Table of Contents

E70 Powertrain Workbook

Subject Page

E70 Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
E70 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
N62B48O1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
New Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Air Intake and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
N52B30O1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
New Belt Drive (N52B30O1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Intake Air Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
E70 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Transfer Case ATC 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Coding Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Transfer Box Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Front and Rear Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Front Axle Gearbox VAG180A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Final Drive Unit HAG188K/188L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
HAG188L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
`Propeller Shaft and Output Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Propeller Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Output Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Automatic Transmission (GA6HPTU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Converter Lockup Clutch Connection Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Casing and Intermediate Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Initial Print Date: 12/06 Revision Date:

Table of Contents
Subject Page

Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Electronic-hydraulic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Torque Converter Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Variable Cooling Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
System Pressure in Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Clutch Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Solenoid Valves (MV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Electronic Pressure Control Valves (EDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Target gear allocation dependent on accelerator pedal gradient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Shift Speed Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Torque Intervention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
LIN-bus Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Gear Selector Lever (GWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Operation and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Haptic Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Manual Gate, Sport Program (M/S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Parking Lock "P" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Automatic Downshift from "M/S" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Interface to the EGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Definition of Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Safe Status for Sending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Indicator in the Gear Selector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Flashing of a Position LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Indicator Flashing Through Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Secure Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Park and Unlock Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Table of Contents
Subject Page

Evaluating the P-button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Evaluating the Unlock Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
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E70 Powertrain Workbook

Powertrain

Model: E70

Production: From Start of Production

After completion of this module you will be able to:

• Describe the new engines used in the E70

• Understand the changes to the powertrain on the E70

• Understand GWS shifter operation on the E70

E70 Powertrain

E70 Powertrain Workbook

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E70 Powertrain Workbook

E70 Engines

N62B48O1
From the start of production, the X5 4.8is will receive the N62TU
engine as introduced on the E65 in 2005. This engine will be
referred to as the N62B48O1 engine to be consistent with the new
engine code designations.
The N62B48O1 features the following:
• New air cleaner and air intake system
• Modified belt drive
• Oil pan (for installation into E70)
The engine management for the new engine is the ME9.2.3 system
which is a further variant of the ME9.2.2 . The processor speed has
been increased to 66 Mhz to cope with the enhanced capabilities of
the engine and chassis systems in the E70.
Most of the engine systems and mechanical components are the
same as on the previous N62TU from 2005. With the exception of
the items outlined above, the engine is mechanically the same as Specification N62B44 (E53) N62B48O1 (E70)
it’s predecessor.
Engine type V-8 90 degrees V-8 90 degrees
As compared to the N62B44 in the E53, the horsepower and Displacement (cm3) 4398 4799
torque have been increased. However, the N62B48O1 complies Stroke/bore (mm) 82.7/92 88.3/93
with the ULEV II requirements. Power output (kW/bhp) 235/320 261/350
The exhaust system has been modified to meet ULEV standards. at engine speed (rpm) 6100 6300

The catalyst design allows the elimination of the secondary air sys- Torque (Nm) 440 475
at engine speed (rpm) 3600 3500
tem.
Compression ratio 10.0 10.5
On of the most notable changes to the physical appearance of the Valves/cylinder 4 4
engine is the air intake system and air cleaner assembly. This Fuel type (RON) 98 98
design allows the new N62 to meet acoustic goals as well as the Firing order 1-5-4-8-6-3-7-2 1-5-4-8-6-3-7-2
necessary requirements for pedestrian protection. Engine management ME9.2 with VVT ME9.2.3 with VVT
Emission standard LEV ULEV II
New Belt Drive Air Intake and Filter
The belt drive on the 4.8 engine has been modified for use on the The new air filter and intake system has been designed to allow
E70. The alternator and A/C compressor have been relocated for increased airflow and improve engine acoustics. It is mounted on
space reasons. the engine rather than on the inner fender or front support as on
past designs.
The belt drive is a double system as standard. The main belt drive
is a ribbed seven groove belt which includes the power steering The intake system features a series of filtered and un-filtered air
pump, alternator and coolant pump. resonators to accomplish these goals.
The A/C compressor is driven by an ELAST drive belt. However, a The new design also allows compatibility with the pedestrian
new feature is a linear tensioner which eliminates the need for a protection features on the E70.
special tool for removal or installation.
Be aware that the A/C compressor and alternator have a new
mounting technique which has a threaded insert to align the belt
drive properly. It is imperative to follow the removal instructions.

Index Explanation Index Explanation

Index Explanation Index Explanation
1 Unfiltered air pipe 6 HFM
1 ELAST drive belt for AC comp 6 Power steering pump
2 Unfiltered air resonator 7 Intake silencer cover
2 Coolant pump 7 Ribbed V-belt
3 Filtered air resonator 8 Air cleaner
3 Tensioning pulley 8 Torsional vibration damper
4 Double-chamber filtered resonator 9 Intake silencer
4 Deflection pulley 9 Linear tensioner
5 Unfiltered air pipe 10 Bracket
5 Alternator 10 AC compressor

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N52B30O1
For the 6-cylinder version of the E70, the new N52KP engine will
be used. This new N52KP is the upper output version as intro-
duced on the E83LCI with some minor changes.
Many of the mechanical changes are the same as on the N52KP
engines in order models (E83/E9X etc).
The N52B30O1 features:
• Plastic cylinder head cover
• Modified oil pan for installation into E70
• Crankshaft has higher degree of balance
(to reduce load on drivetrain)
• New Torsional vibration damper
• Modified belt drive
• 6 mm exhaust valves
• Lightweight “hydroformed” camshafts Specification M54B30 (E53) N52B30O1 (E70)
The engine management system is the MSV80 system which Engine type inline 6 inline 6
includes improvements over the MSV70 system. These items
Displacement (cm3) 2979 2996
include:
Stroke/bore (mm) 89.6/84 88.0/85
• Digital HFM
Power output (kW/bhp) 170/231 163/260
• New throttle valve with magneto resistive feedback at engine speed (rpm) 5900 6600
• 180 amp alternator (Bosch or Valeo) Torque (Nm) 300 305
at engine speed (rpm) 3500 2500
• Oil level/quality sensor (QLT)
Compression ratio 10.2 10.7
The MSV80 engine management complies with the ULEV II Valves/cylinder 4 4
requirements for 2007.
Fuel type (RON) 98 98
The catalyst system allows for the elimination of the secondary
Firing order 1-5-3-6-2-4 1-5-3-6-2-4
air pump.
Engine management (DME) MS43 MSV80
Note: For more detail, see the ST616 training course. Emission standard LEV ULEV II
New Belt Drive (N52B30O1) Intake Air Control
With regard to the 6-cylinder, there are two possible belt drive As with the V-8 engine option, the 6-cylinder uses an engine
arrangements on the E70. mounted air filter and duct system. This arrangement also achieves
the desired sound quality goals and also meets the necessary
The single belt drive uses a 6 rib v-belt with a conventional “spring
crash optimization requirements for pedestrian protection.
loaded” belt tensioner.
If the E70 is equipped one of the following options; Active steering,
Adaptive Drive or the 220 Amp Alternator, there is a double belt
drive.
In this case, the A/C compressor is driven separately by a four rib
ELAST drive belt. As opposed to the V-8 engine, this ELAST belt
does not have a linear tensioner and must be installed with the
special tool as one previous applications.

Index Explanation Index Explanation Index Explanation Index Explanation

A Basic belt drive 4 Power steering pump 1 Hot-film air mass meter 6 Unfiltered air pipe

B Double belt drive 5 Ribbed V-belt 2 Filtered air pipe 7 Intake silencer
Double chambered filtered air
1 Tensioning pulley 6 Torsional vibration damper 3 resonator
8 Air cleaner

2 Alternator 7 A/C compressor 4 Bracket 9 Intake silencer cover

3 Deflection pulley 8 ELAST drive belt for A/C comp 5 Unfiltered air resonator

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E70 Powertrain Workbook

E70 Fuel Tank

Index Explanation
1 Engine air cleaner
2 intake manifold
3 Fuel injectors
4 DM-TL
5 Dust filter
6 Purge canister
7 Fuel filter
8 Fuel level sensor
9 Suction jet pump
10 Intake mesh filter
11 Initial filling valve
12 Non-return valve
13 Electric fuel pump
14 Compensating line
15 Return line
16 Feed line
17 Suction jet pump
18 Non-return valve
19 Fuel level sensor
20 Non-return valve
21 Pressure regulator
22 Breather valve
23 Refuelling vent valve
24 ECM (DME)
25 Fuel tank vent valve (purge valve)
26 Purge air line
27 Central constant pressure valve (Z-DHV)
28 Feed line to engine
 Re-install fuel system components into fuel tank and observe
Workshop Exercise - Fuel Tank the following:

Using the fuel tank training aid, remove the service openings Installation:
from both sides. Remove the fuel pump and both sending Make sure that service cover is
units. installed in correct position.
What’s new about the seals and clamps on the service openings Indentation (2) on clamping ring
on the fuel tank? must line up with raised section (1)
of tank.
Pin on service cover (3) must line
up with indentation on clamping
ring.
Why are the seals and clamps a new design?
Ensure correct positioning of seal.
Always replace seal and clamp in
field service situations.

When installing a new clamp (or clamps) how is proper tightening

torque achieved?

Using the illustration on the page above, compare actual

components to the illustrated ones to gain better understanding
of actual system operation.

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E70 Powertrain Workbook

Transfer Case ATC 700 Coding Resistor

The locking power characteristic of the multi-disc clutch can vary
The ATC 700 transfer case is a further development of the ATC500 slightly due to the mechanical tolerances in the production process.
transfer case known from the E53. The power transfer takes place After measuring the actual locking power on the clutch test rig, a
via a chain drive and multi-disc clutch. resistor is fitted to the actuator motor with its value representing a
reference regarding the progression of the locking power.
Every time the engine is started, the transfer box control unit
measures the resistance and correspondingly selects the optimum
characteristic map for the installed transfer box.
To facilitate accessibility, the coding resistor is no longer fitted on
the casing of the worm drive but rather on the casing of the transfer
box.

Index Explanation Index Explanation

1 Input from automatic gearbox 5 Multi-disc clutch

2 Output to rear axle 6 Actuator lever with ball ramp

3 Output to front axle 7 Chain drive

4 Actuator motor 8 Control wheel

As compared to the ATC 500, there are only minor changes:

• Installation position of coding resistor
Transfer Box Control Unit
• Optimized lifetime gear oil The transfer box control unit is known from the E60 and E90 all-
• New ventilation system wheel drive models. It has a new housing that is not water-tight. It
is arranged under the luggage compartment floor on the left next to
• Transfer case control unit (VGSG) the battery.
NOTES
PAGE
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Front and Rear Differential Final Drive Unit HAG188K/188L

The final drive unit (rear axle differential) HAG188K is already
known from the previous model series. The HAG188L represents
Front Axle Gearbox VAG180A
a further development that is fitted on the E70 with N62B48O1
The front axle gearbox is a new design with an aluminum casing.
engine.
As before, it is centered and mounted as part of the oil pan. In
terms of function, the front axle gearbox remains the same as that The output shafts are now also fitted in a plug-on arrangement to
in the E53 predecessor. the final drive unit as known from the front axle gearbox of the E53.
Since there is now no flange for the output shafts, the final drive
unit is supplied without an oil fill for replacement purposes.

Two different drive flange variants are used for 6-cylinder and
8-cylinder engines.
The propeller shaft is also fitted in a plug-on arrangement to the
• In connection with the N52B30O1 engine, the propeller shaft final drive unit and therefore also has no drive flange. Instead, the
is connected by means of a flexible coupling to the front axle SAE gearing of the drive pinion extend out of the casing of the final
gearbox. drive unit. The propeller shaft is fitted onto the spline.
• In connection with the N62B48O1 engine, the propeller shaft
is pivoted further downward due to the catalytic converters. HAG188L
Angular contact ball bearings are used in the HAG188L instead of
The front axle gearbox is adapted accordingly. For this reason, a the taper roller bearings in the HAG188K. The ball bearings greatly
universal joint is used as the drive flange in this case. The oil filler reduce friction losses. In addition to contributing to lowering fuel
and drain plug is located in the same position as on the E53. consumption, this measure also reduces power loss in the thermal
balance of the axle drive.
`Propeller Shaft and Output Shafts The rear propeller shaft in the E70 is fitted onto the final drive unit.
This arrangement provides many advantages regarding function
and assembly.
Propeller Shafts
A new connection arrangement of the rear propeller shaft to the Output Shafts
final drive unit (rear axle differential) is used on the E70. The output shafts are also fitted in a plug-on arrangement to the
The constant velocity joint of the propeller shaft is now bolted to final drive unit as already known from the front axle gearbox.
the flange of the final drive unit but rather it is fitted onto the unit.
The rear output shafts are now fitted in a plug-on arrangement to
the final drive unit as already known from the front output shafts.
Currently, the two CV boots (gaiters) on the constant velocity joints
cannot be replaced.
The housings of the constant velocity joints for the front and rear
output shafts are no longer powder-coated but now have a bright
finish.

Index Explanation Index Explanation

1 Propeller shaft 4 Drive pinion
2 Retaining clip 5 Flange nut
3 Nut 6 Casing of final drive unit

This arrangement offers various advantages:

• Reduced overall size
• Improved balance characteristics
• Shorter assembly time
• Quieter running
• Higher torsional rigidity
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Automatic Transmission (GA6HPTU)

There are 2 new transmission variants for the X5. The new “TU”
version of the already proven 6HP19/26Z has been improved for The automatic gearbox GA6HPTU for the E70 has been
use in new vehicles including the X5. re-engineered in terms of the following points:
• Torque converter with turbine-torsion damper
The 6HP19 is used in the E70 X5 3.0, while the 6HP26 can be
found in the 4.8 version. • Clutch E
• Adapted electronic transmission control (EGS)
Vehicle Engine Transmission Torque Cap.
• Faster hydraulics through new pressure regulator
E70 X5 3.0 N52B30O1 GA6HP19TU 400 Nm
E70 X5 4.8 N62B48O1 GA6HP26TU 650 Nm • Electric gearshift
Torque Converter The secondary side of the turbine-torsion damper is connected to
A new torque converter is used in the GA6HPTU gearbox. This the input shaft of the gearbox. Since the converter transmits no
torque converter contains an effective torsion damper system vibrations, the torsion damper need not perform any damping work.
known as the turbine-torsion damper (TTD). In this case it functions virtually as a rigid transmission element.
This is a classic torsion damper, in which the primary side (engine When the converter lockup clutch is engaged, the power is trans-
side) is fixed to the turbine wheel of the torque converter. mitted directly from the clutch to the primary side of the turbine tor-
sion damper. Due to the rigid connection to the turbine wheel of
This arrangement brings about an increase in the flywheel mass on
the torque converter, the flywheel mass is increased on the primary
the primary side thus distinctly improving the damping properties.
side.
The power is transmitted via the turbine-torsion damper to the
input shaft of the gearbox. Torsional vibration is filtered out very
effectively.
With this system, it is possible to engage (close) the converter lock-
up clutch much earlier without having to take any deterioration in
comfort into account. This arrangement directly connects the
gearbox to the engine, resulting in a boost in dynamics as well as a
reduction in fuel consumption and exhaust emissions.

Converter Lockup Clutch Connection Stages

The ability of the new torque converter to dampen torsional vibra-
tion with the turbine torsion damper is used to keep the converter
lockup clutch closed as often as possible.
A general statement as to under what conditions the converter
lockup clutch is disengaged (open) or engaged (closed) can still
not be made as this depends on very many factors.
• Load choice signal (accelerator pedal position)
• Engine load status
With the converter lockup clutch disengaged, i.e. in converter
mode, the power flow from the turbine wheel does not take place in • Vehicle speed
the usual manner to the transmission input shaft.
• Transmission fluid temperature
The turbine wheel transmits the power to the primary side of the
• Selected gearshift program
torsion damper.

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Casing and Intermediate Plate Torque Converter Control

The casing and the intermediate plate of the GA6HPTU gearbox The torque converter control including the converter lockup clutch
have been adapted to the new hydraulic unit and the resulting has undergone distinct improvements with regard to the control
channel arrangement. capabilities under all conditions.
The GA6HPTU gearbox is a reengineered version of the 6-speed It is equipped with a new pressure regulator. Raised converter
automatic gearbox that was introduced in the E65 and since then pressure (increased from approx. 0.5 bar to 1 bar at the low end)
used in all model series. ensures faster control of the converter lockup clutch particularly at
low temperatures.
The modifications are specifically targeted at achieving higher
dynamics, lower fuel consumption and reduced pollutant emis- The oil feed comes from the primary connection of the main
sions. pressure control valve, thus improving control at low speeds.
The converter lockup clutch is now engaged with a backpressure
Clutches in order to proportionate more effectively.
The clutch E has been reworked. The clutch E is a drive clutch that
connects the ring gear of the single planetary gear train with the Variable Cooling Oil Flow
long planet gear of the double planetary gear train. The flow of cooling oil is variable in order to reduce power losses.
It is closed in fourth, fifth and sixth gear. The lining of clutch E is No cooling is required for the clutch faces when the converter lock-
made from a new material that offers greater stability in terms of up clutch is engaged (closed). The flow of cooling oil can be
vibration and squeaking. reduced in this state thus also reducing the pump power. The flow
of cooling oil is controlled by the main pressure and can vary
Electronic-hydraulic Control between 10 l/min and 15 l/min.
The electronic-hydraulic control installed in the GA6HP19/26TU
has been optimized in the following areas with regard to faster System Pressure in Reverse Gear
gearshift operations and higher efficiency. The system pressure that is applied in reverse gear has been
increased from 15 bar to 16 bar. This change caters for the higher
• Torque converter control torque and the higher possible total weight. It ensures that clutch
• Cooling oil flow slip is prevented even in extreme situations (e.g. uphill gradient with
trailer).
• System pressure in "R"
Clutch Valves
• Clutch valves
The clutch valves now exhibit a smaller control space. This facili-
• Electronic pressure control valves tates a more spontaneous response as the time required until the
clutch valve reacts to the control pressure applied by the EDS is
The electronic-hydraulic control now has only two solenoid valves
shorter. This results in distinctly shorter gearshift times.
but seven electronic pressure control valves.
 Solenoid Valves (MV) Instead another electronic pressure control valve is used so that
Two solenoid valves are mounted on the hydraulic selector unit. each clutch is now controlled by its own electronic pressure control
These valves are designed as 3/2-way valves, i.e. valves with three valve. The pressure control valve 7 maintains a constant system
connections and two switch positions. pressure during the gearshift operations, thus making shorter shift
times possible.
The solenoid valves are controlled by the electronic transmission
control (EGS) and assume the "opened" or "closed" positions Three different electronic pressure control valves (EDS) are now
making it possible to switch over the hydraulic valves. installed which are all resistant to low temperatures. They enable
stable presentation of the gearshift requirements even at low tem-
The two solenoid valves are used for the electronically switched peratures and when the transmission fluid is cold:
parking lock. One solenoid valve controls the valve for the parking
lock and the other solenoid valve locks the cylinder for the parking EDS with rising characteristic
lock. Electronic pressure control valves 1, 2:
Orange cap, rising characteristic
Electronic Pressure Control Valves (EDS) Technical data:
The electronic pressure control valves convert electrical current
• Pressure range 0 to 4.7 bar
into a proportional hydraulic pressure. They are driven by the EGS (0 mA = 0 bar, 700 mA = 4.7 bar)
and operate the hydraulic valves belonging to the shift elements. • Supply voltage 12 V

The tasks of the electronic pressure control valves are listed in the • Resistance 5.05 Ohm (at 20 °C)

following: Electronic pressure control valves 4, 5, 6:

EDS Valve Corresponding Shift Element Yellow cap, rising characteristic

Technical data:
1 Drive Clutch A
• Pressure range 0 to 4.6 bar
2 Converter lock-up clutch (0 mA = 0 bar, 700 mA = 4.6 bar)
• Supply voltage 12 V
3 Drive Clutch B
• Resistance 5.05 Ohm (at 20 °C)
4 Drive Clutch E EDS with falling characteristic
5 Brake Clutch C
Electronic pressure control valves 3, 7:
6 Brake Clutch D
Blue cap, rising characteristic
7 System pressure Technical data:
• Pressure range 0 to 4.6 bar
The solenoid valve that the EDS (4) in the predecessor model (700 mA = 0 bar, 0 mA = 4.6 bar)
assigned to the clutches (D and E) depending on the gear to be • Supply voltage 12 V
shifted is no longer required. • Resistance 5.05 Ohm (at 20 °C)

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Target gear allocation dependent on accelerator pedal Torque Intervention

gradient When shifting gear at low load or when coasting, the EGS sends a
Target gear allocation dependent on the accelerator pedal gradient so-called torque pulse to the engine management in order to
replaces the previous target gear allocation system dependent on achieve a torque intervention.
the accelerator pedal for the purpose of shifting down while
This is negative when upshifting so that the engine speed is
accelerating.
reduced. When downshifting while coasting, the torque interven-
In the case of accelerator-dependent target gear allocation, based tion is positive in order to boost the engine speed. This torque
on the respective downshift characteristic curves, the EGS intervention facilitates smooth gearshifts without the torque
determines whether a downshift is necessary while accelerating. converter having to intervene in this task.
The gearbox shifts down by one gear if the accelerator pedal is LIN-bus Module
pressed and the first downshift characteristic is reached within a The EGS now contains a LIN-bus module for communication with
certain time. If the accelerator pedal is pressed further, the gearbox the gear selector lever (GWS).
shifts down again to the second downshift characteristic and again
to response to the third downshift characteristic.
In the case of accelerator pedal gradient dependent target gear
allocation, the EGS determines the target gear already at the first
downshift characteristic. The accelerator pedal gradient is used for
this purpose. This is the angle the movement of the accelerator
pedal currently described or expressed more simply, the speed at
which the accelerator pedal is depressed.
The target gear which is now determined in connection with the
first downshift characteristic is engaged by a multiple downshift
function. This serves as a boost to overall dynamics as the
corresponding gear is engaged earlier and the interruption in
tractive power is minimized.

Shift Speed Characteristics

The transmission control now has three different shift speed levels
known as quickshift 1, 2 and 3. The higher the level, the faster the
gearshift. The respective shift speed level is selected as a function
of the selected drive program ("D", "S" or "M") and the accelerator
pedal gradient, i.e. as a function of the speed at which the pedal is
depressed.
Gear Selector Lever (GWS) In addition to the one-touch function, the selector lever can also be
The automatic gearbox in the E70 is operated by means of an pushed in the automatic gate. This is comparable to the function
electric gearshift system. This shifter arrangement is similar to the of the direction indicator stalk in the E90.
E65, however unlike the E65 the E70 is not on the steering column
The drive range is changed by tapping the selector lever. A direct
but rather in the usual position on the center console.
change from "D" to "R" or vice versa can be achieved by tapping
The gear selector lever consists of the selector lever itself with the selector lever twice or by pushing the lever.
indicator and the housing with the control unit.
The Unlock button is located on the left-hand side of the selector
lever.

Haptic Locks
Electrically controlled, mechanically actuated locks ensure that the
selector lever can only be pushed in the logically possible direction,
e.g. only forward from "D".
These locks are also used for the shift lock function, i.e. when a
drive range can be engaged only by pressing the unlock button.
The selector lever is not locked if it is necessary to depress the
service brake in order to engage a drive range for example.
Instead, the function is not executed and a message appears in
the on-board monitor indicating: "Press brake to engage gear".
The lock for moving the lever forward differs from the lock for
moving the lever back.
The forward lock is a double lock and can therefore prevent over-
pressing the lever when a flick is possible. In contrast to this, the
backward lock can only completely prevent the movement.
Operation and Functions
Whenever the selector lever can be pulled back, it can also be
The shift pattern is modeled on the conventional BMW automatic
pulled back beyond the stop even if it no longer has a function.
gearbox. It features an automatic gate and a manual gate. Only the
parking lock is not engaged by pushing the selector lever forward
but rather by pressing a button at the top of the selector lever.
The selector lever is monostable in both gates (manual and auto-
matic). This means, after being moved, the selector lever always
returns to its initial position. In the manual gate this is the same as
automatic gearboxes with Steptronic.
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The following graphics illustrate the operating options. The arrows indicate:
• Yellow arrow - Movement possible only with unlock button pressed.
• Grey arrow - Movement not possible.
• Green arrow - Movement possible.

Manual Gate, Sport Program (M/S)

As before, the sport program is engaged by shifting the selector lever to the left. The selector lever locks in this position. The sport
program can only be engaged from "D".

Parking Lock "P"

The parking lock "P" is engaged by pressing the button at the top of the selector lever when the vehicle speed is < 2 km/h. The gearbox
also automatically selects "P" as soon as the engine is turned off and "N" is not engaged.

Automatic Downshift from "M/S"

The automatic downshift function returns the selector lever from the "M/S" gate to the automatic gate. This occurs, for example, when the
EGS signals gearbox position "P" as is the case when the engine is shut down or the "P" button is pressed.
The selector lever remains locked in the "M/S" gate only if "S" or "M" mode is actually active while driving in forward direction or the
automatic downshift is defective or receives no power supply.
5 downshift attempts are executed at intervals of approx. 5 seconds if the selector lever is blocked from the outside, e.g. by an object.
If the downshift cannot be executed, the check control message: "Move selector lever back into automatic gate" appears after two
attempts. A fault code memory entry is generated.
Interface to the EGS Safe Status for Sending
With the aim of increasing availability, the gear selector lever If a GWS-internal plausibility check determines that the position of
position is sent via the PT-CAN and LIN-bus. This means, a signal the selector lever can be transmitted incorrectly, the system
is still sent to the EGS should the PT-CAN fail. This is not neces- assumes the safe status for sending the message "Operation of
sary for safety reasons. gear selector lever".
Safety is guaranteed by neutrally complementary signals or alive Consequently, all signals of this message are sent invalid on the
counters. The gear selector switch (GWS) is woken by a high-level PT-CAN and the LIN-bus. If it is not possible to ensure that the
on the PT-CAN wakeup line. The GSW itself has no active wake-up signals can be sent invalid, the sending of these messages is
capabilities. completely deactivated.

Definition of Messages Indicator in the Gear Selector Lever

The task of the indicator in the gear selector lever (GWS) is to
Interface From To Message
reliably indicate the drive range currently engaged. The indicator
Gear selector lever consists of the locator light that represents the shift pattern and the
PT-CAN GWS EGS
operation
function lighting. This comprises the various position LEDs that
PT-CAN EGS GWS Show gearbox data indicate the drive range currently engaged.
Gear selector lever The function lights in the gear selector lever are controlled by the
LIN-bus GWS EGS
operation "Indicate gearbox data" message sent from the EGS. It is neces-
sary to monitor the function lighting. For this purpose, the indica-
LIN-bus EGS GWS Show gearbox data
tion is read back and compared with the required indication.
The indicator is active as soon as bus communication is active on
Communication
the PT-CAN or the LIN-bus.
The data blocks are sent both event controlled as well as cyclically
on the PT-CAN. They are sent only cyclically on the LIN-bus. Flashing of a Position LED
Complementary signals are sent for the purpose of securing the A position LED flashing draws the driver's attention to incorrect
transmission link. operation. The locator lighting remains constant and does not flash.
These signals are compared with the actual signals in the respec- The flashing action is triggered by an EGS signal. The frequency is
tive receive control unit. Alive counters serve the purpose of 0.5 Hz.
detecting defects in the transmit control unit. The alive counter in
the respective receive control unit is monitored to establish Indicator Flashing Through Diagnosis
whether it remains at a constant value. The entire function lighting can be made to flash at a frequency of
1 Hz for approx. 10 seconds by means of a diagnosis job for testing
A plausibility check between the signals of the PT-CAN transmis- the indicator.
sion and of the LIN-bus does not take place in the receive control
unit.
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Secure Indicator Status Park and Unlock Button

The indicator is a safety-relevant function so that incorrect indica-
tion must be prevented. The system assumes the secure indicator
status if the possibility of an incorrect indication cannot be ruled Evaluating the P-button
out. The P-button sends the driver's choice to apply the parking lock to
the EGS.
The function lighting is switched off for this purpose. The locator
lighting remains switched on. • The P-button is read by means of two contacts in inverse
logic.
Transfer to the secure status can be triggered by two events:
• The two contacts are evaluated in separate logic and repre-
• Defective communication on the bus or sented by the two signals P1 and P2 independent of each
• An internal defect in the gear selector lever other.

The main transmission path to the EGS is the PT-CAN. If the • Before being sent, the P2 signal is inverted in the gear selec-
"Display gearbox data" message is not received correctly on the tor lever.
PT-CAN, the gear selector lever will change over to the LIN-bus. • The two contacts in the gear selector lever are compared for
If, after changing over to the LIN-bus, a fault is also detected on this diagnostic purposes. A fault code entry is stored if different
communication path, the system will assume the secure status. contacts are applied for longer than 2 seconds.
The plausibility check of the LIN-bus is constantly executed in the • An internal diagnostic function in the gear selector lever
background. If it is necessary to change over to the LIN-bus in the detects a defective contact and enters a corresponding fault
event of a defect, it is possible to switch directly to the secure code in the fault code memory.
indicator state if the system detects beforehand that there are
problems with the communication on the LIN-bus. • The button sticking is detected when at least one contact is
applied for longer than 2 minutes.
A fault code entry is generated in response to changing over to the
secure status due to communication problems. This fault situation • The P1 and P2 signals are sent independent of each other on
is irreversible. If the "Display gearbox data" message is received the PT-CAN and redundantly on the LIN-bus to the EGS.
correctly again, the indicator will be activated normally once again • Due to the confirmation tolerances, one signal can be sent as
after 2 seconds. confirmed before the other.
The gear selector lever immediately changes over to the secure If the required conditions are met (speed, ...), the EGS will engage
indicator status if the diagnostic function in the gear selector lever the parking lock when at least one signal (P1 and/or P2) was sent
detects an implausibility regarding the indicator. as confirmed.
In this case, a corresponding fault code entry is generated. This
fault case is not reversible until the next time the gear selector lever
assumes sleep mode.
 Evaluating the Unlock Button Actuators
The lock to shift to "R" or out of "P" is released by pressing the Three actuators are used. A motor with subsequently connected
unlock button. gear mechanism is used for shifting out of the "M/S" gate and for
the lock (inhibit) to "M/S".
• The unlock button is read by means of two contacts in inverse
logic. A bi-directional spring-centered double magnet is used for the
inhibit in "R" direction. A single magnet with spring reset is used
• The two contacts in the gear selector lever are compared for
for the inhibit in "D" direction.
diagnostic purposes. A fault code entry is stored if different
contacts are applied for longer than 2 seconds. The actuators do not inhibit the shift to "R" and "D" in the case of
fault or if no power is applied.
• An internal diagnostic function in the gear selector lever
detects a defective contact and enters a corresponding fault
code in the fault code memory.
• Before being sent, the P2 signal is inverted in the gear selec-
tor lever.
• The button sticking is detected when at least one contact is
applied for longer than 2 minutes.
• Both signals are sent on the PT-CAN and redundantly on the
LIN-bus to the EGS as soon as a contact is detected as con-
firmed.

Components
Sensors
The selector lever position is detected without contact with the aid
of seven Hall sensors for detecting the selector lever position in the
longitudinal direction of the vehicle as well as four Hall sensors for
detecting the selector lever position in the transverse direction of
the vehicle.
In the event of one individual sensor failing, the software in the gear
selector lever is still capable of calculating the correct position of
the selector lever.

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Remove GWS assembly from center console.

Workshop Exercise - GWS
Observe proper removal steps with regard to bolts.
Demonstrate the emergency release procedure for the E70 What 2 bus systems connect GWS with EGS and Why?
transmission as shown below:

Is there any mechanical connection between GWS and EGS?

Re-install GWS assembly using proper procedures.

Go to diagnostics and look for any status requests or
component activations. List below:

When the transmission park lock is released manually, are there any
indications to the driver/technician?

Apply parking brake for safety. Operate shifter through all

modes (P,R,N,D etc.). Note shifter operation and indicator
lights.
With the vehicle is Drive (sport mode), turn off ignition.
What happens to the shifter when the ignition is turned off?