Technical Training. Product Information.

E89 Complete vehicle.

BMW Service 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 notes and information that needs to be observed strictly in order to guarantee the smooth operation of the system.

Information status and national variants 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 left-hand drive vehicles with European specifications. Some controls 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 variations used 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@.de ©2009 BMW AG, München Reprints of this publication or its parts require the written approval of BMW AG, München

The information contained in this document form an integral part of the technical training of the BMW Group and are intended for the trainer and participants of the seminar. Refer to the latest relevant information systems of the BMW Group for any changes/additions to the Technical Data.

Information status: February 2009 VH-23 / International Technical Training E89 Complete vehicle. Content.

1 Introduction. 1 1.1 Overview 1 1.1.1 Changes compared to the E85 3

2 Body. 4 2.1 Introduction 4 2.1.1 Comparison of body components 4 2.1.2 Dimensions 5 2.2 5 2.2.1 Overview - Retractable hardtop 7 2.2.2 Components 15 2.2.3 Retractable hardtop operation 20 2.2.4 Check control messages 23 2.2.5 Sensor status 24 2.2.6 Auto-remote operation of luggage compartment 25 2.2.7 Emergency actuation 26

3 Drive. 27 3.1 Models 27 3.2 Engines 28 3.2.1 Technical data of N52 engine 28 3.2.2 Technical data of N54 engine 29 3.2.3 Circuit diagram - Drive 29 3.3 Manual gearbox 31 3.4 Automatic gearbox 32 3.5 Rear axle final drive 32

4 and suspension. 33 4.1 Overview 33 E89 Complete vehicle. Content.

5 Electrical/electronic systems. 34 5.1 Introduction 34 5.2 Bus overview 34 5.3 MOST direct access port 37 5.4 Control unit locations 39 5.4.1 Head unit 40 5.5 Aerial locations 41 5.6 Multiple restraint system 44 5.6.1 Circuit diagram 45 5.6.2 Seat occupancy detection, passenger 50 E89 Complete vehicle. 1 Introduction.

1.1 Overview

The new Z4 is the first BMW to have a retractable hardtop. The new model is therefore the successor to the BMW Z4 Roadster and the BMW Z4 Coupe. With its long engine compartment lid, large wheel apertures, long and squat overhang it features all typical elements of a BMW Roadster. These features are further enhanced by the flat front section, the pronounced shoulder line and rear end. In addition, the engine compartment lid that extends over the wheel arches, the large BMW radiator grille, the side gills, the black A-pillar, the contoured roof and rear lights with innovative light technology further cement the characteristic accents.

The two-piece, electrohydraulically operated retractable hardtop made of lightweight aluminium panels takes only 20 seconds to open or close fully automatically. The compact stowage of the roof elements in the luggage compartment facilitates a flat, Roadster-characteristic rear design and a luggage compartment volume between 180 and 310 litres. Large window areas together with the heated glass rear window provide an optimum all-round field of view.

The new Z4

At its launch in May 2009, the E89 will be available with three straight-6 engines with an output from 150 kW/204 bhp to 225 kW/306 bhp. All models are equipped with EfficientDynamics measures and have been optimised in terms of acceleration and fuel consumption. The models are ’Best in Class’ in their segment and already conform to the future exhaust emission standard EURO 5.

The sports automatic with double clutch is optionally available for the BMW Z4 sDrive35i. Compared to the manual gearbox, shifting gear without interrupting tractive power combines the comfort of a BMW with maximum dynamics and the further optimised acceleration and fuel consumption values. An automatic gearbox with optimised gearshift dynamics, direct engine connection and reduced slip is optionally available for the BMW Z4 sDrive30i and BMW Z4 sDrive23i. All Sports automatic transmissions feature shift paddles on the steering wheel.

The new BMW Z4 offers outstanding dynamic driving properties. Equipped with dynamic driving control as standard, the characteristics of the vehicle’s drive and dynamic driving functions can be selected in three levels by the push of a button. As a result, the accelerator pedal characteristics, gearshift program and shift speed of the optional automatic gearbox, DSC response and the optional adaptive M running gear are switched between two characteristic curves.

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Head and elbow clearance as well as ease of entry have been greatly improved compared to the predecessor model. The low seat position near the rear axle creates the typical ride experience in a BMW Roadster. High-grade materials, outstanding workmanship as well as the driver-orientated design of the dashboard and centre console of the Z4 produced at the Regensburg plant ensure Sheer Driving Pleasure. This also includes the BMW iDrive with all its familiar functions used for the first time in the Roadster.

2 E89 Complete vehicle. 1 Introduction.

1.1.1 Changes compared to the E85 • Improved interior and comfort • Retractable hardtop • Bi-xenon as standard (fog lights discontinued) • Through-loading facility • Wheelbase +146 mm • 17” to 19” wheels • Optional adaptive M running gear • Optional sports automatic transmission with double clutch (Z4 sDrive35i) • Cruise control with brake intervention • Dynamic driving control • CIC Professional (with hard disk navigation)

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2.1 Introduction

The following objectives were pursued in the development of the E89 body: • Harmonious overall impression with extended proportions, coupe-inspired roof line and flat rear end • Remote controlled, fully automatic retractable hardtop with load help function • Through-loading facility for carrying two pairs of skies or a golf bag also with the top down • Compared to the predecessor model, more and easier-to-use storage compartments in the vehicle interior as well as a rear storage area behind the seats • Compared to the predecessor model, greatly improved all-round vision provided by a second side window and a larger rear window • Compelling impression (driver-orientated), top-quality appearance and functionality of the interior • Compared to the predecessor model, distinctly reduced noise level at higher speeds

2.1.1 Comparison of body components

Comparison of E89 body components with the E85:

Comparison E85 — E89

Index Description 1 New components (newly developed) 2 Common parts 3 Modified components (developed with minimum expenditure)

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2.1.2 Dimensions

The E89 has grown compared to the E85. The width is now 1790 mm (+9 mm).

Garage dimensions E85/E89

2.2 Retractable hardtop

The retractable hardtop consists of two aluminium roof panels. They are operated by means of an internal linkage. The retractable hardtop and the rear module are driven hydraulically. The hydraulic system consists of 6 hydraulic cylinders that are supplied with pressure by the hydraulic unit via the hydraulic lines. The cylinders are always actuated in pairs. The retractable hardtop is equipped with a headliner without tensioning cables. The seals have no trim strips.

E89 with hardtop half opened

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Closing the retractable hardtop

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2.2.1 Overview - Retractable hardtop

Overview - Mechanical system

Overview - Mechanical system of retractable hardtop

Index Description 1 Roof panel 2 2 Roof panel 1 3 Main pillar mechanism 4 Rear module mechanism 5 Rear module

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Hydraulic circuit diagram

E89 Hydraulic circuit diagram

Index Description A Throttle B Filter C Non-return valve D Emergency operating valve

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E Pilot-controlled non-return valve 1 LH hydraulic cylinder, main pillar 2 RH hydraulic cylinder, main pillar 3 LH hydraulic cylinder, roof panel 4 RH hydraulic cylinder, roof panel 5 LH hydraulic cylinder, rear module 6 RH hydraulic cylinder, rear module 7 Valve for rear module 8 Valve for roof panel and rear module 9 Valve for main cylinder and roof panel 10 Pressure relief valve 11 Changeover valve 12 Hydraulic pump 13 Changeover valve 14 Two-way flow control valve

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Overview - Hydraulics and locking mechanism

Overview - Hydraulics and locking mechanism of retractable hardtop

Index Description 1 LH latch, windscreen cowl panel 2 Drive for locking retractable hardtop 3 RH latch, windscreen cowl panel 4 RH hydraulic cylinder, roof panel 5 RH hydraulic cylinder, main pillar 6 RH hydraulic cylinder, rear module

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7 top module 8 Hydraulic unit 9 LH hydraulic cylinder, rear module 10 LH hydraulic cylinder, main pillar 11 LH hydraulic cylinder, roof panel

Overview - Sensors

Overview - Sensors

Index Description A–K Locations

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1 Microswitch, cowl panel unlocked 2 Microswitch, cowl panel locked 3 Microswitch, cowl panel reached 4 RH microswitch, roof panel closed 5 Hall sensor, roof panel packed 6 Hall sensor, roof panel opened 7 RH microswitch, rear module closed 8 Hall sensor, roof package extended 9 Microswitch, roof module compartment locked 10 Hall sensor, luggage compartment partition 11 LH microswitch, rear module closed 12 LH microswitch, roof panel closed

Circuit diagram - Convertible top module

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E89 Circuit diagram - Convertible top module

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Index Description A Roof module B Rear module 1 Car Access System (CAS) 2 Footwell module FRM 3 Integrated automatic climate control IHKA 4 Centre console control panel (SZM) 5 ”Cowl panel reached” microswitch 6 Front power distribution box 7 Junction box electronics JBE 8 RH microswitch, roof panel closed 9 Drive for locking retractable hardtop 10 Hall sensor, roof package extended 11 LH microswitch, roof panel closed 12 Microswitch, cowl panel unlocked 13 Hall sensor, roof panel packed 14 Microswitch, cowl panel locked 15 Microswitch, roof module compartment locked 16 Hall sensor, rear module opened 17 LH microswitch, rear module closed 18 RH microswitch, rear module closed 19 Heated rear window 20 Rear lid button 21 Release drive 22 Rear lid lock switch 23 LH automatic soft close drive 24 Rear lid lock switch 25 RH automatic soft close drive 26 Luggage compartment light 27 Battery power distribution box 28 Hydraulic unit 29 Convertible top module CTM 30 Hall sensor, luggage compartment partition

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2.2.2 Components

Microswitches and Hall sensors The various positions of the retractable hardtop and of the rear module are detected by 8 microswitches and 4 Hall sensors and signalled to the convertible top module CTM. All microswitches and Hall sensors receive their voltage supply from the convertible top module and have diagnostic capabilities.

After loss of terminal 30 or after emergency operation, the retractable hardtop can still be operated without the need for re-initialisation. The microswitches and Hall sensors ensure the convertible top module reliably detects the position of the retractable hardtop.

Buttons for operating the retractable hardtop Two buttons are provided in the centre console for the purpose of operating the retractable hardtop. These buttons are wired to the convertible top module. When a button is pressed, the convertible top module receives the information and executes the corresponding command. Movement of the retractable hardtop or side windows stops if the button is released while the hardtop is moving. Operation is indicated by a red LED in one button and a green LED in the other. The convertible top module actuates the LEDs via the K-CAN.

The green LED in the button lights up during the opening/closing operation. The red LED signals an operating error or incorrect conditions (e.g. luggage compartment partition not in lower position). The red LED flashes as soon as the retractable hardtop is in an intermediate position and not operated. The LED flashing does not indicate a fault. The flashing LED draws attention to the fact that the vehicle cannot be driven in this situation.

A fault code that cannot be read out is stored under following conditions: • Terminal R On while the button is pressed • When the button is pressed for longer than 20 seconds after roof operation has concluded. The retractable hardtop is then temporarily inoperative. The retractable hardtop can be operated again after pressing the Open button once.

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Buttons for the retractable hardtop

Convertible top module The Convertible top module (CTM) is the central electronic control unit for all functions of the retractable hardtop. The convertible top module is installed on the right in the luggage compartment. The convertible top module controls the retractable hardtop, the rear module, the automatic soft close system and the drive unit for locking the hardtop. The convertible top module also controls the hydraulic pump and the six hydraulic cylinders by way of the three valves in the hydraulic unit. The K-CAN connects the convertible top module to other control units. Information on outside temperature, driving speed and rear lid status etc. is received via the K‐CAN. The convertible top module sends a signal to the car access system (CAS) when the retractable hardtop is opened or closed. The car access system is the master for the power windows. In certain situations, the convertible top module outputs information in the form of check control messages in the instrument cluster.

The convertible top module must be re-encoded after being replaced.

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Location of convertible top module

Index Description 1 Convertible top module 2 26-pin connector for Hall sensors and microswitches 3 2-pin connector to drive unit for locking retractable hardtop 4 41-pin connector for voltage supply, automatic soft close system, buttons, Hall sensors, microswitches and K-CAN 5 18-pin connector for actuating hydraulic unit

Drive for locking the retractable hardtop The drive unit, consisting of an electric motor with gear mechanism, locks and unlocks the retractable hardtop with the cowl panel at the upper windscreen frame. The convertible top module actuates the electric motor. The drive unit is arranged in the middle. The retaining hooks on the right and left are moved by a rotary plate and push rods. The two Hall sensors ’cowl panel locked and unlocked’ monitor the locking procedure.

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Drive for locking the retractable hardtop

Index Description 1 Retaining hook, left 2 Drive for locking retractable hardtop 3 Retaining hook, right 4 ’Cowl panel unlocked’ microswitch and ’cowl panel locked’ microswitch

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When the retractable hardtop is opened, the drive unit locks the hardtop on the base plate in the rear module. This is a crash-lock function, which prevents the retracted hardtop from folding forward in the event of a crash.

Hydraulic unit The hydraulic unit is located in a pan in the luggage compartment floor. The movement direction of the retractable hardtop and rear module are determined by corresponding valve positions and the direction of rotation of the hydraulic pump. The direction of rotation of the hydraulic pump is controlled by two relays. The hydraulic pump generates an operating pressure from 150 to 200 bar.

The temperature in the hydraulic pump is measured to avoid the pump overheating during frequent use of the retractable hardtop. Two cables connect the temperature sensor ground-free to the convertible top module. A line break (open circuit) results in a fault code being entered in the fault code memory. At from a temperature of 90 °C, hardtop closing movement already started is continued up to the secure end position. The movement of the retractable hardtop is stopped immediately at a temperature of 105 °C. The movement can be continued after the temperature has dropped below 90 °C. The hydraulic unit is protected by a 50 amp slow-blow fuse.

The hydraulic fluid does not need to be changed thanks to the lifetime oil fill. Only the approved hydraulic fluid must be used if it is necessary to top up the hydraulic fluid as the result of a leak. Add hydraulic fluid only up to the mark on the reservoir.

If excessive operating noise is heard during operation, the retractable hardtop should be opened and closed several times in order to automatically bleed the hydraulic system via the fluid reservoir.

Instrument cluster KOMBI The instrument cluster provides the outside temperature (bus signal). The instrument cluster uses the check control symbol to show check control messages relating to the retractable hardtop.

Footwell module FRM The footwell module FRM actuates the front power window regulators. The side windows must be lowered in order to open the retractable hardtop (bus signal to convertible top module).

Junction box electronics JBE The junction box electronics JBE actuates the rear power window regulators. The side windows must be lowered in order to open the retractable hardtop (bus signal to convertible top module). The junction box electronics provides the signal indicating whether the rear lid is closed (bus signal).

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The power distribution box in the junction box supplies terminal 30g to the convertible top module. The convertible top module additionally receives terminal 15 from the car access system. This still enables adequate communication with the BMW diagnosis system when, for example, the voltage supply from the junction box is interrupted.

Car Access System (CAS) The car access system is the master control unit for the power window regulators. On request of the convertible top module, the car access system lowers or raises the side windows. In addition, the car access system prevents the rear lid from being opened and movement of the power windows when the retractable hardtop is in an intermediate position. The car access system controls the auto-remote opening function for the retractable hardtop. The signals from the remote control are received by the remote control receiver and sent to the car access system.

Aerial diversity The convertible top module sends a corresponding signal to the aerial diversity module depending on whether the retractable hardtop is closed or open. The aerial diversity function then correspondingly switches over the aerials.

2.2.3 Retractable hardtop operation

Operation The following options are available for operating the hardtop: • Using the button (close and open) • Using the key in the lock barrel in the driver’s door handle (close and open) • Using the remote control (open only) • Using the ID transmitter with Comfort Access option (close, as long as the ID transmitter is within range of the comfort access aerials and open as with the remote control).

Conditions The retractable hardtop can be opened and closed using the button in the centre console only if the following conditions are met: • Terminal R ON • Outside temperature above -12 °C • Boot lid closed • Vehicle stationary (driving speed < 0.7 km/h) • Luggage compartment partition in lowest position • Lateral inclination of vehicle < 11° • Power windows initialised • Battery voltage > 11.5 V • Less than five successive opening/closing operations • Hydraulic fluid temperature for opening < 90 °C and for closing < 105 °C • Electrical system check successful

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• Production, transport and workshop mode FeTraWe not set.

It is not possible to open and close the retractable hardtop while driving. Due to the high current consumption of the retractable hardtop of up to 40 amps, the hardtop should only be operated when the battery charger is connected or the engine is running. For further information refer to the Owner’s Handbook.

The rear power window regulators do not have a pressure sensitive finger guard. This means there is also no one-touch function for closing the rear windows.

Auto-remote closing via the electronic outer door handle module is not possible on vehicles equipped with comfort access. Auto-remote closing is executed via the lock barrels.

Opening the retractable hardtop The retractable hardtop is normally operated by pressing the open or close button in the centre console. The retractable hardtop moves for as long as the button is pressed. The green LED in the button lights up while the retractable hardtop is moving. Movement of the retractable hardtop, rear module or side windows is stopped immediately if the button is released while the retractable hardtop is moving. The red LED then flashes in the button. Movement of the hardtop can be resumed by pressing the button again. Movement of the side windows can be resumed within 10 seconds. If one of the conditions is not met, the red LED will light continuously.

The convertible top module checks the conditions for opening the retractable hardtop when the Open button in the centre console is pressed. If the check is successful, the hardtop is opened as follows: • Lower side windows (if closed or in intermediate position) • Release hardtop at cowl panel • Switch off heated rear window (takes place via junction box electronics) • Unlock and open rear module • Roof panel 2 is released and packed over roof panel 1 • Stow roof panel package in rear module and lock • Close and lock rear module • Close side windows. The hardtop is closed automatically in the reverse order.

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Closing the side windows is coded corresponding to national market specifications.

Operating conditions with Comfort Access

Without option SA 322 With option SA 322 (Comfort (Comfort Access) Access) EURO and Rest of World Open retractable hardtop, Retractable hardtop can be possible with remote control. opened even when the ID Auto-remote function for loading transmitter is more than 4 m and unloading, possible with away. remote control. Retractable hardtop can only be closed even when the ID transmitter is less than 4 m away. Auto-remote function for loading and unloading is possible even when the ID transmitter is more than 4 m away. USA and Canada – (not possible) Retractable hardtop can only be opened even when the ID transmitter is less than 4 m away. Retractable hardtop can only be closed even when the ID transmitter is less than 4 m away. Auto-remote function for loading and unloading is only possible when the ID transmitter is less than 4 m away.

Automatic soft close system The automatic soft close function is installed as standard to conveniently close the rear lid. The automatic soft close system consists of two drive units. The drive units lock the rear lid on the left and right on the rear module carrier. This increases the stability of the rear end.

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Automatic soft close drive

Index Description 1 Automatic soft close drive

Two microswitches are operated when the rear lid locks on the left and right have reached the lock strikers. The signals are sent to the junction box electronics. The convertible top module receives the signals via the CAN-bus. The convertible top module then actuates the two drive units of the automatic soft close system until the rear lid is locked.

Manually shutting the rear lid would make closing via the automatic soft close system unnecessary. For safety reasons, steps must be taken to ensure that the rear lid is really closed. For this reason, the drive units of the automatic soft close system are still actuated.

Both drive units feature a repeat interlock to avoid overheating. The repeat interlock allows the automatic soft close system to be actuated up to 20 times (counter up to 20 increments). The automatic soft close system is then inhibited electrically for approx. 2 minutes.

2.2.4 Check control messages

It is not possible to open or close the retractable hardtop in certain situations. In such cases, corresponding messages are shown in the instrument cluster in the form of check control messages. A short message and additional information are shown on vehicles equipped with a central information display (CID). The check control messages provide explanatory information relating to the red LED in the button that lights up in the case of fault. An active check control message is shown every 5 seconds.

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Check control symbol Check control message Additional information Luggage compartment open -

Roof malfunction! No roof movement possible. If the retractable hardtop does not lock, contact the nearest BMW dealer. Roof operation! Roof movement not completed. Check whether roof movement is blocked. Then press button again. Roof control failed! Roof position and roof locking are not detected. Trip can be continued if roof is locked securely. See Owner’s Handbook for information on checking the roof lock. Roof not locked! Roof not locked. First open or close roof completely before continuing trip. Luggage compartment partition! No roof movement possible. Move luggage compartment partition into required position; see Owner’s Handbook. Roof drive overheated! Roof drive overheated. Temporarily, only closing function is available. Roof operation not possible! Roof operation only possible when vehicle is stationary. Vehicle not parked on level Vehicle not parked on level ground! ground. No roof movement possible.

2.2.5 Sensor status

Retractable Intermediate Intermediate Retractable hardtop open position 1 position 2 hardtop closed ”Roof package  On  Off  Off  Off stowed” Hall sensor

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Retractable Intermediate Intermediate Retractable hardtop open position 1 position 2 hardtop closed LH microswitch, roof  Off  Off  Off  On panel closed RH microswitch, roof  Off  Off  Off  On panel closed Hall sensor, roof  On  On  Off panel packed Microswitch, cowl  On  Off  On  On panel locked Microswitch, cowl  Off  On  Off  Off panel unlocked LH microswitch, rear  On  Off  On  On module closed ”Rear module open”  Off  On  Off  Off Hall sensor RH microswitch, rear  On  Off  On  On module closed Microswitch,  On  Off  Off  Off roof module compartment locked ”Cowl panel  Off  Off  On  On reached” microswitch ”Luggage  On  On  On  On compartment divider” Hall sensor

2.2.6 Auto-remote operation of luggage compartment

Auto-remote function for loading and unloading the luggage compartment The retractable hardtop can also be operated using the remote control or using the key in the door lock. The retractable hardtop can be opened and closed using the ID transmitter on vehicles equipped with the Comfort Access option. The new auto-remote function for loading and unloading provides fast access to the luggage compartment when the retractable hardtop is down. This function makes it easier to load larger items of luggage for instance. The auto-remote function is activated as follows: • Briefly press the rear lid button on the remote control • Then, press and hold the rear lid button on the remote control (no more than one second may pass between releasing and pressing the rear lid button). Initially, the rear module is unlocked and fully opened. The roof package is swivelled out of the luggage compartment. The rear module is then closed and locked. The rear lid is unlocked by the automatic soft close system. the boot lid opens a little. The auto-remote functions via the remote control conform to national market specifications.

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2.2.7 Emergency actuation

Emergency opening of rear module

As there is now no lock barrel and Bowden cable assembly, the rear lid cannot be released in the event of the rear lid lock being defective. At the same time, movement of the retractable hardtop is inhibited by the unknown status of the rear lid. A test module can be used to open the rear module in customer service. This test module ignores the locking conditions for the luggage compartment partition and rear lid.

Emergency actuation of the retractable hardtop

An emergency actuation facility for releasing the retractable hardtop by the customer is not provided. Emergency actuation is, however, possible in the service workshop. The emergency actuation procedure is described in detail in the repair instructions.

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3.1 Models

The following models will be available at the launch:

Z4 sDrive23i Z4 sDrive30i Z4 sDrive35i Engine N52B25O1 N52B30O1 N54B30O0 Power output [kW/bhp] 150/204 190/258 225/306 at [rpm] 6400 6600 5800 Torque [Nm] 250 310 400 at [rpm] 2750 2600 1300 – 5000 Exhaust emission EURO 5 EURO 5 EURO 5 standard Manual gearbox I I-Plus G Automatic GA6HP19Z (TU) GA6HP19Z (TU) GS7D36SG gearbox Rear axle final HAG 188L HAG 188L HAG 215L drive

The following table contains an overview of the changes compared to the E85. A distinction is made between three different categories: • New development denotes a technology has not yet been used at BMW. • Change denotes a component that has been designed or adapted specifically for the E89 but is not a technological innovation. • Carryover denotes a component that is already used in other BMW models.

Component New Change Carryover Remarks development N52B25O1 engine  Adapted to the E89 N54B30O0 engine  Adapted to the E89 and no fuel pressure sensor in the feed line Fuel supply  Similar to E85 with minor adaptations Manual gearbox I  Known from 1 Series and 3 Series Manual gearbox I-Plus  The I-Plus gearbox replaces the H-gearbox.

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Component New Change Carryover Remarks development Manual gearbox G  Known from 1 Series and 3 Series Automatic gearbox  Known from the GA6HP19Z (TU) E70 Sports automatic  Used for the first gearbox with double time in the 335i clutch Rear axle final drive  Known from 1 Series and 3 Series Propeller and drive shafts  Known from the E70

3.2 Engines

The E89 will only be available with straight-6 petrol engines. The two smaller variants will be equipped with the N52 engine with intake manifold fuel injection. The turbocharged N54 engine with direct fuel injection will be fitted in the top model. The digital motor electronics system has been updated and made to comply with EURO 5. While the MSV70 was still used in the E85, this task is performed by the MSV80 in the E89.

3.2.1 Technical data of N52 engine The data of the vehicles are taken as a comparison.

Model Z4 2.5i Z4 sDrive23i Z4 3.0si Z4 sDrive30i Vehicle E85 E89 E85 E89 Engine N52B25U0 N52B25O1 N52B30O0 N52B30O1 Type Straight 6 Straight 6 Straight 6 Straight 6 Displacement [cm³] 2497 2497 2996 2996 Stroke/bore [mm] 78.8/82 78.8/82 88/85 88/85 Power output [kW/bhp] 130/177 150/204 195/265 190/258 at engine speed [rpm] 5800 6400 6600 6600 Torque [Nm] 230 250 315 315 at engine speed [rpm] 3500-5000 2750 2750 2600 Compression ratio ε 11.0 11.0 10.7 10.7 Fuel specification [RON] 98 98 98 98 Fuel [RON] 91-98 91-98 91-98 91-98 Digital motor MSV70 MSV70 MSV80 MSV80 electronics

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Model Z4 2.5i Z4 sDrive23i Z4 3.0si Z4 sDrive30i Vehicle E85 E89 E85 E89 Exhaust emission EURO 4 EURO 5 EURO 4 EURO 5 standard

CO2 emission g/km 197 199 204 199

3.2.2 Technical data of N54 engine

Model Z4 M Roadster Z4 sDrive35i Vehicle E85 E89 Engine S54B33O0 N54B30O0 Type Straight 6 Straight 6 Displacement [cm³] 3246 2979 Stroke/bore [mm] 91.0/87.0 89.6/84.0 Power output [kW/bhp] 252/343 225/306 at engine speed [rpm] 7900 5800 Torque [Nm] 365 400 at engine speed [rpm] 4900 1300–5000 Compression ratio ε 11.5 10.2 Fuel specification [RON] 98 98 Fuel [RON] 95-98 95-98 Digital motor electronics MSS54 MSD81 Exhaust emission standard EURO 4 EURO 5

CO2 emission g/km 292 219

3.2.3 Circuit diagram - Drive

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Electrical system connection, N52 engine

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Index Description 1 Dynamic stability control DSC 2 Digital motor electronics DME 3 Car Access System (CAS) 4 Footwell module FRM 5 Electronic transmission control (EGS) 6 Junction box electronics JBE 7 Front power distribution box 8 Gear selector GWS 9 Accelerator pedal module FPM 10 Brake light switch·BLS 11 Steering column switch cluster, steering angle sensor SZL-LWS

3.3 Manual gearbox

Z4 sDrive23i Z4 sDrive30i Z4 sDrive35i Gearbox designation I-gearbox I-Plus gearbox G-gearbox Nominal torque [Nm] 250 325 600 Max. input speed [rpm] 7000 7000 8500 Gear ratio, 1st gear [i] 4.323 3.498 4.060 Gear ratio, 2nd gear [i] 2.456 2.005 2.400 Gear ratio, 3rd gear [i] 1.659 1.313 1.580 Gear ratio, 4th gear [i] 1.230 1.000 1.190 Gear ratio, 5th gear [i] 1.000 0.809 1.000 Gear ratio, 6th gear [i] 0.848 0.701 0.870 Gear ratio, reverse gear [i] -3.938 -3.187 -3.770 Spread [i] 5.098 4.990 4.670 Weight (not including oil) [kg] 32.2 35.4 53.0

The I-Plus gearbox is designed for smooth operation with outstanding gearshift comfort. The outstanding sports character is achieved by the shortest gearshift ranges (approx. 45 mm) in BMW vehicles. 4th gear is designed as a direct gear so that the engine speed can be reduced again in 6th gear. The gearbox has a lifetime oil fill. Fuel consumption is further reduced by the use of low viscosity oil.

The shift characteristics of 1st, 2nd and 3rd gear is improved by double cone synchronisation. Synchronisation is achieved with carbon friction linings. The weight has been reduced by approx. 8 kg compared to the H-gearbox.

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3.4 Automatic gearbox

An automatic gearbox is optionally available for the E89. Two different types of gearbox are offered depending on the type of engine. N52 engine vehicles are fitted with a conventional automatic gearbox with torque converter and planetary gear train. The Z4 sDrive35i is equipped with the sports automatic gearbox with double clutch. The sports automatic gearbox with double clutch is combined with the electric gearshift as in the 335i. The sports leather steering wheel with shift paddles is used with both automatic gearboxes.

Z4 sDrive23i/Z4 sDrive30i Z4 sDrive35i Sales designation SA 205 Automatic gearbox SA 2TC Sports automatic gearbox with double clutch Gearbox designation GA6HP19Z (TU) GS7D36SG

The automatic gearbox without an electric gear selector is fitted in the E89. Gears are shifted conventionally with a mechanical selector lever. As before, the drive range is engaged by means of a cable assembly and the gears are shifted electrically in the manual gate.

3.5 Rear axle final drive

Z4 sDrive23i Z4 sDrive30i Z4 sDrive35i Final drive designation HAG 188L HAG 188L HAG 215L Plate diameter [mm] 188 188 215 Reduced friction version   

The reduced friction HAG 188L rear axle final drive has a plate diameter of approx. 188 mm. The reduced friction version is characterised by reduced friction loss thanks to the use of ball bearings instead of roller bearings.

32 E89 Complete vehicle. 4 Chassis and suspension.

4.1 Overview

Chassis and suspension E89

Index Description 1 Common parts 2 Modified components 3 New components

The graphic uses colours to show an overview of the common parts, modified components and new components in the E89 compared to the E85 and compared to the E9x and E8x models for the front axle. Some components have been fully adopted, others have been adapted and optimised to the changed conditions and other components are a complete new development. In the same way as the E9x and E8x models, the E89 is based on the well-known principle of the double joint spring strut front axle. The well-proven principle of the central link rear axle from the E85 is retained for the rear axle.

The E89 chassis and suspension are described in detail in a separate product information ’E89 Chassis and Suspension’.

33 E89 Complete vehicle. 5 Electrical/electronic systems.

5.1 Introduction

The electrical and electronic systems of the E89 - Z4 Roadster largely correspond to the systems used in the BMW 1 Series and 3 Series. The electrical system therefore includes the junction box electronics JBE, the footwell module FRM and the roof functions module FZD with the known functions. The lighting system of the E89 has no fog lights. The following points are new features or changes on the E89: • Steering wheel heating • MOST direct access port • Overview of head units • Aerial systems

5.2 Bus overview

34 E89 Complete vehicle. 5 Electrical/electronic systems.

35 E89 Complete vehicle. 5 Electrical/electronic systems.

E89 Bus overview

Index Description ASP Exterior mirrors CA Comfort access CAS Car access system CIC Car information computer CID Central information display CTM Convertible top module CON Controller DAB Digital Audio Broadcasting (as separate control unit only with radio BMW Professional) DKG Double clutch gearbox DME Digital motor electronics DSC Dynamic stability control DSC‐SEN Dynamic stability control sensor DVD DVD changer EGS Electronic transmission control EKPS Electronic fuel pump control EMF Electromechanical parking brake EPS Electromechanical FLA High beam assist FRM Footwell module FZD Roof functions module GWS Gear selector HiFi HiFi amplifier IBOC Digital tuner US (only installed without CIC) IHKA Automatic climate control IHKR Integrated heating/air conditioning control JB Junction box KOMBI Instrument cluster MRS Multiple restraint system PDC Park distance control RAD1 Radio BMW Business RAD2 Radio BMW Professional

36 E89 Complete vehicle. 5 Electrical/electronic systems.

RDC Tyre pressure monitor SBFA Switch cluster, driver’s side SDARS Satellite tuner (US) SINE Siren with tilt alarm sensor SMFA Driver’s seat module SMBF Passenger’s seat module SMC Stepper motor controller SZL Steering column switch cluster TCU Telematics control unit TOP HiFi Top-HiFi amplifier ULF-SBX Interface box (Bluetooth telephony, voice input Basic) ULF-SBX-H Interface box High (Bluetooth telephony, voice input and USB/audio interface) VM Video module VDM Vertical dynamics management

5.3 MOST direct access port

As on all vehicles with an MOST-bus, MOST direct access port is also installed in the E89. The MOST direct access port is located on the left in the footwell.

The two connected plugs must be taken from the common connector (A). The two plugs are then connected together (B). The integrated communication optical module ICOM can now be connected in the usual way to the joined plug.

37 E89 Complete vehicle. 5 Electrical/electronic systems.

MOST direct access port

Index Description A MOST plug connector B MOST-bus disconnected and plug connector joined C ICOM connected with MOST direct access port

38 E89 Complete vehicle. 5 Electrical/electronic systems.

5.4 Control unit locations

Overview of control units

Index Description 1 Adaptive headlight AHL 2 Electromechanical power steering EPS 3 Electronic transmission control EGS/double clutch gearbox DKG 4 CD changer CDC and DVD changer MMC 5 Junction box JB 6 Automatic climate control IHKA/integrated heating/air conditioning control IHKR, radio BMW Business RAD1/radio BMW Professional RAD2/car information computer CIC, centre console switch cluster SZM 7 Roof functions module FZD and high beam assist FLA 8 Top-HiFi amplifier TOP HiFi/HiFi amplifier HiFi 9 Electronic fuel pump control EKPS 10 Convertible top module CTM, park distance control PDC, comfort access CA, electromechanical parking brake EMF, tyre pressure monitor RDC 11 Diversity module 12 Battery 13 Digital Audio Broadcasting DAB/satellite tuner (US) SDARS, video module VM Japan

39 E89 Complete vehicle. 5 Electrical/electronic systems.

14 Interface box High ULF-SBX-H 15 Telematics control unit TCU 16 Passenger’s seat module SMBF, driver’s seat module SMFA 17 USB hub 18 Controller CON 19 Gear selector GWS 20 Multiple restraint system-acceleration sensor MRS acceleration sensor 21 Steering wheel heating is offered for the first time in a BMW Roadster. It is actuated by the steering column switch cluster SZL. 22 Footwell module FRM and car access system CAS 23 Instrument cluster KOMBI 24 E-box with digital motor electronics DME and vertical dynamics management VDM 25 Dynamic stability control DSC 26 Siren with tilt alarm sensor SINE

5.4.1 Head unit

The available head units include the radios BMW Business RAD1 and BMW Professional RAD2 as well as the car information computer CIC. A Business navigation system is not offered for the E89.

40 E89 Complete vehicle. 5 Electrical/electronic systems.

E89 head units

Index Description A Radio BMW Business RAD1 B Radio BMW Professional RAD2 C Car information computer CIC

The available speaker systems include both the stereo system as well as the HiFi and TOP HiFi system. To date, an Individual High End audio system will not be offered for the E89.

The telephony systems features the introduction of the extended connectivity of the music player in the mobile phone. With this system it is possible to select and play audio tracks that are stored on the mobile phone via the iDrive system. Customers can order this option under SA 6NF (Extended connectivity of music player in mobile phone). Details of this optional extra are provided in the product information ’Audio Systems F01/F02’.

5.5 Aerial locations

The aerial system in the E89 consists of the rod aerial for radio and telephone reception. Other components of the aerial system are located in the rear bumper. This is where the aerials for the digital and analogue radio as well as for telephone and TV are housed. The GPS aerial and DAB L-band aerial are located in separate receiver modules in the upper cover of the windscreen.

41 E89 Complete vehicle. 5 Electrical/electronic systems.

The aerial diversity module with aerial amplifier is a special feature. This module is installed in the vehicle as from the BMW Business radio. In all other BMW vehicles with BMW Business radio the aerial diversity module with aerial amplifier has been dropped since September 2007.

42 E89 Complete vehicle. 5 Electrical/electronic systems.

Overview of aerials

Index Description 1 Radio BMW Business RAD1/radio BMW Professional RAD2/car information computer CIC 2 GPS aerial, digital audio broadcasting L aerial DAB-L aerial, GPS aerial 3 Eject box 4 Emergency call-GMS aerial 5 Satellite tuner aerial SDARS aerial (US) 6 Diversity aerial 7 Digital Audio Broadcasting aerial 3 DAB-aerial 3, TV aerial 2 8 FM aerial 3 9 Telephone aerial 2, TV aerial 1 10 FM aerial 2 11 Control unit DAB/SDARS, video module 12 FM aerial 1, AM aerial, telephone aerial 1 13 Plug connection for DAB aerial, FM aerial, GPS aerial 14 Bluetooth aerial

43 E89 Complete vehicle. 5 Electrical/electronic systems.

E89 Aerials

Index Description 1 Satellite tuner aerial SDARS aerial (US) 2 Digital Audio Broadcasting aerial 3 DAB-aerial 3, TV aerial 2 3 FM 3 4 Telephone aerial 2 5 TV aerial 1 6 FM aerial 2 7 FM aerial 1, AM aerial, telephone aerial 1

5.6 Multiple restraint system

The 7th generation multiple restraint system MRS is a consistent further development of the multiple restraint systems fitted in BMW vehicles.

The multiple restraint system detects an accident situation that is critical for the occupants and activates the necessary restraint systems. The restraint system is activated selectively depending on the severity and type of accident.

44 E89 Complete vehicle. 5 Electrical/electronic systems.

A capacitive sensor system is installed for the first time in the seat occupancy detection facility in the US version of the E89. A battery line monitor is provided as in the E85 predecessor model. the functional principle is described in the product information ”Advanced Crash and Safety Management ACSM”.

Only the new features compared to the E85 are referred to in the following.

5.6.1 Circuit diagram

US model

45 E89 Complete vehicle. 5 Electrical/electronic systems.

Circuit diagram MRS 7 US version

46 E89 Complete vehicle. 5 Electrical/electronic systems.

Index Description 1 Airbag front sensor, left 2 Driver’s knee airbag 3 Footwell module FRM 4 Instrument cluster KOMBI 5 Plug connection, battery monitoring line, front 6 Junction box electronics JBE 7 Knee airbag, front passenger 8 Airbag front sensor, right 9 Airbag sensor, front right door 10 Front airbag, passenger’s side 11 Indicator lamp for front passenger airbag deactivation 12 Car access system (CAS) 13 Switch for front passenger airbag deactivation 14 Seat belt force limiter, front passenger 15 Retractor tensioner, front passenger 16 Airbag sensor, front left door 17 Seat occupancy switch, front passenger 18 Seat occupancy pad, front passenger 19 Seat belt buckle contact, front passenger 20 Side airbag, front passenger 21 Seat belt pretensioner, front passenger 22 Safety battery terminal 23 Plug connection, battery monitoring line, rear 24 Telematics control unit TCU 25 Seat belt pretensioner, driver 26 Side airbag, driver 27 Seat belt buckle contact, driver 28 Seat occupancy switch, driver 29 Seat occupancy pad, driver 30 Retractor tensioner, driver 31 MRS control unit 32 Seat belt force limiter, driver

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33 Airbag sensor, front left door 34 Driver airbag

Europe version

48 E89 Complete vehicle. 5 Electrical/electronic systems.

Circuit diagram MRS 7 Europe version

49 E89 Complete vehicle. 5 Electrical/electronic systems.

Index Description 3 Footwell module FRM 4 Instrument cluster KOMBI 5 Plug connection, battery monitoring line, front 6 Junction box electronics JBE 10 Front airbag, passenger’s side 11 Indicator lamp for front passenger airbag deactivation 12 Car Access System (CAS) 13 Switch for front passenger airbag deactivation 16 Airbag sensor, front left door 18 Seat occupancy pad, front passenger 19 Seat belt buckle contact, front passenger 20 Side airbag, front passenger 21 Seat belt pretensioner, front passenger 22 Safety battery terminal 23 Plug connection, battery monitoring line, rear 24 Telematics control unit TCU 25 Seat belt pretensioner, driver 26 Side airbag, driver 27 Seat belt buckle contact, driver 29 Seat occupancy pad, driver 31 MRS control unit 34 Driver airbag

5.6.2 Seat occupancy detection, passenger

US version In accordance with the requirements of NHTSA (National Highway Traffic Safety Administration) a small child in a corresponding child restraint system on the front passenger’s seat must be automatically detected. The MRS control unit automatically deactivates the airbags on the front passenger’s side (front passenger’s airbag, side airbag, knee airbag) when the front passenger’s seat is detected as ’occupied’ by a child restraint system. The indicator lamp for passenger airbag deactivation comes on.

50 E89 Complete vehicle. 5 Electrical/electronic systems.

The seat occupancy detection system on the front passenger’s side consists of a seat occupancy pad with integrated capacitor plate. An electrical field is generated across the capacitor plate and vehicle ground. The seat occupancy mat is connected to an electronic evaluator. The occupancy status is classified based on the evaluation of the electrical field. A person sitting down on the seat changes the electrical field. The change is registered by the electronic evaluator and the corresponding status is determined. The electronic evaluator sends the status information cyclically to the MRS control unit. Data exchange takes place by means of a hardware link. The seat occupancy detection function monitors the inputs and outputs. Possible fault statuses are stored in the fault code memory of the MRS control unit.

The airbags on the front passenger’s side (front passenger’s airbag, side airbag, knee airbag) are deactivated automatically when the seat occupancy pad is defective. The indicator lamp for passenger airbag deactivation comes on.

Seat occupancy detection, front passenger (US version)

Index Description 1 Electronic evaluator 2 Seat occupancy pad

Europe version The seat occupancy detection system on the front passenger’s side detects whether the seat is occupied or not. The seat occupancy pad consists of conductors with pressure sensors. The conductors are connected to the electronic evaluation unit.

51 E89 Complete vehicle. 5 Electrical/electronic systems.

The seat occupancy pad changes its resistance when subjected to weight. The electronic seat occupancy unit evaluates this change in resistance (’seat occupied’ or ’seat not occupied’). The seat is detected as not occupied up to a weight of approx. 12·kg. Seat occupancy detection, however, also depends on the type of seat. The material tension associated with a leather seat or a firm sports seat already acts as pressure on the sensors. In such cases, a weight of less than 12 kg can trigger the ’seat occupied’ status. The signal is sent via direct line to the MRS control unit. The signal is only required for the seat belt warning. A seat warning is given, for example, when the front passenger’s seat is detected as occupied without the seat belt buckle switch sending a signal.

Seat occupancy detection, front passenger (Europe version)

Index Description 1 Electronic evaluator 2 Seat occupancy pad

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