R55 COMPLETE VEHICLE - minitechinfo.com

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R55 COMPLETE VEHICLE

Reference Manual

Initial Print Date: 1/08

Table of Contents

Subject Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Vehicle Views - R56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Vehicle Views - R55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Aerodynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Vehicle Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Club Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Split Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Luggage Compartment Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Dimensions with Rear Seats Folded Down . . . . . . . . . . . . . . . . . . . . . .9Passive Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Panorama Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Chassis and Suspension/Driving Dynamics Systems . . . . . . . . . . . . . .14

Chassis and Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

R55 Body

Revision Date:

2R55 Body

Body

Model: R55

Production: From 2/2008

After completion of this module you will be able to:

• Identify the changes made to the body of the R55 whencompared with the R56.

• Understand the operation of the rear hatch.

• Understand the operation of the right club door.

The R55 (Clubman) will be launched in the Spring of 2008.

It will be available as a COOPER and COOPERS.

In comparison with the R56, the R55 is longer and higher. The width remains the same.

Compared to the R56, the wheelbase and vehicle interior of the R55 has increased by80 mm. In comparison, the rear overhang on the R55 is 158 mm longer.

The knee room available for the rear passengers has increased by 77.5 mm and theheadroom by 16 mm.

3R55 Body

Introduction

R55 Clubman

R56 Cooper R56 Cooper S R55 Cooper R55 Cooper S

Length (mm) 3699 3715 3938 3959

Width (mm) 1683 1683 1683 1683

Height (mm) 1407 1407 1428 1428

3699

1683

146798

5

955

1912

1407

1278

1349

1136

1128

1459

2467 565667TK07-031

0

4R55 Body

Vehicle Views - R56

3714

1683

1461

985

955

1912

1407

1278

1349

1136

1128

1453

2467 565682

TK07-030

8

5R55 Body

Vehicle Views - R55

Aerodynamics

With an optimized aerodynamics concept, the use of local underbody paneling, specifi-cally optimized ram air lips and many aerodynamic details, the R55 COOPER achieves adrag coefficient CX of 0.34.

A new water collection strip on the A-pillar and aerodynamically optimized outside mirrorsas on the R56 with integrated drip lips keep the side window clear even under adverseweather conditions.

The radiator area has been sealed off so that the available cooling air is optimally directedthrough the A/C condenser and radiator.

Partial paneling on the upper grille corresponding to the type of engine achieves optimumfunctionality (CX - cooling capacity).

The outstanding CX value creates the precondition for exceptional vehicle handling, espe-cially Vmax and acceleration from 0-100 km/h. The improvement in CX compared to theR53/R50 alone is reflected in a Vmax gain of 4 km/h.

The improved aerodynamics also means the customer can benefit from reduced (approxi-mately 2%) fuel consumption.

In comparison with the R56, the further improved uplift coefficient of the R55 is the basisfor the outstanding driving dynamics and improvement in driving stability up to top speed.

6R55 Body

Club Door

The club door is located on the front passenger'sside and opens in the opposite direction to the frontdoor.

When opened, the club door enables conveniententry to the rear seat.

As soon as the front door is opened, the club doorcan be opened using the inner door opener. Whenthe front door is closed or the rotary latch lock is inthe lock setting, a safety mechanism that mechani-cally uncouples the door opener prevents the clubdoor from being opened.

A CC message in the instrument cluster shows "Vehicle moving - Club door open" if theclub door is not fully latched.

With the front passenger seat in the easy entry position, the club door increases theentry width by 682.3 mm when compared to the R56.

7R55 Body

Vehicle Components

R56 (197.7 mm)

R55 (880 mm)

Split Doors

The split doors are located at the rear of the vehicle, they provide access to the luggagecompartment and replace the rear hatch on the R55.

When locked or arrested (double locked), the right-hand split door (primary door) isunlatched by pressing the "rear door" remote control button and can then be opened.

The left split door (secondary door) opens completely in one operation with the outerdoor handle. The secondary door can only be opened after the right split door has alreadybeen opened (mechanically interlocked).

In contrast to a conventional rear hatch, the split doors make it possible for the customerto partly open the vehicle corresponding to the space situation behind the vehicle. Thismakes it easier to load and unload smaller objects.

8R55 Body

R55 split doors, closed and open

Compared to the R56, the load sill height of theR55 has been lowered by 23 mm.

The load width has increased by 54 mm compared to the R56.

Compared to the R56, the luggage compartmentof the R55 has grown in length by 261 mm.

Dimensions with Rear Seats Folded DownCompared to the R56, the load height has increased by 16 mm.

The increase in length with the rear seats folded down is 281 mm on the floor.

At shoulder height, the increase in length is 328 mm.

Compared to the R56, the volume has increased by 85 liters.

With the rear seats folded down, the luggage compartment volume has increasedby 250 liters compared to the R56.

9R55 Body

Luggage Compartment Dimensions

Passive Safety

In terms of its structure and occupant protection systems, the R55 represents a new,individualistic vehicle.

The outstanding crash characteristics are attributed to the specific use of high-strengthsteel and tailor-rolled blanks (body structure) as well as lightweight materials such as aluminum (door and chassis/suspension components) and magnesium (cross beam).

The crash loads are transmitted through intelligently designed load paths.

Characteristic features at the front end include special crash cans at the front sub-axlewhich are bolted to the bumper cross member and the crash boxes.

This arrangement provides a further load path which, together with the engine supports,makes it possible to direct energy into the floor structure.

10R55 Body

R55 Passenger Cell

11R55 Body

Corresponding cross members in the bulkhead as well as the so-called ski ramps in the front area of the floor assembly stabilize the footwell. In this way, an extremely rigidpassenger cell is created together with stable seat cross members, the side frame andthe rear support structure.

Together with the A-pillar and B-pillar, the diagonal door reinforcement in the front doorsand extruded aluminum section in the area of the top shoulder form the side impactdeformation zone.

The asymmetry of the vehicle (club door on the right-hand side) makes necessary aspecifically adapted crash layout. The B-pillar is integrated in the club door. The structuralintegrity is ensured by so-called crash hooks and door locks that can withstand highloads at the roof frame and side sills.

Another special feature are the split doors at the rear of the vehicle. The special lock andhinge concept creates a composite structure with the doors and the side frame.

A stable passenger cell is the prerequisite for optimum utilization of the restraint systems.

Force Paths 1

Force Paths 2

12R55 Body

Impact forces are transmitted to the opposite side of the vehicle through the speciallydesigned floor assembly. In the door area, the doors themselves (including club door), thereinforced B-pillar, the seats and the dashboard between the A-pillars secure the stabilityof the side structure. The roof frame also contributes to this high degree of stability.

All these measures ensure the maximum permissible intrusion depth and the maximumpermissible intrusion speed are not exceeded in the event of the vehicle being involved ina side collision.

The rear deformation zone is made up of two longitudinal members, the luggage com-partment floor, the rear paneling, the rear side panels integrated in the side frame and var-ious reinforcement elements.

Force Paths 3

Force Paths 4

13R55 Body

Seats

The front seats on the R55 and R56 are technically identical. However, a new upholsterycode is added for the R55.

Panorama Roof

The panorama roof is identical on the R55 and R56. For the first time, the emergencyrelease tool is not included in the R55 tool kit.

14R55 Body

Chassis and Suspension/Driving Dynamics Systems

Chassis and SuspensionThe front and rear axle on the R55 are identical to those of the R56. Higher strengthmaterials were used on the springs and shocks on the R55 in view of the greater vehicleweight.

This modification is not noticeable when viewing the components from the outside.

Nevertheless, springs and shocks from an R56 must not be installed on an R55.

The greater weight of the R55 was already taken into account by the design layout of thebrake system on the R56. Both brake systems are therefore designed identical. However,the brake discs differ depending on the model. Due to the shape of the body, the brakelines to the rear axle are longer on the R55 than on the R56. With the introduction of theR55, slotted brake anchor plates will be installed on the front axle of both models (R56and R55) to ensure optimum heat dissipation.

Apart from the longer brake cables, the parking brake on the R55 is identical to that onthe R56.

The R55 has the same steering system as on the R56. The steering wheel, steering col-umn and EPS steering gear are also identical on the R55 and R56.

As from 06/2007, the electric steering lock (ELV) will be dropped on the US version of theR55 and R56. This applies to both automatic as well as manual transmission vehicles.

Driving Dynamics Systems

Unlike on the R56, dynamic stability control (DSC) is installed as standard on the R55.

Besides the DSC hydraulic unit and the control unit, the following additional componentsare fitted on the R55:

• DSC sensor

• Steering column switch cluster with optical steering angle sensor

• F-CAN bus system

The stabilization functions as well as the additional functions of dynamic brake control(DBC) and DSC starting assistant in the R55 are identical to those in the R56. Thesefunctions have been simply specifically adapted to the R55 models.

Initial Print Date: 1/08

Table of Contents

Subject Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Changes to the PT-CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Changes to the MOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Changes to the K-CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

General Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Exterior Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Club Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Split Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Audio Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Aerials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Adjusting Rain Sensor Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Modified Activation of Intermittent Wipe . . . . . . . . . . . . . . . . . . . . . . . . . .18

Safety Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

R55 General Vehicle Electronics

Revision Date:

2R55 General Vehicle Electronics

General Vehicle Electronics

Model: R55

Production: From 2/2008

After completion of this module you will be able to:

• Identify the electrical system updates made to the R55

• Familiarize yourself with the updated bus structure

• Understand the operation of the rear tail lights

The vehicle system and the electrical/electronic system are transferred from the MINIR56. Due to the differences in body styling, adaptations and modifications have beenmade to the individual systems.

This document describes the changes that result in an expansion or a functional change.

The description of the systems is subdivided into the following areas:

• Vehicle system

• General electrical system– Exterior lighting– Trailer module– Club Door– Split Doors

• Information and communication systems

• Display and operating elements

• Safety systems

R55 with Open Front Passenger Door and Club Door


Introduction


Due to the transfer of the vehicle system from the R56 with the junction box as a gate-way, the system overview of the vehicle system are more or less identical. The onlyminor differences between the R56 and R55 vehicle systems are the new additionalcontrol units and the modified order of the MOST control units.

The following changes have been made to the various bus systems:

Changes to the PT-CAN

In the R55, DSC is provided as standard.

ASC+T and ABS control units are therefore not included in the bus overview for R55.In the R56, ABS and ASC+T are still available.

Changes to the MOST

The installation location of the IBOC control module is on the left of the luggage com-partment in the R55, and not on the right as in the R56. The MOST port for R55/R56is located above the junction box and no longer above the footwell module.

The MOST configuration is therefore different to that shown in the product informationfor the R56.

This modified configuration also applies for the R56 from 2008 MY.

Changes to the K-CAN

Since the legal guidelines in the USA are fulfilled by the electronic immobilizer fittedas standard, the ELV is not included.

Electrical Systems


Bus Overview

IHK

S

WUP

CC

CF

S

JB

DS

C-S

EN

IBO

C

CD

C

SD

AR

S

SB

XH

igh

SB

X

SC

C

Ko

mb

i

MJO

Y

CID

MR

SO

C3

CA

S

CA

PD

C

SH

D

TP

MS

TPM

-SEN

HiF

i

CIP

FR

MS

ZL

MF

L

MO

ST

PT-

CA

NB

SD

LIN

-Bu

s

D-C

AN

K-C

AN

F-C

AN

K-B

us

IHK

A

IBS

RL

S

G

EP

S

EG

S

DS

CD

ME

4x

Bo

ost

CD

TE07-038

0_2

Exterior Lighting

The exterior lights in the front section of the R55 are identical to those of the R56. Dueto the changes in body styling and design adaptations, the tail lights of the R55 have adifferent shape to those of the R56, but have the same function.

General Electrical Systems


Index Explanation Index Explanation

1 Additional brake light 3 Reflectors

2 Rear lights 4 Rear reflector

A single bulb is used for the tail light and brake light on each side of the vehicle. Thebulbs are activated with a pulse width modulated voltage of 50% for the tail light and 100 % for the brake light. All bulbs in the rear light cluster have an output of 21 W.

The rear fog light is located on the left lamp assembly.

The reverse light is located on the right side of the vehicles. Only one reverse light isused on this vehicle.

The additional brake light is mounted on the outside of the rear window. As in the R56, it is designed as an LED line, but much wider.

For the license plate light, two bulbs with a power of 5 W are used. The license platelights are integrated in the rear bumper trim.

Rear Lamp Assembly (right)


Index Explanation

1 Tail light/brake light

2 Turn-indicator light

3 Right - Reversing lights (Left lamp - rear fog)


Circuit Diagram of Rear Exterior Lights

Index Explanation

1 Footwell module (FRM)

2 Tail light/brake light, right

3 Direction indicator light, rear right

4 Reversing lights in left-hand drive vehicles

5 License plate light, right Tail light/brake light, right

6 Additional brake light

7 License plate light, left

8 Rear fog lights in left-hand drive vehicles

9 Direction indicator light, rear right

10 Tail light/brake light, left


Club Door

The electrical components that were installed in the B-pillar area in the R56 are mountedin the Club Door in the R55. These include the passenger belt, passenger-side satelliteB-pillar, Comfort-Access aerial, loudspeakers and lights in the right-hand B-pillar. Thesecomponents have the same functions as those in the R56.

A 5W bulb is mounted in the Club Door, which acts as an exit light. Whether the ClubDoor is open or closed is detected by two door contacts in the closure system. The sta-tus of these door contacts is read by the junction box.

Electrical Components in the Club Door


1 Club Door door contact - top 5 Rear right-hand woofer

2 Ambient lighting on B-pillar - right 6 Rear right-hand tweeter

3 Passenger-side exterior aerial (Comfort Access) 7 Club Door exit light

4 Passenger-side satellite B-pillar 8 Club Door door contact - bottom

Club Door Circuit Diagram


Club Door Circuit Diagram - Legend


Index Explanation


2 Junction box (JB)

3 Passenger-side door lock with a drive for locking/unlocking and the door contact

4 Door contact for Club Door (top)

5 Ambient lighting on B-pillar - right

6 Door contact for Club Door (bottom)

7 Passenger-side satellite B-pillar

8 Club Door exit light

9 Rear right-hand tweeter

10 Rear right-hand woofer

11 Passenger-side exterior aerial (for Comfort Access)

12 HiFi amplifier

13 Comfort Access control unit

14 MRS 6 control unit

15 Ambient lighting on B-pillar - left

16 Driver-side door lock with a drive for locking/unlocking and thedoor contact and micro-switch for unlocking and central locking


Split Doors

The Split Doors consist of the right-hand Split Door (primary door) and the left-hand SplitDoor (secondary door).

The right-hand Split Door is opened by pressing the button in the right door handle assoon as the vehicle is unlocked. When this button is pressed, it switches against earth.

The junction box reads the status of this button and controls the central-locking drive ofthe right-hand Split Door accordingly. The status of the right-hand Split Door is detectedby a switch in the central locking drive and read by the junction box.

The right-hand Split Door must be opened before pressing the button in the left doorhandle can activate the central-locking drive for the left-hand Split Door via the junctionbox and open the left-hand Split Door.

Electrical Components in Split Doors


1 Heated rear window, right 6 Central locking for right-hand Split Door

2 Heated rear window, left 7 Central locking for left-hand Split Door

3 Rear window wiper, right 8 Left door handle with button

4 Drive for rear window wiper, right 9 Drive for rear window wiper, right

5 Right door handle with button 10 Rear window wiper, left


Both rear windows have integrated rear window heaters, which are supplied with voltageby the junction box. To avoid disturbances of the audio signals when switching the rearwindow heating on/off, each rear window heater has a blocking circuit with a filter.

The rear windows are each cleaned using a rear window wiper. The rear window wipersare each driven by an electric motor controlled by the junction box. The right rear windowwiper is switched using an additional relay.

Since the same junction box is used in the R55 as for the R56, it was not possible to integrate this relay directly into the junction box. The relay is therefore located in thewiring harness on the right-hand side of the luggage compartment (below the PDC control unit). A new (15 A) fuse has also been added in the junction box for the secondrear window wiper.

In conjunction with the light package option (option 563), each door has a 5 W lamp that provides entrance lighting for the rear area.

Circuit Diagram for the Split Doors


Circuit Diagram for the Split Doors - Legend


Index Explanation


2 Junction box (JB)

3 Relay for second rear window wiper

4 Blocking circuit with filter, right

5 Drive for rear window wiper, right

6 Heated rear window, right

7 Central locking for right-hand Split Door

8 Entrance lighting, right-hand Split Door

9 license plate light, right

10 license plate light, left

11 Entrance lighting, left-hand Split Door

12 Door contact for Split Door, right

13 Central locking for left-hand Split Door

14 Door contact for Split Door, right

15 Heated rear window, left

16 Drive for rear window wiper, left

17 Blocking circuit with filter, left

18 Luggage compartment light

The audio system on the R55 is based on the system on the R56. The changes are primarily due to the body changes in the vehicle. Changes include component locationsand aerial antenna rearrangement.

The head units offered are the MINI Boost CD and the Car Communication Computer (CCC).

Aerials

The aerial systems of the R55 are identical to those of the R56. The roof aerials areavailable in two different versions, depending on the equipment specification. The aerialsthat are integrated in the rear window in the R56 have been split between two rear sidewindows in the R55. The exact positions of the individual aerials are shown in the circuitdiagrams on the following page.

Due to the altered design of the tailgate, some electrical components of the R55 areinstalled in different locations than in the R56.

The aerial amplifier with diversity module is now attached to the top left of the C-pillar. Tokeep the cable distances between the IBOC and the aerial amplifier as short as possible,the IBOC is installed on the left hand side in the R55 (in contrast to the right in the R56).The HiFi amplifier is now mounted on the right-hand side.

Audio Systems



1 Aerial amplifier with diversity module 3 HiFi amplifier

2 TV amplifier (not for U.S.) 4 IBOC

Circuit Diagram for Aerials



1 Interface box/High-level interface box 8 SDARS aerial

2 Bluetooth aerial 9 AM/FM1 aerial

3 Head unit 10 Roof antenna

4 SDARS satellite tuner 11 IBOC High Definition radio tuner

5 Base plate 12 Aerial splitter

6 Telephone aerial 13 Aerial amplifier with diversity module

7 GPS aerial 14 FM2-/FM3 aerial

From August 2007, the sensitivity of the rain driving light sensor can be adjusted in all R55 and R56 vehicles using the BC button.

Without the rain sensor, the intermittent wiperoperation has a fixed interval.

With the rain sensor, the wiper operation is controlled automatically depending on the rainintensity and the sensitivity setting.

The procedure for calling this menu is identical to calling the Personal Profile functions (call usingthe BC button and displayed in the SCC). Thesensitivity of the rain sensor can then be set tofour different levels.

Modified Activation of Intermittent Wipe

Intermittent wipe was previously activated by pushing the wiper control lever upwards. Inorder to standardize the method of operation, the intermittent wipe is now activated bypressing the button on the wiper control lever.

The operation is the same as operating the BC button on the steering column. The factthat intermittent wipe is activated is not indicated by an LED. Pressing the button againdeactivates intermittent wipe.

Adjusting Rain Sensor Sensitivity


Rain Sensor Display Adjustment

Early R56 activation of intermittent wipe New R56 Function - Activation by pressing button

The passive safety systems in the R55 are identical to those in the R56, with a fewexceptions. Besides the adjustments due to the modified body styling (Club Door), froman electrical perspective, modifications are also the result of compliance with legalrequirements and crash tests.

Safety Systems


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