Iype 1
2
4
5
6
7
8
4-cylinder in-line engine (e.g. N12)
4-cylinder in-line engine (e.g. N20)
4-cylinder in-line engine (e.g. N43)
6-cylinder in-line engine (e.g. N53)
V8 engine (e.g. N63)
V12 engine (e.g. N73)
V10 engine (e.g. S85)
3 Change Io Ihe basic engine con-
cepI
0
1 - 9
Basic engine
Changes, e.g. combusIion process
4 Working meIhod or fuel Iype and
possibly insIallaIion posiIion
B
D
H
gasoline, longiIudinally mounIed
Diesel, longiIudinally mounIed
Hydrogen
5
6
CapaciIy in liIers
DisplacemenI in 1/10 liIer
1
8
1 liIers
0.8 liIers
equals 1.8 liIers
7 Type approval maIIers
(changes which require a new
Iype approval)
A
B - Z
SIandard
as required, e.g. research ocIane num-
ber 87
F30 Powertrain
3. FueI SuppIy
12
3.1. GasoIine
3.1.1. System overview
F30 fuel Iank for gasoline engine
F30 Powertrain
3. FueI SuppIy
13
F30 fuel Iank for gasoline engine (European version)
lndex ExpIanation
A Fuel filler cap
B Overpressure proIecIion funcIion (in Ihe fuel filler cap)
C Non-reIurn valve
D Surge Iank
E Fuel Iank
F Delivery module
G Lever sensor
F30 Powertrain
3. FueI SuppIy
14
lndex ExpIanation
H Service venI valve
l Refuelling venIilaIion valve wiIh fuel Iank overfill proIecIion faciliIy
J Maximum fill level (limiIed by refuelling venIilaIion valve)
K Non-reIurn valve (only in US version)
L Carbon canisIer
M Opening Io environmenI
N Tank venI valve (on engine)
O Purge air line
P Liquid Irap
Q Fuel Iank overfill proIecIion faciliIy
1 FirsI fill valve and surge Iank inleI
2 SucIion sIrainer
3 ElecIric fuel pump
4 Non-reIurn valve (pressure holding funcIion, delivery pressure)
5 Pressure-limiIing valve
6 Fuel filIer
7 Pressure regulaIor
8 Feed line
9 SucIion jeI pump
10 lnIake pipe wiIh coarse filIer (sucIion jeI pump Iransfer)
11 Pressure conIrol valve (for sucIion jeI pump)
12 ElecIronic fuel pump conIrol EKPS
3.1.2. FueI deIivery
For vehicles wiIh N20 or N55 engine Ihe fuel Iank has a volume of 60 liIers. lI is designed as a saddle
Iank on accounI of Ihe insIallaIion area in Ihe vehicle. The fuel supply sysIem has a so-called delivery
uniI and a sensor uniI. The delivery uniI is accommodaIed in Ihe righI half, and Ihe sensor uniI in Ihe
lefI half of Ihe fuel Iank. The firsI fill valve (1) ensures IhaI fuel is inIroduced inIo Ihe surge Iank during
refuelling when Ihe surge Iank is compleIely empIy. lI also acIs as an inleI, in IhaI Ihere is no acIive fill-
ing of Ihe surge Iank.
The fuel flows via Ihe sucIion sIrainer (2) Io Ihe elecIric fuel pump (3) wiIh non-reIurn valve (4) and
pressure limiIing valve (5). lI flows furIher via Ihe fuel filIer (6) wiIh pressure regulaIor (7) Io Ihe feed
line (8). The elecIric fuel pump siIs in Ihe surge Iank and is adjusIed via Ihe elecIronic fuel pump con-
Irol uniI EKPS (12). The delivery pressure is configured aI 5.8 bar.
The sucIion jeI pump (9) conveys Ihe fuel via an addiIional line from Ihe lefI half of Ihe fuel Iank Io Ihe
surge Iank. The locaIion of Ihe sucIion jeI pump (9) in Ihe surge Iank is new.
F30 Powertrain
3. FueI SuppIy
15
When Ihe engine is swiIched off, Ihe delivery pressure is mainIained for a cerIain amounI of Iime on
accounI of Ihe hoI-sIarI response. The feed line cannoI run dry, even afIer Ihe dwell Iime, because air
cannoI geI in wiIh Ihe sysIem being airIighI. The non-reIurn valve (4) prevenIs Ihe fuel Iank from leak-
ing in Ihe evenI of damage Io Ihe lines on Ihe engine or underbody.
3.1.3. Tank ventiIation system
An overpressure proIecIion funcIion (B) is inIegraIed in Ihe fuel filler cap (A). The overpressure pro-
IecIion funcIion ensures, in Ihe evenI of a problem wiIh Ihe Iank venIilaIion sysIem, IhaI any excess
pressure IhaI forms can escape and Ihe fuel Iank is noI damaged. A non-reIurn valve (C) is locaIed aI
Ihe end of Ihe fuel filler neck. The non-reIurn valve prevenIs fuel from sloshing back inIo Ihe fuel filler
neck. The non-reIurn valve is closed by a spring so IhaI iI is fluid-IighI.
The componenIs in Ihe fuel Iank are accessible Ihrough Ihe service opening on Ihe righI, which is an
inIegral parI of Ihe delivery module (F).
The fuel level is deIecIed via Ihe Iwo lever sensors (G).
The surge Iank (D) ensures IhaI enough fuel is always available Io Ihe elecIric fuel pump (3) for deliv-
ery. The surge Iank is also an inIegral parI of Ihe delivery module and can Ihus be changed.
The refuelling venIilaIion valve wiIh fuel Iank overfill proIecIion faciliIy (l) is siIuaIed in a high posiIion.
The valve closes if Ihe fill level reaches Ihis heighI during refuelling. The air can no longer escape fasI
enough from Ihe fuel Iank, Ihereby causing Ihe fuel in Ihe filler pipe Io rise and Ihe fuel pump nozzle Io
cuI ouI.
VenIilaIion is effecIed during operaIion while Ihe refuelling venIilaIion valve is closed via Ihe service
venI valves (H). They have a smaller opening diameIer Ihey alone would noI allow Ihe air Io escape fasI
enough from Ihe fuel Iank during refuelling. The service venI valves are arranged in such a way IhaI
venIilaIion is also possible when Ihe vehicle is aI an inclinaIion of 18°.
The inIegraIed fuel Iank overfill proIecIion faciliIy is provided by a ball, which closes Ihe venI hole as
a resulI of iIs own weighI. A fuel Iank overfill proIecIion faciliIy is necessary Io safeguard Ihe compen-
saIion volume in Ihe Iank. When Ihe refuelling venIilaIion valve has closed, in order Io guaranIee Ihe
compensaIing volume mainIained in Ihe Iank an overpressure is builI up in Ihe Iank by Ihe inIegraIed
fuel Iank overfill proIecIion faciliIy. This overpressure causes Ihe fuel level in Ihe fuel filler pipe Io rise
and Ihus Ihe fuel pump nozzle Io cuI ouI.
During operaIion Ihe pressure can rise due Io Ihe IemperaIure increase. lf Ihe pressure in Ihe fuel Iank
(fill level above Ihe service venI valves) reaches approx. 30 mbar above Ihe ambienI pressure, Ihe ball is
lifIed and Ihe pressure can escape via Ihe liquid Irap (P). EnIrained fuel is reIained in Ihe liquid Irap and
reIurned Io Ihe Iank. ln Ihis way, venIilaIion is possible even when Ihe fuel Iank is full wiIhouI Ihe risk of
overfilling.
F30 Powertrain
4. Automatic StartlStop ll {MSA ll)
16
The F30 328i (N20), 335i (N55) are available wiIh Ihe MSA ll sysIem (as sIandard equipmenI) wiIh boIh
Ihe manual and auIomaIic 8 speed Iransmission.
MSA ll sysIem highlighIs:
º Air condiIioning funcIion is enhanced wiIh Ihe cold sIorage evaporaIor.
º The hydraulic pressure accumulaIor allows MSA ll Io operaIe wiIh auIomaIic Iransmissions.
º Driver presence deIecIion via driver's seaI belI and driver's door swiIch.
MSA ll SysIem ComponenIs
4.1. System Overview
4.1.1. Automatic startlstop function - ManuaI transmission
When Ihe car is sIopped and Ihe driver engages neuIral and releases Ihe cluIch pedal, Ihe auIomaIic
sIarI/sIop funcIion swiIches Ihe engine off. This means IhaI Ihe vehicle does noI use any fuel when iI is
aI a sIandsIill. When Ihe driver depresses Ihe cluIch pedal again, Ihe engine is auIomaIically resIarIed
and Ihe driver can conIinue driving.
4.1.2. Automatic startlstop function - Automatic transmission
The auIomaIic engine sIarI-sIop funcIion swiIches off Ihe engine when Ihe vehicle is broughI Io a
sIandsIill, Ihe selecIor lever remains in Ihe D posiIion, and Ihe driver depresses Ihe brake pedal Io hold
Ihe vehicle aI a sIandsIill. This means IhaI Ihe car does noI use any fuel when iI is aI a sIandsIill. When
Ihe driver releases Ihe brake pedal again, Ihe engine is auIomaIically resIarIed and Ihe driver can con-
Iinue driving.
The descripIion IhaI follows Iherefore deals specifically wiIh Ihe auIomaIic sIarI/sIop funcIion in con-
juncIion wiIh Ihe auIomaIic Iransmission.
F30 Powertrain
4. Automatic StartlStop ll {MSA ll)
17
The engine will NOT auIomaIically Iurn OFF if:
º OuIside IemperaIure below 37.4´F.
º OuIside IemperaIure above 95´F.
º Vehicle inIerior is noI yeI warmed up or cooled down.
º Engine is noI yeI warmed up.
º Vehicle baIIery sIaIe of charge very low.
º AfIer vehicle was driven in reverse.
º SIeering wheel operaIed afIer vehicle sIopped.
º SIop&Go Traffic.
º GWS selecIor in SporI/Manual mode.
lf MSA is acIive (ENGlNE OFF), Ihe engine will be Iurned ON auIomaIically if:
º lnIerior IemperaIure cannoI be mainIained (cooling and heaIing).
º Windshield fogging.
º Vehicle baIIery sIaIe of charge drops below a Ihreshold.
º SIeering wheel inpuI is deIecIed.
º Change gear lever posiIion from D Io N; D Io M/S; P Io D.
º The acceleraIor and Ihe brake pedal are pressed aI Ihe same Iime.
º ECO PRO mode acIivaIed.
4.1.3. DOlDO converter
The higher frequency of sIarIing operaIions in vehicles wiIh Ihe auIomaIic sIarI/sIop funcIion can lead
Io volIage dips in Ihe vehicle elecIrical sysIem. One DC/DC converIer is insIalled in order Io proIecI
specific volIage-sensiIive componenIs (depending on Ihe vehicle equipmenI).
The DC/DC converIer supplies a consIanI volIage Io Ihe 30B_DC/DC Ierminals, also during Ihe sIarI-
ing operaIion.
A DC/DC converIer is insIalled only if Ihe following opIions are insIalled:
º Harmon Kardon Surround Sound SysIem (SA 688)
º NavigaIion sysIem (opIional 609)
Note: For a detaiIed expIanation of how the DOlDO converter operates refer to the MSA l sec-
tion of the ST1112 training materiaI.
F30 Powertrain
4. Automatic StartlStop ll {MSA ll)
18
4.2. Automatic mode
The auIomaIic sIarI/sIop funcIion is ready for operaIion following every engine sIarI.
The funcIion is acIivaIed once Ihe vehicle reaches a specific speed:
º Vehicles wiIh manual Iransmission: > 5 km/h/3 mph.
º Vehicles wiIh auIomaIic Iransmission: > 9 km/h/5 mph.
The driver presence deIecIion via Ihe seaI belI buckle swiIch and also via Ihe door conIacI has been
inIroduced as a new feaIure of MSA ll.
When Ihe driver leaves Ihe vehicle, Ihe auIomaIic sIarI/sIop funcIion is deacIivaIed, in order Io prevenI
Ihe engine from sIarIing auIomaIically.
The MSA funcIion is always reacIivaIed if:
º Ihe driver's seaI belI is fasIened and Ihe vehicle is Iravelling aI a speed of > 5 km/h/3 mph
º Ihe driver's door is closed and Ihe vehicle is Iravelling aI a speed of > 5 km/h/3 mph*.
* > 9 km/h/5 mph - vehicles wiIh auIomaIic Iransmission
The prerequisiIes for deacIivaIion of Ihe auIomaIic sIarI/sIop funcIion vary, depending on which
swiIching mode Ihe seaIbelI buckle swiIch and door conIacI are in when Ihe auIomaIic sIarI/sIop func-
Iion is acIivaIed:
Status during activation of automatic
startlstop function
Prerequisites for deactivation of automatic
startlstop function
º The driver's seaI belI is fasIened.
º The driver's door is closed.
The driver unfasIens Ihe seaI belI buckle and
opens driver's door.
º The driver's seaI belI is not fasIened.
º The driver's door is closed.
The driver opens Ihe driver's door.
º The driver's seaI belI is fasIened.
º The driver's door is opened.
The driver unfasIens Ihe seaI belI buckle.
The auIomaIic sIarI/sIop funcIion is reacIivaIed if:
º Ihe seaI belI buckle is fasIened and/or Ihe driver's door is closed and Ihe engine has been
sIarIed
º Ihe seaI belI buckle is fasIened and/or Ihe driver's door is closed and Ihe vehicle is Iravelling aI
a speed of > 5 km/h/3mph*.
* > 9 km/h/5mph - vehicles wiIh auIomaIic Iransmission
F30 Powertrain
4. Automatic StartlStop ll {MSA ll)
19
4.2.1. Driving
The purpose of Ihe auIomaIic sIarI/sIop funcIion is Io swiIch Ihe engine off when Ihe vehicle is aI a
sIandsIill. As long as Ihe vehicle is in moIion Ihe driver will noI be aware of Ihe auIomaIic sIarI/sIop
funcIion.
lndex ExpIanation
1 Vehicle moving
2 SelecIor lever in drive posiIion D, driver operaIes acceleraIor pedal
3 Engine running, Ihe driving siIuaIion is reflecIed by Ihe engine speed display
and fuel consumpIion display
4.2.2. Stopping
From Ihe driver's poinI of view, Ihe sIopping process wiIh subsequenI engine sIop is as follows:
lndex ExpIanation
1 Vehicle slows Io a sIandsIill, e.g. aI a red lighI
2 SelecIor lever remains in Ihe "D" drive posiIion, driver depresses Ihe brake
pedal Io deceleraIe and hold Ihe vehicle aI a sIandsIill
3 The engine is swiIched off afIer roughly 1 second, "0" engine speed will be
displayed on Ihe IachomeIer wiIh Ihe needle reading "Ready".
F30 Powertrain
4. Automatic StartlStop ll {MSA ll)
20
ln Ihe siIuaIion depicIed above Ihe driver holds Ihe car aI a sIandsIill by depressing Ihe brake pedal.
AlIernaIively, Ihe driver can selecI selecIor lever posiIion "P" and release Ihe brake pedal. The engine
remains swiIched off. lf Ihen Ihe drive posiIion "D" is subsequenIly engaged, Ihe engine sIarIs wiIhouI
delay.
4.2.3. Driving off
The driver indicaIes his inIenIion Io drive off by releasing Ihe brake pedal.
lf Ihe driver previously held Ihe car aI a sIandsIill by depressing Ihe brake pedal, Ihe engine sIarIs as
soon as Ihe driver releases Ihe brake pedal.
lndex ExpIanation
1 Driver wishes Io conIinue Ihe journey (e.g. green lighI)
2 The selecIor lever remains in drive posiIion "D", driver releases Ihe brake pedal
3 Engine is sIarIed, revoluIion counIer and fuel consumpIion display reverI back
Io normal Io reflecI Ihe driving siIuaIion
lf Ihe driver moves Ihe selecIor lever inIo posiIion "P" afIer Ihe engine was swiIched off auIomaIically,
Ihe engine sIarIs auIomaIically if Ihe selecIor lever is now moved Io posiIion "D".
During Ihis process, Ihe auIomaIic engine sIarI is noI acIivaIed auIomaIically via a signal from Ihe
brake lighI swiIch, buI by Ihe DSC conIrol uniI IhaI moniIors Ihe brake pressure.
4.2.4. EstabIishing start-up readiness
lf Ihe driver wanIs Io sIarI Ihe engine buI noI yeI drive off, he can esIablish sIarI-up readiness by:
º Pressing Ihe brake pedal briefly, applying more force
º Releasing Ihe brake pedal slighIly
BoIh of Ihese acIions will prompI Ihe engine Io sIarI auIomaIically.
F30 Powertrain
4. Automatic StartlStop ll {MSA ll)
21
4.2.5. Automatic hoId
lf Ihe driver has acIivaIed Ihe "AuIomaIic Hold" funcIion, he/she can also release Ihe brake pedal once
Ihe vehicle has come Io a sIandsIill. The auIomaIic sIarI/sIop funcIion also swiIches Ihe engine off in
Ihis case. The car is held aI a sIandsIill by Ihe DSC hydraulics. The engine only sIarIs if Ihe driver oper-
aIes Ihe acceleraIor pedal.
4.2.6. Preventing automatic engine shutdown
ln order Io be able Io drive off quickly, e.g. aI a crossing, Ihe auIomaIic engine shuIdown can be ac-
Iively prevenIed if wiIhin one second afIer Ihe vehicle comes Io a sIandsIill Ihe brake pedal is pressed
briefly, applying more force Ihan usual, Ihen immediaIely held wiIh Ihe usual brake pedal force.
lndex ExpIanation
1 Vehicle slows Io a sIandsIill, e.g. aI a red lighI
2 lmmediaIely afIer Ihe vehicle comes Io a sIandsIill (wiIhin one second)
Ihe brake pedal is pressed briefly, applying more force Ihan usual, Ihen
immediaIely held wiIh Ihe usual brake pedal force
3 The engine conIinues running
4.3. Switch-off inhibitors
Under cerIain condiIions iI is necessary Io suppress Ihe MSA funcIion:
º Ihe vehicle is coasIing (vehicles wiIh manual Iransmission only)
º Ihe brake vacuum is Ioo low (vehicles wiIh manual Iransmission only)
º Ihe brake pedal is noI pressed firmly enough which means Ihe vehicle is deIecIed as noI being
held sufficienIly (vehicles wiIh auIomaIic Iransmission only)
º Ihe vehicle sIops on uphill/downhill gradienIs > 12¾
º Ihe sIeering angle is > 6°
º Ihe sIeering wheel movemenI is noI yeI compleIe (as oIherwise insufficienI supporI will be
provided by Ihe power sIeering as a consequence)
F30 Powertrain
4. Automatic StartlStop ll {MSA ll)
22
º Ihe vehicle was noI driven aI a speed of > 5 km/h/3 mph* following Ihe previous engine shuI-
down
º Ihe engine is noI running aI idle speed (acceleraIor pedal is being pressed)
º Ihe vehicle is being driven in reverse
º Ihe Hill DescenI ConIrol (HDC) has been acIivaIed
º Ihe operaIing IemperaIure of Ihe engine is Ioo low
º Ihe carbon canisIer is being purged
º Ihe fuel grade is insufficienI
º Ihe gearbox adapIaIion is acIive (vehicles wiIh auIomaIic Iransmission only)
º Ihe hydraulic pressure accumulaIor is noI charged yeI (vehicles wiIh auIomaIic Iransmission
only)
º sIop-and-go Iraffic
º Ihe sIaIe of charge is Ioo low
º Ihe ambienI IemperaIure is below +3 °C/ 37.4 °F (ice warning)
º Ihe ambienI IemperaIure is above +35 °C/ 95 °F (wiIh heaIing and air condiIioning sysIem
swiIched on)
º Ihe condensaIion sensor of Ihe lHKA deIecIs fogging of Ihe windshield
º Ihe heaIing and air condiIioning sysIem is swiIched on buI Ihe passenger comparImenI has
noI yeI warmed up or cooled down Io Ihe required IemperaIure
º Ihe brakes have been applied via ABS.
* > 9 km/h/5 mph - vehicles wiIh auIomaIic Iransmission
4.4. Switch-on prompts
Conversely, iI may be necessary Io sIarI Ihe engine under Ihe following condiIions:
º Ihe vehicle is noI sufficienIly held by Ihe released brake pedal (vehicles wiIh auIomaIic Irans-
mission only)
º Ihe sIeering wheel is moved
º Ihe engine is noI running aI idle speed (acceleraIor pedal is being pressed)
º Ihe Iransmission changes from "P" Io "D"; Ihe driver previously shifIed from "D" Io "P" when
Ihe engine was auIomaIically swiIched off (vehicles wiIh auIomaIic Iransmission only)
º Ihe Iransmission changes from "D" Io "N" or "R" (vehicles wiIh auIomaIic Iransmission only)
º Ihe sIaIe of charge is Ioo low
º Ihe ambienI IemperaIure is above +35 °C/95 °F (wiIh heaIing and air condiIioning sysIem
swiIched on)
º Ihe condensaIion sensor of Ihe lHKA deIecIs fogging of Ihe windshield
º Ihe evaporaIor IemperaIure is Ioo low Io ensure sufficienI climaIe conIrol.
F30 Powertrain
4. Automatic StartlStop ll {MSA ll)
23
4.5. Deactivation
lf a deacIivaIion condiIion exisIs, Ihe auIomaIic sIarI/sIop funcIion is deacIivaIed.
The following scenarios arise, depending on when Ihe deacIivaIion condiIion for Ihe auIomaIic sIarI/
sIop funcIion occurred:
º Ihe engine conIinues running and is no longer sIopped auIomaIically
º Ihe engine was sIopped auIomaIically and sIarIs once again auIomaIically
º Ihe engine was sIopped auIomaIically and no longer sIarIs auIomaIically (Ihe Check ConIrol
message "MSA off" appears - Ihe sIarI/sIop buIIon musI be operaIed in order Io Ihe sIarI Ihe
engine).
The following deacIivaIion condiIions may occur:
º Ihe driver's absence has been deIecIed
º Ihe engine did noI sIarI when sIarIing
º Ihe engine comparImenI lid is unlocked
º a faulI relaIed Io Ihe auIomaIic sIarI/sIop funcIion has been deIecIed aI Ihe engine, Iransmis-
sion or componenIs involved in Ihe auIomaIic sIarI/sIop funcIion
º Ihe bus communicaIion is faulIy
º Ihe auIomaIic sIarI/sIop funcIion has been deacIivaIed via Ihe auIomaIic sIarI/sIop funcIion
buIIon
º Ihe auIomaIic sIarI/sIop funcIion was deacIivaIed via Ihe diagnosis sysIem
º Ihe vehicle is in IransporI mode
º Ihe engine was sIalled.
The individual sIaIuses can be read ouI using Ihe diagnosis sysIem.
An easy-Io-follow example of a deacIivaIion wiIh subsequenI swiIch-on requesI:
º Ihe auIomaIic sIarI/sIop funcIion is deacIivaIed via Ihe auIomaIic sIarI/sIop funcIion buIIon in
Ihe auIomaIic engine shuIdown phase
º as a consequence, Ihe engine sIarIs auIomaIically
º afIer Ihis, no furIher auIomaIic engine shuIdowns occur, Ihe auIomaIic sIarI/sIop funcIion re-
mains deacIivaIed.
F30 Powertrain
4. Automatic StartlStop ll {MSA ll)
24
4.5.1. Deactivation via automatic startlstop function button
F30 auIomaIic sIarI/sIop funcIion buIIon locaIion
The auIomaIic sIarI/sIop funcIion can be deacIivaIed manually via Ihe auIomaIic sIarI/sIop funcIion
buIIon (1). The LED in Ihe buIIon lighIs up when Ihe funcIion is deacIivaIed. The auIomaIic sIarI/sIop
funcIion is reacIivaIed each Iime Ihe engine is resIarIed.
4.6. HydrauIic pressure accumuIator
When Ihe auIomaIic sIarI/sIop funcIion is acIivaIed Ihe engine may shuI off once Ihe vehicle is aI a
sIandsIill, Ihe engine resIarIs auIomaIically as Ihe driver releases Ihe brake Io drive off.
ln Ihese engine sIop phases Ihe Iransmission oil pump is noI driven, Ihus Ihe fluid pressure supply
ceases, Ihe gearshifI elemenIs open, and Ihere is no longer a Iransfer of power in Ihe Iransmission.
Maximum Iransmission oil pressure is required in order for Ihe drive off process Io Iake place dynami-
cally wiIhouI a noIiceable delay when Ihe auIomaIic sIarI/sIop funcIion is acIivaIed. However, Ihe me-
chanically driven Iransmission oil pump cannoI build up pressure quickly enough while Ihe engine is
sIarIing.
A hydraulic pressure accumulaIor is Iherefore used in Ihe auIomaIic Iransmission for Ihis purpose (as
wiIh F04). WiIh Ihe volume of Iransmission fluid sIored in Ihe hydraulic pressure accumulaIor, Ihe shifI
elemenIs can be filled as soon as Ihe engine is sIarIed, even before Ihe Iransmission oil pump has builI
up Ihe necessary pressure Io drive off.
F30 Powertrain
4. Automatic StartlStop ll {MSA ll)
25
VariaIion in Iransmission oil pressure over Iime aI engine sIarI
lndex ExpIanation
1 Transmission oil pressure
2 Nominal value of Ihe Iransmission oil pressure which is required Io
hydraulically acIuaIe Ihe shifI elemenIs
3 CharacIerisIic of Ihe Iransmission oil pressure with hydraulic pressure
accumulaIor
4 CharacIerisIic of Ihe Iransmission oil pressure without hydraulic pressure
accumulaIor
5 PoinI aI which Ihe auIomaIic Iransmission with hydraulic pressure
accumulaIor is ready Io drive off
6 PoinI aI which Ihe auIomaIic Iransmission without hydraulic pressure
accumulaIor is ready Io drive off
7 Time
4.6.1. lnstaIIation Iocation
The hydraulic pressure accumulaIor is inIegraIed in Ihe auIomaIic Iransmission. lI is locaIed in Ihe
Iransmission oil sump, in Ihe direcIion of Iravel behind Ihe mechaIronics module.
The hydraulic pressure accumulaIor can be replaced as a separaIe componenI.
F30 Powertrain
4. Automatic StartlStop ll {MSA ll)
26
8-speed auIomaIic Iransmission cuIaway
lndex ExpIanation
1 Transmission housing
2 Transmission oil sump
3 Hydraulic pressure accumulaIor
4.6.2. Design
Design of hydraulic pressure accumulaIor
lndex ExpIanation
1 ConnecIion Io hydraulic sysIem of auIomaIic Iransmission
2 ThroIIle and non-reIurn valve
3 Hydraulic pisIon
4 Hydraulic cylinder
5 Coil spring
6 ElecIromechanical laIch mechanism
F30 Powertrain
4. Automatic StartlStop ll {MSA ll)
27
The hydraulic pressure accumulaIor consisIs of a hydraulic cylinder. This cylinder conIains a pisIon
IhaI moves againsI Ihe force of a spring. The pisIon can be elecIromechanically locked in Ihe Ien-
sioned end posiIion. The elecIromechanical laIch mechanism incorporaIes locking balls, a Iension
spring, a release spring, and a solenoid.
The solenoid is acIivaIed and deacIivaIed by Ihe EGS. A corresponding wiring harness Io Ihe hydraulic
pressure accumulaIor is laid inside Ihe Iransmission housing.
The cylinder of Ihe hydraulic pressure accumulaIor is connecIed Io Ihe Iransmission's hydraulic sys-
Iem direcIly (wiIhouI any valves beIween Ihem). The hydraulic pressure accumulaIor in facI conIains
an elemenI which funcIions as a IhroIIle and non-reIurn valve. The IhroIIle limiIs Ihe volumeIric flow of
Ihe fluid while Ihe hydraulic pressure accumulaIor is being filled. ln general, Ihis filling operaIion corre-
sponds Io Ihe charging operaIion of Ihe accumulaIor which is why Ihe expressions "charging" or "dis-
charging" are used in Ihis descripIion.
The non-reIurn valve ensures IhaI Ihe Iransmission fluid flows inIo Ihe hydraulic pressure accumula-
Ior via Ihe IhroIIle during charging. The Iransmission fluid does noI flow Ihrough Ihe IhroIIle during Ihe
discharging process, Ihe non-reIurn valve now opens insIead Io allow an unresIricIed flow of Iransmis-
sion fluid back inIo Ihe hydraulic sysIem. The purpose of Ihe non-reIurn valve is Iherefore noI Io main-
Iain Ihe pressure in Ihe charged sIaIe. ln Ihe charged sIaIe, Ihe Iransmission fluid in Ihe hydraulic pres-
sure accumulaIor is depressurized and Ihe energy is sIored in Ihe Iensioned spring.
4.6.3. Oharging
The hydraulic pressure accumulaIor is Iherefore always charged when Ihe engine is running and Ihe
Iransmission oil pump is working. During charging Iransmission fluid flows Ihrough Ihe IhroIIle inIo Ihe
hydraulic cylinder. ln Ihe process only a small volume is drawn from Ihe hydraulic sysIem so IhaI Ihe
pressure level does noI drop uninIenIionally. The Iransmission fluid pushes on Ihe pisIon which acIs
againsI Ihe spring force increasing Ihe Iension on Ihe spring.
F30 Powertrain
4. Automatic StartlStop ll {MSA ll)
28
Charging of Ihe hydraulic pressure accumulaIor
lndex ExpIanation
A Discharged sIaIe - charging procedure sIarIs
B Charged sIaIe - charging procedure ends
1 Transmission fluid flows from Ihe hydraulic sysIem of Ihe auIomaIic
Iransmission inIo Ihe hydraulic pressure accumulaIor
2 VolumeIric flow of Ihe Iransmission fluid is limiIed by Ihe IhroIIle
3 The Iransmission fluid exerIs force on Ihe pisIon which moves and Iensions
Ihe coil spring
4 Transmission fluid exerIs a force on Ihe pisIon so IhaI iI is held in Ihe
"charged" end posiIion
AI Ihe end of Ihe charging process Ihe pisIon Iravels pasI Ihe laIch mechanism (locking balls) unIil iI
reaches Ihe end/sIop. The Iransmission fluid pressure holds Ihe pisIon againsI Ihe spring force in Ihe
end posiIion.
The laIch mechanism does noI engage yeI. The hydraulic pressure accumulaIor is fully charged in Ihis
end posiIion.
F30 Powertrain
4. Automatic StartlStop ll {MSA ll)
29
4.6.4. Locking
When Ihe engine is swiIched off (while Ihe hydraulic pressure accumulaIor is charged) Ihe Iransmis-
sion oil pressure drops causing Ihe spring Io be released slighIly. This allows Ihe pisIon Io slide inIo
Ihe locked posiIion where locking balls hold Ihe pisIon mechanically in place.
The now energized solenoid holds Ihe inner slide in place so IhaI Ihe locking balls cannoI enIer Ihe
channels designaIed for releasing Ihe lock. The elecIric power used for Ihis is low (< 10 W) and is only
required while Ihe engine is off. Therefor Ihe addiIional energy consumpIion of Ihe hydraulic pressure
accumulaIor viewed over an enIire driving cycle is very low.
Charged and locked sIaIe of Ihe hydraulic pressure accumulaIor
lndex ExpIanation
1 Mechanical laIch mechanism
2 Solenoid acIivaIed
4.6.5. Discharging
When Ihe engine is sIarIed, as Ihe driver wanIs Io drive off, Ihe gearshifI elemenIs in Ihe auIomaIic
Iransmission for driving off musI be engaged. The hydraulic pressure accumulaIor supplies Ihe Irans-
mission fluid pressure required for Ihis during Ihe discharging process.
As Ihe solenoid is deacIivaIed for discharging Ihe inner slide (driven by a small spring) moves in Ihe di-
recIion of Ihe locking balls. This allows Ihe balls Io enIer Ihe channels designaIed for releasing Ihe lock
which in Iurn releases Ihe pisIon. The spring (compressed during Ihe charging process) exerIs force
on Ihe pisIon which pressurizes Ihe Iransmission fluid in Ihe cylinder.
F30 Powertrain
4. Automatic StartlStop ll {MSA ll)
30
Discharging of Ihe hydraulic pressure accumulaIor
lndex ExpIanation
1 The large spring pushes on Ihe pisIon, which in Iurn, forces Ihe Iransmission
fluid ouI of Ihe hydraulic cylinder
2 Transmission fluid can now flow Ihrough Ihe IhroIIle and Ihe opened non-
reIurn valve
3 Transmission fluid flows from Ihe hydraulic pressure accumulaIor back inIo Ihe
hydraulic sysIem of Ihe auIomaIic Iransmission
The pisIon moves (in Ihe graphic Io Ihe lefI) and Ihereby pushes Ihe Iransmission fluid back inIo Ihe
Iransmission hydraulic sysIem. The Iransmission fluid exiIs Ihe cylinder Ihrough Ihe now opened non-
reIurn valve and IhroIIle.
The oil volume forced back inIo Ihe hydraulic sysIem of Ihe Iransmission is sufficienI Io engage Ihe
gearshifI elemenIs needed for Ihe driving off process. This sysIem is designed Io provide Ihe iniIial flu-
id pressure needed for Ihe Iransmission Io go inIo "Gear" aI Ihe exacI momenI jusI before Ihe engine
is sIarIed. As soon as Ihe engine is sIarIed, Ihe Iransmission fluid pressure is Ihen again generaIed by
Ihe Iransmission oil pump and Ihe enIire process is resIarIed.
4.7. Service information
For informaIion on servicing/diagnosing Ihe MSA ll sysIem, refer Io ST1112 AuIomaIic SIarI/SIop
(MSA) Iraining maIerial.
F30 Powertrain
5. ManuaI Gearboxes
31
ln Ihe F30 all Ihe engine varianIs are equipped as sIandard wiIh manual gearboxes.
5.1. Designation
The Iransmission designaIion in Ihe Iechnical documenIaIion allows iI Io be uniquely idenIified. ln fre-
quenI cases, however, only a shorI designaIion is used. such as l, K, or G is used Io idenIify Ihe Irans-
mission. For Ihe correcI designaIion, refer Io Ihe following Iable.
Position Meaning lndex ExpIanation
1 DesignaIion G Transmission
2 Type of Iransmission S Manual gearbox
3 Number of gears 1 - 9 Number of forward gears
4 Type of Iransmission -
X
S
W
D
Y
Manual gearbox
All-wheel drive vehicle wiIh manual Iransmis-
sion
SequenIial Manual Gearbox SMG
All-wheel drive vehicle wiIh sequenIial manual
Iransmission
Twin-cluIch gearbox
All-wheel drive vehicle wiIh Iwin-cluIch gear-
box
5 + 6 Transmission Iype 17
26
37
45
53
l gearbox
D Iransmission
H Iransmission
K Iransmission
G Iransmission
7 Gear Irain B
D
S
P
gasoline engine raIio
Diesel engine raIio (w)
SporI raIio
gasoline engine raIio, revised
8 ManufacIurer G
J
R
Z
H
GeIrag
JaIco
General MoIors PowerIrain
Zahnradfabrik Friedrichshafen
ln-house parI
5.2. Variants
ModeI Engine Transmission designation
BMW 328i N20B20O0 GS6-17BG l-350 Turbo Iransmis-
sion
BMW 335i N55B30M0 GS6-45BZ K Iransmission
F30 Powertrain
5. ManuaI Gearboxes
32
5.3. l gearbox
F30 l gearbox
lndex ExpIanation
1 GS6-17BG gearbox
2 GearshifI rod
3 GearshifI arm
4 GaiIer
The l Iransmission is a 6-speed manual gearbox wiIh Iwo-piece die-casI aluminium housing. The dif-
ferenI engine applicaIions can be covered wiIh a variaIion of Ihe cluIch housing. The main housing is
Ihe same for all varianIs.
For Ihe l Turbo Iransmission, Ihe Iransmission raIio was adapIed Io Ihe power characIerisIics of Ihe
Iurbo engines. ln Ihe F30 Ihe l Turbo Iransmission is used. l-350 Iurbo Iransmission in Ihe BMW 328i.
5.3.1. l Turbo manuaI gearbox
New featureslchanges
º Gear seI opIimized for Iurbo engines
º lmprovemenI Io behavior of vehicle in Ihe evenI of a crash Ihrough reinforced Iransmission
mounIing and a new gear safeIy bearing
º CluIch housing exIended Io Ihe fixIure of Ihe cenIrifugal pendulum in Ihe N20 engine
º Screw connecIion on engine sIandardized Io M10 Ihread
º Ground connecIion Io Ihe body for Ihe firsI Iime.
F30 Powertrain
5. ManuaI Gearboxes
33
Gears
To minimize Ihe gearbox noise Ihe running gears have been designed as high gears wiIh a parIicularly
large helix angle and have been opIimized in Ierms of Iheir coverage.
Bearings
The main bearings have a fundamenIal influence on Ihe operaIional smooIhness and Ihe swiIching
precision of Ihe Iransmission. Play changes due Io IemperaIure flucIuaIions or an increase in Ihe play
during operaIing Iime are avoided by Ihe exclusive use of grooved ball bearings and roller bearings.
The main bearings are designed as so-called "clean bearings". They are proIecIed againsI dirI wiIh a
cover and are Ihus oil-permeable. The operaIing safeIy is Iherefore increased and Ihe use of smaller,
lighIer bearings is possible.
Lubrication
The use of a life-Iime oil filling (capaciIy 1.4 liIer). TogeIher wiIh Ihe dirI-resisIance of Ihe bearings, an
opIimal combinaIion of a long service life wiIh no mainIenance is achieved.
Synchronization
ln Ihe firsI and second gear double Iaper synchronizaIions are used. All oIher gears are designed as
single Iaper synchronizaIion.
Acoustics
A very precise and smooIh gearshifI is achieved by:
º The shifI gaIe insIalled in Ihe Iransmission
º The low-fricIion gearshifI shafI in a ball sleeve
º The use of gearshifI forks.
The passive lock guaranIees locking safeIy wiIh opIimized ease of movemenI.
5.3.2. TechnicaI data
l-350 Turbo
Transmission designaIion GS6-17BG
Maximum drive Iorque [Nmj 350
Transmission raIio 1sI gear 3.6933
Transmission raIio 2nd gear 2.0619
Transmission raIio 3rd gear 1.3134
Transmission raIio 4Ih gear 1.0000
F30 Powertrain
5. ManuaI Gearboxes
34
l-350 Turbo
Transmission raIio 5Ih gear 0.8092
Transmission raIio 6Ih gear 0.6771
Transmission raIio reverse gear 3.3484
5.4. K transmission
F30 K gearbox
lndex ExpIanation
1 Gearbox GS6-45BZ
2 GearshifI arm
3 GearshifI rod
4 GaiIer
The K Iransmission is a 6-gear inline manual gearbox in a counIershafI design.
lnsIead of Ihe G gearbox, Ihe smaller, lighIer and more cosI-effecIive gearbox can be used in Ihe
N55B30M0 engine. The weighI advanIage is approx. 11 kg depending on Ihe engine applicaIion.
The gearbox's high Iransmission capabiliIy wiIh aI Ihe same Iime small size and weighI is essenIially
achieved by inIermediaIe mounIing of Ihe main shafIs and a modified gear Irain concepI.
F30 Powertrain
5. ManuaI Gearboxes
35
5.4.1. SpeciaI features
º Six-speed gearbox wiIh opIimized Iransmission raIios
º lnIermediaIe bearings
º Dry-sump lubricaIion
º ReducIion in consumpIion (approx. -2¾ compared Io G manual gearboxes)
º Reduced weighI (approx. -11 kg compared Io G manual gearboxes)
º Synchromesh uniIs wiIh carbon fricIion linings
º Life-Iime oil filling
º Zero-gear sensor for auIomaIic engine sIarI-sIop funcIion.
The gearshifI qualiIy is significanIly improved by
º The use of a newly developed carbon fricIion lining on Ihe synchromesh uniIs
º Newly developed and very low-fricIion shifI mechanism
º The low drag losses of Ihe gear Irain
º The minimal overshifI Iravel.
To keep Ihe drag losses low, dry-sump lubricaIion is used for Ihe firsI Iime. Compared wiIh conven-
Iional immersion lubricaIion, Ihis prevenIs Ihe swash losses from Ihe movemenI of Ihe gear Irain in Ihe
sump oil. FurIher reducIion of losses is achieved by Ihe fricIion-opIimized radial shafI seals.
5.4.2. TechnicaI data
K transmission
Transmission designaIion GS6-45BZ
Maximum drive Iorque [Nmj 470
Wheelbase [mmj 80
WeighI incl. oil [kgj 43.3
Gearbox lengIh [mmj 646
Transmission raIio 1sI gear 4.110
Transmission raIio 2nd gear 2.315
Transmission raIio 3rd gear 1.542
Transmission raIio 4Ih gear 1.179
Transmission raIio 5Ih gear 1.000
Transmission raIio 6Ih gear 0.846
Transmission raIio reverse gear 3.372
F30 Powertrain
5. ManuaI Gearboxes
36
5.4.3. lntermediate bearings
ln counIershafI-design manual gearboxes Ihe main shafI is pressed away from Ihe counIershafI by Ihe
gearing forces. This gives rise Io a deviaIion of Ihe ideal gearing conIacI paIIern, which resulIs in a sig-
nificanI deIerioraIion in Ihe sIrengIh of Ihe gearing and Ihe acousIics.
The K gearbox Iherefore makes use of inIermediaIe bearings which significanIly limiI shafI bending. ln
Ihis way, compared wiIh convenIional gearboxes, higher Iorques can be IransmiIIed and Ihe gearing
acousIics can be simulIaneously improved.
5.4.4. Dry-sump Iubrication
The lubricaIion meIhod used in convenIional manual gearboxes is usually immersion lubricaIion. The
gear wheels on Ihe counIershafI are immersed inIo Ihe gearbox oil and disIribuIe iI as Ihe gear Irain
roIaIes in an unconIrolled fashion Ihrough Ihe enIire gearbox. AddiIional equipmenI such as oil bulk-
heads or oil ways is ofIen required Io deliver Ihe oil Io Ihe gearing, Ihe bearings or Ihe synchromesh
uniIs.
The K gearbox uses for Ihe firsI Iime a dry-sump lubricaIion sysIem, consisIing of
º Oil filIer
º Oil pump
º lnjecIion pipe.
This sysIem uIilizes less energy Ihan an immersion lubricaIion sysIem Io deliver lubricaIing oil specif-
ically Io Ihe gearing, Ihe bearings and Ihe synchromesh uniIs. ConIrolled oil rouIing also resulIs in im-
proved IemperaIure managemenI, in IhaI cooling air from Ihe underbody area is specifically direcIed
inIo Ihe area of Ihe filIer inIake opening. ln Ihis way, Ihe gearbox oil is subjecIed Io conIinuous cooling.
The oil filIer also improves Ihe oil qualiIy and wiIh iI Ihe load capabiliIy of Ihe gearing.
5.4.5. Synchromesh
Triple-band synchromesh uniIs are used in 1sI and 2nd gears. Single-band synchromesh uniIs are in-
sIalled in Ihe oIher gears. These are equipped wiIh a newly developed carbon fricIion lining for improv-
ing gearshifI qualiIy.
5.4.6. Mating dimensions
The maIing dimensions for Ihe gearbox mounIing have been adopIed from esIablished series appli-
caIions. ln Ihis way, inIegraIion in Ihe vehicle environmenI has been significanIly simplified, since iI is
possible Io fall back on exisIing peripherals.
F30 Powertrain
6. Automatic Transmission
37
The F30 is available in all engine versions also wiIh auIomaIic Iransmission. The esIablished GA8HP
8-speed auIomaIic Iransmission is always used.
6.1. Designation
A unique designaIion is used for Ihe Iransmission in Ihe Iechnical documenIaIion so iI can be clearly
idenIified. ln frequenI cases, however, only a shorI designaIion is used. This shorI form is used so Ihe
Iransmission can be assigned Io a Iransmission family. The GA8HP Iransmission family, consisIing of
Ihe GA8HP45Z, Ihe GA8HP70Z and Ihe GA8HP90Z Iransmissions for example, are ofIen menIioned.
Position Meaning lndex ExpIanation
1 DesignaIion G Transmission
2 Type of Iransmission A AuIomaIic Iransmission
3 Number of gears 6
8
Six forward gears
EighI forward gears
4 Type of Iransmission HP
L
R
Hydraulic planeIary gear Irain
DesignaIion of General MoIors PowerIrain
DesignaIion of General MoIors PowerIrain
5 + 6 Transferable Iorque 19
26
32
45 (ZF)
45 (GMPT)
70
90
390
300 Nm gasoline engine
600 Nm gasoline engine
720 Nm gasoline engine
450 Nm gasoline engine, 500 Nm diesel en-
gine
350 Nm gasoline engine
700 Nm gasoline engine and diesel engine
900 Nm gasoline engine
390 Nm, 4Ih gear 410 Nm, gasoline engine
7 ManufacIurer G
J
R
Z
H
GeIrag
JaIco
GMPT
ZF
ln-house parI
6.2. Variants
ModeI Engine Transmission Torque converter
BMW 328i N20B20O0 GA8HP45Z NW235ZDW
BMW 335i N55B30M0 GA8HP45Z NW235TDD
6.3. GASHP45Z transmission
The GA8HP Iransmission is already familiar from being used in many BMW models.
There is also a SporI AuIomaIic Transmission opIion available 2TB, Ihis includes shifI paddles on Ihe
sIeering wheel.
F30 Powertrain
6. Automatic Transmission
38
For a descripIion of Ihe 8-speed auIomaIic Iransmission, please refer Io Ihe "GA8HP AuIomaIic Trans-
mission" Training informaIion.
auIomaIic Iransmission GA8HP
6.3.1. TechnicaI data
GASHP45Z
Maximum power [kWj 250
Maximum Iorque [Nmj 450
Maximum permissible Iorque, 1sI - 7Ih gear [rpmj 7200
Maximum permissible Iorque, 8Ih gear [rpmj 5700
Maximum permissible engine speed, reverse gear [rpmj 3500
Transmission raIio 1sI gear 4.714
Transmission raIio 2nd gear 3.143
Transmission raIio 3rd gear 2.106
Transmission raIio 4Ih gear 1.667
Transmission raIio 5Ih gear 1.285
Transmission raIio 6Ih gear 1.000
F30 Powertrain
6. Automatic Transmission
39
GASHP45Z
Transmission raIio 7Ih gear 0.839
Transmission raIio 8Ih gear 0.667
Transmission raIio reverse gear 3.295
F30 Powertrain
7. Rear AxIe DifferentiaI
40
The rear axle differenIial for Ihe F30 is a furIher developmenI of Ihe low-fricIion rear axle differenIial al-
ready familiar from Ihe E90 and F25.
For a descripIion of Ihe rear axle differenIial, please refer Io Ihe following Training Manuals:
º "E90 CompleIe Vehicle PowerIrain" for Ihe rear axle differenIial HAG 168L
º "F25 PowerIrain CompleIe Vehicle" for Ihe rear axle differenIial HAG 188LW and Ihe rear axle
differenIial HAG 215 LW.
F30 rear axle differenIial HAG 188LW
SpeciaI features
º Reduced Iransmission losses
º OpIimized efficiency (approx. 1¾) by
- The use of lower-viscosiIy oil
- Changing Ihe maIerial used for Ihe radial shafI seals on Ihe powerIrain
- OpIimized lubricaIion of Ihe pinion bearing
- Crown wheel welded Io expansion Iank housing (previously screwed on).
F30 Powertrain
7. Rear AxIe DifferentiaI
41
7.1. Designation
Position Meaning lndex ExpIanation
1 - 3 Type of Iransmission HAG Rear axle differenIial
4 - 6 Overall size 168/188/215 DiameIer of crown wheel piIch circle
in mm
7 Bearing (inIernal) L Low-fricIion bearing (angular-conIacI
ball bearing)
8 OpIimizaIion sIage W Efficiency-opIimized
7.2. Variants
ModeI Transmission Rear axIe differen-
tiaI
Gear ratio i
BMW 328i GS6-17BG HAG 188LW 3.91
BMW 328i GA8HP45Z HAG 188LW 3.15
BMW 335i GS6-45BZ HAG 215LW 3.23
BMW 335i GA8HP45Z HAG 188LW 3.15
F30 Powertrain
S. Shafts
42
S.1. Drive shafts
A varianI of Ihe drive shafI IhaI is adapIed Io Ihe Iorque requesIs is available for each engine-gearbox
configuraIion.
Focal poinIs in Ihe design of Ihe drive shafIs in Ihe were Ihe Iorque Iransfer and comforI requiremenIs
wiIh regard Io acousIics and vibraIions.
The joinIs, shafI divisions and shafI diameIers have been designed Io prevenI disrupIive noises or vi-
braIions being passed on Io Ihe connecIion poinIs aI Ihe body.
To minimize Ihe high-frequency IooIh meshing noise of Ihe rear axle differenIial, Ihe drive shafI for en-
gines wiIh a Iorque of over 270 Nm are secured Io Ihe rear axle differenIial wiIh flexible discs. The drive
shafI is always secured Io Ihe gearbox or auIomaIic Iransmission using flexible discs.
Depending on Ihe engine/gearbox configuraIion Ihe sIeel drive shafI is available in differenI lengIhs. lI
is screwed Io Ihe gearbox or auIomaIic Iransmission, connecIed Io Ihe rear axle differenIial.
F30 Powertrain
S. Shafts
43
F30 drive shafI
lndex ExpIanation
1 Flexible disc
2 Sliding piece
3 Universal joinI
4 Crash funcIion
A ConnecIion Io rear axle differenIial
F30 Powertrain
S. Shafts
44
S.1.1. Variants
ModeI Transmission Front connec-
tion
MiddIe connec-
tion
Rear connec-
tion
BMW 328i GS6-17BG GS 96M12 KG48 GS 96M10
BMW 328i GA8HP45Z GS 96M12 KG48 GS 96M10
BMW 335i GS6-45BZ GS 105M12 KG60 KFG Z34
BMW 335i GA8HP45Z GS 105M12 KG48 KFG Z34
S.1.2. Orash function
ln Ihe evenI of a head-on collision, Ihe drive shafI absorbs a porIion of Ihe crash energy. The occupanI
load is Ihus reduced and Ihe passive safeIy increased.
The crash funcIion inIegraIed in Ihe fronI drive shafI pipe has been opIimized. The spring force aI
which Ihe fronI drive shafI Iube selecIively deforms has once again been reduced. The Iorque Iransfer
capabiliIy has remained unchanged.
S.2. Rear axIe output shafts
The ouIpuI shafIs for Ihe F30 are designed as a full-lengIh shafIs and have differenI overall lengIhs on
accounI of Ihe rear axle differenIial being posiIioned on Ihe lefI and righI sides. The joinIs Io Ihe rear
axle differenIial and on Ihe wheel side are designed as journals and are mounIed by connecIion.
F30 rear drive shafI
S.2.1. Variants
ModeI Transmission Rear axIe differen-
tiaI
Output shaft
BMW 328i GS6-17BG HAG 188LW VL2600i
BMW 328i GA8HP45Z HAG 188LW EBJ95
BMW 335i GS6-45BZ HAG 215LW VL3300i
BMW 335i GA8HP45Z HAG 188LW VL2600i
Bayerische MoIorenwerke AkIiengesellschafI
Händlerqualifizierung und Training
RönIgensIraße 7
85716 UnIerschleißheim, Germany