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1、MINI ServiceAftersales Training-Participant s Workbook.R55 Body/Complete Vehicle.The information contained in this Workbook is intended solely for the participant of this seminarrun by MINI Aftersales Training.Refer to the latest relevant MINI Service information for any changes/supplements to theTe2、chnical Data.Information status:May 2007Contact:conceptinfobmw.de 2007 BMW AGMnchen,GermanyReprints of this publication or its parts require the written approval ofBMW AG,MnchenVS-12 Aftersales TrainingParticipant s Workbook.R55 Body/Complete Vehicle.Notes on this WorkbookSymbols usedThe following s3、ymbols are used in this Workbook to facilitate bettercomprehension and to draw attention to important information:3containsinformationtofacilitatebetterunderstandingofthesystemsdescribed and their function.1 identifies the end of a note.Information status and national variantsMINI cars conform to th4、e highest safety and quality standards.Changesin terms of environmental protection,customer benefits and designrender necessary continuous development of systems and components.Such developments can result in differences betweenthis Workbook andthe vehicles used for demonstration purposes in the tra5、ining course.This documentation relates exclusively to left-hand drive vehicles withEuropean specifications.In vehicles with right-hand drive,thearrangement of some controls or components may differ from theillustrationsinthisWorkbook.Furtherdifferencesmayariseastheresultofthe equipment variants use6、d in specific markets or countries.Additional sources of informationFurther information on the individual subjects can be found in thefollowing:-Product Information-Owner s Handbook-MINI diagnosis system-Workshop systems documentation-MINI Service Technical.Contents.R55 Body/CompleteVehicle.Training7、1Introduction1Aerodynamics6Club Door7Split Doors9Luggage compartment dimensions11Passive safety12Seats23Panoramic roof24Towing hitch25Chassis and suspension/driving dynamicssystems26Brief overview of technical comparison R55/R562719Training.R55 Body/Complete Vehicle.IntroductionThe R55(Clubman)will 8、be launched in theautumn of 2007.Initially,themodelsCOOPER,COOPERSandCOOPER D will be available.The R55 ONEwill not be offered in the initial phase.In comparison with the R56,the R55 is longerand higher.The width remains the same.1-R55 ClubmanR56 COOPERR56 COOPER SR55 COOPERR55 COOPER SLength3699 mm9、3715 mm3938 mm3959 mmWidth1683 mm1683 mm1683 mm1683 mmHeight1407 mm1407 mm1428 mm1428 mm29Compared to the R56,the R55 has grown inlength by 239 mm.2-R55 Height dimensionsIndexExplanationIndexExplanation1R56(1407 mm)2R55(1428 mm)3-R55 Length dimensionsIndexExplanationIndexExplanation1R56 COOPER(3699 10、mm)2R55 COOPER(3938 mm)39Compared to the R56,the wheelbase of theR55 has increased by 80 mm.In comparison,the rear overhang is 158 mm longer.Compared to the R56,the vehicle interior hasgrown in length by 80 mm.The knee roomavailable for the rear passengers hasincreased by 77.5 mm and the headroom by11、16 mm.Three children or two adults and one childhave sufficient space in the second row ofseats.A two-seat and a three-seat rear benchseat will be available.4-R55 Wheelbase and overhangIndexExplanationIndexExplanation1R56(2467 mm)3R55(2547 mm)2R56(565 mm)4R55(723 mm)49With the seat in the easy entry12、 position,theclub door on the front passenger s sideincreases the entry width by 682.3 mm.5-R55 Entrance width on front passenger s sideIndexExplanationIndexExplanation1R55(880 mm)2R56(197.7 mm)59Assignment 1:Point out the differences between the R55 and R56.Notes:69AerodynamicsWith an optimized aer13、odynamics concept,theuse of local underbody panelling,specificallyoptimized ram air lips and many aerodynamicdetails,the R55 COOPER achieves a dragcoefficient CX of 0.34.AnewwatercollectionstripontheA-pillarandaerodynamically optimized outside mirrors ason the R56 with integrated drip lips keep thes14、ide window clear even under adverseweather conditions.The radiator area has been sealed off so thatthe available cooling air is optimally directedthrough the A/C condenser and radiator.Partial panelling on the upper grillecorresponding to the type of engine achievesoptimum functionality(CX-cooling c15、apacity).The outstanding CX value creates theprecondition for exceptional vehicle handling,especially Vmaxand acceleration from 0-100km/h.The improvement in CX compared tothe R53/R50 alone is reflected in a Vmax gainof 4 km/h.The improved aerodynamics also means thecustomer can benefit from reduced(16、approx.2%)fuel consumption.In comparison with the R56,the furtherimproved uplift coefficient of the R55 is thebasisfortheoutstandingdrivingdynamicsandimprovement in driving stability up to topspeed.79Club Door6-Exploded view of club doorIndexExplanationIndexExplanation1Club door,outside3Club door,ex17、ploded view2Club door,inside89The club door is located on the frontpassenger s side and opens in the oppositedirection to the front door.When opened,the club door enablesconvenient entry to the rear seat.As soon as the front door is opened,the clubdoor can be opened using the inner dooropener.When t18、he front door is closed or therotary latch lock is in the lock setting,a safetymechanism that mechanically uncouples thedoor opener prevents the club door frombeing opened.A CC message in the instrument clustershows Vehicle moving-Club door open.Withthefrontpassengerseatintheeasyentryposition,the cl19、ub door increases the entrywidth by 682 mm compared to the R56.Assignment 1:Disassemble the club door on the R55.Remove the lock.Notes:99Split DoorsThe split doors are located at the rear of thevehicle,they provide access to the luggagecompartment and replace the rear hatch onthe R55.When locked or 20、arrested(double locked),theright-hand split door(primary door)is releasedby pressing the rear door remote controlbutton and can then be opened.The left split door(secondary door)openscompletely in one operation with the outerdoor handle.The secondary door can only beopened after the right split door21、 has alreadybeen opened(mechanically interlocked).7-R55 split doors,closed and open109In contrast to a conventional rear hatch,thesplit doors make it possible for the customertopartlyopenthevehiclecorrespondingtothespacesituationbehindthevehicle.Thismakesit easier to load and unload smaller objects.22、8-R55 Exploded view of split doorsAssignment 1:Disassemble the split doors.Reinstall and adjust the split doors.Notes:119Luggage compartment dimensionsCompared to the R56,the load sill height ofthe R55 has been lowered by 23 mm.The load width has increased by 54 mmcompared to the R56.Compared to the23、 R56,the luggagecompartment of the R55 has grown in lengthby 261 mm.Luggage compartment dimensions withrear seats folded downCompared to the R56,the load height hasincreased by 16 mm.The increase in length with the rear seatsfolded down is 281 mm on the floor.At shoulder height,the increase in lengt24、h is328 mm.Compared to the R56,the volume hasincreased by 85 litres.With the rear seats folded down,the luggagecompartment volume has increased by 250litres compared to the R56.9-R55 Increase in luggage compartment lengthIndexExplanation1Increase in length(261 mm)129Passive safetyIn terms of its str25、ucture and occupantprotection systems,the R55 represents anew,individualistic vehicle.The outstanding crash characteristics areattributed to the specific use of high-strengthsteel and tailor-rolled blanks(body structure)as well as lightweight materials such asaluminium(door and chassis/suspensioncom26、ponents)and magnesium(cross beam).10-R55 Passenger cell139The crash loads are transmitted throughintelligently designed load paths.11-R55 Material mixIndexExplanationIndexExplanation1Other steels5HC340LAD2DC04,DX54D,DX56D6HC380LAD3HC180BD,HC220BD,HC260BD7HC400TD,HC420XD4HC300BD,HC340LAD8Other metals27、149Characteristicfeaturesatthefrontendincludespecial crash cans at the front subaxle whichare bolted to the bumper cross member andthe crash boxes.This arrangement provides a further load pathwhich,together with the engine supports,makesitpossibletodirectenergyintothefloorstructure.12-R55 Material m28、ixIndexExplanationIndexExplanation1Other steels5HC340LAD2DC04,DX54D,DX56D6HC380LAD3HC180BD,HC220BD,HC260BD7HC400TD,HC420XD4HC300BD,HC340LAD8Other metals15913-R55 Material mixIndexExplanationIndexExplanation1Other steels5HC340LAD2DC04,DX54D,DX56D6HC380LAD3HC180BD,HC220BD,HC260BD7HC400TD,HC420XD4HC30029、BD,HC340LAD8Other metals16914-R55 Material mixIndexExplanationIndexExplanation1Other steels5HC340LAD2DC04,DX54D,DX56D6HC380LAD3HC180BD,HC220BD,HC260BD7HC400TD,HC420XD4HC300BD,HC340LAD8Other metals17915-R55 Material mixIndexExplanationIndexExplanation1Other steels5HC340LAD2DC04,DX54D,DX56D6HC380LAD3H30、C180BD,HC220BD,HC260BD7HC400TD,HC420XD4HC300BD,HC340LAD8Other metals189Corresponding cross members in thebulkhead as well as the so-called ski ramps inthe front area of the floor assembly stabilizethe footwell.In this way,an extremely rigidpassenger cell is created together with stableseat cross mem31、bers,the side frame and therear support structure.16-R55 Material mixIndexExplanationIndexExplanation1Other steels5HC340LAD2DC04,DX54D,DX56D6HC380LAD3HC180BD,HC220BD,HC260BD7HC400TD,HC420XD4HC300BD,HC340LAD8Other metals199Together with the A-pillar and B-pillar,thediagonal door reinforcement in the 32、front doorsand extruded aluminium section in the area ofthe top shoulder form the side impactdeformation zone.17-Force paths 118-Force paths 2209The asymmetry of the vehicle(club door onthe right-hand side)makes necessary aspecifically adapted crash layout.The B-pillaris integrated in the club door.33、The structuralintegrity is ensured by so-called crash hooksanddoorlocksthatcanwithstandhighloadsatthe roof frame and side sills.Another special feature are the split doors atthe rear of the vehicle.The special lock andhinge concept creates a composite structurewith the doors and the side frame.A sta34、ble passenger cell is the prerequisite foroptimum utilization of the restraint systems.The 4 star Euro-NCAP rating is achievedthrough Use of the deformation length under highload Extremely rigid passenger cell Compatible design layout of the front endstructure Highly efficient restraint systemsImpac35、t forces are transmitted to the oppositeside of the vehicle through the speciallydesigned floor assembly.In the door area,thedoors themselves(including club door),thereinforced B-pillar,the seats and thedashboard between the A-pillars secure thestability of the side structure.The roof framealsocontr36、ibutestothishighdegreeofstability.All these measures ensure the maximumpermissible intrusion depth and the maximumpermissible intrusion speed are not exceededin the event of the vehicle being involved in aside collision.19-Force paths 3219The rear deformation zone is made up of twolongitudinal membe37、rs,the luggagecompartment floor,the rear panelling,the rearside panels integrated in the side frame andvarious reinforcement elements.The passenger cell is thus designed to remainas intact as possible under all crash loads.Itshould still be possible to open the doors.Even in the event of the vehicle38、 rolling over,the passenger cell with extremely reinforcedcolumns and cross members provides asurvival space for the occupants.20-Force paths 421-Force application,front229Assignment 1:Demonstrate the force paths on the R55 in a front end,side andrear end crash.Notes:239SeatsThe front seats on the R39、55 and R56 aretechnically identical.However,a newupholstery code is added for the R55.The R55 is available with a 3-seat variant ofthe rear bench seat.The R56 comes only witha 2-seat variant at the rear.249Panoramic roofThepanoramaroofisidenticalontheR55andR56.For the first time,the emergency releas40、etool is not included in the R55 tool kit.259Towing hitchIncontrasttotheR56,atowinghitchisofferedas an optional extra on the R55.22-Towing hitchIndexExplanationIndexExplanation1Towing hitch carrier2Detachable ball hitch269Chassis and suspension/driving dynamics systemsChassis and suspensionThefronta41、ndrearaxleontheR55areidenticalto those of the R56.Higher strength materialswere used on the springs and dampers onthe R55 in view of the greater vehicle weight.This modification is not noticeable whenviewing the components from the outside.Nevertheless,springs and dampers from anR56 must not be inst42、alled on an R55.The greater weight of the R55 was alreadytaken into account by the design layout of thebrakesystemontheR56.Bothbrakesystemsarethereforedesignedidentical.However,thebrake discs do differ depending on themotorization.Due to the shape of the body,the brake lines to the rear axle are lon43、ger onthe R55 than on the R56.With theintroduction of the R55,slotted brake anchorplates will be installed on the front axle of bothmodels(R56 and R55)to ensure optimumheat dissipation.Apart from the longer brake cables,theparkingbrakeontheR55isidenticaltothatonthe R56.The R55 has the same steering 44、system as onthe R56.The steering wheel,steering columnandEPSsteeringgeararealsoidenticalontheR55 and R56.In view of the greater front end weight,theR55andR56dieselmodelsareequippedwitha modified characteristic map for the speed-dependent power steering.As from 06/2007,the electricsteeringlock(ELV)wi45、ll be dropped on the US version of theR55 and R56.This applies to both automaticas well as manual transmission vehicles.TheELV will be retained in the Europe version.Driving dynamics systemsUnlike on the R56,dynamic stabilitycontrol(DSC)is installed as standard onthe R55.Besides the DSC hydraulic un46、it and thecontrol unit,the following additionalcomponents are fitted on the R55:DSC sensor Steering column switch cluster with opticalsteering angle sensor F-CAN bus systemThe stabilization functions as well as theadditional functions of dynamic brake control(DBC)and DSC starting assistant in the R547、5are identical to those in the R56.Thesefunctions have been simply specificallyadapted to the R55 models.279Brief overview of technical comparison R55/R56DriveThe motorization corresponds to that of theR56 N12B16 OO for COOPER N14B16 OO for COOPER S W16D16 OO for COOPER DChassis and suspensionAlthou48、gh the front and rear axle are visuallyidentical,higher strength materials are usedon the R55(spring/damper).In contrast to the R56,DSC is installed asstandard on the R55.The R56 is equippedonly with ABS or ASC+T.Electrical systemThe electrical system on the R55 and R56 islargely identical.However,s49、pecificadaptations are necessary due to the clubdoor,the split doors and the towing hitch.BodyCompared to the R56,the body is longer andhigher.The width remains the same.Theclubdoorislocatedontheright-handsideof the vehicle and enables convenient accessto the rear seat.The split doors at the rear of50、 the vehicle are afurther new feature compared to the R56.They provide access to the luggagecompartment and replace the rear hatch onthe R55.28923-R55 Garage drawing29924-R56 Garage drawing309Dieser Text muss hier stehen,damit die Seite vom API-Client nicht gelscht wird.Dieser Text ist notwendig,damit die Seite nicht quergestellt wird.!BMW ServiceAftersales Training80788 MnchenFax+49 89 382 34450: